EM-180
[YD22DDTi]
PRIMARY TIMING CHAIN
13. Install oil pump housing.
a. Apply a continuous bead of Genuine Liquid Gasket or equivalent
on locations shown in the figure. Refer to EM-111, "
Precautions
For Liquid Gasket" .
A: Leave the start and end areas of the bead slightly protruding
from the surface.
B: Apply liquid gasket along upper end surface of oil pump hous-
ing.
b. Install oil pump drive spacer to crankshaft.
●Install with the front mark (punched mark) facing the front of
the engine.
c. Install O-ring into the groove of rear chain case.
d. Install oil pump housing.
●When installing, align the inner rotor in the direction of the two
facing flats of the oil pump drive spacer.
●When installing, align the dowel pin with the pin hole.
e. Tighten fixing bolts in the numerical order shown in the figure.
f. After tightening all the bolts, re-tighten in the same order.
14. Check gaps on upper oil pan mounting surface.
●Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:
●If the measured value is out of the above range, install again.
15. Install crankshaft pulley.
a. Install crankshaft pulley to crankshaft.
b. Hold crankshaft pulley with the pulley holder (SST).
c. Tighten bolt to 20 to 29 N·m (2.0 to 3.0 kg-m, 15 to 21 ft-lb).
d. Put an alignment mark on crankshaft pulley that aligns with one
of the punched marks on the bolt.
e. Tighten fixing bolt another 60° - 66° [target: 60° (turn by one
notch)].
16. Install secondary timing chain and the associated parts.
JEM144G
JEM145G
JEM133G
Oil pump housing and rear chain case:
Standard : – 0.14 to 0.14 mm (– 0.0055 to 0.0055 in)
Rear chain case and cylinder block:
Standard : – 0.25 to 0.13 mm (– 0.0098 to 0.0051 in)
JEM146G
JEM147G
EM-216
[YD22DDTi]
CYLINDER BLOCK
CRANKSHAFT RUNOUT
●Place V-block onto surface plate to support journals at both ends
of crankshaft.
●Position dial indicator vertically onto No. 3 journal.
●Rotate crankshaft to read needle movement on dial indicator.
(Total indicator reading)
CONNECTING ROD BEARING OIL CLEARANCE
Method by Measurement
●Install connecting rod bearings to connecting rod and cap, and
tighten connecting nuts to the specified torque. Use inside
micrometer to measure connecting rod bearing inner diameter.
(Bearing clearance) = (Connecting rod bearing inner diameter) −
(Crankshaft pin outer diameter)
●If out of specifications, check connecting rod big end inner diam-
eter and crankshaft pin outer diameter, and select appropriate
connecting rod bearing to adjust clearance to specifications.
Refer to EM-207, "
HOW TO SELECT CONNECTING ROD
BEARING" .
Method Using Plastigage
●Remove contamination such as engine oil, dust completely from
crankshaft pins and each bearing surface.
●Cut plastigage slightly shorter than bearing width, place it in
crankshaft direction, avoiding oil holes.
●Install connecting rod bearings to caps, and tighten connecting
rod nuts to the specified torque.
CAUTION:
Never rotate crankshaft.
●Remove connecting rod caps and bearings, and measure plasti-
gage width using scale on plastigage bag.
CAUTION:
If out of specification, take same action mentioned in “Method by Measurement”.
MAIN BEARING OIL CLEARANCE
Method by Measurement
●Install main bearings to the cylinder block and bearing cap, and tighten the bolts to the specified torque.
Then, measure the inner diameter of the main bearings.
(Bearing clearance) = (Bearing inner diameter) − (Crankshaft journal outer diameter)
●If out of specification, check main bearing housing inner diameter and crankshaft journal outer diameter,
and select appropriate main bearing to adjust clearance to specifications. Refer to EM-208, "
HOW TO
SELECT MAIN BEARING" . Standard : 0.05 mm (0.0020 in)
Limit : 0.10 mm (0.0039 in)
FEM116
Standard : 0.031 - 0.061 mm (0.0012 - 0.0024 in)
PBIC0119E
EM142
Standard : 0.039 - 0.066 mm (0.0015 - 0.0026 in)
CYLINDER BLOCK
EM-217
[YD22DDTi]
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Method Using Plastigage
●Remove contamination such as engine oil and dust completely
from crankshaft journals and each bearing surface.
