CYLINDER BLOCK
EM-81
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12. Install the connecting rod bearings to the connecting rod and the
connecting rod cap.
●When installing the connecting rod bearings, apply engine oil
to the bearing surface (inside). Do not apply engine oil to the
back surface, but thoroughly clean it.
●When installing, align the connecting rod bearing stopper pro-
trusion with the notch of the connecting rod to install.
●Check the oil holes on the connecting rod and those on the
corresponding bearing are aligned.
13. Install the piston and connecting rod assembly to the crankshaft.
●Position the crankshaft pin corresponding to the connecting
rod to be installed onto the bottom dead center.
●Apply engine oil sufficiently to the cylinder bore, piston and
crankshaft pin.
●Match the cylinder position with the cylinder No. on the con-
necting rod to install.
●Using a piston ring compressor, install the piston with the front
mark on the piston crown facing the front of the engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big end.
14. Install the connecting rod cap.
●Match the stamped cylinder number marks on the connecting
rod with those on the cap to install.
15. Tighten the connecting rod bolt as follows.
a. Apply engine oil to the threads and seats of the connecting rod
bolts.
b. Tighten bolts to 18.6 to 20.6 N·m (1.9 to 2.1 kg-m, 14 to 15 ft-lb).
c. Put mating (with paint) on each bolt and connecting rod cap, all
in the same direction (when using a protractor).
d. Then tighten all bolts 90 to 95 degrees clockwise (target: 90
degrees) (Angle tightening).
CAUTION:
Always use either an angle wrench or protractor. Avoid
tightening based on visual check alone.
●After tightening the bolt, make sure that the crankshaft rotates smoothly.
●Check the connecting rod side clearance. Refer to EM-89, "CONNECTING ROD SIDE CLEARANCE" .
PBIC0266E
PBIC0267E
SBIA0282E
KBIA0068E
EM-90
[QR]
CYLINDER BLOCK
NOTE:
●The connecting rod small end grade and piston pin hole (pis-
ton pin) grade are provided only for the parts installed at the
plant. For service parts, no grades can be selected. (Only 0
grade is available.)
●Refer to EM-91, "CONNECTING ROD BUSHING OIL
CLEARANCE (SMALL END)" for the values for each grade at
the plant.
●Regarding marks on piston head, Refer to EM-83, "HOW TO
SELECT PISTON" .
PISTON RING SIDE CLEARANCE
●Measure side clearance of piston ring and piston ring groove
with feeler gauge.
●If out of specification, replace piston and/or piston ring assembly.
PISTON RING END GAP
●Check if inner diameter of cylinder bore is within specification.
Refer to EM-93, "
PISTON TO CYLINDER BORE CLEARANCE"
.
●Insert piston ring until middle of cylinder with piston, and mea-
sure gap.
●If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylin-
der and use oversized piston and piston ring.
SBIA0282E
Standard:
Top ring : 0.045 - 0.080 mm (0.0018 - 0.0031 in)
2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Oil ring : 0.065 - 0.135 mm (0.0026 - 0.0053 in)
Limit:
Top ring : 0.11 mm (0.0043 in)
2nd ring : 0.10 mm (0.0039 in)
SEM024AA
Standard:
Top ring : 0.21 - 0.31 mm (0.0083 - 0.0122 in)
2nd ring : 0.32 - 0.47 mm (0.0126 - 0.0185 in)
Oil ring : 0.20 - 0.60 mm (0.0079 - 0.0236 in)
Limit:
Top ring : 0.54 mm (0.0213 in)
2nd ring : 0.67 mm (0.0264 in)
Oil ring : 0.95 mm (0.0374 in)
SEM822B
CYLINDER BLOCK
EM-91
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CONNECTING ROD BEND AND TORSION
●Check with connecting rod aligner.
●If it exceeds the limit, replace connecting rod assembly.
