Engine & identification
Vehicle identification
| No. of cylinders Type | 4/DOHC |
|---|---|
| Capacity (Fiscal) cc | 2438 |
| Compression ratio :1 | 9,5 |
| Suitable for unleaded petrol | Yes |
| Minimum octane rating RON | 95 |
| Ignition system Make | Toyota |
| Ignition system Type | TCCS |
| Ignition system Description | Map-DIS |
| Trigger location | Cam/Crankshaft |
| Fuel system Make | Toyota |
| Fuel system Type | TCCS |
| Fuel system Description | MFI-s |
| Air metering Type | Mass |
| Combined ignition and fuel ECM | Yes |
| Diagnostic socket | Yes |
Ignition system
| Ignition coil supply voltage + with ballast V | 12,0 |
|---|---|
| Secondary resistance Ohm | 9700-16700 |
Firing order
The firing order for the Toyota Hilux 2.4 (1997–2002) is 1-3-4-2.
| Firing order | 1-3-4-2 |
|---|
Valve clearances
Valve clearances for the Toyota Hilux 2.4 (1997–2002) are 0,15-0,25 mm inlet and 0,25-0,35 mm exhaust, measured cold.
| Valve clearance - INLET mm | 0,15-0,25 cold |
|---|---|
| Valve clearance - EXHAUST mm | 0,25-0,35 cold |
Engine oil & fluids
Engine oil
The Toyota Hilux 2.4 (1997–2002) takes 6.0 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 2.6 litres. The specified oil is SAE 75W-90, with classification GL-4/5.
Transfer box
The transfer box has a listed capacity of 1.1 litres. The specified oil is SAE 75W-90, with classification GL-4/5.
Coolant
The listed total cooling-system capacity is 6.9 litres.
See the reference table for the complete coolant entries and their conditions.
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 | SJ |
| Ambient temperature range | -18°C➞38°C |
| Engine oil grade SAE | 10W-30 |
| Engine oil classification API/ACEA | SJ |
| Ambient temperature range | -12°C➞38°C |
| Engine oil grade SAE | 15W-40 |
| Engine oil classification API/ACEA | SJ |
| Ambient temperature range | -7°C➞38°C |
| Engine oil grade SAE | 20W-50 |
| Engine oil classification API/ACEA | SJ |
| Engine with filter(s) litres | 6.0 |
| Other lubricants and capacities | |
| Manual transmission oil grade SAE | 75W-90 |
| Manual transmission oil classification | GL-4/5 |
| Manual transmission litres | 2.6 |
| Differential oil grade - front SAE | 75W-90 |
| Differential oil classification - front | GL-5 |
| Differential front/AT litres | 1.6 |
| Differential oil grade - rear SAE | 75W-90 |
| Differential rear litres | 2.7 |
| Transfer box oil grade SAE | 75W-90 |
| Transfer box oil classification | GL-4/5 |
| Transfer box litres | 1.1 |
| Coolant Type | Ethylene glycol |
| Cooling system - total capacity litres | 6.9 |
| Cooling system | |
| Brake fluid Type | DOT 3 |
| Clutch fluid Type | DOT 3 |
| Power steering fluid Type | Dexron II/III |
| Power steering fluid litres | 0.8 |
Brakes & wear limits
Brake disc thickness
Brake discs on the Toyota Hilux 2.4 (1997–2002) are replaced at a minimum thickness of 18 mm (ventilated) front; the rear brake drums are replaced at a maximum diameter of 297 mm.
| Minimum disc thickness for replacement - ventilated Front | 18 mm |
|---|---|
| Maximum drum diameter for replacement Rear | 297 mm |
Brake disc and drum dimensions
| Disc runout Front | 0,07 mm |
|---|---|
| Minimum pad thickness Front | 1 mm |
| Minimum shoe thickness Rear | 1 mm |
| Parking brake travel No. of notches | 11-17 |
Service & electrical
Ignition timing
Basic ignition timing for the Toyota Hilux 2.4 (1997–2002) is 5°±2° BTDC at 700 rpm.
| Ignition timing | |
|---|---|
| Ignition timing - basic BTDC °Engine/rpm | 5±2/700 |
Spark plugs
The Toyota Hilux 2.4 (1997–2002) uses Denso K16R-U spark plugs with a 0,8 mm electrode gap.
