[Duck Vader]

APN Manifold, Magna Flow Cat, Dynomax Cat-Back exhaust, Fuel Pump Assembly Write-Up

First off, my XJ was having a lot of issues. Fuel was not getting to the engine, and the exhaust was shot. I did the fuel pump first, then the exhaust.

Here is what the exhaust sounded like before.



Here is what it sounds like now.



Sorry for the short video. Was trying to get rid of the pulley squeal, I just had to tighten the belt.

Here is what it sounds like after a few thousand miles and reving it up to 4000rpm.

http://www.jeepforum.com/forum/f11/exhaust-clip-dynomax-491367/

Now for the write up:

Fuel pump assembly:

1. Disconnect the (-) batter terminal.



2. Remove the fuel pump relay and try and start the Jeep to get most of the fuel out of the lines.



3. Remove the fuel hose guard. Mine just feel off from rust.



4. Do what you can to remove as much fuel as you can from the tank before dropping it. I used a siphon.

5. Disconnect fuel line and plugs from tank.

[Duck Vader]

6. Loosen hanger bolts.



7. Drop the tank. Take the passenger side down first, and then pull out the tank.



8. Put in new assembly.



9. Repeat in reverse to put everything back.

[Duck Vader]

APN Manifold, Magna Flow Cat, and Dynomax Cat-Back


New Parts:









As I was doing this, I took some connector cleaner and cleaned all electrical connectors and made sure all connections were secure.

1. PB blaster all bolts the day before for easier installation.

2. Disconnect battery.



3. Disconnect down pipe from old manifold.

4. Take out old down pipe/cat/muffler, etc. Make sure you take out the O2 sensors. I used an angle grinder and cut off the cat and tail pipe so I could just pull out old exhaust.

[Duck Vader]

5. Remove air box.



6. Remove belt.



7. Remove power steering pump and place stand up where the air box was. You can see the bolts you have to remove here. Also, take off the bracket as well, it will give you more room to work.

[Duck Vader]

8. Remove cables from throttle body.

9. Disconnect all electrical connections and vacuum lines from intake manifold.









10. Label and unplug the fuel injector plugs.



11. Remove fuel rail. Just put it to the side after undoing the bracket under the intake manifold holding the fuel line in place. I set it next to the power steering pump.

[Duck Vader]

These are the tools I need to remove the bolts from the manifolds. Ratchet wrench and socket.



12. Start removing the bolts. Once they are all removed (the ones under the manifold are hard to get to, but should be easy to remove with either the wrench or socket). The manifolds are held in place with a two dowels on the lower side. Make sure you are careful when removing the manifold.

13. Remove the manifolds.







13. Remove old gasket and clean up everything.

14. Replace everything in reverse and you are done. Make sure you tighten the bolts for the manifolds in the right order. You can check your Hanes manual or the installation instructions from the APN manifold kit. Also, make sure you put the fuel rail in correct. Make sure all the fuel injectors and in nice and tight before you bolt down the fuel rail.

[Duck Vader]

15. Install the new exhaust. It goes in really easy and just bolts right in. I used vice grips to hold the nuts in place while I tightened the bolts on the down pipe to the manifold.

I am thinking about installing a bracket where the cat meets the down pipe, but it is really secure the way it is now. I might put one on as a “just in case” measure.









In all, it took me about 6 hours (1 of that was trying to find a bolt I dropped, the last one for the manifolds). It was not hard, just a lot of work.

If you have any questions, you can just PM me.

Thanks,

Jason

[XJLI]

nice job!

how did the new downpipe compare to the stocker?

[Duck Vader]

It was really nice. It is crimped as you can see, but it does not have the factory dent.

[Miami_XJ]

well done, the exhaust sounds nice..i thought the dynomax wasn't too loud etc..

[XJLI]

Originally Posted by Miami_XJ

well done, the exhaust sounds nice..i thought the dynomax wasn't too loud etc..

My dynomax is louder than stock, but it aint no flowmaster. It really opens up when you get on it, and with the exhaust all opened up it's much louder than just putting a muffler on.

Flowmaster lies too, they really arent flow masters- dynomax flows better.

Vader, have you opened up your intake at all? If your running the stock airbox you're not getting all you can from the exhaust setup.

[Duck Vader]

Originally Posted by 93XJLI

Vader, have you opened up your intake at all? If your running the stock airbox you're not getting all you can from the exhaust setup.

No because I plan on eventually installing a snorkel down the road. Not for another year or so yet, but after I everything else (recovery, armor, lockers, gears, lift) I was going to install one.

I can really notice a change in the acceleration of the XJ now. It is running a lot smoother than before.

[Ivanito]

Also, I don't know the fitment of the Dynomax catback, but my flowmaster catback muffler fell off twice with clamps (till I had it welded on).

[XJLI]

Originally Posted by Duck Vader

No because I plan on eventually installing a snorkel down the road. Not for another year or so yet, but after I everything else (recovery, armor, lockers, gears, lift) I was going to install one.

I can really notice a change in the acceleration of the XJ now. It is running a lot smoother than before.

ok - then you wouldn't wanna cut up your existing box. With my cowl setup (from the MadXJ site) and just the dynomax muffler I felt a huge difference. Better gas mileage too! I averaged 18 from MD to NY this weekend

[danielhays_98xj]

I got my flowmaster super 40 in on Friday and my dad and I are going to install it on Wednesday. If I can, I will post a video or at least an audio file of it in action. Hopefully it will sound good.