2002 4.0 runs rough
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Joined: Jan 2004
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From: SW Va
Ok, that's a good find, now you know why you had the misfire codes.
I had a brand new 71 1.2L Corolla I4 snap a valve spring accelerating to get on the Interstate on the way to work one morning, it suddenly lost power & sounded just like I was dragging a dried out tree branch underneath. After finally getting to a pull over spot, it wouldn't idle & you could hear the piston smacking the valve, so your top end should have been noisy on that side.
I had a brand new 71 1.2L Corolla I4 snap a valve spring accelerating to get on the Interstate on the way to work one morning, it suddenly lost power & sounded just like I was dragging a dried out tree branch underneath. After finally getting to a pull over spot, it wouldn't idle & you could hear the piston smacking the valve, so your top end should have been noisy on that side.
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Freshman User
Joined: Jun 2012
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From: Jackson, TN
It was noisy, especially in that area. What are the chances of damage from valve to piston contact? I'm thinking of buying a small inspection camera to look through the spark plug hole to check it out, but if the chance for damage is high I may not bother. Also the spring compressor designed to work with this engine is about 112 to 130 dollars depending on source. Nobody around here seems to have one in their loan a tool program.
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Joined: Jan 2004
Posts: 13,851
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From: SW Va
This being an 02 4.0L = ohc & we don't know how long or hard it's been run this way. Maybe a member more knowledgeable about this engine will chime in & enlighten us.
Probably a good idea to come by a bore-scope/camera for a look see, so you sorta know what to expect. surprised to hear no store has the tool for loan.
Did you inquire about a camera, or bore-scope too?
Probably a good idea to come by a bore-scope/camera for a look see, so you sorta know what to expect. surprised to hear no store has the tool for loan.
Did you inquire about a camera, or bore-scope too?
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Joined: Jun 2012
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From: Jackson, TN
I went ahead and bit the bullet and bought an inspection camera (99.00 at Lowe's). A little limited in range of view but did the trick. I got a limited view of the piston top and a good look at the valve which was slightly open. I didn't see any signs of contact so maybe enough spring pressure remained to keep from dropping the valve far enough to get hit. I'm thinking of replacing all the springs while I'm in there, just getting prices on them for now. O'Reilly has Melling for 5.99 each and Rock Auto has Engine Tech for 3.86 each. Not familiar with Engine Tech reputation, but with everything else I need to order, I could almost save the cost of the special tool for install over buying locally.
Anyone have any input on the reliability of those springs? They're the only off-brand part I plan on purchasing.
Anyone have any input on the reliability of those springs? They're the only off-brand part I plan on purchasing.
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Joined: Jun 2012
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From: Jackson, TN
Finally got an update after my long silence. Got all the parts and tools together and changed the broken valve spring. After the aggravation of the one, I decided to gamble on the others. The one I changed was one of the easier ones to get to as well. Couldn't get it to start afterwards so went with changing the fuel pump and it started and ran quite well after that. Small coolant leak to deal with up around the thermostat housing 
got it fixed a little but still some to deal with. runs and drives pretty well for sitting up for so long.
Frustrating side note: After got it running, decided to close hood and take for a short test drive. Closed the door to get around to the front, and apparently the doors decide to lock. No spare key yet. Managed to pry the quarter window off and stick a long screwdriver through to hit lock release. Take it tomorrow to get window resealed. Lesson learned: roll the windows down while working on truck.
Overall not bad for what I paid for it and what I got in it. Thanks for the help guys, I'm sure I'll be back with more questions.
got it fixed a little but still some to deal with. runs and drives pretty well for sitting up for so long. Frustrating side note: After got it running, decided to close hood and take for a short test drive. Closed the door to get around to the front, and apparently the doors decide to lock. No spare key yet. Managed to pry the quarter window off and stick a long screwdriver through to hit lock release. Take it tomorrow to get window resealed. Lesson learned: roll the windows down while working on truck.
Overall not bad for what I paid for it and what I got in it. Thanks for the help guys, I'm sure I'll be back with more questions.
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Joined: Jan 2004
Posts: 13,851
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From: SW Va
Good feedback on successfully completing the valve spring repair, fuel pump replacement & hearing all now seems well.
I did that lock out business once after a oil change & restarting the engine & hopped out while it idled up on ramps, to check for leaks. I hit the door lock as it closed & knew I had just done a nono & the wife wasn't home with her keys. It idled about an hour & a half with me doing a slow burn. Like you I learned to lower a dang window when working on my vehicles.
I did that lock out business once after a oil change & restarting the engine & hopped out while it idled up on ramps, to check for leaks. I hit the door lock as it closed & knew I had just done a nono & the wife wasn't home with her keys. It idled about an hour & a half with me doing a slow burn. Like you I learned to lower a dang window when working on my vehicles.
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Joined: Jun 2012
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From: Jackson, TN
Just a quick follow-up after dealing with the broken valve spring. Put a vacuum gauge on and read 19 inches and steady with good response on blipping the throttle. Was concerned about valve damage initially.
Returning about 17mpg in town and runs nice and smooth. Not bad for over 200K on the clock.
Returning about 17mpg in town and runs nice and smooth. Not bad for over 200K on the clock.
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Joined: Jan 2004
Posts: 13,851
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From: SW Va
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Cargo Master
Joined: May 2004
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Congratulations on getting that 4.0L up and running again. I've got one with about 135 thousand. It's good to hear that they can take a beating and still get up with a little good knowledge and hard work. Thanks.
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