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Toyota 1GD-FTV bites the dust

Recently we did a six-vehicle comparison test in the outback of South Australia in Unsealed 4X4, pitting a bunch of current dual-cab utes against one another. During the testing, the HiLux Rugged X test vehicle’s 1GD-FTV dropped into ‘limp mode’ four times due to dust ingress.

It’s so dusty out here, even the dust has dust!

The new-tech 2.8L 1GD-FTV is the engine utilised across the current HiLux, Fortuner and Prado models after Toyota phased out the 3.0L 1KD-FTV, which itself is beginning to turn up many issues relating to injectors causing engine failure.

Specifically for the new-tech 1GD-FTV, Toyota Australia has admitted there is a design flaw in the air-inlet system that allows dust past the air filter, which in turn corrupt the sensor readings within the mass air flow sensor. The ECU then utilises these readings to determine the correct fuel ratios for the engine to run. The corrupted data then prompts the engine to go into limp mode, which is a potentially dangerous outcome in certain situations, say mid-way through overtaking. During our testing, we managed to reset the ECU & limp mode by disconnecting and reconnecting the battery (have you tried turning it off and back on again?) 

While Toyota Australia’s spokesperson assured us that any dust making its way past the filter, would be very fine (less than 5-microns in size), they further stated that dust of this size is “not known to cause engine damage.” We’re not entirely sure on that one, but we’ve got a filtration expert on speed dial, so we’ll get back to you on that one.

Toyota Australia further went on to say, “as the vehicle is subject to reduced engine power (‘limp mode’) and can continue to be operated safely, it is not a safety related item that would require a recall,” so don’t expect a letter from Toyota asking you to come in and have the flaw rectified. They have only publicly acknowledged the flaw in the wake of our testing, however there was a dealer bulletin released in March last year, advising of the issue, and the owners should be advised to ‘clean their air filter more often in dusty conditions’, as well as to blow the MAF sensor out with compressed air when completing services. 

With all this in mind, a request for a fix has apparently been sent back to Toyota Japan, so hopefully there will be design changes that should eliminate this issue.

After the issues with the 1KD injectors, and now further issues with dust ingress in the 1GD-FTV, it seems that Toyota’s reputation for making indestructible, unbreakable HiLuxes might be starting to waver. Stay tuned, as we’ll get back to you with our dusty expert’s thoughts on the 1GD eating dust as soon as we can get him on the phone!

62 Comments

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  • Interesting issue of a Auto Manufacture using “spin” to disregard a design and manufacturing fault with their product.
    The 2.8 diesel that Toyota has trumpeted in their advertising also ha been shown to have a DPF problem as well, which Toyota have been trying to keep on the QT for nearly 12 months..it might have something to do with “sales” and “Market Share” in the very competitive dual cab ute market.
    Then all this smacks “egg” onto the face of the Toyota marketing hype for the “Toyota Unbreakable” theme that Toyota have been culturing for many years.
    What will be interesting, is the amount journalistic pressure that the motoring media will bring to the table against Toyota for these two known design and manufacturing faults to get a proper outcome for the many Toyota customers who will be effected by purchasing a Toyota 4wd with the 2.8 diesel..being..Prado, HiLux.
    Have a chat to Berima Diesel..they will give the “heads up” on the DPF problem..
    So to “Mr4x4, do your job, call Toyota out on these faults, put the “Blow Torch” to them to get a “fair go” for Toyota customers.
    I know I would like someone in my corner when I have forked out $60K+ on a 2.8 Diesel Prado and Toyota have known about problems with the motor but yet their dealers have failed to notify me.
    It seems under Australian Consumer Law, that this Toyota product may be a “lemon” and it may be time to revisit the “Lemon ” Laws, that govern Lemon Vehicles.

  • I’ve owned two Hiluxes in my life and have had no end of trouble with them to the point that I’d never buy one again. I’m currently driving my 2nd Jeep Wrangler, the vehicle that supposedly breaks down whenever you drive it according to the experts that have never owned one. My first one I sold with over 200,000 trouble free kms on the clock and it’s still going strong for it’s new owner. My current one is now 7 years old and it too has never had an issue and has taken me to some very remote places. Toyota, like Holden are all marketing hype.

  • I agree with Peter Graham on this, you’ve just dropped $60+ on a brand new Toyota only to find its a dust eating fog machine that Toyota refuse to actually fix and would rather just keep doing a manual burn on your DPF (which shortens the life span and gives them something else to sting you for later down the road) and hope you don’t notice the dust issues.

    Unbreakable my ass… maybe the older Toyota vehicles but the new ones are not up to the standard Toyota themselves set with their earlier versions. Also they still haven’t done anything about the moose test fail, if you’re looking at buying or already own a hilux check out the video on you tube.

  • “not known to cause engine damage.”
    The missing words are “sufficient to be a problem until it’s out of warranty”.
    Good onya Toyota.

  • There has never been an engine built in history that can handle dust. Period.
    Dust when past through the combustion process is then silicon oxide.
    Google that.
    Silicon oxide particles, regardless of size is harder than any piston, ring, valve or cylinder wall.
    It penetrates into these components and thus acts like Emery cloth every time these components rotate.
    It is not if, but when, the death of any engine.

  • Considering that nothing was mentioned during the ute comparison, and being fully aware of the problem, i am asking the question why 4×4 it was not disclosed.

  • Modern vehicle design and manufacture with computer design and extensive testing should have picked up this issue way before the vehicle was released. does this mean that toyota knew there was an issue way before now and sugar coated it to get the new model onto the show room floor. Not that i can afford a new vehicle but as a mechanic on this sort of vehicle all my working life (30 Yearsplus) i worry about the longevity of these modern vehicles of all makes and models.

  • Have a chat with the big Diesel boys like Cummins and MTU about how much dust is tolerable in any diesel. The statement from Toyota is outright BS and they know it. Dusted engines in this day and age are doomed and Toyota must be held accountable for this known issue in their vehicles. Media, go for it….!

  • The 200 series Landcruiser has the same problem due to a poorly designed air filter box.
    There’s a few stories of engine failures around on the net, low compression in one or more cylinders, premature injector failure etc. & Toyota usually blame contaminated fuel.
    You’d have to wonder if grit grinding away at the rings & bores & clogging injectors is the real cause.

  • Thanks Jamie. We are driving our second jeep. Both are great towing 4×4’s. If these problems were alleged against jeep the sky would full in. Funny about that!

  • In the dirtbike world incorrectly seating the airfilter so dust is allowed into the engine has a name, it’s called dusting your engine, and it leads to a top end rebuild. Ask a dirtbike rider whether dust in your engine is a problem the manufacturer should just shrug off.

  • How quickly we forgotten the big end bearing failure on the turbo diesel 80 series it took Toyota two years to admit the fault before warranty was given, only because of the court cases.

  • Hence why I won’t buy another modern diesel. Lost there reliability. I may pay a bit more to run my petrol at the pump, but I’ve never had injector problems, timing belt, I don’t need a catch can to catch the crap, I don’t need blanking plates etc. on my 3rd petrol prado, unfortunately my last as there is no more petrol. My next one will be a Y62 V8 patrol

  • Australian fine dust is the worst, years ago the boss of a transport Co. came out on the Diamondtina development road to rev up his drivers for stopping every 80-100 miles to clean their air cleaners, his new Fairlane was brought back on a truck with a worn out motor. This dust is considered the finest and most abrasive in the world so Toyota need to rectify the sealing problem

  • How about a different approach. At face value Toyota instantly owned the problem and were upfront. There have been known problems with many cars, not the least Ranger and Colorado, however it appears they went into deny mode instead of being honest. Damned if they do, damned if they don’t. I’ll take the honest approach, and yes I did fork out my hard earned on a brand new 2.8 SR5. Toyota know they have a reputation to maintain and the first step in fixing anything is to acknowledge the problem before you can ever hope to fix it. For now, they’ve been forthright…..I’ll give them the benefit of doubt……for now….

