ZMotorsports Shop Projects 2.0

[zmotorsports]

My son and I made some good progress last night on the WJ, then my DIL brought my grandson over to visit while we worked, and the Jeep became second priority for the night. He kept pointing to things in the engine bay saying "oooh" and "what's that sound" when I'd zip a bolt out with the cordless ratchet. He's such a curious and inquisitive little guy for only being 14 months old. I hope to be able to spend many, many days in the shop with him as the years go on.

Picking up where we left on the night before, now all of the wiring is disconnected and laid to either side of the engine bay. Coils are all removed as well as the fuel rails and injectors.


Next the intake manifold is removed and access to the engine dipstick was then exposed so that was removed. That stinkin' thing was stuck in the block pretty good. Removing it while trying not to damage or bend it was a chore in itself.


Then the A/C condenser was separated from the radiator and the radiator removed exposing the front of the engine and this should give us enough room to pull the engine.


Last item for the night was removing the water pump and installing a lifting chain after removing the final two bell housing bolts just behind the intake manifold as they were much easier to access from the top with the intake out of the way.




Thanks for looking.

 

[PugetDude]

Getting close...
You will be staring into the abyss soon.

 

[Xti04]

Didnt realize the 4.7s had that issue. Always dreaded the 5.7 lifter rattle and cam replacement.

 

[zmotorsports]

Getting close...
You will be staring into the abyss soon.

Thanks Scott. Yeah, should be out soon, then we can clean and address a few of the wiring looms before going back together. We also will be pulling the dash to replace the A/C evaporator and heater core as the fasteners on the engine side of the firewall will be much easier to access now. I think there will be some waiting for parts, but we have plenty to do until they arrive.

Didnt realize the 4.7s had that issue. Always dreaded the 5.7 lifter rattle and cam replacement.

I think the 4.7's get a bad rap about the valve seats and timing chain issues that plague the interwebs.

Personally, I don't think they're a bad engine at all and feel the biggest issue or issues arise after they get overheated or using extended service intervals. Proper routine maintenance and taking measures to avoid overheating and these engines last quite a while. This one has over 200k miles but yet on many of the Jeep or Ram forums a lot of people report engine failures in the 120k-160k mile range due to one of the above-mentioned conditions.

I guess that could be said about many engines though. Proper maintenance and operation are key, even when some reportedly do have some known failure points.

 

[Jgaz]

Thanks Scott. Yeah, should be out soon, then we can clean and address a few of the wiring looms before going back together. We also will be pulling the dash to replace the A/C evaporator and heater core as the fasteners on the engine side of the firewall will be much easier to access now. I think there will be some waiting for parts, but we have plenty to do until they arrive.



I think the 4.7's get a bad rap about the valve seats and timing chain issues that plague the interwebs.

Personally, I don't think they're a bad engine at all and feel the biggest issue or issues arise after they get overheated or using extended service intervals. Proper routine maintenance and taking measures to avoid overheating and these engines last quite a while. This one has over 200k miles but yet on many of the Jeep or Ram forums a lot of people report engine failures in the 120k-160k mile range due to one of the above-mentioned conditions.

I guess that could be said about many engines though. Proper maintenance and operation are key, even when some reportedly do have some known failure points.

I heard all the same things when I owned my 2001 Dakota with the 4.7 motor. I owned it for 14 years and 178k miles with only a water pump replacement and a set of fuel injectors. Didn’t use any oil.

My nephew then drove it to about 215k with no issues before he sold it. He was seeing increased oil consumption at that point though.

As with most internet info YMMV

 

[zmotorsports]

I heard all the same things when I owned my 2001 Dakota with the 4.7 motor. I owned it for 14 years and 178k miles with only a water pump replacement and a set of fuel injectors. Didn’t use any oil.

My nephew then drove it to about 215k with no issues before he sold it. He was seeing increased oil consumption at that point though.

As with most internet info YMMV

You don't hear nearly as many stories like that compared to all of the ones that had catastrophic failures for "no reason". My son was told it would blow up any day when he bought it 7 years ago with 170k miles on it. It was using just a small amount of oil when he purchased it but over the last year it got substantially worse, to the point you can see a hint of it at times as well as smell it now. For the six years prior, it was about a quart per oil change (3k) miles, which is actually considered normal in many circles.

