Toyota1997–2002Technical specifications

Hilux 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: Hilux
Years: 1997–2002
Fuel: Diesel
Engine code: 2L

Performance & efficiency

Power: 61 kW (83 hp)
Engine size: 2,446 cc
Cylinders: 4 · OHC
Compression ratio: 22.2:1

Fluids & capacities

Engine oil (with the filter): 5.8 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
Fuel/injection pump assembly Part No.	22100-67040
Pump type	Rotary
Injector nozzle Make	Denso
Nozzle opening pressure - new/used bar	148-156/142-152

Injection sequence

The injection sequence for the Toyota Hilux 2.4 (1997–2002) is 1-3-4-2.

Injection sequence	1-3-4-2

Valve clearances

Valve clearances for the Toyota Hilux 2.4 (1997–2002) 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 (1997–2002) takes 5.8 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 2.2 litres. The specified oil is SAE 75W-90, with classification GL-5.

Coolant

The listed total cooling-system capacity is 9.5 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	5.8
Other lubricants and capacities
Manual transmission oil grade SAE	75W-90
Manual transmission oil classification	GL-5
Manual transmission litres	2.2
Differential oil grade - rear SAE	90W
Differential oil classification - rear	GL-5
Differential rear litres	1.8
Cooling system - total capacity litres	9.5
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 Hilux 2.4 (1997–2002) are replaced at a minimum thickness of 23 mm (ventilated) front; the rear brake drums are replaced at a maximum diameter of 272 mm.

Minimum disc thickness for replacement - ventilated Front	23 mm
Maximum drum diameter for replacement Rear	272 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

Battery

The Toyota Hilux 2.4 (1997–2002) uses a 12 V, 85 Ah battery (reserve capacity 150 minutes).

Battery V/RC(Ah)	12/150 (85)

Glow plugs

Glow plugs for the Toyota Hilux 2.4 (1997–2002): Beru GV968 and Bosch 0 250 202 053. Rated 11 V.

Glow plug nominal rating V/A	11
Glow plug activation time secs	2,2
Glow plug - part no. Beru	GV968
Glow plug - part no. Bosch	0 250 202 053

Tuning and emissions

Plunger travel (pump) mm ABDC	—
View more information	—
Crankshaft position (n = ATDC) °BTDC	—
Adjusting method Engine/Pump	Pointer/Dial gauge
Idle speed rpm	650-750
Rated no load speed rpm	5020-5280
Oil temperature °C	80
Idle speed - for smoke test rpm	700-800
Governed speed range - for smoke test rpm	5050-5150
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 (%)	3,00 (73)

Starting and charging

Alternator output A/V/rpm	55/12/3000

Service checks and adjustments

Compression pressure bar	20-32
Oil pressure bar/rpm	2,9-5,4/3000
Radiator cap bar	0,90-1,20
Thermostat opens °C	86
Drive belt tension - alternator/PAS/AC mm	10-14 mm
Drive belt tension - AC mm	17-21 mm

Tightening torques

Cylinder head bolt torque

The cylinder head bolts on the Toyota Hilux 2.4 (1997–2002) are tightened in 3 stages: 78 Nm, then 90°, then a final 90°.

Cylinder head
Renew bolts	No
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	105 Nm
Big end bearings Renew bolts/nuts	No
Big end bearings Stage 1	54 Nm
Big end bearings Stage 2	90°
Sump bolts	18 Nm
Sump drain bolt	34,5 Nm
Flywheel/driveplate	123 Nm
Clutch pressure plate	20 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
Injector/clamp	64 Nm
Injector pipe unions	25 Nm
Injector nozzle to holder	40 Nm
Fuel/injection pump sprocket/gear	64 Nm
Fuel/injection pump flange	20 Nm
Fuel/injection pump mounting	18 Nm
Glow plugs	13 Nm
Chassis tightening torques
Steering track rod end	90 Nm
Brake caliper to carrier Front	39 Nm
Brake caliper/carrier to hub Front	107 Nm
Road wheels	140 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 injection sequence of the Toyota Hilux 2.4?

The injection sequence for the Toyota Hilux 2.4 (1997–2002) is 1-3-4-2.

What glow plugs does the Toyota Hilux 2.4 use?

Glow plugs for the Toyota Hilux 2.4 (1997–2002): Beru GV968 and Bosch 0 250 202 053. Rated 11 V.

How much oil does the Toyota Hilux 2.4 take?

The Toyota Hilux 2.4 (1997–2002) takes 5.8 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 0,20-0,30 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 (1997–2002) are tightened in 3 stages: 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 (1997–2002) are replaced at a minimum thickness of 23 mm (ventilated) front; the rear brake drums are replaced at a maximum diameter of 272 mm.