ENGINE ASSEMBLY
EM-195
[YD22DDTi]
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●Use a manual lift table caddy or equivalently rigid tool such as a
jack or trestle. Securely support bottom of engine and transaxle,
and simultaneously adjust hoist tension.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
21. Remove RH engine mounting insulator.
22. Pull LH engine mounting through-bolt out.
23. Remove mounting bolts at front end of center member.
24. Remove front suspension member mounting bolts and nuts.
25. Remove engine, transaxle and transfer assembly with suspen-
sion member from vehicle downward by carefully operating sup-
porting tools.
CAUTION:
●During the operation, make sure that no part interferes
with body side.
●Before and during this lifting, always check if any har-
nesses are left connected.
●During the removal operation, always be careful to pre-
vent vehicle from falling off the lift due to changes in the center of gravity.
●If necessary, support vehicle by setting a jack or equivalent tool at the rear.
26. Remove power steering pump with piping connected from engine. Move it aside on suspension member.
27. Remove front engine mounting and rear engine mounting through-bolts to remove suspension member.
28. Remove starter motor.
29. Separate engine and transaxle. Refer to MT-15, "
TRANSAXLE ASSEMBLY" .
INSTALLATION
Install in the reverse order of removal.
●Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.
●When installation directions are specified, install parts according to the direction marks on them referring
to components illustration.
●Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
KBIA0256E
KBIA0257E
KBIA0270E
EM-230
[YD22DDTi]
SERVICE DATA AND SPECIFICATIONS (SDS)
Common rail51.0 - 64.0 (5.2 - 6.5, 38 - 47)
Fuel supply pump51.0 - 56.0 (5.2 - 5.7, 38 - 41)
Fuel supply pump sprocket 37.0 - 41.0 (3.8 - 4.2, 28 - 30)
Fuel supply pump rear bracket 27.0 - 37.0 (2.8 - 3.8, 20 - 27)
Front chain case
6.9 - 8.8 (0.7 - 0.9, 61 - 78)*
2
Chain tensioner
8.5 - 10.7 (0.86 - 1.1, 75 - 95)*2
Tension guide21.0 - 26.0 (2.1 - 2.7, 16 - 19)
Slack guide21.0 - 26.0 (2.1 - 2.7, 16 - 19)
Camshaft sprocket 138 - 147 (14.0 - 15.0, 102 - 108)
Fuel supply pump sprocket 38.0 - 41.0 (3.8 - 4.2, 28 - 30)
Oil pump12.0 - 13.0 (1.3 - 1.4, 9 - 10)
Power steering pump51.0 - 56.0 (5.2 - 5.8, 38 - 41)
Rear chain case12.0 - 13.0 (1.2 - 1.4, 19 - 10)
Engine coolant temperature sensor 12.0 - 15.0 (1.2 - 1.6, 9 - 11)
*1 Cylinder head 1) 29 - 38 (2.9 - 3.9, 21 - 28)
2) 180° to 185°
3) 0 (0, 0)
4) 35 to 44 (3.5 - 4.5, 26 - 32)
5) 90° to 95°(angle tightening)
6) 90° to 95° (angle tightening)
Water outlet21 - 28 (2.1 - 2.9, 16 - 20)
Glow plug18.0 - 21.0 (1.8 - 2.2, 13 - 15)
*1 Flywheel103 - 112 (10.5 - 11.5, 76 - 83)
Oil pressure switch13.0 - 17.0 (1.25 - 1.75, 9 - 12)
Oil jet6.1 - 10.7(0.62 - 1.1, 54 - 95)
Oil jet relief valve40 - 58 (4.0 - 6.0, 29 - 43)
Rear oil seal retainer12.0 - 13.0 (1.2 - 1.4, 9 - 10)
EC-19
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ECA ECM Terminals and Reference Value .................1508
On Board Diagnosis Logic ..................................1508
Overall Function Check .......................................1509
Wiring Diagram ...................................................1510
Diagnostic Procedure ..........................................1511
Main 12 Causes of Overheating ..........................1517
Component Inspection ........................................1518
DTC P1233 - P1234 SUCTION CONTROL VALVE 1519
Description ..........................................................1519
CONSULT-II Reference Value in Data Monitor Mode
1519
ECM Terminals and Reference Value .................1519
On Board Diagnosis Logic ..................................1520
DTC Confirmation Procedure ..............................1521
Wiring Diagram ...................................................1522
Diagnostic Procedure ..........................................1523
Component Inspection ........................................1523
Removal and Installation .....................................1524
DTC P1301 - P1304 FUEL INJECTOR ADJUST-
MENT RESISTOR .................................................. 1525
Description ..........................................................1525
ECM Terminals and Reference Value .................1525
On Board Diagnosis Logic ..................................1525
DTC Confirmation Procedure ..............................1525
Wiring Diagram ...................................................1526
Diagnostic Procedure ..........................................1527
Component Inspection ........................................1528
Removal and Installation .....................................1528
DTC P1305 FUEL LEAK .......................................1529
On Board Diagnosis Logic ..................................1529
DTC Confirmation Procedure ..............................1529
Diagnostic Procedure ..........................................1529
Removal and Installation .....................................1529
DTC P1510 ACCELERATOR PEDAL RELEASED
POSITION SWITCH ...............................................1531
Description ..........................................................1531
CONSULT-II Reference Value in Data Monitor Mode
1531
ECM Terminals and Reference Value .................1531
On Board Diagnosis Logic ..................................1532
DTC Confirmation Procedure ..............................1532
Wiring Diagram ...................................................1533
Diagnostic Procedure ..........................................1534
Component Inspection ........................................1535
Removal and Installation .....................................1535
DTC P1606 ECM ...................................................1536
Description ..........................................................1536
On Board Diagnosis Logic ..................................1536
DTC Confirmation Procedure ..............................
