Engine Mechanical System LUBRICATION SYSTEM ..... INTAKE AND EXHAUST SY‘EM-2 SPECIAL SERVICE TOOLS Engine Special service tools 0K130 890 007 Engine stand Used to disassemble and assemble engine. ENGINE MECHANICAL SYSTEM (0K130 160010 Contering tool, cluteh disc Used to install clutch disc and clutch cover. (0K410 101 004 Hanger, engine stand Used to disassemble and assemble engine. OKI 008 Pivot, valve spring lifter Used to remove and install valve. OK552 111 001 Holder, camshaft pulley Used to install camshatt pulley. ‘0K552 131 002 Adapter, compression gauge a Used to measure compression pressure. (0K710 120 004 Installer, valve seal : Used to install valve seal. (0K 993 120 001 Arm, valve spring lifter pO. Used to remove and install valve.SYMPTOM-RELATED DIAGNOSTIC PROCEDURE EMS Problem Possible Cause ‘Action tobe taken ‘White smoke out of Usually caused by wator vapor, which is a normaly product | None required exhaust ‘of combustion on cold day. Excessive white smoke with engine warmed up could be Repair or replace ‘caused by a falled cylinder nead or intake gasket, coud also be cracked block, cylinder head o intake maniold. Black smoke out of ‘Malfunction of fuel system efor to section FL, fuel system exhaust ‘Maifunction of emission system Rel to section EC, emission control system ‘Abnormal combustion | Sticking or bumed valve Replace ‘Weak or broken valve spring Replace Garbon accumulation n combustion chamber Eliminate the carbon Poor idling ‘Waifuncton of ful systom Refer to secton FL, fuel system ‘Malfunction of emission system Rees to section EC, emission ‘contol systern| ‘Uneven cyinder compression Repair oor valve to valve seat contact Repair or replace Broken valve spring Repair Failed cylinder hoad gaskot Replace Turbacharger noise Contaminated ar cleaner element Replace Foreign material in intake duct or compressor housing Clean Foreign material between intake manifold and compressor loan Foreign material in engina exhaust system lean Carbon deposit on turbine housing lean Inerterence betwoen turbocharger rotating parts Ropair or replace Loose connecting parts of intake and exhaust system Tighten Engine knocks when ‘Loose or wom accessory dive beWViensionor Replace necessary hot and at idle Improper ol viscosity Inctall proper ol viscosity for ‘expected temperature Excessive piston pin clearance Install new piston pin andor Connecting rod ‘Connecting rod alignment ‘Check and replace Insufficient piston to bore clearance Hone and ft new pistons Fauty timing bol tensioner or guide Replace Loose damper puiley Tighten or replace Slight nolse at lal, Valve spring clicking on cap, off square or broken Repair or replace becomes louder as engine | Excessive stom to guide clearance Repair speed is increased Excessive valve seat runout Repair Holed exhaust pipe Replace Engine knoks when cold | Excessive piston o wall clearance Replace Loose or broken damper pulley Tighten or replace Knock increase with Excessive piston to bore clearance Replace pision torque Bent connecting rod Replace Engine has heavy knock | Broken damper pulley Replace when hot and torques | Accessory bets too tight or damaged ‘Adjust or replace bett applied Bett tensioner damaged Replace Flywhealoracked or loose clutch plate Replace flywteal or clutch plate Excessive main bearing clearance Repair Excessive rod bearing clearance RepairEM6 ENGINE MECHANICAL SYSTEM Problem Possible Cause ‘Action to be taken Engine has light knock | Improper timing (Check ting ‘when hot and under Piston pin andlor connecting rod Replace light lood conditions Poor qualty fual Replace Exhaust leak at manifold Tighten or replace Excessive rod bearing clearance Repair Engine knocks on initial | Improper oil viscosity Install proper of viscosity start up and knock lasts for expected temperature ‘only a fow seconds. Interference of Damaged compressor blades due to extemal cause Repair or replace ‘turbocharger, poor Interference of turbine and compressor biades with housing Repair or replace rotation Excessive deposit on compressor housing or whee! Clean or repair Excessive carbon depost on the back of turbine blade (Clean or repair Bum out of center housing Replace Leakage from Excessive intl ol applying Bum itnormally ‘turbocharger turbine shaft | Blocked crankcase breather Repair CObstacte in turbocharger ol drain tine (Clean and repair ‘Bum out of center housing (Clean and repiace \Woar on turbocharger bearing, bearing bore.or shaft journal Repair or replace Excessive crankease oll Correct cil amount Leakage from ‘Contaminated air cleaner eloment Replace turbocharger compressor | Blocked duct between compressor and air cleaner Repair Loose compressor and intake system connecting duct Tighten [Leakage from intake manifold Repair (Obstacte in turbocharger of drain tine . Fopair or replace ‘Blocked blowby passage in crankcase Repair ‘Wom or damaged compressor biades Clean or repiace ‘Wear or turbocharger bearing bore, bearing or shattjournal Replace Wear on turbocharger | Contaminated oll Replace Dearing, bore or shaft Insufficient of supply Check Journal ‘Obstacle in turbocharger oll supply fino Check and repair Plugged of fiter Replace Poor ol pump operation Check and repairSPECIAL SERVICE TOOLS. oK993 120 006 Remover, valve seal a ‘Used to remove valve seal ‘0K596 111 001 Ring gear brake set Used to prevent engine rotation. (0K130 111 004 Holder, coupling flange Se Used to remove camshaft gear.EM4 ENGINE MECHANICAL SYSTEM SYMPTON-RELATED DIAGNOSTIC PROCEDURE Engine Diagnostic chart Problem Possible Cause ‘Aton to be taken Insuticlont power Insuticient compression caused by: ‘smoke generation 1. Contaminated ai cleaner eiement 2) Loose hose connection between compressor andintercodter 3. Leakage trom intake maniold 4. Leakage ftom exhaust mano 