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Toyota1984–2019 Critical issues documented

Toyota Hilux AN120: common faults & what to check

The AN120 is the Toyota Hilux built 2015 onward. It was sold here with the 2.4 turbo-diesel, 2.7 petrol, and 2.8L diesel (1GD-FTV). Of the 59 faults documented for the Hilux, 17 apply to this generation, each with its symptoms, what to inspect and a typical repair cost. Free, no account needed.

Check this exact Toyota Hilux

  • Odometer history
  • Money owing
  • Reported stolen
  • Ownership history
  • Official NZ vehicle register data
  • NZ owned and operated

Type the plate for the free basics. The full record is a paid check from $13.49, one car at a time, no subscription.

No NZ plate yet, or buying in Australia? Pick the generation and engine and start a free check below. New to KickTyres? How the check works →

59

Documented faults

Critical

Most serious

$600–$2,500

Typical repair

21

Service milestones

You're looking at the AN120

3 engine variants are documented for this generation. Pick yours to narrow further, or keep reading for the generation as a whole.

Choose a different generation

Now narrow it to the engine

A 1.8 and a 2.4 of the same car do not fail the same way, so the faults below narrow to the engine as well as the year. Free, no account needed.

A 2017 Toyota Hilux is the AN120 generation (2015 to now).

Start your free check on this Toyota Hilux

No plate needed. You get the risk score, the buyer's checklist and the guided inspection for the exact car you picked above — not the whole nameplate.

Toyota Hilux AN120Engine not picked yet

Pick the engine above first: the Hilux came with 3, and without it the report has to show all of their faults. Pick the engine

Free. The paid plate check is separate, and stays optional.

Can't confirm for this car

Toyota Hilux · 2017

Narrowed to the year. No engine is recorded for this vehicle. Pick an engine to see which faults apply.

Tell us the engine, or check the engine code on the car, before relying on this.

  • No engine is recorded for this vehicle.

matched on year only

What to look out for

The checks worth doing on a Toyota Hilux before you hand over any money. Every documented fault is listed below, each with its own page.

  • Costly issue

    Visually inspect the upper arm bush housings for cracking, deformation, or separation of the rubber from the metal sleeve.

    See why

    AN120 Front Upper Control Arm Bush Premature Wear

    The AN120 HiLux double-wishbone front suspension uses rubber-bonded upper control arm bushes that have demonstrated premature deterioration well inside expected service life. The bushes are pressed into a steel housing on the upper arm and are subject to high radial and axial loads on corrugated roads and off-road surfaces typical of Australian and New Zealand use. The rubber compound in early production batches delaminates from the steel outer sleeve, allowing the arm to shift unpredictably under braking and cornering loads. This causes vague steering, clunking over bumps, and measurable changes in caster and camber geometry that accelerate front tyre wear. The failure is progressive and often goes unnoticed until the bush is near complete collapse. Toyota issued revised bush specifications in later production, but in-service vehicles may not have had the improved components fitted at the time of service.

    What you would notice

    • Clunking or knocking from front suspension over bumps or rough road surfaces
    • Vague or imprecise steering feel, particularly under braking
    • Uneven or accelerated front tyre wear, especially inner shoulder
    • Vibration through steering wheel on corrugated roads
    • Vehicle pulling to one side under hard braking

    Typically $650–$1,450 to put right.

  • Common issue

    Drive the vehicle slowly over a speed bump or rough surface and listen for clicking from the front struts.

    See why

    Front Upper Strut Bearing Failure Causing Clicking

    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.

    What you would 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

    Typically $350–$950 to put right.

  • Common issue

    With the vehicle on level ground, inspect the rear leaf spring shackle bushes — look for cracked, collapsed, or extruded rubber.

    See why

    Rear Leaf Spring Shackle Bush Collapse Under Repeated Load

    The GUN125/126 HiLux rear suspension uses a traditional multi-leaf spring setup with rubber shackle bushes at each spring end. The rubber bushes in the rear shackle compress and take a permanent set under repeated loaded use — towing, utility bed loads, farm work. The resultant wear causes the axle to shift fore-aft under braking and acceleration, producing a clunk. Worn shackle bushes cause axle wrap under hard acceleration and vague handling when loaded. A common fault on working HiLux that regularly carry payload at or near GVM.

    What you would notice

    • Clunking from rear suspension under hard acceleration or braking
    • Rear axle tramp or wheel hop when accelerating on loose or slippery surfaces
    • Visible cracking or compression set on leaf spring shackle rubber bushes
    • Axle position variation resulting in uneven gap between tyre and guard

    Typically $250–$650 to put right.

Toyota Hilux service schedule

The 2 engines a 2017 Toyota Hilux was sold with, each with its own intervals. Pick your engine above to narrow this to one. These are the model’s intervals — the car’s own service book is the only thing that can tell you what has actually been done to it.

Eighth Generation (AN120/AN130) · 2015–2026 · 2.8L (1GD-FTV) - GD Turbo Diesel SR5/Cruiser

Diesel

Due by distance

  1. 100,000 km

    Cooling system hoses and serpentine belts get assessed for fatigue around here.

  2. 150,000 km

    Check the suspension bushings and shock absorbers for wear, especially if the ute has been towing.

  3. 200,000 km

    The injectors and fuel system parts are usually checked here so the 1GD-FTV keeps running efficiently.

Eighth Generation (AN120/AN130) · 2015–2026 · 2.4L (2GD-FTV) - Hi-Rider/Workmate Diesel

Diesel

Due by distance

  1. 100,000 km

    Changing the fuel filter on time becomes really important here to protect the common-rail system.

  2. 150,000 km

    Suspension parts such as strut mounts or stabiliser links can weaken from NZ road surfaces by now.

  3. 200,000 km

    Check the cooling system hoses and the radiator so it keeps running at a safe temperature.

See all 17 issues for this oneDocumented for the exact year and engine you picked, including 5 rated critical.
Engine, transmission & cooling1

01Air filter housing lets dust past the filter and kills the air-flow sensor (2015-2018 builds)

The air filter housing on early GUN-series Hilux does not seal properly, so fine dust bypasses the filter element on gravel and unsealed roads.diesel2015–2018EngineRead the full fault: symptoms, where to look, what to ask the seller
Body, brakes, suspension & interior3

02AN120 Front Upper Control Arm Bush Premature Wear

Visually inspect the upper arm bush housings for cracking, deformation, or separation of the rubber from the metal sleeve.2015 onwardSuspensionRead the full fault: symptoms, where to look, what to ask the seller

03Front Upper Strut Bearing Failure Causing Clicking

Drive the vehicle slowly over a speed bump or rough surface and listen for clicking from the front struts.diesel2015 onwardSuspension
CommonSuspension $350–$950 to fix

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

  1. Drive the vehicle slowly over a speed bump or rough surface and listen for clicking from the front struts.
  2. With the vehicle stationary, have an assistant push down sharply on each front corner while you listen at the strut top mount.
  3. Inspect the upper strut mount area for cracking rubber or visible bearing play.
  4. 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

Parts involved: Shock absorber / strut.

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?”

04Rear Leaf Spring Shackle Bush Collapse Under Repeated Load

With the vehicle on level ground, inspect the rear leaf spring shackle bushes — look for cracked, collapsed, or extruded rubber.2015 onwardSuspension
CommonSuspension $250–$650 to fix

The GUN125/126 HiLux rear suspension uses a traditional multi-leaf spring setup with rubber shackle bushes at each spring end. The rubber bushes in the rear shackle compress and take a permanent set under repeated loaded use — towing, utility bed loads, farm work. The resultant wear causes the axle to shift fore-aft under braking and acceleration, producing a clunk. Worn shackle bushes cause axle wrap under hard acceleration and vague handling when loaded. A common fault on working HiLux that regularly carry payload at or near GVM.

