Engines Market

Toyota Hilux 2.5 D-4D Specialists

Toyota Hilux 2.5 D-4D Engine Replacement Compare Prices & Get Quotes

Get quotes today from trusted UK Toyota Hilux 2.5 D-4D engine specialists. Compare prices on reconditioned, rebuilt and used 2KD-FTV engines with warranty - supply and fit available nationwide.

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Toyota Hilux 2.5 D-4D Engine
from£2,200 to £3,600
  • Usedfrom £1,400
  • Reconditionedfrom £2,200
  • Common codes2KD-FTV
Toyota hilux 2.5 D-4D Used Engine — 2KD-FTVToyota hiluxUsed Engine — 2KD-FTVToyota hilux 2.5 D-4D Reconditioned Engine — 2KD-FTVToyota hiluxReconditioned Engine — 2KD-FTVToyota hilux 2.5 D-4D Rebuilt Engine — 2KD-FTVToyota hiluxRebuilt Engine — 2KD-FTV

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How it works

3 Simple Steps to Finding the Right Replacement Engine

Clear information first, then the right engine and specialist for your exact vehicle.

Variant History

Toyota Hilux 2.5 D-4D Engine History & Specs at a Glance

The 2.5 D-4D brought Toyota's proven common-rail diesel technology to the Hilux range, offering a balance of power, torque and fuel efficiency that made it a favourite among farmers, builders and off-road enthusiasts. Powered by the 2KD-FTV engine, it delivered strong low-end pulling power ideal for heavy-duty work and towing.

Toyota Hilux 2.5 D-4D
  1. 2001

    2.5 D-4D introduced with sixth-generation Hilux; 2KD-FTV 2.5-litre common-rail diesel, 88bhp (66kW), 192Nm torque; five-speed manual transmission

  2. 2004

    Seventh-generation Hilux launched; 2KD-FTV carries over with 102hp (75kW), 260Nm torque

  3. 2006

    More powerful 2KD-FTV variant introduced; 120hp (88kW), 260Nm torque

  4. 2007

    High-output 2KD-FTV with VNT turbo: 144hp (106kW), 343Nm torque; six-speed manual transmission

  5. 2011

    Euro V compliance update; 2WD models gain 24hp increase through variable nozzle turbocharging and new injectors; 144hp, 343Nm

  6. 2015

    2.5 D-4D production ends; replaced by 2.4-litre GD-series diesel

Every engine fitted to the Toyota Hilux 2.5 D-4D is covered below, with UK rebuilt pricing and known failure points.

Engine Codes & Pricing

Toyota Hilux 2.5 D-4D Engine Codes Specifications & Replacement Cost

Find your exact engine code, specs and UK replacement cost guide.

2KD-FTV — 2.5L D-4D Turbo Diesel (2001-2015) engine

2KD-FTV — 2.5L D-4D Turbo Diesel (2001-2015)

Power Output
88-144hp (66-106kW) depending on variant; 192-343Nm torque
Years Fitted
2001-2015 (Hilux VI and VII)

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Common Problems

Toyota Hilux 2.5 D-4D Engine Problems Repair Cost vs Replacement

The 2KD-FTV engine powering the Toyota Hilux 2.5 D-4D is renowned for its durability - many units exceed 200,000 miles with proper maintenance. However, age, mileage and heavy-duty use bring several well-documented failure patterns. Rebuilt engines through EnginesMarket include upgraded components addressing the original failure points, plus a minimum 12-month unlimited-mileage warranty.

Common failure points and repair options

Fuel Injector Failure

Affected
Toyota Hilux 2.5 D-4D (2KD-FTV, all years, particularly 2006-2008)
Typical failure mileage
60,000-120,000 miles
Root cause
The Denso common-rail injectors can fail due to poor fuel quality, injector seal failure or general wear. Faulty copper seals between 2006 and 2008 are a known issue. Symptoms include poor fuel economy, rough idling, hard starting and black smoke from the exhaust.

