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Interesting - thanks for the input. Mines definitely the flange gasket. Funny how a pedestrian part like that can be an issue even with a world class company. I had an 89 Mitsubishi Van Wagon, which was a 4 cylinder built for the world market in huge volumes by a world class engine builder. It cracked exhaust manifolds to the point I'd yank them at the U Pull even when there for another vehicle. Felt bad that after I sold it a couple years ago, I later found a small pile of manifolds I had forgotten about.
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back in the day, toyota knew about the problem and would replace the manifold for free. in the 22r they redesigned the shield and the cracking stopped
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Toyota 20R engines are famous for cracked exhaust manifold ( usually between #2 and #3 exhaust ports).
I realize yours is a 22R, but the same issues occurred with that block too.
Turns out the heat shield is the culprit. The excess heat generated by the hot exhaust gets trapped underneath the shield. With no way to dissipate, it ends up cracking the cast iron header.
Unless you feel you absolutely need that heat shield, I’d delete it completely.
Not to be a doomsayer, but the cracked manifold is often mistaken for a leaky exhaust gasket.
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