Engine & fuel system
6 documented faults — symptoms, causes and workshop fixes.
Poor engine performance
Symptoms
Trouble code stored in engine control module (ECM) fault memory: P2121.
Cause
Internal failure of accelerator pedal position (APP) sensor.
Repair
- Replace APP sensor.
Data: Motorwise Workshop. Bulletin 1.
Engine malfunction indicator lamp (MIL) illuminated. Trouble code stored: P0069
Cause
Manifold absolute pressure (MAP) sensor faulty or contaminated with dirt.
Repair
- Fit new MAP sensor.
Data: Motorwise Workshop. Bulletin 7.
Engine runs in limp home mode
Symptoms
Trouble codes stored in engine control module (ECM) fault memory: P0046, P2564.
Cause
Repair
- Fit new turbocharger (TC) control solenoid.
Data: Motorwise Workshop. Bulletin 9.
Rattling noise from engine when idling
Symptoms
Various trouble codes related to EGR system stored in engine control module (ECM) fault memory.
Cause
Carbon deposit build up in intake manifold.
Repair
- Clean carbon deposits from intake manifold.
Data: Motorwise Workshop. Bulletin 10.
Excessive black smoke from exhaust
Symptoms
Poor engine performance.
Cause
Poor sealing of fuel injectors allowing blow-by gas.
Repair
- Renew fuel injector sealing washer.
Data: Motorwise Workshop. Bulletin 11.
Engine malfunction indicator lamp (MIL) illuminated. Possible trouble codes stored: P0671, P0672, P0673, P0674
Cause
Defective glow plugs.
Repair
- Fit new glow plugs.
Parts1 part
| Part | Part number | Qty |
|---|---|---|
| Glow plug | 19850-30030, or 19850-30040 | 4 |
Data: Motorwise Workshop. Bulletin 13.
Brakes
3 documented faults — symptoms, causes and workshop fixes.
Excessive front brake wear
Cause
Brake load proportioning valve incorrectly adjusted causing increased wear to front brakes.
Repair
- Check and adjust brake load proportioning valve.
Data: Motorwise Workshop. Bulletin 4.
ABS warning lamp illuminated
Overview
- Affects
- All models with ABS.
- Fault codes
C0274
Symptoms
Trouble code stored in ABS control module fault memory: C0274.
Cause
Faulty ABS control module.
Repair
- Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
- If no fault(s) found: Replace ABS control module.
Data: Motorwise Workshop. Bulletin 8.
ABS warning lamp illuminated. Trouble code(s) related to front ABS wheel speed sensor(s) stored in fault memory
Cause
Front ABS wheel speed sensor wiring harness damaged.
Repair
- Check for open circuit/high resistance in wiring harness between front ABS wheel speed sensor and ABS control module. Repair/replace component(s) as necessary.
Data: Motorwise Workshop. Bulletin 12.
Steering
1 documented fault — symptoms, causes and workshop fixes.
SRS warning lamp illuminated
Symptoms
Trouble code stored in SRS control module fault memory: B1801.
Cause
Steering wheel spiral cable faulty.
Repair
- Fit new steering wheel spiral cable.
Data: Motorwise Workshop. Bulletin 3.
Clutch & gearbox
1 documented fault — symptoms, causes and workshop fixes.
Air conditioning (AC) inefficient
Cause
AC compressor clutch relay faulty.
Repair
- Replace AC compressor clutch relay.
Data: Motorwise Workshop. Bulletin 2.
Air conditioning & heating
1 documented fault — symptoms, causes and workshop fixes.
Engine runs in limp home mode
Symptoms
Trouble code stored in engine control module (ECM) fault memory: P2008.
Cause
Intake manifold air control solenoid faulty.
Repair
- Fit new intake manifold air control solenoid.
Data: Motorwise Workshop. Bulletin 5.
Wipers & visibility
1 documented fault — symptoms, causes and workshop fixes.
Windscreen wipers intermittent wipe function not working
Cause
Internal failure of combination switch.
Repair
- Replace combination switch.
Data: Motorwise Workshop. Bulletin 6.
Glossary
Technical terms used in this guide.
- ECM
- Engine control module — the electronic unit that manages the engine
- ABS
- Anti-lock braking system — stops the wheels locking under hard braking
- EGR
- Exhaust gas recirculation — feeds some exhaust gas back into the intake to cut emissions
- Trouble Codes
- Standardised fault codes stored by the engine control module, read with a diagnostic tool
- AC
- Air conditioning — the system that cools the cabin
- SRS
- Supplementary restraint system — the airbags and seat-belt pretensioners
- TC
- Turbocharger — the exhaust-driven compressor that boosts engine power
- Accelerator Pedal Position
- The sensor that tells the engine control module how far the accelerator is pressed
- Control Module
- A control unit for one of the vehicle's systems (engine, gearbox, brakes, body, and so on)
- Fault Memory
- The list of stored trouble codes in a control module
- Glow Plugs
- Heaters that help a diesel engine start from cold
- Intake Manifold
- The housing that distributes air into the cylinders
- Manifold Absolute Pressure
- A sensor reading of pressure in the intake — used to work out engine load
- Relay
- An electrically operated switch
- Solenoid
- An electrically operated valve or actuator
- Trouble Code
- A standardised fault code stored by a control module, read with a diagnostic tool
- Wheel Speed Sensor
- A sensor at each wheel used by ABS and stability control
- Wiring Harness
- The bundled cables that carry power and signals around the vehicle
Frequently asked questions
What are the common faults with the Toyota Hilux 2.5 D-4D?
This guide contains 13 workshop bulletins for the Toyota Hilux 2.5 D-4D. Of these, six concern the engine and fuel system and three the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.
Does every Toyota Hilux 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 Hilux 2.5 D-4D faults myself?
Many of them. The documented symptoms can be seen, heard or felt during a test drive.