22re - blow headgasket by running #4 without plug?

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A

aedavis

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I just replaced the head gasket in my 85 4Runner with a new factory Toyota part. It ran fine for a couple hours, but after failing emissions today, I decided to do some minor tuning, including replacing the spark plugs. I buggered up the threads on #4 (closest to firewall) and ended up having to install a threaded insert to fix it. No big deal, right?

After I got the insert installed, vacuumed out the cylinder, and blew out the cylinder with compressed air, I ran the engine with the spark plug out of #4 for about 10 seconds to blow out any remaining chips or debris after installing the insert.

Now the truck won't start. I did a compression test and have good compression on #1, and almost nothing on 2, 3, and 4. Is it possible that running without a spark plug in #4 caused this, or is my luck just abysmal and I blew the $%#$%$#% head gasket again after 4 hours of use?
 
No spark plug is going to mean no pressure buildup in the cylinder - so fairly unlikely that was what directly caused the issue. Since you just replaced the head gasket, I'd lean more towards an issue with the installation. At this point, you're going to have to pull the head again anyway. So you'll soon see what failed.
 
When you replaced the head gasket did you have the head checked to make sure it was not warped? Installing a head gasket is very straight forward, it is only going to fit on one way.

I only payed $500.00 for my 4Runner because of a blows head gasket, no compression on all cylinders.
 
I've had 2 Toyota mechanics and 1 non-Toyota mechanic tell me not to re-use the bolts. The last guy claimed the bolts are designed to be torqued only once. This was after a gasket failure when new bolts were not used ( not me doing the work). All that said, my FSM does not mention using new bolts. Maybe the Toyota guys are trying to sell me new bolts? They are more than $100 bucks a set in Canada. Probably the removal sequence and torquing sequence are more important.
 
My money is on a warped head.
Unless the old head bolts were in poor condition I would defiantly reuse them. Like I mentioned before you can't install a 22RE head gasket the wrong way around, so as long as the gasket was new and in good condition when placed on the block it is very hard to screw it up. Now if the head is no longer true and or the head bolts were not tightened in the correct manner or toque specifications expect compression loss and or coolant leakage. I would take the head off and check for trueness, if it is warped consider a new head or try and get the old head milled to the correct specs. For my rebuild I purchased a brand new head from engine builder, the cost was very reasonable and shipping was free. Years and years if heat cycling and poor maintenance can cause a head to warp and or crack, I've read that in some cases even a reconditioned 20 some year old head will warp again.
 
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