Protip: Once you get the exhaust manifold lightly attached with the two END nuts, install the 4 lower bolts just a turn or two. You can then "Set" the intake on the lowers and wiggle things to get the dowels to seat. Carefully thread in a top bolt to hold everything snug and install the other 4 upper bolts. Torque everything according to the factory manual. DO NOT SKIP THIS. It WILL leak. Installing the LOWER bolts will greatly speed-up the process. At least that worked on my 99 XJ.. Now would also be a great time to replace that lower radiator hose too. :)
did this today, took about 5 hours taking my time and stopping to lunch, i can say, my jeep being in Arizona its whole life i didn't have to deal with any rust and it probably made the job way easier then it could have been
I bought mine new in late 1996. September of this year, I will have her 25 years. Wow! What a journey we have had. She almost died last December. The wiring harness from the ignition computer to the engine sensors cross-circuited due to damaged insolation. The cable harness, from under the bonnet to the fuel tank, became a melted mess. It took me about two days just to remove the wiring harness and some sensors that were melted to the connectors to the wiring harness. I replaced the entire wiring harness from the tank to the computer and sensors and replaced all sensors also. I am certain anybody else would have given up and scraped my rolling time capsule. I almost did myself. But she just got back running this may 2021. I look forward to the next 25 years with my beautiful RMS Stargazer. Jeeps that share my life: 1. 1990 Wrangler YJ ( Murphy is the name because whatever could to wrong often does. She still runs ) 2. 1997 Wrangler Sport TJ ( RMS Stargazer) { primary Jeep } 3. 2012 Wrangler Unlimited Sahara JK ( Spirit of The Lowlands, "Lola," for short) {secondary Jeep}
Will be doing my Exhaust Manifold this weekend. Glad you have a video for this. I have used many of your videos in the past, first time commenting. I look for your videos first and foremost. You are far and away the best XJ video 'how to' there is. Just finished my floor pans in my 96 a few weeks ago, all thanks to your video for that. Really wish you had one for the Heater Core, would have helped. All the other videos for that job sucked. Thank you for doing all these videos. You are a godsend for XJ lovers. Now, if only you had some for CJ7's..... Lol.
Put an engine in my 2000, and what made putting the manifolds on a little less painful was putting the lower bolts in first. I took some white Teflon tape and secured the washer to the head of the bolt. Then threaded the bolt in just enough so it had a good bite. Then I was able to hang the intake manifold on it perfectly, and the washer didn’t slide up and get in the way.. Saved a ton of time..
Thanks for the concise detailed instructions. With sincerity. My Jeep (1995 cherokee country) failed inspection and sat there for 10 months. I finally decided to tackle it rather that put a heat tape or jb weld patch on it again. Hit as many of the bolts as I could with PB Blaster the night before and that helped a lot. As you confirmed in a comment the 95s have a different power steering setup so that took some extra time. My main setback was in not expecting to need to change out my engine mount. Aside from the run to the store I wasnt on level ground and the engine torqued a bit when I did the switch out. Made it interesting trying to reattach the mount bracket. For those thinking of taking on this project you may want to have an engine mount on hand just in case, which will probably be the case if it hasn't been replaced recently. Only $20 at auto store. Use a floor jack and a piece of lumber to support the engine under the oil pan so you can remove the mount bracket. From my research it seems the broken engine mounts could actually be integral in causing the cracks in the pipes. And we would be wise to say no to the crack pipe 😁 Thanks again. I'll be using your videos for many future projects!
Great video. One comment/suggestion, when I take things apart that involves nuts, bolts & screws, after removing the piece that is being held in place by the nut, bolt or screw, I put that nut, bolt or screw BACK in the same place that it was taken from. This prevents missing hardware and I’ve also found that nuts, bolts and screws go back into the same place they came from much easier (most times).
Great video! The only thing I would add, it's a good practice to inspect and clean all bolts and head theads before reassembly. Replace any bolts, studs and washer if needed. There are people that fail to do it and end up having problems.
awesome video! thanks for helping me out with my soon to be new headers/downpipe. already got a magnaflow catback with downtip installed, but still has a small leak further up the system.
Not sure why someone would give a thumbs down on this video? I guess they don't know what a SUPER job you did or they just don't know how to pay attention to detail...lol . Awesome informative video! Great attention to detail and in explaining everything! Awesome video! Thank you for taking time to show every aspect of the job step by step removal and replacement. Thank you so much! Wish every video was like yours. PERFECT! A+++
Thanks man!!! I was able to follow your video and install an aftermarket exhaust manifold on my xj 4.0. I really appreciate it, it went pretty smooth with your instructions. My power steering was a bit different, it had a tensioner bolt, and I used a factory service manual to understand what all the power steering bolts were haha.
Finally a decent, comprehensive look at the Jeep exhaust/intake manifold replacement. I rebuilt the engine of my XJ four years ago ( valve work and seals, one new piston, new rings and rod bearings) and had to ask a friend to install the manifolds due to me not being home for a few weeks. He installed the intake before the exhaust manifold... took him six hours! I can see why! Got it on crooked and I spent some time getting the intake to go on the head dowels but I was looking for more bolts under the intake. Now I know I got it right. Finally I am getting the Jeep back on the road after having it on my shop lift for all these years... (health issues had stopped me in my tracks). Thank you very much.
