Doug Thorley headers...successful install stories.

School Me:

I realize it's long, so thanks ahead of time for reading and some more if you have some helpful info. Also, sorry if this is off topic to this threads original intent OP

Everyone has their bubbles of expertise (except for some on here I feel like are masters of all), and I'll let it be known exhaust is not one of mine... I'm purely interested in the DT Headers to fix my manifold leak, sound/hp/MPG boosts are all just by product pluses to me.... with that being said, I would have already pulled the trigger on a set before realizing install prices are more expensive than the headers themselves. :noidea:

So, what is this like DIY with a basic home garage setup/tools? what specialty items would I need outside of the "basic" setup? As for my own experience, between my 4Runner, Old Speed3, and various friends cars I've done basic mechanic work (batteries, alternators, oil changes, brake pads, air intakes, etc..), but I've never messed around with exhaust. Anytime I don't know how to do something, I turn to the internet (that's you "strangers") to learn how to do it, and few times I bite the bullet and take it to the shop (like when I had the ENTIRE power steering system replaced in the 4Runner).

My main issue from doing more major engine work on the 4Runner myself, is just the weathered condition of the components (spent 10 years and 165k miles in NY, last bit as a hunting cabin truck) that I'm slowly but surely replacing as I'm going. BUT I'm not one to just back down bc I'm inexperienced (how else would I learn?) and figure if I truly can't get it, the shop can always finish the job I've started, I just don't want to cause additional damage.....

So I plan on (for now), to just fix the leak, getting:
-The headers from Jason
-new gasket/bolts kit [MENTION=169058]0verland[/MENTION] mentioned (given the weathered condition of
the ones on the rig)
- and from my reading I'll need a CEL eliminator (I live in an emissions area
and need to pass)

I'll leave the OEM Cats and rest of the exhaust stock until more funds build up for the catback from Jason.... am I correct in thinking that's all I need to fix the leak?

If there's some magic install write up I haven't found yet, well that'd be the golden ticket to the chocolate factory... one besides that 60+ page thread out there.

Flash Runner said:

I realize it's long, so thanks ahead of time for reading and some more if you have some helpful info. Also, sorry if this is off topic to this threads original intent OP

Everyone has their bubbles of expertise (except for some on here I feel like are masters of all), and I'll let it be known exhaust is not one of mine... I'm purely interested in the DT Headers to fix my manifold leak, sound/hp/MPG boosts are all just by product pluses to me.... with that being said, I would have already pulled the trigger on a set before realizing install prices are more expensive than the headers themselves. :noidea:

So, what is this like DIY with a basic home garage setup/tools? what specialty items would I need outside of the "basic" setup? As for my own experience, between my 4Runner, Old Speed3, and various friends cars I've done basic mechanic work (batteries, alternators, oil changes, brake pads, air intakes, etc..), but I've never messed around with exhaust. Anytime I don't know how to do something, I turn to the internet (that's you "strangers") to learn how to do it, and few times I bite the bullet and take it to the shop (like when I had the ENTIRE power steering system replaced in the 4Runner).

My main issue from doing more major engine work on the 4Runner myself, is just the weathered condition of the components (spent 10 years and 165k miles in NY, last bit as a hunting cabin truck) that I'm slowly but surely replacing as I'm going. BUT I'm not one to just back down bc I'm inexperienced (how else would I learn?) and figure if I truly can't get it, the shop can always finish the job I've started, I just don't want to cause additional damage.....

So I plan on (for now), to just fix the leak, getting:
-The headers from Jason
-new gasket/bolts kit [MENTION=169058]0verland[/MENTION] mentioned (given the weathered condition of
the ones on the rig)
- and from my reading I'll need a CEL eliminator (I live in an emissions area
and need to pass)

I'll leave the OEM Cats and rest of the exhaust stock until more funds build up for the catback from Jason.... am I correct in thinking that's all I need to fix the leak?

If there's some magic install write up I haven't found yet, well that'd be the golden ticket to the chocolate factory... one besides that 60+ page thread out there.

Click to expand...

