EM-156
[YD22DDTi]
EXHAUST MANIFOLD AND TURBOCHARGER
TROUBLE DIAGNOSIS OF TURBOCHARGER
Preliminary check:
Make sure that the engine oil level is between “MIN” and “MAX” of the oil level gauge. (When engine oil
amount is more than “MAX”, engine oil flows into the inlet duct through blow-by gas passage, and turbo-
charger is misjudged malfunction.)
Ask the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving.
Replace the turbocharger assembly when any malfunction is found after unit inspections specified in the
table below.
If no malfunction is found after the unit inspections, judge that the turbocharger body has no malfunction.
Check the other parts again.
A: Large possibility
B: Medium possibility
C: Small possibilityInspection item Inspection resultSymptom
(when each inspection item meets each inspection result)
Engine oil
leakageSmoke NoiseInsufficient power/accel-
eration malfunction
Turbine wheelEngine oil leaks C A C C
Carbon is accumulated C A B B
Friction with housing C B A B
Blades are bent or broken — — A A
Compressor wheelInside the air inlet is seriously con-
taminated by engine oil.BB— —
Friction with housing C B A B
Blades are bent or broken — — A A
After checking both turbine and
compressor, inspect rotor shaft
end play.There is resistance when the rotor
shaft is rotated by your fingertips.—CC B
The rotor shaft sometimes does not
rotate by your fingertips.——— A
There is too much play in the bear-
ing.CCB C
Oil return portCarbon or sludge is accumulated in
the waste oil hole.CAC C
EM-170
[YD22DDTi]
INJECTION TUBE AND FUEL INJECTOR
CAUTION:
Check gutter spring in nozzle oil seal on fuel injector for missing.
6. Connect injection tubes individually to each cylinder in order of
3-4-1-2.
7. Connect spill hose. Refer to EM-146, "
INTAKE MANIFOLD" .
8. Install remaining parts in the reverse order of removal.
9. Before starting engine, bleed air from fuel piping. Refer to FL-18, "
Air Bleeding" .
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.
CAUTION:
Do not touch engine immediately after stopped as engine becomes extremely hot.
NOTE:
Use mirrors for checking at points out of clear sight.
SBIA0203E
ROCKER COVER
EM-179
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Loosen holding bolts in reverse order of that shown in the fig-
ure and remove.
6. Remove rocker cover gasket.
INSTALLATION
1. Apply 3.0 mm (0.118 in) dia. on locations shown in the figure.
Use Genuine Liquid Gasket or equivalent.
2. Install rocker cover gasket to rocker cover.
3. Tighten holding bolts in numerical order shown in the figure.
Re-tighten to the same torque in the same order as above.
4. Install nozzle oil seal.
Insert it straight until flange fully contacts rocker cover.
5. Install remaining parts in the reverse order of removal.
6. Before starting engine, bleed air from fuel piping. Refer to FL-18, "
Air Bleeding" .
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.
CAUTION:
Do not touch the engine immediately after stopped as engine becomes extremely hot.
NOTE:
Use mirrors for checking at points out of clear sight.
SBIA0175E
JEM248G
: 7.8 N·m (0.8 kg-m, 69 in-lb)
SBIA0175E
CYLINDER HEAD
EM-209
[YD22DDTi]
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CYLINDER HEADPFP: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-1012,
"Basic Inspection" (WITH EURO-ODB) or EC-1382, "Basic Inspection" (WITHOUT EURO-ODB).
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 battery cable from the negative terminal.
4. Remove charge air cooler. Refer to EM-144, "
Removal and Installation"
5. To prevent fuel from being injected during inspection, remove
fuel pump fuse [ENG CONT 2 (20A)] from fuse box on the left
side of engine room.
Among marks on fuse box, [ENG CONT 2 (20A)] is for fuel
pump fuse.
6. Remove glow plugs from all the cylinders. Refer to EM-162,
"Removal and Installation" .
CAUTION:
Before removal, clean the surrounding area to prevent
entry of any foreign materials into engine.
Carefully remove glow plugs to prevent any damage or
breakage.
Handle with care to avoid applying any shock to glow plugs.
7. Install compression gauge adapter (special service tool) to
installation holes of glow plugs and connect compression gauge
for diesel engine.
