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03-13-07, 08:25 PM
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#1 (permalink)
| | Forum Regular
Join Date: Apr 2003 Location: Washington DC
Posts: 176
| Intake/exhaust manifold separate or together
Okay, so everything I have read says to get a replacement set that has been used together (mating surfaces better aligned). Is there any reason to think that I could pick up a separate exhaust manifold and mate it to my current intake and have a reasonable match (maybe after getting them milled?) or is it better to just pony up and spend the money for new intake AND exhaust together.
thanks in advance
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Chaka
1974 fj40
Washington DC
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03-13-07, 08:28 PM
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#2 (permalink)
| | 250+ Club
Join Date: Oct 2005
Posts: 299
| If you have no emmissions testing to deal with in DC, why not run a header?
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03-13-07, 08:34 PM
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#3 (permalink)
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Join Date: Apr 2003 Location: San Ramon, CA
Posts: 287
| You could mate non-paired intake and exhaust together even though they are not a 'matched set' and check with a straight edge to make sure. I have heard the trick is to use two Toyota OEM gaskets sandwiched together to get a good seal. I used one OEM gasket with a stock intake and Man-A-Fre header with no issues after 3+years.
I would clean both intake and exhaust mainfolds thoroughly and check before installing. I believe you can get a machine shop to plane the surfaces that mate to the head if they are off. Good LucK!
Brian
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72 FJ40 with 1975 2F transplant, 4 speed, Orion TC, FJ60 discs, 2.5" lift
97 40th Anniversary FZJ80, OME 2.5" lift, 33s, 185K
02 4Runner (wife's)
68 Mustang, improved with a warmed up 289 & toplader 4 speed, AKA "Dot'
1987 Honda XL600r DD for leaving at BART
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03-13-07, 08:39 PM
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#4 (permalink)
| | Forum Regular
Join Date: Apr 2003 Location: Washington DC
Posts: 176
| Dbarrett,
I bought all the hardware to put on the exhaust system already so I was hoping ot use them. Maybe I am wrong as a newbie but isn't there a bit of welding to be done with sealing off the intake/exhaust mating surface? so that would end up costing me also, plus the header, plus rerouting the exhaust...
maybe I am missing something, it just seemed bolt on replacement would be easiest... not to mention not having to mess with emissions crap (this is CA emissions vehicle).
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Chaka
1974 fj40
Washington DC
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03-13-07, 08:48 PM
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#5 (permalink)
| | Forum Regular
Join Date: Aug 2004 Location: Grand Bay, Alabama
Posts: 58
| I used a mismatched set on my '76 40 with a '71 F engine in it. I tried bolting it on but wasn't satisfied with the seal on the exhaust side so I had a machine shop mill the assembly for me. It runs great and pulls about 19.5 inches of vacuum. I think the machine work cost about $50.
Leon...
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Sit in the truck...I've got it!
'76 FJ40 w/'71 F engine (with many 2F parts), DUI HEI and Toyota PTO winch.
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03-13-07, 08:49 PM
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#6 (permalink)
| | Forum Regular
Join Date: Apr 2003 Location: Washington DC
Posts: 176
| Leon,
what about the mating surface between the intake/exhaust? any problems with that?
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Chaka
1974 fj40
Washington DC
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03-13-07, 08:53 PM
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#7 (permalink)
| | Forum Regular
Join Date: Aug 2004 Location: Grand Bay, Alabama
Posts: 58
| No, they matched up fine. What I did was leave the interconnecting bolts loose and torque the intake and exhaust to the head. I then tightened the interconnecting bolts and delivered the assembly that way to the machine shop.
Leon...
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Sit in the truck...I've got it!
'76 FJ40 w/'71 F engine (with many 2F parts), DUI HEI and Toyota PTO winch.
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03-13-07, 09:37 PM
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#8 (permalink)
| | Forum Regular
Join Date: Apr 2003 Location: Washington DC
Posts: 176
| Okay so here's the other situation...
I am replacing everything in order to pass inspection. Emissions is a part of it, but I am not so worried about that as the reason I failed the 1st time is a rusted out muffler and tail pipe (which led to removing the manifold, stuck bolt...yadda yadda).
So the question is... if i don't have a perfect fit with a mismatched set, what does that mean for emissions tests? I am sure it is dependent on how bad the fit is, but in rough terms... could I pass emissions with an imperfect fit? My goal is to get this thing on the road!!!! it is getting warm here and I am itchin to ride.
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Chaka
1974 fj40
Washington DC
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03-13-07, 11:00 PM
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#9 (permalink)
| | Site Addict
Join Date: Oct 2005 Location: Hagerstown MD
Posts: 1,756
| Chaka,
Ah my newbian brotha! Still pluggin away at this thing huh? god they are a royal f#$ing pain these trucks! I know what you mean about the itch. It was beautiful today I took my Triumph out for a ride and kept thining about taking the top off of my truck and going for a cruise, BUT alas it's apart again.
Back to the story. I assume you found a proper ex manifold right? You should be able to have that thing machined to a reasonable level of tolerance. Just be sure to specify that the manifolds must be the same thickness measured at the bolting surfaces. they should understand this MAKE SURE they do! I torqued my manfolds up first and then torqued them together on the head... this may or may not be right. I bought a new gasket for mine and plan on having this thing planed and trued again, this time properly. I will use a duble gasket. I did manage to tighten up a mainfold n=bolt and smear some rtv around the thing and it sealed up but I don't know how long that will last. I have to retune the carb now!
Hey let me know when you get that thing running, we'll have to hook up with capital cruisers for the coal miners classic this spring! Take care. ken
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1978 (mostly) FJ-40, lift, 2F, bigger tires and custom swiss cheese body panels to reduce weight!
Various other toys 87 4runner, Motorcycles Ducati and Triumphs with an old Mach III in the mix.
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03-14-07, 05:33 AM
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#10 (permalink)
| | Forum Lifer
Join Date: Jan 2003 Location: Kansastitty
Posts: 7,353
| Quote:
Originally Posted by plaiii  No, they matched up fine. What I did was leave the interconnecting bolts loose and torque the intake and exhaust to the head. I then tightened the interconnecting bolts and delivered the assembly that way to the machine shop.
Leon... |
Chaka, this is the way to do it.
GL
Ed
__________________ My Anger-Management Class really pisses me off
'66FJ40, Fresh 2F, H42/Orion(By Poser... LCR4WD), ARB Front/rear(By Poser... LCR4WD), MetalTech Cage installed by Poser, Screw-ups fixed(by Poser) 4WDB Corvette Master, Mini Truck PS, 3.5" Lift, Warn 8274, 33s on stockers, WhiteKnuckle sliders  | |
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