Symptoms to notice

  • Clunking from rear suspension under hard acceleration or braking
  • Rear axle tramp or wheel hop when accelerating on loose or slippery surfaces
  • Visible cracking or compression set on leaf spring shackle rubber bushes
  • Axle position variation resulting in uneven gap between tyre and guard

What to check

With the vehicle on level ground, inspect the rear leaf spring shackle bushes — look for cracked, collapsed, or extruded rubber. Inspect front spring eye bushes at the same time. If a workshop inspection is possible: On a hoist, grasp the rear axle and attempt to move it fore and aft — any detectable movement confirms bush wear.

Where to look: Rear suspension — leaf spring front eye bush and rear shackle bush, both sides

Parts involved: Rear leaf spring.

Ask the seller

  • “Has the vehicle regularly carried loads at or near GVM?”
  • “Any clunking from the rear when pulling away or under braking?”
  • “Have the leaf spring bushes been replaced?”
Depends on the exact engine — 13 moreDocumented for a specific engine we could not confirm from what you picked. Check the engine code on the car.
Engine, transmission & cooling12

012GD-FTV High-Mileage Oil Consumption Worn Rings

Check the oil level dipstick and ask when oil was last changed and how much was needed topping up.diesel2015 onwardEngine
OccasionalEngine $2,800–$7,500 to fix

Can't confirm for this car

The 2.4L 2GD-FTV engine in high-mileage AN120/AN130 HiLux units above 150,000km develops excessive oil consumption due to worn piston rings or deteriorated valve stem seals. The piston ring wear is accelerated in vehicles with infrequent oil changes or extended service intervals, and in units that have operated with a clogged DPF causing oil dilution from excessive fuel injected during failed regeneration events. Affected engines consume 500ml to 1.5 litres of oil per 1,000km. Symptoms include blue smoke on acceleration, low oil level warnings between services, and carbon fouling on spark plugs and injector tips. A full engine rebuild or short engine replacement is typically required at this stage.

Symptoms to notice

  • Blue-grey smoke from exhaust on acceleration or after idling
  • Oil level dropping more than 500ml per 1000km
  • Oil consumption warning light activating between services
  • Carbon deposits visible on injector tips
  • Increased blow-by pressure from oil filler cap when idling

What to check

  1. Check the oil level dipstick and ask when oil was last changed and how much was needed topping up.
  2. Inspect the air filter housing and intercooler pipes for oil film indicating crankcase ventilation overload.
  3. Check service history for oil change frequency.
  4. Remove the oil filler cap at idle and look for excessive blow-by pressure.
  5. If a workshop inspection is possible: Perform a cylinder compression test and a leakdown test to confirm ring seal condition.

Where to look: Engine internal - pistons, rings, and valve stem seals throughout engine block

Parts involved: Fuel injector, Diesel particulate filter.

Ask the seller

  • “How much oil has been added between services?”
  • “How often has the oil been changed and at what intervals?”
  • “Has there ever been blue smoke from the exhaust?”
  • “Has the vehicle had a compression or leakdown test performed?”
  • “Has the DPF required cleaning or replacement?”

021GD-FTV Timing Chain Guide Premature Wear

With engine cold, start and listen immediately for chain rattle from the front timing cover area — rattle persisting beyond 3 seconds is a red flag.diesel2015–2018EngineRead the full fault: symptoms, where to look, what to ask the seller

032GD-FTV Timing Chain Stretch on Early Production Units

Cold-start the engine and listen for chain rattle from the front.diesel2015–2017Engine
OccasionalEngine $1,800–$4,200 to fix

Can't confirm for this car

Early GUN125/126 HiLux vehicles built from late 2015 through 2017 were subject to documented concerns around premature timing chain stretch and tensioner wear in the 2GD-FTV engine. The chain drive system, under high-cycle towing and load use without strict early oil change adherence, stretched faster than the tensioner could compensate. Affected vehicles showed timing retard, rough running, and in some cases jumped timing. Toyota Australia issued service guidance and an extended warranty programme covering affected early-production vehicles.

The front of a dual overhead camshaft engine with the timing cover removed, exposing the timing chain and sprockets.Example of the part — not this vehicle

The front of a twin-cam engine with the timing cover off — chain, sprockets and guides.

Logansenf · CC BY-SA 4.0 · Wikimedia Commons

Symptoms to notice

  • Rough idle or misfiring particularly when cold
  • Rattling noise from the front of the engine on cold startup
  • Check engine light with timing correlation fault codes (P0016, P0017)
  • Power loss and increased fuel consumption
  • Hard starting in cold conditions

What to check

  1. Cold-start the engine and listen for chain rattle from the front.
  2. Scan for cam-crank correlation fault codes.
  3. Request full service history — early oil change adherence at 5,000 km or less intervals is critical for this engine generation.
  4. Check for any Toyota extended coverage claims or service campaign records in the vehicle file.

Where to look: Front of engine — timing chain, tensioners, and guide rails inside the timing cover

Parts involved: Timing chain.

Ask the seller

  • “Is this a 2015, 2016, or early 2017 build date and has the timing chain been inspected?”
  • “Were early oil changes done on schedule or more frequently than specified?”
  • “Any check engine lights or cold-start rattling noise in the history?”

042GD-FTV EGR Cooler Internal Failure and Coolant Contamination

Check coolant level and condition — milky or discoloured coolant indicates combustion gas contamination.diesel2015 onwardCooling
OccasionalCooling $1,400–$3,200 to fix

Can't confirm for this car

The EGR cooler on the 2GD-FTV engine is prone to internal matrix cracking, particularly in high-cycling urban use where repeated heating and cooling fatigues the cooler. When the cooler fails, coolant leaks internally into the EGR system and is introduced into the intake manifold and combustion chambers. Coolant in the intake causes white exhaust smoke and hydrolock risk if severe. Externally the coolant loss from the EGR cooler is subtle, and the system may overheat before the fault becomes obvious.

Symptoms to notice

  • White exhaust smoke, particularly on startup
  • Sweet coolant smell from the exhaust
  • Unexplained coolant level loss with no visible external leak
  • Overheating or temperature gauge rising under load
  • White or creamy residue on the oil filler cap in severe cases

What to check

  1. Check coolant level and condition — milky or discoloured coolant indicates combustion gas contamination.
  2. Inspect the EGR cooler inlet and outlet pipes for coolant residue or deposit staining.
  3. Check the oil filler cap for white emulsification.
  4. Perform a combustion gas test on the coolant using a block test kit.

Where to look: Engine — EGR cooler mounted on the intake manifold side, coolant lines connecting from the engine cooling circuit

Parts involved: EGR valve.

Ask the seller

  • “Has the EGR system or cooler ever been inspected or replaced?”
  • “Any white smoke from the exhaust, especially on cold morning starts?”
  • “Has the coolant level dropped without an obvious reason?”

051GD-FTV Injector Seizure in Cylinder Head

Check for oil leaks around valve covers, sump and gaskets.diesel2015 onwardEngine
CommonEngine $4,200–$8,400 to fix

Can't confirm for this car

The 2.8L 1GD-FTV injectors are prone to seizing in the cylinder head due to carbon lock between the injector body and the head bore. Removal without the correct extraction tooling frequently damages the head threads or pulls the copper sleeve, requiring head replacement. Toyota issued a Technical Service Bulletin on injector removal procedures. Failed injectors cause misfires, excessive smoke, and fuel dilution of oil.

A removed six-cylinder diesel engine cylinder head on cardboard, valve-gear side facing up.Example of the part — not this vehicle

A six-cylinder diesel head off the engine, valve-gear side up. Cracks run between the valve seats on the face beneath.

Ll1324 · CC0 · Wikimedia Commons

Symptoms to notice

  • Blue or white smoke from exhaust
  • Engine misfire or rough idle

What to check

  1. Check for oil leaks around valve covers, sump and gaskets.
  2. Inspect coolant condition and level.

Parts involved: Cylinder head, Fuel injector.

