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Car Forum / Toyota / Toyota Trucks / January 2006

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22RE Intake Manifold Removal

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smk24ik@netzero.com - 04 Jan 2005 09:32 GMT
Hello,

My "88" 4X4 Truck 22RE has a blown head gasket, water sucking into
#3. Losing water, steam coming out tail pipe, #3 spark plug fouling bad
(although #3 still seems to have good compression), rocker arm cover
coated with brown milk. 170K, 40K on rebuilt long block and timing set,
head was in good shape at that time. Truck was running great untill it
turned into a steam engine.

Going to give it a shot at getting that head off. Think I can handle
everything except possibly the fuel injection intake manifold which
looks like it could be a bear. The Haynes manual is pretty vague in the
subject. I have read previous posts on this list about a possible
"9th" bolt? And while looking under the manifold, I see some metal
tubing which must be disconnected? One possibly called a secondary air
injection tube? There are a couple other metal tubes which seem to go
back behind the head. Haynes says to remove all hoses and wiring, but
don't think that is necessary.

I would be most appreciative if someone could explain, what needs to
disconnected, and how, to move the intake manifold out of the way just
enough to get the head off.

Also, the book says to relieve the fuel pressure first, disconnect
electric fuel pump connection at the fuel tank. Crawled under there
twice, can't find it, I think the tank has to come out to disconnect
it there. What the heck?

Thanks for your expert impute on this matter. Pray the head is OK.
Mark
DeepDiver - 04 Jan 2005 11:22 GMT
> Hello,
>
[quoted text clipped - 4 lines]
> head was in good shape at that time. Truck was running great untill it
> turned into a steam engine.

Word of caution: #3 may appear to have good compression due to water in the
cylinder occupying space that would normally be filled by compressible air.
Basically, the water could be reducing the displacement in that cylinder.
Don't run the engine if there's liquid water in a cylinder, you can do
serious damage.

You also have to worry about the fact that you got water in your crankcase.
That means pulling the oil pan. It also means that there's probably
emulsified water and oil in your engine's oil galleys. I'd be concerned
about getting all gunk that out. A power flush would be best, but I don't
think that's something you can DIY. Perhaps someone else has some better
recommendations on this. But I would consider removing the oil filter and
blowing compressed air through the engine's oil inlet port (the nipple the
filter threads onto). That should help blow out the galleys. But even that
will probably not clean it all out. So after you've finished getting the
engine back together, you might want to consider putting the oil pan on with
a temporary gasket, filling the crankcase with oil, *priming* the system
(that's important!), running the engine a short while, then pulling the oil
pan again to get out any remaining gunk.

As for the root cause, it may not simply be a blown gasket. It's very
possible that the water passages in the head have corroded to the point that
they have bridged into the cylinder dome. This is not as bad as it sounds. A
reputable machine shop can grind out the corrosion, fill in the holds by
welding, and then re-surface the head. When I pulled my head ('89 22RE),
there was some corrosion that had gotten very close to the cylinder domes.
My machine shop did a great repair for me.

> Going to give it a shot at getting that head off. Think I can handle
> everything except possibly the fuel injection intake manifold which
[quoted text clipped - 5 lines]
> back behind the head. Haynes says to remove all hoses and wiring, but
> don't think that is necessary.

Frankly, I don't remember everything I did to get the manifold off. I do
recall that it was tricky in that it required some contosionist positions
from the top and the bottom of the engine compartment. Be sure you have a
good assortment of socket extensions, flex joints, and combination wrenches.
You should also have flare nut wrenches. Probably the worst was getting to
the air injection manifold that runs behind the back of the head (I don't
know if your engine has this). Of course, I pulled my manifolds completely
to R&R all the gaskets and soft parts, so my job was a bit more involved.

> Also, the book says to relieve the fuel pressure first, disconnect
> electric fuel pump connection at the fuel tank. Crawled under there
> twice, can't find it, I think the tank has to come out to disconnect
> it there. What the heck?

The fuel pump is inside the tank; there is an electrical connector at the
access port on the top of the tank. But you really don't need to disconnect
that. If the vehicle has been sitting for a day or so without running, there
probably won't be much--if any--pressure remaining it the fuel lines. What
you definitely do need to do is disconnect the battery. I recommend actually
removing the battery altogether from the vehicle. It gives you more room to
work and ensures you don't accidentally short the terminals with any tools
or parts (very bad, especially with open gasoline lines around). When you're
ready to disconnect the fuel supply line from the fuel delivery rail, wrap a
shop rag around the wrench and connection before cracking the banjo fitting.
If there is any residual pressure, it will get soaked up by the rag (you are
wearing safety goggles, right?). Make sure you properly store and dispose of
any gas soaked rags.

