Ok, here we go,

The XJ is at my local install mechanic, reputable guy does all my jeep Camaro work that I wont tackle.
APN header was ordered and attempted install, NO GOOD header aligns up, bolts up, however tube #6(we will call it) does not allow the manifold to "seat" properly and fit into the dowl pin, tube six is a straight shot to the top on slight angle, not curved like the original. dimpling does not work, APN is closed for day ofcourse, and now I am at a stand still with the jeep half apart. Manifold will not come down as it is hittin tube 6, which will not allow it to seat flush and into the dowl pin. Any help is appreciated, I expected it to fit as any part that is made for a purpose,Im so fed up, feel like just ordering the banks or something that I know will fit right away but not sure if APN will take theres back. Could it have been welded up on too much of angle, or is it bad design as far as it not being curved enough?
Trying pics on here in the thread for manifold differences against the original. also included a pic of the crushed downpipe that we all have replaced which I had a nice mandrel on fabbed and installed.

Thanks guys

 

On the 99 Xj's you have the grind down the bottom of the intake #6 runner

 

From what I understand you have to grind down that area to make it fit flush.

Try searching there might be a write up somewhere telling you exactly where/what to grind.

 

I put a '99 up intake on my '98 & had a the same problem with "runner number 6" when I installed the aftermarket header.

To fix this, I took a hammer to the runner to gain the needed clearance for the intake.

It only takes a couple of light strikes. The metal was stainless steel but it bent pretty easy.

Luck.

 

yeah I had read some of these threads, just seemed to be some guys have to shim some off and some don't, But when I saw this bolted up with the intake sitting on top it wasn't even close, and makes me cringe having to try to shim off or grind that much?

We also lightly bent or dimpled that number six on the header itself and still didn't provide enough clearance, not to mention Im not big on the concept of closing the volume of the tube just to make it fit. Seems like it needed to be seriously bent to fit and I was not willing to do it rather just buy a new header I guess if I have to bend it in that much.

 

It's a common thing. Shoulda read up on this before purchasing the part. Just get to grinding

 

so you guys are saying to hammer/or grind the bottom of the manifold that comes down not the header tube itself?

 

Yeah just seemed like when I read the threads not all people had this problem so I took the chance. Just tried to save a buck ya know

 

ok thanks for the responses, gonna start grinding, we estimate 1/8th inch to get it to fit.
You guys rock!

 

 

Not all 99s need to do this.

On my 99 the APN manifold fit fine at the head with the intake.

My issue was at the interface with the rest of the exhaust. The pipe was slightly longer than the doughnut gasket was thick. To get a good seal I needed to grind down the pipe to be flush with the doughnut so the flange pipe made a good seal.

 

The people without 99+ intake manis don't have to do that.

 

I figured out that i had a 99+ intake after i bought this header....i grinded on the intake and a little bit off the header also but it works great now!