Help with new exhaust manifold!!

cantaloop

cantaloop

New member
So ive had an exhaust leak for a while now, just a little ticking noise. Figured it was my manifold cause the stock cast ones crack all the time. So got a new "mini header" from a dealership, got it installed tonight with all new gaskets and now my exhaust leak is TERRIBLE. Huge ticking noise coming from manifold area. Way worse than before. Looking at the booger welds on this thing i cant help but thing theres a hole somewhere. Anyone have any ideas? Slightly annoying when you spend all this time and money on new parts and it doesnt even do its job.

On the car.
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New one.
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Jee-buss, I'm pretty sure I could drink molten metal and crap better welds than that!

Before we go after the company that made it, did you use new exhaust gaskets, and did you completely clean the mating surfaces? Did you test fit the gaskets to ensure they matched the ports well?

If all the above is squared away, I would definitely go after the company that made it and demand your money back. Might be hard given you've had it installed but still explain the situation and your issue with it and if they won't stand up to their crapsmanship tell your bank to deny the charge.

You might want to go to an exhaust or performance shop and have them copy the pattern down in a sense, just without all the needless brackets and what not so you can have one that works and wasn't welded by a 4yr old.

Were on earth did you buy that, ebay?
 
I feel for you. The first Toyota mini Header I ordered was crap too. The mating surfaces were not flat at all. I sent it back at a loss to myself and the seller.

I ordered a second through Camelback Toyota and it was acceptable but still a pretty ugly part to get from the dealership. Not impressed. Who the he11 does the welding on these manifolds? I inspected it when I picked it up at the dealership. Mine doesn't leak at least.
 
The one I bought for my tacoma was the same crappy welding but no leaks. I did spend some time cleaning up the welds on the inside for better flow. I was wondering how the welding could be so bad. Eventually you would have to get better at it
 
I was unaware you could even get these. Is there any performance increase over the stock cast manifold or are they significantly cheaper? Just thinking if there isn't a performance increase or money reason you could just go back to stock.
 
From all the tacoma sites I read there is a couple horsepower gain over the stock cast ones, plus the fact it won't crack and destroy your valves. They are not expensive so the only real drawback to them is the shoddy welding. I have been very happy with mine once I got over the high school shop welding. They came as standard eguipment on later model 1st gen tacomas and 3rd gen 4runners
 
Another nice side benefit is that it is lower profile so it makes a little more room on that side of the engine bay. I now have more room for pulling the oil filter out that way through the top. I slip a cut off plastic bottle under the filter and then I can pull it straight up and out without spilling a drop. It was harder to do with the stock part.
 
Troybylt said:
Jee-buss, I'm pretty sure I could drink molten metal and crap better welds than that!



Before we go after the company that made it, did you use new exhaust gaskets, and did you completely clean the mating surfaces? Did you test fit the gaskets to ensure they matched the ports well?



If all the above is squared away, I would definitely go after the company that made it and demand your money back. Might be hard given you've had it installed but still explain the situation and your issue with it and if they won't stand up to their crapsmanship tell your bank to deny the charge.



You might want to go to an exhaust or performance shop and have them copy the pattern down in a sense, just without all the needless brackets and what not so you can have one that works and wasn't welded by a 4yr old.



Were on earth did you buy that, ebay?
Click to expand...

Yeah, those welds very pretty disappointing. All new gaskets all around, made sure that they all fit right. I didnt clean the surfaces very well, just brushed off all the carbon gunk on them. And I bought it from a legit toyota dealer in virginia just because that was the cheapest option. $180 vs $230ish at my local dealer. I mean the surfaces LOOK flat and everything appears flush, i'll have to check the old manifold to see if its maybe warped. Gonna have a welder look at it today, maybe theres something i forgot.

Should i try and retorque the bolts when the engine is warm?


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Your answer to your problem is "SMOKE".... When the system is filled with smoke its got to exit somewhere and typically is the best way to find your problem works very well for vacuum system as well
 
Last edited:
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Checked all the connections with soapy water and a vacuum in the tail pipe, and ALL of them were leaking a good amount (bubbling). Everything has been torqued to spec. All new gaskets all around. This is really frustrating. Is the mating surface itself maybe warped? Should i call the dealership i bought it from and try and get a new one shipped to me?


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You can definitely use some permatex copper sealant. I've seen good reviews of people who use it to help with the imperfections. I had a few leaks too and am in the process of redoing my donut and exhaust manifold gaskets. I'm not finished yet, but will let you know what I've had success with when I get back in town. I got a few new studs because I damaged a few. I also got all new exhaust nuts. I'll keep you posted.

Best of luck


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cantaloop said:
Should i have used exhaust sealant?
Click to expand...

I'm assuming you mean leaks at the mating surfaces not at the welding?

No, you should not need any sealant to do what you have done here. A new manifold gasket, EGR gasket, and 2 round down pipe gaskets are all you need. If put in properly and torqued there should be no leaks. Toyota used no sealant here and you are just putting the OEM pieces back together.

Did you buy OEM gaskets?

Man that sucks. As I mentioned earlier, the first exhaust manifold I received had 1 bad flange for the front (I think) 2 cylinders. It was a pain in the butt but I returned it and tried another later when I could inspect it at the dealership.

2 years on that one now and no issues. Good luck.
 
Kanoe said:
I'm assuming you mean leaks at the mating surfaces not at the welding?



No, you should not need any sealant to do what you have done here. A new manifold gasket, EGR gasket, and 2 round down pipe gaskets are all you need. If put in properly and torqued there should be no leaks. Toyota used no sealant here and you are just putting the OEM pieces back together.



Did you buy OEM gaskets?



Man that sucks. As I mentioned earlier, the first exhaust manifold I received had 1 bad flange for the front (I think) 2 cylinders. It was a pain in the butt but I returned it and tried another later when I could inspect it at the dealership.



2 years on that one now and no issues. Good luck.
Click to expand...


Fel pro metal gaskets for the main exhaust one and for the 2 donut ones on the down tube. OEM for the EGR one. And in trying to torque it properly i stripped a stud. But despite how booger blasted those welds look, they werent leaking. So i have 2 options:

1) assume that the manifold is ok. Order new OEM gaskets and LC Engineering studs all around and retry next weekend. Maybe even some sealant for good measure.

2) call the dealership i bought it from and make them give me a new one, if by chancs the mating surfaces are warped. But the fact that ALL 3 of the mating surfaces were leaking a good amount makes me think that it was somehow my fault.

Thanks for your thoughts


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