How to Replace Exhaust Manifold Catalytic Converter Assembly Drivers Side 2003 -2009 Toyota 4Runner

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New Exhaust Manifold Catalytic Converter Assembly from 1AAuto.com 1aau.to/ia/1AEE...
This video shows you how to install a new TRQ direct-fit bolt up catalytic converter assembly on your 2003 -2008 Toyota 4Runner. This vehicle uses an integrated exhaust manifold and catalytic converter assembly. That means you can replace the manifold, or the catalyst, without needing any cutting or welding.
This process should be similar on the following vehicles:
2003 Toyota 4Runner
2004 Toyota 4Runner
2005 Toyota 4Runner
2006 Toyota 4Runner
2007 Toyota 4Runner
2008 Toyota 4Runner
2009 Toyota 4Runner
Tools you will need:
• 12mm Wrench 1aau.to/oa/1AXA...
• 14mm Wrench 1aau.to/oa/1AXA...
• 22mm Wrench
• 12mm Socket 1aau.to/oa/1AXA...
• 14mm Socket 1aau.to/oa/1AXA...
• Blowtorch
• Cutoff Wheel 1aau.to/oa/1AXA...
• 1/2 Inch Ratchet 1aau.to/oa/1AXA...
• 3/8 Inch Drive Ratchet 1aau.to/oa/1AXA...
• Socket Extensions 1aau.to/oa/1AXA...
• Torque Wrench 1aau.to/oa/1AXA...
• Gloves 1aau.to/oa/1AXS...
• Safety Glasses 1aau.to/oa/1AXA...
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Toyota 4Runner 2002-2009 4th Gen: • Toyota 4Runner 2002-20...
⚠ DISCLAIMER:
While TRQ strives to make the information provided in this video as accurate as possible, it makes no claims, promises, or guarantees about the accuracy, completeness or applicability of the content. No information contained in this video shall create any expressed or implied warranty or guarantee of any particular result. All do-it-yourself projects entail some risk. It is the sole responsibility of the viewer to assume this risk. TRQ is not responsible or liable for any loss damage (including, but not limited to, actual, consequential, or punitive), liability, claim, or any other injury or cause related to or resulting from any information posted in this video.

[@TRQ]

√ *Watch the Video* √ *Buy The Part at 1A Auto* 1aau.to/m/Shop-TRQ-Parts √ *Do it Yourself* √ *Save Money*

[@ISupportTheCurr3ntThing]

To anyone watching this. Please do not use an impact on these bolts. Especially if it's a rusted POS like in the video.

[@murrayndumba3290]

Nice work well explained is it okay to add anti sieze on the six studs bolting to the the engine

[@djsonicc]

definitely put copper anti-seize

[@Asmodeus-he2jx]

This gives me hope cuz even at 210,000+ miles and despite the obscene amount of salt dumped on the roads here in winter, mine still doesn't look quite as bad as this one. Maybe I'll manage 😅

[@marshellarts]

