Build your own 3.4 crossover pipe

Jason4X4 · 03-02-2008, 07:13 AM

here you go, I took lots of pics, and I will do what I can for describing what I did, I had a total of $3.00 in it.

obviously this is the factory pipe, it just has the heat shield removed

took and cleaned all the mud off

here is one of the factory welds, I cut the weld, without cutting the pipe

here is what it looks like with one pipe removed, I used a cut off wheel and a die grinder to get in the area where the two pipes came together.

you can see here that I left the factory weld on the pipe, it makes it nice when re-welding it back together, and also you know how far the pipe goes into the flange.

another one with the weld cut

here is the pie with the flanges cut off, I didn't cut the short pipe off of the big flange, it worked wihtout needing to. I also marked right and left on the flew, so I can put it in the same way.

I'm not sure how many pics I can put in one post, so I am going to post this and start another post, so if you can, don't post yet until I am done, thanks.

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Jason4X4 · 03-02-2008, 07:21 AM

first cut on the pipe

how the pipe fits

second cut

what is left, this is the flex

other side of pipe

test fitting

this is the clearance with the pipe in place

both pipes test fit

as you can see, the flex cuts don't line up, so I took it to the grinder to get the angles right

closer

even closer, NOTE, you can also see that I did wind up flipping the flex over, my right mark is now on the left

I wound up getting a piece of pipe to put inbetween here, I think it would have been able to be welded without it, but I wanted to make sure that the flex wasn't going to interfer with the trans bolts

engine clearance

I am going to do another post now, please hold...

Jason4X4 · 03-02-2008, 07:32 AM

side shot before welding

you can see here the how much room there is for the transmission and bolts

another pic before welding

one more

head clearance

tacked in place

driver side clearance

tacked in place

the two pipes are close, but they don't touch, they can be tacked together, but I didn't

all welded up, I am using a flux core wire welder, they look better after I wire brush them

final clearances

this is with the engine in, firewall clearance

there is more room here than it looks like

since we used the factory down pipe, I had to move the o2 sensor cause it was hitting the frame, I also had to cut an ear off of this pipe at the flange, I just don't have a pic of it

welded it to the factory exhaust

used the factory o2 sensor hole as the second o2 sensor hole for the 3.4. yes it is in front of the cat, but it has a dummy box on it.

you can see why I had to move the o2

That;s all I have, this was on an 89 4runner, which I believe is the first gen(?). anyway, it worked for me, so good luck...

mt_goat · 03-02-2008, 07:57 AM

Excellent writeup! I might just add that the later 5VZFE models have a different crossover. I'll try to post a pic of the newer style factory crossover later. What is involved with removing the heat shield on the older style crossover?

Elvota · 03-02-2008, 08:53 AM

Nice job.

Real good savings on the 3.4 swap. Heck, with all the YT 3.4 swap tips out there, we'll soon be dropping 3.0's and making money at the same time.

mt_goat · 03-02-2008, 10:12 AM

Ok, here's the pics of the newer style 5VZFE crossover design, 2001 and up Tacos, (not sure about 4runner years):

As you can see they are very different designs, as are the exhaust manifolds from 2001 and up. The newer style use double wall tubing (most evident in the last pic) and it appears to have no flex coupling. These newer style look like it would be nearly impossible to flip around like you have done with older style. Lets put it this way, it would be easier to build one from scratch. The only thing you could use would be the flanges and if you used the stock exhaust manifolds you would need those flanges badly.

Elvota · 03-02-2008, 10:19 AM

Wonder why the flex joint was eliminated? I was under the impression this allowed the crossover to flex or expand along with the heads.

