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 just got my first Jeep and your channel is hugely important. I appreciate all the camera angles and pro teaching tips! Cheers

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 Scott! I was just searching the utubes last night for a detailed video of head gasket replacement. This details the precursor quite decently. Thanks.

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

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.

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.

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.

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!

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).

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.

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

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

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.

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

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.

All your videos are just perfect .

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.

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

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

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..!!

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

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+++

Great channel. Super XJ content👍

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

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

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

Nice detailed Video. Thank you.

Your videos are awesome super valuable and helpful.

I am form Thailand.Thank you for good information.

Excellent video! 🥇

Great instructional video!

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.

Thank you. You made my day a lot easier.

Super clean job ...

good instructor,thanks for being thorough

very nicely done..well done.

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.

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"

Nice work and explanation

Awesome video man

Great video thanks. Keep it going.

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.

VERY NICE!!!

Excellent video

Nice explanation in this one. Thanks.

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

Nice and color is awesome

Thanks buddy, wicked effort

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

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

Amazing video thank you

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.

Solid vid bro... Thx

good job tex!

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

Nice work

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.

Good job

Sounds good

I learn from you I did mine thank you so much

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

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

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.

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

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

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

I spy a beautiful looking ZR in the background 👍

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?

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

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

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

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

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

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

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?

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?

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

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.

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?

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)

👍

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.

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.

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

Good jop👍🏻

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

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 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?

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?

where did you get the “Straight 6 Empire” hoodie

What is the link for the manifold bolt sequence?