Nice video, but on my 2005 4R, there's quite a bit more work that will possibly add hours to the job, rust or not. That space where he pulls out the catalytic converter, well you must remove a resonator which looks like a small muffler on each side that block the space to extract the Cat manifold. There's also a steel vertical support that is bolted to the engine block and converter flange which is problematic. I have a 2005 4R, so maybe Toyota added some structural header support (known to crack on earlier years) and resonators that weren't on earlier model 4R ? i've decided to leave a more detailed account of the work on my 2005 4R to add to this video. Day 1: Started on L side and followed the video unbolting the exhaust manifold (good info). Be careful using impact hammer and use a 6 sided socket. I tried with a regular ratchet, but the nuts were too tight and decided to carefully use one. Next, after unbolting the exhaust flange between the L and R side to loosen the resonator, you can now push it aside to create the space you'll need to get the cat out. . IMPORTANT NOTE: the nuts on this middle exhaust flange are spot welded on by Toyota, so you have to unbolt them from the bolt head, which is rather unusual. I found out the hard way after spending an hour or so trying to break the nuts free with penetrating oil and heat, before trying the top bolt and seeing the weld on the nuts. LOL In addition, the steel vertical support had to be unbolted and rotated out of the way by removing one of the two bolts and loosening the other. Both bolts can be accessed from the bottom. This support goes goes underneath the converter flange, so best to get it out of the way to more easily extract the cat manifold. Day 2: Unbolted the header on R side and moving the R side side vertical steel support by accessing the top bolt through the passenger wheel well. It was tight and took a lot of effort to loosen. Rotated the support out of the way. Once everything was loose, pushed the R side resonator (attached to the main exhaust and large muffler) out of the way to extract the 2nd cat manifold. Prepared surfaces and started reassembly, but was having trouble getting the hole on the R side vertical steel support to line up after installing the R side cat manifold. Called it a day to attack the problem fresh tomorrow and hopefully finish the job. Day 3: Back to that problematic vertical support which wasn't lining up with the converter flange after torquing the manifold (16 ft. lb). The bolt hole was about 3/8 away from getting the bolt into the flange. Turns out Toyota designed the support so the holes in it are much larger than the bolt, so once they are both loosened, you can move the support to easily line up with the threaded bolt hole on the flange. Install the bolt first into the flange and then tighten the two upper support bolts. After that everything went together fairly smoothly and hooked up the 4 sensors. Best to replace all sensors if you can.afford it, as this is a difficult job and you don't want to have to do it again anytime soon. I suppose on a tight budget you could try your old sensors, but they are difficult to get to, especially the upstream fuel mixture ones, including the challenge of disconnecting the sensor plug in a very tight location. My rig has 260K miles on it so I decided to use my credit card and bite the bullet, replacing them with DENSO units from O'Reillys at half the cost of the dealer same OEM DENSO's. You can find them even less expensive from other wholesale houses or use Chinese counterfeit knockoffs on Amazon at a fraction of the cost and hope for the best. DENSO part # : Upstream fuel ratio sensors # 234-9051 (same for both sides) Downstream oxygen sensor (L-drivers side)---------# 234-4261 Downstream oxygen sensor (R-passenger side) --# 234-4260 The only difference between the downstream are the pigtail lengths of the wires. Everything works and all CEL indicator lights are now off. It only took me 2 1/2 days (more or less 14 hours) to finish the job. LOL Thought I'd get it done in a 6 hours or so after initially watching the video, especially on a rust free Arizona 4R. Avoid the above pitfalls I encountered and have plenty of long extensions and a swivel joint, along with a swivel head ratchet and you can probably get it done in a much shorter time. Then again, a guy at the end of the comments said his V8 took him 2 days to get one manifold side off and then he just wanted to die :-) Total cost of parts for both OEM cats (you can find Toyota dealers on the web who sell wholesale with 30% off) and 4 OEM DENSO sensors from O'Reilly's was around $1,700. Ouch, but when you realize the dealer wanted $ 4,100 ! to do the same work, it PAYS to DIY! Hope this video and my notes help you out. Good luck :-)

[@TRQ]

+@marshellarts Thanks for the feedback! 1aau.to/m/Shop-TRQ

[@DocRC_Cola]

I'm considering doing this on the passenger side exhaust Manifold on a 2011 Tacoma, is the procedure the same? I don't have a lift, can i do this on jack stands? Also if I have to get new bolts or nuts where can I purchase them? Thank you.

[@mannycortez6703]

Should I replace both sides ? I ask because there is only a leak on the driver side .

[@CCCcarts]

Great Video Bud 🎉

[@callmekyle4950]

Doing this on my v8 rn 2 days later got 1 header off now wanting to die

[@chrisaustin4289]

That is a lot of rust!!!!

[@mattsonheidemann7895]

How comparable is this to replacing the exhaust manifold gasket on a 2005 Tacoma?

[@annone-yl4hz]

What stud and nut size? They're not included.

[@Onry1]

Interesting how there's several videos for the Driver's side and 1 ONE video for the passenger side...

[@mikeschlup5279]

Never heard of an extractor socket...where do you get them?

[@mikeschlup5279]

Is the V8 procedure similar?

[@johnthomas8061]

A lot of times you can use the next size down socket and hammer. But they do make extractors. They're spiraled inside. Any auto parts store or till store should have them

[@jonathanbanks4427]

I don't have angle grinder but I have a dremel if I cut the nut will the cat come off or will bolt be welded in or???

[@khalideid8463]

Do u think this part will work for Lexus gx 470 2008 too ?

[@TRQ]

+Khalid Eid This procedure might be different for your application. We do not currently have a how-to video for this particular year, make and model. Thank you for asking! 1aau.to/m/Shop-TRQ

[@sschevmale24]

V8 or v6?

[@evilchild3684]

The torque specs is 22 lb I thought it was 17