2004 Toyota Avensis diesel: common problems and MOT failures

What goes wrong more than usual on a 2004 Toyota Avensis diesel?

Parts flagged at MOT more often on the 2004 Toyota Avensis diesel than on all cars registered in 2004.

• Suspension arm5.4× usual
  Toyota Avensis

  18.3% All 2004 cars

  3.4%

  Failed outright at MOT: 4%, against 0.4% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £120–£180 (one arm) ClickMechanic

  At the viewing: Listen for clunks over bumps and feel for the steering wandering. Worn arm bushes show as cracked rubber near the wheels.

• Sub-frame2.1× usual
  Toyota Avensis

  10.6% All 2004 cars

  5%

  Failed outright at MOT: 0.4%, against 0.3% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £300–£1,000 our estimate

  At the viewing: Look underneath at the frame the suspension bolts to. Flaky rust or holes are expensive to fix.

• Diesel smoke emissions6.6× usual
  Toyota Avensis

  5.3% All 2004 cars

  0.8%

  Failed outright at MOT: 4.4%, against 0.7% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £175–£900 (catalytic converter) ClickMechanic

  At the viewing: Look for smoke when revving the warm engine and for engine or DPF warning lights.

• Steering rack2.4× usual
  Toyota Avensis

  4.1% All 2004 cars

  1.7%

  Failed outright at MOT: 2.2%, against 1% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £100–£450 our estimate

  At the viewing: On a straight road the steering wheel should sit straight. Listen for knocks when turning, and check the steering feels even.

• Other suspension component3.2× usual
  Toyota Avensis

  2.9% All 2004 cars

  0.9%

  Failed outright at MOT: 0.1%, against 0% of all 2004 cars. The rest were advisories or minor defects.

  Rough price £120–£400 our estimate

  At the viewing: Listen for knocks over speed bumps, and look behind each front wheel for a snapped coil spring.

Common 2004 Toyota Avensis diesel MOT failures and advisories

The share of 2004 Toyota Avensis diesel MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.

• Suspension
  50% of testsRough price £120–£400

  At the viewing: Listen for knocks over speed bumps, and look behind each front wheel for a snapped coil spring.

• Lights and electrics
  43% of testsRough price £10–£80

  At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.

• Brakes
  41% of testsRough price £150–£350

  At the viewing: Look for a lip on the disc edges and feel for judder or pulling when braking firmly from about 40mph.

• Tyres
  33% of testsRough price £70–£150

  At the viewing: Check the tread on all four tyres, including the inside edges, and look for cracks or bulges.

• Oil and fluid leaks
  16% of testsRough price £80–£600

  At the viewing: Look under the engine and on the ground where the car is usually parked for fresh oil or fluid.

• Wipers, windscreen and mirrors
  12% of testsRough price £15–£250

  At the viewing: Check for chips in the driver's view, and test the wipers and washers.

Known faults on the 2004 Toyota Avensis diesel

Reported by owners, mechanics and buying guides for this model and age. Check which engine the car has, as some apply to one engine only.

• Early clutch failure (diesel)

  Diesel

  Some clutches failed as early as 10,000 miles, especially on diesels. Most were replaced under warranty.

  At the viewing: Check the clutch bites smoothly and doesn't slip under hard acceleration.

  Source: What Car?: Toyota Avensis (2003-2009) reliability

• Brake recalls and steering column rattle

  All engines

  There were a couple of brake-related recalls. A rattle from the steering column is a known, harmless problem.

  At the viewing: Run the free DVSA recall check on the reg.

  Source: What Car?: Toyota Avensis (2003-2009) reliability

• Wet headlights and melting bulb holders

  All engines

  Some cars get water or condensation in the headlights, and some have melting bulb holders.

  At the viewing: Look inside the headlights for moisture and check every bulb works.

  Source: What Car?: Toyota Avensis (2003-2009) reliability

Questions to ask the seller before buying a 2004 Toyota Avensis diesel

Ask before you travel to see it. A seller who knows the car will have answers, and receipts.

1. Any recent work on the suspension arm? (Flagged at MOT 5.4× as often on the 2004 Toyota Avensis diesel as on other cars the same age.)
2. Any recent work on the sub-frame? (Flagged at MOT 2.1× as often on the 2004 Toyota Avensis diesel as on other cars the same age.)
3. Any recent work on the diesel smoke emissions? (Flagged at MOT 6.6× as often on the 2004 Toyota Avensis diesel as on other cars the same age.)
4. Can I see the service history and receipts for any big jobs?