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
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)
IDX-7
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IDX
ALPHABETICAL INDEX
P
Park/Neutral position switch ............. EC-398
, EC-802,
EC-1322
, EC-1673
Park/neutral position switch (A/T) .................... AT-100
Park/neutral position switch (M/T) ..................... MT-15
PCV (positive crankcase ventilation) . EC-527, EC-967
PGC/V - Wiring diagram .................................. EC-271
PHASE - Wiring diagram ................... EC-258, EC-703
Pilot bushing replacement - See Pilot
converter(QR20DE-QR25DE) ........................... EM-89
Piston assembly(QR20DE-QR25DE) .............. EM-111
Piston pin inspection(QR20DE-QR25DE) ....... EM-107
Piston pin inspection(YD22DDTi) .................... EM-242
Piston ring inspection(QR20DE-QR25DE) ...... EM-108
Piston ring inspection(YD22DDTi) ................... EM-247
Piston to bore clearance(QR20DE-QR25DE) . EM-111
Piston to bore clearance(YD22DDTi) .............. EM-250
PNP/SW - Wiring diagram EC-400, EC-804, EC-1323,
EC-1674
POS - Wiring diagram ........................ EC-251, EC-695
POWER - Wiring diagram .................................... PG-3
Power antenna .................................................. AV-37
Power door lock .................................................. BL-22
Power seat ......................................................... SE-10
Power socket ................................................... WW-31
Power steering fluid level ......................... PS-6, MA-45
Power steering gear .......................................... PS-16
Power steering oil pressure switch EC-1326, EC-1677
Power steering oil pump .................................... PS-27
Power steering pressure (PSP) sensor .......... EC-278,
EC-711
Power steering system bleeding .......................... PS-6
Power supply routing ........................................... PG-2
Power window .................................................. GW-40
Precations for Leak detection dye ................... ATC-12
Precautions (General) .......................................... GI-4
Pre-delivery inspection ........................................ MA-4
Pressure plate - See Clutch cover ..................... CL-16
PRGVLV - Wirng diagram ............................... EC-885
Propeller shaft ..................................................... PR-3
Propeller shaft on vehicle service ........................ PR-3
PS/SEN - Wiring diagram .................. EC-279, EC-712
PST/SW - Wiring diagram ............. EC-1327, EC-1678
Q
Quick-glow system ........................ EC-1305
, EC-1643
R
R/FOG - Wiring diagram ................................... LT-112
Radiator(QR20DE-QR25DE) ................ CO-12, CO-15
Radiator(YD22DDTi) ............................ CO-35, CO-39
Radio - See Audio ............................................... AV-4
Rear air spoiler .................................................... EI-30
Rear bumper ........................................................ EI-17
Rear disc brake ................................................. BR-32
Rear door ............................................................ BL-18
Rear fog lamp ................................................... LT-112
Rear panel finisher .............................................. EI-31
Rear seat ........................................................... SE-32
Rear seat belt ...................................................... SB-4
Rear side window ............................................. GW-13
Rear suspension ............................................... RSU-5
Rear washer .................................................... WW-14
Rear window defogger ...................................... GW-17
Rear wiper ....................................................... WW-14
Refrigerant connection precaution ..................... ATC-5
Refrigerant discharging evacuating charging ATC-141
Refrigerant general precaution .......................... ATC-5
Refrigerant lines ............................................. ATC-141
Refrigerant pressure sensor EC-474, EC-914, ATC-18,
ATC-94
, ATC-157
Refrigeration cycle ........................................... ATC-18
Release bearing (clutch) .................................... CL-14
Removal and installation (A/T) ......................... AT-413
