Toyota2001–2006

RAV4 2.0 D-4D: Common faults & known problems

Common faults & known problems

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

Technical specifications

Engine & fuel system

3 documented faults — symptoms, causes and workshop fixes.

Intermittent non start when ignition switched from off position to start position too quickly

Overview

Affects: All models.
Remedy: Fit modified part

Symptoms

Poor starting when engine is hot.

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: Fit modified engine control module (ECM).

Data: Motorwise Workshop. Bulletin 2.

Whistling noise from engine bay at approximately 2000rpm when engine cold at low vehicle speed

Affects All models with 1CD-FTV engine code, →04/05.Fit modified part

Cause

Unsatisfactory design of fuel filter.

Repair

Fit modified fuel filter and fuel filter mounting.

Parts3 parts

Parts listed in the bulletin
Part	Part number	Qty
Fuel filter	23390-33020	1
Fuel filter mounting (RAV4)	23380-27110, or 2323380-27121	1
Fuel filter mounting (except RAV4)	23380-27101	1

Data: Motorwise Workshop. Bulletin 3.

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 4.

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 7.

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 5.

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 6.

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)
Fault Memory: The list of stored trouble codes in a control module
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
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

Frequently asked questions

What are the common faults with the Toyota RAV4 2.0 D-4D?

This guide contains seven workshop bulletins for the Toyota RAV4 2.0 D-4D. Of these, three concern the engine and fuel system and two the clutch and gearbox. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Toyota RAV4 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 RAV4 2.0 D-4D faults myself?

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