Saygoodbye41

In having trouble tightening the header at cylinder 4, theres no space to get a bite with any tool I have. Any thoughts?

ericjw1991

If your not in California, and you buy a Header for California emissions standards, there will be fitment issues, escpecially between the header lips and the Intake manifold. If you bought one of these, you may need to return it, or modify the header/manifold lips for them to fit together. There may be hammering involved aswell. But I would return it. If your not careful, bad things could happen. Banks sent me one just like it and it was for a CA XJ, and had to return it. I wasn't gonna modify anything to make it fit.

Saygoodbye41

My xj has the 3 cats I guess that's what you mean for ca standard? I'm on a budget and the fitment at the flange and everything else seems to line up perfectly but I have no clue as to a good way to tighten up that 1 damn bolt next to cyl4 piping. I'm hoping for ideas on a tool or if anyone else figured it out off of a scenario similar to this

ericjw1991

I misunderstood. My bad. Do you have a picture of your problem? Is it the upper or lower bold to the head? Are you having a hard time reaching it? If its the lower bolt, I used a long extension on a socket wrench and used electrical tape to hold the bolt's head and flange to the socket. I put the socket in the general area where that bold goes, and used my Cell Phone's camera with the flash for guidance.

Saygoodbye41

It's the bottom bolt. I put all of the bottom bolts in just enough so that the intake manifold could sit on top and all I have to do is tighten the bolts. The problem is, a socket will not fit past this damn pipe. The pic I posted up farther if you look at the 4th pipe when the flanges are faced properly for the application gets in the way. So idk if there is a tool for tight spaces thatd work but I've even tried reaching from the top gap with a s type wrench and crap and cant get a bite.

Saygoodbye41

Sorry, no pic. Idt it would be sufficient enough to help show anything.

Sloerolla

I just put a header on my Jeep. The bolt I believe you are talking about needed an open end wrench and tiny turns, like a 16th of a turn and then flip the wrench and do this till your patience has worn rice paper thin and then do something fulfilling for a while then come back and try some more. The wrench was a ***** to get on the bolt in the first place and hard to get any leverage on to tighten properly and forget about getting a torque wrench on it. And go back three or four times to give all the bolts some more of a turn after one and then a few heat cycles. I used a ratcheting box end wrench for all the other bolts but that particular one I couldn't get the box end on the bolt and had to use the open end and exercise zen patience. Good luck and I hope this helps

Sloerolla

I just put a header on my Jeep. The bolt I believe you are talking about needed an open end wrench and tiny turns, like a 16th of a turn and then flip the wrench and do this till your patience has worn rice paper thin and then do something fulfilling for a while then come back and try some more. The wrench was a ***** to get on the bolt in the first place and hard to get any leverage on to tighten properly and forget about getting a torque wrench on it. And go back three or four times to give all the bolts some more of a turn after one and then a few heat cycles. I used a ratcheting box end wrench for all the other bolts but that particular one I couldn't get the box end on the bolt and had to use the open end and exercise zen patience. Good luck and I hope this helps Oh .. and maybe take the front driveshaft out, if its 4wd. This may give you just a little more room to get your arms up and in there.. perhaps the down pipe as well, if it isn't welded to the cat. Good luck!

MessyJesse

If you get really desperate maybe put in a stubby stud instead of a bolt, then a wrench to get a nut on there...

PatHenry

Harbor freight sells sets of long wrenches, other options might be using a 1/4 extension, putting just the socket on the bolt then feeding the extension through whatever gaps are available.

Definitely take out the front driveshaft and go at it from the bottom when that's easier. I did a lot of gymnastics when I installed the manifolds in my 95 - some of the stuff was easier from the bottom, some from the top... Having the front pipe out of the way was was a huge help in accessing those bolts.

Just think of all the fun you're having now and how you'll get to do it again after 500 miles or so when it's time to re-check the torque!

PatHenry

If you do this, make sure you put the original conical washer on it - they're important to properly spread the clamping force.

ericjw1991

x2 that. Them washers are hard to find, except from the dealership which you will pay dearly. Without the proper force/torque on the header/manifold to the head, things get....interesting, and not in a good way. I made that mistake and it was horrifying.

third coast

Picture included of the header says it fits a Wrangler and a Grand Cherokee. No mention of XJ but not sure that makes any difference. I saw that bolt being a difficult one when I replaced my head. I installed the manifolds and torqued bolts prior to putting the entire assembly on the motor. If you don't get a good seal with the gaskets you will have problems.(all fasteners should be torqued to spec also but I expect you will be happy just to get it tight.
When I looked for the cup washers at a dealer late last year they were no longer available.