Motorcyclists often have trucks. Those trucks are often Tacomas. And sometimes, those have head gasket failures. I learned a LOT before tackling this job myself. I read forums, watched videos, dug through the FSM, and talked to the dealership. My goal was to do a better job, with better parts, all for half the price of a shop.
Here are the finer details that are lacking or confusing in the sources I found, to give you the confidence you need to attempt this with success.
The Tundra and 4Runner also had this motor FYI. Mine is a 2005 Tacoma Trd OR (unfortunately a known head gasket issue year, until halfway through 06).
BONUS TIPS:
DO replace your head bolts and washers.
DON’T replace your timing set and chain (assuming it’s in good shape with bright paint marks).
These head bolts are a 10mm double hex, NOT a triple square. Do NOT use a triple square since the angles are sharper and will damage the bolt head.
CTA Tools 9292 is what I used, nice tool!
TOYOTA PART NUMBERS:
Head gasket “valve grind” kit: 04112-0P061
Oil pump tube upper o-ring: 15188-31050 *not included in valve grind kit*
Oil pump tube lower o-ring: 15119-31050 *not included in valve grind kit*
Tensioner bracket bolt: 90105-10527
Head bolts (x16): 90910-A2006
Head bolt washers (x16): 90201-11034
FIPG sealant: 00295-00103 (dealership confirmed they use this around the water ports in the timing cover, despite the FSM spec’ing a different sealant there)
TORQUES (in ft-lbs unless otherwise specified):
Head bolts: 27 + 180 deg
Two other head bolts, driver side: 22
Cam caps 10mm: 80 *in-lbs*
Cam caps 12mm: 18
LH side guide: 14
Timing chain idler sprocket: 44
Small cam tensioners: 14
Main tensioner bolts: 7.4
Oil pump relief valve: 36
Oil pump cover bolts: 80 *in-lbs*
Oil pump tube: 80 *in-lbs*
Oil control valve filter bolts: 46 *blue loctite*
PCV valve: 20
Timing cover M8s: 17
Oil pan into tuning cover: 17
Exhaust manifold: *note gasket direction! 16
*put gasket oval tab rearward on LH, forward on RH
Oil filter bracket: 14
Upper two idlers: 29
Lower idler: 40
Tensioner bracket: torque rear top/bottom first! 27
Power steering mounts: 32
Alternator: 32
Harmonic balancer: 184
Water pump inner bolts: 80 *in-lbs*
PS pump: 32
Spark plugs: 15 (gap .039-.043)
Intake lower manifold: 19 x 10
Intake upper manifold: 21 x 4 bolts, 2 nuts
Intake support brackets (3): 16