Toyota2003–2009

Avensis 1.6: Common faults & known problems

Common faults & known problems

4 known faults documented in workshop bulletins. Of these, two concern the engine and fuel system and two the clutch and gearbox. Symptoms, causes, repair steps and part numbers are shown where supplied.

Technical specifications

Engine & fuel system

2 documented faults — symptoms, causes and workshop fixes.

Engine idle speed fluctuates between 1000-1500rpm when high electrical load applied

Overview

Affects: All models with 3ZZ-FE engine code, →01/06.
Remedy: Fit modified part

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: Fit modified engine control module (ECM).

Data: Motorwise Workshop. Bulletin 2.

Ticking noise from top half of engine

Overview

Affects: All models with 3ZZ-FE/4ZZ-FE engine codes, →06/07.
Parts: 3 parts

Cause

Unsatisfactory design of hydraulic tappets.

Repair

Remove all hydraulic tappets and check for damage.
Replace damaged hydraulic tappets and associated valves.

Parts3 parts

Parts listed in the bulletin
Part	Part number	Qty
Hydraulic tappet	Refer to manufacturer	As required
Inlet valve	13711-22040	As required
Exhaust valve	13715-22040	As required

Data: Motorwise Workshop. Bulletin 3.

Clutch & gearbox

2 documented faults — symptoms, causes and workshop fixes.

Squeaking noise when clutch pedal depressed or released

Affects rightHandAll models with manual transmission, →02/05. leftHandAll models with manual transmission, →03/05.Fit modified part

Symptoms

Erratic clutch pedal action. Gears difficult to engage.

Cause

Faulty clutch master cylinder.

Repair

Fit modified clutch master cylinder.

Data: Motorwise Workshop. Bulletin 1.

Air conditioning (AC) inefficient

Affects All models with air conditioning (AC).

Cause

AC compressor clutch relay faulty.

Repair

Replace AC compressor clutch relay.

Data: Motorwise Workshop. Bulletin 4.

Glossary

Technical terms used in this guide.

ECM: Engine control module — the electronic unit that manages the engine
AC: Air conditioning — the system that cools the cabin
Control Module: A control unit for one of the vehicle's systems (engine, gearbox, brakes, body, and so on)
Relay: An electrically operated switch

Frequently asked questions

What are the common faults with the Toyota Avensis 1.6?

This guide contains four workshop bulletins for the Toyota Avensis 1.6. Of these, two concern the engine and fuel system and two the clutch and gearbox. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Toyota Avensis 1.6 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 Avensis 1.6 faults myself?

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