5. Leakage from turbocharger mounting flange 6 Interference between turbocharger compressor ‘turbine and case 7, Blocked duct between air cleaner and turbocharger compressor 8. Blocked duct batwean compressor and intake manitold 2. Intererance betwoon intake and exhaust manfolds 410, Leakage trom valvo seat 11. Seized valve stem 12. Weak or broken valve spring 13, Failed oylinder head gasket 14 Cracked or dtried cyinder head 15. Sicking, damaged, or wom piston ring 16, Cracked or worn piston Matunction of uel system Rel to section FL, fue system Sipping otch Fer to section CH, clutch Wrong ie size Foor to section 8S, whoo! andres RResticted exhaust eystem Foor to sooton EME, exhaust som Excessive ol ‘Abnoral ongine ol viscosity Replace consumption Leakage from turbocharger compressor Repair {adhesion of ote housing or whee) Leakage tuboctargor urine Repair Wior o sicking piston fing or groove Replace Wom piston or cylinder Repair or replace Bad valve seal Replace ‘Wom valve stem or guide Replace Engine cranks ‘Maituncton of wel system Refer to section Fl, fua system rrmaliy, but does Mafunation of lcttcal system Reler to socton EE, starting rotstart system RRostrcted exhaust systam Peter to socton EMHE, ‘thas! aston ‘Timing belt and/or related parts Replace Low compression Camshaft wom Blue smoke out of Usualy caused by ll uring inthe combustion chamber rom: | Replace cahaust wom rings, wor val guides, worn valve soaisoraled finder head gasket Contaminated ai cleaner element Loose hose conection betwoon compressor and intercooler | Tighten Leakage tom intake maniold Repair Blocked oi fiter Replace Blocked duct baween air clanor and turbocharger compressor | Ropair Leakage trom turbocharger compressor Repair‘SPECIFICATION EM-7 SPECIFICATION Engine Specification i eee 4J8-COMMON RAIL SYSTEM Type Diesel, 4-Oyeles ‘Number a 6yindars “4-Oylndor inno ‘Combustion chamber Ro-ontrant Dasplaoomert x. in (e) 177 (902) Bore and stroke in (mm) 2 X9.85 07.1 X98) ‘Compression ratio 108 ‘Compression pressure si (kPa, kolem-spm 426.6 (2943, 30)- 200 ‘Valve timing intake ‘Open BTDC 26° Closed ‘ABDC 50° Emraust | Open 'BBDC 50° i | Cosed ‘ATOG 26° | VaWe elsarance(cold engine) | Intake 0: Maintenance-feo in (mm) [Exhaust (0: Maintenance-ee ae idle speed ‘pm 00 =100 Injection order 1342EM-8 ENGINE MECHANICAL SYSTEM ON-VEHICLE SERVICE Engine coolant PROCEDURE oe A waRNING Engine oil A) NEVER REMOVE THE RADIATOR CAP |. Be sure the vehicle is on level ground. WHILE THE ENGINE IS HOT. 2. Warm up the engine to normal operating B) WRAP A THICK CLOTH AROUND THE CAP ‘temperature and stop it. WHEN REMOVING IT. 3. Wait for 5 minutes. 4, Remove the oll level gauge and check the oil leva and condition. Acxoroane2 5. Add or replace oil it necessary. 1. Verity that the coolant level is near the radiator filler neck 2. Check that the level in the coolant reservoir is between the “Full” and “Low” marks. avansoa20 3. Add coolant i necessary. Coolant quality 1. Verify that there is no build up of rust or scale around the radiator cap of radiator filler neck. 2. Verify that the coolant is free of oil. 3. Replace the coolant if necessary.ON-VEHIGLE SERVICE PROCEDURE EM9 Drive belt Inspection 1. Check the drive belts for wear, cracks, and fraying. Replace if necessary. 2. Verity that the drive belts are correctly mounted on the pulleys. 3. Verify that “gy” mark of auto-tensioner align “1 1" mark, iftwo marks align as shown (D, the tension of ‘auto-tensioner is good. If not align as shown @, re- install the auto-tensioner or replace the drive batt. savansoscot 4, Check the A/C drive belt deflection by applying moderate pressure (22 Ib, 98 N, 10 kg) midway between the pulleys. "Caution 4) Measure the belt deffection between the pulleys. 1b) Consider the belt as a new one itt has been used ‘on a running engine for less than five minutes. ©) Check the belt deflection when the engine is cold or at least 30 minutes after the engine is stopped. AIC belt deflection: Now ono: 0.28~0.35 in (7~9 mm) Used one: 0.35~0.43 in (9-11 mm) Adjustment * avonoes 1. Loosen the idler pulley mounting bolt. 2. Adjust the bett deflection by turning the adjusting bolt. Deflection (When applying 22 Ib, 98 N, 10 kg) New one: 0.28~0.35 in (7~9 mm) Used one: 0.95-0.43 in (9-11 mm) 8. After making the adjustment, tighten the idler pulley ‘mounting bot. Tightening torque: (28-38 Ib-ft (37~52N-m, 3.8~6.3 kg-m) Replacement Raise the vehicle and support it with safety stands. Remove the RH side whoo. Loosen the idle pulley mounting bat Remove the A/C drive belt. Lower the auto tensioner with spanner and then remove the drive belt. oaene nvza9058 6. Lower the auto tensioner with spanner and then install the drive belt 7. Install the A/C drive belt. 8. Check the A/C drive belt dettection. (Refer to Inspection and Adjustment, page EM-9)EM-10 ENGINE MECHANICAL SYSTEM Timing belt Removal Raise vehicle and support it with safety stands. Remove the radiator upper hose. Remoge the fuel filter hoses still connected. Remove the No.3 engine mounting rubber. Avaaso9040 6. Remove the RH side wheel. 7. Remove the AIC drive belt. 8. Remove the drive belt. (Refer to Drive belt replacement, page EM-9) 9, Remove the auto tensioner. 10. Remove the water pump pulley. 11. Remove the crankshaft pulley. 12. Remove the upper timing belt cover. 13. Remove the lower timing belt cover. 14, Rotate crankshaft and align timing mark on timing belt pulley with timing mark on engine block. Crankenat ploy 15. Remove the auto tensioner. 