Cpt_Romania
New member
Hello to you all,
I bring you all now the story of how I installed 05-09 Doug Thorley Headers on my 05 4Runner which has 2" BL, but not after I bought the 03-04s Headers and spent 3 months driving back and forth taking my headers off a grand total of 4 times before coming up with a solution!
Let us begin:
So long story short, the 03-04s did NOT fit because of the 02 sensor bung placement on the headers, they were drilled into the bottom of the header making it impossible for my female end to fit, on top of the fact that the steering shaft was entirely in the way. This is the other difference I was talking about that neither myself or Burtman saw coming, guess that's what happens when your blazing a trail into uncharted waters and Doug Thorley said they will NOT sell their headers to people with Body Lifts :moping:
So I left my car at the shop as I tried brainstorming a solution ( the shop is 2 hrs away from my home by the way, so I had to get a ride back home ) and I came to the conclusion that the 05-09s would be the best solution since there were no solutions coming up for extending 02 sensor wires.
Obviously I couldn't return the 03-04 headers because they already had a pair of cats welded to them. Here is the post where I SOLD the 03-04 pair and there's more information there.
http://www.toyota-4runner.org/sale-...ley-magnaflow-combo-$800-portland-|-sold.html
So I got bought a set of 05-09 Headers and another set of Magnaflow Cats, had them welded up again and drove back to the shop and it still wouldn't clear the steering shaft ( we "dimpled" previously a little ) so this is where I lost my mind and took a hammer and blow torch to them until they fit
[ Also I still had the $199 4.7L Air Induction Pump Bypass Kit that you connect to your Air Intake which I didn't even "need" anymore because the 05-09 Headers come with the EGR tube so it's more of a precaution at this point in case the "computer/sensor" goes out, but I'm told it costs a lot of money to replace and if you don't your Check Engine light will stay on ) but the thing is that my check engine light will probably always be on because of one reason or another so it's just an ornament in my engine bay now ] :clap2:
Also if you want to hear what the 4runner sounds like with the headers installed, check out the link below!
https://www.youtube.com/watch?v=PMwzCJZCWtM
Here come the pictures:
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I bring you all now the story of how I installed 05-09 Doug Thorley Headers on my 05 4Runner which has 2" BL, but not after I bought the 03-04s Headers and spent 3 months driving back and forth taking my headers off a grand total of 4 times before coming up with a solution!
Let us begin:
Exhaust tick started, tried to ignore it, it got much worse and I started to hate driving my 4runner. Found this Doug Thorley Header solution and I rationalized in my head that it was worth the money and that it will be the last mod I'll do ( Yeah right -_- )
After talking with Jason from Burtman Industries I learned that the 03-04 headers were "exactly" the same as the 05-09s except for not having an EGR tube and something else, which I'll mention later on.
I ordered the Headers, (2) Magnaflow catalytic converters and the 4.7L Air Induction Pump Bypass Kit and Exhaust Port Plates off of eBay, which you need for the 03-04s because they do not have an EGR tube.
After talking with Jason from Burtman Industries I learned that the 03-04 headers were "exactly" the same as the 05-09s except for not having an EGR tube and something else, which I'll mention later on.
I ordered the Headers, (2) Magnaflow catalytic converters and the 4.7L Air Induction Pump Bypass Kit and Exhaust Port Plates off of eBay, which you need for the 03-04s because they do not have an EGR tube.
So long story short, the 03-04s did NOT fit because of the 02 sensor bung placement on the headers, they were drilled into the bottom of the header making it impossible for my female end to fit, on top of the fact that the steering shaft was entirely in the way. This is the other difference I was talking about that neither myself or Burtman saw coming, guess that's what happens when your blazing a trail into uncharted waters and Doug Thorley said they will NOT sell their headers to people with Body Lifts :moping:
So I left my car at the shop as I tried brainstorming a solution ( the shop is 2 hrs away from my home by the way, so I had to get a ride back home ) and I came to the conclusion that the 05-09s would be the best solution since there were no solutions coming up for extending 02 sensor wires.
Obviously I couldn't return the 03-04 headers because they already had a pair of cats welded to them. Here is the post where I SOLD the 03-04 pair and there's more information there.
http://www.toyota-4runner.org/sale-...ley-magnaflow-combo-$800-portland-|-sold.html
So I got bought a set of 05-09 Headers and another set of Magnaflow Cats, had them welded up again and drove back to the shop and it still wouldn't clear the steering shaft ( we "dimpled" previously a little ) so this is where I lost my mind and took a hammer and blow torch to them until they fit
[ Also I still had the $199 4.7L Air Induction Pump Bypass Kit that you connect to your Air Intake which I didn't even "need" anymore because the 05-09 Headers come with the EGR tube so it's more of a precaution at this point in case the "computer/sensor" goes out, but I'm told it costs a lot of money to replace and if you don't your Check Engine light will stay on ) but the thing is that my check engine light will probably always be on because of one reason or another so it's just an ornament in my engine bay now ] :clap2:
Also if you want to hear what the 4runner sounds like with the headers installed, check out the link below!
https://www.youtube.com/watch?v=PMwzCJZCWtM
Here come the pictures:
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.
.
.
.
.
.
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