TROUBLE DIAGNOSIS
EC-1413
[YD]
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EC
1.INSPECTION START
1. Check service records for any recent repairs that may indicate a related incident.
2. Check the current need for scheduled maintenance, especially for fuel filter and air cleaner filter. Refer to
MA-7, "
PERIODIC MAINTENANCE" .
3. Open engine hood and check the following:
–Harness connectors for improper connections
–Vacuum hoses for splits, kinks, or improper connections
–Wiring for improper connections, pinches, or cuts
4. Start engine and warm it up to the normal operating tempera-
ture.
>> GO TO 2.
2.PREPARATION FOR CHECKING IDLE SPEED
With CONSULT-II
Connect CONSULT-II to the data link connector.
>> GO TO 3.
3.CHECK IDLE SPEED
With CONSULT-II
1. Select “CKPS·RPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
2. Read idle speed.
OK or NG
OK >>INSPECTION END
NG >> GO TO 4.
4.CHECK FOR INTAKE AIR LEAK
Listen for an intake air leak after the mass air flow sensor.
OK or NG
OK >> GO TO 5.
NG >> Repair or replace.
SEF142I
725±25 rpm
SEF817Y
EC-1414
[YD]
TROUBLE DIAGNOSIS
5. BLEED AIR FROM FUEL SYSTEM
1. Stop engine.
2. Use priming pump to bleed air from fuel system. Refer to EC-1404, "
AIR BLEEDING" .
>> GO TO 6.
6. CHECK IDLE SPEED AGAIN
With CONSULT-II
1. Start engine and let it idle.
2. Select “CKPS·RPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
3. Read idle speed.
OK or NG
OK >>INSPECTION END
NG >> GO TO 7.
7. DRAIN WATER FROM FUEL FILTER
Drain water from fuel filter. Refer to EC-1404, "
WATER DRAINING" .
>> GO TO 8.
8. CHECK IDLE SPEED AGAIN
With CONSULT-II
1. Start engine and let it idle.
2. Select “CKPS·RPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
3. Read idle speed.
OK or NG
OK >>INSPECTION END
NG >> GO TO 9.
9. CHECK AIR CLEANER FILTER
Check air cleaner filter for clogging or breaks.
OK or NG
OK >> GO TO 10.
NG >> Replace air cleaner filter.725±25 rpm
SEF817Y
725±25 rpm
SEF817Y
FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
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SECTION
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FUEL SYSTEM
QR
PREPARATION ........................................................... 2
Commercial Service Tool ......................................... 2
FUEL SYSTEM ........................................................... 3
Checking Fuel Lines ............................................ ..... 3
General Precautions ................................................ 3
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND
FUEL PUMP ASSEMBLY ........................................... 4
Removal and Installation .......................................... 4
REMOVAL ............................................................. 4
INSPECTION AFTER REMOVAL ......................... 6
INSTALLATION ..................................................... 6
INSPECTION AFTER INSTALLATION ................. 6
Disassembly and Assembly ..................................... 7
DISASSEMBLY ..................................................... 7
ASSEMBLY ........................................................... 8
FUEL TANK ................................................................ 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ................................................... 10
INSPECTION AFTER INSTALLATION ................ 11
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 12
Standard and Limit ................................................. 12
FUEL TANK ......................................................... 12
Tightening Torque ................................................... 12
YD22DDTi
PREPARATION ......................................................... 13
Commercial Service Tool ........................................ 13
FUEL SYSTEM ......................................................... 14
Checking Fuel Lines ............................................ ... 14
General Precautions ............................................... 14
FUEL FILTER ............................................................ 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 15
INSPECTION AFTER INSTALLATION ................ 15
Air Bleeding ............................................................ 16
Draining Water from Fuel Filter .............................. 16
FUEL LEVEL SENSOR UNIT ................................... 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSPECTION AFTER REMOVAL ....................... 19
INSTALLATION ................................................... 19
INSPECTION AFTER INSTALLATION ................ 20
FUEL TANK .............................................................. 21
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSTALLATION ................................................... 22
INSPECTION AFTER INSTALLATION ................ 22
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 24
Standard and Limit .................................................. 24
Tightening Torque ................................................... 24
FUEL FILTER
FL-15
[YD22DDTi]
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FUEL FILTERPFP:16400
Removal and InstallationEBS00BLA
REMOVAL
1. Remove air duct and upper air cleaner case.
2. Remove fuel filter protector.
3. Disconnect fuel hoses at fuel filter bracket.
CAUTION:
Plug the pipe to prevent fuel from draining.
4. Remove fuel filter with bracket.
CAUTION:
Do not splash fuel during removal. If fuel is splashed,
immediately wipe it off.
5. Using band-type filter wrench (commercial service tool), remove
fuel filter.
6. Turn fuel filter upside down to drain fuel.
7. Remove drain plug from fuel filter.
INSTALLATION
Install in reverse order of removal, paying attention to following:
●Replace O-ring on drain plug with new one.
●Screw the fuel filter by hand until packing contacts sealing surface of bracket. Then tighten it by turning
approximately 2/3 turn.
●After installation, bleed air from fuel path. Refer to FL-16, "Air Bleeding" .
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
1. Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine stopped). Then check for
fuel leaks at connections.
2. Start the engine and rev it up and check for fuel leaks at connections.
SBIA0134E
SBIA0135E
SBIA0136E
Drain plug
: 3.9 - 5.9 N·m (0.4 - 0.6 kg-m, 35 - 52 in-lb)
FL-16
[YD22DDTi]
FUEL FILTER
Air Bleeding
EBS00BLB
After fuel filter is replaced and after fuel system components are
removed/installed, bleed air from fuel path as follows:
1. Move priming pump up and down to bleed air from fuel path.
2. When air is bled, pumping of priming pump becomes heavy stop
operation at that time.
