2004 Toyota HiLux Pickup engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system

expand_moreIntake manifold


Toyota diesel straight-4 2.5 L 2KD-FTV 101 HP	21.39 lbf⋅ft21.39 lbf⋅ft29 N⋅m
Toyota gasoline straight-4 2.4 L 2RZ-FE 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM	21.39 lbf⋅ft21.39 lbf⋅ft29 N⋅m
Toyota diesel straight-4 2.5 L 2KD-FTV 87 HP	21.39 lbf⋅ft21.39 lbf⋅ft29 N⋅m
All other modifications	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m

expand_moreAuxiliary assemblies


Air-conditioning compressor	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Air-conditioning compressor bracket	62.69 lbf⋅ft62.69 lbf⋅ft85 N⋅m

expand_moreAlternator

expand_moreScrews


Bottom	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m


Top screws	45.73 lbf⋅ft45.73 lbf⋅ft62 N⋅m

expand_moreGenerator bracket


On the engine block	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m


Vacuum pump	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m

expand_moreCarburetion

expand_moreInjection hoses

expand_moreToyota diesel straight-4 2.5 L 2KD-FTV 101 HP


Union nuts	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m

expand_moreAll other modifications


Union nuts	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreInjection nozzle (injector)


Toyota diesel straight-4 2.5 L 2KD-FTV 101 HP	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Toyota gasoline straight-4 2.4 L 2RZ-FE 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m
Toyota diesel straight-4 2.5 L 2KD-FTV 87 HP	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
All other modifications	47.2 lbf⋅ft47.2 lbf⋅ft64 N⋅m

expand_moreInjection pump pulley


Toyota diesel straight-4 2.5 L 2KD-FTV 101 HP	22.86 lbf⋅ft22.86 lbf⋅ft31 N⋅m
Toyota diesel straight-4 2.5 L 2KD-FTV 87 HP	22.86 lbf⋅ft22.86 lbf⋅ft31 N⋅m
All other modifications	47.2 lbf⋅ft47.2 lbf⋅ft64 N⋅m

expand_moreCharging

expand_moreTurbo charger


Toyota diesel straight-4 2.5 L 2KD-FTV 101 HP	38.35 lbf⋅ft38.35 lbf⋅ft52 N⋅m
Toyota diesel straight-4 2.5 L 2KD-FTV 87 HP	38.35 lbf⋅ft38.35 lbf⋅ft52 N⋅m

expand_moreAll other modifications


At the exhaust manifold	38.35 lbf⋅ft38.35 lbf⋅ft52 N⋅m

expand_moreCooling system


Coolant pump	9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m
Coolant pump pulley	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m

expand_moreCylinder head

expand_moreCamshaft bearing


Toyota diesel straight-4 2.5 L 2KD-FTV 101 HP	14.01 lbf⋅ft14.01 lbf⋅ft19 N⋅m
Toyota gasoline straight-4 2.4 L 2RZ-FE 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM	11.8 lbf⋅ft11.8 lbf⋅ft16 N⋅m
Toyota diesel straight-4 2.5 L 2KD-FTV 87 HP	14.01 lbf⋅ft14.01 lbf⋅ft19 N⋅m
All other modifications	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreCylinder head screw minimum diameter


Toyota gasoline straight-4 2.4 L 2RZ-FE 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM	0.41 in0.41 in10.4 mm
All other modifications	0.46 in0.46 in11.6 mm

expand_moreCylinder head screws

expand_moreToyota diesel straight-4 2.5 L 2KD-FTV 101 HP

Figure 1. Cylinder head, Cylinder head screws, Toyota diesel straight-4 2.5 L 2KD-FTV 101 HP.


First stage	62.69 lbf⋅ft62.69 lbf⋅ft85 N⋅m
See figure 1.
Second stage	90°90°90°
Third stage	90°90°90°

expand_moreToyota gasoline straight-4 2.4 L 2RZ-FE 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM

Figure 2. Cylinder head, Cylinder head screws, Toyota gasoline straight-4 2.4 L 2RZ-FE 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM.


First stage	28.76 lbf⋅ft28.76 lbf⋅ft39 N⋅m
See figure 2.
Second stage	90°90°90°
Third stage	90°90°90°

expand_moreAll other modifications

Figure 3. Cylinder head, Cylinder head screws, All other modifications.


