Toyota Hilux manual: key points

Despite the fact that the manufacturer takes all possible measures to control the quality of the cars it produces and the auto parts used, each model has components or assemblies, problems with which can only be identified during the operation of the car. As a rule, such malfunctions are caused by the poor quality of the materials used, manufacturing defects, design miscalculations, as well as a poorly debugged or dishonest car assembly process.

Toyota Hilux manual: key points

Also, there is a whole list of malfunctions, the occurrence of which is associated with the neglect by the car owner of the features of the operation and maintenance of the car or any of its systems. Below are the most likely malfunctions that you may encounter while owning a car of this model, the specified period of production and modification. If necessary, the description of the malfunction contains methods for correcting the problem and recommendations for preventing its reoccurrence. If the problem node was upgraded during the production process, the catalog numbers of the parts of the new sample are given.

Also, the chapter may mention information about official service companies or the availability of special service bulletins (Technical Service Bulletin (TSB) – an official document issued by the manufacturer for service centers and containing information about a possible problem with a particular model and ways to eliminate it), which will be useful in communicating with official representatives of the manufacturer when resolving disputes regarding the warranty service of your car. It should be borne in mind that the occurrence of a particular malfunction is not necessarily specific to your car (like Toyota Hilux bolt pattern, for instance) and, conversely, too frequent breakdowns of the same unit or unit on your car may not be a typical malfunction of this model, but may be the result of using non-original low-quality auto parts, as well as car maintenance by specialists who do not have sufficient qualifications or experience in car repair and diagnostics.

Turbocharger whine (pre-2011 models)

When operating a car at low outdoor temperatures and storing it outside heated rooms, some car owners note the appearance of a whistle (and in some cases howl) from the engine compartment when the accelerator pedal is pressed and the engine crankshaft speed is over 1900-2000 rpm. The reason for this whistle is a decrease in the cross section of the pipe of the forced crankcase ventilation system due to its freezing. If ice enters the turbocharging system, it can cause damage to the turbocharger itself, as the blows of breaking pieces of ice cause significant damage to the compressor plates during its operation. A sign of a turbocharger failure will be a loss of traction and increased fuel consumption. Since the malfunction became widespread, TOYOTA upgraded the forced crankcase ventilation system and issued the corresponding service bulletin No. EG-0105T-1111 dated 12/22/2011 (No. EG-0051T-0612 dated 06/11/2012), according to which on pre-facelift Toyota Hilux (KUN15, KUN25, KUN26), in the event of a customer request regarding the appearance of whistling noise in the turbocharger, it is prescribed to replace the turbocharger and install a coolant bypass heater.

Toyota Hilux manual

Brake pedal rattle (models since 2011)

Many owners of restyled models pay attention to the appearance of extraneous noise (knocking, rattling) in the front of the car when driving on small bumps or gravel roads. In addition to possible malfunctions in the front suspension, the lateral play of the brake pedal can be the cause of this noise. The reason for the backlash is the excessive length of the central bushing of the upper axle of the brake pedal, which has been installed since 2011 in order to prevent wear on the side bushings of the pedal.

Incorrect operation of the car radio

A fairly common malfunction of new cars is the incorrect operation of the audio system, which consists in spontaneous turning off and on of the system, no sound, “freezing” of the interface, etc. Most often, failures are observed when the system is in playback mode of recordings from external drives (AUX, Bluetooth) or in CD playback mode. The operability of the system is restored only when the ignition is turned on again and is of a short-term nature. Most likely, the malfunction is related to the incorrect version of the audio system software, but at the moment the malfunction is eliminated by replacing the audio system (replacement is carried out as part of the warranty service).

Knocks in the front suspension

Knocks, squeaks and thuds in the front suspension appear when driving on rough roads, overcoming artificial obstacles, etc. Over time, the knock becomes more pronounced. The most common cause of these knocks is the wear of the bushings of the front suspension anti-roll bar. It is recommended to replace the old bushings with upgraded ones (if any) or with polyurethane ones (for example, from Tochka Opory).

Creaking in the rear suspension

Over time, when driving on uneven surfaces, a strong squeak can be heard from the rear suspension. As a rule, the occurrence of a squeak is preceded by driving in rainy weather / overcoming fords / riding in sand or heavy mud. The creaking may pass a few days after the onset. The most common cause of these noises on models with leaf spring suspension is friction between the individual leaf springs when the suspension is actuated. Also, the situation is aggravated by the sticking of foreign particles on wet leaf springs. This feature of the suspension should not be attributed to a malfunction and it is recommended to reduce the interval for checking the rear suspension and periodically service the springs (wash the springs with a high-pressure water jet (when the rear suspension is not loaded) and lubricate the surface of the sheets with graphite grease). Note: in case of strong and regular squeaks in the rear suspension, the occurrence of which does not depend on weather and operating conditions, make sure that:

  • – there is no displacement of the spring sheets relative to each other and all the spring sheets are intact;
  • – anti-creak pads are installed between the sheets of springs. 

