GEN5 2.4L 2AZ-FE Stripped Head Bolts - Toyota Nation Forum : Toyota Car and Truck Forums


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5th & 6th Generation (2002-2006 & 2007-2011) Toyota Camry Discussion for years: 2002-2006 & 2007-2011 Topics of discussion range from fuel economy, safety, modifications, performance all involving America's favorite family car, the Toyota Camry.

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Old 12-19-2009, 06:24 PM   #1 (permalink)
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GEN5 2.4L 2AZ-FE Stripped Head Bolts

I am considering purchasing a low mileage 2002 I4 Camry. I have been reading up about the problem of stripped head bolts with the GEN5 Camry 2.4L 2AZ-FE engine on this and another forum. It appears to be a design flaw with this engine. I have two questions:

1) Is this a systemic problem with the 2.4L 2AZ-FE engine and it is just a matter of time before the rear three head bolts strip out of the block and coolant begins to leak, or can this problem be avoided somehow or predicted based on symptoms before it occurs?

2) It is my understanding that metal inserts can be installed and the headgasket replaced in your driveway with the engine still in the car. Is anyone aware of a DIY procedure posted on the internet to replace the head gasket and install Timeserts or NS300L inserts on the GEN5 Camry?
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Last edited by dz63; 12-19-2009 at 06:56 PM.
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Old 12-19-2009, 08:10 PM   #2 (permalink)
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Some people speculated that the insulation on the intake manifold is one of the reasons. But Toyota never said it for sure. They just wanted to charge $5000+ to put in a new block. It's a cash cow because this almost always happens after powertrain warranty ~80K miles (dealer economic stimulus package). Time-sert the block should be around $1500.

If dealer is willing to deduct $5000 off a used car that would be great!! But I kinda doubt it.

PM Dave0919 and maybe he will share some of his experience in Time-serting the 2.4L.



Quote:
Originally Posted by dz63 View Post
1) Is this a systemic problem with the 2.4L 2AZ-FE engine and it is just a matter of time before the rear three head bolts strip out of the block and coolant begins to leak, or can this problem be avoided somehow or predicted based on symptoms before it occurs?

2) It is my understanding that metal inserts can be installed and the headgasket replaced in your driveway with the engine still in the car. Is anyone aware of a DIY procedure posted on the internet to replace the head gasket and install Timeserts or NS300L inserts on the GEN5 Camry?

Last edited by JohnGD; 12-19-2009 at 08:13 PM.
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Old 01-15-2010, 02:53 PM   #3 (permalink)
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I have an 02 with that engine and M/T, 115K miles, dumping it avoid that issue. Although no problems yet.
(I need a station wagon anyway)
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Old 01-15-2010, 03:19 PM   #4 (permalink)
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I completed the repair of the head bolt thread problem almost 40K ago. Car runs as new (now at 170K) and still gets 34 MPG. Timeserts are the best way to solve the problem. Can be done at home with basic tools. I can let my kit out for $100 you need to supply the serts and pay postage back to me.
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Old 01-15-2010, 03:38 PM   #5 (permalink)
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Quote:
Originally Posted by dave0919 View Post
I completed the repair of the head bolt thread problem almost 40K ago. Car runs as new (now at 170K) and still gets 34 MPG. Timeserts are the best way to solve the problem. Can be done at home with basic tools. I can let my kit out for $100 you need to supply the serts and pay postage back to me.
Thanks for the offer Dave. I am going to bookmark this thread. Kudos to you for tackling this on your own. If you will oblige, I'd like to ask you some questions:

1. How long did it take you and how much did you spend on parts?
2. What is your skill level. Are you an auto mechanic or just mechnically inclined?
3. What did you use for guidance...a Haynes manual or other?

Any chance, you would be willing to share your experience by writing a short DIY with some tips...for the benefit of the other TN members? From what I have been reading, this is a systemic problem with the 2AZ-FE engine. I don't know if it is inevitable or not, but it seems like the majority of them occur between 60K miles and 140k miles. I have an opportunity to buy a 2002 Camry with 45K miles in the Spring. If the head bolts go on it, I would like to tackle this myself using either the Timeserts or NS300L inserts.

Thanks in advance, dz63
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Last edited by dz63; 01-15-2010 at 03:40 PM.
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Old 01-15-2010, 04:04 PM   #6 (permalink)
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Gen6

How many head bolt threads are needed???
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Old 01-15-2010, 05:16 PM   #7 (permalink)
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10 headdbolts,,,

I am a retired mechanic (froklifts, trucks etc.)

