Toyota2005–2009

Avensis 2.2 D-4D 2AD-FHV: Common faults & known problems

Common faults & known problems

16 known faults documented in workshop bulletins. Of these, 11 concern the engine and fuel system and three the clutch and gearbox. Symptoms, causes, repair steps and part numbers are shown where supplied.

Technical specifications

Engine & fuel system

11 documented faults — symptoms, causes and workshop fixes.

Non start

Affects Avensis (VIN →SB1EB56L70E023958).Fit modified part

Symptoms

No trouble codes stored in memory.

Cause

Air ingress at fuel non-return valve Fig.111788.A .

Repair

  1. Fit modified fuel return pipeB and non-return valveA.
Parts2 parts
Parts listed in the bulletin
PartPart numberQty
Fuel return pipe23761-0R0301
Non-return valve23769-260201

Data: Motorwise Workshop. Bulletin 1.

Sudden power loss on acceleration

Affects Avensis, engine code: 1AD-FTV (VIN →SB1DD56L40E018674). Avensis, engine code: 2AD-FHV (VIN →SB1BA56L50E060478).

Symptoms

Whistling noise from engine.

Cause

Retaining clamps not securing turbocharger (TC) intercooler hoses sufficiently.

Repair

  1. Replace turbocharger (TC) intercooler hoses and retaining clamps.

Data: Motorwise Workshop. Bulletin 2.

Poor idling

Affects All models, →03/07.Software update

Symptoms

Failure to start.

Cause

Engine control module (ECM) software fault.

Repair

  1. Install upgraded engine control module (ECM) software.

Data: Motorwise Workshop. Bulletin 3.

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

  1. Install upgraded engine control module (ECM) 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

  1. Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
  2. If no fault(s) found: Re-program ECM with upgraded software.

Data: Motorwise Workshop. Bulletin 6.

Engine malfunction indicator lamp (MIL) illuminated

Overview

Affects
All models with Diesel particulate filter (DPF).
Fault codes
P1386
Remedy
Software update

Symptoms

Trouble code stored: P1386.

Cause

Engine control module (ECM) software fault.

Fuel additive injector blocked.

Repair

  1. Renew fuel additive injector.
  2. Re-program ECM with modified 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

  1. Check cylinder head surface for distortion. Maximum tolerance: 0.05 mm.
  2. Fit modified cylinder head gasket.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Cylinder head gasket11115-26052-#01

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

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

Data: Motorwise Workshop. Bulletin 9.

Engine runs erratically or fails to start

Overview

Affects
All models with 2.2 Diesel engine.
Remedy
Software update

Cause

Engine control module (ECM) software fault.

Repair

  1. Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
  2. If no fault(s) found: Re-program ECM with modified software.

Data: Motorwise Workshop. Bulletin 10.

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

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

Data: Motorwise Workshop. Bulletin 11.

Sudden power loss on acceleration

Affects All models with 2AD-FHV engine code, →11/06.Fit modified part

Symptoms

Whistling noise from engine.

Cause

Turbocharger (TC) intercooler bottom hose(s) detached.

Repair

  1. Fit modified turbocharger (TC) intercooler bottom hose(s) as necessary.
Parts2 parts
Parts listed in the bulletin
PartPart numberQty
Intercooler bottom hose - RH17343-260221
Intercooler bottom hose - LH17343-260721

Data: Motorwise Workshop. Bulletin 14.

Steering

1 documented fault — symptoms, causes and workshop fixes.

ESP warning lamp illuminated

Incorrect calibration of steering angle sensor.

Overview

Affects
All models with electronic stability program (ESP).
Fault codes
C1288

Symptoms

Trouble code stored: C1288. Unable to program steering angle sensor.

Repair steps

  1. Ensure steering in straight-ahead position.
  2. Ensure steering angle sensor aligned with steering column.
  3. Carry out steering angle sensor calibration.

Data: Motorwise Workshop. Bulletin 12.

Clutch & gearbox

3 documented faults — symptoms, causes and workshop fixes.

Clutch slip

Overview

Affects
All models: Avensis, VIN →SB1EA56L70E038625. Corolla Verso/CombiVan, VIN →NMTEA16R00R036538. Corolla Verso/CombiVan, VIN →NMTEB16R60R036606.
Remedy
Clean & lubricate
Parts
1 part

Symptoms

Oil leak from transmission.

Cause

Clutch assembly contaminated with oil.

Transmission input shaft oil seal leaking due to damage during production.

Repair

  1. Renew transmission input shaft oil seal.
  2. Check clutch assembly for oil contamination. Clean or replace clutch components as necessary.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Transmission input shaft oil seal90311-300171

Data: Motorwise Workshop. Bulletin 5.

Air conditioning (AC) inefficient

Affects All models with air conditioning (AC).

Cause

AC compressor clutch relay faulty.

Repair

  1. Replace AC compressor clutch relay.

Data: Motorwise Workshop. Bulletin 15.

Non start

Overview

Affects
All Diesel models with manual transmission.
Remedy
Fit new part

Symptoms

Starter motor not disengaging. Starter motor not operating.

Cause

Foreign objects and/or debris in starter motor gear mechanism due to excessive clutch friction material wear.

Repair

  1. Inspect clutch assembly. Replace component(s) as necessary.
  2. Fit new starter motor.

Data: Motorwise Workshop. Bulletin 16.

Air conditioning & heating

1 documented fault — symptoms, causes and workshop fixes.

LH headlamp dipped beam flickers after switching on auxiliary heater

Overview

Affects
All models with 1CD-FTV/2AD-FHV engine codes and auxiliary heater, →03/06.
Remedy
Fit modified part
Parts
1 part

Cause

Signal interference to wiring within engine bay wiring harness when high electrical load applied (auxiliary heater).

Repair

  1. Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
  2. If no fault(s) found: Fit modified wiring harness in engine bay.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Wiring harness82114-050601

Data: Motorwise Workshop. Bulletin 13.

Glossary

Technical terms used in this guide.

ECM
Engine control module — the electronic unit that manages the engine
VIN
Vehicle identification number — 17 characters, found at the base of the windscreen and on the V5C logbook
DPF
Diesel particulate filter — traps soot in the exhaust and burns it off periodically
Trouble Codes
Standardised fault codes stored by the engine control module, read with a diagnostic tool
AC
Air conditioning — the system that cools the cabin
ESP
Electronic stability programme — brakes individual wheels to stop a skid
TC
Turbocharger — the exhaust-driven compressor that boosts engine power
Control Module
A control unit for one of the vehicle's systems (engine, gearbox, brakes, body, and so on)
Intercooler
A radiator that cools the air coming out of the turbocharger before it enters the engine
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
Relay
An electrically operated switch
Steering Angle Sensor
Tells the stability-control system which way the steering wheel is pointing
Trouble Code
A standardised fault code stored by a control module, read with a diagnostic tool
Wiring Harness
The bundled cables that carry power and signals around the vehicle
Auxiliary Heater
A separate heater (often fuel-fired) that warms the cabin or engine independently of the main heater
Calibration
Setting a sensor or module so its readings match the real world
Head Gasket
The seal between the cylinder head and the engine block
Oil Seal
A rubber seal that keeps oil in and dirt out, typically around a rotating shaft

Frequently asked questions

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

This guide contains 16 workshop bulletins for the Toyota Avensis 2.2 D-4D. Of these, 11 concern the engine and fuel system and three the clutch and gearbox. Symptoms, causes, repair steps and part numbers are shown where supplied.

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

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

Related guides

Glossary term

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