16, Remove the timing belt.ON-VEHICLE SERVICE PROGEDURE Replacement 41. Check that timing mark on timing belt pulley, camshaft pulley and high pressure pump pulley is aligned with timing mark on engine, 2. Install the timing bet 1), The timing bett is installed in sequence crank shaft pulley, idler No.2, high pressure pump pulley, dlor No.1 and camshaft pulley. %® Notice 4) The auto-tensioner must be mounted onto the ‘engine after the timing belt is installed. b)_ Keep the tension of timing belt when install timing belt. 3. Install the auto-tensioner. 1) Install the auto-tensioner as shown illus. ‘The dowel pin has to be located betwaen the tensioner fork (back plate). Timing bet { eveasoon04 2) Protighten the auto-tensioner. Tightening torque: 2.0lb-ft(3.0N-m , 0.4kg-m) EM-11 % Notice ‘@) Oil must not get in contact with the tensioner. The tensioner has to be replaced by @ new one, ifitis oily. 'b) The positions of the pointer, the back plate and the special washor are in accordance to the ius. 4. Check again if the alignment marks of camshafts, crankshaft and high pressure pump are aligned with the marks on the timing case. 8. Adjust the auto-tensioner, and then tighten it. 1) Align the pointer to the back piate by rotating the spectal washer in counter-clockwise using the hexagon wrench as shown illust. Ponter ‘Special washer 7 evensoB0es 2) Tighten the auto-tensioner lock bolt with holding the special washer by the hexagon wrench ‘when the pointer is aligned with the back plat. Tightening torque = ‘17.4lb-ft (23.5N-m , 2.4kg-m) Pointer Torque vrench vento9008 8) Remove the hexagon wrench.EM-12 ENGINE MECHANICAL SYSTEM % Notice Tightening torque: If the pointer can not be aligned with the back plate, 65~79 lb-ft (88-108 Nem, 9.0~11.0 kgm) then a new belt has to be used. 6. Rotate the crankshatt two full revolutions in ‘clockwise to align the TOG mark. 7. Check again if the alignment marks of camshafts, crankshaft and high pressure pump are aligned with the marks on the timing case. ‘8. Check the alignment of the pointer and back plate, vzns0n007 Allowance misatignment : 5° 9 Ifthe misalignment between pointer and back plate is bigger than ++5°, repeat step 4~8. 10. Install the upper and lower timing belt cover. Tightening torque: 5.1~7.2 lb-ft (6.9-9.8 Nem, 70~100 kg-cm) 11. Install the erankshatt pulley. Tightening torque: 259-280 lb-ft (943~982 Nem, 35~40 kg-m) 12. Install the water pump pulley. Tightening torque: 13.0~20.9 Ib-ft (17.6-28.4 Nem, 1.8-2.9 kg-m) 18, Install the auto tensioner. Tightening torai 13.0~20.9 lb-ft (17.6-28.4 Nem, 1.8-2.9 kg-m) 14. Install the drive belt and A/C drive belt. (Reter to Drive bell, page EM-9) 16. Install the RH side wheel. 16. Install the No.3 engine mounting bracket. Tightening torque: 26.7~39.8 ID-ft (36.2~53.9 Nem, 3.7~5.5 kg-m) 17. Install the No.3 engine mounting rubber. Tightening torque: Nut: 48.1~68,7Ib-f (68.7~83.1 Nem, 6.8-8.5 kgm) Bott 629-260 (859~116.7 Ne, 87-11.9 kgm) 18. Install the fuel Miter. 19. Install the radiator hose. 20. Fill engine coolant with specified type and amount. (Refer to section EM-CL, Cooling system) 24. Start engine and then check for leaks. Compression pressure Inspection 1. Warm up the engine upto the normal operating temperature, then stop the engine and disconnect the connector of fuel cut solenoid 2. Remove ail injection pipes, nozzles and washers. 3. Attach the SST to the nozzle hole. 4. Measure the compression pressure during cranking. Engine model [3 COMMON RAIL | tem 'SYSTEM ‘Compression pressure | Norm $26.6(2545, 50)-200 si (kPa, kglome-tpm | Limit 383.9(2649, 27-200 Cynder to-ylinder pressure differance below 42.7(294,3.9) Psi (kPa, kofom?) 5. Do above step 3~4 again for each cylinder. 6. Ifthe measure value is below the limit, consider it ‘as abrasion or damage of piston and piston ring, misalignment of valve, damage of gasket, and etc..ON-VEHICLE SERVICE PROCEDURE Ladder frame Removal 1. Remove oil pan.(Refer to section EM-LU, Lubrication system) 2. Adjust the V groove TDC mark on the outside of pulley to the TDG mark “T" on the timing cover, by rotating the crank shaft pullay. avaas0e09) 3. When disassembling ladder frame, separate the oil feeding pipe from the oll pump by loosening the oil feeding pipe bot Avea 108095 “4, Loosen the ladder frame fastener bot. Remove ladder frame. EM-13 Replacement 1. Install the ladder frame into block, Check the dowel pin of ladder frame is matched with lower surface of block and insert the oil level gauge into the ladder frame hole. Tightening torque (ladder frame bolt): 32.5 Ieft (44 Nem, 4.5 kg-m) Install crankshaft and oil pump sprocket. Install the oil feeding pipe into the ladder frame, oil pump and block and then tighten bolts. ‘nvzaso6036 4, “Install the oil pan. (Refer to section EM-LU, ‘Lubrication 5. Fill engine oil with spacified type and amount. (Refer to section EM-LU, Lubrication system) 6. Start engine and then check for leaks.EM-14 DISASSEMBLY, INSPECTION AND REASSEMBLY PROCEDURE Notice a) Code ail identical parts(such as pistons, rings, connecting rods, and valve springs) so that they can be reinstalled in the cylinder from which they were removed. ) Clean the parts with steam, blow off any ‘remining water with compressed air. ©) Gare should be taken during the disassembly of ‘any part or system to study its order of ‘assembly. Any deformation, wear or damage should also be noted. Auxillary parts Disassembly 1. Remove inter cooler cover, 2. Remove inter cooler and inter cooler air inlat hose. 3. Remove engine hamess. 4. Remove ventilator hose. 5, Remove fuel injection pipe. ervortoTs ENGINE MECHANICAL SYSTEM 6. Remove air separator and air separator hose/pipe. ‘A separator eFLor.o60 7. Remove ventilation pipe and hose. 8. Remove lower water hose from cylinder block. 9. Remove EGR pipe. 10. Remove alternator, hose, altemator bracket and auto tensioner. 12, Remove turbo charger insulator,DISASSEMBLY, INSPECTION AND REASSEMBLY PROCEDURE 19, Remove turbo charger assembly. EM-15 19, Remove common rail.(Refer to section FL) AVAANOBDSEA, 14, Remove water bypass hose and water bypass pipe. f) Avzasoa056 18. Remove power steering pump bracket. 16. Remove exhaust manifold insulator, exhaust ‘manifold and gasket. 17. Remove EGR valve and gasket. 18, Remove intake manifold and gasket. erur.ase Bok eof S/d) 6 Hee Inetataton holes aveatos0s7 21, Mount engine on the SST (0K 190 990 007). Reassembly ‘Assembly willbe performed in the reverse order.EM-16 ENGINE MECHANICAL SYSTEM Timing belt cover Disassembly 1. Remove No.3 engine mounting bracket. 2. Remove water pump pulley. 3. Remove power steering pump. 4. Remove crankshatt pulley. 5. Remove idiot and bracket. 6. Remove upper timing belt cover. 7. Remove lower timing belt cover. Reassembly 1._ Install upper and lower timing belt cover. Tightening torque: 5.1~7.2 lb-ft (6.9-9.8 Nem, 0.7~1.0 kg-m) 2. Install idler and bracket. Tightening torque: 27-5~-38,3 Not (97,2-61.9 Nem, 3.8-6.8 kg-m) 3. Install crankshaft pulley. Tightoning torque: 283~280 tb-ft (343-302 Nem, 35~40 kg-m) 4. Install power steering pump. Tightening torque: 21.7~28.9 lb-ft (29.4~39.2 Nem, 3.0~4.0 kg-m) 5. Install No.3 engine mounting bracket. Tightening torque: 49.2-68.7 ID-ft (68.6-83.1 Nem, 6.8~9.5 kg-m)DISASSEMBLY, INSPECTION AND REASSEMBLY PROCEDURE EM-17 Timing belt Avan08062 (1) Timing bet (9) Injector bracket (2) Water pump (10) Injector (3) Camshatt pulley (11) Cylinder head cover (@) Tensioner (12) Rocker arm shatt assembly ©) Idler (13) Camshaft cap (© Timing bett pulley (14) Camshatt (7) Upper plate assembly (15) Cylinder head (@) Engine hangerEM18 ENGINE MECHANICAL SYSTEM Disassembly 1. Rotate crankshaft and align timing mark on timing belt pulley with timing mark on engine block. Remove the auto tensioner. Remove the timing bett. 1. Remove the high pressure pump. Install the SST (0KS52 111 001) as shown in the figure and the remove the camshaft pulley. sae avearoecee Remove the idler. . Remove the timing belt pulley. Remove the upper plate assembly. Remove the engine hanger. Remove the injactor bracket and injector. Romove the cylinder head cover. 12. Remove the rocker arm shaft assembly. 19, Remove the camshaft cap and camshaft 14, Remove the cylinder head bolts in the order shown in the figure. @OeO2OBGBOHGDOD 096 ©8 08 2G 6 ‘Ave t06008DISASSEMBLY, INSPECTION AND REASSEMBLY PROCEDURE Inspection Front timing belt 1 Notice 8) Never forcefully twist, tum inside out or bend timing bet. ) Do not allow oil or grease to come in contact with timing belt. 1. Replace timing belt if itis contaminated with oll or grease. 2. Check timing belt for uneven wear, fraying, peeling, ‘cracking and hardening. Replace timing bel if necessary. 3. Bend timing belt into, a “U" shapes as shown in. figure. Distance *A” must be at least 1.0 in (25 mm). A xy asrosoase EM-19 Camshaft pulleys and timing belt pulley A Notice ‘Do not oléan pulleys with cleaning fluids. if needed, ‘use a soft cloth to wipe them clean, and avoid -soratching the pulleys as it will affect integrity of the timing bet. 1. Check pulley teeth for wear, deformities and other ‘damage. Replace pulleys if necessary. Tensioner spring 1. Check the tensioner spring. Replace tensioner spring if necessary. Avex 689 Tensioner and idler Notice ‘Do not clean tensioner pulley or idler pulley with cleaning fluids. if needed, use a soft rag 10 wipe thom clean. Avoid scratching tensioner pulley or idler puley as it can afect integrity of timing belt. 1. Check tensioner pulley and idler pulley for smooth rotation and proper sound. Replace tensioner pulley and idler pulley if necessary. &) © avearo066EM-20 Camshaft 1. Set front and rear camshaft bearing journals on V- blocks. 2. Position a dial indicator on center bearing joumal and zero dial. 3. Rotate camshaft in V-blooks and check runout. Runout: 0.0031 In (0.08 mm) maximum 4, Check camshaft for uneven wear pattems, cracks, ‘or damage. 5. Measure cam lobe heights at two points as shown. Lobe height Intake : 0.8857 in (22.497 mm) Exhaust : 0.8894 in (22.593 mm) 11 @! AveA108067 ENGINE MECHANICAL SYSTEM 6. Chock camshaft bearing joumal diameter (X and Y directions) on both sides (A and B) of joumal as shawn in figure. Minimum diameter: 1.1000~1.1032 in (27.941~27.960'mm) 7. Replace camshatts it necessary. 8. Measure camshaft journal oil clearance. 9. Remove all foreign material and oil from journals and bearing surfaces. 10. Sot camshafts onto cylinder head. 11. Position plastigage® on journals in axial direction. 12. Do not rotate camshafts. 18. Install camshaft caps according to cap number and arrow mark. 14. Install cap nuts. Tighten them in five or six steps in order shown. Tightening torque: 19,0~19.5 Ib-tt (17.6-26.5 Nem, 1.8-2.7 kg-mn) Asoaro107DISASSEMBLY, INSPECTION AND REASSEMBLY PROCEDURE 15. Loosen camshaft cap nuts in five or six steps in AszAr0%07 17. Measure oll clearances. Olt clearance: 0.0016~0.0031 in (0.04~0.08 mm) 18. Ifo clearance exceeds specification, replace cylinder head. ‘ssxo1oanne 19. Install camshafts. 20. Place a dial indicator against end of camshatt. 21. Using a prying tool, move camshaft as far forward as possible. 22. Zero dial. 23. Using prying tool, move camshaft as far rearward as possible, 24, Check gauge to determine how much end play is present. End play: (0.0031~0.0046 in (0.08~0.11 mm) ssxov08aoe Rocker arm and rocker arm shaft 1. Measure the rocker arm inner diameter. Inner diameter: 0.7882-0.7874 In (19.87~20.00 mm) 2. Measure the rocker arm shaft outer diameter. Outer diameter: 0.7875~0.7866 in (19.959~19.980 mm)EM-22 Reassembly 1, Remove alll foreign material from the top of the cylinder block. 