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Exhausting! project jeep yj 4.0 wrangler – Auto Repair Chat

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Part 1: Parts Cannon!! Can it be saved? 95 Jeep Wrangler 4.0 https://youtu.be/XGx5cooQLQY
Part 2: Frustrating Diagnosis! It LIVES AGAIN! Jeep Wrangler 4.0 https://youtu.be/ZPBWAGcc-8M
Part 3: Old Jeeps Die HARD! Thermostatic Switch and Water Pump! 95 Wrangler 4.0
Part 4: Razor Sharp Gears!! NOT Good! Project Jeep 1995 Wrangler 4.0 https://youtu.be/Q5irXiktUbI
Part 5: Smallest Shaft Ever! FRIED Flywheel! | Project JEEP! 1995 Wrangler YJ https://youtu.be/p7x3vBUR-RQ
New "Wife unit" T-Shirts & Designs for the Season! https://youtu.be/6T_32dnOgTg

Customer States: Engine barely runs and has a severe lack of power. It also has the occasional no start or long cranking before it starts. So far I've found vacuum leaks, clogged ports, antifreeze leaks from the water pump and the electric fan is damaged. I had the fuel pump, filter, spark plugs, ignition wires, and a distributor cap and rotor. It also has a new coolant temp sensor, O2 sensor, MAP, intake temp, IAC and throttle position sensor replaced. The ECM / PCM has been replaced too. See part one.
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97 thoughts on “Exhausting! project jeep yj 4.0 wrangler”
  1. Avataaar/Circle Created with python_avatars Daniel Clark says:

    The old inline 6 cylinder engines were around for a long time and were some of the most reliable engines you can find. The car makers got rid of them because of the length of the engine in favor of the V6 engine. The intake and exhaust manifold were put together to help heat up the intake and make the fuel burn more efficiently. And they had problems with cracked exhaust manifolds because of expansion and contractions in the cast iron. Still really reliable engines though. Good job Ray.

  2. Avataaar/Circle Created with python_avatars Daddyoh says:

    Ray, How did those Freeze plugs look that had rust on them?

  3. Avataaar/Circle Created with python_avatars nelson glass says:

    South main auto repair in honor of you did the brake clean prompt…

  4. Avataaar/Circle Created with python_avatars Belinda Harkless says:

    love project jeep!

  5. Avataaar/Circle Created with python_avatars Warren Tinsley says:

    …..turns off video….buys stock in Brakleen….

  6. Avataaar/Circle Created with python_avatars Happy John says:

    It is a good thing this gentleman is skinny. What contortions a fellow has to go through!

  7. Avataaar/Circle Created with python_avatars Mark P says:

    I think AMC designed that engine… And Chrysler kept it around because it was pretty reliable… Not 100% sure but pretty sure that is an AMC design…

  8. Avataaar/Circle Created with python_avatars Kevin McClure says:

    Who makes those extra stubby ratcheting wrenches you use? Those things are the bomb!

  9. Avataaar/Circle Created with python_avatars Steve Wolf says:

    When did the gaskets go on?

  10. Avataaar/Circle Created with python_avatars Brice Graham says:

    Lol that's funny, you said the "enginerds."

  11. Avataaar/Circle Created with python_avatars Brice Graham says:

    Did I hear Day N Nite in the background? If so I didn't know you were a Kid Cudi fan

  12. Avataaar/Circle Created with python_avatars Richard Alexander says:


  13. Avataaar/Circle Created with python_avatars julian revuelta says:

    Merry Christmas to you and yours Ray

  14. Avataaar/Circle Created with python_avatars herb tender says:

    I'm an old wrench turner I worked as a mechanic 60 years , Ray works his way through problems that keeps us , me entertained, click. Thank you for your time and patience learning some new technology to everyone watching click,click.

  15. Avataaar/Circle Created with python_avatars Neal Fenster says:

    The washer looks like a Belleville washer. A spring washer to maintain pressure if the nut comes loose.

  16. Avataaar/Circle Created with python_avatars Russell Styles says:

    I see no reason you could not have put in a few of the exhaust bolts (nuts) in before putting in the intake manifold. edit – yep. Watched farther.

  17. I don't know if others have mentioned this, but the 4.O in-line six can trace it's lineage back to American Motors, who designed it's predecessor, the 232 CID straight six in 1966 (approx.) (The 4.0 is, in its core, a very old-school engine, full of 1960's Detroit technology.) At that time, pushrod six cylinder engines rare, if ever, had a crossflow cylinder head because the pushrods took up too much space where the ports would be fitted if it was a crossflow head.

    I find that putting in studs on the bottom set of bolt holes for the manifold helps immensely in aligning and tightening that assembly. It is especially useful if that engine is installed in an XJ, MJ, or ZJ Jeep, where access to the lower bolts is much harder than on a YJ or TJ.

