Toyota2009–2011

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

Common faults & known problems

15 known faults documented in workshop bulletins. Of these, six concern the engine and fuel system and three the suspension and drivetrain. Symptoms, causes, repair steps and part numbers are shown where supplied.

Technical specifications

Engine & fuel system

6 documented faults — symptoms, causes and workshop fixes.

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 1.

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 2.

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 3.

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 4.

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 8.

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 14.

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 10.

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 12.

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 7.

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 11.

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 15.

Steering

2 documented faults — symptoms, causes and workshop fixes.

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 6.

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 13.

Clutch & gearbox

1 documented fault — symptoms, causes and workshop fixes.

Abnormal noise from clutch master cylinder when clutch pedal depressed or released

Affects All models with 1AZ-FE/2AD-FTV engine codes, →09/06.Fit modified part

Cause

Insufficient clearance between clutch master cylinder pushrod and clutch master cylinder bore.

Repair

  1. Fit modified clutch master cylinder.

Data: Motorwise Workshop. Bulletin 5.

Body & trim

1 documented fault — symptoms, causes and workshop fixes.

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 9.

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
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
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)
Fault Memory
The list of stored trouble codes in a control module
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
Trouble Code
A standardised fault code stored by a control module, read with a diagnostic tool
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 2.0 D-4D?

This guide contains 15 workshop bulletins for the Toyota RAV4 2.0 D-4D. Of these, six concern the engine and fuel system and three the suspension and drivetrain. 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.

Related guides

Glossary term

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