NHTSA ID Number: 10240069
Manufacturer Communication Number: TSB-0040-23
TSB/Document Date: 2023-07-31
Summary
TSB: Some 2023 model year Camry vehicles equipped with an A25A-FKS engine may exhibit a condition in which a popping noise is present when the engine is running. Follow the Repair Procedure in this bulletin to address this condition.
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TSB/Document ID: TSB-0040-23
Replacement Service Bulletin Number:
MFR Communication Date: 2023-06-23
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: BACK OVER PREVENTION
MFR Component System:
MFR Component Subsystem:
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T-SB-0040-23
June 23, 2023
Popping Noise When the Engine is Running
Service
Category
Engine/Hybrid
System
Section
Engine Mechanical
Market USA
Applicability
YEAR(S)
MODEL(S)
2023
Camry
ADDITIONAL INFORMATION
Introduction
Some 2023 model year Camry vehicles equipped with an A25A-FKS engine may exhibit a
condition in which a popping noise is present when the engine is running. Follow the Repair
Procedure in this bulletin to address this condition.
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs
shown below.
MODEL
PLANT
DRIVETRAIN
PRODUCTION CHANGE EFFECTIVE VIN
4T1F11AK#PU156299
4T1C11AK#PU156299
4T1H11AK#PU156299
TMMK1
Camry
4T1R11AK#PU156299
2WD
Serial Numbers 000001 – 499999
4T1K61AK#PU156299
4T1T11AK#PU156299
4T1G11AK#PU156299
4T1S11AK#PU156299
© 2023 Toyota Motor Sales, USA
Page 1 of 6
T-SB-0040-23
June 23, 2023
Page 2 of 6
Popping Noise When the Engine is Running
Production Change Information (continued)
MODEL
PLANT
DRIVETRAIN
PRODUCTION CHANGE EFFECTIVE VIN
4T1F11BK#PU100796
4T1H11BK#PU100796
4T1C11BK#PU100796
TMMK1
4T1R11BK#PU100796
AWD
4T1K61BK#PU100796
Serial Numbers 000001 – 499999
4T1G11BK#PU100796
4T1S11BK#PU100796
4T1T11BK#PU100796
Camry
4T1F11AK#PU806460
4T1R11AK#PU806460
4T1H11AK#PU806460
TMMK2
4T1C11AK#PU806460
2WD
4T1K61AK#PU806460
Serial Numbers 500000 – 999999
4T1G11AK#PU806460
4T1T11AK#PU806460
4T1S11AK#PU806460
Warranty Information
OP CODE
DESCRIPTION
EG2304
R & R Cylinder Head
Combo J
Add: ABS
Combo L
Add: Air Conditioning
TIME
OFP
T1
T2
*
11101-#####**
91
50
*See the Flat Rate Manual.
**Warranty claim MUST be submitted with the correct 10-digit OFP. Choose the correct OFP for the vehicle being
repaired by searching for the parts in the Electronic Parts Catalog using the VIN filter.
APPLICABLE WARRANTY
This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for
60 months or 60,000 miles, whichever occurs first, from the vehicle’s in-service date.
Warranty application is limited to occurrence of the specified condition described in
this bulletin.
© 2023 Toyota Motor Sales, USA
T-SB-0040-23
June 23, 2023
Page 3 of 6
Popping Noise When the Engine is Running
Parts Information
PART NUMBER
PART DESCRIPTION
QTY
11101-29627
Head Sub-assy, Cylinder
1
17173-F0010
Gasket, Exhaust Manifold to Head
1
22271-F0010
Gasket, Throttle Body
1
17171-25010
Gasket, Intake Manifold to Head, No. 1
1
90301-92005
Ring, O (for Cam Timing Control Motor)
1
11193-F0010
Gasket, Spark Plug Tube
4
11115-F0010
Gasket, Cylinder Head
1
11213-25020
Gasket, Cylinder Head Cover
1
90910-02201
B Bolt (for Cylinder Head Set)
6
90910-02202
A Bolt (for Cylinder Head Set)
4
00295-00103
1
00272-SLLC2
Super Long Life Coolant
As Needed
Required Tools & Equipment
REQUIRED EQUIPMENT
SUPPLIER
Techstream ADVI*
PART NUMBER
QTY
TSADVUNIT
Techstream 2.0
TS2UNIT
ADE
1
Techstream Lite
TSLITEPDLR01
Techstream Lite (Green Cable)
TSLP2DLR01
*Essential SST.
