Novak Conversions Jeep Wrangler TJ radiator

Advice needed, 97 TJ 2.5 with coolant in oil

Tooonz

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. Hi let’s start with I have a 97 TJ my son drives. It has a 2.5l with approxi. mately 165K on it. Jeep was extremely clean when we bought it. Ran great. Noticed it had a slight radiator leak,
So I put a fairly new radiator from a friend who was parting out his jeep, when I swapped the radiators I noticed the coolant or lack of coolant in the original radiator was rust orange.
So when I swapped them I flushed the heater core and lines, put fresh coolant in and everything seemed normal. Until winter came.

That;s when we noticed he didn’t have good heat. I flushed the core again replaced the coolant that was low and he would get good heat for a while…until it happened again. This time I flushed it again, each time I noticed orange crap coming out until it flowed clear. Put fresh coolant in got heat back and away he goes again. This was a bi weekly event. I figured at some point all the crap would flush out of the engine. I contemplated an engine flush but damn it was cold outside this winter. So I kept doing a quick flush of the heater core which usually yielded the results we needed. Then all of a sudden I started noticing each time his heat would stop working the coolant level was low. Not crazy low but a little low. Thinking maybe it was a loose clamp or just from the constant flushing maybe there was an air pocket. This progressed until one night he texted me that the engine temp was in the red line and check gauges light came on. I filled it back up with coolant, only to the next day while he wa s on the way to school it died. I went to see what was going on, it was running shitty, coolant seemed a little low but not concerning. I drove it home.

Friend of mine, told me to bring it to his shop, he thought we should change the thermostat, I didn’t think the stat had anything to do with it but out of respect for him letting me use his shop we changed the thermostat. While it as running he said I noticed an exhaust leak let’s putt it up on the lift and see what’s wrong. At that point under his jeep I asked what the hell is that noise coming from the oil pan, it sounded like a “ wooshing “ sound. He said have you checked the oil… we put the jeep down, pulled the dipstick and voila, coffee milk shake.

we pulled the head, and after inspection, unfortunately I didn’t see any points on the head gasket that were obvious, no sign if coolant being burnt in the cylinders or the exhaust ports. So I searched for anyone who still would magnaflux a head, only to find a guy who could only pressure these it . So while I’m waiting to get any news if there is a crack in the head or if it is warped I figured I would post here and see if I can get any advice on this topic.

We certainly have coolant in the oil for sure “ see pics “ I can’t imagine over heating once would crack the block however there aren't too many options on how coolant gets into oil. .

did these 2.5’s have any known issues related to blocks cracking? Or head? Anything else to look for?
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The coolant can only get in because of a cracked head. And maybe by the thermostat housing bolt but I am not sure if it goes all the way through like it does on the 4.0.

But I see another issue...your plugs are jacked.
 
The coolant can only get in because of a cracked head. And maybe by the thermostat housing bolt but I am not sure if it goes all the way through like it does on the 4.0.

So on the 4.0 it's possible for coolant to get into the oil through one of the T-stat housing bolts? I'm really interested in this because I have a new cyl head but still seeing a trace of coolant in the oil. If I recall I used the paper gasket on the stat but I don't remember if I used any sealant, or if I did I don't know if I applied it completely around each bolt hole.

Looking at the cyl head diagrams though it appears as if the threaded holes only go into the water jacket.
 
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The coolant can only get in because of a cracked head. And maybe by the thermostat housing bolt but I am not sure if it goes all the way through like it does on the 4.0.

But I see another issue...your plugs are jacked.

Yeah the plugs got jacked when we pulled the head. Must’ve hit something .
 
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So on the 4.0 it's possible for coolant to get into the oil through one of the T-stat housing bolts? I'm really interested in this because I have a new cyl head but still seeing a trace of coolant in the oil. If I recall I used the paper gasket on the stat but I don't remember if I used any sealant, or if I did I don't know if I applied it completely around each bolt hole.

Looking at the cyl head diagrams though it appears as if the threaded holes only go into the water jacket.

You may be correct. I know the bolts can cause a leak, which is stupid. I certainly could be mistaking as it has been a while since I have had a head in my hands.

A bad gasket will let the two mix.

It may take a couple quick oil changes to get the water out. There is always a trace which gets burned off as the engine runs.
 
So I found out the head was cracked., I'm looking for another head, does anyone know if a 98 head will fit on a 97 without any issues?
 
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Every time the heat went out it was because your coolant level dropped low enough that it wasn't circulating. And based on your description, this has been going on a while.

Crankcase milk shake has poor lubricating qualities. While it's in the shop and things are disassembled, drop the pan and look for trashed bearings/crank. And I would do that before I ordered a head.
 
I havent looked at the 4 cylinder engines. How is the engine so much more condensed. The 6 cylinder has alot of room in the wrangler bay. Anyway this is what i noticed idk what all yellow sulfer looking junk is, but that corner insert is clearly evidence. You have all that yellow, and then the same yellow there but how would a simple gasket leak, cause a weeks need of coolant?! I have a heater core leak and i waste a cup of coolant a month...
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Honestly, i wonder if your son is using 85 octane or doesnt know how to add oil or coolant properly. Did he dump coolant into the oil port?
 
Every time the heat went out it was because your coolant level dropped low enough that it wasn't circulating. And based on your description, this has been going on a while.

Crankcase milk shake has poor lubricating qualities. While it's in the shop and things are disassembled, drop the pan and look for trashed bearings/crank. And I would do that before I ordered a head.

I think his son put coolant into the oil port.
 
I think his son put coolant into the oil port.

So the saga continues… it was a cracked head , I bought a machine es head locally from an automotive machine shop, which turned out to be machined too much, which in turn caused some damage to a lifter. I sourced another engine and used the head off of that, got the jeep running , found the bad lifter after replacing it the engine ran perfect with one major exception . When the engine would get up to temp I would lose all oil pressure. I checked with an external gauge and it was in fact loss of oil pressure when hot. I hoped and replaced the oil pump but in the end I was not able to get oil pressure back. So this weekend I’m pulling the engine. There must be too much damage from that worn lifter all that metal had to go somewhere .
 
So the saga continues… it was a cracked head , I bought a machine es head locally from an automotive machine shop, which turned out to be machined too much, which in turn caused some damage to a lifter. I sourced another engine and used the head off of that, got the jeep running , found the bad lifter after replacing it the engine ran perfect with one major exception . When the engine would get up to temp I would lose all oil pressure. I checked with an external gauge and it was in fact loss of oil pressure when hot. I hoped and replaced the oil pump but in the end I was not able to get oil pressure back. So this weekend I’m pulling the engine. There must be too much damage from that worn lifter all that metal had to go somewhere .

Oh. Ok then. Cracked heads are rare anymore. Especially the tj generation. But i do know they have different block stamps that one is prone to issues like that and the other is called the bullet proof. Some kids dont know or are afraid to ask what is what. I just assumed maybe your son put coolant in the oil port since it looked like that lol. Hope the jeep is working again

Ive done some dumb things myself. I thought grease was for the differential instead of oil... i didnt even understand why grease was for it. Because oil will work better. Then i was corrected and i was correct but remembered being taught to use grease.
 
Novak Conversions Jeep Wrangler TJ radiator