Exhaust manifold problems - Toyota Nation Forum : Toyota Car and Truck Forums
6th Generation (1988-1992) Specific discussion of the AE92

 
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#1 Old 05-08-2010, 09:00 PM
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Exhaust manifold problems

Is there an issue with the Corolla exhaust manifolds? I have a 1992 Corolla that had the original manifold bread in half. The replacement from Toyota was supposed to be improved. About a year ago it cracked about half way around. I ground out the crack and carefully welded it. Then had the surface that goes against the head machined straight. Well, now the it cracked right in the center of the weld. I have another one I got from a junk yard. It is bowed, so I need to get it machined straight before installing. Are manifold problems common with this 1.6 engine? My brother just bought a 1997 Corrolla with the same engine and I can see through the head shield that it has started to crack the exact same place - between 2 & 3.
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#2 Old 05-08-2010, 10:01 PM
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This is a VERY common problem. The same thing happened on my 93 Corolla. It cracked right the way around so I needed to get it welded. I could see it starting to happen again a few months later, so in the end I just got a custom manifold and front pipe made (the same design as the ones on eBay) and have never had a problem again.

Even the engineer who welded it said it was a poor design from factory, and every single 4A-FE and 5A-FE engine I've seen in junkyards have had the exact same problem.

If you want to stop it from happening then I'd strongly suggest buying some headers off eBay


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#3 Old 05-08-2010, 10:40 PM
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Gen6

OK, I looked at some of the ones on eBay. How much modification needs to be done to install the headers or are they a bolt in?

Last edited by chzuck; 05-08-2010 at 10:41 PM.
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#4 Old 05-08-2010, 10:52 PM
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Quote:
Originally Posted by chzuck View Post
OK, I looked at some of the ones on eBay. How much modification needs to be done to install the headers or are they a bolt in?
It will bolt straight on (providing your engine is a 4A-FE, 5A-FE or 7A-FE), but you'll also need to get the front-pipe with it (most sellers sell them both together).

I'm assuming your Corolla is the same shape as my one? The rounded models like mine actually started production in 1991, but these forums only have it classed as 1993-1997.

There's a really good DIY guide in the 7th Gen Corolla forum to help you install the headers:
http://www.toyotanation.com/forum/t334079.html

The hole for the oxygen sensor on my headers was at the front, whereas my factory one was on the side (as it's a Japanese model), so I had to get my sensor wiring slightly lengthened, but the ones on eBay should allow your sensor to screw straight in without the need for lengthening the wire. A bonus is that your performance will increase once you install it too


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#5 Old 05-08-2010, 11:12 PM
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Mine is the model before yours. I think the door tag says it was made in 1991 in Canada. I have 324,000 on it. Put a new head gasket on it at 275,000 miles. That was the first major thing that went wrong with it besides the normal stuff, brakes, exhaust, rotors. I usually don't need to add oil between 3,000 mile oil changes.

Since mine is an older Corolla would the headers for the generation Corolla 1.6 fit mine. I can't believe how cheap some of them were on eBay.

By the way, very nice looking Corolla you have! Also, my compliments on your photos, they are GREAT!

Last edited by chzuck; 05-08-2010 at 11:17 PM. Reason: added some info
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#6 Old 05-08-2010, 11:19 PM
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There are two variations of the 4A-FE (1.6L) - The first generation and the second generation. Your model Corolla only ever came with the first generation engine as far as I know, but since you said your brother bought a 1997 with the same engine, it's best to check which one you have.

This is my engine (2nd generation) -
http://carphotos.cardomain.com/ride_...0058_large.jpg

And this is a 1st generation engine -
http://www.biocrawler.com/w/images/1/1f/4A-FE_2.JPG

I'm not entirely sure if the headers are interchangeable between the two engines, but let me know which engine you've got and we'll go from there


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#7 Old 05-08-2010, 11:33 PM
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Mine is the first generation engine, according to your photos.
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#8 Old 05-08-2010, 11:58 PM
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Originally Posted by chzuck View Post
Mine is the first generation engine, according to your photos.
Ok. In that case, I can't say for sure if the headers for the 2nd gen 4A-FE will be compatible, but hopefully someone will know. Otherwise, try asking one of the sellers on eBay.


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#9 Old 05-09-2010, 01:21 AM
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I just managed to find a very old thread on this forum where someone asked the same question. Apparently the exhaust manifold between the two generations are interchangeable.

Have a read of this (don't mind all the Toyota Nation logos, just scroll across and read between them, lol) -

http://img.toyotanation.com/forum/sh...d.php?t=213710


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#10 Old 05-09-2010, 03:24 PM
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Am I correct in saying the headers are interchangeable between the 1.6 & 1.8 engine as well?
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#11 Old 05-09-2010, 04:14 PM
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Quote:
Originally Posted by chzuck View Post
Am I correct in saying the headers are interchangeable between the 1.6 & 1.8 engine as well?
Yes, I'm fairly sure they are. The only difference that I know of is that the o2 sensor is mounted differently (the 4A-FE has a screw-in type, whereas the 7A-FE has a flange type).


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#12 Old 05-09-2010, 06:05 PM
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Correction. The 4afe has a flange type O2 sensor.....I'm not sure about the 7afe. At least, mine does.....and I have the stock exhaust manifold & downtube.
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#13 Old 05-09-2010, 06:14 PM
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Originally Posted by bcp477 View Post
Correction. The 4afe has a flange type O2 sensor.....I'm not sure about the 7afe. At least, mine does.....and I have the stock exhaust manifold & downtube.
I was talking about the 4A-FE (2nd Gen) headers on eBay that have the screw in type o2 sensor


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#14 Old 05-09-2010, 10:39 PM
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My 92 has the flange mount, but the o2 sensor looks like it is threaded into the two-bolt flange.
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#15 Old 05-09-2010, 10:49 PM
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Quote:
Originally Posted by chzuck View Post
My 92 has the flange mount, but the o2 sensor looks like it is threaded into the two-bolt flange.
Hmm, I suppose in that case you could just get a thread tapped into the 7A-FE headers (between the flange where the o2 sensor goes).


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