1536
Diagnostic Procedure ..........................................1536
DTC P1621 ECM RELAY .......................................1538
ECM Terminals and Reference valve ..................1538
On Board Diagnosis Logic ..................................1538
DTC Confirmation Procedure ..............................1538
Wiring Diagram ...................................................1539
Diagnostic Procedure ..........................................1540
Component Inspection ........................................1541DTC P1660 BATTERY VOLTAGE .........................1542
On Board Diagnosis Logic ...................................1542
DTC Confirmation Procedure ..............................1542
Diagnostic Procedure ..........................................1542
GLOW CONTROL SYSTEM ..................................1544
Description ...........................................................1544
ECM Terminals and Reference Value ..................1544
Wiring Diagram ....................................................1545
Diagnostic Procedure ..........................................1546
Component Inspection .........................................1550
Removal and Installation .....................................1550
EGR VOLUME CONTROL SYSTEM .....................1551
Description ...........................................................1551
CONSULT-II Reference Value in Data Monitor Mode
1551
ECM Terminals and Reference Value ..................1552
Wiring Diagram ....................................................1553
Diagnostic Procedure ..........................................1554
Component Inspection .........................................1556
Removal and Installation .....................................1557
BRAKE SWITCH ....................................................1558
Description ...........................................................1558
ECM Terminals and Reference Value ..................1558
Wiring Diagram ....................................................1559
Diagnostic Procedure ..........................................1560
Component Inspection .........................................1561
PARK/NEUTRAL POSITION (PNP) SWITCH .......1562
Description ...........................................................1562
CONSULT-II Reference Value in Data Monitor Mode
1562
ECM Terminals and Reference Value ..................1562
Wiring Diagram ....................................................1563
Diagnostic Procedure ..........................................1564
START SIGNAL .....................................................1566
Wiring Diagram ....................................................1566
Diagnostic Procedure ..........................................1567
POWER STEERING OIL PRESSURE SWITCH ....1568
Component Description .......................................1568
CONSULT-II Reference Value in Data Monitor Mode
1568
ECM Terminals and Reference Value ..................1568
Wiring Diagram ....................................................1569
Diagnostic Procedure ..........................................1570
Component Inspection .........................................1571
Removal and Installation .....................................1571
AIR CONDITIONER CONTROL ............................1572
Wiring Diagram ....................................................1572
MI & DATA LINK CONNECTORS ..........................1573
Wiring Diagram ....................................................1573
SERVICE DATA AND SPECIFICATIONS (SDS) ...1574
General Specifications ......................................... 1574
Mass Air Flow Sensor ..........................................1574
Engine Coolant Temperature Sensor ..................1574
Common Rail Fuel Pressure Sensor ...................1574
Crankshaft Position Sensor (TDC) ......................1574
Camshaft Position Sensor ...................................1574
Glow Plug ............................................................1574
EGR Volume Control Valve .................................1574
ENGINE CONTROL SYSTEM
EC-33
[QR25(WITH EURO-OBD)]
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EC
System ChartEBS00M0B
*1: This sensor is not used to control the engine system under normal conditions.
*2: These signals are sent to the ECM through CAN communication line.
Multiport Fuel Injection (MFI) SystemEBS00M0C
INPUT/OUTPUT SIGNAL CHART
*1: Under normal conditions, this sensor is not for engine control operation.