Other common problems

Shocks at the beginning or during the movement of the car

Over time, many owners pay attention to the appearance of a single knock (thud or click) when starting the car. The same sound can be heard while the car is moving after dropping the accelerator pedal and then pressing it sharply (models with automatic transmission). On models with manual transmission, a knock is heard when you throw the clutch pedal. If the fault is ignored for a long time, severe vibration may occur. The most likely cause of this knock is the backlash of the cross of the cardan shaft due to bearing wear. The malfunction is also dangerous because for a long time it does not manifest itself in any way, except for a knock and therefore is often ignored. However, during this time there is a gradual destruction of the cross bearings and their seats. The appearance of strong vibration will already indicate the beginning of the destruction of the fasteners and joints of the cardan shaft, which will soon lead to the complete breaking off of the cardan shaft and very serious damage to the vehicle’s transmission. Therefore, when the described symptoms appear, it is necessary to check the condition of the cardan shafts and their crosses. Perhaps they need to be injected, the crosses replaced, or the driveshaft replaced.

A rumble from the side of the wheels while the car is moving

A common cause of a hum while driving is a failed wheel bearing. Also, with destroyed wheel bearings, a strong rattle can be observed from the side of the wheels, and in some cases the vehicle is pulled to the side. Due to the design of the suspension, the bearings are changed only as an assembly with the wheel hubs.

Note: To check the condition of the wheel bearing, mount the wheels in the straight direction of the vehicle, hang the wheels, and by moving the wheel as shown in the figure, check that there is no noticeable play in the wheel bearing. See details here

Problems with 1KD-FTV (3.0L Common Rail) 2KD-FTV (2.5L Common Rail) Engines

The KD series engines were developed from the 1KZ-TE engine, which was known as a very reliable unit and did not cause much trouble to owners and mechanics. The main difference between the new engines is the Common Rail storage fuel system and more advanced elements of the toxicity reduction system. The main problems are connected with them. Particulate filter Modern engine modifications, in addition to the catalytic converter, are equipped with a particulate filter, which periodically undergoes a burn-in procedure during operation and is self-cleaning. The particulate filter burns best on the highway during long-term driving under load at a constant speed. If self-cleaning does not occur, then due to strong resistance at the outlet, the car loses traction. In this case, it is recommended to clean the filter with compressed air. If this does not help, then the filter may be damaged and need to be replaced. It should also be noted that after burning the particulate filter, an increase in the engine oil level is possible. And after the burning procedure, it is better to completely replace the engine oil. This recommendation is mandatory for trucks with a particulate filter, such as Toyota Dyna from 2010.

Toyota Hilux manual

Exhaust Gas Recirculation (EGR), Air Supply System

The recirculation system is designed to reduce the content of Nox in the exhaust gases, which is achieved by reducing the temperature of the exhaust gases in the combustion chamber when they are partially returned to the intake. In the case of using low-quality fuel or due to wear of the fuel equipment, a lot of unburned particles remain in the exhaust gases, which are deposited in a thick layer on:

• EGR valve,
• dampers of the system for changing the geometry of the intake manifold,
• and the intake manifold, the engine stops breathing, the exhaust turns black, the thrust drops.

If traces of oil are visible in the intake system, and even more oil can be drained from the aftercooler (intercooler), then the culprit is a faulty turbocharger. Regular preventive cleaning of the above elements is recommended (every 50,000 – 60,000 km), but if the elements of the air intake system become dirty too quickly, then the cause should be sought in the fuel supply system or in the turbocharging system. Some car enthusiasts and auto mechanics practice blanking off the EGR valve by installing a stainless steel plate. In this case, one must take into account the fact that the engine stops working at the modes specified by the manufacturer, which leads to the appearance of fault codes (this is especially true for systems with an EGR valve position sensor from 08.2004).

