Re: Head bolt failure and Coolant Loss on 2002-2006 Toyota 2.4L engines

Jun 15, 2009 Last reply: 17 years ago 2 Replies


Some owners would notice coolant loss and leaks on the back side of


> the 2.4L engines, resulting in $4000+ of repairs, because head bolts
> simply come loose by themselves. I suspect 2007+ engines will suffer
> the same fate down the road.
>
> "3/6/2008
>
> 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: 6.350½ to 6.465½  (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)."
>
>
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How did that happen, it seems they were over torqued when being made?

Not to be too obvious, but head bolts aren't supposed to just loosen up in the first place. I'm guessing they skipped a step in assembly, or had materials problems.

According to what I saw, the threads aren't robust enough. The fix appears to be Heli-coils. They sure as hell won't pull out!

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