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View Full Version : Routine Maintenance Brings the Suck, A 3.0L Part 2


AxleIke
10-01-2010, 07:42 PM
I have two brothers. My youngest brother has the SC'd 3.4L that I swapped head gaskets on earlier.

My middle brother has a 95 4runner, with the 3.0L V6. Blew the head gasket.

So, changing all that out.

He is leaving for Africa (Peace Corps) in December, and was going to sell his truck. We started doing routine Maintenance on it: wires, air filter, etc... to get it ready to sell.

I found the air filter clogged with what looked like dried mud. Not just dirty, but the ripples in the filter were mostly filled up.

Then it overheated. We flushed the coolant to find an orange sludge mixture. Had actual sludge in it.

Finally, it blew the head gasket after the coolant flush and an oil change. No oil in the pan (at least not enough to hit the dipstick) and spraying coolant out from under the timing cover in the front.

AxleIke
10-01-2010, 07:43 PM
So, the engine is stripped down to the block, and the big stuff is off at the parts cleaners.

Here are a few pics of the tear down:

Shot of how nasty the engine is with the valve covers off:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4486.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4485.jpg

You can see where coolant came spilling out from under the head, and cleaned off the top of the water pump:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4487.jpg


Here you can see the orange-ish colored coolant ports. This is from the, I'm guessing, rusted out coolant system. It was orange sludge essentially, when we first started flushing it. The over flow was FULL of sludge. Almost looked like moab mud.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4489.jpg

This is a shot of the steering box, which got doused when the truck over heated. Not a nice green color at all.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4499.jpg

The EGR is caked with grease and dirt. I'm not too excited about seeing this in an intake:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4488.jpg

This is the passenger head. When we removed the cam on this side, the garage started to REEK of burnt oil/grease. It was not pleasant.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4490.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4491.jpg

Removing the driver head. This is the one that failed I believe. There was a clear "clean" area exiting the front of the head gasket, close to the water pump.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4492.jpg

I have a large amount of cleaning ahead, but thankfully, not as much as last time:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4497.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4498.jpg

Parts off to get cleaned:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4496.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4494.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4493.jpg

Bikeman
10-01-2010, 09:16 PM
Wow. You are a man for taking on that repair!

Hulk
10-01-2010, 10:49 PM
You need some new brothers.

60wag
10-02-2010, 08:48 AM
It looks like you got the preventive maintenance gene and your brothers didn't. I hope they are making your effort worth while.

farnhamstj
10-02-2010, 10:11 AM
You are for sure the nicest brother ever.

AxleIke
10-02-2010, 11:05 AM
LOL! Yeah, they are good guys. The first one bought all the speciality tools I needed for the job, and this one is going to be getting me something. I'll have to see, but I'm thinking some money towards a soft top! :D

J Kimmel
10-02-2010, 08:21 PM
you can't sell that thing after all of that work!

AxleIke
10-04-2010, 11:03 AM
you can't sell that thing after all of that work!

Yeah, I know, but he's leaving and everyone else is set on vehicles.

Besides, I want him to import a turbo diesel 70 series from Africa when he comes back :D

AxleIke
10-07-2010, 10:01 AM
Block is almost clean. Rotary tools with scotch brite pads rock.

I'll grab pics when its done, but all 6 pistons are clean, with a few discolorations in the indented areas, just because they are almost impossible to clean. The head surface is clean, as is the "V" area. The front of the engine, including the water pump surface is clean, and degreased.

My back is sore, and so are my arms.

Injectors are off to witchhunter today. Pretty sure they aren't supposed to have grease inside.

AxleIke
10-18-2010, 12:01 AM
Updates.

Most all parts are clean. The parts washer does a great job on exposed surfaces, but interior ones, like the intake manifold, require some cleaning here. The plenum is giving me fits. Due to the EGR system, there are baked on areas of grease, which is a PAIN to get off.

The rest of the stuff is clean for the most part.

Got the heads machined, and the fuel injectors cleaned up and balanced by witchhunter performance. 3 of the injectors were only flowing at 75 ish percent, due to grease, I assume. All 6 are balanced within 1% now.

Got the block cleaned, the pistons de-carboned, the valves de-carboned, and the very top of the cyinder walls de-carboned. I very carefully removed the cylinder wall carbon with a fine flat head screw driver, and brake cleaner. The rest was done with a combo of a rotory with scotch brite, and a brass wheel on a drill.

Then, put in the two heads, and the water pump. All was going AWESOME until the very last bit this evening.

One of the cam shaft bearing cap bolts pulled the threads. Then, my brother was working on installing the exhaust manifolds. One of the exhaust studs had to be removed at the machine shop. The shop was able to get it out, but it ruined the top few threads on the hole. He ran a tap down, and the threads below were good. Unfortunately, the stress of torquing down the exhaust nuts was enough to pull the remaining threads out of that too.

Sooo, passenger head comes back off for a heli-coil, and something. The bolt for the bearing cap I will either helicoil as well, or simply drill and tap up one size. I have to figure out which is better. Anyway, at least we didn't get farther than this, and tomorrow, my brother will pull the head while I'm at work.

Pictures:

The block all cleaned up:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4500.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4501.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4502.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4503.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4504.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4505.jpg

Heads clean, machined, and de-carboned

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4507.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4506.jpg

Intake Manifold:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4508.jpg

Heads on:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4509.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4510.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4511.jpg

Driver side head with camshaft installed and ready to get buttoned up.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4512.jpg

More to come this week hopefully.

