2004 Toyota Highlander Engine Problems

While driving to work, your TRAC OFF light, engine light, and oil light all came on at the same time. Your mechanic diagnosed the problem as oil sludge buildup inside the engine, which can damage engine components if not addressed. This issue was subject to a Toyota recall in 2002, but you weren't notified about it when you bought the car used in 2010. Fixing this typically involves an engine flush or oil system cleaning, and in severe cases may require engine repair or replacement.

The outer ring of your crankshaft pulley has separated from the inner ring, which is causing damage to multiple engine systems and may be affecting your steering. Your vehicle's make, model, and year have an existing recall for this exact issue, but your specific VIN number isn't included in the recall coverage. You'll likely need the crankshaft pulley replaced to address the separation and restore proper system function.

WE HAVE A VEHICLE WITH A 2.4LITER/4 CYLINGER ENGINE THAT IS LOOSING OIL AT A RATE OF 1QRT PER 1000 MILES AND NOW THERE IS A COOLANT LEAK COMING FROM THE GASKET SEAL BETWEEN THE ENGINE BLOCK AND HEAD. THERE IS NO GUAGE THAT TELLS YOU HOW MUCH OIL IS MISSING UNTIL IT'S TOO LATE AND THE ENGINE STARTS TO OVER HEAT. BOTH THE OIL AND COOLANT IS LEAKING ON ROADS, PARKING LOTS AND DRIVEWAYS, WHAT WE HAVE FOUND IS THAT THE BOLTS THAT ARE NEAREST THE LEAK ARE STRIPPED, THEY EITHER STRIPPED IN ASSEMBLY OR FLAILED DO TO OVERHEATING OF THE BLOCK DO TO THE ENGINE BLOCK NOT HAVING SUFFICIENT COOLING BECAUSE OF A HEAVY FOAM PAD THAT RESTRICTS AIR FLOE AROUND THE ENGINE CAUSING THE HEAD TO FLEX AND LEAK AT THE GASKET SEAL BASED ON ONLINE COMPLAINTS THERE ARE HUNDREDS, IF NOT THOUSANDS OF OWNERS WITH THIS SAME PROBLEM. SEEMS THAT SOME OF THESE ENGINES ARE HAVING SUCCESS BY DRILLING, TAPPING AND INSERTING NEW COILS INTO THE ALUMINUM BLOCK, WHICH MAY OR MAY NOT BE A PERMANENT SOLUTION. IT SEEMS THAT TOYOTA IS AWARE OF THE PROBLEM AND REFUSES TO REPAIR THE DAMAGE. THE MOST COMMON SUGGESTED REPAIR IS TO REPLACE THE MOTOR AND WE ASSUME THAT THEY PROBLEM WILL HAPPEN AGAIN SINCE THEY HAVE REDESIGNED THE PROBLEM.. REPLACEMENT IS AT THE OWNERS COST FOR MATERIALS AND LABOR AT APPROX $6,000-$8,000.

WAS DRIVING ON THE HIGHWAY ABOUT 60-65 MPH WHEN ENGINE BEGAN OVER HEATING. PULL OVER RADIATOR WAS LOW. PUT ANTIFREEZE IN DROVE HOME CHECK WAS ALLOW AGAIN. THE NEXT CALLED TOYOTA DEALER, WITH OUT EVEN LOOKING THEY SAID YOU PROBABLY HAVE A BLOWN HEAD GASKET. BUT WHEN WE TEAR IT DOWN AND IF THE HEAD BOLTS ARE STRIPPED OUT IT WILL COST UPWARDS OF 2000.00. SO NOW I HAVE THE CAR IN AN INDEPENDENT SHOP. I'M OUT ALMOST 800.00 NOW, AND THE CARS STILL NOT FIXED. I BELIEVE TOYOTA KNEW ABOUT THIS PROBLEM LONG BEFORE I BOUGHT THIS CAR. I WENT ON THE INTERNET AND FOUND THE HAS BEEN HAPPENING IN 2001-2006 MODELS.I THINK THEY SHOULD BE HELD RESPONSIBLE. *TR

