2002 Hilux
from Wintoy
Toyota has introduced a broad range of engine improvements to a streamlined lineup of its top selling HiLux

The improvements include far wider take-up of turbo-diesel power in its four wheel drive range, and universal
use of electronic fuel injection across all 28 HiLux models.

HiLux, already Australia's top selling one tonne utility, is expected to significantly increase volume as a result
of the realignment.

The new HiLux turbo-diesel produces more power and torque.

The recalibrated engine delivers 315Nm of torque - the most in its class by a margin of 35Nm.

EFI, already fitted to HiLux' petrol engines and the turbo-diesel, is now also fitted to the naturally aspirated
diesel engine.

It delivers more power, torque and even better economy.

Toyota has carefully reconstituted its big HiLux range to better meet customer needs.

Three high grade SR5 four wheel drive models have been discontinued in favour of boosting even more
affordable models.

Turbo-diesel power will now be available in the most popular standard models in parallel with petrol and
naturally aspirated diesel variants.

Four HiLux Turbo-diesel models are offered - all four-wheel-drive models.

They are: Single Cab Pick-up, Single Cab Cab/Chassis, Double Cab Pick-up and Double Cab SR5 Pick-up.

Value for money has been a major criteria in the remake of the range.

HiLux is the world's top volume one tonne utility.


Toyota's new HiLux range has 28 models, with the choice of two and four-wheel drive, three cabins, four
engine and two equipment grades.

All models have the safety option of dual SRS airbags and ABS anti-skid brakes, with the exception of two
workmate models.

There are 13 4x2 models and 15 4x4 models.

The three cabins are Standard Cab, Xtra Cab and Double Cab.

The four EFI-equipped engines are: 2.0 litre petrol (exclusive to 4x2 Workmate), 2.7 litre petrol, 3.0 litre
diesel and 3.0 litre turbo-diesel.

Equipment grades are standard and high-grade SR5.

All HiLux models have independent front suspension.

All HiLux 4x4 models have manual transmission and SR5 grade 4x4 models have the added convenience of
Toyota's automatic disconnecting front
differential, for on-the-move H2-H4 changes.

The full HiLux 4x2 line-up is:

* 2.0 litre petrol Workmate Pick-up manual
* 2.0 litre petrol Workmate Cab/Chassis manual
* 2.7 litre petrol Single Cab Pick-up manual
* 2.7 litre petrol Single Cab Cab/Chassis manual
* 2.7 litre petrol Single Cab Cab/Chassis automatic
* 2.7 litre petrol Double Cab Pick-up manual
* 2.7 litre petrol Double Cab SR5 Pick-up manual
* 2.7 litre petrol Double Cab Pick-up automatic
* 2.7 litre petrol Double Cab SR5 Pick-up automatic
* 2.7 litre petrol Xtra Cab Pick-up manual
* 2.7 litre petrol Xtra Cab Pick-up automatic
* 3.0 litre diesel Single Cab Cab/Chassis manual
* 3.0 litre diesel Double Cab Pick-up manual

The full 4x4 line-up is:

* 2.7 litre petrol Single Cab Pick-up
* 2.7 litre petrol Single Cab Cab/Chassis
* 2.7 litre petrol Double Cab Pick-up
* 2.7 litre petrol Double Cab SR5 Pick-up
* 2.7 litre petrol Xtra Cab Pick-up
* 3.0 litre diesel Single Cab Pick-up
* 3.0 litre diesel Single Cab Cab/Chassis
* 3.0 litre diesel Double Cab Pick-up
* 3.0 litre diesel Double Cab SR5 Pick-up
* 3.0 litre diesel Xtra Cab Pick-up
* 3.0 litre diesel Xtra Cab Cab/Chassis
* 3.0 litre turbo-diesel Single Cab Pick-up
* 3.0 litre turbo-diesel Single Cab Cab/Chassis
* 3.0 litre turbo-diesel Double Cab Pick-up
* 3.0 litre turbo-diesel Double Cab SR5 Pick-up


Hilux Re-Powers 4x4 Petrol Range


Toyota has repowered its HiLux naturally aspirated diesel models with a three-litre electronically injected

The eight repowered diesel models have improved performance, driveability and fuel economy (and hence
greater range).