06Fifth (exhaust) injector failure on the 2.8 1GD-FTV - warning lights and limp mode

diesel2015–2019EngineRead the full fault: symptoms, where to look, what to ask the seller

07DPF blocking and failing to regenerate (2.8 1GD-FTV diesel, Oct 2015 to Apr 2020 builds)

Check the dashboard for DPF or engine warning lights.diesel2015 onwardEngineRead the full fault: symptoms, where to look, what to ask the seller

082GD-FTV DPF Clogging on Short Urban Trips

Ask seller for DPF service history and confirm whether the vehicle is used on predominantly short urban trips.diesel2015 onwardEngineRead the full fault: symptoms, where to look, what to ask the seller

091GD-FTV EGR Valve Failure and Intake Carbon Build-Up

Check for oil leaks around valve covers, sump and gaskets.diesel2015 onwardEngine
CommonEngine $1,120–$2,240 to fix

Can't confirm for this car

The 1GD-FTV EGR system accumulates carbon deposits that restrict flow and cause valve sticking, triggering fault codes P0400-range and limp mode. Intake manifold cleaning is required alongside valve replacement to prevent recurrence. The EGR cooler can also develop internal cracks allowing coolant weeping into the intake on high-mileage engines.

Symptoms to notice

  • Coolant loss or steam from engine bay
  • Fault codes or irregular readings when scanned

What to check

  1. Check for oil leaks around valve covers, sump and gaskets.
  2. Inspect coolant condition and level.

Parts involved: EGR valve.

101GD-FTV AdBlue Dosing Pump Heater Failure

Scan the vehicle for P20EE (SCR NOx catalyst efficiency below threshold) or P207F (reductant quality poor) fault codes.diesel2015 onwardEngine
OccasionalEngine $750–$1,800 to fix

Can't confirm for this car

HiLux models fitted with the 1GD-FTV 2.8L engine and SCR emissions system use an AdBlue (diesel exhaust fluid) dosing pump with an integrated heating element. The heater prevents AdBlue crystallisation in cold weather and keeps the pump and lines operational. The heating element fails with age and exposure, particularly in units that have experienced freeze-thaw cycles. A failed heater results in AdBlue crystallisation inside the pump, blocking the dosing injector. The vehicle ECU detects insufficient reductant dosing and triggers a NOx derate warning. If not rectified within the allowed grace distance the engine is electronically restricted to a maximum speed of approximately 25km/h. The complete dosing pump assembly must be replaced.

Symptoms to notice

  • AdBlue or SCR system warning light on dashboard
  • NOx emissions warning message displayed
  • Vehicle speed limited to 25km/h after grace period expires
  • AdBlue consumption drops to zero or near-zero
  • Fault codes P20EE or P207F stored in ECU

What to check

  1. Scan the vehicle for P20EE (SCR NOx catalyst efficiency below threshold) or P207F (reductant quality poor) fault codes.
  2. Inspect the AdBlue tank and lines under the vehicle for crystalline white AdBlue deposits indicating a pump or line leak.
  3. Check AdBlue fluid level and quality.
  4. Ask whether the vehicle has ever triggered a NOx or AdBlue derate warning.

Where to look: AdBlue dosing pump and SCR system, underside of vehicle near rear axle

Parts involved: Fuel injector.

Ask the seller

  • “Has the AdBlue or SCR warning light ever come on?”
  • “Has the vehicle ever entered a speed-restricted derate mode?”
  • “Has the AdBlue dosing pump or SCR system been serviced?”
  • “How often has AdBlue fluid been topped up?”

112GD-FTV EGR Cooler Bypass O-Ring Coolant Leak

Check coolant reservoir level and top-up history in service records.diesel2015 onwardCoolingRead the full fault: symptoms, where to look, what to ask the seller

126-speed automatic transmission valve body solenoid wear

During test drive, observe engagement from Park to Drive — it should be smooth and immediate.diesel2015 onwardTransmission
OccasionalTransmission $1,200–$3,500 to fix

Can't confirm for this car

The 6-speed automatic transmission fitted to AN120 Hilux develops solenoid wear in the valve body, causing delayed engagement, gear hunting, and occasionally harsh or erratic shifts. The failure mode is accelerated by infrequent transmission fluid changes or heavy towing use. Toyota issued internal workshop guidance on inspection and fluid service intervals to address this pattern.

Symptoms to notice

  • Delayed engagement when selecting Drive or Reverse from Park
  • Hunting between gears at highway cruise speed
  • Harsh or clunking shifts, particularly 1-2 and 2-3
  • Transmission warning light or check engine light
  • Slipping under load with normal fluid level

What to check

  1. During test drive, observe engagement from Park to Drive — it should be smooth and immediate.
  2. Drive at 80-100 km/h and note any hunting or indecisive gear changes.
  3. Check transmission fluid condition — dark or burnt-smelling fluid indicates overdue service.

Where to look: Automatic transmission — valve body inside the gearbox oil sump

Parts involved: Mechatronic / valve body.

Ask the seller

  • “Has the automatic transmission fluid ever been changed and when?”
  • “Are there any hesitations, shudders, or delays when selecting gears?”
  • “Has the vehicle been used regularly for towing?”
Body, brakes, suspension & interior1

01Brake booster vacuum hose chafing and failure

Toyota issued a Technical Service Bulletin in 2019 documenting brake booster vacuum hose chafing on AN120 Hilux diesel models.diesel2015 onwardBrakes
OccasionalBrakes $200–$600 to fix

Can't confirm for this car

Toyota issued a Technical Service Bulletin in 2019 documenting brake booster vacuum hose chafing on AN120 Hilux diesel models. The hose runs in a location where it contacts the engine or chassis, wearing through the outer casing over time. A damaged or collapsed hose reduces brake booster assistance, increasing pedal effort and reducing stopping performance — a direct safety concern.

Symptoms to notice

  • Noticeably firmer brake pedal requiring more foot pressure to stop
  • Hissing sound from engine bay under hard braking
  • Longer stopping distances than expected
  • Pedal feeling hard immediately at the top of travel rather than having initial softness

What to check

With the engine off and then on, press the brake pedal and compare feel — with the engine running, the booster should provide assistance making the pedal noticeably easier. Inspect the vacuum hose from the brake booster to the engine for chafing, cracks, or contact points with metal edges.

Where to look: Engine bay — brake booster vacuum hose running from brake booster to intake manifold or vacuum pump

Ask the seller

  • “Has the vehicle been checked for the Toyota brake booster vacuum hose TSB?”
  • “Does the brake pedal feel normal or unusually firm?”
  • “Has a Toyota dealer or workshop inspected the brake system recently?”
Other Toyota Hilux engines and years42 documented issues that do not apply to the one you picked.
Engine, transmission & cooling26

01Cracked pistons on the Euro IV 3.0 1KD-FTV diesel (KUN16/KUN26 Hilux)

Start the engine and listen for a heavy knock at idle and any misfire or rough running.diesel2008–2014Engine
OccasionalEngine $8,000–$16,000 to fix

Does not apply

The Euro IV version of the 3.0 1KD-FTV turbo diesel in the KUN26 Hilux is known for cracking pistons, most often between 100,000 and 150,000 km. Toyota acknowledged the problem in service bulletins (EG-0172T-0511 and EG-0008T-0112) and fitted stronger pistons and improved injectors, with Australian Hilux engines from July 2014 (engine number A477120 on) getting the fix. There is no recall or extended warranty now. A cracked piston usually means a full engine rebuild or replacement engine, so proof of new pistons or a replacement engine adds real value.

Symptoms to notice

  • Loud knock at idle
  • Rough running, feels like it is on three cylinders
  • Black or grey smoke from the exhaust
  • Sudden loss of power
  • Oily fumes or pressure pushing out of the oil filler cap when the engine runs

What to check

  1. Start the engine and listen for a heavy knock at idle and any misfire or rough running.
  2. Watch the exhaust for smoke on start up and when you accelerate hard on the test drive, and feel for missing power.
  3. With the engine idling, carefully loosen the oil filler cap: strong fumes or the cap being pushed up points to blow-by from a cracked piston.
  4. Ask how many kilometres it has done, and if it is over 100,000 km ask whether the pistons, injectors or engine have been replaced, with receipts.
  5. If a workshop inspection is possible: ask for a compression or cylinder leak-down test and a crankcase blow-by check, and have the engine number checked against Toyota's change point.

