Toyota1996–2002Technical specifications

Hiace PowerVan 2.4: Technical specifications

Workshop data for the 2.4-litre diesel (engine code 2L). Covers engine, fluids, brakes, service, torques and air conditioning: the figures to check before a job or a parts order.

Common faults & fixes

Summary

Match the engine code (2L) to the vehicle before ordering parts or applying these figures.

Vehicle specifications

Overview

Make: Toyota
Model: Hiace PowerVan
Years: 1996–2002
Fuel: Diesel
Engine code: 2L

Performance & efficiency

Power: 57 kW (77 hp)
Engine size: 2,446 cc
Cylinders: 4 · OHC
Compression ratio: 22.2:1

Fluids & capacities

Engine oil (with the filter): 6.7 litres

All 104 specifications below

Engine & identification

Vehicle identification

No. of cylinders Type	4/OHC
Capacity cc	2446
Compression ratio :1	22,2

Injection system

Fuel/injection pump assembly Make	Denso
Fuel/injection pump assembly Type	VE
Pump type	Rotary
Injector nozzle Make	Denso
Nozzle and holder assembly Part No.	DN4PD57
Nozzle opening pressure - new/used bar	148-156/142-152

Injection sequence

The injection sequence for the Toyota Hiace PowerVan 2.4 (1996–2002) is 1-3-4-2.

Injection sequence	1-3-4-2

Valve clearances

Valve clearances for the Toyota Hiace PowerVan 2.4 (1996–2002) are 0,20 mm inlet and 0,36 mm exhaust, measured hot.

Valve clearance - INLET mm	0,20 hot
Valve clearance - EXHAUST mm	0,36 hot

Engine oil & fluids

Engine oil

The Toyota Hiace PowerVan 2.4 (1996–2002) takes 6.7 litres of engine oil with the filter.

See the reference table for the complete engine oil entries and their conditions.

Manual gearbox

The manual gearbox has a listed capacity of 2.0 litres. The specified oil is SAE 75W-90.

Coolant

The listed total cooling-system capacity is 10.9-12.5 litres.

Grades, filling conditions and capacities

Lubricants and capacities — complete reference
Engine oil options
Ambient temperature range	-29°C➞12°C
Engine oil grade SAE	5W-30
Engine oil classification API/ACEA	CF/B1, B3
Ambient temperature range	-18°C➞38°C
Engine oil grade SAE	10W-30
Engine oil classification API/ACEA	CF/B1, B3
Ambient temperature range	-12°C➞38°C
Engine oil grade SAE	15W-40
Engine oil classification API/ACEA	CF/B2, B3
Ambient temperature range	-7°C➞38°C
Engine oil grade SAE	20W-50
Engine oil classification API/ACEA	CF/B2, B3
Engine with filter(s) litres	6.7
Other lubricants and capacities
Manual transmission oil grade SAE	75W-90
Manual transmission litres	2.0
Automatic transmission fluid Type	Dexron II
Automatic transmission (drain & refill) litres	2.4
Differential oil grade - rear SAE	90W
Differential oil classification - rear	GL-5
Differential rear litres	1.2
Cooling system - total capacity litres	10.9-12.5
Brake fluid Type	DOT 3
Power steering fluid Type	Dexron II
Power steering fluid litres	0.8

Brakes & wear limits

Brake disc thickness

Brake discs on the Toyota Hiace PowerVan 2.4 (1996–2002) are replaced at a minimum thickness of 26 mm (ventilated) front; the rear brake drums are replaced at a maximum diameter of 272 mm.

Minimum disc thickness for replacement - ventilated Front	26 mm
Maximum drum diameter for replacement Rear	272 mm

Brake disc and drum dimensions

Disc runout Front	0,09 mm
Minimum pad thickness Front	1 mm
Minimum shoe thickness Rear	1 mm
Parking brake travel No. of notches	4-7

Service & electrical

Battery

The Toyota Hiace PowerVan 2.4 (1996–2002) uses a 12 V, 80 Ah battery (reserve capacity 150 minutes).

Battery V/RC(Ah)	12/150 (80)

Glow plugs

Glow plugs for the Toyota Hiace PowerVan 2.4 (1996–2002): Beru 688 MJ, Bosch 0 250 202 053 and Lucas/CAV HDS235.

