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Top issues
18 known problems · 6 high
high
Cooling system fragility
All engines
high
Timing belt neglect
3 of 6 engines
high
Head gasket failure / warped head
2.6L G6 petrol
Recalls
1 on recordREC-000319
2019-12-23
Defect: A Takata NADI 5AT driver airbag inflator may allow moisture ingress, degrading the airbag propellant.
Hazard: Critical: inflator rupture in a crash could send sharp metal fragments into the cabin, risking death or serious injury.
Remedy: Ford dealer urgent inspection, free of charge; owners advised to contact Ford's Takata Hotline immediately.
Affected: 138 units, Courier 1998-1999 (PRA 2019/18075, campaign 19S53)
Official notice: www.vehiclerecalls.gov.au · details checked 2026-09-30
Check a specific car by VIN at vehiclerecalls.gov.au.
At this odometer
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Before and after
Before: Ford Courier 2nd gen (UC/UD, 1977-1985)
After: Ford Ranger PJ (2006-2011) →
Price (AUD)
$3k-$16k
Body styles
Single cab (cab chassis / styleside), Super cab (extra cab), Crew cab (dual cab)
Drivetrain
Rear-wheel drive (2WD), Part-time 4WD (dual-range, manual hubs/auto-locking)
Origin
Japan
Built in
Japan
Overview
Australia's quietly-everywhere tradie and farm ute for two decades. The Courier is a rebadged Mazda B-series (UF platform 1985-1998 covering the PC/PD codes, then the UN platform 1998-2006 covering PE/PG/PH), built in Japan and sold here alongside its Mazda Bravo twin. It was a simple, leaf-sprung-rear workhorse offered in 2WD and part-time dual-range 4WD, in single, super (extra) and crew (dual) cab bodies. Engine choice defines the buy: the G6 2.6L petrol four ran almost the entire production span and is a tough, simple unit (with a timing BELT, not a chain, despite what some part listings imply); the early R2 2.2 diesel is gutless old-tech; the WL 2.5 naturally-aspirated diesel is slow but durable; and the WL-T 2.5 turbo-diesel (from 1999) is the pick of the diesels but is famously under-cooled and prone to cracked heads if run hard or if the cooling system is neglected. A 4.0L German Cologne V6 petrol arrived only for the final PH (2004-2006) run with a 20mm ride-height lift. These are now cheap, high-km vehicles where condition, cooling-system health and service history matter far more than the badge - but parts are everywhere and they are genuinely easy to work on.
Engines & variants
2.6L G6 petrol
Engine
2.6L SOHC 12v MPFI petrol I4 (Mazda G-series)
Engine code
Config
I4 NA
Displacement
2606cc
Power
92kW @ 4600rpm
Torque
206Nm @ 3500rpm
Drivetrain
RWD or part-time 4WD (dual-range)
Economy
12-15 L/100km real world
Tow (braked)
1800kg
Tow (unbraked)
750kg
Transmission
5MT, 4AT
Timing chain / belt / gear
Belt-driven (replace ~100,000km / 5 years)
Pros
- Simple, tough, long-running Mazda four with huge parts support
- Available in 2WD and dual-range 4WD across the whole run
- Cheaper to buy and run than the turbo diesel for light duty
- Easy and cheap to work on for a home mechanic
Cons
- Modest power - works hard when loaded or towing
- Thirstier than the diesels under load
- Can ping on 91 RON on hot days - some owners run 95 RON
- Timing belt is an interval cost people forget on cheap utes
Known problems
high
Timing belt neglect
The G6 is belt-driven, not chain-driven as some parts listings suggest. A snapped belt on a high-km bargain ute causes valve damage on an interference engine, and many cheap examples have unknown belt history.
Fix: Replace the timing belt, tensioner and water pump together if history is unknown; then keep to ~100,000km / 5 years.
high
Head gasket failure / warped head
Overheating from a tired cooling system can blow the head gasket and warp the alloy head - a documented G6 outcome.
