Toyota RAV4
BMW-licensed N47 derivative with a timing chain on the gearbox side — chain inspections require separation of the gearbox. Two official recalls (EGR cooler leak, fuel/turbo oil leak) affect vehicles from 2015–2018; check recall status by VIN before purchase. Reliable for long-distance driving, unsuitable for short runs.
Diesel SUV for commuters
105 kW BMW diesel in the XA40 — efficient, but uninspired. This generation of RAV4 had priorities other than driving fun.
Engine Weaknesses 7
Electrostatic charging in the diesel fuel filter can loosen the low-pressure line fitting, allowing fuel to escape into the engine bay. Fire risk on Avensis and RAV4 model years 2015–2017.
Symptoms: Fuel smell in the engine bay; in worst case visible leak under the vehicle
The EGR cooler can develop internal leaks and allow coolant into the exhaust tract. The deposits can smoulder in the intake and cause heat damage. Official recall for model years 2015–2018.
Symptoms: Engine warning light on, power loss, in worst case smoke developing from the intake area
Timing chain on the gearbox side (BMW N47 design). Chain stretch leads to rattling; repair requires separating the engine from the gearbox — more complex than on other diesel engines.
Symptoms: Metallic rattling from the engine bay on cold start or at low revs; noise diminishes as the engine warms up
Bolts at the turbocharger outlet were not tightened correctly, allowing exhaust gases to escape into the engine bay. Toyota recalled Avensis and RAV4 (model years 2015–2017); repair: complete turbocharger replacement.
Symptoms: Burning smell in the passenger compartment, visible smoke from the engine bay, possible power loss
At higher mileage soot deposits form in the common-rail injectors, leading to rough running and reduced power. Biodiesel blends accelerate deposit build-up.
Symptoms: Rough running, harsh idle, power loss, elevated fuel consumption
The diesel particulate filter only regenerates on longer motorway runs at above 600 °C. Predominantly short-trip use prevents active regeneration and leads to permanent blockage and limp mode.
Symptoms: DPF warning light on the dashboard; noticeably reduced power in limp mode; elevated fuel consumption
On vehicles beyond 150,000 km some drivers report increased oil consumption. Regular oil level checks are essential; infrequent oil changes make the situation worse.
Symptoms: Dropping oil level between service intervals, occasional light smoke on acceleration
Vehicle Weaknesses 10
Heated washer nozzles can allow salt water to enter the heating element through a faulty sealant, which can cause a short circuit and in the worst case a vehicle fire.
The parking brake on the RAV4 XA40 is a known weak point.
The 2.0-litre petrol engine can develop a leaking or seized water pump.
From around 100,000 km the steering rack develops a knocking noise, particularly on rough roads. Replacement with a used or new part is labour-intensive and costly.
Vehicles from salt-heavy regions show paint bubbling at wheel arches, sills and bonnet edges after 7–9 years. Thin factory paint promotes early corrosion.
Vehicles from model years 2014–2015 experienced excessive transmission oil loss due to a production defect. Both manual and automatic transmissions are affected.
The RAV4 XA40 is flagged above-average frequently for headlight issues at roadworthiness inspections.
The A/C condenser in the front bumper area is vulnerable to stone chip damage, causing slow refrigerant loss. The replacement part is costly; if caught early, soldering or sealing may suffice.
Like its predecessor the XA30, the XA40 steering rack cracks when manoeuvring or at full lock. The cause is universal joint wear. Mechanics rate it as a comfort issue.
The XA40 has poor sound insulation around the wheel arches and floor from the factory. After extended use or gravel roads the cabin becomes noticeably louder. Aftermarket sound deadening can be retrofitted.
Reports & Tests
1589 owner complaints filed with NHTSA (2013–2018). Most reported: Electrical (507), Other (299), Engine (183).