Toyota Fortuner Common Problems

The Toyota Fortuner is the seven-seat wagon built on the HiLux ute, sold here as the AN160 series (GUN156) from October 2015 in GX, GXL and Crusade trim. Every Australian Fortuner has the 2.8-litre 1GD-FTV turbo-diesel and part-time 4WD. Early cars made 130 kW, with 420 Nm in the six-speed manual and 450 Nm in the six-speed automatic. The August 2020 update lifted that to 150 kW and 500 Nm and left the automatic as the only gearbox. Toyota said in late 2025 that the Fortuner would leave the local range in mid-2026 with no direct replacement. The drivetrain has a tough reputation, but 2015 to 2020 cars carry the DPF fault behind a major class action, and the ride is firm.

DPF blockages, warning lights and white smoke (2.8L 1GD-FTV, 2015 to 2020)

The diesel particulate filter on 2015 to 2020 Fortuners, HiLuxes and Prados often failed to burn off soot in normal use, especially on short trips and in town. Owners reported repeated DPF warning lights, foul-smelling white smoke, lost power and repeat dealer visits.

Toyota's fixes came in stages. A 2017 service campaign reprogrammed the engine computer to run hotter, longer burns. A manual DPF burn button arrived on mid-2018 builds, and Toyota offered to retrofit it to earlier cars. In May 2020 Toyota developed the repair the court treated as effective: updated exhaust hardware and software, fitted free to affected vehicles. Some owners also report trouble with the exhaust fuel injector that feeds the burn, often called the fifth injector.

Toyota has offered extended DPF warranty cover on some affected vehicles, so ask a dealer whether any applies to the VIN. Out of warranty, a replacement DPF is a several-thousand-dollar job, roughly $3,000 to $6,000. Cars from the August 2020 update have drawn fewer complaints, but any DPF diesel suits highway running better than short trips.

The class action

In 2022 the Federal Court found HiLux, Prado and Fortuner diesels acquired between 1 October 2015 and 23 April 2020 were not of acceptable quality. Appeals followed. In October 2026 Toyota agreed to a $750 million settlement of that case and a second, related class action. The settlement needs Federal Court approval, so check its current status before counting on any payment.

EGR cooler leaks and intake carbon build-up (2.8L 1GD-FTV, 2015 to 2020)

Alongside the DPF, early 1GD-FTV engines drew complaints about the exhaust gas recirculation (EGR) system. Some reports describe EGR cooler leaks, mainly on pre-2018 cars, and soot building up in the EGR valve and intake over time. Signs include coolant loss with no visible leak, white smoke, rough running and reduced power.

A leaking EGR cooler has to be replaced, roughly $1,500 to $3,000 out of warranty, and a heavily coked intake needs a strip and clean. Later engines appear to suffer less, though the evidence is thin.

Dust on the airflow sensor and limp mode (2.8L 1GD-FTV, 2015 to 2025)

In 2017 Toyota issued a service bulletin for the 1GD-FTV after fine dust got past the air filter and coated the mass airflow (MAF) sensor. The engine computer then misreads the airflow and drops into limp mode: power falls away and stability and traction control switch off, which is a real problem when towing or off-road.

Toyota's advice was to service the air filter more often in dusty conditions and to clean the MAF sensor. Some owners also report the airbox can crack when it is opened, letting dirt reach the turbo. A new MAF sensor is roughly $200 to $500.

Gear hunting and shift shock (six-speed automatic, 2015 to 2025)

Some owners report the six-speed automatic hunts between gears on hills and when towing, drops out of sixth at highway speed, or thumps on some shifts. Dealers have told some owners this is normal. There is no widely reported pattern of gearbox failure, so treat it as a driveability issue to test for.

If the car has towed a caravan or boat, ask whether the transmission fluid has been changed, roughly $300 to $600 at a specialist.

Harsh ride and suspension complaints (all models, 2015 to 2025)

The most common owner complaint is the ride. Reviewers and owners describe it as harsh and busy on broken bitumen compared with the Ford Everest and Mitsubishi Pajero Sport. Owners are split on the coil-sprung rear: some find it too soft with a load or trailer, others too stiff when empty. Some owners fit airbags or an aftermarket suspension kit, roughly $1,500 to $3,500 fitted for a quality kit.

That is a design trait rather than a failure. Look for leaking shock absorbers and uneven ride height, and make sure any lift kit is a known brand and legal in your state.

Recalls and safety

Fortuners built in the second half of 2015 were recalled in 2018 because insulation on an airbag control chip could peel, which can switch off the front or side airbags. This is unrelated to the Takata airbag recalls. Late in 2020, diesel HiLux and Fortuner vehicles built in mid to late 2018 were recalled because a resin piston in the brake booster could weaken and break, removing brake assist and lengthening stopping distances. The DPF work above was handled through service campaigns, not a recall. Have a Toyota dealer check the VIN for open recalls and campaigns, and see our recalls page for current notices.

Buying a used Toyota Fortuner? What to check

• DPF history: On a 2015 to 2020 car, ask whether the 2020 DPF fix was done and look for repeat DPF visits in the service book. A Toyota dealer can confirm the work against the VIN.
• Smoke and warning lights: Start it cold and drive it for at least 20 minutes, watching for a DPF or engine light, white smoke or a raw diesel smell.
• Coolant level: Check the reservoir and ask about top-ups. Unexplained coolant loss on an early car can point to an EGR cooler leak.
• Airbox and filter: Open the airbox and look for dust past the filter and cracked housings, especially on cars used on dirt roads.
• Automatic gearbox: On a hill and at highway speed, check that it holds sixth, shifts without hunting or thumps, and engages drive and reverse cleanly.
• 4WD system: Select 4H and 4L, and the rear diff lock where fitted, and make sure the dash lights confirm each one.
• Handbrake and brakes: Test the handbrake on a steep slope, since a few owners report weak hold, and check the pedal feels firm with the engine running.
• Underbody and accessories: Look for bent bars, scraped sills and chassis damage from off-road use, and check that every accessory works.
• Servicing: Look for a full record at Toyota's scheduled intervals, which for these diesels are roughly every 6 months or 10,000 km. Gaps matter more on a DPF diesel.

Run a PPSR check for finance and write-off history before you pay, and use the Toyota Fortuner buying checklist on the inspection.

The verdict

The pick is a Fortuner from the August 2020 update on: the 150 kW engine has the revised DPF hardware and AEB is standard. A 2015 to 2020 car can still be a sound buy if the 2020 DPF fix has been done and the history shows no repeat DPF or EGR work, but it should be priced below a later car. Walk away from any early car with unexplained smoke, warning lights or missing service records. If ride comfort matters more than toughness, drive an Everest or Pajero Sport back to back first.