79 FJ40 Manifold Removal – How to Question

[1979 FJ40ish]

Never done anything like this before. I’m trying to remove the manifolds from my 1979 FJ40 2F engine. I have everything unbolted and disconnected except where the pipe from the EGR Cooler connects to the bottom rear of the manifold.

It looks like I will also need to unbolt the EGR Cooler from the engine to allow the EGR pipe to drop down a bit so the studs on the bottom of the manifold will clear the pipe.

Is it possible to remove the manifolds without dropping the EGR Cooler?

Do I need to drain the coolant from the engine before unbolting the pipe from the bottom of the manifold?

If I do need to unbolt the EGR Cooler from the engine, do I first need to drain the coolant from the engine?

 

[wimberosa]

No draining of coolant needed. This is a cooler for hot gases. The rear connection to the manifold with that EGR pipe should be disconnected and the cooler itself can be unbolted from the engine to let it drop down. You almost assuredly will not be able to disconnect the EGR pipe from the cooler itself as it tends to weld itself on over time (nor should you have to disconnect the pipe from the cooler).

 

[1979 FJ40ish]

Thank you - this is the best news I've had today.
The manuals I have don't have much information about the EGR Cooler. It appears to be attached to the engine with 2 bolts, and I'm assuming no gasket. Correct?

 

[wimberosa]

No gasket against the engine. That finned little submarine shaped EGR cooler is a self contained unit with just the inlet and outlet ports coming from manifold and EGR valve. If you want to see what the inside looks like or what size bolts it takes to replace ... just check my build thread in my sig.

 

[1979 FJ40ish]

I finally got the manifolds off my 79 FJ40. What a job! I'm waiting for them to come back from the media blaster. Much to my surprise, while heavily rusted, the damper was still intact and functioned when heat was applied to it.

I ordered a new gas filter (see the photo in the link below). There are no marking on the new filter. Does it make any difference what hose is attached to what nipple? If yes, how can I sort it out?

Thanks

https://forum.ih8mud.com/attachments/1737303539795-webp.3819342/

 

[60 40]

Makes no difference but you need to cap any of the "nipples" on the gas filter that you don't use or you will have a vacuum leak.

 

[1979 FJ40ish]

Thanks

 

[nabbasi]

Something I learned on my recent-ish manifold fun…

1) it’s commonly recommended to use the Remflex gasket (part 7009A). I didn’t do that, and used the OEM gasket the first time, and had leaks. I reinstalled with the remflex gasket snd it is excellent.
2) I might not have had an issue with OEM if I had mated the manifolds loosely, then installed the manifolds to the head, then tightened the manifolds together.

 

[1979 FJ40ish]

Thanks for the tip.