2.5 / 3.0 D-4D (KD) engine: faults and reliability

• 2.5 D-4D 102-120 hp (2KD-FTV, 2005-2011)

  2005–2011 · 102–120 hp · 2KD-FTV

  With caution

  RAC rates the injector seal failure of the Hilux 2.5 D-4D as a potentially very serious problem and advises that a main dealer inspect the oil pickup before you buy.^[3]

• 2.5 D-4D 144 hp (2KD-FTV, 2011-2016)

  2011–2016 · 144 hp · 2KD-FTV

  With caution

  We have found no faults specific to this version; the documented risk of the 2.5 is the injector seal problem described by RAC, and BilKoll mentions injector wear on both Hilux engines from 2005 to 2015.^[3][10]

• 3.0 D-4D 163-166 hp (1KD-FTV, Land Cruiser J120, 2003-2006)

  2003–2006 · 163–166 hp · 1KD-FTV

  With caution

  Autofácil documents blocked injectors in quite a few units of the first 3.0 D-4D Land Cruisers 120-125, and MotorReviewer places the broken copper seats in the 3.0 from late 2004 to 2007.^[1][11]

• 3.0 D-4D 173 hp (1KD-FTV, Euro 4, Land Cruiser J120, 2006-2009)

  2006–2009 · 173 hp · 1KD-FTV

  With caution

  It coincides in date with the Euro 4 pistons that Toyota-Club.net rates among the least successful, and with the end of the copper seat period; check the oil pickup and rule out heavy towing or engine remapping.^[1][3][5]

• 3.0 D-4D 171 hp (1KD-FTV, Hilux, 2005-2016)

  2005–2016 · 165–171 hp · 1KD-FTV

  With caution

  It brings together the 3.0 risks documented on the Hilux: copper injector seats, injector wear and, according to the sources, turbo actuator failures and EGR blockage.^[2][10]

• 3.0 D-4D 190 hp (1KD-FTV, Euro 5, Land Cruiser J150, 2010-2015)

  2010–2015 · 190 hp · 1KD-FTV

  With caution

  AutoBild calls its Denso injectors an unpredictable risk, although only 4% of its readers reported damage, and Toyota-Club.net notes no problems with the piston of the Euro 5 version; AutoBild considers the 2.8 that replaced it more robust.^[4][5]

Buy: No known serious faults, or they have already been corrected, in this version. With caution: Worth buying if something specific is verified: history, a replaced part or a completed campaign. Avoid: High risk of a serious fault that is hard to check for or prevent.

1. 1Critical severityFrequency: CommonCylinder head and blockCracked pistons in the 3.0 D-4D (1KD-FTV)Some 3.0 D-4D (1KD-FTV) engines with the pistons of the Euro 4 era suffer cracks in one or more pistons, usually between 100,000 and 150,000 km, with loss of power, knocking and smoke. Toyota issued technical bulletins, but according to CarsGuide there was no recall in Australia.Appears at around 100,000 km
2. 2Critical severityFrequency: OccasionalInjectionLeaking copper injector seats and blocked oil pickupThe copper seats under the injectors can stop sealing and let combustion gases into the oil; soot blocks the crankcase oil pickup and, in the worst case, the engine runs out of lubrication. RAC rates it as a potentially very serious problem on the Hilux 2.5 D-4D.
3. 3High severityFrequency: OccasionalInjectionDenso injector failure in the 3.0 D-4D (blockage and wear)The Denso injectors of the 3.0 D-4D can clog or wear out: AutoBild describes them as an unpredictable risk and puts one injector at €1,500-1,800 in Germany, although only 4% of its magazine's readers reported damage on the Land Cruiser 150.Appears at around 70,000 km
4. 4Medium severityFrequency: OccasionalTurboVariable-geometry turbo actuator failure in the 3.0 D-4DThe variable-geometry turbo of the Hilux 3.0 D-4D can stop regulating boost pressure because the electric actuator fails or because soot blocks the geometry, and the car goes into limp mode. Unsealed 4x4 says the actuator is now sold separately, without replacing the whole turbo.
5. 5Medium severityFrequency: OccasionalEmissions controlEGR valve and intake manifold blocked by soot in the 3.0 D-4DIn the Hilux 3.0 D-4D soot can block the EGR valve and the intake manifold passages, with loss of power, rough idle and higher consumption. Unsealed 4x4 notes that this happens to common rail diesels with EGR in general and that the usual fix is to remove and clean.

