My 2022 Fortuner spends more than 10 days at the workshop: Here's why

They have a list of 18 parts to be changed and they have them in stock

Sharaf drops in a query via this page.

My name is Sharaf. I have been following Team-BHP for a long time. When I had the itch to get a big SUV, Team-BHP helped me to shortlist the Ford Endeavour. However, by the time I was ready, Ford stopped operations in India. Again, Team-BHP convinced me to go ahead and get a Toyota Fortuner, which I did. Team-BHP helped me in everything related to the purchase, DIY detailing and maintenance, which I am very much enjoying nowadays.

However, recently I had to face DPF issues in my vehicle and my vehicle is at the service centre for the past few weeks. Now I need Team-BHP’s help and guidance on to handle this situation. I have explained my experience from the beginning below.

I purchased a Toyota Fortuner 4x4 during the last week of March 2022. I was happy with the vehicle and had many enjoyable drives with it. I was aware of the DPF-related issues before the delivery itself, and I was constantly observing the vehicle's behaviour. Initially, everything was ok, and the DPF auto regeneration was happening around the 200–250 km mark.

When the vehicle completed 7,000 km, the AdBlue refill was done. When the vehicle reached 9,500 km, I booked the 10,000 km service at the nearest Toyota Service Centre. On the day of the appointment, during the morning time, while driving back from the airport, I was observing DPF regeneration happening and suddenly, the "DPF regeneration is needed; please visit the service centre" warning came up. The check engine indicator was on, and the vehicle went into limp mode. Immediately I took the vehicle to the service centre, and the SA said that along with the 10,000 km service, they would check the issue. As per them, forced regeneration should be good enough to solve the issue. As I had learned from Team-BHP about similar issues faced by other BS6 Fortuner owners, I explained and inquired, but they were clear that only forced regeneration was good enough. I agreed, and I got the vehicle back after the periodic service and DPF regeneration.

In Team-BHP, as a few other owners mentioned that they faced DPF issues immediately after forced generation, I wanted to check that and did a 250 km drive covering hilly areas and highways. During the ride, I didn't get any DPF issues. However, now the DPF regeneration was happening way earlier, at around 100–150 km intervals. So during my test trip, I observed 3 successful regenerations happening, and I was happy to think the earlier DPF issue may not be as serious as the one others had faced.

After that, I was using the vehicle just as before and didn't face any issues other than the observation of DPF regeneration earlier than before. After some time, my vehicle was due for its 20,000 km service, and as usual, I booked an appointment at the same service centre. Unfortunately, one day before the appointment, again the DPF warning was shown, and the vehicle went into limp mode in the middle of a trip. Somehow, I took the vehicle home (as it was Sunday, I couldn't take it to the service centre). The next day, I took the vehicle to the service centre and explained the situation. This time also, they were casual about the issue and mentioned only regeneration should be enough. So I dropped the vehicle at the service centre, thinking I could pick it up in the evening after work. Later that day, around 1 hour before my promised pickup time, I got a call from the SA, and he mentioned that their senior engineer checked my vehicle and recommended changing some parts including all 4 fuel injectors and reprogramming the ECU. The SA told me in the same sentence that it would take 2–3 days to get the parts. I was able to quickly recover from the shock and disappointment as I had already gone through the state, in a way, while going through other owners' similar experiences on Team-BHP.

Meanwhile, the SA mentioned that as they would be replacing, they were not doing the forced manual regeneration now. However, as I was expecting some urgent hospital visits (delivery related) and as it will take 2-3 days to get the parts, I asked him to do the regeneration and return the vehicle. I would drop the vehicle off after 2 days. He said he would discuss it and would call me back. He called me back after some time and this time, he mentioned that he checked and they had the parts available and could start the work immediately. Because of my situation at home, I asked whether they could provide an alternate vehicle. He said that was not possible, so I didn't have any other option. I said I would take delivery of the vehicle after regeneration and drop it off for the recommended work after 2 days. After internal discussions, he agreed, and I got the vehicle back.

