NHTSA Complaint #10583688 — 2003 TOYOTA HIGHLANDER

HEAD GASKET BOLTS STRIPPED OUT CAUSING COOLANT TO LEAK AND LOSS OF CYLINDER COMPRESSION. THIS OCCURRED ON A TOYOTA 2.4 LITER ENGINE. THIS IS A COMMON FAILURE MODE ON THESE ENGINES DUE TO A DESIGN DEFECT. THE THREAD FATIGUES AT THE INTAKE SIDE OF THE ENGINE BECAUSE THE MANIFOLD IS PLASTIC AND THERE IS A RUBBER INSULATOR BETWEEN THE MANIFOLD AND BLOCK WHICH TRAPS THE HEAT IN THAT PART OF THE BLOCK AND FATIGUES THE ALUMINUM THREADS ON THE HEAD BOLTS. THIS HAPPENS ON MANY MODELS FROM 2001-2006 THAT UTILIZE THE TOYOTA 2.4 LITER ALUMINUM ENGINE. THIS IS A $2,500-$5,000 REPAIR. TOYOTA HAS ISSUED A SERVICE BULLETIN ON THIS. I BELIEVE THEY SHOULD HAVE SOME RESPONSIBILITY IN FIXING THIS DESIGN PROBLEM. ENGINES SHOULDN'T FAIL AT 100,000 MILES WITHOUT CAUSE SUCH AS OVERLOADING OR ABUSE. I DON'T HAVE A TOW PACKAGE AND HAVE GARAGED THIS VEHICLE. THERE WAS NO CAUSE AND EFFECT. THIS FAILURE I'VE COME TO LEARN IS COMMON FOR THIS ENGINE. *TR