Head Gasket Failure
Symptoms
The head gasket blows, allowing coolant into the combustion chambers and/or oil passages. White smoke from the exhaust, coolant loss without visible external leak, overheating under boost, milky oil on the filler cap, and bubbles in the coolant overflow tank. In severe cases, hydrolock (coolant filling a cylinder and bending a connecting rod on startup).
Cause
Toyota designed the 7M head with only 10 head bolts, insufficient clamping force for the cylinder pressures generated under boost. The factory composite head gasket degrades over time and eventually fails. Thermal cycling accelerates the process. Every 7M-GTE will eventually blow a head gasket on the factory bolts, it's a matter of when, not if.
Fix
Strip the head, machine it flat (check for warpage, common after overheating), install a Cometic multi-layer steel (MLS) head gasket, and secure it with ARP head studs (part number 203-4205).
The ARP studs provide dramatically more clamping force than the factory bolts.
While the head is off, replace the valve stem seals.
Retorque the studs to ARP's specification (typically 85 ft-lb with ARP moly lube).
Total cost: $1,500-2,500 including machining, gaskets, studs, and labour.
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