Page 2449 of 3051
GUSSETNLEM0101S03InstallationNLEM0101S0301Pushing 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-192
Page 2450 of 3051
Removal and InstallationNLEM0102
JEM265G
PREPARATIVE WORKNLEM0102S01Remove the following parts.
+Engine coolant (drain)
Refer to LC-59, 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 TURBOCHARGERNLEM0102S02RemovalNLEM0102S0201+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-193
Page 2451 of 3051
InstallationNLEM0102S0202+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 GASKETNLEM0102S03InstallationNLEM0102S0301Install the gasket so that the alignment protrusion faces the No. 4
port.
Disassembly and AssemblyNLEM0103
SEM268G
TURBOCHARGERNLEM0103S01DisassemblyNLEM0103S0101After 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-194
Page 2452 of 3051
CAUTION:
Do not disassemble or adjust the turbocharger body.
AssemblyNLEM0103S0102When 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
InspectionNLEM0104EXHAUST MANIFOLDNLEM0104S01Check the distortion on the mounting surface in the six directions
using a straightedge and a feeler gauge.
Limit: 0.3 mm (0.012 in)
TURBOCHARGERNLEM0104S02
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-195
Page 2453 of 3051

SEM270G
Rotor ShaftNLEM0104S0201+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 PlayNLEM0104S0202Place 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 WheelNLEM0104S0203+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 WheelNLEM0104S0204+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
Waste Gate ActuatorNLEM0104S0205+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-196
Page 2454 of 3051

Trouble Diagnosis of Turbocharger=NLEM0104S0206Preliminary check:
+Check that the engine oil level is between MIN and MAX of the
dipstick. (When the engine oil amount is more than MAX, the
oil flows into the inlet duct through the blow-by gas passage,
and the turbocharger is misjudged failure.)
+Ask the customer if he/she always runs the vehicle in idle
engine speed to cool the oil down after driving.
+Replace the turbocharger assembly when any malfunction is
found after unit inspections specified in the table below.
+If no malfunction is found after the unit inspections, judge that
the turbocharger body has no failure. Check the other parts
again.
Inspection item Inspection resultSymptom (when each inspection item meets
each inspection result)
Oil leak-
ageSmoke NoiseInsuffi-
cient
power/
accelera-
tion failure
Turbine wheelOil leaks.n
nn
Carbon is accumulated.n
jj
Friction with housing.nj
j
Blades are bent or broken.
Compressor wheelInside the air inlet is seriously con-
taminated by oil.jj
Friction with housing.njj
Blades are bent or broken.
After checking both turbine and compressor,
inspect rotor shaft end play.There is resistance when the rotor
shaft is rotated by your fingertips.nnj
The rotor shaft sometimes does
not rotate by your fingertips.
There is too much play in the
bearing.nnjn
Oil return portCarbon or sludge is accumulated
in the waste oil hole.n
nn
Operation of Waste gate actuator+The actuator does not operate
smoothly when vacuum pres-
sure is gradually applied.
+Stroke amount is not in compli-
ance with the vacuum pressure.j
: Large possibility
j: Medium possibility
n: Small possibility
EXHAUST MANIFOLD, TURBOCHARGERYD
Inspection (Cont'd)
EM-197
Page 2455 of 3051
Removal and InstallationNLEM0099
SEM503G
PREPARATIVE WORKNLEM0099S01Remove engine cover.
JEM247G
ROCKER COVERNLEM0099S02RemovalNLEM0099S0201Loosen holding bolts in the reverse order of that shown in the fig-
ure and remove.
CAUTION:
Do not remove mass damper on top. If damper must be
removed, remove all traces of old locking sealant from threads
of bolts and holes, and apply new locking sealant on the bolts
before tightening.
InstallationNLEM0099S0202+Tighten holding bolts in the numerical order shown in the fig-
ure.
+Re-tighten to the same torque in the same order as above.
ROCKER COVERYD
Removal and Installation
EM-198
Page 2456 of 3051
JEM248G
+Apply 3.0 mm (0.118 in) dia. of specified liquid gasket (Refer
to EM-158, ªLiquid Gasket Application Procedureº.) on locac-
tions shown in the figure.
ROCKER COVERYD
Removal and Installation (Cont'd)
EM-199