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  #76  
Old January 29th, 2018, 18:10
Mikep_86441 Mikep_86441 is offline
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Re: Going Through a Beater XJ 4.0. Ugly but Warp Free

Glad to have these header cracks welded up !!

https://youtu.be/SI6Fxu3-Jng
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  #77  
Old January 29th, 2018, 18:10
Mikep_86441 Mikep_86441 is offline
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Re: Going Through a Beater XJ 4.0. Ugly but Warp Free Welds !

Glad to have these header cracks welded up !!

https://youtu.be/SI6Fxu3-Jng
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  #78  
Old January 30th, 2018, 05:32
Mikep_86441 Mikep_86441 is offline
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Re: Going Through a Beater XJ 4.0.

Quote:
Originally Posted by Ecomike View Post
That flat file is the only tool I would ever use, short of a machine shop... It is slow as hell, but that is good, as it limits over removal of metal, and shows you with each stroke where the high spots are!!!!

A strong word of warning, number one, I would bolt the Exh manifold to the head, before welding those cracks, as not doing so guarantees warping the manifold!!! Even then it may already be warped.

I have found that file to be an awesome (slow as hell) but awesome tool for getting the Exh manifold faces flat and parallel, but even then, I had to add a copper silicone covered, copper shim on top on the gasket to deal with a huge warped gap between the inner two tubes and the head on mine. Did that in 2007 and it never once leaked or cracked.

8Mud has also done this years ago, he coached me. Lastly do not remove too much metal on the faces as the bolts over lap the intake and exhaust manifolds and if you remove too much metal to get it flat and parallel the bolts loose tension on the manifold spot you sanded down!!!!

Files are a great tool for going slow. I keep an assortment for such occasions. The thermostat housing sure fit a lot nicer after some very minor freehand material removal.

As for the welding, I build up, probably over built up, the welding material on the repair. But it worked, except for a pinhole that I'll fix today. Didn't warp fortunately, even without clamping to the head. I'm a big fan of tack welds to help things stay straight. I haven't welded but one time in 2009 since 30+ years ago. So I was pleased, even though it's ugly. We'll see how pleased I stay after the first time the engine warms up.
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  #79  
Old February 6th, 2018, 15:30
Mikep_86441 Mikep_86441 is offline
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Re: Going Through a Beater XJ 4.0. Intake Carbon Removal !!

After watching some eye opening videos on how to remove carbon from an intake manifold, I finally found my own way using carb cleaner and paper towels. Check it out !!!

https://youtu.be/Gpz16Gy-VJA
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  #80  
Old February 16th, 2018, 16:32
Mikep_86441 Mikep_86441 is offline
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Re: Going Through a Beater XJ 4.0. Smoke/Fog Vacuum Leak Test !!

Finally got the smoke test finished to check the intake manifold for leaks before it's bolted to the head.

https://youtu.be/Zdmv215NaZY
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  #81  
Old February 17th, 2018, 18:01
Mikep_86441 Mikep_86441 is offline
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Re: Going Through a Beater XJ 4.0. Head, Manifolds Assembled !!

Gettin' there !!! The head and manifolds are bolted together !!

https://youtu.be/lwILOLI1I-o
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  #82  
Old February 25th, 2018, 22:58
Mikep_86441 Mikep_86441 is offline
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Re: Going Through a Beater XJ 4.0. PS Leak + Misc.

Details like leaking PS pumps get in the way.

https://youtu.be/vb4GDakpnGo
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  #83  
Old March 5th, 2018, 18:43
Mikep_86441 Mikep_86441 is offline
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Re: Going Through a Beater XJ 4.0. The head is back on !!

Dropped the cylinder head with manifolds back on the engine this afternoon. I'll torque all of the bolts tomorrow.

https://youtu.be/r45WHHpKrMk
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  #84  
Old March 6th, 2018, 15:59
Ecomike's Avatar
Ecomike Ecomike is offline
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Re: Going Through a Beater XJ 4.0.

