1980 Jeep Cherokee Chief build advice needed

[NorthMN]

After deciding that I’ll be taking off the manifolds and getting some great advice from all of you... I’m back for more.

After scanning through the forum I’ve decided to do a few more upgrades than I initially planned. All links to products will be below.

1) Take off exhaust manifold, paint, and apply gasket (came in 3 parts), and apply/torque in new bolts bought on alloyboltz. Will use Permatex copper on the gaskets as well.

2) In taking off the manifold I personally don’t see the need in the Air injector pump and lines since I don’t have emission test in MN. I’d like to remove this and utilize an emission block of bolt kit. As with all projects I’m sure it’s a little more involved than just ripping of the pump, bolts, and lines that run to the bolts. Any advice or information I’m missing would be greatly appreciated.

3) Since the exhaust manifold is coming off I might as well replace the intake manifold with an edelbrock intake manifold. This will allow me to potentially upgrade the carburetor from 2 barrel to 4 barrel later on down the line. Never done this so not sure what all it will take. If intake manifold is not replaced I’ll using the 2 barrel to 4 barrel carb kit.

4) Finally since no more emissions standards needs to be had a new muffler(no cat), and potentially new pipes will be added. If just the muffler I’ll do it myself, if new pipes are required I’ll take it to an exhaust shop.I would prefer the original Y pipe be used if I’m just replacing the muffler. New doughnut gaskets will be installed in exhaust flange.

As I’ve stated before I’m new to this asylum and just getting my mechanic skills. Any advice you have would be greatly appreciated. I’m a little tired of paying $800-$900 in mechanic bills for this Jeep and want to start working on it myself (within my comfort zone).

https://alloyboltz.com/product/amc-v-8- ... ifold-kit/

https://www.bjsoffroad.com/AMC-V8-Exhau ... _2000.html

https://www.bjsoffroad.com/AMC-Metallic ... int_p_2410. VM

https://www.bjsoffroad.com/Edelbrock-Pe ... p_663.html

https://www.bjsoffroad.com/Edelbrock-Pe ... p_662.html

https://www.bjsoffroad.com/Edelbrock-In ... _1907.html

https://www.bjsoffroad.com/Carburetor-T ... p_667.html

https://www.bjsoffroad.com/2-Barrel-Car ... p_557.html

My apologies I’ve tried uploading a few pictures of the Jeep to the forum and apparently the file size is to large.

[tgreese]

I suggest that composition gaskets for the manifold-to-head and the doughnut will not last long. Depends on how much you drive. The factory bolted the exhaust manifolds directly to the cylinder head, iron on iron. That seals fine and does not wear out. If you need to, have the manifolds surfaced at your local machine shop so they will seal to the head. Long-time exhaust leaks at the head will erode both surfaces and prevent this iron on iron seal. The doughnuts were also replaced with an iron ring - you may find that you have those iron parts already. They were available aftermarket - look around.

If you must use gaskets, I would suggest either copper header gaskets or Remflex gaskets.

Also realize that removing exhaust manifolds can be difficult. Broken bolts are common. In that case, I would remove the head or heads and have the local machine shop remove the remains of the bolt(s). Not that big a job to pull the heads, and gets into that intake manifold area that you are interested in.

[fulsizjeep]

Hi new guy! I can appreciate your comments regarding $800-900 mechanic trips. 20 years ago, I was facing serious money issues. Just about everything I did to two FSJs was done with used parts (even tires) and did the work myself. I will not rebuilt a tranny but leave that to the experts. I put two different used trannys in my GW before I took one to a rebuilder. It's been working great since 2007. That's too much work to have it fail within a couple months. <ramble off>

I have been driving FSJs since 1976. I have never bought a new intake. I have only ever bought one new carb. I can find good used intakes and carbs for half the cost of new or less. I don't get in a hurry in my search. It saves money.

On the intake gasket, consider this instead of what you posted:
https://www.bjsoffroad.com/Intake-Manif ... p_666.html

Consider waiting until you have an intake and 4 bbl carb on hand before you go there. I have never been a fan of the 4 to 2 bbl adapters.

Consider a Holley carb. If you will be doing much off-roading, make that a Truck Avenger. Most AMC V8s don't need more than the 470 cfm but you should be fine with the 670 also. They are easy to work on. Too me, Edelbrock carbs are wheel chocks. To each their own.

Your paint link is broken.
https://www.bjsoffroad.com/AMC-Metallic ... _2410.html

That's about it. Food for thought. If you go a different way, it won't hurt my feelings. Good luck with your projects.

[NorthMN]

Tegreese

This is my daily driver. I picked up a mechanic stethoscope and took a listen to the manifold and exhaust flange. Manifold might have a slight leak, but the flange for sure has a leak.

To my knowledge the manifold has never been resurfaced so I’ll take a look into that and try and find a machine shop near me that can do it! If possible I would like to avoid gaskets since every one on this forum advises against them if you can keep the original iron on iron connection.

As for the iron ring I’ll take a look. The engine was hot when I was using the stethoscope and couldn’t climb underneath to get a closer look at the exhaust flange. It definitely has a gap so I’m assuming (and hoping) that it has an iron ring or doughnut gasket in place. If not then I’ve got a massive gap on the exhaust flange. I’m trying to find the exhaust flange bolt size since I’m pretty sure they’ll break off when I try and take it off.

After scanning through these forums I’ve realized that snapped exhaust manifold bolts are common. I’ll do the normal measure of Pb blaster, then heat, then torque. I’ve also purchased a screw/bolt extractor kit so I hopefully won’t need to take it into a shop.

Thank you for your help I really appreciate it!

[NorthMN]

Fulsizjeep

I’m with you on I won’t even touch the Tranny and will let the pros deal with that if need be.

I’ll take a look into the gasket you recommended Thank you! I’m not going to start this project until I have all parts on hand. Only reason I was going to go with an edelbrock 4 barrel was because the intake was going to be edelbrock. This is my daily driver and wanted to increase the horse power a little bit so that’s why I was looking into upgrading the intake and carb. It has a new 2 barrel carb that I’ll still keep if I switch over to the 4 barrel. Since this is my only car I can’t just rip the engine out and do a full rebuild ally use projects need to be something I can do while it stays on the engine mounts which I why I went this route. I’ll take a look into the Holley carb. Sorry the pain hyperlink didn’t work https://www.bjsoffroad.com/AMC-Metallic ... _2410.html

Thank you for your help I really appreciate it!