Workshop Manuals Factory service & repair Toyota

Toyota common faults and how to fix them

Faults that are well known on Toyota models we hold manuals for: what the owner notices, what causes it, and the pages in our manuals that cover the repair.

P0420 Toyota: catalyst efficiency code on the Camry, Corolla, Matrix and RAV4 (2001–2004)

Symptoms

The check engine light comes on and code P0420 (catalyst system efficiency below threshold, bank 1) is stored, sometimes with P0430 on V6 engines or P0136 for the rear oxygen sensor. The car usually drives normally. Some cars also give off a rotten-egg (sulphur) smell from the exhaust.

Cause

On several early-2000s Toyotas the engine computer's catalyst monitor was too sensitive, and on some the original catalytic converter lost efficiency early. Toyota issued bulletins for the 2002–2004 Camry 2.4 (2AZ-FE), the 2003–2004 Corolla and Matrix 1.8 (1ZZ-FE) and the 2001–2002 RAV4 (1AZ-FE). The fixes are a revised ECM calibration, a redesigned catalytic converter, or both.

Fix

First check for exhaust leaks ahead of the rear oxygen sensor and look at the oxygen sensor readings, as a leak or a lazy sensor sets the same code. Then check the bulletin for the car. The Camry check engine light bulletin EG024R-04 reprograms the ECM and fits the redesigned catalyst; the ECM recalibration must only be done once. The Corolla bulletin does the same, and for a P0420 Toyota RAV4 the fix is a revised calibration alone. A 2003 Corolla or Matrix with P0136 and P0420 together needs a new ECM.

Repair instructions on this site

Sources: Toyota technical service bulletins EG024R-04, EG028R-04, EG026R-04, EG011-02 and EG010-02.

Tacoma ball joint recall: front lower ball joints on the Tacoma, Sequoia and Tundra

Symptoms

Steering gets heavier, the wheel is slower to return to the centre after a turn, and there may be a clunk or knock from the front suspension over bumps. In extreme cases a worn lower ball joint can separate from the steering knuckle, which can cause loss of steering control.

Cause

Toyota recalled the front lower ball joints twice. NHTSA recall 05V225000 (about 775,000 vehicles) says a manufacturing issue could leave the surface of the ball scratched, leading to excessive wear and looseness. Recall 07V013000 (about 533,000 trucks and minivans) says improper finishing could let the joint's internal lubrication deteriorate, so it wears and loosens early. The first appears in our Tacoma and Sequoia manuals, the second in our Sequoia and Tundra manuals.

Fix

Check with a Toyota dealer whether the recall work has been done; the remedy is new front lower ball joints. To inspect for wear, raise the front, load the joint and check for play as the manual describes. The Tacoma lower ball joint replacement procedure covers removal from the knuckle and the torque figures. The Tacoma ball joint recall notice lists what the dealer replaces. Have the alignment checked afterwards.

Repair instructions on this site

Sources: NHTSA recalls 05V225000 and 07V013000.

Toyota floor mat recall and sticking accelerator pedal (2004–2010)

Symptoms

The accelerator pedal stays down, or returns slowly, after you lift off. With a trapped pedal the car can keep accelerating hard. A sticking pedal feels stiff or slow to come back, most often when the cabin is cold and damp.

Cause

Two separate recalls. NHTSA recall 09V388000 covers 2004–2010 Toyotas whose accelerator pedal can be trapped wide open by an unsecured or incompatible driver's floor mat. Recall 10V017000 covers the 2005–2010 Avalon, 2007–2010 Camry, 2009–2010 Corolla, Matrix and RAV4, 2010 Highlander, 2008–2010 Sequoia and 2007–2010 Tundra: a friction lever inside the pedal assembly wears smooth, and with condensation the pedal can be slow to return or stick part-way.

Fix

Check with a Toyota dealer that both recalls have been done. For the Toyota floor mat recall, use only the correct mat for the car, secured on its retaining clips, and never stack mats. The Toyota sticky pedal recall remedy modifies or replaces the pedal assembly. If a pedal sticks while driving, press the brake firmly and shift to neutral.

Repair instructions on this site

Sources: NHTSA recalls 09V388000 and 10V017000; Wikipedia — 2009–2011 Toyota vehicle recalls.

Tundra air injection pump: P2440 and P0418 codes (2007–2010)

Symptoms

The check engine light comes on. Typical codes are P0418, P0419, P2440, P2441, P2442, P2443, P2446 and P2447, all for the secondary air injection system, which only runs for a short time after a cold start.

Cause

The Tundra and Sequoia V8s pump fresh air into the exhaust for a short time after a cold start to heat the catalytic converters. Water gets into the air injection pump and its switching valves, so they stick or fail. Toyota bulletin 0329-08 covers 2007–2008 Tundra and 2008 Sequoia models, and bulletin 0350-09 covers 2010 Tundra models built in the Texas plant.

Fix

Read the codes and follow the bulletin's diagnosis, which checks the pump and the two air switching valves before replacing anything. Replace the failed Tundra air injection pump or valves with the revised parts listed. For later trucks, P2440 Toyota bulletin 0350-09 gives the same repair. Toyota updated the warranty coverage on these parts, so check with a dealer before paying.

Repair instructions on this site

Sources: Toyota technical service bulletins T-SB-0329-08 (rev. 2) and T-SB-0350-09 (rev. 1).

Repair instructions for every Toyota model: Toyota workshop manuals