Covering the throttle body throat with paper, or plastic rubber-banded in place, can prevent fastener from finding its way into your engine. I bought a smoking (not smokin') '98 Volvo and found a hole in the #5 piston. The former owner made a simple repair into a mess by dropping a nut into the intake manifold.
I did that once with an old 73 Beetle. I dropped one of the carburetor nuts into the carb without realizing it. A few minutes later the motor started ticking REALLY LOUD. Luckily the top of the piston just got an impression of the nut pressed into it.
OutJeeping... THANK YOU for a most excellent "how to do it" video here!! I watched it several times before attempting an exhaust manifold replacement on my 1999 Jeep Cherokee 4.0L XJ. All went slowly, surely, like clockwork.......off, cleaning, back together........UNTIL I couldn't easily reinstall my power steering pump. The 3 bolts just would NOT align/thread into the aluminum intake manifold. Hmmm... Something wrong for sure. But what? Started looking ALL over with my bright flashlight, from all angles and saw the front intake head dowel alignment pin was off by 1/8th of an inch. Too low. Not aligned. Not fully seated. DANG! Ended up disassembling half of what I reinstalled, loosened up all the intake/exhaust bolts, pulled/wiggled the intake until I was sure it WAS aligned and holding on both the front & back head pins. Snugged all bolts, then retorqued them all and finished the reassembly. Runs GREAT and SO quiet. A previous commenter gave us a "pro tip" on threading the 4 lower intake bolts in a couple turns, then lowering the intake down. Would be impossible to "start" these bolts really with the replacement exhaust manifold having huge expansion chambers, limiting socket/extension access and visibility of two of the bolts. A lot was totally done by feel and reaching around, up and under the intake manifold. Guys... Pay attention to the 2 head alignment pins for the gasket AND the aluminum intake! The exhaust manifold is a "no brainer" as it hangs from the 2 end studs from the beginning. Cheers! Randy "C-17A"
A great effort showing all the nuances and difficulties. I am still intimidated by this job, so I am still suffering with the air-noise and likely power reduction due to the leak on my 99 XJ. I can't see the leaking/cracking area, so I am just assuming that leak is there. I am also still researching which manifold to buy. I am in California, so it has to be 50-State legal. I like the type you installed with the flex sections, but I don't know if it is legal in all 50 states.
Thanks for the video. Did mine yesterday and while I was in it I repaired the factory “pinch” or “double dents” that are in the top of the down pipe. Fascinating internet debate on those. Some say needed for axle clearance (which doesn’t pass the sniff test) and mostly seems to be an emission tweak that got them through either California or Federal testing. Either way, it’s fully open now and power is noticeably increased. Walker brand replacement pipe is not mandrel bent so I opted to repair. Weeeee.
Great Scott! I was just searching the utubes last night for a detailed video of head gasket replacement. This details the precursor quite decently. Thanks.
Nice instructional video. I just got the same manifold and it is a nice part. Checking where it mounts on the engine with a straight edge there was no gaps. However I put like a pipe cleaner through one of the pipes (cylinder #3) going into the main pipe and it would catch on the inside where the weld is. I’m going to get a small inspection mirror and see if there is a small area where the air flow could have a small restriction then I’m going to get a flexible shaft for a dermal tool and smooth that area out.
@@officialWWM It does take some time for sure. I would have some liquid wrench to help with the old rusty bolts. The bolts on the underside of the intake manifold are hard to get to. I'm glad I did it myself. I priced it out and was quoted 970 bucks for a shop to do it. I got the new manifold from Amazon for 100 bucks so I saved a ton of money.
Hi Austin.. Mike again to let you know all went with header installation. No leaks what so ever. Actually, with the aftermarket performance header it sound great along with a deep rumbling muffler. Thanks again.
Liked and subscribed!!!! Phenomenal instruction, presentation and video. Thank you!!! My 2005 wrangler my need the exhaust manifold replaced soon. Much difference? Looks like the air conditioning lines may be an issue on my end. Any advice?
I'm not familiar with the wrangler setup, but if you have to you can remove ac components like the AC compressor and condenser and move them out of the way and keep them all attached still.
I have a 99 XJ Sport... same, same -even red. SO I am getting an EXAUST MANIFOLD - with flex pipe... as you show in this tutorial. Question: mine has a noticeable sputtering noise when you on the gas, and I think my gas milage and torque is just getting worse. Once I do this job, will that likely restore some lost power and gas mileage? I hope so! It's got 230K + on it, but no major issues, runs fine, just a little hesitation sometimes. I am going to do a basic tune up also. (plugs, wires and cap/rotor) Do I need to be worried about anything else?
I've never had an issue with broken off bolts on the several exhaust manifolds I've done. Until the last one I did on my friends Jeep I broke the very last Bolt.
For your sludge build up, drop a can of Sea Foam in the tank (full) They also make a product that you can spray into the throttle body to hel clean the top end. I've used the fuel/oil additive and am happy with the results. Very good instructional video, great job. God bless.
Yeah I've been meaning to do the seafoam treatment on this Jeep, I've done it on my other Jeep in the past and it looks a lot better when I did all the gaskets in the engine.
OutJeeping Hello Austin. You mentioned in a different video that you changed the exhaust on your 2001. I have a 2001 as well and would like to do the same thing. Would you be able to provide some direction on what you did and what parts you used? I would appreciate any help you can offer. Thank you.
