Toyota Alphard: common faults & what to check

Symptoms to notice

• Triangle warning light with exclamation mark on dash
• Hybrid system warning light illuminated
• Vehicle enters reduced power or limp mode
• Traction loss warning during acceleration
• P315A and/or P3190 DTCs stored in hybrid control module

What to check

1. 1.Scan hybrid system for P315A and P3190 codes using Toyota TechStream or compatible scanner.
2. 2.Inspect transaxle for fluid contamination and evidence of resolver harness chafing near the transaxle case.
3. 3.Check hybrid transaxle oil condition at the inspection port for metallic contamination.
4. 4.Have a hybrid specialist perform MG2 resolver signal amplitude test.

Symptoms to notice

• Cold-start metallic rattling from the front of the engine, especially on first start of the day in cold weather
• Persistent timing chain rattle at idle that does not clear after warm-up
• P0016, P0017, P0018, or P0019 fault codes indicating cam-crank correlation error
• Rough running or loss of power caused by jumped timing if guides have failed and chain has slipped

What to check

Cold-start the engine and listen for a metallic rattling from the front of the engine that diminishes after 3–5 seconds of oil pressure build-up. Persistent rattle after warm-up is more serious. Pull oil service history to confirm intervals. Use Techstream to check for P0016/P0017/P0018/P0019 camshaft correlation codes. If a workshop inspection is possible: A borescope inspection via the oil fill port can reveal guide debris.

Symptoms to notice

• White or sweet-smelling exhaust smoke on startup or under sustained load
• Coolant level dropping with no visible external leak
• Milky or frothy residue on oil dipstick or inside oil filler cap
• Engine overheating or erratic temperature gauge
• Bubbling in coolant reservoir with engine running

What to check

Cold-start the engine and watch exhaust for white sweet-smelling smoke. With engine at idle, check coolant reservoir for rising bubbles (combustion gas ingress). Inspect oil filler cap and dipstick for emulsification. Ask for full coolant top-up history. If a workshop inspection is possible: Pressure-test cooling system cold.

Symptoms to notice

• Intermittent hard starting or extended cranking before the engine fires
• Engine stalling at idle or while driving with no warning
• Engine management or fuel system warning light illuminating
• Rough idle and hesitation under light to moderate load
• No-start condition after the vehicle has been sitting in the sun (heat accelerates impeller deformation)

What to check

Before any other inspection, check the vehicle's VIN against Toyota's recall completion database (recalls.gov.au for Australia; toyota.co.nz for New Zealand). If the recall shows as outstanding, request Toyota complete it at their cost before purchase. Look in the service records for any note of hard starts, stalling, or fuel system complaints. A dealer can print a recall completion certificate confirming the impeller has been replaced.

Symptoms to notice

• Shudder or vibration pulling away from a stop
• Engine revs flare without matching acceleration (slipping)
• Whining noise from the front that rises with road speed
• Jerky or delayed response when shifting from Park to Drive, worse when cold

What to check

Ask specifically for CVT fluid change records — 'sealed for life' or a blank history on a 150,000 km import is a warning. Start the van cold and drive it: pull away gently, then briskly, feeling for shudder or rev flare; drive at 60–80 km/h listening for a whine. Try a gentle uphill start with passengers aboard, which loads the CVT hardest. A pre-purchase inspection with a transmission fluid check is cheap insurance here.

Symptoms to notice

• Hybrid system warning light with PCU or inverter overtemperature fault code stored
• Hybrid system enters forced shutdown while driving, vehicle coasts to a stop
• Faint grinding or absence of hum from the front-left engine bay area (failed pump bearing)
• Hybrid inverter coolant reservoir level low with no visible external leak
• Vehicle starts in petrol-only mode and disables hybrid drive after a short time

What to check

1. 1.With the vehicle running and warmed up, listen for the faint continuous hum of the inverter coolant pump from the forward-left engine bay area — absence of this hum may indicate pump failure.
2. 2.Check the hybrid inverter coolant reservoir (a separate smaller reservoir from the main engine coolant, usually located near the PCU) and confirm the level is at MIN–MAX. Request any stored hybrid fault codes via OBD-II; a PCU overtemperature or coolant pump fault code confirms the issue.
3. 3.Inspect coolant hoses to the PCU for leaks or wetness.

