mrmel2you Posted May 18, 2016 Share Posted May 18, 2016 Finally got the head on The Beast today :) But when I went to put the exhaust manifold on, only the two outside bolts lined up. Unable to get any of the other bolts to line up (ehaust manifold or intake manifold). Wondering if the manifold expanded or whatever. When I took everything apart to rebuild the head, the two outside bolts on the exhaust manifold were broken off in the head. All other bolts were in and looked fine, ez-outted the broken ones----and now nothing wants to line up. Am I missing something here? Help :) Link to comment Share on other sites More sharing options...
mrmel2you Posted May 18, 2016 Author Share Posted May 18, 2016 I fought with this issue for over 3 hours today. I tried prying, jacking on it from the bottom, you name it---I tried it. Even tried bolting just the exhaust manifold on by itself, then tried bolting on the intake manifold by itself----neither one wanted to bolt on with all of their own bolts. Yes, it's the same head that came off of it, never been out of my sight :) Both manifolds have been under the hood of The Beast, never totally taken out. I'm using the same bolts that came out of it. Took a cardboard box and punched holes into the top of it and placed each bolt in the holes as they came out (so I would know which bolt came from where). Everything else bolted up with no problem whatsoever. But these manifolds are driving me nuts. Link to comment Share on other sites More sharing options...
shelbyluvv Posted May 18, 2016 Share Posted May 18, 2016 Start the corners and leave then loose. Very loose, like one or two threads started. Then do the center. Leave everything super loose until all the bolts are started. Link to comment Share on other sites More sharing options...
mrmel2you Posted May 18, 2016 Author Share Posted May 18, 2016 Tried that----still didn't line up, center one was still off by almost a quarter of an inch :( It's almost like the #1 exhaust chamber had spread out towards the front of the engine. I can get either the front and center bolt in, or the center and back one in----but all of them at the same time. Cleaned all the threads with a chaser, using all new bolts and washers (NOS parts) and they are the same and correct length/thread pitch/diameter. Even tried using the original bolts, got the same results. Oh well, round 2 with The Beast tomorrow. Getting late here and 6:30 comes way too early for this ol' fella. Hopefully I can get things sorted out in the morning, getting kinda "antsy" to hear what The Beast sounds like running on all 4 for a change, instead of sounding like a sick wannabe Geo, LOL :) Thank you for your suggestion "shelbyluvv" :) Papa Mel has left the building, good night to all and Happy Trails everyone :) Link to comment Share on other sites More sharing options...
87Chief Posted May 18, 2016 Share Posted May 18, 2016 Is it a 4 cylinder? Maybe they gave you the wrong header? I've never done one before but maybe they gave you an HO header for 92+? Link to comment Share on other sites More sharing options...
mrmel2you Posted May 18, 2016 Author Share Posted May 18, 2016 "Bignuke", The manifolds are the same ones that came with the truck. I took both off the day before, now the bolt holes are not wanting to line up right :( Getting ready to go out and see if it was something I was overlooking or whatnot. Would really love to get this buttoned up sometime today :) Wish me luck, Happy Trails everyone :) Link to comment Share on other sites More sharing options...
HOrnbrod Posted May 18, 2016 Share Posted May 18, 2016 Sounds like it might be time to break out a Dremel tool and "egg" out the manifold mounting hole(s) just enough to start all the bolts. Also place a straightedge across the manifolds' mounting surface to make sure they haven't been bent somehow. Link to comment Share on other sites More sharing options...
schardein Posted May 18, 2016 Share Posted May 18, 2016 Was the motor hot/warm when you took it apart? Link to comment Share on other sites More sharing options...
mrmel2you Posted May 18, 2016 Author Share Posted May 18, 2016 Motor was cold, parked it the day before. Got the 2 end bolts in, center of the manifold is about a quarter of an inch below the bolt hole in the head. Made some progress, but not through wrenching/prying/cussing yet, LOL :) Link to comment Share on other sites More sharing options...