DaveInDenver
10-18-2010, 07:37 AM
What did you have done to the heads and who did the work?

AxleIke
10-18-2010, 08:19 AM
Mountain High Performance (http://mtnhiperf.com/), and they removed the one exhaust stud, and took .008" off of the headgasket surface so the new gasket has a good surface to adhere to.

AxleIke
10-19-2010, 11:46 AM
Thanks dudes.

Helicoils are in. Quite a slick little operation they are. Too bad they are completely thread specific, and for the two, it set my brother back 100 bucks. Ah well, if I ever need M10x1.25 or M8x1.25, I have a bunch of helicoils and nice sets to install them with now.

HeliCoils!

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4515.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4514.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4513.jpg

Yesterday we picked up a new headgasket for the RH side, and I got the head back on, the exhaust manifold on and torqued, and the camshaft in and torqued. Also got the seals in, and used FIPG to seal the end caps, and the plug on the rear of the head.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4516.jpg

Also, over the weekend, got the new water pump, and thermostat in. Again, good layering of FIPG to keep things sealed up nicely.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_4517.jpg

Installed the new PCV valve last night, but it got late, and I didn't get the valve covers on yet. To be continued...LOL!

Jacket
10-19-2010, 12:11 PM
Dude - I don't know if it'll run, but it sure looks pretty! Nice job. You are soon going to be the master of the Toyota V6 head gasket job.

Uncle Ben
10-19-2010, 12:17 PM
Dude - I don't know if it'll run, but it sure looks pretty! Nice job. You are soon going to be the master of the Toyota V6 head gasket job.

x2! :thumb::thumb: :bowdown::bowdown::bowdown::alexthemasterofhead:

nakman
10-19-2010, 12:18 PM
Looking great Isaac.. on Helicoils, fwiw we've got about every size of install tool smaller than that at the shop here. Things just don't get that big in plastics, I think the biggest I've got is M6, but we go down all the way to M2. On the English side from 2-56 all the way up to 1/4-20, stopping at all the common threads, we've got the taps, helicoils, and install tools for all of it.

Not that I want to get into loaning out tools, but I could likely helicoil something for someone, some day, if you strip something and can't just make it bigger.

Jacket
10-19-2010, 12:23 PM
x2! :thumb::thumb: :bowdown::bowdown::bowdown::alexthemasterofhead:

:lmao::lmao:

AxleIke
10-19-2010, 01:03 PM
Dude - I don't know if it'll run, but it sure looks pretty! Nice job. You are soon going to be the master of the Toyota V6 head gasket job.

Thanks man. No, not a master yet. This has already taken WAY longer than it should have. I'm just way OCD about this crap. It bugs me if it isn't just right. Maybe I can get a record for being the slowest to rebuild a top end.

x2! :thumb::thumb: :bowdown::bowdown::bowdown::alexthemasterofhead:

Har, har, har. Funny guy here, Funny guy.

Looking great Isaac.. on Helicoils, fwiw we've got about every size of install tool smaller than that at the shop here. Things just don't get that big in plastics, I think the biggest I've got is M6, but we go down all the way to M2. On the English side from 2-56 all the way up to 1/4-20, stopping at all the common threads, we've got the taps, helicoils, and install tools for all of it.

Not that I want to get into loaning out tools, but I could likely helicoil something for someone, some day, if you strip something and can't just make it bigger.

Great to know! Thanks for the tip! If anything else strips out, I'll let you know and see if you can get it done!

AxleIke
11-03-2010, 01:04 PM
Updates:

Its finally back together. First go around was bad news. It turns out that the heads are exact copies of each other, EXCEPT where the tensioner pulley bolts up. There is a hole on the other head, that is threaded correctly, but there isn't a spot machined out so the pulley can sit flush.

So...I pulled everything back apart. Switched the heads, and threw in new head gaskets, again. Buttoned everything up.

It runs.

Sorta.

It runs fine at higher RPM, but surges really bad at idle and low RPM. Either I have a vacuum clog/leak, or its the throttle position sensor. I pulled the TPS last night and threw the multimeter on it. The idle circuit seems to be having some issues, but it really needs to be tested on the truck.

Good thing I just picked up a fancy vacuum/brake bleed kit from craftsman so I can apply vacuum to the throttle body without the truck running. :D

Set the timing to 10deg BTDC with the diag hack, and after pulling the hack, it dropped to 8. At least the timing belt seems to be correctly installed.

The PAIR reed valve hose is cracked, so that is getting replaced. I also bypassed the VSV (vacuum switching valve) on the EGR, which helped some. I may be having some issues with that VSV.

Fun fun fun!

Beater
11-03-2010, 03:18 PM
nothing worse than chasing down a suction loss...

DanS
11-03-2010, 08:11 PM
I just finished the head gaskets on my sister's 3.0.

Vacuum leaks for us too. In my case it was the RH PCV valve hose, it got knocked off at some point, and after the intake was back on it's pretty hidden.

Either way, get a can of starter fluid, and with the engine idling give a short squirt where you think the leak is. If the engine smoothest out or races a little then you've at least found the general area to investigate.

Dan

AxleIke
11-04-2010, 12:23 PM
Good idea Dan. I'll be working out several issues at once.

I'm about 90% sure the throttle position sensor is fried. The actual sensing is fine, but the idle circuit resistance does not match up anywhere with the proper readings in the FSM.

Ordered a new one, should be here tomorrow. I'll tackle it again this weekend.