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Toyota2007–2024 Critical issues documented

Toyota Highlander XU40: common faults & what to check

The XU40 is the Toyota Highlander built 2007–2014. It was sold here with the 3.5 V6 petrol. Of the 12 faults documented for the Highlander, 3 apply to this generation, each with its symptoms, what to inspect and a typical repair cost. Free, no account needed.

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12

Documented faults

Critical

Most serious

$300–$1,400

Typical repair

26

Service milestones

You're looking at the XU40 · 3.5 V6 petrol

Everything below is narrowed to this variant. Pick a different one to change it.

Choose a different generation

Now narrow it to the engine

A 1.8 and a 2.4 of the same car do not fail the same way, so the faults below narrow to the engine as well as the year. Free, no account needed.

Which engine is in it?

3.5 V6 petrol· 3.5 litre petrol

A 2008 Toyota Highlander is the XU40 generation (2007 to 2014).

Start your free check on this Toyota Highlander

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Toyota Highlander XU40

Free. The paid plate check is separate, and stays optional.

Can't confirm for this car

Toyota Highlander · 2008

Narrowed to the year. No engine is recorded for this vehicle. Pick an engine to see which faults apply.

Tell us the engine, or check the engine code on the car, before relying on this.

  • No engine is recorded for this vehicle.

matched on year only

What to look out for

The checks worth doing on a Toyota Highlander before you hand over any money. Every documented fault is listed below, each with its own page.

  • Common issue

    During the test drive, cross a speed bump slowly with a light grip on the wheel and feel for a knock through the column (not from the suspension).

    See why

    Steering intermediate shaft clunk over low-speed bumps

    XU40 Highlanders/Klugers develop a clunk or knock through the steering column caused by the steering intermediate shaft losing lubrication, felt through the wheel over small bumps and during low-speed turns. Toyota issued a service bulletin and dealers replaced or re-greased the shaft. Annoying rather than dangerous, but it is often quoted as a full shaft replacement.

    What you would notice

    • Clunk felt through the steering wheel over speed bumps or driveways
    • Knock when turning at car-park speeds
    • Slight notchiness in the wheel

    Typically $300–$900 to put right.

Toyota Highlander service schedule

What falls due, and at what distance, for each generation of the Toyota Highlander. These are the model’s intervals — the car’s own service book is the only thing that can tell you what has actually been done to it.

Fourth Generation (XU70) · 2023–2026 · 2.4L (T24A-FTS) - Turbocharged performance trim

Petrol

Due by distance

  1. 40,000 km

    Check the transmission fluid and give the brake system a thorough flush so the turbo model keeps its sharpness.

  2. 80,000 km

    An important check on the turbo hoses and the cooling system parts, which is what keeps it reliable long term.

  3. 120,000 km

    Assess the suspension dampers and confirm the electronic sensors are calibrated correctly for good fuel economy.

Fourth Generation (XU70) · 2020–2026 · 2.5L (A25A-FXS) - Hybrid electric trim

Hybrid

Due by distance

  1. 100,000 km

    Have the hybrid coolant system checked in full so the electric motor cooling circuit keeps working properly.

  2. 150,000 km

    Good point to check the hybrid battery cooling fan filter for dust, which affects how well the battery stays cool over time.

  3. 200,000 km

    Sensible stage for a qualified technician to run a full diagnostic scan of the hybrid battery health and check the module voltages match.

Fourth Generation (XU70) · 2020–2023 · 3.5L (2GR-FKS) - V6 SUV trim

Petrol

Due by distance

  1. 60,000 km

    Check the drive belt and look at the transmission fluid for any early signs of breaking down.

  2. 100,000 km

    Check the spark plugs and confirm the coolant system is working as well as it should.

  3. 150,000 km

    A full suspension refresh with new struts and bushings keeps the comfortable ride Toyota is known for.

Third Generation (XU50) · 2013–2019 · 2.7L (1AR-FE) - 4-cylinder entry level

Petrol

Due by distance

  1. 100,000 km

    Have the transmission fluid fully serviced and check the condition of the serpentine belt.

  2. 150,000 km

    Watch the suspension parts for wear, and make sure the spark plugs have been renewed on schedule.

  3. 200,000 km

    Plan a full check of the cooling system hoses and the radiator so it does not overheat.