DirtyComanche Posted May 18, 2016 Share Posted May 18, 2016 If it's warped that bad, I'd probably go looking for a new one. But I'm really wondering what you have wrong if you can't even get the intake manifold to fit with the exhaust off. As previously asked, what engine is this? 2.5L or 4L? Link to comment Share on other sites More sharing options...
benjy_26 Posted May 18, 2016 Share Posted May 18, 2016 Sounds like it might be time to break out a Dremel tool and "egg" out the manifold mounting hole(s) just enough to start all the bolts. Also place a straightedge across the manifolds' mounting surface to make sure they haven't been bent somehow. I had to do this to get my 2.5's exhaust manifold back on. I spoke to a mechanic friend about it and apparently it's common enough to see manifold warp slightly that there's a tool out there to spread them back out. Link to comment Share on other sites More sharing options...
DirtyComanche Posted May 18, 2016 Share Posted May 18, 2016 Lisle makes a tool for spreading small block Chevy engines. I actually have one somewhere, and it does work. It's just a simple jackscrew setup. But if its warped enough it broke the bolts, I think its done. Link to comment Share on other sites More sharing options...
mrmel2you Posted May 19, 2016 Author Share Posted May 19, 2016 No telling how long ago that the bolts broke off in the head (it's a 2.5) before I got it. The gasket that was on it (exhaust side) had #1 and #4 ports burnt/blown out about halfway. Has had a really bad exhaust leak ever since I bought it, I now know why. Wondering if (after who knows) how many miles the po drove it like this, that maybe after the 2 outter bolts broke off, it created just enough heat to cause the manifold to warp at the ends (I don't know). I do know that when I took the head off, all the bolts on the head/exhaust manifold/intake manifold came out with no problems whatsoever. There was no strange sounds (pinging, creaking etc...) coming from either manifold when removing the bolts, no binding of the bolts or manifolds either. Easiest head I've ever had to pull, only took about 45 minutes-----but getting it back together? A little over 2 days-----and still counting :( Link to comment Share on other sites More sharing options...
mrmel2you Posted May 19, 2016 Author Share Posted May 19, 2016 :bowdown: Praise to the Jeep Overlords :bowdown: :clapping: WOO-HOO :clapping: , Papa Mel finally got the head and intake manifolds back on "The Beast" today (then it started raining :rant: ). Tell ya all how I did it and maybe save someone else from having the same issue(s) that I went through. After a lot of cussing/wrenching/prying/hammering/and jacking, I did it. Mind ya now, this is on a 2.5 popcorn popper :) Loosely, put in the rear outter exhaust manifold bolt, followed by the one in the middle (on top). Now if your manifold has "spread" as in my case, you will notice that the front hole (in the exhaust manifold) will not line up with the one in the head. I used a small 3/8" square metal chisel between the front exhaust manifold port and the intake manifold port. I then took a small hammer and started hammering the chisel down and the intake manifold spread apart just enough to get the bolt started. Loosely tighten that bolt down. Then, from underneath the vehicle, I place a fllor jack under the exhaust down pipe and kept jacking it up until all the other bolts lined up. Sounds simple, right? Only took this ol' fella a few days to finally figure it out, LOL :) Now I can't wait for this rain to quit so I can get out there and finish it up. Really anxious to hear it run on 4 cylinders for once, instead of on three, LOL :) All in all, had a great day :) Happy Trails everyone, Papa Mel :) Link to comment Share on other sites More sharing options...
mrmel2you Posted May 20, 2016 Author Share Posted May 20, 2016 Got everything buttoned up, checked--double checked--triple checked, all vacumn lines/electrical connections/bolts/nuts etc... Refilled the radiator (water and antifreeze) checked the plug gaps, plug wires etc.. Tried to start it up, that was a no go. Almost burned up the starter :( Took the cover off the tbi unit and below the butterfly found fuel puddling up in it. Now what??? Bad injector in the tbi??? Bad tbi unit??? Will do more checking on it tomorrow, this guy is beat. Link to comment Share on other sites More sharing options...
