Mike,
Frustrating that the issue cropped up again, despite your efforts.

I am starting to loosely look around for a wrecked, low-mileage '01-'02 to purchase complete. Since my '01 now has 578,000 miles on it (original owner, original starter, original injectors), I do on occasion wonder when it will grenade! Engine & transmission have never been out or messed with.
If I can find a suitable candidate, the plan would be to completely harvest the engine & transmission and set them aside for the future...


Andreas

Brillo,

I haven't had the time to mess with it yet as I made a bone head mistake and bought another 2002 that turned out to be a huge mistake. Long story. So now I have to try and get rid of this new acquisition and hopefully recoup some of my outlay and start working on the wife's 2002 Sport again. I can't even put into words how furious I am with myself for buying a truck that has after the fact turned out to be a rust bucket. Again long story and nobody can make me feel worse about this screw up than I already do. I drove 3 hours to NJ from CT. to get this thing towing a trailer and I should have walked away but after that tortuous drive I guess I thought I needed to come home with something? I don't know what was going through my mind honestly? But now I have to unload this boat anchor hoping that I get close to what I paid ($3500) for this thing back so I can move forward. I am usually really frugal and smart I don't know what happened this time? I am completely gutted. But I will dig in to the wife's truck and get it fixed up hopefully and will let you know what I find when I tear it apart AGAIN!

And understand it is repairable I just don't have any patience left to deal with another project. It has 215k miles and runs beautiful but from the signs I'm seeing it needs to go.

Have you considered using it as a parts vehicle and moving the motor into your rig with the blown head gasket? $3500 doesn't sound too bad for a parts vehicle with a good motor, tranny, 4wd parts, etc and only a rotted frame. But then again, everything is expensive as hell in my neck of the woods.

I have considered that option but with all the crap I keep discovering on it I believe getting rid of it is the best course of action for me. I just noticed your in Fair Oaks Ca.? I lived in that area back between 84-93 when I was in the USAF at Mather AFB. I actually lived just down the road in Carmichael. Man back then that area was the best place anywhere to live in my opinion. Unfortunately urban sprawl has taken over and the last time we were there to visit in 2015 it was unrecognizable. Made me super sad.

Well I got the heads off yesterday. Totally forgot in just 6 months how much crap needs to be removed to do this job. There was coolant in the #5 cylinder as I thought. The gasket was actually a composite type gasket (fel-pro) I’m pretty sure. I can’t see anything glaringly wrong to be honest but I’m admittedly lack in ability to diagnose a bad gasket by just inspecting? I checked the head as best I can physically and do not see any obvious cracking?

My machine shop guy told me to bring him the heads and he will go through them to make sure they are still good. I have to clean the deck surface of the block up and check it for any warping still. I’ll post some pics shortly they have to be resized.

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The big headache I'm worried about is getting the exhaust re-attached. I had a serious b i t c h of a time getting it back on and bolted up the last time I did this job and it took me and my wife working together to bend and pry to get it back together. I'm thinking this time I am going to get the manifolds loosely attached to the heads before actually bolting the heads down to the block? I took the nuts and studs completely out of the heads to get them off. not sure how you would get them off with the studs still in the head?

Dont be to hard on yourself. As that is how I learned. :-) Is the chassis clean? Frame clean? As clean Chassis around here extremely rare. You get to it when you can. No biggie. :-) I have faith in you...

How I did it is with the engine completely out. I can see you doing it that way. Make sure everything bolts and aligns properly. I used to have issues with the bolts on the header pipe. Those 3 studs. Never reuse those compress gaskets nor those exhaust stud nuts. As they can work themselves loose if you replace them. :-( [ I did this mistake on late model 80s pickup truck] Then it developed a low end knock. I Just replaced the engine with another replacing the gaskets and nuts with the other engine. This same engine is when I learned about Toyota parts. My timing chain aftermarket failed. Ground the case away. Dumped antifreeze into my engine oil. I caught it quick but if i used an oem mfg timing chain tensioner that never would have happened. :-) This was in the late 90s this occurred.

Its always a gamble with used engines. Unless you can check them prior to pulling them. Its a guess on its condition.

All I can add is swapping engines or even pulling heads in a 99 5VZ makes old big block muscle cars seem grade school easy. Maybe its my age showing. I salute your effort !

I see nothing glaringly wrong with your pics EXCEPT maybe that the block wasn't very clean near the edges? Scrape it clean, and then an old large FLAT honing stone run over it helps to see if there are any dips or peaks. No scotch brite pads or any flaky abrasive crap please. ( dont "roadkill" it!) Also, don't know if those head bolts go into coolant passages, but ARP thread sealant is your friend on assembly.

PS I threatened that if i ever had the cams out, i'd send them over to DELTA Camshafts for a little regrind!