Repair options

Repair tierDealer priceSpecialist price
Injector cleaning / refurbishment£200-£400£150-£300
Injector replacement (individual)£400-£600 per injector£250-£400 per injector
Injector replacement (full set)£1,600-£2,200£1,000-£1,600
Full Replacement - rebuilt/reconditioned engine£4,000-£5,500£2,800-£3,800 (matches Section 4 rebuilt figure for this code)
Our recommendation
Have injectors tested at the first sign of trouble - catching a failing injector early can prevent damage to the entire fuel system. If two or more injectors have failed, replacing the full set is often more cost-effective than individual replacements. Use only high-quality diesel fuel to extend injector life.
-> Compare rebuilt 2KD-FTV Toyota Hilux 2.5 D-4D engine prices

EGR Valve Clogging & Carbon Build-Up

Affected
Toyota Hilux 2.5 D-4D (2KD-FTV, all years)
Typical failure mileage
40,000-80,000 miles
Root cause
The EGR (Exhaust Gas Recirculation) system recirculates exhaust gases, leaving carbon deposits that build up in the intake manifold, EGR valve and ports. This restricts airflow, causing rough idling, reduced fuel economy, power loss and limp mode when sensors detect poor airflow.

Repair options

Repair tierDealer priceSpecialist price
EGR valve cleaning£200-£350£120-£200
EGR valve replacement£500-£800£350-£500
Intake manifold cleaning (walnut blasting)£400-£800£250-£500
Our recommendation
Regular EGR cleaning every 40,000-60,000 miles is sensible preventative maintenance on the 2KD-FTV engine. Short urban journeys accelerate soot buildup - if your Hilux is used mainly for short trips, consider more frequent cleaning intervals.
-> Compare Toyota Hilux 2.5 D-4D EGR repair costs

Turbocharger Wear

Affected
Toyota Hilux 2.5 D-4D (2KD-FTV, higher-mileage examples)
Typical failure mileage
80,000-150,000 miles
Root cause
The turbocharger operates under high thermal and mechanical stress. Symptoms include loss of boost, whining noise, blue/grey smoke and reduced low-end torque. Common causes include oil starvation (blocked oil feed lines) and worn bearings.

Repair options

Repair tierDealer priceSpecialist price
Turbo actuator / boost control repair£300-£600£200-£400
Turbocharger refurbishment£800-£1,200£500-£900
Turbocharger replacement£1,500-£2,500£800-£1,500
Our recommendation
Diagnose the boost system thoroughly before replacing the turbo - many "turbo failures" are actually boost control issues. Use high-quality engine oil and change it regularly to prevent oil starvation. If the turbo has failed, have the oil feed lines inspected and cleaned to prevent the new turbo from failing prematurely.
-> Compare Toyota Hilux 2.5 D-4D turbocharger repair costs

Don't Let Engine Failure Write Off Your Toyota Hilux 2.5 D-4D

Whether you're dealing with injector failure, EGR clogging or turbocharger wear, a rebuilt 2KD-FTV engine from our network of UK specialists includes upgraded components addressing the original failure points. Every engine carries a minimum 12-month unlimited-mileage warranty, with nationwide delivery and supply & fit options available. Compare quotes today - it's free, fast and obligation-free.

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FAQ

Toyota Hilux 2.5 D-4D Engine ReplacementFrequently Asked Questions

Everything Toyota Hilux 2.5 D-4D owners usually ask before choosing a rebuilt, reconditioned or used replacement engine.

Why Choose Us

Compare Toyota Hilux 2.5 D-4D Engine Prices Today

Whether you need a used 2KD-FTV to keep costs down or a fully rebuilt engine with upgraded components and 12-month warranty, comparing quotes through EnginesMarket is free, fast and carries no obligation. Enter your registration above and let our network of UK Toyota Hilux 2.5 D-4D specialists compete for your business.

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