That 60 page thread is full of little tips and tricks for the DIY'er but the bulk of the install information is pretty well documented in DT's install instructions themselves.

http://www.dougthorleyheaders.com/images/documents/THY-563-SS-C-INST_A.pdf

Here is what I learned from the DT Header install on my 2005 4runner V8. I did not do this myself, but will tell you what the shop told me about the installation. First off, purchased the DT headers, Stage 8 bolt kit, since I was paying for labor I was not going to have them weld cats on that had 176,000 miles on them. Bought two Magnaflow heavy load cats from the exhaust shop. Installation was 8hrs. Old manifolds and their rusted fasteners will be your first challenge. They removed most of the fasteners and I think broke two. Their biggest challenge they said was installing the DT headers was the drivers side/upper back two bolts behind the air injection rail on the top of the manifold. He said he actually had to use a magnet to get the bolts in and started. If you are sticking with factory cats or putting new OEM cats on you will not need a CEL eliminator. This is only if you are eliminating the cats. On the subject of cats I called Magnaflow and talked to them and had the shop order Magnaflow #99205hm heavy load cats. These are the primary cats that need to be welded on. To get this part of install right, the headers have to be temporarily installed, the cats put in place and mocked up with the rest of the exhaust, tack welded in place, headers with cats are then removed and permanently tig welded all the way around. I put a cat back exhaust with a Thunderbolt muffler on it other than the resonator that is right at the end. I also had them install Hewitt technologies bypass kit on the air injection system, so that I never have to worry about the air injection pump failing, which is costly to replace. With the bypass kit it never comes on with a cold start. Air injection is only on 2005-2009 V8's. Very happy with the results. The shop had me come back twice for a retorque. Good luck with your installation, I would recommend replacing the primary cats, do you really want to do it twice if the old ones fail?. The shop where I had work done at was
Exhaust Special T's in Muskegon MI. Cost was a little under $1500- 8 hours labor, two cats and cat back exhaust.

I'm in the middle of this project now and ordered all new hardware. But I didn't order any of the exh manifold studs, hoping that the nuts will come off w/o spinning the studs. So far, the few nuts that I have been able to access did come off easily.

In order for me to access the lower row of manifold nuts, I might just raise the engine one side at a time in order to bring the nuts up higher. I'll make sure that the radiator fan doesn't come into contact with the fan shroud.

Let's see how well this works!

I am looking to do this MOD in the near future. I am curious as to part numbers for the High Flow CAT's that people have used. Had any issues with MIL's coming up? Trying to decide whether or not to just stick with the factory CAT's...

I continue hearing about this Jason Burtman guy... Anyone have contact info??

J.Derrick86 said:

I am looking to do this MOD in the near future. I am curious as to part numbers for the High Flow CAT's that people have used. Had any issues with MIL's coming up? Trying to decide whether or not to just stick with the factory CAT's...

I continue hearing about this Jason Burtman guy... Anyone have contact info??

Click to expand...

His number. You can call or text.
717-319-2100

Email
[email protected]

Website
Burtman Industries

Hey there to the guys who installed and removed cats did you just straight pipe in place of cats? And how loud or smelly is the exhaust now ?? Lol

That_Titanium_4RNR said:

His number. You can call or text.
717-319-2100

Email
[email protected]

Website
Burtman Industries

Click to expand...

Thanks for this!

Any of you guys 2003/2004 v8 4runners?? With a suspension lift??? I hear it’s better to buy the 2005-2008 shorty headers from DT as they come with the egr tube? Is this true? Can anyone confirm? As well any problems installing the headers around steering shaft due to a lift ???

T4R416 said:

Any of you guys 2003/2004 v8 4runners?? With a suspension lift??? I hear it’s better to buy the 2005-2008 shorty headers from DT as they come with the egr tube? Is this true? Can anyone confirm? As well any problems installing the headers around steering shaft due to a lift ???

Click to expand...

If you have an 03-04, there's absolutely no reason to buy the version for the later trucks.

Interference with the steering shaft only comes into play with body lifts, not suspension lifts.

