Toyota Hilux workshop manual

The history associated with Toyota Hilux covers eight generations, where the pick-up has won a character among the world’s many reliable and trustworthy commercial vehicles. Theoretically, the real history regarding the Toyota Hilux starts outside of Toyota engine business. The Hino Briska

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The history associated with Toyota Hilux covers eight generations, where the pick-up has won a character among the world’s many reliable and trustworthy commercial vehicles. Having survived severe environments within the Arctic and Antarctic – and all points in between – the credentials with this ultra-tough device were confirmed certainly. It has offered over 17.3 million products and it is Europe’s best-selling pick-up, therefore Hilux is obviously the workhorse of choice for several organizations.

Theoretically, the real history regarding the Toyota Hilux starts outside of Toyota engine business. As an alternative, the Hilux finds its roots in Briska line of smaller pick-ups made by Japanese commercial car manufacturer Hino engines since 1961. Toyota’s records with pick-ups goes back toward SB model of 1947 but halfway through production of the second-generation Briska, Toyota partnered with Hino engines and forced ahead small design improvements.

The Hino Briska was rebranded the Toyota Briska from 1967, signalling a refocusing of this Hino brand towards creation of method- to heavy-duty commercial automobiles alternatively.

It had been March 1968 when Toyota dealerships in Japan took delivery of the first real Toyota Hilux pick-up. This new model bore the N10 chassis code, and though it absolutely was conceived by Toyota, the newest Hilux always been engineered and built at Hino Motors’ Hamura Plant.

Upon their launch, the Hilux swelled Toyota’s light-duty pick-up consist of 2-3 split designs, the newest pick-up joining the present Corona and Masterline. The second two were car-based derivatives and Toyota relocated swiftly to stage them aside to be able to delineate between Toyota’s light commercial car range and its own passenger vehicles.

The latest Hilux – their title a contraction of ‘high’ and ‘luxury’ – used an independent framework construction with a double wishbone/coil spring suspension system arranged at the front and rigid axle/leaf springtime arrangement at back.

First, the Toyota Hilux started as a short-wheelbase model run on a four-cylinder 1.5-litre R-series petrol system with a column-shift, four-speed guide gearbox driving the trunk tires. Just over a year into manufacturing in April 1969, the Hilux range is grew to incorporate a long-wheelbase model. February 1971 observed the arrival of a gutsier 1.6-litre variation that replaced the beds base engine. Traveler ability had been for three staff sat informed on a bench chair.

For essential united states marketplace, Toyota made some special changes. In the first place, the Hilux title isn’t used – alternatively, the pick-up had been just badged because the ‘Toyota Truck’ to stop misunderstandings over their name and purpose. The American markets just got larger 1.9- or 2.0-litre R-series powerplants, and just the short-wheelbase chassis using its 1.85m lengthy sleep ended up being offered to purchasers.

The second-generation Hilux was launched in May 1972 for the 1973 design 12 months, and noted the model’s introduction into UK market. Essentially a reworked type of its predecessor, the N20 series showcased an updated human body with somewhat extended wheelbases, more comfortable interior and carry-over system range.

1974 Toyota Hilux

In addition improved for the second-generation were Hilux’s protection qualities – they today had servo-assisted double braking system master cylinders and load-sensing brake proportioning valves. And soon after publish, the North American markets saw the introduction of a long-wheelbase design with a 2.25m running sleep. A column-mounted four-speed guide gearbox is the typical transmission setup, though buyers had been today in a position to indicate a floor-mounted gearshift, deleting the three-person workbench in favour of two specific seats.

N20 Toyota Hilux much longer

A higher specification model was launched for some areas from 1974 onwards, providing a more effective 2.0-litre R-series engine and recommended three-speed automated gearbox, the first of their type previously suited to the Hilux.

This move upmarket ended up being mirrored in the US in 1975 aided by the introduction of a larger 2.2-litre motor and SR5 trim designation, combined with option of a five-speed manual gearbox. In October 1975 the 2.0-litre engine was removed in every various other markets, consolidating the Hilux to 1 1.6-litre device to satisfy new emissions requirements.
Versatile Equipment

Flexibility was the watchword for the third-generation N30 show Hilux with regards to went on sale in September 1978. No matter design – there have been now three standard-length and four long-wheelbase derivatives – the third-gen Hilux is designed to provide saloon-like requirements and trip comfort. This generated an evolution of predecessor’s double wishbone front side suspension system that replaced the coil springs for a torsion bar.

