Page 1697 of 2267
12. Remove exhaust manifold with turbocharger unit.
Disassembly
1. Remove oil tubes and water tubes. Before removing tubes, put
mating marks on tube connectors and turbocharger.
2. Unbend locking plates for turbocharger unit fastening nuts.
3. Remove exhaust outlet cover, exhaust outlet, and heat insula-
tor brackets.
4. Remove exhaust manifold from turbocharger unit.
NEM206 Exhaust
manifold
Turbocharger
NEM207 Turbocharger
water return
tube
Turbocharger
oil feed tube Turbo-
charger
water
feed tube
Turbocharger
oil return tube
SEM367F Exhaust manifold side
Turbocharger side
SEM026F
NEM208
TURBOCHARGERCD20T
Removal (Cont'd)
EM-157
Page 1698 of 2267
Inspection
Perform the following checks. If NG, replace turbocharger unit.
OIL AND WATER TUBES
Check tubes for clogging.
ROTOR SHAFT
1. Check rotor shaft for smooth rotation.
SEM366F Check for cracks
Wastegate valve actuator
Compressor wheel
Compressor housing
Center housing
Check for leaks
Check for leaks
Turbine housingTurbine wheelCheck for leaks Wastegate valve Actuator rod
SEM029F
SEM030F
TURBOCHARGERCD20T
Inspection
EM-158
Page 1699 of 2267
2. Check rotor shaft for carbon deposits.
3. Measure rotor shaft runout.
Runout (Total indicator reading):
Standard
0.056 - 0.127 mm (0.0022 - 0.0050 in)
4. Measure rotor shaft end play.
End play:
Standard
0.013 - 0.097 mm (0.0005 - 0.0038 in)
IDo not allow wheels to turn when axial play is being mea-
sured.
TURBINE WHEEL
Check turbine wheel for the following:
IOil
ICarbon deposits
IDeformed fins
IContact with turbine housing
COMPRESSOR WHEEL
Check compressor wheel for the following:
IOil
IDeformed fins
IContact with compressor housing
.SEM031F Rotor shaft
SEM032F
SEM827D
SEM828D
SEM829D
TURBOCHARGERCD20T
Inspection (Cont'd)
EM-159
Page 1700 of 2267
WASTEGATE VALVE
Remove rod pin and check wastegate valve for cracks, deforma-
tion and smooth movement. Check valve seat surface for smooth-
ness.
WASTEGATE VALVE ACTUATOR
Apply compressed air to wastegate valve actuator and check it for
smooth movement.
IDo not apply compressed air to the actuator continuously.
IThe air pressure should be in the range of 73.3 to 101.3
kPa (733 to 1,013 mbar, 550 to 760 mmHg, 21.65 to 29.92
inHg).
Assembly
Assembly is the reverse order of disassembly.
IInstall gasket between exhaust manifold and turbocharger with
small hanging flap side facing exhaust manifold.
IBend locking plates along the side of turbocharger fastening
nuts.
Always use new locking plates.
Installation
1. Install exhaust manifold fixing nuts.
SEM830D
SEM831D
NEM228 Small hanging flap
SEM367F Exhaust manifold side
Turbocharger side
NEM209 Tighten in numerical order
p4
p2p1
p3
TURBOCHARGERCD20T
Inspection (Cont'd)
EM-160
Page 1701 of 2267
2. Installation is the reverse order of removal.
IInstall oil tubes and water tubes in the following order, aligning
the mating marks.
a. Oil feed tube
b. Water return tube
c. Water feed tube
d. Oil return tube
NEM207 Turbocharger
water return
tube
Turbocharger
oil feed tube Turbo-
charger
water
feed tube
Turbocharger
oil return tube
TURBOCHARGERCD20T
Installation (Cont'd)
EM-161
Page 1702 of 2267
NEM226
43-55
(4.4 - 5.6,
32 - 41)
Rear engine
mounting
43 - 55 (4.4 - 5.6, 32 - 41)
64 - 74 (6.5 - 7.5, 47 - 54)
64-74
(6.5 - 7.5,
47 - 54)
49 - 59 (5.0 - 6.0, 36 - 44)43 - 55 (4.4 - 5.6, 32 - 41)
62 - 78 (6.3 - 8.0, 46 - 58)
Front mounting
bracket
49 - 59 (5.0 - 6.0, 36 - 44)
77 - 98 (7.9 - 100, 57 - 72)
49-59
(5.0 - 6.0,
36 - 44)Insulator
77 - 98 (7.9 - 100, 57 - 72)
43-55
(4.4 - 5.6,
32 - 41)
: N´m (kg-m, ft-lb)
SEC. 112
ENGINE REMOVALCD20T
EM-162
Page 1703 of 2267

WARNING:
ISituate vehicle on a flat and solid surface.
IPlace chocks at front and back of rear wheels.
IDo not remove engine until exhaust system has com-
pletely cooled down.
IFor safety during subsequent steps, the tension of wires
should be slackened against the engine.
IBefore removing front axle from transaxle, place safety
stands under designated front supporting points. Refer to
GI section for lifting points and towing.
IBe sure to hoist engine and transaxle in a safe manner.
IFor engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG
or Eurofast.
CAUTION:
IWhen lifting engine, be careful not to strike adjacent parts,
especially accelerator wire casing, brake lines, and brake
master cylinder.
IAlways use engine slingers when hoisting the engine.
IWhen removing drive shaft, be careful not to damage tran-
saxle oil seal.
1. Remove engine undercovers and splash covers.
2. Remove front exhaust tube.
3. Disconnect lower water hose from radiator and drain coolant.
4. Drain transaxle oil.
5. Remove power steering mounting bolt. (See left.)
6. Drain coolant from cylinder head.
7. Disconnect water hoses and electrical wiring from radiator and
remove radiator.
8. Disconnect fuel tubes and vacuum tubes.
9. Release power steering belt adjusting nut and remove power
steering pump from engine.
Bind pump properly to the vehicle.
10. Remove A/C compressor.
11. Disconnect or remove electrical wiring where necessary.
12. Release clutch lever cable.
13. Release tachometer cable from transaxle housing.
14. Remove front wheels.
15. Remove brake caliper mounting bolts and bind caliper properly
to vehicle LH & RH.
.SEM531D
SEM532D
ENGINE REMOVALCD20T
EM-163
Page 1704 of 2267
16. Disconnect tie rod ball joints and lower ball joints (LH & RH).
17. Remove stabilizer.
18. Remove drive shafts from transaxle.
1) RH: Split drive shaft center thrust bearing.
2) RH & LH: Remove hub mounting bolts and remove drive shaft
carefully from transaxle.
19. Mount suitable slingers to cylinder head. Use a suitable hoist
to release the force on the engine mountings.
20. Remove upper mounting (Right side).
21. Release transaxle shift linkages.
22. Release left engine mounting.
SEM534D
SEM535D
SEM536D
ENGINE REMOVALCD20T
EM-164