mrmel2you Posted May 20, 2016 Author Share Posted May 20, 2016 Did a little checking in the forums to get some info on the fuel puddling issue in the tbi. Then my "old school training" kicked in. I unplugged the injector, after a few cranks---it fired right up. Turned it off, plugged the injector back, starts right up and no more fuel puddling :) To say that I'm shocked with how this thing runs, after running on only 3 cylinders for who knows how long, is an understatement. Idles smooth, like a new, has a ton more pep, no knocking and not smoking (2 big pluses for me). Can't wait to get The Beast on the road tomorrow for a little drive around the lake :) Next projects---#1-tackling the cancer on the floorboards, #2-getting the exhaust system replaced, #3-shocks/brakes/tie-rods and ends/bushings/ball joints, #4-------gotta win the lottery so I finish 'er up, LOL :) Many many thanks to everyone for all the help and info, I could not have done without you guys :) You're all the BEST of the BEST :) Papa Mel is ouuta here for now, Happy Trails everyone :) Link to comment Share on other sites More sharing options...
mrmel2you Posted May 21, 2016 Author Share Posted May 21, 2016 Well, fired The Beast up today and took it for a spin around the lake today (Shawnee Co. Lake, Topeka, Ks.). Made it all the way out there and back with no problems. Turned the corner on our block and she stumbled a little. Made it up the drive and it died. Cranked it a few times, nothing. Noticed the left turn signal was not working, popped of the tbi cover and looked under the butterfly----dry as a bone, half tank of gas, can hear the fuel pump cycle with the ignition. Pulled apart all the connectors under the hood and cleaned them and put them back together. Checked all relays and fuses, checked out good. Fuel pressure is within specs at the tbi. On a good note though, while I was out for the drive, it ran like a new truck. It's a lot quicker and smoother running than what I was expecting it would. That's it for today, tomorrow is another day :) Happy Trails everyone :) Link to comment Share on other sites More sharing options...
DirtyComanche Posted May 21, 2016 Share Posted May 21, 2016 Weird that it died. CPS wires get routed wrong and burned/pinched? Link to comment Share on other sites More sharing options...
mrmel2you Posted May 21, 2016 Author Share Posted May 21, 2016 On all the connections that I unplugged, I used a piece of masking tape and labeled both halves as #1-#1, #2-#2 etc... Did not want to take any chances of mixing up any of the wiring connections. Did the same thing for all the vacuum lines also :) Even took pictures with my phone and a Canon camera of everything that I had to take apart, just to be sure :) As I said, it ran fine (for about an hour) the lake is only about 10 minutes away and takes about 30-40 minutes to drive around it. Only drove there and back home :( At a loss right now, but have company coming over and might not get to work on it until Monday. Will keep everyone posted :) Happy Trails everyone, Papa Mel :) Link to comment Share on other sites More sharing options...
mrmel2you Posted May 22, 2016 Author Share Posted May 22, 2016 Worked on The Beast for a bit today, had to take a break, had company come over. Went back out about 15 minutes later, it fired right up :) Not sure what the heck happened, but happy as a fat kid in a candy store right now, LOL :) Drove it around for a bit, still has a stumbling issue whenever I go to stop. Other than that, runs super smooth--peppy too :) Link to comment Share on other sites More sharing options...
benjy_26 Posted May 22, 2016 Share Posted May 22, 2016 I had a stumbling issue at stops on my 2.5. I used a BWD gasket kit and fuel pressure regulator from Oreillys and it solved that issue for the most part. I think it's in their catalog as a TBI rebuild kit. Link to comment Share on other sites More sharing options...
benjy_26 Posted May 22, 2016 Share Posted May 22, 2016 http://m.oreillyauto.com/h5/r/oap/site/c/detail/BWD0/10822/06289.oap?year=1987&make=Jeep&model=Comanche&vi=1181472&ck=Search_Throttle+body+repair_1181472_-1&search=true&keyword=Throttle+body+repair&reset Link to comment Share on other sites More sharing options...
benjy_26 Posted May 22, 2016 Share Posted May 22, 2016 I think that's the kit I used. Link to comment Share on other sites More sharing options...
mrmel2you Posted May 22, 2016 Author Share Posted May 22, 2016 Thank you for the link "benjy_26" will have to check into it and give it a try :) Hopefully it will help me out :) Link to comment Share on other sites More sharing options...
benjy_26 Posted May 22, 2016 Share Posted May 22, 2016 No prob. Hopefully it'll help some! Link to comment Share on other sites More sharing options...
Recommended Posts
Create an account or sign in to comment
You need to be a member in order to leave a comment
Create an account
Sign up for a new account in our community. It's easy!
Register a new accountSign in
Already have an account? Sign in here.
Sign In Now