Toyota Avensis recalls

Driver's air bag inflator may rupture upon deployment.�

Fix: Replace the drivers air bag assembly.�

77,926 vehicles · built 22 Aug 2002 to 24 Apr 2006

A possibility that the Exhaust Gas Recirculation (EGR) cooler could develop an internal coolant leak

Fix: Replace the EGR cooler in all involved vehicles and if necessary replace the inlet manifold.

24,241 vehicles · built 6 May 2015 to 4 May 2018

An incorrect tightening torque was applied at the moment of injector re-installation.

Fix: Check the injector clamp bolt torque and replace the parts if necessary.

321 vehicles · built 11 May 2015 to 13 Mar 2018

Possible fuel leak from fuel tank.

Fix: Replace the fuel tank emission control Canister.

85,909 vehicles · built 28 Jan 2008 to 22 Apr 2015

Possible inadvertent air bag deployment.

Fix: Replace the airbag sensor assembly.

131,435 vehicles · built 22 Aug 2002 to 24 Apr 2006

Passenger air bag may cause injury if activated.

Fix: Replace affected air bag assembly.

99,588 vehicles · built 28 Jan 2003 to 21 Apr 2006

Affected vehicles have a 2.0 litre turbocharged diesel engine. There is a possibility that the bolts on the exhaust-side of the turbocharger assembly may not have been correctly tightened during manufacture.

Fix: On affected vehicles check bolts. Where necessary replace the turbocharger.

• AVENSIS: 442 vehicles · built 22 Jun 2016 to 26 Oct 2016
• AVENSIS: 442 vehicles · built 22 Jun 2016 to 25 Oct 2016

The subject vehicles are equipped with right front seat side airbags which may not deploy in a collision as intended.

Fix: Recall the vehicles that are likely to be affected and replace the right front seat side airbags.

• AVENSIS: 243 vehicles · built 6 Oct 2016 to 21 Oct 2016
• AVENSIS: 243 vehicles · built 6 Sep 2016 to 21 Oct 2016
• AVENSIS: 243 vehicles · built 31 Aug 2016 to 15 Dec 2016
• AVENSIS: 243 vehicles · built 9 Sep 2016 to 21 Oct 2016

Internal cluctch pistons may have been incorrectly manufacturerd. This may cause incorrect transmission operation.

Fix: On affected vehicles inspect clutch opertaion. Depending on out come either replace clutch component or transmission unit.

14 vehicles · built 24 Oct 2008 to 31 Oct 2008

The roof window glass may not have been correctly installed . This may allow the glass to separate from its frame. Initially this will lead to wind noise but continued use could cause the glass to detach from the frame.

Fix: Replace roof glass.

42 vehicles · built 19 Aug 2013 to 21 Dec 2013

The subject vehicles are equipped with front passenger airbag inflators which could have been assembled with improperly manufactured propellant wafers. Improperly manufactured propellant wafers could cause the inflator to rupture and the front passenger airbag to deploy abnormally in a crash. This could result in increased risk of injury to the occupant and the possibility of a fire.

Fix: Recall the vehicles that are likely to be affected to replace the airbag.

542,751 vehicles · built 29 Jan 2003 to 22 Dec 2007

The subject vehicles are equipped with front passenger airbag inflators which could have been assembled with improperly manufactured propellant wafers. Improperly manufactured propellant wafers could cause the inflator to rupture and the front passenger airbag to deploy abnormally in a crash. This could result in increased risk of injury to the occupant and the possibility of a fire.

Fix: Recall the vehicles that are likely to be affected to replace the airbag.

85,405 vehicles · built 8 Jan 2001 to 15 Nov 2003

It is possible that the splines of the extension shaft on vehicles equipped with Electric Motor assisted Power Steering (EMPS) may not have received the correct hardness treatment. This can cause the spline to distort and wear and eventually result in loss of steering.

Fix: Recall affected vehicles check and if necessary replace the shaft.

61,910 vehicles · built 21 Aug 2002 to 14 Oct 2008

On Toyota Avensis Previa and Lexus GS fitted with a Toyota or Lexus genuine or Brink branded (only on Avensis) detachable towing hitch the possibility exists that the detachable towing ball in some exceptional cases (under severe mechanical stress) might develop a crack. In a worst case the detachable towing ball might fracture and/or fail.

Fix: Lexus/Toyota dealers will replace the detachable towing ball and housing at no cost to vehicle owners.

• AVENSIS: 901 vehicles · built 22 Jan 2003 to 14 Oct 2008
• AVENSIS: 901 vehicles · built 28 Jan 2003 to 13 Oct 2008
• AVENSIS: 901 vehicles · built 12 Mar 2003 to 10 Apr 2006
• AVENSIS: 901 vehicles · built 18 Apr 2005 to 13 Oct 2008

If the rear suspension arm is adjusted as part of a wheel alignment or other repairs whilst in service it is possible that backlash can occur. This can allow corrosion to develop and cause the threads to deteriorate. Ultimately this could result in failure of the arm with a resultant loss of control of the vehicle.

Fix: Recall all affected vehicles to check the torque on the arm. Where necessary the arm will be replaced.

65,863 vehicles · built 22 Oct 2008 to 18 Jan 2011

It is possible that during the manufacturing process the wall thickness of the high pressure supply pipe may have been reduced. If the driving conditions of the vehicle cause fuel pressure fluctuations this could cause cracking and result in a fuel leak. Also due to gasket fatigue and prolonged usage the high pressure fuel pump check valve may be come loose and leak.

