SECONDARY TIMING CHAIN
EM-167
[YD22DDTi]
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SECONDARY TIMING CHAINPFP:13028
Removal and InstallationEBS00LRT
CAUTION:
●After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike
piston heads.
●When installing camshafts, chain tensioners, oil seals or other sliding parts, lubricate contacting
surfaces with new engine oil.
●Apply new engine oil to parts marked in illustration before installation.
REMOVAL
●For preparative work for removing/installing secondary timing chain to remove/install electronic fuel supply
pump. Refer to EM-147, "
FUEL SUPPLY PUMP" .
●To prepare for removing/installing secondary timing chain to remove/install camshaft. Refer to EM-158,
"Removal and Installation" .
1. Remove engine coolant reservoir tank.
2. Remove RH engine mount insulator and bracket. Refer to EM-193, "
Removal and Installation" .
3. Pull power steering reservoir tank out of brackets to move power steering piping.
CAUTION:
To avoid removing power steering reservoir tank out of brackets move it with power steering pip-
ing aside.
PBIC1238E
EM-172
[YD22DDTi]
PRIMARY TIMING CHAIN
PRIMARY TIMING CHAIN
PFP:13028
Removal and InstallationEBS00LRU
CAUTION:
●After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike
piston heads.
●When installing camshafts, chain tensioners, oil seals or other sliding parts, lubricate contacting
surfaces with new engine oil.
●Apply new engine oil to parts marked in illustration before installation.
EM-174
[YD22DDTi]
PRIMARY TIMING CHAIN
REMOVAL
1. Remove engine coolant reservoir tank.
2. Remove charge air cooler and bracket. Refer to EM-122, "
Removal and Installation" .
3. Remove air cleaner and air duct. Refer to EM-120, "
Removal and Installation" .
4. Remove rocker cover. Refer to EM-156, "
Removal and Installation" .
5. Remove RH engine mount insulator and bracket. Refer to EM-193, "
Removal and Installation" .
6. Pull power steering reservoir tank out of brackets to move power steering piping.
CAUTION:
To avoid removing power steering reservoir tank out of brackets move it with power steering pip-
ing aside.
7. Remove oil pan. Refer to EM-133, "
Removal and Installation" .
8. Remove oil filter bracket. Refer to LU-22, "
OIL FILTER BRACKET" .
9. Remove injection tube and fuel injector. Refer to EM-144, "
Removal and Installation" .
10. Remove secondary timing chain and associated parts. Refer to EM-167, "
Removal and Installation" .
11. When removing rear chain case, remove camshaft sprockets. Refer to EM-158, "
Removal and Installa-
tion" .
12. Remove crankshaft pulley.
a. Hold crankshaft pulley with the pulley holder (SST).
b. Loosen crankshaft pulley fixing bolt and pull out the bolt approx-
imately 10 mm (0.39 in).
c. Using pulley puller (SST), remove crankshaft pulley.
●Use two M6 bolts with approx. 60 mm (2.36 in) shank length
for securing crankshaft pulley.
13. Remove oil pump housing.
●Loosen bolts in the reverse order of that shown in the figure
and remove them.
●Use seal cutter (SST) etc. for removal.
14. Remove front oil seal from oil pump housing.
●Punch out the seal off from the back surface of the oil pump
using a flat-bladed screwdriver.
●Be careful not to damage the oil pump housing.
7. Chain guide 8. Spacer 9. Front chain case
10. Crankshaft pulley 11. Front oil seal 12. Oil pump housing
13. Primary timing chain 14. Oil pump drive spacer 15. Crankshaft sprocket
16. Secondary timing chain 17. Rear chain case 18. Power steering pump
JEM131G
JEM132G
JEM133G
PRIMARY TIMING CHAIN
EM-177
[YD22DDTi]
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INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and excessive wear at roller links. Replace
chain if necessary.
INSTALLATION
1. Install rear chain case.
a. Apply a continuous bead of Genuine Liquid Gasket or equivalent
on locations shown in the figure. Refer to E M - 111 , "
Precautions
For Liquid Gasket" .
A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by starting and ending
at areas of bead as shown in the figure. Apply so that the portion
marked * comes at an external location but cannot be viewed
externally after engine assembly.
D: Leave the start and end areas of the bead slightly protruding
from the case surface.
SEM984C
JEM139G
PBIC1255E
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-182
[YD22DDTi]
CYLINDER HEAD
CYLINDER HEAD
PFP:11041
On-Vehicle ServiceEBS00LRV
CHECKING COMPRESSION PRESSURE
1. Warm up engine thoroughly. Then, stop it.
2. Using CONSULT-II, make sure no error codes are indicated for self-diagnosis items. Refer to EC-1412,
"Basic Inspection" .
●Do not disconnect CONSULT-II until the end of this operation; it will be used to check engine rpm and
for error detection at the end of this operation.
3. Disconnect the negative battery terminal.
4. Remove charge air cooler. Refer to EM-122, "
Removal and Installation"
5. To prevent fuel from being injected during inspection, remove
fuel supply pump fuse [ENG CONT (20A)] from fuse box on the
left side of engine compartment.
