ExhaustHigh
DPF blocking on light-duty urban use
- Typically appears
- 80,000+ miles
- What to inspect
- Run at sustained speed and confirm no warnings
2016–2025 Toyota Hilux · common problems & known faults
The default UK pickup for trades and agriculture. Buyers expect hard use, but they will not accept corrosion.
Compiled & reviewed by the VehicleFaults Research Team · last reviewed August 2026
Quick answer
The most commonly reported faults on the 2016–2025 Toyota Hilux are Chassis and underbody corrosion on older, farm-used trucks, DPF blocking on light-duty urban use and Clutch and transfer case wear on working trucks. Of the documented issues, 1 rated critical and 4 rated high · these are the ones worth inspecting first. Full inspection points, onset mileage and what to check are listed below.
Reliability snapshot
Based on the documented faults on this page for the Toyota Hilux.
2.4/ 10
- Critical
- 1
- High
- 4
- Medium
- 2
- Low
- 1
Guidance only · reflects reported patterns, not a specific car's condition.
Toyota Hilux problems by year
Which faults an average example has usually reached depends on its age. Pick a model year for the faults that matter on that build.
Known faults to check
BodyCritical
Chassis and underbody corrosion on older, farm-used trucks
- Typically appears
- Age-related
- What to inspect
- Inspect the chassis rails thoroughly from underneath
SuspensionMedium
Rear leaf spring and bush wear from overloading
- Typically appears
- 90,000+ miles
- What to inspect
- Check ride height and inspect springs for cracking
TransmissionHigh
Clutch and transfer case wear on working trucks
- Typically appears
- 100,000+ miles
- What to inspect
- Test four-wheel-drive engagement and clutch bite
EngineHigh
Cold start diesel knock, rough idle, or white smoke from unburnt fuel.
- Typically appears
- 50,000-80,000 miles
- What to inspect
- Start the engine from stone cold. Listen for a harsh, metallic clatter that does not settle within a few seconds, and check for a lumpy idle or white smoke from the exhaust indicating injector wear.
EmissionsHigh
AdBlue warning light, mileage countdown to non-start, or crusty white buildup.
- Typically appears
- 40,000-70,000 miles
- What to inspect
- Turn on the ignition to check for an 'AdBlue malfunction' warning. Look under the vehicle at the exhaust SCR unit for white, crystalline urea leaks around the dosing valve.
InteriorLow
Touchscreen unresponsive, random reboots, or visible bubbles under the screen surface.
- Typically appears
- 3-5 years
- What to inspect
- Cycle the ignition and test the infotainment screen. Tap the corners of the display to ensure touch response and inspect the screen edges for a cloudy or bubbled appearance indicating delamination.
DrivetrainMedium
4WD fails to engage, accompanied by a flashing 4WD light on the dashboard.
- Typically appears
- 60,000-100,000 miles
- What to inspect
- With the engine running in neutral, switch the dial from 2H to 4H. Listen for the ADD actuator click and ensure the 4WD icon illuminates solidly within five seconds without flashing.
Inspecting a Toyota Hilux?
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Check this exact carFrequently asked questions
What is the number one Hilux check?
Chassis corrosion. Get underneath every single one, whatever the age or mileage.
Do high miles matter?
Far less than condition. These trucks are bought on structural integrity and four-wheel-drive function.
Which spec sells fastest?
Double cab Invincible with a canopy or roller cover, to trades and lifestyle buyers alike.
Is the newer 2.8-litre engine as reliable as the 2.4-litre?
Both the 2.4 and 2.8 engines share the same architecture and are generally robust. The 2.8-litre, introduced in 2020, features an upgraded balance shaft and improved cooling. However, it uses more AdBlue and is slightly more prone to SCR system faults. Mechanically, both offer excellent longevity if serviced annually.
How do the towing capacities differ across the AN120/AN130 range?
Early 2016 models were rated at 3,200kg for towing. Toyota upgraded the chassis and cooling in late 2017, increasing the legally braked towing capacity to the class-standard 3,500kg. Always check the V5C or the VIN plate on the passenger door pillar to confirm the specific gross train weight of the exact truck you are appraising.
Does the 8th generation Hilux use a timing belt or a timing chain?
Both the 2.4-litre and 2.8-litre diesel engines in this generation utilise a heavy-duty timing chain rather than a rubber belt. The chain is designed to last the lifetime of the engine and has no scheduled replacement interval. However, regular oil changes every 10,000 miles or 12 months are critical to prevent chain tensioner wear.
Sources & further reading
Faults are compiled from documented recalls, technical bulletins, owner reports and mechanic sources, then reviewed for accuracy. This is guidance only · not a substitute for a professional inspection.