Jio

I am almost done with all maintenance and tune ups on my xj. I am interested in a completely new exhaust system (headers, intake manifold, pipes, mufflers etc.)

I want to know what is the best complete set up that works best on my xj. Not looking for as much performance as I do want better fuel economy. All input is greatly appreciated.

Aaron99WhiteXJ

A lot of people will recommend APN headers, flowmaster muffler either 40 or 44, some 2.5 in diameter piping (better airflow), and you might want to take a look at high flow cats (although some people say they can't pass inspection which is why I don't run one).

Jio

I read a lot about apn needing to be grinded down. Is there anything that would be a direct fit?

XJwonders

Check out banks and borla

http://bankspower.com/products/show/415/97

Vonguido

APN header, custom down pipe w/o the kink, and performance curve 2.5 cat back exhaust w/ high flow spun metallic cat, and magnaflow muffler. iirc APN headers had problems w/ 99's I could be wrong though. I have a 98 and it will bolt up fine to mine when I get one this spring.

Jio

Read banks tend to crack more than others. I'll look into borla but they're pretty pricey.

Jio

I'll research this set up a little. Sounds good. Thanks.

XJEvo

Just installed these ebay headers on my 99. No grinding/modifications required. Install went smooth.

http://www.ebay.com/itm/180803180801...84.m1497.l2649

Jio

Nice. How are they running? Performance improved? Gas milage?

Jio

As for grinding, that comment was more towards the intake manifold. Input on this will help. Thanks.

XJEvo

I like them. The quality of the welds is great. Acceleration is a little better and my gas mileage went up 2-3 mpg on the highway. But my old header was cracked in 4 different places so even replacing it with an OEM header would have done the same thing.

And yeah I meant I didn't have to modify my intake manifold to get the headers on.

Jio

Did you use the stock intake manifold or buy new one?

ksrummel

Did you use the header wrap on yours?

ksrummel

More than likely he used the same intake manifold. 99 was the year they switched to a better flowing intake manifold where the outside tubes are curved and not straight. I have a 98 but am installing the 99+ intake manifold along with new header and complete exhaust

Fred/N0AZZ

There really are only 2 quality units made and both have an excellent warranty with Banks being the best "Lifetime" and they mean it. Borla also makes a quality setup, then only if you want to go custom made for the engine your running them on dyno checked. It leaves but little choices as custom made headers and stainless to boot run into a lot of money fast I know.

I don't care what real header you put on anyone should get them cermamic coated with Jet Hot being the first name that comes to mind. They have coated 16 sets for me no money better spent.