Symptoms to notice

• Metallic rattle from engine front on cold start
• Rattle persisting beyond 10 seconds or remaining at operating temperature

What to check

Cold-start from overnight cold and listen for metallic rattle from the front of the engine. Normal: clears in under 5 seconds. Rattle at operating temperature indicates worn components.

Symptoms to notice

• Air conditioning system producing no cold air despite the compressor appearing to run, or AC that only cools intermittently
• Loud squealing or burning rubber smell from the engine bay when the AC is switched on, caused by the clutch slipping
• Drive belt failure or premature wear caused by compressor clutch seizing in the engaged position and overloading the belt

What to check

1. 1.With the engine running and AC switched on, visually confirm the clutch plate is engaging and rotating with the compressor pulley.
2. 2.Switch the AC off and confirm the clutch disengages and the pulley freewheels.
3. 3.Listen for a rapid cycling click (compressor switching on and off more than once per 10 seconds) indicating low refrigerant.
4. 4.Inspect the front of the compressor for oily residue indicating shaft seal leakage — refrigerant oil staining will be visible around the seal.
5. 5.Check the drive belt for glazing or cracking from clutch slip.

Symptoms to notice

• Loud rattling or chattering noise from the front of the engine lasting 2–10 seconds only on cold start, disappearing once oil pressure builds
• Check engine light with fault codes P1349 or P1346 stored in the ECU (VVT-i system malfunction)

What to check

1. 1.Cold-start the engine from fully cold (overnight soak) and listen at the front of the engine for a distinct rattling or chattering noise lasting 2 to 10 seconds before disappearing as oil pressure builds.
2. 2.Note whether a check engine light is present — codes P1349 (VVT system malfunction bank 1) or P1346 (bank 2) confirm actuator fault.
3. 3.Inspect oil condition; dark, degraded oil accelerates actuator wear.
4. 4.Request maintenance records to verify oil change intervals.

Symptoms to notice

• Front vents blow cold but rear roof vents blow weak or warm air
• Airflow noticeably weaker than expected on max fan
• A/C gradually loses its chill over weeks after a regas (leak)
• Hissing or clicking from the dash or roof unit when A/C engages

What to check

1. 1.On the test drive, run the A/C on max with rear zone on and physically hold your hand over the rear roof vents as well as the front — both should go properly cold within a couple of minutes, even on a cool day.
2. 2.Listen for the compressor cycling on and off rapidly.
3. 3.Check the rear air intake grille (cabin side trim) isn't blocked with dust.
4. 4.Ask when the system was last regassed and whether it held.

Symptoms to notice

• Red triangle master warning light on dash
• Hybrid system inoperative warning displayed
• Vehicle enters limp mode or will not start
• Inverter cooling system low fluid warning

What to check

1. 1.Check the inverter cooling reservoir (separate from the engine cooling circuit) for correct level and condition — fluid should be clear pink Toyota Super Long Life coolant.
2. 2.Scan for HV system DTCs using Techstream: P0A09 (DC/DC converter performance), P0A94 (DC/DC converter performance), and motor-generator codes P0A78/P0A7A indicate inverter-side issues.
3. 3.Confirm no warning lights are currently stored.
4. 4.Ask whether any hybrid system warnings have appeared, even temporarily.

Symptoms to notice

• Unexpected hard automatic braking on the highway with no obstacle in the travel lane
• PCS warning buzzer and indicator activating under overhead motorway signs or bridges
• Pre-collision alert triggered by oncoming headlights at night
• Owner has switched off PCS or TSS via the in-car menu to prevent false activations
• Radar sensor fault code stored in the pre-collision control ECU

What to check

1. 1.Inspect the forward radar sensor at the lower front grille for cracks, paint overspray, aftermarket tow bar wiring, or any obstruction.
2. 2.Check whether TSS/PCS is still enabled on the vehicle — an owner who has disabled it may be hiding a fault.
3. 3.On a highway test drive, observe whether the PCS indicator activates without cause under motorway gantry signs.
4. 4.Confirm with a Toyota dealer that all published TSS-P software calibration updates have been applied to this vehicle's VIN.

