Rav 4 T180 Catylitic Converter Problems.

[Bugsey]

Whilst driving my T180 the engine management light came on, after various phone calls to my main dealer and with help from the Rac, my Rav was put on a low loader and taken to my main dealer. It turns out that i need a new Catylitic Converter, at a cost of £900.00. Today i was informed by the Main dealer that the engine has to come out to fit a new one with a total cost of £1600.00. My rav is just over 4 years old with 55k miles and just out of warranty (february). Firstly can anyone answer why the Cat would fail with no warning sign and also do they really cost so much and are the dealership pulling the wool over my eyes as having to remove the engine to replace the Catylitic Converter. Many Thanks.

[Offroadster]

Whilst driving my T180 the engine management light came on, after various phone calls to my main dealer and with help from the Rac, my Rav was put on a low loader and taken to my main dealer. It turns out that i need a new Catylitic Converter, at a cost of £900.00. Today i was informed by the Main dealer that the engine has to come out to fit a new one with a total cost of £1600.00. My rav is just over 4 years old with 55k miles and just out of warranty (february). Firstly can anyone answer why the Cat would fail with no warning sign and also do they really cost so much and are the dealership pulling the wool over my eyes as having to remove the engine to replace the Catylitic Converter. Many Thanks.

Hi Bugsey. I had a similar problem last November and had the Cat replaced under warranty. The Cat they fitted was a modified one, a bigger bore pipe as the old one was blocked. Did they give you the fault code!!? Have you tried emptying the tank of fuel and using BP Ultimate or Shell V Power, I did that and it cleared but they changed the Cat anyway. I dont think the engine came out as it was not with the dealer long enough. But I think they drop the front suspension to change the Cat. Hope this helps you getting it sorted.

[Bugsey]

Whilst driving my T180 the engine management light came on, after various phone calls to my main dealer and with help from the Rac, my Rav was put on a low loader and taken to my main dealer. It turns out that i need a new Catylitic Converter, at a cost of £900.00. Today i was informed by the Main dealer that the engine has to come out to fit a new one with a total cost of £1600.00. My rav is just over 4 years old with 55k miles and just out of warranty (february). Firstly can anyone answer why the Cat would fail with no warning sign and also do they really cost so much and are the dealership pulling the wool over my eyes as having to remove the engine to replace the Catylitic Converter. Many Thanks.

Hi Bugsey. I had a similar problem last November and had the Cat replaced under warranty. The Cat they fitted was a modified one, a bigger bore pipe as the old one was blocked. Did they give you the fault code!!? Have you tried emptying the tank of fuel and using BP Ultimate or Shell V Power, I did that and it cleared but they changed the Cat anyway. I dont think the engine came out as it was not with the dealer long enough. But I think they drop the front suspension to change the Cat. Hope this helps you getting it sorted.

Thanks Offroadster, The fault code was P2002, do you think fuel is an issue with these cars, being that i tend to buy my fuel at Sainsburys.

[Offroadster]

Whilst driving my T180 the engine management light came on, after various phone calls to my main dealer and with help from the Rac, my Rav was put on a low loader and taken to my main dealer. It turns out that i need a new Catylitic Converter, at a cost of £900.00. Today i was informed by the Main dealer that the engine has to come out to fit a new one with a total cost of £1600.00. My rav is just over 4 years old with 55k miles and just out of warranty (february). Firstly can anyone answer why the Cat would fail with no warning sign and also do they really cost so much and are the dealership pulling the wool over my eyes as having to remove the engine to replace the Catylitic Converter. Many Thanks.

Hi Bugsey. I had a similar problem last November and had the Cat replaced under warranty. The Cat they fitted was a modified one, a bigger bore pipe as the old one was blocked. Did they give you the fault code!!? Have you tried emptying the tank of fuel and using BP Ultimate or Shell V Power, I did that and it cleared but they changed the Cat anyway. I dont think the engine came out as it was not with the dealer long enough. But I think they drop the front suspension to change the Cat. Hope this helps you getting it sorted.

Thanks Offroadster, The fault code was P2002, do you think fuel is an issue with these cars, being that i tend to buy my fuel at Sainsburys.

Yes most deffinately. I recently had issues with a blocked EGR, I find the engine is smoother with BP Ultimate. Although more expensive I think it is worth it in the long run

[ormi]

you are ment to remove the engine but it can be done by dropping the subframe very tight though as the cat is some size!!

[duncerduncs]

Is it worth checking with Toyota UK to see if that part has an extended warranty?

I know the EGR valve has been extended to 5 years and some people have had problems with their dealer not knowing and trying to charge them for it!

Best of luck

[Bugsey]

Is it worth checking with Toyota UK to see if that part has an extended warranty?

I know the EGR valve has been extended to 5 years and some people have had problems with their dealer not knowing and trying to charge them for it!