High pressure fuel pump

The problematic place of any non-new diesel engine is the high pressure fuel pump (high pressure fuel pump), the resource of which directly depends on the quality of the diesel fuel used. Owners are most likely to encounter the problem of a breakdown of the injection pump when they refuel their car at random gas stations of unknown companies, which often sell low-quality fuel with a high sulfur content, which not only does not meet environmental standards, but also leads to pollution and increased wear of injection pump parts . The most common symptoms of a malfunctioning injection pump include “floating” idle speed and difficult starting of a hot engine. Also, an early replacement or repair of the high-pressure fuel pump is foreshadowed by unpredictable engine shutdowns while driving (the engine can stall both on XX and when you press the accelerator pedal). Troubleshooting is possible either by replacing the injection pump with a new one, or by restoring the old pump with the replacement of worn (broken) parts.

Operation of the low oil pressure indicator, as a result of the problem of low-quality fuel injector washers

On some vehicles (see below), the following problem was fixed – the low oil pressure indicator worked intermittently. This case was recognized by the manufacturer as a warranty, a revocable company was produced. The warranty covered the following vehicles: HiLux manufactured from 10/2006 to 04/2008, with VIN: KUN26 FZ29G# 09003162 to 09022896.

The problem was associated with the use on the conveyor of low-quality sealing washers for nozzles (nozzle seats), which were originally copper in color (copper). These washers are made of soft metal, which is crushed when the nozzles are tightened. The material was chosen to achieve better heat dissipation from the injector nozzle body in order to reduce the effect of temperature on fuel delivery. For some time, low-quality washers were supplied to the conveyor, which burned out. In this case, there was a breakthrough of gases under the valve cover, an emulsion of soot and oil clogged the oil lines. As a result, there was an “oil starvation”, which led to costly repairs.

The characteristic signs of this malfunction are: strange behavior of the low oil pressure indicator, abundant black carbon deposits on the valve cover and oil receiver, inability to remove the nozzle. The correct washer should be white. This part number is 11176-30011. Uneven wear of the brake pads, souring of the brake caliper pistons and reduced service life of the brake system elements. The most common cause of reduced braking performance and service life of brake system components is failure to follow the manufacturer’s recommended brake fluid change intervals. It is important to replace it at least once every two years. See the Maintenance chapter for more details. Note: For part numbers of brake repair kits, see the Consumable Parts Catalog chapter.

Take it on the road / hand it over to the mechanic

The publication contains an operating manual, detailed information on vehicle maintenance, diagnostics, repair and adjustment of engine system elements (including gasoline and diesel engine control systems, diesel engine fuel system, diesel engine turbocharging, diesel engine exhaust emissions reduction system , ignition, starting and charging), elements of mechanical (manual transmission) and automatic (automatic transmission) transmissions, transfer case (including the all-wheel drive connection system), front and rear (including the forced rear differential locking system) gearboxes, brake elements systems (including anti-lock braking system (ABS), emergency braking system (BA), traction control (TRC) and vehicle stability control (VSC)), steering, suspension, bodywork, air conditioning and ventilation systems.

Instructions are given for diagnosing 13 electronic systems: control of gasoline and diesel engines, automatic transmission, ABS, VSC, air conditioning, SRS, remote central locking, power windows, Multivision, immobilizer, cruise control and Multiplex. 434 fault codes P0, P1, P2, C0, C1, U0, B1, B2, Flash are described in detail; conditions for their occurrence and possible causes. 166 detailed wiring diagrams (102 systems) are presented for various configuration options, a description of most of the electrical equipment elements. Information for professional diagnostics and repair of electrical equipment of various vehicle systems is presented in the MotorData online diagnostic system.

Using quick clicks on interactive links, you can solve the problem faster and save time. Possible malfunctions and methods for their elimination, mating dimensions of the main parts and their permissible wear limits, recommended lubricants, working fluids and catalog numbers of consumable spare parts necessary for maintenance and the most demanded repairs, sizes of recommended tires and disks are given. The presented typical malfunctions of Hilux models and how to eliminate them will help you when operating the car.

The book will be useful for both beginners and advanced car owners, as well as car repair and diagnostic professionals. The car owner will find useful: operating instructions, maintenance (with frequency and necessary materials), malfunctions that are most typical for this car, a catalog of the most frequently requested spare parts, instructions for self-repair.

Professionals will benefit from: complex repair operations, allowable part sizes, diagnostic data and detailed electrical equipment diagrams. In addition to essential assistance in self-repair, the books of the Professional series can help you out on the road if you have to use the services of a car service that is unfamiliar or unfamiliar with the features of your car model. When giving the car to the service station, leave our book in the car, and in case of any difficulties, the mechanic will be able to use it, which will greatly speed up the repair of your car. High-quality presentation of the material allows you to reduce the time of car maintenance and make it more efficient.