1991Jeep_Man

My exhaust leak on my cracked header got worse, and Im gonna do my best to replace it this weekend. If anyone has any advice to give me, knows any links to some really good how-tos, or anything else referring to the APN header, please chime in. I would very much appreciate it. I bought some permatex #59214 high temp thread sealant for the bolts and some copper gasket spray for the gasket.

Also, I am planning on replacing the motor mounts as well. Does the oil filter adapter need to be removed, or just the oil filter? Any thread sealant?

Thanks for any help!

cpnwrench

howdy,

before you begin the project,,,,spray the bolts the best you can with PB blast or AeroKroil or WD40 for at least a day before you try to remove the old header/exhuast manifold bolts!!!

trust me on that!

if you do, they will come out like butter.

i did mine on my vette, i sprayed them for three days about every 8 to 10 hours every day, and they came right out.

I have not replaced my exhaust gasket on my jeep yet, but when i do, I will be doing the same technique to get them loose, as I for sure do NOT want to snap one of them b*^@tches off!!!!

and most of all TAAKE YOUR TIME!!

good luck sir

cpnwrench

1991Jeep_Man

Thanks! Would it be safe to spray the bolts with PB Blaster (Jeep owner's best friend), and then drive somewhere? I know it is good to get them PB'ed, but I need to drive through town to the place Im replacing the header.

dukie564

i would do it at night so it can sit without evaporating / burning off. Driving there should be fine

1991Jeep_Man

I guess I will go ahead and ask. Is this job very difficult?

From what I've seen, it's a matter of labeling hoses and lines, unbolting stuff, and viola. The wierdest thing I'm seeing is the belt. I have never adjusted/removed a belt from my XJ, and the whole power steering pump adjuster thing seems strange. Is this difficult? Btw, I have a Haynes manual. Does this give me an advantage?

I've also seen people say this job takes between anywhere from 2 to almost 8+ hours. I have also seen a lot of people mention broken bolts.

dukie564

shouldn't be that hard.

Belt is adjusted by loosening the pivot bolts on the front of the power steering pump and turning the adjusting nut on the bottom right side.

As far as installing the header?
http://www.ineedparts.com/pdf/20009_install.pdf
http://www.naxja.org/forum/showthread.php?t=1024506

1991Jeep_Man

I am grateful!

Thanks Dukie. I appreciate the links too!

Anyone on those motor mounts? lol

dukie564

yes you need to remove the oil filter adapter to replace the passenger mount.
http://www.ehow.com/how_4483740_moto...erokee-xj.html
http://www.jpmagazine.com/howto/31818/index.html

cpnwrench

howdy,

One thing I would do, is to take pictures and download to pc/mac prior to starting

Then you have something to go by when re assembling if you get confused.

Also yes mark hoses and wires, also, try to take photos as you are dissassembling.......

the haynes manual is pretty good and it does lay out the steps for removal of the exhaust manifold, even though it will keep referring you to other sections (i.e. disconnect battery section, etc etc), but mostly it is mechanical aptitude and attention to detail when you are doing this....

TAKE YOUR TIME,,,,,worst thing you can do and this is how things get lost and broken.........

as for bolt locations for the manifold/header, might want to have a marked cardboard with the bolt hole locations so you can stick them in there to hold them after you have them all out....just a thought.

as for the PB blast put some on tonight a couple times every three or four hours or so...just soak the hell outta it. (put cardboard/rags underneath to catch the drippings.) then again tommorow.

best of luck sir and post some pics of your progress so if you run into problems we can help maybe?

cpnwrench

1991Jeep_Man

That sucks about the oil filter adapter. I have a 91 XJ, and have no idea what bit it uses for that center bolt. Whichever it is, it's probably the one I don't have. Wonderful.

1991Jeep_Man

Does anyone have any advice on the oil filter adapter?

1991Jeep_Man

Well, I just went out and put a batch of PB blaster on all but the lower bolts. There's simply no way to get to those lower bolts until I actually start the project.

Boomer573

Another option to try and has NEVER failed me is using wax. This works best when you can get a torch on the bolts, but has worked on motors that are warm. I usually work on tractors in the 1930-1950's. Some bolts haven't been removed in a half of century or more! Torch use: heat to cherry red, let it cool (usually I spit on the bolt, when it doesn't bounce off and it sizzle) then put the wax on it. I usually either canning wax or used one of my wifes candles. Allow to cool and it will come off. As the nut cools off it draws the wax into the threads, breaking the bond. On one tractor a bolt was not reachable because it ran off kerosene and gas. I started the tractor, placed a empty feed sack in front of the radiator to allow it to heat up faster, and then applied the wax. PB Blaster is the best. Apply over several times over several days. Another trick is to wack the bolt with a brass drift punch a few times (used with PB blaster)