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2001 4Runner - Swapping out valve cover gaskets - **Pictures!**

Discussion in '3rd Gen 4Runners (1996-2002)' started by ramonortiz55, Jan 12, 2017.

  1. Jan 12, 2017 at 8:42 AM
    #1
    ramonortiz55

    ramonortiz55 [OP] New Member

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    Decided to do a detailed writeup for swapping the valve cover gaskets on my 2001 4runner.

    This job took me nearly two days - It was my first time doing this and I do like to take my time while working on cars. I've been known to start working on a car, leave it alone and come back and finish it a few days later. LOL.

    I know some of you are not as patient as me, I just am never in a rush when working on cars.

    So this it the list of items needed with Toyota Part numbers:

    1. Valve cover gaskets - Part #11213-62020 - 2 Total
    2. Spark Plug Tube gaskets - Part #11193-16010 - 6 Total
    3. Intake Plenum Gaskets - Part #17176-62040 - 2 Total
    4. Washer Seals - Part #90210-05007 - 16 Total
    5. Camshaft Plugs - Part #11188-62010 - 2 Total
    6. Halfmoon Plugs - Part #11183-62010 - 4 Total
    7. PCV Valve Grommet - Part #90480-18001 - 1 Total
    8. Toyota FIPG seal packing - Part #00295-00103 - 1 Tube

    **Throw the PCV Valve Grommet and Spark Plug Tube Gaskets in the Freezer a night before. I will explain why later**

    Mandatory parts picture:



    My research links: http://www.yotatech.com/f2/5vzfe-leaky-valve-covers-fixed-56k-beware-149594/

    Now let's tackle this job!

    First step is removing the airbox assembly, loosen airbox bolts and straps:

    [​IMG]

    [​IMG]

    unplug mass airflow sensor and any other connectors in the vicinity:

    [​IMG]

    There will be a smaller airbox towards the firewall with some airlines connecting into it, remove the airhoses and the small airbox:

    [​IMG]

    [​IMG]

    Don't forget the airhoses that run towards the front of the engine towards the piping of the airbox:

    [​IMG]

    [​IMG]

    Loosening these thinner clamps will help removing the piping to the airbox:

    [​IMG]



    [​IMG]

    Remove another plug, this one is right besides the accelerator cable:

    [​IMG]

    Three cooling lines will be feeding into the throttle body, these can be removed also:

    [​IMG]

    [​IMG]

    [​IMG]

    Another plug:

    [​IMG]

    Remove the accelerator cable off the throttle, this can be done by clocking the body of the spring and sliding it out carefully:

    [​IMG]

    Another picture of everything removed:

    [​IMG]

    Remove the two top nuts that are holding the throttle in position:

    [​IMG]

    Now remove the bottom bolts that are holding the throttle in position:

    [​IMG]

    Pull off the throttle gently, pay real close attention how the metal gasket is oriented. It needs to go back the same way or your truck will explode:

    [​IMG]

    Next, we will remove the upper intake manifold. Make sure to give it a good stare before you start. Nice, hard, evil stare. You're going to own that intake manifold. It's yours. Touch it. Feel it. Be the Manifold:



    To remove it loosen these brackets that hold the speedometer cable:



    and these other brackets that are on the driver's side of the manifold. (the bracket with the blue paint might need to be removed from the other end if you cant fit a ratchet at the upper bolt):



    disconnect this hose at the far end of the manifold, on top:



    Next, remove all the other bolts that hold down the intake manifold - Not pictured. Manifold should then come off.



    Now time to remove the lower intake manifold -

    If for some reason you couldn't take the speedometer bracket off due to it being too congested, you can take it off now:



    This stainless tubing has hose attached to the ends, take off the hose. I didn't have to remove the tubing itself, just the hose.



    Remove the computer diagnostics port that is attached on the driver's side of the manifold:



    At the back of the lower intake manifold, there is a bolt holding the wiring harness, remove it.



    At this time, the bolts holding the lower intake manifold can now be removed.



    Remove the remaining bolts holding the lower intake manifold down:



    Once the lower intake manifold is removed, cover up the exposed intake chambers with a rag, tape, etc to prevent stuff from falling in there. You do NOT want a bolt falling in there. Might as well jump off a bridge:



    Moving onto the passenger side valve covers, remove the spark plug wires and coil packs:



    disconnect the injectors:



    Remove the bolts holding down a wire bracket - This will not be able to be removed completely, but taking the bolts off will make the job easier. It will give you room to work with.



