RE-SMOG! Need Help!

[pcperks]

So the 60 I bought apparently had a partial Desmog done to it, with all the EGR gear pulled. I got a new EGR system and have been working on installing it, but am having a problem with where the tube from the cooler hooks up to the block or the exhaust. I think the headers may have been changed out because I don't see any place for it to connect.

If anyone has any pictures on where it is or what it connects to it would be greatly appreciated. I'm starting to think this may have just gotten really expensive if I have to change out headers and everything. Please post a pic or send me a PM if you can help me out.

 

[hank14]

You might be better off posting a picture of what you have under the hood and we can go from there.

 

[hank14]

If you have headers instead of the factory exhaust manifold, there probably isn't a place to connect the j-tube from the cooler.

 

[Cruiserdrew]

If you have a header, and it isn't the downey header with the EGR port, you will need either new headers or a new mainfold. Of the two, I personally think a regular manifold is a better choice.

I have run a set of Downey headers on my FJ40 for years and they are fine, just noisier and hotter than the stock manifold.

I believe I read the Mark's Offroad is handling the Downey (smog legal) headers, so you might give him a call.

Resmogging a truck is an extremely painful process, so good luck.

 

[pcperks]

Yeah, it's really painful in the wallet. Apparently I do need to get an exhaust manifold and down pipe to replace to headers that are on it. So much for the previous owner telling me no major work had been done on it.

From some posts I've been reading, it seems like it's best to swap the intake and exhaust manifold as a set since they bolt together. Is that right or can I get away with just the exhaust? Cruiserparts has them for $150 and say they aren't warped. But for intake and exhaust bolted together already is $250. Is the headache of trying to match them up worth the extra money?

 

[goodol84]

what kind of headers are they?? someone might be willing to swap you straight across..stock manifold for a decent header..hint, hint.

 

[Butt Ugly Chuck]

From some posts I've been reading, it seems like it's best to swap the intake and exhaust manifold as a set since they bolt together. Is that right or can I get away with just the exhaust? Cruiserparts has them for $150 and say they aren't warped. But for intake and exhaust bolted together already is $250. Is the headache of trying to match them up worth the extra money?

Depends on your access to a machine shop willing to plane the whole assembly as one unit. My local shop didn't flinch, only charged me something like $35, and did a good job. Some shops want A LOT more than that and some won't even touch it. Ask some mudders in your area about local shops. A matched, un-warped set of manifolds will be worth it if you can't find someone willing to work on an un-matched or warped set.

Butt

 

[pcperks]

what kind of headers are they?? someone might be willing to swap you straight across..stock manifold for a decent header..hint, hint.

They're old and in nasty shape unfortunately. They had heat shield wrapped around them which made them rust more with moisture getting trapped inside. When I was putting the egr cooler in with them in the way most of it tore off it was so old and you could see they were rusted pretty good. I'm finding some manifolds online, and then will probably save up the money to replace all of the exhaust while I'm at it. New Cat and muffler, the whole deal. Might as well knock it all out at once and not have to deal with it again.

 

[Butt Ugly Chuck]

Might as well knock it all out at once and not have to deal with it again.

Now you just went and jinxed yourself!!!

Butt

 

[Cruiserdrew]

Toyota sells the manifold set brand new and complete with heat riser for about $700 or so. I remember I bout one about 5 years ago when I got sick of messing with the old one. It's been perfect since. To be honest, that is the route I would go.

Is all your air injection stuff there and intact? How about the cat?

 

[tigerfj60]

pcperks I have 1 set if you need bring back to stock PM me.

 

[Norris Marshak]

Considering the possible problems of a used manifold-worn heat riser shaft and bushing, worn horn gaskets, in addition to an unmilled mating surface, you'd be better with the new manifold. Rick Arflin at at Ralph Hayes Toyota is a good source: 25% discount to MUD and TLCA members. Check the MUD supporting Vendor List. Hopes this helps. N.M.

 

[pcperks]

Toyota sells the manifold set brand new and complete with heat riser for about $700 or so. I remember I bout one about 5 years ago when I got sick of messing with the old one. It's been perfect since. To be honest, that is the route I would go.

Is all your air injection stuff there and intact? How about the cat?

All the rest looks like it's there. The hoses seem to be all in different places then normal so I still have to sort through that mess. It got too hot out here in the desert for me to work on it too long today. I really need to get an air conditioned garage. Tired of working on it outside and getting up early in the morning to get it done.

tigerfj60, pm sent. In addition to the manifold I guess I need the down pipe too. Or at least the fitting since I know someone who can weld and shape pipe really good.

