Toyota2005–2009

Corolla Verso CombiVan 2.2 D-4D 2AD-FTV: Common faults & known problems

Common faults & known problems

12 known faults documented in workshop bulletins. Of these, 10 concern the engine and fuel system and one the steering. Symptoms, causes, repair steps and part numbers are shown where supplied.

Technical specifications

Engine & fuel system

10 documented faults — symptoms, causes and workshop fixes.

Non start

Affects Corolla Verso/CombiVan (VIN →NMTEB16R50R014595). 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

Fit modified fuel return pipeB and non-return valveA.

Parts2 parts

Parts listed in the bulletin
Part	Part number	Qty
Fuel return pipe	23761-0R030	1
Non-return valve	23769-26020	1

Data: Motorwise Workshop. Bulletin 1.

Sudden power loss on acceleration

Affects Corolla Verso/CombiVan, engine code: 2AD-FHV (VIN →NMTEB16R30R067215). 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

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

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

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

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 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

Renew fuel additive injector.
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

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 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

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 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

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 11.

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

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

Data: Motorwise Workshop. Bulletin 12.

Clutch & gearbox

1 documented fault — 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

Renew transmission input shaft oil seal.
Check clutch assembly for oil contamination. Clean or replace clutch components as necessary.

Parts1 part

Parts listed in the bulletin
Part	Part number	Qty
Transmission input shaft oil seal	90311-30017	1

Data: Motorwise Workshop. Bulletin 5.

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
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
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
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 Corolla Verso CombiVan 2.2 D-4D?

This guide contains 12 workshop bulletins for the Toyota Corolla Verso CombiVan 2.2 D-4D. Of these, 10 concern the engine and fuel system and one the steering. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Toyota Corolla Verso CombiVan 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 Corolla Verso CombiVan 2.2 D-4D faults myself?

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