Toyota2003–2006

Avensis 2.0 D-4D: Common faults & known problems

Common faults & known problems

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

Technical specifications

Engine & fuel system

6 documented faults — symptoms, causes and workshop fixes.

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 2.

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 3.

Poor or non start

Affects All models with 2.0 Diesel engine, →11/04.Fit modified part

Symptoms

The engine control module (ECM) fault memory cannot be accessed using diagnostic equipment.

Cause

Fuel rail pressure (FRP) sensor faulty.

Repair

Fit modified fuel rail complete with fuel rail pressure (FRP) sensor.

Parts2 parts

Parts listed in the bulletin
Part	Part number	Qty
Fuel rail - D-4D	23810-27030	1
Fuel rail - D-CAT	23810-27040	1

Data: Motorwise Workshop. Bulletin 5.

Poor starting from cold

Overview

Affects: All models.
Fault codes: P0380C1201
Remedy: Fit new part

Symptoms

Trouble codes stored: P0380, C1201.

Cause

Defective glow plugs.

Engine control module (ECM) software fault.

Repair steps

Fit new glow plugs.
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.

Parts

Parts listed in the bulletin
Part	Part number	Qty
Glow plug	19850-27010	4

Data: Motorwise Workshop. Bulletin 6.

Lack of power

Affects All models with 1CD-FTV engine code, →05/05.Fit modified part

Symptoms

Hissing noise from engine bay.

Cause

Turbocharger (TC) intercooler bottom hose split.

Repair

Fit modified turbocharger (TC) intercooler bottom hose.

Parts1 part

Parts listed in the bulletin
Part	Part number	Qty
Turbocharger (TC) intercooler hose	17343-27030	1

Data: Motorwise Workshop. Bulletin 10.

Sudden power loss on acceleration

Affects All models with 1CD-FTV engine code.P0627Fit modified part

Symptoms

Trouble code stored in engine control module (ECM) fault memory: 78 (2), 78 (8), P0627.

Cause

Fuel flow control valve faulty.

Repair

Fit modified fuel flow control valve.

Parts1 part

Parts listed in the bulletin
Part	Part number	Qty
Fuel flow control valve	04221-27011	1

Data: Motorwise Workshop. Bulletin 12.

Brakes

1 documented fault — symptoms, causes and workshop fixes.

Brakes squeal

Overview

Affects: All models.

Cause

Replacement brake pads fitted without anti-squeal shims.

Repair

Ensure brake pad anti-squeal shims are fitted.
Replacement shims available separately.

Data: Motorwise Workshop. Bulletin 1.

Steering

2 documented faults — 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

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

Data: Motorwise Workshop. Bulletin 7.

Squeaking noise from engine area

Affects All models with 1CD-FTV engine code.

Cause

Auxiliary drive belt(s) worn.

Auxiliary drive belt tensioner faulty.

Power steering pump faulty.

PAS pump pulley faulty.

AC compressor faulty.

Repair

Check components and replace as necessary.

Data: Motorwise Workshop. Bulletin 11.

Clutch & gearbox

4 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 4.

Strong odour in vehicle interior due to excessive clutch slip

Affects All models with 1CD-FTV engine code and manual transmission, →11/05.Fit modified part

Symptoms

Clutch slip.

Cause

Unsatisfactory design of clutch assembly causing premature wear.

Repair

Fit modified clutch centre plate and modified clutch pressure plate.

Parts2 parts

Parts listed in the bulletin
Part	Part number	Qty
Clutch centre plate	31250-05110	1
Clutch pressure plate	31250-05051	1

Data: Motorwise Workshop. Bulletin 9.

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 13.

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

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

Data: Motorwise Workshop. Bulletin 14.

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

Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
If no fault(s) found: Fit modified wiring harness in engine bay.

Parts1 part

Parts listed in the bulletin
Part	Part number	Qty
Wiring harness	82114-05060	1

Data: Motorwise Workshop. Bulletin 8.

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
Fuel Rail: The pipe that distributes high-pressure fuel to the injectors
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
MAF: Mass air flow — a sensor that measures how much air the engine is breathing
PAS: Power assisted steering — hydraulic or electric help when you turn the wheel
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)
Fault Memory: The list of stored trouble codes in a control module
Glow Plugs: Heaters that help a diesel engine start from cold
Intercooler: A radiator that cools the air coming out of the turbocharger before it enters the engine
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 Drive Belt: The belt that drives the alternator, water pump, steering pump or air-conditioning compressor
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
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 Avensis 2.0 D-4D?

This guide contains 14 workshop bulletins for the Toyota Avensis 2.0 D-4D. Of these, six concern the engine and fuel system and four the clutch and gearbox. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Toyota Avensis 2.0 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 2.0 D-4D faults myself?

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