Relying on Carfax, one of our staffers missed damage to a bumper cover before buying a used Toyota Sienna. A dealer estimated the repair at over $1,000. (Click the image for a closer look at the bad bumper.)
[PHOTO: Consumer Reports]

A recent case involving one of our own Consumers Union staffers illustrates why a used-car history report doesn’t substitute for thorough, pre-purchase inspections by a mechanic and yourself.

The staffer decided to forgo a mechanic’s inspection and buy the certified used 2005 Toyota Sienna minivan based on a “clean” Carfax report. Months later, however, he discovered that a plastic fog lamp insert in the front bumper cover had fallen out, leaving traces of epoxy - obvious signs that someone had glued it in after it had fallen out once before. Checking more closely, he found that several plastic posts attaching the lower and upper parts of the bumper cover were broken.

Most likely, the previous owner resorted to makeshift repairs after driving the vehicle into a curb or other object. The dealer that sold him the vehicle denied knowing about the problem, which he said wasn’t covered by his extended warranty. And the full cost of a repair? A dealer quoted him more than $1,000.

Such a minor accident, though costly, isn’t likely to show up on a vehicle history report. Carfax and other providers rely largely on insurance total-loss records and, in some cases, police accident reports. A run-in with a curb wouldn’t likely generate either of those. And our recent study of used car history reports found that the providers sometimes miss even major accident damage that can leave a car little more than a rusting pile of metal.

As for our staffer, he says regrets not having the minivan inspected by a mechanic before he bought it. And he admits he should have done a better job looking over the vehicle himself. Had he done so, there’s a good chance would have discovered the damage before buying and avoided a costly repair. —Anthony Giorgianni