I bought this thing knowing I was going to have to do some work on it, but I'm already finding out just how much it takes to make this thing go. But like everyone says, it's an addiction and I'm hooked. Guess I gotta pay to play.

 

[tigerfj60]

All the rest looks like it's there. The hoses seem to be all in different places then normal so I still have to sort through that mess. It got too hot out here in the desert for me to work on it too long today. I really need to get an air conditioned garage. Tired of working on it outside and getting up early in the morning to get it done.

tigerfj60, pm sent. In addition to the manifold I guess I need the down pipe too. Or at least the fitting since I know someone who can weld and shape pipe really good.

I bought this thing knowing I was going to have to do some work on it, but I'm already finding out just how much it takes to make this thing go. But like everyone says, it's an addiction and I'm hooked. Guess I gotta pay to play.

is this down pipe do you need?

 

[pcperks]

Nope, the one from the exhaust manifold that connects to the rest of the exhaust pipe. Since it had headers on it, that part isn't there. I've been trying to find a picture of it for reference but haven't found one yet.

Edit: in the picture you posted, what I need connects to the opening at the top of the picture I believe.

 

[texast6]

i have the down pipe from manifold to cat, let you have it cheap, dont know if it would be worth shiping from texas, but if all else fails pm me

 

[pcperks]

So I am getting a used manifold set, and a complete exhaust that is apparently in really good shape. (Thanks to carpediem84) On top of that, I went through all the vacuum systems and found a broken VSV, broken tube on the HAC, and the bottom torn out of the VCV, all of which I've ordered. Maybe some day I'll actually quit finding stuff wrong with the smog controls and be able to go and get it registered here in CA. With all the stuff I am finding wrong, I have no clue how this thing was even running in the first place. Of course once I replace all this stuff, it will probably not run or run like crap.

 

[pcperks]

Got all my stuff in a couple days ago, and since I have an awesome job, I'm off all day today and this weekend so I started on getting everything put in. Talk about a PITA!

So I pulled the carb off the manifold, which wasn't as easy as I thought it was going to be, but still not too tough. Then a few more nuts and bolts and off came the intake manifold. Which will probably be for sale on ebay sometime soon as it is in good shape, since the exhaust manifold I bought came as a set with the intake as well. So for anyone that runs headers and needs a new intake manifold....

I pulled the entire exhaust off from the headers all the way back. The headers were a headache as they wouldn't come apart, so I ended up having to cut them and lift them out. A couple more cuts and the cat and muffler came out somewhat smoothly.

While this didn't seem like a whole lot, for whatever reason it took me a lot longer then I thought it would. It was getting pretty hot out, even thought it's not nearly as hot as it normally is, so I decided to stop for the day since I needed to get some stuff from the parts store anyway.

So tomorrow it is time to put in the "new" exhaust to replace the headers along with a newer cat and muffler. Then it's time to get the EGR all hooked up, a couple new valves, and then enjoy the vacuum hose nightmare of making sure everything is connected right. If all goes well, hopefully be back to driving it this weekend.

 

[pcperks]

So yesterday was spent putting in the complete exhaust. Once I got that all done, I finally felt like I had accomplished something on this 60, since nothing I have started so far seemed like it had gotten finished. Then I put everything back together and started on all the vacuum line mess. And it was a mess. With a partial desmog, and who knows what other kind of rig jobs, it took me awhile to get all the lines going to the right place.

I'm still trying to figure out a couple ones that I don't see in the emissions manual, but will do some more searching on here to try and figure them out. I know one is for the A/C idle up and isn't covered in the manuals. The other is on the passenger side under the air cleaner. I've got some of the connections made, but can't find the others. If anyone has a diagram or a picture of that, it would be really helpful.

Oh yeah, and it started and ran... but was running pretty rough. Guess once I have all the lines done, it will need to get the carb re-adjusted for having all the smog stuff back on there.

 

[Cruiserdrew]

Wow-hard to believe Ridgecrest has a smog requirement.

If you need any pics of specific hose routing or what ever, let me know. My 84 should be a clone of that 83.

I desmogged a 76 2F and it runs really nice. It starts easily, never hiccoughs etc. It is now simple to work on as well. It's really a shame that we are forced to maintain smog compliance in these old trucks.