Can't put off this work any longer. I need to get throught inspection and its time to get this engine running the way its way designed. I need to replace the secondary air intake, exhaust manifolds and while I've at it the injectors. And of course whatever else I break in the process.

Pulled the upper air intake manifold so that I could fix the secondary air intake tube and exhaust manifold leak. EGR was a real b%&#+! but I won out. Previous owner had plugged the ferrules with what looks like JB Weld. Those ferrules appear to be in pretty bad shape. I've soaked them with PB and tommorrow I'm going to see if I can get them out.

Any suggestions, their pretty rusted and most likely have been stripped. Why else would they plugged them? Should I use an bolt extractor or can I just crush them since there hollow and work them out without trashing the threads?

While I've got the upper intake out I plan to clean it up tonight because it's a mess. If I remember correctly brake cleaner is a good solvent for the intake manifold? What works best without harming the throttle body.

As always, certainly would appreciate your recommendations. Thanks.

Roy

 

Clean everything with purple cleaner or greased lightning, then hose it down, alot cheaper than brake cleaner, hosing with water will not hurt anything just blow everything with air real good, and for the stuck thing, try a torch and heat it.

 

Excellent. Just so happens I have a bottle of Grease Lightning on hand. Great stuff for getting the road grime off the camper. Thanks.

Roy

 

Just remember to blow out the tb, air bypass and tps. For stubborn crap I sometimes use ezoff oven cleaner, excellent on metal but be careful with aluminum it burns it as in turns it black.

 

So you have the upper intake off and what exactly are you trying to do with the secondary air injection tubes? If you are going to try and hook it back up good luck. I tore the rail off mine and plugged the hose. There is probably jb weld on there cause if the tubes are open exaust comes out. Makes a hell of a racket too. As far as your intake gasket at the engine leaking it could just be those 6 inlet tubes.
If the secondary air injection system is not hooked up it will throw a code for it. P0411 on mine. I ignore it though

 

Replace it. I have a new rake and ferrules and just need to get the old ferrules out of the head. Of course, removal of the head is my last resort. I''ve been soaking them in PB for the past several days and will probably try to latch on with a vise grip to see if I can break them loose.

No, it was the exhaust which is typical. I had it on the lift and identified the rear manifold at #5 and 6 with a sniffer. Plenty of soot build up as well.

Never threw any codes but then again I've only had the truck a little under a year and still finding things disconnected that shouldn't be. This truck is a keeper so I want to put it back together as designed. Hopefully it'll last another 20 years...

Thanks for the comments though.

Roy

 

Ok, I took the TB, EGR, idle control off the upper intake to clean out all the build up. Looks 100% better now.

Need a sanity check. Before I start putting it all back together do the gaskets need an adhesive (if so applied to which side) or do they go on dry?

Roy

 

none need silicone. just make sure the surfaces are clean.

 

Well now I did it, just as I feared. I got 5 of the ferrules loose but #1 cracked off at the head leaving the the inner tube and the threads in the head.

So now I have a dilemna. Options:

a.Try a work around using the tube in place??? Might be possible to make it look like the secondary air intake manifold is attached. At least five would be working.
b. Plug #1 back up and leave it.
c. Pull the head to extract the broken bolt.
d. Find a way to extract with the head in place.

Most likely will have to remove the engine lift backet to get some more work space to attempt any extraction.

This sucks, I still have so much more to do...

Any help, suggestions are always appreciated. Thanks.

Roy

 

My condolences...I think that secondary air injection has to be my least favorite design flaw of the later I6s. When I replaced mine the first 5 came out ok but I nearly lost a chunk of ferrule nut in the last hole all the way in the back. I'm having trouble really picturing your scenario, but I was able to extract mine with some patience and an easy out.

Pretty scary isn't it, trying not to drop anything down those holes?

Also, when you put the new air rail on, take great care to tighten each of those ferrules a little at a time and repeatedly make sure that the tube is pressed in enough. I did all that and my new one blew out in a month. Now I'm just going to deal until inspection.