CON4PRESSION PRESSUREBELT / TENSION INSPECTION

R B 2 6 D E TITR B 2 0 E D E D E T/ C A 1 8/i R B 2 s D E N G T N E E

gaugeinstallation Compression . Warmup theengine remove 6 spark and plugs. all . Attachthe adapter theAllencompression to gaugeand plughole. setrtin a spark

pressureinspection Compression ' Depress acceleration pedalfully. the Turnthe ignition position crank switch START to and the engine.Readcompression pressure the enginespeedoncethe gaugeneedle and stopsmovrng. . Whenenginespeedis out of specifications, gravity the battery checkthe specific of and perform againif the battery functioning test properly. is . lf the compression pressure stillnotstandard, is inspect components the around the combustion chamber (valves, valveseat,hydraulic piston valvelifters, rings, cylinder bore, cylinder head,cylinder headgasketetc.).Correct malfunctions repeat any and compression test.

3. BELTTENSION INSPECTION ADJUSTMENT AND

Inspection Theinspection should performed be when engine or more the cold thanthirty minutes after theengine been has stopped.

RB26DETTRB2ODE, / RB2sDE / DET ENGINE

an.trs

Standard
Power steeringbelt With HICAS Air corditionercompressor belt Fan belt

Poly-V lowmaintenancebelt Poly-V lowmaintenance belt Poly-V lowmaintenance belt

I - 10
8 - 10 6-8

9- 10 10-12
7-9 4-6

tc

16 12 7.5

3-5

EN-43

& INSPECTIONADJUSTMENT TENSION BELT

E i / R B 2 6 D E T/TR B 2 O ED E / D E T/ C A 1 8 / R B 2 s D E N G I N E

RB2OEENGINE

. llew belt Powersteering belt comPressor Air conditioner

Fan bett Poly-V lowmaintenance belt

Tension limit
9- 11 7-9 4-6

8- 10 6-8 3-5

15
12 7 5

Poly-Vlowbelt maintenance
Poly-V lowmaintenance belt

C A 1 8 iE N G I N E
Belt defction (run) lokg of force lE appfcd at tha ' V Po3ltionl

Adluslrnsnl
Power steeringpump bett belt comPressor Air conditioner
Fan belt

Tenrlon llnit

Poly-V lowbelt maintenance Poly-V lowmaintenance belt Poly-V lowmaintenance belt

I - 11 6-8 4-5

10-12 7-9 4.5 - 5.5

12

Caution: .1 Whenthe beltis replaced morethanfor the slightly the witha newbeltincrease tension . of usedbeltto allowfor wear-in the newbelt. "Adjustment" value. to the exceeds limit,adjust the 2. Whenthe beltdeflection whenthe beltis installed. grooveis aligned correctly 3. Makesurethe pulley

Adjustment
lTEM PART .... , ,
Adjustment bolt in power steering pump Adjustment bolt in idler Pulley Adiustment bolt in alternator

Power steering belt Air conditioner compressor belt Fan belt

EN.44

VALVE CLEARANCE INSPECTION ADJUSTI\,4ENT &

R B 2 6 D E i i R B 2 ' E D E D E Ti C A I B i/ R B 2 5 D E N G I N E E

4 . V A L V EC L E A R A N C EN S P E C T I O N N D A D J U S T M E N T I A
Additionalwork required(removethe followingparts): . Air duct . Rocker cover Inspection . Inspect valveclearance the whenthe engineis cold. . Remove airduct,ornaments the rockercover. the and . Rotate crankshaft aligncrankshaft the and pulleymarkwiththe beltcoverindicator. . No. 1 cylinder at the compression is stroketop deadcentrewhenboththe intakeand exhaust sidecamsdo notmovethe valvelifters.
i V"lu"" to be adjusted lntake side

INTAKESIDE EXHAUST IDE S F i r i n g r d e r :1 - 5 - 3 - 6 - 2 - 4 o

C y l i n d eN o . 1 , 2 , 4 r
Cylinder No. 1 , 3, 5

Exhaustside

. Rotate crankshaft revolution the one (360.) andalignthemarkon thecrankshaft pulley with the beltcoverindicator. (No. 'l cylinder piston exhaust T.D.C),

INTAKE IDE S EXHAUST IDE S

C y l i n d e rN o . 3 , 5 , 6

Cyiinder No. 2, 4, 6

Valve clearancestandard value

PART INTAKE
Valve clearance (cold) mm
0 4 5 + 'I r r

(20+t-5C)

0.38r.1' o:, 0 . 4 4 , ' 00 3

(Reference value: warm) mm

0 . 5 1 ', " ' :

Caution: Alwayscheckthe valves whentheyarecold.

E N. 4 5

& INSPECTION ADJUSTMENT VALVE CLEARANCE

E / R B 2 6 D E T/TR B 2 O ED E / D E T/ C A IB i/ R B 2 5 D E N G I N E

Valve clearancemeasurement . Insert 0.15 - 0.20mm gauge fromsparkplugside. (A) a

a (B) side.Select gauge gauge fromopposite Insert to reduce clearance 0 m. the that thickness will

Note: Do not use morethantwo gauges(B). gauge. feeler UseJIS 150A25 = Vatveclearance Gauge(A) + Gauge(B) gauge and(B): (A) using for Reasons measurement '1.The valveclearance to is setting largercompared previous engines. to gaugescannotbe placedparallel the 2. Large surface. measurement . Thickfeelergaugehavehighrigidity cannotbe bent and will so easily, the measurement be incorrect. . The errorfactorincreases a number thingaugesare of if will andthe measurement be incorrect. layered Valve clearanceadjustment . The valveclearance by is adjustment performed thickness. a selecting shimof suitable (t) . Whenthe measurement valveclearance is outof (T) the measure shimthickness and soecification, the it replace witha shimthatwill produce standard dearance. method Shim thicknesscalculation 1. Example: (t) valveclearance is 0.50mm: Whenthe intake = 0.05mm value) 0.50(t)- 0.45(specified value. . The valveclearance 0.05mm greater thanthe specified is the . Usea shim0.05mm thicker shimto reduce valveclearance. thanthe current

(T) shimthickness 2. Current . Measure centre removed the to shim determine of the shim. of thickness thecurrent Caution: again shims the Donotreuse measured
3. Shim selection (T) shimthickness is 2.40mm. Current mm + 0.05mm = 2.450 2.4O F\ '401 Selectnewshimwithstampedmark124 --2.440-2.455). I +f value range 0.03mm. standard a Select shimwithin 4. Shim types and classification Thereare 70 typesof shims. Sizesrangefrom2.275 mm in 0.05mm increments. mmto 3.325 EN-46
T = 2.440- 2.455mm

LUBRICATION SYSTEM INSPECTION

R B 2 6 D E - _ R E 2 : : D E D E T/ C A 1 8 i /R B 2 5 D E N G I N E E

5. LUBRICATION SYSTEM INSPECTION 5-1 LUBRICATION LEVELINSPECTION OIL Inspection . The engineoil levelshouldbe checked before starting the engine if theengine beenstarted, inspection or has the mustbe carried ten minutes out afterthe enqinehas been turnedoff. . The oil levelshouldbe between H and L lineson the the levelgauge. . The oil mustnothaveanywhiteturbidity dirt. or period Lubrication replacement oil

BetweenL&Hmark

RB20DETRB26DETT Every / 5,000km 6 months or CA18i RB2OE i Everv 15.000km 12 months or Everv 10.000km 6 months or RB2ODERB25DE /

S D . S E . S G S F c l a s so i l

SE,SF,SG class oil

SD class oil

Everv 15.000km 12 months SE,SF,SG class or oil Everv 10.000km 12 months or SD class oil

Note: UsegenuineNissan X for / vehictes. [Turbo (7.5W- 30)]for service RB26DETT RB20DET UsegenuineNissanSG class[ExtrasaveX (7.5- 30)]for service CAI Bi/ RB20E,DE / for RB25DE vehicles. Oil quantity ITEM
H RB25DE/RB2ODE/RB2OE RB2ODET/RB26DETT/4WD 4.0 :.,...L.' 3.0 3.5
1,1

Approx.3.8 Apptox.4.2 Approx.3.2

Approx. 4.2 Approx.4.6 Approx.3.6

cA18i

E N. 4 7

INSPECTION SYSTEM LUBRICATION

E / R B 2 6 D E T/TR B 2 O E D E / D E T/ C A I B i/ R B 2 5 D E N G I N E

INSPECTION 5-2 OIL PRESSURE gauge . Remove oil pressure the switchand connect oil pressure the to is . Afterwarming engine, makesurethe oil pressure appropriate the enginespeed. the
80"C) (Oi1 temperature

GA18'

Approx. 1 Approx. 1 .5 Approx.3 Approx.3

A p p r o x .1

Approx.3 Approx. 4

4000
Approx. 4.6

Approx.4

RB2OE

/ RB26DETT RB25DE/ RB2ODE

cA18i

ylinder biocknghtsrde,

7,' .:: {fessureswrlcn

pressure "

REPLACEMENT 5.3 OIL FILTER Removal . Useoil filterwrench(special the tool)to remove filter. service Caution: the oil Catchany dripping withragetc.whenremoving filter. lnstallation on surface the mounting . Beforeinstalling newoil filter, cleanthe oilfilterbracket the withnewengineoil. blockand coatthe oilfilterseallipslightly cylinder . Screwin the oil filteruntila slightresistance feltandthemtighten2l3turn' is Caution: the Makesurethe oil will notleakafterstarting engine.

or / RB26DETT Everv10.000km 12 months RB2ODET CA18i RB2OE /

oil SD.SE.SG SF class

oil or 15,000km 12months SE,SF,SG class Every oil or 10,000km 12months SD class Every or Everv15.000km 12 months / RB2ODERB25DE or Everv10.000km 12 months oil SE,SF,SG class SD classoil

EN.48

R B 2 6 D E T TR B 2 C E D E ' D E T / C A I B i/ R B 2 5 D E N G I N E E

EXHAUST SYSTEI\,4 INSPECTION

RB2OE

RB2ODE/DET/RB2sDE

cA18i

6.EXHAUST SYSTEM INSPECTION

(RB26DETT/ 6-1 AIR CLEANER ELEMENT INSPECTION RB2OE DE / DET) / lnspection . Remove bandsshownin the diagram the and remove aircleaner the element. . Thereshouldbe no excessive or damaoeon the air cleaner dirt element. Periodic replacementinterval

Every60,000 km RB2OEDE / RB2ODET

RB26DETT

6-2 TURBOCHARGER (RB26DETT RB2oDET) tNSPECT|ON / Functioninspection . Remove intakemanifold the hose,and placea cap on the hose. Connect canister test hoseto intakemanifold attachpressure gauge(compound gauge). and . Perform engineoperation andcheckthatpressure the test doesnot riseabove approximately - 0.9kg/ cm,. 0.B a. Whenthe pressure doesnot reachspecified level. Checkfor vacuumleakin intake exhaust gas leak. or systemor exhaust pressure b. Whenthe pressure exceeds maximum the level(approx. - 0.9 kg / cm,). 0.8 Checkif swingvalvecontroller rubberhoseis disconnected cut. or Checkif swingvalvecontroller (stays motion malfunctions closed). RB26DETT RB2ODET
G1508 009 0 EG1508 001 0

EN--19

SYSTEMINSPECTION EXHAUST
T R B 2 6 D E T/TR B 2 O D EE N G I N E

Swing valve controller inspection tubeside. . Remove swingvalvecontroller rubberhosefromthe vacuum the 0.7 . The controller muststartoperating air approx. - 0 8 kg / cm2 whencompressed rod an intothehoseby using is 0.8 approx. - 0.9kg/ cm' (RB2ODET) forced (RB26DETT), is verified air air gun. Stopblowingcompressed as soonas controlrod operation Caution: Usethe LPG is air if may be damaged excessive pressure applied. Thediaphragm ls 1 kg / cm' ) to verifythat the air gun pressure pressuregauge(specialservicetook for - 0.9 kg / cm' (RB20DET) beforetestingthe or 0.7 approx. - 0.8 kg / cm' (RB26DETT) 0.8 arrnose. RB2ODET

6-3 RECIRCULATIONVALVEINSPECTION Functioninspection (place cap the valvecompressor . Remove hoseon upperflow sideof the recirculation the is closedquickly. on end of the hose)and checkif air blowsbackwhenthrottle

RB26DETT

RB2ODET

Unitinspection -400+/-150 (RB26DETT) pressure +f 30mmHg . Usea hand pump create negative to to must valve (RB2ODET). recirculation diaphragm start liftupandthe The 50mmHg will vacuum oressure bemaintained.

EN-50

EXHAUST SYSTEM INSPECTION

C A1 8 E N G N E

6-1 AUTOMATIC TEMPERATURE ADJUSTMENT CLEANERINSPECTION AIR Systemdiagram

Freshair ducl When cold
n alf -----=

Arrcleaner

lntake manifold Freshair duct When warm Temperature sensor

' @
Warma t t
SPIbody

Functioninspection . Remove airductandstartthe enqine.Insoect vacuummotorooeration the the whenthe engine coldandwarm. is

Intakemanifold

When cold Whenwarm

Closed Open

Temperature sensorpreset temperature: Approx. 40oC. COMPONENT PARTSINSPECTION Temperaturesensor inspection . Remove hoseto the vacuummotorand connect the the gauge. vacuum . Startthe engine pressure and checkthe negative when the temperature the temperature of sensor was cooled/ warmedby the drier. pressure Whenwarmedup No negative Whencooled pressure Negative created Vacuummotor inspection . Remove vacuum the hosefromthevacuummotor and mnnectvacuum handpump. . Usea handvacuumpumpto createnegative pressure -150mmHg). (approx. . Makesurethefreshairducton the change-over valve willclosewhenthe negative pressure applied is and it will openwhenthereis no negative pressure applied. 6.2 AIR CLEANERELEMENT INSPECTION Inspection . Remove clipsandthe nutsand remove aircleaner the the element. . Thereshouldbe no excessive or damagein the air dirt cleaner element. EN-51
Temperature sensor(whencold)

lntake manifold

A,.'nflow fiP- @''*' illL \v

To'nta[emanifoE! _IO vdcl.rum gauge

."-,",".'.Applynegative

Visual cnecK

INSPECTION FUELSYSTEM
RB25DE DE / CA18ENGINE / i

7 F U E L S Y S T E MI N S P E C T I O N
(RB25DE) EASYINSPECTION . Turn ignition to switch ONposition. the "Fuel . Select pump" the"Function mode. test" in
. Inspect pulsation holding fuelhosewithhand the by the
. F U E LP U M P. IS THEREA PULSAT]ON W E V E R Y3 S E C O N D S H E N
INt TUEL UI'tr J NtrLU '

OR CANYOU HEARTHE O O P E R A T I ON O I S E F T H E R FUEL UMP ELAY? P

. Holdthe fuelfilterand makesurethe hoseis hardand pulsation be feltwhenthe fuelpumpis operating. can

\a/
,@\

METER USINGTHE FUEL PRESSURE INSPECTION FUEL PRESSURE fuel pressure(RB25DE) Releasing OACTVETEST.O ' Revtheengine n "Active @ . Select"Fuelpumprelay"in ,,Aniivorcsr,, mode. test"mode RELAY OFF FUELPUI\,4P 'STOP'to . Press over the stoptheengine.Crank engine (POS) 950rpm CAS-RPM (lf the enginedoesnot startcrank3 - 4 two or threetimes. the timesafterremoving fuse). . Restart engine the and remove fuelpumpfuse. (Q\ the . Afterthe enginestops,crankthe engine4 - 5 1;ts5 1e r(EV the consume fuelin the pipe. (lf the enginedoesnotstart the crank4 - 5 timesafterremoving fuse). Caution: The batterymay becomeweak easily,use boostercableto connectto anotherbatteryif necessary. fuel pressure(CA18i/ RB20E) Releasing . Revtheengine. "Release pressure" "Operation . Select mooe. support" in fuel

ruelenessuRe I

P I WHILE DLING RESS 'START" STOPTHE TO FUELPUMPOPERATION, STOPS, AFTERENGINE O T C R A N K H EE N G I N E V E R TII\,4ES. TWOOR THREE

. Afterstarting engine, the remove fuelpumpfuse After the the enginestops,crankthe engineover2 - 3 timesto the consume fuelin the pipe. (lf the enginedoesnotstart the 3 - 4 timesafterremoving fuse). crank Caution: cable use booster weakeasily, may become The battery if battery necessary. to to connect another

E N. 5 2

FUELSYSTEM INSPECTION
R B 2 6 D E - - R B 2 O ED E / D E T / C A 1 B i / R B 2 s D E G I N E / EN

7 . ' I F U E L P R E S S U R EN S P E C T I O N I Releasing fuel pressure(RB2ODE DET/ RB26DETT) / . Afterstarting engine, the remove fuelpumpfuse.After the theengine stops, crank engine the over2 - 3 times to consume fuelin theoioe. the . lf the enginedoesnotstart,remove pumpfuseand the crank engine - 4 times consume fuelrnthe the 3 to the oioe. Caution: The battery may become weakeasily, usebooster so cables to connect to another it battery necessary. if Fuelpressuremeterinstallation (RB26DETT RB20E/ DE / DET/ CA18i/ RB2sDE) / . Connect fuelpressure the meterbetween fuelfilter the ano thefuelline. . Attach fuelpumpfuse. the Fuel pressureinspection . Startthe engineand checkif the fuelpressure at is standard value. . lf the enginedoesnotstart,checkfuelpressure after5 seconds whenthe ignition switchhas beenturnedON.

