Toyota2006–2009

RAV4 2.2 D-4D 2AD-FHV: Common faults & known problems

Common faults & known problems

28 known faults documented in workshop bulletins. Of these, 11 concern the engine and fuel system and four the steering. Symptoms, causes, repair steps and part numbers are shown where supplied.

Technical specifications

Engine & fuel system

11 documented faults — symptoms, causes and workshop fixes.

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 1.

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 2.

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 5.

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 6.

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 7.

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 8.

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 9.

Engine malfunction indicator lamp (MIL) illuminated

Overview

Affects
All models with 2.2 Diesel engine.
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 01850), replace high-pressure fuel pump with modified version.

Data: Motorwise Workshop. Bulletin 10.

Noise and vibration through vehicle at 2500-3500rpm

Overview

Affects
All models with 2AD-FHV engine code and 6-speed automatic transmission, →12/11.
Parts
1 part

Cause

Turbocharger (TC) intercooler bottom pipe vibrating against radiator lower support panel.

Repair

  1. Fit rubber pad to turbocharger (TC) intercooler bottom pipe where contact has occurred.
  2. Ensure suitable clearance between turbocharger (TC) intercooler bottom pipe and radiator lower support panel.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Rubber pad17117-260101

Data: Motorwise Workshop. Bulletin 14.

Service interval indicator cannot be reset

Overview

Affects
All models with Diesel engines, →08/09.
Remedy
Software update

Symptoms

Service interval indicator not illuminating when service due.

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 engine control module (ECM) with upgraded software.

Data: Motorwise Workshop. Bulletin 20.

Lack of power

Overview

Affects
All models with Diesel engines, →10/11.
Fault codes
P2002
Remedy
Fit modified part
Parts
2 parts

Symptoms

Engine malfunction indicator lamp (MIL) illuminated. Trouble code stored: P2002.

Cause

Unsatisfactory design of fuel filter.

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: Fit modified fuel filter. Fit fuel filter cap. Re-program ECM with upgraded software. Note: To carry out an effective repair a software upgrade will be required - refer to manufacturer.
Parts2 parts
Parts listed in the bulletin
PartPart numberQty
Fuel filter cap23380-261121
Fuel filter23390-330301

Data: Motorwise Workshop. Bulletin 27.

Electrical & ignition

1 documented fault — symptoms, causes and workshop fixes.

Seat belt warning buzzer and warning lamp on when passenger's seat is unoccupied

Affects All models, →01/07.Fit modified part

Cause

Passenger's seat occupation pressure sensor too sensitive.

Repair

  1. Fit modified passenger's seat occupation pressure sensor.
Parts2 parts
Parts listed in the bulletin
PartPart numberQty
Seat occupation pressure sensor - RHD71052-420611
Seat occupation pressure sensor - LHD71051-420411

Data: Motorwise Workshop. Bulletin 4.

Brakes

2 documented faults — symptoms, causes and workshop fixes.

ABS warning lamp illuminated

Affects All models.C1249Fit new part

Symptoms

Trouble code stored in ABS control module fault memory: C1249.

Cause

Brake pedal position (BPP) switch faulty.

Repair

  1. Fit new BPP switch.

Data: Motorwise Workshop. Bulletin 23.

Engine malfunction indicator lamp (MIL) illuminated. Trouble code stored: P0607

Overview

Affects
All models with four wheel drive and trailer socket.
Fault codes
P0607
Remedy
Fit modified part
Parts
2 parts

Cause

Corrosion of connectors in trailer socket.

Brake pedal position (BPP) switch faulty.

Repair

  1. Check trailer socket for corrosion. If corrosion present: Fit new trailer socket.
  2. If no corrosion present: Fit modified brake pedal position (BPP) switch.
Parts2 parts
Parts listed in the bulletin
PartPart numberQty
Trailer socketZ457P-00560-011
Brake pedal position (BPP) switch84340-690251

Data: Motorwise Workshop. Bulletin 25.

