head / intake manifold removal - Toyota Nation Forum : Toyota Car and Truck Forums

jarrodH · 02-06-2005, 06:06 PM

Hi. I am trying to take my head off of my 92 toyota truck (22re) and following the chiltons manual, its pretty difficult. Ive spent my whole weekend trying to get this head off, and i still havnt gotten it removed yet. First a head bolt broke and was siezed in the head so after trying and failing to pull the head off, we took a "saws all" electric saw to the bolt and cut it in half between the head and the bolck. Now that isnt restricting it anymore, but it seems no matter what i disconnect, the intake manifold and head still wont come off. Its still being hung up by something. In a rage of frustration, ive yanked the wire harness right off of the firewall, ive pulled every single harness connector i can see around the intake manifold off, and its still caught up on a part of the wire harness that goes through the bottom of the intake manifold in between the runners. And God only knows where that thing goes. And to make matters worse, the manual says to remove the head with both manifolds on, but i took the exhaust manifold off, and planned on just taking the intake manifold off instead of fighting it and all the hoses and wires, so i took the bolts and nuts off of the intake manifold where it attaches to the head, and even though i cannot see anymore bolts, the F'ing thing WILL NOT SEPERATE FROM THE HEAD!!!! After closer inspection i noticed what looked like an allen bolt that goes through the housing for the thermostat, but i cant get at it because there is too much stuff in the way. SOOO..... i try to take the upper air chamber of the intake manifold off so i can get better access to the allen bolt, but even after unbolting that part of the intake manifold, it will not come off either, I cannot see whats holding it up.

This is very very frustrating for me. I need some help. Does anyone know anything that i might have overlooked, or why i am having such a hard time with this thing? It originally started with a broken timing chain replacment, turned into a valve job so i had to tear the head off (which isnt even off) and now my entire engine bay is torn apart and i have nothing to show for it! Someone please help! i am at my wits end. Ive contemplated junking the whole piece of shit because its frustrating me so much, even thought of taking the sledge hammer to it, but thought better after i thought of all the time and money that was involved in getting this thing fixed.

slacker · 02-06-2005, 06:39 PM

easiest if you unplug it at the computer , L inner kick panel , and pull the harness out from the firewall ... easy peasy ....

Then IF you have to remove the harness , its way easier .

ttownjoeshow · 02-06-2005, 10:24 PM

wow man, thats harsh... i have just pulled the head off my '86 22R usen the haynes manual, it said that i hadto take everything off!! the EGR pipes are clamped to the back bottom of the head. it took me about 7 hours being my first time....its aluminum but still fairly heavy.
But i'm taking the head off of my '86 22R-E tomorrow, so i should be able to help you out hordes then

jarrodH · 02-07-2005, 02:13 AM

thanks man. Ive let it be for about 8 hours now. Im getting up the ambition to go take another crack at it. Its 2:10 a.m. here right now, so ill probably drive to the store and get myself a large coffee to wake me up, then turn on my lights outside by my truck and have another go at it.

Im sure if i have a little more patience and a positive attitude, i should be able to make some more progress on it. All i need to do is get that sucker off, then it'll all be easy from there.

ttownjoeshow · 02-07-2005, 02:21 AM

no prob! i wouldda started her today but i'm hungover and its below freezin. yeah we're in the same timezone. But good luck hope she works out fer you!!

tech100 · 02-07-2005, 02:27 AM

Ahh the "secret bolt".....you have to remove that allen head bolt.........good luck

jarrodH · 02-07-2005, 02:49 AM

thanks guys. I just went outside for a bit and like i said with a little patience, was able to get the upper air chamber of the intake manifold off, so now i have better access to that allen bolt. Its almost 3 now, and im tired, so i shut my worklights off and im gonna go to bed and try to get up early tomorrow and work on it some more before i have to go to work. Hopefully i can get that allen bolt off. Thats all that stands between me and getting that head inside my house so i can work on it and install the new valves. Oh yeah, i almost forgot, then i gotta tap the broken stud of the headbolt out of the head, and then get the other broken part of it out of the block

Maybe ill go to sears and get some easy outs if i cant just take the vice grips to it.

HighRaven · 02-07-2005, 10:57 AM

there is also a brace on them that attatches to the intake so that the head doesnt have to support the weight of all the stuff on that side. iv had my head off twice and the last time i did it in about an hour.

jarrodH · 02-07-2005, 12:14 PM

yeah i found that brace (if thats the only one). That little metal bar with the flat mounting points.

ttownjoeshow · 02-07-2005, 12:17 PM

yup i'm sure that the one they was talkin about... i'll be goin out to go at mine here in like 20 mins