Fix: Recall all affected vehicles for the replacement of the fuel pipe and fuel pump check valve plus gasket.

• AVENSIS: 15,639 vehicles · built 23 Aug 2002 to 9 Sep 2003
• AVENSIS: 15,639 vehicles · built 10 Jul 2000 to 22 Dec 2002
• AVENSIS: 15,639 vehicles · built 9 Jun 2003 to 16 Jun 2003
• AVENSIS: 15,639 vehicles · built 19 Sep 2003 to 18 Jun 2008
• AVENSIS: 15,639 vehicles · built 9 Jul 2003 to 9 Jul 2008
• AVENSIS: 15,639 vehicles · built 26 Aug 2005 to 2 May 2008

It has been identified that on affected vehicles condensation resulting from cold-weather use of the heater or other causes may form on the worn surface of a component within the throttle pedal assembly known as the friction device. If this occurs there is a possibility that in the worst case the accelerator pedal may return slowly or does not return to the engine idle position.

Fix: Recalled vehicles will have a precision-cut steel reinforcing bar fitted into the accelerator pedal assembly which will create a space in order to reduce the surface tension between the friction device and a component referred to as the pedal arm. The subject bar also strengthens the reaction force of the spring that returns the accelerator pedal to it's non-pressed position.

174,426 vehicles · built 1 Nov 2008 to 31 Dec 2009

It has been identified thaton certain vehicles equipped with a genuine Toyota towing hitch the hitch installation bolts were over-tightened. In the worst case the bolts may break under certain conditions of usage.

Fix: Recalled vehicles will have the hitch installation bolts replaced and tightened to the correct torque.

• AVENSIS: 6 vehicles · built 29 Oct 2008 to 10 Feb 2009
• AVENSIS: 6 vehicles · built 28 Oct 2008 to 10 Feb 2009

On certain Avensis vehicles equipped with 16 inch steel wheels due to the shape of the wheel trim there is a possibility that the edge of the wheel trim may interfere with the sidewall of the tyre. Should this occur whilst the vehicle is being driven the wheel trims may rotate which could lead to interference with the tyre valve. In the worst case and if the vehicle is continuously driven in this condition loss of tyre pressure could ensue.

Fix: Recalled vehicles will have the steel wheels (standard equipment) replaced with aluminium alloy wheels.

39 vehicles · built 8 May 2006 to 19 Jun 2006

It is possible that the connections at the intermediate shaft and sliding yoke of the steering column may become loose and if the symptoms are ignored steering control can be lost.

Fix: Recall the vehicles that are likely to be affected and replace the steering intermediate shaft. In addition inspect the sliding yoke and intermediate shaft extension and replace if necessary. This recall is staggered starting with Prius and Corrolla. Avensis customer letters will be sent out over the next three months

39,372 vehicles · built 1 Jan 2003 to 31 Dec 2005

Anti-chipping paint (foam filled vinyl chloride) was applied in error to the clamping area where the rear lower suspension arm brackets are connected. This could lead to the bolts loosening over time.

Fix: Recall the potentially affected vehicles. Check and if necessary remove the incorrectly applied paint then re torque the bolts.

1,372 vehicles · built 16 Aug 2004 to 3 Sep 2004

In rare cases the VSC (vehicle Stability Control) warning light may illuminate and the system stop working due to the Yaw rate sensor becoming disconnected internally. In even rarer cases the VSC may not function correctly even if the VSC light is not illuminated (partial disconnection). In these circumstances the VSC will not function. The VSC helps to prevent the vehicle from slipping sideways as a result of a strong front wheel skid or a strong rear wheel skid during cornering. The normal braking system is unaffected.

Fix: Recall vehicles that are likely to be affected and inspect. If necessary replace the Yaw rate sensor.

321 vehicles · built 25 Jun 2004 to 7 Jul 2004

It is possible on certain Avensis models fitted with Electric Motor assisted Power Steering (EMPS) that the intermediate steering shaft was incorrectly assembled this can result in premature wear of the shaft splines. This is identified by the abnormal noise produced however if the vehicle continues to be driven in this condition it may become difficult or in the worst case impossible to steer.

Fix: Inspect and if necessary replace the intermediate steering shaft.

• AVENSIS: 10,627 vehicles · built 15 Jan 2003 to 5 Nov 2003
• AVENSIS: 10,627 vehicles

The brake pipes leading into the ABS actuator may have been incorrectly positioned. This could cause an imbalance in performance under heavy braking.

Fix: Check and reposition the brake pipes if necessary.

1,537 vehicles · built 15 Jan 2003 to 14 Mar 2003

The crimping connector of the inflator cartridge may be incorrectly assembled with the curtain airbag on certain vehicles. In the event of airbag activation full deployment of the curtain shield cannot be guaranteed due to this condition.

Fix: Replace the curtain shield airbag.

31 vehicles · built 8 Mar 2003 to 17 Mar 2003

There is a possibility that the car spoiler may become loose or detached.

Fix: Recall affected vehicles to revise spoiler fixing method to bolts.

916 vehicles · built 1 Feb 1999 to 30 Jul 2000

There is a possibility that excessive residual stress remains on the check valve of the fuel pump during the assembly process. If the vehicle is driven with the residual stress the check valve may leak fuel.

Fix: Recall affected vehicles to re-tighten the fuel pump check valve and replace the relevant fuel pipe to protect against stress fracture.

3,088 vehicles · built 10 Jul 2000 to 28 Jun 2001