I happen to have a older 3.4 crossover for sale... in perfect shape... if someone is looking for the flanges and such.

mt_goat · 03-02-2008, 10:23 AM

BTW I've been told the flanges are different between the older style and newer style. Yeah I think I like the older style crossover better, but I've heard that the newer style exhaust manifolds have better flow.

jasond · 03-02-2008, 10:31 AM

When I was working on cutting the flanges off of mine for the exh shop, I noticed that if you cut the flanges off and flip them so that the part that meets the exh manifold faces you, a 2" hole saw fit perfect inside of it. It wont mess up the flange, cuts the factory welds, and leaves you with the perfect starting point for welding up a new exhaust system and/or a crossover.

mt_goat · 03-02-2008, 10:32 AM

There is another possibility, the stock 5VZFE crossover could be used and then routed back to the drivers side under the truck much like guys have to do with headers. I'll probabily look into doing that if my custom crossover ever has a crack develop.

mt_goat · 03-02-2008, 10:36 AM

Quote:

Originally Posted by jasond

When I was working on cutting the flanges off of mine for the exh shop, I noticed that if you cut the flanges off and flip them so that the part that meets the exh manifold faces you, a 2" hole saw fit perfect inside of it. It wont mess up the flange, cuts the factory welds, and leaves you with the perfect starting point for welding up a new exhaust system and/or a crossover.

Was that the older style crossover Jason?

jasond · 03-02-2008, 02:41 PM

Quote:

Originally Posted by mt_goat

Was that the older style crossover Jason?

It was the newer style.

mt_goat · 03-02-2008, 04:22 PM

Quote:

Originally Posted by jasond

It was the newer style.

Do you still have the rest of it? What does that double wall tubing look like from a cross section, I mean is there some kind of material between the walls?

jasond · 03-02-2008, 07:58 PM

Quote:

Originally Posted by mt_goat

Do you still have the rest of it? What does that double wall tubing look like from a cross section, I mean is there some kind of material between the walls?

I gave the rest of it to the scrap metal guys. There was nothing between the walls of the tubing where I cut it, just air.

RobD · 03-02-2008, 08:36 PM

I tried to re-use that double flange connector, like you did, but it ended up not fitting between the frame and my firewall! I had to pull the whole engine out and have it cut off and replaced with a single collector.

Problem was that I paid to have an exhaust shop do it! Argh!

And do it again, the right way. Glad to see you got yours to fit.

screamer76 · 03-03-2008, 01:28 PM

thanks for posting this. great photo documentation. that's going to make things alot easier on us when we try it, assuming we don't have robd's problem. i wonder if there's a difference in the clearance on first and second gen 4runners? definitely something else to think about. thanks again- john

Jason4X4 · 03-03-2008, 04:27 PM

where in Tucson are you, I go down there frequently, maybe i'll have to stop by.

screamer76 · 03-03-2008, 08:46 PM

Quote:

Originally Posted by Jason4X4

where in Tucson are you, I go down there frequently, maybe i'll have to stop by.

this is kind of a nomadic swap. i'm removing the 3.4 around 22nd and pantano. from there it goes to my work(dodge and ft lowell), where i will be doing the timing belt and water pump, oil pan and dipstick, spark plugs and wires, and hopefully the crossover fitting before i even remove the 3.0(only driver). we have a big shop with a polished concrete floor, rollup door and forklift(aka. engine hoist). since the housing market croaked, we're not using that shop for work at all. i'm going to try to make the stay there as short as possible just in case business picks up. once the 5vz is in my 4runner, i'll be towing it to my house(glenn and campbell) to do the wiring and other stuff without having to feel pressured. so far it seems like the biggest hurdle is going to be scheduling. i can't get back to work on the removal of the 5vz for probably a week and a half, since i can only work on it over the weekend and the seller is going out of town this coming one. i was hoping to have it all ready to be pulled after working on it yesterday, but i got a horrible case of food poisoning this weekend, which had me throwing up from midnight till 6am saturday night. i wasn't going to let anything stop me from starting, but i did get there an hour and a half later than i wanted, and had to leave by a certain time. still, i feel like i made decent progress for the time spent and physical condition of myself. anyway, hopefully the engine will be at our shop by the 16th. you're welcome to come check it out if you're down here on a saturday or sunday in the few weekends after that. input from someone who's done one of these certainly couldn't hurt. i'll let you know for sure when i get the 3.4 relocated. take care- john

RanchoToyotaTruck · 03-26-2008, 01:28 PM

GREAT INFO!! I have been doing this same thing on all of my swaps.
The crossover pipes are ALL the same on Tacoma's and 4Runners from 1995.5 to 2000 then they went to the double wall set up as seen in the above pictures.

