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 Part No. | 22100-54750 |
| Pump type | Rotary |
| Injector nozzle Make | Denso |
| Nozzle and holder assembly Part No. | DN4PD57 |
| Nozzle opening pressure - new/used bar | 148-156/142 |
| Leak rate (dribble) bar/secs | 129/10 |
Injection sequence
The injection sequence for the Toyota Hilux 2.4 (1988–1997) is 1-3-4-2.
| Injection sequence | 1-3-4-2 |
|---|
Valve clearances
Valve clearances for the Toyota Hilux 2.4 (1988–1997) are 0,20-0,30 mm inlet and 0,40-0,50 mm exhaust, measured cold.
| Valve clearance - INLET mm | 0,20-0,30 cold |
|---|---|
| Valve clearance - EXHAUST mm | 0,40-0,50 cold |
Engine oil & fluids
Engine oil
The Toyota Hilux 2.4 (1988–1997) takes 5.9 litres of engine oil with the filter.
See the reference table for the complete engine oil entries and their conditions.
Manual gearbox
The specified manual gearbox oil is SAE 75W-90.
See the reference table for the complete manual gearbox entries and their conditions.
Coolant
The listed total cooling-system capacity is 9.2 litres.
Grades, filling conditions and capacities
| Engine oil options | |
|---|---|
| Ambient temperature range | -29°C➞10°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 | 5.9 |
| Other lubricants and capacities | |
| Manual transmission oil grade SAE | 75W-90 |
| Manual transmission litres | 1,9/2,2 |
| Automatic transmission fluid Type | Dexron II |
| Automatic transmission (drain & refill) litres | 2.4 |
| Differential front/AT litres | 2.3 |
| Differential oil grade - rear SAE | 90W |
| Differential oil classification - rear | GL-5 |
| Differential rear litres | 2.2 |
| Cooling system - total capacity litres | 9.2 |
| 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 Hilux 2.4 (1988–1997) are replaced at a minimum thickness of 18 mm (ventilated) front; the rear brake drums are replaced at a maximum diameter of 256 mm.
| Minimum disc thickness for replacement - ventilated Front | 18 mm |
|---|---|
| Maximum drum diameter for replacement Rear | 256 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 | 11-17 |
Service & electrical
Battery
The Toyota Hilux 2.4 (1988–1997) uses a 12 V, 80 Ah battery (reserve capacity 130 minutes).
| Battery V/RC(Ah) | 12/130 (80) |
|---|
Glow plugs
Glow plugs for the Toyota Hilux 2.4 (1988–1997): Beru 688 MJ, Bosch 0 250 202 053, Champion CH103 and Lucas/CAV HDS235.
| Glow plug nominal rating V/A | 7/8 |
|---|---|
| Glow plug activation time secs | 20 Max |
| Glow plug - part no. Beru | 688 MJ |
| Glow plug - part no. Bosch | 0 250 202 053 |
| Glow plug - part no. Champion | CH103 |
| Glow plug - part no. Lucas/CAV | HDS235 |
Tuning and emissions
| Plunger travel (pump) mm ABDC | 0,54-0,66 |
|---|---|
| View more information | — |
| Crankshaft position (n = ATDC) °BTDC | — |
| Adjusting method Engine/Pump | Pointer/Dial gauge |
| Dynamic timing v = BTDC, n = ATDC | v |
| - Time Trac Stanadyne, Snap-on °/rpm | 9,5/790 |
| Idle speed rpm | 700 |
| Idle speed - alternative rpm | AT=800 |
| Rated no load speed rpm | 5150 |
| Oil temperature °C | 80 |
| Idle speed - for smoke test rpm | 700-800 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
| Starter motor Make | Denso |
|---|---|
| Starter motor Type | 2,0kW |
| Maximum cranking amps A | 216-264 |
| Alternator Make | Denso |
| Alternator Type | 60A |
| Alternator output A/V/rpm | 30/14/2000 |
| Regulated voltage V | 13,8-14,8 |
Service checks and adjustments
| Compression pressure bar | 19,6-31,4 |
|---|---|
| Oil pressure bar/rpm | 2,9-5,4/3000 |
| Radiator cap bar | 0,74-1,03 |
| Thermostat opens °C | 86-90 |
| Drive belt size - alternator mm | 9,5x975 |
| Drive belt size - PAS/AC mm | 12,5x850 |
| Drive belt tension - alternator/PAS/AC mm | 10-15 |
Tightening torques
Cylinder head bolt torque
The cylinder head bolts on the Toyota Hilux 2.4 (1988–1997) 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° |
| Cylinder head instructions | — |
|---|---|
| Other engine tightening torques | |
| Main bearings Renew bolts/nuts | No |
| Main bearings Stage 1 | — |
| Big end bearings Renew bolts/nuts | No |
| Big end bearings Stage 1 | 54 Nm |
| Big end bearings Stage 2 | 90° |
| Oil pump to cylinder block | 23 Nm |
| Sump bolts | 18 Nm |
| Sump drain bolt | 39 Nm |
| Flywheel/driveplate | 123 Nm |
| Clutch pressure plate | 19 Nm |
| Crankshaft pulley/damper centre bolt | 167 Nm |
| Camshaft sprocket/gear | 98 Nm |
| Camshaft carrier/cap | 25 Nm |
| Camshaft/rocker cover | 5 Nm |
| Inlet manifold to cylinder head | 24 Nm |
| Exhaust manifold to cylinder head | 52 Nm |
| Injector/clamp | 64 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 | |
| Steering wheel | 34 Nm |
| Steering track rod end | 90 Nm |
| Brake caliper/carrier to hub Front | 123 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 |
| Air conditioning refrigerant Type | R12 |
| Air conditioning refrigerant quantity grams | 750±50 |
| Air conditioning oil Type | Dens Oil 6 |
Frequently asked questions
What is the injection sequence of the Toyota Hilux 2.4?
The injection sequence for the Toyota Hilux 2.4 (1988–1997) is 1-3-4-2.
What glow plugs does the Toyota Hilux 2.4 use?
Glow plugs for the Toyota Hilux 2.4 (1988–1997): Beru 688 MJ, Bosch 0 250 202 053, Champion CH103 and Lucas/CAV HDS235.
How much oil does the Toyota Hilux 2.4 take?
The Toyota Hilux 2.4 (1988–1997) takes 5.9 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 Hilux 2.4?
Valve clearances for the Toyota Hilux 2.4 (1988–1997) are 0,20-0,30 mm inlet and 0,40-0,50 mm exhaust, measured cold.
What is the cylinder head torque for the Toyota Hilux 2.4?
The cylinder head bolts on the Toyota Hilux 2.4 (1988–1997) 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 Hilux 2.4?
Brake discs on the Toyota Hilux 2.4 (1988–1997) are replaced at a minimum thickness of 18 mm (ventilated) front; the rear brake drums are replaced at a maximum diameter of 256 mm.