Page 1665 of 2267
Left side
p1Turbocharger assembly
p2Exhaust manifold
p3Gasket
p4Air inlet hose
p5Air hose
p6Lock plate
p7Exhaust outlet
p8Exhaust outlet cover
p9Turbocharger oil return pipe
p10Turbocharger oil return hose
p11Insulator
p12Turbocharger oil feed tube
p13Turbocharger water feed tube
p14Turbocharger water return tube
p15Bracket
NEM375
p2
20 - 31 (2.0 - 3.2, 14 - 23)
p12
20 - 31 (2.0 - 3.2, 14 - 23)
p6
22 - 29 (2.2 - 3.0, 16 - 22)
p4
p3
p7
p8
p3
p3
p9
10 - 13 (1.0 - 1.3, 7.2 - 9.4)
22 - 29 (2.2 - 3.0, 16 - 22)
p15
p11
7.2 - 9.6
(0.73 - 0.98,
63.7 - 85.0)
.p10
p15
6.3 - 8.3
(0.64 - 0.85, 55.8 - 73.5)
20-31
(2.0 - 3.2, 14 - 23)
13-19
(1.3 - 1.9,
9 - 14)
p14
5.1 - 6.5
(0.52 - 0.66,
45.1 - 57.5)p5
p1
20-31
(2.0 - 3.2, 14 - 23)p13
5.1 - 6.5
(0.52 - 0.66,
45.1 - 57.5)
SEC. 140×144
îî: Apply liquid gasket
: N´m (kg-m, in-lb)
îî
: N´m (kg-m, ft-lb)
: Do not re-use
OUTER COMPONENT PARTSCD20T
EM-125
Page 1666 of 2267
1. Warm up engine sufficiently.
2. Remove spill hoses.
3. Disconnect injection tubes on nozzle side and loosen injection
tubes on pump side. Release clamps on injection tubes.
IUse two wrenches to prevent delivery holder on pump
side from loosening.
4. Remove all injection nozzles using S.S.T. KV119E0030.
5. Turn ignition switch off and disconnect harness connector
(black colored) at injection pump.
6. Fit compression gauge to cylinder head.
NEM241
SEM501D
NEM242
NEM243
SEM505D
COMPRESSION PRESSURECD20T
EM-126
Page 1667 of 2267
7. Crank engine and read compression gauge indication.
Cranking speed: 200 rpm
Compression pressure: kPa (bar, kg/cm
2, psi)
Standard
3,138 (31.4, 32, 455)
Limit
2,452 (24.5, 25, 356)
Limit of difference between cylinders
490 (4.9, 5, 71)
8. If the pressure appears low, pour about 3 m(0.11 Imp fl oz)
of engine oil through nozzle holes and repeat test.
For indications of test, refer to the following table.
Gauge indication during tests Trouble diagnosis
lPiston rings are worn or damaged.
lIf two adjacent cylinders are low, gasket is damaged.
lValve is sticking.
lValve seat or valve contact surface is incorrect.
COMPRESSION PRESSURECD20T
EM-127
Page 1668 of 2267
9. Replace nozzle gaskets and re-install injection nozzles.
New nozzle gaskets must be installed in the direction shown.
Nozzle to cylinder head:
: 54 - 64 N´m (5.5 - 6.5 kg-m, 40 - 47 ft-lb)
10. Install injection tubes using two wrenches as shown.
Injection tubes:
: 22 - 25 N´m (2.2 - 2.5 kg-m, 16 - 18 ft-lb)
11. Install spill hoses.
12. Initialize the ECM.
Refer to EC-section (ªHOW TO ERASE DTCº).
NEM244 Nozzle side
Combustion
chamber side
SEM501D
NEM242
NEM241
COMPRESSION PRESSURECD20T
EM-128
Page 1669 of 2267
Removal
1. Drain oil.
2. Remove oil pan using tool as illustrated.
1) Insert Tool between oil pan and cylinder block.