Fuelpressure measurement

Whenignition switchis ON (kg/cm,) During idling (kg/cm,)

Approx. 3.0
Approx.2.5

Approx.2.5 Approx.3.0
A p p r o x . 2 . 0 A p p r o x . 2 . 5 5 Approx. .0 1

ldling whenpressure regulator vacuum hoseis removed (kg/cmr)

Approx. 3.0

Approx.2.5 Approx.3.0 Approx. 1.0

cA18i

RB2ODE. DET

RB26DETT

ressre u

7-2 THERMO-WAX tNSPECT|ON (CA18i) . Inspect waxstroke the whenin following temperature. 25
Approx.25 80 Approx.30

EN-53

INSPECTION GAS CONTROL EVAPORATIVE

/ RB26DETT RB2OE DE / DET / CA18i/ RB25DEENGINE /

GAS CONTROLSYSTEMINSPECTION 8 EVAPORATIVE

chamber Throttle valve Purgecontrol

Checkvalve gas : Evaporative <F Purqeair Activecarbon fray Freshair Filter

Fueltank

8-,I PURGECONTROLVALVE INSPECTION CANISTER Inspection -400 . Usevacuumhandpumpto applyapproximately pressure negative engine) mmHgRB25DE mmHg(-100 pressure maintained. is andmakesurethevacuum . In thatcondition, checkthatsmallamountof aircan be path. vacuum fromthe manifold sucked FUEL TANK VACUUMRELEAFVALVE(RB2sDE) Inspection . Clean valvehousing. the . lf thefueltankvacuum youwill hear releaf valveisnormal, whenthe air is soundfromthe valvewithsmallresistance the suckedin through cap. . Replace cap ASSYif the valveis closedor no the is resistance felt.

EG1513 000 0

EN-54

BLOWBY GASREDUCTION DEVICE INSPECTION

R B 2 6 D E T TR B 2 iE D E D E Ti C A 1 8/i R B 2 s D E N G I N E E

BLOWBY GAS REDUCTION E V I C EI N S P E C T I O N D

biowby control valve

9-1 BLOWBY CONTROLVALVEINSPECTION (EXCLCA18i) Inspection . Checkthe blowby control valveflowpath.

A i r is blown A i r is drawn t n

Air passes
No air passes

(CA18i) Inspection . Remove aircleaner the rockercoverhosewhenthe '1 enginerev is approximately000 rpmand checkthat freshair is drawnin.

E\

PARTS ON-VEHICLE
RB26DETENGINE T

PARTS OF 1O REMOVALAND INSTALLATION ON-VEHICLE

AIR 1O-1INTERCOOLER DUCTASSEEMBLY
Front tufuocharger outlettube

,r--aolt 1.6

Intercooler IPoint4]

Resonato.lube

Bol1.6 2.1p] t -

I
E

ts-t
Replace after every disassembly

o-'--Nut (2)i.6 - 2.19

Additionalwork requ ired: . Undercover . Frontbumper

Cleaningair hoses & air duct [Point1] . Useairgun to removeany dustand rubbish before air ducts. eachair hosesand removing

Remove& installeach air hoses and tubes [Point2] Removal . Placealignment markon eachair hoseand tubesbefore removal. lnstallation . Align alignment and marks wheninstallation make the the sureto tighten clampsecurely.

EN-56

ON.VEHICLE PARTS
i32' DEiT ENGINE

[Point3]

Removeand installthe intercooler inlet hose

Removal . First remove resonator thetubeB before the and removinq hoseA. Installation . AttachhoseA, thenattachresonator the tubeB as a and single to install. unit Removeand installintercooler [Point4] Removal 1. Remove bumper the finisher thebumper and reinforcement. 2. Separate rntercooler andouflethoses. the inlet 3. Remove mounting andtwo nuts. Detach the bolt intercooler without scratching fins. the Caution: 1. An aluminium areusedandcanbe damaged fins easily. Do not placeobjects the intercooler allowtoolsor on or otherhardobjects contact fins. to the 2. Themainunit(tank, tube) fin cannot disassembled. be Installation . Installation operation the reverse the removal is of operation.Perform stepsin orderof 3, 2, 1. the Tightening torque (kg-m): 0.93- 1.2

..--*-t

t : i , Outlet hose "l Kq_m

E l,4ountinq bolt 0.93 1.2

Nrounting

lnlet hose 0 . 9 3- 1 . 2

Removeand installrecirculation hose [Point5] . Remove install recirculation and the hoseandtubeas shown in thefigureon right.

Installrecirculation hoseclamp [Point6] . Wheninstalling recirculation the hoseclap,makesureit willnotcontact bumper finisher.

7] Recirculation valveinspection [Point Unitinspection . Usehand pump apply vacuum to negative vacuum -150 of +/-20mmHg check recirculation diaphragm and that valve pressure maintained. lifts vacuum and is

Recirculation valve

Removeand installturbocharger outlet tube . Remove and install turbocharqer et tubeas shown the ou in thefigureon right.

[Point8]

PARTS ON-VEHICLE
ENGINE RB26DETT

ASSEMBLY ELEMENT 1O-2 AIR GLEANER

To rear turbocharger To front turbocharger

ACI
Air hose

I *n-'
Additionalwork required: . Remove outlethose turbocharger

OUCI

-s

Arr cleanercase

Air hose and air duct cleaning [Point1] . Usean air gunto blowoff any dirtand dustbefore element. the removing aircleaner Removeand installair cleanerelement [Point2] Removal outlethose. turbocharger 1. Remove

four bandclipsfromthe air cleaner.Liftair 2. Remove element. the coverand remove air cleaner cleaner lnstallation . lnstall reverse orderof removal. in [Point3] . Makesurethe aircleaner is element notdirtyor damaged. Periodic replacementinterval: Every 60,000km
= _ \-:= -Connector ,.' ll. Arr flow meter

),)\

[Point 4] for . Firstconnect airflowmeterconnector frontturbo the cover. the air cleaner andtheninstall charoer

EN-58

ON-VEHICLE PARTS
RB26DETENGINE T

1O-3 CONNECTORASSY (1) Collector ASSYremovaland installation

No.3 Throtlle charnber No 2 Throttle chamber Knockpin (6)

s;
-----

__-/0
/'/ N.o 1

1,,,ffi ;:t, Poinr (1 erJJ,i:*; sprlntI'i-, 2) ,ll;A,washer ""gH-= "{ y

.\
--a

,t1\9 \ur{r2, \,

--\3nno.t

t" - V7,i";::;*;el Hose qvl to"Tj,:ld' /R .-tt":" Io! ,

n"'"

o'n,e ,thutb"'

warer L""," *'"-ruW,fl*6pltr== ruDe r, ^,^,:."j:,-91^,^ i <?'- - i *_ :, :dR.

t$,5 ,,",K
Bort 0.64 O.r'
Fi.

F:l"i;r6,i""

eirtio-zrp)Bort' 4) ffi1.30-ouo
"^,,?" - " ,m

neptace after every d'sassembty

\-.4 Ks''

Additionalwork required: . Release pressure thefuellines[Point1] fuel in . Draincooling water[Point2] . Acceleration control wire[Point3] . Air inlethose . EGIharness connector, harness clamp . Allhoses

Releasefuel pressure [Point 1] . Starttheengine . Afterstarting engineremove fuelpumpfuseand the the waituntil engine the stops.Crank engine or three two times to consume remaining the fuelpipes. fuel in . lf thevehicle doesn't start,remove fuelpumpfuseand the crankthe engine fourto fivetimesto consume fuel remaining thefuelpipes. in Caution: The battery may becomeweakeasily, use booster cableto connect another to battery necessary. if

E N. 5 9

PARTS ON-VEHICLE
E R826DETT NGINE

Drainingthe coolingwater [Point2] . Makesureto draincooling fromthe watercompletely plug. the blockby removing drain cylinder Caution: doesnotspillon the fronttube. Makesurethe coolant Acceleratorwire adjustment [Point 3] . Loosenlocknutto provide slackfor the adequate pulloutercasein the direction the of wire accelerator and acceleralor. . Return locknut 1.0to 1.5turnsfromthe position the the (whenthereis no playin cable) drumstartsmoving throttle andtighten. Tighteningtorque (kg-m): 0'8 - 1.0 Removethrottle chamber links [Point 4] . Remove mounting by nutsindicated arrowmarksin the the linksfrom chamber threethrottle diagram.Separate side. collector . Remove harness sensorandthe fromthethrottle the valveswitch. throttle

Fuel PiPeremoval [Point5] . Remove by threeboltsindicated the arrowsand separate the fuelpipe. Air hose removal [Point 6] side. . Seoarate air hoseA, B and C fromthe collector the
Air hose

Booster vacuum removal [Point 7] vacuum . Remove clampboltand remove booster the the and it tube by separating fromthe collector the air chamber.

Removeand installair chamberbolts [Point8] Removal . Separate air chamber removing threebolts. by the lnstallation . lnsertboltB in air chamber bolthole,beforeperforming finalassemblY. torque (kg-m): 1 . 6- 2 . 1 Tightening EN-60

ON.VEHICLE PARTS
i 326DETT NGINE E

Removeand installcollectornut [Point9] Removal . Remove nutsin the reverse the orderof thefiqureon the right. Installation . Install nutsin theordershownin thefigureon right the uniformly two to threestages. in Tightening torque (kg-m): 1.6- 2.1

[Point 10] Removeand installair chamber Remove . Separate airhoses B, C, vacuum the A, hosesD, F and MC valveconnector remove airchamber. and the Installation . Position airchamber place, the in connect air hosesC, the D, A, vacuumhosesF.E. thenconnect AAC valve.

[Point11] Removeand installAACvalve Removal . Detach AAC valveby firstremoving the fourbolts. Caution: (1) MC valvecannot disassembled. be (2) gasketwitha newone. Replace Installation . Install gasketandtheMC valve. Tightening torque(kg-m) 0.64 0.85 [Point 12] AAC valve inspection . Measure MC valveresistance the

Resistance (20.C) O
(2)

Approx.9 10

Collector ASSYdisassembly and assembly

' (4)pl 0.64 O.B5 Bort

(2) Bort gl 0.64 0.85

aB g

- Acceleralion work unit Knockpin (2) Intaketemperature sensor

(w
/ \,
Collector [Point1]

20-3.0

EN

o l

PARTS ON-VEHICLE
E R826DETT NGINE

: Additionalwork required "Throttle . Collector valveswitch refer ASSYinstallation to adjustment valveswitch for systeminspection" thethrottle proceoures.

CollectorinsPection [Point1] in . Measure collector for surface distortion installation the up, (opposing directions, down,lefi' right' six directions and horizontally verticallY). 0.15 L i m i t( m m ) :

AND INSTALLATION REMOVAL CHAMBER THROTTLE 10.4 SIX IN-LINE

No. 3 Throttle No. 2 Throtfle chamber \ chamber lPoint1,

1. lPornt 2l

660-'
$ disassembly neptace afterevery

Additionalwork required: . CollectorASSY and installation removal . Canister hose Throttlechamberinspection [Point1] . Checkfor any cracksandthatsupplemental pathsare air notobstructed.
air Supplemental

chamber Installthrottle [Point2] . lnstall chambers. No. 1 to No.3 throttle Caution: the wheninstalling chamber. Do not makeany mistake
-t\ -

l Throttle

chamber No. 3 Throttle

EN-62

ON-VEHICLE PARTS
R 3 2 6, : T T E N G I N E f

10.5 SIX IN.LINE THROTTLE CHAMBER LINK ADJUSTMENT

A c c e i e r a l od r u m f u l r

,,,

df' ]

Detarl parta of

\'

Throltle chamber f ully \\ closed stopper Fsat r- I ()\-

<Y-\\1"-

.---_.. \ sx{$r-5-i i
Detailof partb

K:X\
/tr'

1] Install acceleratorwork unit [Point . Install tn-line six throttle chamber theaccelerator and work unit connect 1,2 and3 throttle and No. linkage.

Bolt(4) 0.64- 0.85

=-

6 in-linethrottlechamberlink adjustment [Point2] 1. Loosen nutsA and B for eachthrottle link.Turnthe centreadjustment eachthrottle anticlockwise of link to shorten linkage. the

2. Shorten eachthrottle untilacceleration link drumcontacts fullyclosed stopper the accelerator on workunitside.

3. Shorten eachthrottle link,so thethrottle chamber lever openswiderthanfullyclosed stopper the throttle on chamber side. Caution: ( 1 ) D o n o tl o c k t h e u t A a n dB . n (2) Thethrottle chamber leveropening angleshoutd be adeouate.

EN-63

PARTS ON.VEHICLE
RB26DETENGINE T

the feelergaugebetvveen 4. Insert 1 mm thickness on drumandfullyclosedstopper the accelerator drum work unitside. Securethe accelerator accelerator so it does not move.
Fully closed

,'-!t)
'trf

gaugeinserted, the centre turn 5. Withthickness the to link In adjustment No.2 throttle clockwise lengthen the levercontacts chamber link throttle untilthethrottle side chamber on fullyclosedstopper the throttle

You link the 6. Whenturning throttle withyourfingers. will contacts stopper whenthefullyclosed feelresistance link the lever.Shorten throttle to the chamber thethrottle is pointjust beforethis resistance felt

7. Carryout the steps4, 5, and 6 to adjustthe No. 3 and 1 links. throttle

three the 8. Tighten locknutA and B afterthe adjusting No aretightened, 1 - 3 links.Afterthe nuts throttle of linksmustturnwiththe samedegree throttle smoothness. Caution: link Makesurethe centreadjustment willnotrotatewhenthe locknutis tightened. gaugefromfullyclosedstopper the 9. Remove thickness workunitside. on the accelerator Caution: nut. stopper fullyclosed Do notadjust

L-

ca
1

throttle openandclosethe six in-line 10. Completely and repeatedly makesurethateachthrottle chambers movessmoothly. chamber

EN-64

ON-VEHICLE PARTS
R B 2 6 D E TE N G I N E T

10.6 INTAKE MANIFOLD ASSY (1) IntakemanifoldASSYremovaland installation

B o l t( 5 ) 1 . 6- 2 . 1

Intakemanrfold gasket

1lp) lPornt

Air p,us z1/ E dra,n leornt

,fryfj

ii\ \s4!**^^'Yt-:.
B o l (t 4 )1 6 - 2 1

1]pJ lPoint
B o l t( 2 )1 . 6-

Intake manifold ASSY

llgl tPoint
afterevery disassembly E Repiace
kg- m

Additionalwork required: . Collector ASSYremoval and installation . Throttle chamber removal and installation . ECCSharness connector all hoses and . Wateroutlethose . Blowbyhose [Point1] Remove& installIntakemanifoldASSY bolts and nuts

Removal . Removal the reverse is ordershownin thefiqureon the rioht. Installation . Install boltsandthenutsin theordershownin thefigure the on the right.Tighten gradual in stepsto uniform tightness.

'I

'10 6

2 4 2 are nuts

30:4

60:5
6 5: 2

1 ,4 , 1 0 ,1 2 ,1 4 7,9

Air drain plug [Point2] . Carryoutthe operation whenengineis cool. Caution: Do notremove airdrainplugwhentheengine hot. the is . Whentopping thecoolant, up always remove airdrain the plugto allow within engine escape air (this prevents the to overheating). Tightening torque (kg-m): 0.7- 0.8 EN-65

PARTS ON-VEHICLE
RB26DETENGINE T

& (21 Intakemanifolddisassembly assembly

gl (5) Bolt 0.6a o.8a

Balancetube lPoint6]

( B o t t 2 ) 1 . 6- 2 . 1

6l IPoint E o-rins
Water temperature

2] ASSY[Point FueltubeIntector

O-ring

a;
-'l lntake ml

;:J;id'senffi2o-30
outlet 5l

rrp ) e o r t t z. ez . r
Air regLrlator Fi L-l| Eort(2) 0.64 - o. gasket Liquid Replace after every disassembly kg-m

'.\

FF=".;," "g ,-p Ffii;il Screw(2) 0.23- 0.91---'

--r.*^

\^ ,on',u - r.,

{s

rog-----5 "j,lI F.",, ptec, ; r

_Waler bypassconne^to'

+::;;9,s

Intakemanifoldinspection [Point'l] . Measure intakemanifold in for surface distortions six the up, directions: down,right' (at directions opposite different locations. in andvertically) several left,horizontally 0.15 L i m i t( m m ) :

[Point2] FueltubeASSY is . Replace regulator withnewoneswhenpressure O-ring and installed. removed Caution: the Caremustbe takennotto scratch fueltubeo-ringsurface regulator. the pressure wheninstalling [Point 3] O-ring (for fuel injector pressure regulator) when handling Precautions . NeverreuseO-rings. or . CoattheO-ring oil withengine (10W-30or equivalent) but L45 oil silicon (NUCsilicon or equivalent), do notapply the as solvent thismay remove oilcoating. . AvoidusingdirtyO-rings and do not allowdirt,dustor or to objects adhereto O-rings otherequipment foreign surfaces. E N. 6 6

q4,4u",F.]"

x>q)

ON-VEHICLE PARTS
r 3 2 D E T TE N GN E

Do notdecenter rotatethe fuelinlectors the or and pressure regulator wheninserting themintothefueltube. Do notstoreO-rings location in subject ozone,high to temperature in thedirect or sunlight.

