Potential faults on the Toyota Fortuner 2.5 D4D

Hilux 2.5 problems may also rear its head in the Fortuner 2.5


Previously we highlighted some of the problems experienced with the Toyota Hilux 2.5 D4D. If we consider that the engine of the Hilux 2.5 D4D was actually taken from the Fortuner 2.5, and that the Fortuner is basically a Hilux with a closed load bed and extra seats, then we may come to the conclusion that problems experienced with the Hilux 2.5 may also rear its head in the Fortuner 2.5.

Nonetheless, research has not brought too many complaints to light regarding the Fortuner 2.5, but that does not exempt Fortuner 2.5 vehicle owners from facing any of the known setbacks these D4D engines may bring to the table.

In the Hilux 2.5 discussion, the following possible problem areas were mentioned: Injector issues; Suction control valve issues; Destructive consequence of using low-grade oil, and a Lack of performance in low gears.

It will cost Fortuner vehicle owners only time to read through the following issues. Be aware of these issues because ignorance may cost you more than the time spent reading them.


Injector Issues

The D4D engine commonly presents itself with injector problems and the main reason for this is dirty diesel being used. Additives are being added to diesel (apart from the Sulphur already in fuel) in order to comply with legislation regarding harmful emissions. These additives create sticky deposits in the fuel system and whenever these deposits (even in miniature quantities) find their way into the injector, you are in for some trouble. Faulty injectors need to be replaced if you don’t want to end up with engine failure.

To prevent this from happening, you can stay clear from the biggest killer of injection systems, namely dirty diesel (such as bio-diesel). Bring your vehicle to your nearest Steves Auto Clinic and have the injectors regularly tested. At Steves Auto Clinic we will apply a reputable injector cleaner and also replace your vehicle’s diesel injector filter (these should be done at least every 10 000 km if you want to reduce/prevent injector failure). The cost of having these done will far outweigh the costs of replacing broken injectors.

Some vehicle owners actually prefer to have an extra inline diesel filter and a water trap (connected in series to the already present filter) installed in order to give extra protection to those sensitive injectors. One can never be too safe, can you? Steves Auto Clinic, at the request of vehicle owners, can assist in this regard.


Suction Control Valve

Does your 2.5 D4D, while at cruising speed, all of a sudden lose power and you hear a tremendous noise as if a bearing broke inside the engine? This may be a cause for much concern and you may wonder what the problem is and what needs to be done! If you had injectors replaced, then you have to make sure that the suction control valve (SCV) is also replaced. The SCV gets clogged, no thanks to dirty diesel being used. As mentioned in the previous point, it may be wise to install a second (additional) filter in order to minimise the risk of particles slipping through the original filter and entering the SCV. Professional and friendly technicians at Steves Auto Clinic may assist you in both of these aspects.


Low Grade Oil Being Used

This is a common problem, and this tendency should be avoided. As in the case of any of the D4D engines, be assured that you vehicle’s engine will meet a painful death at the hand of low grade oil being used. Using low grade oil will result in an excess of heat building up due to poor friction. This in turn will result in carbonisation and supply blockages (as seen in the oil pick up below). If this ever happens, be sure to embrace yourself for an engine replacement because sludging to this extent can never fully and properly be cleared from the oil galleries.

Low Grade Oil


It is good practice, if you want to prevent the occurrence of this, to take your vehicle to a reputable workshop – such as Steves Auto Clinic – and have the injectors and diesel pump flow and pressure characteristics checked. This ought to be done every 60 000 km, to be on the safe side.


Little Performance In Low Gears

Any issues with regard to your vehicle being sluggish in low gears? The Fortuner 2.5 puts out the same amount of torque (343 Nm) as the more powerful 3.0 D-4D but the lack in power (106 kW) can be felt when pulling away, with quite a bit of turbo lag especially when mated with the 4 speed auto. There is however a solution if your vehicle experience this lack in power. Steves Auto Clinic excels in helping you to get more torque from your Toyota, so put that vehicle of yours in gear and let its wheels find a way to one of our workshops where well-trained technicians will assist you with the installation of a Unichip of your choice. A lot of great feedback has been given from Fortuner owners who chipped their vehicles. Having your vehicle chipped will increase its torque but it may also improve its fuel consumption dramatically.

Apart from the previously mentioned issues that should be taken notice of, two additional problem areas has been identified that are Fortuner specific. We know of many owners complaining about the Fortuner’s inferior suspension. Apparently Fortuner owners who love camping and do a lot of towing, find the suspension to be very hard. It has been suggested that the Fortuner’s handling would greatly improve with the installation of upgraded shocks. This is surely something that may be considered, and we are the right people to assist you with this.

Finally, there are complaints about the Fortuner’s stiff clutch and that the clutch start to fail round about 80000 km. May this be a town-driven Fortuner phenomenon? Most owners who made mention of this type of failure uses their Fortuners in city traffic; few complaints in this regard have come from owners driving their Fortuners in the countryside. If it is typical of the Fortuner to have a heavier clutch that do not last that long, then this should be mentioned in order to allow Fortuner owners to make informative and preventative decisions.

Whenever you think that any of the issues mentioned in this article are rearing its head in your vehicle, then do the right thing and visit an SAC branch near you – we will quickly and professionally address any of these faulty issues.


Related Articles:
A few potential faults on the Toyota Hilux 2.5 D4D
My Toyota Hilux 3.0 D4D and the setbacks I may encounter as its owner!
Unichip Plug & Play | Toyota Hilux 2.5 & 3.0 D4D Uni chip Performance chips


Within the above article, potential problems, causes and fixes have been identified as founded on the experience of vehicle owners and repairers, online sources such as discussion blogs, technical service bulletins and SAC experience. This information is provided solely for reference purposes. SAC strictly instruct readers that only properly qualified individuals should carry out repairs and/or modifications on your vehicles. It should also be made clear that the number of times an item is identified within this discussion should by no way be seen as an indicator of a model’s reliability or the frequency with which they may occur. Two of the exact same vehicles, owned by tow entirely different owners, driven in entirely different ways and on different terrains, and looked after in their own unique ways, will each behave differently. As mentioned, this information is provided solely for reference purposes but we hope – in the process of doing so – to empower you with relevant information which may enable you to make informative decisions whenever you experience any of the mentioned setbacks.