Best of luck

Hi 'duncerduncs' Guess what those wonderful people at Toyota HQ have swallowed the complete cost of parts and labour, with a lot of help from the service manager at the Dealership. How chuffed am I. I cant thank my Dealership and Toyota customer relations enough as I was looking at a £1600.00 bill. Toyota are in my book.

[ratchet2112]

Hi all,

funny I should check the forum tonight as my T180 is currently at the dealers, it is there on the back of the engine management warning light coming on in the space of 5-6 weeks, each time having the EGR reset but today they admitted that it was a failed catalytic converter and this would take a few days to replace.

The service dept also suspected if this happened again (after last time 3 weeks ago) they suspected that this was the case and admitted this to me today.

My 3 year warranty ran out in june of this year and I thought long and hard about extending by another two years at a cost of £700-thank god I did!!!

At service this year I had two rear shock absorbers replaced and this being my third visit in as many weeks with the same problem, I suspect I would have been deep in the red!

Anyone keeping a hold of their T180's beyond 3 years and quering wether to extend, THINK HARD, I had some honest advice which has saved me a packet.

Cheers

[DONFRAMAC]

Hi all,

funny I should check the forum tonight as my T180 is currently at the dealers, it is there on the back of the engine management warning light coming on in the space of 5-6 weeks, each time having the EGR reset but today they admitted that it was a failed catalytic converter and this would take a few days to replace.

The service dept also suspected if this happened again (after last time 3 weeks ago) they suspected that this was the case and admitted this to me today.

My 3 year warranty ran out in june of this year and I thought long and hard about extending by another two years at a cost of £700-thank god I did!!!

At service this year I had two rear shock absorbers replaced and this being my third visit in as many weeks with the same problem, I suspect I would have been deep in the red!

Anyone keeping a hold of their T180's beyond 3 years and quering wether to extend, THINK HARD, I had some honest advice which has saved me a packet.

Cheers

These problems are often fuel-related, and a regular dose of a reputable fuel system-cleaner, such as "FORTE", is reputed to clean much better than others including redex. Mercedes have been using it at annual servicing, and have only recently changed to an alternative brand. I used it for 8 years, on the advice of a Rover foreman, where it was used on all their annual servicing. I continued with the following 5-years with a new Yaris D4-D. The effect of adding the 400 ml is rapid, and thorough, cleaning and de-coking, even the CAT and EGR being well cleaned, needing a new bottle only every 3-6 months, as it treats 100 litres of fuel. A Toyota salesman confirmed to me that it works, as his father uses it every year to make sure his old car passes the MoT.

My local Ford garage are cheap, at only £7.50p + VaT., but I have seen it at twice that price on the internet. (it is really a trade product, so if I had not had it detailed on my service invoice at Rover, I would not know about it. p.s., a dearer version comes with a pouring spout, so keep that spout if you get one.)

I am currently using the petrol version of "FORTE", the only change of packaging is the colour of the cap on the black triangular plastic bottle. Price is the same.

[Big_Stu]

Who is your dealer - I am happy to travel for good service

[Parkie]

Hi, we have a 4.5 yr old Rav 4 T180 which we have recently been told that the catalytic converter needs to be replaced due to the enegine management lights coming on. we were told that this would cost in the region of £1800, however without promptimg we were also told that the dealer would ask Toyota to shoulder some of the cost of this. I'd really appreciate some help as to whether this is a known fault and whether Toyota are recognising this and absorbing the total customer cost.

[anchorman]

Welcome to the club.

You really need to read the fault code. You can by a reader off eBay for about £25 then we can point you in the right direction.

[Parkie]

Welcome to the club.

You really need to read the fault code. You can by a reader off ebay for about £25 then we can point you in the right direction.

thanks for the response, we had the AA out who reset the system, which he believed was related to the fuel system filter. He suggested that when the light came on again get it back to the dealer. The dealer called yesterday to inform us that the CAT was faulty and needed replacing. It was the unprompted offer to approach Toyota to co-fund the cost that made us look into it further. The car is currently with Toyota waiting our decision.

Do you know of any history of this, the car is 4.5 yrs on 50k miles

[wardude]

Is there anything you can do to help prolong a cats life? ie give it a good thrash every now and then to clean the crap out etc? Do short trips in the car cause a problem with a cat? Also found this article below

The catalytic converter, like the rest of the emissions system, typically has a warranty length that exceeds the term of the warranty for the rest of a typical car

A catalytic converter should never fail! If it does, then there is an underlying cause. Just

replacing the converter will not fix the problem. If the catalytic converter has failed, one of

the problems below most likely contributed to its failure.

Engine Tune-up Required

Any time an engine is operating outside proper specifications, unnecessary wear and damage may be caused

to the catalytic converter. The damage is often the result of:

• An incorrect air/fuel mixture

• Incorrect timing

• Misfiring spark plugs

Excess Fuel Entering Exhaust

The fuel that powers a vehicle is meant to burn in the combustion chamber only. Any fuel that leaves the

combustion chamber unburned will enter the exhaust system and light-off when it reaches the catalytic converter.