The eight diesel models (two 4x2 models and six 4x4 models) have Toyota's 3.0 litre 5L-E engine, which has
an electronically controlled injection

The 5L-E engine has nine percent more power (an additional 6kW) and 3Nm more torque than the superseded
5L engine.

It delivers 71kW at 4000rpm and 200Nm of torque at 2600rpm. Torque has been increased from 2300rpm to
4200rpm. Power has been increased above 2400rpm.

The repowered HiLux diesels also reduce black-smoke emissions while improving performance and economy.


Toyota has recalibrated its HiLux Turbo-diesel engine to improve torque.

The improved Turbo-diesel has 20Nm more torque at lower engine revolutions.

HiLux Turbo-diesel now delivers maximum torque at 2000rpm, compared with 2400rpm with the previous

Toyota's electronically injected 3.0 litre 1KZ-TE engine was launched in Australia in December 1999.

It was the first electronically injected diesel engine in the one-tonne 4x4 utility class and Toyota's first
EFI-equipped diesel in Australia.

The improved 1KZ-TE engine has redesigned cylinder head and pistons, a redesigned turbocharger, a
redesigned fuel injection pump and new injector

The fuel injection pump has been upgraded to ROM type, similar to that used on the Prado Turbo-diesel

The 2982cm3 single-overhead camshaft Toyota 1KZ-TE engine is the most advanced turbocharged diesel in
the class.

It has a lightweight, compact, water-cooled turbocharger for a balance of performance, fuel economy and

Advanced features also include ceramic glow plugs, a vane-type fuel pump, cross-flow alloy cylinder head and
twin counter-rotating balance shafts.

Toyota designed the 1KZ-TE engine for a combination of performance, economy, package efficiency,
reliability and low NVH.

The 1KZ-TE engine has a deep-skirt, externally ribbed, linerless construction cylinder block for maximum
rigidity and low noise.

The block material is wear-resistant alloy cast iron and the bores have been plateau-honed for more efficient
piston ring sealing.

The fully balanced steel crankshaft has five journals and runs in aluminium alloy bearings.

Special attention has been paid to minimising reciprocating mass.

Connecting rods are lightweight carbon steel to suit high engine speeds and high engine torque.

Each connecting rod has an internal oil passage, which feeds an oil gallery in the piston.

The small-end bearings are tapered to reduce weight and the big-ends have plastic region tightening bolts to
maximise clamping force for the size of the

The pistons are aluminium alloy to maximise high-temperature strength and reduce weight.

The pistons have an FRM (fibre reinforced metal) top ring groove to improve wear resistance and an oil
gallery inside the ring land to improve piston

Bore and stroke dimensions are under-square at 96mm by 103mm, to maximise torque.

Cross-Flow Head:

HiLux Turbo-diesel has an aluminium alloy cylinder head for high thermal conductivity and light weight.

The cylinder head has a cross-flow configuration, to improve intake and exhaust efficiency.

The shape of the combustion chamber and the injection nozzle location have been optimised to increase engine
performance and reduce exhaust

Plastic region tightening cylinder head bolts are used to maximise clamping force.

Cylinder head gasket pressure resistance and sealing performance have been optimised by adopting a steel
laminate type gasket.

Gasket thickness is tailored to each engine to ensure correct compression ratio and avoid any protrusion of
the pistons above the cylinder block deck.

The 1KZ-TE's single overhead camshaft acts directly on the valves, to ensure the valve actuation more
accurately follows camshaft profiles.

Camshaft drive is by timing gears to the injection pump gear, then a toothed rubber belt with an automatic
tensioner and a belt idler.

The compact fuel injection nozzles have a double-cut needle.

The needle clearance has been optimised to reduce exhaust emissions and noise during idling. The glow plugs
have ceramic tips, to improve reliability.

