Thinking about buying a used Toyota Hilux (1984–2017) in New Zealand? We've documented 40 known faults for this model spanning engine, cooling, suspension, 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.
40
Documented faults
Critical
Most serious
$500–$2,000
Typical repair
7
Systems covered
Known Toyota Hilux faults
Every fault below is documented specifically for this model — researched and verified before it’s published.
011KD-FTV Cylinder Head Crack Between Combustion Chambers
CriticalVery commonEngine $3,500–$8,500 to fix
The 1KD-FTV 3.0 D-4D cylinder head develops cracks in the fire-deck between adjacent combustion chambers (most commonly between cylinders 2-3 and 3-4). Coolant from the internal galleries migrates into the combustion chamber and is burned off as white exhaust smoke. Toyota Australia and NZ acknowledged the fault and ran a Customer Support Programme offering goodwill head replacement for affected vehicles. Prolonged operation accelerates crack propagation and can cause catastrophic overheating or hydrolock.
Symptoms to notice
Persistent white or grey exhaust smoke under load despite engine at normal temperature
Unexplained coolant level drop with no visible external leak
Sweet smell from exhaust and coolant reservoir bubbling under pressure
Engine overheating events, especially under towing or hill-climbing load
What to check
Inspect coolant for brown emulsification. If head is removed, inspect fire-deck with dye-penetrant for hairline cracks between valve bridges. If a workshop inspection is possible: Pressure-test the cooling system cold; observe for combustion gas bubbles in the overflow tank. Remove all glow plugs and perform a block test (combustion gas analyser on coolant cap) to confirm cross-contamination.
Where to look: Cylinder head fire-deck, between combustion chambers 2-3 and/or 3-4
Ask the seller
“Has the cylinder head ever been inspected, crack-tested, or replaced?”
“Has the vehicle been part of the Toyota Customer Support Programme for the 1KD-FTV head?”
“Is there any history of coolant loss, overheating, or white smoke?”
“Can you show the last coolant service record and current coolant condition?”
The front strut top mount bearing on AN120 and AN130 HiLux models is a known wear point. The bearing allows the strut to rotate during steering inputs. Under the load conditions typical of ute use including rough terrain, heavy payloads, and off-road driving, the bearing races and retainer degrade from approximately 60,000-100,000km. Failed bearings produce a pronounced clicking or clunking sound when driving over bumps or when turning at low speed. The noise is often mistaken for CV joint or ball joint failure. Replacement requires removal of the strut assembly and is straightforward but both sides typically fail close together.
Symptoms to notice
Clicking or clunking from front suspension over bumps
Noise increases during slow-speed steering input
Clunk felt through steering wheel when hitting potholes
Occasional knocking sound when reversing over uneven surfaces
What to check
Drive the vehicle slowly over a speed bump or rough surface and listen for clicking from the front struts. With the vehicle stationary, have an assistant push down sharply on each front corner while you listen at the strut top mount. Inspect the upper strut mount area for cracking rubber or visible bearing play. Check for any recent strut or top mount replacement invoices.
Where to look: Front strut top mount, inside engine bay at each front suspension turret
Ask the seller
“Has the front suspension made any clicking or knocking sounds?”
“Have the front strut top mounts or bearings been replaced?”
“Has the vehicle been used off-road or carried heavy loads regularly?”
EngineCritical
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CoolingCritical
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Body & RustCritical
BrakesCritical
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Fluid LeaksMajor
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38 more documented faults on the Toyota Hilux
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 40 documented faults for the Toyota Hilux, the recurring problem areas are engine, cooling, and suspension. A Toyota Hilux 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 Hilux?
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We've catalogued 40 known faults for the Toyota Hilux, covering engine, cooling, and suspension. 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 Hilux?
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Most single repairs on the Toyota Hilux fall between $500–$2,000 at NZ independent-workshop rates. Some of the 40 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 Hilux?
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Yes. A Toyota Hilux 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.