Here is the ASE mechanic's account of the cause of CATASTROPHIC engine failure in a 2000 Sienna SLUDGE MOBILE from Toyota. Contact the owners via this site if you have a similar story.
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Charlene Blake
To whom it may concern:
On December 22 Tom R. Was hired by Mark and Robin Burpee to examine the 2000 Toyota Sienna that they had leased. The vehicle in question was in an inoperable state and located in the service area at Sunshine Toyota in Battle Creek, Michigan. The Burpee's met me in the service area after I had performed my initial examination and I spoke with them in length about the condition of the vehicle and how it had come to be in an inoperable state.
My credentials for determining the malfunction of this vehicle are to follow the conclusion of this statement.
The following is my belief as to what caused the vehicle in question to malfunction,
1. September 4 - Lack of lubrication to cam support journal #1. Possible cause:
A) malfunctioning pressure release valve
B) plug in oil galley line
The following time line of events lead me to the conclusion that a malfunctioning pressure release valve was the cause of lack of lubrication to cam support journal #1.
At 8:30 am on September 4 Robin Burpee started the vehicle attempting to take her children to daycare and report to work by 9:15. The vehicle had previously sat, un-started, from Thursday evening August 30 until 8:30 on September
4; the Burpee's utilized their other vehicle over the holiday weekend. The daily low air temperatures for this
5 day period ranged from 45 degrees F to 66 degrees F; with relative humidity levels ranging from 88% to 100%.
Mrs. Burpee traveled approximately 3/4 of a mile, after starting the vehicle with no difficulties, and then the Low Oil Pressure Warning Light became illuminated. Mrs. Burpee stopped the vehicle to check the oil.
The engine smelled as if it was operating hQt however the gages on the automobile dash read normal at this time the Low Oil Pressure Warning Light was still illuminated. There were no out of the ordinary sounds being admitted from the engine.
She turned off the vehicle and checked the oil; with the dip stick, reading the oil at normal levels. The automobile sat for approximately 5 minutes then she rechecked the oil and when the levels were still reading normal she restarted the engine.
The engine started, once again, with no difficulties. The Low Oil Pressure Warning Light was! LQ1 illuminated (and never became illuminated again) and the engine appeared to be functioning normally. Mrs. Burpee remained concerned about the vehicle and let the engine run idle for approximately 5 additional minutes to see if the Low Oil Pressure Warning Light would re-illuminate. When everything appeared to be normal Mrs. Burpee was now late for work and choose to
Drive her children to daycare. At the next stop the vehicle cut out and when re-started ran without any apparent difficulties. The engine appeared to be operating normal and no warning lights came on in the dash.
Once at her children's daycare, approximately 7 miles from her home, Mrs. Burpee checked the oil again and read the dipstick. The reading indicated the oil level was below the full level and she borrowed a quart of oil from the daycare provider. The oil she borrowed was Quaker State and the automobile took the entire quart of oil and then the dipstick read "Full Level".
Once Mrs. Burpee arrived at work she once again checked the oil and everything appeared to be functioning normally. After she left work, at 4:00 P.M., Mrs. Burpee picked her children up after work and traveled to Three Rivers where she had the oil changed at Fast Lane Oil Change; as she was still concerned about the well-being of the automobile.
Mark Burpee, Robin's husband was out of town on business and unavailable for consultation. However, Mrs. Burpee knew that her husband only used Valvoline oil when he changed the oil in the vehicle. She asked the service manager at the Fast Lane Oil Change to use Valvoline in the oil change and to check and see if they could tell why the "Low Oil Pressure Warning Lighf' had come on earlier in the day and she proceeded to tell the technicians what had happened.
The technicians indicated that everything looked normal both on top and underneath the vehicle, that the oil in the automobile seemed fine and that there should be no reason for further concern. Mrs. Burpee instructed the technicians to also change the air filter at the time of the oil change. (See invoice #56077 Fast Lane Oil Change) Mrs. Burpee never had the "Low Oil Pressure Warning Lighf' illuminate while she was driving the vehicle again.
The fact that the Low Oil Pressure Warning Light did not remain illuminated leads to the conclusion that the Oil Pressure Valve malfunctioned rather than the oil galley line being plugged. If the oil galley line had been plugged the Low Oil Pressure Warning Light would have remained illuminated after Mrs. Burpee restarted the vehicle; and for whatever period of time transpired between the time the oil galley line had became plugged to the time the vehicle reached over 30,000 miles.