JONBOY345 said:

If you have an 03-04, there's absolutely no reason to buy the version for the later trucks.

Interference with the steering shaft only comes into play with body lifts, not suspension lifts.

Click to expand...

Ok brother thank you so much.!! And how about this whole egr tube thing.. having to buy a bypass and plates... and that “if you buy 05-09 headers it comes with it..” ?

T4R416 said:

Ok brother thank you so much.!! And how about this whole egr tube thing.. having to buy a bypass and plates... and that “if you buy 05-09 headers it comes with it..” ?

Click to expand...

The 03 - 04 trucks don't have the tubes from the factory, so the plates and tubes aren't needed. Those are only needed on trucks from 05 - 09.

JONBOY345 said:

The 03 - 04 trucks don't have the tubes from the factory, so the plates and tubes aren't needed. Those are only needed on trucks from 05 - 09.

Click to expand...

Yeah ok I was confused with reading another post... thank you so much.!

I'm new to the world of the 4runner. I just bought a 2005 SR5 with the V8 last week and I'm awaiting the dreaded intake manifold leak to start. I want to be proactive and do the AIP bypass kit before it goes sideways, but I'm also looking into the DT headers for the performance and MPG bonuses anyway. If i plan on doing the bypass anyway will i need the 2005 headers or will any year work.

Bearinamansuit said:

I'm new to the world of the 4runner. I just bought a 2005 SR5 with the V8 last week and I'm awaiting the dreaded intake manifold leak to start. I want to be proactive and do the AIP bypass kit before it goes sideways, but I'm also looking into the DT headers for the performance and MPG bonuses anyway. If i plan on doing the bypass anyway will i need the 2005 headers or will any year work.

Click to expand...

Yes you will needs the headers for your year model engine.

AuSeeker said:

Yes you will needs the headers for your year model engine.

Click to expand...

Thanks for the info. Nice rig BTW.

Very good information here. I have a 2006 Limited 4.7 and this is slowly in the process of getting the new exhaust. My question is this. The Doug Thorley Y-pipe...does it for better with the long tubes or short tubes? Other than that question, this is how my exhaust is panning out to look:

DT Long Tubes
DT Down pipe
2.5” X-pipe
5”x9” round race mufflers
Dump after Muffler.
Doing O2 simulator on back sensors

Anything else needed? Everything will be stainless and plan on using grade 8 locking header bolts.

Perreyrl said:

Very good information here. I have a 2006 Limited 4.7 and this is slowly in the process of getting the new exhaust. My question is this. The Doug Thorley Y-pipe...does it for better with the long tubes or short tubes? Other than that question, this is how my exhaust is panning out to look:

DT Long Tubes
DT Down pipe
2.5” X-pipe
5”x9” round race mufflers
Dump after Muffler.
Doing O2 simulator on back sensors

Anything else needed? Everything will be stainless and plan on using grade 8 locking header bolts.

Click to expand...

For reference I have a full 2.5" dual system with an x pipe and 2 6"×18" round magnaflow mufflers, only 2 stock cats on the manifolds. And dumped before the axle. Yours will be crazy loud, because mine is medium loud.

So are you going to chop up your DT y pipe and turn it into an x pipe? Why not just build an x pipe from scratch, way cheaper.

Perreyrl said:

Very good information here. I have a 2006 Limited 4.7 and this is slowly in the process of getting the new exhaust. My question is this. The Doug Thorley Y-pipe...does it for better with the long tubes or short tubes? Other than that question, this is how my exhaust is panning out to look:

DT Long Tubes
DT Down pipe
2.5” X-pipe
5”x9” round race mufflers
Dump after Muffler.
Doing O2 simulator on back sensors

Anything else needed? Everything will be stainless and plan on using grade 8 locking header bolts.

Click to expand...

The ypipe was designed with the long tubes in mind so that they bolt together instead of having to weld on flanges etc.

That_Titanium_4RNR said:

The ypipe was designed with the long tubes in mind so that they bolt together instead of having to weld on flanges etc.

Click to expand...

Ok cool! Thanks as that’s what I really needed to know.