Getting ready to do EGR/manifold/throttlebody, etc. cleaning-have lots of questions-long post-sorry

Thanks the suggestions on the catch cans guys. When the time comes I will be sure to check them out.

So here is an update. I had to work the past couple of days, so I was off today and continued this morning. I jack standed the car, and proceeded to drain the coolant. I went ahead and did a complete drain of the entire engine cooling system. Using some new 5/16" diameter clear vinyl tubing, it slide right onto the drain stopcock port and I then cut it about a foot and ran it into a freshly cleaned milk gallon jug. I filled the entire jug, closed stopcock, then put tubing into cleaned soda 2 liter bottle and continued. It got down to barely a trickle. I let it go for about 30 minutes, and then just closed the port and lowered the car back down.




I then started dismantling the throttle body. Draining the coolant really did help. I bought some doggy training pads (basically like a big diaper) and laid one under the coolant hoses so in the event when I took them off any coolant that came out would be caught by the pads, but none really came out which was nice. I then proceeded to remove the throttle body. Man it was oily.

There was a small pool of oil sitting at the bottom of the manifold where the throttle body bolts on. I managed to soak most of it up with a paper towel.


Next I completely removed the manifold assembly. It too is pretty filthy.


So with everything out, I took a look at and into the cylinders. They too are filthy and very oily.




I then proceeded to work on the EGR cooler. Now here is where some coolant did come out, but again using the pads I managed to catch most of it. When I took off the large coolant hose on the side a fair amount of coolant came out. Some did drip down onto back of engine and onto my garage floor, but I had some cardboard and another pad down there to catch it. I wiped most of it up with a paper towel. Once I have the EGR cooler off I will clean up the rest. I got all the rest of the coolant hoses off the cooler, but I had to stop at those bolts in the back. I need that ratching 12mm box end wrench. I am going to harbor freight in the morning to get the wrench, some long needle nose pliars (luckily I had some long 90dgree ones which helped), along with some torx sockets (need a T8 socket to take off the studs that those nuts are on).
So my plan is once I have all parts off, I will clean off everything. I want to plug the egr cooler and pipe and fill them with something to soak. I want to take the sensors off the TB and soak them as well, and the manifold either soak it or fill it somehow as well. What is the best thing to use to do this? I have read about people using hot water/oxiclean, oven cleaner, carb cleaner, brake cleaner, purple power? (not sure what that is). What do you guys recommend?
I also want to clean the cylinder and inside. NAB in his video just wipes them out with a rag. Is that the best thing to do? I know not to really spray anything in there or wipe the top (fuel injectors are there), but can I spray something on a rag and then wipe them out? What about the exterior surface around the cylinders. You can see by my pics it is pretty oily/filthy.

Thanks for your continued help and suggestions.

 

Thanks. I need to go to grocery store tomorrow too, so I will pick up some oven cleaner to try too. I already have oxiclean for when I do the laundry. Yeah that TB is pretty gunky, hence the reason why I wanted to be able to pull off to clean separately. If anyone else has any other suggestions for cleaning all this stuff I'm all ears.

 

Yeah I am going to see if I can borrow my neighbors to use. Thanks! I am going to post up an upate shortly!

 

Why would I think about new engine. The amount of oil I found is consistent with pretty much what everybody else has been finding there.

 

So I just want to give you guys an update. I have pretty much been working everyday since I last posted (healthcare worker). So I am off today and I worked more on the car. I went to harbor freight and picked up a ratching box wrench set with 12mm, along with a Torx socket set that included a T8 and when I got home this morning I got to work. It is cold and wet here today, so working out in the garage with door open was pretty miserable, but I got the rest of the stuff off (EGR cooler). Here are some pics





The nuts and studs on the backside of the EGR came off with the help of that ratching 12mm box wrench and the small T8 socket on a small 1/4" socket wrench. I had to soak the studs and nuts with WD40 to get them to move better. I had a hell of a time getting the nut off that very bottom stud-you can't even really see if at all. My long socket and socket wrench barely got on there. I finally managed to loosen it enough and then reaching around and down from the back with my arm I was able to spin it off by hand and not drop it. I doubt I will be able to get that nut back on when it comes time to put all this back together.
Now onto the problems I had.
Take a look at this picture.

The part I really want you to focus on (which is actually out of focus on the pic) is the stud. I got the nut off this stud okay, but when I tried to take out the stud with the T8 socket, it started coming out fine at first and then it got harder to do. I sprayed some WD40 where I could (EGR was still on it), and then turned it back in and then tried going out again and then the torx end of the stud snapped off in the socket!
I managed to slide the EGR off and get it out(really had to push down on the hose below it and to the right side to get it to slide off. In the process of doing this I forgot about the gasket on the backside of the egr cooler where those back studs are. I can't find it anywhere. I looked all over the back lower part of the engine and the ground under the car but I don't see it anywhere. I thought I remember seeing it on there before I took out the screws.
Anyways, I guess I will have to order a new one (hopefully I can) from Toyota, but I am not sure what to do with that front stud. I tried clamping some locking vice grips on it, but they just spin and they are starting to mangle up the remaining threads on it. I don't think I am going to be able to get it out, so what I think I am going to do is just cut it off where the threads end and make it a small post that will allow the front part of the EGR to slide on and sit on it. I just wont be able to secure it at that stud with the nut anymore. It will still be held on by other nuts (one on top, the one on the bottom stud if I can get it, and the 2 back studs).
I am stopping here for today. I have to work the next 3 days again (joy), but I am off this weekend, so my plan is to work on cleaning all the parts on Saturday. I have oxiclean, oven cleaner, some engine degreaser, brake cleaner, and carb cleaner. I do have some questions about cleaning this stuff and what I should avoid getting wet. I know the back half of main half of the EGR cooler along with the EGR pipe I can just soak or fill with oxiclean or whatever I choose to do and then pressure wash spray them to get all the crap out, but I am wondering about these parts

Front part of EGR cooler


The part of it circled in red-can I take that off so I can just soak the whole thing or should I just carefully clean it by hand?

Manifold

Can I take these parts off or should I? If so can I just soak this entire piece? I have a large tub and could fill it with oxiclean/hot water and soak it in there.

Throttle body

Same questions as above-safe to remove to soak entire thing or just hand clean? I am assuming none of these things I am asking to remove are safe to do so, but I just want to see what you guys say/recommend.

Some other thoughts
After I clean all these parts I would like to clean up the parts they go onto. I will be hand cleaning around and gently inside the cylinders where the manifold bolts on, but can you take out the fuel injectors and clean them? Just a thought that popped in my head.

PCV valve
I thought I remember seeing in one of the egr cleaning threads on here that someone removed the entire plate where the pcv valve connects and found passages in there loaded with oil and cleaned it all up, but another person didn't recommend doing this because it is not a good idea because it is gasketed in with some kind of gasket epoxy or something. Just wondering.

In my spare time at work when I have had some downtime, I have been trying to read up in the OCC thread that mendel posted a link to in his first response to me. I think I will be ordering the parts soon for it using Dan's amazon link recommended OCC. I do like the idea of putting it lower below the level of the PCV valve. Mendel, you did this right? Can you only check it/drain it when the car is on stands during an oil change? How did you secure it down there again? Has anyone else done this?

Anyways, sorry again about another long post in this thread of mine. I look forward to what everyone has to say.
Thanks!

PS
If anyone has any other suggestions for the broken stud please let me know as well.