3. Crank the engine until it starts. Do not crank the engine for more
than 30 seconds.
4. If the engine does not starts, stop cranking and repeat step 1
above.
5. If the engine does not operate smoothly after it has started, race
it two or three times.
6. If air cannot be bled easily (pumping of priming pump does not become heavy), disconnect feed-side of
hose between fuel filter and electronically controlled fuel injection pump. After that, operate priming pump
and confirm that fuel comes out.
CAUTION:
Prepare a tray to collect fuel. Prevent fuel from adhering to rubber parts, especially the engine
mount insulator.
Draining Water from Fuel FilterEBS00MRU
1. Prepare a tray at the drain hose open end.
2. Loosen drain cock, and operate priming pump to drain water
from fuel filter.
CAUTION:
●Water in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volume.
●Drained water is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mount insulator.
3. After draining, close drain cock by hand.
CAUTION:
If drain cock is tightened excessively, it may be damaged
and fuel will leak. Do not use tools to tighten drain cock.
4. Bleed air in fuel piping. Refer to FL-16, "
Air Bleeding" .
5. Start engine and check for fuel leakage.
SBIA0137E
SBIA0138E
AT-8
PRECAUTIONS
●Converter is contaminated with engine coolant containing antifreeze.
●Internal failure of stator roller clutch.
●Heavy clutch debris due to overheating (blue converter).
●Steel particles or clutch lining material found in fluid filter or on magnet when no internal parts in unit are
worn or damaged — indicates that lining material came from converter.
The torque converter should not be replaced if:
●The fluid has an odor, is discolored, and there is no evidence of metal or clutch facing particles.
●The threads in one or more of the converter bolt holes are damaged.
●Transaxle failure did not display evidence of damaged or worn internal parts, steel particles or clutch plate
lining material in unit and inside the fluid filter.
●Vehicle has been exposed to high mileage (only). The exception may be where the torque converter
clutch dampener plate lining has seen excess wear by vehicles operated in heavy and/or constant traffic,
such as taxi, delivery or police use.
EURO-OBD SELF-DIAGNOSIS — EURO-OBD —
●A/T self-diagnosis is performed by the TCM in combination with the ECM. The results can be read through
the blinking pattern of the O/D OFF indicator lamp or the malfunction indicator lamp (MIL). Refer to the
table on AT- 4 2 , "
SELF-DIAGNOSTIC RESULT TEST MODE" for the indicator used to display each self-
diagnostic result.
●The self-diagnostic results indicated by the MIL are automatically stored in both the ECM and TCM mem-
ories.
Always perform the procedure “HOW TO ERASE DTC” on AT- 3 9 , "
HOW TO ERASE DTC" to com-
plete the repair and avoid unnecessary blinking of the MIL.
●The following self-diagnostic items can be detected using ECM self-diagnostic results mode* only when
the O/D OFF indicator lamp does not indicate any malfunctions.
–PNP switch
–A/T 1st, 2nd, 3rd, or 4th gear function
*: For details of EURO-OBD, refer to EC-44, "
ON BOARD DIAGNOSTIC (OBD) SYSTEM" (QR25DE) or EC-
777, "ON BOARD DIAGNOSTIC (OBD) SYSTEM" (QR20DE).
●Certain systems and components, especially those related to EURO-OBD, may use a new style
slide-locking type harness connector.
For description and how to disconnect, refer to PG-68, "
HARNESS CONNECTOR" .
Wiring Diagrams and Trouble DiagnosisECS004Q4
When you read wiring diagrams, refer to the following:
●GI-13, "How to Read Wiring Diagrams"
●PG-2, "POWER SUPPLY ROUTING"
When you perform trouble diagnosis, refer to the following:
●GI-10, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES"
●GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident"
TROUBLE DIAGNOSES FOR SYMPTOMS
AT-221
[EURO-OBD]
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5.CHECK A/T FLUID CONDITION
1. Remove oil pan.
2. Check A/T fluid condition.
OK or NG
OK >> GO TO 6.
NG >> GO TO 8.
6.DETECT MALFUNCTIONING ITEM
1. Remove control valve assembly. Refer to AT- 4 4 8 , "
Control Valve Assembly" .
2. Check the following items:
–Shift valve A
–Shift valve B
–Shift solenoid valve A
–Shift solenoid valve B
–Pilot valve
–Pilot filter
OK or NG
OK >> GO TO 7.
NG >> Repair or replace damaged parts.
7.CHECK SYMPTOM
Check again.
OK or NG
OK >>INSPECTION END
NG >> 1. Perform TCM input/output signal inspection.
2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector.
SAT171B
AT-222
[EURO-OBD]
TROUBLE DIAGNOSES FOR SYMPTOMS
8. DETECT MALFUNCTIONING ITEM
1. Remove control valve assembly. Refer to AT- 4 1 3 , "
Installation" .
2. Check the following items:
–Shift valve A
–Shift valve B
–Shift solenoid valve A
–Shift solenoid valve B
–Pilot valve
–Pilot filter
3. Disassemble A/T.
4. Check the following items:
–High clutch assembly
–Torque converter
–Oil pump assembly
–Reverse clutch assembly
–Low & reverse clutch assembly
OK or NG
OK >> GO TO 7.
NG >> Repair or replace damaged parts.