Page 217 of 3189
Removal and InstallationNJEM0109
YEM053
SEM565G
PREPARATIVE WORKNJEM0109S011. Drain engine coolant. Refer to LC-43, “Changing engine cool-
ant”.
2. Remove engine cover. Refer to the figure at left.
3. Remove injection tube.
4. Remove blow-by hose (on rocker cover side).
5. Remove or relocate fuel pipes.
6. Remove or relocate wires/harnesses and tubes/pipes.
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INTAKE MANIFOLDYD
Removal and Installation
EM-33
Page 218 of 3189

JEM238G
FUEL PIPINGNJEM0109S02RemovalNJEM0109S0201To 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.
InstallationNJEM0109S0202After 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 MANIFOLDNJEM0109S03RemovalNJEM0109S0301Loosen bolts and nuts in the reverse order of that shown in the
figure.
InstallationNJEM0109S0302When 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 VALVENJEM0109S04Handle with care avoiding any shocks.
Do not disassemble or adjust.
YEM054
WATER HOSENJEM0109S05InstallationNJEM0109S0501Install 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-34
Page 219 of 3189
SEM491G
InspectionNJEM0110INTAKE MANIFOLDNJEM0110S01Check distortion on the mounting surface with a straightedge and
feeler gauge.
Limit: 0.1 mm (0.004 in)
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Inspection
EM-35
Page 220 of 3189
Removal and InstallationNJEM0101
JEM264G
PREPARATIVE WORKNJEM0101S01Remove the following parts.
Under cover
Engine coolant (drain)
Refer to LC-43, “Changing Engine Coolant”.
Radiator upper hose
Cooling fan
Refer to LC-42, “Radiator”.
Radiator mount bracket
Water inlet pipe
Exhaust front tube (disconnect)
Refer to FE-26, “Removal and Installation”, “EXHAUST SYS-
TEM”.
CATALYSTNJEM0101S02RemovalNJEM0101S0201Remove 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-36
Page 221 of 3189
GUSSETNJEM0101S03InstallationNJEM0101S0301Pushing gussets against the oil pan and the catalytic converter,
temporarily tighten the mounting bolt. And then tighten it to the
specified torque.GI
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Removal and Installation (Cont’d)
EM-37
Page 222 of 3189
Removal and InstallationNJEM0102
JEM265G
PREPARATIVE WORKNJEM0102S01Remove the following parts.
Engine coolant (drain)
Refer to LC-43, “Changing Engine Coolant”.
Air duct, air inlet pipe
Water inlet pipe
Catalytic converter
Exhaust manifold cover
Insulator
Each wiring and piping (disconnect/move)
JEM266G
EXHAUST MANIFOLD AND TURBOCHARGERNJEM0102S02RemovalNJEM0102S0201Loosen 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-38
Page 223 of 3189
InstallationNJEM0102S0202When 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.
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EXHAUST MANIFOLD, TURBOCHARGERYD
Removal and Installation (Cont’d)
EM-39
Page 224 of 3189
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-40