Blown Headgasket - Faulty block
 

Hi - I'm a newbie to the site. I have a 4 cyl 2003 LE and at 125 KM the headgasket developed a leak. I tried to get it in to the dealer but they were busy and didn't rent loaners to out of city customers so took it to a certified repair shop. They pulled the head and proceeded to put a new gasket in but when they tried to tighten the head bolts 3 of them ( just where the leak happened to be) wouldn't tighten and when they checked why, the threads from the aluminum block had come out on the bolts. I am wondering if anyone else has had this problem. This was obviously a defective area of the casting in the block. So far I have heard of one other situation exactly like mine in a post on this site about a year ago. Thanks for any info you can give me.

RE: Blown Headgasket - Faulty block
 

Might be able to install something like a Heli-Coil into the block. Toyota may have a TSB out on this.

RE: Blown Headgasket - Faulty block
 

I had the exact, to the letter problem with my 2003 Camry with 86k miles. the head gasket began leaking OIL on 1 corner. When I checked the head bolt, it was loose. It pulled the threads out of the block.
I removed the head and Helicoiled all 10 block threads with Helicoil kit# #1130. But, I would just buy an 11mmx1.5 helicoil kit with 25mm length of threads and weld an extension on the installation tool and tap to help install. Save the $175 for the kit.

I started the car up last night, and so far, so good. Overall it took me about 10-12 hours and about $300. A dealer would charge $1600-2000 I think.

There is another site where 6 or 7 people had the exact same problem. My belief is that 11mm head bolts are too small and it puts too much stress on the threads.

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