Yet Another Exhaust Man Question....

[NJFJ40]

OK - Finally got around to fixing my leaking exhaust manifold. Got the air cleaner and carb off and started removing the bolts and nuts from the block. But, my rig is an 02/80 FJ40 with all the smog gear. This means I have the hardlines for the vacuum system running towards the front Driver's side and partially blocking the manifold for removal. Not sure if I have to remove - and if I do I have alot more notes to take (there are alot of vacuum lines there but I do have the FSM). Also have the EGR pipe and valve very close to the manifold.

So, any advice? I searched and read today and didn't see any related discussion on this topic. I'd just like to know what all I have to remove so I don't remove too much and create more work for myself or try and do it without removing enough parts and break something or cause more PITA labor.

I am using stock manifold (no headers) and have a new OEM manifold gasket which will go on dry (as per instructions). I also got new studs and bolts for when I re-install and new EGR gasket as well as the heat riser insulator and gasket. I will torgque to factory spec and then re-tighten after I drive it some. May go in a third time just to ensure all is well. Will use anti-seeze on all bolts. Did I miss anything?

TIA,

AndrewT

 

[crewzerdog]

I did my 4/79 FJ40 a few times - got faster at it each time but still a PITA. You didn't mention if you have factory P/S - if you do you can figure on removing that bracket as well to get at the front manifold bolts. I removed the EGR and cooler; along with the hard vacuum lines - remove the bolt at the front of the head to take these off or you risk breaking those darn vac lines. Also, I removed the air rail as it made tightening the carb nuts on the passenger side much easier as well as getting the carb insulator plate back on top of the intake manifold. Don't forget a new gasket for the exhaust manifold to exhaust pipe. You don't have to remove the smog pump but plan on moving some of those hoses out of the way. Again, this is a &*%$# of a job and you don't want to do this again so hope you had the intake/exhaust manifolds surfaced FLAT as one unit. Good luck.

 

[Otis]

I have also done my fj40's a few times and think crewzerdog's advice is good. The job is much easier with as much stuff out of the way as possible. Also, take some photos of the vacuum lines before removal and mark or number them to make it easier to put back together. Here is a pic of what mine looked like when I had the manifold out: