Recalls: Toyota Mk.7 Hilux cab chassis
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.7 Hilux cab chassis
Toyota Mk.7 Hilux 4×4 with bullbars: hazard lamps may not work
In October 2007, a recall was issued for four-wheel drive Toyota Mk.7 Hilux cab chassis vehicles with the chassis codes GGN25 and KUN26 which were fitted with Toyota genuine alloy ‘Forge’ or ‘Breaker’ bullbars. When these vehicles were operating a trailer, the wiring and flasher relay unit capacity was insufficient to operate all the turn signal lamps for the hazard wiring function; individual turn signal lamps (left or right), however, were not recalled (PRA 2007/9572).
Toyota Mk.7 Hilux cab chassis: inner bonnet panel may crack
In October 2007, a recall was issued for certain Toyota Mk.7 Hilux cab chassis vehicles (see below) due to a condition in which the inner bonnet panel may crack near the retaining latch mechanism due to prolonged driving on corrugated surfaces. If the vehicle continued to operate in this condition, the fracture would extend around the welds, resulting in increasing movement and rattling noise (PRA 2007/9573). The recalled vehicles were as follows:
- For Hilux 4×2 –
- Model code: TGN16R; 2.7-litre petrol engine (2TR-FE);
- Model code: KUN16R; 3.0-litre turbo-diesel engine (1KD-FTV); and,
- Model code: GGN15R; 4.0-litre petrol V6 engine (1GR-FE);
- For Hilux 4×4 –
- Model code: KUN26R; 3.0-litre turbo-diesel engine (1KD-FTV); and,
- Model code: GGN25R; 4.0-litre petrol V6 engine (1GR-FE).
2005-10 Toyota Mk.7 Hilux 4×4: tailshaft bearing brackets may detach
In September 2010, a recall was issued for four-wheel drive Toyota Mk.7 Hilux cab chassis vehicles produced from 29 January 2005 to 20 February 2010 due to a condition in which the rear tailshaft centre bearing brackets may detach as a result of frequent accelerations and decelerations on severely corrugated roads with large numbers of cattle grid crossings (PRA 2010/11961). The recalled vehicles were in the following VIN ranges:
- MR0 DU22G 00001001 to 00002144;
- MR0 FU22G 02000004 to 02301336;
- MR0 FU29G 04000001 to 04302451;
- MR0 HU29G 06000001 to 06001102;
- MR0 DZ22G 00001002 to 00016664;
- MR0 FZ22G 01000002 to 01173049;
- MR0 FZ29G 01509067 to 01723263;
- MR0 HZ22G 03500003 to 03510703; and,
- MR0 HZ29G 04004397 to 04019471.
2004-09 Toyota Mk.7 Hilux: driver’s airbag may not deploy
In April 2014, a recall was issued for Toyota Mk.7 Hilux vehicles that were manufactured from July 2004 to December 2009 and fitted with a driver’s airbag. In these vehicles, the spiral cables’ electrical connection for the driver’s airbag module may be damaged over time and, if this occurred, the airbag may not operate in the event of an accident. The airbag warning light, however, should illuminate to warn the driver – in advance – if the airbag module has become damaged (PRA 2014/14058). The recalled vehicles had VINs in the following ranges:
- MR0 CU12G # 00001002 to 00008754;
- MR0 CX12G # 00001002 to 00052216;
- MR0 CZ12G # 00002424 to 00023440;
- MR0 DU22G # 00001001 to 00002125;
- MR0 DZ22G # 00001001 to 00016082;
- MR0 EU12G # 04000000 to 04004744;
- MR0 EU12G # 04500002 to 04502007;
- MR0 EU19G # 06000001 to 06001493;
- MR0 EU19G # 06300000 to 06300746;
- MR0 EX12G # 02000000 to 02032781;
- MR0 EX12G # 02300000 to 02314930;
- MR0 EZ12G # 04000002 to 04008224;
- MR0 EZ12G # 04150000 to 04154045;
- MR0 FU22G # 02000004 to 02003122;
- MR0 FU22G # 02300001 to 02301336;
- MR0 FU29G # 04000000 to 04005047;
- MR0 FU29G # 04300000 to 04302451;
- MR0 FZ22G # 01000001 to 01029377;
- MR0 FZ22G # 01150002 to 01172340;
- MR0 FZ29G # 01509067 to 01554108;
- MR0 FZ29G # 01700000 to 01721999;
- MR0 GU12G # 08000000 to 08003438;
- MR0 GU19G # 09000003 to 09001245;
- MR0 HU29G # 06000001 to 06001000;
- MR0 HZ22G # 03500007 to 03507481; and,
- MR0 HZ29G # 04004397 to 04018624.
Problems and faults: Toyota Mk.7 Hilux cab chassis
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 Hilux: 1KD-FTV cracked pistons
For 2006-14 Toyota Mk.7 Hilux (KUN26) 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. Despite these changes, however, cracked pistons have been reported in revised vehicles (although the failure rate is lower). For the Toyota Mk.7 Hilux (KUN26), these production changes were implemented in July 2014 from engine no. A477120.
2005-07 Toyota Hilux 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?
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.
