Thinking about buying a used Toyota Fortuner (2005–2021) in New Zealand? We've documented 23 known faults for this model spanning engine, suspension, transmission, and cooling. 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.
23
Documented faults
Critical
Most serious
$750–$2,200
Typical repair
5
Systems covered
Known Toyota Fortuner faults
Every fault below is documented specifically for this model — researched and verified before it’s published.
011KD-FTV Euro IV Piston Crown Cracking
CriticalCommonEngine $6,000–$14,000 to fix
When Toyota updated the 1KD-FTV to Euro IV emissions compliance (approximately 2007 onwards), the revised combustion chamber piston design omitted the fibre-reinforced metal insert that had protected the piston crown in earlier units. Under sustained high-speed or high-load driving — especially with any injector leak-off or timing deviation — the thinner piston crown cracks radially from the bowl edge, causing catastrophic combustion gas blow-by into the crankcase and rapid engine destruction. Toyota documented this fault in TSB EG-0048T and the failure is extensively evidenced by engine reconditioners across Australia and New Zealand. Chip-tuned examples and those towing at highway speeds are at highest risk.
Symptoms to notice
Strong crankcase blow-by visible at the oil filler cap when running
Rapid drop in compression on one or more cylinders
Heavy white or grey smoke from the crankcase breather under load
Severe oil consumption with no external leak
Engine misfire or rough running after extended highway driving
What to check
Check for white or grey crankcase smoke from the breather hose. Confirm the vehicle has never been chip-tuned. Perform a cold-start blow-by test: with the engine running, remove the oil filler cap; sustained smoke or strong pulsing pressure indicates piston or ring failure. Ask for a compression test across all four cylinders — a failed piston typically shows one cylinder significantly lower than the rest.
Where to look: Engine pistons, particularly cylinders 3 and 4 on the exhaust side of the bore
Ask the seller
“Has the vehicle ever been remapped or chip-tuned, even by a previous owner?”
“Has it regularly towed at or near its maximum rated tow capacity on long highway runs?”
“Is there a current compression test result or any workshop report on engine internals condition?”
02Rear Leaf Spring Fatigue and Permanent Sag
MinorCommonSuspension $900–$2,200 to fix
The Fortuner uses a rear multi-leaf spring pack that is susceptible to fatigue and permanent set when the vehicle is regularly operated at or near its payload rating, used with a heavy canopy, or driven with consistently heavy loads. The springs lose their designed arch height, causing the rear end to sit noticeably lower than factory height, increasing the likelihood of bump-stop contact and premature shock absorber wear. The issue is documented across the Hilux/Fortuner shared platform and is exacerbated by the high tare weight of accessories common in the 4WD market. Re-arching is documented as a temporary fix that returns to the same sag within a short service life.
Symptoms to notice
Rear of the vehicle sits visibly lower than the front when unladen
Asymmetric ride height between driver and passenger rear corners
Metallic creaking or clunking from the rear over bumps
Rear bump stops showing signs of regular contact or compression
Increased body roll and vague handling feel compared to when new
What to check
Park the unloaded vehicle on flat ground and measure the rear ride height from the centre of the wheel hub to the top of the wheel arch; compare driver's and passenger sides and note whether the rear appears lower than front. Bounce each corner and listen for metallic clunking indicating spring pack separation or worn inter-leaf pads. Look for shiny metal-on-metal contact marks between individual spring leaves.
Where to look: Rear suspension, leaf spring packs both sides
Ask the seller
“Has the vehicle regularly carried heavy loads, towed, or been fitted with a steel canopy or drawer system?”
“Have the rear springs ever been replaced or re-arched?”
“What aftermarket suspension work has been done, and by whom?”
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Fluid LeaksMajor
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21 more documented faults on the Toyota Fortuner
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 23 documented faults for the Toyota Fortuner, the recurring problem areas are engine, suspension, and transmission. A Toyota Fortuner 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 Fortuner?
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We've catalogued 23 known faults for the Toyota Fortuner, 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 Fortuner?
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Most single repairs on the Toyota Fortuner fall between $750–$2,200 at NZ independent-workshop rates. Some of the 23 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 Fortuner?
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Yes. A Toyota Fortuner 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.