MY CAR BEGAN OVERHEATING AT 140K MILES. TOOK IT TO A MECHANIC AND HAD THE WATER PUMP AND THERMOSTAT REPLACED. THE CAR OVERHEATED AGAIN A WEEK LATER. TOOK IT BACK TO THE MECHANIC AND HE TOLD ME THE HEAD GASKET WAS BLOWN AND HAD TO BE REPLACED. WHEN HE WENT TO REPLACE THE GASKET HE FOUND THAT THREE HEAD BOLTS WERE STRIPPED ON THE BLOCK. THE CYLINDER HEAD BOLTS SEPARATING FROM LOWER PART OF ENGINE BLOCK CAUSED A COOLANT LEAK. THIS IS OBVIOUSLY A MANUFACTURING ERROR. THIS CAR WAS BOUGHT BRAND NEW AND HAS BEEN DRIVEN BY THE SOLE OWNER. HAD OIL CHANGES EVERY 3,000 MILES AND NEVER HAD AN ISSUE BEFORE NOW. PLEASE PLACE A RECALL FOR THIS DEFECT. THIS IS NOT THE OWNERS FAULT, NOR SHOULD IT BE THEIR RESPONSIBILITY. *TR

AS SHOWN ON YOUR COMPLAINT SECTION I AMONG MANY MANY OTHERS HAVE BEEN SOLD A DEFECTIVE 2.4 LITER ENGINE 4 CYLINDER. THE HEAD BOLTS BECOME STRIPPED AND MIGRATE LOOSE OVER TIME AND THERE IS NO REPAIR SOLUTION. YOU HAVE TO SCRAP THE ENGINE AND MAYBE THE WHOLE VEHICLE NO MATTER HOW GOOD OF CONDITION ITS IN. THIS PROBLEM CAUSES A BLOWN HEAD GASKET AND RESULTING MAJOR LEAKAGE OF ANTIFREEZE WHICH IS A LIFE THREATENING CHEMICAL BABIES AND PETS DRINK AND DIE FROM. I FIRST FOUND THIS POOL OF ANTIFREEZE ON MY GARAGE FLOOR AND I HAVE 2 DOGS! NOT TO MENTION GETTING STRANDED OUT IN TRAFFIC OR A DESOLATE AREA WHEN ENGINE OVERHEATING OCCURS PUTTING YOUR OWN LIFE IN DANGER FROM BECOMING A STRANDED MOTORIST. *TR

VEHICLE HAD LOST SOME WATER/COOLANT AND BEGAN TO GET HOT. REPLACED FLUID AND DROVE HOME. KEPT LOOSING FLUID, SO I TOOK IT TO THE SHOP. THEY THOUGHT IT HAD A BLOWN HEAD GASKET. TOOK IT TO ANOTHER SHOP WHICH DISCOVERED THAT 3-4 OF THE HEAD BOLTS ARE STRIPPED; THEY ARE STEEL AND THE BLOCK IS ALUMINUM. REPAIR KIT EXISTS AND HAS BEEN ORDERED. SO, TOYOTA MUST KNOW ABOUT THIS PROBLEM AND COULD HAVE ISSUED AN ADVISORY TO ALL OWNERS. EXPECTED THIS MOTOR TO LAST 150-250 THOU MILES, BUT THIS IS A BUILT IN PROBLEM THAT COULD HAVE BEEN AVOIDED. TOYOTA SHOULD COVER THE REPAIR COSTS. *TR

