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    Jeep starts and idles for a minute, then sputters out

    good job ! thanks for following thru to the end and posting the final remedy
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    Starting issue

    sounds like my 91, my fix was exhaust leaks. check the torq on your exhaust manifold and look for cracks on the underneath side of the maifold
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    Jeep starts and idles for a minute, then sputters out

    does your fuel gauge on your dash work ? Your Fuel Gauge is a good indicator of the condition of your In-Tank Submersible Electric Fuel Pump Ground ! Turn your Ignition key to the On position with out starting the Engine. If the Fuel Gauge moves to the full position and stays there and...
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    Jeep starts and idles for a minute, then sputters out

    Harbor Freight sells a $16.00 Vacuum/Fuel pump Tester. It's well worth the price considering it will take the guess work out of the question for the rest of your life! Check your exhaust system for proper torq/cracks/leaks or warps up stream of the Oxygen Sensor. If air is entering the system...
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    Failed CA Smog

    good job my friend
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    Failed CA Smog

    doubt it's just the gasket but you'll see , I don't remember how many Expansion Plugs are under the gasket but make sure you you scratch and scrape and poke them with a sharp object to look for weak spots. Now is the time to replace them . I Think they were 3/4" plugs. I'll be in San Jose on...
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    Freeze plugs

    I just did this repair. I used the copper plugs with the lip and put a light layer of sealant on the plug to aide the installation. clean the hole in the block with sandpaper. the ones under the bellhousing were not leaking so I left them alone. Make a note that one of the plugs under the...
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    Failed CA Smog

    yup, same thing happened to me. My Tech said to look for exhaust leaks between the combustion cylinder and the o2 sensor, So it looks like your vaccum cleaner diagnosis is spot on. I removed my exhaust manifold and found 3 major cracks on the underneath side, I purchased a new manifold from...
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    Exhaust manifold replacement: what else should I do at the same time? Share some wisdom & save me some time

    tease me all you want ...I'm just glad to see there's 4 active members on this Forum :ROFLMAO::sleep:
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    Exhaust manifold replacement: what else should I do at the same time? Share some wisdom & save me some time

    oops , I posted the wrong info.... the block expansion plugs are 1 3/4 "
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    A Repetitive Manifold Problem

    My "91" had two of the cupped washers missing. I didn't want to go to the hasel of locating new ones so I simply made my own ! I chucked up a 3/4" or 7/8" Hole saw in my drill press and drilled two plugs from a piece of 3/8" flat plate . the result was two Discs 3/4" in diameter with a hole in...
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    Exhaust manifold replacement: what else should I do at the same time? Share some wisdom & save me some time

    No it's not hard at all .yes the discs, on my "91" the large ones were 2'' AND THE SMALL ONES under the Exhaust Manifold Gasket on the Head were 3/4" . Drain coolant and simply drive a flat screw driver thru the Brass freeze Plug and pry out old plug. Clean the block opening with a wire wheel...
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    Trying to diagnose an exhaust manifold leak on 89 YJ 4.2

    attack a small piece of toilet paper to a stick and hold it by the suspected leak. An exhaust leak will blow and flutter the toilet paper ! you'll have to get creative to block the fan breeze or just remove the belt during the test
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    Exhaust manifold replacement: what else should I do at the same time? Share some wisdom & save me some time

    straight edge the mating surface of both your exhaust and intake manifold. I found both of mine to be out of tolerance and used my 48" floor mounted Belt sander to dress the mating surfaces. cranking down the bolts to seal a crooked exhaust manifold is a prim reason for a cracked exhaust...
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    Exhaust manifold replacement: what else should I do at the same time? Share some wisdom & save me some time

    exhaust leaks between the combustion cylinder and the O2 sensor will not pass a smog check . The 02 Sensor sees the fresh Oxygen entering through the cracks by way of the Venturi Effect and adds more fuel to the mixture to compensate for the misinformation. the results are a rich fuel mixture...
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    YJ runs fine for 10-20 miles, then hesitates, sputters, and stalls

    Don't discount this possibility ! take your coil off and shake it. Mine rattled and I replaced it. Also I haven't seen anyone suggest checking Vaccum , If you don't have a gauge..... take a picture of the throttle body where all the Vaccum lines connect. Leave the fuel pressure regulator and...
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    Have you seen pre-fabricated parts to move seat / slider closer to wheel - 1992 Wrangler

    I have a 91 yj and had to move the stock seat back 2 or 3 inches. I simply re-drilled the 4 holes in the top of the seat pedestal and re-mounted the seat farther back. Ask your Hubby to remove the 4 nuts holding the seat down and pull the seat out, you might be able to reposition the holes far...
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    Loss of power

    No Joy. I still had a flat spot. And when I wiggled the CPS plug I caused a major miss at Idle. I removed the CPS plugs nut and keeper from the fuel rail and moved the Wire loom to experience a total power loss to the spark plugs. looks like a replacement female CPS connector is the next step. I...
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    Loss of power

    I replaced, plugs, plug wires, Distributor Cap and rotor. that made a remarkable difference but there's still a small flat spot at high RPMs. I have an o2 sensor ordered for pick up today. I'll install that and then clean the Throttle Body weather it need it or not and post my results. ( No CEL...