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1GD-FTV Dustgate: We asked an expert

Chances are that by now you’ve heard about the issues with Toyota’s most widely used engine, the 1GD-FTV, eating up dust. As promised in last weeks post, we took the investigation just that much further, and asked an expert in automotive filtration for his thoughts on the 1GD-FTV Dustgate saga.

If you happened to miss the previous post, the long and short of it, is that through a design fault in the induction system of the 1GD-FTV engine (used in the HiLux, Fortuner, & Prado), dust particles of “5 microns and smaller” are getting past the air filter, sticking to the MAF sensor, corrupting the sensor readings and causing the 1GD’s to go into limp mode. Limp mode is able to be cleared by resetting the ECU (battery disconnected for five minutes), and Toyota has released a ‘dealer bulletin’ advising service personnel to ‘blow out the MAF sensor when performing services with compressed air’. They are not, however, undertaking a recall on the issue, but have requested that the R&D team look into fixing this issue for future models.

Associate Professor Mullins not to scale*

Now, with all that in mind, we got in touch with Ben Mullins from Curtin University, who is an Associate Professor with an interest in testing and researching automotive filtration systems – everything from oil, fuel, and specifically useful for us, air.

We handed over the statements from Toyota Australia regarding the dust ingress, and further to sending the vehicle into limp mode, we asked him what impact it could have on the engine. This is what he told us:

“I am surprised by the comments from Toyota. Firstly, 5 microns is regarded as a “coarse” particle in the air pollution world. It has been shown that fine particles (e.g diesel soot) can cause engine wear. Soot particles are <300 nm (0.3 microns) in size – albeit at high quantities in the oil.”

In other words, if those dust particles are making their way into turbochargers and internal engine components (which they are, as proven by the fact they’re sticking to the MAF sensor, on the wrong side of the air filter and causing ECU issues), they will be definitely contributing to an engine wearing out faster. Ben continues:

“Also, whomever made the comments about more frequent filter replacement/checks or compressed air cleaning is misguided. The issue here is probably the filter sealing rather than the filter itself, so disturbing the filter more frequently would likely make things worse. Proper tests would need to be done to see if the problem is the filter or the sealing, however flat panel filters can be difficult to seal, which is why heavy-duty engines generally don’t use them except for cabin air.”

In other words, constantly changing the filter isn’t going help if the filter system is ineffective. There is a chance that the filter housing isn’t sealing correctly, so dusty air is bypassing the filter. Ben, once again:

“Another common misconception is that changing your air filter more frequently is better for your engine. Air filters are not sieves, so capture the least amount of particles when new, and get better when they load with dust. So if the filter is the problem, changing it more often will let more dust through! Heavy vehicle manufacturers and filter manufacturers recommend changing filter based on pressure drop as this ensures both the longest filter lifespan and the least dust in your engine.”

Australia is dusty – It’s a fact of life for anyone looking to do any real outback touring…

At the end of the day, what we’re taking from Associate Professor Mullins’ comments, is that it is quite likely the dust ingress will cause long term issues/damage to the Toyota engines. That is despite Toyota Australia unequivocally stating that “dust of that size (5 microns/5000 nanometres) is not known to cause engine damage”. We’re more likely to take the word of an Associate Professor over a wide reaching statement from Toyota’s PR department (unless of course they can prove to us that dust ingress won’t harm an engine).

It will be interesting in the future to see if the engines do not last as long as one would expect from dust ingress, especially after Toyota Australia’s comments.

Do you think that Toyota should be issuing a recall for the 1GD-FTV Dustgate, or just blowing out the MAF sensor per their bulletin? Let us know in the comments below.

134 Comments

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  • This is the first time I have bought a toyota of any kind it’s a sr5 hilux and i won’t be buying another one again.

  • Being in the market for a new 4WD its a really simple decision. while there is an issue even if percentage is small that the vehicle could go into limp mode I simply WON’T consider the current models at all until both Toyota and the wider community confirm its fixed. Why would you take the risk. Good old Murphys law always confirms that if its going to go wrong it will at the worst possible time and unfortunately my experience on things confirm that is usually the case. So if the vehicle was to go into limp mode it will happen at the worst time not when you are just driving out of the comfortable caravan park.

    I know when the engine on my 100 series decided to destroy itself it was 3 hours from home not driving around the block.

  • good point Wally, but you are making a fundamental assumption.
    Japanese engineers do not design much at all.
    Japanese engineers copy from European designs – that is the basis of the whole Japanese motor industry.
    Land Rover designed the Range Rover in the 1960’s and it took Toyota engineers the best part of 30 years to produce a very poor copy of it in 1988 with the 80 series LandCruiser. It proved to be so poor that they are still trying to get the design right. Meanwhile Land Rover has moved generations ahead….

  • I PAID OVER 60000 DOLLARS FOR MY PRADO AND AM DISSAPOINTED THAT TOYOTA ARE NOT FIXING THIS PROBLEM. SURLY TOYOTA HAVE AN ENGINEER WHO COULD DESIGN A PROPER AIR FILTER SYSTEM. AFTER ALL IT IS A 4WD AND DESIGNED TO TRAVEL ON DIRT ROADS.

    • good point Wally, but you are making a fundamental assumption.
      Japanese engineers do not design much at all.
      Japanese engineers copy form European designs – that is the basis of the whole Japanese motor industry.
      Land Rover designed the Range Rover in the 1960’s and it took Toyota engineers the best part of 30 years to produce a very poor copy of it in 1988 with the 80 series LandCruiser. It proved to be so poor that they are still trying to get the design right. Meanwhile Land Rover has moved generations ahead….

    • good point Wally, but you are making a fundamental flawed assumption.
      Japanese engineers do not design much at all.
      Japanese engineers copy form European designs – that is the basis of the whole Japanese motor industry.
      Land Rover designed the Range Rover in the 1960’s and it took Toyota engineers the best part of 30 years to produce a very poor copy of it in 1988 with the 80 series LandCruiser. It proved to be so poor that they are still trying to get the design right. Meanwhile Land Rover has moved generations ahead….

  • Have just completed the Gibb River Road up in the Kimberley in peak season with my 2017 Hilux, fitted with a safari snorkel which I kept facing forward the whole time. Didn’t have any dust issue’s at all considering how much it would have been sucking in following cars and caravans along the 660km stretch of road, let alone all the station roads and tracks.

  • What about the Toyota 79 series V8 air filter. That also allows dust into the engine. Check your top air filter housing and induction pipe you’ll get a shock.
    The filter fits poorly in the housing!!
    Maybe this could be the reason for the oil consumption???

  • I think a big company like Toyota should rectify problems when they arise, they have a huge R&D and plenty of cash to fix things, I have 3 Toyotas, one is a Landcruiser VDJ200 and the gearbox is trash, and it is disappointing that these Hilux’s have been on the market for so long and a fix has not been developed and supplied to all owners. its only a filtration issue, aftermarket supplies develop parts for vehicles almost the day after release. Whats going on Toyota?

  • Toyota has a very popular following, a high purchase price, and one of the highest sales figures in the country…………………………..OH the arrogance!!!!!!!!!!!!

  • I’ve had an 80 Landcruiser and a 120 series Prado which is my current car. Had no problems with the Prado but I know some people have. I get mine serviced every 7000km, so maybe that’s helped. I’m due to change over this year and was looking at another Prado but this issues is making me think twice. But what’s the alternative? I don’t want a ute or a Jeep and Disco’s costa plenty! Thinking of looking at the Everest but they had issues with the ad blue sensor shutting the motor down.
    Question. How will we know if/when Toyota has fixed this issue?

  • Toyota is already struggling against some stiff competition in the ute market, they will shoot themselves in the foot if they dont come up with a fix for this, & fast!!

  • Last Saturdays motoring section in the Brisbane Courier Mail listed the HiLux problems with DPF, dust & some driveshaft problems. They went on to list the following faults with the undermentioned vehicles:
    Ford Ranger- Some complete engine replacements, intercooler pipes splitting, rear main oil seals leaking & harsh transmission shifts for which Ford has introduced running changes. Ford is yet to disclose the cause of the catastrophic engine failures which were initially diagnosed as being caused by poor quality fuel. As with Toyota however only customers who complained get their vehicles fixed. There is also a recall for certain Ranger & BT50 utes to fit a heat shield near the DPF. NISSAN- Dealers revealed the Navara ute can leak engine & transmission oil but maintain the problem isn’t widespread. HOLDEN- Holden service technicians say some Colorado utes use excessive oil and to date there is no fix ISUZU- Isuzu owners have discovered cracks under the bonnet-near the suspension tower-in current generation D-Max utes. Investigations are ongoing , some customers may be unaware of the potential flaw.
    I hope this helps everyone understand that they all have problems not just Toyota. My information from reliabl;e sources is that Toyota Japan have been asked to sort out the dust problem.

  • A recall wont do any good until the dust leak is identified and a fix is able to be implemented. In the meantime a smear of silastic on both the top and bottom seals should do the trick. Will be a pain when removing the filter for replacement but will save the engine from destruction. A purchase of a second hand one will be very risky.

  • …. IS the product “Fit for Purpose ?” …. simple question with an already deduced answer. Somebody take Toyota to task !! Bloody woeful attitude …. Oh What a Feeling !! ….. see how easy it is to bend our customers over and shaft them …. and we’re laughing all the way to the bank …. I for one will never buy and overpriced Toyota. Maybe time to look at a D-Max or MU-X ???

  • IN HE 1970s i was involved with vokswagen australia VW had a major problem with air filtration,keep in mind the air filter system in the1970s was poor design compared to todays technology.
    The problem was with VW komby campervans, they used to drive on bad gravel roads and they took in a lot of dust and bulldust and it wore the engines out prematurely, and the same does apply to the dust intake problem Toyota has with the Hilux,so if you do a lot of dusty road driving don,t take no for an answer from Toyota,because your engine will wear out prematurely and if you are out of warranty don,t expect any help from Toyota

  • I am done with Toyota after my FJ Cruiser was delivered with warped discs/rotors causing massive vibration when braking. I argued with the Service Manager who refused to replace them, even though i offered to pay for aftermarket high spec rotors. He threatened to void my warranty if I did this. He machined my rotors which fixed the problem temporarily thus removing a substantial portion of wear and life from my rotors. Done and Dusted with Toyota (Sorry about the Pun)

  • Two things need to happen:
    1. Toyota fix
    2. People walk away from Toyota
    They have been overpriced and overrated for years compounded by an arrogant ethos when issues arise.
    Vote with your $$.
    A mate just crossed the Simpson and his first text was a long list of all the issues with his 200.
    Toyota – oh what a flop!

  • Two things need to happen:
    1. Toyota fix; and
    2. People walk away from Toyota.
    If number 1 doesn’t occur then number 2 will prevail…………..
    They have been over-rated and overpriced for years and compounded by arrogant ethos when problems arise.
    Have a mate who just crossed the Simpson and his first text was a list of all the problems he had with his 200.
    Toyota – Oh what a flop!

  • Getting a proffesor to tell us that dist is bad for an engine, are you taking the piss, how’s about you get an engineer to tell as where the dust is getting through??

  • I used a 50/50 mix of turps and Belray dirtbike filter oil and soaked the factory filter in it and let it dry in the sun. Worked a treat on my 1KZTE powered Prado back in 08. which used to suck dust very regularly and that’s with a snorkel and not driving close behind other vehicles on dirt roads. I bet this will do the same on these. I’m a dirt biker so keeping air clean is a persistent maintenance issue I’m all over.

  • I’m just pleased to see Toyota getting a roasting! And, no I’m not a Nissan, Jeep or Land Rover fan either

  • when i had major problems with my landcruiser in 1983 toyota basically told me to get stuffed, not their problem. i have not been near their brand since, saved a lot of money and heartache

  • For a recall to happen, I would think Toyota would need a solution.
    Maybe they don’t know what the cause of this issue is yet, so as yet they don’t have a solution. I reckon once they are nutted out the cause and how to rectify it properly they may recall affected cars.

  • What about the LAndcruiser 200 series has the Same problem but I haven’t had it go into limp mode just notice the dust on the wrong side of the air filter, heard of a few turbos blowing up though due to dust Ingres

  • The net needs to be cast wide wider than just the hilux. The L/C 200 has dusting issues as well.
    The number of dusted diesel engines lying around the country is phenomenal

  • Geoff.
    Toyota has, over decades paid high profile people to promote hi luxes with terms like “unbreakable”, “tough”,”reliable” etc. to the point where you can ask some starry -eyed new Toyota owner why they chose a Toyota and the answer will almost invariably be “because they are a tough truck mate”.Such is the power of advertising. The fact is they are no better than a Triton which costs 10-15k less.

  • I like Ron’s comments concerning “diff oils last the life of the car”; that’s correct Ron and its a bloody short life!

  • Are people remembering to plug the drain hole in the bottom of the filter housing? Leave that unplugged and she’ll let plenty of extra dust through, and if doing water crossings, a good gutload of water

  • The V8’s in the 70 & 200 series have the same issue. The dust goes past the seal. I approached Toyota about it when I bought brand new 76 series in 2008.
    Now have a Vdj 200. Same thing.
    Bloody garbage. Don’t know if I’ll be buying another after this cruiser.
    Toyota built their name on reliability and inbreakable. They are purposely trying to wear cars out prematurely so we have to buy new ones.
    They keep going like this and they will lose their good reputation.

  • Toyota don’t care anymore, just out to profit with their overpriced second rate 4 wds. Owned a 93 HZJ75 Troopy, best vehicle I have ever owned but wouldn’t touch one now

  • I was 50/50 whether to buy new a Hilux or a Ranger. I know both have their issues as do all the others . I have just signed for a Ranger based on your initial article on this subject being my tipping point. I am out of the heavy truck design industry & know well how “dusting” an engine is dynamite.

  • Snorkel sock had one on my Hilux no issues ever have done 10 trips no issues
    would love to know if the mines are having the same issues as there are thousands of them out there
    that are running in dust every day of there lives

  • we always bought Toyota’s until my last one, a 2013 Prado Driving back from Tasmania with van on the back. All of a sudden we started loosing power then someone called on the radio and told us we were leaving a smoke trail worthy of 007. Needless to say we came to a halt on the side of the F5, called the NRMA who kindly took us home. It turns out that we had a wrecked injector which constantly dribbled fuel into the cylinder. We had a cracked and holed piston, we were informed that this caused by contaminants in the fuel which had gone through the fuel filter. I wasted my time calling it a warranty problem, Toyota refused point blank to honour the warranty, stating it was not their fault I must have put in contaminated fuel. I will never buy a Toyota again. DO NOT expect them to do anything about the dust problem

    t

  • Typical Toyota arrogance, I worked for what was then one of Australia’s largest Toyota dealers, and to question Toyota’s statements was a mortal sin. They always had the attitude that they were beyond reproach and could commit no sin. The response to this problem is so typical it is ridiculous.

  • Hey Dennis , what has this problem got to do with the government, your the one that bought an unbreakable Toyota , not the govt

  • I have a Landcruiser 79 duak cab 2017 model. Sa mb e issue she sucks dust and apparently its acceptable……. What a joke Toyota your reputation is going down hill fast. Listeb to the people we nake you who you are

  • 1 ounce of dust with common rail and its all over, ask your dealers to connduct oil samples at your next service, it will show high levels of silicone proving filter bypass, you will also find elevated levels of bearing material . Sample kits are cheap insurance against dealers who do not wish to honnor warranty, if in doubt have it done privately prior to having it inspected by the dealer.

  • inlet recall or 700 000 engine replacements your choice tightass toyota and how about a warranty the same as everyone else, time to catch up, as per usual.

  • I was about to start looking at purchasing a Toyota 4 X 4, thanks to the publicity surrounding this issue, my money won’t be going to Toyota.

  • It’s not rocket science to effectively seal an air filter from dust ingress, so what’s the problem all Toyota needs to do is press out a new air filter box top assembly and gasket or seal and make sure that the filter itself is sealed top and bottom, or is it a case of numbers, the problem here is not many of these cars will go into really dusty situations like The Gunbarrell Hwy or even The Tanami track so Toyota has really got it head in the sand, I have been. Toyota fan for years and have had many Toyota 4×4,s but after the oil burning issue in the 200 Series and injector problems and now this on the 2.8 diesel motors I am starting to wonder why that Toyota is seen as the King off the road when issues like this arise

  • This Appears to be tha same issue as they have with the V8 vdj76 air cleaner. The plastic air cleaner box sealing surface is not flat and the air cleaner elements are likewise not flat so you can’t get a full seal for the want of trying. Toyota just keep telling me it’s ok, within spec. I hate the sight of any dust in the intake pipes and would happily fit an aftermarket filter housing if one existed eg a Donaldson cartridge filter or something like the 1Hz had.

  • Unbreakable??// And correct me if I’m wrong, but are there any major flaws with the -at times – 3rd best selling ute the Triton? Widely considered the standout value for money ute on the market. Perhaps Mitsubishi fudged some fuel figures buy otherwise make great vehicles. Toyota. No way. Go out and buy something else and have heaps of cash left over for accessories and extra fuel money to go out and use it.

  • I bought a new Hilux in 2016 and I have always been a proud Toyota owner. If Toyota have any integrity they should do a recall on the vehicles that have been identified with this problem. Toyota might end up with a bit of a problem themselves when loyal Toyota owners like myself start looking at their competitors when its time to purchase a new ute.

  • Seems K & N make a filter for this model Part Number 33-3045 $58.99 (USD) Through Summit Racing.
    Only use K & N on my Chevy’s NEVER had an issue

      • They are better than standard, easy to wash and re-oil. They catch dust better than ‘dry’ filters, breath better and you save money by reusing them. From all the comments here, anything is better than standard. And on the topic of parts and prices, why is a Trico w/sceen wiper about $37.99 at AutoBarn/SuperCheap when the same part is around $5.15 (Aust Dollars) on RockAuto.com. Just check the price of Cooper tyres at your local tyre shop, then go online and see how much they cost in the USA (Summit Racing).

        The Australia Tax is alive and well. Speaking of taxes, has the 3×3 petrol tax in NSW expired? I’m sure it’s been more than 3 years since Nick Greiner was NSW Premier.

  • Sounds like a case of good old planned obsolescence on the part of the manufacturer. If Toyota engines lasted forever, then Toyota would sell a lot fewer new vehicles. If they pack up after 10 years or less, then all those people who depend on them out in the outback or rural areas will be forced to buy new vehicles. One way of achieving that is to install a defective filter from brand new and refuse to fix the issue. If every manufacturer does the same thing, the sales keep rolling in for all concerned…

  • My new 200 with only 6.000kms on it already has dust ingress inside the air box and below the filter element after only 600kms of dirt. And that’s WITH a snorkel!!! I cleaned it out and secured material on the top and bottom of the element to provide a better seal to cure the problem. Too early to say if it is now fixed as I haven’t been on dirt since. Dirt ingress certainly ruins engine longevity whether they’re petrol or diesel. Toyota should provide a simple cost effective fix (like I’ve done) to enhance future sales and reputation. Otherwise, their “King off the road” slogans will be buried with the dust.

  • I have just purchased a Prado (not yet paid for) and am very concerned at the engine wear risks. I contacted Toyota Aust yesterday who couldn’t/wouldn’t address the issue and basically told me if there is a problem get a service facility to fix it! Not much of an option stuck out in central Australia.
    This is very concerning and disappointing response from Toyota. Now considering whether I proceed with purchase. Toyota – take responsibility.

  • Toyota has in the past been very quick to protect their reputation by admitting that their may be a problem and they are investigating. They should look at what VW has done to their brand by doing an ostrich. They need to protect their brand and come out and talk to their customers about this dust ingress. Dust in engines is not on and they need act quickly.

  • This is nothing new, the 1VD -FTV has been by-passing the flat filter element for years. Well known issue to Toyota and absolutely zip done about it. I have rebuilt numerous of these and the most common cause of failure by a good margin has been dust – regardless of single or twin turbo. Not good enough Toyota.

  • When my bt50 gearbox failed at 85,000ks, I wrote to Mazda saying I should have stuck with Toyota’s. Let’s hope Toyota solve the issues quickly. Otherwise there is no standout vehicle in this market and we all just have to put up with vehicles getting past warranty time and distance. BTW Mazda paid for the gearbox repair even though it was passed warranty time.

  • What is it with Toyota??… first up it’s the DPF issues and now this air filter saga…. so what’s next? This company has for too long put a premium price on their product which doesn’t meet their claims of reliability. This matter, along with other problems that Toyota like to whitewash should be something for the ACCC to look into as they did recently with Ford & Holden.

  • Toyota should definitely issue a recall. Toyota sell these cars for between $50-70+K knowing they have this fundamental safety issue, not to mention guaranteed engine degradation. I just purchased and sr5 about two weeks before reading this article and ask mr 4×4 who in the Ozi government Toyota owners need to petition to get some action, as it’s clear Toyota has no intention of remedying this issue of their own accord.

  • Very common issue in the mining world for VDJ79 V8 & VDJ200 V8. The engines dust and blow up basically. Every filter tried is the same. The only fix is a $850.00 sealed air box or maybe some cloth tape around the outside of the filter. Google sealed air boxes there is a few mob’s around making them. They will love this news !

  • John,
    I have a great solution for toyota.
    Why dont they stick the air hose from the compressor down their own throats , turn the air compressor on and see if it can blow the s$# out of their a#$@s right down to 5 micron, then ask, how do you feel now?

  • Toyota should definitely be issuing a recall. They are selling these cars for $50-70k knowing they have fundermental safety flaws, not to mention gaurinteed engine degradation. I ask 4×4 who in the ozi government Toyota owners should be petitioning to get some action as it is clear Toyota are not interested in remedying the situation themselves.

  • OK the real problem is poor sealing between two halves of a plastic box held together with 4 flimsy spring clips. If Toyota doesn’t know how to solve the problem then recommend a suitable after market system. Alternatively ask someone at John Deere, those guys know about working all day in the dust.

  • I have always been a toyota fan and owned several of their cars. Currently have 200 series LC. I will no longer deal with Toyota. Its not just this issue they fob off its EVERY issue that is brought to their attention. I had a dust issue for 5 years in my new LC dust coming into the cab and covering everything in dust including me. They told me it was normal and they didn’t know what I was complaining about. 5 years of constant complaining they finally found the inner door membranes weren’t stuck down letting dust into cab. I received car back damaged and 1/4 tank of fuel used and 103km’s clocked up and the service manager said the time they spent fixing my car far outwayed any damage or fuel costs!! Treatment by the manager and service manager was disgusting.

  • What swayed me in purchasing my Toyota over the rest was Toyota’s renowned reliability. After reading all the articles I feel like I have bought a real lemon. Firstly the DPF issue, now dustgate!
    Oh what a feeling?
    Common Toyota!