Installand removewater bypass connector Removaland cleaning . Remove eightwaterbypass connector bolts. lnsertdriver in clearance between intakemanifold waterbypass and connector moveit lightly remove and to connector. . Usea scraper remove gasket. and liquid Caution: Also removeliquidgasketin the grooves. . Wipeoff mounting surface withwhitegasoline etc. lnstallation . Cutthenozzle gasket endof liquid (KP510 00150) inthe position shownin the figure. Usea tubepresser apply to gasket.Install bypass connector within20 minutes of gasket. applying liquid . Applyliquid gasket (KP10 00510) waterbypass to connector surfaces fourlocations, in theninstall water bypass connector within20 minutes. Caution: (1) Applyliquid gasket coating mm wide. 3.0 (2) Coaton theinside installation of holes shown. as Tightening torque (kg-m): 1.6-2.1

[Point4]

Tube presser WS3993

Water outlet elbow [Point 5] Removaland cleaning . Remove wateroutletelbowboltand insertscrew two driverhandle shown. Moveit up anddownto remove as theelbow. . Remove gasketfrom intakemanifold water liquid and outletelbowby usinga scraper. Caution: Alsoremove gasket thegrooves. liquid in . Wipeoff mounting surface withwhitegasoline etc. Installation . Cutthenozzle gasket endof liquid (KP510 00'150) inthe position shownin thefigure.Usea tubepresser apply to thegasket. . Applythe liquid gasket (KP1 00510) intake 0 to manifold surfaces fourlocations. in theninstallwithin20 minutes Caution: (1) Applythe liquid gasket coating mm wrde 3.0 Tightening torque (kg-m): 1.6- 2.1 E N. 6 7

Waleroullet

PARTS ON-VEHICLE
E R826DETT NGINE

[Point 6] Remove and install balancetube O-ring Removal . Checkthe sizeof the O-ring tube. balance whenremoving lnstallation . Alwaysreplace O-ring wtthnewoneswheninstalling the tube. balance . Therearethreedifferent O-ringsizes. Makesureto install size. the correct

3 4

1 Cylinder, 2,3, 4, 5, 6 1 Cylinder , 2, 5. 6 3, Cyinder 4

. Be careful to pinchthe O-rings duringinstallation. not ASSY TURBOCHARGER 1O-7 ASSYremoval& installation (1) Turbocharger
FRONTSIDE REARSIDE

*"ry:-/-----ll;at -'-j---,.-_ tf:"11,% --,,-

bl cylinderock 1-,

\g"*9t-*l

!nf""";n",, ,* , ,\F-, s ,",,,110,0-'', *".n",E F@.-!:1;, ,,?*lT,YF! ts-t

$ Reptaceafter every disassembly

' y's,e -H$$,i:x,lr,;;:|tk#ffii; I#,2$;;?f #P/'' l^ Y'^,.;}^,tfy. t^... o" . \"'n"i"""np: Oilpi

s'4q"*;';1+ ffis{*e :*,,J4i ?iF.-:',',"^* _

C5p-perwashe{ r-r / --'-

ttose

6q1q1z1o.M-ls -*

1.+n"'1""

Sffi\ffi;'-" vJP,""*1, '---ff$B"*r"*" nipo'\=-^8

g:i;r:h /

iils

".d'Hry>-;;;';;;";--,"'"if:,"*:
EN-68

ON-VEHICLE PARTS
R 3 2 6 E T TE N G I N E D

Additional work required: . Remove and install undermver . Draincooling water . Separate exhaust fronttube . Remove gas and install exhaust sensor connector . Intercooler inlettubeand hose air . Air inlet hose Note: Alsoremovecooling waterfromenginedrainplug. (lf wateris onlydrained fromtheradiator draincock, waterinside the cvlinder block notbe will drained completely).

(2)

Frontturbocharger ASSYremoval installation &

Removal sequence (1) Loosen flarenutsoftubesA and B. the (2) Remove boltsanddetach tubeA. (3) Loosen flarenutsoftubesC and D on the turbosioe. (4\ Remove hoseB and bolts. (5) Remove boltsanddetachtubeE. (6) Remove threebolts, coverandgroundcable. (7) Remove boltsanddetachtubeH. Makesure two thatboltmounted uppersideis shorter on thanlower side. (8) Remove threebolts, coverandground cable.

(9) (10)

Remove return oil hose. Remove threeboltsanddetachbracket.

(11) Remove turbocharger four nuts. (12) Lowerturbochargercarefully. (13) Remove exhaust six manifold nuts. (14) Pullthe exhaust manifold direction andthenrarse in 1 it in direction to avoidturbocharger 2 stud. (15) Remove exhaust manifold. (16) Pulloutturbocharger.

h.

-'

-:

Installation sequence . Installation the reverse the removal is of sequence. . Placeturbocharger bottom the engine in of compartment before installing exhaust the manifold.

E N- 6 9

PARTS ON-VEHICLE
E R826DETT NGINE

(3) Rear turbochargerASSY removal & installation Additionalwork required: . Front and installation ASSYremoval turbocharger Removalsequence manifold and (1) frontturbocharger theexhaust Remove ASSY bolt,and two Remove nutsand the clipsecuring Q\ the seoarate tubeA. cover. (3) manifold threeboltsanddetachexhaust Remove (4) RemoveeyeboltB, C and E. tube D fromcylinder boltsand separate tvvo (5) Remove blockside. (6) threeboltsanddetachbracket. Remove 11 afterthisstepis sameas number to 16 of The sequence and removal installation. thefrontturbocharger

sequence Installation . Installation reverse removal sequence. of is . Loosen watertubeflarenut beforeinstalling eyeboltB. the

(4)

& ASSYdisassembly assembly Turbocharger

FRONTSIDE

Air inlettube

EGasket

tr
\
(2)g Bolt 1.6 2.1 I E Gasket _ Bolt(2)1",4
0.64- 0851

038-05' ?:J'lt'F 3*'3'.# gev"oortzo-V

WasherE

*BeW"/.fiM Y'1"!*q*F:i:i /'t,"1,.,"

xg-m $ neptaceaftereverydtsassemblY

EN-70

ON.VEHICLE PARTS
R3 2 6 D E T T N G I N E E

Additionalwork required: . Turbocharger ASSYremoval installation and Watertube inspection [Point1] . Aftercleaning waterinletandoutlet the tubeswithradiator cleaner, blowwithcompressed and checkfor rustor air anyclogging.

Oil feed tube inspection [Point2] . Aftercleaning oil feedtubewithengine the conditioner, blowwithcompressed and checkfor any clogging. air

Engine

3] Remove install and lockplate [Point . Spread lockplate pawls a screwdriver loosen the with and nuts. . Position plates turbocharger lock and mounting nuts. After tightening nuts, the pawls bend lockplate onto the
nuIS.

Eyeboltdetermination [Point 4] 'J' . Oilfeed (turbocharger side)eye boltsare stamped

lq.) L *
Crack burn Inspectron Actuator 7] [Point

(5)

Turbocharger inspection unit

Crack inspection Coolrng waterinlellPorntB] gas leak Exhaust inspection location

SwingvalveIPoint3j

-.----

Compressorwheel [Point5]

Turbine rotor{Point1,2,4l rq:i,:::lOil leak inspecttontocation

R o t o .s h a l t P on t 6 . 8 l

E N. 7 1

PARTS ON.VEHICLE
E R826DETT NGINE

Rotor shaft inspection [Point1] . Makesurethe rotorshaftrotates withno smoothly whenturnedby finger. or heaviness dragging
shaft

:"j'^'::..
Turbinerotor inspection lPoint2] . Oilmust adhere surface. to not . There nocarbon accumulation. is . Thevanes theturbine must bebent. not of . There nointerference turbine housing. with is

or 7\ll No oenoing
r V -'-'!t-''-. v No nterietence wlh the housing

Swing valve insPection [Point3] . Remove rod actuator pin and makesurethe swingvalve or deformation cracks. without movessmoothly . Makesurethereare no misaligned seatingsurfacein housing. turbine

Rotor shaft play inspection lPoint 4l . Setthedialgaugeand measure playandthrust clearance rotor . Insert dialgaugein oil returnholeand measure the shaftplay. Rotorshaftplay(mm) (mm) clearance Thrust 0.056 0.127 0.013 0.096

Compressorwheel inspection [Point5] . Oil mustnotadhere suction inlet. to houstng. . Theremustbe no interference compressor with . Wheelmustnotbe bentor damaged.

\@

No oil adhere. or No bending other d am a g e .

Rotor shaft inspection [Point 6l . Theremustbe no carbon sludgeaccumulation.

t No carbon e s luO0

EN.72

ON-VEHICLE PARTS
RB26DETENGINE T

[Point7] Swing valvecontrollerinspection . Connect swingvalvecontroller the rubber hoseon the actuator side. . Checkthe swingvalvecontroller whenthe actuator is rod installed removed. or . Checkto see if the controller willoperates rod whenthe compressed pressure air (approx. - 0.8 kg / cmr)is 0.7 applied.Stopblowing as soonas rod operates. air

[Point8] Oil & coolingwater inletand outlet cleaning . Useengineconditioner cleanthe oilfeedand return to passages. . Useradiator cleaner cleancoolino to waterfeedand return Dassaoes.

. Clean airgun. with

. Cleanthe compressor wheel,turbine wheel,compressor =housrng turbine and housing samemethods. with

EN-73

PARTS ON-VEHICLE
R B 2 6 D E TE N G I N E T

(6)

failurediagnosis(Oil leaks,smoke(whiteor blue smoke),lack Turbocharger of power, poor acceleration,abnormal noise)

Pointsto be checkedbeforediagnosis: on the oil 1. Theengine levelmustbe between MINandthe MAXmarks theoillevelgauge. oil engine willflowintointake the MAXline, is oil (Whenihe engine level higherthan may passandtheturbocharger be gas recirculation the blowby ductthrough to determined be malfunctioning). if to 2. Checkwithcustomer deiermine oil is cooledwhenidlingafterdriving' the replace in chartis detected a unitinspection, in lf any malfunction thefollowing ASSY turbocharger

sr;{tl ..r .::r . ,.

Oil on rotors Carbon has accumulated Turbinerotor Rotor scrapes agair6t the housing Turbimevanes are bent or folded inletis dirtywithoil Suction wheel Compressor Rotor scrapes agairEt the housirE Turbinevanes are bent or folded There is resisianceor scraping when rotatedby firEer Turbineand compressor Rotorshat play irEPection Rotation fingeris not Possible by Corsiderable shakingbetween rotor shafl and turbo ASSY Carbon sludgehas accumulated oil Look throLEh hole withPenligm) in waste oil f|ob (inspect intenor The valvedoes not mo\r'e when pressureis smoothly (LlSually opens applied gradually. at pressuregreaterthan 0.6 - 0.7 kg/cm')
ZI
l \

z\
@

l\

z__l

o
@

o
!9'

o
C
(/

A A

z__.\
l \

o
ll

A
@

Swing valveoperation (usearr gunor atr PumP)

@ Highlypossible

O Possible

possible Slightly

E N. 7 4

ON-VEHICLE PARTS
i 3 . al : - i ENGTNE

1O-8 EXHAUST MANIFOLD ASSY REMOVAL INSPECTION &

FRONTSIDE Exhaustmanifold cover REARSIDE Exhaust manifoid

Bo (319 r

0 3 8- 0 . 5 1 l P o r n4 l t gasket Exhaustmanifold

Bolt(3)p 0.38 0.5'1 4l lPoint

\ a

I
N u t( 6 )1 . 8- 2 . 4 21pJ lPoint
l-/ kq-m $

W
lPoint

,u,,,.Iii"-r oQ4,*, 2l 3l
lPornt PJ

Replace after every disassembly

Additional workrequired: . Turbocharger removal installation and . Gasleak inspection 1] IPoint

1] Gasleakinspection [Point . Afierremoving exhaust manifold, make sure there are notraces gasleaks of fromanyparts. . After installation, theengine check any the crank and for
oas teaKS.

Remove and installexhaustmanifoldnuts [Point2] Removal . Removal the reverse installation is of seouence showntn the diagram the right. on Installation . Theinstallation sequence shownin thediagram right. is on Tightening torque (kg-m): 1.8-2.4

; REARSIDE

Exhaustmanifoldinspection [Point3] . Measure exhaust the manifold surface distortions for in sixseparate (opposite directions directions, down.left, up, right, horizontally vertically) a number locations. and in of Limit(mm): 0.3

EN-75

PARTS ON-VEHICLE
RB26DETENGINE T

Install exhaust manifold cover [Point 4] . Attachthe exhaust coverboltsin thefollowing manifold (bothfront& rear) sequence. by indicated A. boltsfor positions tighten 1 . Temporarily positions B. indicated 2 . Tightenboltsin the torque. tightening boltsin holesA to specified 3 . Tighten - 0.51 Tighteningtorque (kg-m): 0.38

FRONTSIDE A
:

REARSIDE B

fi-'-_--------, .\

\'--<i

.r__r1 )t/
: B

10-9

SPARKPLUGS p) eott o.oa o. 1a; transistor O f n a m e nb o l t( 2 )0 . 2 3- 0 . 3 1 9 t Screw(3)

bolt Ornament (B) 0.23 0.319 ornament

\,,.#

)r-

'w:
I

lgntion aor bracket -i '. :eo

*d ='v

p 5CarF. Ug

l g n r t r o c o t l harness n

le/ Kg_m

Additionalwork required: . Remove install inletPiPe air and . Remove hose blowbY and install Removeand installignitioncoil bracket [Point1] Removal coil . Holdthecoilbodywhenremoving ignition bracket. the Caution: it whenremoving Do notholdthe coilconnector lnstallation when . Makesureto attach ignition harness coil the head to coil the installing ignition bracket the cylinder SParkPlug maintenance [Point2] as . Gapinspection adjustment not necessary a is and platinum is used. tip . Replace plugevery'100,000 km. the clean . Whenusinga compressed sparkplugcleaner, air pressure 6 kg/cm2for no more of the plugsat maximum than20 seconds. EN.76
\Bolt0.23 0.31

Seatingmetal

Platinum\tip \

JLT

fFt

ON.VEHICLE PARTS
R B 2 6 D E TE N G I N E T

10.10

ROCKER COVERREMOVAL INSTALLATION &

Rockercoverscrew (left& right10 each)

Filler cap O-r'ng--,@

-a

Grommet

Rocker cover Rocker cover gasket 1|/

3l lPoint

s3;Tl":":.1'

'/a.tt

.A

,.'

orlamenl

Rocker

Rocker gasket cover 3l IPoint

Additionalwork required: . Remove install inlet pipe and air . Remove and install blowbv hose

Removeand install rocker cover screw [Point 1] Removal . Remove screws reverse the in sequence shownin the figureon the right. Installation . Perform installation thesequence in shownin thefigure on theright.

Rocker cover installationsurface inspection . Checkthatno oil,dirtor foreign material adheres the to cylinder headinstallation surface. [Point2]

lnstall rocker cover gasket [Point 3] . Makesurethe rockercovergasketis positioned securely groove in pinching protrusion. without twisting, or

EN-77

PARTS ON-VEHICLE
RB26DETENGINE T

10-11

TIMINGBELT REMOVAL& INSTALLATION

Urommer lpoint / 4]
^ T t m r n gb e l l c o v e r L o o e r '

c r a n k -\ s r e s e n s { \ , - _ * \ l n \ 2]
[Point

(2),,,J,,_ elBo,t J --ffi<l;{:gi' :::'^ ,,1 _=-.:;.-"^.,, =-ffi|"*\-,Fiql

_liirQ@,"6;{ryt \h\'10,
d"^^ :.

"':]:;:,N+ t?* q ;,,,,;['t'l \^&\f,ffi*;,

\ [::"1:N
v

*ffi'Pffi
I \Al,

l;i,""?l' \ fi\f , - x - . . )

_#

5----J

C o n i c aw a s h e r l

"rr::Jil';'"":;"''' hW\$, [*,"1J;1\::;q $

\tr (towerr 4] ort I r'mrn9 cover lpornt

\3\J

\ Y-

\,',,i,nno",,p,aterPo,nt.r

, . i , . -oil It Engine

I g o t t , 3 to . : - o s

$ neplace after every disassembly

Additional work required: . Draincooling water . Remove and install . Undercover . Radiator, shroud fan . Cooling fan . Supplemental belts . WaterpumPPulleY . Sparkplugs position 1] . CheckNo. '1cylinder T.D.C compression [Point . Install ringgearstopper[Point3]

(top dead enter)inspection [Point1] No. 1 cylinderpressureT.D.C . Aligncrankpulley timingmarkand beltcovertiming is At (0o indicator position). thistime,No. 1 cylinder in is position whenthecamshaft located T.D.C compression situations. in as described the following

Timing indicator

,r 7\

-<-!tr

EN-78

ON-VEHICLE PARTS
R3 : ' - - ) = - - E N G I N E

No. 1 cylinder at compression deadcentre is top (T.D.C) whenbothintake theexhaust and sidecamsdo not movethevalvelifters.