Symptoms to notice

• Sliding door fails to open or close electrically
• Door reverses or stops mid-travel without obstruction
• Grinding or clicking from the door mechanism area
• Door does not latch firmly on electric close
• Door-open warning light remains on with door physically closed

What to check

1. 1.Cycle both sliding doors fully open and closed at least four times each using the interior button, exterior handle, and key fob.
2. 2.Listen for motor strain or cable grind.
3. 3.Confirm each door latches firmly at fully closed position with no push required.
4. 4.Inspect the lower door sill wiring harness for cracking or chafing.

Symptoms to notice

• Hybrid system will not initialise — READY light does not illuminate after pressing start
• All dashboard warning lights come on but vehicle remains immobile
• Accessory systems such as audio and windows may still operate normally
• Weak relay clicking sounds when start button is pressed
• Vehicle requires jump-start to the 12V auxiliary battery to enter READY mode

What to check

1. 1.Test the 12V auxiliary battery under load using a battery conductance tester rather than a simple voltage check, as resting voltage can appear normal on a degraded battery.
2. 2.Check the date code on the battery label to determine age.
3. 3.Inspect battery terminals for corrosion.
4. 4.With the hybrid system in READY mode, verify DC-DC converter output is between 13.5 and 14.8V to confirm the converter is charging the 12V battery correctly.

Symptoms to notice

• Knocking or rattling from steering rack at low speeds
• Vibration through steering wheel during slow manoeuvring

What to check

Drive over rough surfaces at low speed and listen for rattle from the steering rack area.

Symptoms to notice

• Squealing or grinding from engine front when AC is switched on
• Noise stops when AC is switched off

What to check

1. 1.Test AC during test drive.
2. 2.Listen for squealing from engine front when AC is engaged.

Symptoms to notice

• Brake pedal feels hard or requires excessive foot force to achieve normal deceleration
• Spongy or inconsistent pedal feel that varies between applications
• Brake or master warning light on dashboard
• Electric vacuum pump audible running continuously at idle
• Noticeably increased stopping distance

What to check

1. 1.With ignition on and engine off, pump the brake pedal five times to deplete the vacuum reserve, then start the hybrid system to READY mode and verify pedal assist is restored within two to three pedal applications.
2. 2.Inspect the electric vacuum pump for operation by listening for the motor, and check the vacuum line from pump to booster for cracking or leaks.
3. 3.Scan for brake system DTCs including C-series codes.

Symptoms to notice

• Clunking or knocking from front suspension over speed bumps or rough surfaces
• Steering wander or vague straight-line tracking
• Uneven or accelerated front tyre wear on inner or outer edge
• Vibration through steering wheel at motorway speed
• Visible play when wheel is rocked at the 9 and 3 o'clock position on a hoist

What to check

1. 1.Inspect lower ball joint rubber boots for tears or grease expulsion.
2. 2.Check for corrosion around the ball joint housing that may have accelerated seal failure.
3. 3.If a workshop inspection is possible: With vehicle on a hoist, rock each front wheel at 9 and 3 o'clock to check ball joint play, then at 6 and 12 o'clock to check wheel bearing.

Symptoms to notice

• Vehicle visibly leaning or sitting unevenly when parked on level ground, with one or more corners at different height
• Suspension warning light illuminated on the instrument cluster with fault mode active
• Automatic height adjustment system not responding to load changes, such as remaining high when fully loaded
• Techstream scan revealing a C1xxx series suspension height sensor signal fault code for one or more corners

What to check

With the vehicle on level ground, visually check that the vehicle sits level side to side and front to rear. A corner that is visibly higher or lower than the others points to a sensor or actuator fault. Use Techstream to read individual ride height sensor voltage values — all should be within a narrow band on a level surface. Inspect sensor linkage arms for corrosion, cracked potentiometer housings, and loose or broken linkage rods.