THE ENGINE OVERHEATED DESPITE THE NO INDICATION OF HIGH TEMPERATURES FROM THE TEMPERATURE GAUGE. WE HAD IT TOWED TO THE DEALER WHO MISDIAGNOSED IT INITIALLY. WE THEN DROVE IT BACK FROM DEALER (7 MILES) TO OUR HOME AND IT OVERHEATED AGAIN. NOW THE DEALER SAYS AT A BARE MINIMUM THE HEAD GASKET NEEDS REPLACEMENT ($3200) AND IT COULD NEW AN ENTIRELY NEW ENGINE. I DON'T KNOW HOW THIS IS POSSIBLE AT 86,000 MILES. AFTER DOING SOME RESEARCH I HAVE FOUND OTHERS WITH THIS PROBLEM ESPECIALLY 4 CYLINDERS BUT IT IS NOT RECALL. PLEASE HELP, I AM UNEMPLOYED AND NEED THIS CAR! *TR

THE THREADS IN THE ENGINE BLOCK BECAME STRIPED LEAKING COOLANT INTO THE ENGINE/PISTONS. RECOMMENDATION WAS TO REPLACE THE ENGINE. *TR

VEHICLE BEGAN LEAKING COOLANT FROM THE CENTER OF THE ENGINE. NO WARNING LIGHTS OR SENSORS HAVE GONE OFF PERIOD. CALLED TOYOTA DEALERSHIP AND MANUFACTURE LINE AND BOTH TOLD ME THEY HAVE NEVER HEARD OF THE PROBLEM, WHICH IS UNTRUE I FOUND HUNDREDS OF INDIVIDUALS WITH THE SAME ISSUE. *TR

THE THREADS IN THE ENGINE BLOCK BECAME STRIPED LEAKING COOLANT INTO THE ENGINE/PISTONS, BLOWING THE HEAD GASKET. *TR

TL* THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. THE CONTACT STATED THAT WHILE AT THE DEALER FOR ROUTINE MAINTENANCE, THE TECHNICIAN NOTICED THAT THE FRONT DIFFERENTIAL WAS LEAKING FLUID ONTO THE EXHAUST. THE TECHNICIAN ADVISED THE CONTACT THAT THE SEAL AND THE GASKETS FOR THE FRONT DIFFERENTIAL WOULD HAVE TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 113,000.

ENGINE WAS LEAKING COOLANT. CAR WAS BROUGHT TO REPAIR SHOP WHERE IT WAS DISCOVERED THAT THE ENGINE CYLINDER'S HEAD BOLTS WERE STRIPPED CAUSING THE LEAK. LATER WAS INFORMED DAMAGE WAS DUE TO THE PLACEMENT OF THE INSULATION FOAM RUBBER PIECE BETWEEN THE INTAKE MANIFOLD AND THE ENGINE BLOCK THAT CREATED AN UNEVEN DISPERSION OF HEAT, CREATING FATIGUE IN THE ALUMINUM BLOCK ALLOWING THE HEADBOLT TO STRIP. CONTACTED TOYOTA WHO REFUSED TO ACKNOWLEDGE MANUFACTURING DEFECT. REPAIRS TOTALED $2,000 DUE TO THIS MANUFACTURING ERROR. *TR

TL* THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. THE CONTACT STATED THAT SHE NOTICED A LEAK FROM UNDER THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSIS WHO STATED THAT THE LEAKING FLUID WAS ANTIFREEZE. THE CONTACT WAS ALSO ADVISED THAT THE CYLINDER HEAD BOLTS AND THREADS WOULD NEED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS CONTACTED BUT PROVIDED NO ASSISTANCE. THE FAILURE AND THE CURRENT MILEAGE WAS 103,000. THE CONSUMER STATED THERE IS A SAFETY ISSUE WITH THE VEHICLE, DUE TO POOR MANUFACTURING AND CHEAP MATERIAL OF THE HEAD BOLTS UNDER THE ENGINE. COOLANT WAS LEAKING AND CAUSED THE ENGINE TO SEIZE. UPDATED 11/29/12 UPDATED 11/27/12 *CN THE CONSUMER STATED THIS MALFUNCTION OF THE VEHICLE COULD HAVE CAUSED THE ENGINE TO SEIZE AND OVER HEAT RESULTING IN A PERSON BEING STRANDED. UPDATED 12/10/2012 *JS

