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-96
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CYLINDER BLOCK
Method of Using Plastigage
●Remove engine oil and dust on the crankshaft journal and the
surfaces of each bearing completely.
●Cut a plastigage slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
●Tighten the main bearing bolts to the specified torque.
CAUTION:
Never rotate the crankshaft.
●Remove the bearing 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 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 the standard is not met, replace main bearings.
OUTER DIAMETER OF LOWER CYLINDER BLOCK MOUNTING BOLT
●Perform only with M10 (0.39 in) bolts.
●Measure outer diameters (d1, d2) at two positions shown in the figure.
●Measure d2 at a point within block A.
●When the value of d1- d2 exceeds the limit (a large difference in
dimensions), replace the bolt with a new one.
OUTER DIAMETER OF CONNECTING ROD BOLT
●Measure outer diameter (d) at position shown in the figure.
●When “d ” exceeds the limit (when it becomes thinner), replace
the bolt with a new one.
EM142
Standard: There must be crush height.
SEM502G
Limit: 0.13 mm (0.0051 in) or more.
SBIA0285E
Limit: 7.75 mm (0.3051 in) or less.
SBIA0286E
EM-98
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SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Standard and LimitEBS00KNX
GENERAL SPECIFICATIONS
DRIVE BELTS
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
SPARK PLUG
CYLINDER HEAD
Unit: mm (in) Engine typeQR20DE QR25DE
Cylinder arrangement4.in-line
Displacement
cm
3 (cu in)1,998 (121.92) 2,488 (151.82)
Bore and stroke mm (in) 89.0 x 80.3 (3.504 x 3.161) 89.0 x 100.0 (3.504 x 3.937)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Compression ratio 9.0 9.5
Compression pressure
kPa (bar, kg/cm
2 , psi) / 250 rpmStandard 1,190 (11.9, 12.1, 173) 1,250 (12.5, 12.8, 181.3)
Minimum 990 (9.9, 10.1, 144) 1,060 (10.6, 10.8, 153.7)
Differential limit between cylinders 100 (1.0, 1.0, 14)
Tension of drive belts Auto adjustment by auto-tensioner
Item Limit
Surface distortionIntake manifold collector 0.1 (0.004)
Intake manifold 0.1 (0.004)
Exhaust manifold 0.3 (0.012)
MakeNGK
Standard typeLFR5A-11
Hot typeLFR4A-11
Cold typeLFR6A-11
Spark plug gap mm (in) 1.0 - 1.1 (0.039 - 0.043)
Item Limit
Head surface distortion 0.1 (0.004)
PBIC0283E
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.
PRECAUTIONS
EM-111
[YD22DDTi]
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Precautions For Liquid GasketEBS00ODW
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
EM-112
[YD22DDTi]
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsEBS00LR6
Tool number
Tool nameDescription
ST0501S000
Engine stand assembly
1. ST05011000
Engine stand
2. ST05012000
BaseDisassembling and assembling
KV10106500
Engine stand shaft
KV11105900
Engine sub-attachmentUsed with KV10106500
KV10115600
Valve oil seal driftInstalling valve oil seal
Use side A.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
f: 5 (0.20)
Unit: mm (in)
KV10107902
Valve oil seal puller
1. KV10116100
Valve oil seal puller adapterRemoving valve oil seal
KV11103000
Injection pump drive gear pullerRemoving crankshaft pulley
NT042
NT028
NT799
NT603
S-NT605
NT676
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
EM-117
[YD22DDTi]
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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