Where to look: Engine internals (pistons), checked through the oil filler and exhaust

Parts involved: Fuel injector, Turbocharger.

Ask the seller

  • “Has the engine ever had pistons, a rebuild or a replacement engine?”
  • “Have the injectors been replaced, and when?”
  • “Has a Toyota dealer done any service bulletin work on the engine?”
  • “How many kilometres has the engine done?”

021KZ-TE Timing Belt Snap (Interference Engine)

Check for a timing belt service sticker on the engine bay, cam cover, or radiator shroud showing the replacement date and odometer reading.diesel1999–2005EngineRead the full fault: symptoms, where to look, what to ask the seller

031KZ-TE head gasket & head cracking (endemic)

Watch for: White steam from exhaust on a warmed engine.diesel1997–2005EngineRead the full fault: symptoms, where to look, what to ask the seller

041KD-FTV Cylinder Head Crack Between Combustion Chambers

Inspect coolant for brown emulsification.diesel2000–2016EngineRead the full fault: symptoms, where to look, what to ask the seller

051KZ-TE EGR Valve Carbon Buildup Leading to Cracked Pistons

Request an EGR valve inspection or ask if it has been cleaned, blocked, or removed.diesel1999–2005Engine
OccasionalEngine $3,500–$7,500 to fix

Does not apply

The 1KZ-TE's EGR (exhaust gas recirculation) system recirculates hot exhaust gases back into the intake, which causes progressive carbon buildup on the EGR valve, inlet tract, and intake ports. A stuck-open EGR valve causes excessive exhaust gas dilution of the intake charge, raising combustion temperatures beyond design limits. Sustained high combustion temperatures crack the aluminium pistons — an expensive internal engine failure. Many owners eliminate the EGR system entirely as a preventive measure; a blocked or removed EGR is therefore not automatically a red flag and should be verified.

Symptoms to notice

  • Excessive black smoke under acceleration
  • Rough idle or hunting idle
  • Loss of power, particularly at altitude or under load
  • Increased fuel consumption
  • Rattling or knocking from engine internals (advanced piston damage)

What to check

  1. Request an EGR valve inspection or ask if it has been cleaned, blocked, or removed.
  2. Check intake manifold for heavy carbon deposits by looking through the air inlet with a torch.
  3. Listen carefully for any metallic rattling from the engine at idle and under light acceleration — piston damage produces a distinct rhythmic knock that worsens with load.

Where to look: EGR valve on the exhaust/intake crossover pipe, top of engine; pistons inside the engine block

Parts involved: EGR valve.

Ask the seller

  • “Has the EGR valve been cleaned, blanked, or removed?”
  • “Has the engine ever been smoke-tested or had a compression test done?”
  • “Is there any history of excessive black smoke or power loss?”

061KD-FTV Head Gasket Failure

Check for oil leaks around valve covers, sump and gaskets.diesel2000–2016Engine
CommonEngine $3,360–$6,720 to fix

Does not apply

The 3.0L 1KD-FTV has a well-documented head gasket failure pattern driven by thermal cycling between the aluminium head and cast-iron block. Coolant loss, white exhaust smoke, and hydrolocking are the primary symptoms. Toyota issued revised head bolt torque specifications and extended warranty coverage in several markets, but high-mileage examples remain at high risk. A warped cylinder head is almost always found alongside the blown gasket, adding machining cost. Common from 150,000km onwards.

A removed multi-layer steel head gasket held up, showing staining around the cylinder bore.Example of the part — not this vehicle

A used multi-layer head gasket. Discolouration between a cylinder and a water gallery is the tell.

John Furman · CC BY-SA 3.0 · Wikimedia Commons

Symptoms to notice

  • Blue or white smoke from exhaust
  • Coolant loss or steam from engine bay

What to check

  1. Check for oil leaks around valve covers, sump and gaskets.
  2. Inspect coolant condition and level.

Parts involved: Head gasket.

072L-T / 2L-TE turbo-diesel cylinder head cracking (turbo engines, not the 3L or 5L)

The 2.4-litre turbocharged 2L-T and later 2L-TE fitted to LN65 and LN106 Hilux crack their cylinder heads.diesel1984–1997EngineRead the full fault: symptoms, where to look, what to ask the seller

08L-series diesel timing belt and belt-driven water pump (2.4 2L, 2.8 3L, 3.0 5L / 5L-E diesel)

diesel1984–2005EngineRead the full fault: symptoms, where to look, what to ask the seller

091KD-FTV common rail injector cracking and fuel dilution

Pull the dipstick and smell the oil — diesel contamination is detectable by fuel smell and a thin, watery feel.diesel2005–2007EngineRead the full fault: symptoms, where to look, what to ask the seller

102KD-FTV Head Gasket Failure from EGR Overheating

Check coolant level and look for white or cream residue on the coolant cap.diesel2005–2015Engine
CommonEngine $1,500–$4,500 to fix

Does not apply

The 2KD-FTV 2.5 diesel is prone to head gasket failure caused by the EGR system overheating the combustion chamber area of the head gasket. Results in coolant entering combustion chambers producing white smoke and eventual engine damage.

A removed multi-layer steel head gasket held up, showing staining around the cylinder bore.Example of the part — not this vehicle

A used multi-layer head gasket. Discolouration between a cylinder and a water gallery is the tell.

John Furman · CC BY-SA 3.0 · Wikimedia Commons

Symptoms to notice

  • White smoke from exhaust when coolant enters the combustion chamber from a failed head gasket
  • Coolant level dropping without a visible external leak

What to check

Check coolant level and look for white or cream residue on the coolant cap. Perform a combustion gas test on the coolant. White smoke from the exhaust on a warm engine warrants immediate investigation.

Where to look: Cylinder head gasket at the EGR-affected combustion chamber areas

Parts involved: Head gasket, EGR valve.

Ask the seller

  • “Has the 2kd-ftv head gasket failure from been inspected or repaired?”

115L-E and 3L diesel head gasket failure

Check the coolant reservoir for an oil sheen or bubbling when the engine is warm.diesel1984–2005EngineRead the full fault: symptoms, where to look, what to ask the seller

1222R / 22R-E timing chain guide collapse and timing cover wear-through

The 2.4-litre 22R and fuel-injected 22R-E run a single-row timing chain against plastic guides.petrol1984–1997EngineRead the full fault: symptoms, where to look, what to ask the seller

13Head gasket failure at cylinder 6 (4.0 V6 1GR-FE)

Check the coolant reservoir level against its marks and ask when it was last topped up — steady unexplained loss is the flag.petrol2005–2015Engine
OccasionalEngine $3,000–$5,500 to fix

Does not apply

The 4.0 petrol V6 has a documented head gasket weak spot at the rearmost cylinder (cylinder 6): the gasket lets coolant seep into the cylinder, with the failure most reported on earlier builds of the engine. The classic pattern is slow unexplained coolant loss, then a rough cold start with a cylinder-6 misfire (code P0306) that clears as the engine warms. It fails gradually rather than catastrophically, but the repair means heads off a big V6. The same failure is documented across the 4Runner, FJ Cruiser, Prado and Hilux applications of this engine.

A removed multi-layer steel head gasket held up, showing staining around the cylinder bore.Example of the part — not this vehicle

A used multi-layer head gasket. Discolouration between a cylinder and a water gallery is the tell.

