Intake manifold and valve cover gaskets.

The weather was nice today so I decided to do my valve cover gaskets. I didn't do the intake manifold gasket when i did my knock sensor repair so i figured I'd do that too.
On to the pics!

And so our story begins...


Pass side


I wonder why I smell burning oil every time I drive.


Pass side prepped and ready


Drivers side prepped and ready


I need new coils.


Intake off and out.


Ain't she purdy?


Valve covers off and out.


Everything off and laid out.


Tools needed for the job.


Not to bad of a job. Took about 2.5 hours to remove everything. But that's with moderate mechanical skills, taking pics, and taking it slow. The VC bolts had almost NO resistance when I was taking them out. My impact didn't even click. It was like hand tight then 1/2 a turn. The gaskets are hard as a rock. I'm taking a break for lunch and going to buy a torque wrench to properly tighten everything back down.

 

Nice work
You’re organized

 

Don’t forget the FIPG (form in place gasket) for the half moons and VC corners near the cams.

Yes you need new coils too but those can be done later. Get the Densos!

 

Consider replacing the starter while you're in there....

 

It's easy enough to pull that thing I'll do it if it goes out.

 

Ok, how the hell do you replace the spark plug tube seals? They dont go in and aren't pliable. Even with heat.

 

Bend those tabs back with some Needle Nose or Linesman Pliers. There are 4 tabs. You can just bend three back and leave the 4th factory as a guide. Judging by your pics your drivers side is cooked pretty good. Those old gaskets will be hard to remove but should come out with a screw driver or even better a small hooked pry bar.

Be very careful when putting the new tube gaskets back in that you do not tear them. Take your time. Once seated hammer the tabs back down lightly to flatten. Do not pound or the valve cover could crack.

 

Yup. I figured it out too late. Killed one seal. It refuses to go back round.

 

This is a cleaned up passenger side VC on my 02’ with new tube gaskets freshly installed.

 

Outstanding OP!!

 

That FIPG from Toyota is the best!

Lookin good OP. You're right, the manifold doesn't look that bad to remove.

 

Well, what began so well ended horribly. I fucked up a plug well seal because I didn't realize there was a metal ring in there. What a horrible design. Metal doesnt get fatigued when you bend it, right? I even got my heat gun out thinking I could heat them up before I realized there was a metal ring in there. So I gave up on that cover and moved on to the next. All good after I figured it out. Cylinder 5 was a bitch to get out. I'm positive they have never been changed. No marks on the tabs at all. They were hard as a rock and had 0 give. I should've left them since they weren't leaking after 315k miles. Then between that and digging tools out of my terribly disorganized van, and nothing wanting to work right I was done. It was dark and getting cold. Then as I was going to put the drivers VC on my rtv decided to blow out the back end. I got pissed and threw it. It went right up my windshield getting it all over my windshield. I'm just not good at this shit and have no clue what I'm doing. After this I think I'm done working on it. Anyways, heres a few more pics.

Valve covers cleaned up.


The inside.


Mating surface cleaned up.


Drivers side.


Drivers side w/new pos plug well seals.


Pass side w/the seal of shame.


The old pos seals. I had to knock them out and pry and it just wasn't ok.


My workspace.


New IM gasket in. I did put it back on but didn't bolt it in or get a pic.


The final straw.



I'm gonna go get a new set and some rtv tomorrow. I was hoping to get this all finished and pull my axles out to take them in to get new bearings pressed on on Monday. I guess we'll see what happens. TBC.

 

Don't get discouraged, man. Drink a beer, sleep on it, and hit it fresh in the daylight tomorrow. Hopefully you're local dealer has replacements in stock so you can pick up where you left off. You got this far, and you seem detail oriented.

I also recommend the Toyota FIPG that Professional Hand Model spoke of. Expensive but it will never leak. Very good stuff.

 

Nice work and shit happens! So long as you learn from it your better than when you started!

