YJ Exhaust Replacement - JeepForum.com
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post #1 of 5 Old 02-28-2010, 03:08 PM Thread Starter
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1995 YJ Wrangler 
Join Date: Feb 2010
Location: Michigan
Posts: 189
YJ Exhaust Replacement

My first of many questions--go easy on me!

Just ordered complete exhaust system for 1995 yj 2.5--pacesetter header, all pipes, Dynomax Superturbo cat back. I'm a little nervous to tackle the manifold removal/header installation, but going to give it a Jeep owner's best effort to do it on my own.

Chilton guide says that you have to drain the radiator and it also says that the fuel supply and return pipes need to be disconnected. From what I've read in other forum posts, it doesn't sound like this is necessary. Could someone shed some light on the steps necessary to tackle this project. Any other tips would be greatly appreciated. Please keep in mind that some of the *&%# bolt heads are snapped off and I am going to have to extract these too.

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post #2 of 5 Old 02-28-2010, 06:16 PM
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1995 XJ Cherokee 
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Location: California
Posts: 113
I just replaced the exhaust manifold on my YJ without draining the radiator. I don't see why that would be necessary.

I did have to disconnect the fuel rail and injectors but it was pretty easy.

Just follow the instructions that came with your parts and you shouldn't have a problem.

I don't have too much experience when it comes to auto mechanics and it was simple for me, so if you can follow directions go for it.

One thing that I did that made it easy was to put all the bolts and nuts in zip lock bags and label the bags where they came from.

I also used tape and marked the different hoses and lines so that I could easily identify where they went.

Trust me, if I can do it, then you can do it.
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post #3 of 5 Old 02-28-2010, 06:28 PM
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2012 JK Wrangler 
Join Date: Mar 2007
Location: Chester, VA
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I didn't drain the radiator when I replaced my exh header a while back...

Take lots of photos so you can get all the hoses pack in the right spots. A good steady pull on the fuel rail and the the entire assembly will pop out but make sure you have all the bolts out (some are a little hard to see) I'd pickup a set of new oil rings when you instal the injectors.

A good set of gear wrenches worked great to get access to the exh manifold bolts... I found it was easier to get to several of them from under the jeep as opposed to from the top.

One day my Jeep will be .....

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post #4 of 5 Old 11-30-2014, 07:24 PM
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1994 YJ Wrangler 
Join Date: Nov 2014
Location: Washougal
Posts: 18
Magnaflow.... ceramic headers

I see this is an old thread without much activity, which makes me wonder.... why isn't there more talk about exhaust tweaking on jeeps????

I'm considering putting ceramic headers (junkyard find) and a 3" Magnaflow exhaust (recycled from an F150 that is going to the junk heap).... my YJ is a stock '94 Sahara model..... 4.0L 6cylinder.....

Thoughts? Comments? Concerns?
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post #5 of 5 Old 11-30-2014, 08:29 PM
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1990 YJ Wrangler 
Join Date: Jun 2007
Location: San Diego
Posts: 18,603
the most common exhaust mod with a big benefit is the TJ style downpipe. This will wrap in front of the oil pan instead of crossing under the bell housing where is becomes a rock target.

headers and other supposed upgrades never seem to really make any difference in performance

"The right to be heard does not necessarily include the right to be taken seriously." —Hubert Humphrey

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1995 yj , exhaust , exhaust manifold , replacement

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