Recalls: Toyota Mk.5 HiAce van
Overview
Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.
Recalls: Toyota Mk.5 HiAce Van
2004-05 Toyota HiAce van: fuel pump failure
In October 2007, a recall was issued for model code TRH201 and TRH221 Toyota HiAce vans (i.e. those vans fitted with the 2.7-litre petrol engine) that were manufactured from 21 December 2004 to 10 February 2005. In these vehicles, the fuel pump could wear prematurely due to insufficient clearance between the coils of the internal motor – this could lead to the fuel pump not functioning, preventing the engine from restarting or stalling while driving (PRA 2007/9591).
Toyota HiAce van with 1KD-FTV engine: exhaust gas and fuel leaks
In July 2012, a recall was issued for Toyota Hiace vehicles that were fitted with 3.0-litre turbo-diesel engines (engine code: 1KD-FTV). In these vehicles, the exhaust gas recirculation (EGR) system pipes may fracture and cause exhaust gases to leak into the cabin of the vehicle. Furthermore, over-tightening of the fuel injector pipes could cause the injectors to crack – this could result in the leakage diesel fuel which could cause an engine fire or road hazard (PRA 2012/13194). The recalled Toyota HiAce vehicles were in the following VIN ranges:
- JTF HT02P 00001029 to 00074361;
- JTF PT22P 00001029 to 00074361; and,
- JTF ST22P 00001029 to 00074361.
2013 Toyota HiAce van: valve springs could break
In November 2013, a recall was issued for Toyota Hiace vehicles that had petrol engines and were manufactured from 25 May 2013 to 30 August 2013. In these vehicles, the engines contained valve springs that could have been produced with corrosive pitting on the surface of the spring. The corrosive pitting could lead to fatigue fracks which, over time, could result in the breakage of the valve spring. If this occurred, the driver may notice an abnormal noise and rough engine performance. In some cases, the engine could stall while the vehicle was being driven, increasing the risk of a rear-end collision (PRA 2013/13826). The recalled Toyota HiAce vehicles had serial numbers in the following ranges:
- 00079104 to 00081747;
- 00041135 to 00042651; and,
- 06138937 to 06140997.
2015-16 Toyota HiAce LWB Diesel Crew van: single latch sliding door
In November 2016, a recall was issued for Toyota HiAce LWB (long wheelbase) Diesel Crew vans (chassis code: KDH201) that were manufactured from 6 January 2015 to 26 October 2016. These vehicles had a single latch mechanism for their side sliding doors which did not satisfy the requirements of the relevant Australian Design Rule (ADR). The recalled Toyota HiAce LWB Diesel Crew vans had VINs in the following range, though not all such vehicles were affected: JTF HT02P # 00158948 to JTF HT02P # 00212280 (PRA 2016/15739).
2009-12 Toyota HiAce with automatic transmission: may not be possible to change gears
In November 2016, a recall was issued for Toyota HiAce vehicles that were manufactured from 9 December 2009 to 21 March 2012. In these vehicles, shifting the gear lever moved a manual valve inside the automatic transmission to engage the intended gear position. Due to a lack of strength in the manual lever pivot connection, the intended gear shift position may not match vehicle behaviour such that it may not be possible to shift out of ‘Park’ or shift out of a forward or reserve drive position. If the driver was unable to shift out of park or shift out of a forward or reverse drive position, the risk of a collision could be increased. For the recalled vehicles, the manual lever used to control gear selection was to be replaced with a new one (PRA 2016/15764). The recalled Toyota HiAce vehicles had VINs in the following ranges:
- JTF HT02P # 0052623 to JTF HT02P # 00092929 (produced from 9 December 2009 to 21 March 2012);
- JTF PT22P # 00005883 to JTF PT22P # 00009250 (produced from 10 December 2009 to 15 February 2012);
- JTF ST22P # 00013343 to JTF ST22P # 00007650 (produced from 11 December 2009 to 17 February 2012);
- JTF HX02P # 0049660 to JTF HX02P # 00068284 (produced from 9 December 2009 to 20 February 2012);
- JTF PX22P # 00019420 to JTF PX22P # 0032225 (produced from 10 December 2009 to 8 February 2012); and,
- JTF SX22P # 06077019 to JTF SX22P # 06125275 (produced from 10 December 2009 to 20 March 2012).