Substantially, a top-of-the-range Super Deluxe model ended up being launched from publish; its prolonged taxi was 90mm longer than standard, dramatically enhancing interior space. The Super Deluxe had been later supplemented with a complete double-cab version with four doorways as well as 2 rows of seats. All higher-grade versions got front disc brake system as standard, and buyers could today indicate a Toyota-embossed tailgate. A majority of these progress are borne out of Toyota’s careful learn of this US marketplace, where in actuality the vehicle consistently doubled as a passenger car and leisure car. Perhaps the address associated with Japanese pamphlet when it comes to Hilux proclaimed that it was “born in Japan, lifted in the US”.

1978 Toyota Hilux

The new dual-purpose nature of Hilux ended up being strengthened because of the first four-wheel drive design in October 1979, which used the driveline and gearbox transfer situation through the 40-series Land Cruiser allied to a reworked type of the now-reinstated 2.0-litre R-series petrol system. Diesel energy accompanied with a 2.2-litre L-series engine, designed for the very first time in both rear- and four-wheel drive platforms.

1982 Toyota Hilux 4x2

Toyota further emphasised Hilux’s traditions consumption in 1981 if the manufacturer partnered with Winnebago companies as well as 2 more automobile human anatomy makers in the US marketplace to produce SUV-type leisure vehicles. In line with the four-wheel drive Truck chassis taxi, these companies included various fibreglass body to your steel framework across the rear rims.

Indeed, the success of these early walkthrough conversion rates led straight to Toyota’s publish for the Hilux-based 4Runner and Hilux Surf facility truck designs which showed up at the beginning of the fourth-generation’s lives period.

Toyota revealed the fourth-generation N40 chassis Hilux in November 1983, as well as for a while it had been available alongside their forerunner, which remained available for sale in the domestic market as a rear-wheel drive base design.

1983 Toyota Hilux 4x4

But the more recent generation vehicle had been instantly characterised from the older sibling by their attractively blistered arches and restored interior. Exactly what performedn’t changes had been their track record of near-indestructibility; an undeniable fact that has been underlined by BBC Top equipment with its unsuccessful attempts to ‘kill’ one hard-worked instance.

Top Gear's indestructible Hilux

Solitary- and double-cab versions are offered by launch, like an innovative new raised-bed design with three bottom-hinged edges. These additions enhanced the number of Hilux modifications from 17 to 20.

Purchasers of rear-wheel drive brands could select from four machines – 1.6- or 1.8-litre petrol, and 2.2- or 2.4-litre diesel – while four-wheel drive products put either a 2.0-litre petrol or perhaps the biggest 2.4-litre diesel.

Considering that the launch associated with the N40, the global marketplace for recreational motors had grown exponentially, with SUVs like the Ford Bronco and Nissan Pathfinder out of the blue showing up on forecourts.

Toyota reacted swiftly sufficient reason for efficiency by modifying the short-frame sleep regarding the Hilux, the removal of the bulkhead from back of this cab, including an one-piece fibreglass-reinforced vinyl canopy, suitable a bench chair inside back, and softening a corner suspension.

Larger motors were installed, including 2.4-litre turbo and 3.0-litre V6 petrol engines, although the larger dimensions among these devices needed the development of a larger forward track while the switch from an excellent front side axle to an unbiased set-up.

The vehicle that lead using this unexpected refresh was released to the globe from might 1984 onwards as either the Hilux browse or 4Runner – basically a three-door station truck with off road capacity similar to that of the Land Cruiser. Toyota additionally used changes through the A-pillar forwards through the entire whole Hilux number.

September 1988 marked the development of the brand new fifth-generation N50 chassis Hilux, with modified bodywork that represented most visual and real progress on the outbound variation.

1990 Toyota Hilux 2wd

Built to the 3 core principles of power, sturdiness and comfort, the newest model’s indoor is much more car-like when it comes to its gear degree and dashboard design. Outside, the outside bodywork today featured integrated screen sashes inside doors and a one-piece running bay that eliminated the be concerned about rust developing in seams.

