Recalls: Toyota XA20 RAV4
Overview
Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.
Recalls: Toyota XA20 RAV4
Toyota XA20 RAV4: headlamps may stop working
In October 2005, a recall was issued for Toyota XA20 RAV4 vehicles due to potential overheating of the headlamp dimmer switch contact points due to high internal electrical resistance (caused by residue build-up on the surface of the contract points). This could result in the headlamps becoming inoperative (PRA 2005/8110).
2003 Toyota XA20 RAV4: Takata airbag recall #1
In November 2014, a recall was issued for Toyota XA20 RAV4 vehicles that were manufactured from 29 July 2003 to 19 August 2003. In these vehicles, the propellant wafers inside the driver’s side front airbag were of insufficient density. In the event of airbag deployment, the combustion rate of the propellant may increase inside the inflator, causing the inflator housing to rupture and metal fragments to scatter (PRA 2014/14456). The recalled vehicles had VINs in the following ranges:
- JTE HD20V # 00001012 to JTE HD20V # 00001914;
- JTE HD20V # 00002475 to JTE HD20V # 00002795; and,
- JTE YD20V # 00001002 to JTE YD20V # 00001150.
2003-05 Toyota XA20 RAV4: Takata airbag recall #2
In May 2015, a recall was issued for Toyota XA20 RAV4 vehicles that were produced from 31 July 2003 to 25 October 2005. In these vehicles, the inflator propellant wafers within the driver’s front airbag may be susceptible to moisture intrusion. If this occurred, the inflator assembly may rupture during deployment and metallic fragments could contact the occupant. While the recall was issued in May 2015, it was not expected that replacement parts would be available until early 2016 (PRA 2015/14700). The recalled vehicles were in the following VIN ranges:
- JTE HD20V # 00001008 to JTE HD20V # 0075726; and,
- JTE YD20V # 00001013 to JTE YD20V # 00005030.
2003 Toyota XA20 RAV4: Takata airbag recall #3
In April 2017, a recall was issued for Toyota XA20 RAV4 vehicles that were manufactured from 29 July 2003 to 19 August 2003. In these vehicles, propellant wafers in the driver’s airbag could absorb moisture over time. In the event of a collision, the airbag may expand too aggressively and rupture the airbag inflator housing, causing metallic fragments to be dispersed throughout the cabin – these posed a serious risk of injury to vehicles occupants (PRA 2017/16014). The recalled Toyota XA20 RAV4 vehicles had VINs in the following ranges:
- JTE HD20V # 00001012 to JTE HD20V # 00002796; and,
- JTE YD20V # 00001002 to JTE YD20V # 00001150.
2001-05 Toyota XA20 RAV4: replacement front seatbelt may not restrain occupant
In November 2022, recall campaign XGG73 was issued for 2001-05 Toyota XA20 RAV4 vehicles. In vehicles that had been fitted with replacement front passenger or driver seatbelts, those seatbelts may extend further than intended after locking. In the event of a collision, the seatbelt may therefore not restrain the occupant as intended, increasing the risk of injury. To fix, the seatbelt assembly was to be replaced. For the VINs of the recalled vehicles, please see REC-005565.
Search online for recalls by VIN
To see if a Toyota vehicle has been recalled, you can conduct a search on the Toyota Australia website using its VIN.
Problems and faults: Toyota XA20 RAV4
Overview
This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.
To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.
2004-05 Toyota XA20 RAV4 (2AZ-FE): head gasket failure and coolant leaks due to stripped cylinder head bolt threads
In March 2011, Toyota USA issued Technical Service Bulletin 0015-11 which identified that 2004-05 Toyota XA20 RAV4 vehicles that had 2.4-litre 2AZ-FE engines may experience loose cylinder head bolts due to damaged threads in the cylinder block. Although not explained in the bulletin, loose cylinder bolts could cause rapid coolant loss, engine overheating and serious damage.
The three cylinder head bolt threads that were susceptible to stripping were located on the intake side of the block and between the cylinders (i.e. not the front and end bolt threads). These threads were at the thinnest part of the cylinder block, a design attribute to accommodate the curvature of the plastic air intake and a layer of insulating foam. While the foam insulated the plastic air intake from the cylinder block, it could also trap heat and create a ‘hotspot’ around the threads and head gasket in that area. It is understood that this heat could damage the head gasket (‘head gasket failure’) and that movement of the steel head bolts could strip the threads in the aluminium block. It is therefore important that coolant levels are monitored.
