Toyota2001–2007

Hiace PowerVan 2.5 D-4D 102 hp: Common faults & known problems

Common faults & known problems

5 known faults documented in workshop bulletins. Of these, two concern the engine and fuel system and one the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Technical specifications

Engine & fuel system

2 documented faults — symptoms, causes and workshop fixes.

Lack of power

Overview

Affects: All models with 2KD-FTV engine code.
Fault codes: P0088P0093
Parts: 1 part

Symptoms

Black smoke from exhaust. Engine speed will not increase above 1000rpm. Engine stalls. Possible trouble codes: P0088, P0093.

Cause

Fuel pump (FP) sticking.

Repair

Replace fuel pump (FP)A.
Secure fuel pump (FP) wiring harnessB.

Parts1 part

Parts listed in the bulletin
Part	Part number	Qty
Fuel pump (FP)	22100-30090	1

Data: Motorwise Workshop. Bulletin 2.

Alternator warning lamp flickers when accelerating/decelerating

Overview

Affects: All models, 2005→.
Remedy: Fit new part

Cause

Engine control module (ECM) internal damage.

Repair

Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
If no fault(s) found: Fit new engine control module (ECM).

Data: Motorwise Workshop. Bulletin 4.

Brakes

1 documented fault — symptoms, causes and workshop fixes.

Brakes squeal

Overview

Affects: All models.

Cause

Replacement brake pads fitted without anti-squeal shims.

Repair

Ensure brake pad anti-squeal shims are fitted.
Replacement shims available separately.

Data: Motorwise Workshop. Bulletin 1.

Air conditioning & heating

1 documented fault — symptoms, causes and workshop fixes.

Low heater output

Sand particles in engine coolant causing thermostat to stick open.

Overview

Affects: All models with 2KD-FTV engine code (→engine No.7203753).

Symptoms

Failure of engine to reach normal operating temperature.

Repair steps

Drain cooling system.
Remove thermostat.
Rinse cooling system with water.
Renew thermostat and seal.
Fill cooling system.

Data: Motorwise Workshop. Bulletin 3.

Wipers & visibility

1 documented fault — symptoms, causes and workshop fixes.

Engine misfire under load

Affects All models with 2.5 Diesel engine.

Cause

Fuel injector sealing washer leaking.

Repair

Renew fuel injector sealing washer.

Data: Motorwise Workshop. Bulletin 5.

Glossary

Technical terms used in this guide.

ECM: Engine control module — the electronic unit that manages the engine
Trouble Codes: Standardised fault codes stored by the engine control module, read with a diagnostic tool
FP: Fuel pump — the pump that supplies fuel from the tank
Control Module: A control unit for one of the vehicle's systems (engine, gearbox, brakes, body, and so on)

Frequently asked questions

What are the common faults with the Toyota Hiace PowerVan 2.5 D-4D?

This guide contains five workshop bulletins for the Toyota Hiace PowerVan 2.5 D-4D. Of these, two concern the engine and fuel system and one the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Toyota Hiace PowerVan 2.5 D-4D have these faults?

No. These are patterns documented across the model by workshops, not predictions for an individual vehicle. Where a fault applies only to certain vehicles or VIN ranges, that is listed with the fault.

Can I check for Toyota Hiace PowerVan 2.5 D-4D faults myself?

Many of them. The documented symptoms can be seen, heard or felt during a test drive.