  • Toyota have a fiduciary responsibility to their shareholders/customers. A recall is likely if there is a relevant monetary implication ( aka collapse in sales or lawsuit from safety failure for eg ). The more this story airs, the more likely sales will be impacted, and the more likely a recall will happen. Keep up the noise !

  • 200’s have been happily dusting up for 10 years and no recall – don’t hold your breath. We have a fleet of these hilux’s – dash’s falling out, extra grease nipples tapped into the driveshafts, Christ knows how many DPF change/upgrade/cleans, and then they have the gall to ask for $7k each to change the DPF’s out of warranty!! Never again Toyota, never again.

  • Very disappointed… I bought a Toyota for the first time 2 years ago because I was sick of other 4wd manufacturer issues I had dealt with over the last few cars. So decided to buy Toyota due to the renowned reliability, With this issue along with the DPF issues, drive shaft issues I am sufficed to say Toyota is no different to any other vehicle manufacturer. In fact this current model of Prado, Hilux and Fortuner would have to be the worst out of all current 4wd models around as far as manufacturer related issues. Disgrace!!!! Toyota you are killing your reputation.

    • the only “part of a Toyota that has “renowned reliability” as you put it Darren Coleman is the endless Toyota advertising. I owned Toyotas for 20 years a starting with a brand new 80 series LandCruiser. They are not in my opinion reliable at all. In fact thinking back it was probably the most unreliable vehicle I ever owned. Cracked piston rings from brand new, cracked chassis, gearbox problems, constantly wearing out of suspension and steering components, leaking transfer case and diff pinion seals…
      It all makes my current truck (Range Rover) seem extremely reliable.
      All Toyota was ever good at was copying engineering from European manufacturers and even then poorly.

      oh, and sorry Toyota are very good at spending your money on advertising stating that they are unbreakable and reliable! What utter nonsense!

  • I grew up with oilbath air cleaners, mix dust and oil and you get a paste. Wouldn’t that be the same with dust and diesel? I would amagine this would soon destroy a motor. Is the problem being caused by the air cleaner not being large enough for the suction of the turbo? Large agricultural and industrial equipment use large “Donaldson” type systems which have huge breathing capacities.

  • Have had a good look at my 2017 Prado with 15k Kim on the clock. The plate beyond the filter with all the holes in it was covered in a dust film that I have removed. Just been serviced! The removable rubber seal on the filter looked a bit uneven and had caught a small quantity of dust around the lip. Tidied this up and made sure the seal was equal on all sides, with corners sitting neatly. Very alarmed as we heading outback in a few weeks.

  • People pay up to $10k more for Toyota’s because of their renouned reliability Toyota need to recognize this and fix this design fault ASAP

  • Toyota should issue a statement to all owners outlining the problem and what they are doing about. S find out about it through publications such as this.

  • Any one that thinks this is not a serious issue worthy of immediate action by Toyota has rocks for brains.
    I have always had the great respect for this company having owed an 80,100 and200 series, camry’s etc
    Currently own a new Prado Kakadu , Rav 4 Cruiser.
    On the Prado the voice activation just does not work, the dealer telling me that due to the small market size in AU that they are not interested.
    While the voice issue is not as critical as the dust the pattern of That’s Tough emerging from Toyota is disturbing.
    “Do the right thing Toyota”

  • How hard can it be?
    Toyota needs to find where the dust is getting in fix it. But it seems no-one has yet identified the exact poor sealing joint.

  • Hi Wes, never mind 1GD-FTV Dustgate – at least the engines still sorta work – have you looked into 1KD-FTV Pistongate ? – the abrupt failure of the engine at between 80k and 120k due to piston cracking. It has just landed me (and many other unhappy owners) with bills of between $10k-15K for a rebuilt or replaced engine -in my case for a 2012 registered Prado 150 with 110k on the clock. Toyota’s line is the standard “move along, nothing to see here – you must have been abusing your engine” but they have subsequently redesigned the piston to put more metal around the gudgeon pin. See the following Facebook page for more information – https://www.facebook.com/groups/175229933295296/ – a group of people trying to get up a class action against Toyota

    • Rob, I am sure Facebook is good for something ( I haven’t found it yet) but providing good information is in my experience not one of them. There are in fact five different piston designs for the 1KD-FTV over the Hilux/Prado range and all differ in the combustion bowl design and non feature heavier Gudgeon Pin bosses. Piston cracking as found in this and other engines is not related to Piston strength, but stress arising from thermal overload. The causes of thermal overload are varied but are essentially a result of abnormal combustion. See page 34 and 42 from Kolbenschmidt piston damage analisis.
      file:///C:/Documents%20and%20Settings/Campbell/My%20Documents/B.E.R.S/piston_damage.pdf

      • I was wrong about the gudgeon pin bosses – the issue is related to the removal of some sort of fibrous coating around the edge of the crown of the piston – it was removed when they went to Euro 4 compliance. The Facebook page has pictures and copies of Toyota Service Bulletins relating to the issue, with a revised piston specified to be retrofitted. That is what we now believe is the cause of the premature failure. Re abnormal combustion, its a possibility, but I had my injectors checked during the rebuild specifically to address that possibility. Injectors came back all good.
        P.S. I can’t see the document you posted as the link is to an internal path on your PC.

