NHTSA Complaint #10777806 — 2004 TOYOTA HIGHLANDER

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. SEEMS THAT SOME OF THESE ENGINES ARE HAVING SUCCESS BY DRILLING, TAPPING AND INSERTING NEW COILS INTO THE ALUMINUM BLOCK, WHICH MAY OR MAY NOT BE A PERMANENT SOLUTION. IT SEEMS THAT TOYOTA IS AWARE OF THE PROBLEM AND REFUSES TO REPAIR THE DAMAGE. THE MOST COMMON SUGGESTED REPAIR IS TO REPLACE THE MOTOR AND WE ASSUME THAT THEY PROBLEM WILL HAPPEN AGAIN SINCE THEY HAVE REDESIGNED THE PROBLEM.. REPLACEMENT IS AT THE OWNERS COST FOR MATERIALS AND LABOR AT APPROX $6,000-$8,000.