First stage	57.53 lbf⋅ft57.53 lbf⋅ft78 N⋅m
See figure 3.
Second stage	90°90°90°
Third stage	90°90°90°

expand_moreValve cover


Toyota diesel straight-4 2.5 L 2KD-FTV 101 HP	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m
Toyota diesel straight-4 2.5 L 2KD-FTV 87 HP	6.64 lbf⋅ft6.64 lbf⋅ft9 N⋅m
All other modifications	8.85 lbf⋅ft8.85 lbf⋅ft12 N⋅m

expand_moreEngine block

expand_moreConnecting rod bearing

expand_moreToyota diesel straight-4 2.5 L 2KD-FTV 101 HP


First stage	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Second stage	90°90°90°

expand_moreToyota gasoline straight-4 2.4 L 2RZ-FE 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM


First stage	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
Second stage	90°90°90°

expand_moreAll other modifications


First stage	39.83 lbf⋅ft39.83 lbf⋅ft54 N⋅m
Second stage	90°90°90°

expand_moreCrankshaft central screws


Toyota diesel straight-4 2.5 L 2KD-FTV 101 HP	269.21 lbf⋅ft269.21 lbf⋅ft365 N⋅m
Toyota diesel straight-4 2.4 L 2L 82 HP	101.05 lbf⋅ft101.05 lbf⋅ft137 N⋅m
Toyota diesel straight-4 2.5 L 2KD-FTV 87 HP	269.21 lbf⋅ft269.21 lbf⋅ft365 N⋅m
Toyota diesel straight-4 3.0 L 5L 90 HP	173.33 lbf⋅ft173.33 lbf⋅ft235 N⋅m
All other modifications	123.17 lbf⋅ft123.17 lbf⋅ft167 N⋅m

expand_moreCrankshaft pulley


All Toyota gasoline straight-4 2.4 L 2RZ-FE engines	191.77 lbf⋅ft191.77 lbf⋅ft260 N⋅m
All Toyota diesel straight-4 3.0 L 5L engines	14.01 lbf⋅ft14.01 lbf⋅ft19 N⋅m
All other modifications	269.21 lbf⋅ft269.21 lbf⋅ft365 N⋅m

expand_moreDrive plate


Toyota diesel straight-4 2.5 L 2KD-FTV 101 HP	54.58 lbf⋅ft54.58 lbf⋅ft74 N⋅m
Toyota diesel straight-4 2.5 L 2KD-FTV 87 HP	54.58 lbf⋅ft54.58 lbf⋅ft74 N⋅m
All other modifications	72.28 lbf⋅ft72.28 lbf⋅ft98 N⋅m

expand_moreFlywheel


Toyota diesel straight-4 2.5 L 2KD-FTV 101 HP	106.95 lbf⋅ft106.95 lbf⋅ft145 N⋅m

expand_moreToyota gasoline straight-4 2.4 L 2RZ-FE 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM


First stage	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m
Second stage	90°90°90°


Toyota diesel straight-4 2.5 L 2KD-FTV 87 HP	106.95 lbf⋅ft106.95 lbf⋅ft145 N⋅m
All other modifications	90.72 lbf⋅ft90.72 lbf⋅ft123 N⋅m

expand_moreMain bearing

expand_moreToyota diesel straight-4 2.5 L 2KD-FTV 101 HP


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Second stage	90°90°90°

expand_moreToyota gasoline straight-4 2.4 L 2RZ-FE 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM


First stage	28.76 lbf⋅ft28.76 lbf⋅ft39 N⋅m
Second stage	90°90°90°


All other modifications	75.97 lbf⋅ft75.97 lbf⋅ft103 N⋅m

expand_moreEngine control


Camshaft drive belt deflection pulley	24.34 lbf⋅ft24.34 lbf⋅ft33 N⋅m

expand_moreCamshaft timing chain guide rail


2.4 i 4WD with gasoline straight-4 2.4 L 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM engine (1997.8–2005.7)	21.39 lbf⋅ft21.39 lbf⋅ft29 N⋅m

expand_moreCamshaft timing chain tensioning rail


2.4 i 4WD with gasoline straight-4 2.4 L 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM engine (1997.8–2005.7)	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m