Third Generation (XU50) · 2013–2019 · 3.5L (2GR-FE/2GR-FKS) - V6 performance trim

Petrol

Due by distance

  1. 100,000 km

    Time for a thorough check of the suspension bushings and the condition of the drive belts.

  2. 150,000 km

    Good stage to assess the cooling system, look at the radiator for seepage, and flush the coolant if there is no recent record of it.

  3. 200,000 km

    Focus on the spark plug service, which means taking the intake manifold off, and check the transmission fluid so the shifts stay good.

Second Generation (XU40) · 2009–2013 · 2.7L (1AR-FE) - 4-cylinder efficiency trim

Petrol

Due by distance

  1. 150,000 km

    Flush the cooling system and check every rubber coolant hose.

  2. 200,000 km

    Keep an eye on the alternator and starter motor, whose parts have been through plenty of heat by now.

  3. 250,000 km

    Assess the suspension bushings and struts, which may be past their best.

First Generation (XU20) · 2004–2007 · 3.3L (3MZ-FE) - V6 upgrade

Petrol

Due by distance

  1. 150,000 km

    Confirm the timing belt service history, as that job matters more than most on the 3MZ-FE engine.

  2. 200,000 km

    Assess the suspension bushings and struts to keep the Highlander riding smoothly.

  3. 250,000 km

    Good chance to have a technician check the alternator and starter motor so you can rely on it.

First Generation (XU20) · 2000–2003 · 3.0L (1MZ-FE) - V6 trim

Petrol

Due by distance

  1. 150,000 km

    Cooling system parts such as the radiator and water pump are worth a professional inspection from here.

  2. 200,000 km

    Check the timing belt service history, as this interference engine depends on a healthy belt to avoid serious damage.

  3. 250,000 km

    The original alternator or starter motor may be near the end of their working life by now.

First Generation (XU20) · 2000–2007 · 2.4L (2AZ-FE) - 4-cylinder base model

Petrol

Due by distance

  1. 150,000 km

    Check the water pump and the serpentine belt tensioner for signs of fatigue.

  2. 200,000 km

    Good point to check the radiator and find out whether suspension parts such as the struts have been renewed.

See all 3 issues for this oneDocumented for the exact year and engine you picked, including 1 rated critical.
Body, brakes, suspension & interior1

01Steering intermediate shaft clunk over low-speed bumps

During the test drive, cross a speed bump slowly with a light grip on the wheel and feel for a knock through the column (not from the suspension).2007–2013Suspension
CommonSuspension $300–$900 to fix

XU40 Highlanders/Klugers develop a clunk or knock through the steering column caused by the steering intermediate shaft losing lubrication, felt through the wheel over small bumps and during low-speed turns. Toyota issued a service bulletin and dealers replaced or re-greased the shaft. Annoying rather than dangerous, but it is often quoted as a full shaft replacement.

Symptoms to notice

  • Clunk felt through the steering wheel over speed bumps or driveways
  • Knock when turning at car-park speeds
  • Slight notchiness in the wheel

What to check

During the test drive, cross a speed bump slowly with a light grip on the wheel and feel for a knock through the column (not from the suspension). Turn lock to lock at walking pace listening for a clunk near the firewall.

Where to look: Steering intermediate shaft between the column and the rack, at the firewall

Ask the seller

  • “Has the steering intermediate shaft been replaced under Toyota's service bulletin?”
  • “How long has the clunk been present?”
Depends on the exact engine — 2 moreDocumented for a specific engine we could not confirm from what you picked. Check the engine code on the car.
Engine, transmission & cooling1

012GR-FE water pump leaks — often well before 150,000 km

With the engine cold, check the coolant reservoir level and look for pink dried coolant trails below the water pump area at the front of the engine.petrol2007–2020Cooling
CommonCooling $700–$1,400 to fix

Can't confirm for this car

The 3.5 V6's water pump is a known weak point across XU40 and XU50 Highlanders/Klugers, commonly weeping or failing from as little as 80,000-130,000 km. It leaks coolant from the weep hole and can howl before it fails; a failed pump means overheating, and on this engine overheating risks head gaskets. It is a routine but not cheap repair given the pump's location.

