What are the most common Toyota Highlander problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2002-2002 Toyota Highlander has 1 documented issues. The most frequently reported are: 2.4L 2AZ-FE Head Gasket and Head Bolt Thread Failure. Of these, 1 is rated critical and should be addressed promptly.

Is the Toyota Highlander reliable?

The 2002-2002 Toyota Highlander has 1 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 1 issue is rated critical: 2.4L 2AZ-FE Head Gasket and Head Bolt Thread Failure. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Toyota Highlander problems?

Repair costs for known Toyota Highlander issues range from $2,500 to $5,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 2.4L 2AZ-FE Head Gasket and Head Bolt Thread Failure, typically costs $2,500-$5,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

2002 Toyota Highlander Problems: 1 Issues Every Owner Should Know

2002 Toyota Highlander Problems: 1 Issues Every Owner Should Know | Au7o

All 1 Known Issues

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On the 2001-2007 Toyota Highlander 2.4L 2AZ-FE, the 2001-2007 Highlander with the 2.4L 2AZ-FE 4-cylinder engine suffers from a design flaw where the aluminum head bolt threads strip out of the engine block. The plastic intake manifold traps heat against the block, causing thermal fatigue of the aluminum threads. This leads to head gasket failure, coolant leaks, and overheating. In severe cases, the stripped threads make a simple head gasket replacement impossible, requiring thread repair inserts (Time-Serts) or complete engine replacement. This is a known issue across Toyota vehicles using the 2AZ-FE engine.

This issue also affects: Acura MDX, Acura TL, Audi Q7

Common Symptoms

Coolant loss without visible external leaks
White sweet-smelling exhaust smoke
Engine overheating
Chocolate milk appearance of oil (coolant mixing)
Oil level higher than normal
Rough running or hard starting when cold
Coolant bubbling in overflow tank

How to Fix

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

UpgradeMulti-layer steel head gasket set for a reliable, long-lasting seal (Fel-Pro Head Gasket Set)
View on Amazon
UpgradeHigh-strength head studs provide even clamping force and prevent repeat failures (ARP Head Stud Kit)
View on Amazon

Typical repair cost:$2,500 - $5,000

Research This Issue

0+ owners have reported this issue

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Community Reported

Medium Confidence0 reportsLast reported by owners Invalid DateReviewed Invalid Date

⚠️NHTSA Recalls11 recalls

SEATS:FRONT ASSEMBLY:SEAT HEATER/COOLER

Southeast Toyota Distributors, LLC (SET) is recalling certain 2005-2011 4Runner, Highlander, Sequoia, and Sienna, 2005-2010 Avalon and Tundra, 2006-2008 Camry Solara, 2006-2010 Highlander hybrid, 2006-2011 Rav4 and Tacoma, 2007-2010 FJ Cruiser, 2007-2011 Camry hybrid, 2009-2010 Venza, 2010-2012 Prius, 1988-1990 and 2005-2010 Camry, and 1989 and 2009-2010 Corolla vehicles equipped with aftermarket accessory seat heaters with a copper strand heating element. The electrical wiring in the seat heaters may be damaged when the seat cushion is compressed.

Campaign #16V39600002/06/2016

ENGINE AND ENGINE COOLING

TOYOTA IS RECALLING CERTAIN MODEL YEAR 2004 AVALON VEHICLES; 2004 AND 2005 CAMRY, CAMRY SOLARA, HIGHLANDER, AND SIENNA VEHICLES, 2006 HIGHLANDER HYBRID; 2004 AND 2005 LEXUS ES330 AND RX330; AND 2006 LEXUS RX400H VEHICLES MANUFACTURED FROM JUNE 1, 2004 THROUGH MARCH 31, 2005, EQUIPPED WITH THE 1MZ-FE OR 3MZ-FE ENGINE. THE AMOUNT OF ADHESIVE AGENT APPLIED BETWEEN THE OUTER RING AND THE TORSIONAL RUBBER DAMPER (INNER RING) IN THE CRANKSHAFT PULLEY MAY BE INADEQUATE. IF THE ADHESIVE IS INSUFFICIENT, THERE IS A POSSIBILITY THAT THE OUTER RING MAY BECOME MISALIGNED AND IT MAY NOT PROPERLY ROTATE WITH THE INNER RING, CAUSING NOISE AND/OR ILLUMINATION OF THE BATTERY DISCHARGE INDICATOR LIGHT.

Campaign #11V53900009/11/2011

VEHICLE SPEED CONTROL:ACCELERATOR PEDAL

TOYOTA IS RECALLING CERTAIN MODEL YEAR 2004-2006 HIGHLANDER, HIGHLANDER HYBRID, AND MODEL YEAR 2004-2007 LEXUS RX330, RX350, AND RX400H VEHICLES. IF THE FORWARD RETENTION CLIP USED TO SECURE THE FLOOR CARPET COVER, WHICH IS LOCATED IN FRONT OF THE CENTER CONSOLE, IS NOT INSTALLED PROPERLY THE COVER MAY LEAN TOWARD THE ACCELERATOR PEDAL AND INTERFERE WITH THE ACCELERATOR PEDAL ARM.

Campaign #11V11200024/02/2011

VEHICLE SPEED CONTROL:ACCELERATOR PEDAL

ON CERTAIN SPORT UTILITY AND HYBRID VEHICLES, THE TWO RETAINING CLIPS FOR THE DRIVER'S SIDE FORWARD CENTER CONSOLE CAN BECOME LOOSE. IF BOTH CLIPS SEPARATE FROM THE FLOOR CARPET COVER, THE COVER MAY LEAN TOWARD THE ACCELERATOR PEDAL, CAUSING INTERFERENCE WITH THE ACCELERATOR PEDAL ROD.

Campaign #06V25300013/07/2006

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER

TOYOTA IS RECALLING CERTAIN MODEL YEAR 2005-2006 AVALON, MODEL YEAR 2004-2006 HIGHLANDER, MODEL YEAR 2004-2006 LEXUS RX, AND MODEL YEAR 2006 LEXUS GS AND IS VEHICLES. BRAKE FLUID CONTAINING POLYMERS IS USED THAT ACTS AS LUBRICANTS FOR CERTAIN BRAKE SYSTEM COMPONENTS. IF REPLACEMENT BRAKE FLUID IS USED THAT DOES NOT CONTAIN SUCH POLYMERS, OR THAT CONTAINS ONLY SMALL AMOUNTS, A PART OF THE RUBBER SEAL LOCATED AT THE REAR OF THE BRAKE MASTER CYLINDER MAY BECOME DRY, AND THE SEAL MAY CURL DURING MOVEMENT OF THE PISTON. IF THIS OCCURS, A SMALL AMOUNT OF BRAKE FLUID COULD SLOWLY LEAK FROM THE SEAL INTO THE BRAKE BOOSTER.

Campaign #10V49900021/10/2010

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2002 Toyota Highlander Problems: 1 Issues Every Owner Should Know

All 1 Known Issues

2001-2007 Toyota Highlander: 2.4L 2AZ-FE Head Gasket and Head Bolt Thread Failure#