NHTSA Complaint #10559691 — 2003 TOYOTA CAMRY

THIS IS TO REPORT A FAILURE ON ENGINE MODEL #2AZ-FE (EFFECTS 2002-2007 CAMRYS, HIGHLANDERS AND RAV4) DUE TO STRIPPED CYLINDER HEAD BOLTS ON THE BACK SIDE OF THE ENGINE. THERE IS AT LEAST ONE TECHNICAL SERVICE BULLETIN ISSUED BY TOYOTA TSB2740 THAT RELATES TO THIS RECOGNIZED PROBLEM OF STEEL CYLINDER HEAD BOLTS STRIPPING OUT OF THE ALUMINUM ENGINE, ESPECIALLY ON THE FIREWALL OR BACKSIDE OF THE ENGINE POSSIBLY DUE TO A FOAM INSULATION PIECE TO PROTECT A PLASTIC MANIFOLD PART FROM HEAT. IT IS SUGGESTED THAT THE FOAM PIECE ALLOWS A HEAT BUILD UP ON THE ENGINE SIDE. THE COSTS TO REPAIR THIS PROBLEM WAS $2,131. AND INCLUDES MACHINING THE WARPED HEAD, NEW HEAD GASKET AND BOLTS AND A LONG THREAD INSERT SET. I AM VERY DISAPPOINTED TO LEARN THAT TOYOTA KNEW YEARS AGO OF THIS DESIGN PROBLEM AND ISSUED A TSB; BUT DID NOT RECALL FOR A SOLUTION BEFORE THIS LED TO METAL FAILURE AND ENGINE OVERHEATING. MANY OF THESE ENGINES WILL FAIL AFTER THE WARRANTY PERIOD OF 60K HAS EXPIRED. IF YOU HAVE ANY SUGGESTIONS AS TO REMEDIES WITH TOYOTA CORP FOR THIS FAILURE, I WOULD APPRECIATE KNOWING ABOUT IT. I AM GLAD TO REPORT THIS AS I SEE THAT MANY, MANY ENGINE FAILURES HAVE BEEN CAUSED BY THIS BASICALLY UNADDRESSED DESIGN PROBLEM. THANK YOU. *TR