Four problems related to manifold/header/muffler/tail pipe have been reported for the 1997 Toyota Camry. The most recently reported issues are listed below.
In July, 2003 (please refer to odi id number: 10030262) our 1997 Toyota Camry ce (manual transmission) began leaking large amounts of gasoline. It was determined internal pressure had caused the tank to bulge out and rip at the seams. After two soldering attempts were made to patch the tank, the entire tank was replaced with a new one. A pressure test was conducted but no problems were found. In February 2005 the gas tank started leaking again. The same bulge from inside out was found as had previously been seen with the old and since replaced tank. The tank was removed & sent out for welding, returned and tests were conducted on the charcoal filter & vacuum switch. Both tested fine. The vacuum switch was replaced as the cost of replacing the charcoal filter was too expensive and since it didn't show failure, it didn't appear to be necessary. The mechanic suggested periodic tests in case the problem was intermittent. Also, the heat distributor (I believe that's the name for the metal between the exhaust pipe & the gas tank to keep the tank from overheating & exploding) was found to have been "wrinkled" but from the pressure of the in-out expansion of the tank, not from an out-in push that would have been caused from driving over something. Less than two weeks later, the gas leak returned. Toyota was contacted and we were referred to the local dealership customer service manager. The csm coordinated with the service department to have the car put up on the rack and looked at. Three individuals, including the csm declared it was an "external leak from the patch" and felt it was nothing they were willing to investigate further. They did suggest replacing the tank and doing further investigations to attempt to duplicate the process, however, the expenses are so extraordinary, we have opted to replace the tank with a used one and look at other replacement vehicle options, possibly selling parts or towing to a junk yard.
At about 70k miles, my 1997 Toyota Camry starting exhibiting problems of huge amounts of smoke from tail pipe at cold startup. I understand that this is related to the engine sluge or gelling problem. I believe this problem is related to the TSB-628696 as noted in the NHTSA. However, Toyota has declined to cover the repair, but is willing to cover only the parts, but the labor is being charged to me. They are not honoring the extended coverage that they have announced for this TSB tc02002 and NHTSA item number: 628696. This is totally ridiculous.
I received a letter last year from Toyota explaining a gelling problem and to watch out for blue smoke coming from the tail pipe when starting the car. I went into sears for an oil change and they indicated that it looked like moisture was getting in the oil and it looked sludgy. I took the car to the Toyota dealership for them to check out this gelling. The letter indicated that Toyota would pay for the part/installation. I got the estimated back from Toyota and they said I did not have any gelling or sludge in the oil/engine, but that I did have rotted valve stem seals and head gasket leaks, and oil pan leaks and thats why there was blue smoke. The car is barely 7 years old and I have changed the oil faithfully at 3000 miles. I did not have the problem fixed, because I wanted a second opinion from a mechanic that was referred to me that is trustworthy. I plan on taking the car in(an appt. Was made for 2 days after I took it to the Toyota dealership) and I have questions in hand about how this could have happened when I have not had 1 indication that the engine is going bad/valves are leaking(I. E. There have been no noises, leaking of antifreeze or other fluid when I park my car o/n or for a few hours).
I have 1997 Toyota Camry with 39,000 miles and large amount of white exhaust comes out of tailpipe when car is first started in the morning or when engine is cold.