Engine & identification
Vehicle identification
| No. of cylinders Type | 4/DOHC |
|---|---|
| Capacity cc | 2494 |
| Compression ratio :1 | 18,5 |
Injection system
| Air metering Type | Mass |
|---|---|
| Pump type | Common rail |
| Nozzle opening pressure - new/used bar | 159-171/154-166 |
| Crankshaft position (CKP) sensor/engine speed (RPM) sensor Ohm | 1850-2450 |
| Injector Ohm | 2,5-3,1 |
| Intake air temperature (IAT) sensor Ohm/°C | 221-265/20 |
Injection sequence
The injection sequence for the Toyota Hilux 2.5 D-4D (2001–2005) is 1-3-4-2.
| Injection sequence | 1-3-4-2 |
|---|
Valve clearances
Valve clearances for the Toyota Hilux 2.5 D-4D (2001–2005) are 0,20-0,30 mm inlet and 0,35-0,45 mm exhaust, measured cold.
| Valve clearance - INLET mm | 0,20-0,30 cold |
|---|---|
| Valve clearance - EXHAUST mm | 0,35-0,45 cold |
Engine oil & fluids
Engine oil
The Toyota Hilux 2.5 D-4D (2001–2005) takes 7.3 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-4/5.
Transfer box
The transfer box has a listed capacity of 1.6 litres. The specified oil is SAE 75W-90, with classification GL-4/5.
Coolant
The listed total cooling-system capacity is 10.0 litres.
Grades, filling conditions and capacities
| Preferred engine oil | |
|---|---|
| Ambient temperature range | All temperatures |
| Engine oil grade SAE | 5W-30 |
| Engine oil classification API/ACEA | CF/B1, B3 |
| Engine oil options | |
| Ambient temperature range | -18°C➞ |
| Engine oil grade SAE | 10W-30 |
| Engine oil classification API/ACEA | CF/B1, B3 |
| Ambient temperature range | -12°C➞ |
| Engine oil grade SAE | 15W-40 |
| Engine oil classification API/ACEA | CF/B2, B3 |
| Ambient temperature range | -7°C➞ |
| Engine oil grade SAE | 20W-50 |
| Engine oil classification API/ACEA | CF/B2, B3 |
| Engine with filter(s) litres | 7.3 |
| Other lubricants and capacities | |
| Manual transmission oil grade SAE | 75W-90 |
| Manual transmission oil classification | GL-4/5 |
| Manual transmission litres | 2.2 |
| Automatic transmission fluid Type | Dexron II/III |
| Automatic transmission (drain & refill) litres | 2.0 |
| Automatic transmission (dry fill) litres | 10.1 |
| Differential oil grade - rear SAE | 90W |
| Differential oil classification - rear | GL-5 |
| Differential rear litres | 1.8 |
| Transfer box oil grade SAE | 75W-90 |
| Transfer box oil classification | GL-4/5 |
| Transfer box litres | 1.6 |
| Cooling system - total capacity litres | 10.0 |
| Brake 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 2.5 D-4D (2001–2005) 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 |
Service & electrical
Tuning and emissions
| Idle speed rpm | 700±50 |
|---|---|
| Oil temperature °C | 80 |
| Water temperature °C | 75-85 |
| Governed speed range - for smoke test rpm | 4500-4700 |
| 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) |
| Smoke opacity - homologation value m-1 (%) | 2,50 (66) |
Starting and charging
| Battery V/RC(Ah) | 12 |
|---|---|
| Maximum cranking amps A | 180 |
| Alternator output A/V/rpm | 70/12/- |
Service checks and adjustments
| Compression pressure bar | 27 |
|---|---|
| Oil pressure bar/rpm | 2,2/3000 |
| Radiator cap bar | 1,10 |
| Thermostat opens °C | 80-84 |
| Drive belt tension - alternator/PAS/AC mm | 196-392 |
Glow plugs
| Glow plug nominal rating V/A | 12 |
|---|---|
| Glow plug activation time secs | 2,3 |
Tightening torques
Cylinder head bolt torque
The cylinder head bolts on the Toyota Hilux 2.5 D-4D (2001–2005) are tightened in 4 stages: 40 Nm, then 85 Nm, then 90°, then a final 90°.
| Cylinder head | |
|---|---|
| Tighten | 40 Nm |
| Tighten | 85 Nm |
| Tighten | 90° |
| Tighten | 90° |
| Cylinder head instructions | — |
|---|---|
| Cylinder head | |
| View more information | — |
| Other engine tightening torques | |
| Main bearings Renew bolts/nuts | — |
| View more information | — |
| Main bearings Stage 1 | 50 Nm |
| Main bearings Stage 2 | 90° |
| Big end bearings Renew bolts/nuts | No |
| Big end bearings Stage 1 | 35 Nm |
| Big end bearings Stage 2 | 90° |
| Oil pump to cylinder block | 21 Nm |
| Sump bolts | 16 Nm |
| Sump drain bolt | 34 Nm |
| Flywheel/driveplate | 178 Nm/74 Nm |
| Clutch pressure plate | 19 Nm |
| Crankshaft pulley/damper centre bolt | 365 Nm |
| Camshaft sprocket/gear | 98 Nm |
| Camshaft carrier/cap | 19 Nm |
| Inlet manifold to cylinder head | 29 Nm |
| Exhaust manifold to cylinder head | 52 Nm |
| Exhaust downpipe to manifold | 43 Nm |
| Water pump | 13 Nm |
| Injector/clamp | 21 Nm |
| Injector pipe unions | 33±2 Nm |
| Fuel/injection pump sprocket/gear | 64 Nm |
| Fuel/injection pump flange | 31 Nm |
| Fuel/injection pump mounting | 21 Nm |
| Glow plugs | 13 Nm |
| Crankshaft position (CKP) sensor/engine speed (RPM) sensor | 8 Nm |
| Engine coolant temperature (ECT) sensor | 20 Nm |
| Engine oil pressure switch | 15 Nm |
| Chassis tightening torques | |
| 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 quantity cm³ | 110 |
| Air conditioning oil viscosity ISO | 46 |
Frequently asked questions
What is the injection sequence of the Toyota Hilux 2.5 D-4D?
The injection sequence for the Toyota Hilux 2.5 D-4D (2001–2005) is 1-3-4-2.
How much oil does the Toyota Hilux 2.5 D-4D take?
The Toyota Hilux 2.5 D-4D (2001–2005) takes 7.3 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 2.5 D-4D?
Valve clearances for the Toyota Hilux 2.5 D-4D (2001–2005) are 0,20-0,30 mm inlet and 0,35-0,45 mm exhaust, measured cold.
What is the cylinder head torque for the Toyota Hilux 2.5 D-4D?
The cylinder head bolts on the Toyota Hilux 2.5 D-4D (2001–2005) are tightened in 4 stages: 40 Nm, then 85 Nm, then 90°, then a final 90°.
What is the minimum brake disc thickness for the Toyota Hilux 2.5 D-4D?
Brake discs on the Toyota Hilux 2.5 D-4D (2001–2005) are replaced at a minimum thickness of 23 mm (ventilated) front; the rear brake drums are replaced at a maximum diameter of 272 mm.