PRECAUTIONS
GI-5
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Use approved bonding agent, sealants or their equivalents when required.
Use tools and recommended special tools where specified for safe and efficient service repairs.
When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.
Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate cov-
ers.
Take caution that keys, buckles or buttons do not scratch paint.
WARNING:
To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module)
system. The connectors should be disconnected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.
Precautions for All Mode 4 × 4 SystemEAS000GQ
Even if the 2WD mode is selected, the All mode 4 × 4 system occasionally changes from 2WD to 4WD auto-
matically depending on the driving conditions.
When spinning the front wheels by running the engine with the front wheels jacked up or mounted on the free
rollers / or a chassis dynamometer, be careful because the vehicle may suddenly move due to the driving
force from the rear wheels.
To avoid personal injury and vehicle damage, use one of the following methods when working with the front
wheels drive force and spinning freely.
Remove the propeller shaft.
Use free rollers / chassis dynamometer designed for 4WD vehicles.
Precautions for Three Way CatalystEAS000FR
If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To
prevent this, follow the instructions.
Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.
When checking for ignition spark or measuring engine compression, make tests quickly and only when
necessary.
Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to
the catalyst.
Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three
way catalyst.
Precautions for FuelEAS000P9
GASOLINE ENGINE
Use unleaded gasoline with an octane rating of at least 95 (RON).
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel
other than that specified could adversely affect the emission control devices and systems, and could
also affect the warranty coverage validity.
DIESEL ENGINE
Diesel fuel of at least 50 cetane.
If two types of diesel fuel are available, use summer or winter fuel properly according to the following temper-
ature conditions.
Above –7°C (20°F) ... Summer type diesel fuel.
Below –7°C (20°F) ... Winter type diesel fuel.
SGI234
GI-6
PRECAUTIONS
CAUTION:
Do not use home heating oil, gasoline or other alternate fuels in your diesel engine. The use of
those can cause engine damage.
Do not use summer fuel at temperatures below –7°C (20°F). The cold temperatures will cause wax
to form in the fuel. As a result, it may prevent the engine from running smoothly.
Do not add gasoline or other alternate fuels to diesel fuel.
Precautions for Multiport Fuel Injection System or Engine Control SystemEAS000FT
Before connecting or disconnecting any harness connector for
the multiport fuel injection system or ECM:
Turn ignition switch to “OFF” position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
Before disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure.
Be careful not to jar components such as ECM and mass air
flow sensor.
Precautions for Turbocharger (If Equipped)EAS000FU
The turbocharger turbine revolves at extremely high speeds and
becomes very hot. Therefore, it is essential to maintain a clean sup-
ply of oil flowing through the turbocharger and to follow all required
maintenance instructions and operating procedures.
Always use the recommended oil. Follow the instructions for
proper time to change the oil and proper oil level.
Avoid accelerating engine to a high rpm immediately after start-
ing.
If engine had been operating at high rpm for an extended period
of time, let it idle for a few minutes prior to shutting if off.
Precautions for HosesEAS000FV
HOSE REMOVAL AND INSTALLATION
To prevent damage to rubber hose, do not pry off rubber hose
with tapered tool or screwdriver.
To reinstall the rubber hose securely, make sure that hose inser-
tion length and orientation is correct. (If tube is equipped with
hose stopper, insert rubber hose into tube until it butts up
against hose stopper.)
SGI787
SGI292
SMA019D
SMA020D
GI-32
SERVICE INFORMATION FOR ELECTRICAL INCIDENT
Do not apply excessive shock to the control unit by dropping or
hitting it.
Be careful to prevent condensation in the control unit due to
rapid temperature changes and do not let water or rain get on it.
If water is found in the control unit, dry it fully and then install it in
the vehicle.
Be careful not to let oil to get on the control unit connector.
Avoid cleaning the control unit with volatile oil.
Do not disassemble the control unit, and do not remove the
upper and lower covers.
When using a DMM, be careful not to let test probes get close to
each other to prevent the power transistor in the control unit
from damaging battery voltage because of short circuiting.
When checking input and output signals of the control unit, use
the specified check adapter.
SAIA0255E
SEF348N
EM-52
[QR]
TIMING CHAIN
3. Install crankshaft sprocket and balancer unit timing chain.
Make sure that crankshaft sprocket is positioned with mating
marks on cylinder block and crankshaft sprocket meeting at
the top.
Install it by aligning mating marks on each sprocket and bal-
ancer unit timing chain.
4. Install balancer unit timing chain tensioner.
NOTE:
Chain guide and tensioner move freely with the staking pin as
the axle. Therefore, bolt hole position of the three points could
be changed during removal. If points change, temporarily fix the
two mounting bolts on chain guide, and move tensioner to mate
the bolt holes.
Be careful not to let mating marks of each sprocket and timing
chain slip.
After installation, make sure the mating marks have not
slipped, then remove stopper pin and release tensioner
sleeve.
5. Install timing chain and related parts.
Install by aligning mating marks on each sprocket and timing
chain.
Before and after installing chain tensioner, check again to
make sure that mating marks have not slipped.
After installing chain tensioner, remove stopper pin, and make
sure that tensioner moves freely.
CAUTION:
For the following note, after the mating marks are
aligned, keep them aligned by holding them with a
hand.
To avoid skipped teeth, do not rotate crankshaft and
camshaft until front cover is installed.
