Engine & fuel system
6 documented faults — symptoms, causes and workshop fixes.
Booming noise on starting engine after parking overnight when ambient air temperature is below -10°C
Symptoms
Vibration through vehicle on starting engine after parking overnight when ambient air temperature is below -10°C.
Cause
Unsatisfactory design of rear lower engine mounting rubber.
Repair
- Fit modified rear lower engine mounting.
Parts1 part
| Part | Part number | Qty |
|---|---|---|
| Rear lower engine mounting | 12371-37210 | 1 |
Data: Motorwise Workshop. Bulletin 3.
Tapping noise from engine after cold start for approximately 5seconds when ambient air temperature is between 0-5°C
Cause
Condensation build up in intake manifold.
Repair
- Fit modified intake manifold.
Parts1 part
| Part | Part number | Qty |
|---|---|---|
| Intake manifold | 17120-37050 | 1 |
Data: Motorwise Workshop. Bulletin 4.
Tapping noise from engine after cold start for 5-10seconds when ambient air temperature is below 0°C
Overview
- Affects
- All models with 2ZR-FXE engine code, →12/11.
- Remedy
- Software update
Cause
Engine control module (ECM) software fault.
Unsatisfactory design of injectors.
Repair steps
- Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
- If no fault(s) found: Re-program ECM with upgraded software.
- Inspect part number on injectors. If part number 23209-39146, replace injectors.
Parts
| Part | Part number | Qty |
|---|---|---|
| Injector | 23209-39245 | 4 |
Data: Motorwise Workshop. Bulletin 5.
Engine malfunction indicator lamp (MIL) illuminated. Possible trouble codes stored: P0A2C, P0A2D
Water ingress into engine bay fuse box/relay plate due to incorrectly fitted cover.
Overview
- Affects
- All models with hybrid drive system.
Repair steps
- Check engine bay fuse box/relay plate for corrosion. Repair/replace component(s) as necessary.
- Dry out engine bay fuse box/relay plate as necessary.
- Ensure engine bay fuse box/relay plate cover fitted correctly.
Data: Motorwise Workshop. Bulletin 6.
Engine difficult to start after standing for 3hours or more
Cause
Unsatisfactory design of injectors.
Repair
- Inspect production number on injectors If production number 0692, replace injectors.
Parts1 part
| Part | Part number | Qty |
|---|---|---|
| Injector | 23209-39145 | 4 |
Data: Motorwise Workshop. Bulletin 7.
Engine malfunction indicator lamp (MIL) illuminated. Trouble code stored: P0401
EGR valve not operating properly due to build up of deposits. Fix: fit a modified part.
Overview
- Affects
- All models with 2ZR-FXE engine code, →12/12.
- Fault codes
P0401- Remedy
- Fit modified part
Repair steps
- Fit modified EGR valve.
- Re-route EGR valve wiring, leaving sufficient slack to allow for engine movement: Remove insulation tape from wiring harness Apply adhesive tape to area indicated.
- Re-program engine control module (ECM) with upgraded software. Note: To carry out an effective repair a software upgrade will be required - refer to manufacturer.
Parts
| Part | Part number | Qty |
|---|---|---|
| EGR valve | 25620-37120 | 1 |
| EGR valve gasket | 25685-37010 | 1 |
Data: Motorwise Workshop. Bulletin 8.
Brakes
2 documented faults — symptoms, causes and workshop fixes.
Handbrake lever difficult to operate when driver's seat in fully forward position
Overview
- Affects
- All models built in UK and Turkey, →07/07.
Cause
Incorrect adjustment of handbrake mechanism.
Repair
- Adjust handbrake mechanism to obtain 3-6 notches at handbrake lever whilst applying 200 N.
- Carry out brake bedding-in procedure: Drive vehicle at 25 mph (40 kph). Apply handbrake lever 1 notch. Drive vehicle for 400 metres. Release handbrake lever. Wait 5 minutes. Repeat above procedure twice.
Data: Motorwise Workshop. Bulletin 1.
Handbrake lever difficult to operate when driver's seat in fully forward position
Overview
- Affects
- All models built in Japan, →11/07.
- Remedy
- Fit modified part
Cause
Incorrect adjustment of handbrake mechanism.
Poor manufacture of handbrake cables.
Repair steps
- Fit modified handbrake lever assembly and handbrake cables.
- Adjust handbrake mechanism to obtain 3-6 notches at handbrake lever whilst applying 200 N.
- Carry out brake bedding-in procedure: Drive vehicle at 25 mph (40 kph). Apply handbrake lever 1 notch. Drive vehicle for 400 metres. Release handbrake lever. Wait 5 minutes. Repeat above procedure twice.
Parts
| Part | Part number | Qty |
|---|---|---|
| Handbrake cable | 46420-12720 | 1 |
| Handbrake cable | 46430-12610 | 1 |
| Clamp | 46402-12030 | 1 |
| Handbrake lever assembly | 46201-12352-** | 1 |
Data: Motorwise Workshop. Bulletin 2.
Steering
1 documented fault — symptoms, causes and workshop fixes.
Increased engine noise in passenger compartment
Steering column sealing boot cracked/damaged. Fix: fit a new part.
Overview
- Affects
- All LHD models.
- Remedy
- Fit new part
Symptoms
Driver's footwell carpet wet after heavy rain. Steering operation not smooth when manoeuvring or parking.
Repair steps
- Remove steering column sealing boot and discard.
- Fit protective cover to new steering column sealing boot Secure protective cover with retaining strap, ensure a clearance of 0.5 - 1.5 mm.
- Fit new steering column sealing boot complete with protective cover.
Parts
| Part | Part number | Qty |
|---|---|---|
| Protective cover | 45254-02020 | 1 |
| Steering column sealing boot | Refer to manufacturer | 1 |
Data: Motorwise Workshop. Bulletin 9.
Glossary
Technical terms used in this guide.
- ECM
- Engine control module — the electronic unit that manages the engine
- LHD
- Left-hand drive — steering wheel on the left
- Control Module
- A control unit for one of the vehicle's systems (engine, gearbox, brakes, body, and so on)
- EGR Valve
- The valve that meters exhaust gas back into the intake
- Intake Manifold
- The housing that distributes air into the cylinders
- Re-Program
- Update the software on a control module using the manufacturer's diagnostic tool
- Relay
- An electrically operated switch
- Wiring Harness
- The bundled cables that carry power and signals around the vehicle
Frequently asked questions
What are the common faults with the Toyota Auris 1.8 Hybrid Synergy Drive?
This guide contains nine workshop bulletins for the Toyota Auris 1.8 Hybrid Synergy Drive. Of these, six concern the engine and fuel system and two the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.
Does every Toyota Auris 1.8 Hybrid Synergy Drive have these faults?
No. These are patterns documented across the model by workshops, not predictions for an individual vehicle. Where a fault applies only to certain vehicles or VIN ranges, that is listed with the fault.
Can I check for Toyota Auris 1.8 Hybrid Synergy Drive faults myself?
Many of them. The documented symptoms can be seen, heard or felt during a test drive.