  18. Avataaar/Circle Created with python_avatars mike a says:

    Door Trim Tool. I found one on the side of the road about 10 years ago. It is the handiest tool in my tool box. I don't know how I ever got along without one.

  19. Avataaar/Circle Created with python_avatars DSM-6 says:

    These kinds of vehicles are what drives dolly innovation. LOL Some external wheels to clear your lift.

  20. Avataaar/Circle Created with python_avatars S N. says:

    Great video project! Love to see old Jeeps get some love. As for the 4.0L, AMC designed and went to production in 26 months. Just in time to be released in September of 1986 fo rthe '87 model year, much to the chagrin of Chrysler execs. Even though Chrysler execs had the purchase of AMC in the bag, prior to their actual takeover in January '87, they decreed the AMC 258 shall not be installed into the XJ platform even under the cries of customers demanding better power with a six. But AMC got around the order with the 4.0L borrowing some of the design cues from the 258. The XJ/MJ was designed for a V6, hence the short hood design but the absolute dog of GM, the 2.8L was what they could get by the 1984 debut instead of anything else. Fast forward to 5 million 4.0L engines made and more stringent upcoming emissions standards for 2007. Chrysler would not spend money to make it emissions compliant and thus the '06 model year was the last. They chose instead to install an engine from the minivan line into the new plastic JK Wrangler until their own Pentastar design was available.
    For those not in-the-know, you can use the 258 crank and rods with the stock 4.0L pistons and come out with a 4.5L with no other mods required. In terms of intake manifolds, both 'Log" and "Horseshoe" flow fairly equally despite the myth about the "Horseshoe" style intake being "a lot" better. In terms of the "best" head? The 7120 (lacking provision for the block's head locating dowel pins) or the 0630 (with the dowel pin locator holes) are the best flowing factory heads. Both heads will work on all 4.0L blocks. Only the raising roof of the exhaust port increases flow and in the case of the infamous 0331 smog head casting, was raised but over all made with a smaller cross-section to control emissions and still keep the engine legal without an EGR (which was deleted from the '91 and later using the Chrysler SBEC-II ECU).

  21. Avataaar/Circle Created with python_avatars Keith Malmberg says:

    You can do the exhaust with out removing the intake. It makes most of the work harder and unseen.
    I did it on a 92 YJ with the 2.5l 4 banger and a 2000 XJ with the 4l 6.
    Both because I did a cold deep water crossing with a really hot exhaust and cracked the cast bit.

  22. Avataaar/Circle Created with python_avatars Hola! Ryan Hedges says:

    Love all your videos mate.

  23. Avataaar/Circle Created with python_avatars Edward Mcloughlin says:

    Most likely wrong, but one or two of the freeze plugs looked like they were ready to fail?

  24. Avataaar/Circle Created with python_avatars Ian Hood says:

    Would wrapping the exhaust help mitigate issues that having the manifolds on the same side prevent?

  25. Avataaar/Circle Created with python_avatars Oral Pierce says:

    Hi Ray keep up the good work and love your show. I have a 87 yj thinking of electric fan upgrade. Want to know what all needs to be done. Do I have to upgrade the charging system and everything to make it work

  26. Avataaar/Circle Created with python_avatars Phương Ma says:

    Ray that intake and exhaust closed to each other is to heat up in cold starting, they design that way like old carburetor electric choke

  27. Avataaar/Circle Created with python_avatars dhldriver says:

    Super clean shiney shine shine!

  28. Avataaar/Circle Created with python_avatars Noob of noobs says:

    The rectangle ports are the intake toe round ports are the exhaust you said the opposite

  29. Avataaar/Circle Created with python_avatars Aaron Parriette says:

    What brand is the 1/4" ratchet you are using? I'm always on the lookout for a long handle 1/4" and I can never find one.

  30. Avataaar/Circle Created with python_avatars Saienide says:

    I've found a reason for me

    To change who I used to be

    A reason to start over new

    And the reason is you

  31. Avataaar/Circle Created with python_avatars Shade Tree Mech says:

    Hey, Ray, looks like you left your socket on that rear most nut on the exhaust manifold.

  32. Avataaar/Circle Created with python_avatars Gee F says:

    And the owner of this Jeep is : R a y ! 😂😂

  33. Avataaar/Circle Created with python_avatars Eldon Howard says:


  34. Avataaar/Circle Created with python_avatars Brett McLaughlin says:

    The 4 liter straight 6 engine was great other than being a real gas guzzler, it had amazing power and torque, something that the 2015 V6 in my Rubicon unlimited doesn't have. From my experience the Straight 6 was the best engine Jeep had other than perhaps the 390ci V8 American Motors engine that came by special order back in the 1970's.( If my memory is correct)

  35. Avataaar/Circle Created with python_avatars JJHoover70 says:

    would've looked into replacing the freeze plugs

  36. Avataaar/Circle Created with python_avatars S Fnnll says:

    Sometimes I miss my '70 Grand Prix with 400 cu in V8. A few bolts and hoses, the radiator and fan were out and I could stand on the ground in the engine compartment changing the timing belt and gears, or whatever was needed in there. I think all cars then were required to have a hidden secret bolt on the water pump.

