With the drain plug out, it will run out naturally. (gravity works really well...)

You can use whatever ya like to help remove the crap. But, careful of the quality of the brush you use. Some of the cheaper wire brushes "shed"... and leaving those in your motor could lead to a very bad scene.

 

Thank you HeyYou.

 

If you are yankin the water pump, consider a new termostat. With that much sludge in your engine you may consider a new PCV and seafoam ran in fresh oil with a new filter.

 

I'm putting in a new 195 Thermostat as soon as I get the intake back on. The PCV is a dealer part and less than a year old with less than 5000 miles so i'll hang on to it. I'm not crazy about seafoam in the oil. I'm afraid it may loosen all that gunk and stop up my oil pump or pickup tube. I'm going to do the smoke out by running it through the brake booster vaccum line.

 

Figured I would give a final report on my Plenum install and tune up. Everything went in perfectly and to be honest this was about an easy install as I can imagine. I spread it out over 3 days spending about 3 hours friday, 6 saturday, and maybe 3 on Sunday.

The hardest part: Cleaning!!!! And "burping" the coolant system!!!!

I had oil over everything. My valve cover gaskets were leaking, I had "Cajun Crust" all in my lifter valley, Throttle body was caked with residue, a million gasket surfaces that need a scrub, and there was about a quart of oil in my intake. I used Purple Power, steel brushes, drill powered steel brush and a ton of towels to clean everything. This easily took more time than the actual tear down and install. I also now have more RTV on my hands than on my engine, but NO LEAKS!!!

Burping the coolant system was a chore. I just never could get all the air out of the system. I have finally gotten most of it out, but I still feel like there isn't enough coolant in the system. The truck never gets over the 200 mark on the gauge, but I've only added about 16 quarts to the 20 quart system. BUT I didn't remove the coolant plugs from the block. I tried and they started to round off so I gave up. Like Kenny Rogers said, "you got to know when to fold'em!"



This was my most effective "burping" method. Redneck I know!




Most Intresting: Torque sequence

I still can't believe that is all the torque nesscary to hold the plenum and the intake (12FTLBs). I so wanted to really torque those things down but I followed the TSB and used loctite on everything.

What I messed Up:

I forgot to apply loctite to the plenum bolts. I'm hoping this doesn't come back to bite me in the A$$! I also decided no to cut the runners out of the intake. I don't really have a reason other than I just didn't cut them. I understand the logic behind the method, but something told me I'd screw it up. I still have to replace the front 02 sensor and gut the cat. I may end up just getting a new Y pipe though.

The Results: Pure Glory!
I replaced the timing chain, installed the new aluminum plenum pan, cap, rotor, wires, plugs, and valve cover gaskets cleaned the IAC. The slop in my timing chain was absolutely ridiculous! I had at least an inch and a half of slop. My truck is better than when I first got it. It idles so smooth and when I step on the pedal I get whiplash.

For anyone who reads this thread before doing there Plenum:

The install isn't nearly as hard as it sounds. I was apprehensive at first about tearing into my motor, but it really isn't bad. I can't stress enough the importance of a good torque wrench, correct RTV, and good cleaning methods. Just take your time and mark all your wires, sandwich baggy all your bolts, and have your FSM ready if you have a question.



I'd also like to say thanks to HeyYou, DHvaughan, and a host of others for all the help. You all are wizards of these trucks!

 

Cool I f
Gotta get to doing my timing chain
With the mods I have and having 156k on it I'm sure it would help

 

Ah, the satisfaction one gets from a completed job. Priceless.

Congrats! Now, enjoy it!!

I used a hill for the same purpose you used the bump. Think it was zman that mumbled about the 'high pucker-factor' burping method.

 

Lastrights change that timing chain! You don't realize just how much a double roller set will help you over the stock slop.

HeyYou or anyone, do you think it is ok that I didn't loctite the plenum pan bolts? Do you think there could be a gallon of water in the block since I didn't drain it?

The high pucker factor is the only way I was able to get air bubbles out!

 

Cooling system sounds right to me.

As for the bolts....... if you don't have lock washers, or something similar on them, another set of intake gaskets is a hell of a lot cheaper than replacing the cam/lifters.... (which is what you will most likely lose if a bolt falls out.....) I would be paranoid every time I drove it, that I was gonna drop a bolt. I know it's a pain in the ***, but, I would pull the intake again.......

I parked my truck on a hill at an angle, pucker factor was EXTREMELY high, thought I was gonna roll...... and I think I STILL have air bubbles...... Damn thing.