Another 2005 V6 4.0 1gr-fe Head Gasket Failure

Here we go, 175k miles, 2005 V6 Prerunner started misfiring on startup, never noticed rad temps running high. I replaced the plugs, swapped out coils, cyl 4 misfire and random misfire codes continued....so I borrowed a buddies radiator pressure test kit, sure enough it dropped a few PSI in a couple minutes, no visible radiator leaks. Shit! I think I topped off the coolant in the res from the low to high mark once in the past 2 years. It was now again at the low mark....oh boy!

I've got the heads back on now with new headgaskets (OEM), Toyota absolutely changed the HG design, the ones I pulled from the truck were very different. Cams are re-timed, timing chain is ready to go back on.

My question...should I pull the oil pan to seal the timing chain cover properly? From what I've read most avoid this because of the need for the front differential to be removed, which my Prerunner doesn't have, but it still seems like a major pain in the ass. This whole job has been really...but I'd like to kick my ass less if possible.

I'm worried about the o-ring on the bottom of the timing chain cover that seals the oil pump, but also I just think I'll smear my FIPG all over the place trying to get the cover in place along the dowels. Maybe I'm over thinking this.

 

I did not pull my oil pan and its fine. Just made sure to not miss any spots using the sealant.

I did replace the oil pump seal because its 15years old and why not for a $5 part that I would need to do all the work over again if it failed. I basically replaced anything that was plastic or rubber inside the engine that I could get my hands on while it was apart.

 

No, it is not necessary

 

Glue the oring into timing cover real well and put rtv on cover as well as oil pan lip, as the cover has to slide across that surface, not just set down on it. Also make a few dry runs without rtv to get your self ready.

 

Awesome! I replaced the oil pump o-ring as well, mine was broken in 2 places when I pulled it out, very brittle, makes me wonder what projects lie ahead.

 

What did you use for glue? I have the o ring smothered in grease right now.

 

No reason to glue it just put a little bit of grease in the grooves to hold the seal in place. You can put a tiny bit on the seal itself to help with sliding on the surface. A little goes a long way. I used this method and test fitted it a couple times and it never came off once.

Yes, you can seal the cover without taking the oil pan off. I am almost 2000 miles with no leaks.

 

I used a thin layer of rtv under the oring and let it sit for about 20 minutes

 

You got this OP, worst case is you put it all together and see oring on floor under truck. Ive seen it happen personally.

 

Personally, if you made it this far, you should be fine with sealing the timing cover. It’s a little daunting at first but just test fit it a couple times. After a few tries, you’ll be able to feel how you need to slide the cover on. The harder part in my own opinion, is getting the gear on the oil pump to line up with the crankshaft. Even though mine was lined up, it still wanted to move around. Even after I test fit the cover multiple times, it still took me two tries to get the cover on with the FIPG in place because of the oil pump gear.

 

Do this, I did a few test to get the motion right and make sure I wouldnt smear the rtv too much and still kinda smeared it bumping into stuff.

 

I’m no mechanic, this was a big undertaking for me. But I did not expect the timing cover install to be the part where I really started doubting myself. That oil pump gear can line up with the notch on the crank in either direction right? It seems like it would go on either way. I will def test fit tonight before applying FIPG.

 

Nightmare fuel.

 

Yes, I believe so. The shape is symmetrical. I was stressed as well when I did it. So much so that I posted about it in the thread I had going. Just make sure you put the FIPG on all the spots shown in the service manual. Double and triple check the locations before you put on the FIPG. Don’t forget the water pump part area too.

 

Little update, finally got the timing chain cover on, feel good about it. Anyone noticed this section of the SM saying to replace the bolt on the belt tensioner? Haven't been able to find any threads on this, and I haven't seen anyone mention this in videos during installation.

 

Good to hear about you getting the timing cover on. At this point, all the challenging stuff has been done. No, I can’t say that I noticed that about replacing the bolt.

 

I reused mine for the tensioner

 

My saga continues, I decided to try to clean my fuel injectors, and noticed I'm missing a retaining clip on one of them. I'm thinking it probably flew off when I pulled it out, any one have luck with rebuild kits online, or should I just replace this one?

 

Do they sell that separate or do you need to buy a new injector?

 

Doesn't look like it, now that I've done more research. Ordered a replacement online, was hoping to crank her over this weekend! Oh well.