NOTE
Only ONE of the Techstream units listed above is required.
GTS+ software version 2023.02.001.02 or later is required.
Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.
© 2023 Toyota Motor Sales, USA
T-SB-0040-23
June 23, 2023
Page 4 of 6
Popping Noise When the Engine is Running
Repair Procedure
1. Confirm the condition exists.
Is there a popping noise present when the engine is running?
YES — Continue to step 2.
NO — This bulletin does NOT apply.
Continue diagnosis using the applicable Repair Manual.
2. Inspect the cylinder head for
machine markings.
Figure 1. Engine Bay
A. Leaning into the engine bay, towards
the bulkhead side, use a phone or
borescope to point the camera to see
the backside of the engine.
1
NOTE
Focus on the middle of the head casting,
just above the exhaust manifold.
B. Make the water-jacket plug the reference
point for the machine markings location.
NOTE
The water-jacket plug is located on the
middle of the head casting, just above
the exhaust manifold.
1
© 2023 Toyota Motor Sales, USA
Area of Focus (for Phone or Borescope)
T-SB-0040-23
June 23, 2023
Page 5 of 6
Popping Noise When the Engine is Running
Repair Procedure (continued)
C. Verify the machine number markings drilled into the casting, using the water-jacket plug
as the starting point of reference.
NOTE
The markings will appear just below the water-jacket plug in the form of drilled dots.
D. Locate the leftmost casting rib as shown in Figures 2 and 3.
Is there more than one dot located to the left of the leftmost casting rib?
YES — This bulletin does NOT apply.
Continue diagnosis using the applicable Repair Manual.
NO — Continue to step 3.
NOTE
Some dots may be smaller or drilled lighter than others.
Figure 2. Indications of a Suspect Cylinder Head
Figure 3. Indication of Non-suspect Cylinder Head
4
1
3
1
2
1
Left Side: One Casting Rib
2
One Marking Present
3
Right Side: Three Casting Ribs
4
Water-jacket Plug
1
© 2023 Toyota Motor Sales, USA
More Than One Marking Present
T-SB-0040-23
June 23, 2023
Page 6 of 6
Popping Noise When the Engine is Running
Repair Procedure (continued)
3. Replace the cylinder head sub assembly.
A. Remove the cylinder head sub assembly.
Refer to TIS, applicable model and model year Repair Manual:
2023 Camry:
Engine/Hybrid System – Engine Mechanical – “A25A-FKS (Engine Mechanical):
Cylinder Head Gasket: Removal”
B. Disassemble the cylinder head sub assembly.
Refer to TIS, applicable model and model year Repair Manual:
2023 Camry:
Engine/Hybrid System – Engine Mechanical – “A25A-FKS (Engine Mechanical):
Cylinder Head: Disassembly”
C. Transfer ALL valve spring retainers, ALL springs, and ALL valves, from the old
cylinder head onto the NEW cylinder head.
Refer to TIS, applicable model and model year Repair Manual:
2023 Camry:
Engine/Hybrid System – Engine Mechanical – “A25A-FKS (Engine Mechanical):
Cylinder Head: Reassembly”
D. Install the NEW cylinder head sub assembly.
Refer to TIS, applicable model and model year Repair Manual:
2023 Camry:
Engine/Hybrid System – Engine Mechanical – “A25A-FKS (Engine Mechanical):
Engine Unit: Reassembly”
4. Test-drive the vehicle to confirm the condition no longer exists.
© 2023 Toyota Motor Sales, USA
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