2. Place the new cylinder head gasket in position. "A. Caution ‘Measure the length of cylinder head bolt, replace If necessary. ‘Long bolt: 8:2 in (182 mm) ‘Short bolt: 3,7 In (83 mm) 3. Install the cylinder head. 4, Apply an engine oil into the surface and thread of oylinder head bolt, and install the oylinder head bots to the cylinder head. 5, Tighten the cylinder head bots in the order shown inthe figure. Tightening torque: ‘Angle contort [Long bolt: 25.32 ft (24.3 Nem, 3.5 kg-n}+45°470" ‘Short bolt: 25.32 lb-ft (24.3 Nem, 3.5 kg-m) OAS ® Soo ® si $ POs 7 vos betes) Ceres Ce Fey) Ce * l | | I 4 oe ©9 O08 © ® ‘AvoAt0B008 6. Remove all foreign material and oil rom the journals and bearing surface. ‘Set the camshaft onto the cylinder head. Install the camshaft caps according to the umber and arrow mark. es Bees se PN ENGINE MECHANICAL SYSTEM 9. Install the camshaft cap nuts and tighten them in ‘wo or three steps in the order shown in the figure. Tightening torque: 13.0-19.5 lb-ft (17.6-26.5 Nem, 1.8-2.7 kg-m) Asearo107 28 Notice ‘Do not exchange intake rocker arm shaft and ‘exhaust rocker arm shafi each other. + Intake side: Yellow + Exhaust side: Black 410. Install the intake rocker arm shaft and exhaust rocker arm shaft and tighten them in two or three steps in the order shown in the figure. Tightening torque: 13.0-10.5 ID-ft (17.6-26.5 Nem, 1.82.7 kg-m) veao32e5DISASSEMBLY, INSPECTION AND REASSEMBLY PROCEDURE 11. Install the cylinder head cover. Tightening torque: 5.1~6.5 Ibeft (6.9~8.8 Nem, 7090 kg-cm) a Notice Inspect clearance between dowel pin of camshaft ‘end and phase sensor, before install cylinder head cover. Clearance: 0.019-0.059in (0.5~1.5mm) 019-0059 (05-150) Blane Camebat | p. See avaatoa08« 12. Install the injactor and install the injector bracket. (Refer to section FL) Tightening torque: 14.5~15.9 lb-ft (19.6-21.6 Nem, 2.0~2.2 kg-m) 13. Install the front and rear engine hanger. 14, Install the upper plato assembly. 415. Install the idles, Tightening torque : 29.71b-ft (40.2Nem , 4.1kg-mn) 3% Notice Be careful that the iders does not change. Ilr No.1( » 2.36in( » 60mm)),kdler No-2(« 2:16in (» 5mm) EM-23 16. Install the high pressure pump. 41) Tighten the high pressure pump assembly fixing bolts after installed the high pressure pump to the timing case. Tightening torque : 15,9-18.Bib-ft (21.6-25.5N-m , 2.2~2.6kg-m) 2) Prestighten the high pressure pump pulley lock ‘ut after installed the high pressure pump pulley to the high pressure pump shaft with key. '3) Fix the high pressure pump pulley by used to two setting bolts after aligned the high pressure ‘pump pulley timing mark as shown illus, 44), Tighten the high pressure pump pulley lock nut. Tightening torque : 47-Olb-ft (63.7N-m , 6.5kg-m) '5) Install the high pressure pump bracket to the high pressure pump and eylinder block. "A. Caution First tighten the cylinder block side bolts and ‘then second tighten the pump side bolts after checking that there is no clearance between bracket and pump. Tightening torque : Pump sido : 15.9~18.8ib-ft (21.6~25.5Nem , 2.2~2.6kg-m) Cylinder block side : 25.3-29.Tib-ft (34.3-40.2Nem , 3.5-4.1kg-m)EMA24 ENGINE MECHANICAL SYSTEM 2) Install the camshaft fixing tool (SST) between two camshatt pulleys. Tering cas, 3) Tighten the camshaft pulley lock nut. gene Tightening torque : Seestem {47 Olb-ft (63.7Nem , 6.5kg-m) 159-188 8 4) Remove the camshatt fixing too! (SST). 216-25 50m, V 22-28Kgm) 19. Install ho timing batt. ee 41). The timing bel is installed in sequence crank 35-41 kgm) ‘shaft pulley, idler No.2, high pressure pump enor. pulley, idler No.1 and camshaft pulley. 17. Align the crankshaft pulley timing mark. %® Notice "Z. caution 8). The auto-tensioner must be mounted onto the When the crankshaft Is rotated without timing engine after the timing bet is instalted. belt, could damage piston and valve. 1b) Keep the tension of timing belt when install Betore assemble the-cylinder head, allgn TDC timing bet. for No.1 piston. 18. Align the camshaft pulley timing mark. 4) Align “EX'mark of the left camshaft pulley and. "IN" mark of the right camshaft pulley to the cylinder head top face as shown illust "B Caution Cynder head op face Timing mark veAr08005 When the camshaft Is rotated without timing belt, could damage piston and vaive. Before assemble the cylinder head, align the camshaft pulley timing mark 20. Install the auto-tonsioner. 1) Install the auto-tensioner as shown illust. ‘The dowel pin has to be located between the ‘tensioner fork (back plate). ok pt Dowol pin Lock bot f ev2n103008 2). Pretighten the auto-tensioner. Tightening torque : 2.0lb-ft (3.9N-m 0.4kg-m) 3 Notice 8) Oi must not get in contact with the tensioner. The tensioner has to be replaced by @ new one, Hits oll. 'b) The positions ofthe pointer, the back plate and the special washer are in accordance to the ustISASSEMBLY, INSPECTION AND. REASSEMBLY PROCEDURE EM-25 DISASSEMBLY, INSPECTION AND REASSEMBLY PROCT ee 21. Install the touch idler. Tightening torque : 17-Albeft (23.5Nem , 2.4kg-m) 22. Remove two setting bolts from the high pressure pump pulley. 128. Check again ifthe alignment marks of camshafts, ‘crankshaft and high pressure pump are aligned with the marks on the timing case. 24, Adjust the auto-tensioner, and then tighten it. 4) Align the pointer to the back plate by rotating the special washer in counter-clockwise using the hexagon wrench as shown illust. fevzasosees 2) Tighten the auto-tensioner lock boit with holding ‘the special washer by the hexagon wrench ‘when the pointer is aligned with the back plate. ightening torque : 417.Albeft (23.5Nem , 2.4kg-m) 3) Remove the hexagon wrench. Notice I the pointer can not be aligned with the back plate, then a new belt has to be used. 25, Rotate the crankshaft two full revolutions in clockwise to align the TOC mark. 126. Check again if the alignment marks of camshatts, crankshaft and high pressure pump are aligned with ‘the marks on the timing case. 127. Check the alignment of the pointer and back plate. ‘Allowance misalignment: 5° £28. Ifthe misalignment between pointer and back plate ts bigger than (:5°), repeat stop 23-27.EM.26 ENGINE MECHANICAL SYSTEM Cylinder head savexroonea {1) Valve cotter (4) Valve spring lower seat (2) Vaive spring upper seat (8) Valve (8) Valve spring (©) Valve seat Disassembly 93. Pull the valve seal out by using the SST (0K993. 