    Working through an 82 Z28, an 88 and 94 Ford Explorers, 2007 Honda Accord kept getting tighter and tighter. Plus the thrill of buying all new metrics. Went through the same tool additions at work when we switched from Boeing to Airbus.
    Finally a 2022 RAV 4 Hybrid with the bells and whistles, and I can spot the oil filler, air filters, and fuse box.;
    I'm waiting for you to dig into one of them before I dare to start ripping and tearing.

    Love your channel, don't let the trolls grab ya from under the interweb basement stair bridges where they hide from their moms and pass judgement.

    After 40 years aviation tech on USMC F-4s, De Havilland Herons,; Cessnas, to Boeings, 737- 200,300,400; 727-100,-200 757; 767; 777; Fokkers, Japaneese YS-11's, McDonnel Douglas DC9, DC10 We've learned to adapt. go by the book when that part should be there, but eng decided it would be harder to get to hidden elsewhere. (It fits perfect on the drawing).
    Occasionally we find the golden part that most of the entire Aircraft is built around, and we gotta change it .Keep pulling stuff loose 'till it falls off. Fun times with commercial aviation.

    You have YOURSELF a great day, and we'll be waiting for the next gravity drop. If the members haven't worn it out yet.


  37. Avataaar/Circle Created with python_avatars Leonard Mattos says:

    I have been watching this guy since he started posting, I learn something new every time! Thank you and please keep us all enthralled and entertained.

  38. Avataaar/Circle Created with python_avatars Cody Blanchard says:

    Next investment should be a top side creeper

  39. Avataaar/Circle Created with python_avatars T MANN says:

    You would save a shitload in Brakeleen if you had a parts washer.

  40. Avataaar/Circle Created with python_avatars Al Pha says:

    I thought this is a cooking channel ,,smokem if you brought em.

  41. Avataaar/Circle Created with python_avatars Howard Benally says:

    Hi ray remember you’re Business will succeed with you’re wife help try not stay late remember you have awesome families and as always you and your families be safe 🇺🇸🇺🇸

  42. Avataaar/Circle Created with python_avatars Robert Montgomery says:

    Rusty ? 😂 Only a Floridian would call those rust free bolts “rusty”.

  43. Avataaar/Circle Created with python_avatars Daniel Ventura says:

    I would not run an intake manifold over the exhaust manifold without a heat shield of some sort.

  44. Avataaar/Circle Created with python_avatars Raziels_fate says:

    "jeep dirt" careful how much of that you lose…. could be all that's holding it together haha!

  45. Avataaar/Circle Created with python_avatars Neil duncan says:

    If only jeep updated the head to be a crossflow with port fuel injection…..I think the 4.0 is abetter engine than current V6's less power yes…but more durable and easier to work on

  46. Avataaar/Circle Created with python_avatars Chris says:

    Ray, you are entertaining and awesome to watch. I work for myself, I hate to tell you this but when you work for yourself there is no after hours. It's just a longer day than usual. 😜
    When I went to work for myself I told my old boss if I work as hard for myself as I do for you I can't help but succeed. I did and it's obvious that you will too. Congratulations on being your own Boss.
    You are literally doing everything on this Jeep, are you sure it's not yours?

  47. Avataaar/Circle Created with python_avatars Zyxalis says:

    I had a 1987 wrangler in high school back in 05. Took me a month of nights and weekends to do that clutch in MA in Feb with no garage.
    It was hell.

    Also you Florida guys got it made with no salt on the roads. Wrenching on northern cars is something else entirely. Every bolt would have fought you on that job.

  48. Avataaar/Circle Created with python_avatars Flies2FLL says:

    My understanding is that the hot tip on these 4.0's was to install the fuel injection from a GM 4.3 liter V6.

  49. Avataaar/Circle Created with python_avatars Russell Trupia says:

    Hi Ray just wanted to tell you how much I enjoy your channel,awesome job👍👍

  50. Avataaar/Circle Created with python_avatars Mark Wolfe says:

    The 4.0 got a tubular header from the factory on the YJ and XJ, they always crack where the pipes come together, that was an OEM header you pulled off.

  51. Avataaar/Circle Created with python_avatars Andy Tate says:

    Bloody ads are getting worse. Every 5 minutes is a little ridiculous

  52. Avataaar/Circle Created with python_avatars Brady Rodgers says:

    Lucky you didn't have to grind anything off the exhaust header flange to clear the power steering pump brackets. Some aftermarket headers have that issue.

  53. Avataaar/Circle Created with python_avatars Brady Rodgers says:

    The back sensor on the head goes to the coolant temperature gauge in the dash. The coolant temp sensor on the thermostat housing sends a signal to the ecm (pcm).