Does anyone here ever have trouble installing their exhaust header? I can't get the bolt holes on my manifold to line up with the ones on the engine without using some bar to bend the pipe. After that's done I have issues threading the rest of the bolts into place. What am I doing wrong? :/
Unfortunately, it's quite common with many engines from the heat cycling. Sometimes they get so bad you have to toss them and get another one.
No. This is not acceptable. This header is a replacement for the cracked garbage I've been using up until now and these bolt holes are within 1/4" of lining up with the holes on the head. I don't have a ton of cash to spare for yet another header and I need this working today.
I had the same problem when I reinstalled my stock one. Didn't take long to figure out why both the front and rear ones were busted off to begin with. What I did was put the rear one on the rear stud and start the nut. Then I installed the two middle ones with the rear middle one first and then the front middle one. My front stud was then off around a eighth to three sixteenths. I then used a pry bar and pryed the exhaust manifold down and after many not so nice words and attempts I finally found a way to not only pry it down but also slightly forward allowing me to finally install the front stud. I then started the nut and then went back and installed the rest of the bolts. Then I torqued them to spec and in the correct order. Don't know if all of the exhaust manifolds are warped like mine was but anyway thats how after many failed attempts I finally got mine on and tightened up. Hope this helps with your problem and question. I also used new grade eight bolts and washers I purchased from our local jeep dealer. Anyway good luck and be careful!
This installation theory would have helped me a little earlier. I gave up and gave it to a machinist. His problem now. :/
Oh and something very interesting that probably threw everything off in the first place. When I unbolted the manifold, there was no rear bolt. So I'm actually missing a manifold bolt.