KNOWN FAULTS · Toyota

Toyota Proace / Proace Verso (II) common problems.

2016–2026 · Diesel / Electric

Sources are not verified in real time and no entry confirms that your car is affected.

4 known faults with sources

Engines: 1.5 / 1.6 / 2.0 D-4D (Diesel)

Applies if: The Proace D-4D engines are PSA BlueHDi units with AdBlue.

AdBlue system failure (start countdown)Exhaust and emissions (AdBlue)

Engine / equipment: 1.5 / 1.6 / 2.0 BlueHDi with AdBlue (Peugeot, Citroën, DS, Opel)
Period mentioned: Approx. 2014 onwards
Symptoms: Emission system fault message and a “starting impossible in X km” countdown, AdBlue/UREA warning and engine light.
Possible cause described: Failure of the AdBlue tank pump module (circuit board, pressure sensor or heater) or of the AdBlue injector. The engine does not stop while driving, but once the countdown reaches zero it will not restart.
Check for the garage: Diagnose with Diagbox or equivalent: AdBlue pressure, flow test and tank temperature.
Cost cited in the source: Complete module or tank: approx. €600–1,500 (estimate)A rough figure from the original database, not an up-to-date quote.

Engines: 1.5 / 1.6 / 2.0 D-4D (Diesel)

Applies if: Only the 1.5 (PSA DV5 engine).

1.5 BlueHDi camshaft chainValve timing

Engine / equipment: 1.5 BlueHDi (DV5): Peugeot 208/2008/308/3008/5008/508/Rifter, Citroën C3/C4/C5 Aircross/Berlingo, Opel, DS, Fiat
Period mentioned: 2017–2023
Symptoms: Rattle from the top of the engine, loss of power; in severe cases the chain breaks and the engine fails.
Possible cause described: The 7 mm chain linking the two camshafts wears prematurely, influenced by soot in the oil. Stellantis replaced it with an 8 mm chain in 2023 and opened an inspection campaign.
Check for the garage: Ask the dealer whether the car is in the campaign (free inspection and replacement if needed) and whether the 8 mm chain is fitted.
Cost cited in the source: €700–1,400 for the chain; €4,000–7,000 if it breaksA rough figure from the original database, not an up-to-date quote.

Engines: 1.5 / 1.6 / 2.0 D-4D (Diesel) · Proace Electric (Electric)

Applies if: Toyota USA tech tip for all its models: it applies if the judder began after wheels, pads or discs were removed or changed.

Brake judder from wheel nuts over-tightened or tightened unevenly (Toyota tech tip)Brakes

Engine / equipment: Any Toyota: it depends on how the wheels are tightened
Period mentioned: 2016 tech tip for all its models
Symptoms: Vibration in the steering wheel and the pedal when braking, even gently and at any speed, often shortly after wheels, pads or discs were changed.
Possible cause described: Toyota points out in a tech tip that if the wheel nuts are over-tightened or tightened unevenly (a single one is enough), the brake disc is left with runout and brake judder appears. It happens above all when they are run fully home with an impact gun instead of a torque wrench in a star pattern.
Check for the garage: Ask the garage to loosen and re-tighten the nuts with a torque wrench, to the manual's torque and in a star pattern, and to measure whether the discs have been left warped; if so, they will need skimming or replacing.
Cost cited in the source: No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Engines: Proace Electric (Electric)

Applies if: Only vans built from 2020 to 2023 (Mahle charger).

Mahle on-board charger failing on Stellantis and Toyota electric vans (2020–2023)High-voltage battery

Engine / equipment: Peugeot e-Expert, Citroën ë-Jumpy, Opel Vivaro-e, Fiat E-Scudo and Toyota Proace Electric; also the Fiat e-Doblò
Period mentioned: 2020–2023
Symptoms: It stops charging on AC (at home or at public posts) while still charging at DC rapid chargers; charging-fault warnings.
Possible cause described: The Dutch consumer programme Radar (2025) explains that these models were fitted with a Mahle on-board charger that fails relatively often and that Stellantis changed supplier without a recall. In 2021 Stellantis extended the charger warranty to four years on nearly all of them (not the Fiats), and Toyota covers its Proace for five years or 200,000 km; out of warranty it costs thousands of euros. Belgian consumer association Test-Achats publishes an owner’s complaint with the same list of models.
Check for the garage: Try charging at an AC post before buying; ask the dealer for the build date and whether the charger has already been replaced; keep the invoice in case you claim non-conformity.
Cost cited in the source: Out of warranty, thousands of euros (Radar).A rough figure from the original database, not an up-to-date quote.