Own a 99 or older 4.0L? You must read this!

[kirksjeep]

I found this on Jeep Forum, and I think if I can get the parts I am going to do this.  Do not read if you do not want 25+HP and 18+Ft/lbs of torque at the rear wheels, for under $100.  All you need is a 00+ intake manifold, 99+ power steering pump w/ bracket, and a new serpentine belt.   

http://www.mallcrawlin.com/forum/showthread.php?t=6355

here is another write up of the swap: claims 15 HP

http://www.go.jeep-xj.info/HowtoIntakeManifold1.htm

[PaulW]

good find, nice info.  i think i'll have to do that to my grand when i have time for yet another project.

[Swagger]

have you even started on your XJ yet?

[PaulW]

have you even started on your XJ yet?

not yet, i'm waiting to close on the house so i have a place to do it.  it's stuffed in self storage right now next to my welder, tool box and other misc tools.

[calvynandhobbs]

Kirk, you gotta stop putting all of these ideas in my head. It's going to take me forever to do all these upgrades you've  been posting.

[kirksjeep]

Kirk, you gotta stop putting all of these ideas in my head. It's going to take me forever to do all these upgrades you've  been posting.

 

[PaulW]

Kirk, you gotta stop putting all of these ideas in my head. It's going to take me forever to do all these upgrades you've  been posting.

 

my best upgrade ever, remove gas cap install new vehicle

[Swagger]

easiest and most expensive

[PaulW]

easiest and most expensive

sometimes

[kirksjeep]

I started the intake manifold swap last night.  So far it has been very straight forward.  I pulled the old power steering pump, disconnected all the vacuum lines, and electrical connections, pulled the throttle body off, pulled the fuel injectors out of the manifold ( left them connected to the fuel rail), and then pulled the manifold off.  One word of advice for doing this is to have long arms the 4 bolts under the manifold can be taken off from the engine bay with a little contortion.

I cleaned the "new" manifold up a little and I was surprised by the amount of gunk in it, but it wasn't much more then the amount of gunk in the one I took off of my YJ.  I guess these engines just create a lot of carbon build up.  After seeing how much there was on the stock manifold with only 66k, I'm going to spray more intake cleaner in my XJ with 196K. 

I bolted the "new" manifold up, attached the fuel injectors, installed the throttle body, and installed all electrical connections, and most of the vacuum lines.  I have to buy some T- connectors and a small chunk of rubber hose to connnect all the vacuum lines.  I am going to rent a Power Steering pump pully remover today and swap the pullies from the original and the new one, this is only needed since the new pully has two chunck of the edge missing, and my original looks fine. 

I don't think my stock belt will fit, but once I get everything bolted in place I'll check it.  I'm going to replaced the belt either way since I have never replaced it, and it might be the original and 17 years old. 

[gearhead1985B]

I got the power steering pump remover tool thingy

[kirksjeep]

I got the power steering pump remover tool thingy

I rented one from Autozone, but thanks.

I ended up having to replace the pulley instead of using my old one since the newer one has the holes in it to access the bolts.  The guy at autozone tried to swap the pulley at the counter and ended up messing up the collar of the pulley and then told me I should go to Deans and get another pump .  I took my pump and tool back home and ended up having to very, very carefully cut the pulley off the pump.  I put 2 very small nicks in the shaft, but I doubt it will have any effect.  The new pulley went on just fine.  From there the pump and bracket just bolt right up.  The stock belt will work if I route it a little different around the water pump, but I'm going to get a new one. 

As far as additional parts, I bought about 2' of hose for the low pressure side of the power steering box to reservoir connection, and 2 hose clamps for it.  I also picked up a pack of assorted vacuum connections ( T,Y, adaptors, etc..), 1' of 3/16 hose and 1' of 5/32 hose.

I'll test drive it tomorrow.

[kirksjeep]

The stock belt is 96.7" and is too long, the next size down is 94.0" which seems like it will work.  I say seems because I'm still not done with it.  There is a tab on the drivers side of the crank pulley that looks like a screw driver would slide in to it for something, but I'm not sure why it is there.  I have ground about 1/4" off the tab but it is still too close to the belt to put any more tension on it.  The way it is now it squeals like a pig at start up, but goes away after a few seconds.  If I rev the engine it squeals for a split second and it also squeals at full lock of the wheels. 

That's the bad, but I took it for a test drive and 
WOW, WOW, WOW.  It runs like I still had the stock size tires on it.  I even managed to get a little chirp out of the tires when shifting into second gear.  Between the custom head pipe, and now the improved intake, I can feel a significant gain in power. 

It also feels like the power steering pump is a little better then the YJ one.  I'll pull the belt back off tomorrow and do a little more grinding so I can put some more tension on the belt. I also need to finish wiring my lights on the rear bumper, but after that I should be ready for Mohawk.

[kirksjeep]

Today I did a little more grinding, and now the belt fits just fine no more squeeling even with the A/C (air compressor) and turning the tires lock to lock.