Toyota2000–2006

RAV4 1.8: Common faults & known problems

Common faults & known problems

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

Technical specifications

Engine & fuel system

1 documented fault — symptoms, causes and workshop fixes.

Unable to remove in-tank fuel pump

Overview

Affects: All models with in-tank fuel pump assembly retaining ring.
Remedy: Fit new part

Cause

Retaining ring for fuel pump assembly seized to fuel tank.

Repair

Cut through retaining ring to enable removal from fuel tank. Avoid damaging fuel tank threads.
Inspect fuel tank threads for damage. If fuel tank threads damaged or new retaining ring will not tighten: Fit new fuel tank.

Data: Motorwise Workshop. Bulletin 5.

Electrical & ignition

1 documented fault — symptoms, causes and workshop fixes.

Failure of speedometer

Water ingress into vehicle speed sensor (VSS) wiring harness multi-plug. Fix: clean and lubricate.

Overview

Affects: All models.
Remedy: Clean & lubricate

Repair steps

Locate and disconnect vehicle speed sensor (VSS) wiring harness multi-plug at kick panel.
Inspect harness multi-plug terminals. Repair/replace wiring as necessary.
Check sunroof water drain tubes for correct routing or blockages. Clean or replace water drain tubes as necessary.

Data: Motorwise Workshop. Bulletin 4.

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.

Clutch & gearbox

2 documented faults — symptoms, causes and workshop fixes.

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 2.

Poor gear shifting when up-shifting

Engine control module (ECM) faulty. Fix: fit a new part.

Overview

Affects: All models with automatic transmission (AT).
Remedy: Fit new part

Repair steps

Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
If no fault(s) found: Fit new engine control module (ECM).
Obtain and reprogram all keys.

Data: Motorwise Workshop. Bulletin 3.

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)
In-Tank Fuel Pump: The fuel pump mounted inside the fuel tank
Multi-Plug: A multi-pin electrical connector on a wiring harness
Relay: An electrically operated switch
Reprogram: Update the software on a control module using the manufacturer's diagnostic tool
Wiring Harness: The bundled cables that carry power and signals around the vehicle

Frequently asked questions

What are the common faults with the Toyota RAV4 1.8?

This guide contains five workshop bulletins for the Toyota RAV4 1.8. Of these, two concern the clutch and gearbox and one the engine and fuel system. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Toyota RAV4 1.8 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 RAV4 1.8 faults myself?

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