Need Help, 03 Camry 2.4L 2AZ-FE coolant leak

[costello57]

I have an 03 Camry, 2.4L 2AZ-FE, with 117000 miles. I have developed a coolant leak in the back of the motor that I am having a problem finding. It has no symptoms of head gasket, ie; no water in oil, no excessive smoke, no bubbles in the coolant. I am aware of the headbolt issue with this motor, but other than the leak, I have no problems. I plan to tear it down until I find the problem, but was wondering if there are any other common problems that would cause this leak. (Does coolant run through the intake? Are there coolant lines between the block and intake?) It is impossible to see. I even used a video bore scope and still can't pinpoint the leak. I'm stumped. Any help or advice would be greatly appreciated.

[njerald]

All you have to do is Search for head bolt thread failure and you'll find plenty of others in your same boat...................

[JohnGD]

It's a common problem on the 2AZ-FE. You either Time-sert or, if unsuccessful, get a new engine block (!).

Toyota issued a TSB 2 years ago about this failure: TSB 01507, NHTSA #10021542, Dated April 6 2007. I guess most people are out of the powertrain warranty by now.

Also AERA issued:

Coolant Loss on 2002-2006 Toyota 2.4L, 2AZFE engines

The following information concerns the loss of coolant on some 2002-2006 Toyota 2.4L, 2AZFE engines. The location of this condition has been noted at the rear of the engine where the cylinder head bolts to the cylinder block.
It has been reported that stripped head bolt threads have been found on some of these engines during tear down. When the two rear head bolts lose their clamping ability they allow coolant to seep out at the rear of the cylinder head.

To repair this condition, engine builders report using thread repair tooling used for various GM engines. Specifically, Cadillac 4.6L engines use the same threaded head bolts (Figure 1). The head bolts for this Toyota engine may be reused if they are not damaged and meet the following length specification.

Using a vernier caliper, measure the length of the head bolts from the seat to the end.

Specified bolt length: 6.350˝ to 6.465˝ (161.3 mm to 164.2 mm). If the length is greater than the maximum, replace the bolt.

This information was provided by the Engine Builders Association (AERA).


Read how one TN member fixed his:
Repairs to my 2002 2AZFE complete

Originally Posted by costello57

I have an 03 Camry, 2.4L 2AZ-FE, with 117000 miles. I have developed a coolant leak in the back of the motor that I am having a problem finding. It has no symptoms of head gasket, ie; no water in oil, no excessive smoke, no bubbles in the coolant. I am aware of the headbolt issue with this motor, but other than the leak, I have no problems. I plan to tear it down until I find the problem, but was wondering if there are any other common problems that would cause this leak. (Does coolant run through the intake? Are there coolant lines between the block and intake?) It is impossible to see. I even used a video bore scope and still can't pinpoint the leak. I'm stumped. Any help or advice would be greatly appreciated.

[islandboy57]

Sigh.. Toyota really needs to step up and help customers out with this repair. If my current driving habits hold up, I won't hit 100K until 2019. Anyway, I don't know how "common" the issue is but there have been more than a few people discussing it here on TN.

[toyomoho]

And at other car forums.

[islandboy57]

Originally Posted by toyomoho

And at other car forums.

Yeah I saw your posts on a couple of other forums. I'm debating whether or not to chance it and chalk up the $1K time-sert kit as "sh*t happens" if needed.. Or to trade in my car before I hit the 60K mark. Ah well, we'll see I guess. No sense getting all excited over nothing..

[JohnGD]

Enough for AERA Engine Rebuilders Association to put out a fix to all its members. (!)

[islandboy57]

^ Sigh.. I guess there's always the off chance that Toyota will offer repairs on an as-needed basis in the future. HA HA, just kidding.. I must have been dreaming for a sec there. Shame on Toyota

Now I really wish I'd gone for the 1MZ when I was shopping around. Ah well. Looks like my car is worth $10K as a trade-in (closer to $12K private party) which is ~$140/month in depreciation per month in the time I've had it. Not too shabby!

[etc]

Post your feedback on this issue here, so that others will know to avoid the bad years.

http://www.carsurvey.org/reviews/toyota/camry/2002/

[dave0919]

Turn the wheels to the left, with a good light look at the area between the block and the intake manifold from the rear of the right wheel, if you see antifreeze soaking the thick foam "packing--black rubber--gasket" it's coming from the headgasket. the bolts holding the head to the block are not holding and cannot be tightend.

It is repairable "if" the engine has not been overheated, use or have timeserts installed and replace the headbolts. if over 100K install a new waterpump and belt tensioner(?) as well.

[BKSmooth]

My 2005 Camry 2AZ-FE is at about 108,200. I have noticed it running a little low on coolant, and (since I was a sucker and bought the lifetime oil changes when I bought it new) the stealership noted that the coolant was "low" on the last two trips; I disregarded the minor consumption. As an example, my OOOBS '97 Tahoe went through coolant all the time. Now I'm finding stuff like this on the web when searching for unrelated items.

As a pharmacist aspiring to be a physician, I certainly have seen my fair share of unnecessary drug recalls and FDA alerts over isolated incidents as well as what financial motives can make a business entity ignore... I'd like to believe this is an isolated issue, but can't get myself to overlook it!

Is the "rubber foam" the gasket between the intake manifold and the motor? If there's a leak, would I expect it to be wet to the touch?

[islandboy57]

I wouldn't worry too much about minor coolant use. After about four years I had mine refilled and I haven't noticed any drastic coolant use. My aunt's Avalon and Corolla are the same. I know the 2GR uses the "pink stuff", not sure on the 1ZZ.

[BKSmooth]

Right on. I am certainly utilitarian when it comes to my cars and had planned to drive this Camry to at least 225K. At half-way through, the suspension, steering, interior, etc. is fine but not factory fresh and it's taken a beating on the exterior (couldn't care less) in the parking lots.

I've seen people reporting that they had traded their cars in earlier than desired over this concern. I feel like I've gotten good use out of this car considering I got it out the door for 20K, but heck, I checked my KBB on it and I'm looking at low 5's on trade-in.

Of course, had I not run across that thread, I'd have just gone along and thought nothing of it . What concerns me is a 3,500 mile week-long roadtrip I've got planned in April from DFW --> AZ --> NV --> CA and back...