Severity colours: low, medium, high, critical. How we rate them

Manufacturer

Toyota Motor Corporation

Family

Toyota KD (diésel common rail D-4D), sucesora de la serie KZ

Fuel

Diesel

Displacement

—

Cylinders

4

Fuel system

Turbo

Injection

Common rail

Timing

Timing belt (dry)

Power

102–190 hp

Peak torque

420 Nm

Production

since 2000

Makes

Toyota

Technical data^{[1][6][7][8][9]}

1. 2003–2006

   3.0 D-4D 163-166 hp (1KD-FTV, Land Cruiser J120, 2003-2006)

   The first versions of the 3.0 in the German Land Cruiser J120: 120 kW (163 hp) from January 2003 to October 2004, and 122 kW (166 hp) from October 2004 to November 2006, according to ADAC. Autofácil's data sheets give 343 Nm with the 163 hp and 410 Nm with the 166 hp.^[11][15][18]

2. 2005–2011

   2.5 D-4D 102-120 hp (2KD-FTV, 2005-2011)

   The first 2.5 D-4D of the European Hilux, 2,494 cc: Wikipedia gives 102 hp without intercooler and 120 hp with intercooler, RAC cites 101 hp at launch and 118 hp afterwards, and Autofácil lists the 120 hp version (88 kW and 325 Nm) in 2009. ADAC records only the 144 hp version, from December 2011.^{[3][13][14][17]}

3. 2005–2016

   3.0 D-4D 171 hp (1KD-FTV, Hilux, 2005-2016)

   The Hilux 3.0 produces 126 kW (171 hp) and 343 Nm; Autofácil offers it in 2009 with a five-speed automatic gearbox, and ADAC lists it from December 2011 to August 2016 with Euro 5, particulate filter and timing belt. Wikipedia gives the 2005 version as 121 kW (165 hp) and RAC cites 169 hp, on the Invincible trim only.^{[3][7][13][17]}

4. 2006–2009

   3.0 D-4D 173 hp (1KD-FTV, Euro 4, Land Cruiser J120, 2006-2009)

   The 127 kW (173 hp) and 410 Nm version that ADAC lists from November 2006 to November 2009, with Euro 4 emissions standard, oxidation catalyst, no particulate filter and timing belt; RAC places the power increase and the Euro 4 adaptation in early 2007.^[12][15][19]

5. 2010–2015

   3.0 D-4D 190 hp (1KD-FTV, Euro 5, Land Cruiser J150, 2010-2015)

   The Land Cruiser J150 version of 140 kW (190 hp) and 420 Nm, with Euro 5, particulate filter and timing belt. ADAC lists it from January 2011 to October 2013, and AutoBild says it was fitted until autumn 2015, when the 2.8 D-4D replaced it.^[4][9][16]

6. 2011–2016

   2.5 D-4D 144 hp (2KD-FTV, 2011-2016)

   With the 2011 Hilux facelift the 2.5 rises to 106 kW (144 hp) and 343 Nm. ADAC lists it in Germany from December 2011 to August 2016, with timing belt, common rail injection and particulate filter.^[8][13][14]

• Timing kit

  • Buy part at Autodoc (affiliate link, opens in a new tab)

• Oil filter

  • Buy part at Autodoc (affiliate link, opens in a new tab)

• Air filter

  • Buy part at Autodoc (affiliate link, opens in a new tab)

• Diesel fuel filter

  • Buy part at Autodoc (affiliate link, opens in a new tab)

• Glow plugs

  • Buy part at Autodoc (affiliate link, opens in a new tab)