As many of these 4.7 liters are out there and how many Chrysler models they were used in, I can't criticize them too awfully much.

 

[Bigblue&Goldie]

We pre-ran the Baja 1000 this year in a ZJ Jeep Speed build with a bone stock 5.9L. My buddy has been ringing this thing's neck out for years. I asked him how many miles were on it and he said it had over 300k miles before the odometer was disconnected! Granted, the thing leaks like a sieve, but I about fell over when he told me that! I was also nervous as hell going out to BFE Mexico in the middle of the night with a 300k mile motor until I realized that's probably 75% of the cars down there.....

 

[JCQuick]

Well its out I'm watching now this is good video. Seems like at the start you seemed a little nervous ATTN fellow Z watchers the TB tours video is out

 

[Scuderia-F1]

Well its out I'm watching now this is good video. Seems like at the start you seemed a little nervous ATTN fellow Z watchers the TB tours video is out

Best episode EVER on that channel!

 

[JCQuick]

Took me a while to watch the whole thing but it was fantastic. Only thing I was disappointed in was no mention of the steve O / GJ bench idea but he did mention the GJ at the start Great video

 

[SilverJimmy]

Post a picture of your original 9/16” and 7/16” combo wrenches. I probably have the matching 1/2” wrench. I can swap ya if you want that Disturbance in the Force to be calmed…

 

[ptt49er]

Awesome shop @zmotorsports!

Link...

 

[Ralf99]

Congratulations on the video Mike, both you and your shop come across a treat.

 

[PugetDude]

Great video, Mike!
Much better looking on camera... (you, and the shop!)

 

[Mr.zippy]

I just finished the video Mike, it was perfect! I thought I was the only person that saved chopsticks, lol. I use them all the time!

 

[zmotorsports]

Well, it's been a busy day but I finally got a chance to watch the TBT video that Dustin did.

I was very happy with the way it turned out.

I appreciate the comments.

Here's a link to the video.

 

[TJT]

I'm a subscriber to that channel and I started the video before reading the title. Chuckled to myself that I recognized you from here.

Then spent the next hour hoping you'd talk about the US General boxes in the custom bench.

Awesome interview/tour, thank you for sharing.

 

[richfinn]

I stumbled across this YT video yesterday, I should have really known you were a GJ guy when you started talking about torquing carburettor screws , cool looking place you have there

 

[steves_001]

Awesome Video! Was fun to watch. You certainly have some interesting tools for all the stuff you work on.

 

[bigdave_185]

Well, it's been a busy day but I finally got a chance to watch the TBT video that Dustin did.

I was very happy with the way it turned out.

I appreciate the comments.

Here's a link to the video.

Wonderful morning coffee video to watch Mike! That’s always neat to hear the stories behind the tools.

 

[FranksGarage]

Mike really well done as always. Every time I watch a toolbox tour of yours I see a few more tools I need. The Holly carb tools and the Kent Moore turbo boost pressure gauge this time.

 

[zmotorsports]

Thank you for all of the kind words guys. I am flattered by the outpouring of comments.

For once, I don't have much to say, other than I very much appreciate all of the comments.

 

[zmotorsports]

Not one to rest on my laurels, I guess it's time to get back to work now and get my head out of the clouds.


I hope everyone had a great weekend and as I went about my work over the weekend, I had such a great feeling of happiness, even before I saw the video. Maybe it was the fact that my wife and I have our 35th Anniversary coming up in a few days and our son and DIL have their fifth coming up in a few weeks, however, I think much of it was the Memorial Weekend with the sense of pride, patriotism and even As I went about my work all weekend, I just couldn't help but to think about all of the men and women who have fought and sacrificed and continue to fight and sacrifice each and every day so that me and my family can have the opportunities that we do.

I want to thank all of those in the military and those that have been in the military for their dedication and devotion to this great country in which we live in. Even in the turmoil and unsettled environment we are in today, this is still the greatest country in the world and opportunities exist here that do not exist anywhere else. All because of those who have fought and continue to fight for those rights and freedoms.