John Furman · CC BY-SA 3.0 · Wikimedia Commons

Symptoms to notice

  • Coolant level dropping slowly with no visible leak
  • Rough, lumpy running for the first seconds of a cold start, then smooth
  • White exhaust smoke on start-up
  • Check-engine light with a cylinder 6 misfire code (P0306)

What to check

  1. Check the coolant reservoir level against its marks and ask when it was last topped up — steady unexplained loss is the flag.
  2. Start the engine stone cold and listen for a rough first ten seconds that clears as it warms, and watch the exhaust for white smoke while it does.
  3. Unscrew the oil filler cap and look for creamy residue.
  4. Ask whether it has ever logged a cylinder 6 misfire or had head gasket work.
  5. If a workshop inspection is possible: a cooling-system pressure test and a combustion-gas (block) test on the coolant confirm the leak, and a steam-cleaned white spark plug in cylinder 6 is the classic tell.

Where to look: Rearmost cylinder of the right-hand bank (cylinder 6), under the head on that side

Parts involved: Head gasket.

Ask the seller

  • “Has it ever lost coolant or shown a P0306 misfire code?”
  • “Has the head gasket ever been replaced?”
  • “Any overheating history?”

14VNT Turbocharger Variable Nozzle Vane Seizure

If vanes are stiff, a soak-and-clean of the variable vane assembly may restore function; severe cases require turbo replacement or specialist rebuild.diesel2005–2015EngineRead the full fault: symptoms, where to look, what to ask the seller

151KD-FTV VNT Turbo Actuator Corrosion & Stuck Vanes

With engine off, locate the VNT actuator arm on the turbocharger and attempt to move it manually — it should travel freely with a spring return.diesel2005–2015EngineRead the full fault: symptoms, where to look, what to ask the seller

16Standard clutch slipping on the 3.0 D4D manual - often replaced well before 100,000 km

diesel2005–2015TransmissionRead the full fault: symptoms, where to look, what to ask the seller

17Fuel Injector Copper Seat Seal Failure and External Combustion Gas Leak

Inspect each injector clamp area for carbon tracking (black or dark brown sooty deposits radiating outward from the injector bore).diesel2005–2007Engine
OccasionalEngine $500–$2,800 to fix

Does not apply

The 1KD-FTV common-rail injectors seal against the cylinder head combustion chamber via a copper crush washer at the injector tip. With high mileage and repeated heat cycling, the copper washer deforms or the injector seat in the head becomes carbon-fouled, allowing combustion gas to bypass the seal. Gas tracks up the injector bore in the head, depositing heavy carbon around the injector clamp and potentially allowing the injector to become seized in the bore. Extraction of a seized injector without specialist tooling frequently results in damaged injector bores requiring expensive head repair.

A single common-rail diesel fuel injector photographed against a plain background.Example of the part — not this vehicle

A common-rail diesel injector. Contamination damages the nozzle at the tip.

Panoha · CC BY-SA 3.0 · Wikimedia Commons

Symptoms to notice

  • Carbon tracking or black sooty deposits around the injector clamp and wiring harness near one or more injectors
  • Ticking or light knocking sound from the valve cover area under light throttle, distinct from normal injector clatter
  • Fuel consumption increase and slightly rough idle on the affected cylinder
  • Coolant smell or exhaust gases detectable near the injector area with engine running

What to check

Inspect each injector clamp area for carbon tracking (black or dark brown sooty deposits radiating outward from the injector bore). Apply an unlit gas leak detector or soapy water around each injector base with the engine running to detect escaping gases. If a seized injector is suspected, do not attempt removal without proper injector extraction tooling — forced extraction regularly pulls the threaded seat insert out of the head. Plan for injector bore re-tapping or head replacement if the bore is damaged.

Where to look: Injector bores in cylinder head, visible at the injector clamp hold-down area on top of the engine

Parts involved: Fuel injector.

Ask the seller

  • “Have the injectors ever been removed, cleaned, or replaced?”
  • “Is there any carbon staining or black residue visible around the injector hold-down clamps?”
  • “Has the vehicle had any injector-related fault codes or rough idle complaints?”

181KD-FTV Timing Chain Tensioner Wear & Cold Rattle

Arrange to cold-start the engine and listen immediately for metallic rattling from the timing cover at the front of the engine.diesel2005–2015EngineRead the full fault: symptoms, where to look, what to ask the seller

19EGR Cooler Internal Crack and Coolant Ingestion

Perform a block test to rule out head crack first.diesel2005–2015CoolingRead the full fault: symptoms, where to look, what to ask the seller

20Timing chain and guide wear — start-up rattle (2.4 2RZ-FE / 2.7 3RZ-FE)

The petrol four-cylinder Hilux of this era drives its cam with a single-row chain running on plastic guides, and both wear with age and kilometres.petrol1998–2005Engine
OccasionalEngine $1,000–$2,200 to fix

Does not apply

The petrol four-cylinder Hilux of this era drives its cam with a single-row chain running on plastic guides, and both wear with age and kilometres. The first sign is a rattle for a few seconds on cold start while the tensioner takes up slack, growing over time into a constant rattle; a broken guide lets the chain slap the case and in the worst case jump timing. NZ owner communities treat chain, guides and tensioner as an expected job on high-kilometre examples. It is a different noise from the cracked exhaust manifold tick these engines also suffer — manifold tick is loudest under load, chain rattle is worst at cold idle.

The front of a dual overhead camshaft engine with the timing cover removed, exposing the timing chain and sprockets.Example of the part — not this vehicle

The front of a twin-cam engine with the timing cover off — chain, sprockets and guides.

Logansenf · CC BY-SA 4.0 · Wikimedia Commons

Symptoms to notice

  • Rattle from the front of the engine for a few seconds on cold start
  • Constant rattle at idle that changes with engine speed
  • Slapping or whirring from behind the radiator fan

What to check

  1. Start the engine from stone cold: a few seconds of front-of-engine rattle that fades is early tensioner wear, and a rattle that stays is worn guides or a stretched chain.
  2. Rev gently off idle and listen for the noise to sharpen with speed.
  3. Ask whether the timing chain kit has ever been done and for the invoice — on anything over about 200,000 km with no record, price the job in.
  4. If a workshop inspection is possible: the tensioner's extension can be measured (near full extension means a stretched chain) and the case checked for chain-slap wear.

Where to look: Front of the engine — timing chain case behind the radiator fan

Parts involved: Timing chain.

Ask the seller

  • “Has the timing chain kit (chain, guides, tensioner) ever been replaced?”
  • “Does it rattle when started first thing in the morning?”

213RZ-FE / 2RZ-FE cast-iron exhaust manifold cracking between the centre runners

petrol1997–2005EngineRead the full fault: symptoms, where to look, what to ask the seller

221KD-FTV Injector Fuel Return O-Ring Failure and Oil Dilution

Pull the dipstick and smell the oil — diesel contamination is unmistakable.diesel2005–2015EngineRead the full fault: symptoms, where to look, what to ask the seller

23EGR Valve Carbon Clogging on Diesel Variants

Check for P0401/P0404 EGR fault codes.diesel2005–2015Engine
CommonEngine $300–$800 to fix

Does not apply

The 1KD-FTV and 2KD-FTV diesel EGR valves accumulate heavy carbon deposits causing rough idle, power loss, and EGR-related fault codes on urban-use and short-trip examples.

Symptoms to notice

  • Rough idle and reduced power under load with black smoke on acceleration
  • P0401/P0404 EGR system fault codes stored on scan tool

What to check

  1. Check for P0401/P0404 EGR fault codes.
  2. Note rough idle and black smoke on acceleration.
  3. If a workshop inspection is possible: Remove the EGR valve and inspect bore for heavy carbon deposits.

Where to look: EGR valve on diesel intake system

Parts involved: EGR valve.

Ask the seller

  • “Has the egr valve carbon clogging on been inspected or repaired?”

24Rear tailshaft centre bearing bracket recall (N70 Hilux 4WD, 2005-2010)

On the test drive, feel for a vibration through the floor that grows with speed and listen for a clunk under the cab when you take off and back off.2005–2010Transmission
CommonTransmission $0 to fix

Does not apply

N70 (Mk7) Hilux 4WDs built from January 2005 to February 2010 were recalled (PRA 2010/11961) because the brackets holding the rear tailshaft centre bearing can come loose with hard driving on badly corrugated roads. A loose tailshaft vibrates and in the worst case can drop and damage the underbody. This applies to all engines of the 4WD models. The fix is free at a Toyota dealer.