Removal and installation (Transfer) ................... TF-57
Reverse idler shaft (M/T) ...................... MT-23, MT-41
Reverse lamp switch (M/T) - See Back-up lamp switch
(M/T) .................................................................. MT-15
Reverse main gear (M/T) ...................... MT-23, MT-41
Rocker cover(QR20DE-QR25DE) .................... EM-44
Rocker cover(YD22DDTi) ............................... EM-178
Room lamp ....................................................... LT-132
Room lamp - See Interior lamp ......................... LT-132
ROOM/L - Wiring diagram ................................ LT-132
RP/SEN - Wiring diagram .................. EC-475, EC-915
RRO2 - Wiring diagram ..................... EC-852, EC-868
S
S/LOCK - Wiring diagram ....................... BL-24
, BL-45
S/SIG - Wiring diagram .................. EC-1345, EC-1696
SCTC/V - Wiring diagram ............. EC-1232, EC-1265,
EC-1271
, EC-1276, EC-1281, EC-1571, EC-1604,
EC-1610
, EC-1615, EC-1620
SEAT - Wiring diagram ...................................... SE-11
Seat belt inspection .......................................... MA-47
Seat belt pre-tensioner disposal ..................... SRS-42
Seat belt, front ..................................................... SB-3
Seat belt, rear ...................................................... SB-4
Seat, front .......................................................... SE-24
Seat, rear ........................................................... SE-32
Self-diagnosis (Transfer) ................................... TF-32
SEN/PW - Wiring diagram ................. EC-373, EC-776
Sheft warning system ...................................... BL-104
SHIFT - Wiring diagram ................................... AT-399
Shift control components (M/T) ............. MT-25, MT-43
Shift fork (M/T) ...................................... MT-25, MT-43
Shift lever ........................................................... MT-16
Shift lock system .............................................. AT-398
Shift schedule .................................................. AT-530
Shift solenoid valve A (A/T) ............................. AT-128
Shift solenoid valve B (A/T) ............................. AT-128
Side air bag (satellite) sensor ......................... SRS-39
Side window - See Rear side window ............... GW-13
Spark plug replacement(QR20DE-QR25DE) ... MA-26
IDX-8
ALPHABETICAL INDEX
Spark plug(QR20DE-QR25DE) ........................ EM-32
Specification value ............................. EC-120, EC-620
Speedometer ........................................................ DI-4
Spiral cable ..................................................... SRS-33
SROOF - Wiring diagram ................................... RF-11
SRS - See Supplemental Restraint System ..... SRS-6
SRS - Wiring diagram/LHD ............................. SRS-11
SRS - Wiring diagram/RHD ............................ SRS-13
SRS Trouble diagnoses .................................... SRS-8
Stall test (A/T) ...................................... AT-65, AT-257
Standardized relay ............................................. PG-77
START - Wiring diagram ........................ SC-24, SC-25
Start signal ..................................... EC-1345, EC-1696
Starter ................................................................ SC-23
Starting system .................................................. SC-23
Steering gear and linkage inspection ................ MA-45
Steering knuckle ................................................ FAX-7
Steering linkage ................................................. PS-16
Steering wheel and column ..................... PS-8, PS-11
Steering wheel turning force ................................ PS-8
Stop lamp .............................................. LT-98, LT-118
Stop lamp switch ................................ EC-405, EC-809
STOP/L - Wiring diagram ...................... LT-98, LT-118
Suction control valve .... EC-1231, EC-1275, EC-1280,
EC-1570
, EC-1614, EC-1619
Sunload sensor ............. ATC-114, ATC-116, ATC-123
Sunroof .............................................................. RF-10
Super lock .......................................................... BL-42
Supplemental Restraint System ....................... SRS-6
Supplemental restraint system - Wiring diagram/LHD ..
SRS-11
Supplemental restraint system - Wiring diagram/RHD .