Hola Amigo... Excelente Tus Videos, estoy aprendiendo mucho... tengo una Jeep Cherokee Sport 1997 XJ 4.0 L... Original... Saludos Grandes para Todos desde Bariloche Patagonia Argentina 👍
Just replaced mine. Honestly not as bad as I thought it was gonna be. Only took a few hours. But the bolts on the underside are a pain to get to. PB blaster will be your best friend
This channel helped me alot, all of the things i do to my jeep was based on your DIY. today i'm doing this and bought same exhaust manifold. i already took everything out just waiting for the new exhaust manifold to come. QUESTION : if i ever want to upgrade to High Output intake manifold, do i need anything? is the connection and hose connection for vacuum lines same?
Yes I believe all of the vacuum lines are the same. As long as you are not swapping from a renex intake, which would have different vacuum ports and throttle body changes.
@@OutJeeping Thank you thank you thank you. This is a very informative video I love how detailed you show the process. I would like to replace the exhaust manifold with the style that you put on yours which one on the link was yours? Thanks again 😎🇺🇸
I found a two peace exhaust manifold that just a backyard manufacturer made for me. I wish I could remember where he is. I am sure the jeep community would appreciate it. It was just a small welding shop.
Awesome vid man and to anyone capable or you have not done it now would be a really good time to slap a head gasket in and lifters check your rods rockers
I'm watching this because I had too many beers last night when I tried this the first time.... Totally forgot about loosening the belt tensioner bolt hahahaha.
Another great how to, from OutJeeping! Thanks Austin, your videos are why my Trusty Rusti is running the way she is. If you see this comment, I've got a question. I have a 2000 XJ 4.0L. It's mostly stock; however, the previous owner did and engine swap from a 95 TJ. So, there's a few odds and ends that are different from most Stock 00 XJs. I dont know if they kept the 00 head on the 95 block, or used the 95 block and head. My question is How can I tell if the manifold is the 95 one piece or the 00 2 piece, w/o tearing everything down? Or, will both of those manifolds fit in either head? Looking at the manifold from under the jeep, it actually looks a bit different than both styles, almost like it might be a custom piece. Everything has been wielded from manifold to tail pipe, and I need to replace the front pipe more than anything. I dont think a stock y-pipe on the 00 will fit this manifold. There are no flanges, I think it will be best and easiest to just get a new manifold and front pipe like you did in this video, but I need figure out which pieces to get. Thanks for you videos, Keep Jeeping!
You should be able to look underneath to see if the down pipe is split into a y pipe. If it's a y pipe it would be the 2000 design with cast 2 piece manifolds. It would have either pre cats or none on the y pipe. Depending when it was built in 2000 all that can vary in what it came with from the factory.
Awesome video …. I agree with comment from ‘Den Samme’. I wish I had the workspace indoors to work on my Jeep Wrangler LJ, but since I don’t - the dealer will have to do the work - $2400 - Ouch !! Now that I see how involved this is … I can’t complain about the hourly fees. NEXT time, I’ll be a bit more proactive and try this DIY. Except i would want to change all hardware for new and clean/powder coat/Cerakote parts as I go with every project until my engine bay is all nice and tidy. Hahahaha. Thanks for the video.
Great vid.. need it done asap. I hear that tapping when accelerating. My acceleration is a bit sluggish from a stop. Loss of acceleration for sure. Very informative video. Just one question. How long would you say you took getting the job done. About 3 hours?
This would be a great time to replace that pesky Crank Sensor that's on the TOP back of the trans bellhousing. Make sure to buy the DEALER one. The cheaper aftermarket ones tend to fail early. Also replace those engine mount to block bolts! They tend to shear off due to the holes not being cut deep enough at the factory. Add another washer under the bolt head and use some blue locktite.
I have the same issue with my 99 xj. Was going to take it off and re weld the weld that’s cracked by the bottom connector. What are your thoughts on that? Should be fine right?
I have heard of a lot of people doing that. You we need to make sure the sealing surface doesn't get warped or anything like that as well so it seals up good. But with all that work it might just be better and piece of mind to replace it with a new one. But that is good cheap option as well.
On the 2000+ 4.0L they use a 2 pieces cast manifold design that is slightly different. They are less prone to cracking compared the the header style manifold in the video. You will have to keep with that 2 piece design if your Jeep is equipped with pre-cats. They however make replacement of those cast manifolds as well, replacement process is very similar to what is showed in the video.
Can you give more details on how did you bent the exhaust hanger @34:10? My jeep is lifted 5.5 inches but has an SYE and my exhaust still hits the cross member. I'd like to bend it but don't want to run the risk of cracking anything. How did you do it?
Link for torque sequence (ended up finding it online)? good video.. Just finished, maybe 10 hours total, but also changed the valve cover gasket. Longest part was cleaning everything, hardest part was getting the exhaust flange off. I was able to get a torque wrench on all the bolts/nuts with creative use of adapters/extensions. Now time to change the radiator...
Hey Austin, I’ve got a 2000 Xj .. they come with a 2 piece set up for the exhaust manifold… do you know if I can swap it out for that one you installed on this Jeep ? Or will it not work..
It will fit but won't work with the o2 sensors if you have a total of 4 of them. But they do make headers that will work with all o2 sensors. They fit 2000+ TJ's as well.
