Two problems related to engine cooling system have been reported for the 2004 Toyota RAV4. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Toyota RAV4 based on all problems reported for the 2004 RAV4.
2. 4l engine was loosing coolant and overheating. I thought it was a bad water pump due to the leaking on the right side of the engine. After taking it to my local repair garage, I learned that the cause was 3 stripped out bolts holding the head onto the block. Solution. . . . New engine at $5500. Toyota refuses to acknowledge this mfg defect and a couple dealerships I talk with including the one I bought it from "never heard of this problem before" the exact same response given leads me to believe that that was what Toyota told them to say about this reoccurring problem.
On Dec. 6,2009, my Rav4 overheated and the check engine light came on. Took it to the local dealer the next day and the diagnosis was that the head gasket had blown. The course of action was to grind the valves and replace. When this was attempted, 4 bolts that attach to the engine could not be secured. The only option was a new/rebuilt engine. The cost -$3700. I have learned that other 2004 rav owners have experienced similar problems and Toyota will not stand behind their product and replace the defective parts nor help with labor costs. I have contacted their California customer service center and was told they could do nothing because I was no longer protected by a warranty. In addition to taking over 5 weeks to reach this conclusion, my car is still not repaired as I ponder what I should do. Customer satisfaction appears not to be a major concern of local dealer nor Toyota corporate.