1996 Tacoma 4x4 with a blown head gasket:

I will preface this: My knowledge of mechanics is not great, so please talk to me like I am clueless, I am in the process of learning as much as I can.

My father purchased a 2022 SR5 Trail Ed on Tuesday, and has decided that he is alright with me getting his '96 up and running after letting it sit in the backyard since it popped off in 2010. Engine is already slightly disassembled, when he was trying to fix it himself he realized he didn't have what he needed to stabilize the cam, and he didn't have the means at the time to continue. Curious as to how challenging/costly it would be to drop an '04 motor into it. The existing engine is still in pretty solid shape, as the only issue it had was the HG blowing out. I'm pretty sure she needs a suspension replacement (probably the radiator as well, if Im being realistic), but my main priority at the moment is figuring out what route to go engine wise. I do not intend to take her out rock crawling or anything like that, but I do enjoy dune-hopping and general offroading. Over-land capable would be nice, but is not a necessity at this point.


TLDR, would it be better to rebuild the existing engine and replace what gave out, or to buy an '04 for the fuel injection upgrade/general longevity?

 

If this is a 5vz V6 and you get a newer engine to swap in, you will need to use your existing throttle body. The Tps sensor is 4 wire and newer ones are 3 wire. You can't swap the sensors because the shaft is machined different.

Swapping the head isn't too bad, but things are a little tedious. First make sure none of the old parts are lost. 12 years is along time and bolts and such sometimes walk away.

Since it blew a gasket you will need to have the head resurfaced at a machine shop. You should check the valve lash too while it's out.

The 5vz is a non interface engine, so if the cam rotates the valve won't hit the piston.

You might try to find out why it overheated in the first place. Stuck thermostat, clogged radiator, ect.

You will want to download part or all of the factory service manual for order of operation and torque specs.

You will probably need to buy some tools along the way.

The engine swap is probably easier because there are no tolerances to check or timing to set. But it's more work overall.

Let us know what engine it has and we can go from there.

 

I'm fairly certain it is the 5vz V6, but waiting on my father to get back to me. Will update when he responds.

He replied like 2 seconds after I posted this. He agrees, so yes.

Edit2- He also said that the engine never overheated. He said that the gasket failed and a small amount water got into the combustion chambers when the truck was sitting. He did not drive it after it first blew white smoke, he said there is no warping or cracking at all.
His opinion is that all the truck needs is a replacement gasket.

 

Well that should save you some time and money.

You can get genuine toyota gaskets and parts from Yotashop.com. Be sure to get new head bolts too, they are 1 time use only. Unfortunately these are sold in a full set, so you will have spares. Get valve cover gasket and spark plug tube seals too. Might as well make it all fresh.

How is your tool collection?
Start soaking all the exhaust bolts in PB blaster now.

 

We have a whole bunch of shit, and one of my brothers is a mechanic with a bunch of engine work experience who is now offering to help. The only thing I think we still don't have is the tool to stabilize the cam, which to my knowledge is relatively pricey. He is also saying we'll need to flush her out which is pretty much a given after sitting for almost 12 years.
He thinks it will run with just the gasket replacement so that's good news. I thought she needed a lot more work, but he said Toyotas are built well and having her sit shouldn't have destroyed anything; especially with our climate.

 

Change the ball joints. uhm its gonna take a good amount of money it seems to me. If you have a family member that will do all the work then yeah. I would just rebuild the engine. You have pics?

 

I'm not sure what tool you are referring to on the cam. I did mine without anything special.

I would search you tube for a 5vz head gasket video to get an idea of the entire job. You will also want to replace timing belt and water pump at this time.

 

I'll try and take some when I get home from work today.

 

I'm basing that off of what my dad said. He said when he tried to fix it in 2010 there was something he needed to stabilize the cam and that he couldn't move forward at that point. I will ask for clarification.

 

So he said that he read ahead in the manual, it said that the cam needed to be immobilized and a certain tool was required to perform that task. He didn't have the ability to get that tool at the time, so he gave up.

 

Sorry about the wait, I work 6 days a week usually for around 12 hours a day and time is hard to manage for me. Here are some pictures.

 

Looks like it's at TDC. Passenger gasket is the culprit?

Look up the timing belt procedure.

Remove that properly. You will need a impact gun with a 19mm to remove crank pulley. This may move crank position. Re align to 0° Tdc on lower plastic cover. Pull the exhaust manifold/ cross over pipe. Remove PS bracket/lay pump to side still hooked up to lines.

Then look up cam/head removal.