A baffle plate and a camshaft cover inside the cylinder head cover reduce consumption of engine oil by
reducing gas blow-by.

Twin Balance Shafts:

Toyota's 1KZ-TE engine has twin balance shafts to reduce engine vibration. The two counter-rotating balance
shafts are gear driven, to rotate at twice crankshaft speed.

The timing gear train also drives the oil pump, vacuum pump and fuel injection pump.

The combination of EFI and Toyota's vane-type injection pump provides optimum fuel injection timing and

Features of the fuel pump include a spill control valve, timing control valve, fuel temperature sensor, engine
speed sensor and correction resistors.

Low Noise & Weight:

The HiLux turbo-diesel engine's NVH counter measures include twin balance shafts, high-rigidity cylinder
block, and scissors gears on both the back
and front of the timing gear idler gear.

The cylinder head cover is made of resin to reduce weight and noise.

A two-valve type venturi reduces vibration on engine shutdown.

Engine service weight has been minimised by adopting an aluminium cylinder head, gear and belt camshaft
drive, resin cylinder head cover and an aluminium radiator core.


Toyota HiLux's body was designed to optimise durability and safety. The HiLux has high body strength and
rigidity, to meet durability, safety and NVH targets.

Box sections in the body have been closed and large sections have been adopted in many instances -
particularly the apron upper member around the engine bay.

Special attention was paid to joint rigidity in the panels under the bonnet.

Many body panels are pressed from high-strength steel sheet, including the bonnet, front guards, outer door
panels and tailgate.

This adds to strength and dint resistance, while meeting strict weight targets.

One-piece body side sections and high-rigidity doors also contribute to overall body strength. In addition,
HiLux has a double-skin tray.

HiLux 4x2 and 4x4 have independent front suspension. HiLux 4x4's suspension has been calibrated to suit
Australian off-road conditions, while maximising ride comfort.

All HiLux standard grade models have true one-tonne capacity as a workhorse/fleet vehicle.

Special attention has been paid to seat comfort, interior noise levels and ventilation - both for cool air flow and
cabin heating - to maximise occupant comfort.

At Toyota Australia's request, HiLux retains quarter-vent windows on all models except SR5.

Eight exterior colours are offered across the HiLux range for the standard grade models - two solids and six

HiLux SR5 models are offered in a choice of four metallic colours.

The HiLux range has been protected by an extensive Toyota anti-corrosion package.

Virtually all major panels in the vehicle, except the roof, are pressed from anti-corrosion steel sheet.

Maximum use has been made of anti-chipping paint, PVC and urethane coatings and waxes and sealers, to
protect the body.

Anti-chipping protection includes PVC on the underbody and inner fenders, and soft-chip primer on the front
edge of the bonnet and the rocker panels
The End

Toyota's HiLux utility range has electronic injection throughout.

The introduction of electronic injection on the HiLux naturally aspirated diesel engine means all four HiLux
engines have the performance, driveability,
fuel economy and emission benefits of EFI.

The four HiLux engines are:

* 2.0-litre single overhead camshaft petrol, exclusive to 4x2 Workmate
* 2.7-litre Twin Cam Multi-valve petrol in 4x2 and 4x4
* 3.0-litre single overhead camshaft diesel in 4x2 and 4x4
* 3.0-litre turbo-diesel in 4x4.



Toyota has increased the torque and availability of its turbo-diesel engine for the HiLux range.

The improved HiLux Turbo-diesel engine has 20Nm more torque at lower engine revolutions.

The Turbo-diesel range has also been expanded to include workhorse 4x4 models.

Toyota HiLux is Australia's top-selling Pick-up/Cab Chassis.

Toyota has recalibrated its electronically injected 3.0 litre 1KZ-TE turbo-diesel engine to deliver maximum
torque 400rpm lower in the revolution range.

The improved engine delivers 85kW of power at 3600rpm and 315Nm of torque at 2000rpm.

Toyota's new HiLux Turbo-diesel has the most torque in the one-tonne diesel utility class.

It has 35Nm more torque than its nearest one-tonne turbo-diesel utility competitor.