Finally, four-wheel drive products got unique arch flares that widened the general human anatomy by 40mm, while rear-wheel drive brands have a narrower style with standard flat-sided front wings and back one-fourth panels.

1996 Hilux 4wd Double Cab

The system number similarly differentiated between four- and rear-wheel drive brands; the latter either obtained a brand new 1.8-litre Y-series petrol or 2.4-litre L-series diesel, the former a gutsier 2.0-litre Y-series or 2.8-litre diesel. Later inside N50’s manufacturing the engine selection of the rear-wheel drive designs had been enhanced to fit that of the four-wheel drive models.

Meanwhile, the 3.0-litre V6 petrol motor had been reserved for double-cab products therefore the second-generation Surf/4Runner, and in answer to diversifying buyer requirements, how many rear-wheel drive models readily available because of the four-speed automatic gearbox had been increasing.

The second-generation Hilux Surf/4Runner appeared the 1990 model season, once again constructed on the Hilux system; indeed, the models had been practically identical through the B-pillar ahead. However, whereas the first-generation design had a straightforward FRP structure together with the pick-up sleep, the brand new car showcased a totally incorporated steel body with five doorways and all-new coil sprung rear suspension.

1995 Toyota 4Runner

This design is stopped in 1995, and from the third-generation onwards the Hilux Surf/4Runner turned to make use of the Land Cruiser Prado platform.

Further changes are in store for the N50 Hilux across global markets. Toyota forged a relationship with Volkswagen in 1989 to help expand their position in European countries, thereafter the German producer launched the Taro, a barely-disguised badge-engineered type of the Hilux. The decision was also made that whenever the N50 stopped production, the US market would switch from the Hilux/Truck number towards the bigger, most truly truck-like Tacoma pick-up.

With all the multipurpose Hilux Surf/4Runner range now forging ahead separately, Toyota gently refocused this new sixth-generation Hilux pick-up range into two clear limbs – company usage and private usage.

The range is introduced in Japan in September 1997 and is easily distinguished from earlier generation versions by a swage line that carefully tapers downwards toward leading indicators. Once again it was available with two- or four-wheel drive transmission and either single- or double-cab human body configurations. The system line-up consisted of 2.0- and 2.7-litre four-cylinder petrol products along with 2.4-litre turbo and 3.0-litre obviously aspirated diesels.

Personal-use designs were now borderline stylish, built with additional equipment and equipment to raised suit their particular recreational intentions, including a lengthier and bigger cabin with improved noise insulation. Business-use designs, however, had been much more fundamental and supplied reduced specification level.

N60 Toyota Hilux Dual Taxi

The largest changes for sixth-generation is that Hilux designs today was included with separate front suspension – the very first time in the history of the Toyota Hilux. An excellent axle might have been the traditional setup for off road use but modern Land Cruiser brands have proved the effectiveness of independence without having to sacrifice a lot of suspension system vacation, while delivering big progress in ride quality and handling.

Arguably this development helped the sixth-generation Hilux recapture its lead-in the commercial one-ton pick-up marketplace. This condition is immortalised in July 2004 if the British number expanded to include a new high-spec Invincible design, though which could have experienced some thing regarding the current airing of this Top equipment programme talked about prior.

Predicated on an altered version of the N60’s ladder framework underpinnings, the seventh-generation N70-chassis Hilux expanded somewhat in stature to be categorized as a mid-size pick-up. This change gifted the automobile with better path presence, interior area, and load capability – all progress identified from customer states.

2005 Toyota Hilux

Perhaps above every other Hilux generation before it, this 7th iteration saw many, successive improvements throughout their lives, allowing the model to consistently go beyond customer requirements and ever-tightening emissions criteria.

As an example, soon after their October 2005 launch when you look at the UK, a 3rd system style was inserted amongst the single-cab two-door and double-cab four-door variants. Called the excess taxi, they provided seating for four behind only two doorways and a lengthier burden bay than that the standard double-cab.

2009 Toyota Hilux Excess Cab

A new twin-cam 3.0-litre 16-valve D-4D diesel engine became obtainable in January 2007 to complement the current 2.5-litre D-4D, thereby elevating the entire range to Euro 4 emissions guidelines.

Soon later, this modern-day device was put to your ultimate test of reliability by effectively powering Top Gear’s current assault on the Hilux’s profile into North Magnetic Pole – an initial for almost any car. Further challenges spotted the Hilux offer transport for an expedition south Pole and rise an erupting volcano in Iceland to access lava samples, each of which they survived. Little ponder the Invincible grade remained for sale in this generation also.

Top Gear Polar Hilux

A thorough re-style ended up being used in October 2011 for 2012 design season, encompassing smoother architecture from the A-pillar forwards. In, top of the dashboard was brand new and housed modern models of this Toyota Touch media program for several mid- and high-grade designs. Eventually, the two diesel machines now fulfilled Euro 5 emissions laws while being more powerful and affordable than previously.

By 2015, Hilux had accumulated 16 million selling globally, and also within the last few seasons of manufacturing they maintained class prominence in Europe by securing practically one-quarter of most pick-up business. Toyota demonstrably have no intention of Hilux losing its profile once the full and super-tough motoring option because of its eighth generation.

1st UK customer deliveries of the newer 8th generation Hilux began on 1 July 2016. Why not make your very own contribution to their record by visiting the local Toyota centre and organising a test-drive.

ifth generation
Fifth generation
1991 Toyota HiLux 2-door taxi framework.jpg
1988–1991 Toyota HiLux taxi framework
Also Known As Toyota 4×2
Toyota 4×4
Volkswagen Taro
Production August 1988–1997
System Japan: Toyota, Aichi; Hamura, Tokyo
Argentina: Zárate
Colombia Envigado, Colombia
Germany: Hanover
New Zealand: Thames
Philippines: Santa Rosa, Laguna
Thailand: Samrong Tai
United States: Fremont, California
Body and chassis
System design 2-door, 4-door vehicle
Layout Front motor, rear-wheel drive / four-wheel drive
Related Toyota 4Runner/Hilux Browse
Toyota Classic
Engine 1.8 L 2Y-U I4
2.4 L 22R-E I4
3.0 L 3VZ-E V6
2.4 L 2L diesel I4
2.8 L 3L diesel I4
Transmission four-speed manual
five-speed handbook
four-speed automated
Wheelbase regular cab: 2,616 mm
regular taxi lengthy bed: 2,850 mm
Xtracab: 3,086 mm
Xtracab V6: 3,096 mm
Size regular cab: 4,435 mm
regular taxi lengthy bed: 4,724 mm
Xtracab: 4,905 mm
DLX regular cab long bed 4WD: 4,719 mm
DLX regular taxi 4WD: 4,430 mm
Circumference 1,689 mm
Height 1988–91 regular cab: 1,544 mm
1988–91 regular taxi lengthy bed: 1,539 mm
1988–91 Xtracab 2WD: 1,549 mm
1988–91 regular cab longer bed 4WD: 1,704 mm
1988–91 Xtracab 4WD: 1,709 mm
1991–97 regular taxi: 1,590 mm
1991–97 regular taxi: 1,595 mm
1991–97 Xtracab 4WD: 1,755 mm
1991–97 regular cab 4WD: 1,750 mm

The next redesign, in 1988, created a longer-wheelbase solution, 3,099 mm rather than 2,616 mm the regular wheelbase. Its one-piece cargo-box wall space eliminated the rust-prone seams which were found in earlier products. The V6 Xtracab SR5 received Motor Trend magazine's vehicle of the season honor that season. The Xtra Cabs now showcased even more area behind the leading seats as compared to last generation which permitted recommended jump-seats for rear passengers, a feature more consistent with competition of the time.

In 1991, US production started within NUMMI plant in Fremont, California, nonetheless some trucks marketed in the usa throughout the 91–95 design years were still stated in Japan.

The Hilux received a minor renovation in 1991, which was a small grille change and newer Toyota emblem that were recently used.

It absolutely was during this generation that Toyota discontinued the Hilux in america, changing they aided by the new Tacoma for 1995 model 12 months.