    At this time, the valve cover can be removed:



    So beautiful, so clean. Thanks to frequent oil changes :)



    At the end of the engine heads there will be a wiring harness attached to a bracket, close to where my hand is at. If you feel around, you will find it. This will need to be removed:



    Looks like this:



    There are two halfmoon plugs per side:

    one in the front:



    one in the back:



    one camshaft plug in the back that is being held down by two bolts:




    The halfmoon plugs can be removed with some channel locks. Gently pry upward. UPWARD. You may wiggle a little. Just not much. Don't want to crack the head. :anonymous:

    Removed:





    Remove the camshaft plug:







    At this time, make sure your supervisor approves your work:

     
    Bob, stealthES13 and Palerider like this.
  2. Jan 12, 2017 at 8:42 AM
    #2
    ramonortiz55

    ramonortiz55 [OP] New Member

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    After you have received supervisor approval, clean off the old gasket material using any scraping tool. Make sure to scrape well in the areas where the halfmoon and camshaft plugs go:



    After that is done get your valve cover and flip it over. The spark plug tube gaskets will now be replaced:



    Grab a small screwdriver and tap the gasket from the other side:





    Pull out the PCV grommet:



    Now remove the old washers seals:



    I did this by tapping it from the other end with a small flat head screwdriver:





    At this point, go back to the freezer and grab the THREE replacement gaskets and the PCV grommet:



    Pop the new PCV grommet in:



    Pop the new replacement gaskets in. Some people use a large socket to get them to sit right. Since I froze them, they were able to shrink. Making my job easier:



    Sit the new valve cover gasket carefully:



    Notice the areas that will need seal packing, this is where the FIPG goes. Be generous. Don't skimp out, you want a nice noticeable ooze when you sit it on the head:



    Install with new camshaft plug:



    Now goes the halfmoon plugs:



    Same procedure, a nice noticeable ooze:



    The Toyota manual indicated to add extra FIPG to the indicated locations:



    I made sure it was on there :D





    Set the cover on carefully:



    Torque the valve cover bolts down to



    The procedure for the driver's side is the same as the left, with the exception of a wiring harness section going above the valve covers:



    I didn't chase down the harness to see what it was for, I just worked around it.

    Once the driver's side is done, install everything as it was removed. Replace the plenum gaskets between the manifolds.



    Done!
     
    Last edited: Sep 7, 2017
    TWJLee, DTOM_plz, stealthES13 and 3 others like this.
  3. Jan 12, 2017 at 9:53 AM
    #3
    3034Runner

    3034Runner New Member

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  4. Jan 12, 2017 at 10:57 AM
    #4
    ramonortiz55

    ramonortiz55 [OP] New Member

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    Thanks man!
     
    Palerider and 3034Runner like this.
  5. Jan 12, 2017 at 9:10 PM
    #5
    Palerider

    Palerider New Member

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    Installed Rago brackets and 4" cube ditch lights. Weather tech mats. Cargo net. Cargo mat. Ordered Gobi rack with ladder.
    Dude. That's impressive. Thanks for sharing. I'm pretty sure you can fix just about anything. Great job Ramon.

    I nominate you the "Go to guy" with questions on mods!! Can I get a second?
     
    Last edited: Jan 12, 2017
  6. Feb 5, 2017 at 1:15 PM
    #6
    guyhaz

    guyhaz New Member

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    1996 4runner. All stock.
    Great write up...thanks for sharing! This is next on my list of to do's for mine.
     
  7. Feb 18, 2017 at 8:12 PM
    #7
    DTOM_plz

    DTOM_plz New Member

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    man this is great the only issue i have with mine is one of the spark plug gaskets is bad so ive been lookin at this gasket kit in my garage for about a month dreading this project. now i dread it less. thanks Ramon
     
    ramonortiz55 [OP] likes this.
  8. Feb 18, 2017 at 10:29 PM
    #8
    ramonortiz55

    ramonortiz55 [OP] New Member

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    gla
    glad it helps!
     
  9. Mar 18, 2017 at 6:24 AM
    #9
    trdsport

    trdsport New Member

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    Thanks a Great one !! Why did you have to leave the New gaskets in freezer overnight..so it shrink a bit & easy for install..?
     
  10. Mar 18, 2017 at 8:13 PM
    #10
    ramonortiz55

    ramonortiz55 [OP] New Member

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    yup! shrinks them up a bit for easier install.
     
  11. Apr 21, 2017 at 12:52 AM
    #11
    Gonloopy

    Gonloopy New Member

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    I've just had this done on my Surf because the plug gaskets were damaged and there was oil in the plugs. A simple job that ended up costing $634. I had all my belts replaced at the same time. Great photos and write up to show what was done.
     
  12. Apr 21, 2017 at 9:35 AM
    #12
    ramonortiz55

    ramonortiz55 [OP] New Member

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    i am glad this worked out for you
     
  13. Apr 11, 2019 at 2:57 AM
    #13
    TWJLee

    TWJLee New Member

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    What is the best way to clean the valve covers, and also the aluminum intake?
    May as well clean it up and make it look nice if doing all this work !
    Polish it up a bit and maybe paint the valve covers— with what kind of paint?
     
  14. May 16, 2019 at 6:55 PM
    #14
    DFA

    DFA New Member

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    This is amazing. I'm pretty sure I'm leaking oil from here so this guide will be fantastic when I tackle this job
     

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