    • Have just replied to join this Facebook group as the KD-FTV engine in our Prado blew up because of faulty injectors. Not good enough Toyota and still not building a good product!

  • Toyota always goes for a cheap solution. I had a 2013 Diesel Prado and developed a severe injector rattle. They replaced two out of 4 injectors under warranty. I wanted them to do all four. Same issue with the dust problem. They don’t want to pay for a proper fix.

  • This is the sameToyota that i had take the same approach when a hilux i drove on bitumen roads around Orange and 10000k services, had 2 short motors replaced due to sludging of the oil due to fuelling issues. I was told that Orange was harsh conditions and that services were actually required ever 5000ks. It was a design issue and was told that they would rectify the problem only in the cases with serious problems. When the service manager told me this he didn’t see that 2 short engines in close succession was a serious problem. My private mechanic had his sons 5yr old HIlux fixed by the same Toyota dealer, while Toyota didn’t see anything wrong with mine.
    This is how Toyota works and i hope there is a bit of serious ‘puckering’ happening. Haven’t since bought a Toyota and never will.

    • I’ve had dealings with Orange Toyota and let me tell you, if the motor fell out of my Prado as I was driving past the dealership, I’d pay to have the car towed to Bathurst.

  • I’ve exclusively owned Toyota 4WDs since 1984 and it saddens me to say that the solution is to buy a Ford Ranger

  • Despite any warranty concerns, for those hoping for a strong engine after that period, is there a better aftermarket alternative?

  • With us relying on our vehicles to get us into and out of isolated places more and more often I would say a any 4×4 stuck in limp mode 1/2 way int he middle of whoop whoop on a track that demands 100% of the vehicles performance IS a safety issue (as well as trying to pass a road train on a dusty road).
    It seems that again a multi national company is caught not understanding today’s world of communication by thinking it’s PR statement in vague terms is going to be happily accepted. Toyota needs to communicate better and demonstrate why their vehicles is supposed to be one of the more elite 4×4’s for sale and not just pack of the all encompassing bunch!

  • This is more serious than Toyota acknowledges. Grit bypassing the filter will eventually give induction sand blasting, valve damage cylinder wear and most important, watch the value of your car plummet at trade in time. Cars in limp mode should only be driven short distance, but what if you are in the Tanami or somewhere remote towing a large caravan or trailer and there’s the point Phil made about overtaking when the car goes into limp mode is life threatening . Toyota needs to design a new air filter yesterday as a recall fix and the Govt needs to intervene.

  • I understand this style of filter has been used in more than just these Toyota models…..
    The m a f sensor is only collecting a minute amount of the dust in the inlet manifold so the rest must be doing serious damage to all the elements that make up the air path past the m a f sensor.
    Toyota must act fast to make good for all owners of these vehicles or they will end up with a reputation looking like the VW group’s.

  • At my age my Fortuner is my forever car. I do use it on dusty roads and could not afford a new engine because of early wear.
    I bought Toyota for uts reputation as a good long term car builder but perhaps???????
    I dont care if I have to get aftermarket parts to fix it as I have already fitted a catch can and fuel filter.
    All I need is a worksble solution rather than a wait and see approach. Thats bullshit.

  • Its time people saw Toyota for what they are. I am sick of hearing “unbreakable”. How long have we had Prado/s blowing up? And people pay the Toyota tax – higher prices – for cars that are no better, or worse than many competitors.

  • A load of cock wollop sick of reading about nit picking of utter rubbish. Yes dust can cause wear its like emery paper you can rub your bores with 120 grade emery it will take off material and take quiet a while or you can sit there with 3200 grade rubbing away for five years to get 4 thou of wear. What about all the other brands of 4×4 that you promote on here that have a list of engine and gearbox failures and you wouldnt even get a response from the manufacturer they also generally operate in limp home mode 24/7. Lets face it they dont make cars like they used too all you guys just want comfort towing around caravans larger than my house. I will stick to my 25yr old Hilux and recycle all your dust !!

