Toyota Hilux 1997-2005 2.7L 3RZ-FE Exhaust Manifold Header Gasket DSF803

DSF803 exhaust manifold / header gasket is designed for selected Toyota Hilux models from 1997 to 2005 fitted with the 2.7L 3RZ-FE petrol engine.

Manufactured from 1.5mm gasket material without a fire ring, DSF803 provides a replacement sealing gasket for compatible exhaust manifold and header/extractor applications.

Important: Exhaust gasket applications can vary. Compare the port shape, bolt-hole centres and overall dimensions shown in the product images with the gasket being replaced before ordering.

Key Features

• Exhaust manifold / header gasket
• Designed for selected Toyota Hilux 2.7L 3RZ-FE applications
• 1.5mm thickness
• Without fire ring
• Suitable for compatible factory exhaust manifold and aftermarket header/extractor applications
• Quality replacement exhaust gasket

Construction

• Thickness: 1.5mm
• Fire Ring: No
• Port Size: See product images
• Bolt-Hole Centres: See product images

Additional Options

• High-temperature exhaust sealant is recommended with this non-fire-ring gasket where appropriate
• Other exhaust manifold, header, flange and exhaust system gaskets are available from Best Mufflers

Vehicle Fitment

• Make: Toyota
• Model: Hilux
• Year Range: 1997-2005
• Engine: 3RZ-FE
• Capacity: 2.7L / 2694cc
• Configuration: DOHC 16-Valve Inline 4-Cylinder Petrol
• Selected Series: RZN-series applications including RZN149R and RZN169R
• Drive: Selected 4x2 and 4x4 applications

The Australian sixth-generation HiLux was introduced in 1997 with new petrol-engine options. Australian vehicle data confirms the 2694cc 3RZ-FE in RZN-series HiLux models from 1997 and continuing into 2005.

Fitment Notes

• Designed for selected Toyota Hilux 2.7L 3RZ-FE applications
• Compare the gasket shape with your original gasket before ordering
• Check the port dimensions and bolt-hole centres shown in the product images
• Remove all traces of the old gasket and sealing material before installation
• Ensure the cylinder-head and manifold/header sealing surfaces are clean and flat
• This gasket does not use a fire ring
• High-temperature exhaust sealant is recommended where appropriate

What’s Included

• 1 x DSF803 exhaust manifold / header gasket

Recommended With

• High-temperature exhaust gasket sealant
• Replacement exhaust manifold/header mounting hardware where required

Installation Tips

Remove all traces of the old gasket and sealing material before installing the new gasket. Inspect the cylinder-head and exhaust manifold/header sealing faces and ensure they are clean, flat and free from damage.

For this non-fire-ring gasket, apply a thin smear of suitable high-temperature exhaust sealant around the exhaust ports where appropriate. Allow the sealant to become touch dry before installation.

After installation and initial heat cycling, inspect the gasket area for exhaust leaks. Re-check and re-tighten the manifold/header bolts after approximately 500km where appropriate, following the correct tightening sequence and torque specifications for the application.

Warranty & Compliance

DSF803 is intended as a replacement exhaust sealing gasket for compatible applications. Correct gasket selection, surface preparation and installation are essential for reliable sealing and service life.

FAQ

What vehicles does DSF803 suit?
DSF803 is designed for selected Toyota Hilux models fitted with the 2.7L 3RZ-FE petrol engine. Australian 3RZ-FE HiLux applications are found in the 1997-2005 model range.

How thick is the DSF803 gasket?
The gasket is approximately 1.5mm thick.

Does DSF803 have a fire ring?
No. DSF803 does not use a fire ring.

How do I check whether DSF803 matches my vehicle?
Compare the port shape, bolt-hole centres and overall dimensions shown in the product images with your existing gasket before ordering.

Should I use exhaust sealant with DSF803?
Sealant is recommended for this application where appropriate. Apply a thin smear of suitable high-temperature exhaust sealant around the gasket ports, allow it to become touch dry, then install the gasket.

Should the manifold bolts be re-tightened?
We recommend checking the installation after the initial heat cycles and re-checking the manifold/header bolts after approximately 500km where appropriate.

Can I pick up from the store?
Yes. Pick up is available but must be pre-arranged before collection.

How much is freight?
Regular post without tracking is included. If you require tracking or a faster delivery option, including Express Post, please select your preferred option during the checkout process.

Do you ship to the USA?
Yes. Best Mufflers regularly ships exhaust systems and exhaust parts to customers throughout the United States.

Please note that import duties, tariffs, taxes, and customs clearance fees are not included in the product or shipping price. Once your order is processed and the applicable charges are calculated, we will send you a secure payment link to finalise the import duties and tariff charges before dispatch.

Customer Support

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