Symptoms to notice

  • Pink coolant crust or drips low on the front of the engine
  • Coolant level dropping between checks
  • Whining/growling bearing noise rising with revs
  • Sweet coolant smell after a drive

What to check

  1. With the engine cold, check the coolant reservoir level and look for pink dried coolant trails below the water pump area at the front of the engine.
  2. Listen at idle for bearing whine.
  3. Ask when the water pump was last replaced — a receipt is common on well-kept cars.

Where to look: Front of the transverse V6, behind the drive belt on the passenger side of the engine bay

Parts involved: Water pump.

Ask the seller

  • “Has the water pump been replaced, and at what mileage?”
  • “Has it ever overheated?”
  • “Is coolant being topped up between services?”
Fluid leaks1

012GR-FE V6 rubber oil line rupture — can dump engine oil in seconds

With a torch, look near the oil filter for a short rubber hose joining two metal oil pipes — an all-metal line means the update was done.petrol2007–2012Fluid LeaksRead the full fault: symptoms, where to look, what to ask the seller
Other Toyota Highlander engines and years9 documented issues that do not apply to the one you picked.
Engine, transmission & cooling2

01Denso low-pressure fuel pump recall — engine can stall without warning

Run the VIN through Toyota NZ/AU's recall checker (or ask a dealer) and confirm the fuel pump recall shows as completed.petrol2018–2020Engine
OccasionalEngine $0–$1,400 to fix

Does not apply

Highlanders/Klugers built roughly 2018-2020 were caught in the massive worldwide Denso fuel pump recall: the pump impeller can swell and seize, causing rough running or a sudden stall that will not restart. Toyota Australia and Toyota NZ replaced pumps free under recall. Most have been done by now, but unrepaired JDM or parallel imports can slip through — always verify by VIN.

Symptoms to notice

  • Rough running or hesitation, especially when hot
  • Check-engine light with fuel-pressure codes
  • Engine stall while driving, then no restart

What to check

Run the VIN through Toyota NZ/AU's recall checker (or ask a dealer) and confirm the fuel pump recall shows as completed. There is nothing visual to inspect — this is a paperwork check.

Where to look: In-tank fuel pump, under the rear seat/fuel tank

Parts involved: Water pump.

Ask the seller

  • “Has the Denso fuel pump recall been completed on this VIN?”
  • “Has it ever stalled or struggled to restart when hot?”

028-speed automatic (UA80) torque converter shudder and harsh low-speed shifts

On the test drive, hold a steady light throttle at 50-70 km/h on a slight incline and feel for a fine rumble/shudder lasting a few seconds.petrol2017–2020TransmissionRead the full fault: symptoms, where to look, what to ask the seller
Electrical3

01Recall: steering spiral-cable weld can disable the driver's airbag (23V480 / 23TA08)

With ignition on, check the airbag/SRS warning light comes on then goes out (a light that stays on can indicate a spiral-cable fault).2023Electrical
RareElectrical

Does not apply

On certain 2023 Highlander (Kluger) and Highlander Hybrid, an electrical connection inside the steering-column spiral cable (clock spring) may be insufficiently welded and can separate, deactivating the driver's airbag and often the horn and steering-wheel controls. Toyota's recall 23V480 (Toyota 23TA08) inspects and replaces the spiral cable free. A dead airbag warning light is a serious red flag on these cars.

Symptoms to notice

  • Airbag / SRS warning light stays on
  • Horn or steering-wheel buttons intermittent or dead
  • SRS fault code stored

What to check

  1. With ignition on, check the airbag/SRS warning light comes on then goes out (a light that stays on can indicate a spiral-cable fault).
  2. Test the horn and all steering-wheel controls.
  3. Ask a Toyota dealer to confirm recall 23V480 (23TA08) was completed.

Where to look: Steering-column spiral cable (clock spring) behind the steering wheel

Ask the seller

  • “Is the airbag/SRS warning light off?”
  • “Has the spiral-cable airbag recall (23V480) been done?”
  • “Do the horn and steering-wheel buttons all work?”