TL* THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. THE CONTACT STARTED THE VEHICLE AND THE CHECK ENGINE AND VOC WARNING LIGHTS ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHO INSPECTED THE VEHICLE AND ADVISED THAT THE CRANKSHAFT PULLEY NEEDED TO BE REPLACED. THE DEALER ADVISED THAT THERE WAS A CRACK IN THE PULLEY THAT COULD CAUSE THE POWER STEERING PUMP TO BECOME COMPROMISED. THE CONTACT REFERENCED NHTSA CAMPAIGN ID NUMBER: 11V539000, (ENGINE AND ENGINE COOLING) BUT THE VIN WAS NOT INCLUDED. THE VEHICLE WAS TAKEN TO A MECHANIC WHO ALSO INFORMED HER THAT THE CRANKSHAFT PULLEY NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE WHO CONFIRMED THAT THE VEHICLE WAS NOT UNDER RECALL. THE CONTACT FILED A COMPLAINT WITH THE MANUFACTURER WHO OFFERED NO FURTHER ASSISTANT. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 90,000.

COOLANT LOSS DUE TO STRIPPED HEAD BOLTS IN THE ENGINE BLOCK. NO SMOKE OR HEAT OR WARNING ON DASH. HAVE TO CHANGE ENGINE BLOCK COSTING $6,000 FOR PARTS AND REPAIR. DEALER NOT RESPONDING. ALWAYS HAVE RECEIVED MAINTENANCE WITH THE SAME DEALER/SERVICE CENTER. *TR

MY CAR STARTED HEATING UP AS I ACCELERATED ONTO THE HIGHWAY. I SAW THE DIAL GOING INTO THE RED ZONE. I PULLED OFF THE HIGHWAY AND WAS TOWED AT MY EXPENSE TO HILLTOP RICHMOND TOYOTA. I WAS TOLD THAT AFTERNOON THAT THE HEAD GASKET AND THE WATER PUMP BOTH BLEW OUT. I NOW HAVE A $2,500 REPAIR ON MY HANDS. AFTER RESEARCHING THIS I FOUND THAT THIS IS HAPPENING TO MANY TOYOTA OWNERS AND THAT WAS VERIFIED BY THE DEALERSHIP PERSON AS WELL. TOYOTA IS USING BOLTS THAT STRIP WHICH CAUSE THE HEAD GASKET TO FAIL. THERE ARE ALSO SEVERAL REPORTS ABOUT A FOAM PIECE IN THE BLOCK THAT ALSO FAILS AS IT IS FAULTY AS WELL. *TR

COOLANT LOSS DUE TO STRIPPED HEAD BOLTS IN THE ENGINE BLOCK. ENGINE OVER HEATED. NO HEAT.*TR

TL*THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. WHILE DRIVING APPROXIMATELY 40 MPH, THE CONTACT NOTICED THAT THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO INFORMED THE CONTACT THAT THE CYLINDER BEHIND THE INTAKE MANIFOLD WAS LEAKING AND THAT SHE WOULD NEED TO REPLACE THE ENGINE. THE DEALER ADVISED THE CONTACT THAT SINCE THE VEHICLE WAS NO LONGER UNDER WARRANTY THEY WOULD NOT BE ABLE TO PROVIDE HER WITH ANY ASSISTANCE. THE MANUFACTURER WAS NOTIFIED AND THE CONTACT WAS WAITING FOR A RESPONSE. THE VEHICLE WAS NOT REPAIRED DUE TO THE COST. THE CURRENT AND FAILURE MILEAGE WAS APPROXIMATELY 78,000.

