Complaint 2129561

Complaint Summary

ENGINE

Owner Narrative

Formal Complaint to NHTSA – Summary I am submitting this formal complaint regarding repeated mechanical and electrical failures involving my 2017 Toyota Highlander, purchased as a Toyota Gold-Certified vehicle with an extended Platinum Warranty. Despite strictly following Toyota’s maintenance guidelines and using only certified dealerships for all services, the vehicle has become inoperable multiple times, requiring five separate tows and resulting in repair costs exceeding $10,000. In June 2025, a Toyota dealership replaced the engine after diagnosing a warped head due to water pump failure. Following this, the vehicle began experiencing repeated charging system failures and electrical malfunctions. Multiple components—including the alternator, battery, and sensors—were replaced at another Toyota dealership based on ongoing issues, but the problems persisted. On September 2, 2025, a Toyota technician identified a missing ground wire nut as the likely root cause of these electrical failures. He confirmed the issue originated during the engine installation and that the unsecured ground caused system malfunctions. After repairs, the vehicle was again returned with a loud engine knocking noise, later traced to an improperly secured component from a prior repair. These events have raised significant concerns for the safety of myself and my family. Improper installation of major components and misdiagnosis by certified service providers have led to hazardous driving conditions, unexpected vehicle shutdowns, and unnecessary costs. I am requesting that the National Highway Traffic Safety Administration investigate this matter for potential safety defects related to improper engine installation, grounding failures, and faulty electrical diagnosis by certified Toyota service centers. Documentation, invoices, and repair records are available upon request. Thank you for your attention to this critical safety issue.

Owner-submitted narrative on file with NHTSA. Complaint narratives are self-reported and have not been verified.