0212V auxiliary battery goes flat from parasitic drain

Check the 12V battery date and health, and ask how the car behaves after being parked several days.2021 onwardElectricalRead the full fault: symptoms, where to look, what to ask the seller

03Infotainment screen freezes, blank-outs and random reboots

Sit in the vehicle for a full test drive and cycle the head unit through reversing camera, audio, phone mirroring and climate screens.2021 onwardElectrical
CommonElectrical $0–$2,500 to fix

Does not apply

XU70 Highlanders (sold as Kluger in NZ/AU) with the 8-inch or 12.3-inch multimedia head unit commonly suffer the screen going blank, freezing, becoming unresponsive to touch, or rebooting itself while driving, sometimes several times a day. Toyota addressed it under Technical Service Bulletin T-SB-0055-22, which in worse cases calls for replacing the multimedia integration control module with an updated part. This is a software and module trait of early XU70 build years rather than a wear item, so it can appear at very low kilometres and is not km-dependent. Many cases are covered under the basic warranty, and a Home plus Volume-Down hard reset often clears it temporarily.

Symptoms to notice

  • Screen goes black or blank while driving
  • Touchscreen unresponsive to inputs
  • System reboots itself repeatedly
  • Reversing camera or audio drops out
  • Bluetooth or CarPlay disconnects

What to check

  1. Sit in the vehicle for a full test drive and cycle the head unit through reversing camera, audio, phone mirroring and climate screens.
  2. Watch for the display freezing, going blank or rebooting.
  3. Ask whether TSB T-SB-0055-22 has been applied and check the reversing camera actually shows on screen when selecting reverse.

Where to look: Centre dashboard multimedia display and integration control module

Ask the seller

  • “Has the infotainment screen ever frozen, gone blank or restarted itself?”
  • “Has TSB T-SB-0055-22 or a multimedia software update been carried out?”
  • “Was the integration control module ever replaced under warranty?”
Body, brakes, suspension & interior3

01Hybrid brake pedal lurch during regen-to-hydraulic transition

hybrid2021 onwardBrakes
OccasionalBrakes $0–$900 to fix

Does not apply

On the 2.5 hybrid XU70, drivers report a momentary loss of braking or a slight forward lurch as the system hands over from regenerative to hydraulic braking, most noticeable braking gently downhill or at low speed. Toyota covered it in Technical Service Bulletin T-SB-0059-23, which reprograms the brake actuator assembly control module to smooth the transition; complaints on 2020-2022 hybrids have also been logged with NHTSA. It is a control-software calibration trait of the hybrid brake blending, not a hydraulic or pad wear defect, so it is not km-related and can be felt from new. The reprogram is the fix; owners note it has generally been handled under the basic (not hybrid-system) warranty.

Symptoms to notice

  • Brief lurch or push forward when braking
  • Momentary soft or dropped pedal feel
  • Grabby or inconsistent braking at low speed
  • Most noticeable braking gently downhill

What to check

On the test drive, brake gently at low speed and while going down a slight grade, feeling for a momentary lurch or a soft spot as regen hands over to the hydraulic brakes. Ask whether the brake actuator control module reprogram under TSB T-SB-0059-23 has been performed and whether the owner has noticed any inconsistent pedal feel.

Where to look: Brake actuator assembly and its control module (hybrid brake system)

Ask the seller

  • “Have you felt any lurch or momentary loss of braking when slowing gently?”
  • “Has the brake actuator reprogram (TSB T-SB-0059-23) been carried out?”
  • “Does the brake pedal feel consistent at low speed and downhill?”

02Recall: second-row seatback may fail to lock (26V128)

Fold each second-row seatback down and return it upright, confirming it locks with a positive click and won't tip forward when pushed.2021–2024Interior
OccasionalInterior

Does not apply

On 2021-2024 Highlander (Kluger in NZ/AU) and Highlander Hybrid, the return springs in the second-row seat recliner assemblies can fail so a seatback does not lock upright after being adjusted. A back that isn't locked may not properly restrain an occupant in a crash. Toyota's recall 26V128 replaces the recliner return springs free of charge; confirm it was done on an imported car.

Symptoms to notice

  • Second-row seatback doesn't click firmly into the upright locked position
  • Seatback tips forward too easily
  • Rattle or movement from a second-row seatback

What to check

Fold each second-row seatback down and return it upright, confirming it locks with a positive click and won't tip forward when pushed. Ask a Toyota dealer to check the VIN for recall 26V128 (seat recliner return spring).

Where to look: Second-row seat recliner assemblies

Ask the seller

  • “Has the second-row seatback lock recall (26V128) been completed?”
  • “Do both second-row backs lock firmly upright?”

