RTH - Head removal, main wiring harness removal

[oilbrnr]

Following the FSM on page EM-30 step (m) says to disconnect the engine wire from the cylinder head and intake manifold.

From that rather cryptic description, I take it that I'm to feed the harness and all disconnected connectors up between the #4 and 5 intake runner. If so, is that possible doing this solo, or is it just better to go ahead and take off the upper intake manifold and leave the lower attached to the head until the head is removed?

Seems like a mighty large bundle of wires to feed out and back in upon assembly and not cause some trauma to the old harness.

(I really can't believe what a piss-poor design the whole intake/wire harness/fuel management design is for a vehicle that should be pretty field serviceable in less than ideal situations)

Thanks for the help. I've got to get this head off and to the machine shop on Monday!

 

[blkprj80]

Most people either leave the harness in place and swing it over out of the way along with the intake, or they pull the harness from the ECU behind the glove box.

If you try to pull all that s*** up from the bottom, you will need to disconnect two transmission connectors over on the RH side of the tranny, along with the o2 sensors. It sucks, especially if it's greasy under there.

When I pulled my engine, I fed all that stuff down through the intake, and later pulled the whole harness and replaced it with new as it was really crispy.

When you go back together, be sure you bring the harness up through the right opening. I've seen where others have been off a bit, and while the harness will connect, it isn't very happy.

Good Luck!

 

[mason]

I left the entire intake manifold in place when I replaced my head gasket. It's not the typical way to do it, but it worked for me.

 

[Kernal]

Mason; can you describe your procedure. No thread hijack intended to the OP.

 

[oilbrnr]

I've got everything disconnected from below and on the tranny. I just can't feed it all back up by myself.

Makes me think now though, if that is the case maybe I should just pull the harness out of the ecu and leave the rest with the head as I pull it.

 

[sPudmonkEy]

Idahodoug. Period. Great guy, great video. You should pm him, I imagine he'd be helpful.

 

[mason]

These were a few of my responses to the same question:

Looks like you didn't take the intake manifolds apart....

Beno,

The head came out without taking that apart, but I'm going to take it apart anyway to clean the whole assembly. I was moving at a good pace, and everything was breaking down without any problems--almost. The ECT sensor didn't unplug, it came apart. Gonna have to order a new one on Monday. I did take the fan, shroud and air filter box out which gave me enough room to sit and stand in there.

-Eddie

How did you manage to take the head off without taking the air intake manifold off?

I unbolted the EGR from the intake manifold, disconnected the PHH metal tube from the manifold, then unbolted the main wiring harness from the firewall, then just twisted the head clockwise out off the block so the EGR and PHH tube would come right out beneath the wiring harness. It was heavy, but I did it by myself and with the hood on.

Just as an update, after I got the head and combustion chambers all cleaned, took it to the machinist and he said it was perfectly level. Said it was good to go back in without any milling.

Got the head installed back in it this afternoon, and was really worried about the amount of torque I had to put on those bolts. The 29 lbs was no big deal, it was the two 90 degree extra runs that made me think I was gonna bust something.

The rest will have to wait till tomorrow.

BTW, how do these trucks run without the ECT sensor? Mine crumbled apart, and I probably won't get a new one till Tuesday or Wednesday.

-Eddie

Thread is here: https://forum.ih8mud.com/80-series-tech/167398-my-head-gasket-pictures.html

But I botched the job the first time (follow-up thread here: https://forum.ih8mud.com/80-series-tech/167701-help-serious-problems-after-head-gasket-job.html).

I hydrolocked the head bolts, and had to pull it all apart and do it again. Never did take the manifold apart (either time), as they looked fine. 71,000 miles and almost 7 years later, it's still 100%. If I had to do it again, I'd probably do it the same way. Just seemed a little easier (to me, anyway). But I could be wrong. Recommended method (and the one used by most) is pulling the manifold apart.

-Eddie

 

[oilbrnr]

Had to take my son to a soccer game and then have been doing off hours job related stuff, so I haven't gotten back out to the garage this afternoon.

I'm I thinking right at this point though, disconnect from ECU and proceed with removal? Unless it is a real PITA to pull the firewall boot and unplug from the ECU, it seems like the easiest route to proceed.

 

[oilbrnr]

Ha! Got that biache out!!!! Had to get my buddy to come over and help.

Now just to get the exhaust off. Then should be good to go.

 

[blkprj80]

Looks like you pulled it up from beneath. My hat's off to you sir! Good work!

 

[oilbrnr]

Looks like you pulled it up from beneath. My hat's off to you sir! Good work!

Yeah, but look what I had to do! Not easy turning an 80 on its' side without doing body damage!

What a PITA job.