The Toyota RAV4 arrived in Australia in 1994 as one of the first proper compact SUVs — car-based rather than truck-based, practical and reliable. Two generations dominate the used market: the first-generation SXA10/SXA11 (1994–2000) with the 2.0-litre 3S-FE four-cylinder, and the second-generation ACA20/ACA21 (2000–2005) running the 2.0-litre 1AZ-FE with a timing chain. Both carry Toyota's strong reliability reputation, and high-mileage survivors are genuinely common. Each generation does have documented weak points though — particularly the 2nd-gen automatic transmission and the 1AZ-FE's tendency to consume oil — so knowing what to look for matters.
Engine oil consumption — 2nd-gen 1AZ-FE (2000–2005)
The most widely discussed mechanical problem with the ACA20 RAV4 is excessive engine oil consumption in the 1AZ-FE four-cylinder. Forum discussions on Whirlpool and RAV4World document owners experiencing consumption rates of around one litre per 1,000 kilometres — far above normal.
Carbon deposits clog drainage holes in the piston skirt, preventing the oil ring from scraping cylinder walls properly. Oil migrates past the compression rings and burns in the combustion chamber. Symptoms include a low dipstick reading between services and occasional bluish smoke on startup or under load. A proper repair — piston removal, ring replacement, valve carbon clean — is a significant job at roughly $1,500–$3,500. Before buying any ACA20, check the oil level and ask the seller how often it has been topped up between services.
Automatic transmission & ECM fault — 2nd-gen (2001–2003)
The 2nd-gen RAV4 with the four-speed automatic has a well-documented and widely reported fault involving the engine control module (ECM) sending incorrect signals to the transmission. All 2001–2003 automatic RAV4s (XA20 series) should be regarded as potentially affected.
Symptoms
- Harsh, abrupt gear changes — particularly 1–2 and 2–3 shifts
- Gearbox "snatching" into gear from a standing start
- Transmission engaging reverse with a hard clunk
- Check Engine / MIL light illuminated with fault codes P0750, P0753, P0755 or P0758 (shift solenoid faults)
- Problems can be intermittent — appearing when warm and disappearing on a cold restart
The ECM develops an internal fault causing it to command incorrect gear shifts; fault codes return after clearing. Left unaddressed, clutch-pack wear follows. Toyota USA launched a Customer Support Program for ECM replacement on affected 2001–2003 automatics, but Toyota did not extend a formal recall to Australian-market vehicles. Australian owners on the Toyota Owners Club Australia forum dealt with this at their own cost. The fix is ECM replacement (with updated software) at roughly $800–$2,000, or a remanufactured board at lower cost. Budget for this or verify it has been done before buying any 2001–2003 automatic.
Timing belt — 1st-gen 3S-FE (SXA10/SXA11, 1994–2000)
The 1st-generation RAV4 runs a timing belt (not a chain) on its 3S-FE engine, with Toyota recommending replacement at 100,000 km intervals. The good news: the 3S-FE is a non-interference engine, meaning a broken belt will not cause piston-to-valve contact. The engine will simply stop. That said, you still want to verify belt service history — an un-serviced belt on a high-kilometre SXA10 is a roadside breakdown waiting to happen.
When the belt is replaced it is wise to also renew the water pump at the same time, as the water pumps on the 3S-FE are known to be a wear item. Budget $400–$700 for a quality belt-and-pump service at an independent workshop.
By contrast, the 2nd-gen 1AZ-FE (ACA20, 2000–2005) uses a timing chain with no scheduled replacement interval — a genuine advantage for long-term ownership, provided oil changes are kept up (oil starvation accelerates chain wear).
Air conditioning — compressor and refrigerant issues
Air conditioning problems surface regularly across both generations, which matters in Australia's climate. Common complaints include the A/C light illuminating without the compressor clutch engaging, and the system blowing warm air.
On ACA20 models specifically, some owners report the magnetic clutch relay failing and preventing the compressor from engaging — a relatively inexpensive fix (relay replacement, roughly $80–$200). Refrigerant leaks from aging hoses and condenser corrosion are also reported, with regassing and leak repair costing $200–$500 at a licensed air-conditioning repairer. Always test the air conditioning on a warm day before purchase — check it actually blows cold and that the compressor engages when you press the A/C button.
Speedometer and electrical gremlins — ACA20 (2001–2003)
Some XA20 owners report intermittent or complete speedometer failure. The Australian Toyota Owners Club forum documents this as typically caused by moisture ingress into the vehicle speed sensor (VSS) connector rather than sensor failure — cleaning corroded contacts has restored function for many owners. A windscreen seal leak can allow water to reach the cluster and cause the same symptom. Check for fogging inside the instrument cluster. If the VSS itself has failed, budget roughly $150–$400 fitted.
Underbody rust and sill corrosion
These RAV4s are now 20–25 years old at minimum, and underbody rust deserves inspection. The most commonly flagged area is the rear of the sill panels inside the wheel arches, where road grime and moisture accumulate. Suspension mounting points and subframe surfaces can also show corrosion on coastal or high-rainfall examples. Surface rust on brackets and exhaust hangers is minor; rust penetrating sill seams or suspension mounts is a structural concern and a potential RWC issue.
Recalls & safety
The most significant documented recall affecting these years is the Takata airbag inflator recall (ACA22/ACA23, MY2003–2005), listed on ACCC Product Safety Australia. Propellant degradation from heat and humidity can cause the driver-side inflator housing to rupture and project metal fragments — a "do not drive" level recall. Verify any 2003–2005 RAV4 has had the inflator replaced by contacting Toyota Australia (1800 987 366) or confirming by VIN at your Toyota dealer.
Carify has recall and safety data mapped to individual model years. Check the year-specific pages for your vehicle: 1999 RAV4 recalls, 2000 RAV4 recalls, and 2003 RAV4 recalls. You can also browse the full recalls landing page for an overview of Toyota recall history.
Buying a used Toyota RAV4? What to check
- Check the dipstick (ACA20): Low oil between services is the clearest signal of 1AZ-FE piston-ring consumption. Ask how often top-ups have been needed.
- Road-test the auto transmission (2001–2003): Drive both cold and warm. Any snatching or harsh shifts point to the known ECM fault — confirm it has been replaced or reconditioned.
- Timing belt history (SXA10/SXA11): Confirm the 3S-FE belt has been done at or before 100,000 km. Look for a workshop sticker; budget for replacement if absent.
- Test the air conditioning: Confirm the compressor clutch engages and the system blows cold within 60 seconds on a warm day.
- Inspect the underbody: Check rear sill seams, wheel arch lips and suspension mounts for rust penetration — not just surface discolouration.
- Check the speedo (ACA20): Confirm consistent readings — intermittent dropout points to a corroded VSS connector or cluster contacts.
- Takata airbag recall (2003–2005): Verify with Toyota by VIN that the driver-side inflator has been replaced.
- Run a history check: Early RAV4s change hands often. A PPSR check reveals outstanding finance, write-off history, or stolen flags before you commit.
The verdict
The Toyota RAV4 SXA10 and ACA20 remain some of the most durable compact SUVs the used market has to offer in Australia. High-mileage survivors are genuinely common, and parts availability is good. The issues above — particularly the 1AZ-FE oil consumption and the 2001–2003 ECM/transmission fault — are real and can be expensive if ignored, but neither is a dealbreaker on a car that has been properly maintained or already had the work done. Buy one where the oil-consumption history is transparent, the automatic shifts cleanly, and the Takata recall has been completed, and you are likely to get a reliable workhorse. Check the full car problems and recalls hub to compare the RAV4 against other models in its class before you decide.