Dropped? Ouch, LOL
__________________
Quote=8Mud: "Go ahead and put up the best fence you can build, I'll bet on some Mexican with a few dollars of nails and a pile of scrap lumber."
34 MPG , '85 2WD Cherokee Pioneer with custom installed, 64 hp, 2.2 L Nissan SD22 Diesel 5 spd Manual; & 4 Renix XJs, '87 Wagoneer 4.0, 4WD, 89-Cherokee, 4WD, '87 Cherokee 2WD, & '89 Cherokee Pioneer 2WD, all 4dr. #2091
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  #85  
Old March 7th, 2018, 17:23
Mikep_86441 Mikep_86441 is offline
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Re: Going Through a Beater XJ 4.0.

The head was carefully torqued down today. Had to modify a couple of sockets so the rear most head bolt could be reached with a torque wrench.

https://youtu.be/wfAU_bbj7Uw
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  #86  
Old March 12th, 2018, 15:44
Mikep_86441 Mikep_86441 is offline
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Re: Going Through a Beater XJ 4.0. Oil Pump Primed !!

Made an oil filter strap wrench for tight places. Also got the oil pump primed !!

https://youtu.be/atlZ9dapzHs
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  #87  
Old March 15th, 2018, 21:15
Mikep_86441 Mikep_86441 is offline
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Re: Going Through a Beater XJ 4.0.

The '88 4.0 is running again! Oil pressure was just under 40psi when the temp was almost to 210. Only a test drive will tell. The new lifters rattled for about 3 seconds on the first startup. I did pump them up by hand and prime the oil pump before startup. They are very quiet now. Just have a heater hose leak, and need to replace the track bar. I can actually hear the leaky muffler now since I welded up the header cracks. Hopefully the welds will hold up. Need to find a super quiet muffler. Broke a lot of the plastic vacuum lines when I pulled the head. All of that needs fixing too.
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  #88  
Old March 18th, 2018, 22:51
Mikep_86441 Mikep_86441 is offline
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Re: Going Through a Beater XJ 4.0. Knocking Cured !!!

Silent running !! Lots-O-Power !!!

https://youtu.be/K-RoYazr08Y
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  #89  
Old March 20th, 2018, 18:27
Mikep_86441 Mikep_86441 is offline
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Re: Going Through a Beater XJ 4.0. Hot Staple Fan Shroud Repair !!

I was reaching back towards the firewall when I munched the aux fan shroud!!

Here is the DIY Hot Staple/Plastic Welding Repair video !!

https://youtu.be/-AnpFsiNQb4
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  #90  
Old March 26th, 2018, 21:15
Mikep_86441 Mikep_86441 is offline
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Re: Going Through a Beater XJ 4.0. Test Drives !!!

The '88 XJ 4.0 made it's first run into the hills yesterday. Tons-o-torque. Smooth as silk. Today it made a highway run. Full throttle acceleration was crazy good ! As I climbed towards my destination, it started warming up. Got to the red zone on the gauge pulling a grade. Pulled over into a parking lot, looked her over. The overflow bottle was empty. Full yesterday. No leaks found. Hoses were very firm. It only took 10 minutes to cool down with the stock aux fan running. So off I went up the next grade at 80% throttle. Runs so nice. Temp rose some, but didn't over heat this time.

All of the time in town, way under 210 on the gauge in 60 degree weather. Pulling the grade out of town, warmer, but didn't overheat, until the long slightly uphill highway at 75mph. Then it over heated to the red zone on the gauge, again. Pulled over on a side road. Climbed a burm nose up, and then tail up to try and purge some air in the cooling system. Nope.

Started running warmer on the highway so I slowed down eventually to 55mph. Temp ran about 20 degrees past 210 if I kept it at 55. Any faster and it would get hotter. So 55 it was.

All new cooling system parts. Radiator was rodded out. Why so hot only at highway speed? Acts like a collapsing hose to me. Well?
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