Wish I could hire you for a replacement cracked manifold 2011 Jeep Grand Cherokee overland. 😢was going to purchase this used Jeep but with the known problems and having to invest more money was since less.
Even with the aluminum ones it's still a pain in the ass to remove the fuel lines, I started switching connections like that to the Chevy squeeze clips.
What would you suggest for the best replacement header? I've got a 2000 cherokee sport, notorious for cracked manifolds. I want it to last if i do it. Someone also told me my model is 2 pieces and pricey- not too sure how legitimate that claim was though
Great detailed video. It's now October, how is the manifold holding up? I can't believe its $58. Online Jeep parts stores are charging $200 for what looks like the exact same manifold.
It's a no name brand from ebay. Here is a similar one: www.ebay.com/itm/355138230289?fits=Year%3A1999%7CModel%3ACherokee%7CMake%3AJeep&itmmeta=01HSE33ZWAQ0W9G1EW0AWBEPRS&hash=item52afe35811:g:tNEAAOSwoGplJOuJ&itmprp=enc%3AAQAJAAAA0AaPXxfGJ%2F3NPQKjjKyenkP519CqmQ34hMj4VKhx6rCG7Xy3ay%2BATQJ3ffu8IqGx4weiesoJ4o56vwz158HZFPnmwAwcaESTNsgewifttV8GvpmdZn8yBXapM94YQMAwC677nkYuS65BU%2BUIVx8FGlsdyKK%2BQxoDvZdIAYFzxtCkDXA6JwJ7dXJr1W%2Fv2bWX0kE5jrj7pmjPVjnvdKoKfPMtIA7JQsjvc3tzz9%2FLspKV7y%2FMldqSF6YZmNkDnZWHWGGav%2Fcou1vBYG1PQ8h5NEE%3D%7Ctkp%3ABlBMUMD-j8PLYw
What hose is connected to the external part of the manifold(on the left side) and what does it connect from? I am trying to figure that out and no luck so far. Thank you!
There should be one or two smaller hoses coming out the side depending on the year. One is for the evap system and the other is vacuum to power the HVAC controls as well as cruise control.
300k miles. You are the real deal, kid. I love my xj. We have been together for 15 yesrs, on the daily.
Just turned over to 350k miles last week too
Protip: Once you get the exhaust manifold lightly attached with the two END nuts, install the 4 lower bolts just a turn or two. You can then "Set" the intake on the lowers and wiggle things to get the dowels to seat. Carefully thread in a top bolt to hold everything snug and install the other 4 upper bolts. Torque everything according to the factory manual. DO NOT SKIP THIS. It WILL leak. Installing the LOWER bolts will greatly speed-up the process. At least that worked on my 99 XJ.. Now would also be a great time to replace that lower radiator hose too. :)
That’s how I did it too. Took a lot of pain out of trying to fish around and find the holes.
Fishing wasn’t too bad but that ever changing combo of extensions was fun.
Great idea! I installed a header on my '87 and wish I had know that. About to do that on my "new" '98 and will definitely use that. Thanks
thank you!
This is a solid idea!
did this today, took about 5 hours taking my time and stopping to lunch, i can say, my jeep being in Arizona its whole life i didn't have to deal with any rust and it probably made the job way easier then it could have been
I just got my first Jeep and your channel is hugely important. I appreciate all the camera angles and pro teaching tips! Cheers
I bought mine new in late 1996. September of this year, I will have her 25 years. Wow! What a journey we have had. She almost died last December. The wiring harness from the ignition computer to the engine sensors cross-circuited due to damaged insolation. The cable harness, from under the bonnet to the fuel tank, became a melted mess. It took me about two days just to remove the wiring harness and some sensors that were melted to the connectors to the wiring harness. I replaced the entire wiring harness from the tank to the computer and sensors and replaced all sensors also. I am certain anybody else would have given up and scraped my rolling time capsule. I almost did myself. But she just got back running this may 2021. I look forward to the next 25 years with my beautiful RMS Stargazer.
Jeeps that share my life:
1. 1990 Wrangler YJ ( Murphy is the name because whatever could to wrong often does. She still runs )
2. 1997 Wrangler Sport TJ ( RMS Stargazer) { primary Jeep }
3. 2012 Wrangler Unlimited Sahara JK ( Spirit of The Lowlands, "Lola," for short) {secondary Jeep}
I think this is the best xj channel, especially for the beginner!
Will be doing my Exhaust Manifold this weekend. Glad you have a video for this. I have used many of your videos in the past, first time commenting.
I look for your videos first and foremost. You are far and away the best XJ video 'how to' there is.
Just finished my floor pans in my 96 a few weeks ago, all thanks to your video for that. Really wish you had one for the Heater Core, would have helped. All the other videos for that job sucked.
Thank you for doing all these videos. You are a godsend for XJ lovers.
Now, if only you had some for CJ7's..... Lol.
Well I got a J10 and they do have similar drive trains, but that's about it. Glad I could help!
I agree, very precise with the step-by-step.
Put an engine in my 2000, and what made putting the manifolds on a little less painful was putting the lower bolts in first. I took some white Teflon tape and secured the washer to the head of the bolt. Then threaded the bolt in just enough so it had a good bite. Then I was able to hang the intake manifold on it perfectly, and the washer didn’t slide up and get in the way.. Saved a ton of time..