1988–1995: 1.8 L 2Y-U I4, 58 kW at 5,000rpm 140 N·m at 3,200rpm
1988–1995: 1.8 L 2Y I4, 61 kW at 4,800rpm 140 N·m at 2,800rpm
1989–1997: 2.4 L 22R-E SOHC EFI I4, 84 kW at 4,600 rpm and 192 N·m at 3,400 rpm
1989–1995: 3.0 L 3VZ-E V6, 112 kW at 4,800 rpm
1989–1997: 2.4 L 2L-II diesel I4, 66 kW at 4,200 rpm and 167 N·m at 2,400 rpm
2.8 L 3L diesel I4, 67 kW at 4,000 rpm and 188 N·m at 2,400 rpm

Volkswagen built and marketed all of them under the Volkswagen Taro name from February 1989 to March 1997.

This generation offered in Thailand since the Toyota Hilux Mighty-X.

For sales in Colombia, Ecuador and Venezuela, the Hilux was stated in Colombia from 1994 to 1998 by the SOFASA organization. For deals in Argentina, Brazil, and Uruguay, the Hilux is produced in Argentina from 1997 through 2005. For selling in Bolivia, Chile, Paraguay and Peru, the Hilux was imported from production facilities in Japan from 1989 to 1997.

South US areas:

single taxi framework
solitary cab lengthy bed
xtra cab
staff taxi

Sixth generation
Sixth generation
1997-2001 Toyota Hilux 2-door energy 01.jpg
Manufacturing 1997–2005
Assembly Japan: Hamura, Tokyo
Colombia Envigado, Colombia
Philippines: Santa Rosa, Laguna
Thailand: Samut Prakan
Venezuela: Cumaná
Human anatomy and framework
Human anatomy style 2-door vehicle
4-door truck
Layout front side system, rear-wheel drive / four-wheel drive
Relevant Toyota 4Runner/Hilux Browse
Toyota Hilux Recreation Driver
Toyota Kijang
Motor 2.0 L I4
2.4 L I4
2.7 L I4
3.4 L V6
2.4 L D-4D turbo diesel
2.5 L D-4D turbo diesel
2.8 L diesel I4
3.0 L diesel I4
Transmission 5-speed guide
4-speed automated
Wheelbase Average Cab: 2,850 mm
Extensive Taxi: 3,090 mm
Staff Cab: 2,855 mm
Length Regular Cab: 4,690 mm
Longer Cab: 5,035 mm
Team Cab: 4,790 mm
Width average Cab & All 2WD brands: 1,665 mm
Staff Cab & longer Cab: 1,790 mm

4WD standard Cab/Extended taxi: 1,775 mm
4WD Crew Cab: 1,795 mm
2WD Regular taxi: 1,600 mm/1,650 mm

2WD Extended & team Cab:1,695 mm


1998–2001 2.0 L 1RZ-E 8 device SOHC I4
1998–1999 3.0 L 5L diesel I4, 72 kW
1995–2004 2.4 L 2RZ-FE 16-valve DOHC I4, 106 kW
1995–2004 2.7 L 3RZ-FE 16-valve DOHC I4, 112 kW
1995–2004 3.4 L 5VZ-FE 24-valve DOHC V6, 142 kW

The Hilux had been stated in Colombia for product sales in Colombia, Venezuela, and Ecuador from 1998 to 2005 because of the SOFASA company. In Venezuela and Ecuador, the single-cab 2WD chassis/long bed is named the Stout II). For deals in Bolivia, Chile, Paraguay, Peru, it absolutely was imported from Japan from 1998 through 2004. This design had not been marketed in Argentina or Brazil because fifth-generation Hilux have got a redesign and upgrade.

South US areas:

solitary cab framework
single taxi longer bed
staff taxi

Toyota changed manufacturing from Hilux Mighty-X toward Hilux Tiger in the belated 1990s and made it the worldwide export hub. The Thailand-made Hilux Tiger experienced the following variations:

1998–1999: Hilux Tiger aided by the 3.0 L 5L motor
2000–2001: Hilux Tiger aided by the 3.0 L 5L-E EFI system
2001: Hilux Tiger with 1KZ motor
Belated 2001 – late 2004: Hilux Tiger SportCruiser with D4D motor

In 2005, Toyota stopped production of the Hilux vehicle for the Japanese marketplace. It was the past generation Hilux to-be for sale in Japan.