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Not knowing when to admit defeat is either a sign of bravery or stupidity. The Rodeo was leaking oil and coolant from various spots in the engine, so Will decided it needed to be 'fixed'. This snowballed into practically a full engine rebuild - valve cover gaskets, head gaskets, timing belt, radiator hoses, water pump, thermostat... Well, after ripping apart the thing (ok the heads didn't come off, but everything else did) the truck is back together, and running no worse than it did before. In fact, it still leaks oil.
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Here's the last shot of the engine before I started taking it apart. After seeing it in peices, it really looks pretty good in this shot.
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First thing to go was the air intake stuff. It's in the way of a lot of things, and it's relatively easy to get off. What SHOULD have been the first thing to go was the fuse for the fuel pump. Before taking on the fuel injection, valve covers, and everything else down that way, you are supposed to run the fuel out of the engine by pulling the fuse on the fuel pump and cranking the engine for 30 seconds. Yeah, I didn't do that, and the manual doesn't mention it until well after you've rendered the engine unstartable.
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Here's the air intake hose in all it's glory. Attached to the left hand side is the Air Mass Indicator.
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Next to come out are the spark plug coil packs on the drivers side. The one in the back is a pain to get to.
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Here's the drivers side valve cover with all the coil packs removed. You can see the air intake and throttle body just above them. To the right of the air intake is the EGR pipe (the copper looking pipe) and EGR valve (just outside the shot).
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Here's a shot of the throttle body/air intake/EGR valve. You can also see the disconnected PVC hose in the lower left.
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Next to go was the accelerator cable. It is routed out of the back of the firewall over the Air Intake Plenum, then across the front of the engine and finally connected to the throttle. The supports are all labled with "E". To detach the cable, you unscrew the large nut on the right of the throttle body completely off of the cable sleeve, exposing the cable. You then rotate the throttle to the left to release tension and can slide the cable through the gap in the mounting bracket, as well as off the throttle.
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Next up, radiator hoses. These were a PAIN to get off. Also, finding the radiator drain plug was next to impossible - it was buried in the padding that the radiator sits on at the bottom. The only way to get the radiator drained was to just pull the plug on the bottom hose and let it just gush out. The top hoses weren't much easier - this is a shot of the smaller "T" pipe that connects several peices of the upper radiator hose routings.
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Here's the rest of the emissions stuff just before it was dismantled. The throttle body, EGR, and IAC (whatever that is) are on the upper right. The big metal thing in the middle is the Air Intake Plenum and fuel injection system. If you sight line up the yellow stickies starting at the back of the engine at the letter "E" through to the front of the engine at the letter "E", you can see the row of bolts that need to be removed to get the sucker off. What you don't see is the giant bolt in the back on the heater hoses that's also screwed into the Plenum.
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This is a giant failure of engineering. We had to pry the big metal engine lifting bracket away from the Plenum after unbolting it, then unscrew the bolt holding the heater hoses to the Plenum. The bolt was wedged between the engine lifting bracket and the Plenum, preventing both the removal of the plenum, and the removal of the bolt. The hose bracket appears to be welded or otherwise attached to the engine lifting bracket, so it really didn't need a seperate mounting screw. If it really did, then it could have easily been moved an inch to the right and used the existing bolt hole on the engine mounting bracket. Sigh.
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Here's the engine after the Air Intake Plenum was removed. This also illustrates the first part that I do not have a replacement for that was destroyed in the disassembly - the Air Intake Plenum gasket. 2 day lead time at Advance Auto.
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Here's another shot of the engine. You can see the radiator hoses have been removed, the Air Intake Plenum is off, and there's a LOT of gunk in there.
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Next up thermostat and timing belt removal. In this shot you can see that the thermostat has been removed (round hole front and center) and the passenger side timing belt cover has been removed. Several of the retaining bolts also had spacers on them and clips for various hoses mounted on the ends of the spacers. You can see in the foreground that the radiator is still in, but not for long. I pulled the radiator out to provide more room to work, then removed tension from all the belts. After removing all the belts from their pulleys, the whole fan and pulley assembly just unbolted from the front of the engine and came out.
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This is the main crankshaft pulley and retaining bolt. Supposedly it's very difficult to get off, and requires a special tool. It was actually not nearly that bad - putting the car in 5th and setting the parking brake put enough reisitance on the main crankshaft to get the bolt out. I used a gear puller on the pulley (being careful to attach it to something OTHER than the pulley surfaces themselves) to get the pulley off. Once it was removed, I was able to remove the lower timing belt cover and get to the water pump for removal.
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Not a lot of pictures got taken between the time the timing belt covers came off and when the whole timing belt assembly and water pump came out. I will definately regret this. This is a shot of the front of the engine after all the aforementioned things came off. The brown paper looking thing is the water pump gasket. The shiny silver hole to the right of it is a pulley for the drivers side timing belt routing. In the bottom right there's a silver bolt sticking out of a black tensioner track - that's where the pulley for the oil pump went I believe. You'll also notice that things are looking a little wet in this shot. You would not believe how much coolant is hiding behind the water pump...
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This is what the engine looked like at the end of day 1. I have yet to touch the valve covers or head, but the air intake, emissions stuff, throttle, air plenum, radiator hoses, radiator, fan, timing belt, and water pump have all been removed. After I finish getting the gasket mess off of the water pump mounting surface, I'll give the whole thing another bath in degreaser before taking the valve covers out. Working time elapsed so far: ~8 hrs.
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You are looking at a hateful pair of heater hoses staring back over the valve cover they guard with evil intent. Not only was the air intake plenum a PITA to get off because of their top mounting bolt, but the back right valve cover screw was almost impossible as well thanks to their lower mounting bolt. Needless to say, I'm not impressed with the engineering involved here.
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And here's what the sucker looks like after another ~4 hours of solid work. You may be scratching your head and saying "but Will, that looks an awful lot like a picture I've already seen." Yes, it does. What you may not be able to tell is that there are a grand total of 18 valve cover bolts that have been removed over the course of those 4 hours. Well, I also got the horrible water pump gasket off finally as well. Still, not a lot of progress here, and currently the valve covers are stuck on the engine. I've even resorted to a hammer to no avail.
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Ok, so 18 valve cover bolts were not enough. After wailing on the covers with a hammer for a good two hours I went back and double, triple checked to see that I really really got all the bolts out. Hmm, what might THOSE bolts be doing in there... Turns out I had missed two per valve cover, and after pulling them out, the covers came right up. The evil heater hoses and engine lifting bracket were in the way again so I couldn't actually get the covers off though. After destroying a couple hoses and beating the engine bracket with a hammer, the covers finally were freed, rewarding me with a view of camshafts and a disturbing orange glow.
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There's a spark plug down there somewhere... And it's dirty. These came out suprisingly easily. They were filthy, crusty, and old looking.
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Ok, I know, I know - this looks like every other picture of the engine, but in THIS one, it's another 5 hrs into the project, and I am just about ready for the putting back together phase of things. I have all the parts I am going to take off all over the garage, and I have all the parts I want to put back on in a pile. 17 hrs so far.
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