Toyota2001–2007Technical specifications

Hiace PowerVan 2.5 D-4D: Technical specifications

Workshop data for the 2.5-litre diesel (engine code 2KD-FTV). Covers engine, fluids, brakes, service, torques and air conditioning: the figures to check before a job or a parts order.

Common faults & fixes

Summary

Match the engine code (2KD-FTV) to the vehicle before ordering parts or applying these figures.

Vehicle specifications

Overview

Make: Toyota
Model: Hiace PowerVan
Years: 2001–2007
Fuel: Diesel
Engine code: 2KD-FTV

Performance & efficiency

Power: 65 kW (88 hp)
Engine size: 2,494 cc
Cylinders: 4 · DOHC
Compression ratio: 18.5:1

Fluids & capacities

Engine oil (with the filter): 7.3 litres

All 104 specifications below

Engine & identification

Vehicle identification

No. of cylinders Type	4/DOHC
Capacity cc	2494
Compression ratio :1	18,5

Injection system

Pump type	Common rail
Nozzle opening pressure - new/used bar	159-171/154-166
Crankshaft position (CKP) sensor/engine speed (RPM) sensor Ohm	2,065-3,225
Injector Ohm	2,5-3,1
Intake air temperature (IAT) sensor Ohm/°C	2211-2649/20

Injection sequence

The injection sequence for the Toyota Hiace PowerVan 2.5 D-4D (2001–2007) is 1-3-4-2.

Injection sequence	1-3-4-2

Valve clearances

Valve clearances for the Toyota Hiace PowerVan 2.5 D-4D (2001–2007) are 0,20-0,30 mm inlet and 0,35-0,45 mm exhaust, measured cold.

Valve clearance - INLET mm	0,20-0,30 cold
Valve clearance - EXHAUST mm	0,35-0,45 cold

Engine oil & fluids

Engine oil

The Toyota Hiace PowerVan 2.5 D-4D (2001–2007) takes 7.3 litres of engine oil with the filter.

See the reference table for the complete engine oil entries and their conditions.

Manual gearbox

The manual gearbox has a listed capacity of 2.0 litres. The specified oil is SAE 75W-90, with classification GL-4/5.

Coolant

The listed total cooling-system capacity is 10.0 litres.

Grades, filling conditions and capacities

Lubricants and capacities — complete reference
Preferred engine oil
Ambient temperature range	All temperatures
Engine oil grade SAE	5W-30
Engine oil classification API/ACEA	CF/B1, B3
Engine oil options
Ambient temperature range	-18°C➞
Engine oil grade SAE	10W-30
Engine oil classification API/ACEA	CF/B1, B3
Ambient temperature range	-12°C➞
Engine oil grade SAE	15W-40
Engine oil classification API/ACEA	CF/B2, B3
Ambient temperature range	-7°C➞
Engine oil grade SAE	20W-50
Engine oil classification API/ACEA	CF/B2, B3
Engine with filter(s) litres	7.3
Other lubricants and capacities
Manual transmission oil grade SAE	75W-90
Manual transmission oil classification	GL-4/5
Manual transmission litres	2.0
Automatic transmission fluid Type	Dexron II/III
Automatic transmission (drain & refill) litres	1.6
Automatic transmission (dry fill) litres	7.2
Differential oil grade - rear SAE	90W
Differential oil classification - rear	GL-5
Differential rear litres	1.2
Cooling system - total capacity litres	10.0
Brake fluid Type	DOT 3
Power steering fluid Type	Dexron II/III
Power steering fluid litres	0.8

Brakes & wear limits

Brake disc thickness

Brake discs on the Toyota Hiace PowerVan 2.5 D-4D (2001–2007) are replaced at a minimum thickness of 26 mm (ventilated) front; the rear brake drums are replaced at a maximum diameter of 272 mm.