●Cut plastigage slightly shorter than bearing width. Place it in
crankshaft turning direction, avoiding oil holes.
●Install main bearings and bearing cap and tighten to the speci-
fied torque.
CAUTION:
Never rotate crankshaft.
●Remove main bearings and bearing caps, and measure plasti-
gage width using scale on plastigage bag.
CAUTION:
If out of specification, take same action mentioned in “Method by Measurement”.
MAIN BEARING CRUSH HEIGHT
●When the bearing cap is removed after being tightened to the
specified torque with main bearings installed, the tip end of bear-
ing must protrude.
●If out of specification, replace main bearings.
MAIN BEARING CAP BOLT DEFORMATION
●Measure the outer diameter of threaded area, d1 and d2, at the
points specified in the figure.
●When the necked point is identified at a point other than where
specified, measure at the point as d2.
●Calculate the difference between d1 and d2.
CONNECTING ROD BOLT DEFORMATION
●Install nuts to connecting rod bolts. Check that the nut can be
screwed smoothly on bolt threads by hand to the last thread on
the bolt.
●If the nut does not screw in smoothly, measure the outer diame-
ter of the bolt thread at the point specified in the figure.
●If a necked point is identified, measure at that point.
●If the measurement exceeds the limit, replace connecting rod
bolts and nuts.
EM142
Standard : Crush height must exist.
SEM502G
Limit : 0.13 mm (0.0051 in)
JEM219G
Standard : 8.90 - 9.00 mm (0.3504 - 0.3543 in) dia.
Limit : 8.75 mm (0. 3445 in) dia.
JEM220G
PRECAUTIONS
LU-3
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[QR]PRECAUTIONSPFP:00001
Precautions For Liquid GasketEBS00ODQ
REMOVAL OF LIQUID GASKET
●After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the old liquid gasket
sealing.
CAUTION:
Be careful not to damage the mating surfaces.
●In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason a tool such as a flat-blade
screwdriver is used, be careful not to damage the mating
surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.
●Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
●If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.
●As for the bolt holes, normally apply the liquid gasket inside
the holes. If specified, it should be applied outside the holes.
Make sure to read the instruction in this manual.
●Within five minutes of liquid gasket application, install the mat-
ing component.
●If the liquid gasket protrudes, wipe it off immediately.
●Do not retighten after the installation.
●After 30 minutes or more have passed from the installation, fill
the engine oil and engine coolant.
CAUTION:
If there are instructions in this manual, observe them.
PBIC0275E
PBIC0003E
EMA0622D
SEM159F
PRECAUTIONS
LU-15
[YD22DDTi]
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[YD22DDTi]PRECAUTIONSPFP:00001
Precautions For Liquid GasketEBS00MRV
REMOVAL OF LIQUID GASKET
●After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the old liquid gasket
sealing.
CAUTION:
Be careful not to damage the mating surfaces.
●In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason a tool such as a flat-blade
screwdriver is used, be careful not to damage the mating
surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.
●Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
●If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.
●As for the bolt holes, normally apply the liquid gasket inside
the holes. If specified, it should be applied outside the holes.
Make sure to read the instruction in this manual.
●Within five minutes of liquid gasket application, install the mat-
ing component.
●If the liquid gasket protrudes, wipe it off immediately.
●Do not retighten after the installation.
●After 30 minutes or more have passed from the installation, fill
the engine oil and engine coolant.
CAUTION:
If there are instructions in this manual, observe them.
PBIC0275E
PBIC0003E
EMA0622D
SEM159F
PRECAUTIONS
CO-3
[QR]
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[QR]PRECAUTIONSPFP:00001
Precautions For Liquid GasketEBS00MRX
REMOVAL OF LIQUID GASKET
●After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the old liquid gasket
sealing.
CAUTION:
Be careful not to damage the mating surfaces.
●In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason a tool such as a flat-blade
screwdriver is used, be careful not to damage the mating
surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.
●Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
●If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.
●As for the bolt holes, normally apply the liquid gasket inside
the holes. If specified, it should be applied outside the holes.
Make sure to read the instruction in this manual.
●Within five minutes of liquid gasket application, install the mat-
ing component.
●If the liquid gasket protrudes, wipe it off immediately.
●Do not retighten after the installation.