Fix: Keep the cooling system fresh (radiator, thermostat, fan). Machine the head and replace the gasket if affected.
medium
Ignition / fuel delivery no-start and rough running
Aged distributor, cap, rotor, leads and idle/fuel components cause hard starting, rough idle and stalling on older G6 cars.
Fix: Refresh distributor cap/rotor/leads, clean the idle air and fuel system; check timing.
2.2L F2 petrol
Engine
2.2L SOHC carburettor/EFI petrol I4 (Mazda F-series)
Engine code
F2
Config
I4 NA
Displacement
2184cc
Power
63-68kW
Torque
approx 170-176Nm
Drivetrain
RWD or part-time 4WD (dual-range)
Economy
11-14 L/100km real world
Tow (braked)
1500kg
Tow (unbraked)
750kg
Transmission
5MT, 4AT
Timing chain / belt / gear
Belt-driven (replace ~100,000km / 5 years)
Pros
- Very simple early Mazda four - cheap and easy to service
- Proven, robust bottom end for light farm/town work
- Carby versions are dead simple to fix roadside
Cons
- Low power - genuinely slow loaded or up hills
- Only on the earliest PC cars, all now very old and high-km
- Superseded by the larger, stronger 2.6 G6
- Carby versions can be fiddly to tune well
Known problems
medium
Age-related wear (earliest PC)
These are the oldest Couriers; expect perished hoses, worn carby/fuel parts, tired suspension bushes and electrics.
Fix: Budget a full consumables refresh; thorough pre-purchase inspection.
high
Timing belt neglect
Belt-driven engine; an unknown-history belt on a 30+ year old ute risks valve damage if it lets go.
Fix: Replace belt, tensioner and water pump on purchase if history is unknown.
2.2L R2 diesel
Engine
2.2L indirect-injection naturally-aspirated diesel I4 (Mazda R-series)
Engine code
R2
Config
I4 diesel NA
Displacement
2184cc
Power
47kW @ 4000rpm
Torque
142Nm @ 2000rpm
Drivetrain
RWD or part-time 4WD (dual-range)
Economy
8-10 L/100km real world
Tow (braked)
1500kg
Tow (unbraked)
750kg
Transmission
5MT
Timing chain / belt / gear
Belt-driven (replace ~100,000km / 5 years)
Pros
- Frugal, simple mechanical indirect-injection diesel
- No electronics - easy to keep alive and fix anywhere
- Long-lived if cooling and oil changes are kept up
- Cheap to run for light farm/town duty
Cons
- Genuinely slow - struggles loaded, towing or on hills
- Old indirect-injection tech - smoky and noisy when tired
- All examples now very high km and very old
- Glow-plug and mechanical-injection wear with age
Known problems
medium
Injector pump / injector wear
The mechanical injection pump and injectors wear at high km, causing hard starting, smoke and lost power.
Fix: Diesel-specialist pump and injector rebuild; many have already been done - ask for records.
high
Overheating / head gasket if cooling neglected
Like most old indirect diesels, a tired radiator or thermostat can cook the head gasket on this engine.
Fix: Keep the cooling system fresh; machine head and replace gasket if it has overheated.
2.5L WL diesel (NA)
Engine
2.5L SOHC indirect-injection naturally-aspirated diesel I4 (Mazda WL)
Engine code
Config
I4 diesel NA
Displacement
2499cc
Power
62-65kW @ 3500rpm
Torque
approx 165Nm @ 2000rpm
Drivetrain
RWD or part-time 4WD (dual-range)
Economy
8-10 L/100km real world
Tow (braked)
1800kg
Tow (unbraked)
750kg
Transmission
5MT
Timing chain / belt / gear
Belt-driven (replace ~100,000km / 5 years)
Pros
- Simple, frugal naturally-aspirated diesel with no turbo to fail
- Durable bottom end with basic maintenance
- Cheaper to buy than the WL-T turbo version
- Easy to service - same family as the popular WL-T
Cons
- Slow - clearly down on the turbo WL-T, hard work loaded/towing
- Indirect injection is noisy and smoky when tired
- Shares the WL family's marginal cooling - watch head health
- Timing belt is an interval cost on these cheap utes
Known problems
high
Cylinder head cracking / overheating
The WL family is known to crack heads, made worse by the marginal factory cooling system if run hard or neglected.