2. The cam shaft ran unsupported by journal #1 for approximately 3,500 miles over a period of 76 days. There were, however, no indications to the Burpee's that this was the case. No parameters had been programed into the Electronic Control Module by Toyota to indicate to the Burpee's that the engine was in a state of deterioration.
The following occurred as a result of the cam shaft running unsupported by journal #1
A} lack of lubrication caused excessive heat in the engine causing a portion of the aluminum head to melt.
B} Oil returning from cylinder head area via cam support journal #1 is compromised by excess heat (1600 degrees F)
3. On November 19, due to lack of support, the timing belt jumped time creating poor performance.
A) Mrs. Burpee drove the vehicle for approximately 5 miles to a phone so she could call her husband. The vehicle obtained a top speed of 30 MPH. Mr. Burpee could see that the timing belt case had cracked and that the repairs needed were beyond his capabilities. At that time, Service Manager, Jeff Corbett was contacted and the vehicle was towed to Sunshine Toyota.
4. As a result of inspection by Toyota personnel and the possible rewing of the vehicle's engine the forward cam shaft broke due to work hardening.
Conclusion:
I believe that the incidents that occurred on September 4th began the deterioration of the 2000 Toyota Sienna's engine and oil leased by Robin Burpee. I examined the engine and spoke with Mrs. Burpee about the events that had occurred on that day. Then, over the next two plus months, the engine continued to deteriorate. On November 19, the timing belt slipped reducing engine performance and then and only then did it become apparent that there was engine malfunction.
A) I believe that the "sludge" that is present in the engine was created by excessive heat caused by the afore mentioned conditions and not by the neglect or lack of proper maintenance by the Burpee's.
B. All points on both cams, except for the timing pulley area, showed no signs of wear or lack of lubrication.
C. When I examined the oil passage of the interior of the broken cam it was ~ of sludge.
D. 40 psi of oil pressure is normal in a normal operating engine. For the Low Oil Pressure Warning Light to become illuminated the oil pressure had to reach 3 - 6 psi (depending on the manufacturers specifications) or less and this happened in a relatively short period of time.
This indicates to me that the pressure release valve malfunctioned, remaining in the open position. The valves proper function is critical when the engine is cold. I believe that the valve remained open causing the psi to drop to damaging levels.
When speaking personally to Jeff Corbett, Service Manager for Sunshine Toyota on December 26, he indicated to me that at the least the vehicle needed a new cylinder head and a new oil gumg and then he would still remain concerned as to the well being of the engine. I question why the vehicle would need a new oil pump, if it is indeed Toyota's position that the reason for the breakdown of this engine was the result of a "plug in the oil port resulting from lack of proper maintenance by the Burpee's."
Could it be because of the concern that the oil gressure valve may: indeed have malfunctioned and Mr. Corbett fears that it could happen again?
I also question the statement by Mr. Corbett that the cam shaft was broken and the engine was still operational while the vehicle was in the Burpee's possession. It is my belief that the cam shaft broke after the vehicle was in the possession of Toyota Service personnel and only after the possible rewing of the vehicle's engine did the forward cam shaft break due to work hardening of the metal.
I have advised the Burpee's that the repair of the damaged vehicle should indeed be covered under warranty. If Toyota refuses to repair the vehicle under warranty I have advised the Burpee's to seek legal assistance.
I feel for the vehicle to be repaired properly the entire engine needs to be replaced. There most likely is damage to the lower end of the engine caused by lack of lubrication and from the dispersal of metal fragments as a result of the cam breaking.
Simply replacing the cylinder head and installing a new oil pump will not assure that there will not be further difficulties down the road.in any event, if Toyota chooses to only repair the engine or to replace the engine, I recommend that the Burpee's receive, in writing, that the warranty should start over from point of repair; as I foresee further problems may develop.
If I can be of further assistance, or answer questions pertaining to this vehicle, please feel free to contact me.
Sincerely,
TomR
BS Automotive Mechanics - Western Michigan University
Masters of Automotive Mechanics - Western Michigan University Member SAE - Society of Automotive Engineers
ASE Master Technician - Automotive Service Excellence
Michigan Certified Automotive Test Site - Automotive Technician Tester NA TEF Certified - National Automotive Technicians Education Foundation Program administrator for The Presidents Council on Education of Automotive Technology Facilitator for Kalamazoo County Ranked in the top 5 in nation 26 years in Automotive Teaching
Charlene
Vienna, Virginia
U.S.A.
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