    Toyota Execs – you have an opportunity to turn a negative into a positive. You undoubtedly spend a small fortune on marketing to sell cars and social media is now the unstoppable court of public opinion. I suggest some marketing dollars diverted into restoring your reputation would be well spent. A potential fatality while overtaking….yep, that’s worth addressing

  • Wow serious stuff, I have been a Toyota fan since my 1984 Hilux and had numerous Toyotas since 2 years ago I bought a BT50 it probably has its faults to ,but I have not had any and I have towed a 3 tonne caravan for 40k so far
    I was considering a Fortuner as a family car to tow with as well, is this problem just with the Hilux or is it all 2.8 litre diesels in Toyota brand, I might have to look at a Mux the boys on All4 Adventure swear by the Dmax they have and they give em a floggin

  • So many sheep in Australia buy Toyota.!
    What a laugh now being exposed for all the problems we knew they had.
    Don’t hold back media
    All the suckers waiting for a recall notice hahaha

  • Not just toyota…i had 2012 px ranger manual….cheap chinese bearings in gearbox had me trading the lemon after 125k kms. Sounded like a ballbearing in a tincan…these new utes are a joke….i fell fot the joke thinking that spending $55k + on a vehicle would give me 15 – 20 years of happy motoring…never again….all you show pomg tradesmen can have your over rated utes ….more money than brains…ford you are a disgrace….

  • I’d be looking at fitting an oil-bath filter after the paper filter. They catch any sized particles and it wouldn’t get too clogged if it was just picking up what gets through (or past) the paper filter.

  • I have 2005 V6 Prado done over 300K and still pulls like a train, I was looking too upgrade to a new one, but the only choice is a sticking plague problem diesel version, guess I’m going to look after the old girl and keep her going now.

  • Both of my 200 have had the dusting problem. Toyota forward a Technical report saying there would be no problem. Now I run oil cleaners on dirt and clean them often. No dust gets through.

  • Always good news when Toyota is in the poo. ( and no, I’m not a Nissan or Jeep man either)

  • Should be pretty easy to fix with a gasket or spacer if its at the filter element – perhaps a K&N Filter. Put a little grease on the rubber gasket even. Not sure how Toyota know its letting 5 microns or less past but haven’t come up with a fix. Apart from the leak issue which will no doubt get sorted, there could be a nice feature here – incorporate an extra sensor with the MAF sensor to tell you when to change the air filter! Condition based maintenance – cheaper than a sensor to measure pressure drop across the filter.

  • Toyota your best hilux was the ln106 everything worked well for many years and it had a real front diff too .i see these new 2.8 d blowing dpf smoke everywhere to much to often fix these problems guys your really pissing people off . . I now drive a 2000 model 105 series petrol cruiser another great car u produced but the last of the good stuff .

  • absolutely right one jundred percent. being a diesel mechanic myself. no dust into the engine it will cause servere engine component wear. typical toyota hiding their problems as usual . the have done this for years . i remember when nissan were having issues with the zd30 well toyota had a field day with this one . but nissan never hid anything just went on to rectify the problem.

  • When getting your car dealer serviced, let the service manager know hat you know about the issue. Ask them if it is covered by warranty and for how long. Ask when the recall will be to fix the problem.
    If everyone does this they will need to listen when things go wrong

  • I hear you, I bought my first jeep 4 years ago, its been faultless. I’ve been pretty surprised at the negativity toward Jeep, every recall, every news article about an owner with a bad one it is like Jeep is the worst car ever made. Yet I see the same thing with other makes, bad faults that the maker won’t fix and stories of major failures in toyotas, fords and nissans and people don’t give it another thought. Strange.

  • You need only to talk to Nick Underwood of Western 4WD magazine. The Autumn 2018 edition details his problems with dust getting into his V8 diesel, with 220,000 kms on it, such that it had to be replaced at a cost of $20,000.