expand_moreCamshaft timing gear


Toyota gasoline straight-4 2.4 L 2RZ-FE 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM	54.58 lbf⋅ft54.58 lbf⋅ft74 N⋅m
All other modifications	72.28 lbf⋅ft72.28 lbf⋅ft98 N⋅m

expand_moreChain tensioner


2.4 i 4WD with gasoline straight-4 2.4 L 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM engine (1997.8–2005.7)	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m

expand_moreDrive belt tensioner device


On the engine block	15.49 lbf⋅ft15.49 lbf⋅ft21 N⋅m


Toothed belt guard	8.11 lbf⋅ft8.11 lbf⋅ft11 N⋅m

expand_moreToothed belt tensioning roller


Toyota diesel straight-4 2.5 L 2KD-FTV 101 HP	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
Toyota diesel straight-4 2.4 L 2L 82 HP	28.76 lbf⋅ft28.76 lbf⋅ft39 N⋅m
Toyota diesel straight-4 2.5 L 2KD-FTV 87 HP	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m
All other modifications	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m

expand_moreToothed belt tightener


Toyota diesel straight-4 2.5 L 2KD-FTV 101 HP	9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m
Toyota diesel straight-4 2.5 L 2KD-FTV 87 HP	9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m
All other modifications	14.01 lbf⋅ft14.01 lbf⋅ft19 N⋅m

expand_moreEngine lubrication

expand_moreOil drain plug


Toyota diesel straight-4 2.5 L 2KD-FTV 101 HP	25.08 lbf⋅ft25.08 lbf⋅ft34 N⋅m
Toyota gasoline straight-4 2.4 L 2RZ-FE 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM	27.29 lbf⋅ft27.29 lbf⋅ft37 N⋅m
Toyota diesel straight-4 2.5 L 2KD-FTV 87 HP	25.08 lbf⋅ft25.08 lbf⋅ft34 N⋅m
All other modifications	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m

expand_moreOil sump


Toyota diesel straight-4 2.5 L 2KD-FTV 101 HP	11.8 lbf⋅ft11.8 lbf⋅ft16 N⋅m
Toyota gasoline straight-4 2.4 L 2RZ-FE 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM	9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m
Toyota diesel straight-4 2.5 L 2KD-FTV 87 HP	11.8 lbf⋅ft11.8 lbf⋅ft16 N⋅m
All other modifications	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m

expand_moreEngine management


Glow plugs	9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m

expand_moreKnock sensor


2.4 i 4WD with gasoline straight-4 2.4 L 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM engine (1997.8–2005.7)	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m

expand_moreExhaust system

expand_moreExhaust manifold


Toyota gasoline straight-4 2.4 L 2RZ-FE 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM	36.14 lbf⋅ft36.14 lbf⋅ft49 N⋅m

expand_moreAll other modifications


On the engine block	38.35 lbf⋅ft38.35 lbf⋅ft52 N⋅m

expand_moreIgnition system

expand_moreSpark plugs


2.4 i 4WD with gasoline straight-4 2.4 L 138 HP at 5000 RPM, 217 N⋅m at 4000 RPM engine (1997.8–2005.7)	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2004 Toyota HiLux Pickup user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.

Before doing any DIY service please check your insurance policy and Toyota warranty policy for your region. In some regions DIY service may invalidate your warranty.

Maintenance Items

Engine Fastener Tightening Specifications
Front Suspension Fastener Tightening Specifications
Rear Suspension Fastener Tightening Specifications
Transmission Fastener Tightening Specifications

Service Intervals

Conquer your fears and never give up!

DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Toyota HiLux Pickup service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.

Doing basic service for your 2004 Toyota HiLux Pickup you're not only saving money, but also also improving your technical skills and learning something new.

2004 Toyota HiLux Pickup generations

In 2004 Toyota offered 2 generations of the HiLux Pickup. Engine fastener tightening specifications may vary in different generations. Be sure that you are looking at the rigt modification.

2004 Toyota HiLux Pickup Fifth generation second facelift Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

2004 Toyota HiLux Pickup generations

Seventh generation

Toyota HiLux Pickup Fifth generation second facelift model years

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