Excellent video, good explanations, calm demeanor and excellent pacing of the content. You my good sir is the Bob Ross of the wrenching community 👏
Thanks for the concise detailed instructions. With sincerity. My Jeep (1995 cherokee country) failed inspection and sat there for 10 months. I finally decided to tackle it rather that put a heat tape or jb weld patch on it again. Hit as many of the bolts as I could with PB Blaster the night before and that helped a lot. As you confirmed in a comment the 95s have a different power steering setup so that took some extra time. My main setback was in not expecting to need to change out my engine mount. Aside from the run to the store I wasnt on level ground and the engine torqued a bit when I did the switch out. Made it interesting trying to reattach the mount bracket. For those thinking of taking on this project you may want to have an engine mount on hand just in case, which will probably be the case if it hasn't been replaced recently. Only $20 at auto store. Use a floor jack and a piece of lumber to support the engine under the oil pan so you can remove the mount bracket. From my research it seems the broken engine mounts could actually be integral in causing the cracks in the pipes. And we would be wise to say no to the crack pipe 😁 Thanks again. I'll be using your videos for many future projects!
Great video I will watch again and take my notes then get it done. I am disabled so it will take me a little more time. Thanks for the video.
Great video. One comment/suggestion, when I take things apart that involves nuts, bolts & screws, after removing the piece that is being held in place by the nut, bolt or screw, I put that nut, bolt or screw BACK in the same place that it was taken from. This prevents missing hardware and I’ve also found that nuts, bolts and screws go back into the same place they came from much easier (most times).
I also let them soak in pb blaster before I put them back to prevent seize ups.
Great video! The only thing I would add, it's a good practice to inspect and clean all bolts and head theads before reassembly. Replace any bolts, studs and washer if needed. There are people that fail to do it and end up having problems.
This video is the best on youtube, step by step with clear instructions. So helpful.
Perfect timing, with this quarantine we're in I'm planning on replacing my cracked manifold and installing 4 hole injectors. Great video.
watch this first dyno on 1 hole 4 hole and 12 hole injectors
Thank you for posting this video. I have a 97 and will be doing this job soon. So glad I found your channel. Thanks Brother!
Fantastic video tutorial. Took some time trying to get those bottom manifold bolts in place but other than that… perfect!!
awesome video! thanks for helping me out with my soon to be new headers/downpipe. already got a magnaflow catback with downtip installed, but still has a small leak further up the system.
Not sure why someone would give a thumbs down on this video? I guess they don't know what a SUPER job you did or they just don't know how to pay attention to detail...lol . Awesome informative video! Great attention to detail and in explaining everything! Awesome video! Thank you for taking time to show every aspect of the job step by step removal and replacement. Thank you so much! Wish every video was like yours. PERFECT! A+++
Thanks for watching, I appreciate your comment! Feel free to check out my other videos for more how-to content.
I have a support tabs on the axel are smashed sideways. How do I fix. Heat and hammer???
Thanks man!!! I was able to follow your video and install an aftermarket exhaust manifold on my xj 4.0. I really appreciate it, it went pretty smooth with your instructions. My power steering was a bit different, it had a tensioner bolt, and I used a factory service manual to understand what all the power steering bolts were haha.
Yeah pre 96 4.0's had a different belt routing than what is shown in the video.
Finally a decent, comprehensive look at the Jeep exhaust/intake manifold replacement. I rebuilt the engine of my XJ four years ago ( valve work and seals, one new piston, new rings and rod bearings) and had to ask a friend to install the manifolds due to me not being home for a few weeks. He installed the intake before the exhaust manifold... took him six hours! I can see why! Got it on crooked and I spent some time getting the intake to go on the head dowels but I was looking for more bolts under the intake. Now I know I got it right. Finally I am getting the Jeep back on the road after having it on my shop lift for all these years... (health issues had stopped me in my tracks). Thank you very much.
Covering the throttle body throat with paper, or plastic rubber-banded in place, can prevent fastener from finding its way into your engine.
I bought a smoking (not smokin') '98 Volvo and found a hole in the #5 piston. The former owner made a simple repair into a mess by dropping a nut into the intake manifold.
I did that once with an old 73 Beetle. I dropped one of the carburetor nuts into the carb without realizing it. A few minutes later the motor started ticking REALLY LOUD. Luckily the top of the piston just got an impression of the nut pressed into it.
OutJeeping... THANK YOU for a most excellent "how to do it" video here!! I watched it several times before attempting an exhaust manifold replacement on my 1999 Jeep Cherokee 4.0L XJ. All went slowly, surely, like clockwork.......off, cleaning, back together........UNTIL I couldn't easily reinstall my power steering pump. The 3 bolts just would NOT align/thread into the aluminum intake manifold. Hmmm... Something wrong for sure. But what? Started looking ALL over with my bright flashlight, from all angles and saw the front intake head dowel alignment pin was off by 1/8th of an inch. Too low. Not aligned. Not fully seated. DANG! Ended up disassembling half of what I reinstalled, loosened up all the intake/exhaust bolts, pulled/wiggled the intake until I was sure it WAS aligned and holding on both the front & back head pins. Snugged all bolts, then retorqued them all and finished the reassembly. Runs GREAT and SO quiet. A previous commenter gave us a "pro tip" on threading the 4 lower intake bolts in a couple turns, then lowering the intake down. Would be impossible to "start" these bolts really with the replacement exhaust manifold having huge expansion chambers, limiting socket/extension access and visibility of two of the bolts. A lot was totally done by feel and reaching around, up and under the intake manifold. Guys... Pay attention to the 2 head alignment pins for the gasket AND the aluminum intake! The exhaust manifold is a "no brainer" as it hangs from the 2 end studs from the beginning. Cheers! Randy "C-17A"
Thank you for sharing this information with your fellow Jeepers I found it very informative.👍👍
DustyRoads= The American Dream?