Friday night I arrived home from work and went straight to work edging, trimming and mowing the lawn. My plan was to be done before the wife arrived home from work so we could have some dinner and sit on the deck and relax. That didn't quite work out the way I had planned.

After edging, I made it about 3/4 the way around the yard with the line trimmer when it ran out of line. No worries, I keep a roll of nylon trim line on hand and it's a rather quick job to remove the end and rewind some line onto the hub. First pull after adding line and the stinkin' pull rope snapped. For hell's sake, I think I have replaced all of the pull ropes on almost every piece of OPE of mine over the past few months now. With that being a bit bigger job to split the motor from the shaft, I grabbed the Stihl line trimmer that I got from my BIL last year and rebuilt. This was the first time using it and to be honest, I don't like it so it's going up for sale.

I was just barely walking around the yard with the walk-behind mower when the wife arrived home from work so I was definitely running behind according to my plan. Oh well, it was nice to just mow the lawn and enjoy the yard knowing the wife was sitting on the deck and she was home.

Saturday morning the rain started so before my son came over to pull the engine from his Jeep, I thought I'd hurry and replace the pull rope on the old Homelite line trimmer.

Motor removed from the shaft and cover which housed the pull rope removed.


New pull rope installed and end melted.


Before reassembling, I grabbed some SD-20 degreaser and thoroughly cleaned the housing as it was pretty dirty inside.


Fully reasssembled, tested and hung back on the wall in the garage.



About that time my son arrived so we picked up where we left off on his Jeep a couple nights earlier.

 

[zmotorsports]

With the 4.7 liter disconnected it was time to ****** it out of the engine bay.

Unfortunately, the motor mounts were the hang up. Once they were removed the engine easily came free from the transmission bell housing.


Pulled forward to the core support and it looks like it will easily clear the firewall as well as both sides.


Almost out. We did have to remove the front tires/wheels in order to set the nose down low enough for the oil pan to clear the core support.


And it's out.


Bolted to the engine stand for disassembly.


We were pleased to see how good the inside looked as we opened it up.


The cams showed very little wear and the inside had that nice gold tinge from the oil.


Only a very small amount of sludge or carbon buildup was present, and this was near where the PCV pickup joined the oil spout.


Timing chains and components showed very little wear as well. The guides barely had a few wear marks visible and nothing was damaged or pieces missing.


Even the coolant passages were relatively clean.


Stay tuned for more pictures.

 

[zmotorsports]

Continuing on with the inspection.

When we started pulling things off the top of the engine while still in the engine bay, we did notice that on top of the front timing cover between the heads there was some oil buildup so we wondered where the leak was coming from. I think we discovered it. Looks like oil has been leaking past the gasket in this area as it has shifted slightly from the casting.


My son then continued on by removing the oil pan.


A little sludge in the bottom of the oil pan but not what I could call bad at all. This actually could have been from the first 170k miles, before my son purchased it as I know he has been religious about his oil changes for the past 7 years that he's owned it.


Pickup tube and windage tray next to be removed.


Nothing in the pickup tube. That was a good find. We do have a new pickup tube coming as we weren't sure what it would look like inside, but we were pleased to see how clean the screen looked.


After removing the windage tray the connecting rods looked great as well. Nothing felt sloppy or like there was no slop or play in the rods to crank.


I actually hadn't noticed until my son turned the engine a bit to start removing the oil pan, that this engine was in fact a bed plate engine.



Stay tuned for more pictures.

 

[zmotorsports]

Last of the pictures for today.

One last thing we wanted to inspect was a cylinder and some valves. Cylinder #4 spark plug removed and showed no real carbon buildup on the plug.


Boroscope in the intake revealed no real carbon deposits on the intake valves either.


Very little in one area.


Cylinder didn't look great, but not terrible either. About what one would expect from 206k mile engine that was starting to burn a little oil.


Swapping the engines around to put the new one on the stand for assembly.


Wrapped up and ready to clean parts and start reassembly of the covers.


