If one is thinking about adding a performance exhaust system, headers, CAI and chip (Jet) - what would the logical/best order of installation be? And any suggestions on the best brands?
It depends if you are doing this in stages based on ease of intallation or money.
If you are going for bang for the buck, this order:
2. Exhaust (muffler, Cat back or custom-- what ever you like or can afford)
3. Jet chip or ECM program
Headers are not yet out for the 4.0L, so they would likely be last on your list no matter what.
In terms of ease of install:
1. Jet Chip -- 5-10 min job
2. CAI- 1 hour
3. Exhaust- varies but most time consuming and may need a pro to do some work
4. Headers- Passenger-- easy, Driver side--- a real pain
If the headers are available by the time of your install, I strongly suggest you do them along with the exhaust as it will be easier while the OEM exhaust is allready lose or removed.