Remove lockercoveroil fillercap fromintakeside the and checkthatfrontendof the camshaft facesintake side.

Intakeside

Installcrank anglesensor [Point2] . Apply grease driveunit(spline) chassis to during installation. . Thereis a flange inside driveunitspline thespline the so position. hasonlyoneinsertion Check alignment the visually before assembly. . Checkthatthe crankanglesensorcan be easilyinserted in beltcoverholesandsensormoveslightly rightand to left,thentighten bolts. the . Whenthesensor doesn'tmovelightly, loosenbeltcover bolts position to whenthecrankangle sensor wasinserted. Movethebeltcoverlightly honzontally vertically align and to it so the beltcoverholesand the camshaft centreare aligned.Thentighten boltsso the crankanglesensor the moves lightly.

[Point3] Removal

Remove& installcrankpulleyand the bolt

. Remove starter the motorand attach rinooear the stopper.

. Usea pulley puller (steering wheelpuller) remove to crank '1.0 pulley (bolt size:MGx length below headapprox. 5 0m m ) .

EN-79

PARTS ON-VEHICLE
RS26DETENGlNE T

lnstallation . Position washerfor the crankpulleyboltsso the the sideand the not surface markedR contacts crankpulley thenassemble. . Applyengineoil to thethreads the crankpulleybolts. of Tighteningtorque (kg-m): 45.5- 47.5 Remove& installtiming belt cover [Point4 ] Removal . The timingbeltcoveris separated upperand lower into the remove parts.Aftercrankanglesensoris removed, timingbeltcoverin the orderof upperandthenlower. lnstallation procedures. . lnstallation in reverse of sequence removal is Caution: the or Caremustbe takennotto scratch damage driedliquid the and packing whenremoving installing timingbeltcover. (kg-m): 0.3- 0.5 Tighteningtorque

Remove& installbell tensionernuts [Point5] . Secure tensioner hexagonal when wrench with the nuts. installing belttensioner the removingand Caution: studwhendisassembly Do not looseninserted Tighteningtorque (kg'm): 4.4- 5.9

Installconicalwasher [Point6] . Payattention installation of direction the conical to washers.The washershouldbe setwithfacewith pulleyside sidefacingthe tensioner chamfered

spring tensioner Install 7] [Point pulley . Assemble tesioner to spring thebelttensioner the in asshown thefigure. with . Thetensioner together the must assembled be spring pulley thecylinder block. in belttensioner

. Hookthetensionerspring theupperside ofthetensioner on pulley free. is studwhenthetensioner spring

EN-BO

ON.VEHICLE PARTS
a i . E DE - T E N G I N E

Tensioner spring specifications

Freeangb (-)
1 . 8m m A p p r o x . 2 0 " A p p r o x1 6 3 " . Yellow-green

puley ,Whenset

Installcranktiming pulley& ptate [Point8] . Caremustbe takenof the rearandfrontpositioning when installing timing plate, crank belt pulley the the timing and plate. timingpulley

Timingbelt alignmentmarkverification and installation. . Painta markon the beltthatindicates rotation direction if painton the upperbeltis unclear whendisassembly. . Position alignment the markson the intake andthe exhaust cam pulleys withthe respective cover belt alignment marks.(No.1 cylinder at T.D.C) is

[Point9]

Cam

, . r am ( r nQa K e )

,;i'/5 . Position alignment the pulley markon thecranktiming with therespective pumphousing oil alignment marks.At this mrng timethe groovemustbe straight (no.1 cylinder at up is T.D.C). . Movethe belttensioner clockwise - 80 degreeangre, 70 and secureit temporarily the belttensioner with nut. . Install beltby aligning timingbeltandthe pulley the the marks.Alignthe number ridges exhaust of of cam pulley alignment markandthecrank pulley (inner) alignment mark as shownin the figureon right. . Afterloosening nutsandadjusting belttension, the the secure tensioner the hexagonal the with wrenchso it will notrotate together tighten nut. and the Caution. (1) Makesurethetimingbeltengages correctly withthe pulley anddoesnotfloatwhenassembling the timing belt. (2) Replace possible belts whenever whendisassembly is performed.

EN-81

PARTS ON.VEHICLE
E RB26DETT NGINE

[Point10] Timing belt tensionadjustment . Remove sparkplugandalignthetimingbeltalignment the belt timing on to each marks andinstall markandthepulley pulley. is wrench . Loosen tensioner nut securing so the belttension the sPring. by applied thetensioner . In thiscondition, more rotate crankpulleyclockwise the andstopslowly the thantwoturnsto check beltmovement point. T.D.C compression at No. 1 cylinder . Insertthe hole. Holdthe wrenchin hexagonal hexagonal doesnot move,and the tensioner by tensioner handso tightening nut securing to specified the tighten tensioner IOrque. Tighteningtorque (kg-m): 4.4- 5.9 . Theinitial be should on tension thebeltin thiscondition 20 approximately kg.

lPoint 11] Installidler & tensionerpulley . Do not looseninserted lf studswhendisassembly. studs solution studwithlocktite coatinserted are loosened, (JapanLocktite or equivalent. KK)

[Point12] TimingbeltinsPection at . Replace are belt timing if anyproblems indicated theinspection.

Toothmissing Crackedtooth
Cracks on rear side

Camshaft lock Crank sensorlock Tensionerlock E ngine overheat with belt cover etc. lnterference

Wear and cracks on theside

Worn teeth

Beltmisalignment Belt platemalfunction

in Slidingmotionresistance crank sensor and the camshaft Oil seal malfunction Water leaks in water PumP

Oil or water adhesion

Caution: Do nottwistor bendthe timingbelt . Makesurethereis no oilfilmorwateron thebelt. EN-82

ON-VEHICLE PARTS
-=:.]:-T ENGINE

10-12

CYLINDER HEAOASSY

(1) lnstall& removecylinderheadASSY

C,rnder headbol lvl12Y1l (14) 5

Cylinder headbolt(M6x'1 @ .0) f,,' II ll \ SpringwasherH H \cr Washer'--?

0 92- i.?lpoinr 2]91

\fr

(3) Loosen boltscompletely o_-(4)Tighten 3 kg-nr to ( 5 )A n g l e r e n cB 5 ' - 9 0 ' w h *,"nch 11+f 05 ,.t:rlr"

rl l?ii:"1"..*.". (2)Tlghten 11kg-m to

Cylinder headbolt(M6x1.0)

o^- 12 [Point 2]p) v-->pnng wasner

headASSY

0.92 1.2 2]F: lPoint " R/' c

{r------J

Cylinder headbolt(1,46x'1 .0)

Springwasher

I
$

is-t

Cam pulley [Point3]

69

Cylinder headgasket[Point2]

Replaceafter everydisassembly

Additionalwork required: . Drainand refillcooling water[Point'1] . Remove and install; . Collector . Throttle chamber . Intake manifold . Turbocharger, exhaust manifold . Timing belt . Rockercover . Sparkplugs . lnstallNo. 1 cylinder compression T.D.Cposition [Point3] Drain& refillcoolingwater [Point1] Removal . Remove cooling watercompletely fromthe cylinder block plug. drain Caution: . Makesurecooling waterwill enterexhaust not fronttube. Refill . Referto "Cooling waterfillingprocedures" details. for

-5-:!9r,"#
=:4 ,;\l v

.l o1 . - , ---.-^tn
I

I'

rl) i ,J"1 O-i

i ^i-l--'' .-i@!Y Plr

EN-83

O\. . :''CLE PARTS

E RB26DETT NGINE

Removeand installcylinderheadbolts lPoint 2] Removal . Remove boltsin reverse on to sequence thefigures the right. lnstallation . Install boltsin sequence shownin thefigureon right. the . The cylinder by (M12xl .5)aretorqued two-step 11 7 3 headbolt the method.Tighten boltsin two steps. 5 1 - 14 M12x1 (1) Tighten 3 kg-m. to (2) Tightened 11kg-m. to (3) Loosenboltscompletely kg-m. 0 E ".1 (4) Tighten 3 kg-m. to (5) Turnbolts85 - 90oclockwise whenanglewrenchis :i useo. - 11.5 kg-mwhentorquewrench boltsto 10.5 Tighten is used. Caution: F to Whenanglewrenchis notused,neverattempt anglevisually. the approximate tightening . Takecarenotto hitor scratch gasket seatandthe bore the gasketis installed. grommet whenthe . Cleanthe cylinder andthe cylinder headlowersurface to blockuppersurface removeallwater,oil and foreign air Usecompressed gun is whengasket installed. ob.iects to blowoutthe boreholes

1 5 9 14 1 5- 1 7 M 6 x 1 . 0

:t

."f
:t

[Point3]

T.D'G No. 1 cylindercompression verification . Before block, headASSYto cylinder the installing cylinder positioned at pulley mustbe andthe cam the crankpulley T.D.Cposition compression the No. 1 cylinder . Alignthecrankpulley belt markandthetiming cover timing (0" timingindicator Position).

T i m i n gi n :^----/-dq

. Align intake theexhaust pulley mark alignment cam and the marks. alignment belt to respective cover

EN-84

ON-VEHICLE PARTS
R3 2 6 D E . i T N G I N E E

(2)

CylinderheadASSYdisassembly assembly &

va ve spflngTetarner

valve lpoint riner 14]--(>ShimlPornt 6l'Valve collet[P; nl 181 g Nut0.92- 1.2lpo]nt5r -

-)"'d

:9'": :HX':Jit
\

17 1s'20) '

-, '@d^t

, vdlveorlseallpoint231 - valveguide[Pornt 2a] -/ ^valveseat lPoint 25] valve[Poinl21,22] -- Exhaust

w".n", - i 'P -J$ prare aarre - '2 = - 2 pJeorro.s - ,.-D washer

Springwasher-, \

g & q-_

)? 3=-r-

v=\

exnausr {Po'nt 221 valve 21 o,o^ @ ( E - - o "tn O

Bolr0 . s 2 . 2 r p o i 5] B o r r92 - - 2 lPointn t 5 r r

g/-,Y"tJ"tL"n"o oracket 5] lpoint

!-_
. -

q.r !

^ -":1
-*gp

-3t*oruJf,lJi!P!*0rpoinr13, 15,21,24,251 ";@fl<.'

camshaft,exhaust s.oe)

ro rp"i"iag 'i-,zr _ q(ar

*,;:feffi."jffi4R-g*;. P
"_rJ

Ilk q *^@-"ffi,x
"

ffi4pF

da5;tl _ P;i';.] O"*\ rei'",,si

F<\

fts,

:;::" "";"*:i;r;$ ."I?IT9Y\W1 "Q\2.1-2.7 -_, 12)2.1 *e ,,F.\ _(N

**

pr"rJ1e"'i u""tplare 3]--. l \ back [Point el;t

atb-....''

'".. ''

,"e-, \: *\--:

@.c"..*n {Point uampullev campurrev rl 2l lHornl

t,.o*."ur TrEn ' tpoint

";; t - '*

'ao'r,os:- r, ._-S-.- --'eo'tt - so.gZ r.z

to

gasket Liqurd
kg-m Engineoil

e-

-- *:-

crank angte sensor bracket 1l JPornt iir, z., _z.rp;

&ilJ,Y,':"rt":i1T'-1.erPo,nr2rg

Replace afterevery disassembly

Additionalwork requ ired: . Remove and install cylinder headASSY

Crankanglesensor

Instalcrank anglesensorbracket [Point1] . The crankanglesensorbracket positioned is ontothe cylinder headby usingknowpins.Alignthe positions correctly wheninstalling crankanglesensor. the Grankangle sensorbracketbolt tighteningtorque (kg-m): 2.1- 2.7

Solt(2) 2.1 - 2.7

\",i

(2) Bolt 2.1- 2.7

Remove& installcam pulley [Point2] Removal . Fixpulley witha pulley holderor sprocket wrenchand remove cam pulley bolts. Pulleyholder: KV10109900or KV10109300, sT31520000, sT31530000 EN-85

Boll (4) 1.4- 1 Pu ey holder

...\-=<:.7

PARTS ON-VEHICLE
RB26DETENGINE T

lnstallation . Alignthecampulley pin knock knock holeandthecamshaft pinto install cam pulleY. . Usepulleyholder sprocket cam wrenchto tighten or pulley bolt. 'l pulleybolt tighteningtorque (kg-m): 1.4- .9 Cam . To removeand install cam pulleybolts.usethe proper part the toolsto secure hexagonal in frontof camshaft.

[Point3]

Remove& installtiming belt cover back Plate

Removal . Removebackplateboltand detachbackplate. lnstallation . Assemble tubewithbackplateandthen tnstal canister backolate. torque(kg-m):MO0.64- 0.85 Backplatebolt tightening M 8 1 . 6- 2 . 1

Camshaftend play inspection [Point4] . Setthe dialgaugein frontof camshaft shownin the as whenthe run-out width Readthedialgauge diagram. movesin frontor reardirection. camshaft Standardvalue (mm): 0.030- 0.080

Remove& install cam bracket [Point 5] Removal (Exhaust and intake camshaft) . Placemarksto indicate bracketposition and its the the beforeremoving cam bracket direction in . Remove themgradually boltsby loosening cam bracket shownin thefigure. sequence in reverse stages several lnstallation . Align crankpulley belt and indicator thetiming timing the '1cylinder at is (0") covertimingindicator so No. is position.(Thisoperation not T.D.C compression as headis removed singleunit). whencylinder necessary . Turnthe camshaft No. '1cylinder at compression is so is is T.D.Cposition.(Operation easierif the camshaft T turned60obeforeor afterNo. 1 cylinder D.Cpointwhen unit). as headis installed single cylinder . Verifl/ position No.1 cylinder at mmpression D.C T is of the pin in frontendof camshaft. bv knock

13

11

610

1l

12 8

EN-86

ON-VEHICLE PARTS
RB26DETENGINE T

To install camshaft, temporarily tighten No. 1cam bracket and checkthatcamshaft thrustsection positioned is securely. Tighten camshaftbolt540"(1.5 turns) theordershownin in thefigureon the previous page. Cam brackettighteningtorque (kg-m):0.92- 1.2 Caution: (1) Coatthe camjournals and end of the cam shaftwith engineoilbefore installation. (2) Do notrotate camshaft.(Thevalveand pistons may interfere).

Valveclearance adjustment [Point6] No. 1 cylindercompression point T.D.C . Turnthe camshafts (intake exhaust) No. 1 cylinder and so is at thecompression position. T.D.C . Checkknockpin position camshaft of frontendto verify No.1cylinder position. compression T.D.C . No. 1 cylinder at the compression is stroketop dead centre whenboththe intake andexhaust sidecamsdo not movethevalvelifters.
PART ITE[I
INTAKE IDE S EXHAUST IDE S Firingorder: 1 - 5 - 3 - 6 - 2 - 4 CylinderNo. 1, 2, 4 CylinderNo. 1, 3, 5 Exhaustside

Valveswhich can be adJusted lntake side

'180". Rotate intakeand exhaust the camshaft No. 6 cylinder at compression is stroketop deadenter I whenboththeintake theexhaust and sidecamsdo notmove thevalvelifters.

Valveswhichcan be adjusted

Intakeside

INTAKESIDE
EXHAUST IDE S

C y 4 i n d e r o .3 , 5 , 6 N C y i n d e rN o .2 . 4 , 6 \2O+l-5C)

Valveclearancespecifications
INTAKE
Valve clearance (cold) mm 0.45- l 0 . 5 1 -l

EXHAUST
0 3 8 '- ,
O JJ

(Reference value: warm) mm

Caution: Alwaysinspect whenthe engineis cold. EN.87

PARTS ON-VEHICLE
RB26DETENGINE T

Reference: Compensationby room temperature o+/-5

+0.02 10
J

20

30 +/- 5 -0.01

+0.01

Valve clearancemeasurement . Insert 0.15- 0.20mm gauge(A)fromsparkplugside. a side. Selecta gauge Insertgauge(B)from opposite to the that thickness willreduce clearance 0 m. Note: Do not use morethantwo gaugesfor (B). gauge. feeler UseJIS 150A25 = Valveclearance Gauge(A) + Gauge(B) gauge and(B): (A) using for Reasons measurement to is setting largercompared 1. Thevalveclearance previous engines. to Largegaugescannotbe placedparallel the 2. surface. measurement . Thickfeelergaugehavehighrigidity cannotbe bent and will so easily, the measurement be incorrect. . The errorfactorincreases a number thingaugesare if of will andthe measurement be incorrect. layered Valve clearanceadjustment . Thevalveclearance by is adjustment performed selecting thickness. a shimof suitable . Whenthe measurement (t) valveclearance is out of (T) theshimthickness and replace measure specification, clearance. the it witha shimthatwill produce standard method 1. Shim thicknesscalculation Example: (t) valveclearance is 0.50mm: Whenthe intake = value) 0.05mm 0.50(t)- 0.45(specified . Thevalveclearance 0.05mm greater thanthespecified is value. . Usea shim0.05mm thicker shimto thanthe current the reduce valveclearance. 2. Currentshim thickness(T) . Measure centerof removed the shimto determine the shim. of thickness the current Caution: shimsagain. the Do notreuse measured
Do not reuse after

EN-88

ON-VEHICLE PARTS
R326 E-i ENGINE D

3. Shim selection . Current (T) shimthickness is 2.40mm. + 0,05mm = 2.450 2.40I\ mm . Selectnewshimwithstampedmark 124.401 (T =2.440-2.455). +f Select shimwithin a standard value range 0.03mm. 4. Shim types and classification . Thereare 70 typesof shims.Sizesrangefrom2.275mm to 3.325mm in 0.05mm increments.

