New Exhaust manifold fitment

[robinl]

Hi everyone,

I'm a new owner and first time poster, so be gentle!!

Exciting day.  Just received my new exhaust manifold.  Looks lovely.  Doesn't fit on the head.  It's at least 3mm out left to right on the studs and 5mm out on the lower supports.

The manifold head is a substantial 10mm s/s plate.  Should I expect to have to ream out holes or should it fit from the box?

If I start to ease it and mess about, I won't be able to return it so your help with expectations would be useful.  Thanks
Robin

[Carolyn]

Hello and welcome.

It should fit out of the box.  What manifold have you bought?  Are you sure it's not for a 2ZZ??

Try to find a toyospoerts one for the 1ZZ?

[robinl]

Thanks.  It's a JDM Performance one.  Looks the business and the reviews talked about easy fitment.  They do say get professional fitment for better results but surely a professional would want it to fit out the box as well?  I chose it because it had the mounting for the heat shields, but they don't fit either.  I wanted to check that it's not me or my expectations before returning it. 

Shame really.  I was really looking forward to it going on.

[Gaz mr-s]

If you bought from a company put up a link?

[robinl]

Just says for the MR2 Spyder MRS so I assumed 1ZZ

[robinl]

Hi,

It's this one.  https://jdmperformance.net/products/racing-exhaust-manifold-toyota-mrs-mr2?variant=44053771616491&country=GB&currency=GBP&utm_medium=product_sync&utm_source=google&utm_content=sag_organic&utm_campaign=sag_organic&tw_source=google&tw_adid=&tw_campaign=21632381514&tw_kwdid=&gad_source=1

I initially didn't want to name them incase it was my expectations at fault!

[Carolyn]

I susoect it's for a 2ZZ.

Send it back.

https://www.ebay.co.uk/itm/204135729654?itmmeta=01KB8JJMSR9F7JHSDBJ4XQ57KK&hash=item2f877009f6:g:0kUAAOSwpstjXW92

[Gaz mr-s]

I looked up the website, nothing else obvious that they may have mixed it up with.  Is there a part number on it you can check on the web?

The chances are if you call them up they're going to think you're a blether.

It sounds like you have the existing one off.  If I were you I'd fit it where it can then take pics showing where it doesn't line-up.

And when you do get one that fits, don't use the perforated gasket, they're weak junk usually.  The existing one can usually be re-used, - it's common practice.

[Gaz mr-s]

if it is 2zz-fit the outside holes on the flange are 'high',  the 1zz low.

[robinl]

Just had another go.  It's too close to not being for the 1ZZ I think.  If I remove the fouling lower support, I can get the narrow end of each stud in the hole.  Got to stop myself as I can see me damaging the threads and then not being able to get the lower supports to line up.  I'll speak to the supplier on Monday and see what they say. 

I'll have the rest of the weekend off!  It's been good fun up until now though.

[robinl]

Thanks Carolyn and everyone.

Is this the one that most people use then?  At least I can get rid of the heat shields. 

[Gaz mr-s]

There are cheaper inferior ones than yours.  The majority aren't machined to use crush gaskets.

It's not the best in the UK though, that's a company called Zero exhausts, but he's reportedly going to be retiring soon.

[Joesson]

@robini

From my reading of this thread it seems that you have removed the OE manifold and are now trying to place the new manifold onto the retained head studs.
It could be that there are existing  lower mounts in the way and hindering alignment.
Rather than offering the new manifold to the retained studs with risk of damage have  you considered checking the hole / stud positions with the OE gasket/ or the new gasket?
For information, the head studs are removable / replaceable.

[robinl]

Hi Joesson,
I've had a night of it.  I loosened the lower mounts to get the out of the way.  That allowed the new manifold to sit on the narrow ends of the studs.  But too tight to go any further and would damage the stud threads if I tried.  I've replaced a couple of the studs but they are all in good shape.  I offered up the old gasket to the new manifold and theres a couple of mm out. 

I put the stock manifold back on to make sure I've not buggered something up and it was fine.

Frustrated and given up for tonight.  Will look at alternative tomorrow.  Thanks for your advice.

[Iain]

Ive been running a 'gravity' one for a few years now and had no issues. Doesnt have brackets for the heat sheilds though but some exhaust wrap cures alot of that problem.

[robinl]

Does the gravity one have the lower bracket attachments?

[Gaz mr-s]

Does the gravity one have the lower bracket attachments?

The crush-ring fit flange of yours is a far bigger advantage.

Very few do have the brackets.

[benlumley]

There are cheaper inferior ones than yours.  The majority aren't machined to use crush gaskets.

It's not the best in the UK though, that's a company called Zero exhausts, but he's reportedly going to be retiring soon.

Retiring end of next year. I ordered a 2zz one a few weeks back and spoke to him.

[Joesson]

Retiring end of next year. I ordered a 2zz one a few weeks back and spoke to him.



From what I've read on here a 2zz engine in a Mk 3 Roadster is like Marmite, certainly not for the "retiring", but if that is what you are planning for
I can't  fault your preparation.

[Gaz mr-s]

From what I've read on here a 2zz engine in a Mk 3 Roadster is like Marmite, certainly not for the "retiring", but if

Kevin, Zero owner.....