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SOLVED: Following up here. I did replace CAT, no change. Ran all sorts of cleaners through fuel: BG44, various brands of injector and chamber cleaners no change. Best test was Nox= 707@15mph and 830@25mph/FAIL. Finally, swapped out Dist Cap + Rotor. BAM. Easy Pass. Nox=7@15mph, 108@25mph...

Interested to know if you solve this. Is the cowl a removable/replaceable part?

Great info. I replaced the O2 sensor, Oil+Filter, Air filter, CCV and PCV hoses, Ran a bottle of Fuel injector cleaner, and a bottle of CATAclean through 2 tanks of fuel. Drove for 30mins before getting test. Still failed NO2. I'm assuming 30mins is enough to heat up the Cat? In any case, I'm...

Reading there is no EGR in the HO XJ's...? So, cat for me...

Good to know, tech1001. I cannot for the life of me figure out how to post photos on this site. Anyone got any info on how to? The only thing I failed was NO at 25mph. Max allowed 613, I measured 739. At 15mph it was 711 and 677, PASS. At 25mph: CO% was 0, HC was 18, %CO2 was 15.2, %O2 was 0.

Thx 75SV1. I think it's the silicon one. I found the part #s and ordered the proper grommets/elbows for the 1991. They are different. They look to be 1-piece grommet+elbow. A lot of comments said the front one did not fit tight. I am going to assume this is not a problem. I am going to dig into...

Nice setup- wow that is clean- looking for the grommets and elbows for my 1991... I'm seeing them on Amazon for 1994+... Anyone know if there's a difference...? I know they changed the VC on the 4.0 around then...

Also..My VC gasket is a felpro and less than 3 yrs old, hasnt overheated, it's in pretty good shape...

Man it's been so long since I serviced that K&N I forgot there's oil on it. But 99% sure this is engine oil. filter is almost black. Oil on AF cover from hose outlet from engine. Is that front grommet on VC to air filter supposed to be airtight? Mine is not. I do think I'm getting a lot of blow by.

Oops - it a Stock 1991 XJ 4.0 Sport 5 speed, 317k miles, runs like a champ. Original owner. Thx

Ooooh man let me know how what you find out. What brand was your latest one? You can search for my huge thread on this. I went with a Blue Top and that company and those guys were totally awesome, but I had a few issues with tightness on my rebuilds. I eventually had them rebuild my old/original...

So, maybe a noob question, but I'm new to this issue. I'm trying to pass smog (CA, uggg) and I'm failing in just the last category, NO at 25mph. Anyway, going through everything, and I find my air filter (K&N) is covered in oil. So now I'm reading about CCV/PCV valves. I know I replaced these in...

thx Lawsoncl- ya ok I see, just that middle insert is different. I have that. Just need the big piece that the inserts snap into. Not much out there.. seem like someone should be making a new one. I'll hit the (few) yards around here I guess..

Ya. hard to find. not much on the google machine..

Oh wow man ok got it. That side piece/tray part of the plastic shifter cover there where the bulb screws in completely broken off on mine. I see the screw hole there too, hence the hole in the bracket beneath. Its snapped off so clean it looks like it was never there. THANK YOU. I need to get a...

Ok - silly question here. But I'm trying to reassemble my shift lever area on my 1991 5 speed. I just had a shop put in a new clutch, and its all apart. The light for the transfer case lever position indicator is just dangling off to the side. I for the life of me cannot figure out where it goes...

Pretty sure its the fronts with the issue but need to investigate further ebrake? really? elaborate? Mine is 5 speed too. 1991 Sport

Reviving this super old thread. I recently had my front brakes done at a shop (400m ago) (pads, rotors, flex lines, calipers) but I was totally unaware of this break in procedure. My brakes are really hard to "feather" right now, like I keep locking them up at stop signs, etc. They just go from...

UPDATE-SOLVED: Ok, i think this issue has been solved (for now.) The new throwout bearing has been installed, as well as a NEW PILOT BEARING. I saw the old pilot bearing and it was not tight on the shaft, if was definitely shot. The shop actually put in a whole new clutch again as well, just to...

UPDATE: Ok, I received the Timken TB. I gotta say, it looks pretty similar to the National. Nothing on the box says where it was manufactured. The box just says "Timken parts are carefully chosen from select manufacturers." Not encouraging. Both TBs have plastic bodies and are plastic/metal in...