**Lysmachia** · 03-26-2008, 02:05 PM

GREAT THREAD! - Subscribed!! Just about to tackle my 3.4!

RanchoToyotaTruck · 04-08-2008, 03:55 PM

Here are a few of my crossover pipes
also built using most of the stock parts

slacker · 04-19-2008, 08:22 AM

I built mine for $30.00 ( + consumables , and my time )

**Lysmachia** · 04-20-2008, 02:14 AM

Quote:

Originally Posted by Elvota

Wonder why the flex joint was eliminated? I was under the impression this allowed the crossover to flex or expand along with the heads.

I happen to have a older 3.4 crossover for sale... in perfect shape... if someone is looking for the flanges and such.

How Much Steve? I assume that will fit fine with my 1997 3.4 in my 2nd Gen...

Now that the weather is much nicer We are ready to begin the surgery. At least I already have the 3.0 pulled and out of the way!

syber_kowboy · 11-12-2008, 03:56 PM

Quote:

Originally Posted by slacker

I built mine for $30.00 ( + consumables , and my time )

Are those stock flanges with custom pipes and a stock flex joint? Did you buy the pipe and shape it yourself? Thanks

**Lysmachia** · 11-12-2008, 07:32 PM

God I forgot about how awesome this thread was.....

03-02-2008, 07:57 AM	#4 (permalink)
mt_goat Contributing Member Join Date: Nov 2002 Location: Oklahoma State Posts: 8,919	Excellent writeup! I might just add that the later 5VZFE models have a different crossover. I'll try to post a pic of the newer style factory crossover later. What is involved with removing the heat shield on the older style crossover? __________________ ~Dale~ 93 4X4 ext-cab, auto, SR5, 3.4 V6, supercharged, 2.1" pulley, URD fuel mods, Aquamist WI, IPT valve body mod, dual cases, 4" superlift front, Alcan springs rear, 33 BFG MT, ARB locked front & rear, 5.29 US Gears, RB 1" Body Lift, 1.5" ball joint spacers, manual hubs, TJM T-17, Warn m8000.

03-02-2008, 08:53 AM	#5 (permalink)
Elvota Contributing Member Join Date: Jun 2005 Location: Phx, AZ Posts: 3,436	Nice job. Real good savings on the 3.4 swap. Heck, with all the YT 3.4 swap tips out there, we'll soon be dropping 3.0's and making money at the same time. __________________ ================ 1990 4Runner \| V6 3.4 \| 5spd \| 240 someoddthousand miles \| SR5 \| SAS \| RLS \| 35's \| ARB \| TJM \| 217 to 1 \| W8000 - four wheels \| three sticks \| two hands \| one trail - RIGITY DIGITY visit the sticki chronicles

03-02-2008, 10:12 AM	#6 (permalink)
mt_goat Contributing Member Join Date: Nov 2002 Location: Oklahoma State Posts: 8,919	Ok, here's the pics of the newer style 5VZFE crossover design, 2001 and up Tacos, (not sure about 4runner years): As you can see they are very different designs, as are the exhaust manifolds from 2001 and up. The newer style use double wall tubing (most evident in the last pic) and it appears to have no flex coupling. These newer style look like it would be nearly impossible to flip around like you have done with older style. Lets put it this way, it would be easier to build one from scratch. The only thing you could use would be the flanges and if you used the stock exhaust manifolds you would need those flanges badly. __________________ ~Dale~ 93 4X4 ext-cab, auto, SR5, 3.4 V6, supercharged, 2.1" pulley, URD fuel mods, Aquamist WI, IPT valve body mod, dual cases, 4" superlift front, Alcan springs rear, 33 BFG MT, ARB locked front & rear, 5.29 US Gears, RB 1" Body Lift, 1.5" ball joint spacers, manual hubs, TJM T-17, Warn m8000. Last edited by mt_goat; 03-02-2008 at 10:26 AM.