A great effort showing all the nuances and difficulties. I am still intimidated by this job, so I am still suffering with the air-noise and likely power reduction due to the leak on my 99 XJ. I can't see the leaking/cracking area, so I am just assuming that leak is there. I am also still researching which manifold to buy. I am in California, so it has to be 50-State legal. I like the type you installed with the flex sections, but I don't know if it is legal in all 50 states.
OMG; the only video on TH-cam that correctly explained the lower manifold bolts. Thanks so much!
Thanks for the video. Did mine yesterday and while I was in it I repaired the factory “pinch” or “double dents” that are in the top of the down pipe. Fascinating internet debate on those. Some say needed for axle clearance (which doesn’t pass the sniff test) and mostly seems to be an emission tweak that got them through either California or Federal testing. Either way, it’s fully open now and power is noticeably increased. Walker brand replacement pipe is not mandrel bent so I opted to repair. Weeeee.
I know this is a older video from this year , but great job and explanation on how to do this .
Glad it was helpful!
Great Scott! I was just searching the utubes last night for a detailed video of head gasket replacement. This details the precursor quite decently. Thanks.
All your videos are just perfect .
thank you for this! I, not a mechanic and don't know shit about cars, followed your steps.
Nice instructional video. I just got the same manifold and it is a nice part. Checking where it mounts on the engine with a straight edge there was no gaps. However I put like a pipe cleaner through one of the pipes (cylinder #3) going into the main pipe and it would catch on the inside where the weld is. I’m going to get a small inspection mirror and see if there is a small area where the air flow could have a small restriction then I’m going to get a flexible shaft for a dermal tool and smooth that area out.
Thank you. You made my day a lot easier.
Your videos are always so informative, thank you so much for doing what you do!
The video helped a lot. I just replaced my manifold and it was really helpful to see how you did it first.
Was it hard to do?
@@officialWWM It does take some time for sure. I would have some liquid wrench to help with the old rusty bolts. The bolts on the underside of the intake manifold are hard to get to. I'm glad I did it myself. I priced it out and was quoted 970 bucks for a shop to do it. I got the new manifold from Amazon for 100 bucks so I saved a ton of money.
@@EdwinHuntsman thanks, I actually did mine yesterday and while I’m glad I did it myself, let’s just say, I won’t be in a hurry to do it again, lol!
good instructor,thanks for being thorough
I am form Thailand.Thank you for good information.
Hi Austin.. Mike again to let you know all went with header installation. No leaks what so ever. Actually, with the aftermarket performance header it sound great along with a deep rumbling muffler. Thanks again.
Glad I could help!
Good video....great job explaining everything..!! I need to do the same thing to my rig and the insight is valuable..! Glad I found your channel..!!
Have a quality flex pipe welded in to eliminate any flex to the manifold. I had this done on my yj , haven't had a problem since.
Great vid. Your channel helps a lot with my 2000 XJ.
Liked and subscribed!!!! Phenomenal instruction, presentation and video. Thank you!!! My 2005 wrangler my need the exhaust manifold replaced soon. Much difference? Looks like the air conditioning lines may be an issue on my end. Any advice?
I'm not familiar with the wrangler setup, but if you have to you can remove ac components like the AC compressor and condenser and move them out of the way and keep them all attached still.
Thanks for the vid bro, really helped me replace mine on my 97 Jeep Cherokee
The best Ive seen in a long time, very nice job
The link to the manifold on ebay is dead - can you put in a new link to the one you like?
Is there a gasket in between the front pipe and the exhaust manifold?
There’s seems to be some confusion on the web about using a donut gasket/flange.
Great video Austin, I have to do this for my 1999 XJ. Thanks again
Perfect time to have replaced the freeze plugs on an older 4.0.
And add a block heater!
I have a 99 XJ Sport... same, same -even red. SO I am getting an EXAUST MANIFOLD - with flex pipe... as you show in this tutorial. Question: mine has a noticeable sputtering noise when you on the gas, and I think my gas milage and torque is just getting worse. Once I do this job, will that likely restore some lost power and gas mileage? I hope so! It's got 230K + on it, but no major issues, runs fine, just a little hesitation sometimes. I am going to do a basic tune up also. (plugs, wires and cap/rotor) Do I need to be worried about anything else?
Good video. No broke off bolts in head. Lucky!!!
I've never had an issue with broken off bolts on the several exhaust manifolds I've done. Until the last one I did on my friends Jeep I broke the very last Bolt.
I spy a beautiful looking ZR in the background 👍
Great tutorial video!!! 👍
For your sludge build up, drop a can of Sea Foam in the tank (full) They also make a product that you can spray into the throttle body to hel clean the top end. I've used the fuel/oil additive and am happy with the results. Very good instructional video, great job. God bless.