| Spark plugs Original equipment | Denso |
|---|---|
| Spark plug Type | K16R-U |
| Electrode gap mm | 0,8 |
| Spark plugs Make | NGK |
| Spark plug Type | BKR5EYA |
| Electrode gap mm | 0,8 |
Tuning and emissions
| Tuning conditions | — |
|---|---|
| View more information | — |
| Ignition timing | |
| Ignition advance checks °Engine/rpm | ECM Controlled |
| Idle speed rpm | 700±50 Not adjustable |
| Oil temperature °C | 80 |
| CO level at idle speed - tailpipe Vol. % CO | 0,5 Max Not adjustable |
| HC level at idle speed ppm | 100 |
| CO2 level at idle speed Vol. % CO2 | 14,5-16 |
| O2 level at idle speed Vol. % O2 | 0,1-0,5 |
| Increased idle speed for CO test rpm | 2300-2700 |
| CO content at increased idle speed Vol. % | 0,3 |
| Lambda at increased idle λ | 0,98-1,02 |
Service checks and adjustments
| Compression pressure bar | 8,8-12,3 |
|---|---|
| Oil pressure bar/rpm | 2,5-4,9/3000 |
| Radiator cap bar | 0,75-1,05 |
| Thermostat opens °C | 80-84 |
Tightening torques
Cylinder head bolt torque
The cylinder head bolts on the Toyota Hilux 2.4 (1997–2002) are tightened in 4 stages: 20 Nm, then 39 Nm, then 90°, then a final 90°.
| Cylinder head | |
|---|---|
| Tighten | 20 Nm |
| Tighten | 39 Nm |
| Tighten | 90° |
| Tighten | 90° |
| Tighten | M8=21 Nm |
| Cylinder head instructions | — |
|---|---|
| Cylinder head | |
| View more information | — |
| Other engine tightening torques | |
| Main bearings Renew bolts/nuts | No |
| Main bearings Stage 1 | 39 Nm |
| Main bearings Stage 2 | 90° |
| Big end bearings Renew bolts/nuts | No |
| Big end bearings Stage 1 | 45 Nm |
| Big end bearings Stage 2 | 90° |
| Sump bolts | 13 Nm |
| Sump drain bolt | 37 Nm |
| Flywheel/driveplate | 88 Nm/74 Nm |
| Clutch pressure plate | 19 Nm |
| Crankshaft pulley/damper centre bolt | 260 Nm |
| Camshaft sprocket/gear | 74 Nm |
| Camshaft carrier/cap | 16 Nm |
| Inlet manifold to cylinder head | 29 Nm |
| Exhaust manifold to cylinder head | 49 Nm |
| Spark plugs | 20 Nm |
| Fuel rail | 21 Nm |
| Crankshaft position (CKP) sensor/engine speed (RPM) sensor | 9 Nm |
| Knock sensor (KS) | 44 Nm |
| Chassis tightening torques | |
| Rear hub - wheel bearing housing bolts | 69 Nm |
| Steering wheel | 34 Nm |
| Steering track rod end | 90 Nm |
| Brake disc to hub Front | 64 Nm |
| Brake caliper/carrier to hub Front | 123 Nm |
| ABS sensor Front | 8 Nm |
| ABS sensor Rear | 8 Nm |
| Road wheels | 105 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 | R134a |
| Air conditioning refrigerant quantity grams | 550±50 |
| Air conditioning oil group | PAG |
| Air conditioning oil Type | Dens Oil 8 |
| Air conditioning oil viscosity ISO | 46 |
Frequently asked questions
What is the firing order of the Toyota Hilux 2.4?
The firing order for the Toyota Hilux 2.4 (1997–2002) is 1-3-4-2.
What spark plugs does the Toyota Hilux 2.4 use?
The Toyota Hilux 2.4 (1997–2002) uses Denso K16R-U spark plugs with a 0,8 mm electrode gap.
How much oil does the Toyota Hilux 2.4 take?
The Toyota Hilux 2.4 (1997–2002) takes 6.0 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 (1997–2002) are 0,15-0,25 mm inlet and 0,25-0,35 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 (1997–2002) are tightened in 4 stages: 20 Nm, then 39 Nm, then 90°, then a final 90°.
What is the ignition timing for the Toyota Hilux 2.4?
Basic ignition timing for the Toyota Hilux 2.4 (1997–2002) is 5°±2° BTDC at 700 rpm.