Header Install Attempts - anyone? - 84 FJ60

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Mar 29, 2006
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I like to do my own wrenching but this would be my 1st header install. My buddy had his header installed by his FJ60 mechanic because he thinks it's too much trouble to free up the drivers side engine bay and reconnect all those vacuum hoses and what not in the right places. So anyways...the mechanic is moving out of town, so I only have a couple of weeks before he leaves....How bad/hard is it to install some MAF headers on a FJ60? Should I dare or leave it to the experts?
 
Do you have the inevitable intake manifold leak? If so, it's worth the trouble. Take lots of pix of the hoses 'cause you'll need 'em (& the emissions control manual).

The rear manifold nuts are hard to get at & impossible to torque properly IMHO. There's an ugly oil cooler or something with a rusty metal flex line that's a screaming bitch to get off & back on. Other than that, it's a technically moderate, physically difficult job unless you're a double-jointed monkey.

But it's rewarding & you'll know your cruiser much better at the end, particularly emissions control & carb. Great opportunity to change the vac lines (mark 'em with stick-on tags that match ones on the connections. You can change one at a time that way. Make copies of the manual pages & write notes on 'em.

I used MAF's 6-2-1 ceramic coated headers on my '83 & really liked them, but the head/head gasket crapped out less than 3,000 mi later. Now they're for sale, along with the carb heater setup (put the complete stock engine from my '84 back in).

Exhaust tip from my Midas neighbor - hook things up starting in the front & work to the rear.
 
Last edited:
Sorry for the hijack, I have a question about installing a header. You might already know or might be interested in knowing. When installing a header, where the exhaust and intake manifolds bolt together. Do you need to cover the hole that will be left in the bottom of the intake manifold when removing the exhaust manifold? Why are they even bolted together?

TIA-
 
Tinker said:
Do you have the inevitable intake manifold leak? If so, it's worth the trouble. Take lots of pix of the hoses 'cause you'll need 'em (& the emissions control manual).

The rear manifold nuts are hard to get at & impossible to torque properly IMHO. There's an ugly oil cooler or something with a rusty metal flex line that's a screaming bitch to get off & back on. Other than that, it's a technically moderate, physically difficult job unless you're a double-jointed monkey.

But it's rewarding & you'll know your cruiser much better at the end, particularly emissions control & carb. Great opportunity to change the vac lines (mark 'em with stick-on tags that match ones on the connections. You can change one at a time that way. Make copies of the manual pages & write notes on 'em.

I used MAF's 6-2-1 ceramic coated headers on my '83 & really liked them, but the head/head gasket crapped out less than 3,000 mi later. Now they're for sale, along with the carb heater setup (put the complete stock engine from my '84 back in).

Exhaust tip from my Midas neighbor - hook things up starting in the front & work to the rear.

Thanks for the reply, I'll have to take another look down before I decided. Any tips on aftermarket gaskets that might work a little better?
 
PA -
The "hole" is the carb heater plenum - you don't have to "plug" it if you live in a warm climate. If not, you need another source of engine heat like the MAF coolant-fed carb heater kit.

S&S -
I used the SOR kevlar one & liked the way it worked (I like kevlar in general). General concesus on this forum is that FelPro's gasket is the best. I just used their replacements for 5.7 Vortec intake manifold gaskets & am in awe. Or disgust of GM's originals.
 
TINKER says>>>>There's an ugly oil cooler or something with a rusty metal flex line that's a screaming bitch to get off & back on.


this is not an oil cooler. its a exhaust cooler for the egr valve....and yes it is APITAZZZZ to get off....
 
header

I just installed a header from downey offroad on my 85 fj60 . It was a pain but in the process I discovered several problems i was aware of. One the engine mount was broken, and the intake manafold was cracked so much for a weekend job. other then the unexpected items it wasnt to bad. thanks to curriser parts for a use manafold at a reasonable price and fast shipping it was ready to head for the muffler shop the next week. It was worth the hassle. Now I heard of lots of people haveing Problems with downey offroad, but i had no problems what so ever of course i was able to go to thier shop and deal with them directly.they had good advice and there kit was complete with all the tings needed to do the job right.
 
Tinker said:
PA -
The "hole" is the carb heater plenum - you don't have to "plug" it if you live in a warm climate. If not, you need another source of engine heat like the MAF coolant-fed carb heater kit.


Thanks...


:cheers:
 
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