Engine Exhaust System Problems of Toyota Highlander

The contact owns a 2015 Toyota Highlander. While driving approximately 65 mph, the subframe fractured due to the rear bolts on the frame being too tight. The vehicle was towed to a dealer where it was diagnosed that the rear bolts were not properly installed from the factory associated with the torque. The dealer inspected the subframe and stated that it did not need to be replaced. The dealer replaced the rear hybrid drive motor, rear differential, the entire exhaust system from the motor to the muffler, and the driver side suspension control arm. The contact stated that the subframe needed to be further inspected and replaced. The contact also waited longer than two weeks for the parts to receive the repairs due to the failure. The vehicle was repaired and the contact took the vehicle to another dealer who inspected the frame. The second dealer, a manufacturer's technician, further inspected the vehicle and stated that the subframe was cracked. The technician stated that the contact had the option of receiving a repair of the frame being welded or various parts would need to be removed to replace the subframe, which was an extensive repair. The contact was uncertain of the best course of action to permanently repair the condition. The VIN was not available. The approximate failure mileage was 11,562.

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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.

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Valve springs. While driving at 65 mph the vehicle stalled without warning. I managed to steer across 4 lanes of fast traffic to a complete stop. The car was towed to the closest Toyota dealer and was diagnosed as piston failure. The car was towed 140 miles to motorcars Toyota for repair. The technician inspected and diagnosed: "a valve spring on the #2 cylinder broke in front head and dropped into the # 2 cylinder, destroying the piston and severely damaging the short block assembly. Block had a hole in it and #2 piston was broken in half". Repair included: replacing short block assembly, front head, exhaust cam, valve, spring. I had to pay aprox. $6000 for a problem Toyota publicly admitted some 2008 v8 models had. Faulty valve springs was actually a recall but only for Lexus models. Not fair!.

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A couple of months ago white smoke emitted from the exhaust pipe. Last week, on a trip within 400 miles of my home, the engine and vsc light came on intermittently. I immediately called Toyota and was told that the car could stop suddenly and leave us stranded so I made an appt for Monday morning. The car rode very rough for the last two hours and it seemed as if it is ready to stall anytime. Toyota charged me $ 321. 00 for a compression and diagnostics test. Toyota found that I had low compression. Toyota also offered to take apart my engine for 2667. 00 to see if the rings were damaged. I refused the work and picked up my car. We called an engine repair business. The owner knew the make, model and year of my car and asked if we had just hit the 100,000 mile marker. We had. He told us of the oil sludge problem, settlement and faulty aluminum engines. I have researched similar characteristics with the Highlander and see that it is a common problem for the 2002 Highlander. The sludge situation would only be covered if it was within 8 years of the purchase date. What about the many consumers who still have this problem and it is past the eight years? I bought this Highlander in 2005, had it serviced regularly and we also changed the oil ourselves. In 2008 I brought the car into the Toyota dealership for a tune up and an oil change prior to a long trip. On the way home, the engine light came on and we pulled over to a local gas station and there was literally no oil in my engine. Toyota did the oil change but did not put 5 quarts of oil into my car for this long trip. When I returned I did confront the dealership but they denied any wrongdoing. We have, since that time period had to add oil continuously. It turns out that I will need to replace my engine for 4500. 00.

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My 2003 Highlander heat gage indicated the engine was starting to get hot. I pull into service station to check coolant level and noticed coolant leaking on the ground. I waited for about 15 minutes to assure myself it was safe to take off the radiator cap. I could not see any coolant so, I purchased a gallon of pre-mixed coolant and poured in about 1/2 to 3/4 gallon to bring it up to full. I made the trip home without the car getting hot, but noticed the leak was still there. I had the vehicle looked at by a local Toyota dealer and was told the car needed major repairs. There is a technical support bullitin on the engine in question. A 2. 4 litre (4 cylinder) engine common on camarys and Highlanders. I feel Toyota should have to repair this vehicle in light of the fact Toyota has known of the design defect on other models (camary and Highlanders). When I took the car in for repairs the service scheduler knew exactly what problem I was describing to him about my car. This indicated to me, Toyota has informed their dealers of the problem or, they wouldn't have sent a service bullitin on the very fix to my cars problem. The service bullitin described (3) head bolts around the intake manifold would stretch and fail to seal the head thus, leak coolant. The bullitin even describes installing heli-coils in the (3) affected bolts to solve the problem. This appears to be another failure of Toyota taking responsibility for known defects in their automobiles. I bought and paid for this vehicle in good faith on the reliability record of the Toyota company's past record. I now feel I have been treated unfairly by this company. I would understand if this was an isolated occurance, but it is not and Toyota knows this full well. Service bullitins don't get sent to all dealers for a single occurance. Please help !.

