Page 185 of 2493

JEM238G
FUEL PIPINGNJEM0109S02RemovalNJEM0109S0201+To prevent fuel from flowing out, plug the opening of the hose
with a blind plug after disconnection.
+Be careful not to spill fuel in the engine compartment.
InstallationNJEM0109S0202+After repairing, bleed air in pipes by shifting priming pump up
and down until the touch is heavy.
+For further air bleeding, idle at least 1 minute or more.
SEM489G
INTAKE MANIFOLDNJEM0109S03RemovalNJEM0109S0301+Loosen bolts and nuts in the reverse order of that shown in the
figure.
InstallationNJEM0109S0302+When stud bolts come off, install with the following torque:
: 10 - 11 N´m (1.0 - 1.2 kg-m, 87 - 104 in-lb)
+Tighten fixing bolts in the numerical order shown in the figure.
EGR VOLUME CONTROL VALVENJEM0109S04+Handle with care avoiding any shocks.
+Do not disassemble or adjust.
SEM490G
WATER HOSENJEM0109S05InstallationNJEM0109S0501+Install water hose by referring to identification marks; avoiding
twisting.
+When an insert stopper is not provided with the pipe, insert the
hose up to dimension A. When the pipe is shorter than dimen-
sion A, insert hose fully until it reaches the end.
Dimension A: 25 - 30 mm (0.984 - 1.181 in)
+When an insert stopper is provided on the pipe side, insert the
hose until it reaches the bulge.
+When marking is provided on the pipe, insert hose until it cov-
ers half of the marking.
INTAKE MANIFOLDYD
Removal and Installation (Cont'd)
EM-107
Page 186 of 2493
SEM491G
InspectionNJEM0110INTAKE MANIFOLDNJEM0110S01Check distortion on the mounting surface with a straightedge and
feeler gauge.
Limit: 0.1 mm (0.004 in)
INTAKE MANIFOLDYD
Inspection
EM-108
Page 187 of 2493
Removal and InstallationNJEM0101
JEM264G
PREPARATIVE WORKNJEM0101S01Remove the following parts.
+Under cover
+Engine coolant (drain)
Refer to LC-43, ªChanging Engine Coolantº.
+Radiator upper hose
+Cooling fan
Refer to LC-42, ªRadiatorº.
+Radiator mount bracket
+Water inlet pipe
+Exhaust front tube (disconnect)
Refer to FE-27, ªRemoval and Installationº, ªEXHAUST SYS-
TEMº.
CATALYSTNJEM0101S02RemovalNJEM0101S0201+Remove the catalyst, refer to above illustration.
CAUTION:
Do not disassemble.
InstallationNJEM0101S0202Install two locking pins into both sides of the catalytic converter. Be
careful not to confuse locking pins with insulator mounting bolts.
Catalytic converter locking pin:
Flange bolt (black)
Insulator mounting bolt:
Washer bolt (silver or yellow)
CATALYSTYD
Removal and Installation
EM-109
Page 188 of 2493
GUSSETNJEM0101S03InstallationNJEM0101S0301Pushing gussets against the oil pan and the catalytic converter,
temporarily tighten the mounting bolt. And then tighten it to the
specified torque.
CATALYSTYD
Removal and Installation (Cont'd)
EM-110
Page 189 of 2493
Removal and InstallationNJEM0102
JEM265G
PREPARATIVE WORKNJEM0102S01Remove the following parts.
+Engine coolant (drain)
Refer to LC-43, ªChanging Engine Coolantº.
+Air duct, air inlet pipe
+Water inlet pipe
+Catalytic converter
+Exhaust manifold cover
+Insulator
+Each wiring and piping (disconnect/move)
JEM266G
EXHAUST MANIFOLD AND TURBOCHARGERNJEM0102S02RemovalNJEM0102S0201+Loosen exhaust manifold mounting nuts in the reverse order
specified in the figure.
+Rotate the exhaust manifold and turbocharger assembly so
that the rear side (EGR tube mounting side) faces upward. And
then pull out the assembly from between the engine and the
air conditioning piping.
CAUTION:
Be careful not to deform each turbocharger piping when pull-
ing out the assembly.
EXHAUST MANIFOLD, TURBOCHARGERYD
Removal and Installation
EM-111
Page 190 of 2493
InstallationNJEM0102S0202+When a stud bolt is pulled out, tighten it to the following torque:
: 18 - 21 N´m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
+Tighten the exhaust manifold mounting nuts in the following
procedure:
a) Tighten the nuts in the order specified in the figure.
b) Re-tighten the nuts 1 to 4.
EXHAUST MANIFOLD GASKETNJEM0102S03InstallationNJEM0102S0301Install the gasket so that the alignment protrusion faces the No. 4
port.
Disassembly and AssemblyNJEM0103
NEM379
TURBOCHARGERNJEM0103S01DisassemblyNJEM0103S0101After applying penetration lubricant (Lucen, etc.) to the mounting
nuts, check for the penetration of the lubricant, and then loosen the
nuts to remove.
EXHAUST MANIFOLD, TURBOCHARGERYD
Removal and Installation (Cont'd)
EM-112
Page 191 of 2493
CAUTION:
Do not disassemble or adjust the turbocharger body.
AssemblyNJEM0103S0102When a stud bolt is pulled out, tighten it to the following torque:
: 24 - 27 N´m (2.4 - 2.8 kg-m, 18 - 20 ft-lb)
JEM267G
InspectionNJEM0104EXHAUST MANIFOLDNJEM0104S01Check the distortion on the mounting surface in the six directions
using a straightedge and a feeler gauge.
Limit: 0.3 mm (0.012 in)
TURBOCHARGERNJEM0104S02
SEM269G
CAUTION:
When the compressor wheel, turbine wheel, or rotor shaft is
damaged, remove all the fragments and foreign matter left in
the following passages in order to prevent a secondary failure:
Suction side: Between turbocharger and air cleaner
Exhaust side: Between turbocharger and catalytic con-
verter
EXHAUST MANIFOLD, TURBOCHARGERYD
Disassembly and Assembly (Cont'd)
EM-113
Page 192 of 2493

SEM270G
Rotor ShaftNJEM0104S0201+Check that the rotor shaft rotates smoothly without any resis-
tance when it is rotated by your fingertips.
+Check that the rotor shaft is not loose when it is moved verti-
cally or horizontally.
Standard value for rotor shaft oil clearance:
0.086 - 0.117 mm (0.0034 - 0.0046 in)
SEM271G
Rotor Shaft End PlayNJEM0104S0202Place a dial gauge at the rotor shaft end in the axial direction to
measure the end play.
Standard: 0.036 - 0.090 mm (0.0014 - 0.0035 in)
SEM272G
Turbine WheelNJEM0104S0203+Check that there is no oil adhesion.
+Check that there is no carbon accumulation.
+Check that blades of the turbine wheel are not bent or broken.
+Check that the turbine wheel does not interfere with the turbine
housing.
SEM273G
Compressor WheelNJEM0104S0204+Check that there is no oil adhesion inside the air inlet.
+Check that the compressor wheel does not interfere with the
compressor housing.
+Check that the wheel is not bent or broken.
SEM274G
Wastegate Valve ActuatorNJEM0104S0205+Connect the handy pump to the actuator, and check that the
rod strokes smoothly in compliance with the following pres-
sure.
+Pressure to be applied at actuator part to move rod end as
follows:
Standard (Pressure/rod stroke amount):
115.44 - 120.76 kPa (1,154 - 1,208 mbar, 866.0 - 906.0
mmHg, 34.1 - 35.7 inHg)/0.38 mm (0.0150 in)
140.54 - 149.86 kPa (1,405 - 1,498 mbar, 1,054.3 -
1,124.2 mmHg, 41.5 - 44.3 inHg)/4.0 mm (0.157 in)
EXHAUST MANIFOLD, TURBOCHARGERYD
Inspection (Cont'd)
EM-114