Avensis 08 2.2 d4D 2nd Head Gasket Gone again - anyone have TSB details please

[mikeyc123]

Hi.

Back on the forum after a number of years of running with no issues. Purchased a 2.2 D4D 08 plate estate (reg August 2008) Avensis many moons ago, It had the dreaded head gasket problem. I didnt have extended warranty but Toyota did the new engine under their extended we have a problem thing. that was at the cars mileage of 50,700 miles in August Nov 2012.

Fast forward to today and over the last month I;ve been losing a lot of coolant, had pressure test done at a garage, white marks on bonnet cover, sound of water behind dash on start etc, all the same tell tail signs as last time and water pump replaced but still an issue, still driving etc (for now). Now March 2019, car on 105,000 miles,

I did some googling and foudn there is apparently a bulletin for the repair to be done if car is less than 110,000 miles (from memory and less than 8 year old). I contacted Toyota warranty, to say hey, if my new engine has the same problem as the last one will you repair it again for free, they said its over 8 years so no, I said I get that buy you only put a new engine in 7 years ago and it has only lasted 55,000 miles before suffering the same fault again, so technically the engine is still less than 8 years old, but I was told any warranty work would only be covered for one year.

They said take it to a local dealer who did last repair dealer, we will contact them to say you are coming and they will do a check to see if head gasket has gone. It went in today and they did some sniffer test and apparently it has gone, So I may now have a battle, I collected the car and was told service are on to Toyota warranty to see what can be done.

Does anyone have any details of the technical notice/bulletin they can share please and if they think the above should be covered ? I guess technically it shouldn't be, but it seems poor for the new replacement engine to fail again after another 50,000 miles. The car is in immaculate condition and I really dont want to part with it. I achieve avg 32.5mpg and love it the old tank/heubik (apart from the low beam).

Cheers

MC

[FROSTYBALLS]

The goodwill cover that Toyota provided for the AD engine head gasket issues was for a period of 7 years or 111,846 miles, whichever occurred first, from the vehicle's first registration.

Toyota's guidelines were as below:

"AD Engine Out of Warranty Guidelines (0730J)

We are pleased to advise that we have received more formalised guidelines from TME for the handling of AD engine problems on out of warranty vehicles. The coverage and processes are summarised below.

Conditions Covered

1) Oil consumption worse than 0.5 litre per 621 miles (1,000 km)

2) Overheating & Head Gasket failure due to carbon deposits on the pistons

For all other out of warranty conditions related to AD engine problems, where the customer complaint can be directly linked to a “carbon clogging” concern, i.e. EGR Valve, DPNR, 5th Injector, EGR Cooler, blocked manifold, etc., we would accept this as being linked to an oil consumption condition.

Vehicles Covered

Those vehicles fitted with AD diesel engines;

��Avensis with 1AD or 2AD (Prod. Date: Apr 2005 to Feb 2009)

��RAV4 with 2AD (Prod. Date: Jul 2005 to Dec 2008)

��Auris with 1AD or 2AD (Prod. Date: Sep 2006 to Sep 2009)

��Verso with 2AD (Prod. Date: Apr 2005 to Nov 2008)

Age / Mileage Covered

These guidelines cover vehicles up to 7 years old and 111,846 miles (180,000 km), whichever the sooner. This is conditional on there being a retail customer complaint and the vehicle having been reasonably maintained".

Unfortunately, your car, being 10-11 years old, is beyond Toyota's cover on age - the 7 years/111,846 mile cover doesn't apply to replacement engines.

[mikeyc123]

Hi Frosty balls - thanks very much, guess its time to find a garage that will take a trade in !

[mikeyc123]

So Toyota confirmed they wouldn't cover the work and wanted circa £6200 for the work for a reconditioned engine to replace the new engine that was put in at 50,000 miles, apparently that only had a 1 year warranty. So it would seem the life span of a Toyota diesel 2.2 engine is only 50,000 miles. This is really disappointing, I had always had thoughts of running the Toyota avensis up to the 150k mark on a single engine, not that it would require 3 new engines.

In light of this I have bought a new car from a different manufacturer and will never touch Toyota again. Skoda has my business now.

Thanks for forum help over the years, you've been very helpful

[FROSTYBALLS]

Then again very few manufacturers would have covered an out of warranty repair on the original engine - certainly I cannot see VAG doing the same.

Best wishes with your new car.

[mikeyc123]

true - but sadly I had subscribed to the mantra that Toyota engines are built to last - sadly not the case as the original one didn’t or the replacement one .

I can only hope I never have to put it to the test with the VAG - at least there aren’t pages and pages of people talking about a known problem with the engine (yet) that I can find - but once bitten twice shy - once this ones warranty has expired I will be getting an extended one as I can’t afford another new car 😉

Thanks for your help frosty. 🙂

[Heidfirst]

5 hours ago, mikeyc123 said:

I can only hope I never have to put it to the test with the VAG - at least there aren’t pages and pages of people talking about a known problem with the engine (yet) that I can find - but once bitten twice shy - once this ones warranty has expired I will be getting an extended one as I can’t afford another new car 😉🙂

where have you been & where have you been looking ...?  😛

Having said that I have said before & will again - I subscribe to not running any modern, common rail, emission-equipped turbodiesel out of warranty no matter the manufacturer.

Also, from what you have said you have done 50k in 7 years or ~7k per annum - that is petrol rather than diesel territory unless you have a specific reason for a diesel such as towing.