PRECAUTIONS
GI-5
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Use approved bonding agent, sealants or their equivalents when required.
Use tools and recommended special tools where specified for safe and efficient service repairs.
When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.
Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate cov-
ers.
Take caution that keys, buckles or buttons do not scratch paint.
WARNING:
To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module)
system. The connectors should be disconnected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.
Precautions for All Mode 4 × 4 SystemEAS000GQ
Even if the 2WD mode is selected, the All mode 4 × 4 system occasionally changes from 2WD to 4WD auto-
matically depending on the driving conditions.
When spinning the front wheels by running the engine with the front wheels jacked up or mounted on the free
rollers / or a chassis dynamometer, be careful because the vehicle may suddenly move due to the driving
force from the rear wheels.
To avoid personal injury and vehicle damage, use one of the following methods when working with the front
wheels drive force and spinning freely.
Remove the propeller shaft.
Use free rollers / chassis dynamometer designed for 4WD vehicles.
Precautions for Three Way CatalystEAS000FR
If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To
prevent this, follow the instructions.
Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.
When checking for ignition spark or measuring engine compression, make tests quickly and only when
necessary.
Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to
the catalyst.
Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three
way catalyst.
Precautions for FuelEAS000P9
GASOLINE ENGINE
Use unleaded gasoline with an octane rating of at least 95 (RON).
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel
other than that specified could adversely affect the emission control devices and systems, and could
also affect the warranty coverage validity.
DIESEL ENGINE
Diesel fuel of at least 50 cetane.
If two types of diesel fuel are available, use summer or winter fuel properly according to the following temper-
ature conditions.
Above –7°C (20°F) ... Summer type diesel fuel.
Below –7°C (20°F) ... Winter type diesel fuel.
SGI234
GI-6
PRECAUTIONS
CAUTION:
Do not use home heating oil, gasoline or other alternate fuels in your diesel engine. The use of
those can cause engine damage.
Do not use summer fuel at temperatures below –7°C (20°F). The cold temperatures will cause wax
to form in the fuel. As a result, it may prevent the engine from running smoothly.
Do not add gasoline or other alternate fuels to diesel fuel.
Precautions for Multiport Fuel Injection System or Engine Control SystemEAS000FT
Before connecting or disconnecting any harness connector for
the multiport fuel injection system or ECM:
Turn ignition switch to “OFF” position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
Before disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure.
Be careful not to jar components such as ECM and mass air
flow sensor.
Precautions for Turbocharger (If Equipped)EAS000FU
The turbocharger turbine revolves at extremely high speeds and
becomes very hot. Therefore, it is essential to maintain a clean sup-
ply of oil flowing through the turbocharger and to follow all required
maintenance instructions and operating procedures.
Always use the recommended oil. Follow the instructions for
proper time to change the oil and proper oil level.
Avoid accelerating engine to a high rpm immediately after start-
ing.
If engine had been operating at high rpm for an extended period
of time, let it idle for a few minutes prior to shutting if off.
Precautions for HosesEAS000FV
HOSE REMOVAL AND INSTALLATION
To prevent damage to rubber hose, do not pry off rubber hose
with tapered tool or screwdriver.
To reinstall the rubber hose securely, make sure that hose inser-
tion length and orientation is correct. (If tube is equipped with
hose stopper, insert rubber hose into tube until it butts up
against hose stopper.)
SGI787
SGI292
SMA019D
SMA020D
HOW TO USE THIS MANUAL
GI-9
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ComponentsEAS0015G
THE LARGE ILLUSTRATIONS are exploded views (See the following) and contain tightening torques,
lubrication points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information neces-
sary to perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to the
appropriate PARTS CATALOG .
Components shown in an illustration may be identified by a circled number. When this style of illustration
is used, the text description of the components will follow the illustration.
SYMBOLS
SAIA0399E
SYMBOL DESCRIPTION
Tightening torque
The tightening torque specifications of bolts and nuts may be presented as either a range or a standard tightening
torque.
Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease.
Should be lubricated with oil.
Sealing point
Checking point
Always replace after every disassembly.
PApply petroleum jelly.
Apply ATF.
Select with proper thickness.
Adjustment is required.
ENGINE OIL
LU-9
[QR]
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3. Loosen oil filler cap and then remove drain plug.
4. Drain engine oil.
5. Install drain plug with new washer. Refer to EM-25, "
OIL PAN
AND OIL STRAINER" .
CAUTION:
Be sure to clean drain plug and install with new washer.
6. Refill with new engine oil.
Engine oil specification and viscosity:
Refer to MA-17, "
RECOMMENDED FLUIDS AND LUBRICANTS" .
Engine oil capacity (Approximate):
Unit: (lmp qt)
CAUTION:
The refill capacity depends on the engine oil temperature and drain time. Use these specifica-
tions for reference only.