1. Remove the valve cotter by using the SST (0K993 120 006). 120 001 / 0K993 120 004). ‘Aveasos068 2. Remove the valve spring upper seat, valve spring, valve spring lower seat and valve,DISASSEMBLY, INSPECTION AND REASSEMBLY PROCEDURE EM27 Inspection Valve mechanism 1, Inspect each valve for following: ‘a. Damaged or bent valve stem b. Rough or damaged face c. Damaged or unevenly worn stem tip 2. Resurface or replace valve as needed. Margin thickness: Intake: 0,047 In (1.2 mm) Exhaust: 0.043 in (1.1 mm) stent ssxoraante Valve spring 1. Inspect each valve spring for cracks and damage. 2. Measure free length and out-of-square. Replace valve springs as needed. Free length: 2.066 In (52.47 mm) ‘Out-of-square: 2° maximum wargn neem Valve taco ange as" Bsxor0A10 3. Measure diameter of each valve stem. Diameter Intake: 0.2742~0.2748 In (6.965~6.980 mm) Exhaust: 0.2734~0.2740 in (6.945~6.960 mm) asxor0Attt 4, Measure inside diameter of each valve guide at points shown in figure. Diameter intake and exhaust valve guide: 0.2759~0.2767 in (7.010~7.030 mm) Oxtotaquare AsoAr0139EM28 ENGINE MECHANICAL SYSTEM Reassembly 1. By using the proper tool, press the valve seal. veasoe7o 2. Install the valve, valve spring lower seat, valve spring and valve spring upper seat. 3. By using SST (0K993 120 001 / 0K99S 120 004), ‘compress the valve spring and place the valve cotter securely. 4. By using a plastic hammer, tap the stem lightly to assure proper fit.DISASSEMBLY, INSPECTION AND REASSEMBLY PROCEDURE Cylinder block AveRI0807 14 (1) Oilpan {2) Oilfeed pipe (8) Timing belt case (4) Ladder frame {5) Oil strainer {6) Oil pump (7) Clutch cover and clutch disc (MTX only) (8) Flywheel (MTX only) (8) Rear cover (10) Connecting rod cap (11) Connecting rod (12) Main bearing (43) Piston and piston pin (44) Piston rings (15) Main bearing cap (16) Main bearing (17) Crankshatt (18) OijetEM-30 ENGINE MECHANICAL SYSTEM Disassembly 1. Remove the clutch cover, clutch disc and flywheel. 2. Remove the oil pan mounting bolts. 3. Remove oil pan with a screwdriver or suitable tool. "A. coution 4) Do not force tools between cylinder block and oll pan as this may damage sealing surface. ‘b) Do not damage sealing surface when removing old sealant. 4. Remove the oil feed pipe. 5. Remove the timing bet case. 6. Remove the ladder frame. 7. Remove the oil strainer and oil pump. 8. Remove the lever, tensioner and guide. 9, Remove the rear cover. 10. Before removing the conneoting rod, measure the ‘connecting rod side clearance. Side clearance: 0.0055~0.0159 in (0.14~0.89 mm) 11. Remove connecting rod cap. 12, Measure the connecting rod bearing oll clearance. 1) Remove all foreign material and oil from the crank pin and bearing surface. 2) Position Plastigage atop the crank pin in the axial direction, 3) Install the connecting rod cap and tighten. Tightening torque: Tighten 50.6 Ib-t (68.6 Nem, 7.0 kg-m), tighten 21.7 lb-ft (29.4 Nem, 3.0 kg-m) and then tighten 90°. avor000 4) Loosen the connecting rod cap nuts. 5) Measure the ol clearance at each erank pin. ll clearance: 0.00169~0.00303 in (0.043-0.077 mm) 19. Remove the connecting rod and piston. 14, Before removing the main bearing cap, measure the crankshaft end play. End play: 0.0055~0.0159 In (0.14-0.38 mm) ANTOIOANESDISASSEMBLY, INSPECTION AND REASSEMBLY PROCEDURE 16. Remove main bearing cap. 16. Measure the main bearing ol clearance 41), Remove all foreign material and oil trom the joumals and bearing surface. 2) Position Plastigage atop the journals in the, axial direction. 3) Install the main bearing cap and tighten as shown in the figure. Tightening torque: Pretighten 54.97 Ib-ft (74.5 Nem, 7.6 kg-m), and then tighten 60°. ANTOIORIB6 4) Loosen the main bearing cap bolts and remove main bearing cap. 5) Measure the oil clearance at each journal. it clearance: 'No.1,24,5: 0.00177~0.00811 in (0.045~0.079 mm) ‘No.3: 0.00287~0.00387 In (0.068~0.101 mm) 17. Loosen the main bearing cap bots in two or three ‘steps in the order shown in the figure. 18. Remove the main bearing cap, main bearing and crankshaft. veatosor2 19. Remove the balance shaft and thrust plate. 20. Remove the balance gear. 21. Remove the oil jet. 22, Remove the snap ring with snap ring pliers and then remove the piston pin. 28. Using a piston ring expander, remove piston rings. EM-31 Inspection Piston ® Notice ‘Replacing a piston also requires replacing piston rings. 1. Check circumference of piston for damage, scoring, ‘or unusual wear pattems. Replace piston as needed. ‘ha wear ‘nveno8073 2. Check outside diameter of each piston at 2 90° right angle to piston pin, 0.16 in (15 mm) above lower end of piston. Piston diameter ‘A grade: 3.8195~3.8201 in (97.015~97,030 mm) B grade: 3.8201~3,8207 In (97.030~97.045 mm) 3% Notice Itpiston is collapsed or bell mounthed, replace piston. vensos07EM-32 ENGINE MECHANICAL SYSTEM 3. Cheok piston-to-oylinder liner wall clearance by subtracting piston diameter from the largest cylinder liner wall ciameter at each cylinder. Clearance: 0.0028~0.0039 in (0.070~0.098 mm) 4. I learance exceeds maximum, replace piston or cylinder liner. Piston rings 1. ligert a new piston ring into a piston ring groove ‘and check piston ring-to-side clearance. Piston ring ‘groove clearance. Piston ring groove clearance: ‘Top ring: 0.0028~0.0040 In (0.076~0.102 mm) ‘Second ring: 0.0016~0.0031 in (0.040~-0.00 