SYSTEM DESCRIPTION
The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of
time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the
ECM memory. The program value is preset by engine operating conditions. These conditions are determined
Input (Sensor) ECM Function Output (Actuator)
●Camshaft position sensor (PHASE)
●Crankshaft position sensor (POS)
●Mass air flow sensor
●Engine coolant temperature sensor
●Heated oxygen sensor 1
●Throttle position sensor
●Accelerator pedal position sensor
●Park/neutral position (PNP) switch
●Intake air temperature sensor
●Power steering pressure sensor
●Ignition switch
●Battery voltage
●Knock sensor
●Refrigerant pressure sensor
●Heated oxygen sensor 2 *1
●TCM (Transmission control module) *2
●Wheel sensor
●Air conditioner switch
●Electrical loadFuel injection & mixture ratio control Fuel injectors
Electronic ignition system Power transistors
Fuel pump control Fuel pump relay
On board diagnostic system MI (On the instrument panel)
Heated oxygen sensor 1 heater control Heated oxygen sensor 1 heater
Heated oxygen sensor 2 heater control Heated oxygen sensor 2 heater
Power valve control VIAS control solenoid valve
EVAP canister purge flow controlEVAP canister purge volume control
solenoid valve
Air conditioning cut control Air conditioner relay
Cooling fan control Cooling fan relays
Sensor Input Signal to ECMECM func-
tionActuator
Crankshaft position sensor (POS)
Engine speed
Piston position
Fuel injec-
tion & mix-
ture ratio
controlFuel injectors Camshaft position sensor (PHASE)
Mass air flow sensor Amount of intake air
Engine coolant temperature sensor Engine coolant temperature
Heated oxygen sensor 1 Density of oxygen in exhaust gas
Throttle position sensor Throttle position
Accelerator pedal position sensor Accelerator pedal position
Park/neutral position (PNP) switch Gear position
Ignition switch Start signal
Knock sensor Engine knocking condition
Battery Battery voltage
Power steering pressure sensor Power steering operation
Heated oxygen sensor 2 *
1Density of oxygen in exhaust gas
Wheel sensor Vehicle speed
Air conditioner switch Air conditioner operation
EC-36
[QR25(WITH EURO-OBD)]
ENGINE CONTROL SYSTEM
SYSTEM DESCRIPTION
The ignition timing is controlled by the ECM to maintain the best air-
fuel ratio for every running condition of the engine. The ignition tim-
ing data is stored in the ECM. This data forms the map shown.
The ECM receives information such as the injection pulse width and
camshaft position sensor signal. Computing this information, ignition
signals are transmitted to the power transistor.
e.g., N: 1,800 rpm, Tp: 1.50 msec
A°BTDC
During the following conditions, the ignition timing is revised by the
ECM according to the other data stored in the ECM.
●At starting
●During warm-up
●At idle
●At low battery voltage
●During acceleration
The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed
within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not
operate under normal driving conditions. If engine knocking occurs, the knock sensor monitors the condition.
The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition.
Air Conditioning Cut ControlEBS00M0E
INPUT/OUTPUT SIGNAL CHART
SYSTEM DESCRIPTION
This system improves engine operation when the air conditioner is used.
Under the following conditions, the air conditioner is turned off.
●When the accelerator pedal is fully depressed.
●When cranking the engine.
●At high engine speeds.
●When the engine coolant temperature becomes excessively high.
●When operating power steering during low engine speed or low vehicle speed.
●When engine speed is excessively low.
●When refrigerant pressure is excessively low or high.
SEF742M
Sensor Input Signal to ECM ECM function Actuator
Air conditioner switch Air conditioner “ON” signal
Air conditioner
cut controlAir conditioner relay Throttle position sensor Throttle valve opening angle
Crankshaft position sensor (POS) Engine speed
Engine coolant temperature sensor Engine coolant temperature
Ignition switch Start signal
Refrigerant pressure sensor Refrigerant pressure
Power steering pressure sensor Power steering operation
Wheel sensor Vehicle speed
TROUBLE DIAGNOSIS
EC-71
[QR25(WITH EURO-OBD)]
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EC
Fail-safe ChartEBS00M0U
The ECM enters fail-safe mode, if any of the following malfunctions is detected due to the open or short circuit.
When the ECM enters the fail-safe mode, the MI illuminates.
