EM-232
[YD22DDTi]
CYLINDER BLOCK
e. Hoist engine and install it to the engine stand (special service
tool).
NOTE:
It is possible to set engine sub-attachment and engine stand
shaft to the engine stand at first, then install engine later.
Widely use engine stand can be used.
CAUTION:
Use an engine stand that has a load capacity [219 kg (483
pound) or more] large enough for supporting the engine
weight.
NOTE:
The figure shows an example of general-purpose engine
stand that can hold mating surface of transmission with drive
plate and rear plate removed.
4. If they need to be replaced, replace pilot bushing.
Using the pilot bushing puller (special service tool), remove
the pilot bushing from rear end of crankshaft.
5. Drain engine oil. Refer to LU-21, "
Changing Engine Oil" .
JEM193G
PBIC0085E
PBIC2588E
EC-204
[QR (WITH EURO-OBD)]
DTC P0138 HO2S2
DTC P0138 HO2S2PFP:226A0
Component DescriptionEBS010OL
The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates volt-
age from approximately 1V in richer conditions to 0V in leaner condi-
tions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
CONSULT-II Reference Value in Data Monitor ModeEBS010OM
Specification data are reference values.
On Board Diagnosis LogicEBS010ON
The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity before the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the voltage is unusually high during
the various driving condition such as fuel-cut.
DTC Confirmation ProcedureEBS010OO
CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
SEF327R
MONITOR ITEM CONDITION SPECIFICATION
HO2S2 (B1)
Engine: After warming up
Keeping the engine speed
between 3,500 and 4,000 rpm
for 1 minute and at idle for 1
minute under no load.Revving engine from idle to 3,000
rpm quickly.0 - 0.3V ←→ Approx. 0.6 - 1.0V
HO2S2 MNTR (B1)LEAN ←→ RICH
SEF305UA
DTC No. Trouble diagnosis name DTC detecting condition Possible cause
P0138
0138Heated oxygen sensor 2
circuit high voltageAn excessively high voltage from the sensor
is sent to ECM.
Harness or connectors
(The sensor circuit is open or shorted.)
Heated oxygen sensor 2
DTC P0139 HO2S2
EC-211
[QR (WITH EURO-OBD)]
C
D
E
F
G
H
I
J
K
L
MA
EC
DTC P0139 HO2S2PFP:226A0
Component DescriptionEBS010OU
The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates volt-
age from approximately 1V in richer conditions to 0V in leaner condi-
tions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
CONSULT-II Reference Value in Data Monitor ModeEBS010OV
Specification data are reference values.
On Board Diagnosis LogicEBS010OW
The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity before the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the switching response of the sen-
sor's voltage is faster than specified during the various driving condi-
tion such as fuel-cut.
SEF327R
MONITOR ITEM CONDITION SPECIFICATION
HO2S2 (B1)
Engine: After warming up
Keeping the engine speed
between 3,500 and 4,000 rpm
for 1 minute and at idle for 1
minute under no load.Revving engine from idle to 3,000
rpm quickly.0 - 0.3V ←→ Approx. 0.6 - 1.0V
HO2S2 MNTR (B1)LEAN ←→ RICH
SEF302U
DTC No. Trouble diagnosis name DTC detecting condition Possible cause
P0139
0139Heated oxygen sensor 2
circuit slow responseIt takes more time for the sensor to respond
between rich and lean than the specified time.
Harness or connectors
(The sensor circuit is open or shorted.)
Heated oxygen sensor 2
Fuel pressure
Fuel injector
Intake air leaks
EC-264
[QR (WITH EURO-OBD)]
DTC P0420 THREE WAY CATALYST FUNCTION
DTC P0420 THREE WAY CATALYST FUNCTIONPFP:20905
On Board Diagnosis LogicEBS010Q8
The ECM monitors the switching frequency ratio of heated oxygen
sensors 1 and 2.
A three way catalyst (manifold) with high oxygen storage capacity
will indicate a low switching frequency of heated oxygen sensor 2.
As oxygen storage capacity decreases, the heated oxygen sensor 2
switching frequency will increase.
When the frequency ratio of heated oxygen sensors 1 and 2
approaches a specified limit value, the three way catalyst (manifold)
malfunction is diagnosed.
DTC Confirmation ProcedureEBS010Q9
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
WITH CONSULT-II
TESTING CONDITION:
Open engine hood before conducting the following procedure.
Do not hold engine speed for more than the specified minutes below.
1. Start Engine and warm it up to the normal operating temperature.
2. Turn ignition switch OFF and wait at least 10 seconds.
3. Start engine and keep the engine speed between 3,500 and 4,00 rpm for at least 1 minute under no load.
4. Let engine idle for 1 minute.
5. Select “DTC & SRT CONFIRMATION” then “SRT WORK SUP-
PORT” mode with CONSULT-II.
6. Start engine.
7. Rev engine up to 2,000 to 3,000 rpm and hold it for 3 consecu-
tive minutes then release the accelerator pedal completely.