●After 30 minutes or more have passed from the installation, fill
the engine oil and engine coolant.
CAUTION:
If there are instructions in this manual, observe them.
PBIC0275E
PBIC0003E
EMA0622D
SEM159F
PRECAUTIONS
CO-23
[YD22DDTi]
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[YD22DDTi]PRECAUTIONSPFP:00001
Precautions For Liquid GasketEBS00MRY
REMOVAL OF LIQUID GASKET
●After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the old liquid gasket
sealing.
CAUTION:
Be careful not to damage the mating surfaces.
●In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason a tool such as a flat-blade
screwdriver is used, be careful not to damage the mating
surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.
●Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
●If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.
●As for the bolt holes, normally apply the liquid gasket inside
the holes. If specified, it should be applied outside the holes.
Make sure to read the instruction in this manual.
●Within five minutes of liquid gasket application, install the mat-
ing component.
●If the liquid gasket protrudes, wipe it off immediately.
●Do not retighten after the installation.
●After 30 minutes or more have passed from the installation, fill
the engine oil and engine coolant.
CAUTION:
If there are instructions in this manual, observe them.
PBIC0275E
PBIC0003E
EMA0622D
SEM159F
EC-20
[QR25(WITH EURO-OBD)]
INDEX FOR DTC
[QR25(WITH EURO-OBD)]INDEX FOR DTCPFP:00024
Alphabetical IndexEBS00M01
Check if the vehicle is a model with Euro-OBD (E-OBD) system or not by the “Type approval number” on the
identification plate. Refer to GI-43, "
IDENTIFICATION PLATE" .
NOTE:
If DTC U1000 is displayed with other DTC, first perform the trouble diagnosis for DTC U1000. Refer to
EC-122
.
×: Applicable –: Not applicable
Items
(CONSULT-II screen terms)DTC*
1
TripMI lighting
upReference page
CONSULT-II
GST*
2ECM*3
APP SENSOR P2138 2138 1×EC-373
APP SEN 1/CIRC P2122 2122 1×EC-355
APP SEN 1/CIRC P2123 2123 1×EC-355
APP SEN 2/CIRC P2127 2127 1×EC-361
APP SEN 2/CIRC P2128 2128 1×EC-361
A/T 1ST GR FNCTN P0731 0731 2×AT- 1 3 1
A/T 2ND GR FNCTN P0732 0732 2×AT- 1 3 7
A/T 3RD GR FNCTN P0733 0733 2×AT- 1 4 3
A/T 4TH GR FNCTN P0734 0734 2×AT- 1 4 9
ATF TEMP SEN/CIRC P0710 0710 2×AT- 11 6
BRAKE SW/CIRCUIT P1805 1805 2 –EC-349
CAN COMM CIRCUIT*6U1000
1000*51×EC-122
CKP SEN/CIRCUIT P0335 0335 2×EC-227
CMP SEN/CIRCUIT P0340 0340 2×EC-233
CTP LEARNING P1225 1225 2 –EC-337
CTP LEARNING P1226 1226 2 –EC-339
CYL 1 MISFIRE P0301 0301 2×EC-217
CYL 2 MISFIRE P0302 0302 2×EC-217
CYL 3 MISFIRE P0303 0303 2×EC-217
CYL 4 MISFIRE P0304 0304 2×EC-217
ECM P0605 0605 1 or 2× or –EC-260
ECM BACK UP/CIRC P1065 1065 2×EC-267
ECT SEN/CIRCUIT P0117 0117 1×EC-149
ECT SEN/CIRCUIT P0118 0118 1×EC-149
ENG OVER TEMP P1217 1217 1×EC-323
ENGINE SPEED SIG P0725 0725 2×AT- 1 2 7
ETC ACTR P1121 1121 1 or 2×EC-276
ETC FUNCTION/CIRC P1122 1122 1×EC-278
ETC MOT P1128 1128 1×EC-290
ETC MOT PWR P1124 1124 1×EC-285
ETC MOT PWR P1126 1126 1×EC-285
FUEL SYS-LEAN-B1 P0171 0171 2×EC-200
FUEL SYS-RICH-B1 P0172 0172 2×EC-206
HO2S1 (B1) P0132 0132 2×EC-163
HO2S1 (B1) P0133 0133 2×EC-169