Engine & fuel system
4 documented faults — symptoms, causes and workshop fixes.
Poor idling
Symptoms
Failure to start.
Cause
Engine control module (ECM) software fault.
Repair
- Install upgraded engine control module (ECM) software.
Data: Motorwise Workshop. Bulletin 1.
Poor cold starting
Overview
- Affects
- All models with 1CD-FTV engine code.
- Fault codes
P0380- Remedy
- Software update
Symptoms
Trouble code stored: P0380.
Cause
Defective glow plugs.
Repair
- Check glow plugs, replace as necessary.
- Re-program ECM with modified software.
Data: Motorwise Workshop. Bulletin 2.
Intermittent power loss on acceleration
Exhaust gas recirculation (EGR) valve not operating properly. Fix: re-program with updated software.
Overview
- Affects
- All models.
- Remedy
- Software update
Symptoms
Engine jerking.
Repair steps
- Check air filter, replace if required.
- Check mass air flow (MAF) sensor, replace if required.
- Clean exhaust gas recirculation (EGR) valve and associated parts.
- Re-program ECM with modified software.
Data: Motorwise Workshop. Bulletin 3.
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.
Wipers & visibility
1 documented fault — symptoms, causes and workshop fixes.
Engine misfire under load
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
- EGR
- Exhaust gas recirculation — feeds some exhaust gas back into the intake to cut emissions
- MAF
- Mass air flow — a sensor that measures how much air the engine is breathing
- Control Module
- A control unit for one of the vehicle's systems (engine, gearbox, brakes, body, and so on)
- Glow Plugs
- Heaters that help a diesel engine start from cold
- Re-Program
- Update the software on a control module using the manufacturer's diagnostic tool
- Trouble Code
- A standardised fault code stored by a control module, read with a diagnostic tool
- Recirculation
- Air-conditioning mode that recirculates cabin air instead of drawing in outside air
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, four concern the engine and fuel system and one the wipers and visibility. 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.