Hi Guys, Bit of background, Motor Mechanic, 35 Years experience- Workshop manager – Fleet Manager (service manager’s nightmare) I purchased a brand new 2010 RAV4 SX6 and after delivery, had to take the vehicle on a 450 Km trip back home. Being generous, I let my excited partner drive the first half of the journey. The outside temperature was 24DegC, the Moon roof was tilted open which created a vacuum in the cabin and the A/C boost fan was off, fresh air vents open. After travelling 180 Km, I was dosing and noticed that my partners driving was becoming erratic and noticed that she was dosing as well. We were travelling at 130Km/h which is legal in NT. I woke her up, got her to stop and took over the driving. It was then I noticed the exhaust gas smell, which was so bad that it made my eyes water. My partner was so affected by the fumes that she was very nauseous. We opened all the windows and still the smell persisted. I had to close all the windows and put the fresh air boost fan on High When I arrived at my destination, I immediately notified the Toyota Dealer by email as it was weekend. I then called on the Monday Morning and stated my case, first to the salesman who took it further and got their PR person involved. I eventually got the vehicle back to the dealer. The service manager could not replicate the condition. On a test drive with me in the vehicle, he did acknowledge the fact that he knew of other vehicle owners in other parts of the country who were experiencing the same phenomenon. The rear bumper bar was removed from the vehicle to enable the Workshop technicians to inspect the exit vents, which proved to be working as designed. The problem was then dismissed, because it could not be consistently proved. I recently had the vehicle serviced (10,000 Km) by the agents and on the way home had for at least 5Km a strong exhaust smell in the vehicle which then went away. Upon inspection, the engine sump was found to be overfilled by ½ Litre oil. In closing; to this day, I cannot use the Moon Roof and I cannot put the AC system on to recirculate, which is a bummer as these cost heaps.
