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Old 05-25-2019, 02:58 PM #16
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Originally Posted by BostonJon View Post
Not yet. The problem seems intermittent but there is definitely fresh coolant in the valley (only on the driver side) whenever I drive the car and the level in the overflow reservoir slowly drops over time.

This may be totally crazy, but my theory is that the bypass pipe is leaking, filling up the chamber where the knock sensors are, and itís seeping past the intake gasket and out into the valley. From there, it drips out the back of the valley and onto the ground. Iím just speculating because I donít know how else fresh coolant is showing up in the driver side valley. If it were the hoses under the TB, the coolant would be in the passenger side valley, but that side is totally dry.

Iíve ordered the water bypass pipe, FIPG, knock sensor harness, and intake gaskets and plan to dive in and do it in the next few weeks.
It's almost certainly the intake manifold gaskets (some part diagrams might call it the lower intake manifold gasket). There's coolant passageways that go from the block through the intake manifold into the cylinder heads. These gaskets corrode and fail over time, it's very common. What's not common is the amount of coolant you are seeing.
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Old 05-25-2019, 04:09 PM #17
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Quote:
Originally Posted by gamefreakgc View Post
It's almost certainly the intake manifold gaskets (some part diagrams might call it the lower intake manifold gasket). There's coolant passageways that go from the block through the intake manifold into the cylinder heads. These gaskets corrode and fail over time, it's very common. What's not common is the amount of coolant you are seeing.
Thanks for that info. The truck has 400k miles and I donít see any evidence that anyone has gone deep enough into the intake to replace the (lower) intake manifold gaskets. I donít have any white exhaust so I donít think itís a head gasket. The bypass pipe and lower gaskets are a pain to get to but itís not a complicated project and the parts are cheap (even OEM) so Iíll get those swapped out and report back.
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Old 05-25-2019, 05:55 PM #18
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Going that deep into it replace every rubber hose on top of the engine. Including the two coolant lines to the IAC as well as the vacuum line that goes from the IAC to the two sides of the intake manifold for the idle air assist or what ever they call it.

I had weeping heater hose lines from weak spring clamps. I also had a small split in the coolant line going to the IAC. Both of these caused dripping behind the engine. Plus Iíve also had a failed manifold gasket filling up the valley.


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Old 05-26-2019, 12:16 AM #19
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Going that deep into it replace every rubber hose on top of the engine. Including the two coolant lines to the IAC as well as the vacuum line that goes from the IAC to the two sides of the intake manifold for the idle air assist or what ever they call it.

I had weeping heater hose lines from weak spring clamps. I also had a small split in the coolant line going to the IAC. Both of these caused dripping behind the engine. Plus Iíve also had a failed manifold gasket filling up the valley.


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Or you could be like me and bypass the IAC altogether... not recommended for climates that see freezing weather.
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Old 06-01-2019, 06:32 PM #20
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Quote:
Originally Posted by BostonJon View Post
Not yet. The problem seems intermittent but there is definitely fresh coolant in the valley (only on the driver side) whenever I drive the car and the level in the overflow reservoir slowly drops over time.

This may be totally crazy, but my theory is that the bypass pipe is leaking, filling up the chamber where the knock sensors are, and it’s seeping past the intake gasket and out into the valley. From there, it drips out the back of the valley and onto the ground. I’m just speculating because I don’t know how else fresh coolant is showing up in the driver side valley. If it were the hoses under the TB, the coolant would be in the passenger side valley, but that side is totally dry.

I’ve ordered the water bypass pipe, FIPG, knock sensor harness, and intake gaskets and plan to dive in and do it in the next few weeks.
If you remove your Radiator cap did u notice your coolant leak return dripping from the rear and coming down the driver side on the bell housing

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Old 06-01-2019, 07:01 PM #21
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A little update....

Last night I finally tore into the project and got the intake manifold off. I found quite a bit of coolant in the area under the intake manifold. Interestingly, there was green coolant (previous owner) and red coolant (I flushed with distilled water and switched to Toyota red when I bought it) under there. I noticed that the intake manifold gasket - particularly the front and rear channels where coolant flows - were pretty badly corroded and no longer had any of the rubber around the mating surface. My theory is that this allowed coolant to seep out through the mating surface between the intake manifold and the head. Most of it likely burnt off when the car was hot but when the car was cool, it seeped into the valley and down the back of the head and onto the ground. I think this is why I was seeing more coolant on the ground after the car had been sitting for a while.

I donít think the water bypass pipe was leaking but I replaced it while I was in there. Also swapped out the knock sensor harness. I did not have time to get everything back together so I donít yet know if this will solve the problem, but from what Iíve seen in there Iím optimistic that I found the issue.

Iím going to clean my injectors and put on new o-rings later this week and get it all buttoned up and test it.

Stay tuned....
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Old 06-01-2019, 07:36 PM #22
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Help - coolant in the valley - why?

Edit: Just saw your last post.

