I just changed the exhaust manifold on my 97 Wrangler 4.0 today. I was a
bit nervous prior to starting after reading others' experiences but it
actually went surprisingly well. As a reference, aside from the FSM, I used
this link
http://4wheeldrive.about.com/gi/dyna...cle%26sid%3D21.
The entire job took just under four hours and I didn't have any real
heartbreakers. I would like to restate a couple of important points.
Pre-spraying the bolts with something is critical. I used PB based on it's
reputation and was very happy that I did. Get the tool that removes the
fuel line from the rail. I bought the wrong one (didn't fit) and ended up
having to fabricate something to do the job. I got a set of wobble
extensions and they were lifesavers. They allowed me to reach most of the
bolts without the difficulty normally encountered with a universal joint
swivel (aside from the exhaust flange). The most difficult part is removing
the manifold from the downpipe. It's a little tricky to find the proper
ratchet position to get to the nuts, but it's possible. I replaced the
stock manifold with one of the new style with the bellows. If anyone is
contemplating doing this job and has any questions, feel free to ask. I'm
allowing the full 24 hours for my RTV to set up before cranking and feeling
really good about the job, but my confidence is high. Thanks to all the
posters who went before me and left nuggets of advice that made my day
easier...........


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