Hope this helps.

- Michael
Roger Brown - 04 Jan 2005 16:37 GMT
There is one hard-to-find bolt under the thermostat housing.  It is long, allen head and hidden underneath the intake.  A
Factory Service Manual is a big help:
    http://www.4crawler.com/4x4/FSM.shtml
I have a writeup on some of the rebuild work:
    http://www.4crawler.com/4x4/CheapTricks/EngineMods/index.shtml

--
  Roger
dale_t63 - 01 Jan 2006 23:29 GMT
I;m replacing the head gasket, found the 6mm allen bolt. Whats the best way
to remove the bolt , having a little trouble
thanks
Bill Hall - 02 Jan 2006 04:17 GMT
When all else fails;;;;;; You may have to do what I had to do! Drill through
the bolt head with a 5/16 bit and insert a fairly long "drift pin". Then
lightly tap on the drift pin until you break the bolt loose. A new bolt from
Toyota runs $1.87. Worked for me.If you have stripped the allen head out (
not unheard of), you can turn the bolt with needle nose vise grips.
Bill
> I;m replacing the head gasket, found the 6mm allen bolt. Whats the best
> way
> to remove the bolt , having a little trouble
> thanks
Bill Hall - 02 Jan 2006 04:24 GMT
CORRECTION, CORRECTION**************   That's a 3/16 bit.   Sorry,fingers
too big!
Bill
> When all else fails;;;;;; You may have to do what I had to do! Drill
> through the bolt head with a 5/16 bit and insert a fairly long "drift
[quoted text clipped - 7 lines]
>> to remove the bolt , having a little trouble
>> thanks
dale_t63 - 03 Jan 2006 15:16 GMT
Thanks Bill, The allen bolt is stripped(gr-rrr) How does a drift pin work?
Bill Hall - 03 Jan 2006 19:00 GMT
Did you get my response? Didn't show up on the newsgroup!! If not ,I'll
resend.
Bill
> Thanks Bill, The allen bolt is stripped(gr-rrr) How does a drift pin work?
dale_t63 - 05 Jan 2006 13:27 GMT
Got it off..thanks everyone.
dale_t63 - 01 Jan 2006 23:32 GMT
What is the Best Way to remove bolt, having a little trouble getting it
loose.
thanks in advance
William J. Brown - 02 Jan 2006 01:48 GMT
>What is the Best Way to remove bolt, having a little trouble getting it
>loose.
>thanks in advance

Hey!
Soak it with WD-40 or something similar. Soak it over night.
Even better, start soaking it while the motor is still warm -
but keep drenching it as much as you can hourly.
Bill
Bruce L. Bergman - 02 Jan 2006 03:22 GMT
>What is the Best Way to remove bolt, having a little trouble getting it
>loose.
>thanks in advance

 You need a real penetrating oil - and WD-40 is NOT one.  Repeat
after me, "The WD in WD-40 stands for Water Displacement"

 It's the best stuff to have on hand for quickly drying out the
ignition system after you drive through rain puddles.  But the main
ingredients are Kerosene and Stoddard Solvent, meaning it is NOT a
long-term lubricant, and is at best only a marginal penetrating oil.

 Kroil or PB Blaster are two much more effective petroleum based
penetrants.  And if you ever need to work on HVAC or food processing
equipment, MARS "Rust Buster" is NSF approved for incidental food
contact - and it doesn't stink nearly as bad when you get it hot.

 Get the penetrant down to the base threads you're trying to get
open, and soak it several times a day over the course of a few days.

 If the bolt isn't moving more than a partial turn without applying
extreme pressure, STOP FORCING IT! - soak it again, come back
tomorrow, try again.  Otherwise you start snapping bolts off, which
suddenly makes a simple job into a whole lot more complex procedure.

 If you can stand the smell of hot solvents and it is still drivable,
driving the car is OK in between treatments.  It can actually help, as
the gap between stud and block (or bolt and nut) will expand and
contract with engine heat.  When you arrive you let the engine cool
down for 10 minutes and blast it again.  It will soak in.

    --<< Bruce >>--

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Bruce L. Bergman, Woodland Hills (Los Angeles) CA - Desktop
Electrician for Westend Electric - CA726700
5737 Kanan Rd. #359, Agoura CA 91301 (818) 889-9545
Spamtrapped address:  Remove the python and the invalid, and use a net.

 
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