Symptoms to notice

  • Vibration through the floor that rises with speed
  • Clunk from under the middle of the ute when taking off or easing off

What to check

On the test drive, feel for a vibration through the floor that grows with speed and listen for a clunk under the cab when you take off and back off. Look under the middle of the ute with a phone torch for a sagging tailshaft. Ask the seller for the service history and look for a dealer invoice or service stamp showing recall PRA 2010/11961 (tailshaft bracket) was done. A buyer can also give the VIN to any franchise dealer and ask them to check for open recalls before paying. If a workshop inspection is possible: on a hoist, check the centre bearing bracket bolts and rubber.

Where to look: Under the middle of the vehicle, centre bearing of the rear tailshaft

Ask the seller

  • “Has the tailshaft bracket recall been done?”
  • “Has it been driven a lot on gravel or corrugated roads?”

25Timing chain tensioner cold-start rattle (4.0 V6 1GR-FE)

petrol2005–2015Engine
OccasionalEngine $400–$3,000 to fix

Does not apply

On higher-kilometre 4.0 V6s the timing chain tensioner can bleed down overnight, so the chain slaps for the first seconds of a cold start until oil pressure comes up. A brief rattle is a warning to act on rather than an emergency; a rattle that lingers, or comes back on hot restarts, points to a worn tensioner and on neglected engines to worn chains and guides. A tensioner alone is a modest job — if the chains and guides are worn the front of the engine comes apart and the bill steps up sharply.

The front of a dual overhead camshaft engine with the timing cover removed, exposing the timing chain and sprockets.Example of the part — not this vehicle

The front of a twin-cam engine with the timing cover off — chain, sprockets and guides.

Logansenf · CC BY-SA 4.0 · Wikimedia Commons

Symptoms to notice

  • Metallic rattle for one to five seconds on the first cold start of the day
  • Rattle returning on hot restarts as wear progresses

What to check

Arrive before the seller has started the truck and listen to the very first cold start of the day — this fault only speaks then, and a warmed-up engine hides it completely. A one-to-two-second flutter is early wear; a longer clatter, or one that returns when hot, means budgeting for the tensioner at least. Ask how long it rattles on cold mornings and whether the tensioner has ever been replaced. If a workshop inspection is possible: oil pressure and tensioner extension can be checked, and the timing cover area inspected for chain-slap marks.

Where to look: Front of the engine behind the drive belts — chain tensioners in the timing cover

Parts involved: Timing chain.

Ask the seller

  • “Does it rattle on the first start of the day, and for how long?”
  • “Has the tensioner or the chain set ever been replaced?”

26Timing chain tensioner rattle and high-kilometre chain wear (2.7 2TR-FE)

The 2.7 petrol four is one of Toyota's most reliable engines, and the one noise worth taking seriously on it is chain related.petrol2005–2015Engine
OccasionalEngine $350–$2,500 to fix

Does not apply

The 2.7 petrol four is one of Toyota's most reliable engines, and the one noise worth taking seriously on it is chain related. Owners report a brief rattle on the first cold start while the tensioner waits for oil pressure, and on very high-kilometre engines a constant chain slap that means the chain and guides are due. Toyota changed the specified oil across the engine's life (5W-30 on earlier engines, 0W-20 later), and engines run on the wrong oil or long intervals show it first at the tensioner. A sub-two-second start-up flutter is common and benign; a rattle that persists or appears at hot idle is the expensive version.

The front of a dual overhead camshaft engine with the timing cover removed, exposing the timing chain and sprockets.Example of the part — not this vehicle

The front of a twin-cam engine with the timing cover off — chain, sprockets and guides.

Logansenf · CC BY-SA 4.0 · Wikimedia Commons

Symptoms to notice

  • Brief rattle on the first cold start of the day
  • Persistent rattling or knocking at idle on high-kilometre engines

What to check

Listen to the first cold start of the day: a flutter under two seconds that never returns is normal for this engine, while a longer clatter or rattling at hot idle means tensioner or chain work. Ask what oil it runs and how often it is changed. On a high-kilometre truck with start-up rattle, price a tensioner as the minimum and a chain kit as the worst case. If a workshop inspection is possible: tensioner extension can be measured and chain stretch checked against the service limit before committing to the full job.

Where to look: Front of the engine — timing chain cover behind the fan

Parts involved: Timing chain.

Ask the seller

  • “Does it rattle when started cold, and does the noise ever stay?”
  • “What oil is used and how often is it changed?”
Electrical1

01Driver airbag spiral cable recall (N70 Hilux, 2005-2009)

Turn the ignition on and check the airbag light comes on then goes out.2005–2009Electrical
CommonElectrical $0 to fix

Does not apply

N70 (Mk7) Hiluxes built from July 2004 to December 2009 were recalled (PRA 2014/14058) because the spiral cable behind the steering wheel, which carries power to the driver airbag, can be damaged over time so the airbag may not go off in a crash. This applies to all engines. The fix is a free spiral cable replacement at a Toyota dealer. A damaged cable often also stops the horn or steering wheel buttons working.

Symptoms to notice

  • Airbag warning light stays on
  • Horn or steering wheel buttons work only sometimes

What to check

  1. Turn the ignition on and check the airbag light comes on then goes out.
  2. Turn the steering wheel lock to lock and press the horn at each end.
  3. Ask the seller for the service history and look for a dealer invoice or service stamp showing recall PRA 2014/14058 (spiral cable) was done.
  4. A buyer can also give the VIN to any franchise dealer and ask them to check for open recalls before paying.
  5. If a workshop inspection is possible: a scan tool will show any stored airbag circuit fault.

Where to look: Behind the steering wheel, in the clock spring

Ask the seller

  • “Has the airbag spiral cable recall been done?”
  • “Has the airbag light ever been on?”
Body, brakes, suspension & interior11

01Rear Leaf Spring Main Blade Fracture at Second Eye

Look for surface cracks, rust-filled stress fractures, or visible misalignment between the main blade and the second leaf.2005–2015Suspension
OccasionalSuspension $900–$2,200 to fix

Does not apply

On leaf-spring rear suspension models (SR and SR5 variants), the main leaf blade is subject to cracking at or near the second eye — the forward wrap-around anchor point. Fatigue cracks initiate at the eye bushing bore where bending stress concentrates, particularly in vehicles used for towing or loaded operation. A full fracture causes the rear axle to shift rearward suddenly, creating serious steering and control hazard. Reported in both NZ and Australian markets on higher-mileage working vehicles.

Symptoms to notice

  • Visible crack or fracture line across the main leaf blade near the second eye bore
  • Rear of vehicle sitting unevenly or lower on one side under load
  • Clunking or banging sound from rear suspension over bumps, distinct from worn shackle bushes
  • Rear axle shifting rearward or crabbing under acceleration after fracture

What to check

  1. Look for surface cracks, rust-filled stress fractures, or visible misalignment between the main blade and the second leaf.
  2. Clean the blade surface if heavily corroded to expose any crack lines.
  3. Replace as an axle-paired set.
  4. If a workshop inspection is possible: With the vehicle unladen on a hoist, visually inspect the full length of the main leaf blade on both sides, paying particular attention to the area within 150 mm of the second eye bore.

Where to look: Rear leaf spring pack, main (top) blade at the forward second eye anchor point

Parts involved: Rear leaf spring.

Ask the seller

  • “Has the rear leaf spring pack ever been inspected for cracks or replaced?”
  • “Has the vehicle been used for heavy towing, farm work, or regular loaded operation?”
  • “Are there any clunking noises from the rear suspension?”