  • “Put a little grease on the rubber gasket even.”…..Nup, don’t! Mineral derived grease will perish rubber gaskets. Instead use vegetable derived oil on rubber type seals and gaskets – olive, peanut, pumpkin etc.

  • considering none of the utes appear to be made in Japan any more, both Toyota and Ford need a good dose of” carma” and come good on the fact that poor attention to detail at the factory and selling models with known major issues i.e. EGR valves on PJ, PK Rangers that shit themselves and allow waert in the 3 Ltr to self destruct turbos, 5 speed autos in PJ’s with such an abysmal lifespan that they shit themselves around 120-140K kM’s, just look at all the mustang and F series trucks that shit themselves at 80-100 K miles, and it’s no wonder they never came with 5 year unlimited k’s! Toyotas with shit injectors in the 3 litre models, 4.5 litre landcruisers that chew oil, moonshot top gearing in the 200 6 speed autos that are useless unless in the Territory at 130 kM’s +. I am still waiting on the airbag replacement’s on the PJ, as Ford don’t care if I die in an accident forever waiting! Ford did not care a shit that it cost me $4,500 to re-buid the auto at 125K k M’s.

  • 200 series cruiser has had and still has the dusting problem from the beginning of production. It’s not just a Hilux problem. Toyota have dropped the ball and are too lazy to pick it up and admit they have a fail. A proper engine manufacturer will tell you no dust induced is the way it should be. Shame on you Toyota. I bet the big wigs are not taking any notice of these problems, if you are make some comments you lazy money grabbing lot.

  • Having just travelled around Australia we noticed that the Prado and hilux was the most unreliable vehicles we saw, speaking to some of the vehicle owners the problems was the injection system.

  • In Australia we’re getting new diesels that are built around the EU standards and they openly admitt we have dirty diesel but the manufacturers don’t put different injectors in for us so its only destined to eventually fail somewhere down the track.
    I’m a second owner 06 hdj-100 vx with original alternater and water pump i change the oil every 5,000 and it still starts snd runs better than my 012 hilux
    The timing rattle at 2000rpm on my hilux makes it sound like shit and it blows out more smoke than my cruiser which i could never figure out why they scrapped such a great motor it burns so clean and no glow plugs to replace and my oil is still a honey colour after 5000k not my 1kd-ftv its black just going around the block after oil change and its only done 42,000
    My wife wants to get a 200 but i keep telling her no way to hard to work on youreself and still has heaps of problems alot of money a half baked engineering nightmare..why wouldn’t they put two air cleaner boxes in or at least design somethig that works i mean after 11 yrs comeon its taking the piss now isnt it..
    I think most motoring companies don’t want to build cars to last anymore where’s the profit in that i spose more money in parts..

  • I have an MUX and it is a great 4 x 4. Was considering a Prado but after driving one I was not very impressed and now after reading the 2.8 issues I am more than glad I didn’t buy the Prado. I have owned several Toyotas including BJ 42, 100 series, Hi Lux, 95 series Prado and they were all great cars, but it would appear that Toyota has now dropped the ball and if they don’t sort out these issues will quickly be overtaken by other manufacturers.

  • Is the dust going through the air filter or is it between the engine and the filter. If its going through the filter an aftermarket filter should fix it. I am in the market for a new 4×4 but they all seem to have serious issues. The ford has a charging issue as well as transmission issues. The BT 50 Mazda being replaced by another brand , and the others are to low . If the D max had better clearance I would buy that probably.

