Replaced head gasket. And then...

Did you fill up anything around with water then?

 

Was the egr circuit cleaned before starting the car after head gasket removal?

 

An internal leaking egr cooler would allow coolant into every cylinder. To test this theory disconnect the coolant lines from the cooler and connect the lines to each other.

It may be easier to look into intake manifold for coolant contamination where ultimately the egr flows into.

 

Was thinking you filled something up with water to clean it and not all of the water evaporated or dried out and the water left over went into all cylinders.

 

Could you pressure test the EGR cooler?

If you want to avoid spillage, drain a couple of liter of coolant (from the rad drain) into a clean container before pulling off off any hoses. This will avoid any spillage. Disconnect and plug all but one coolant pipes running into the EGR cooler, and apply pressure or vacuum to the remaining pipe, see if it holds.

Pour the drained coolant back into the reservoir after all coolant lines are reconnected. Leave the bleed bolt (on hose atop the EGR cooler) open till coolant starts coming out, then quickly shut. Squeeze the main rad hoses as you're refilling might help. Coolant level will likely end up a little high, but driving (if and when) will drop it back to normal.

 

Have you put a pressure tester on the coolant tank? That would be the easiest thing.
If it doesn't hold pressure, you'll be able to see, or hear where it' s leaking.
You could put the spark plugs out and look and listen to each cylinder for coolant...

 

Assuming you're taking it to a machine shop for that, at least they can check to see if something isn't straight first. I'm curious whether taking material off the deck and head surface will affect the engine.

1. valve clearance will change between the valve head and pistons
2. chamber volume at TDC will be smaller resulting in higher pressures
3. centerlines will change between the cams and crankshaft, affecting the timing chain tensioner, I'd like to think it's capable of handling the extra slack.
4. are there any accessories/brackets that bolt to both the head and the block? If so, those bolt hole locations will now be closer together and may not match the bracket.

Do you have a copy of the Toyota repair manual? The engine mechanical section actually has a comment that if the head bolts are not removed in the correct order, damage to the head may result. They also specify that if either the head or block deck are out of tolerance for warpage, they are to be replaced. There's no spec listed for machining.

 

It is doubtful that block is warped. It's cast iron. The head is either cracked, or warped.
Slight possibility that the gasket was bad.
Or the holes the head bolts go into have/had water or dirt in them and you weren't able to get the
bolts tightend tight enough, even though you were able to torque them.

 

I believe the block is cast aluminum with iron cylinder liners
https://www.motorreviewer.com/engine.php?engine_id=155

Daniel Richard, did you use any type of sealant (Permatex, etc.) in addition to the HG? Did the progressive torquing sequence seem to go well? Like did it feel even and normal, with nothing binding or releasing as you finished it? Any chance one of the alignment pins caused a hang-up so the head could not be properly seated even though the torque sequence was completed? (just throwing a bunch of random thoughts at you to think about as you take it apart)

If you had 1+2 leaking before, and now have 1-2-3-4 leaking, it seems that the problem is not a pre-existing condition, it must be something related to the repair.

Did you follow videos or the manual when doing the work?

 

^ That's making a lot of sense.

 

That's what I meant... the sleeves are cast iron. I was just thinking of the mating surfaces.
Thanks for clarifying it.

 

Engine swap probably next

 

You mentioned that aftermarket head bolts were used. Were these TTY bolts and did their length match the originals?

Incorrect bolts providing the improper clamping force can cause all four cylinders to leak.