Downey Header/EGR Probs

[Muddin' Mama]

I just had the Downey header installed on my 22RE about 3 weeks ago & used a brand new OEM exhaust gasket, rather than the Downey one. OK, so now I'm tripping EGR codes. So the EGR valve was replaced along with the sensor & I'm still tripping codes. After a call to Downey - they want me to install THEIR gasket, which has a history of leaking, but they declare is better designed now than in the past & will fit better than the OEM one & has the openings for their special "tube" built into the header to allow for the hotter gasses temp on the outake to engage the EGR. Anyone else ever had this problem? Anyone actually using the Downey gasket? Any comments?(sorry for the length of this post)

BTW, this is from Downey:
"According to Jim, their header is designed to send the hot exhaust gasses back to the EGR – there’s a special vent tube on the header that allows that. By installing an OEM gasket & not the Downey, there may be some incompatibility issues with the way the gasket not only fits, but may also not have the facility to send hot gasses to the EGR. He told me that prior to 1988, their headers had issues with the EGR, Toyota’s computer system & the actual temp of the gasses that would trip the sensor/valve – they were too cool & would trip check engine lights. In order to allow a higher temp to engage the EGR valve itself, they created a special tube that sent the super heated gasses from the “out” tubes right to the system, to trip it. It was his opinion that somewhere in the OEM gasket, either there isn’t the “hole” needed to allow this special tube to send the hot enough gasses to the EGR, that something may be blocking it, that the OEM gasket is for the wrong year & may not quite match the actual manifold surface because it is made of an inflexible metal."

[4xfred]

;D MM, I've seen alot of strange stuff. This gasket prob. isn't too far fetched. I say put Downey's gasket on & see what happens. If the EGR still doesn't function properly, it just became their prob., not yours. Later...

[muddiver]

I replaced the gasket for my downy header right after I bought my truck. One of the smaller gaskets that seal the egr injector tube to the header was ripped. I suspect it was a poor installation. Haven't had any leaking issues with it though. For what it'll cost, I'd say try downey's also. Plus it's easy to change. Here's the kicker though....within just the past 2 weeks my truck has been spitting out the occasional egr code also. Don't know if it's related to the header or not. The header was on the truck when I bought it, almost a year ago and I just now started giving me the error code. I thought it might be the egr temp sensor, but I'd be very interested to hear what you find out with your truck. Post back if you try the other gasket and let us know......thanks

[Muddin' Mama]

Well, tomorrow will be the test for the Downey gasket & I can let y'all know if things are still problematic after that.

We pulled the codes after 140 miles of driving set them off again (we reset the check engine light after installing new EGR parts) & it's still the EGR (code = 71). The vacuum is good, so I suspect the EGR system should be functioning properly with the new parts & that this still gets back to the exhaust gasket. If we compare the 2 gaskets & the OEM is not compatible with all the header ports, then that has to be the problem & the Downey is definately going on & if things are still FUBAR, then it WILL be Downey's problem.

Muddiver: What year is your truck? Did you replace the gasket with the Downey or OEM? (can I ask 10 more questions? LOL!!!!) Be prepared to cough up about $100 for just the temp sensor...

[toy94x4]

That's interesting that the Downey header is causing that because about 2 years ago I installed the LC Engineering header on my '94 22re. Less than 200 miles after I installed it I started getting the same egr codes as you. I contacted LCE and they said they've never had a problem before and neither had anybody else who installed there header that I talked to. I tore apart the whole egr system and cleaned it up and still no fix. I know I installed all the gaskets correctly for the tube hole to line up. I've since given up trying to fix it because the truck does not run any worse and I still get over 20mpg. The only thing it does is idle goofy every now and then. But since otherwise it runs great, I just ignore the light because I refuse to drop over $100 on a componant that "might" fix it. I know we have 2 seperate headers but this is the first time I've seen somebody with the same problem so I thought I'd speak up and let ya know you're not the only one.

[Muddin' Mama]

Weird. & The thing is, I've searched every good Toyota 4x4 BB out there, too, & I've NEVER read anything about the EGR & header relationship being mentioned. & Especially with the Downey install, which, by consensus, seems to have had leaking gasket problems in the past, hence the OEM was used. The entire EGR system, if replaced, will run about $260 total. The temp sensor alone is around $100. Grrrrrrrrrrrrrrr.

Ya, the old girl runs rough @ idle, my MPG is down &, even though it's just an annoyance, I'm getting way tired of that pesky "check engine" light...LOL!!!!!

Thanx for the info. ;D

[muddiver]

My truck is a 91P/U with 22re, five speed combo. The gasket I used for replacement was Downey's. I am looking at a fel-pro original replacement gasket and one from downey as I type this(ordered two from downey at the time). Yep there is a difference in the port cutouts between the two. I'm not convinced the header on my truck is my prob. as I said it has been on there at least a year(and probley longer) with no error codes. I was planning on pulling apart the egr system components and cleaning everything out like 94x4. And I won't spend the bucks replacing components that may or may not fix the problem either. I still get the same mileage with absolutley no difference in the performance of the truck. The code seems to set off every 600-800miles. It is interesting to hear that LC's header has caused this too. I think there header is designed to work with a stock gasket. I wonder if it's a temp. difference??

[Muddin' Mama]

I guess we'll find out - the Downey gasket went on yesterday, along with new EGR gaskets & lots of sealer. I had been tripping codes every 140 miles after the initial one, about 600 miles after the header went on. I drove maybe 600 miles RT for a weekend of wheeling & the code tripped on my way out of town, we cleared it, I wheeled, drove home & it went on again about 150 miles after that. The original EGR filter looked pretty clean & there was good vacuum when we tested it - benefit of the doubt, it was replaced.

There is an appreciable difference in design between the Downey & OEM gaskets (most notably the size of the porting holes) & I have read that the LCE pulls the same thing, but is machined to work specifically with the OEM gasket. My understanding is that the Downey allows for hotter temp gasses to be sent to the EGR system, so maybe it is a temp sensor issue?

[Muddin' Mama]

Alrighty then, a Downey header/gasket - EGR update.

After more than 500 miles on the aftermarket Downey gasket install, the truck runs great (way better than the OEM gasket) & no EGR or any other type of codes are being tripped. Make sure the damn thing is sealed up tight with lots of coppercoat. My only complaint is the Downey lacks a heat shield. Other than that, we are doin' great.

Thank you for all your imput.

[DeadlyPeace]

I put a Downey Header on my truck a few years back and didn't think about it at the time that I needed the heat shield for smog. If you do need one for smog or would just like to have one, Downey does supply them also. Better then any of the aftermarket ones that I've seen too.

[Muddin' Mama]

Thank you for your reply!

My concern with the lack of a heat shield is the close proximity of the spark plug wires to the header. I mean, that sucker gets way hot. Sounds like another call to Downey then...grrrrrrrrrrrrr. They should just send that along with the header & gasket anyhow. *sigh*