Engine & fuel system
5 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
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
| 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
| Part | Part number | Qty |
|---|---|---|
| Glow plug | 19850-27010 | 4 |
Data: Motorwise Workshop. Bulletin 6.
Sudden power loss on acceleration
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
| Part | Part number | Qty |
|---|---|---|
| Fuel flow control valve | 04221-27011 | 1 |
Data: Motorwise Workshop. Bulletin 11.
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
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 10.
Clutch & gearbox
4 documented faults — symptoms, causes and workshop fixes.
Squeaking noise when clutch pedal depressed or released
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
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
| 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
Cause
AC compressor clutch relay faulty.
Repair
- Replace AC compressor clutch relay.
Data: Motorwise Workshop. Bulletin 12.
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 13.
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
| 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
- 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
- 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-CAT?
This guide contains 13 workshop bulletins for the Toyota Avensis 2.0 D-CAT. Of these, five 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-CAT 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-CAT faults myself?
Many of them. The documented symptoms can be seen, heard or felt during a test drive.