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. :)

@officialWWM

2 жыл бұрын

That’s how I did it too. Took a lot of pain out of trying to fish around and find the holes.

@pauldolan1493

2 жыл бұрын

Fishing wasn’t too bad but that ever changing combo of extensions was fun.

@huudathot

Жыл бұрын

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

@danhouse3799

Жыл бұрын

thank you!

@vipertrudeau9964

Жыл бұрын

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

@indridcold8433

3 жыл бұрын

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}

@handmadeindustrial

2 жыл бұрын

I think this is the best xj channel, especially for the beginner!

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!

Excellent video, good explanations, calm demeanor and excellent pacing of the content. You my good sir is the Bob Ross of the wrenching community 👏

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.

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).

@ultramarine3527

2 жыл бұрын

I also let them soak in pb blaster before I put them back to prevent seize ups.

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.

This video is the best on youtube, step by step with clear instructions. So helpful.

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.

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.

@OutJeeping

7 ай бұрын

Well I got a J10 and they do have similar drive trains, but that's about it. Glad I could help!

@greenhead333

4 ай бұрын

I agree, very precise with the step-by-step.

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.

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.

@OutJeeping

4 жыл бұрын

Yeah pre 96 4.0's had a different belt routing than what is shown in the video.

Fantastic video tutorial. Took some time trying to get those bottom manifold bolts in place but other than that… perfect!!

Great video Austin, I have to do this for my 1999 XJ. Thanks again

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.

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!

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.

Thank you for sharing this information with your fellow Jeepers I found it very informative.👍👍

@DustySteel

2 жыл бұрын

DustyRoads= The American Dream?

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..!!

Thanks for the vid bro, really helped me replace mine on my 97 Jeep Cherokee

All your videos are just perfect .

FANTASTIC video as always. You make it look easy. Thanks for your videos the explanation is great. 👍👍

Perfect timing, with this quarantine we're in I'm planning on replacing my cracked manifold and installing 4 hole injectors. Great video.

@todhollo1961

3 жыл бұрын

watch this first dyno on 1 hole 4 hole and 12 hole injectors

I am form Thailand.Thank you for good information.

Your videos are always so informative, thank you so much for doing what you do!

Great vid. Your channel helps a lot with my 2000 XJ.

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.

Nice detailed Video. Thank you.

The best Ive seen in a long time, very nice job

Great channel. Super XJ content👍

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+++

@OutJeeping

3 жыл бұрын

Thanks for watching, I appreciate your comment! Feel free to check out my other videos for more how-to content.

@frankiejsmith6398

Жыл бұрын

I have a support tabs on the axel are smashed sideways. How do I fix. Heat and hammer???

Great instructional video!

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.

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 👍

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"

Your videos are awesome super valuable and helpful.

good instructor,thanks for being thorough

Excellent video! 🥇

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.

@scottdoubleyou563

3 жыл бұрын

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.

I know this is a older video from this year , but great job and explanation on how to do this .

@OutJeeping

3 жыл бұрын

Glad it was helpful!

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

Thank you. You made my day a lot easier.

Super clean job ...

Nice work and explanation

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.

@OutJeeping

4 жыл бұрын

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.

@markwaycaster8273

4 жыл бұрын

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.

very nicely done..well done.

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

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.

Great video thanks. Keep it going.

Good video. No broke off bolts in head. Lucky!!!

@OutJeeping

3 жыл бұрын

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.

Good video bud , i'll watch a few more times and be ready to do my cherokee .

@dougnoal7041

Жыл бұрын

A year later I finally got the job done on my Cherokee . Video was very helpful !

Nice explanation in this one. Thanks.

Amazing video thank you

Awesome video man

Excellent video

Solid vid bro... Thx

Nice and color is awesome

The video helped a lot. I just replaced my manifold and it was really helpful to see how you did it first.

@officialWWM

2 жыл бұрын

Was it hard to do?

@EdwinHuntsman

2 жыл бұрын

@@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.

@officialWWM

2 жыл бұрын

@@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!

Awesome video! I think when I do this I’m going to heat wrap the header.

I learn from you I did mine thank you so much

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.

@OutJeeping

Жыл бұрын

Glad I could help!

good job tex!

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.

Nice work

OMG; the only video on KZread that correctly explained the lower manifold bolts. Thanks so much!

thank you for this! I, not a mechanic and don't know shit about cars, followed your steps.

Great tutorial video!!! 👍

I spy a beautiful looking ZR in the background 👍

Nice job Austin.Hope that took care of your exhaust leak.....

VERY NICE!!!

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.

Good job

Sounds good

good job

Nice. I wish there were more options for the Renix as there are for the HO.

Perfect time to have replaced the freeze plugs on an older 4.0.

@joebourgoin6554

3 жыл бұрын

And add a block heater!

Hi, great video, just about to do this job on mine, do you have the link to the tightening sequence? Thank you

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.

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...

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?

@OutJeeping

3 жыл бұрын

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.

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?

@OutJeeping

4 жыл бұрын

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'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.

Hi there, Good detail video , I cannot see the link for the Toque Sequence

Lol big old potato fingers. 😂 Thanks for the upload. Always good tutorial.

@wjb111

4 жыл бұрын

😂😂

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.

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?

Interesting, I must have bought the same manifold because my "donut" sucked as well. I bought another one from Rock Auto.

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

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?

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.

Awesome video, super easy to follow. Just finished my swap. Only thing that I noticed was the exhaust manifold that I used, which was purchased from your eBay link. The thicknesses of the flange is slightly thinner than the intake manifold flange. This causes the washers to tilt when tightened down. Saw some comments on the forums about people welding little washers to make up for the thickness difference. Just want to know if you had the same issues when you put this on the jeeps you worked on with this header. Thanks

@OutJeeping

4 жыл бұрын

Yeah I went out and double checked on the jeep and the thickness is the same and the washers are straight on there. What year is your jeep?

@CherokeeXJ22

4 жыл бұрын

@@OutJeeping I have a 1998 Cherokee. Could have just been a fluke or something. Most of the bolts needed to be shimmed but there were two that were really close to perfect. All that I did was took a washer and cut about a quarter off the one side, just enough to clear the intake manifold side. Worked great. Just a little tricky to hold them in place.

Ok cool thanks 😊

Great vid! Do you know if that particular manifold will fit '00-01s with the updated intake manifold? (with the earlier style front pipe)

@OutJeeping

3 жыл бұрын

It will fit but the O2 sensors will not work if you have pre-catilitic convertors right after the exhaust manifold.

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?

Great video. I noticed you used no sealant on the gasket. I'm a ex mechanic here in NZ and was taught to use sealants on manifold gaskets. What's your thoughts on the matter?

Good jop👍🏻

How many bolts are on the bottom side of the intake manifold? I'm currently undertaking this particular job on my 97..