NOTE:
Before installing chain tensioner, it is possible to change the
position of mating mark on timing chain for that on each
sprocket for alignment.
6. Install front oil seal to front cover. Refer to EM-67, "
Removal and Installation of Front Oil Seal" .
7. Install front cover with the following procedure:
a. Install O-rings to cylinder head and cylinder block.
PBIC2183E
KBIA0124E
PBIC2182E
EM-70
[QR]
CYLINDER HEAD
CYLINDER HEADPFP:11041
On-Vehicle ServiceEBS00KNP
CHECKING COMPRESSION PRESSURE
1. Warm up engine thoroughly. Then, stop it.
2. Release fuel pressure. Refer to EC-49, "
FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-562,
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
3. Disconnect fuel pump fuse to avoid fuel injection during mea-
surement.
4. Remove ignition coil and spark plug from each cylinder. Refer to EM-31, "
IGNITION COIL" and EM-32,
"SPARK PLUG" .
5. Connect engine tachometer (not required in use of CONSULT-II).
6. Install compression tester with adapter onto spark plug hole.
Use the adapter whose picking up end inserted to spark plug
hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it
may be caught by cylinder head during removal.
7. 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 cyl-
inder.
Compression pressure:
Unit: kPa (bar, kg/cm2 , psi) /rpm
CAUTION:
Always use a fully changed battery to obtain specified engine speed.
PBIB0508E
KBIA0130E
SBIA0533E
Engine type Standard Minimum Differential limit between cylinders
QR20DE 1,190 (11.9, 12.1, 173) / 250 990 (9.9, 10.1, 144) / 250
100 (1.0, 1.0, 14) / 250
QR25DE 1,250 (12.5, 12.8, 181) / 250 1,060 (10.6, 10.8, 154) / 250
ENGINE ASSEMBLY
EM-83
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Use alternator bracket mounting bolt holes for the front side.
2. Lift with hoist and secure engine in appropriate position.
3. Use a manual lift table caddy (commercial service tool) or equiv-
alently rigid tool such as a transmission jack. Securely support
bottom of engine and transaxle, and simultaneously adjust hoist
tension.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
4. Remove RH engine mounting insulator.
5. Pull LH engine mounting through-bolt out.
6. Remove center member.
7. Remove engine and transaxle assembly from vehicle downward by carefully operating supporting tools.
CAUTION:
During the operation, make sure that no part interferes with vehicle side.
Before and during this lifting, always check if any harnesses are left connected.
During the removal operation, always be careful to prevent vehicle from falling off the lift due to
changes in the center of gravity.
If necessary, support vehicle by setting jack or suitable tool at the rear.
8. Remove starter motor. Refer to SC-23, "
STARTING SYSTEM" .
9. Remove rear engine mounting bracket.
10. Separate the engine and the transaxle. Refer to MT-19, "
TRANSAXLE ASSEMBLY" .
INSTALLATION
Note the following, and install in the reverse order of removal.
Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting
insulator.
When installation directions are specified, install parts according to the direction marks on them referring
to the figure of components. Refer to EM-81, "
Removal and Installation (2WD Models)" .
Make sure that each mounting insulator is seated properly, and tighten mounting nuts and bolts.Slinger bolts:
Front
: 57.9 N·m (5.9 kg-m, 43 ft-lb)
Rear
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
SBIA0271E
KBIA0256E
PBIC2748E
EM-224
[YD22DDTi]
ENGINE ASSEMBLY
Removal
1. Install engine slingers into front right of cylinder head and rear
left of cylinder head.
2. Lift with hoist and secure engine in position.
3. Use the manual lift table caddy (commercial service tool) or
equivalently rigid tool such as a jack or trestle. Securely support
bottom of engine and transaxle, and simultaneously adjust hoist
tension.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
4. Remove RH engine mounting insulator.
5. Pull LH engine mounting through-bolt out.
6. Remove center member.
7. Remove engine and transaxle assembly from vehicle downward by carefully operating supporting tools.
CAUTION:
During the operation, make sure that no part interferes with vehicle side.
Before and during this lifting, always check if any harnesses are left connected.
During the removal operation, always be careful to prevent vehicle from falling off the lift due to
changes in the center of gravity.
If necessary, support vehicle by setting a jack or equivalent tool at the rear.
8. Remove starter motor. Refer to SC-23, "
STARTING SYSTEM" .
9. 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.Slinger bolts:
: 33.5 N·m (3.4 kg-m, 25 ft-lb)
SBIA0191E
KBIA0256E
PBIC2188E
ENGINE OIL
LU-9
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3. Loosen oil filler cap and then remove drain plug.
4. Drain engine oil.
5. Install drain plug with new washer. Refer to EM-27, "
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 LUBRICANTS" .
Engine oil capacity (Approximate):
Unit: (lmp qt)
CAUTION:
The refill capacity depends on the engine oil temperature and drain time. Use these specifica-
tions for reference only.
Always use oil level gauge to determine the proper amount of engine oil 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. Refer to LU-7, "
ENGINE OIL LEVEL" . Oil pan drain plug:
: 34.3 N·m (3.5 kg-m, 25 ft-lb)
PBIC2410E
Drain and refill With oil filter change 4.1 (3-5/8)
Without oil filter change 3.7 (3-1/4)
Dry engine (Overhaul)4.7 (4-1/8)