Suspension & drivetrain

3 documented faults — symptoms, causes and workshop fixes.

Knocking noise from front suspension when driving over speed humps

Overview

Affects
All models, →12/10.

Cause

Internal fault with front shock absorbers.

Repair

  1. Replace front shock absorbers with modified version.
  2. Check front wheel alignment and adjust if necessary.

Data: Motorwise Workshop. Bulletin 18.

Knocking noise from front suspension when manoeuvring or parking

Excessive friction between front suspension strut upper mounting and shock absorber bump stop. Fix: fit a modified part.

Overview

Affects
All models with four wheel drive.
Remedy
Fit modified part

Repair steps

  1. Disassemble front suspension struts.
  2. Fit modified shock absorber bump stop and plastic washer. Ensure plastic washer fitted on top of shock absorber bump stop.
  3. Reassemble suspension struts and refit.

Parts

Parts listed in the bulletin
PartPart numberQty
Front bump stop48331-420502
Plastic washer48334-420102

Data: Motorwise Workshop. Bulletin 24.

Knocking noise from rear suspension over uneven surfaces

Overview

Affects
All models, →04/12.
Remedy
Fit modified part
Parts
3 parts

Cause

Unsatisfactory design of rear anti-roll bar link rod bushes causing damage to anti-roll bar link rods.

Repair

  1. Fit modified rear anti-roll bar link rods.
  2. Fit modified bushes to rear anti-roll bar link rods.
Parts3 parts
Parts listed in the bulletin
PartPart numberQty
Anti-roll bar link rod48830-420212
Anti-roll bar link rod bush48817-050102
Anti-roll bar link rod bush48817-050202

Data: Motorwise Workshop. Bulletin 28.

Steering

4 documented faults — symptoms, causes and workshop fixes.

Knocking noise from steering mechanism when driving over rough roads

Affects All models, →04/08.Fit modified part

Cause

Unsatisfactory design of steering rack.

Repair

  1. Fit modified steering rack.

Data: Motorwise Workshop. Bulletin 15.

Knocking noise from steering column when steering wheel turned

Affects All models, →07/10.Fit modified part

Cause

Unsatisfactory design of steering column lower shaft.

Repair

  1. Fit modified steering column lower shaft.
Parts2 parts
Parts listed in the bulletin
PartPart numberQty
Steering column lower shaft45221-420801
Clamp90460-640031

Data: Motorwise Workshop. Bulletin 17.

Knocking noise when turning steering wheel

Affects All models, →07/07.Adjust & tighten

Symptoms

Knocking felt through steering wheel when turning.

Cause

Fascia crossmember mounting bolts loose.

Repair

  1. Retighten fascia crossmember mounting bolts to 20 Nm.

Data: Motorwise Workshop. Bulletin 21.

Electric power steering (EPS) warning lamp illuminated

Overview

Affects
All models.
Fault codes
U0105U0121
Remedy
Fit modified part

Cause

Electric power steering (EPS) control module failure.

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 electric power steering (EPS) control module.

Data: Motorwise Workshop. Bulletin 26.

Clutch & gearbox

1 documented fault — symptoms, causes and workshop fixes.

Noise from gearbox when decelerating in 2nd or 3rd gear

Overview

Affects
All models with Diesel engines and manual transmission, →05/07.
Remedy
Fit modified part
Parts
4 parts

Symptoms

Rattling noise from gearbox with engine idling and gearbox in neutral.

Cause

Gear selector cable transmitting noise into vehicle interior.

Insufficient sound proofing in vehicle interior.

Repair

  1. Fit modified gear selector cable mounting bracket.
  2. If necessary, fit sound proofing kit under carpet to floor pan.
Parts4 parts
Parts listed in the bulletin
PartPart numberQty
Gear selector cable mounting bracket335A0-420101
Bolt90119-08C603
Sound proofing kit (LHD)04008-031421
Sound proofing kit (RHD)04008-032421

Data: Motorwise Workshop. Bulletin 16.

