Toyota Prado Diesel Problems

There are probably hundreds of reasons for this to occur, starting with the fuel system and including (but not ending with) something to do with the electronics that control modern turbo-diesel engines. Other causes can be clogged EGR valves or faulty injectors. You need to have the vehicle scanned to see if the on-board computer has detected the fault and logged it. But don't rule out something simpler like a fault with the DPF or even a dirty air filter. Either way, black smoke suggests either a problem with the air-fuel mixture or the way it's being burned.

But don't ignore the problem as black smoke from a diesel engine can also mean it's running hot and that can lead to all sorts of problems including internal engine damage. Unlike a petrol engine which will tend to run cooler on a too-rich mixture (too much fuel, not enough air) a diesel running rich can easily run too hot.

White exhaust smoke in a diesel engine is usually the result of a fuel system problem. Possible causes are dirty, worn or leaking fuel-injectors, but a modern common-rail diesel fuel system is pretty complex, so a scan of the vehicle might be a good idea too.

Some owners of these modern diesels have been reporting very short injector lifespan, although some workshops seem to get good results with ultra-sonic injector cleaning. Even then, the problem can recur, and some mechanics reckon brand-new injectors are the only way to go.

Don’t rule out a problem with the engine’s internal seals, the turbocharger and the DPF system, either, as these can all contribute to smoke of various colours at various times.

When Toyota launched the facelifted HiLux late last year, much was made of the fact that consumer concerns had been noted and that the DPF problems experienced by many owners had been addressed. The problem is that until these new versions of the HiLux have done their share of kilometres, we won’t be in a position to know for sure whether Toyota has, indeed, cured the problem.

Meantime, it remains that unless your driving habits include a 30-minute drive at highway speeds every two or three weeks, a modern turbo-diesel with a DPF may not be the best choice. It is worth noting, though, that HiLuxes (and Prados and Fortuners) built after June 2018 have been fitted with a manual regeneration function for the DPF which means the driver can manually force a DPF burn-off without waiting for the car to do so itself. Toyota has also announced that the worst affected versions of the HiLux will now be covered by an extended, 10-year warranty on any DPF issues going forward. More information can be found here.

Toyota did have a spate of diesel engine failures some years ago when it was discovered that the fuel injector seals were leaking and letting fuel into the oil stream.

Sludge would build up on the oil pickup and eventually it be blocked and the engine would lose oil pressure. As you say the pickup can be inspected through the oil drain hole, so you should be able to see if there is a problem there. It is worthwhile changing the injector seals every 45,000 km.

I don’t believe that what you want is out there, and can only reiterate past advice, buy a Patrol/Pajero/Prado/LandCruiser.

The Pajero is a rugged vehicle that is very good on-road and off, it is roomy, safe and well equipped, while the Prado is a large, reliable, and tough seven-seater. It’s very comfortable, but the diesel’s performance is lacklustre. It’s hard to beat the Pajero.

There are quite a few reports of problems with the dpf clogging on the latest 2.8-litre diesel, but a Toyota spokesman told us there is currently no service campaign or recall related to the Diesel Particulate Filter (DPF) on any of the three vehicles you reference.

One possibility that has affected the Toyota diesel in the past is fuel leaking past the fuel-injector seals and contaminating the oil causing a build-up of sludge that eventually blocks the oil pick-up and starves the engine of oil. It's a long shot, but a possible explanation.

It would seem likely that the oil pickup has become blocked, starving the engine of oil. That's a problem with the turbo-diesel engine, caused by fuel leaking past the seal on the fuel injectors and contaminating the oil. The cracked dashboard is also a common problem. If you feel strongly about it you could approach Toyota with a request for a refund of the cost of repairs.

If they’ve been changed I see no need to do it again. It’s unfortunate that you have replaced them before Toyota contacted you, but it’s done and I don't think you’ve got any comeback on the company now.