97 Camry Rod Went Through Engine Block

My boyfriend's '97 Camry was in the shop for an EGR flow insufficient engine code (PO401). While being tested at the shop, they reved up the engine and a rod blew straight through the engine block and oil splattered everywhere. We were informed that Toyota has made an 8 year extended warranty to vehicles with his Camry's engine type due to sludge problems. We are pretty sure this car is a victim because he has gone through a valve cover in less than 10,000 miles and has oil leaks that you can smell when you get out of the car when the engine is warm. It also had a leaking head gasket. The main deal is that the car only has 48,000 miles which is very low mileage for this year of car and the rod should never come through the engine block. The shop where it happened felt horrible because they didn't want him to think it was their fault. It can't be their fault because you can't toy with an engine to make it do that. You would have to drain the oil out and run it hard. This baffles me!

I've never actually heard of a rod being thrown through the block due to the sludge problem. I never even heard of cases where it had gotten that bad. But Toyota has made many TSBs and announcements about the sludge issue, and they say that they will take care of all necessary repairs. Although don't be surprised if your local dealer gives you the run around about it, because it wouldn't be the first time that's happened to any one of us.

Actually, I was on a website where people shared their experiences with sludge, and there were a few that it actually happened to while they were driving.

I find it really amazing how sludge can lead to your car throwing a connecting rod. And I find it really amazing how it's a manufacture-related problem.

Here's a good site that discusses this problem.

http://www.yotarepair.com/Sludge_Zone.html

You could throw a rod if you had so much back pressure on the engine from the PCV valve that's it blowing oil out any little crevace it can make. It musta blew all the oil out at some point, producing oil related failure of the engine.

Nope, I'm wrong... The sludging causes the oil ports on the head (and everywhere else) to clog, thus causing oil failure to the head first. The head is thus cooked.

Hello:How can a person tell if their engine has a sludge problem?Any easy to spot symptoms?
Thanks in advance.
Best Regards...Chuck Lubbe
My boyfriend's '97 Camry was in the shop for an EGR flow insufficient engine code (PO401). While being tested at the shop, they reved up the engine and a rod blew straight through the engine block and oil splattered everywhere. We were informed that Toyota has made an 8 year extended warranty to vehicles with his Camry's engine type due to sludge problems. We are pretty sure this car is a victim because he has gone through a valve cover in less than 10,000 miles and has oil leaks that you can smell when you get out of the car when the engine is warm. It also had a leaking head gasket. The main deal is that the car only has 48,000 miles which is very low mileage for this year of car and the rod should never come through the engine block. The shop where it happened felt horrible because they didn't want him to think it was their fault. It can't be their fault because you can't toy with an engine to make it do that. You would have to drain the oil out and run it hard. This baffles me!

See Link From Dom24mac to explain EVERYTHING about engine oil, sludge, etc. Lots of really good info. Thanks Dom24mac!

http://www.yotarepair.com/Sludge_Zone.html

Good to know that there are some people who are not on the defensive about this problem. My grandfather who was there when it happened, and has been a mechanic since he was 14 years old said that the sludge causes lubrication problems, thus its hard for the proper amount of air to be fed into the engine. The car had numerous problems leading up to this: rumbling when cold and sometimes stalling, tons of white smoke at startup (not water), and a knocking when cold. Also, it was going through valve covers. We have been told by several mechanics that sludge can cause this problem. A rod should NEVER go through the block under ANY circumstance, and that is why Toyota should be held responsible. Especially in a car that has been maintained, has fresh oil, and only has 50k miles.