CONNECTING ROD BEARING (BIG END)
Install the connecting rod cap without the connecting rod bearing
installed. After tightening the connecting rod bolt to the specified
torque, measure the connecting rod big end inner diameter using an
inside micrometer.
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Inner Diameter of Connecting Rod (Small End)
Measure inner diameter of bushing.Bend
Limit:
0.15 mm (0.0059 in) per 100 mm (3.94 in) length.
To r s i o n
Limit:
0.30 mm (0.0118 in) per 100 mm (3.94 in) length.
SEM003F
SEM038F
Standard: 48.000 - 48.013 mm (1.8898 - 1.8903 in)
PBIC0119E
Standard: 20.000 - 20.012 mm (0.7874 - 0.7879 in)
PBIC0120E
CYLINDER BLOCK
EM-95
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CRANKSHAFT RUNOUT
●Place a V-block on a precise flat table to support the journals on
the both end of the crankshaft.
●Place a dial gauge straight up on the No. 3 journal.
●While rotating the crankshaft, read the movement of the pointer
on the dial gauge. (Total indicator reading)
CONNECTING ROD BEARING OIL CLEARANCE
Method of Measurement
●Install the connecting rod bearings to the connecting rod and the
cap, and tighten the connecting rod bolts to the specified torque.
Using a inside micrometer measure the inner diameter of con-
necting rod bearing.
(Oil clearance) = (Inner diameter of connecting rod bearing) –
(Outer diameter of crankshaft pin)
●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-83, "
HOW TO SELECT CONNECTING ROD BEARING" .
Method of Using Plastigage
●Remove engine oil and dust on the crankshaft pin and the sur-
faces of each bearing completely.
●Cut a plastigage slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
●Install the connecting rod bearings to the connecting rod cap,
and tighten the connecting rod bolts to the specified torque.
CAUTION:
Never rotate the crankshaft.
●Remove the connecting rod cap and bearings, and using the
scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is same as that described in “Method of Mea-
surement”.
MAIN BEARING OIL CLEARANCE
Method of Measurement
●Install the main bearings to the cylinder block and bearing cap. Measure the main bearing inner diameter
with the bearing cap bolt tightened to the specified torque.
(Oil clearance) = (Inner diameter of main bearing) – (Outer diameter of crankshaft journal)
●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-85, "
HOW TO
SELECT MAIN BEARING" . Limit: Less than 0.05 mm (0.002 in)
PBIC0271E
Standard : 0.028 - 0.045 mm (0.0011 - 0.0018 in)
Limit : 0.10 mm (0.0039 in)
PBIC0119E
EM142
Standard
No. 1, 3 and 5 journals : 0.012 - 0.022 mm (0.0005 - 0.0009 in)
No. 2 and 4 journals : 0.018 - 0.028 mm (0.0007 - 0.0011 in)
Limit : 0.1 mm (0.004 in)
EM-110
[YD22DDTi]
PRECAUTIONS
[YD22DDTi]PRECAUTIONSPFP:00001
Precautions for Drain Engine CoolantEBS00LQZ
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00LR0
●Before starting work, make sure no fire or spark producing items are in the work area.
●Release fuel pressure before disassembly.
●After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyEBS00LR1
●When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
●Exercise maximum care to avoid damage to mating or sliding surfaces.
●Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
●Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
●When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and ReplacementEBS00LR2
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and InstallationEBS00LR3
●Use torque wrench to tighten bolts or nuts to specification.
●When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.
●Replace with new liquid gasket, packing, oil seal or O-ring.
●Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
●Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, engine oil sliding surfaces well.
●Release air within route when refilling after draining coolant.
●After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust systems for leakage.
Parts Requiring Angular TighteningEBS00LR4
●Use an angle wrench for the final tightening of the following engine parts:
–Cylinder head bolts
–Main bearing cap bolts
–Connecting rod cap nuts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
●Do not use a torque value for final tightening.
●The torque value for these parts are for a preliminary step.
●Ensure thread and seat surfaces are clean and coated with engine oil.