TL*THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. THE CONTACT WAS DRIVING APPROXIMATELY 45 MPH, AND NOTICED THAT THE TEMPERATURE GAUGE RAPIDLY INCREASED TO HOT AND THE ENGINE BEGAN TO OVERHEAT. THERE WERE NO WARNING LIGHTS ILLUMINATED. THE CONTACT PARKED THE VEHICLE FOR ONE HOUR AND THEN RESUMED DRIVING WITHOUT THE ENGINE OVERHEATING. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR DIAGNOSTIC TESTING WHERE THEY WERE INFORMED THAT THE ENGINE BLOCK BOLTS WERE STRIPPED AND THE ENGINE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 130,000.

2004 TOYOTA HIGHLANDER. CONSUMER EXPRESSES DISCONTENT REGARDING TOYOTA *TGW THE CONSUMER STATED ON FOUR OCCASIONS, THE VEHICLE STALLED IN HEAVY TRAFFIC. ON THE FOURTH OCCASION, IT NOT ONLY STALLED, BUT ROLLED BACKWARDS INTO ANOTHER VEHICLE BEHIND THE CONSUMER. THE CONSUMER HAS SINCE TRADED THE VEHICLE. (CONSUMER DIDN'T STATE IF THERE WAS PROPERTY DAMAGE) *JB

TL*THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 MPH THE ENGINE STARTED TO OVERHEAT AND SMOKE. NONE OF THE WARNING LIGHTS APPEARED NOR DID THE TEMPERATURE GAUGE INFORM HIM THAT IT WAS GOING TO OVERHEAT. THE VEHICLE WAS INSPECTED BY A INDEPENDENT MECHANIC WHO INFORMED HIM THAT THE THREADS FROM THE ENGINE BOLT STRIPPED AND HE NEEDED TO REPLACE THE ENGINE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 151,000. THE VIN WAS UNAVAILABLE.

TL* THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. THE CONTACT STATED THAT THE VEHICLE WAS LOOSING COOLANT BECAUSE OF A FRACTURED STRIP HEAD BOLT IN THE ENGINE, CAUSING THE VEHICLE TO SMOKE AND OVERHEAT. THE VEHICLE WAS TAKEN TO THE DEALER BUT WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 95,000.

THE TEMPERATURE CONTROL ON MY 2004 TOYOTA HIGHLANDER KEEPS SWITCHING BY ITSELF FROM HOT TO COLD AND HOT AGAIN. I HAVE TO ACTUALLY TURN THE AC ON EVEN WHEN THE OUTSIDE AIR COMING IN IS MODERATE BECAUSE THE TEMPERATURE CONTROL WILL SWITCH BY ITSELF TO HOT AND I CAN'T SWITCH IT OFF. THIS OCCURS EVERY TIME I DRIVE AND MORE SO WHEN I GO OVER A BUMP OR MAKE A TURN. I TURN THE VENT ON FOR OUTSIDE AIR, BUT THE TEMPERATURE CONTROL GETS LOCKED ON TO HOT AND I CAN'T TURN IT OFF. I HAVE CALLED THE DEALER AND THEY HAVE SAID THAT IT WOULD COST AROUND $1000.00 TO FIX IT. THEY WANT TO REPLACE THE WHOLE CONTROL UNIT. I HAVE READ VARIOUS FORUMS OF NUMEROUS OWNERS HAVING THIS SAME ISSUE. IT SEEMS TO BE A PROBLEM WITH TOYOTA NOT LEAVING ENOUGH SLACK IN A RIBBON CABLE WITH 3 CONNECTIONS THAT CONNECT FROM THE CIRCUIT BOARD TO THE CONTROL KNOB. THE WIRES BREAK OFF FROM THE SOLDERING ON THE KNOB. THIS SOUNDS LIKE A KNOWN DEFECT TO ME THAT TOYOTA IS AWARE OF, BUT CHOOSES TO IGNORE. APPARENTLY A CHEAPER FIX IS TO RE-SOLDER THE CABLE, BUT THEY REFUSED TO DO THAT. I THINK THEY SHOULD BE FIXING THIS FOR FREE. THIS IS JUST ANOTHER EXAMPLE OF TOYOTA IGNORING KNOWN ISSUES WITH THEIR VEHICLES. *TR

