How to remove '79 FJ40 exhaust manifold to replace gasket.

[igniter3]

Hello Folks,

What is the easier way to remove the exhaust manifold to replace the manifold gasket?
Do I have to remove any other parts before the exhaust manifold can be remove?
Any help will be greatly appreciated.
Thanks,

Charly

 

[mydogpea]

You'll have to remove the intake as well. Downpipe might have to be removed to.
Vacuum lines, make sure you mark them so you know where they go when reinstalling
Fuel line to carb.
PCV hose

Have fun.

 

[igniter3]

mydogpea, Thanks for your input....

 

[Fast Eddy]

It's almost always easier, in the end, to remove more stuff than less stuff. Pull the exhaust down pipe, the linkage, the carb, probably all the vacuum lines, etc.

 

[Heron]

Just finished replacing my 76 manifold gaskets.
I soaked the mounting hardware including the exhaust pipe attach bolts for several days beforehand with Blaster.
It is hard to see and reach some of the fasteners so I recommend removing some of the obstacles in the way. will save you some time and skinned knuckle.
Like mydogpea said. Mark the removed items so you can get them back in the right place.
Be prepared for a longer project than you anticipate, because once removed you may find there is more to it than just the gasket.
I had to take my assembled intake and exhaust to the machine shop for resurfacing. If you decide to replace the gasket between the intake and exhaust
be sure to do it first and use a flat surface such as a table saw to realign after replacing the gaskets and exhaust butterfly, if needed.
I could not find the recommended torque for the manifold bolts a Bud recommended 30-40 for the big bolts and 20-30 for the small end bolts.

Be sure to use Toyota gaskets.

 

[Fast Eddy]

Be sure to use Toyota gaskets.

A lot of people recommend a Remflex gasket instead. Search.

You may want to get the solid stainless insulator from SOR for between the manifolds to protect the aluminum intake from cracking.

 

[Racer65]

I'm sure you can see that this job requires lots of patience on a '79 and later FJ40, due to the amount of emissions plumbing on that side of the engine Bay. Take plenty of pictures.

I currently have the air cleaner assembly and carb out of the car just so that I can re-tighten up the manifold bolts, which are inaccessible otherwise. The bolt in the back is only like an inch away from the firewall and barely accessible. Heron is right that you should plan for several sub-projects while the car is opened up.

In hindsight, I should have just pull the engine on Day 1 and do everything outside the car.

 

[mydogpea]

33 ft. lbs. on manifold bolts.

 

[Downey]

I might as well add that years of hot/cold/hot/cold has turned your exhaust manifold into "glass", treat it like it's glass (no stress during removal) and you might not crack it!!! Not only do you not find an over-abundance of used exhaust manifolds for sale (because many crack during removal), but you also have to hope they do not crack during reinstallation. I guess you needed something else to worry about at this point- - - sorry.

 

[roma042987]

looks like good advice on here so far I've redone two in the last few months. ended up using a stainless block off plate where flapper goes. There are multiple gaskets that will need replaced: intake gasket, the two gaskets between the intake and exhaust, and four ring gaskets and two springs for the exhaust horns. you will probably need to sand blast the exhaust manifold to get all of the crud out of the seats for the exhaust horn rings. I had several bolts break off in the exhaust manifold. (the ones that bolt it to the intake) so be prepared for that. I ended up installing studs there because they are stronger. once the intake and exhaust manifold are secured like others have said definitely take them to a machine shop and have them milled. While you are this deep into it by the way would be an excellent time to replace the head gasket and have the head gone through by a cylinder head shop for new seals.

 

[igniter3]

Thank you so much for all of your folks inputs.....
I just bought the exhaust manifold gasket kit that came with the two intake
gaskets from O'Reilly Auto Parts, Fel-Pro brand.
Anyone of you know this gasket is good enough to use? cheap only $25.
The gasket does look good and solid.
Thanks again,