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
EM-117
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Use the Chart Below to Help You Find the Cause of the Symptom.EBS00LR9
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not relatedLocation
of noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemRefer-
ence page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
Top of
engine
Rocker
cover
Cylinder
headTicking or
clickingCA—AB—Tappet
noiseValve clearanceEM-163
Rattle C A — A B CCamshaft
bearing
noiseCamshaft oil clearance
Camshaft runoutEM-160EM-159
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—BB—Piston pin
noisePiston to piston pin
clearance
Connecting rod bush-
ing oil clearance (Small
end)EM-210
EM-212
Slap or
rapA ——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-214EM-211
EM-211
EM-212
Knock A B C B B BConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance (Small
end)
Connecting rod bear-
ing oil clearance (Big
end)EM-212EM-216
Knock A B — A B CMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-216EM-216
Front of
engine
Timing
chain
coverTapping or
tickingA A —BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-167
EM-172
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belts
(Sticking
or slip-
ping)Drive belts deflection
EM-118
CreakingA B ABABDrive belts
(Slipping)Idler pulley bearing
operation
Squall
CreakA B —BABWater
pump
noiseWater pump operationCO-39,
"WATER
PUMP"
EM-118
[YD22DDTi]
DRIVE BELTS
DRIVE BELTS
PFP:02117
Checking Drive BeltsEBS00LRA
●Before inspecting the engine, make sure the engine has cooled
down; wait approximately 30 minutes after the engine has been
stopped.
●Visually inspect all belts for wear, damage or cracks on contact-
ing surfaces and edge areas.
●When measuring deflection, apply 98 N (10 kg, 22 lb) at the
marked point ( ).
CAUTION:
●When checking belt deflection immediately after installa-
tion, first adjust it to the specified value. Then, after turn-
ing the crankshaft two turns or more, re-adjust to the
specified value to avoid variation in deflection between
pulleys.
●Tighten idler pulley lock nut by hand and measure deflection without looseness.
Belt Deflection:
*: When engine is cold.
Tension AdjustmentEBS00LRB
●Adjust belts with the parts shown below.
CAUTION:
●When a new belt is installed as a replacement, adjust it to the value specified under “New” value
because of insufficient adaptability with pulley grooves.
●If the belt deflection of the current belt is out of the “Limit for re-adjusting”, adjust to the
“Adjusted” value.
●When checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust it to the specified value to avoid vari-
ation in deflection between pulleys.
●Make sure the belts are fully fitted into the pulley grooves during installation.
●Handle with care to avoid smearing the belts with engine oil or cooling water etc.
●Do not twist or bend the belts with strong force.
JEM249G
Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
New Adjusted Limit for re-adjusting
Air conditioner compressor belt 4 - 5 (0.16 - 0.20) 6 - 7 (0.24 - 0.28) 8.5 (0.335)
Alternator and water pump belt 9.0 - 10.5 (0.354 - 0.413) 11.0 - 12.5 (0.433 - 0.492) 16.5 (0.650)
Applied belt Belt adjustment method
Air conditioner compressor belt Adjusting bolt on idler pulley
Alternator and water pump belt Adjusting bolt on alternator
EXHAUST MANIFOLD AND TURBOCHARGER
EM-129
[YD22DDTi]
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Disassembly and AssemblyEBS00LRI
REMOVAL
1. After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and
then loosen the nuts to remove.
CAUTION:
Do not disassemble or adjust the turbocharger body.
2. When a stud bolt is pulled out, tighten it to the following torque:
INSPECTION AFTER REMOVAL
Surface Distortion
Check the distortion on the mounting surface in the six directions
using a straightedge and a feeler gauge.
PBIC0679E
1. Exhaust manifold 2. Gasket 3. Oil inlet tube
4. Water tube 5. Turbocharger 6. Oil outlet tube
: 24 - 27 N·m (2.4 - 2.8 kg-m, 18 - 20 ft-lb)
Limit : 0.3 mm (0.012 in)
JEM267G