1991 Toyota HI LUX 2.4L Diesel · H204 HTA

The 2.4-litre diesel HiLux is reasonably economical for a vehicle of this type, typically returning 28-32 mpg depending on load and use. Road tax for a vehicle of this age and engine size sits in a low band, likely £165-£190 per year. Insurance will vary considerably depending on usage classification, but as a commercial-type vehicle it may be cheaper to insure than a passenger car of equivalent value.

Maintenance costs are the main concern given the vehicle's age and mileage. Older diesels of this vintage typically require more frequent attention to injectors, cooling system components, and suspension bushes. Budget realistically for £600-£1,200 per year in general maintenance, excluding any major structural repairs. Replacement parts for the HiLux are generally available and reasonably priced due to the model's popularity and parts commonality across generations.

Considering fuel, tax, insurance, and typical maintenance for a high-mileage diesel of this age, the estimated annual running cost is £1,200-£1,800. This does not include any major corrosion repairs which could add significantly to ownership costs in the short term.

Begin with a thorough inspection of the rear vehicle structure where both nearside and offside sections were flagged as having significantly reduced rigidity. Place the vehicle on a ramp if possible and look for holes, flaking metal, or heavy surface rust along chassis members, cross members, and suspension mounting points. Tap suspect areas with a screwdriver handle — solid metal produces a clear ring, while corroded metal sounds dull. Pay particular attention to the spring hangers, as a corrosion advisory was also noted on the front spring hanger in 2023.

The brake system needs close examination. The front brake disc was noted as worn, pitted, or scored at both the December 2025 failure and the January 2026 pass, and front brake pads were flagged as wearing thin in 2024. Inspect both front discs for runout and lip, and check the rear brake system thoroughly including drums, shoes, and adjusters. Anti-roll bar linkage damage on the nearside front should also be visually checked — this is a relatively minor repair but indicates the vehicle is being used on rough surfaces.

Finally, check under the bonnet for the source of the persistent oil leak. Common culprits on the 2.4D engine include the front crankshaft seal, camshaft seals, and rocker cover gasket. Also inspect the exhaust system, given a major leak was flagged at the 2024 test. Ensure the offside front seat belt buckle is functioning correctly, as this was still showing damage at the most recent test.