1997 Jeep TJ - Project Teal-J II, Part 4

Our first step was to soak all the nuts and bolts we would be removing in JB 80 to help to break the bond between any rusted fasteners and act as a lubricant, making removal easier.

Next, we loosened the bolts that attached the header to the block. Some of these are accessible from the top of the engine bay, while others require an approach from the bottom of the vehicle.

Installing a new header on a TJ is difficult and time consuming because to get the header out, the intake manifold must also come off. To accomplish this, the power-steering pump must be unbolted from the intake manifold. To prepare for this step, we loosened the adjusting pulley so the serpentine belt could be removed.

After the belt is off, the power-steering pump assembly can be unbolted from the intake manifold.

The next step is to unplug all the sensors, throttle cable, vacuum hoses, wiring for the fuel injectors and whatever else is attached to the intake manifold. Depressurizing the fuel-injection system also is recommended along with using a special tool to remove the fuel lines. We found that we did not have to do this; instead of fully removing the manifold, we simply rotated it up and over while taking care not to damage the fuel lines. Once that was accomplished, we were able to remove the exhaust manifold.

Factory Jeep manifolds are notorious for cracking, so we were glad to replace ours with a new header from PaceSetter. In addition to looking much better, the PaceSetter headers feature mandrel-bent 1 ½-inch tubing and a 2-inch collector to help increase flow and add horsepower.

We like the nice, thick flange that the PaceSetter headers come with. The headers are available in black paint, but we chose the Armor Coat option, which won't discolor or dull and reduces underhood temperature. It also gives the header a nice appearance and resists corrosion. Another important feature of this TJ header is that it is smog-legal in all states.

With the old header out of the way, remove the old gasket material, make sure all mating surfaces are clean, and pop the supplied new gasket into place. Then the header can be installed and the intake manifold put back into position. While it might look simple, expect the header install to require the majority of your install time.