Priority Detected items (DTC)
1
●U1000 CAN communication line
●P0102 P0103 Mass air flow sensor
●P0112 P0113 P0127 Intake air temperature sensor
●P0117 P0118 Engine coolant temperature sensor
●P0122 P0123 P0222 P0223 P1225 P1226 P1229 P2135 Throttle position sensor
●P0327 P0328 Knock sensor
●P0335 Crankshaft position sensor (POS)
●P0340 Camshaft position sensor (PHASE)
●P0500 Vehicle speed sensor
●P0605 ECM
●P0705 Park/Neutral position (PNP) sensor
●P1706 Park/Neutral position (PNP) switch
●P2122 P2123 P2127 P2128 P2138 Accelerator pedal position sensor
2
●P0031 P0032 Heated oxygen sensor 1 heater
●P0037 P0038 Heated oxygen sensor 2 heater
●P0132 P0133 P0134 P1143 P1144 Heated oxygen sensor 1
●P0138 P0139 P1146 P1147 Heated oxygen sensor 2
●P0444 P0445 EVAP canister purge volume control solenoid valve
●P0550 Power steering pressure sensor
●P0650 MI
●P0710-P0725, P0740-P0755, P1705 P1760 A/T related sensors and solenoid valves
●P1065 ECM power supply
●P 1111 I n ta k e v a l v e t i m i n g c o n t r o l s o l e n o i d v a l v e
●P1122 Electric throttle control function
●P1124 P1126 P1128 Electric throttle control actuator
●P1805 Brake switch
3
●P0011 Intake valve timing control
●P0171 P0172 Fuel injection system function
●P0300 - P0304 Misfire
●P0420 Three way catalyst function
●P0731-P0734 A/T function
●P1121 Electric throttle control actuator
●P1217 Engine over temperature (OVERHEAT)
DTC No. Detected items Engine operating condition in fail-safe mode
P0102
P0103Mass air flow sensor circuit Engine speed will not rise more than 2,400 rpm due to the fuel cut.
EC-78
[QR25(WITH EURO-OBD)]
TROUBLE DIAGNOSIS
1 - 6: The numbers refer to the order of inspection.Air Positive crankcase ventilation sys-
tem334444444 41EC-428
Incorrect idle speed adjustment 33 1111 1EC-73
Electric throttle control actuator 112332222 2 2EC-276
,
EC-278
,
EC-1018
IgnitionIncorrect ignition timing adjustment33111 11 1EC-73
Ignition circuit 11222 22 2EC-379
Main power supply and ground circuit 22333 33 23EC-116
Mass air flow sensor circuit 11222 22 2EC-138,
EC-999
Engine coolant temperature sensor circuit 11222322312EC-149
Throttle position sensor circuit 12 22222 2EC-886
Accelerator pedal position sensor circuit3212 2EC-893
Heated oxygen sensor 1 circuit 1232 22 2EC-163
,
EC-169
,
EC-178
,
EC-295
,
EC-301
Knock sensor circuit 2 2 3EC-222
Crankshaft position sensor (POS) circuit 2 2EC-227
Camshaft position sensor (PHASE) circuit 2 2EC-233
Vehicle speed signal circuit 2 3 3 3EC-250
Power steering pressure sensor circuit 2 3333EC-255
ECM 22333333333EC-260,
EC-267
Intake valve timing control solenoid valve cir-
cuit332 13223 3EC-125,
EC-271
VIAS control solenoid valve circuit 1
PNP switch circuit 3 3 3 3 3 3 3EC-345
Start signal circuit 2EC-401
Refrigerant pressure sensor circuit 2 3333 4EC-412
Electrical load signal circuit3333EC-416
Air conditioner circuit 223333333 3 2AT C - 3 3
SYMPTOM
Reference
page
HARD/NO START/RESTART (EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
SPARK KNOCK/DETONATION
LACK OF POWER/POOR ACCELERATION
HIGH IDLE/LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEATS/WATER TEMPERATURE HIGH
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
BATTERY DEAD (UNDER CHARGE)
Warranty symptom code AA AB AC AD AE AF AG AH AJ AK AL AM HA
TROUBLE DIAGNOSIS
EC-91
[QR25(WITH EURO-OBD)]
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EC
63 L/WCamshaft position
sensor (PHASE)[Engine is running]
●Warm-up condition
●Idle speed1.0 - 4.0V
[Engine is running]
●Engine speed is 2,000 rpm.1.0 - 4.0V
64 OR/LAccelerator pedal
position sensor 2
power supply[Ignition switch “ON”]Approximately 2.5V
65 RSensor's power sup-
ply[Ignition switch “ON”]Approximately 5V
66 W/LPower supply for
ECM (Buck-up)[Ignition switch “OFF”]BATTERY VOLTAGE
(11 - 14V)
67 PPower steering pres-
sure sensor[Engine is running]
●Steering wheel is being turned.0.5 - 4.0V
[Engine is running]
●Steering wheel is not being turned.0.4 - 0.8V
71 PU/RCrankshaft position
sensor (POS)[Engine is running]
●Warm-up condition
●Idle speedApproximately 3V
[Engine is running]
●Engine speed is 2,000 rpmApproximately 3V
72 OR Mass air flow sensor[Engine is running]
●Warm-up condition
●Idle speed1.1 - 1.5V
[Engine is running]
●Warm-up condition
●Engine speed is 2,500 rpm.1.6 - 2.0V TER-
MINAL
NO.WIRE
COLORITEM CONDITION DATA (DC Voltage)
PBIB0525E
PBIB0526E
PBIB0527E
PBIB0528E