If coolant leaks are detected early, it is possible that only the head gasket may have failed and that the cylinder bolt threads are still intact. Symptoms of a failed head gasket include:
- A gradual loss of coolant;
- The engine running at a higher temperature than normal;
- Coolant mixing with the engine oil, apparent from a milky residue in the oil; and,
- A gurgling sound heard through the dashboard.
The symptoms of stripped cylinder block threads, however, are more obvious and serious:
- Rapid coolant loss and overheating;
- A strong smell of coolant;
- The insulating foam for the intake manifold is damp or wet; and,
- The cylinder head bolts can be pulled-out with very little effort, potentially by hand.
From Technical Service Bulletin 0015-11, the repair procedure for stripped cylinder head bolt threads was described as follows –
- Confirm the cylinder head bolt or bolts were loose due to damaged threads;
- Remove the short block assembly from the vehicle;
- the cylinder block assembly for flatness to ensure it meets specifications for re-use;
- Prepare the cylinder block for ‘Time Sert’ thread repair inserts;
- Use the core drill to repair the bolt holes;
- Use the tap to cut new threads for the insert;
- Use the insert driver to install the insert; and,
- Re-assemble and install the short block assembly with inserts installed.
While the 2AZ-FE engine had ten cylinder head bolts, only the six cylinder head bolts between the cylinders could be repaired (i.e. not the two bolts at the front or the two bolts at the back of the cylinder block). If any damage was found in these four bolts at the front and back of the cylinder block, the cylinder block itself was to be replaced. For more detailed instructions, please refer to the technical service bulletin.
2004 model year Toyota XA20 RAV4: accessory drive belt squeal/belt tensioner rattle
In September 2004, Toyota issued Technical Service Bulletin EG040-04 for 2004 model year Toyota RAV4 vehicles that:
- Had 2.4-litre 2AZ-FE engines; and,
- VINs preceding JTE#D2#V#40029797.
The 2AZ-FE engine in these vehicles may exhibit squealing and/or rattling noises from the engine compartment, especially on start-up from cold. According to the bulletin, a revised V-ribbed belt tensioner assembly (part number 16620-28011, replacing part number 16620-28010) was introduced to correct this condition. To fix, both the drive belt and accessory belt tensioner were to be replaced.
2000-02 Toyota XA20 RAV4: speedometer fluctuations or variations with cruise control
In October 2002, Toyota issued Technical Service Bulletin TC004-02 for 2000-02 model year Toyota XA40 RAV4 vehicles that had manual transmissions. According to the bulletin, these vehicles may exhibit the following conditions:
- A fluctuating speedometer needle; and/or,
- Slight variations in speed while using cruise control at highway speeds.
To fix, the speedometer drive gear and pinion shafts were to be replaced.
2000-03 Toyota XA20 RAV4: harsh gearshifts and check engine light
In July 2010, Toyota USA initiated Customer Service Campaign (CSC) 10034070-9912 for Toyota XA20 RAV4 vehicles that were produced from July 2000 to July 2003 and had automatic transmissions. These vehicles may exhibit the following symptoms:
- Harsh gearshifts; and,
- Illumination of the ‘check engine’ light related to diagnostic codes P0750, P0753, P0755, P0758 and/or P1760.
To fix, the engine control module (ECM) was to be replaced.
As part of the Customer Service Campaign, the warranty was extended for these symptoms to a period of 10 years or 150,000 miles from the vehicle’s in-service date, whichever occurred first.
2004-05 Toyota XA20 RAV4: ‘check engine’ light and P0011, P0012 or P0016
In February 2007, Toyota issued Technical Service Bulletin EG007-07 for ‘2005 model year’ Toyota XA20 RAV4 vehicles that had the 2.4-litre 2AZ-FE engine. These vehicles may experience illumination of the ‘check engine’ light with Diagnostic Trouble Code (DTC) P0011, P0012 or P0016 stored in the Engine Control Module (ECM). According to the service bulletin, these symptoms may be caused by the VVT-i actuator and this was to be fixed by replacing the camshaft timing gear assembly (replacing part number 13050-28020 with part number 13050-28021).
Toyota XA20 RAV4: other problems and faults
- Groaning noises from the front brakes could be corrected by fitting and revised brake pads.
- Squeaking and rattling noises from the A-pillars, rear windows and glove box could be fixed by the installation of felt inserts.
- For rattles or vibrations from the roof racks, an improved cross-bar with an additional thumbscrew was available.