J = 2.440- 2.455mm

Installcamshaftfront oil seal [Point 7] . Caremustbe takennotto scratch makea burrin the oil or seal. Usea socket smaller thantheseal(41mm)anddnve it intosamelevelas frontsurface the oil sealretainer. of . Applya coatof engine to the entireperimeter oil seal oil of lrD. Caution: Do not scratch oilsealandlio. the

Installcamshaftrearrubberplug [Point8] . Before plug,wipeoffanyoil,wateretc. installing rubber the on thesurface cleanthoroughly. and . Whenassembling rubberplug,coatit withadhesive the (threebond1211) or equivalent.

Intakeand exhaust camshaftclassification [Point 9] . Intake and exhaust camshaft be identified can by pointcolourand presence a spinegear identification of for driving crankanglesensor. the

Intakecamshaft Exhaustcamshafi

Pink White

No Yes

gea. for dnving Spline crankangle

[Point10] Camshaftknock pin insertion . Theprotrusion distance 5 mm for camshaft is pin knock insertion. Knock pin protrusiondistance(mm): 5

EN.89

PARTS ON-VEHICLE
R826DETT NGINE E

[Point'11] Camshaftinspection Cam height inspection

. Usea micrometer measure height. cam to

Exhau$t 3Ue 40.28 8.28

heig.ht,stt dard.value Cam.

40.58 8.58

Camjournalexternaldiameterinspection of . Usea micrometer measure external diameter the the to journal. camshaft
No. 1 - No. 7

27.935- 27.955

[Point12] Camshaftrun-outinspection . Support (No.1 and No.7) by end bothcamshaft journals on usingV-blocks thefixedsurface. . Avoidthe oil groovein the centreof the No.4 journaland position dialgaugevertically. the . Rotate camshaft handone rotation readthe and by the widthon thedialgauge. movement width . The run-out equalto one-half the movement of is on indicated thedialgauge. Standardvalue (mm): 0.05

l
D i a l g a u g e\ h )al q.-

[Point13]

inspection diameter interior headcambracket Cylinder

.

. Tighten cam bracket specified torque to the '1.2 torque (kg'm): 0.92 Cam bracket bolt tightening . Usethe boregaugeor insidemicrometer measure to diameter. interior
1 No. -No.7 28.000- 28.O21

' :--.. , , - r: > -v,

i r \-t_l r!)/\| | !,::>--:a

'l

mrcrometerI -,,,,-:1

EN-90

ON-VEHICLE PARTS
R 3 2 ' f E * I E N GN E

oil inspection [Point14] Camshaft clearance . The oil clearance be calculated can fromthe camshaft journal outside diameter thebracket and interior diameter 'l measured [Point 1] and[Point 3]. in 1 = (Oilclearance) (Cambracket interior diameter) journalexterior (Camshafi diameter)
N o .1 - N o . 7 0.045- 0.086

[Point 15] Valvelifter inspection . Checkthe contact and sliding surfaces wearor for scratches.Replace damaged. if . Usethe micrometer checkthevalvelifteroutside to diameter. Standard value (mm): 30.995 30.965

[Point16] Cylinderheadlifter bore inspection . Checkboresurface wearor scratches. for . Useinsidemicrometer measure to valvelifterhole diameter. Standard value(mm): 31.0- 31.020

[Point17] Valve lifter-to-lifterhole clearanceinspection . Checkthe clearance usingvalues thevalvelifter for oul srdediameter andvalvelifterholediameter measured in 15] and[Point 16]. [Point = (Clearance) (Valve lifterholediameter) (Valve lifteroutside diameter) Standard value (mm): 0.025- 0.065

[Point18] Remove& installvalve spring When the cylinderhead is removedfrom the vehicle: . Usethevalvespring compressor remove to and install the valves. When the cylinderheadis installedin the vehicle: . Usethevalvespring compressor install to valvespring.
Vaive

EN-91

PARTS ON.VEHICLE
RB26DETENGINE T

[Point19] Remove& installvalve collet Removal . Usetweezers remove collet. to lnstallation jelly . Applya smallcoating petroleum to the internal of of surface the collet. . Usea magnetscrewdriver. installation collet 1. Uoper . Attachcolletto the lowersideof the magnetic in bladeand install the valvestem. screwdriver installation 2. Lowercollet . Attach collet uppersideof themagnetic to the in bladeand install the valvestem. screwdriver
Magnel

[Point20] Valvespring inspection Freelengthand pressureload inspection . Usethevalvespring testerto carryoutthe inspection.

46.54 24.0
White

22.5

Caution: the to loadis the forcerequired compress spring lnstallation to length 35 mm. insPection Perpendicular . Placea try squareby the spring it contacts spring Turn so between clearance the the springand measure maximum the andthe rightangleto determine upperspringsurface distance. out-of-souare '1.8 Limit(mm):

sPring [Point21] Installvalve . Install endtowards withnarrow pitchtypespring uneven colourside). head(identification cvlinder

EN-92

ON-VEH ICLEPARTS
R 3 2 6E T T E N G I N E ]

inspection [Point22] Valveguide clearance . Protrude valveapproximately5 mm towards the 1 the combustion chamber and measure valvedeflection lhe bv swinging in direction it parallel thedialgauge. to . Theclearance equal halfof thedialgauge is to reading. Intake
Limit(mm) 0.1

D i a lg a u g e

Exhaust
0.1

.H.gb

'-J.O

. lf clearance exceeds limit,verifythe valvestemdiameter andreplace valveor valveguide. the

23] Valve inspection [Point Outside diameter measurement

1-e

- l

--1r

l:
c
L b a

'!

o E
q

f -fli-?r-ite , t \

| /-,i,: lry- -----cJ

l N

lll

--r-;'

Vatue

e
t.J

f z.o ^
?q +03

q 45" 30'

^ ^ .0.02c 1 0 0 . 9 8 + / - 0 .97.45+t-0.15s + s - l 2o u - o 0 3 ! 1 99.98+/-0.195.48+/-0.15

7 ^ --0 0 8 5 ( 1 . 2 ) ' " 009c

^ ^ 0.02c o u - o - o s s 30' +t-15' 45

Be especially careful handling disposal valvesas the exhaust in and of valvesarefittedwith metallic sodium.

[Point241 Remove& installvalveoil seal Removal . Usevalveoil sealpullerto remove valveoil seal. the

Installation . Usevalveoil sealdriftto install valveoil seal. the Drift KV10107501 Drift attachment KV10114800 Caution: Coatinside thevalve of sealwithenqine before oil installation.
Valveoii sealdriftattachment _iiaJ, KV1011480 l

EN-93

PARTS ON-VEHICLE
E R826DETT NGINE

. lnstall valveoilsealas shown.

Valveorl seal

TIntake

Y,

[Point 25] Remove & install valve guide Removal chamber . Usevalveguidedriftandtap it fromcombustion sideto remove.

lnstallation . Reamthe cylinder headguideholeusingthe valveguide (whenusing0.5 mm over temperature reamerat normal sizeservicePart).
lntake side Exhaustside 10.46- 10.478 1 1 4 6 - 1 1. 4 7 8 .

150 to headinanoilbath approximately the Heat cylinder tool guide or press-fit to press drift and to 160"C usea valve side. fromcamshaft valve ouide

Camshaftside

. The press-fit are dimensions shownin thefigureon right.

10.8+f0.1

. Reaminsideof inserted valveguidewiththe valveguide reamer.

Valveg0ld6.reamer ( K V 1 0 11 1 6 0 0 i n t a k e l r<V101 07700 -(exhausr) _

E N. 9 4

ON-VEHICLE PARTS
I326C E-I.T NGINE E

[Point26] Valveseat Inspection . Inspect condition contacting the of surface thevalveseat of andthevalve. . Replace valveseator thevalveif contacting the surface is too largeor improper, grindbothsurfaces or and lapwith abrasive comDound. Adjustments . Whensurfacing valveseatdueto poorcontact, inspect the valveguideclearance valvestepholeclearance. and . Usethevalveseatcutteror thevalveseatqrinder and finish standard to value. Caution: Whenusingvalveseatcutter, pressfirmlyandcutevenly with bothhands produce to uniform cutting surface. Removal . Minimize valve the seatthickness cutting thenremove. by it, Installation (1) Drive valve the seatintocylinder headusing valve the seatdrifteras shown, (2) Whennot usingthe valveseatdrifter: . Coolthe valveseatfor approx. minutes 5 usingdry-ice . Heatthe cylinder headto approx. 80oC. . Inject valveseatintothecylinder the head. Caution: Do nottouchcooledvalveseatwithbarehands. . Exhaust valveseatsareavailable 0.5mmoversize. in When usingoversize valveseats,cutand grindthe seating recessin cvlinder fix valveseats. to

o.K

_po*"

(Cutter diameter)

Exhaust side --

co, co :or _o do_ (Cutter I diameter)

p,
JO

fio, ffio.
32 32
29.6

?A

+0 113 + i - 01 s 30 0 097

34.3
34.3 32.5

37 .s

O,O ^r

^ ^ 0

+0.016 36.5
.^ + 0 . 0 1 6 'r? _a -196 0
q +0 016

^^ - -015

+/-u.{J:

5.8
^ ^ 0 o o , o1 +/-u.ut 5.8

0.5

",

32\:::

::

2 96

EN-95

PARTS ON.VEHICLE
E RB26DETT NGINE

[Point27] Cylinderhead inspection . Clean carbon compound, sealing oil, andremove gasket, matter. andotherforeign

headin six of the Measure lowersurface the cylinder for any distortion. to directions check 0.2 Limit(mm): the is Whenthe distortion just overthe limit,resurface head. cylinder over excessively the limit,replace exceeds lf the distortion head. the cylinder

gauge Straight

10-13

AND INSTALLATION WATERPUMPREMOVAL

adjustbar Alternator

ton1',o oa- o.esg'1-\ I

B o l ( 2 )3 . 2- 4 . 3 I t

GQi,
'
t'tl''\>
r- -l r,":'. ' \

peort1zy s.z
gasret D Liquid
kg-m

4.3

pl (6) Bolt 1.6 2.1

Additional work required: . Drainand refillcooling water . Remove and install: . Cooling waterPumP relaY fan, . Alternator bolt adjustment . Timingbeltcover, timingbelt Remove& installwater pump [Point1] Remove . Caremustbe takennotto get coolant the timingbelt. on if anywaterdoesspill Wipe it off immediately . Remove waterpumpboltsin the reverse ordershown. the

1 M 6( 1 )
M10 {lonq)

EM10 (short)
11 M8

EN-96

ON-VEHICLE PARTS
R826DETT NGINE E

Installation . Install boltsin the numbered the sequence shown.

M6 7, 8 , 9 , 1 0 ,1 1 1 2 ,

1 6
A

tv8 r\41 0

0.64 0.85 't.6- 2.1 3.2- 4.3

2,3,4.5

Removaland cleaning . Insert stubbyscrewdrivers the boltholesand moveit up in anddownto remove wateroumo. the Caution: Takecarenotto damagethe screwsin cylinder blockside. . Usea scraper remove liquid gasket to all fromthesurface. Caution: Alsoremovethe liquidgasketremaining grooves. in . Wipethe installation surface withwhitegasoline. Installation . Cutthe nozzleendof liquid gasket tube(KP510 00150) as shownin the figureand usetubepresser application. for . Applycontinuous gasket beadof liquid (KP510 00150) to waterpumpsealing surface. Caution: Be sureliquid gasket 2.0to 3.0mm wide. is Installation must be carriedout within5 minutes afterliouid gasket application.

gasket2.0 - 3.0 rnm Llquid wrdealongthe groove

Water pump inspection [Point 2] . Rotate waterpumpby handand checkfor abnormal the soundandsmoothoperation. . Theremustbe no tracesof waterleaks.

EN-97

PARTS ON-VEHICLE
RB26DETENGINE T

10-14

REMOVAL& INSTALLATION THERMOSTAT

Thermostat [Point2] housrng Thermostat [Pornt1]

*r,,
16 Borti3) -2.1Fj

EILiquidgasket
ht

t",aK g - m
Additional work required: . Disconnect connect waterinlethose and . Drainand refillcooling water Caution: waterfrom enginedrainplugto removecooling Loosen block. thecylinder

'l] Remove& install thermostat housing [Point Removaland cleaning . lnsert screwdriver and housing into handle thermostat the the to remove housing. move it up anddownlightly . Usea scraper removethe liquidgasket. to Caution: Makesureto removeliquidgasketin grooves. . Wipeoffthe surface withwhitegasoline.
?aq't

lnstallation . Cutnozzle gasket (KP510 00150) tubeas endof liquid snown. gasketto sealing surface . Applya continuous beadof liquid 5 minutes within the usingthetubepresser.Install housing liquidgasket aftercoating
2.0 - 3.0 mm wideto centerof flat matingsurfaceand innerseating surfaces of boit holes.

EN-98

ON-VEHICLE PARTS
ia2a l:--r. ENGTNE

Installthermostat [Point2] . 'Top'markfiiggle valve)mustfaceup whenthermostat is inserted housino. in

Thermostat inspection [Point3] . Checkthevalveopening temperature maximum and valve tift. . Hangthe thermostat stringin valveandsubmerge by in heated waterin double walled container stirwaterwhile and heating up. it . Theopening temperature thetemperature is whenthevalve opensandthermostat fromstring. falls

76.5 10/90

10-15

INSTALL REMOVE & OIL COOLER, OIL FILTER

Additionalwork required : . Disconnect connect and switchharness connectors . Drainand refillcooling water Caution: Loosen engine drainplugto remove cooling waterfromcylinder block.(lfwateris onlydrained fromtheradiator drain cock, cylinder the block notdrain will completely).

EN-99

PARTS ON-VEHICLE
RB26DETENG]NE I

Remove& installoil filter [Point1] Removal gauge. the 1. Remove oillevel pressure vacuumhose control turbocharged 2. Remove and movethevacuumhoseoutof theway. clamp clampout of theway. (lf the oilfilter 3. Movemainharness the comeloose,remove oilfilterusingthefilterwrench) oil 4. Useoilfilterwrenchto remove filter. lnstallation . Wipeoff dustetc.fromthe oilfiltermounting bracket newoilfilter.Applya thincoatof beforeinstalling surface engineoil to oil filterO-ringbeforeinstallation. . Screwthe oilfilteron bracket handuntila slight by 2/3 an felt,thentighten additional turnsusing is resistance for andcheck oil leaks. wrench.Starttheengine theoilfilter Removal . Facelowerpartof oil filterdownand moveout in the through of direction the arrowin figureright. Remove collector. behindmanifold aDerture

()

-@/^
1/

noup,".

wrench

Small ratchet -V

h/

OIL PAN,OIL PUMP& OIL STRAINER 1O-16 (1) Remove& instaltoil pan,oil pump & oil strainer
g oil pannut(7) - 4 . 3l P o i n1 ] t @-'3.2 -springwasher f
Oil strainer [Point3]

E oil pumpgasket
O i l p u m p , i t( B ) l P t rt 4l 0 . 9 2 - 1 . lPoint
d

2] [Point Eloil pan

a Ele ts '11 Frontoll

?7*\

Oil pump pDrain ptug

Copper wa\sher
\t\$r \
t

i",l Kg-m f | E n g i n eo i t $ neptaceafter every disassemoly

oit panbolt(a)Fl 0 . 6 4 0 . 8 5 P o r n1 l l t \ - 4 . 3t P o i n1 1 p j ( 3 O i lp a nb o l t 1 4 ) . 2 t

),

Additionalwork required: . EngineASSY . Drainand refillengineoil E N- 1 0 0

ON-VEHICLE PARTS
RB26DETENGINE T

Remove& installoil pan bolts & nuts [Point1] Removal . Remove boltsand nutsin reverse orderof installation sequence shownin thefigureon right. Installation . Install nutsand boltsin the orderof sequence the shownin thefigureon right. Caution: Makesurethereareno dirt,dustor otherforeign objects oil on installation surface.
Bolt t Nut 3ize

M,E EEM
tv l)Al )o ".i

(Bolt) N/6
M 1 0( B o l t )

I
14

0.64 0.8s
3.2- 4.3 3.2- 4.3

4 , 7 , 8 ,1 0 ,1 1 .1 2 .1 4 ,1 5 , 1 6 ,1 7 ,1 8 ,1 9 . 2 1 . 2 2 1 , 2 , 3 , 5 ,6 , 9 , 1 3

lV10 (Nut)

Remove& installoil pan [Point2] Removal& cleaning . Usea sealcutterto removeand cleanthe oil pan. . Usea scraper removeliquidgasketfrommating to surface. Caution: gasketandsealmaterial Usea scraper remove liquid to all on the cylinder blockandoil panflangegroove.Remove all gasketand otherforeign objectsin the oil pan. . Cleanall contact surfaces withwhiteoasoline. Installation . Cutoffthenozzle of liquid gasket tip (KPs10 00510) at pointshownin thefigureon right.

