90 XJ PaceSetter Header Problems
 

Just installed some Pacesetter Headers replacing my Factory cracked Manifold, once i got everything back together I Heard a loud exhaust leak. I dicked around with a tube on the ear trying to pinpoint the problem. It sounded as though it was coming from the rear of the manifold (#5 or 6). I proceeded to tighten all the bolts to see if i missed any (the bolt behind exhaust tube #4 is a ***** to get to). They are all torqued to spec, but still this noise. The Muffler expert I was recommended said it was due to the header not sitting correctly on the head. The pacesetter kit comes with these funny washers that allow it to be tightened due to the fact that it is thinner than the intake manifold. Anyone have any pointers so that I can be sure it is flat on the cylinder head before i put everything back together? Or anyone run into problems with their pacesetter installs?

I've never seen a set of pace setter headers for any vehicle that didn't have issues. They all need some form of work to get to seal properly.

Just started taking throttle body and fuel rail off and found that the EGR tube that i had to fab to fit the pacesetter header is completly blown out, probably what is causing the noise. Any suggestions of something to use for the egr? Pacesetter reccomended cutting it and using high temp hose to connect the two, but that obviously doesn't work.

What did you do to fix the EGR tube problem you were having?

Forgot to say I just installed the pacesetter header and have the same issue with the EGR tube. I also have a problem with the y connector pipe lining up with the rest of the exhaust but Pace setter is looking into that problem for me :icon_rolleyes:

i installed a pace header on my MJ a few years ago i cut the egr tube and made plugs out of the pipe. no leaks