EM-130
[YD22DDTi]
PRECAUTIONS
[YD22DDTi]PRECAUTIONSPFP:00001
Precautions for Draining 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.
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.
Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
make sure that dowel pins are installed in the original position.
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 Angle TighteningEBS00LR4
Use an angle wrench (special service tool: KV10112100) 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 angle
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.
EM-132
[YD22DDTi]
PREPARATION
PREPARATIONPFP: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
Pulley pullerRemoving crankshaft pulley
ED19600610
Compression gauge adapterChecking compression pressure
NT042
NT028
NT799
NT603
S-NT605
NT676
ZZA1188D
EM-134
[YD22DDTi]
PREPARATION
EM03470000
Piston ring compressorInstalling piston assembly into cylinder bore
KV10109300
Pulley holderFixing crankshaft pulley
a: 68 mm (2.68 in)
b: 8 mm (0.31 in) dia.
KV11106010
Hexagon wrenchRemoving and installing chain tensioner
a: 5 mm (0.20 in) (Face to face)
b: 20 mm (0.79 in)
KV11106020
Hexagon wrenchRemoving and installing slack guide
a: 6 mm (0.24 in) (Face to face)
b: 20 mm (0.79 in)
KV11106030
Positioning stopper pinFixing fuel pump sprocket
a: 6 mm (0.24 in) dia.
b: 80 mm (3.15 in)
KV11106040
TORX wrenchRemoving and installing fuel pump sprocket
nut
a: T70
b: 26 mm (1.02 in)
KV11106050
Hexagonal wrenchRemoving and installing fuel pump sprocket
a: 6 mm (0.24 in) (Face to face)
b: 42 mm (1.65 in) Tool number
Tool nameDescription
NT044
NT628
NT801
NT803
NT804
NT805
SBIA0224E
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
EM-139
[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-185
Rattle C A — A B CCamshaft
bearing
noiseCamshaft oil clearance
Camshaft runoutEM-182EM-181
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 clearanceEM-246
EM-248
Slap or
rapA ——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-250EM-247
EM-247
EM-248
Knock A B C B B BConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance
Connecting rod bear-
ing oil clearance (Big
end)EM-248EM-252
Knock A B — A B CMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-253EM-252
Front of
engine
Timing
chain
caseTapping or
tickingA A —BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-193
EM-198
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belts
(Sticking
or slip-
ping)Drive belts deflection
EM-140
CreakingA B ABABDrive belts
(Slipping)Idler pulley bearing
operation
Squall
CreakA B —BABWater
pump
noiseWater pump operationCO-43,
"WATER
PUMP"
EM-140
[YD22DDTi]
DRIVE BELTS
DRIVE BELTSPFP:02117
Checking Drive BeltsEBS00LRA
Before inspecting engine, make sure engine has cooled down;
wait approximately 30 minutes after 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 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 specified value 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 engine coolant.
Do not twist or bend the belts with strong force.
PBIC1251E
Applied beltBelt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
New Adjusted Limit for re-adjusting
A/C 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
A/C compressor belt Adjusting bolt on idler pulley
Alternator and water pump belt Adjusting bolt on alternator
DRIVE BELTS
EM-141
[YD22DDTi]
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A/C COMPRESSOR BELT
1. Remove RH engine undercover.
2. Loosen idler pulley lock nut (A).
3. Turn adjusting bolt (B) to adjust. Refer to EM-140, "
Checking
Drive Belts" .
4. Tighten lock nut (A).
ALTERNATOR AND WATER PUMP BELT
1. Loosen adjusting lock nut (C).
2. Loosen alternator fixing bolts (D) (each on front and rear).
3. Turn adjusting bolt (E) to adjust. Refer to EM-140, "
Checking Drive Belts" .
4. Tighten nut (C) and bolt (D) in this order.
Removal and InstallationEBS00LRC
REMOVAL
1. Loosen each belt. Refer to EM-140, "Tension Adjustment" .
2. Remove A/C compressor belt. Refer to EM-141, "
A/C COMPRESSOR BELT" .
3. Remove alternator and water pump belt. Refer to EM-141, "
ALTERNATOR AND WATER PUMP BELT" .
INSTALLATION
1. Install each belt on pulley in the reverse order of removal.
2. Adjust belt tension. Refer to EM-140, "
Tension Adjustment" .
3. Tighten nuts and bolts provided for adjustment to the specified torque.
4. Make sure again that each belt tension is as specified.Nut A:
: 35 N·m (3.6 kg-m, 26 ft-lb)
PBIC1252E
Nut C:
: 21.5 N·m (2.2 kg-m, 16 ft-lb)
Bolt D:
: 50.5 N·m (5.2 kg-m, 37 ft-lb)
EM-186
[YD22DDTi]
CAMSHAFT
Be careful of the intake and exhaust valve arrangement. The
valve arrangement is different from that in a normal engine.
NOTE:
The camshafts have, alternately, either intake valve or exhaust
valve. (Refer to figure.)
1. Remove charge air cooler. Refer to EM-144, "
Removal and Installation" .
2. Remove air duct. Refer to EM-142, "
Removal and Installation" .
3. Remove rocker cover. Refer to EM-178, "
Removal and Installation" .
4. Remove fuel injector. Refer to EM-167, "
Removal and Installation" .
5. Set the No. 1 piston to TDC on its compression stroke.
Turn crankshaft pulley clockwise so that the knock pin on
camshaft left side faces straight above. (No position indicator,
etc. is provided on the crankshaft pulley.)
6. Put an alignment mark with paint, etc. on crankshaft pulley and
on oil pump housing as an angle indicator.
7. While referring to the figure, measure the valve clearance
marked in the table below.
NOTE:
The injection order is 1-3-4-2.
SBIA0178E
PBIC2533E
JEM177G
Measuring pointNo. 1No. 2No. 3No. 4
INT EXH INT EXH INT EXH INT EXH
When the No. 1
cylinder is in the
TDCXXX X
SBIA0180E
OIL SEAL
EM-191
[YD22DDTi]
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Removal and Installation of Front Oil SealEBS01FBN
REMOVAL
1. Remove the following parts.
RH engine undercover
Drive belt; Refer to EM-140, "DRIVE BELTS" .
Crankshaft pulley; Refer to EM-198, "PRIMARY TIMING CHAIN" .
2. Remove front oil seal with a suitable tool.
CAUTION:
Be careful not to damage oil pump housing and crankshaft.
INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown in
the figure.
Using the suitable drift [62 mm (2.44 in) dia.], force fit the seal
until it hits the bottom.
CAUTION:
Do not touch lips of oil seal. Make sure seal surfaces are
free of foreign materials.
3. Install in the reverse order of removal.
AEM385
SEM715A
JEM142G