MajorCommonEngine

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

DPF blocking and failing to regenerate (2.8 1GD-FTV diesel, Oct 2015 to Apr 2020 builds) is a common engine fault on the Toyota Hilux on the 2015 onward cars, and we rate it major. Putting it right costs $800 to $4,000 at New Zealand independent workshop rates. Below is what goes wrong, the symptoms to notice on a test drive, where to look, and what to ask the seller before you hand over any money. It is one of 59 documented faults on the Toyota Hilux.

Vehicle: Toyota Hilux
Engine: 1GD-FTV
Years: 2015 onward
Fuel: diesel
System: Engine

This page covers the Toyota Hilux as a model. Some faults only affect particular engines or build years — enter a plate below to narrow the list to one car.

All Toyota Hilux faults59 documented faults on this model

What you are looking at

No photograph available

We do not hold a verified photograph of the Diesel particulate filter yet. We would rather show none than show a picture of a different part.

What goes wrong

The 1GD-FTV 2.8L diesel in AN120-series Hilux is equipped with a diesel particulate filter (DPF) that requires periodic regeneration at sustained highway speeds to burn off accumulated soot. Vehicles used predominantly for urban or short-trip driving do not reach the exhaust temperatures required. Blocked DPFs trigger limp mode, and if left unresolved the DPF substrate can overheat and crack, requiring costly replacement. In Williams v Toyota (May 2022, upheld on appeal) the Federal Court of Australia found the DPF system in 1GD-FTV and 2GD-FTV Hilux sold from October 2015 to April 2020 was not of acceptable quality, and Toyota runs a customer support programme for these vehicles.

What you would notice

DPF warning light on dashboard
Reduced power or limp mode activation
Vehicle initiating active regeneration at idle — audible and hot exhaust
Increased oil level on dipstick as regeneration fuel dilutes engine oil
White or grey smoke during forced regeneration cycle

How to check it

Where to look. Underside of vehicle — DPF canister in exhaust system, forward of centre

Check the dashboard for DPF or engine warning lights.
Ask the owner if the DPF light has been on and about their typical driving pattern.
Request an OBD scan for DPF soot load percentage.
Check service history for DPF-related entries.

Parts involved: Diesel particulate filter.

What it costs to put right

$800 to $4,000 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

Ask the seller

“Has the DPF warning light ever come on?”
“Is the vehicle used mainly for city driving or short trips?”
“Has the DPF ever been cleaned or forced into active regeneration?”

Now check the Toyota Hilux you are actually looking at

Everything above is true of the model, and it is free. What it does not tell you is whether THIS car has been looked after: its odometer history and whether the reading has ever gone backwards, whether there is still money owing on it, whether it has been reported stolen, how many owners it has had and what it is really worth today. That comes from the official records for that plate. Enter the plate for the free details, or get the full history and a market valuation from $13.49.

Not sure what you would be paying for? See what a full KickTyres check includes.

Where this comes from

The failure described above is documented in published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.

Toyota Hilux buyer questions

Is dpf blocking and failing to regenerate (2.8 1gd-ftv diesel, oct 2015 to apr 2020 builds) serious on a Toyota Hilux?

We rate it major and common on the Toyota Hilux. The 1GD-FTV 2.8L diesel in AN120-series Hilux is equipped with a diesel particulate filter (DPF) that requires periodic regeneration at sustained highway speeds to burn off accumulated soot. Vehicles used predominantly for urban or short-trip driving do not reach the exhaust temperatures required. Blocked DPFs trigger limp mode, and if left unresolved the DPF substrate can overheat and crack, requiring costly replacement. In Williams v Toyota (May 2022, upheld on appeal) the Federal Court of Australia found the DPF system in 1GD-FTV and 2GD-FTV Hilux sold from October 2015 to April 2020 was not of acceptable quality, and Toyota runs a customer support programme for these vehicles.

How much does it cost to fix on a Toyota Hilux?

$800 to $4,000 at New Zealand independent workshop rates. That figure is for this job on its own. A car showing the symptoms on this page is usually worth either walking away from or negotiating down by at least the repair figure.

Which Toyota Hilux years are affected?

Our research records this fault on the 2015 onward Toyota Hilux. Build dates move around, especially on imported cars, so treat the range as the years to look hardest at rather than a guarantee either way. The official records tell you the exact build and first registration date for the car in front of you.

How do I check for it before I buy?

Check the dashboard for DPF or engine warning lights. Ask the owner if the DPF light has been on and about their typical driving pattern. Request an OBD scan for DPF soot load percentage. Check service history for DPF-related entries. Look here: Underside of vehicle — DPF canister in exhaust system, forward of centre