COOLANT LOSS DUE TO STRIPPED HEAD BOLTS IN THE ENGINE BLOCK. ENGINE OVER HEATED. *TR

I HAVE HAD TO HAVE MY EMISSION SYSTEM/CATALYTIC CONVERTER REPLACED TWICE NOW. THE FIRST TIME WAS IN 2004, WITHIN THE FIRST 6 MONTHS OF OWNING THE VEHICLE AND THE MOST RECENT TIME WAS MAY 2008. *TR EACH TIME THE SYMPTOM WAS A SULFUR SMELL THAT I UNDERSTAND FROM THE DEALER HAPPENS TO SOME 2004 TOYOTA HIGHLANDERS.

WHILE RESEARCHING ANOTHER MATTER CONCERNING MY 2004 TOYOTA HIGHLANDER ON YOUR SITE, I READ COMPLAINT #10161055 CONCERNING A HESITATION PROBLEM THE OWNER WAS HAVING AND WANTED TO SAY THAT I HAVE EXPERIENCED THE SAME PROBLEM. IT IS NOT CONSTANT, HOWEVER IT DOES HAPPEN FREQUENTLY. *JB

THERE IS A SULFUR SMELL WHEN I STOP OR BACK UP ON HILLS. THE DEALER SAID THAT THEY WOULD REPLACE THE CATALYTIC CONVERTER (PARTS ARE ON ORDER) AND THAT THIS WAS A DEFECT IN SOME VEHICLES. IF AN OWNER MENTIONS THE SMELL, THEY DO THE REPAIR UNDER WARRANTY. SHOULDN'T OWNERS BE MADE AWARE OF THE PROBLEM? *NM

DT: THE CONTACT STATED WHILE PULLING INTO A PARKING SLOT HEARD A GRINDING NOISE FOLLOWED BY THE VEHICLE LURCHING INTO ANOTHER PARKED VEHICLE. HE TOOK THE VEHICLE TO THE DEALER. THE DEALER COULD NOT DUPLICATE THE SUDDEN ACCELERATION. THE DEALER REPLACED THE MASS AIR FLOW SENSOR, OXYGEN SENSOR, AND REPROGRAMMED THE ECU. THE DEALER COULD NOT DETERMINE WHAT CAUSED THIS PROBLEM. *AK

MY 2004 TOYOTA HIGHLANDER HESITATES FOR A COUPLE OF SECONDS WHEN I ACCELERATE FROM ABOUT 40 TO 50 MPH SUCH AS GETTING ONTO A FREEWAY. I HAVE NEVER EXPERIENCED THIS IN ANY OTHER VEHICLE. I FIND THIS HESITATION TO BE VERY DISCONCERTING AND MAKES ME WORRY ABOUT MERGING INTO TRAFFIC. *JB

INDICATOR LIGHTS ON DASH SAY CONTACT YOUR DEALER. ONE IS THE TIRE PRESSURE AND THE OTHER IS THE ENGINE. HAVE CARRIED TO DEALER 3 TIMES AND STILL OCCURS. THEY ARE SUPPOSED TO PICKUP TOMORROW AND CORRECT TIRE PRESSURE LIGHT. ONLY LISTED LAST DATE

EXCESSIVE SULFUR DIOXIDE IN 2004 V6 TOYOTA HIGHLANDER, THERE IS ALREADY A TSB ON THE V4, BUT I OWN A V6 AND HAVE HAD THIS PROBLEM FOR ALMOST A YEAR NOW (STOP AND GO AND ACCELERATION, THERE IS A ROTTEN-EGG SMELL). I'VE BEEN TOLD BY 2 TOYOTA SERVICE STATIONS THAT IT IS THE GAS. THIS IS DEFINITELY NOT THE CASE. I'VE TRIED EVERY TYPE OF GAS AVAILABLE.

ENGINE HESITATION AND DELAYED ACCELERATION. *NM