mm) Oil ring: 0.0012-0.0028 in (0.030~0.070 mm) Limit: 0.0118 in (0.90 mm) ASZAt0081 clearance exceeds the limit, replace piston. Inspect plston rings for damage, abnormal wear, or breakage. Replace piston rings if necessary. Insert piston ring into cylinder by hand, ‘Square ring in cylinder by inverting a piston into coylinder and pushing ring to the bottom of its travel in oylinder eae 9p Aszar00s! 7. Place a feeler gauge in end gap and check end gap clearance. End gap clearance: ‘Top ring: 0.0118-0.0177 in (0.20-0.45 mm) ‘Second ring: 0.0157~0.0217 In (0.40~0.55 mm) Oil rall: 0.0078~0.0187 in (0.20-0.40 mm) ‘Limit: 0.0694 In (1.50 mm) asros0208 ‘8. Replace piston ring if necessary.DISASSEMBLY, INSPECTION AND REASSEMBLY PROCEDURE EM33 Piston pin 1. Measure each piston pin diameter at X and Y EM42, ENGINE MECHANICAL SYSTEM Replacement 1. Install radiator. 2. Install radiator bracket. 3. Reconnect coolant lower hose. 4, Reconnect reserve tank hose. 5. Reconnect coolant upper hose. Install cooling fan assembly. 7. Refill engine coolant. Water pump Removal Drain engine coolant. Raise vehicle and suppor it with safety stands. Remove RH side wheel. . Loosen AVC drive belt tension by turing idler adjusting bott. J anooro01e-t 5. Remove A/C drive belt. . Lower auto-tensioner with spanner and then remove drive belt. F caret v2ns2003 8. Remove water pump pulley. 9. Remove crankshaft pulley. 10. Remove lower timing bet cover. 11. Remove water pump. evzara00eREMOVAL AND REPLACEMENT PROCEDURE Replacement |. Install new gasket and water pump. 2. Install lower timing bett cover. Tightening torque: 5.1~7.2 lbeft (6.9~8.8 Nem, 0.7~1 kg-m) ‘e Install crank shaft pulley. Tightening torque: 259~280 lb-ft (943-292 Nem, 25~40 kg-m) Install water pump pulley. Tightening torque: 19.0~20.9 lb-ft (17.6~28.4 Nem, 1.82.9 kg-m) * 5. Install auto-tensioner. Tightening torque: 13.0-20.9 lb-ft (17.6-28.4 Nem, 1.82.9 kg-m) 6. Lower auto-tensioner with spanner and then install drive bet. ~. Install AIC drive bet. ‘Adjust belt deflection by turning adjusting bolt. Deflection (when applying 22 Ib, 88 N, 10 kg) New one ; 0.28~0.35 in (7~9 mm) ‘Used one : 0.35~0.43 In (0-11 mm) ° 2. Install RH side wheel. Tightening torque: (65-79 Ib-ft (68~107 Nem, 11 kg-m) 10. Refi engine coolant. EM-43 Thermostat Removal 1. Remove two bolts securing thermostat housing. 2. Remove thermostat and gasket. 3. Replace thermostat necessary. Replacement 4. Install thermostat. 2. Install new gasket and thermostat housing.—EM-44 ENGINE MECHANICAL SYSTEM SPECIAL SERVICE TOOL Lubrication system Special service tool 0K670 140015 ll pressure gauge ee) Used to inspect cil pressure. SYMPTOM-RELATED DIAGNOSTIC PROCEDURE Lubrication system Diagnostic chart Problem Possible Cause ‘ation Engine hard starting improper engine ol Replace lnaufient engine oll Aas ol Excessive ol intemal engine wear oer to Section EM consumption Oileak Repair ‘Ol pressure drop Ineufcient oll ‘Add ol Oilleekoge Pepa Wom and/or damaged oil pump gear Replace ‘Wom plunger (inside ol pump) oF weak spring Replace Clogged ol strainer Cloan Excessive main beering or connecting rod bearing clearance | Refer to Saction EM Warning am (il pressure drop "As described above iyminates while ‘Malfunction of oll pressure switch Inspect oi pressure switch ‘engine is running Malluneton of electrical system Inspect olectrcal systemSPECIFICATION EM-45 SPECIFICATION Lubrication system Specification them J3 COMMON RAIL SYSTEM Latin Forced ype Otpump | Type Troshold gear Rolle! pressure, al a, Kafer) 782-02.4 (589-697, 55-65) ‘Gitter | Type Fullfow type, Paper alomont Rolet pressure difreriial pal kPa, gem) T1.4-17.1-(8~118, O8~1.2) ‘Olipréssire swich activation pressure pal (kPa, Kyler) 28-49 @0~34, 02-0.36) Oilcapactty [Total (dy engine) Us ot iter. imp ot 7:50 0-4, 62) Oil pan Us qt (liter, Imp gf) 5.92 (6.6, 4.9). Oi fiter Us qt (liter, imp ot) 0.63 (0.6, 0.5) Engine ol ‘APl servos CF-4, OO-% SAE 10W-30EM-46 ENGINE MECHANICAL SYSTEM ON-VEHICLE SERVICE 7 filter replacement PROCEDURE * Sauktoogtarmmet ne Engine oil replacement AAWARNING BE CAREFUL WHEN DRAINING BECAUSE OIL 1S HOT AND COULD CAUSE PERSONAL INJURY. 1. Warm engine to normal operating temperature and tum engine off. Position a suttable container under oil pan. 2. Remove oll filer cap and oll pan drain plug. 3. Allow oil to be fully drained. 44. Install drain plug with new gasket. Tightening torque: 23.1-30.4 lb-ft (91.4~41.2 Nem, 3.24.2 kg-m) 5. Refill engine with specified type and amount of engine oil.(Refer to specification table; page EM- LU) Install ol filer cap. Run engine and check for leaks. Check ol level by level gauge and add oil if necessary. exe Oil pressure check 4. Disconnect and remove oll pressure switch. 2. Install oil pressure gauge into oil pressure switch installation hole. 3. Warm engine to normal operating temperature. 4. Run engine and note gauge readings. Oil pressure: 45.5-71.1 psi (314~400 kPa, 3.2~5.0 kglom 3,000 rpm_ ‘5. If pressure Is not within specication, check for ‘cause, and repair. (Refer to Symptom-related diagnostic procedure; page EM-LU-2.) 6 Remove oil pressure gauge and install oil pressure switch. Tightening torque: 8,713.0 Ibeft (11.7~17.6 Nem, 1.2~1.8 kg-m) 2. Apply a'small amount of clean engine ol to rubber seal of new fitter. 3._ instal ol iter and turn t by hand until rubber seal contacts base. 4, Tighten fiter 1-1/6 turns with fter wrench. Tightening torque: 16-18 Ib>ft (21.6-24.5 Nem, 22-25 kg-m) 5. ' Start engine and check for leaks. 