2004 Toyota Highlander: engine overheating

Filed Sep 26, 2015 · Engine · 150,000 miles · CA

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.

Filed Feb 4, 2015 · Engine · 140,000 miles · TN

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.

Filed Dec 4, 2014 · Engine · 225,100 miles · MI

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.

Filed Jul 14, 2014 · Electrical, Lights · 139,664 miles · VA

I noticed that my original equipment/manufacturer passenger-side low-beam headlight lens had a burnt spot on the inside of the lens (clearly melted lens material). I checked the headlight bulb, which is a factory-installed kaito model hb3 low-beam bulb. The bulb was discolored black and smoky looking with an obvious bulge of melted glass in one side of the bulb. The low-beam headlights still work, but the bulb seemingly has overheated, melting both the bulb glass and the inside of the lens assembly.

Filed Apr 6, 2013 · Engine, Transmission · 103,500 miles · NV

Vehicle was driven normally and parked. While parked, owner noticed small leak under front axle, investigated and leak appeared to be transmission fluid or antifreeze. Owner drove vehicle next day, parked and noticed leak was larger. Owner took vehicle to dealer next morning and was told the head gasket was failing. Dealer said alternatives were to repair head gasket ($3200+), replace engine or buy another vehicle. Owner declined repair and took vehicle to independent mechanic, who confirmed head gasket leak and recommended either sealant ($250) or head gasket repair ($1200). Owner chose sealant. About four days after sealant fix, owner was driving vehicle and stopped at a starbucks drive-through. Minutes into the wait, the vehicles temp gauge began to climb rapidly. Owner revved engine and temp declined. Owner drove vehicle home and inspected engine, discovered coolant had begun to spray from overflow reservoir. Owner let vehicle cool. Next day, owner drove vehicle at modest speed across town, watching the temp gauge. Temp would increase incrementally, then decline, but no overheating appeared. Third day, owner did same, but this time, as owner approached his home, the temp gauge shot to red. Owner parked in driveway, opened hood and found overflow reservoir bubbling, coolant spray and overflow on frame. Prior to these incidents, about one year ago the owner had been told by toyota dealer that a few engine mounts were cracked and needed replacement, which was done. No other major repairs or issues have existed with vehicle. Vehicle is not 10 years old, its 103,500 miles has been generally light highway and short-distance city driving. Oil and other maintenance has been routinely performed.

Filed Mar 14, 2013 · Engine · 86,000 miles · CT

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!

Filed Mar 2, 2012 · Engine · 100,449 miles · PR

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.

Filed Feb 17, 2011 · Engine · 118,000 miles · PA

Coolant loss due to stripped head bolts in the engine block. Engine over heated. No heat.

Filed Jan 11, 2011 · Engine · 130,000 miles · KY

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.

Filed Dec 20, 2010 · Engine · 151,000 miles · NH

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.

Filed Dec 14, 2010 · Engine · 95,000 miles · TX · fire

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.

Filed Nov 12, 2010 · Lights · 73,000 miles · IN

Recently discovered two white melted bumps in the exact center of the headlamp casing where the daytime running lamp beams pass through the plastic. Have only had the vehicle since july 2010 and the incident occured during a 19 hour drive, most of which took place during daylight hours. Headlights were not turned on until sunset. Concerned that factory lights are hot enough to melt the plastic that is factory installed. Obvious defect, could cause fire. Impaired vision at night also a result as plastic is now permanently damaged. Also concerned that issue could worsen and hole could appear, causing rain and elements to come in direct contact with lighting system. Another obvious danger. Disengaging daytime lights is not an option, no control over overheating other to turn on headlights 100% of time. Also concerned with this solution, as defect could potentially be similar in these as well. Attempted to have dealer look at problem, however warrantly period has expired. After researching online, found several similar instances on models ranging from 2004-2007. Feel strongly that issue should be investigated as passenger saftey is at risk.