 

Hang in there. That looks like a major project and you've made it this far. I've done this same job on an 02 Corolla and it was a lot easier. This looks tough. I don't understand why they designed the plug well seals like that either.

As frustrating as it is, think about all the money you'll save by doing this job yourself plus the sense of accomplishment you'll have once it's done.

Now pull up your britches, smack your wife on the ass and finish it!

 

Stay at it. You've gone further than many others would. I essentially have a phobia of any mechanical work involving little fiddly bits where needle nose, those sharp dental looking hooks, or any other tweezer-like tools are needed. Something always breaks for me.

The rest will go smoothly.

 

You got this bmf4049! Nothings damaged that can’t be fixed right now. Take a breather and take your time putting all back. Make sure you use the fipg in those strategic spots.

Anyone else attempting just the VC gasket change it is best to do one side at a time. Do your put back on one side then crack open and do the other.

I think where many go wrong on this one are the tube seals and not using FIPG. Also, it pays to use all OEM Toy parts. They cost triple, but fit perfect in this case.

Bmf4069 you will get this done. Hang in there and if you need anymore assistance holler up here. I think you have it figured out though.

 

You ever notice how dentists have really really really nice hands?

 

The Tundra will be better than new once you get it done bmf4069. She needed this repair you and are doing good!

 

Not hand model quality but they're high ranking for sure

 

Bmf4069 are you still with us? We are patiently waiting on your successful results.

 

Well I finally pulled up my big girl panties and got back out there. Had to order another 8 plug well seals. Didn't want mismatched seals.





IM and VC back on.



My helper came out to lend a hand.



Everything buttoned back up.



After having to jump it it wouldnt start. Acted like it wanted to then died. No fuel. My stupid ass put the washers together on the fuel rail regulator. After spending half an hour prying the washers apart, I got it back together and he started right up. But, it had a definite miss and threw a code. I forgot to hook the injector and coil back up on 7. Ugh. Cleared the code and fired it back up. Purrs like a kitten.
Then the smoke happened. From the bottom of the VCs. I decided to hit the bolts a little more and snug em up. I slipped off the top of 8 and hit the injector which started dumping fuel out. Fml. Stopped the truck and reseated it. Leak stopped, but I may have to replace the injector seals now.
So this is awesome. And after this I get to do the rear axle seals, brakes, and bearing. Let's see how i can screw that up.

 

I can understand your frustration. Im not sure what the percentage is of people that do their own repairs and maintenance on their vehicles but I'm sure it's low. Like a few percent. Look how busy dealers and shops are.

Buy yourself something nice with the money you saved, and laugh as everyone else puts mods on their credit cards

(Not hating on others that have their trucks worked on, just trying to be funny and lift the OPs spirits)

 

Glad you got it done. Most jobs never go perfectly, so keep that in mind before getting down on yourself. There is this saying: Its ALWAYS something.

 

For 15 years, I never put a wrench on the 02’ let alone changed the oil. Too busy with other things. My life changed a bit and decided to get back to my roots of when I used to do all my repairs years ago.

Wrenching is therapy.

And to your point, bmf saved some serious money and he deserves to buy himself a nice 12 pack of Lager.

 

Shit happens. Frustrating as heck but look at the big picture......YOU are getting it done! OK........can't wait for rear axle seal fix pics...

 

Couldn't agree more. I'm also learning the other reasons people don't work on their cars. I just had a baby a few months ago haha. I can barely get out there to even wash the truck!

 

Very true. That's what my other car stands for, SHO = Shit Happens Often. The problem is Murphy hears me get the tools out and drops everything to come chill with me. I think my problem is I'm not used to messing up. I've been an electrician for 14 years. Got my masters license after 9. I'm pretty damn good and dont mess up that often. I'm the one they call when they cant figure shit out. I get under a car and that counts for nothing.

But yeah, axles might come out next weekend. I could do it today, but I wanna run the truck and see if it leaks or smells like burning oil. I also need to pull the driveshaft and do a full rebuild. And all my diff juice. And my front brakes and suspension. So let the shit show continue!