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

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!!

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.

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.

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