Warped manifold?

[Morks]

Swapping engines in my 2004 tj. I am unable to properly line up my intake manifold because it is contacting the exhaust... Tried shaving down the intake slightly just to see and nothing. The exhaust manifold is sealing the ports however. So not sure what the issue is other than a warped manifold putting a 2003 4.0 liter in, so shouldn't be any issues...

 

[Gilaguy23]

Ive had and seen many exhaust manifolds warp to where they blow gaskets or leak and make an annoying racket, never to the pointthey would not fit together if that makes sense.. In my case there were the 300/6cyl and 360 or FE ford engine manifolds.I cant say Ive heard of the same issue on the 4.0,just the common cracking is pretty typical.

 

[Irun]

It's been a while since I've removed a manifold, but there are dowel pins on the head that need to be lined up and properly set into the manifold. I'm not 100% sure, but believe they're between intake runners 1-2 and 5-6. If the intake isn't lined up on them properly it won't set straight and can appear warped. Also, you run the risk of cracking the manifold, when tightening it. Double check those as a starter.

 

[Morks]

It's been a while since I've removed a manifold, but there are dowel pins on the head that need to be lined up and properly set into the manifold. I'm not 100% sure, but believe they're between intake runners 1-2 and 5-6. If the intake isn't lined up on them properly it won't set straight and can appear warped. Also, you run the risk of cracking the manifold, when tightening it. Double check those as a starter.

Yeah, the manifold would not allow me to put it on the dowels. Ended up shaving a decent amount of material off the exhaust, about where the intake manifold contacts it, near the dowels. Even then I couldn't seal it properly if I tightened the exhaust and then intake. Ended up having to, once snug, go quarter-turn evenly all the way around, making sure it all seated flush. Once I get the jeep running I will comment if that worked or not...