Always use oil level gauge to the determine when the proper amount of engine oil is in the
engine.
7. Warm up engine and check area around drain plug and oil filter for oil leakage.
8. Stop engine and wait for 10 minutes.
9. Check the engine oil level. Refer to LU-7, "
ENGINE OIL LEVEL" . Oil pan drain plug:
: 34.3 N·m (3.5 kg-m, 25 ft-lb)
PBIC2410E
Drain and refill With oil filter change 3.9 (3-3/8)
Without oil filter change 3.5 (3-1/8)
Dry engine (Overhaul)4.5 (4)
LU-22
[YD22DDTi]
ENGINE OIL
3. Loosen oil filler cap and then remove drain plug.
4. Drain engine oil.
5. Install drain plug with new washer. Refer to EM-147, "
OIL PAN AND OIL STRAINER" .
CAUTION:
Be sure to clean drain plug and install with new washer.
6. Refill with new engine oil.
Engine oil specification and viscosity:
Refer to MA-17, "
RECOMMENDED FLUIDS AND LUBRICANTS" .
Engine oil capacity (Approximate):
Unit: (lmp qt)
CAUTION:
The refill capacity depends on the engine oil temperature and drain time. Use these specifica-
tions for reference only.
Always use the oil level gauge to determine when the proper amount of engine oil is in the
engine.
7. Warm up engine and check area around drain plug and oil filter for oil leakage.
8. Stop engine and wait for 10 minutes.
9. Check the engine oil level. Refer to LU-20, "
ENGINE OIL LEVEL" .
PBIC0527E
Oil pan drain plug:
: 34 N·m (3.5 kg-m, 25 ft-lb)
Drain and refill With oil filter change 5.2 (4-5/8)
Without oil filter change 4.9 (4-3/8)
Dry engine (Overhaul)6.3 (5-1/2)
CL-2
PRECAUTIONS
PRECAUTIONSPFP:00001
CautionECS004JW
Recommended clutch fluid is brake fluid “DOT 3” or “DOT 4”. Refer to MA-17, "Fluids and Lubri-
cants".
Never reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas.
When removing and installing clutch piping, use Tool.
Use new brake fluid to clean or wash all parts of master cyl-
inder and operating cylinder.
Never use mineral oils such as gasoline or kerosene. It will
corrode the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, clean it with a dust collector. Do not
use compressed air.Tool number : GG94310000 or Commercial equivalent
PCIB0272E
TRANSAXLE ASSEMBLY
MT-35
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b. While lifting reverse shift fork, align cam with 5th-reverse
bracket.
c. Install reverse lever assembly to clutch housing, and then
tighten mounting bolts to the specified torque. Refer to MT-22,
"SHIFT CONTROL COMPONENTS" .
22. Install check ball, shift check sleeve, check spring and a new
check plug to clutch housing.
CAUTION:
Do not reuse check plug.
Do not drop check ball.
23. Install the magnet onto clutch housing.
24. Apply multi-purpose grease to differential oil seal lip, and then
install a new differential oil seal to transaxle case using the drift.
CAUTION:
Do not reuse differential oil seals.
25. Install selected input shaft rear bearing adjusting shim onto input
shaft.
For selection of adjusting shims, refer to MT-47, "INPUT
SHAFT END PLAY" .
26. Install selected differential side bearing adjusting shim and dif-
ferential side bearing. For selection adjusting shim, refer to MT-
48, "DIFFERENTIAL SIDE BEARING PRELOAD" .
27. Install baffle plate and oil gutter to transaxle case.
28. Install transaxle case following the procedures below.
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
For selection of adjusting shims, refer to MT-48, "MAINSHAFT END PLAY" .
b. Temporarily install a new snap ring of mainshaft rear bearing into transaxle case.
CAUTION:
Do not reuse snap ring.
c. Apply recommended sealant to mating surfaces of transaxle
case and clutch housing.
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
PCIB0790E
SCIA0390E
SCIA0887E
PCIB0816E
TRANSAXLE ASSEMBLY
MT-45
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31. Install baffle plate and oil gutter to transaxle case.
32. Install transaxle case following the procedures below.
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
For selection of adjusting shims, refer toMT-51, "MAINSHAFT END PLAY" .
b. Temporarily install a new snap ring of mainshaft rear bearing into transaxle case.
CAUTION:
Do not reuse snap ring.
c. Apply recommended sealant to mating surfaces of transaxle
case and clutch housing.
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
d. With snap ring of mainshaft rear bearing temporarily installed,
place transaxle case over clutch housing.
e. Through bore plug mounting hole, with snap ring stretched, and
lift up mainshaft assembly from the control assembly mounting
hole.
f. Securely install snap ring onto mainshaft rear bearing.
PCIB0816E
SCIA0892E
SCIA0893E