Fix: Keep cooling system in top order; replace/repair head and gasket if cracked. Heads are comparatively easy to swap on this engine.
high
Timing belt neglect
Belt-driven; a snapped belt damages valves on an interference diesel, and cheap examples often have unknown belt history.
Fix: Replace belt, tensioner and water pump together if history is unknown; keep to ~100,000km.
2.5L WL-T turbo diesel
Engine
2.5L SOHC indirect-injection intercooled turbo diesel I4 with twin balance shafts (Mazda WL-T)
Engine code
WLAT
Config
I4 turbo
Displacement
2499cc
Power
84-86kW @ 3500rpm
Torque
280Nm @ 2000rpm
Drivetrain
RWD or part-time 4WD (dual-range)
Economy
8-11 L/100km real world
Tow (braked)
1800kg
Tow (unbraked)
750kg
Transmission
5MT, 4AT
Timing chain / belt / gear
Belt-driven (replace ~100,000km / 5 years)
Pros
- Best of the Courier diesels - ~33% more power than the NA WL
- Strong low-down torque for towing and loaded work
- Intercooled with balance shafts - reasonably refined for the era
- Cracked heads are relatively easy/cheap to replace vs other turbo diesels
Cons
- Notoriously under-cooled - cracked heads are the signature failure
- 5th-gear gearbox bearing can fail under the extra torque
- Turbo boost loss from leaking vacuum/intercooler hoses
- Eats glow plugs; cooling system must be kept immaculate
Known problems
high
Cracked cylinder head from overheating
These engines were factory under-cooled and are notorious for cracking heads, especially driven hard, towing or with a tired cooling system - the single most-cited WL-T failure in Australia.
Fix: Keep the cooling system immaculate (radiator, thermostat, fan, coolant); fit a quality radiator. Heads are comparatively straightforward to replace on this engine.
medium
5th-gear bearing failure
The Mazda/Ford manual gearbox is prone to 5th-gear bearing failure, as the turbo's extra torque can strip it - owners are advised to drop to 4th on hills and avoid 5th while towing.
Fix: Gearbox rebuild with the 5th-gear bearing/synchro; drive sympathetically in top gear under load.
medium
Turbo boost loss (vacuum / intercooler hoses)
Power loss and delayed boost when warm typically come from disconnected or leaking vacuum hoses on the turbo actuator, or popped intercooler hoses under load.
Fix: Pressure-test and replace perished vacuum/intercooler hoses and clamps; check the turbo actuator.
low
Glow plug wear
Owners report these engines going through glow plugs, causing hard cold starting.
Fix: Replace the glow plug set; check the glow relay and wiring.
4.0L Cologne V6 petrol
Engine
4.0L SOHC German Cologne V6 petrol
Engine code
Config
V6 NA
Displacement
3998cc
Power
154kW @ 5250rpm
Torque
323Nm @ 3000rpm
Drivetrain
RWD or part-time 4WD (dual-range)
Economy
14-17 L/100km real world
Tow (braked)
1800kg
Tow (unbraked)
750kg
Transmission
5MT, 5AT
Timing chain / belt / gear
Chain-driven
Pros
- By far the most powerful Courier - smooth, strong V6
- 20mm ride-height lift over the four-cylinder models
- Chain-driven - no timing belt interval
- Genuinely effortless loaded/towing compared with the fours
Cons
- Thirsty - the heaviest fuel bill in the range
- Only on the final PH (2004-2006) cars, lower volume
- Petrol resale weaker than the sought-after turbo diesel
- More complex than the simple four-cylinder Couriers
Known problems
low
Fuel thirst
Not a fault, but 14-17 L/100km loaded is the reality of a 4.0 V6 in a ute.
Fix: Accept the fuel bill or consider LPG; the V6 suits gas conversion.
medium
Cooling system / timing chain guides at high km
Aging Cologne V6s can develop coolant leaks and, at very high km, timing-chain guide/tensioner wear.
Fix: Refresh cooling system; address chain guides/tensioner if rattling at cold start.