Minimum disc thickness for replacement - ventilated Front	26 mm
Maximum drum diameter for replacement Rear	272 mm

Brake disc and drum dimensions

Minimum pad thickness Front	1 mm
Minimum shoe thickness Rear	1 mm
Parking brake travel No. of notches	4-7

Service & electrical

Tuning and emissions

Idle speed rpm	700±50
Oil temperature °C	80
Water temperature °C	75-85
Governed speed range - for smoke test rpm	4500-4700
Maximum time at governed speed secs	1,0
Test mode A/B	B
Probe type 1/2	1
Conditioning Accelerations/rpm	3
Smoke opacity - EU limit m-1 (%)	3,00 (73)
Smoke opacity - homologation value m-1 (%)	2,50 (66)

Starting and charging

Battery V/RC(Ah)	12
Maximum cranking amps A	180
Alternator output A/V/rpm	70/12/-

Service checks and adjustments

Compression pressure bar	27
Oil pressure bar/rpm	2,2/3000
Radiator cap bar	1,10
Thermostat opens °C	80-84
Drive belt tension - alternator/PAS/AC mm	196-392

Glow plugs

Glow plug nominal rating V/A	12
Glow plug activation time secs	2,3

Tightening torques

Cylinder head bolt torque

The cylinder head bolts on the Toyota Hiace PowerVan 2.5 D-4D (2001–2007) are tightened in 4 stages: 40 Nm, then 85 Nm, then 90°, then a final 90°.

Cylinder head
Tighten	40 Nm
Tighten	85 Nm
Tighten	90°
Tighten	90°

Cylinder head
Cylinder head instructions	—
View more information	—
Other engine tightening torques
Main bearings Renew bolts/nuts	—
View more information	—
Main bearings Stage 1	50 Nm
Main bearings Stage 2	90°
Big end bearings Renew bolts/nuts	—
View more information	—
Big end bearings Stage 1	35 Nm
Big end bearings Stage 2	90°
Sump bolts	16 Nm
Sump drain bolt	34 Nm
Flywheel/driveplate	178 Nm
Clutch pressure plate	19 Nm
Crankshaft pulley/damper centre bolt	365 Nm
Camshaft sprocket/gear	98 Nm
Camshaft carrier/cap	19 Nm
Inlet manifold to cylinder head	29 Nm
Exhaust manifold to cylinder head	52 Nm
Exhaust downpipe to manifold	43 Nm
Water pump	13 Nm
Injector/clamp	21 Nm
Injector pipe unions	33±2 Nm
Fuel/injection pump sprocket/gear	64 Nm
Fuel/injection pump flange	31 Nm
Fuel/injection pump mounting	21 Nm
Glow plugs	13 Nm
Crankshaft position (CKP) sensor/engine speed (RPM) sensor	8 Nm
Engine coolant temperature (ECT) sensor	20 Nm
Engine oil pressure switch	15 Nm
Chassis tightening torques
Steering wheel	50 Nm
Steering track rod end	91 Nm
Brake disc to hub Front	64 Nm
Brake caliper/carrier to hub Front	123 Nm
Road wheels	102 Nm

Air conditioning

No. of AC service connectors	2
Air conditioning restrictor type	Expansion valve
Compressor clutch/magnetic coupling	Yes
Compressor variable displacement solenoid	No
Air conditioning refrigerant Type	R134a
Air conditioning refrigerant quantity grams	550±30
Air conditioning oil group	PAG
Air conditioning oil Type	Dens Oil 8
Air conditioning oil quantity cm³	—
Air conditioning oil viscosity ISO	46

Frequently asked questions

What is the injection sequence of the Toyota Hiace PowerVan 2.5 D-4D?

The injection sequence for the Toyota Hiace PowerVan 2.5 D-4D (2001–2007) is 1-3-4-2.

How much oil does the Toyota Hiace PowerVan 2.5 D-4D take?

The Toyota Hiace PowerVan 2.5 D-4D (2001–2007) takes 7.3 litres of engine oil with the filter. See the reference table for the complete engine oil entries and their conditions.

What are the valve clearances for the Toyota Hiace PowerVan 2.5 D-4D?

Valve clearances for the Toyota Hiace PowerVan 2.5 D-4D (2001–2007) are 0,20-0,30 mm inlet and 0,35-0,45 mm exhaust, measured cold.

What is the cylinder head torque for the Toyota Hiace PowerVan 2.5 D-4D?

The cylinder head bolts on the Toyota Hiace PowerVan 2.5 D-4D (2001–2007) are tightened in 4 stages: 40 Nm, then 85 Nm, then 90°, then a final 90°.

What is the minimum brake disc thickness for the Toyota Hiace PowerVan 2.5 D-4D?

Brake discs on the Toyota Hiace PowerVan 2.5 D-4D (2001–2007) are replaced at a minimum thickness of 26 mm (ventilated) front; the rear brake drums are replaced at a maximum diameter of 272 mm.