6. Tum engine of, and wait 5 minutes. Check oil level and add oil if necessary.REMOVAL AND REPLACEMENT RROCEDURE EM-47 REMOVAL AND REPLACEMENT PROCEDURE Oil pump Removal 4. Remove oll pan. 2. Adjust V groove TDC mark on outside of pulley to ‘TDC mark *T* on timing cover, by rotating crank- shaft pulley. avaatopcat 3. Remove oil feeding pipe from ladder frame. ot teeding pine aveatt0ot 4, Remove oil pump with four bots. 8. Remove oll pump. Replacement 4. Remove oil pump after loosen the chain by push the end of chain tensioner with the chain tensioner lever. 2. Install oil feeding pipe. Tightening torque: 16.6 lb-ft (23 N-m, 2.3 kg-m) 3. Install oil pan. Oil cooler . Removal 4. Remove fresh air duct. | Remove ventilator mounting bracket. Gasket ‘oflcooler Oliproscure swe oiler aveANIO02A 3. Remove oil fter assembly with two nuts and eight bolts. 4, Remove four nuts securing oil cooler. 5, Remove oll cooler from oil fiter assembly. Replacement 1. Install new “O” rings and oil cooler to oil iter assembly. Tightening torque: 10.8~18.0 lb-ft (14.7+24.5 Nem, 1.5~2.5 kg-m) 2. Inistall new gasket and cil fiter assembly to oylinder block. ‘8. Install ventilate mounting bracket. 4. Install fresh air duct.EN~48 ENGINE MECHANICAL SYSTEM ON-VEHICLE SERVICE PROCEDURE Turbocharger : After checking the turbocharger, replace the assembly in case of ‘abnormality. Symy ‘Check point Check result Lowpowe por Oli leak ‘Smoke | Abnormal rol ‘sccelertion ‘Turbine rotor Oil leakage a e a 4 Carbon deposit a e o ° Frition wth housing 4 ° ° ° Bent or broken blade . e ‘Compressor oll Contaminated intake inet wih of 3 ° Fcton with housing a ° ° 2 Bont or broken blade . ° “Turbine and comprossor | Heavy or oalching feeling when rolatad by Tiger ‘ ° ‘check in both directions |_No movement when rotated fy Excessive looseness in bearing ° . Carbon deposit in drain oil hole 4 4 ° 4 [Observation on olfhale_| Carbon depostin drain of hole a e 4 a ‘Operation of waste gate | No smooth operation when applied after e vale (atecn usec) | removing postive pressure © =: High possibility (©: Medium possibility 4: Low possibility Turbocharger On-vehicle Inspection 1. Warm up the engine to the normal operating temperature. 2. Disconnect the hose between the air inlet tube and ‘the boost compensator from the air inlet side, 3. Install the pressure gauge by inserting the S-way ‘connector. 4, lead the maximum vaive on the pressure gauge afte stating the engine and increasing the engine speed. Pressure gauge reading| ‘Check point No posite pressure or | = Air exhaust gas leakage low pressure + Abnormal turbocharger: ‘Above the spacifiod ~ Leakage by separation or supercharging pressure | breakage of actuator hose: (Standard value) + Abnormal operation of actuator Removal 1, Discharge the coolant. 2. After removing the air duct, keep foreign material {rom entering the turbocharger inlet. 3. Remove the turbocharger insulator. 4. Remove the turbocharger water outlet pipe. 5. Remove the turbocharger oil supply pipe. 8. Remove the exhaust and front pipes. 7. Remove the turbocharger inlat and outlet pipes. 8, Remove the turbocharger by loosening tha ‘turbocharger mounting botts. "Caution 8) Don't carry the actuator by holding the ‘actuator rod and the actuator hose. ‘b) Use the stud bott of specitied type when It Is damaged. it one of different material is used, may be elongated at high temperature and that can result in ges leakage. ¢) The turbocharger is operated at high temperature and high speed that sufficient care should be taken on inclusion of forelgn ‘material into the oll pipe, deformation of the ll pump and etc.. ) After removing the turbocharger, attach the ap or tape on the alr and exhaust gas inlets {for foreign material not to be included. ©) If the ol in the sensor housing flows out fo the turbine and the compressor housing inside, it can be wrongly judged as turbocharger trouble that the turbocharger should be placed horizontally as originally ‘mounted after removal.ON-VEHICLE SERVICE PROCEDURE EM-49 Installation Install them in the reverse order of removal. "d.caution a) When installing a new turbocharger, pour ‘small amount of oll into the lubricant inlet of the turbocharger. 'b) When starting the engine, be sure to connect the lubricant supply pipe and Idle It for 1~2 minutes at low speed. Then increase the engine speed after lubricant has been supplied to the turbocharger sufficiently. Inspection |. Check if the rotor shaft is rotated smoothly when, tured by a finger. 2. Check ff thera is looseness on the rotor shaft when moved up and down. 3. Install a dial gauge at the end of the shaft and check the free travel. Free travel (0.001~0.003 in (0.026~0.074 mm) 4. Check if tere is oil attached or carbon deposit on the turbine or the compressor whee's.. 5. Check if there is deformation or crack on the turbine ‘or the compressor whee!s. 6. Check if the turbine or the compressor wheels are interfered with housings. 7. Checki the waste gate valve is operated smoothly and if there is no deformation or crack after removing the fixing pin ofthe actuator rod. 8. Check if there is poor contact between the waste gate valve and the turbine housing seat. Tuborcharger actuator’ Inspection Disconnect the air hose from the actuator. 2. Gomeet he pressure str oe ond ofthe actuator pipe and connect the other end to the actuator, ‘3. Install the dial gauge on the straight line of the ‘actuator rod. 4. Check ifthe actuator is operated and ifthe reading of the dial gauge is moved by 0.08 In (2.0 mm) ‘when pressure of 1080~1170 mmig is applied by the pressure tester. "A .Caution If pressure over 1.5 kg/ont Is applied, the actuator may be damaged. 5. Ifit is not operated or it does not reach the standard pressure, replace the actuator.EM-50 Intercooler Inspection 41. Check if there is crack or damage on the intercooler visually and replace itif itis abnormal. 2. Check ifthe pin is damaged and adjust ity a driver if damaged. 3. Check if there is leakage after applying pressure of 1.5 kgiom’. ENGINE MECHANICAL SYSTEM