Grantf, did you apply sealant on the top inside corners of the front cover? Look at EM-78 on page EM-21 of you 77 FSM.

yes I did. I used ulta grey, a small tab on each corner. I may have damaged the forward part of the head gasket on installation.

I recall the small head bolt on the passenger side being difficult to start threading, perhaps because somehow something happened to the head gasket in that area, but I do not know what could have happened. It was a new head gasket and removal and replacement whent smooth (other than that one bolt).

Anyhow looks like I am going to remove the front cover again, $H!T

Feel your pain man! At least you'll know what happened when you take it off again. Like you said, probably chingerd the gasket just enough!

Agreed with rdb - I had the same issue with my '86 4Runner's water pump. All g-damn day to get the the old one off and the new one on and...a leak. I could see where I buggered the gasket afterward, but it was heartbreaking. Still, that was about 5 years ago and the 2nd one is still holding. Anyway, hoisting my beer in your direction. It sucks, but at least the timing chain is holding up. This is the best worst-case-scenario...

Grantf

That's a normal problem when you do the front cover. (I've been told anyway) I had to do my brother four times before I got it right. This is what I ended up doing. I pulled the cover off again. (for the fourth time). I cut the old head gasket where it would mate to the top of the front cover. (carefully) Then I purchased a new head gasket and cut the front of it off to match the one I pulled from the motor. I then placed the new head gasket atop the cover and covered both sides liberally with copper silicone (RTV its copper colored). Then I put everything back together and I have no leaks. It sounds like a PIA but its the only way I've found that works. I've tried using anaerobic sealant between the cover and the head gasket with no luck. I know it sounds like a complete PIA but I think you're going to have to do this AGAIN to fix said oil leak. :mad:

Hope that helps

Jan

I totally missed youre post at first. You know that does not sound like a bad idea. I was thinking of making a gasket but the thickness might be different. The head gasket really does not cost that much.Anyhow I will concider youre suggestion an option after I have the cover off and have a look.

I know the FSM states to put sealant on the corners, but to be safe, I used RTV all around, I had also used copper spray sealant on the head gasket even though its supposed to go on dry and no leaks at all. I've used the copper spray before and never had a head gasket leak. Just my 2 cents.

I know the FSM states to put sealant on the corners, but to be safe, I used RTV all around, I had also used copper spray sealant on the head gasket even though its supposed to go on dry and no leaks at all. I've used the copper spray before and never had a head gasket leak. Just my 2 cents.

Good point there mjr, copper spray does work if the gasket is in good shape. It all depends on condition. When I did mine a few years back I put RTV on the whole top of the cover and I haven't had a leak yet. When I did my brother's I did the same thing and oil leaked out like a siv.

Jan

I know that sucks for you Grant. I used a rubber hammer and came up from the bottom with it but mine was 20 feet away from the car on a stand. Maybe a piece of wood from the bottom and a hammer. Permatex red brush on sealant is what I sealed mine up with.

It's been a while: For some time now I have been driving my Toyota and working a side job that just came to a short break. None to soon! I have not had a weekend in 5 weeks. Today I pulled the valve cover and shure enough, There is the head gasket pushed into the timing chain area!

Here is what I have done: I loosened the two small front bolts and cleaned the area thoroughly with brake cleaner, then squeezed ultra grey into the gasket void, let it sit for about 20 min then tightened the bolts just till they contacted the head. waited another hour and tightened them down.

I will let it cure till tomorrow evening and see if it leaks.

I know this is not the best way to fix it but I just don't have time to pull the head or the front cover these days. I think the best solution down the road is another head gasket.

Edited September 23, 201212 yr by grantf

Started the car today. The leak is gone (at least for now). My only regret was that I simply was not paying attention while replacing the front cover. It would have been easy to see as the valve cover was removed. Leason learned.

Way to go Grant. Some fine days ahead for a drive.

thanks, Looking forword to the fall driving.