Thinking about buying a used Toyota Allion (2001–2021) in New Zealand? We've documented 15 known faults for this model spanning engine, suspension, transmission, and body & rust. Each researched and verified before it's published. The most serious issues here are rated critical. Two are set out in full below — the rest, with the symptoms, repair costs and checks for each, are free with an account.
15
Documented faults
Critical
Most serious
$400–$2,500
Typical repair
6
Systems covered
Known Toyota Allion faults
Every fault below is documented specifically for this model — researched and verified before it’s published.
01Stripped head-bolt threads in the alloy block causing sudden coolant loss (2.0 1AZ-FSE)
CriticalOccasionalEngine $1,800–$5,000 to fix
AZ-series blocks cast before mid-2007 have shallow head-bolt threads at the thinnest rear section of the aluminium block. The threads can strip without warning, letting the head lift, which blows the head gasket and dumps coolant — the same well-documented failure seen on 1AZ/2AZ RAV4, Avensis and Camry. Caught early it is repairable with thread inserts (Time-Sert style); driven on while overheating, the engine is usually scrap. It is an occasional rather than universal failure, but it is catastrophic when it happens, so treat any coolant-loss history on a 2.0 T240 seriously.
Symptoms to notice
Coolant level dropping with no visible leak, or sudden total coolant loss
Overheating on hills or motorway driving
Sweet coolant smell or steam from the engine bay
White residue or crusty coolant staining around the rear of the cylinder head
Bubbles in the coolant reservoir with the engine running
What to check
With the engine cold, open the radiator cap and reservoir: the coolant should be clean, bright and at the full mark. Look along the head-to-block joint (especially the rear, firewall side) for pink/white crusty staining. Start the car and watch the reservoir for bubbling. On the test drive, watch the temperature gauge closely and take a route with a decent hill. Ask directly about any history of overheating or repeated coolant top-ups — and walk away or budget for a thread-insert repair if the answers are vague.
Where to look: Cylinder head bolts at the rear (firewall side) of the engine block; check coolant reservoir and head-to-block joint
Ask the seller
“Has the car ever overheated or lost coolant?”
“Has the head gasket ever been replaced, and were thread inserts fitted at the same time?”
“How often does the coolant need topping up?”
02Electric Power Steering Rack Rattle and Knock
MinorCommonSuspension $180–$3,200 to fix
The ZRT260 Allion uses a column-assist electric power steering (EPS) system. The steering rack internal yoke spring and yoke pad wear, allowing the rack bar to develop axial play within the housing. This produces a rattle or clunk that is most pronounced at low speeds over sharp bumps or during slow-speed parking manoeuvres. Toyota issued a revised yoke plug design for this rack, but many vehicles in the import fleet have not received the fix. In more advanced cases, the EPS motor control unit can develop intermittent faults producing a momentary loss of power assistance.
Symptoms to notice
Rattle or knock from the steering rack/lower dash area when traversing sharp bumps or road seams at low speed
A momentary clunk felt through the steering wheel when turning at slow speed during parking
Intermittent EPS warning light on the instrument cluster with loss of power assistance
What to check
With the engine running and wheels on the ground, rock the steering wheel briskly back and forth through 30 degrees — a rattle or knock from the lower dash/firewall area confirms rack yoke play. Scan for EPS DTCs. Inspect the rack yoke access plug for signs of prior adjustment or replacement.
Where to look: Behind the engine, mounted to the firewall — column-assist EPS motor on steering column and rack unit at the base of the bulkhead
Ask the seller
“Has the steering rack ever rattled or knocked, particularly during low-speed parking?”
“Has the EPS warning light appeared on the instrument cluster?”
“Has any steering rack yoke adjustment or replacement been carried out?”
SuspensionCritical
TransmissionMajor
TransmissionMajor
EngineMajor
EngineMajor
Body & RustMajor
EngineMajor
EngineMajor
SuspensionMajor
BrakesMajor
EngineMinor
CoolingMinor
EngineMinor
13 more documented faults on the Toyota Allion
Symptoms, what to check, where to look and what to ask the seller — for every fault above. Free with an account, no card needed. One account covers one vehicle, so make it the car you’re actually looking at.
This page covers the model. Enter the plate of the actual car you’re looking at and see its year, engine, safety rating and register flags — free, no account needed.
Like any used car, it depends on the specific example and its service history. Across the 15 documented faults for the Toyota Allion, the recurring problem areas are engine, suspension, and transmission. A Toyota Allion with a full service history and no signs of the issues listed on this page can be a sound buy but each one needs to be checked individually before you commit.
What are the most common problems with a used Toyota Allion?
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We've catalogued 15 known faults for the Toyota Allion, covering engine, suspension, and transmission. Two are written out in full on this page. The rest — with the symptoms to notice, what to inspect, and typical repair costs for each — are free once you create an account.
How much do repairs cost on a Toyota Allion?
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Most single repairs on the Toyota Allion fall between $400–$2,500 at NZ independent-workshop rates. Some of the 15 documented faults cost less and a few cost considerably more, and no one car needs them all. Knowing which ones to look for before you view is what lets you negotiate the price down or walk away.
Should I get a pre-purchase inspection on a Toyota Allion?
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Yes. A Toyota Allion inspection focused on its known weak points is the single best way to avoid an expensive mistake. KickTyres gives you a guided, model-specific inspection plus a market valuation and negotiation figure for $17.90 far less than the cost of missing one of the faults on this page.