Iíd imagine that those gaskets were the problem then.

Good luck with it!

Last edited by Mantilgh; 06-01-2019 at 07:40 PM.
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Old 06-01-2019, 08:19 PM #23
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Quote:
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Edit: Just saw your last post.

Iíd imagine that those gaskets were the problem then.

Good luck with it!
I checked out all the heater hoses because that would have been the easiest fix. They were all dry and there was no explanation for coolant in the driver side valley.
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Old 06-02-2019, 12:03 AM #24
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That happened to the 97 Limited Puppy hauler. Since I had the intake off I had the heads gone over. Valley full of coolant.

Getting a good bead of sealant on the bypass tube was a challenge. I donít know why an o-ring wouldnít have worked.


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Old 06-03-2019, 11:43 AM #25
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Quote:
Originally Posted by BostonJon View Post
A little update....

Last night I finally tore into the project and got the intake manifold off. I found quite a bit of coolant in the area under the intake manifold. Interestingly, there was green coolant (previous owner) and red coolant (I flushed with distilled water and switched to Toyota red when I bought it) under there. I noticed that the intake manifold gasket - particularly the front and rear channels where coolant flows - were pretty badly corroded and no longer had any of the rubber around the mating surface. My theory is that this allowed coolant to seep out through the mating surface between the intake manifold and the head. Most of it likely burnt off when the car was hot but when the car was cool, it seeped into the valley and down the back of the head and onto the ground. I think this is why I was seeing more coolant on the ground after the car had been sitting for a while.

I donít think the water bypass pipe was leaking but I replaced it while I was in there. Also swapped out the knock sensor harness. I did not have time to get everything back together so I donít yet know if this will solve the problem, but from what Iíve seen in there Iím optimistic that I found the issue.

Iím going to clean my injectors and put on new o-rings later this week and get it all buttoned up and test it.

Stay tuned....
I have the same thing happening, thought it was the bypass pipe but haven't dug into yet. Definitely interested in what you find, I've just been topping off the coolant reservoir every couple weeks for about the last 5.5 years now ha.
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Old 06-03-2019, 11:55 AM #26
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attached is a picture i took the other night, which i think makes it pretty obvious what was happening. at the bottom of the picture (front of the truck) - especially on the right (driver) side - you can see the pink coolant that was in the valley. you can also see that the rubber gasket material around the dual coolant passage ways was in pretty bad shape. most of it was still stuck to the head when i took the old metal gasket off. there was also some more minor leakage (seepage?) on the passenger side (left side of the picture) at the single coolant passageway. I think the rearmost passageway gasket was bad too and this is the leakage that I was seeing down the back of the motor and onto the bell housing. the coolant leak in the front was making its way down behind the timing belt and onto the water pump housing. i thought i also had a water pump leak but I'm hoping it was just coolant dripping down.

I never had the telltale white smoke of a head gasket failure so I think my leak was luckily limited to the valve cover gaskets.

i should note that this was a tedious and time consuming job, but not a particularly difficult one.

i may put some threadlocker on my valve cover bolts because I realized that they were extremely loose already after re-doing my valve covers less than a month ago. no wonder so many of us have VC leaks.
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Old 06-03-2019, 12:00 PM #27
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Quote:
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I have the same thing happening, thought it was the bypass pipe but haven't dug into yet. Definitely interested in what you find, I've just been topping off the coolant reservoir every couple weeks for about the last 5.5 years now ha.
i noted this above, but i'm fairly confident that my bypass pipe was fine. the FIPG material on the mating surface of the pipe and head was still pliable and I did not see any corrosion around the mating surface. how that I see how/where it is mounted, I don't think a bypass pipe leak would show up as coolant in the valley because the valley is situated higher than the bypass pipe. rather, a bypass pipe leak would fill the cavity under the intake manifold and drip down the back of the engine (the only way out).

in hindsight, it seems logical that the mating surface of the intake manifold gasket would be suspect - especially if it's never been replaced. in my naivety, i didnt know that coolant circulated through the intake manifold. had I known that, I might have suspected this gasket in the beginning.
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Old 06-03-2019, 12:07 PM #28
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I would buy some new Densos off ebay for about $25 a pair. Also, with a soft metal brush, clean off the mating surfaces of the intake manifold and cyl heads before you put on gaskets.
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Old 06-03-2019, 12:11 PM #29
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I would buy some new Densos off ebay for about $25 a pair. Also, with a soft metal brush, clean off the mating surfaces of the intake manifold and cyl heads before you put on gaskets.
that's what i bought. i plugged the valve holes with some painters tape and used a soft wire brush on a the end of a drill to carefully clean the mating surfaces. it cleaned up nicely and everything is back together. I just havent had time to get the plenums back on, refill with coolant, and test it. maybe this weekend i'll get to it.

i should also note that the recommendation in post #16 from gamefreakgc was spot on.
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Old 06-07-2019, 12:47 AM #30
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Well was this a successful resolution to your problem
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