If “INCMP” of “CATALYST” changed to “COMPLT”, go to step 10
8. Wait 5 seconds at idle.
SEF484YF
DTC No. Trouble diagnosis name DTC detecting condition Possible cause
P0420
0420Catalyst system efficiency
below threshold
Three way catalyst (manifold) does not operate
properly.
Three way catalyst (manifold) does not have
enough oxygen storage capacity.
Three way catalyst (manifold)
Exhaust tube
Intake air leaks
Fuel injector
Fuel injector leaks
Spark plug
Improper ignition timing
PBIB0566E
EC-334
[QR (WITH EURO-OBD)]
DTC P1146 HO2S2
DTC P1146 HO2S2PFP:226A0
Component DescriptionEBS010SJ
The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates volt-
age from approximately 1V in richer conditions to 0V in leaner condi-
tions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
CONSULT-II Reference Value in Data Monitor ModeEBS010SK
Specification data are reference values.
On Board Diagnosis LogicEBS010SL
The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity of the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the minimum voltage of sensor is
sufficiently low during the various driving condition such as fuel-cut.
SEF327R
MONITOR ITEM CONDITION SPECIFICATION
HO2S2 (B1)
Engine: After warming up
Keeping the engine speed
between 3,500 and 4,000 rpm
for 1 minute and at idle for 1
minute under no load.Revving engine from idle to 3,000
rpm quickly.0 - 0.3V ←→ Approx. 0.6 - 1.0V
HO2S2 MNTR (B1)LEAN ←→ RICH
PBIB0554E
DTC No. Trouble diagnosis name DTC detecting condition Possible cause
P1146
1146Heated oxygen sensor 2
minimum voltage monitoringThe minimum voltage from the sensor is not
reached to the specified voltage.
Harness or connectors
(The sensor circuit is open or shorted.)
Heated oxygen sensor 2
Fuel pressure
Fuel injector
EC-342
[QR (WITH EURO-OBD)]
DTC P1147 HO2S2
DTC P1147 HO2S2PFP:226A0
Component DescriptionEBS010SS
The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the heated oxygen sensor 1 are
shifted, the air-fuel ratio is controlled to stoichiometric, by the signal
from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates volt-
age from approximately 1V in richer conditions to 0V in leaner condi-
tions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
CONSULT-II Reference Value in Data Monitor ModeEBS010ST
Specification data are reference values.
On Board Diagnosis LogicEBS010SU
The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the heated oxygen sensor 1. The oxygen
storage capacity before the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the maximum voltage of the sensor
is sufficiently high during the various driving condition such as fuel-
cut.
SEF327R
MONITOR ITEM CONDITION SPECIFICATION
HO2S2 (B1)
Engine: After warming up
Keeping the engine speed
between 3,500 and 4,000 rpm
for 1 minute and at idle for 1
minute under no load.Revving engine from idle to 3,000
rpm quickly.0 - 0.3V ←→ Approx. 0.6 - 1.0V
HO2S2 MNTR (B1)LEAN ←→ RICH
SEF259VA
DTC No. Trouble diagnosis name DTC detecting condition Possible cause
P1147
1147Heated oxygen sensor 2
maximum voltage monitoringThe maximum voltage from the sensor is
not reached to the specified voltage.
Harness or connectors
(The sensor circuit open or shorted.)
Heated oxygen sensor 2
Fuel pressure
Fuel injector
Intake air leaks
TF-76
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsEDS000I6
Inspection and AdjustmentEDS0004Y
PRELOAD TORQUE BEFORE DISASSEMBLY
PRELOAD TORQUE AFTER DISASSEMBLY AND REASSEMBLY
BACKLASH
Unit: mm (in)
COMPANION FLANGE RUNOUT
Unit: mm (in)
SELECTIVE PARTS
Gear ring Bearing Adjusting Shim (Transfer Case Side)
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.Applied model QR20DE QR25DE YD22DDTi
Transfer model TY20A
Oil capacity (Approx.) (lmp pt)0.31 (1/2)
Gear ratio0.404
Number of teeth Drive pinion 17
Drive gear 42
Item Specification [N·m (kg-m, in-lb)]
Pinion bearing (P
1 )0.10 - 0.39 (0.01 - 0.04, 1 - 3)
Gear ring bearing to pinion
bearing (Total preload)With all oil seals P
