The 2.2 D4D engine is one of Toyota’s most common engines in European models like the RAV4, Avensis and their other crossovers. And while excellent reliability is always expected from Toyota, you have to realize that simply the fact this is a diesel engine brings on a whole new plethora of possible issues.
In this article, I will uncover all the common Toyota 2.2 D4D engine problems and what you can expect if you’re buying one on the used car market.
First, we are going to cover the specs of the Toyota 2.2 engine, then we are going to discuss the Toyota 2.2 D4D engine problems and see what troubles this engine, and lastly we will cover the common applications of this engine. So, let’s get started.
Basic Toyota 2.2 D4D Engine Specs
Now let’s first learn some of the specs of the 2.2L engine. For those who don’t know, this engine was the 2.2L 2AD-FHV.
The 2AD-FHV is a turbo diesel engine that was produced by Toyota between 2005 and 2015. This engine was included in a lot of Toyota models, which we are going to cover later on.
The important thing to note is that this engine is an inline-4 engine. This means that the engine has four cylinders. The block itself, as well as the cylinder head, are made out of aluminum.
The head design is DOHC, in other words, this engine has a dual overhead camshaft layout and four valves per cylinder. In total, there are 16 valves.
This engine uses common rail fuel injection, as well as turbocharging. This turbo that is used in the model is a variable geometry turbo. It means that it can adjust itself on the fly without suffering turbo lag.
On top of that, you also have EGR and DPF systems. These systems are mandatory because the vehicle had to be Euro IV compliant in order to sell in the European markets.
But here are the most important specs of this engine.
- Configuration: inline-4
- Displacement: 2.2L
- Cylinder Bore: 86 mm
- Piston Stroke: 96 mm
- Block & Head Material: Aluminum
- Head Design: DOHC, 4 valves per cylinder
- Compression Ratio: 15.7:1 or 15.8:1
- Turbocharger: Yes
- Horsepower: 177 hp (132 kW)
- Torque: 400 N-m (295 lb-ft)
Common Toyota 2.2 D4D Engine Problems
Common problems with the Toyota 2.2 D4D engine include:
- Cylinder Head Deformations and Head Gasket Failures
- High Oil Consumption
- Clogged DPF
- Injector Failures
- Injector Washers Have To Be Replaced
- VGT Turbo Is Prone To Jam
- SCV Valve Failure
- EGR Valve & EGR Cooler Failure
We listed the common problems with the Toyota 2.2 D4D engine, and now we need to further elaborate on these issues and learn more about how serious they are.
This is more than needed in order for you to become a real expert on a particular problem. Only with the proper research, you will be able to tell how serious this problem is based on the symptoms that are shown. So, let’s get started.
Cylinder Head Deformations and Head Gasket Failures
The biggest problem with the 2.2 D4D engine by Toyota is the problem with the cylinder head. The cylinder head is prone to deforming.
This is reportedly caused by overheating. When the engine overheats, the cylinder head gets bent a little bit.
So, the head does not lay flat against the deck of the block. In this case, the head gasket will also fail because the engine is overheated.
Common symptoms of this problem include coolant loss and overheating issues. If the temperatures are rising, and you lose coolant, this is one of the possible causes.
The solution to this problem is rather complex. The head has to be removed and machined. If it’s too tweaked, it would require removing a ton of material and then you will be left with no material. The head gasket will need to be replaced in this case.
So, leaving the car to overheat for quite some time is not something that you want because the repairs can be very expensive.
Now let’s move on to the next Toyota 2.2 D4D engine problems.
High Oil Consumption
High oil consumption is also present in this engine. And this oil consumption reportedly happened very early in the life of the engine. Which is a completely abnormal thing to happen.
The problem was addressed by Toyota, and they replaced the pistons on the faulty engines, but the problem still persisted.
The problem was reportedly patched in 2008 when they released modified parts that were fitted on these engines.
Newer engines do not have this issue with high oil consumption present. Or at least not at that scale as the first couple of model years of these engines.
Another very common problem with the 2.2 D4D engine is the clogged DPF. For those who don’t know, the DPF is the Diesel Particulate Filter.
This is a special filter that is installed in the exhaust, this particulate filter collects the harmful particles and then when it is time to regenerate the driver should drive on the highway at a higher RPM so this process is done correctly.
What people do is that they are not aware of this component. They drive around town without regenerating the DPF and they end up clogging up this DPF.
When clogged, this filter will require manual cleaning with a special machine in order to work properly once again. Or replacement, which can be very expensive to do.
Fuel injector failures are also common on these engines. These engines are using Piezo injectors that are not quite known for their longevity.
And when it comes to diesel engines, you also need to understand that these injectors are some really expensive expendable components.
They are usually good for 150,000 to 200,000 km and once these numbers are reached problems will arise.
They can end clogged up, or they can end up leaking. Both situations are pretty bad. They are also much harder to rebuild, and we actually don’t recommend buying rebuilt piezo-based fuel injectors.
So, if you have problems with some of your injectors, you might need to rebuild them in order to avoid further issues.
Injector Washers Have To Be Replaced
Another thing that many people are unaware of is the injector washers. These special washers are located between the injector and the cylinder head.
These washers have to be replaced every 60,000 km. What 99.9% of the owners do not do. They never replace these washers and the injectors will literally get glues onto the cylinder head with a sort of black tar that accumulates around them.
In these situations, it is a real pain to remove the injectors from the cylinder head without damaging the injector.
That’s why replacing the washers is key if you want to avoid these unfortunate outcomes when you have to destroy an injector to remove it.
Let’s continue with the next Toyota 2.2 D4D engine problems.
VGT Turbo Is Prone To Jam
Another very common problem with the 2.2 D4D engine is the situation when the VGT turbo jams and does not deliver enough power.
The turbo used in this engine uses variable geometry, which means that the turbo is adjusting the flaps on the fly while it is working.
So, these flaps can end up jammed in one position, and this will mean that the turbo will only work in one mode.
This could result in loss of power and also other problems. The solution is to refurbish this turbo or replace it with a new one.
SCV Valve Failure
Another problem that was reported on these 2.2 engines is the SCV valve failure. SCV is short for “Suction Control Valve”.
This valve has the purpose of controlling the fuel pressure in these common rail diesel engines. And whenever this valve fails, you will get some symptoms.
These include check engine light, loss of power, engine stall, and no start issues. Replacing it will solve the issue.
EGR Valve & EGR Cooler Failure
The last problem on our list is the issue with the EGR valve. The EGR is the exhaust gas recirculation valve.
This valve can end clogged up with carbon and requires that you often clean it. If you don’t, the valve will fail.
In addition to this problem, there is an issue with the EGR cooler, this EGR cooler can leak coolant and cause coolant loss.
This was a factory error and these coolers were recalled by Toyota. So, make sure that the car you’re buying either wasn’t affected or had this issue resolved.
Which Models Have The Toyota 2.2 D4D Engine?
- 2005 – 2015 Toyota Avensis
- 2006 – 2015 Toyota RAV4
- 2007 – 2011 Toyota Auris
- 2005 – 2012 Toyota Verso
- 2006 – 2010 Lexus IS 220d
What are Some Common Problems With the Toyota 2.2 D4D Engine?
Common problems include cylinder head warping and head gasket failure, oil consumption, SCV valve failure, VGT turbo failure, injector failure, EGR valve, and EGR cooler failure.
Is The Toyota 2.2 D4D Engine Reliable?
This engine is pretty good. But avoid the early model years since these are more prone to problems. Go for a 2011 or newer model, these engines had many of these common issues patched.