Applyliquidgasketto innersealing surfaces the oil pan on as shownin the figureon right. Installation mustbe performed within5 minutes.

EN- 101

PARTS ON-VEHICLE
RB26DETENGINE T

. Applyliquid gasket (KPs10 00150) areas7 mm inside to of the oil pan boltholes. fromcenter Caution: 4.0 gasket applied mm wide. is (1) Makesurethe liquid the beforerefilling engineoil Waitat least30 minutes Q\ installation. after andenginecoolant

Installoil strainer [Point 3] when . Makesurethe O-ringis installed in securely groove the installing oil strainer. Tighteningtorque (kg-m): 1.6- 2.1(Mg) 0.64- 0.85(M6)

Oil PumPbolt [Point4] . Thereare4 typesof bolts. Makesureto usethe correct boltswhenthevare installed.

20 2 35 45

0 . 9 2- 1. 2 0 . 9 2- 1 . 2

3
4

0.92 1.2
0 . 9 2- 1 . 2

55

Remove& install front oil seal [Point 5l Removal . Usea toolsuchas screwdriver remove frontoil sealfrom to the frontcover. lnstallation . Caremustbe takennotto scratch damagethe oil seal or Useoilsealdriftandinsertit at samelevelasfront retainer. housing. of surface the oil PumP the . Applyengine or chassis grease areaaround oil to oil seallip.

Oil leak& oil pressureinspection [Point6l . Afterinstallation warmup the engineand checkfor any oil andtheoilPressure. leaks gauge . Remove pressure switchand attachoil pressure oil oil whenmeasuring Pressure.
ldling

2000

6000

3 Approx.1.5 Approx. A p p r o x . 4 . 6

EN - 102

ON.VEHICLE PARTS
R326 EiT ENG]NE D

(21

Oil pan disassembly assembly &

B o l i 2 l 0 6 4 - O . Ap t S

Bolt(4)

t",/

Boto.6a-0.85I

74r' ri\
\ie-".
Rrffla ^l.la

ti, lv/ Kg_m

(3)

Oil pump disassembly assembly &

Purnphousrng [Pornt

Innergear [Pornt 2]

Outergear [Point1]

piug Regulator a.O z Opl

19*n-'
Oil pump inspection [Point1] . Checkinnergear,outergearand housing any scratches wear. for or . Usethickness gaugeto measure following the clearances:

Outergear and housing clearance

0.114 0.2
Below .180 0

2 3
4

Outergear and innergear clearance gear and housing lnner side clearance Outergear and housrng srdeclearance gear and housing lnner flangeclearance

0.05 0.07 0.05 0.1 1 0.045 0.091

position is obtained subtracting housing Measurement 5 by the flangeoutside diameter fromthe innergearinsidediameter.

EN- 103

PARTS ON-VEHICLE
ENGINE RB26DETT

Regulatorinspection [Point2] . Checkoil pressure and the surface valvesliding regulator for spring anywearanddamage. (m Valveand valve hole clearance m): 0.04- 0.097

Installinnergear [Point3] . Caremustbe takento install innergear in a specific the direction. . Facethe sidewiththe grooveto the coverside.

Coverside

E N- 1 0 4

ON-VEHICLE PARTS
I 3 2 :E E N GN E

10-1 (1)

COLLECTOR ASSY Collector ASSYremoval& installation

Air reiease plug IPoint

Acceleration bracket wife [Point2] Collector ASSY

,.,^ IS--.gasket E Collector

Fi.

I Y
collector (a)$l oort
1 . 8 2 . 2l P o i n3 l t

:'j:i,i",ili'lr ?3' g ft.,

Ks-m $./.1
E Replace afterevery disassembly

Additionalwork required : . Release pressure thefuel lines fuel in [Point1] . Drain& refillcooling water[Point4] . Acceleration [Point2] wire . Airduct . Harness connector . All hoses

Release fuel pressure [Point1] . Starttheengine. . Afterstarting engine the remove fuelpumpfuseandwait the untilthe enginestops. Crankenginetwo or threetimesto consume remaining the fuelpipes. fuel in . lf thevehicle doesn't start,remove fuelpumpfuseand the crankthe engine fourto fivetimesto consume fuel remaining thefuelpipes. in Caution: The battery may become weakeasily, booster use cableto connect another to battery necessary. if

Acceleratorwire adjustment [Point 3] . Loosenlocknutto provide adequate slackfor the accelerator and pulloutercasein the direction the wire of accelerator. . Return locknut 1.0to 1.5turnsfromthe oosition the the throttle drumstartsmoving (whenthereis no playin cable) andtighten. Tightening torque (kg-m): 0.8- 1.0 E N- 1 0 5

PARTS ON-VEHICLE
RB2OE NGINE E

Remove& installcollectorbolts [Point3] Removal . Remove boltsin the reverse orderof the figureon the right. lnstallation . Install boltsin theordershownin thefigureon right the in uniformly two to threestages.

Air releasePlug [Point4] . Formoreinformation system on referto the section cooling on later in themanual. . Carryout the operation whenengineis cool. Caution: plugwhenthe engineis hot. Do not removethe air release . Remove airrelease the plugto release airwithin the the water. cooling whenrefilling completely engine Caution: Care must be taken not to over tightenthe air releaseplug bolt. Tighteningtorque (kg'm): 0.7- 0.8

(21

& disassembly assembly ASSY Collector

Throttlechambergasket

2l tPoint $
Throttle chamber [Point1] - Throttle chamberbolt (4)

1l 1.8 2.2 tPoint pl

6 bo t p ) M c v a l v e A S S Y l ( 4 ) 0 . 8- 1 . 1

Fi.

lv.l Kg-m $ neptaceafler every disassemol,

Additional work required: . Remove ASSY collector and install

E N- 1 0 6

ON-VEHICLE PARTS
i32]: E\GINE

Remove& installthrottlechamberbolt [Point1] Removal . Remove boltsin the reverse the orderof thefiqureon the right. Installation . lnstall boltsin theordershownin thefigureon right the uniformly two stages. in Tighteningtorque(kg-m): Firststage 0.9- 1.1 Secondstage 1.8- 2.2

Throttle chamber gasket [Point 2] . Checkthe installation direction before installinq throttle the gasket. chamber

I =il;10.2 (1) INTAKE MANIFOLD ASSY Remove install & intake manifold ASSY
gast<et Intakemanifold $ -_.4 -_

t-.1

Fi

Replace afterevery disassembly

Additional work required: . Remove andinstall collectorASSY . ECCSharness connectorand hoses all

E N- 1 0 7

PARTS ON.VEHICLE
RB2OE NGINE E

[Point1] Remove& installintakemanifoldASSYbolts and nuts Removal . Remove boltsandnutsin the reverse orderof thefigure the on right. lnstallation . Install boltsand nuts in theordershownin thefigureon the 1 17 right,

(2)

& IntakemanifoldASSYdisassembly assembly

.J
\*

Arr regulator

{4
p) Air ;egulator 0.5- 0.6 bolt
FueltubASSY e

I P o i n1 l t Fueldamper -

;*,,i
7i

Water outlet

reguralor

Boltt-,4 1 . 8 2.2

(2) Bolt 1.6 2.191

Replaceafter every disassemble

Fuel tubebolt1.0- 1.2

sasket El Liquid

I *s-'

: Additionalwork required . Remove ASSY manifold intake andinstall

Fueltube ASSY [Point1] . Replace O-ringto newoneswhenremoving and the and regulator thefueldamper. the pressure installing Caution: or Caremustbe takennotto scratch damagethe fueltube and regulator thefuel the areawheninstalling pressure O-ring damoer.

regulator Pressure
Fueltube injector Fuel damper

E N- 1 0 8

ON-VEHICLE PARTS
RB2OE NGINE E

[Point 2] O-ring(for fuel injector,pressureregulatorand fuel damper) Precautions when handling . CoattheO-ring -30 withengine (7.5W or equivalent) oil or silicon (NUCsilicon or equivalent), do notapply oil L45 but solvent thismay remove coating. as oil . Avoidusing dirty O-rings do notallow and dirt,dustor foreign objects adhereto O-rings otherequipment to or surfaces. . Caremustbe takennotto scratch, twistor stretch themov toolsor operator's fingernails wheninstalling O-rings. . Do notdecenter rotatethefuel injectors the or and pressure regulator wheninserting themintothefueltube. . Do notstoreO-rings location in subject ozone,high to temperature in directsunlight. or

10.3 REMOVE INSTALL & EXHAUST MANIFOLD ASSY

Exhaust manifold plor sensor 1 - 5.1 4.

? ' * o i

p ruut - s.z z.a ieornt" zj

P.P yoke P [potnt3) . Washer 4] fPoint ,

ri \-/ Kg-m Replaceafter every disassemble

Additionalwork required: . Under cover . Assemble disassemble and exhaust fronttube . O, sensor connector

Gas leak inspection [Point1] . Afterremoving exhaust the manifold, makesurethereare no tracesof gas leaksfrom any parts. . Afterthe installation, crankthe engine and checkfor any oas leaks.

E N- 1 0 9

PARTS ON.VEHICLE
RB2OE NGINE E

Removeand installexhaustmanifoldnuts lPoint 2l Removal . Removal the reverse installation shownin sequence of is on the diagram right. lnstallation . The installation on is sequence shownin the diagram rioht.

11

10

Yoke [Point 3] . Makesure notto makemistake No. 3 and No.4 between are yokeas configurations different.

22
24

Installwasher [Point4] . Makesurethewasheris facingthe correct way when installing.

+
l\4anifoldside

10.4

COVER LOCKER & REMOVE INSTALL

LOCKeTCOVer

Fillercap

Additionalwork required: . Air duct . Air duct bracket . Blowbyhose

[Point1] Remove& installlockercover bolls Removal . Removal the reverse installation shownin sequence of is on the diagi'am right. lnstallation . The installation on is sequence shownin the diagram rioht.

11

E N- 1 1 0

ON-VEHICLE PARTS
RB2OE NGINE E

10-5

TIMING BELTREMOVAL INSTALLATION &

8 e t l e " sc . e r ,., vvasner Tens oner spr no fPoint7l i ConicatwasherI

glNur4 4 l"."il,t] ".\ ",

"

tl6'8

i -}- dso *

Timrng belt cover(upper) 4] IPornl

Timingbeltcover Crankpulley[Point3]

pump Power steering pulrey

p a o r r o ;t . z .
{ri^.. l-/ borr ( 2 )0 . 3-

Cranktrrnrng platelPoint belt CranktimingpulleylPoint11] . T i m i n g e l tl P o i n 9 , 1 0 , ' 1 2 13 ] b t Cranktimingpulleyplate[Point8]

0.5

I ts-.
o E Engine il after

Additionalwork required: . Drain andrefillcooling water . Remove and install followinos: the . Undercover . Radiator, shroud . Cooling fan . Supplemental belts . Water pumppulley . Sparkplugs . CheckNo. 1 cylinder position compression T.D.C [Point1] . Install gearstopper ring [Point3]

(top deadenter)inspection [Point1] No. 1 cylinderpressureT.D.C . Align crankpulley the timing markandthebeltcover indicator. thistime, At timing the distributor rotorshouldbe in the position shownin the diagram below, No. 1 cylinder or position. in thecompression T.D.C

E N- 1 1 ' l

PARTS ON-VEHICLE
RB2OE NGINE E

[Point2] Installring gear stopper . Remove starter the motorand install ringgearstopper' the

'' -*v-ror puller(steering wheelpuller) 3] [Point Pulley . Remove crank puller. pulley using pulley the by the head mm) 40 below M6 (bolt size: x 1.0 length
2718

[Point4] lnstalltiming belt cover . Attachthe gasket(sponge on rubber) the timingbeltcover (upper) shownin the figure. as

[Point5] Remove& installbelt tensionernuts . Securethe belttensioner wrench firmlywitha hexagonal nuts. the and installing belttensioner whenremoving

[Point6] Installconicalwasher . Paycloseattention the installation of direction the to washers.The washershouldbe set withfacethe conical pulleyside sidefacingthe tensioner chamfered

aI I I r I -[__T--r
\_J t
Nrt

\\

Conical washer

spring tensioner 7] IPoint Install . Assemble tensioner the so spring it engages belt the pulley shown thefigure right. on in as tensioner

. The tensioner withthe together springmustbe assembled pulleyin the cylinder block. belttensioner

EN-112

ON-VEHICLE PARTS
RB2OE NGINE E

Fixthebelttensioner hookthespring topofthe and on studvoltby rotating springanticlockwise. the

pullfy Spri

1 . 8m m

Approx.20'

Approx.227'
When free Timingbeit pulle'

[Point8] Installcrank pulleyand plate . Be careful observe to frontand rearpositioning timing of beltplate, cranktimingpulley plate andcranktimingpulley wheninstallation oerformed. is

]--lu

---------

tar

t.t

E-

tr
ll
o)o"u

il

- -lf-markverification [Point9] Timingbelt alignment . Checkif the cam pulleyalignment markis aligned withthe pulley crank timing alignment markwhenNo.1 cylinder is at compression T.D.C. . Check number ridges the of between campulley the and pulley thecrank timing alignment marks.

Markon eachpulley thealignment position white at with paintif thetiming paint) not beltalignment mark(white is clear. Position timingbeltso the backsurface the arrowis facing the engine frontandalignthealignment paint) mark(white withcam pulley the cranktiming pulley and alignment mark wheninstalling newtiming a belt. Checkthe ridgesafterthe installation.

EN- 113

PARTS ON-VEHICLE
E RB2OE NGINE

timing belt [Point 10] Install . Assemble tensioner the springso it engages belt the point7). pulley(follow tensioner . The tenstoner withthe together mustbe assembled spring pulleyin the cylinder block, belttensioner . Insert hexagonal intothe belttensioner wrench hexagonal the to holeand rotateclockwise tighten nuttemporarily . Alignthetiming alignment marks witheachpulley marks belt belton to pulley. timing andinstall . Tighten tensioner tightening nutsto specified securing the 4.4- 5.9 torque (kg-m): torque.Tightening

[ P o i n t1 1 ]C r a n kt i m i n gP u l l e Y . Makesureto install cranktimingpulley a correct way in the Somecranktimingpulleyhastwo key groovesand marks. alignment
Keygroove

[Point12]Timing belt tensionadjustment . Loosenall rockershafttightening bolts. . Rotate tensioner two anticlockwise to threetimes the to wrench. (itis notnecessary rotatebelts) hexagonal using . Fixthe tensioner the wrenchand tighten usinghexagonal torque. (At thisstagespecific tightening nutsto specified to will tension be applied the beltsautomatically).

[Point13]Timing belt insPection . Replace any indicates problem. timingbeltif inspection

missing Tooth Cracked tooth Cracks on rear stde Wear and cracks on the side

@
/,ilh nn Jary ]!lg

Camshaftlock Crank sensor lock lock Tensioner Engineoverheat with belt cover etc. lnterference

.J.D

Beltmisalignment Belt plate malfunction

Worn teeth

in S lidingmotionresistance crank sensor and the camshaft Oil seal malfunction Water leaks in water PumP

Oil or water adhesion

OIL OIL PAN,OIL STRAINER, FILTER & 9.6 REMOVE INSTALL . Referto RB20DE, DETsectionlateron in the manualfor detail E N- 1 1 4

ON.VEHICLE PARTS
R B 2 O D / D E TE N G I N E E

10-1 (1)

COLLECTOR ASSY Remove& installCollector ASSY

Accelerator wire bracket [Point2]

cottector /2)lctl bott 1.8- 2.2IPoint 3lrci --{{

e

Co ecror ASSI
| ,---_,--4
l

gasket E Collector

plug [Point4] Air release collectofbolt \2) 1 B - 2.2 lPornt p) 31

tli

&

\-,i k g - m Repiaceafter every disassembly

Additionalwork required : . Release pressure thefuelline[Point fuel in 1] . Acceleration control wire[Point2] . Drainand refillcooling water . Air duct(RB2ODE), inletpipe(RB20DET) Air . EGIharness connector, harness clamp . All hoses

fuel pressure [Point1] Release . Afterstarting engineremove fuelpumpfuseand the the waituntiltheengine stops.Crankengine or threetimes two to consume fuel remaining the fuel pipes. in . lf the vehicle doesn't start,remove fuelpumpfuseand the crankthe enginefourto flvetimesto consume fuel remaining thefuelpipes. in Caution: The battery may become weakeasily, use booster cableto connectto anotherbatteryif necessary.

[Point 2] Acceleratorwire adjustment . Loosenlocknut to provide adeouate slackfor the accelerator wireand oulloutercasein direction the of accelerator. Return locknut 1.0to 1.5turnsfromthe the position throttle the drumstartsmoving(whenthereis no playin cable) andtighten. Tightening torque (kg-m): 0.8- 1.0 E N -1 1 5

PARTS ON.VEHICLE
R B 2 O D / D E TE N G I N E E

[Point 3] Remove & install collector bolts Removal . Remove nutsin the reverse orderof thefigureon right. the Installation . Install nutsin the ordershownin thefigureon right the in to uniformly tvvo threestages.

