Toyota Australia has launched a Customer Service Exercise covering almost 17,000 HiLux Rogue utes after identifying a potential problem with their power-operated roller covers.

The campaign involves approximately 16,995 HiLux Rogue vehicles produced between May 29, 2020 and April 8, 2024.

According to Toyota, the electrically operated roller cover fitted over the HiLux Rogue’s tub can become jammed or fail to open or close. If this happens, the electric motor operating the cover may continue running and potentially overheat.

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There is no advance warning that the problem is developing, with owners likely to discover it only when attempting to operate the roller cover. However, Toyota says a burning smell or smoke may be noticed if the motor overheats.

Owners who experience either symptom have been advised to stop operating the roller cover and contact a Toyota dealer to arrange repairs.

Toyota says affected vehicles remain safe to drive, and the campaign relates only to the roller-cover system rather than the HiLux’s drivetrain or other vehicle systems.

Dealers will inspect the roller-cover motor for evidence of overheating and replace it where necessary. Technicians will also inspect and adjust the width of the roller-cover tracks, update the system’s ECU software and install metal drive-pin connectors where required.

The revised software changes the system’s limit-switch logic and is designed to reduce the possibility of the motor overheating.

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It also introduces additional functionality, allowing owners to open and close the roller cover using either the vehicle’s key fob or the lock and unlock switches on the driver’s door.

Toyota estimates the complete inspection and repair process could take approximately 3.5 hours, although vehicles may need to remain at dealerships for longer depending on workshop schedules.

The company says the latest campaign represents a further countermeasure for the issue, meaning some owners who have previously had a Customer Service Exercise completed may be contacted again.

Toyota Australia will contact registered owners directly. Anyone who believes their HiLux Rogue falls within the affected production period can also contact a Toyota dealer to check its status.

Owners can alternatively call the Toyota Campaign Helpline on 1800 987 366, quoting the vehicle’s 17-digit VIN.