2023-2024 Toyota Camry/RAV4 Oil Leak Between Oil Pan and Crankcase

Symptoms

Owners of affected 2023-2024 Toyota Camry, Camry HV, RAV4, RAV4 HV, and 2024 Grand Highlander Hybrid vehicles may notice an oil leak originating from the engine. Specifically, the leak occurs between the oil pan sub-assembly and the stiffening crankcase assembly. This is the primary symptom of the Toyota Camry oil leak issue.

Diagnosis / Trigger Conditions

A technician will confirm the presence and location of the oil leak by visually inspecting the area where the oil pan sub-assembly meets the stiffening crankcase assembly. This inspection helps determine if the leak matches the condition described in TSB T-SB-0096-24. If the leak is confirmed in this specific area, the repair procedure outlined in the bulletin applies.

Repair Procedure Summary

The repair for this Toyota Camry oil leak involves resealing the oil pan sub-assembly. The general procedure includes:

1. Confirmation: A technician will first visually confirm the oil leak is present and originates from the specified area between the oil pan sub-assembly and the stiffening crankcase assembly. Figure 1 in the bulletin illustrates the exact inspection area.
2. Removal: The oil pan sub-assembly is then carefully removed. This step requires consulting the appropriate model-year specific Repair Manual for detailed instructions, with specific steps noted for Camry, Camry HV, Grand Highlander HV, RAV4, and RAV4 HV models.
3. Cleaning: All existing oil pan sealer (FIPG) and any oil residue must be thoroughly cleaned from both the removed oil pan sub-assembly and the crankcase stiffening assembly.
4. Resealing and Reinstallation: New FIPG Oil Pan Sealer (part number 00295-00103) is applied, and the oil pan sub-assembly is reinstalled according to the Repair Manual's installation steps, which vary slightly by model and engine type (A25A-FKS or A25A-FXS).
5. Verification: Finally, the technician will confirm that the oil leak has been successfully resolved.

Required Tools or Parts

The primary material required for this repair is FIPG Oil Pan Sealer, part number 00295-00103. While a 'Pan Sub-assy, Oil' (part number 12102-F0010) is listed as a reference, the bulletin explicitly states that the oil pan sub-assembly should NOT be replaced as part of this repair, as the issue is with the seal.

Owner Action

If you observe an oil leak on your 2023-2024 Toyota Camry, Camry HV, RAV4, RAV4 HV, or 2024 Grand Highlander Hybrid, especially around the oil pan area, it is recommended to have your vehicle inspected by a Toyota dealer. This repair is covered under the Toyota Powertrain Warranty (60 months or 60,000 miles, whichever comes first) for USA market vehicles, and under the Toyota Basic Warranty (36 months or 60,000 kilometers) for Mexico market vehicles. The dealer will use OP Code EG2411 for warranty claims related to this specific Toyota Camry oil leak condition.

Source: NHTSA ID 11010346