IDo not drive seal cutter into oil pump or rear oil seal
retainer portion, or aluminum mating surfaces will be
damaged.
IDo not insert screwdriver, or oil pan flange will be
deformed.
2) Slide Tool by tapping it with a hammer, and remove oil pan.
Installation
1. Before installing oil pan, remove all traces of liquid gasket from
mating surface using a scraper.
IAlso remove traces of liquid gasket from mating surface of
cylinder block.
IBe sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) wide.
Use Genuine Liquid Gasket or equivalent.
2. Apply liquid gasket to inner sealing surface as shown at left.
SEM230D
SEM231D
SEM350B Scraper
SLC906
SEM909B
OIL PANCD20T
Removal
EM-129
Page 1670 of 2267
3. Apply liquid gasket to oil pan front oil seal and rear oil seal.
4. Apply a continuous bead of liquid gasket to mating surface of
oil pan.
IAttaching should be done within 5 minutes after coating.
5. Install oil pan and tighten bolts in the order shown in the fig-
ure.
Wait at least 30 minutes before refilling engine oil.
Oil pan bolts:
: 6.3 - 8.3 N´m (0.64 - 0.85 kg-m, 55.8 - 73.5 in-lb)
SEM894BA
SEM351B Tube presser
SEM369D Engine
front
OIL PANCD20T
Installation (Cont'd)
EM-130
Page 1671 of 2267

Camshaft Timing Belt
CAUTION:
a. Do not bend or twist timing belt.
b. After removing timing belt, do not turn crankshaft and camshaft separately because valves will
strike piston heads.
c. Ensure that timing belt, camshaft sprocket, crankshaft sprocket and belt tensioner are clean and
free from oil and water.
p1Front camshaft sprocket
p2Idler
p3Belt tensioner
p4Crankshaft sprocket
p5Belt cover lower
p6Belt cover center
(Engine mounting bracket)
p7Timing belt
p8Belt cover upper
p9Gasket
p10Front camshaft sprocket plate
REMOVAL
1. Drain engine coolant from radiator.
2. Remove upper radiator hose and upper belt cover.
3. Remove water pump pulley.
SEM368FA 6.4 - 8.4
(0.65 - 0.86, 56.6 - 74.3) Lubricate with new engine oil.
N´m (kg-m, in-lb)
N´m (kg-m, ft-lb)
Locking sealant5.3 - 7.3
(0.54 - 0.74,
46.9 - 64.6)3-5
(0.3 - 0.5, 27 - 44) 87 - 107
(8.9 - 10.9,
64 - 79)
32-40
(3.3 - 4.1, 24 - 30)
32-40
(3.3 - 4.1, 24 - 30)
142 - 152
(14.5 - 15.5,
105 - 112)
3 - 5 (0.3 - 0.5, 27 - 44)43 - 58 (4.4 - 5.9, 32 - 43)
SEC. 112×120×130×135
: îDo not re-use
SEM047F Upper radiator hose
TIMING BELTCD20T
Camshaft Timing Belt
EM-131
Page 1672 of 2267
4. Set No. 1 cylinder at TDC on its compression stroke. (TDC is
indicated by crankshaft pulley notch without painted mark.)
5. Remove starter motor, and install ring gear stopper using
mounting bolt holes.
6. Remove crank pulley bolt.
7. Remove crank pulley using puller.
Be sure to securely attach puller jaws. Attach jaws only to
the rear side of pulley.
8. Remove lower belt cover.
9. Remove timing belt.
(1) Loosen tensioner pulley bolt, turn tensioner pulley counter-
clockwise then tighten bolt.
(2) Remove camshaft sprocket plate.
(3) Remove idler pulley.
(4) Remove timing belt with crankshaft sprocket.
CAUTION:
Do not allow any magnetic materials to contact crankshaft
sprocket.
(5) Remove tensioner pulley and return spring.
SEM369F
SEM681D
SEM520D LoosenTighten
SEM515D
SMA398A
TIMING BELTCD20T
Camshaft Timing Belt (Cont'd)
EM-132