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2005 Toyota Highlander engine problems

severe 11 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →

Complaints
11
Recalls
1
Avg fix
$3,100
1fire

When does it fail?

Of the 11 engine complaints filed for the 2005 Toyota Highlander, here's the actual mileage breakdown — failures cluster heaviest at 125,000-150,000 mi.

0-25k
0 (0%)
25-50k
0 (0%)
50-75k
0 (0%)
75-100k
0 (0%)
100-125k
0 (0%)
125-150k
1 (100%)
150k+
0 (0%)

Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.

What stands out

No new NHTSA engine complaint has been filed on this vehicle in over 12 years — the issue may be aging out of the active population.

Related recalls

severe NHTSA 11V539000 November 9, 2011

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

In some cases, the belt for the power steering pump may become detached from the pulley which could result in a loss of power steering and a sudden increase in steering effort, increasing the risk of a crash.

Fix: Toyota will notify owners, and dealers will check the crankshaft pulley to identify whether it was produced by the u.s. Supplier. If so, the dealer will replace the pulley with a new one at no charge. The safety recall is expected to begin during early january 2012. Owners may contact Toyota at 1-800-331-4331.

Is there a fix? Manufacturer service bulletins

The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.

Service Bulletin T-PANT-2024-004- Mar 2024

This is to advise of various price adjustments that will affect Toyota Genuine Motor Oil and Long Life Coolant, effective March 1, 2024. These products are ordered through the Toyota Complete Maintenance Care (TCMC) website.

full bulletin at NHTSA ↗
Service Bulletin DOR-M3J3F-07 Jun 2020

These SKUs are Exhaust Manifolds with Catalytic Converters. The customer communication requested return of unsold inventory due to a loss of CARB certification. These SKUs can no longer be sold as they do not meet CARB standards, but parts on vehicles are not effected.

full bulletin at NHTSA ↗
Service Bulletin DOR-M9J4S-07 Jun 2020

These SKUs are Exhaust Manifolds with Catalytic Converters. The customer communication requested return of unsold inventory due to a loss of CARB certification. These SKUs can no longer be sold as they do not meet CARB standards, but parts on vehicles are not effected.

full bulletin at NHTSA ↗
Service Bulletin T-SB-0134-16-Rev Jul 2019

TSB: REVISION NOTICE July 01, 2019 Rev2: ? Applicability has been updated to 2019 ? 2020 model year Toyota vehicles. ? The Techstream Preparation and Process Overview sections have been updated. October 30, 2017 Rev1: ? Applicability has been updated to include 2018 model year vehicles. Any previous printed versions of this bulletin should be discarded. SUPERSESSION NOTICE The information contained in this bulletin supersedes SB No. T-SB-0012-13. Service Bulletin No. T-SB-0012-13 is obsolete and any printed versions should be discarded. Be sure to review the entire content of this bulletin before proceeding. Flash reprogramming allows the Electronic Control Unit (ECU) software to be updated

full bulletin at NHTSA ↗
Service Bulletin T-SB-0134-16 Sep 2016

TSB: Supersession Notice. Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual Service Bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU?s information.

full bulletin at NHTSA ↗

Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.

The failure pattern owners describe

This batch shows serious electronic throttle management issues. Owners describe the vehicle accelerating on its own when shifting from Park to Drive, reaching 30 mph without pedal input—yet the tachometer stays at normal idle RPM, pointing to an electronic glitch rather than mechanical runaway. Multiple dealership visits found nothing reproducible.

More common is throttle hesitation: slow response when accelerating, followed by a sudden surge that catches owners off guard during merging. One owner had it happen at 20,000 miles; dealers said it's a "design feature" and reprogramming the engine control module didn't help. Another mode is outright refusal to accelerate—pedal pressed, engine won't respond for a couple of seconds. Toyota's own response to one owner was that this is "normal" for their drive-by-wire setup.

One report describes engine fire at low city speed with zero warning from gauges or lights—grill melting, hood scorched, release cable destroyed by heat. One owner reported overheating with adequate coolant and no other symptoms.

The common thread: electronic throttle and engine management faults that dealers cannot diagnose or repair, combined with one catastrophic thermal event.

Same Toyota Highlander engine reports on nearby years: 2006 · 2008

Failure modes owners describe

Unintended acceleration from stop

Vehicle accelerates on its own when shifting from Park to Drive without driver input, reaching speeds up to 30 mph. Tachometer does not show elevated engine speed while parked, suggesting electronic cause. Occurs intermittently and has been to multiple dealerships without reproduction or repair.

