MississippiComanche Posted October 30 Share Posted October 30 Hey my 2.5L Comanche has a pretty bad exhaust leak. I hooked up shop vac to my tail pipe and switched the vac to push out air. I immediately found lots of air wooshing out behind where the EGR tube connects to the exhaust header...so I have concluded that I need a header. I'm getting ready for a parts order. Here's what I got. Here is header I picked out, it comes with the gasket and hardware: https://www.rockauto.com/en/moreinfo.php?pk=292047&cc=1181472&pt=5860&jsn=13709 I am buying the Standard Motor Products 1605 Throttle Body Repair Kit. Thought this would be a great time to service the throttle body since I have to remove it from the intake manifold. I also picked out front right and front left motor mounts made by Anchor. https://www.rockauto.com/en/moreinfo.php?pk=315179&cc=1181472&pt=5552&jsn=13708 Can yall think of anything else I'm missing? Link to comment Share on other sites More sharing options...
eaglescout526 Posted October 30 Share Posted October 30 Looks like you have everything in order there. Hell I think I have a exhaust manifold laying around. And last I remember, Chrysler had maybe one or two left as NOS. But you got it all. I’d highly recommend ditching the gasket that comes with it and just get the intake gasket. I’ve had bad experiences with the full gasket not sealing or lining up right. But that’s just a recommendation. Also I like the vacuum idea of blowing air to find a leak….but I can see that blowing unwanted carbon and debris into the engine. Link to comment Share on other sites More sharing options...
MississippiComanche Posted October 30 Author Share Posted October 30 @eaglescout526 So you're saying they make a standalone intake gasket? What did you do for the exhaust gasket? Just make your own or do they have a separate one for that too? I just thought there was the full gasket. Link to comment Share on other sites More sharing options...
eaglescout526 Posted October 30 Share Posted October 30 I have the part number at home for the separate intake gasket. AMC didn’t put a gasket on the exhaust and probably due to the same reason I keep having issues with the full gasket. There is the full gasket but it’s not something Chrysler ever made for the 2.5L. Im not saying dont use the full one since it’s free with the manifold but I’m just more informing ya of the issues I have had. Link to comment Share on other sites More sharing options...
MississippiComanche Posted October 30 Author Share Posted October 30 Is this the part you are referring to? https://www.moparpartsgiant.com/parts/mopar-gasket-intake-manifold~53020112.html I'll leave the gasket off the exhaust header if you are 100% positive thats what I need to do. I consider you to be the 2.5 guru. Link to comment Share on other sites More sharing options...
eaglescout526 Posted October 30 Share Posted October 30 Yes that’s the gasket. I think the ship quantity is 2 of them but doesn’t hurt to have one extra. I am 100%. Save your less of a battle trying to get all the bolts in and holes lined up on the full manifold. Fun fact, there’s supposed to be a stud according to the parts catalog at the last manifold bolt. My 88 and 84 have not had them. Link to comment Share on other sites More sharing options...
MississippiComanche Posted October 30 Author Share Posted October 30 what kinds of issues have you been having with the full gasket? I'm assuming some leaking. Also do you have the original exhaust manifold or do you have an aftermarket one? Link to comment Share on other sites More sharing options...
eaglescout526 Posted October 30 Share Posted October 30 What I encountered was fitment issues, bolt holes not lining up, exhaust leak and vac leak. On the XJ during my trial of getting the engine to run from the swap, the intake portion was wet as if fuel was leaking and that was a problem. originals. They need to go through an electrolysis bath to see what shape they are in though now what I think about it. Link to comment Share on other sites More sharing options...
MississippiComanche Posted October 30 Author Share Posted October 30 I found this video on YouTube of a guy basically saying that all of the 2.5L aftermarket exhaust manifold flanges don't align with the intake manifold flanges....because they are cheap Chinese bs. Most of the aftermarket flanges are usually made too thick, and a few are made too thin. I will most likely have to do some grinding myself or take it in to a machine shop to get it to align properly. Link to comment Share on other sites More sharing options...
eaglescout526 Posted October 30 Share Posted October 30 Sounds about right. I’ve never bought a new one and just kept using my originals. So I see three options, new one from Chrysler fix your original or used. I almost wonder if HO guys have a problem but Renix may not. Link to comment Share on other sites More sharing options...
MississippiComanche Posted October 31 Author Share Posted October 31 It has a hole big enough to stick my finger in. I don't think there's a way to salvage the original exhaust manifold Link to comment Share on other sites More sharing options...
eaglescout526 Posted October 31 Share Posted October 31 Holy crap! What did you do?! Haha. Honestly impressive. Link to comment Share on other sites More sharing options...
MississippiComanche Posted October 31 Author Share Posted October 31 just the result of living in a wet subtropical climate and 36 years of rusting. Link to comment Share on other sites More sharing options...
MississippiComanche Posted October 31 Author Share Posted October 31 @eaglescout526 I found a thread on the Jeep YJ Forum explaining the same gasket situation you were referring to. https://www.jeepforum.com/threads/4-2l-exhaust-manifold-without-gasket.217206/ They said the intention is to have the head and exhaust manifold machined and then installed without a gasket. Also the reasoning behind the full gasket that auto part stores sell...is they don't think most people will go through the trouble of getting the manifold resurfaced. Link to comment Share on other sites More sharing options...
eaglescout526 Posted October 31 Share Posted October 31 Huh. I learned something new today. I mean most people don’t go and say I should get my manifolds machined when they have their head off for rebuild. Not something one thinks about. Link to comment Share on other sites More sharing options...
MississippiComanche Posted October 31 Author Share Posted October 31 I'm wondering if I will be able to seal an aftermarket exhaust manifold without the gasket. Link to comment Share on other sites More sharing options...
eaglescout526 Posted October 31 Share Posted October 31 I don’t see entirely why not. Link to comment Share on other sites More sharing options...
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