Fixing oil leaks
 

I finally started getting into the engine last night to fix some oil leaks. I did not know where they were coming from, so I figured I would do all the usual problems and see where that gets me. The oil leaks were pretty bad, the whole engine was covered so I was not sure where to start, plus it would leave 3" spots every time I parked it, so I figured a good top to bottom was in order. I replaced the rear main seal, but probably did not need to, and while I was down there I changed out the oil pump and put a mopar pan gasket on there. Everything went really smooth other than the exhaust bolts that I broke and need to replace, but that is to be expected for a 1997.


Now my questions:

First: I am going to get the oil pressure sending unit and install one. I think that the cheapo part has a 1 year warranty, and only takes 5 minutes to install. Anyone have recommendations on this part, or should I go with the $60 mopar part? I usually stick to OEM parts for electrical and sensors, but in this case I could buy 3 and I have not found any places where people have had problems with the auto parts store branded part.

Second: If the plenum pan gasket is going out, what is the best long term fix for this? I did see a thread somewhere where the guy replaced the pressed steel pan with a billet aluminum one. Any recommendations about what to do here? I am going to do everything else first and see if I can get the leaks to stop and clean up. But if there is still a leak I will set aside a weekend and pull the intake manifold off. I'm fine with keeping the stock pan, and probably RTV sealing the crap out of it with high temp if that would work better than the stock gasket. I have read about 10 threads where swapping out the gasket either did not work, or lasted a year or so before it started leaking do to the pan being warped.

Assuming 4.0L?

What about your Valve cover gasket? Oil flows down hill. Also if you have the 90 degree oil filter adaptor the O rings go bad on those, I think there are ways to get rid of it all together.

The OP has a '97 5.2L vehicle.

There are two TSB documents that are important for the vehicle.

One is the TSB 09-05-00 for the intake plenum pan gasket.

The other is the TSB 18-48-98 for the spark plug wire routing.

Both should be properly performed. Each fixes known problems.

Replace the intake manifold bolts during the TSB. They are single use parts because they stretch when tightened. I used the linked Fel Pro parts.

On mine, I chased the holes and bolts w/ a tap and die to ensure they could be tightened properly and not bottom in the bore before grabbing the plenum plate.

Assuming that means the wye pipe flange to exhaust manifold bolts.

On mine, I had to cut those bolts, replacing them w/ McMaster-Carr armor coated bolts, washers and nuts. These are 91286A213, 93827A225 and 98180A130.

The Mopar 4004 0001AB retainers is a BIG help for assembly.

The parts are shown in the image URL.

The passenger side rear bolt is best assembled w/ two talented mechanics, or one w/ luck and two long extensions.


http://i101.photobucket.com/albums/m52/wingless-pics/Jeep/Engine/4004%20001AB%20Exhaust%20Tee%20Nuts%20McMaster%209 1286A213%2093827A225%2098180A130.jpg