Symptoms to notice

• Clunking or thudding sensation through the steering wheel under firm braking or when transitioning over road undulations
• Steering feel that is vague or imprecise, with the vehicle tracking inconsistently on straight roads
• Front wheel alignment that shifts outside specification without any identified steering or suspension component damage

What to check

Look for cracking, tearing, or separation of the rubber bonding from the steel sleeve. With the vehicle on the ground, have an assistant apply and release the brakes firmly while you observe the subframe from underneath for movement relative to the body. Check front wheel alignment records for unexplained toe or camber drift between services. If a workshop inspection is possible: Inspect each subframe mount from underneath with the vehicle on a hoist.

Symptoms to notice

• Steering pulling to one side consistently, particularly under braking
• Vague or imprecise steering feel when changing direction
• Alignment settings drifting out of specification within weeks of a fresh alignment
• Clunking from the front suspension over speed bumps or rough surfaces
• Uneven or accelerated tyre wear on the inner edge of front tyres

What to check

Any movement beyond 2mm indicates bushing failure. Inspect the inner bushing rubber for radial cracks, separation from the metal sleeve, or distortion with a torch. Request the most recent wheel alignment printout and check if the front caster or toe values were at or near the tolerance limit. If a workshop inspection is possible: With the vehicle on a hoist, grasp each front lower arm and attempt to move it forward and rearward in the vehicle longitudinal direction.

Symptoms to notice

• Steering pull to one side that may change direction with throttle or braking input
• Vague or imprecise steering feel at highway speed
• Clunking or knocking from front suspension over road irregularities
• Uneven front tyre wear on inner or outer shoulder
• Vehicle wanders and requires constant steering correction

What to check

Apply controlled force to the arm and check for bush movement. Inspect front tyres for abnormal wear patterns. Road-test and note steering pull under braking and separately under acceleration to confirm bush failure pattern. If a workshop inspection is possible: Raise vehicle on a hoist and inspect both front lower control arm rear bushes for cracking, rubber separation from the metal sleeve, or visible deformation.

Symptoms to notice

• Clunking from front suspension over bumps
• Imprecise handling feel when cornering

What to check

Inspect the boot for splitting. If a workshop inspection is possible: With vehicle raised, lever the lower arm and check for ball joint play.

Symptoms to notice

• Vehicle pulling to one side under braking
• One disc hotter than the other after moderate use

What to check

1. 1.Check for pulling under braking.
2. 2.Feel for uneven wheel heat.
3. 3.Inspect guide pins.

Symptoms to notice

• Rear of the van sits visibly low, especially with people or luggage in
• Bottoming-out clunk over speed bumps or driveways
• Floaty, bouncy ride that keeps oscillating after a bump
• Knocking from the rear over rough seal

What to check

Stand back and sight along the van from the side — the rear wheel arch gap should be similar to the front. Push down hard on the rear bumper corner and let go: it should rebound once and settle, not keep bouncing. Look behind the rear wheels for oil-streaked shock absorbers. On the test drive, take a speed bump at normal pace and listen for a bottoming clunk.

Symptoms to notice

• Knocking from rear suspension over rough surfaces
• Imprecise rear handling feel

What to check

1. 1.Inspect rear suspension arm bushes for cracking.
2. 2.Push arms — any movement indicates collapsed bushes.

Symptoms to notice

• Scraping or grinding noise as the door traverses the full track
• Door sags visibly at the rear corner when fully open
• Door requires a firm push to fully latch closed
• Visible flat spots, cracking, or deformation on the lower door roller
• Centre track shows corrosion pitting, grit accumulation, or gouging

What to check

Open both doors fully and crouch down to inspect the lower roller (visible beneath each door) for flat spots, cracking, or uneven wear. Run a finger along the exposed centre track for rough spots, pitting, or corrosion. With the door fully open, apply light upward pressure to the rear of the door panel — noticeable vertical play indicates roller wear. Observe whether the door drops visibly at the rear relative to the body line when fully open.