This can super-heat the converter far above operating conditions and cause a converter meltdown.

Possible causes include:

• Incorrect fuel mixture

• Incorrect timing

• Corroded spark plugs

• A faulty oxygen sensor

• Sticking float

• Faulty fuel injector or a malfunctioning check value

Oil or Antifreeze Entering Exhaust

Oil or antifreeze entering the exhaust system can block the air passages by creating heavy carbon soot that

coats the ceramic catalyst. These heavy carbon deposits create two problems; they prevent the catalytic converter

from reducing harmful emission in the exhaust flow and two, clog the pores in the ceramic catalyst and

block exhaust flow, increasing backpressure and causing heat and exhaust to back up into the engine compartment.

Possible causes include:

• Worn piston rings

• Faulty valve seals

• Failed gaskets

• Warped engine components

Deteriorated Spark Plug or Spark Plug Wires

Spark plugs that don’t fire or misfire cause unburned fuel to enter the exhaust system. The unburned fuel

ignites inside the converter and could result in a partial or complete meltdown of the ceramic catalyst.

Oxygen Sensor Not Functioning Properly

An oxygen sensor failure can lead to incorrect readings of exhaust gasses. The faulty sensor can cause a too

rich or too lean condition. Too rich and the catalyst can melt down. Too lean and the converter is unable to

convert the hydrocarbons into safe elements and may not pass a state inspection. The damage is often the

result of a:

• Faulty oxygen sensor

• Thermostat that is stuck open or is too cold for the application

Road Damage or Broken Hangers

The ceramic catalyst inside a catalytic converter is made from a lightweight, thin-walled, fragile material. It is

protected by a dense, insulating mat. This mat holds the catalyst in place and provides moderate protection

against damage. However, rock or road debris striking the converter or improper or broken exhaust system

support can cause catalyst fracture. Once the ceramic catalyst is fractured, the broken pieces become loose

and rattle around and break up into smaller pieces. Flow is interrupted and backpressure in the exhaust system

increases. This leads to heat buildup and loss of power. Possible causes of catalyst fracture include:

• Road debris

• Striking the converter, loose or broken hangers

• Potholes or off-road driving

[anchorman]

Blimey O'Rielly where did that lot come from!!!

All good info though.

Now about the warranty and that ties in with the fault list. TGB do often seem to pick up the whole cost for this job so I would go ahead and let them start the ball rolling. As far as the list goes then the underlying causes are to do with an ECU upgrade and carbon build up from oil consumption.

If Toyota take it on they will make modifications to the cat and perform the ECU flash. They may consider engine work if oil consumption is considered excessive (more that 1 litre per 1000 miles) but you can help by not using supermarket fuel. Its going to have to be fixed so the less you have to pay the better.

[wardude]

Yeah I know Don. I really went mad dident I lol

As for this ECU flash. Is there a way to tell its been done on my car? I use barley any oil at all. In last 10k miles I must have topped it up once and it was a tiny amount. Aint had any cat problems (touch wood).

[duncerduncs]

When I had my old T180, the dealer put a little sticker on the car confirming the ECU upgrade had been done, I just cant remember where they stuck it!

[wardude]

When I had my old T180, the dealer put a little sticker on the car confirming the ECU upgrade had been done, I just cant remember where they stuck it!

I thought they put a sticker on. Having looked everywhere I cant find one. Maybe it has come off or maybe so far I have just been lucky. However I rarley put oil in between service and im doing 300 miles a week. Summit must be working

[shcm]

There doesn't appear any consistency in where the sticker is put.

The same dealer put Anchs on the air filter housing (under bonnet) and mine low down on the B post/pillar.

[wardude]

There doesn't appear any consistency in where the sticker is put.

The same dealer put Anchs on the air filter housing (under bonnet) and mine low down on the B post/pillar.

cheers, ill have a decent look tomoz

[anchorman]

I've also seen one inside the glove box.

[wardude]

Cheers

I had a look and cant see a sticker anywhere. My car was serviced from new by a main Toyota dealer. Is it common practice for them to do this ecu flash at a service or would they just do it if a problem was reported??. Like I said my car uses next to no oil which I find strange after reading how much oil some folk use in their T180s

[MarsKy]

Cheers

I had a look and cant see a sticker anywhere. My car was serviced from new by a main Toyota dealer. Is it common practice for them to do this ecu flash at a service or would they just do it if a problem was reported??. Like I said my car uses next to no oil which I find strange after reading how much oil some folk use in their T180s

I still have an unopened bottle of oil I bought nearly 3 years ago for topping up my T180. Apart from servicing, it's never needed a drop.

I have had the ECU flashed - but I've never found a sticker. They offered to do it when it went in for its 2 year service - I didn't ask for it. There wasn't any kind of recall to lure you into getting it done.

But any Toyota dealer should have it on record whether it's been done.

[wardude]

cheers matey