Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Toyota Highlander owners, lightly cleaned up (personal details are redacted by NHTSA).
Hello, I am the Buyer of the subject Vehicle, Upon doing my research, I found out several reports stating that The subject vehicle's 2.4L engine has manufacturing defect, that causes Head Bolts to get stripped/melt down in to oil causing Engine failures and Life threating risk in the middle of the road.
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. …
My trac off lights, engine and oil light came on when I was driving to work. I work far from home so I took it to the valvoline near my job to check the oil. I didn't want to drive my car home if there was no oil. They checked the oil, underneath my car and said everythingwas fine and to take to my mechanic to check the engine. I took it to my mechanic who kept it for 4 days and said its the oil sluge and he was trying to save the engine. My mechanic said they had a Lexus in the week before with the same problem. I checked online and found out there was recall for this problem in 2002, and Toyota only contactedthe original owners not all people who had registered cars. I bought this second hand through car max in 2010 and this should have been corrected then. My car has 145,000.00.
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.
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.
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.
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.
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.
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 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
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.
Related recalls
Engine and engine cooling
Toyota is recalling certain model year 2004 avalon vehicles; 2004 and 2005 camry, camry solara, highlander, and sienna vehicles, 2006 highlander hybrid; 2004 and 2005 Lexus es330 and rx330; and 2006 Lexus rx400h vehicles manufactured from June 1, 2004 through March 31, 2005, equipped with the 1mz-fe or 3mz-fe engine.
Remedy: Toyota will notify owners, and dealers will check the crankshaft pulley to identify whether it was produced by the U.S. Supplier. If so, the dealer will replace the pulley with a new one at no charge.
Engine complaints in other Highlander years
Frequently asked questions
How common are engine problems on the 2004 Toyota Highlander?
NHTSA has 36 complaints about the engine & cooling of the 2004 Toyota Highlander, 13% of the model year's 286 complaints. The component named most often is engine (5 mentions).
Is there a recall for 2004 Toyota Highlander engine problems?
Yes — NHTSA recall 11V-539 (engine and engine cooling, Nov 9, 2011). Recall repairs are free at authorized dealers.
At what mileage do 2004 Toyota Highlander engine problems start?
Half of the complaints with a recorded mileage happened before about 103,000 miles, and 15% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 1 fire and 0 injuries to engine & cooling problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.