The new, more torquey HiLux Turbo-diesel engine is now available in three less expensive workhorse models.

The new HiLux 4x4 Turbo-diesel models are: Single Cab Pick-up, Single Cab Cab/Chassis and Double Cab

Toyota also offers high-grade HiLux 4x4 Turbo-diesel Double Cab SR5 Pick-up.

The Double Cab SR5 Pick-up now has stylish locally developed side steps.

Toyota has also upgraded all SR5 models (4x4 and 4x2) with a new high-grade 3-in-1 audio unit.

The new 2DIN-size audio head unit has an electronic touch tune AM/FM stereo radio, full logic cassette deck
and a single CD player.

Two HiLux 4x4 Turbo-diesel Single Cab SR5 models have been discontinued.

The new HiLux 4x4 range has 15 models, with the choice of Turbo-diesel, EFI-equipped 2.7 litre petrol and
3.0 litre naturally aspirated diesel engines.

Toyota also offers 13 4x2 models, with the choice of EFI-equipped 2.0 litre petrol, 2.7 litre petrol and 3.0 litre
diesel engines. HiLux 4x2 and 4x4
models are available in either single cab, extra cab or dual cab body styles to suit driver requirements.

All HiLux diesel models and all 2.7 litre petrol models have the availability of dual SRS airbags and ABS
anti-skid brakes.

The HiLux 4x4 Turbo-diesel models have the options of: Metallic paint, Safety Pack (dual SRS airbags and
ABS) or Safety Pack with Metallic paint.

The safety option consists of dual SRS airbags and ABS anti-skid brakes.

Airbag SRS-equipped models have the additional feature of force limiting front seatbelt pretensioners.



Toyota HiLux has dual SRS airbag and ABS anti-skid brake availability.

A safety option pack combining dual SRS airbag and ABS is offered on all HiLux 4x4 models, all 4x2 diesel
models and all 4x2 2.7 litre petrol models
- 26 of the 28 model HiLux range.

Toyota HiLux was the first vehicle in its class with dual SRS airbag availability.

All HiLux models specified with dual airbag SRS are fitted with dual front bucket seats and are also equipped
with state-of-the-art force-limiting front
seatbelt pretensioners, to help reduce load on the occupants in severe accidents.

HiLux ABS is a three-channel, four-sensor system.

The anti-skid brake system for 4x4 models includes a single-axis longitudinal linear G-sensor, which senses
the level of grip and adjusts the braking
strategy (algorithm) to minimise stopping distance.

The HiLux ABS system has been extensively tested in Australia, including the settings for 4x4 operation and

The parameter for ABS operation in low range is when the vehicle speed exceeds 10km/h.



Toyota designed HiLux to meet the highest current and anticipated relevant world-wide safety standards.

The HiLux body was developed using Toyota's Global Outstanding Assessment process, in which Toyota
reviews current and anticipated safety
standards and designs the vehicle to meet those standards.

HiLux was tested to the then latest European collision safety standards, US and Japanese requirements, plus
Toyota's own strict in-house goal of
having the highest passive safety level in the class.

HiLux meets the following international crash-test requirements:
* front crash barrier test at 56km/h (with airbags)
* 40 percent deformable offset front barrier test at 60km/h (with airbags)
* ECE/R95 dynamic side intrusion test on 4x2 models only (test is not applicable to 4x4, due to the
impactor/vehicle height relationship)
* FMVSS 216 roof strength test
* and 50km/h rear moving barrier crash test.

The body design incorporates a full dynamic side collision impact absorbing structure and side intrusion
beams in the doors.

It has been reinforced to meet front and rear impact requirements.

Passive safety features include:
* rear seat head restraints for Double Cab models
* a three-way collapsible steering column
* automatic locking retractor rear seatbelts in all Double Cab models (to assist in securing child safety
capsules/child safety seats
* two child restraint anchorage points in all Double Cab models
* a seatbelt warning lamp in high-grade 4x4 Double Cab SR5
* and a roll-over fuel cut-off valve for diesels.