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Brand new 2009 Toyota Highlander defective front O2 sensor made out of ceramic built into all cars in japan then shipped to u. S. First sign of sensor damage the cars traction control light goes on. Soon after the front O2 ceramic sensor heats up. Then the car will not start. When you try to start it up at this point engine has caught on fire. The general manager of dealership stated that Toyota knows of this defective part but will not recall. We believe owners should be notified. The part was replaced. However, we did not feel car was safe after seeing engine on fire. The dealership would not refund money. Our only option allowed was to trade in car for another at our cost. This all happened within 3 days of taking delivery of the vehicle and having only driven it 40 miles.

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Replacement of a charcoal canister on a 2003 Toyota Highlander. No accidents occurred as a result of the replacement of this part; however, I am concerned about the number of reports of having to replace this very expensive part. Also if the part is a safety hazard (may cause an engine fire) it should not be at the expense of the owner. The part is an emission control device that is surely required by the government. This action is taken because I noticed, while researching charcoal canisters that Toyotas come up frequently as having to have this type repair. At this writing I am unable to confirm the part is defective as it is the original part that came with the vehicle when I purchased it brand new. This is not a pre-owned vehicle.

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. Each time the symptom was a sulfur smell that I understand from the dealer happens to some 2004 Toyota Highlanders.

When I use the a/c and turn it off a bad odor comes from the vent . This is a new 2006 Highlander, the next day I brought it to the dealer he said take for service , they told me to drive it for a few more days . I put 1500 miles and the odor is still there . I took it for service again . The mechanic said to use a deodorizer on the vent. I am not a satisfied customer. I want this issue resolved. I paid for the Highlander not the smell that came with it.

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My 2002 Toyota Highlander's check engine light seems to come on every 10,000 miles. This has been happening since 2004, at about 43000 miles, when I first took it to a local dealer mechanic. It is now 2009, 111000 miles later, and again the check engine light comes on queue. Originally, the dealer mechanics told me they had corrected it prior to my warranty expiring. When my warranty expired, they told me that I needed to get an overhaul on my catalytic/exhaust system, which was quoted to cost about $5000 to fix! I believe my car was worth no more than $7000 at the time. An independent mechanic told me that there was nothing wrong with my catalytic system and that there may be a problem with the detection system. I've been shown how to reset the check engine light by the Toyota dealer personnel, I suspect, because it is happening to other Highlander owners. I am bringing this issue up now because it seems like a recall should have been issued years ago. I hope someone from Toyota will recognize and fix this issue.

Black smoke came out of the exhaust pipe, and vehicle consumed excessive oil. Dealership wanted to replace the valve seal and piston o-ring s, but the parts were on back order. Vehicle is at the dealership for repairs and consumer was asked to use a rental car since vehicle's parts for repair where not available at that time. Consumer received a call from dealer that vehicle was ready top be picked up. When consumer picked up the vehicle, he noticed that vehicle is once again smoking and experienced hesitation. Took vehicle to dealership and replaced the timing belt which caused the hesitation. However, the problem with the smoke coming out and occasional hesitation still exist.

Shortly after the second oil change, 10000 miles the exhaust system started making noise. It started as a loud sound from the muffler and now has become a rattling sound and loud exhaust noise. The banging/rattling sound is worst during left hand turns. Dealer stated we damaged the exhaust pipe and the brackets needed repair $175. The mechanic was unable to show me any physical damage to the exhaust system. I noticed the new Highlanders have a different and smaller muffler which does not bang into adjacent parts. I wonder if I am not the only one with this problem.