When I picked up the vehicle after regeneration, it was behaving normally, but I didn't use it and kept it at home, thinking I would use it only if a hospital emergency arose. After two days, on Thursday, I dropped the vehicle off at the service centre for the recommended work and the SA promised me that I could pick it up on Monday. I trusted him and was hoping that by Monday everything would be sorted out. Meanwhile, I was checking on the Carrot app and I observed that on Saturday, the vehicle engine was running for close to 30 minutes, multiple times. I thought they might be checking after the injector was changed.

I called the SA and inquired; he mentioned that the work is in progress and everything is okay. On Monday morning, the SA called me and told me that the injectors had been changed. However, during their inspection, they found some issues, and they needed to change the ECM. I was completely disappointed. On top of that, he further mentioned that the particular part number was on the backorder list and they didn't know when the part would be available. They needed to send a request and TKM would respond with an ETA for the part.

So, my beloved vehicle has been in the service centre for the past 10 days, and I still don't know when I can get it back. Till now, I haven't got an ETA for the ECM that needs to be changed.

From the community, I would like to know if any 2021 BS6 Toyota Fortuner owners had to change the ECM for DPF issues. I read about many Fortuner owners facing DPF issues, but no one mentioned replacing the ECM to fix it. Or is it a case where the service centre fried the ECM during the reprogramming of the ECU?

Also, one more thing I would like to share here is that while talking to the service centre, it seems there is a defined standard procedure for such DPF issues for Toyota vehicles. They have a list of 18 parts to be changed and they have them in stock. So it seems just like they did in Australia, they are not doing a formal recall, but rather fixing it case by case.

Hope I can continue my wonderful driving experience with my vehicle.

Here's what BHPian ads295 had to say on the matter:

It is very VERY rare for an ECU to fail. So rare that I think manufacturers do not produce ECUs for replacement use, only for new cars.

I suggest you take ownership of this problem and find a good garage. An ECU will take horrendously long to source, and will most likely not solve the issue at all, notwithstanding the costs involved.

Here's what BHPian mtbrinjal had to say on the matter:

Recently faced DPF issue twice in one trip on my 2021 Fortuner 4x4 during a trip to Ladakh. It was the first time I had seen the warning “DPF Full Manual Regeneration needed. See Owners Manual.”

Had to perform Manual Regeneration twice because first time was incomplete. Thereafter took the car directly to Shree Toyota Leh where there were 5-6 local Innova Crysta taxi drivers with same issue. They had Check Engine Light and Manual Regeration was disabled. I was told to continue driving as manual regeration had cleared my dpf. They explained it’s because of the altitude.

But the second time it happened was in the plains at GT road near Karnal, while driving at over 80 kmph. This time Check Engine light was on and Manual Regeration button did nothing. Took the car next morning to Karnal Toyota. The technician told me that sometimes the DPF progress bar directly “jumps” to the warning mark, and at that point Manual Regeration cannot be performed. Car has to be taken to Worksop where they cancel Check Engine light and then only manual Regeration can be done. The technician told me to get injectors replaced if the DPF problem comes back.

I don’t know when and if I am going to see this issue again but I am worried about driving the car since then especially on mountains. Beats the entire point of owning a 4x4 and that too the “reliable” Fortuner. Certainly cannot relax during the drive as I have now developed a habit of pressing the Manual Regeration button to check DPF status.

Here's what BHPian WDYWFM had to say on the matter:

I own a 2021 Innova Crysta Diesel and the car went into limp mode twice in the first year of ownership. The DPF would be normal (1 bar) and in the next instance would go to maximum and the check engine light turns on. In this mode, the engine power is restricted and manual re-generation does not happen. When the second such instance occurred, the SA said the injectors have to be replaced. Post the replacement, the car is working fine (been ~6000Km so far). Auto regeneration kicks in at 200kms on average (but is variable; sometimes kicks in at 150km). While I was initially disappointed with the reliability of a toyota, the proactive replacement of the parts (and things working subsequently, so far at least) gives some re-assurance.

I recommend to get the parts replaced as per SA and enjoy your car

Here's what BHPian niINja had to say on the matter:

Why do I get a feeling that they messed up the ECM while reprogramming and now want to replace it?

ECMs are generally very robust and the failure rate is low.

Read BHPian comments for more insights and information.