MA-32
ENGINE MAINTENANCE (YD22DDTI)
7. Refill reservoir tank to “MAX” level line with engine coolant.
8. Repeat steps 3 through 6 two or more times with radiator cap installed until engine coolant level no longer
drops.
9. Check cooling system for leaks with engine running.
10. Warm up engine, and check for sound of engine coolant flow while running engine from idle up to 3,000
rpm with heater temperature controller set at several position between “COOL” and “WARM”.
Sound may be noticeable at heater unit.
11. Repeat step 10 three times.
12. If sound is heard, bleed air from cooling system by repeating steps 3 through 6 until engine coolant level
no longer drops.
FLUSHING COOLING SYSTEM
1. Install reservoir tank if removed, and radiator drain plug.
CAUTION:
Be sure to clean drain plug and install with new O-ring.
If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-235, "ASSEM-
BLY" .
2. Fill radiator with water until water spills from the air relief hole, then close air relief plug. Fill radiator and
reservoir tank with water and reinstall radiator cap.
3. Run engine and warm it up to normal operating temperature.
4. Rev engine two or three times under no-load.
5. Stop engine and wait until it cools down.
6. Drain water from the system. Refer toMA-30, "
DRAINING ENGINE COOLANT" .
7. Repeat steps 1 through 6 until clear water begins to drain from radiator.
Checking Cooling SystemELS000C4
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
engine coolant escaping from the radiator. Wrap a thick cloth around the cap. Slowly turn it a quarter
turn to allow built-up pressure to escape. Carefully remove the cap by turning it all the way.
CHECKING COOLING SYSTEM HOSES
Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.
CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator as follows.
Be careful not to bend or damage the radiator fins.
When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator
shroud and horns. Then tape the harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downwards.
2. Apply water again to all radiator core surface once per minute.
3. Stop washing if any stains no longer flow out from the radiator.
4. Blow air into the back side of radiator core vertically downwards.
Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2 , 71psi) and keep distance more than 30 cm
(11.8 in).
5. Blow air again into all the radiator core surface once per minute until no water sprays out.
ENGINE MAINTENANCE (YD22DDTI)
MA-33
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CHECKING RADIATOR CAP
Check valve seat of radiator cap.
–Check if valve seat is swollen to the extent that the edge of the
plunger cannot be seen when watching it vertically from the top.
–Check if valve seat has no soil and damage.
Pull negative-pressure valve to open it, and make sure that it is
completely closed when released.
–Make sure that there is no dirt or damage on the valve seat of
radiator cap negative-pressure valve.
–Make sure that there are no unusualness in the opening and
closing conditions of negative-pressure valve.
Check radiator cap relief pressure.
–When connecting radiator cap to the radiator cap tester (com-
mercial service tool) and the radiator cap tester adapter (special
service tool), apply engine coolant to the cap seal surface.
Replace radiator cap if there is an unusualness related to the above three.
CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue
or foreign material.
CHECKING RADIATOR SYSTEM FOR LEAKS
To check for leaks, apply pressure to the cooling system with
radiator cap tester (commercial service tool) and radiator cap
tester adapter (special service tool).
WARNING:
Never remove the radiator cap when the engine is hot. Seri-
ous burns could occur from high pressure engine coolant
escaping from the radiator.
CAUTION:
Higher test pressure than specified may cause radiator
damage.
PBIC2816E
SMA967B
Standard:
78 - 98 kPa (0.78 - 0.98bar, 0.8 - 1.0 kg/cm
2 , 11 - 14 psi)
Limit:
59 kPa (0.59bar, 0.6 kg/cm
2 , 9 psi)
SLC755AC
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm
2 , 23 psi)
SLC134B
MA-34
ENGINE MAINTENANCE (YD22DDTI)
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
If anything is found, repair or replace damaged parts.
Checking Fuel LinesELS000CE
Inspect fuel lines, filler cap and tank for improper attachment, leaks,
cracks, damage, loose connections, chafing or deterioration.
If necessary, repair or replace faulty parts.
Changing Fuel FilterELS000CF
REMOVAL
1. Remove air duct, air cleaner case and mass air flow sensor assembly. Refer to EM-142, "AIR CLEANER
AND AIR DUCT" .
2. Remove fuel filter protector.
3. Remove fuel hoses from fuel filter bracket.
CAUTION:
Plug the pipe to prevent fuel from draining.
4. Remove fuel filter with fuel filter bracket.
CAUTION:
Do not splash fuel during removal. If fuel is splashed,
immediately wipe it off.
5. Using band-type fuel filter wrench (commercial service tool),
remove fuel filter.
6. Turn fuel filter upside down to drain fuel.
7. Remove drain plug from fuel filter.
SMA803A
PBIC2501E
SBIA0135E
SBIA0136E
ENGINE MAINTENANCE (YD22DDTI)
MA-35
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INSTALLATION
Install in reverse order of removal, paying attention to following:
Replace O-ring on drain plug with new one.
Screw the fuel filter by hand until packing contacts sealing surface of bracket. Then tighten it by turning
approximately 2/3 turn.
After installation, bleed air from fuel path. Refer to FL-18, "Air Bleeding" .
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
Start the engine and rev it up and check for fuel leaks at connections.
Changing Air Cleaner FilterELS000CG
VISCOUS PAPER TYPE
The viscous paper type air cleaner filter does not require any clean-
ing operation between renewal.
Changing Engine OilELS000CH
WARNING:
Be careful not to burn yourself, as the engine oil is hot.
Prolonged and repeated contact with used engine oil may cause skin cancer: try to avoid direct
skin contact with used engine oil. If skin contact is made, wash thoroughly with soap or hand
cleaner as soon as possible.
