Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Toyota Sienna owners, lightly cleaned up (personal details are redacted by NHTSA).
Was driving on highway at 60-65 mph. The car continued to accelerate. Pressed on brake and wasn't slowing the vehicle. The driver was weaving in and out of cars as the van started to creek up to 92 mph. The driver and passengers thought they were going to crash and possible die. The driver tried the brake multiple times and nothing. The driver said the accelerator pedal wasn't pressed all the way down to the floor. It was half way and driver had to go down and pull up on the pedal while driving. The van then started to slow and driver was able to pull over to have the van evaluated . The throttle body was reached and cleaned of carbon because it said that this may have been part of the issue. Never has this van taken off like this. The throttle body cable wasnt loose or disconnected either. So far we havent been able to recreate but 3 people could have been killed.
Drivers side seat belt broke and was replaced. Fuel sensor not replaced causes vehicle to hesitate at times at freeway speed
Radiator ruptured and the engine overheated; hose replaced in steering column recall; rust protective tape recall; dvd screen replaced and the entire dvd player replaced(screen still not easily visible in middle row); passenger seat belt replaced; middle passenger seat belt failing; gasoline smell inside of car with ac on recirculation; driver's window fell inside door in snow storm and was not considered a safety issue to get a loaner vehicle even though the vehicle could not be locked; tires completely bald and leaking under 30,000 miles, dvd player must be at a high db volume and when returned to radio/cd will almost deafen you; interior lights have to be manually over ridden or will drain battery; car hesitates 1-2 seconds when trying to quickly accelerate and then lurches forward alarmingly; cruise control is not functioning; waiting to have fuel mixture sensor replaced. …
I wrote to Toyota sept. 7, 2007, concerning an acceleration problem with my 2004 Sienna minivan, following many visits to the dealer to evaluate and fix it. The throttle response is delayed, in my case; it lags during initial acceleration from a stop, but more importantly, it lags when immediate acceleration is needed for passing, and accelerating after slowing for a turn. The factory rep who responded to my letter said the dealer would reevaluate the problem. The dealer rep drove the van, experienced the same problem, and concluded it was a "quirk" of the car, that could not be fixed unless, perhaps, the computer controlling the throttle was replaced. They would not do that unless a recall was ordered, he said. Needless to say, I thought that was the final word, until other problems began to surface with the "fly by wire" system in toyotas. …
"clunking" noise noted on steering the 2004 Toyota Sienna just a few months after it was bought. It had gone through 3 recalls already when first the fuel tank, then the door sills, then the middle row seatbelt bezel, and finally recently, the rear hatch struts were all replaced. Vehicle was test driven, but no mention of "clunking" documented. However, all this time, the clunking had become more noticeable, and vehicle had gone through 2 alignments already, with only about 42,000 miles on it. Last serviced for alignment, dealer did note clunking and recommended replacement of intermediate steering shaft. It is now becoming more difficult to steer the vehicle, especially at low speeds, and "k-turns" now require more maneuvers, and the steering radius has increased potentially causing collisions with objects or pedestrians if compensatory action is not initiated. …
I attempted to merge onto the expressway and after pushing the gas pedal the van suddenly accelerated beyond my control. I eased off the pedal and the van continued to serge ahead with no way for me to stop or slow it down as the brakes would not work. I saw the RPM reach level 6 and speed increase to 70 in seconds but as it was the expressway, I was able to keep my distance from cars in front of me. I switched the lever to the neutral position and the van slowed down and then I went back to drive and it roared back up to 70 MPH with the RPM again at 6 and I tried turning the cruise control on and then braking to see if it would shut down the gas but no luck. I went back and forth from d to n for about 2 minutes and then on one of the movements from n to d it shut down back to normal. …
Toyota, Sienna 2004. Vehicle was taken to dealer on a recall to replace the fuel tank. Consumer picked up vehicle and filled tank, and gas leak out to the ground. Consumer believed that the fuel tank had a defective gasket or seal. A week after the recall was performed, the service engine and cvs lights illuminated. It turned out that the gas cap wasn't placed on properly. Consumer's husband fueled the vehicle and gas began to spill out. Not where the nozzle go in but underneath the van. Gas fumes started penetrating throughout the vehicle. Consumer evacuated her 4 year old and newborn. The next day vehicle was take to the dealer. Mechanic was made aware the previous day events and emptied the gas tank. The mechanic found the seal was either installed wrong or it became dislodged where the recall was performed. This was the cause of the leaking.
Sudden massive fuel leakage under my new 2004 Toyota Sienna Mini van under normal operation condition. I bought a new 2004 Toyota Sienna from the dealer in March 2003. When I stopped the vehicle at a traffic light, all of a sudden a massive fuel leakage under the vehicle. The fume of the fuel filled up the passenger compartment. All passengers needed to be immedately exited the vehicle. The vehicle has less than 1400 miles and did not have any accident or even a slight impact before. Before the incident, the vehicle has been fixed by the dealer for a recent Toyota recall for fuel tank issue. The vehicle has been towed back to the nearest dealer for further investigation.
On my 2004 Toyota Sienna minivan the rear hatchback gas struts have failed. This is a dangerous situation that could easily get a small child killed. I almost had this happen when my 5 year old was helping to get groceries out while I was holding the gate open it slipped and came crashing down. Luckily he had just moved and it missed him. These gas struts are a recall item on the power operated lift gates, why aren't they on the manual ones. And the cost of replacements is terrible, $180/ea. [redacted]
Massive gasoline leak under driver side. The entire car was filled with fume from the gasoline. We and the kids had to exit the van asap. Van has to be towed to the dealer. We bought this van on May 2003 and during October we brought this van back to the dealer to have the gas tank replace because of a recall by the manufacturer. We have no accident with this van and we keep the van in top condition. We are really concern on what had happened.
Related recalls
Fuel system, gasoline › Storage › Tank assembly
On certain sport utility vehicles, a part of the fuel tank May become damaged when crashed in the insurance institute for highway safety's (iihs) 40 MPH frontal offset crash test conditions, due to the severe impact forces generated.
Remedy: Dealers will replace the fuel tank. Owner notification began August 1, 2003. Owners should contact Toyota at 1-800-331-4331.
Fuel System complaints in other Sienna years
Frequently asked questions
How common are fuel system problems on the 2004 Toyota Sienna?
NHTSA has 49 complaints about the fuel & propulsion system of the 2004 Toyota Sienna, 2% of the model year's 2,062 complaints. The component named most often is storage › tank assembly (26 mentions).
Is there a recall for 2004 Toyota Sienna fuel system problems?
Yes — NHTSA recall 03V-291 (tank assembly, Aug 12, 2003). Recall repairs are free at authorized dealers.
At what mileage do 2004 Toyota Sienna fuel system problems start?
Half of the complaints with a recorded mileage happened before about 10,000 miles, and 74% before 25,000 miles.
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.