Not thrilled to find this power steering pump leaking. But it has to be fixed anyway. Now is the easiest time to make the repair since the intake manifold is out, it leaves a lot of room to get this distraction fixed !!
Had to use a crowsfoot to reach the center manifold bolt. After tightening down all of the manifold bolts, it’s clear to me now that assembling the head and manifolds off of the engine is far easier and more accurate.
The fog test was an excellent final test for vacuum leaks on the intake manifold. All openings were sealed up with tape first, then 2 or 3 psi of compressed air was used to pre-check for gross leaks, which worked very well !! I used a stethoscope to listen closely for hissing produced by leaks. A piece of tubing held to the ear would also work. Now I’ll have high confidence that the intake is leak free once it’s bolted to the cylinder head.
An important step in prepping the intake manifold for the 4.0 Jeep engine, is to remove all of the carbon inside the first 2 inches of the intake runner, and especially the fuel injector ports. This carbon is soft and doesn’t require fire or even oven cleaner. Just a little carb cleaner, a few paper towels, and a hack saw blade, as you will see. There is no more carbon after the first 2 inches.