Legendary rally-bred hot hatch with a homologation special pedigree. Purpose-built with a widened body, unique GR-FOUR AWD system, and Toyota's most powerful production three-cylinder engine. Developed by Toyota's rally team to be thrashed - track days don't void warranty. Main concerns: timing chain tensioner on early cars, gearbox crunching if shifted cold, and fragile front grille/windscreen prone to stone damage. Engine is robust when stock but tuning beyond 400hp risks piston failure. Watch for boost sensor failures and AWD overheating on track. Toyota backs reliability with 10-year/100,000-mile warranty if serviced at dealer every 10,000 km.
Early cars suffer crunching from cold, hurried shifts damage synchros · more· less
The Aisin 6-speed manual gearbox can develop crunching on 1st-to-2nd and 2nd-to-3rd shifts, particularly when cold. Some early 2020 Track Edition models had issues at just 600 km where synchronization rings wore prematurely. Toyota replaced affected gearboxes under warranty for cars in a certain VIN range. The gearbox is rated for 450 Nm (336 lb-ft) at flywheel - beyond this, fifth gear synchro and sleeve fail quickly. Gear changes improve when oil is changed around 10,000 km. A DIY fix involves adjusting the gear shift cable linkage. Toyota dealers should address this under warranty if within coverage period. Never rush cold shifts.
Front grille and windscreen stone damage€300 - €1,200
Thin windscreen and fragile lower grille prone to chips and cracks · more· less
The GR Yaris windscreen is notably thin due to weight-saving, and owners report chips turning into full cracks within seconds at moderate speeds. A small chip "not much bigger than the tip of a ballpoint pen" can crack the screen 30 seconds later at just 50 km/h. Toyota quoted €1,000 for replacement in some markets, though insurance typically covers it (€25-90 with coverage). The plastic lower grille is fragile and costs €400-500 to replace because it forms the main bumper structure. Debris passing through the large grille mesh can damage the intercooler behind it, an even costlier repair. Many owners install protective mesh (€150) or full PPF (€1,000-1,500 for front end) to prevent damage.
Boost pressure sensor failure€150 - €400
Sensor fails causing zero boost, common on early cars · more· less
A known issue where the boost pressure sensor/solenoid fails, resulting in loss of turbo boost power. Specialists have seen this multiple times and recognize it immediately. Symptoms include overboost fault typically in 1st gear when launching or setting off quickly, or the ECU requesting less boost as protection. The P010515 fault code indicates overboost. Earlier production cars are more affected - Toyota appears to have addressed this in later builds. Quick sensor replacement solves the issue. Also check all rubber hoses to the airbox, particularly those controlling the airbox flap, as a disconnected hose can cause the ECU to cap boost at around 0.9 bar.
The GR Yaris has "very cheap plastic and little to no sound deadening" leading to widespread rattle complaints. Common sources: A-pillar trim (even when sound appears to come from dash speakers), glovebox lid moving 2-3mm when shut, driver door handle trim buzzing, rear quarter panel vibration at 2,700 rpm, and sensor housing behind rearview mirror. One dealer found wiring loom routing issues where the harness was pinched by the dash - Toyota requires photos of this specific issue for warranty claims. DIY fixes include thick foam tape on A-pillar edges, felt tape on mirror sensor housing, and fastening unused rear seatbelts. Toyota dealers have removed entire dashboards to add padding. The scuttle plate being in compression has also caused rattles. Gets worse after a few thousand miles.
Clutch premature wear€2,100 - €3,000
Some owners report clutch failure at low mileage around 14,000 km · more· less
A small number of owners have experienced clutch failure at relatively low mileage - one case at just 14,000 km (2,000 miles) requiring a second standard clutch replacement. The GR Yaris suffers from poor pressure plate response time - the spool down from pressing the clutch to the pressure plate actually releasing the clutch disk is too slow. Toyota initially refused warranty replacement claiming hard driving, but after owner contacted Toyota Japan during an eight-week dispute, the clutch was replaced under warranty. OEM clutch costs €2,057.82 and flywheel €863.59 including VAT, totaling approximately €2,921 for parts alone. Aftermarket options like Helix or Pumaspeed kits cost €800-1,400 plus €590 labor. This appears to affect only a minority of cars but is worth monitoring.
AWD transfer case overheating (track use)€0 - €1,500
Multi-plate clutch overheats during sustained track use, disconnects rear axle · more· less
During extended track sessions, the electronically controlled multi-plate clutch in the transfer case can overheat, causing the system to disconnect the rear axle for protection. This isn't a failure - it's electronic protection preventing damage - but ends track use for that session. High load at low speed is worst, such as gymkhana or parking lot antics. The transfer case itself gets hot but has no temperature feedback to the 4WD controller; only the ITCC unit monitors temperature. Factory GR Yaris already has cooler line location prep that just needs to be connected. Toyota recommends changing transmission, transfer case, and differential fluids at half the specified distance or after track use. Some tuned cars with 255-265mm width tires have broken transfer case housings. Transfer case oil seal/bearing failures have been reported around 68,000 km where the bearing cage (plastic) breaks into pieces.