02Brake pedal piston can break - safety recall on diesel Hilux built March 2018 to May 2019 (Toyota campaign 20SMD-105)

Toyota recalled Hilux utes built in 2018 and 2019 because a piston in the brake pedal assembly can break after repeated pedal use.diesel2018–2019Brakes
OccasionalBrakes $0–$2,200 to fix

Does not apply

Toyota recalled Hilux utes built in 2018 and 2019 because a piston in the brake pedal assembly can break after repeated pedal use. If it breaks, the driver loses braking assistance and the ute needs far more pedal effort and a much longer distance to stop. The remedy is free at a Toyota dealer and quick, but recall completion on used utes is patchy - work vehicles that have never gone back to a franchise dealer are the ones most likely to still be outstanding. Campaign coverage and the campaign code vary between markets, so the only reliable answer comes from running this ute's VIN through the local Toyota or transport agency recall lookup rather than assuming it was handled. This is a separate item from the brake booster vacuum hose that chafes through on these utes - that one is wear, this one is a recalled part with a free factory fix.

Symptoms to notice

  • Brake pedal that feels hard and needs heavy effort
  • Longer stopping distance than the ute used to need
  • A change in pedal feel that came on suddenly
  • No symptom at all before the part lets go

What to check

Ask the seller for the VIN and run it through the Toyota New Zealand or Toyota Australia recall lookup, and the NZTA recall check, to see whether this recall is still outstanding on this exact ute. Ask for any dealer invoices or a recall-completion printout covering it. On the test drive, pay attention to how much effort the brake pedal takes compared with other utes you have driven, and whether the pedal feels firm and consistent or unusually hard. Do one firm stop from about 50 km/h on a safe empty stretch and feel whether the ute pulls up straight without needing unusual pressure. If the recall shows as outstanding, that is not automatically a reason to walk - it is a free dealer job - but it should be booked in before the ute is driven much further.

Where to look: Brake pedal assembly under the dashboard on the driver's side.

Ask the seller

  • “Has the brake pedal recall been completed on this VIN?”
  • “Are there any outstanding recalls showing against this ute?”
  • “Has the brake pedal feel changed at all while you have owned it?”

03Rear Leaf Spring U-Bolt Rust and Loosening

Inspect each U-bolt for rust, corrosion, and nut loosening.2005–2015Body & Rust
CommonBody & Rust $150–$600 to fix

Does not apply

The KUN26 Hilux rear leaf spring U-bolts corrode and loosen on examples exposed to salt water and coastal environments, causing rear axle location loss and potential catastrophic handling failure.

Symptoms to notice

  • Rear axle clunking under load and acceleration from loose U-bolts
  • U-bolts visibly corroded or nuts that turn freely without torque

What to check

  1. Inspect each U-bolt for rust, corrosion, and nut loosening.
  2. U-bolts that can be turned by hand indicate complete nut thread failure.
  3. Look for rust streaks down the leaf spring pack face from corroded U-bolts.

Where to look: Rear axle U-bolts clamping the leaf spring pack to the axle housing

Parts involved: Rear leaf spring.

Ask the seller

  • “Has the rear leaf spring u-bolt rust been inspected or repaired?”

04Rear leaf spring fatigue and U-bolt corrosion

Inspect all leaf spring leaves for cracking, fatigue, or separation.1984–2005SuspensionRead the full fault: symptoms, where to look, what to ask the seller

05Rear Axle Wheel Bearing Failure Under Load

Spin each rear wheel by hand listening for roughness or grinding.2005–2015Suspension
OccasionalSuspension $500–$1,300 to fix

Does not apply

The rear semi-floating axle wheel bearings on the KUN25/KUN26 are subject to accelerated wear when the vehicle is regularly operated at or near payload capacity, or used for towing. The bearing is a tapered roller type pressed into the axle housing and supports both radial and thrust loads. Contamination via a leaking axle seal compounds wear. Failure produces initially intermittent, then persistent rumbling that intensifies under cornering load. Bearing collapse can allow the axle shaft to shift inward, causing brake drag or total loss of drive to one wheel.

Symptoms to notice

  • Low rumbling or grinding noise from the rear that changes pitch with vehicle speed and worsens under lateral load (cornering)
  • Heat buildup at the rear hub after normal driving compared to the opposite side
  • Detectable lateral play in the rear wheel when the axle shaft is pushed and pulled axially
  • Gear oil contamination inside the rear brake drum from a failed adjacent axle oil seal

What to check

Spin each rear wheel by hand listening for roughness or grinding. Check for heat discolouration on the axle tube around the bearing bore. If a workshop inspection is possible: With the vehicle on a hoist and the handbrake released, grasp each rear tyre at the 3 and 9 o'clock position and attempt to rock it — any detectable play indicates bearing wear. Remove the rear drums and inspect for oil contamination from the axle seal.

Where to look: Rear axle housing, inboard of each rear brake drum at the axle tube end

Parts involved: Wheel bearing.

Ask the seller

  • “Is there any rumbling noise from the rear of the vehicle, especially on corners?”
  • “Has the vehicle been regularly loaded to capacity or used for heavy towing?”
  • “Have the rear wheel bearings or axle seals ever been replaced?”

06Front suspension ball joint and kingpin wear

On solid-axle models, check swivel hub bearing and kingpin play.1984–2005Suspension
CommonSuspension $400–$1,200 to fix

Does not apply

LN-series Hilux from 1984 to approximately 1997 used a solid front axle with kingpins and swivel hub bearings. LN167 and later models switched to independent front suspension with conventional upper and lower ball joints. Both designs develop significant wear at high mileage. Worn kingpins allow wheel wobble and are a common WoF failure; worn IFS ball joints cause clunking and vague steering.

The front wheel of a car splayed outward with the lower control arm hanging down after a ball joint separation.Example of the part — not this vehicle

A separated lower ball joint: the control arm has dropped and the wheel has splayed out under the guard.

Elfix · CC0 · Wikimedia Commons

Symptoms to notice

  • Steering wheel wobble or shimmy, especially at 80-100 km/h
  • Clunking from front suspension over bumps or on full steering lock
  • Uneven tyre wear across the front axle
  • Excessive play when rocking front wheel top-to-bottom
  • WoF failure for kingpin or ball joint play

What to check

On solid-axle models, check swivel hub bearing and kingpin play. If a workshop inspection is possible: Jack the front axle and rock each front wheel top-to-bottom and side-to-side. On IFS models, check upper and lower ball joint boots for splitting and test joint play with a pry bar under the wheel.

Where to look: Front axle — swivel hubs and kingpins on pre-LN167 solid-axle models; upper and lower ball joints on IFS models (LN167 onwards)

Parts involved: Ball joint.

Ask the seller

  • “Has the vehicle passed a recent WoF including front suspension?”
  • “When were the front ball joints or swivel hub bearings last serviced?”
  • “Has the front suspension been lifted or modified?”

07Front Axle Shaft CV Joint Wear on 4WD Variants

With vehicle in 4WD, drive slowly in a full-lock turn and listen for a regular clicking noise.2005–2015Suspension
CommonSuspension $400–$1,200 to fix

Does not apply

The 4WD KUN26 Hilux front axle CV joints wear causing clicking during low-speed 4WD turns and vibration under load.

A concertina rubber constant-velocity joint boot fitted to a car driveshaft.Example of the part — not this vehicle

The rubber CV boot on a driveshaft — this is the part that splits and throws grease.

Ildar Sagdejev ( Specious ) · CC BY-SA 4.0 · Wikimedia Commons

Symptoms to notice

  • Clicking from front axle during full-lock low-speed turns in 4WD
  • Vibration from front axle under moderate load in 4WD

What to check

With vehicle in 4WD, drive slowly in a full-lock turn and listen for a regular clicking noise. CV boot inspection — split boots accelerate joint wear significantly.

Where to look: Front axle shaft CV joints inside the steering knuckles

Parts involved: CV joint and boot.

Ask the seller

  • “Has the front axle shaft cv joint been inspected or repaired?”

