Toyota2007–2013

Auris 2.2 D-4D: Common faults & known problems

Common faults & known problems

14 known faults documented in workshop bulletins. Of these, eight concern the engine and fuel system and three the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Technical specifications

Engine & fuel system

8 documented faults — symptoms, causes and workshop fixes.

Poor idling

Affects All models, →03/07.Software update

Symptoms

Failure to start.

Cause

Engine control module (ECM) software fault.

Repair

Install upgraded engine control module (ECM) software.

Data: Motorwise Workshop. Bulletin 1.

Engine malfunction indicator lamp (MIL) illuminated

Affects All models, →03/07.P0400Software update

Symptoms

Engine control module (ECM) in limp home mode. Trouble code stored: P0400.

Cause

Engine control module (ECM) software fault.

Repair

Install upgraded engine control module (ECM) software.

Data: Motorwise Workshop. Bulletin 2.

Poor cold starting

Overview

Affects: All models with 1CD-FTV engine code.
Fault codes: P0380
Remedy: Software update

Symptoms

Trouble code stored: P0380.

Cause

Defective glow plugs.

Repair

Check glow plugs, replace as necessary.
Re-program ECM with modified software.

Data: Motorwise Workshop. Bulletin 3.

Intermittent power loss on acceleration

Exhaust gas recirculation (EGR) valve not operating properly. Fix: re-program with updated software.

Overview

Affects: All models.
Remedy: Software update

Symptoms

Engine jerking.

Repair steps

Check air filter, replace if required.
Check mass air flow (MAF) sensor, replace if required.
Clean exhaust gas recirculation (EGR) valve and associated parts.
Re-program ECM with modified software.

Data: Motorwise Workshop. Bulletin 4.

Engine malfunction indicator lamp (MIL) illuminated

Overview

Affects: All models.
Fault codes: P0400
Remedy: Software update

Symptoms

Engine runs in limp home mode. Trouble code stored: P0400.

Cause

Engine control module (ECM) software fault.

Repair

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.

Data: Motorwise Workshop. Bulletin 7.

Engine overheating

Overview

Affects: All models with 2.0/2.2 Diesel engines, →12/07.
Remedy: Fit modified part
Parts: 1 part

Symptoms

Loss of coolant.

Cause

Cylinder head gasket faulty.

Repair

Check cylinder head surface for distortion. Maximum tolerance: 0.05 mm.
Fit modified cylinder head gasket.

Parts1 part

Parts listed in the bulletin
Part	Part number	Qty
Cylinder head gasket	11115-26052-#0	1

Data: Motorwise Workshop. Bulletin 8.

Engine malfunction indicator lamp (MIL) illuminated

Overview

Affects: All models with Diesel particulate filter (DPF).
Fault codes: P2002
Remedy: Software update

Symptoms

Engine runs in limp home mode. Trouble code stored: P2002.

Cause

Engine control module (ECM) software fault.

Diesel particulate filter (DPF) pressure sensor vacuum pipe blocked.

Diesel particulate filter (DPF) blocked.

Repair steps

Check all DPF pressure sensor vacuum pipes are correctly fitted and have no leaks.
Check operation and condition of DPF.
Re-program ECM with upgraded software.

Data: Motorwise Workshop. Bulletin 9.

Engine malfunction indicator lamp (MIL) illuminated

Overview

Affects: All models with 2.0/2.2 Diesel engines.
Fault codes: P0093

Symptoms

Diesel odour in passenger compartment. Trouble code stored: P0093.

Cause

High-pressure fuel pump leaking.

Repair

Inspect production date code on high-pressure fuel pump.
If production date before 02/2010 (01M 02700), replace high-pressure fuel pump with modified version.

Data: Motorwise Workshop. Bulletin 10.

Brakes

3 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 5.

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

Parts listed in the bulletin
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 6.

Strong odour from rear brakes

Affects All models, →03/09.Fit modified part

Symptoms

Excessive fuel consumption. Noise from rear brakes.

Cause

Rear brake pads seize in brake caliper carrier due to corrosion and dirt ingress.

Repair

Fit modified rear brake pads.

Data: Motorwise Workshop. Bulletin 12.

Steering

2 documented faults — symptoms, causes and workshop fixes.

Rattling noise from steering column at low speeds over uneven surfaces

Affects All models, →2008.Fit modified part

Cause

Excessive free play in EPS motor drive gears.

Repair

Fit modified steering column.

Data: Motorwise Workshop. Bulletin 11.

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

Parts listed in the bulletin
Part	Part number	Qty
Protective cover	45254-02020	1
Steering column sealing boot	Refer to manufacturer	1

Data: Motorwise Workshop. Bulletin 14.

Body & trim

1 documented fault — symptoms, causes and workshop fixes.

Water ingress into load area

Affects All models, →02/10.

Symptoms

Load area carpet wet.

Cause

Damaged or incorrectly fitted air ventilation outlet grilles, located behind rear bumper.

Repair

Check fitment and condition of air ventilation outlet grilles, replace if necessary.

Parts1 part

Parts listed in the bulletin
Part	Part number	Qty
Air ventilation outlet grille	62940-02011	2

Data: Motorwise Workshop. Bulletin 13.

Glossary

Technical terms used in this guide.

ECM: Engine control module — the electronic unit that manages the engine
EGR: Exhaust gas recirculation — feeds some exhaust gas back into the intake to cut emissions
DPF: Diesel particulate filter — traps soot in the exhaust and burns it off periodically
LHD: Left-hand drive — steering wheel on the left
MAF: Mass air flow — a sensor that measures how much air the engine is breathing
Caliper: The part that squeezes the brake pads onto the disc
Control Module: A control unit for one of the vehicle's systems (engine, gearbox, brakes, body, and so on)
Glow Plugs: Heaters that help a diesel engine start from cold
Limp Home: A protective mode that limits power so the vehicle can be driven to a workshop
Re-Program: Update the software on a control module using the manufacturer's diagnostic tool
Trouble Code: A standardised fault code stored by a control module, read with a diagnostic tool
Head Gasket: The seal between the cylinder head and the engine block
Recirculation: Air-conditioning mode that recirculates cabin air instead of drawing in outside air

Frequently asked questions

What are the common faults with the Toyota Auris 2.2 D-4D?

This guide contains 14 workshop bulletins for the Toyota Auris 2.2 D-4D. Of these, eight concern the engine and fuel system and three the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Toyota Auris 2.2 D-4D 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 2.2 D-4D faults myself?

Many of them. The documented symptoms can be seen, heard or felt during a test drive.