03Recall: front lower bumper cover can loosen or detach (23V720)

Check the front lower bumper cover is firmly attached along its whole edge with no sagging, gaps or missing clips; gently tug the lower corners.2021–2023Body & Rust
OccasionalBody & Rust

Does not apply

On 2020-2023 Highlander (Kluger) and Highlander Hybrid, minor impact to the front lower bumper cover can cause it to loosen or detach during normal driving, becoming a road hazard. Toyota's recall 23V720 repairs or replaces the upper and lower front bumper covers free of charge. Check the cover is secure and the recall was completed.

Symptoms to notice

  • Front lower bumper cover loose, sagging or with uneven gaps
  • Rattling or scraping from the front bumper
  • Bumper cover previously detached or refitted

What to check

  1. Check the front lower bumper cover is firmly attached along its whole edge with no sagging, gaps or missing clips; gently tug the lower corners.
  2. Ask whether recall 23V720 (front bumper cover) was carried out.

Where to look: Front lower bumper cover

Ask the seller

  • “Has the front bumper cover recall (23V720) been done?”
  • “Has the front bumper ever come loose or been refitted?”
Fluid leaks1

01Oil leak from the cam sensor bolt holes (3.5 V6 2GR-FKS)

petrol2017–2018Fluid Leaks
OccasionalFluid Leaks $1,500–$4,000 to fix

Does not apply

The 3.5 V6 2GR-FKS fitted to the facelifted Kluger from 2017 can leak engine oil from the bolt holes of the camshaft position sensors, which screw into the camshaft housings on top of the engine. Toyota issued service bulletin T-SB-0073-18 for the same engine in the 2017-2018 Highlander (the American name for the Kluger). The fix is a new camshaft housing on the leaking side plus upgraded bolts, which is a big labour job because the top of the engine has to come apart. Engines built after the production change have the improved parts. Left alone it is a slow oil leak that can drip onto the exhaust and leave the engine low on oil.

Symptoms to notice

  • Burning oil smell after a drive
  • Oily film or wet patches on top of the engine around the cam sensors
  • Oil drips under the car after parking
  • Oil level dropping between services

What to check

Open the bonnet and use a phone torch to look at the top and back of the engine for wet, dark oily patches or caked dust around the sensors and the valve covers. After a test drive, sniff for burning oil and look under the car for fresh drips. Ask whether any oil leak or cam housing work was done under warranty and ask for the service history. If a workshop inspection is possible: have the engine checked on a hoist with a UV dye test to confirm whether the leak is from the cam sensor bolt holes, and ask the workshop to check with Toyota whether the engine serial number is before the production change.

Where to look: Top of the engine, camshaft housings under the intake plenum, at the camshaft position sensors

Ask the seller

  • “Has Toyota or a workshop ever fixed an oil leak at the top of the engine?”
  • “Has the camshaft housing been replaced under a service bulletin?”
  • “Does it need oil topped up between services?”

Toyota Highlander faults in detail

Narrowed to the Toyota Highlander · 2008. Each of these has its own page: the symptoms, where to look, what to ask the seller and what the repair costs. Free, no account needed.

2GR-FE V6 rubber oil line rupture — can dump engine oil in secondsCritical · Fluid Leaks

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Toyota Highlander buyer questions

Is the Toyota Highlander reliable?

Like any used car, it depends on the specific example and its service history. Across the 12 documented faults for the Toyota Highlander, the recurring problem areas are engine, fluid leaks, and electrical. A Toyota Highlander with a full service history and no signs of the issues listed on this page can be a sound buy but each one needs to be checked individually before you commit.

What are the most common problems with a used Toyota Highlander?

We've catalogued 12 known faults for the Toyota Highlander, covering engine, fluid leaks, and electrical. All 12 are written out in full on this page, with the symptoms to notice, what to inspect, and typical repair costs for each. Free to read, no account needed.

How much do repairs cost on a Toyota Highlander?

Most single repairs on the Toyota Highlander fall between $300–$1,400 at NZ independent-workshop rates. Some of the 12 documented faults cost less and a few cost considerably more, and no one car needs them all. Knowing which ones to look for before you view is what lets you negotiate the price down or walk away.

Should I get a pre-purchase inspection on a Toyota Highlander?

Yes. A Toyota Highlander inspection focused on its known weak points is the single best way to avoid an expensive mistake. KickTyres gives you a guided, model-specific inspection plus a market valuation and negotiation figure for $24.90 far less than the cost of missing one of the faults on this page.