mnmontana

Hey all, Figured I would be nice and hopefully help someone else that was in the same boat as me... I had a performance exhaust (which ill trade for nearly anything thatll fit my truck.. email me if you want it - asdf mont @ hotmail .com)

And passing smog with a performance exhaust in Cali, is impossible when your wife refuses to get an 'under the table inspection'....


So here is the exhaust I found that requires NO welding, and should be 100% smog compliant:



Exhaust manifold: http://www.partsamerica.com/ProductD...e=1359&PTSet=A



For header to Cat: http://www.partsamerica.com/ProductD...pe=688&PTSet=A



The cat: http://www.partsamerica.com/ProductD...pe=145&PTSet=A



Cat to muffler: http://www.partsamerica.com/ProductD...ype=15&PTSet=A



Here is the gaskets that Maremont recommends:
(2) 521627 gaskets -http://www.partsamerica.com/productdetail.aspx?MfrCode=MAR&MfrPartNumber=G51

(1) 521023 gasket, http://www.partsamerica.com/ProductD...artNumber=G262

(1) 521632 gasket

And lastly, the hangers:
(4) 528766 hangers
(1) 528870 hanger.




As for actual steps involved... I will post this part by part in replys.

SR5

wow great info

mnmontana

Removal of the old exhaust:



Step 1 - Get 2 or 3 cans of 'PB BLASTER' should be next to the WD-40 in the chemicals isle of your favorite parts store.

Soak the nuts and bolts, 3 or 4 times a day, for 3 weeks BEFORE you start this. Warning, it will smoke and smell REALLY bad if you run the truck after spraying this nasty stuff.


Side note:
I have done hundreds of exhaust bolts in my life, and have always broken, or ruined at least 1 bolt/stud with every exhaust... I tried this 'PB Blaster' trick that my buddy recommended, and wow... what a difference!! worth every freakin penny!

Ok, so, now that you have soaked your exhaust bolts (all of them from the block to the rear bumper) daily for weeks...

Start your truck, let it run for 5 to 10 minutes. Then let it sit for 20 minutes, basically let it get hot, then cool till if you touch it, its kinda warm/hot, but doesnt burn.


You will most likely have to cut your exhaust right after the CAT (Before the cat wasnt possible on mine) , in order to pull it out from ontop of the truck, so crawl under your truck with a hacksaw and get cracking, er cutting.




Then start removing the bolts. Mine came off smooth as butter, except 1 which apparently the prev owner had stripped in side the head...

mnmontana

Pull off the exhaust manifold, and be carefull to save the 2 metallic plates that are on top of the exhaust.

iamsuperbleeder

WHOA

big picture...

mnmontana

Make sure to clean off head, and remove any type of residue/crud/ gasket sealant/ chrome spray paint (if the prev owner was an idiot)....


becarefull not to make any gouges, or deep cuts into the metal, as they will end up being a leak.

Now lay the gasket against the pins, on the head.

mnmontana

Now slide the manifold onto the pins in your head, like so:

iamsuperbleeder

you know there's an "edit" button and you can put this all on one post, right???

mnmontana

Then the gaskets again




Remember those plates off the old exhaust that I said you should save? put those on now, over those gaskets.

Now put the bolts/stufs/nuts on with a torque wrench, should be 33 lbs of pressure.

iamsuperbleeder

on that note, youre EGR valve is not hooked up, cause those plates are blocking off the holes that runs to the EGR valve via a tube that bolts in place of those "plates"

mnmontana

Now crawl underneath the truck, inside the 'dorman box' there are 3 pins with nuts, these go on the bottom of the manifold, where the pipe bolts onto.



Screw the pins into the manifold.



Then slide that pipe you got (manifold to cat) from the back of the truck, to the front, over the crossmember n such.

Like this:



Put the 2 smaller gaskets (should be in the dorman manifold box) onto the exhaust pipe (1 gasket on each pipe fitting, total of 2 that stick through), and carefully slide the pipe onto the pins without letting the gaskets fall off.


it should look like this:









There are 2 large ring gaskets, use these to connect the cat to exhaust pipe. Nothing felt right with all the gaskets I got, so I used these, and it works fine.

Slip 2 botls through, and crank em down a bit.



If you want to place your o2 sensor on the manifold (like I did) go back to the top of the truck, remove the plate here and gasket, becare full not to ruin this gasket, as you will need it. Go to the the pipe right before the cat, put the gasket here, and the plate.

Install the gasket and o2 sensor.

Now install the black plate with 3 tiny bolts , like this:








I am still waiting for the rest of my exhaust (from the cat tot he rear tail pipe - 1 single piece) so Ill post that here when it arrives.




But now is a good time to move that bracket on the manifold to cat pipe, slide it down the length of the pipe and up untill it lines up with the bracket on your transmission dip stick, and bolt it on.

iamsuperbleeder

I'm not trying to be a PITA, but check out number 10 here...

https://www.yotatech.com/rules/updated/index3.htm

This is a good write up, but I'm just saying it's hard to look at those pics man...

mnmontana

Yeah, you have a valid point... I was just being lazy... lol, ill go through and resize.

myyota

Those holes your talking about are for air injection, 86 4Runners don`t use that set up so those holes in the exhaust manifold are blocked off.

iamsuperbleeder

ah ok, my 91 has the tube; I replaced the manifold on it...