Body & trim

4 documented faults — symptoms, causes and workshop fixes.

Front bumper detached at side mounting brackets

Affects All models built in Japan, →06/08.Fit modified part

Cause

Poor manufacture of front bumper side mounting brackets.

Repair

  1. Fit modified front bumper side mounting brackets.

Data: Motorwise Workshop. Bulletin 3.

Front door not opening using interior door handle in very cold conditions

Affects All models, →04/07.Fit modified part

Cause

Unsatisfactory design of door lock mechanism release cable.

Repair

  1. Fit modified door lock mechanism release cable.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Door lock mechanism release cable69750-420312

Data: Motorwise Workshop. Bulletin 12.

Instrument panel not working

Overview

Affects
All models, →07/06.
Remedy
Fit modified part

Symptoms

Erratic instrument panel operation.

Cause

Instrument panel faulty.

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 instrument panel.

Data: Motorwise Workshop. Bulletin 19.

Front edge of bonnet vibrates whilst driving at high speed

Affects All models.

Cause

Excessive clearance between bonnet and bonnet slam panel.

Repair

  1. Fit sealing strips to front edge of bonnet.
Parts3 parts
Parts listed in the bulletin
PartPart numberQty
Sealing strip, RH52543-420101
Sealing strip, LH52544-420101
Sealing strip, centre53396-420201

Data: Motorwise Workshop. Bulletin 22.

Wipers & visibility

2 documented faults — symptoms, causes and workshop fixes.

Rear wiper not working

Overview

Affects
All models, →02/08.
Remedy
Fit modified part
Parts
1 part

Cause

Rear wiper arm frozen in cold conditions, causing internal failure of wiper motor.

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 rear wiper motor.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Rear wiper motor85130-420611

Data: Motorwise Workshop. Bulletin 11.

Radio interference when rear wiper is operating

Overview

Affects
All models, →02/08.
Remedy
Fit modified part
Parts
2 parts

Cause

Rear wiper motor faulty.

Repair

  1. Fit modified rear wiper motor.
  2. Fit modified rear wiper motor wiring harness.
Parts2 parts
Parts listed in the bulletin
PartPart numberQty
Rear wiper motor85130-420611
Rear wiper motor wiring harness82375-420101

Data: Motorwise Workshop. Bulletin 13.

Glossary

Technical terms used in this guide.

MIL
Malfunction indicator lamp — the engine warning light on the dashboard
ECM
Engine control module — the electronic unit that manages the engine
Nm
Newton-metres — the standard unit for how tightly a bolt is done up
ABS
Anti-lock braking system — stops the wheels locking under hard braking
DPF
Diesel particulate filter — traps soot in the exhaust and burns it off periodically
BPP Switch
Brake pedal position switch — behind the pedal, it triggers the brake lights
BPP
Brake pedal position — the switch behind the pedal that triggers the brake lights
TC
Turbocharger — the exhaust-driven compressor that boosts engine power
Anti-Roll Bar
A bar that links the left and right suspension to cut body roll in corners
Control Module
A control unit for one of the vehicle's systems (engine, gearbox, brakes, body, and so on)
Fascia
The dashboard and the surrounding interior panel
Fault Memory
The list of stored trouble codes in a control module
Instrument Panel
The dashboard display that shows warning lights and messages
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
Selector Cable
The cable that connects the gear lever to the gearbox
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
Bushes
Rubber mountings that let a suspension or body joint move without metal-to-metal contact
Head Gasket
The seal between the cylinder head and the engine block

Frequently asked questions

What are the common faults with the Toyota RAV4 2.2 D-4D?

This guide contains 28 workshop bulletins for the Toyota RAV4 2.2 D-4D. Of these, 11 concern the engine and fuel system and four the steering. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Toyota RAV4 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 RAV4 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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