Repair will take 3 to 5 days (should have the valve seals replaced if over 100K) and get the head surface checked for flatness. Mine was fine with 3 bolts stripped.

USE A 12pt SPLINE TOOL TO REMOVE THE BOLTS the heads are not as hard as they should be. You can drill them out if needed.
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Old 01-18-2010, 11:16 PM   #8 (permalink)
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03 highlander headbolts stripped

I also have the same issue with the 03 highlander, its a shame toyota wont step up and save the reputation that got most of us to own their vehicles.
I have removed and rebuilt the transmission on my 92 exploder so i believe with some insight from Dave 0919 i can do this
I have some questions.

1. What tools would i need


2 How many tylenols should i take before doing this repair.

Last edited by lindsayd; 01-18-2010 at 11:25 PM. Reason: incomplete
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Old 01-19-2010, 11:15 PM   #9 (permalink)
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Sounds like you have the tools needed. Use a bottle jack to hold the engine up after removing the pan. 2 nuts will remove the studs on the front cover. use a new or "good" 12pt tool to remove the head bolts, some will be hard to get started. If they round out, drill them out. A good 1/2" drill is a must. Might want to replace the water pump and belt tensioner..

DAve
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Old 01-20-2010, 12:47 AM   #10 (permalink)
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I also have the same issue with the 03 highlander, its a shame toyota wont step up and save the reputation that got most of us to own their vehicles.
If you don't mind me asking, how many miles do you have on your Highlander?
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Old 01-20-2010, 09:36 PM   #11 (permalink)
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03 highlander

the highlander has 260,000 miles, ive enjoyed every one. I plan to get many, many more.
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Old 01-24-2010, 09:29 PM   #12 (permalink)
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Help Im squirming here!

i have purchased a manual that basically describes removing the entire front of the engine {crank pulley etc} to get the head off , can you tell me how you did it Dave0919, Help Im squirming here! Thanks ............
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Old 01-25-2010, 12:02 PM   #13 (permalink)
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This weekend I just completed the repair on the threads on my 03 2.4 Camry. I will tell you, after much research it's not a rare failure as previously posted, but more likely inevitable. It's hard to imagine that the foam is causing the failure, but something certainly is. All the failures are the three center bolts on the intake side. Mine failed at 177k miles, and was meticulously maintained.

I decided to use the NS300L inserts available from huhnsolutions.com. Go to his website and read the differences between the Time Serts, Helicoils, and the NS300L. The NS300L has more aggressive threads to hold to the aluminum block, and are longer, giving greater thread contact and more stability, and I felt would be a more permanent repair. The kit was very easy to use, and everything you need is included. If you have mechanical ability and are capable of removing the head, the rest is just time consuming. Remember, you're drilling 4 inches deep into your block ten times (yes, do ALL the holes, not just the stripped ones!), so allow a full day to complete that step. It is not an evening job but a process. Just take your time and don't rush it, and keep the holes clean while drilling and tapping. Blow them out often.

I was considering doing the repair and unloading the car even though i do like it, but after doing the repair I feel very confident and will be keeping it. I know it's stronger than when Toyota built it!
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Old 01-25-2010, 04:22 PM   #14 (permalink)
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costello57,



Welcome to the TN forum. Kudos to you on the head bolt repair. Not many people would tackle that themselves. If you will oblige, I would like to ask a few questions:

1. How did you arrive at the conclusion that your head bolts were stripped (ie. what were the symptoms), and did it occur gradually over time or just suddenly?
2. How much did the repair end up costing you and how long did it take you to complete?
3. What is your mechanical background and how would you describe your level of proficiency experience with auto repairs? Is this something that a serious DIYer could tackle?

Is there any chance you would consider writing up a brief DIY procedure with the basic steps that you took (including any tips or things to watch out for) for the benefit of the rest of the TN members?

Thanks, dz63
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Old 01-25-2010, 06:56 PM   #15 (permalink)
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Quote:
Originally Posted by costello57 View Post
This weekend I just completed the repair on the threads on my 03 2.4 Camry. I will tell you, after much research it's not a rare failure as previously posted, but more likely inevitable. It's hard to imagine that the foam is causing the failure, but something certainly is. All the failures are the three center bolts on the intake side. Mine failed at 177k miles, and was meticulously maintained.
On your original post earlier this month you said the Head Bolts failed at 117000 miles and now you say 177K miles. I am sure it's a typo, but when did it fail?
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