2018-19 Toyota Mk.5 HiAce: low-pressure fuel pump may stop working
In November 2020, recall campaign VGG05 was issued for Toyota Mk.5 HiAce vehicles that were manufactured from June 2018 to January 2019. In these vehicles, the low-pressure fuel pump could stop operating – if this occurred, the engine may stall and the vehicle may not restart; alternatively, the engine may not run smoothly. Beyond this, warning lights and messages may be displayed on the instrument panel. To fix, the low-pressure fuel pump was to be replaced. For the VINs of the recalled vehicles, please see PRA 2020/18242.
Problems and faults: Toyota Mk.5 HiAce van
Overview
This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.
To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.
2006-14 Toyota HiAce: 1KD-FTV cracked pistons
For 2006-14 Toyota HiAce vehicles with 3.0-litre 1KD-FTV engines that comply with Euro IV emissions standards, the pistons are susceptible to cracking. While the size of the cracks varies, they can amount to a localised rupture. In affected vehicles, piston cracking is most common between 100,000 km and 150,000 km. Issued in September 2014 by Toyota, Technical Service Bulletin EG-008T-0112 acknowledged the problem of cracked pistons for the Euro IV 1KD-FTV engine.
Symptoms of a cracked piston include:
- A sudden, strong knocking noise from the engine;
- Black smoke from the exhaust;
- A loss of power;
- The engine ‘running rough’ (i.e. on 3 cylinders); and,
- Excessive crankcase pressure.
The pre-Euro IV 1KD-FTV engines did not experience this problem because the piston had a metal fibrous structure fused into the piston crown. The piston design, however, was changed for the Euro IV 1KD-FTV engine.
To reduce the risk of cracked pistons in a Euro IV 1KD-FTV engine, it is recommended that:
- The engine not be subjected to chip tuning;
- The vehicle not be driven for under load for extended periods; and,
- That the fuel injectors are serviced every 100,000 kilometres.
While these measures will reduce the likelihood of failure, they do not rectify the design fault of the pistons.
According to the technical bulletin, two production changes – ‘improved injectors to prevent wrong combustion’ and more robust pistons – were implemented in 2014, though AustralianCar.Reviews does not have an exact date for the Toyota HiAce. Despite these changes, however, cracked pistons have been reported in revised vehicles (although the failure rate is lower).
2005-07 Toyota HiAce with 1KD-FTV engine: injector seal failure
Initially, the 1KD-FTV engine had copper seats at the base of the common rail injector to provide a seal against the combustion chamber.These seats, however, can fail and cause the following problems:
- Blow-by gases enter the tappet cover and mix with the engine oil – this bakes and carbonises the engine oil;
- Blow-by gases block the oil sump pick-up;
- The engine can be starved of oil;
- The lack of lubrication cause excessive friction and heat, causing the bottom end bearings to melt and engine failure.
Symptoms of a failed common rail injector seal include:
- White smoke and a rattling noise after a cold start; and,
- A blocked oil sump pick-up.
AustralianCar.Reviews understands that new aluminium seats were introduced for the 1KD-FTV engine from August 2007. AustralianCar.Reviews recommends that owners of vehicles with the 1KD-FTV engine which have copper injector seats have them replaced with the updated injectors and the oil sump pick-up cleaned if there is evidence of the copper injector seats allowing blow-by gases to pass. At each service, the oil sump pick-up should be inspected and, if required, cleaned by removing the oil sump covers, taking out the screen and spraying it with a carbon cleaner or degreaser.
For further information, please see pradopoint.com and What Causes the Hilux and Prado Clogged Oil Sump Pickup?
Toyota HiAce with 1KD-FTV engine: injector failure
It is not uncommon for the injectors in the 1KD-FTV engine to fail around 120,000 to 140,000 kilometres, though they may fail as early as 75,000 kilometres or last 250,000 kilometres. Symptoms of a failing injector include:
- A loud ‘knock’ noise that is audible when the windows are down, particularly when the engine is cold;
- Poor fuel economy;
- An erratic or rough idle; and,
- Rough running, particularly under load at low engine speeds
The shorter lifespan of these injectors is attributable to the high fuel pressure (from 30 to 160 MPa), multiple injections per combustion stroke, small tolerances and fuel quality. As a preventative measure, it is recommended that the injectors be replaced every 100,000 kilometres. At each service, it is recommended that a diagnostic test be conducted to measure feedback volumes or total volumes for the injectors to see if they are working properly.
