93 Toyota 4x4

I have a 1993 4x4 22RE, had problems tracking down an exhaust leak. I tried to feel around the best I could w/ my hand but never felt anything, finally located the spot after pulling the exhaust manifold.The #4 lower exhaust port was leaking. Factory original gasket (122,000 miles), at about 7' o'clock the gasket material was black indicating the leak. I had the manifold resurfaced as the surface looked kind of rough. Well got everything buttoned back up and I can still hear the leak. Luckily it is somewhat muted and I doubt anyone would notice it, but it is still present just not as annoying as before.

I checked and re welded the down pipe connection at the "Y" as some welds were suspect. The head surface while not shinny metal was clean. The gasket used was a Mahle brand. I would appreciate any ideas on what to look for or how to cure the problem.

I will probably pull the manifold again and replace the gasket AGAIN AT $30 a pop, maybe OEM Toyota gasket, not sure if this will be any better. I would prefer a known heavy duty thicker gasket as the metal sealing area isn't that thick. Also should I be able to reuse the doughnut gaskets at the down pipe or is it best to replace them<<<

wyoming9

iTrader: (1)

You can try Permatex #2 form a gasket a trick from the old days.

You might be able to double up your exhaust gaskets .

Reusing the doughnuts it would be a pain to drop it again because they leak.

Your doing it if you think there good do what you think.

*** Is it possible the exhaust manifold has a crack that only leaks once it gets hot**

Or maybe not till it is tightened down

osv

factory Toyota 22re exhaust gaskets are not very good to begin with, and most of us make the situation worse by not running the exhaust manifold support bar.

this is what run, I've been able to take it on and off a couple of times, so it's re-useable to some extent, just torque it down on the easy side the first time you use it:
http://catalog.remflex.com/TOYOTA_He...ket_p/7010.htm

it's super thick material, but the set that I got didn't have the egr holes in it, so if you have to do smog check, you may have to drill small holes in the material... don't use too big of a bit, the material will shred pretty easily.

93 Toyota 4x4

Permatex #2 on exhaust gaskets....not something I would do. I do like #2 but not exhaust. Well the 1st leak was definitely due to a bad gasket. Now I suspect sealing problems at the manifold/head surface, but resurfacing the manifold should have taken care of the problems. Manifold look good as far as cracks go. I am just SO SURPRISED to have a leak still present after resurfacing, that why I did it, the surface didn't look like it would seal if I just cleaned with a wwire brush and slapped it back on.

yodafan93

http://catalog.remflex.com/TOYOTA_He...ket_p/7002.htm
remflex gasket. a little pricey but unless you have a crack, it'll seal up any leaks.

93 Toyota 4x4

I'll give that a try, just have to measure the ports. Wish those had the heat shield between 2 and 3.

osv

that explains the difference, one is for 22re with stock manifold(has egr ports), the other is for 22re header applications.

I got the header gasket, but it failed smog because the ports are blocked, I had to drill 'em out :-/ and get re-tested.

maybe do that, rather than getting the stock version, because the header version looks beefier... it actually leaves material hanging outside of the gasket area... just use a small bit to drill the egr holes, if you need 'em.

osv

there isn't anything to measure, it fits fine... I'm trying to figure out a way to rig up the heat shield.

believe it or not, some turbo race motors seal fine with hi-temp gasket sealer, they don't need gaskets... it's totally counter-intuitive, but it works.

93 Toyota 4x4

I'm going to drill out the machine rivets in the original and use some pop rivets to put the shield on the replacement.

ordered the 7010 ( the top one on post #7) which is the 1 7/16x 2 3/8.

look at the picts, the ports are two different port sizes.

BTW- torqued the replacement gasket a hair more...over the 33 ft lbs recommended torque and the leak is BARELY noticeable. I can hear it, but if one didn't know the truck then it wouldn't be heard. Drive it for a while so the leak will soot up, at least that way I can tell where it's coming from.