Yeah I've been meaning to do the seafoam treatment on this Jeep, I've done it on my other Jeep in the past and it looks a lot better when I did all the gaskets in the engine.
OutJeeping Hello Austin. You mentioned in a different video that you changed the exhaust on your 2001. I have a 2001 as well and would like to do the same thing. Would you be able to provide some direction on what you did and what parts you used? I would appreciate any help you can offer. Thank you.
Hi there, Good detail video , I cannot see the link for the Toque Sequence
Hola Amigo... Excelente Tus Videos, estoy aprendiendo mucho... tengo una Jeep Cherokee Sport 1997 XJ 4.0 L... Original... Saludos Grandes para Todos desde Bariloche Patagonia Argentina 👍
Thanks buddy, wicked effort
Just replaced mine. Honestly not as bad as I thought it was gonna be. Only took a few hours. But the bolts on the underside are a pain to get to. PB blaster will be your best friend
This channel helped me alot, all of the things i do to my jeep was based on your DIY. today i'm doing this and bought same exhaust manifold. i already took everything out just waiting for the new exhaust manifold to come. QUESTION : if i ever want to upgrade to High Output intake manifold, do i need anything? is the connection and hose connection for vacuum lines same?
Yes I believe all of the vacuum lines are the same. As long as you are not swapping from a renex intake, which would have different vacuum ports and throttle body changes.
What brand did u happens to go with for the manifold ? Great video man !
It was a cheap no name brand eBay manifold. Link is in description
@@OutJeeping
Thank you thank you thank you. This is a very informative video I love how detailed you show the process. I would like to replace the exhaust manifold with the style that you put on yours which one on the link was yours?
Thanks again 😎🇺🇸
How has it held up?
I found a two peace exhaust manifold that just a backyard manufacturer made for me. I wish I could remember where he is. I am sure the jeep community would appreciate it. It was just a small welding shop.
Awesome vid man and to anyone capable or you have not done it now would be a really good time to slap a head gasket in and lifters check your rods rockers
I learn from you I did mine thank you so much
The ticking noise the jeep makes in the beginning, is that from the cracked manifold?? My jeep is making the same noise.
Just valve train noise that these 4.0L love to make.
How many bolts are on the bottom side of the intake manifold? I'm currently undertaking this particular job on my 97..
I'm watching this because I had too many beers last night when I tried this the first time.... Totally forgot about loosening the belt tensioner bolt hahahaha.
Another great how to, from OutJeeping! Thanks Austin, your videos are why my Trusty Rusti is running the way she is.
If you see this comment, I've got a question. I have a 2000 XJ 4.0L. It's mostly stock; however, the previous owner did and engine swap from a 95 TJ. So, there's a few odds and ends that are different from most Stock 00 XJs. I dont know if they kept the 00 head on the 95 block, or used the 95 block and head.
My question is How can I tell if the manifold is the 95 one piece or the 00 2 piece, w/o tearing everything down? Or, will both of those manifolds fit in either head? Looking at the manifold from under the jeep, it actually looks a bit different than both styles, almost like it might be a custom piece. Everything has been wielded from manifold to tail pipe, and I need to replace the front pipe more than anything. I dont think a stock y-pipe on the 00 will fit this manifold. There are no flanges, I think it will be best and easiest to just get a new manifold and front pipe like you did in this video, but I need figure out which pieces to get.
Thanks for you videos, Keep Jeeping!
You should be able to look underneath to see if the down pipe is split into a y pipe. If it's a y pipe it would be the 2000 design with cast 2 piece manifolds. It would have either pre cats or none on the y pipe. Depending when it was built in 2000 all that can vary in what it came with from the factory.
Good video bud , i'll watch a few more times and be ready to do my cherokee .
A year later I finally got the job done on my Cherokee . Video was very helpful !
FANTASTIC video as always. You make it look easy. Thanks for your videos the explanation is great. 👍👍
Awesome video …. I agree with comment from ‘Den Samme’. I wish I had the workspace indoors to work on my Jeep Wrangler LJ, but since I don’t - the dealer will have to do the work - $2400 - Ouch !! Now that I see how involved this is … I can’t complain about the hourly fees. NEXT time, I’ll be a bit more proactive and try this DIY. Except i would want to change all hardware for new and clean/powder coat/Cerakote parts as I go with every project until my engine bay is all nice and tidy. Hahahaha. Thanks for the video.
Where did you acquire the Exhaust manifold & Gasket please…Steve
Where did you get your windshield visor? I appreciate your videos, good job Thanks!
I found it used on FB marketplace
Great vid.. need it done asap. I hear that tapping when accelerating. My acceleration is a bit sluggish from a stop. Loss of acceleration for sure. Very informative video. Just one question. How long would you say you took getting the job done. About 3 hours?
This would be a great time to replace that pesky Crank Sensor that's on the TOP back of the trans bellhousing. Make sure to buy the DEALER one. The cheaper aftermarket ones tend to fail early. Also replace those engine mount to block bolts! They tend to shear off due to the holes not being cut deep enough at the factory. Add another washer under the bolt head and use some blue locktite.
So does the new manifold flow better than stock?
