A solid, reliable workhorse popular with taxi drivers and high-mileage commuters. Toyota's own 1AD-FTV diesel is robust - many examples exceed 300,000 km with proper maintenance. Main concerns: diesel injector failures (90% of engine issues trace here), DPF blockage from short journeys, EGR valve carbon buildup, and clutch/dual mass flywheel wear on high-mileage cars. Uses timing chain (no belt replacement needed). Verify rear suspension arm recall and Takata airbag recall completed before purchase.
Injectors fail when hot, causing rough running and power loss · more· less
According to diesel specialists, 90% of D-4D engine problems trace back to injectors. Symptoms include power loss after the engine warms up, rough running, and intermittent stalling. Contaminated diesel accelerates wear. A single injector costs €200-400; replacing all four with coding runs €800-2,500 depending on whether you use independent specialists or Toyota dealers. Injectors must be coded to the ECU after replacement using Toyota Techstream or equivalent diagnostic tool. Typically occurs between 100,000-180,000 km.
DPF blockage€200 - €1,800
Filter clogs from short journeys, causes limp mode and fuel smell · more· less
The Diesel Particulate Filter traps soot and burns it off during regeneration cycles. Short urban journeys prevent the engine reaching regeneration temperature (requires sustained driving at 60+ km/h for 20-30 minutes). Symptoms: DPF warning light, rough running, fuel smell in cabin, reduced power. Forced regeneration at dealer costs €150-200. Professional ultrasonic cleaning costs €300-500. Full DPF replacement runs €1,200-1,800. Driving with a blocked DPF can damage the turbocharger, pushing costs to €3,000+.
EGR valve carbon buildup€150 - €400
Valve sticks from carbon deposits, causing black smoke and erratic idle · more· less
The EGR (Exhaust Gas Recirculation) valve recirculates exhaust gases but becomes coked with carbon over time. Symptoms include black smoke from exhaust, erratic idle, and "dead spots" at low revs when warm. Cleaning the EGR valve is a DIY job (€20-50 for cleaning spray) or €100-150 at a garage. If cleaning doesn't help, replacement valves cost €80-150 for aftermarket or up to €270 for OEM, plus €50-100 labor. Typically needs attention around 80,000-120,000 km.
Clutch and dual mass flywheel wear€800 - €1,500
DMF and clutch wear together, causing judder and noise · more· less
The dual mass flywheel (DMF) absorbs engine vibrations but wears over time. Symptoms include clutch judder, rattling at idle, and difficulty engaging gears. The Avensis is known for clutch problems - listen for whining or grinding from the front during test drives. When replacing the clutch, always replace the DMF simultaneously as labor overlaps. Clutch kit costs €90-200, DMF costs €200-400. Combined replacement with labor runs €800-1,500 at independent garages. Typically needed between 150,000-250,000 km depending on driving style.
Turbocharger vane sticking€500 - €1,500
Variable geometry vanes stick from carbon, reducing boost · more· less
The IHI RHF4 variable geometry turbocharger is generally durable, but at higher mileage the vanes can stick or have limited movement due to carbon buildup. Symptoms include reduced power, whistling sounds, and smoke from exhaust. Gentle driving and short trips worsen this issue. Turbo cleaning/reconditioning costs €300-600; full replacement with remanufactured unit costs €800-1,500. Regular spirited driving and quality oil help prevent vane sticking.
Glow plug failure€150 - €350
Failed glow plugs cause hard starting in cold weather · more· less
Glow plugs preheat the combustion chamber for cold starts. Replacement interval is 80,000 km per Toyota's schedule. Symptoms of failure include extended cranking in cold weather, white smoke on startup, and rough running when cold. Parts cost €60-120 for a set of four. Labor is straightforward but penetrating lubricant applied days before helps prevent seized plugs. DIY replacement takes about an hour; professional replacement costs €150-350 total.
Steering rack noise€100 - €800
Knocking or squeaking when turning, especially at low speeds · more· less
A recall addressed steering column rattling, but separate steering rack issues cause squeaking or knocking when turning. Often starts as intermittent knocking during parking maneuvers. Can be caused by worn steering column spline connection or rack itself. Greasing may temporarily help. Steering rack repair kits cost €20-40; full rack replacement runs €400-800 including labor. If it passes MOT without advisories, many owners tolerate the noise as it's often not safety-critical.
Headlight condensation€50 - €400
Moisture accumulates inside headlight housings · more· less
A known Avensis issue - condensation forms inside headlights, especially on cold mornings. Can return even after resealing. DIY fixes include drilling small drain holes at the bottom, resealing with clear silicone or headlight butyl, and placing silica gel packets inside. Professional resealing costs €50-100 per light. If the seal is completely failed or lens cracked, replacement headlight assemblies cost €150-400 for aftermarket or significantly more for OEM.
Highly reliable for a diesel, but requires proper driving habits
The Avensis T27 with Toyota's own 1AD-FTV engine is among the most reliable diesel cars in its class, with many examples exceeding 300,000 km. Taxi drivers routinely report trouble-free high-mileage ownership. The key is regular servicing, quality diesel fuel, and avoiding predominantly short urban journeys that prevent DPF regeneration. Most issues are well-documented and affordable to fix at independent specialists.
Pre-Purchase Inspection Checklist
General checks
Service history
Complete Toyota dealer or specialist records essential. Oil change interval is 10,000 km or 1 year.
Tires
Check tread depth, age (date codes), and uneven wear patterns indicating alignment issues.
Cold start
Must start engine completely cold. Listen for unusual sounds during first 30 seconds.
Body condition
Check bumpers for scrapes (parking sensors only on top models). Inspect alloy wheels for curb damage.
Test drive
Minimum 30 minutes including motorway driving to allow DPF regeneration assessment.
Specific for this vehicle
Check for DPF warning light
Drive for 20+ minutes and watch for DPF light. Ask about driving patterns - predominantly short trips are a red flag.
Listen for injector problems
After engine is warm, listen for rough running or misfires. Power loss when warm indicates failing injectors.
Test clutch for judder
During test drive, feel for vibration when pulling away slowly. Rattling at idle suggests worn DMF.
Check headlights for condensation
Inspect both headlight housings for moisture or water marks inside the lens.
Inspect rear suspension arms
Look for corrosion on rear suspension arm threads. Subject of safety recall - verify completed.
Check for black smoke on acceleration
Have someone follow while you accelerate hard. Black smoke indicates EGR or turbo issues.
Verify recall status with Toyota
Contact dealer with VIN to confirm rear suspension arm and airbag recalls completed.
Recalls and Technical Service Bulletins
Rear suspension arm (2009-2012 models)Verify completed
Contact Toyota with your VIN to verify all recalls have been completed. The rear suspension arm recall is particularly important - if adjusted during alignment without proper torque procedure, the arm can fail causing loss of vehicle control.
Warranty Status
Factory warranty (3 years / 100,000 km)Expired on all T27s
Extended DPF warranty (5 years)Expired
Toyota Relax extended warrantyAvailable at servicing dealers
All Avensis T27 models are now outside their original factory warranty. Toyota offered an extended 5-year warranty on DPF-related issues for 2.2 D-4D models due to regeneration problems, but this has now expired. Extended warranty options may be available through Toyota dealers for well-maintained examples with full service history.
This report is for informational purposes only and does not constitute professional advice. Estimates may be inaccurate. Always have a qualified specialist inspect the vehicle before purchase. We accept no liability for decisions made based on this information.