7.10 8 1,3,4,6, 2 , 5 , 9 .1 1

105 65
4Q

30

Plug [Point4] Air release . Formoredetailreferto cooling systemlaterin the manual. Caution: plugwhenthe engineis still the Do not remove air release warm. . Makesureto removeair releaseplugwhenrefilling the enginecompletely air waterto release withinthe cooling prevention). (overheat 0.7- 0.8 Tighteningtorque (kg-m):

& (21 CollectorASSYdisassembly assembly

*:;::*;l;;,'"'*>e H41,

B o l ( a )0 . 9- 1. 19 t

gasket 2]E Castetq3 Throttle chamber lPoint

chamber Throttle Throttlechamberbolt (4) 1 . 8- 2 . 2 [ P o i n 1 ] $ I t

a://
I
$

z2- --..*)",. no""

E N- 1 1 6

ts-t
Repiaceaftef every disassemble

Additionalwork required: . Remove ASSY collector and install

ON-VEHICLE PARTS
R B 2 O D / D E TE N G I N E E

Remove& installthrottlechamberbolts [Point1] Removal . Remove boltsin the reverse the orderof thefigureon right. Installation . Install boltsin the ordershownin the figureon right the uniformly two stages. in Tighteningtorque (kg-m): First stage 0.9- 1.1 Secondstage 1.8- 2.2

[Point2] Throttlechambergasket . Checkthe installation direction beforeinstallino throttle the gasket. chamber

.)

oVo
10-2 (1)
INTAKEMANIFOLD ASSY Remove& install intake manifold ASSY

lntakemanifoid ASSY

Fi

\-.4

Replaceafter everv disassemble

Additionalwork required : . Remove& install connectorASSY . ECCSharness connector, hoses all

E N- 1 ' 1 7

PARTS ON-VEHICLE
R B 2 O D / D E TE N G I N E E

[Point1] Remove& installintakemanifoldASSYbolts and nuts Removal 'io I 6 . Remove boltsand nutsin the reverse orderof thefigure the on right. lnstallation . lnstall boltsand nuts in the ordershownin thefigureon the rioht.
B 7 2 3

13 14

1 11 2

(2) Intake manifold ASSY disassembly& assembly pl eott a t"t 1r;gnt t I t.o,, injector lPornt ' p) aonrZtO.6a O.SA

?_

Air regutator

,-- 1,
ASSY Fuel tube Injector

prpe Water-outlet nSSY

Bolt(6) 1 Bolt(2) 0.4 -

lntake manifold

a
Fi

Liquidgasket

\",i K g - m

Additionalwork required: . Remove& installintakemanifold ASSY [Point1] Fueltube ASSY . Replace O-ringto new oneswhen removing and the regulator the fueldamper. and the installing pressure Caution: or Caremustbe takennotto scratch damagethe fueltube regulator' the areawheninstalling pressure O-ring

[Point 2] O-ring (for fuel injector pressure regulator) when handling Precautions . NeverreuseO-rings. but . Coatthe O-ring withengineoil (7.5W-30or equivalent), do notapplysolventas this may removethe oil coating. . AvoidusingdirtyO-rings do notallow dirt,dustor and or to foreignobjects adhereto O-rings otherequipment. . Caremustbe takennotto scratch, themby twistor stretch O-rings wheninstalling fingernails toolsor operator's . Do notdecenter rotate fuelinjectors the pressure and the or themintothefueltube wheninserting regulator EN-118

ON.VEHICLE PARTS
R 8 2 ,D ] D E TE N G I N E 1E

1O-3 REMOVE INSTALL & EXHAUST MANIFOLD ASSY

Exhaust gasket manifold Exhaustmanifold

(3) Bolt 0.a 0.5I

')@ washer potnt ti 2, | ) Nut2.8 3.2IPoint 3l

Fi

YokeIPoint 3]

\",1xg-m
after every drsassemble $ Reptace

B o r t ( 7 i4 - o 5 I 0.

Additional work required: . Undercover . Disassemble exhaust fronttube . Exhaust sensorconnector . Gasleakinspection 1] [Point RB20DET only . Inter cooler inlet air tubehose . Turbocharger

[Point1] Gas leakinspection . Afterremoving exhaust the manifold, makesurethereare no tracesof gas leaksfrom any parts. . Afterthe installation, crankthe engineand checkfor any gas leaks.

[Point2] Removeand installexhaustmanifoldnuts Removal . Removal the reverse installation is of seouence shownin thediagram right. on Installation . The installation sequence shownin the diagram right. is on

E N- 1 1 9

PARTS ON.VEHICLE
R B 2 O D / D E TE N G I N E E

[Point 3] Yoke . Makesure notto makemistakebetweenNo. 3 and No.4 is yoke as configuration different. P (mm)
22 24

c 0.5

[Point4] Installwasher . Makesurethe washeris facingcorrect way when installing.

side Manifold

1O-4

REMOVE& INSTALLSPARK PLUG

Ornament

bolt Ornament (B)0.30- 0.39 F i \

narness

l'/

\,-

Groundcable .2 Bolt 1.0 - '1 lPo]nt1l Washer

\ ,/ c l g n i t i o n o i lb r a c k e t 2] ,,-'1 lPoint \ ./'/-/.

3l fPoint ri \".4 .-'--'/

plu Spark s 2 . o 3 . 0

Ll9l *n-'

Additional work required: . Air duct(RB20DE), inletpipe(RB20DET) Air . Blowbyhose . Powertransistor [Point1] Remove& installignitioncoil bracketbolt . Length the bracket between RB2ODE RB2ODET and bolt of are different.

22

25

E N- 1 2 0

ON.VEHICLE PARTS
R B 2 O D / D E TE N G I N E E

Installignitioncoil bracket [Point2] B o l t' 1 . 0 . The ignition bracket coil thickness differs between RB2ODE and RB20DET vehicles. . Wheninstalling ignition bracket cylinder coil to head,check thatgroundlineis connected securely.

'1.2

3] [Point Sparkplugmaintenance . TheGapinspection adjustment notnecessary and is as plat,num is used. tip . Change spark plug the every 100,000 km. . When using compressed spark plug air cleaner, clean the plugs maximum pressure 6 kg/cm2for more at of no than 20seconds. . Donotusewirebrush clean plugs. to

10-5

REMOVE INSTALL & ROCKER COVER

Filler ap c

(B) 9Ornamentbolt 0.30 0.39

Locker coverbolt0.2 - 0.4 [Point'1]

e--^ Lockercovergasket .-4,

Grommet

Orname'nt
Lockercovergasket
Fi

l".i xs-m Additionalwork required: . Air duct(RB20DE), inlet(RB20DET) Air . Blowbyhose

[Point 1] Remove& install rocker cover screws Removal . Perform removal reverse in orderof seouence shownin the figureon right. Installation . Perform installation sequence in shownin thefigureon rloht.

EN- 121

PARTS ON-VEHICLE
R B 2 O D / D E TE N G I N E E

TIMINGBELT & 10-6 REMOVE INSTALL

4] Timingbelt cover(upper) [Pornt T r m r n g e l t[ P o i n 9 , 1 0 , 1 2 ] b t

(31 pl pol ] ?ol'_,0,-9 o.o.t.

-",ffi..' j"t# " -r,,'"'WW'il. W i,r ^, *?tgO,S'Po;**,)H P" r\ n,r,'*i.lvS::"fu

g* @aS1 conicar Bett 111 9. '10. tensroner [Pornt

609\ -^6)-... llil'3E w{ I-

\-

washer """"";'.fffi\,
,.."/b'\])D

"iE"-t, (rower) 4] bert cover t, [Point o\",.]#in

t"*t'iilln'flil3#:?lF:ill3] SJ"P,; wasner\' Bolt44-59 ldlerpullevlPoint'111

q"fl,:-';,, ..""1,","iixilJ,',os-oaap) 91,n.,

n" Jl Ens oi
$ disassemblY afterevery Reptace

Additional work required: . Undercpver . Drainand refillcooling water . Radiator, shroud fan . Cooling fan . Supplemental belts . WaterpumpPulleY . Sparkplug . No. 1 cylinder position 1] T.D.C compression [Point . Install ringgearstopper [Point2] (top deadenter)inspection No. 1 cylinderpressureT.D.C [Point1] . Alignthe crankpulley timingmarkandthe beltcover position). thistime,the No. 1 At (0" indicator timing whenthe T.D.Cposition is cylinder in the compression in is camshaft locatedas described the following situations.

top is No. 1 cylinder at the compression deadcentre sidecamsdo not whenboththe intakeandthe exhaust movethevalvelifters.

EN - 122

ON-VEHICLE PARTS
R B 2 O D i D E TE N G I N E E

. Remove lockercoveroilfillercap fromintakeside the and checkthatthefrontendof the camshaft faces intake side.

Installcrank anglesensor [Point2] . Applychassis greaseto the driveunit(spline) during installation. . Thereis a flange inside driveunitspline thespline the so hasonlyone insertion position. Checkthe alignment visually before assembly. . Checkthatthe crankanglesensorcan be easilyinserted rnbeltcoverholesand sensormoveslightly rightand to left,thentighten bolts. the . Whenthe sensor doesn'tmovelightly, loosenbeltcover bolts position to whenthecrankanglesensor wasinserted. Movethe beltcoverlightly horizontally vertically align and to it so the beltcoverholesand the camshaft centreare aligned.Thentighten boltsso the crankanglesensor the moveslightly.

l l rn 4 1 n

3] & crankpulley andthe bolt [Point Remove install . Remove starter the motor attach ringgear and the stopper.
K V ' 1 00 5 6 1 0 1

. Usea pulley puller (steering puller) remove wheel to crank pulley size: M6x 1.0length (bolt below head approx. 50mm)

Remove& install timing belt cover lPoint 4] . The timingbeltcoveris separated upperand lower into parts.Aftercrankanglesensoris removed, remove the timingbeltcoverin the orderof upperandthen lower. . Installation in reverse procedures. is sequence removal of Caution: Caremustbe takennot to scratch damagethe dried or packing liquid whenremoving installing timing and the belt cover.

EN- 123

PARTS ON-VEHICLE
R B 2 O D / D E TE N G I N E E

Remove& installbelt tensionernuts [Point5] . Secure tensioner hexagonal when wrench with the belttensioner. the removingand installing Caution: studwhendisassembly. Do not looseninserted

n-<'( /'.)
Hexagonal wrencn

Installconicalwasher [Point6] . Payattention the installation of direction the conical to withfacethe washers.Thewashershouldbe set pulleyside. sidefacingthetensioner chamfered

Installtensionerspring [Point7] pulley . Assemble tesioner to spring the belttensioner the as shownin thefigure. withthe . Thetensioner together mustbe assembled spring pulley thecylinder block. in belttensioner

; iqipipnr,,.o
. Hook tensioner sideof thetensioner on spring theupper the pulleyis free. studwhenthetensioner spring

|,

\,. "r \ /4 a Tensioner spflng

spring sPecifications Tensioner

1.8

20" Approx.

Approx.163"

Yellow

[Point8] lnstallcranktiming pulley& plate when . Caremustbe takenof the rearandfrontpositioning and the plate, cranktimingpulley the timingbelt installing plate. pulley timing

EN - 124

ON-VEHICLE PARTS
i:. ]: fEi ENGINE

Timingbettalignmentmarkverification [Point9] and installation . Paint markon thebeltthatindicates a rotation direction if paint theupper on beltis unclear whendisassembly. Position alignment the marks theintake the on and exhaust cam pulleys withthe respective cover belt alignment marks.(No.'l cylinder at T.D.C) is Position alignment the markon thecranktiming pulley with the respective pumphousing oil alignment marks.At this timethe groovemustbe straight (no. 1 cylinder at up is

rD.c).

Movethe belttensioner clockwise - 80 degreeangle, 70 andsecureit temporarily the belttensioner with nut. . lnstall beltby aligning timingbeltandthe pulley the the marks.Alignthe number ridges exhaust of of cam pulley alignment markandthecrankpulley (inner) alignment mark as shownin thefigureon right. . Afterloosening nutsandadjusting belttension, the the secure tensioner the hexagonal the with wrenchso it will notrotate together tighten nut. and the Caution: (1) Makesurethetimingbeltengages correcfly withthe pulley anddoesnotflatwhenassembling the timing belt. (2) Replace possible beltswhenever whendisassembly is performed.

Cranklrmrng

[Point10] Timing belt tensionadjustment . Remove sparkplugandalignthetiming the beltalignment markandthepulley marks andinstall timing on to each belt pulley. . Loosen tensioner the securing so the belttension nut is applied thetensioner by spring. . In thiscondition, rotate crankpulley the clockwise more thantwoturnsto check beltmovement stopslowly the and at No. 1 cylinder compression T.D.Cpoint. . Insertthe hexagonal wrenchin hexagonal hole. Holdthe tensioner handso the tensioner by doesnot move,and tighten tensioner the securing to specified nut tightening toroue. Tighteningtorque (kg-m): 4.4- 5.9 . The initial tension the beltin thiscondition on shouldbe approximately kg. 20

EN- 125

PARTS ON-VEHICLE
R B 2 O D / D E TE N G l N E E

[Point11] Installidler & tensionerpulley stud coatinserted . Do notloosen lf studswhendisassembly. studsareloosened, inserted (JapanLocktite or equivalent. KK) solution withlocktite

[Point12] Timing belt insPection . Replace at are timingbeltif any problems indicated the inspection Cause
Toothmissing Cracked tooth Cracks on rear side Wear and cracks on the side

<?

Camshaft lock Crank sensorlock Tensionerlock E ngine overheat with belt cover etc. lnterference Belt misalignment Belt plate malfunction in Slidingmotionresistance crank sensor and the camshaft Oil seal malfunction Water leaks in water PumP

Worn teeth

Oil or water adheston

Caution: on is surethere nooilfilmor water thebelt belt the Donottwistor bend timing . Make

PUMP WATER & 10.6 REMOVE INSTALL

plaott1ryo.64-085
,t
\')/

lt

(2) Botr 3.2- 4

{s'

19 ns-'

pump 1, Water lPoint 2]

ti E

t\

ffih,u-,,
E N- 1 2 6

Additionalwork requ ired: . Drainand refillcooling water . Timingbeltcover

ON-VEHICLE PARTS
R B 2 O D / D E TE N G I N E E

Remove& installwater pump [Point1] Remove . Caremustbe takennotto get coolant the timingbelt. on Wipeit off immediately anywaterdoesspill. if . Remove waterpumpboltsin the reverse the ordershown. Installation . Install blotsin the numbered the seouence shown. . Wipeoffoil liquid gasket fromthe cylinder blockandon the waterpumpandwipethe surface withwhitegasoline. . Applycontinuous gasket beadof liquid (KP5'10 50)to 00'l waterpumpsealing surface. Caution: Be sureliquid gasket 2.0to 3.0 mm wide. is Installation mustbe carried within5 minutes out afterliquid gasket application.
gasket2.0 - 3.0 mm Liquid wide alongthe groove

Waterpump inspection [Point2] . Rotate waterpumpby handand checkfor abnormal the soundandsmoothoperation. . Theremustbe no tracesof waterleaks.

10-7

REMOVE& INSTALLTHERMOSTAT
Thermostat [Point2j Thermostat housinglPoint 1

a \

ff'\,,

t o-z lPl p r-rquio nr"*"?o'ttt'

Fi

!',1 ks-m

Additionalwork required: . Disconnect connect and waterinlethose. . Drainand refillcooling water Caution: Loosenenginedrainplugto removecooling waterfrom cylinder block.

EN- 127

PARTS ON-VEHICLE
R B 2 O D / D E TE N G I N E E

Remove& installthermostathousing [Point1] Removal and . lnsert screwdriver housing into handle thermostat the housing. the to move it up anddownlightly remove fzo - 3.0 mm wldeto centerof flat lnstallation . Remove liquidgasketon the thermostat and I matingsurfaceand innerseating housing old withwhite blockandwipeoffthe surface the cylinder gasoline. . Cutnozzle tube. gasket (KP510 00150) endof liquid . Applya continuous gasketto sealing surface beadof liquid within5 minutes the usingthe tubepresser.Install housing liquidgasket. aftercoating

Installthermostat [Point2] is . 'Top'mark(igglevalve)mustfaceup whenthermostat in inserted housing.

Thermostat insPection [Point 3] valve . Checkthevalveopening and temperature maximum tift. in . Hangthe thermostat stringin valveand submerge by and walledcontainer stirwaterwhile waterin double heated it heating up. . Theopening whenthevalve is temperature thetemperature falls opensandthermostat fromstring

76.5 '10l90

E N- 1 2 8

ON.VEHICLE PARTS
R B 2 O D i D E TE N G I N E E

1O-8REMOVE INSTALL & OIL PAN,OIL STRAINER AND OIL FILTER

O-ring 6

Oil pan bolt (30) 0 . 5- 0 . 7

lvll Kg_m

Oil strainer bolt ( 2 )1 . 6- 2 . 1

oil I Engine gasket Liquid E aflerevery drsassembry E Reolace

Additional workrequired : . Front stabilizer . Radiator shroud fan, . Right leftengine gusset & . Engine plate rear (lower) vehicles) (A/T . Enoine oil

Remove& installoilfilter [Point1] Removal . Useoil filterwrenchto remove oilfilter. the Installation . Beforeinstalling newoilfilter, wipeoffdustetc.from cylinder blockmounting surface.Applya thincoatof engine to oilfilter oil O-ring. . Screwoil filteron bracket handuntila slightresistance by isfelt,thentighten additional turnwithoilfllter an 2/3 wrench. Aftertightening, startengineand checkfor oil leaks.

