^how did you get them to do that? your sig says you have an 03 runner

I just bought it a few weeks ago

Yep I have this issue as well on my 03' limited that I just bought about a month ago. You guys have given me the motivation to get this fixed, I wonder if it falls under the 3 month 3 thousand mile dealer warranty? Anybody? Rotten egg smell sucks.

Thanks!

03' limited w/nav, 22" Effen Hurricane rims, JL amps and subs.

T-SB-0342-09

September 21, 2009

Excessive Sulfur Odor

Service Category

Engine/Hybrid System
Section
Intake/Exhaust

Market
USA



Applicability

TSB SUPERSESSION NOTICE

The information contained in this TSB supersedes TSB No. EG005-06.
^ Applicability has been updated to include 2007 - 2009 model year 4Runner vehicles.

TSB No. EG005-06 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding.

Introduction

Some customers may complain of excessive sulfur odor on 2006 - 2009 model year 4Runner vehicles equipped with the 2UZ-FE engine under the following conditions:
^ Stop and go driving

^ Heavy acceleration

In order to reduce the sulfur odor new catalytic converter assemblies have been made available. Follow the repair procedure to replace the catalytic converter assemblies.

For more complete understanding of the root cause, refer to TSB No. EG003-03, "Sulfur Odor from Exhaust."



Warranty Information

APPLICABLE WARRANTY
^ This repair is covered under the Toyota Specified Major Emission Control Component Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date.

^ Warranty application is limited to occurrence of the specified condition described in this bulletin.



Parts Information

Repair Procedure



Refer to the Technical Information System (TIS) applicable model year 4Runner Repair Manual:


---------------------------------------------------------------------------------------------------------------------

ENGINE
EG020-04

June 14, 2004
Title:
EXCESSIVE SULFUR DIOXIDE ODOR

Models:
'03 - '04 4Runner (2UZ- FE)

Introduction

Some customers may complain of excessive sulfur dioxide odor on 2003-2004 model year 4Runner (2UZ- FE) vehicles under the following conditions:
^ Stop and go driving.

^ Heavy acceleration.

In order to reduce the sulfur dioxide odor, the Electronic Control Module (ECM) (SAE term: Powertrain Control Module/PCM) fuel cut control logic has been modified and a new catalyst is provided. Follow the repair procedure to reflash the ECM and replace the catalytic converter assembly.
NOTE: For more complete understanding of the root cause, refer to TSB No. EG003-03 "Sulfur Odor From Exhaust," dated February 24, 2003.

Applicable Vehicles
^ 2003 - 2004 model year 4Runner vehicles equipped with the 2UZ-FE engine produced BEFORE the Production Change Effective VINs shown below.

I'm having this tick problem too, which a mechanic told me is probably a cracked manifold. My 4R has 93k no emissions warranty fix for me apparently

Anyone know the root-cause of this? Design flaw? Lack of proper maintenance? Etc etc?

Its a design flaw. The welds at flange on the header are prone to failure. To further complicate things you cant see the spot where the weld fails until you remove the headers (which on our trucks is a pretty big PITA).

There is usually a hairline gap where the flange meets the pipe right where they bolt up to the head.

To further add insult to injury nobody makes an aftermarket header for a 2005 V8 4runner so we are stuck with Toyota ones which cost an arm and a leg.

Fun fun, I'm saving my pennies to afford a replacement for mine at the moment...

Anyone have a cost to remove the manifolds, weld them, and re-install with new gaskets? That is likely going to be the way to go here.

Although Im sure it could be welded I think it would be really tough. The surface where its welded cannot protrude out or the header wont fit so I think it would have to be welded and then ground down and there really isnt much material there. And if you warped the flange you'd have a leak caused by that too...

Here is a closeup of where the leaks normally happen.

I have an 04 V8 that has started this noise when you start it, then it quiets down as it gets warmer, sounds like an old lifter tick. I was afraid of something like this, as mine is at 145K miles, and I am sure the dealer will smile and wave at me when I ask for it to be serviced under a TSB.

pretty sad failure, nothing with exhaust is fun to work on.

Well this sucks!!! I hear a similar noise in mine when I first start it up in the morning. I guess I'm off to a dealer, thanks cabowally for the TSB info. Of course mine is only at 56k miles.

Ducman,

Great pic. I was wondering where the crack was and to my surprise, that is a real bear of a spot to weld. I'm wondering if it is even worth fixing on my 03. I'm hoping to keep it for another 2 years and get something newer. I definately will not spend $3K on this fix. Not worth it.....

Yeah well the Manifold runs about $600 plus the gasket and probably new bolts so probably close to $700 total. Plus a Saturday of your time and some skinned knuckles

My dealer said they will weld it but won't replace the manifold because the TSB is only for the V6 but according to this info I should have some ammo for them to replace them instead of welding them.

Crap... mine just started doing this 2 weeks ago. I feared this was the case. We had it at the dealer and my wife asked them about it and they said they suspected it was a cracked manifold and told her it was a $1,500 job (roughly). Mine has 120,520km's (74,890 miles). I can't stand that ticking sound.

Man I still owe over $400 on that last service from 2 weeks ago (rotors and ceased brake caliper).