Poor backup support

In 2002 I’ve relocated to Nelspruit from Johannesburg for work. I got involved into mountain biking and slowly started to explore the Lowveld. The only problem then was that I had small children who at that stage could not cycle with to enjoy the beauty that I experienced, so the next step for me was to by a 4x4.

After searching online for some time in 2004 I bought a 1997 Toyota Land Cruiser Series 95 Prado with the 3.4L V6 Petrol engine. The more I’ve off-roaded the more extra’s I’ve identified to get fitted to the car to get it purpose fit for my needs. First was to get rid of the CAT, fit a stainless free-flow exhaust system and then Steve’s installed a chip in the hope to reduce fuel consumption. I then got a long-range fuel tank installed; next on the list was an Old Man Emu suspension. I then got a roof rack fitted with a rooftop tent, portable NL dual battery system for a 90L NL fridge. As the camping experience crew on the family, I then bought an off-road trailer and fitted mud terrain tires.to the Prado to improve grip when towing off-road. With the trailer being tow to remote areas, mostly without a second vehicle for support, I got front and rear lockers installed, aftermarket steel bumper to mount winch on, then came the spot lights and rear steel bumper.

All these extras added some weight that reduced the performance and fuel consumption, so since the vehicle were serviced by Steve’s Auto I took it to them for a stage 2 conversion to regain some power, hopefully to reduce fuel consumption and to due some preventative maintenance. This work was done in February 2015 with the Odometer at 281551Km.

On Monday the 14th August 2017 I was on my way to Kgalagadi from Nelspruit when just past Hotazel I’ve noticed the temperature gauge rising to ¾. I’ve placed the transmission in Neutral and switched the engine off to allow as much possible cooling through the radiator while the car was still moving. With the car pulled off the road, I got out and opened the bonnet to investigate, but it soon became clear that a headgasket blew. After allowing the radiator to cool down sufficiently I’ve refilled the radiator and slowly returned to Kuruman continuously keeping an eye on the temperature. I’ve contacted Steve’s to inform them about my dilemma, but since the nearest branch was Johannesburg I had to make an alternative plan. At this stage the mileage were standing on 305545km. I’ve contacted Kuruman Toyota who revered me to an engineering works, but this gentleman said he would not be able to help me that week, but I have to ask Toyota to strip and then he would inspect the heads and block for damage. Toyota agreed to dismantle and ordered the required parts. The service manager then suggested to remove and replace only the blown gasket to save time, but I insisted to check both heads and replace both gasket not to have a compression difference between the left and right bank. Then I was informed that during the removal process the inlet pipe to the radiator broke off when removing the cooling hose and that the ***ley also got broken, so they had to order new parts. The heads were sent to the engineering shop and as expected both heads sealing faces were perfectly flat and only needed a cleanup. If the engine overheated from the blown gasket, the heads would have warped and would have needed skimming.

At this stage the staff at Kgalagadi Transfortier Park were so kind to postpone my booking that I’ve done before starting my travels.

Initially I were told that they would try to get me back on the road, but they informed me they received the parts late, but will try for Friday. Friday I was told that the car would be ready on Saturday. Saturday arrived and it became late, so I went down to the service center where I found that the Mechanic was still struggling with an overheating problem when the thermostat was fitted. They did not had the right thermostat in stock, but AutoZone had a replacement part available, which I then bought, but this proved to have the same problem. The Mechanic and Service Manager then informed me that I can continue my journey without the thermostat, but should order one once I get to a place where I can wait at least 6 day’s for the part to arrive from SA. I was also informed about a worn bearing noise that came from the alternator and that I should get it checked out when possible.

During this 6-day excursion Steve’s Auto Clinic offered a replacement vehicle, but my vehicle was already kitted for my needs and would not serve for my purpose.

I packed my gear into the Prado and left Kuruman for Kgalagadi via Hotazel and then gravel road. A while later when slowing down I could smell petrol, but due to limited time before the gate closes I could not stop to inspect, but only had a look once checked in. I could not find the source of the petrol fumes until a couple days later when I noticed the green unleaded stain running down the gearbox bell housing.

Only once I got to Windhoek I could strip down the intake down to the injectors where I found two O-rings on the injectors that were clearly the old O-rings and not even the new O-rings that came in the gasket set. I had to shop around as all retailers wanted to sell an O-ring kit and I only needed 6 of the same size O-rings that I eventually go from Wurth at a cost of R6-00.

From there I travelled down to Walvisbay where I left the vehicle at a friends place while I left for work. During this time I my wife ordered a thermostat from Nelspruit Toyota that she then brought with on our return to Walvisbay. As fitting a thermostat is not rocket science, I opted to do it myself, but even with this thermostat the engine continued to run warmer than normal.

I then took the car to Walvisbay Toyota where they tried to fit the thermostat with the same results, but said that the bearing noise are not the alternator, but possibly from the waterpump that possibly spin on the shaft once the thermostat are fitted. They then proceeded to order the part that arrived 6 day’s later. I were thus confined to the Walvis area, so I could not continue my planned trip.

After receiving the part the engine was stripped and found that the water pump was still in perfect order. After re-assembly they overheating issue was still present when thermostat was installed. They then performed a gas test and found exhaust gasses in the water.

The service Manager then contacted Kuruman Toyota and they requested that I return the car to them for repairs, but to settle the cost inhouse. I have then voiced my concern about long term damage that could then be caused as clearly something were not done correctly during installation of the gaskets. I was told that it was not an option to get the repair done in Walvis and had to return to Kuruman on my way home. When I stopped at Kuruman Toyota the service Manager felt the pressure of the water hose and told me to return home and then take the car to the Nelspruit dealership for repairs.

The car were checked in and after 4 day’s of testing the heads were removed to find that the gaskets were fitted wring way round. Again I’ve asked what the long-term damage could have been and I was informed that it would have to be monitored during the coming months.

December I left for Mozambique and thankfully all went well until we went for a Sunday outing to Kaapsehoop when the car suddenly lost power and a nocking sound became apparent when the motor are under load. Back at Toyota Nelspruit to be checked it was found that piston No.2 lost compression and the nocking sound is piston slap from a collapsed ring caused by long term heat exposure from insufficient cooling due to blocked cooling ports caused by wrongfully fitted gasket.

Up to now this blown gasket cost me almost R50000-00 and now Toyota said that they would not assist me to get my engine repaired. I do understand that my 5VZ-FE engine have done lots of mileage, but any person who paid Toyota to get repairs done would expect to get more kilometers after an expensive repair and if the work was done correctly in the first place, I could have easily got 500000km out of the motor.

After all this I now understand why Toyota Kuruman are called Leach Toyota. They will suck you dry for your last cent.