SRS-13
Suspension ....................................................... MA-46
Symbols and abbreviations ........................ GI-9, GI-22
Symptom matrix chart .......................... EC-84, EC-584
Synchronizer (M/T) ............................... MT-23, MT-41
System readiness test (SRT) code .................... EC-56
T
Tachometer ........................................................... DI-4
Tail lamp ............................................. LT-103, LT-116
TAIL/L - Wiring diagram ...................... LT-103, LT-145
Tailgate lamp .................................................... LT-103
TC boost control solnoid valve ...... EC-1061, EC-1506,
EC-1659
TC boost sensor ............................................ EC-1151
TCC/V - Wiring diagram ................. EC-1062, EC-1660
TCM circuit diagram ........................................... AT-21
TCM inspection table ........................... AT-94, AT-286
THEFT - Wiring diagram .................................. BL-104
Thermal protector ............................................ ATC-95
Thermostat(QR20DE-QR25DE) ....................... CO-23
Thermostat(YD22DDTi) .................................... CO-46
Three way catalyst function ............................. EC-264
Three way catalyst precautions ............................ GI-5
Three way catalyst(QR20DE-QR25DE) ........... EM-25
Throttle control motor relay ................ EC-306, EC-737
Throttle position sensor (TPS) ......... EC-171, EC-231,
EC-368
, EC-370, EC-424, EC-658, EC-680, EC-771,
EC-773
, EC-830
Throwout bearing - See Clutch release bearing CL-14
Time control system .......................................... BCS-3
Timing chain(QR20DE-QR25DE) ..................... EM-46
Timing chain(YD22DDTi) .................. EM-193, EM-198
Torque converter installation ............. AT-415, AT-523
TPS1 - Wiring diagram ..................... EC-233, EC-682
TPS2 - Wiring diagram ..................... EC-173, EC-660
TPS3 - Wiring diagram ..................... EC-426, EC-832
Transmission case (M/T) ...................... MT-22, MT-40
Trouble diagnoses .............................................. GI-10
Turbocharger charge air cooler(YD22DDTi) ... EM-144
Turbocharger precautions ..................................... GI-6
Turbocharger(YD22DDTi) ............................... EM-151
TURN - Wiring diagram .......................... LT-87, LT-89
Turn signal lamp ................................... LT-87, LT-118
Two trip detection logic ....................... EC-52, EC-565
V
Vacuum hose (brake system) ............................ BR-25
Vacuum hose drawing (Engine control) EC-32, EC-545
Vacuum pump(YD22DDTi) ............................. EM-163
Valve clearance(QR20DE-QR25DE) ................ EM-64
Valve clearance(YD22DDTi) ........................... EM-185
Valve guide ....................................................... EM-77
Valve guide(QR20DE-QR25DE) ....................... EM-77
Valve lifter(QR20DE-QR25DE) ......................... EM-56
Valve lifter(YD22DDTi) ................................... EM-183
Valve seat(QR20DE-QR25DE) ......................... EM-79
Valve seat(YD22DDTi) ................................... EM-219
Valve spring(QR20DE-QR25DE) ...................... EM-80
Variable induction air control system (VIAS) ... EC-457,
EC-897
Vehicle speed sensor (VSS) EC-276, EC-403, EC-709,
EC-807
VIAS - Wiring diagram ...................... EC-459, EC-899
W
WARN - Wiring diagram .......................... DI-36
, DI-44
Warning chime .................................................... DI-56
Warning lamps .................................................... DI-35
Washer, front ..................................................... WW-4
Washer, rear .................................................... WW-14
Water control valve(QR20DE-QR25DE) ........... CO-23
Water pump(QR20DE-QR25DE) ...................... CO-21
Water pump(YD22DDTi) ................................... CO-43
Water temperature gauge ..................................... DI-4
Weatherstrip - See Exterior ............................... BL-21
Wheel alignment (front) .................................... FSU-6
Wheel alignment (rear) ..................................... RSU-6
Wheel balance ....................................... WT-4, MA-43
Wheel bearing (rear) ........................... RAX-6, RAX-10
Wheel hub (front) ............................................... FAX-7
Wheel hub (rear) ............................................. RAX-10
Wheel sensors (ABS) ..................................... BRC-46