    • My Hilux is a D/cab SR5 2002 and every one tells me the next model has more power and comfort put they would have my model again for the hassle free that comes with it.
      The wife doesn’t like Ford so will look at an Isuzu when I come to replacement time, the fancy stuff is just more to go wrong 5 plus years down the track, stick to the basics that work and last I hope.

      • Craig,
        Yep, my ol’ reliable bus is a 95 Hilux Dual Cab with optional extras like ‘no limp home mode’. Nearing half a million kays but has never failed me., (fingers xed). Has made it to places where later models have failed. Yeah, I’d like something more powerful, quieter and trendier but when on the tracks that matters for nought…and so easy to work on.

  • If Toyota know of this problem and don’t want a national recall i hope Toyota don’t charge customers for cleaning this sensor. Toyota get your act together and solve this problem. Your pride is on the line.

  • My Rugged X is my 1st Toyota ever, I’m 68 not 18. In fact I’m a Nissan MAN. Just haD advice from Nissan THAT the mags on my V8 y62 could crack so hand them in for a new set, valves alone cost $385 as they are pressure gauges also. I don’t see Toyota unbreakable comIng into play. Oh well I’ll have to use my Toyota Recovery Vehicle to retrieve the Rugged X when up the back Paddock and it goes LIMP. If I did the same she would get a jiggilo to do the job!!

    • typial toyota unbreakable over rated and first to bag nissan if there is a problem but hide their problems . allways done it and allways will . im a nissan man drive my third zd30 no issues at all.

  • Deny, deny, deny, then major racall due to substantial warranty work/cost blowout and then potential class action. Is that what Toyota wants, not to mention loss of prestige and status in the 4WD and off road community. Man up Toyota and stop hiding behind your PR departments skirts

  • 100% they should be recalled, and put to task on there misleading comments, after the amount of issues this new model has had, DPF, Timing chain and now this fundamental basic, Toyota need to wake up your customers have had enough

  • Remove the filter and “BLOW” out the MAF with compressed air! Are they mad?
    All that is going to happen is that the dust is blown further into the inlet!
    Vacuum the area instead and suck that area clean!
    In the computer game, we vacuum the components, we don’t blow dust and dirt everywhere. This is no different!

  • undertaking an overtaking manoeuvre whilst towing a van or a boat and entering limp mode midway is a daunting prospect particularly in the face of oncoming vehicle traffic which no one should have to experience. Toyota need to sort this out in a hurry.

  • This happened to me outside Gympie car went in to limp mode Toyota answer dirty air filter sensor. my reply i don’t do dirt roads they cleaned it and so far no more issues. That was 6 months ago

  • Toyota needs to fix this, we by Toyota because we live remote and dust is a daily issue, also the new Prado auto I terrible is also needs fixing sick of sitting on 100 and having it hunting all the time between 1600 and 3000 Revs

    • I know two owners of new Prados, bought because of their upgraded tow rating , who would now happily go back to their older Prados because of the gearbox issue . The gearbox management system was supposedly changed to achieve the higher rating …..massive failure . There may be an aftermarket fix if enough owners complain.

      • Had the same problem with the gearbox last year on a trip to the cape then again last month on the Birdsville track. When I mentioned it to the service manager at my Toyota dealer all I got was no comment and a dumb look on his face.

  • seems cars manufacturers designed vehicles to last the warranty period and only consider the first owner, with electrics that are complicated and expensive to repair,and statements like “diff oils last the life of car” – – – they mean warranty period.

  • Recalls are only issued for safety related problems.

    I agree that Toyota should be doing something about this issue but it is incorrect to call for them to “issue a recall” What’s not to say that they are already working on a solution and the service bulletin that they’ve issued is simply to get something done in the mean-time while a proper solution is completed and ready to roll out. You can’t expect Toyota to make owners ground their vehicles until they can issue a service bulletin with a permanent fix… They may need to re-manufacture parts or filters which requires further R&D and testing before they can release them to market.

    I’m not trying to advocate for Toyota here, it’s disappointing that this is a problem on a brand new vehicle but to call form them to simply “issue a recall” isn’t correct – they can’t fix a problem without first having a solution and as mentioned above, it isn’t a safety related issue, so they don’t need to “issue a recall”.

    • I take your point Ben, but if I’m half way through passing a road train when my ute unexpectedly goes into limp mode, that’s pretty likely a safety issue. P

      • I agree with Phil this is a safety issue, I didn’t expect Toyota to do a VW and stallion fixing the issue, we need the government to step up and demand car companies recall when there are safety issues.
        Paul

    • Toyota said “dust of that size (5 microns/5000 nanometres) is not known to cause engine damage”.
      Basic science: the absence of data is not data.

    • It doesn’t have to be a safety recall. Other brands who care issue maintenance bulletins based on premature wear, our Honda was recalled for premature wheel bearing wear.

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