03-02-2008, 10:19 AM	#7 (permalink)
Elvota Contributing Member Join Date: Jun 2005 Location: Phx, AZ Posts: 3,436	Wonder why the flex joint was eliminated? I was under the impression this allowed the crossover to flex or expand along with the heads. I happen to have a older 3.4 crossover for sale... in perfect shape... if someone is looking for the flanges and such. __________________ ================ 1990 4Runner \| V6 3.4 \| 5spd \| 240 someoddthousand miles \| SR5 \| SAS \| RLS \| 35's \| ARB \| TJM \| 217 to 1 \| W8000 - four wheels \| three sticks \| two hands \| one trail - RIGITY DIGITY visit the sticki chronicles

03-02-2008, 10:23 AM	#8 (permalink)
mt_goat Contributing Member Join Date: Nov 2002 Location: Oklahoma State Posts: 8,919	BTW I've been told the flanges are different between the older style and newer style. Yeah I think I like the older style crossover better, but I've heard that the newer style exhaust manifolds have better flow. __________________ ~Dale~ 93 4X4 ext-cab, auto, SR5, 3.4 V6, supercharged, 2.1" pulley, URD fuel mods, Aquamist WI, IPT valve body mod, dual cases, 4" superlift front, Alcan springs rear, 33 BFG MT, ARB locked front & rear, 5.29 US Gears, RB 1" Body Lift, 1.5" ball joint spacers, manual hubs, TJM T-17, Warn m8000. Last edited by mt_goat; 03-02-2008 at 10:27 AM.

03-02-2008, 07:21 AM	#2 (permalink)
Jason4X4 Registered User Join Date: Jun 2006 Location: Chandler, AZ Posts: 92	first cut on the pipe how the pipe fits second cut what is left, this is the flex other side of pipe test fitting this is the clearance with the pipe in place both pipes test fit as you can see, the flex cuts don't line up, so I took it to the grinder to get the angles right closer even closer, NOTE, you can also see that I did wind up flipping the flex over, my right mark is now on the left I wound up getting a piece of pipe to put inbetween here, I think it would have been able to be welded without it, but I wanted to make sure that the flex wasn't going to interfer with the trans bolts engine clearance I am going to do another post now, please hold...

03-02-2008, 07:32 AM	#3 (permalink)
Jason4X4 Registered User Join Date: Jun 2006 Location: Chandler, AZ Posts: 92	side shot before welding you can see here the how much room there is for the transmission and bolts another pic before welding one more head clearance tacked in place driver side clearance tacked in place the two pipes are close, but they don't touch, they can be tacked together, but I didn't all welded up, I am using a flux core wire welder, they look better after I wire brush them final clearances this is with the engine in, firewall clearance there is more room here than it looks like since we used the factory down pipe, I had to move the o2 sensor cause it was hitting the frame, I also had to cut an ear off of this pipe at the flange, I just don't have a pic of it welded it to the factory exhaust used the factory o2 sensor hole as the second o2 sensor hole for the 3.4. yes it is in front of the cat, but it has a dummy box on it. you can see why I had to move the o2 That;s all I have, this was on an 89 4runner, which I believe is the first gen(?). anyway, it worked for me, so good luck...

03-02-2008, 10:31 AM	#9 (permalink)
jasond Registered User Join Date: Jul 2006 Posts: 231	When I was working on cutting the flanges off of mine for the exh shop, I noticed that if you cut the flanges off and flip them so that the part that meets the exh manifold faces you, a 2" hole saw fit perfect inside of it. It wont mess up the flange, cuts the factory welds, and leaves you with the perfect starting point for welding up a new exhaust system and/or a crossover.