8. Connect the battery cable to the negative terminal.
9. With accelerator pedal fully depressed, turn ignition switch to
“START” for cranking. When the gauge pointer stabilizes, read
the compression pressure and engine rpm. Perform these steps
to check 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.
PBIC0680E
: 20 N·m (2.0 kg-m, 15 ft-lb)
SEM112G
Standard Minimum Difference limit between cylinders
2,991 (29.9, 30.5, 434)/200 2,452 (24.5, 25.0, 356)/200 490 (4.9, 5.0, 71)/200
EM-214
[YD22DDTi]
CYLINDER HEAD
c. Tighten 180 degrees in numerical order as shown (angle tight-
ening).
d. Loosen completely in reverse order of that shown in the figure.
e. Tighten all bolts in numerical order as shown.
f. Tighten 90 degrees in numerical order as shown (angle tighten-
ing).
g. Tighten another 90 degrees in numerical order as shown (angle
tightening).
CAUTION:
When the angle wrench (special service tool) 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 pro-
tractor.
4. Install glow plug.
CAUTION:
To avoid damage, glow plugs should be removed only when required.
Handle with care to avoid applying shock. When dropped from approx. 10 cm (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 in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-17, "
RECOMMENDED FLUIDS AND LUBRICANTS" .
Before starting engine, bleed air from fuel piping. Refer to FL-18, "Air Bleeding" .
Run engine to check for unusual noise and vibration.
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
: 0 N·m (0 kg-m, 0 ft-lb)
:39.2 N·m (4.0 kg-m, 29 ft-lb)
JEM166G
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
ENGINE ASSEMBLY
EM-225
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INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-17, "
RECOMMENDED FLUIDS AND LUBRICANTS" .
Before starting engine, bleed air from fuel piping. Refer to FL-18, "Air Bleeding" .
Run engine to check for unusual noise and vibration.
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
ENGINE ASSEMBLY
EM-229
[YD22DDTi]
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9. Remove power steering oil pump with piping connected from engine. Move it aside on suspension mem-
ber. Refer to PS-37, "
HYDRAULIC LINE" .
10. Remove front engine mounting and rear engine mounting through-bolts to remove suspension member.
11. Remove starter motor. Refer to SC-23, "
STARTING SYSTEM" .
12. Separate engine and transaxle and transfer assembly. Refer to MT-19, "
TRANSAXLE ASSEMBLY" .
INSTALLATION
Install in the reverse order of removal.
Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.
When installation directions are specified, install parts according to the direction marks on them referring
to figure of components. Refer to EM-222, "
ENGINE ASSEMBLY" .
Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-17, "
RECOMMENDED FLUIDS AND LUBRICANTS" .
Before starting engine, bleed air from fuel piping. Refer to FL-18, "Air Bleeding" .
Run engine to check for unusual noise and vibration.
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
ENGINE OIL
LU-7
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ENGINE OILPFP:KLA92
InspectionEBS00KO3
ENGINE OIL LEVEL
NOTE:
Before starting engine, put vehicle horizontally and check the engine oil level. If engine is already started, stop
it and allow 10 minutes before checking.
1. Pull out oil level gauge and wipe it clean.
2. Insert oil level gauge and make sure the engine oil level is within
the range shown in the figure.
3. If it is out of range, adjust it.
ENGINE OIL APPEARANCE
Check engine oil for white turbidity or heavy contamination.
If engine oil becomes turbid and white, it is highly probable that it is contaminated with engine coolant.
Repair or replace damaged parts.
ENGINE OIL LEAKAGE
Check for engine oil leakage around the following area.
Oil pan
Oil pan drain plug
Oil pressure switch
Oil filter
Oil cooler
Intake valve timing control cover and intake valve timing control solenoid valve
Front cover
Mating surface between cylinder block and lower cylinder block
Mating surface between cylinder block and cylinder head
Mating surface between cylinder head and rocker cover
Crankshaft oil seals (front and rear)
OIL PRESSURE CHECK
WARNING:
Be careful not to burn yourself, as engine oil may be hot.
Engine oil pressure check should be in “ Parking position” (A/T models) or “Neutral position” (M/T
models), and should apply parking brake securely.
1. Check engine oil level. Refer to LU-7, "
ENGINE OIL LEVEL" .
2. Remove RH undercover.
PBIC0249E