●Among marks on fuse box, [ENG CONT 2 (20A)] is for fuel
supply pump fuse.
6. Remove glow plugs from all the cylinders. Refer to EM-138,
"Removal and Installation" .
CAUTION:
●Before removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.
●Carefully remove glow plugs to prevent any damage or
breakage.
●Handle with care to avoid applying any shock to glow plugs.
7. Install adapter to installation holes of glow plugs and connect
compression gauge for diesel engine.
8. Connect battery negative terminal.
9. Set the ignition switch to “START” and crank. When gauge
pointer stabilizes, read compression pressure and engine rpm.
Repeat the above steps for each cylinder.
●Always use a fully-charged battery to obtain specified engine
speed.
Compression pressure
Unit: kPa (bar, kg/cm2 , psi)/rpm
●When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.
●If engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.
●If compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.
–If compression pressure becomes normal after applying engine oil, piston ring may be worn or dam-
aged. Check piston ring for malfunction. If any, replace piston ring.
–If compression pressure is still low after applying engine oil, valve may be malfunctioning. Check valve
for malfunction. If contact malfunction is found, replace valve or valve seat.
●If compression pressure in adjacent two cylinders is low after applying engine oil, pressure may be
leaking from gasket. In this case, replace cylinder head gasket.
10. Complete this operation as follows:
PBIC0680E
: 18 - 21 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
SEM112G
Standard Minimum Difference limit between cylinders
2,893 (28.9, 29.5, 419)/200 2,452 (24.52, 25.0, 356)/200 490 (4.90, 5.0, 71)/200
CYLINDER HEAD
EM-183
[YD22DDTi]
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a. Turn the ignition switch to “OFF”.
b. Disconnect battery negative terminal.
c. Install glow plug and install all the parts removed in step 4.
d. Install fuel supply pump fuse [ENG CONT (20A)].
e. Connect battery negative terminal.
f. Using CONSULT-II make sure no error code is indicated for items of self-diagnosis.
Removal and InstallationEBS00LRW
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
REMOVAL
1. Drain engine coolant. Refer to CO-29, "Changing Engine Coolant" .
2. Remove the following parts:
●Charge air cooler (Refer to EM-122, "Removal and Installation" .)
●Rocker cover (Refer to EM-156, "Removal and Installation" .)
●Air cleaner and air duct (Refer to EM-120, "Removal and Installation" .)
●Vacuum pump (Refer to EM-139, "Removal and Installation" .)
●Injection tube, spill tube and fuel injector (Refer to EM-144, "Removal and Installation" .)
●Intake manifold (Refer to EM-123, "Removal and Installation" .)
●Exhaust manifold and Turbocharger (Refer to EM-127, "Removal and Installation" .)
●Secondary timing chain (Refer to EM-167, "Removal and Installation" .)
●Camshaft (Refer to EM-158, "Removal and Installation" .)
SBIA0193E
1. Glow plug 2. Cylinder head assembly 3. Cylinder head bolt
4. Thermal transmitter 5. Engine coolant temperature sensor 6. Gasket
7. Water outlet 8. Glow plate
EM-186
[YD22DDTi]
CYLINDER HEAD
*: Measured with head bolts tightened
2. Apply a continuous bead of Genuine Liquid Gasket or equivalent
on the surface shown in the figure.
A: Apply bead so that it does not protrude into oil passage. Refer
to E M - 111 , "
Precautions For Liquid Gasket" .
B: Minimize the overlapping area of the bead, with start and end
areas of bead as shown in the figure.
Apply so that the portion marked * comes at an external loca-
tion but cannot be viewed externally after engine is assembled.
3. Install cylinder head assembly.
●Tighten bolts in numerical order as shown in the figure
according to the following procedure:
a. Apply engine oil to bolt threads and seat surfaces.
b. Tighten bolts to 29 to 38 N·m (2.9 to 3.9 kg-m, 21 to 28 ft-lb).
c. Tighten 180° to 185° [target: 180°] (angular tightening).
d. Loosen completely to 0 N·m (0 kg-m, 0 in-lb) in the reverse order
of that shown in the figure.
e. Tighten bolts to 35 to 44 N·m (3.5 to 4.5 kg-m, 26 to 32 ft-lb).
f. Tighten 90° to 95° [target: 90°] (angular tightening)
g. Tighten another 90° to 95° [target: 90°] (angular tightening).
●When an angle wrench is not used, paint an alignment
mark on the head of cylinder head bolt and cylinder head
surface before tightening. Check the angle with a protrac-
tor.
4. Install glow plug.
●To avoid damage, glow plugs should be removed only
when required.
●Handle with care to avoid applying shock. When dropped
from approx. 100 mm (3.94 in) or higher, always replace
with a new one.
●Before installing, remove carbon depositing on mounting hole of glow plug with a reamer.
5. Install engine coolant temperature sensor and thermal transmitter.
PBIC1256E
JEM149G
JEM166G