1. Warm up engine, put vehicle horizontally and check for engine oil leakage from engine components.
2. Stop engine and wait for 10 minutes.
3. Loosen oil filter cap and then remove drain plug.
4. Drain engine oil.
5. Install drain plug with new washer. Refer to EM-157, "
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 LUBRI-
CANTS" .
Engine oil capacity (Approximate):
Unit: (lmp qt)
Fuel filter drain plug:
: 4.9 N·m (0.50 kg-m, 43 in-lb)
PBIC0526E
Oil pan drain plug:
: 34 N·m (3.5 kg-m, 25 ft-lb)
PBIC0527E
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)
MA-36
ENGINE MAINTENANCE (YD22DDTI)
CAUTION:
The refill capacity depends on the engine oil temperature and drain time. Use these specifica-
tions for reference only.
Always use the dipstick 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.
Changing Oil Filter (TYPE A)ELS000CI
REMOVAL
1. Open oil filter installation/ removal cover on RH engine undercover.
2. Using the oil filter wrench, remove the oil filter.
CAUTION:
Be careful not to get burned when the engine and engine oil are hot.
When removing, prepare a shop cloth to absorb any engine oil leakage or spillage.
Do not allow engine oil to adhere to the drive belts.
Completely wipe off any engine oil that adhere to the engine and the vehicle.
The oil filter is provided with a relief valve.
INSTALLATION
1. Remove foreign materials adhering to the oil filter installation surface.
2. Apply engine oil to the oil seal circumference of the new oil filter.
3. Screw the oil filter manually until it touches the installation surface, then tighten it by 1/2 turn. Or tighten to
specification.
INSPECTION AFTER INSTALLATION
1. Start engine, and check there is no leak of engine oil.
2. Stop engine and wait for 10 minutes.
3. Check the engine oil level and add engine oil. Refer to MA-35, "
Changing Engine Oil" .
PBIC0249E
SMA010
Oil filter:
: 18 N·m (1.8 Kg-m, 13 ft-lb)
MA-38
ENGINE MAINTENANCE (YD22DDTI)
5. Remove O-ring from oil filter body.
Push O-ring in one direction, lift the slack part using fingers,
and remove O-ring from oil filter body.
CAUTION:
Do not use a screwdrivers etc. as they may cause dam-
age to oil filter body.
INSTALLATION
1. Completely remove all foreign objects adhering to the inside of oil filter body or O-ring mounting area
(body side and bracket side).
2. Install oil filter and O-ring to oil filter body.
Push oil filter into filter body completely.
3. Install oil filter body to oil filter bracket.
INSPECTION AFTER INSTALLATION
1. After warming up engine, check there is no leaks of engine oil.
2. Stop engine and wait for 10 minutes.
3. Check the engine oil level and add engine oil. Refer to MA-35, "
Changing Engine Oil" .
Draining WaterELS000CJ
1. Prepare a tray at the drain hose open end.
2. Loosen drain cock, and operate priming pump to drain water
from fuel filter.
CAUTION:
Water in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volume.
Drained water is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mount insulator.
3. After draining, close drain cock by hand.
CAUTION:
If drain cock is tightened excessively, it may be damaged
and fuel will leak. Do not use tools to tighten drain cock.
4. Bleed air in fuel piping. Refer to FL-18, "
Air Bleeding" .
5. Start engine and make sure there is no fuel leakage.
JLC292B
Oil filter body:
: 22 N·m (2.2 Kg-m, 16 ft-lb)
SBIA0138E
CHASSIS AND BODY MAINTENANCE
MA-39
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CHASSIS AND BODY MAINTENANCEPFP:00100
Checking Exhaust SystemELS000B9
Check exhaust pipes, muffler and mounting for improper attachment,
leaks, cracks, damage, chafing or deterioration.
If anything is found, repair or replace damaged parts.
Checking Clutch Fluid Level and LeaksELS000BA
If fluid level is extremely low, check clutch system for leaks.
Checking Clutch SystemELS000BB
Check fluid lines and operating cylinder for improper attachment,
cracks, damage, loose connections, chafing and deterioration.
Checking M/T OilELS000BC
Check for oil leakage.
(For details, refer to MT-12, "
Checking M/T Oil" .)
SMA211A
SFIA0066J
SMA859
MA-40
CHASSIS AND BODY MAINTENANCE
Changing M/T OilELS000BD
1. Drain oil from drain plug and refill with new gear oil.
(For details, refer to MT-12, "
Changing M/T Oil" .)
2. Check oil level.
For 2WD models
For 4WD models
CAUTION:
Do not reuse gasket.
Checking A/T FluidELS000BV
1. Warm up engine.
2. Check for fluid leakage.
3. Before driving, fluid level can be checked at fluid temperatures of 30 to 50°C (86 to 122°F) using “COLD”
range on A/T fluid level gauge.
a. Park vehicle on level surface and set parking brake.
b. Start engine and move selector lever through each gear position. Leave selector lever in “P” position.
c. Check fluid level with engine idling.Oil grade and viscosity:
Refer to MA-17, "
RECOMMENDED FLUIDS AND
LUBRICANTS" .
Oil capacity (reference):
Approx. 2.2 (3-7/8 lmp pt)
Oil level “L” : 55.0 - 61.0 mm (2.17 - 2.40 in)
PCIB1477E
Oil level “L” : 168.0 - 174.0 mm (6.61 - 6.85 in)
Drain plug:
: 34.5 N·m (3.5 kg-m, 25 ft-lb)
PCIB1478E
SMA146B