When: Intermittent, shift Park to Drive

Symptoms owners cite: Vehicle accelerates without gas pedal input; Reaches speeds up to 30 mph; Tachometer does not show high RPM in Park; Intermittent occurrence

Repairs/costs cited: Multiple dealership visits; issue could not be duplicated so no repair performed

Throttle hesitation and surge during acceleration

Slow throttle response when accelerating, followed by sudden lurch forward during merging and low-speed acceleration. Multiple owners report stuttering and surging behavior starting at 20,000 miles. Dealer acknowledged as 'design feature' of electronic throttle. ECM reprogramming attempted but ineffective.

When: Starting at 20,000 miles; during merging and low-speed acceleration

Symptoms owners cite: Slow throttle response after depressing pedal; Sudden lurch forward (surge); Stuttering during acceleration; Safety risk during merging

Repairs/costs cited: ECM reprogrammed under warranty without resolution; dealers unable to provide solution

Recalls/TSBs owners mention: Dealer stated issue is a design feature of electronic throttle

Acceleration refusal (limp mode)

Vehicle refuses to accelerate when pressed, lasting approximately 2 seconds before resuming. Occurs at various speeds (2 mph and 30 mph documented). Toyota stated this is a 'normal phenomenon' in their drive-by-wire systems.

When: Intermittent; during low-speed driving and at cruising speed

Symptoms owners cite: Refuses to accelerate when pedal pressed; Temporary loss of power (2-second delay); Occurs at low and cruising speeds

Repairs/costs cited: ECM recalibration attempted; issue could not be duplicated

Recalls/TSBs owners mention: Toyota stated this is a normal phenomenon in drive-by-wire systems

Hesitation during shifts and acceleration

Vehicle hesitates during acceleration and sometimes during deceleration. ECM recalibration improved shifting hesitation but reduced fuel economy. Another dealer's diagnostic showed no issues detected.

When: During acceleration and deceleration

Symptoms owners cite: Hesitation during acceleration; Hesitation during deceleration; Occurs intermittently

Repairs/costs cited: ECM recalibrated; improved shifting hesitation but reduced gas mileage

Engine fire with no warning indicators

Vehicle emitted smoke from engine hood area while driving at low city speeds. Grill and hood were melting and scorched. No trouble lights or high-temperature gauge readings preceded the incident. Fire Department unable to open hood due to melted release cable. Vehicle required towing.

When: While driving at low city speeds; no prior warning

Symptoms owners cite: Smoke from engine hood area; Melting grill and scorched hood; Extreme heat causing cable melting; No warning lights or gauge indication

Repairs/costs cited: Vehicle towed to repair facility after fire suppression

Engine overheating without coolant loss

Engine overheated while driving to pick up children from school. Coolant level full in radiator and brakes functioning normally, indicating isolated cooling system malfunction.

When: During normal driving

Symptoms owners cite: Engine overheating; Coolant level adequate; No brake issues

Synthesized from 11 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.

What owners are reporting 2 most recent

engine · 145,000 mi · filed 12/09/2013

My wife was driving our 2005 Toyota within the city limits at a low rate of speed and noticed smoke coming out of the front engine hood area. There were no trouble lights showing for the engine at the time, nor was the temperature gauge showing a high temperature. She pulled over and found the grill area and front engine hood were melting and scortched. She called police / fire to respond to the…

engine · filed 12/06/2005

Consumer 2005 highlander has experienced hesitation during accelerations and sometimes deceleration. *ts the dealer recalibrated the ECM which improved the hesitation problem while shifting but also reduced the gas mileage. The vehicle was taken to another dealer and their computer indicated that everything was fine. *nm

Had engine trouble with your 2005 Toyota Highlander? File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.

Common questions

How serious is the engine problem on the 2005 Toyota Highlander?

It's a meaningful issue. 11 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.

At what mileage does the engine typically fail?

Based on the 11 complaints filed, engine issues most often appear around 73,983 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.

What does it cost to fix?

Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.

Are there any recalls related to engine?

Yes — 1 active recall(s) cover engine issues on this vehicle. Recall fixes are always free regardless of mileage or warranty status. Use the VIN decoder at the top of the page to check if your specific vehicle is affected.

Related

Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA) public records database. Verify the raw federal record at nhtsa.gov/vehicle/2005/Toyota/Highlander. Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are independent-shop national averages and may differ in your area. Some links on this page are affiliate links.
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