Low-speed pre-ignition (LSPI) causes piston disintegration, affects both stock and modified · more· less
A small number of G16E-GTS engines have experienced catastrophic piston failure where pistons disintegrate, punching holes through the block. The suspected cause is Low Speed Pre-Ignition (LSPI) where fuel/oil droplets auto-ignite. This appears to be related to oil control issues that worsen with age and kilometers. Toyota has superseded pistons, block, valve springs, valves, and cams across Gen 2 and Gen 3 engines, using different piston part numbers for each generation. Manufacturing tolerances mean some engines are more affected than others. Most failures appear on higher-mileage engines or significantly modified cars. Stock engines rarely fail - many forum members question how many truly stock GR Yaris engines have failed with verifiable sources. The engine is overbuilt and tunable to 400-500hp on stock internals. WRC Yaris cars push 450hp on the same engine. One warranty claim was denied after Toyota detected the vehicle drifting at 173 km/h with engine overheating to 120°C.
Valve spring failure (high-rpm/track use)€1,200 - €2,500
Factory valve springs are weak point for sustained high-rpm use · more· less
The factory valve springs are a known weak point on the G16E-GTS engine, particularly for track use or tuned cars running high RPM. The GR86 and GR Yaris share this valve train weakness - the rocker arms have nothing to prevent them from dislodging. Toyota has been aware of this for approximately 5 years but hasn't upgraded the factory valve train. Up to stock redline of 7,000 rpm, upgraded valve spring kits from Kelford/Lamspeed address this issue. The Kelford KVS264 kit costs approximately €800-1,200 installed and supports factory or performance camshafts. For extreme builds (65 psi, 11,000 RPM), the KVS264-X extreme kit is available. This is primarily a concern for track-focused or heavily tuned cars, not stock street-driven examples.
Rally-proven reliability, but expensive consumables
The GR Yaris was developed by Toyota's rally team to be driven hard - track days don't void warranty. Toyota backs the car with a 10-year/100,000-mile warranty if serviced at dealers every 10,000 km. The G16E-GTS engine is robust when stock, and many owners report zero issues even with spirited driving. However, being a performance AWD car, it burns through tires and brakes faster than regular hatchbacks. Stone damage to the fragile grille and windscreen is the most common complaint. Early production cars (2020-2021) had more gearbox and sensor issues that Toyota addressed in later builds.
Pre-Purchase Inspection Checklist
General checks
Service history
Complete Toyota dealer records essential for 10-year warranty eligibility. Verify 10,000 km service intervals maintained.
Tires
Check tread depth (rear wears faster on AWD), age (date codes), and uneven wear patterns. OE Michelin Pilot Sport 4S cost €450-550 per set.
Cold start
Must start engine completely cold. Listen for timing chain rattle in first 10 seconds (tensioner issue).
Body condition
Check front bumper, bonnet, and rear arches for excessive stone chips. Inspect windscreen carefully.
Test drive
Minimum 30 minutes including varied speeds, hard acceleration, and shifts through all gears when warm.
Specific for this vehicle
Test ALL gear shifts when gearbox is fully warmed up
Drive for 20+ minutes, then test 1st-to-2nd and 2nd-to-3rd shifts multiple times. Any crunching indicates synchro wear. Early cars (2020-2021) more susceptible.
Inspect front grille and windscreen for damage
Check for cracks in the plastic lower grille (€400-500 to replace). Look for windscreen chips or cracks. Original windscreens are thin and chip easily.
Check for interior rattles on rough roads
Listen for rattles from A-pillars, glovebox, dashboard, door cards. Not a mechanical issue but indicates build quality.
Verify boost builds properly under hard acceleration
Accelerate hard from low RPM in 2nd/3rd gear. Boost should build smoothly and linearly. Loss of power or hesitation indicates boost sensor failure.
Look for signs of track use or modifications
Check for aftermarket parts, unusual tire wear, upgraded brake pads. Ask about track use - not necessarily bad but affects wear on consumables.
Inspect rear differential and transfer case for leaks
Look under the car for oil leaks around transfer case rear output shaft and rear differential. Bearing failures reported around 68,000 km.
Verify radar sensor recall (2020-2021) completed
Contact Toyota with VIN to confirm recall XGG08 completed. Affects pre-collision system initialization.
Check service records for transfer case and diff fluid changes
Toyota recommends halving service intervals if car used on track. Verify fluids changed appropriately.
Pre-collision system (PCS) malfunction (May 2020 - Aug 2021)Verify completed
Contact Toyota dealer with VIN to verify recall XGG08 has been completed. The radar sensor recall affects pre-collision system operation - if not initialized properly, the system may be inoperative with no warning indicator to the driver. Inspection takes 30 minutes; remedy takes approximately 1 hour.
Warranty Status
Factory warranty (3 years / 60,000 miles)Check specific car
Extended warranty (10 years / 100,000 miles)If serviced at Toyota dealer
Track day usageDoes NOT void warranty
The GR Yaris comes with a standard 3-year/60,000-mile warranty. If serviced by a Toyota dealer every 10,000 km (6,000 miles), the car receives an additional 12 months of warranty every year, extending coverage up to 10 years or 100,000 miles total. Uniquely, using the GR Yaris for track days does NOT void the warranty - Toyota designed this car to be driven hard. However, modifications or tuning will void warranty coverage.
This report is for informational purposes only and does not constitute professional advice. Estimates may be inaccurate. Always have a qualified specialist inspect the vehicle before purchase. We accept no liability for decisions made based on this information.