  • the dust issue is not confined to toyota in my 40 years as a mechanic i have seen many 4wd requiring a maf sensor clean especially if travelling thru dust behind another vehicle. as for hilux i am now on my second, 2006 and 2011, no problems at all, have a good look at how easy a hilux is to work on compared to the others, nothing is to hard and parts are readily available, they all have their horror stories, i could tell plenty about other brands, but from my 40 years experience i won’t go past a toyota

  • I’ve had my Hilux since 2016. Had one episode with the DPF at around 8000ks due to low speed driving and short trips and had the 2nd battery cradle replaced. Apart from that, no other issues. I check the engine regularly and so far the inlet is as clean as a whistle. no signs of any dust ingress, assuming that it is getting past the filter. just shy of 40,000ks and everything is still tight, no rattles and no strange noises. Regularly take it off road. I dont thrash it but i certainly use it for its intended purpose. First Hilux ive had and apart from a couple of small issues at the start couldn’t be happier! 🙂

  • as anyone that cuts gemstones knows, dust is a combination of many types of mainly quartz and mixs of materials, they are all able to slowly grind away on any moving parts, as for wear? of cause it will wear. may take it out past your warranty so no problem for the maker, it,s your problem, and that’s what they want !!!

  • Y62 now you’re talkin, once you drive on you will wonder why you ever bothered with a Toyota.
    Fantastic large 4×4 for Prado money.

  • In 2017 I done a fair bit of research when looking to buy a new 4×4. Reliability and price played a big part of my decision , gadgets less so. In the end, to me there was one clear winner, so I bought it…. Isuzu D-Max (the quiet achevier in the car industry)

  • my son owns a mechanical workshop. He owns a 2009 petrol Prado. I own a 2008 200 series petrol Landcruiser. Jointly we own a 2008 TRD petrol hilux. Why petrol? Diesel 4×4 repairs support his family. If he relied on petrols ,he would starve. He services 2 four litre hilux utes for a customer. one has travelled about 450000 klms and the other just over 600000. Still the original motors and never replaced an injector.

  • Agree totally- had a 200 series -brilliant vehicle – except it dusted at 300k like they all do and Toyota will not acknowledge it. Dealer was fantastic but Toyota spin will not have it. I told them they have too many in in the eastern suburbs of Sydney and Melb. to look at the problems outside.

  • I own a Toyota Prado turbo diesel which I bought new In 2002; it has done 285,000kms regularly towing the 3 caravans I have owned over the years, has had no significant problems and is still going strong. Oil and oil filter are changed every 5000Km and the injectors get a regular dose of Nulon Diesel Fuel System Cleaner. From hearing and reading of problems owners have had with their new turbo-diesel utes and wagons there is no way I would buy a new one! There’s still plenty of life left in my old Prado, parts are easy to come by and DIY maintenance such as oil and filter changes, fuel and air filters and brake pads is easy.

  • Toyota states “less than 5 microns”. Which is the same as the fuel filter rating?
    Will the “less than 5 micron” dust making its way to the combustion chamber do any more damage than the “less than 5 micron” particles that may past through the fuel system into the combustion chamber?

  • Bought a new SR5 in Feb 2017, did a 11,500km Cape York trip over 8 weeks, never missed a beat, and i like yo go hard. Did a 12,000km Cape trip in June 2018, never missed a beat. I Take care of my filters, change oils at 5,000km. Now 37,ooo on her, never had a DPF fault. Toyota wont sponsor Callinan, you never see him criticise Amotok,s his sponsor

  • Bought a new SR5 in feb 2017. Did a 11,500km Cape york trip in 2017, did a 12,000km Cape york trip in 2018, and i like to go hard. Never missed a beat. I manage my filters properly, change my eng oil every 5k using synthetic DPF rated 5w30. Never had a DPF issue. Lot of nin owner critics running on 2nd hand hearsay info around.

  • Well i.m dissapointed.i was goingvto buy a rugged x this year.just turned me tightvoff toyota gor good. Theyre certainly not what they used to be

  • I have a 2001 105 cruiser 4:5 running on petrol and gas injection with 450k plus on the clock. Items replaced
    1. Alternater at 230k
    2 Radiator at 300k
    3. New battery at 200k
    That’s it. Apart from regular maintenance ( oils, filters , lube etc ) wouldn’t catch me in one of these new diesels and I’m a diesel mechanic . I get a good laugh watching all these high tech diesels puttin around on short trips here and there. Ticking time bombs…

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