Old one crated back up and loaded on the trailer for return.



Thanks for looking.

 

[Jgaz]

I love looking at the background of your shop in the pictures.
So much red toolbox goodness and I’m so jealous of the “elbow room“ you have.
Thanks for posting

 

[zmotorsports]

I love looking at the background of your shop in the pictures.
So much red toolbox goodness and I’m so jealous of the “elbow room“ you have.
Thanks for posting

Thank you. I do have a bit more room here but it still felt like it's filled up quick. I have to remember how tight my last shop was as it seems like many times I had to go outside just to change my mind.

 

[PugetDude]

Last of the pictures for today.

One last thing we wanted to inspect was a cylinder and some valves. Cylinder #4 spark plug removed and showed no real carbon buildup on the plug.


Boroscope in the intake revealed no real carbon deposits on the intake valves either.


Very little in one area.


Cylinder didn't look great, but not terrible either. About what one would expect from 206k mile engine that was starting to burn a little oil.


Swapping the engines around to put the new one on the stand for assembly.


Wrapped up and ready to clean parts and start reassembly of the covers.


Old one crated back up and loaded on the trailer for return.



Thanks for looking.

It's a great day on the GJ when we get to see BOTH Z's using an M12 cordless tool.

 

[zmotorsports]

It's a great day on the GJ when we get to see BOTH Z's using an M12 cordless tool.

I don't know about that Scott. Rare day is a more accurate phrase than great day.

 

[PugetDude]

I don't know about that Scott. Rare day is a more accurate phrase than great day.

Perspective, Mike. I see it as a major step in your personal growth.

 

[aka Larry]

Mike maybe I missed it, but what's the reason for the new engine? Was the old one getting tired or is it just an upgrade?

 

[customh]

Mike maybe I missed it, but what's the reason for the new engine? Was the old one getting tired or is it just an upgrade?

You don't hear nearly as many stories like that compared to all of the ones that had catastrophic failures for "no reason". My son was told it would blow up any day when he bought it 7 years ago with 170k miles on it. It was using just a small amount of oil when he purchased it but over the last year it got substantially worse, to the point you can see a hint of it at times as well as smell it now. For the six years prior, it was about a quart per oil change (3k) miles, which is actually considered normal in many circles.

As many of these 4.7 liters are out there and how many Chrysler models they were used in, I can't criticize them too awfully much.

A little hidden in the post above.

 

[aka Larry]

A little hidden in the post above.

Thanks for the heads up!

 

[ScepterToad]

Really cool video on the shop there Mike! Well done!

 

[TimeWarpF100]

Great video Mike!
"Nothing like having a place for everything and everything in its place"

My wife reminds me of that all the time but I simply to not have room much less trying to get it all organized.

 

[aka Larry]

Cool video Mike. Glad I knew it was you otherwise I would have thought I was watching the worlds longest Snap-On commercial...LOL.

 

[zmotorsports]

Cool video Mike. Glad I knew it was you otherwise I would have thought I was watching the worlds longest Snap-On commercial...LOL.

Oh come on Vincent, I think I showed a tool or maybe two that weren't Snap-on in my toolbox. My wife thinks I have a problem. I don't understand what she's talking about.

 

[SilverJimmy]

What I liked was seeing all the same tools that currently I have. What I didn’t like was seeing all the tools that I don’t have….
And now I might need a bigger box!

 

[zmotorsports]

What I liked was seeing all the same tools that currently I have. What I didn’t like was seeing all the tools that I don’t have….
And now I might need a bigger box!

Funny story Sterling.

While my son and I were working on his Jeep the other day, my DIL brought my grandson over to hang out in the shop with us while we worked. I LOVED it and loved watching him absorb everything (that's not the funny part though).

My wife heard us out there with my grandson so she came out as well. My son was putting an air tool back in the drawer and made a comment about how it didn't fit and the drawer would hit them when closing. I just off-handedly mentioned that "yeah, it's a tight fit and things have to go in a certain order and orientation as I am out of room in my toolbox".

My DIL said "oh, I bet Snap-on makes a bigger toolbox". Without evening blinking my wife told her to be quiet.