Hi, great video, just about to do this job on mine, do you have the link to the tightening sequence? Thank you
Great channel. Super XJ content👍
I have the same issue with my 99 xj. Was going to take it off and re weld the weld that’s cracked by the bottom connector. What are your thoughts on that? Should be fine right?
I have heard of a lot of people doing that. You we need to make sure the sealing surface doesn't get warped or anything like that as well so it seals up good. But with all that work it might just be better and piece of mind to replace it with a new one. But that is good cheap option as well.
What about the 3 catalytic coverters....two of them are on the original headers...only one exist now?
On the 2000+ 4.0L they use a 2 pieces cast manifold design that is slightly different. They are less prone to cracking compared the the header style manifold in the video. You will have to keep with that 2 piece design if your Jeep is equipped with pre-cats. They however make replacement of those cast manifolds as well, replacement process is very similar to what is showed in the video.
What is the link for the manifold bolt sequence?
Excellent video! 🥇
Can you give more details on how did you bent the exhaust hanger @34:10? My jeep is lifted 5.5 inches but has an SYE and my exhaust still hits the cross member. I'd like to bend it but don't want to run the risk of cracking anything. How did you do it?
The exhaust bolt that is blocked by the pipe. What is the trick if the socket doesn’t fit with the manifold in the way?
Your videos are awesome super valuable and helpful.
Link for torque sequence (ended up finding it online)? good video.. Just finished, maybe 10 hours total, but also changed the valve cover gasket. Longest part was cleaning everything, hardest part was getting the exhaust flange off. I was able to get a torque wrench on all the bolts/nuts with creative use of adapters/extensions. Now time to change the radiator...
I just did a quick google image search of the torque sequence and it pops up.
What size ratchet wrench did you use to loosen the idler pullet nut (bolt?) Thanks!
15mm I believe
@@OutJeeping Thank you!
Nice detailed Video. Thank you.
Nice job Austin.Hope that took care of your exhaust leak.....
Hey Austin, I’ve got a 2000 Xj .. they come with a 2 piece set up for the exhaust manifold… do you know if I can swap it out for that one you installed on this Jeep ? Or will it not work..
It will fit but won't work with the o2 sensors if you have a total of 4 of them. But they do make headers that will work with all o2 sensors. They fit 2000+ TJ's as well.
Wish I could hire you for a replacement cracked manifold 2011 Jeep Grand Cherokee overland. 😢was going to purchase this used Jeep but with the known problems and having to invest more money was since less.
Even with the aluminum ones it's still a pain in the ass to remove the fuel lines, I started switching connections like that to the Chevy squeeze clips.
What would you suggest for the best replacement header? I've got a 2000 cherokee sport, notorious for cracked manifolds. I want it to last if i do it. Someone also told me my model is 2 pieces and pricey- not too sure how legitimate that claim was though
Great instructional video!
Great detailed video. It's now October, how is the manifold holding up? I can't believe its $58. Online Jeep parts stores are charging $200 for what looks like the exact same manifold.
So far it has held up great, and I have put about six thousand miles on it. I don't hear any exhaust leaks so I'm assuming there is still no cracks.
That link is old what brand are you using for the manifold? Is it a Dorman?
It's a no name brand from ebay. Here is a similar one: www.ebay.com/itm/355138230289?fits=Year%3A1999%7CModel%3ACherokee%7CMake%3AJeep&itmmeta=01HSE33ZWAQ0W9G1EW0AWBEPRS&hash=item52afe35811:g:tNEAAOSwoGplJOuJ&itmprp=enc%3AAQAJAAAA0AaPXxfGJ%2F3NPQKjjKyenkP519CqmQ34hMj4VKhx6rCG7Xy3ay%2BATQJ3ffu8IqGx4weiesoJ4o56vwz158HZFPnmwAwcaESTNsgewifttV8GvpmdZn8yBXapM94YQMAwC677nkYuS65BU%2BUIVx8FGlsdyKK%2BQxoDvZdIAYFzxtCkDXA6JwJ7dXJr1W%2Fv2bWX0kE5jrj7pmjPVjnvdKoKfPMtIA7JQsjvc3tzz9%2FLspKV7y%2FMldqSF6YZmNkDnZWHWGGav%2Fcou1vBYG1PQ8h5NEE%3D%7Ctkp%3ABlBMUMD-j8PLYw
Thanks man appreciate it, I ended up going with the Dorman and just got it done. No leak for now, cheers 🤙🏻
What hose is connected to the external part of the manifold(on the left side) and what does it connect from? I am trying to figure that out and no luck so far.
Thank you!
As in left side look at the engine from the drivers side? And on top of the manifold or on the manifold side?
@@OutJeeping on the manifold itself on the side. Between second and third cylinder’s
There should be one or two smaller hoses coming out the side depending on the year. One is for the evap system and the other is vacuum to power the HVAC controls as well as cruise control.
Great video. Big thanks. Do you recall what was your effort in real time?
Roughly 3-4 hours. Most of the time spent was cleaning the gasket surfaces.
where did you get the “Straight 6 Empire” hoodie
Awesome video! I think when I do this I’m going to heat wrap the header.
Great video thanks. Keep it going.
Link to intake manifolds
Hey Austin, what kit did you use (link isn’t working) and is it still holding up?
It was just a cheap one from ebay. Has a crack in it already. But that could be from the rest of the exhaust having loose mounts or bad motor mounts.
Super clean job ...