08KUN26 Front Upper Ball Joint Premature Wear

diesel2005–2015SuspensionRead the full fault: symptoms, where to look, what to ask the seller

09Brake Caliper Guide Pin Seizure

Check for pulling under braking.2005–2015Brakes
CommonBrakes $200–$700 to fix

Does not apply

Front and rear brake caliper guide pins seize from mud, dust, and salt causing uneven pad wear — particularly common on off-road and coastal Hilux examples.

Symptoms to notice

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

What to check

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

Where to look: Front and rear brake calipers

Parts involved: Brake disc and pads.

Ask the seller

  • “Has the brake caliper guide pin seizure been inspected or repaired?”

10Inner bonnet panel cracking recall (N70 Hilux, 2005-2007)

Open the bonnet and use a phone torch to look at the underside skin around the latch for cracks.2005–2007Body & Rust
OccasionalBody & Rust $0 to fix

Does not apply

Early N70 (Mk7) Hiluxes, petrol and diesel, 4x2 and 4x4, were recalled in October 2007 (PRA 2007/9573) because the inner bonnet panel can crack near the latch after a lot of driving on corrugated roads. A cracked panel can let the bonnet work loose. The fix is free at a Toyota dealer.

Symptoms to notice

  • Bonnet rattles or sits unevenly
  • Visible cracks in the inner bonnet skin near the catch

What to check

Open the bonnet and use a phone torch to look at the underside skin around the latch for cracks. Close it and check it sits flush and does not rattle when pushed. Ask the seller for the service history and look for a dealer invoice or service stamp showing recall PRA 2007/9573 (bonnet panel) was done. A buyer can also give the VIN to any franchise dealer and ask them to check for open recalls before paying.

Where to look: Underside of the bonnet around the latch

Ask the seller

  • “Has the bonnet recall been done?”
  • “Has the bonnet ever been replaced?”

11Door drain holes left blanked on early GUN builds - water sits inside the doors

2015–2016Body & Rust
OccasionalBody & Rust $80–$1,500 to fix

Does not apply

A batch of 2015-2016 Hilux left the factory with the drain holes in the bottom of the doors either plugged with plastic blanks or filled with sealer, and those plugs were meant to be taken out before the ute was handed over. Where that never happened, water from rain, washing or a creek crossing collects inside the door skin with nowhere to go. Owners notice it as water sloshing in the door when they open and shut it. Left alone the water sits against the bottom of the door skin and rusts it from the inside out, which in New Zealand eventually becomes a warrant of fitness problem and a panel bill. The fix costs almost nothing if it is caught early and a great deal once the metal has gone.

Symptoms to notice

  • Water sloshing or gurgling inside a door when you open or close it
  • Damp carpet or a musty smell in the footwell
  • Bubbling paint along the very bottom edge of a door
  • Rust staining on the lower door seam

What to check

  1. Open and shut each door firmly and listen at the bottom of the door for water sloshing about inside - that is the whole test and it takes about ten seconds per door.
  2. Crouch down and look along the very bottom edge of each door for the row of drain slots, and check they are open rather than blanked with plastic plugs or smeared with sealer.
  3. Run a finger along the bottom seam of each door and feel for bubbling paint, a rough edge, or rust staining, all of which mean water has been sitting in there for a while.
  4. With the door open, look at the door bottom from the inside as well, and check the footwell carpet for damp.
  5. Ask whether the ute has done creek crossings or been pressure washed regularly.

Where to look: Bottom edge of each door, inside the door skin below the trim card.

Ask the seller

  • “Do you ever hear water moving around inside the doors?”
  • “Have the door drains ever been cleared or opened up?”
  • “Has the ute been through water crossings?”
Fluid leaks4

011KZ-TE Injector Body Crack & External Diesel Leak

With engine warm and running, inspect each injector body, return line banjo fittings, and clamp bolts for wet fuel or dried brown staining.diesel1999–2005Fluid LeaksRead the full fault: symptoms, where to look, what to ask the seller

02KUN26 Front Differential Pinion Oil Seal Failure

Inspect the front differential pinion input flange and shaft seal area for gear oil weeping, staining, or drips.diesel2005–2015Fluid LeaksRead the full fault: symptoms, where to look, what to ask the seller

031KD-FTV Injector Return Pipe O-ring Leak

diesel2005–2015Fluid LeaksRead the full fault: symptoms, where to look, what to ask the seller

04Rear Differential Pinion Oil Seal Leak

Look for oil staining, weeping from the seal lip, or oil flung onto the tunnel and crossmember.2005–2015Fluid Leaks
CommonFluid Leaks $280–$750 to fix

Does not apply

The pinion seal at the front of the rear differential housing deteriorates with age and mileage, allowing gear oil to weep or flow past the flange and onto the driveshaft, tunnel, and surrounding components. In NZ conditions involving water crossings and gravel roads, grit ingestion accelerates seal lip wear. If the leak goes unnoticed, the differential runs low on gear oil leading to pinion and crown wheel wear or failure. This is a very common finding on workshop inspection of KUN25/KUN26 vehicles with over 100,000 km.

Symptoms to notice

  • Gear oil weeping or pooling visible on the driveshaft yoke and front face of the differential housing
  • Burnt gear oil smell from the undercarriage after highway driving
  • Differential gear oil level below minimum on inspection despite no noted service interval issue
  • Orange-brown oily residue mixed with road dust on the underside of the diff nose

What to check

  1. Look for oil staining, weeping from the seal lip, or oil flung onto the tunnel and crossmember.
  2. Check the differential oil level via the filler plug.
  3. Examine the flange for scoring or wear grooves in the seal contact zone — a worn flange requires replacement along with the seal.
  4. If a workshop inspection is possible: Inspect the pinion flange and the seal face at the front of the differential housing on a hoist.

Where to look: Rear differential housing, pinion flange at the front face where the driveshaft connects

Parts involved: Differential.

Ask the seller

  • “Has the rear differential pinion seal ever been replaced?”
  • “Is there any oil staining visible on the underside near the diff nose or driveshaft?”
  • “When was the differential gear oil last checked or changed?”

Toyota Hilux faults in detail

Narrowed to the Toyota Hilux · 2017. Each of these has its own page: the symptoms, where to look, what to ask the seller and what the repair costs. Free, no account needed.

1GD-FTV Timing Chain Guide Premature WearCritical · Engine2GD-FTV DPF Clogging on Short Urban TripsMajor · Engine2GD-FTV EGR Cooler Bypass O-Ring Coolant LeakMajor · CoolingAir filter housing lets dust past the filter and kills the air-flow sensor (2015-2018 builds)Major · EngineAN120 Front Upper Control Arm Bush Premature WearMajor · SuspensionDPF blocking and failing to regenerate (2.8 1GD-FTV diesel, Oct 2015 to Apr 2020 builds)Major · EngineFifth (exhaust) injector failure on the 2.8 1GD-FTV - warning lights and limp modeMajor · Engine

Compare the Toyota Hilux

What these repairs cost on other cars

Some of the Toyota Hilux’s documented faults are repairs other models share. Each page lists the documented NZ cost for every model it affects.

Buying guides that cover the Toyota Hilux

Other Toyota models

Toyota Prado64 documented faultsToyota RAV463 documented faultsToyota Camry54 documented faultsToyota Alphard52 documented faultsToyota Vellfire49 documented faultsToyota Corolla47 documented faults

Toyota Hilux buyer questions

Is the Toyota Hilux reliable?

Like any used car, it depends on the specific example and its service history. Across the 59 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?

We've catalogued 59 known faults for the Toyota Hilux, covering engine, cooling, and suspension. All 59 are written out in full on this page, with the symptoms to notice, what to inspect, and typical repair costs for each. Free to read, no account needed.

How much do repairs cost on a Toyota Hilux?

Most single repairs on the Toyota Hilux fall between $600–$2,500 at NZ independent-workshop rates. Some of the 59 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?

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 $24.90 far less than the cost of missing one of the faults on this page.