1 + 0.16 - 0.22 (0.016 - 0.023, 1.4 - 1.9)
Without transfer case oil seal and adapter case oil seal P
1 + 0.06 - 0.12 (0.006 - 0.013, 0.6 - 1.1)
Item Specification [N·m (kg-m, in-lb)]
Pinion bearing (P’
1 )0.40 - 0.78 (0.04 - 0.08, 4 - 6)
Gear ring bearing to pinion
bearing (Total preload)With all oil seals P’
1 + 0.45 - 0.47 (0.045 - 0.048, 3.9 - 4.1)
Without transfer case oil seal and adapter case oil seal P’
1 + 0.35 - 0.37 (0.035 - 0.038, 3.1 - 3.2)
Item Specification
Drive gear to drive pinion gear 0.13 - 0.19 (0.0051 - 0.0075)
Item Runout limit
Companion flange face 0.1 (0.004)
Inner side of the companion flange 0.1 (0.004)
Thickness Part number* Thickness Part number* Thickness Part number*
0.80 (0.0315)
0.83 (0.0327)
0.86 (0.0339)
0.89 (0.0350)
0.92 (0.0362)
0.95 (0.0374)
0.98 (0.0386)
1.01 (0.0398)
1.04 (0.0409)
1.07 (0.0421)
1.10 (0.0433)
1.13 (0.0445)
1.16 (0.0457)
1.19 (0.0469)33147 AD300
33147 AD301
33147 AD302
33147 AD303
33147 AD304
33147 AD305
33147 AD306
33147 AD307
33147 AD308
33147 AD309
33147 AD310
33147 AD311
33147 AD312
33147 AD3131.22 (0.0480)
1.25 (0.0492)
1.28 (0.0504)
1.31 (0.0516)
1.34 (0.0528)
1.37 (0.0539)
1.40 (0.0551)
1.43 (0.0563)
1.46 (0.0575)
1.49 (0.0587)
1.52 (0.0598)
1.55 (0.0610)
1.58 (0.0622)
1.61 (0.0634)33147 AD314
33147 AD315
33147 AD316
33147 AD317
33147 AD318
33147 AD319
33147 AD320
33147 AD321
33147 AD322
33147 AD323
33147 AD324
33147 AD360
33147 AD361
33147 AD3621.64 (0.0646)
1.67 (0.0657)
1.70 (0.0669)
1.73 (0.0681)
1.76 (0.0693)
1.79 (0.0705)
1.82 (0.0717)
1.85 (0.0728)
1.88 (0.0740)
1.91 (0.0752)
1.94 (0.0764)
1.97 (0.0776)
2.00 (0.0787)
2.03 (0.0799)33147 AD363
33147 AD364
33147 AD365
33147 AD366
33147 AD367
33147 AD368
33147 AD369
33147 AD370
33147 AD371
33147 AD372
33147 AD373
33147 AD374
33147 AD375
33147 AD376
RFD-32
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationEDS001ZE
Drive Gear VibrationEDS001ZF
To ta l P r e l o a dEDS001ZJ
Side Gear Clearance AdjustmentEDS001ZG
Drive Pinion Gear Preload AdjustmentEDS001ZH
Side Bearing Preload AdjustmentEDS001ZI
THRUST WASHER FOR ADJUSTMENT OF SIDE GEAR BACK CLEARANCEEDS002V9
*: Always check with the Parts Department for the latest parts information.
DRIVE PINION GEAR PRELOAD ADJUSTING SHIMEDS002VA
*: Always check with the Parts Department for the latest parts information.Applied model QR20DE, QR25DE, YD22DDTi
Final drive modelR145
Drive gear pitch diameter 145
Gear ratio2.466
Number of teeth (Drive gear/Drive pinion) 37/15
Oil capacity (approx.)
0.55 (1 lmp pt.)
Number of pinion gears2
Drive pinion adjustment spacer type Collapsible
Vibration limit at drive gear back 0.05 mm (0.0020 in) or less
Total preload with oil seal installed 1.33 - 2.15 N·m (0.14 - 0.21 kg-m,12 - 19 in-lb)
Drive gear backlash 0.10 - 0.15 mm (0.0039 - 0.0059 in)
Side gear back clearance 0.2 mm (0.008 in) or less. Every gear shall rotate smoothly with no abnormal feeling of drag.
Adjustment of drive pinion gear Collapsible spacer
Drive pinion gear preload 0.69 - 1.17 N·m (0.07 - 0.11 kg-m,7 - 10 in-lb)
Adjustment of side bearing Adjusting shim
Side bearing preload 0.64 - 0.98 N·m (0.07 - 0.09 kg-m,6 - 8 in-lb)
Thickness Part number* Thickness Part number*
0.74 mm (0.0291 in)
0.77 mm (0.0303 in)
0.80 mm (0.0315 in)38424 4N200
38424 4N201
38424 4N2020.83 mm (0.0327 in)
0.86 mm (0.0339 in)38424 4N203
38424 4N204
Thickness Part number* Thickness Part number*
1.70 mm (0.0669 in)
1.73 mm (0.0681 in)
1.76 mm (0.0693 in)
1.79 mm (0.0705 in)
1.82 mm (0.0717 in)
1.85 mm (0.0728 in)
1.88 mm (0.0740 in)
1.91 mm (0.0752 in)
1.94 mm (0.0764 in)
1.97 mm (0.0776 in)38154 4N200
38154 4N201
38154 4N202
38154 4N203
38154 4N204
38154 4N205
38154 4N206
38154 4N207
38154 4N208
38154 4N2092.00 mm (0.0787 in)
2.03 mm (0.0799 in)
2.06 mm (0.0811 in)
2.09 mm (0.0823 in)
2.12 mm (0.0835 in)
2.15 mm (0.0846 in)
2.18 mm (0.0858 in)
2.21 mm (0.0870 in)
2.24 mm (0.0882 in)38154 4N210
38154 4N211
38154 4N212
38154 4N213
38154 4N214
38154 4N215
38154 4N216
38154 4N217
38154 4N218