03-02-2008, 10:32 AM	#10 (permalink)
mt_goat Contributing Member Join Date: Nov 2002 Location: Oklahoma State Posts: 8,919	There is another possibility, the stock 5VZFE crossover could be used and then routed back to the drivers side under the truck much like guys have to do with headers. I'll probabily look into doing that if my custom crossover ever has a crack develop. __________________ ~Dale~ 93 4X4 ext-cab, auto, SR5, 3.4 V6, supercharged, 2.1" pulley, URD fuel mods, Aquamist WI, IPT valve body mod, dual cases, 4" superlift front, Alcan springs rear, 33 BFG MT, ARB locked front & rear, 5.29 US Gears, RB 1" Body Lift, 1.5" ball joint spacers, manual hubs, TJM T-17, Warn m8000.

03-02-2008, 08:36 PM	#15 (permalink)
RobD Registered User Join Date: Jun 2006 Location: Calgary, AB Posts: 1,726	I tried to re-use that double flange connector, like you did, but it ended up not fitting between the frame and my firewall! I had to pull the whole engine out and have it cut off and replaced with a single collector. Problem was that I paid to have an exhaust shop do it! Argh! And do it again, the right way. Glad to see you got yours to fit. __________________ 1991 4Runner, 3.4 5VZFE swap, OME shocks/springs, 33" BFG All Terrain T/A KOs, Pioneer head unit, Infinity speakers, XM Satellite radio

03-03-2008, 01:28 PM	#16 (permalink)
screamer76 Registered User Join Date: Nov 2007 Location: tucson,az Posts: 211	thanks for posting this. great photo documentation. that's going to make things alot easier on us when we try it, assuming we don't have robd's problem. i wonder if there's a difference in the clearance on first and second gen 4runners? definitely something else to think about. thanks again- john

03-03-2008, 04:27 PM	#17 (permalink)
Jason4X4 Registered User Join Date: Jun 2006 Location: Chandler, AZ Posts: 92	where in Tucson are you, I go down there frequently, maybe i'll have to stop by.

03-26-2008, 01:28 PM	#19 (permalink)
RanchoToyotaTruck Registered User Join Date: Jan 2008 Location: Rancho Cordova Posts: 106	GREAT INFO!! I have been doing this same thing on all of my swaps. The crossover pipes are ALL the same on Tacoma's and 4Runners from 1995.5 to 2000 then they went to the double wall set up as seen in the above pictures. __________________ YOUR 3.4l SWAP SOURCE PM me for discount TOYOTA PARTS!!!! <----It's just a Jeep body, the rest is all Yota baby!! www.ranchotoyotatruckparts.com For parts orders please call 1-877-551-5575 and remember to mention YotaTech for your discount! Thanks!!

04-08-2008, 03:55 PM	#21 (permalink)
RanchoToyotaTruck Registered User Join Date: Jan 2008 Location: Rancho Cordova Posts: 106	Here are a few of my crossover pipes also built using most of the stock parts __________________ YOUR 3.4l SWAP SOURCE PM me for discount TOYOTA PARTS!!!! <----It's just a Jeep body, the rest is all Yota baby!! www.ranchotoyotatruckparts.com For parts orders please call 1-877-551-5575 and remember to mention YotaTech for your discount! Thanks!!

04-19-2008, 08:22 AM	#22 (permalink)
slacker Registered User Join Date: Jan 2006 Location: BC Canada Posts: 2,114	I built mine for $30.00 ( + consumables , and my time ) __________________ 86 4x4 , fiberglass bed , 1/2 doors , hood ... more to come . 84 2WD "hotrod" Intercooled 7MGTE 83 Trekker SR5 CURRENT BUILD My home page MY PAGE 2WD fourm I frequent NEW Trekker forum

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