Glow plug activation time secs	2-4
Glow plug - part no. Beru	688 MJ
Glow plug - part no. Bosch	0 250 202 053
Glow plug - part no. Lucas/CAV	HDS235

Tuning and emissions

Plunger travel (pump) mm ABDC	0,5-0,66
View more information	—
Crankshaft position (n = ATDC) °BTDC	—
Adjusting method Engine/Pump	Pointer/Dial gauge
Idle speed rpm	700±50
Idle speed - alternative rpm	AT=800±50
Rated no load speed rpm	5150
Oil temperature °C	80
Idle speed - for smoke test rpm	650-750 AT=750-850
Governed speed range - for smoke test rpm	5100-5150
Maximum time at governed speed secs	1,0
Test mode A/B	B
Probe type 1/2	1
Conditioning Accelerations/rpm	3
Smoke opacity - EU limit m-1 (%)	2,50 (66)

Starting and charging

Maximum cranking amps A	216-264

Service checks and adjustments

Compression pressure bar	19,6-31,4
Radiator cap bar	0,74-1,03
Thermostat opens °C	86-90
Drive belt tension - alternator/PAS/AC mm	7-14

Tightening torques

Cylinder head bolt torque

The cylinder head bolts on the Toyota Hiace PowerVan 2.4 (1996–2002) are tightened in 4 stages: 38 Nm, then 78 Nm, then 90°, then a final 90°.

Cylinder head
Tighten	38 Nm
Tighten	78 Nm
Tighten	90°
Tighten	90°

Other engine tightening torques
Cylinder head instructions	—
Main bearings Renew bolts/nuts	No
Main bearings Stage 1	50 Nm
Main bearings Stage 2	103 Nm
Big end bearings Renew bolts/nuts	—
View more information	—
Big end bearings Stage 1	34 Nm
Big end bearings Stage 2	120°
Oil pump to cylinder block	23 Nm
Sump bolts	18 Nm
Sump drain bolt	39 Nm
Flywheel/driveplate	123 Nm/98 Nm
Clutch pressure plate	19 Nm
Crankshaft pulley/damper centre bolt	235 Nm
Camshaft sprocket/gear	98 Nm
Camshaft carrier/cap	25 Nm
Camshaft/rocker cover	12 Nm
Inlet manifold to cylinder head	24 Nm
Exhaust manifold to cylinder head	52 Nm
Exhaust downpipe to manifold	62 Nm
Water pump	23 Nm
Injector/clamp	65 Nm
Injector pipe unions	25 Nm
Injector nozzle to holder	37 Nm
Fuel/injection pump sprocket/gear	64 Nm
Fuel/injection pump flange	21 Nm
Fuel/injection pump mounting	18 Nm
Glow plugs	13 Nm
Chassis tightening torques
Rear hub	290 Nm
Steering track rod end	91 Nm
Brake disc to hub Front	71 Nm
Brake caliper to carrier Front	34 Nm
Brake caliper/carrier to hub Front	147 Nm
Road wheels	103 Nm

Air conditioning

No. of AC service connectors	2
Air conditioning restrictor type	Expansion valve
Compressor clutch/magnetic coupling	Yes
Compressor variable displacement solenoid	No

Frequently asked questions

What is the injection sequence of the Toyota Hiace PowerVan 2.4?

The injection sequence for the Toyota Hiace PowerVan 2.4 (1996–2002) is 1-3-4-2.

What glow plugs does the Toyota Hiace PowerVan 2.4 use?

Glow plugs for the Toyota Hiace PowerVan 2.4 (1996–2002): Beru 688 MJ, Bosch 0 250 202 053 and Lucas/CAV HDS235.

How much oil does the Toyota Hiace PowerVan 2.4 take?

The Toyota Hiace PowerVan 2.4 (1996–2002) takes 6.7 litres of engine oil with the filter. See the reference table for the complete engine oil entries and their conditions.

What are the valve clearances for the Toyota Hiace PowerVan 2.4?

Valve clearances for the Toyota Hiace PowerVan 2.4 (1996–2002) are 0,20 mm inlet and 0,36 mm exhaust, measured hot.

What is the cylinder head torque for the Toyota Hiace PowerVan 2.4?

The cylinder head bolts on the Toyota Hiace PowerVan 2.4 (1996–2002) are tightened in 4 stages: 38 Nm, then 78 Nm, then 90°, then a final 90°.

What is the minimum brake disc thickness for the Toyota Hiace PowerVan 2.4?

Brake discs on the Toyota Hiace PowerVan 2.4 (1996–2002) are replaced at a minimum thickness of 26 mm (ventilated) front; the rear brake drums are replaced at a maximum diameter of 272 mm.