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Old 07-26-2018, 11:27 AM
mprhoodlum mprhoodlum is offline
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Default Excessive oil in intake ports

My 96 4.0 developed a lead on the back side of the pass. head. I thought it might have been either a freeze plug or a head gasket leaking. Turns out it was the intake gasket. When I pulled the intake I found a tremendous amount of what looks like burned oil in the intake ports. I have had problems in the past with the number 6 plug gas fouling. I've replaced the plugs twice but didn't find excessive oil at all. Could this be an intake gasket leak from the oil gallery to the intake where oil is being sucked up into the ports? The truck doesn't have any noticeable oil consumption, but I do change the oil every 3000 miles. The EGR tube into the intake also showed a lot of burned oil.

Thanks for any suggestions.
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Old 07-27-2018, 06:22 PM
Undrstm8ed Undrstm8ed is offline
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Default Re: Excessive oil in intake ports

Quote:
Originally Posted by mprhoodlum View Post
My 96 4.0 developed a lead on the back side of the pass. head. I thought it might have been either a freeze plug or a head gasket leaking. Turns out it was the intake gasket. When I pulled the intake I found a tremendous amount of what looks like burned oil in the intake ports. I have had problems in the past with the number 6 plug gas fouling. I've replaced the plugs twice but didn't find excessive oil at all. Could this be an intake gasket leak from the oil gallery to the intake where oil is being sucked up into the ports? The truck doesn't have any noticeable oil consumption, but I do change the oil every 3000 miles. The EGR tube into the intake also showed a lot of burned oil.

Thanks for any suggestions.
First off, I'd say if its not a complete fail, your PCV is beyond needing to be changed foremost.

2nd I'd watch a few videos on sea foaming your engine and clean up what you cant get at with a small gasket scraper and get that out of those intake plenums IF NOT yank the whole intake plenum upper and lower and manually do it properly by soaking in a bit of gasoline or kerosene and taking both a small wire brush and a stiff bristle tooth brush and clean that all out.

Also, the condition of that oil is atrocious and your truck deserves better of you. Change your oil more often (5000-7500miles depending on use and by use I mean harder or offroad use the lower more frequent miles) and I'd switch to a synthetic - Mobile 1, if ya wanted or needed a suggestion in the OEM weight. and dont fill past the 5 qts, and when you check it, make sure its after an hr or two of driving it so all the oil is in the pan before taking a measurement off the dipstick because you may be adding oil when you dont need it. Too much oil creates too much crank case pressure. If you ever find the dipstick pushed out of its hole, even slightly thats a bit of proof. That may be why you had a gasket failure.. Bad PVC and too much pressure in the crank case.

I would almost bet that the intake tube from the large 1" hose coming off the pass side valve cover is also gooped up. Consider investing in a couple cans of brake cleaner and some disposable rags to clean those out with.

Now for the bad parts. It doesn’t take an aeronautical physicist to know that the majority of any blow-by issues can be traced to leakage past the rings. But there are several different paths. Yes, a weak connection between the ring face and the cylinder wall is a common source, but don’t ignore the possibility that the pressure is squirting past the back side of either the top or second ring due to worn ring groove clearances. Rings are designed to fit with very specific clearances to allow the rings to function properly. Twist is built into both the top and second rings to allow them to function at their highest efficiency. If the ring lands are worn or not completely flat, this will reduce sealing efficiency. The only proper repair for this issue is a new set of pistons.

How many miles are on this truck and how many of them are HARD miles?

You could have a bad oil pump, bad rings, or combination thereof.
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Old 07-28-2018, 06:18 PM
mprhoodlum mprhoodlum is offline
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Default Re: Excessive oil in intake ports

Thank you for your response.The truck has approx. 160k miles, 10k of which I have put on it. I change my oil at around 3000 miles. This truck does NOT get any hard miles on it ever.
What puzzled me is the fact that the plugs have absolutely no indication of oil burning and the truck neither consumes oil or smokes. I did replace plugs and plug wires probably two years ago. Most of the oil consumption is limited to the lower intake.
My guess is that you are correct about the PCV valve. That has not been replaced since I have had the truck. Needless to say, Everything will be cleaned and/or replaced before I put it back together.
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Old 07-29-2018, 12:47 AM
Undrstm8ed Undrstm8ed is offline
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Default Re: Excessive oil in intake ports

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Old 08-06-2018, 12:43 PM
mprhoodlum mprhoodlum is offline
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Default Re: Excessive oil in intake ports

Turns out the head was cracked on No. 4 cylinder. The truck had fouled two plugs over the past two years at least. When I pulled the head off it looked wet from the coolant leaking into the cylinder. It was the no.4 cylinder instead of no. 6 that was fouling plugs. My memory is not what it used to be. LOL
I have a couple of questions:

1)I got a head off of a neighbor's 4.0 engine and found that he had the same problem with junk in the lower intake and intake runners on the heads. Is there an inherent problem or failure that would cause this? Is there something else I need to look at besides the PCV valve?

2) The exhaust manifolds did not have gaskets from the factory. Do I need to put the gaskets on that came with the head set? If the manifolds seal properly without a gasket I would really rather go without gaskets. It can't burn out if it's not there.

I have thoroughly cleaned both heads, replaced valve stem seals, lapped all valves just to make sure none were warped. The EGR tube and upper and lower intakes have been cleaned.

Last edited by mprhoodlum; 08-06-2018 at 12:46 PM.
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Old 08-06-2018, 08:59 PM
Undrstm8ed Undrstm8ed is offline
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Default Re: Excessive oil in intake ports

Quote:
Originally Posted by mprhoodlum View Post
Turns out the head was cracked on No. 4 cylinder. The truck had fouled two plugs over the past two years at least. When I pulled the head off it looked wet from the coolant leaking into the cylinder. It was the no.4 cylinder instead of no. 6 that was fouling plugs. My memory is not what it used to be. LOL


Quote:
Originally Posted by mprhoodlum View Post
1)I got a head off of a neighbor's 4.0 engine and found that he had the same problem with junk in the lower intake and intake runners on the heads. Is there an inherent problem or failure that would cause this? Is there something else I need to look at besides the PCV valve?
Not that I have experienced, I am pushing 350K+ and not an issue yet. But depending on previous owners and yourself, its all in how you treat it right? I dont drive like an old man but I dont "BEAT" on my truck trying to see what it takes to break it but I use it like a truck, offroad at that.

Quote:
Originally Posted by mprhoodlum View Post
2) The exhaust manifolds did not have gaskets from the factory. Do I need to put the gaskets on that came with the head set? If the manifolds seal properly without a gasket I would really rather go without gaskets. It can't burn out if it's not there.
I'd almost wonder if a previous mechanic left them off or question whether your truck was built on a Monday or a Friday? lol The gasket is there because of two things, sealing and keeping opposite metal(s) compositions from corrosion issues and concerns.

Our trucks arent generally built with those kinds of specs. Now I have heard that CAT tolerances are so tight that they dont need to use head gaskets between the heads and blocks of some of their equipment.


UOTE=mprhoodlum;2746102]1)I have thoroughly cleaned both heads, replaced valve stem seals, lapped all valves just to make sure none were warped. The EGR tube and upper and lower intakes have been cleaned.[/QUOTE]

Sounds like a good start.
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