Swapping Intake Manifolds

cher96 · Mar 9, 2009

My friend totaled his 2004 Wrangler... He's parting it out.
I want his intake manifold.
I had read intake manifolds from 99 to 2002 XJs swap directly in.
Will his 2004 Wrangler 4.0 intake manifold fit my 1996 XJ 4.0?
What concerns may I run into swapping manifolds?
I appreciate the advise. Thank you.

CanMan · Mar 9, 2009

You'll need to reroute some vacuum lines and extend the AIT sensor(I believe thats the one) harness lines. Other than that, its an easy mod.

cher96 · Mar 9, 2009

Thanks. Will the throttle body on the 2004 work. I noticed the MAP sensor kinda looked different.

CanMan · Mar 9, 2009

The MAP sensor is attached to the throttle body on the new ones, but all you would have to do is remove it and run a vacuum like to yours attached on the firewall. Or extend your harness. Or just use your throttle body.

ILLXJ · Mar 9, 2009

CanMan said:
The MAP sensor is attached to the throttle body on the new ones, but all you would have to do is remove it and run a vacuum like to yours attached on the firewall. Or extend your harness. Or just use your throttle body.

The MAP sensor on a 96 isn't on the firewall. It's on the TB. Should be able to swap them. JIM.

cher96 · Mar 9, 2009

Thank you both so much.
My 96 XJ MAP sensor is on the throttle body. It just looks different.
If I am correct...
I can swap the 04 intake with the fuel rail, injectors, throttle body and just add a few inches of wire and vacuum line and change out the MAP sensor.

That is great! Thank you.

Gojeep · Mar 9, 2009

Here is my write up showing what needs to be done:
http://www.go.jeep-xj.info/HowtoIntakeManifold1.htm

ILLXJ · Mar 9, 2009

I didn't do any thing to the MAP wiring when I did mine. Did have to extend some vac. lines though. JIM.

cher96 · Mar 9, 2009

I would love to attach 2 photos; one of the 2004 manifold and one of the 96 manifold.

Would anyone, could anyone tell me where to run the vacuum hoses on the 96 onto the a swapped 2004 intake manifold ?

I read Gojeeps write up and I think because it looks like an earlier XJ than mine... I am a bit confused.

Thank you.

CanMan · Mar 9, 2009

ILLXJ said:
The MAP sensor on a 96 isn't on the firewall. It's on the TB. Should be able to swap them. JIM.

:doh:

Thats right, OBD2.

cher96 · Mar 9, 2009

I have the 2004 Intake Manifold with everything on it.

I'm going to install the 62mm TB and TB Spacer before I put it on my XJ.

This is my DD so down time needs to be minimal.

Does anyone have photos of their Intake Manifold swap on a 96 to 98 XJ showing vacuum lines they could point me to on the net?

Thank you.

POLAR_JEEP_04 · Mar 9, 2009

what about the power steering pump? I have read that it bolts up differently

gradon · Mar 9, 2009

Mine's a 96 and it is a straightforward swap--don't overthink it. Lets see on the top of the manifold starting by the firewall from right to left:
rear valve cover line, IAT, and MAP(you'll probably cap the left one as you have the 96tb with the map fitting--mine is a bored 94 tb).
On the side of the manifold are three fittings: One for the purge solenoid, middle one for the brake booster, and the other one for some HVAC line that goes in the firewall by the evap cannister.

https://www.paypal.com/us/cgi-bin/w...f5a5f5ae42e779d4b5655493f6171509c5b2ec019b86#

blue95xj · Mar 10, 2009

POLAR_JEEP_04 said:
what about the power steering pump? I have read that it bolts up differently

96 is the year they change p/s pump and bracket. So for a 96 all you need is the intake itself.

On my 95 I still have the original pump with the new bracket and tensioner. But it's kinda rigged and I am not happy with it. The only reason did it was because the 96+( might be 99+) have a plastic pulley that fell apart on me because it had a chip on the edge and I was in a pinch.

cher96 · Mar 10, 2009

I am not sure but I think the Fuel Injectors are different on the 2004 Intake compared to the 96. I think the connectors may not fit.

I think I have to use my injectors off the 96 Intake.

Am I correct?
Thanks.

sharq · Mar 10, 2009

cher96 said:
I am not sure but I think the Fuel Injectors are different on the 2004 Intake compared to the 96. I think the connectors may not fit.

I think I have to use my injectors off the 96 Intake.

Am I correct?
Thanks.

if thats the case then it wont be a big deal to swap the injectors. if you want to get fancy you can swap to LT1 injectors. they atomize the fuel better. just make sure the o-rings are in decent shape or just get new ones for cheap insurance. lube the o-rings a bit when you go to install them and theyll go in a lot easier.

CanMan · Mar 10, 2009

cher96 said:
I am not sure but I think the Fuel Injectors are different on the 2004 Intake compared to the 96. I think the connectors may not fit.

I think I have to use my injectors off the 96 Intake.

Am I correct?
Thanks.

The injector connectors are different from the 96 compaired to the 04.

Id run your fuel rail and injectors for ease of installation.

cher96 · Mar 10, 2009

Thanks everyone. I think I have it now.
If I have any trouble... I'll just post to this thread.
Thanks.

rob92xj · Mar 15, 2009

I'm at a stand still with my stroker/ late model intake swap. What drivebelt is everyone using on the pre-96 XJ? I have about 10 different belts and non of them fit.

blue95xj · Mar 15, 2009

I just went to the parts store and asked for one for a 99.

Swapping Intake Manifolds

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