. Remove boltsin reverse the sequence figureon right. of Installation . Install boltsin sequence the shownin figureon right.

[Point2] Remove

Remove install panbolts & oil

1 9 1 5 17 3 1 5 1

9131721

E N- 1 2 9

PARTS ON-VEHICLE
R B 2 O D / D E TE N G I N E E

Remove & install oil Pan [Point 3] Removal . Usesealcutterto remove oil pan. the Caution: oil (1) the Afterremoving oil pan,remove liquidgasketon the groove using panflange andtheoilblock theoil scraper.Makesureto removeliquidgasketdropped the inside oil Pan. Caremustbe takennotto damagethe oil pan Q\ . Remove enginemounting nuts(oilpanside)and use the the hoistcraneto movetheoil panforward.Takeoffthe oil the removing oilpan. before the boltsusing wrench strainer Caution: too Caremustbe takennot to pullthe hosesand harnesses crane. usingthe hoist up muchwhenlifting the engine lnstallation . Thefollowing out procedure mustbe carried within5 minutes: . Applyacontinuous gasket(KPS10 00150) beadof liquid presser' to sealingsurfaceusinga tube . Install oil panwithin5 minutes aftercoating. the

' ,

, , , i '

(WS3993) Tubepresser
Liquidgasket

Oil leakand oil pressureinspection [Point4] . Startthe engine check anyoilleakandtheoil for and pressure the release oil To Dressure. checkthe oil gauge. switchand usethe oil pressure oressure

Installoil strainer [Point 5] properly . Checkto makesurethe O-ringis installed before strainer. the installing oil Tighteningtorque (kg-m): 1.6- 2.1

E N- 1 3 0

ON.VEHICLE PARTS
R S 2 O D EE N GN E T

10-9REMOVE& TNSTALL TNTERCOOLER (RB2oDET)

"'i5=;"*3h"Sj"=@jluri"""
Turbocharger

*;;"_O M_@4p :::="" .*- . il"*';b,mffi3Tff;:: -'ry4e"';ol .o""' ll-, u" "^^,66;
H *XgF/ g.

cramp-g

Arrrose \=/

Airn^<a

i";:'iF

^ in'"'-"nn'"' s;il'-l

ff"ct

Inter-cooler bracket Inter-coolef

ri. \",1Kg-m

Additionalwork required: . Leftfrontfenderprotector . Fender stay . Bonnet lPoint 1l

Remove& installbonnet [Point1] . Remove sidebonnetboltsonly(Liftup leftsideof the left bonnet operate). to

Remove& installintercooler [Point2] . Remove fenderprotector the thenremovecoolerboltsto removeinter-cooler. Takecarenot to damagethefins. Caution: The finsare aluminium can be damaged and easily.Never placeanything the intercooler allowtoolsor otherharo on or objects contact fins. to the Themainunit(tank, fins, tube) cannot disassembled. be

EN - 131

PARTS ON-VEHICLE
R B 2 O D EE N G I N E T

ASSY (lncludefault diagnosis) Remove& Installturbocharger 10-10 (1) Removal& installation

)) # P5 ;::"\T'a'"^'''"'ffi"fl. {,*"gEK#"O:
.<=t4\

1--#r\ B"!t!TUq
1",/ Kg-m after every disassemblY $ Reptace

l$ -;; leo";'o ,**"I,T::[- Q'*-''

\\.,1,,*

work required: Additional . Under cover . Assemble disassemble front exhaust tube & . O^sensor connector . lniercooler inlet hoses tubes, air . Airinlet oipe

wateroutlettube Remove 1] [Point . Remove water the outlet tubebyfirstremoving clamp the block. on located therearsideof thecylinder

Water outlet tube

Inspection . Aftercleaning waterinletandoutlettubewith radiator air blowwithcompressed and checkfor rustor cleaner. clogging.

EN - 132

ON-VEHICLE PARTS
R B 2 O D EE N G I N E T

Removeoil feed tube [Point 2] . Remove oilfeedtubebyfirstremoving cylinder the the block andturbocharger eyebolts.

Inspection . After cleaning feedtube oil withengine conditioner, blow withcompressed andcheck clogging. air for
....' :-

Removeoil returnpipe [Point3] . Remove oil returnpipeby firstremoving oil pan the the clampandthe turbocharger bolts.

Remove& install lock plate [Point 4] Removal . Spreadthe lockplatepawlswitha screwdriver loosen and thenuts. Installation . Position lockplates the andturbocharger mounting nuts. Aftertightening nuts,bendlockplatepawlsontothe the nuts.

Fl

Eyeboltdetermination [Point 5] . Oilfeed(cylinder block sideandturbocharger eyebolts side) "G", arestamped Installation order 1. Turbocharger mainunit 2. Waterfeedtube 3. Oil feedtube 4. Wateroutlet tube 5. Oil returnpipe

EN- 133

PARTS ON-VEHICLE
R B 2 O D EE N G I N E T

(2\ Turbochargerunit insPection

7] Actuator [Point pressureleak Excessive location Exhaustgas leak tnspection valve[Point3] CrackinspectionCrack lnspection Turbinewheel l P o i n 1 ,2 , 4 l t

wheel Compressor [Point5] Coolingwater Rotorshaft[Pornt B] 6, [PointB] ilocation ) Oil leak inspection

Rotor shaft insPection [Point1] . Theremustbe no heaviness dragging theshaftmust and or shaftis turnedby finger. whenrotor turnsmoothly

wheelinspection Turbine 2] [Point . Oilmust adhere surfaces. to not . There accumulation. be must nocarbon . Thevanes theturbine not rotor must bebent. of . There housing. with must nointerference turbine be

Swing valve insPection [Point3] . Remove rod actuator pinand makesurethe swingvalve or deformation cracks without movessmoothly in . Makesurethereare no misaligned surfaces seating housing. turbine

Rotor shaft play inspection [Point4] playandthrust . Position dialgauge andmeasure the clearance. 0.084 0.107 Rotorshaftplay(mm): (mm): 0.045- 0.140 Thrustclearance

E N- 1 3 4

ON-VEHICLE PARTS
R B 2 O D EE N G I N E T

Compressor wheel inspection [Point5] . Oil mustnotadhere suction to inlet. . Theremustbe no interference compressor with housing. . Wheelmustnotbe bent,foldedor otherwise damaqed.

'qf;:l,Tiltrl
'd^"1,"9"a.

6] Rotorshaftinspection [Point . There must nocarbon be sledoe accumulation.

Swing valve controller inspection [Point 7] . Remove swingvalvecontroller the rubber hoseon the compressor housing side . Check swing the valvecontroller whenever actuator the rod is installed removed. or . Usetheairgunto blowcompressed approx. - 0.9 air 0.8 kg/cm2 hoseand makesurethe swingvalvecontroller into rodoperates.Stopblowing as soonas the rod air operates. Caution: Makesureto verifythe airgun pressure usingthe LPG pressure gaugebeforetesting air hose. lf air pressure the is applied excessively diaphragm the may be damaged.

Operatessmoothly

Oilandcooling waterinletandoutlet cleaning . Useengine conditioner clean oilfeedandreturn to the passages. . Useradiator cleaner clean to coolinq water feedandreturn passages. . Clean using airgun. the

8] [Point

. Cleanthe compressor wheel,turbine wheel,compressor housing andturbine housing withsamemethods.

EN- 135

PARTS ON-VEHICLE
R B 2 O D EE N G I N E T

(3)

failurediagnosis(Oil leaks,smoke(whiteor blue smoke),lack Turbocharger abnormalnoise) of power,poor acceleration,

Pointsto be checkedbeforediagnosis: gauge. on the mustbe between MINandtheMAXmarks theolllevel level 1. Theengineoil oil the is thanMAXline, engine willflowintotheintake oil (whentheengine level higher may passandtheturbocharger be gas recirculation the ductthrough blowby to determined be malfunctioning). when idlingafierdriving' if to customer determine oil is cooled 2. Checkwith the replace in chartis detected a unitinspection, in lf any malfunction thefollowing ASSY turbocharoer

1,.

Smoke
Oil on rotors Carbonhas accumulated Turbinerotor Rotor scrapesagainstthe housarE vanesare bent or folded Turbrme Suctioninlet is dirty with oil Compressorwheel Rotor scrapes agairEt the hosing Turbinevanes are bent or folded There is resistanceor scraping when rotatedby finger Turbineand compresor Rotor shat play arsPection Rotationby finger is not Possible
Cor6iderable shaking between rotor shaft and turbo ASSY

rAbnofmal noas

A A A

Or

A
C

a
C

o
l\

C
@

.A A

C
A
ll

z__.\
ll

o
^1_\

Carbonsludgehas accumulated Look throwh oil lrole (inspectinteriorwith Pen light) in waste oil hole Ti valvedoes rnt mo\ when pressureis smoothly (t6uallyoPens applied gradually. at pressuregreaterthan 0.6 - 0.7 kg/cm') possible Slightly

Swing valveoperation (usearr 9unor alr pump)

O Highlypossible

Possible

l\

E N- 1 3 6

ON.VEHICLE PARTS
C A l B ]E N G I N E

10,1 INTAKE MANIFOLD ASSY (1) Remove& instalintakemanifoldASSY tn,ou," bort t.e- z.zp) Oody (4)
Gasket $
RTC heater lPoint 4l

T,

Breather hose

Intake manifold ASSY IPoint

-( '|l

gasketE
\-,1 kg-m $ Reptace after every disassembly

Additionalwork required: . Release pressure thefuellines fuel in . Drainand refillcooling water . Air cleaner ASSY . Fuelhose . Waterhose . Intake sidehigh{ension cable . Vacuum hosesand ECCSharness connectors . Acceleration IPoint1] wire . Watertemperature sensor connector . Thermal transmitter connector

Accelerationwire adjustment [Point 1] . Loosenlocknutto provide adequate slackfor the accelerator and pulloutercasein the direction the wire of accelerator. Return locknut 1.0- 1.5turnsfromthe the position throttle the drumstartsmoving(whenthereis no playin cable) tighten. and Tightening torque (kg-m): 0.8- 1.0

Remove& installintakemanifold [Point2] . Removal the reverse installation is of sequence shownin thefigureon the right. . The installation sequence shownin thefigure. is Note: Neverreusethe gasket. E N- 1 3 7

PARTS ON-VEHICLE
CA18ENGINE i

Intakemanifoldinspection [Point3] . Measure intakemanifold in for surface distortions four the and horizontally (atopposite directions; directions separate of in vertically) a number locations. 0.15 Limit value(mm):

Straight

PTCheaterinsPection [Point4] . Make on is there nocrack thePTCheater. sure

throttlebodyASSY & (2) Disassemble assemble

cover screw Fueliniector {2)0 20 .- 0 26I \g , $o-ring =----dG
cl,el lnjector,0j,", ,, _ e ,.-t Btackel

'ut'rntector cover

$o-nng-.....-"
'egulator 4l Pressure lPo,nt

^'

.*?" ':"t, [l i fl

uT

-V,a \|g--

- Sc'ew OO+- OSSp) {4]

rh,ort," uppe. ouuy^-_ -__

Thermowax lPornt

/ s"u' ^, eoin, J1
S/

^,V&d*o. ^7*ir9"" o,o- o,u 7]

0 Screw 20 - 0 26p

=\E adtust screw I hrottle

er th e yrpo \ ro. ointgt Lowerbodint _.,. --@ ffi,u

olo

.or-n g

screw Bracket =,"ref\rilff}:!,,3"il:(2)p -,, E1^.<-1

-6f"\

Fuel injectorharness

ri k g - m \-/

a ReplaceaftereverydisassernblY
E N- 1 3 8

ON-VEH ICLEPARTS
.A'3 ENGNE

Remove& install throttle body ASSY . Firstremovefour throttlebody boltsto removethrot e body ASSY . Afterthe installation checkthe tightening torque. 't.8- 2.2 Bolt tighteningtorque (kg-m): . Alwaysreplace gasketwith newones.

[Point1] Removeupperthrottle body . Firstremove fuelinjector the coverthenseparate fuei the injector connector. . Loosen four upperthrottle bodyscrewsto remove.

[Point2] Fuelinjector Removal . Firstremovethe injector coverto removeupperO-ring, thenextract fuel injector. . Caremustbe takennotto scratchor damagethe fuel injector and throttle bodysealsurface. Cautionswhen handlingO-ring . Never reuseO-rings. . CoattheO-ring withengine (7.5W - 30 or equivalent) oil butdo notapplysolvent themas thismay remove oil to the coatrng. . Do not allowdirt,dustor foreignobjectsto adhereto O-rings otherequipment or surfaces. . Caremustbe takennotto scratch, twistor stretchO-rings wheninstalling. notinsert in thefueltubeby Do it makingit stretch slightly. . Do notstoreO-rings location in subject ozone,high to temperature in directsunlight. or Installation Replace bothupperand lowerO-rings newones. to Coatthe lowerO-ringwithengineoil and install throttle to body. Placethefuel injector insidethe throttle bodyand set the position placing injector injector by the connector the and injector cover. (resistance Useoil sealdriftto insertthe fuel iniector must be felt). Coatthe upperO-ring withengine Useoilsealdriftto oil. insert O-ring. the

/--\.
l:

-lniector cover

'..-r'\

Conneclor:rJ rubber \9

\^ Injector wrflng
connector
F u e lI n i e c t o r

E N- 1 3 9

PARTS ON-VEHICLE
C A ' 1 8E N G I N E i

Cam ASSY [Point3] Removal . Remove camASSYfromthe upperthrottle body. the Caution: Extracare must be taken as there are tensionon the cam spring. Inspection . Lookfor anydeformation wearon the cam spring. or 24.5- 26.5 Cap spring free length(mm): lnstallation . Makesureto install cam ASSYand the cam springin the rightdirection. . Reolace seatwithnewones. the
Free length I

reguator Pressure

regulator Pressure 4] [Point Removal . Remove pressure body' throttle from regulator theupper the . Carry pressure inspection. outthefuel

IPoint5] Removal

drum Throttle drum& A / T control

. Firstremove nutsandremove A / T control drum. the the . Removethrottle adjustscrewand returnspringand remove body. drumfromthe lowerthrottle thethrottle Inspection . Inspectvisually cracksordeformation if thereareanywarn, retainer, colour.Also inspect and on springretainer, rotationcontactsurface. . Checkdeformation warnon thethrottle adjustment and spring. screwand return 19.5- 21.5 Returnspring free length(mm): lnstallation . Caremustbe takento install partsin correct direction the drum throttle spring, the installing armASSY return when controldrum. andA,/T

Springretarner (plastrc)

\0.J
\

f<

(plastic) /,Retainer Color(plastic

E N- 1 4 0

ON-VEHICLE PARTS
C A l 8 iE N G I N E

Remove dashpot [Point 6] . Firstremove dashpot the bracket remove dashpot. to the Inspection . Checkvisually anydeformation cracks the rubber for or on oan.

Remove thermoswax [Point7] . First remove throttle bracket remove the wire to thermo wax. Inspection . Check thepinwillextend if when thermo is the wax warmeo. Caution: Donotpull thepin. out

Thermowax

[Point8]

FIGD solenoid& ldle revolution adjustment solenoid

Removal . RemoveFIDCsolenoid and idleuo solenoid fromlower throttlebody. Caution: Watchoutfor springandthe valveas it mayjumpout. Inspection . Checkthatno warnorforeignmatteradheres valvehead. to . Checkthe spring deformation warn. for or '11 12 Spring free length (mm): lnstallation . Checktheorientation thevalvewhen of installino.

Lower throttle body inspection [Point 9] . Checkfor any clogging the air passage carrying in by out air blowinspection. . Checkfor any cracks lowerthrottle on body.

EN- 141

PARTS ON-VEHICLE
C A l 8 iE N G I N E

10-2

EXHAUSTMANIFOLDASSY
qasket Exhaustmanifold - ,f4f;^

ddl V/,^-,T
fru

-rw--4;

Washer

t: l,aa

"* if::'liHllli 'u'

o,

gl o,r" "-(.,:-'r.,lpoint f
manifold Exhaust lPoint2]

R.

Heat shieldPlate ri. l-/ Kq-m $ Replaceafter everydisassembly

work required: Additional . Under cover . Exhaust tubenuts front . O,sensor connector . Exhaust sensor temperature . Hotairduct

Remove& installexhaustmanifold [Point1] Removal . Removal the reverse installation shownin sequence of is thefigure. lnstallation . The installation is sequence shownin the figureon right. . Checkthe standard torqueafterinstallation. tightening

Exhaustmanifoldinspection [Point2] in . Measure exhaust for surface distortions four manifold the and horizontally (opposite directions: directions separate of in vertically) a number locations).

gauge Straight

Remove& install O, sensor [Point 3] (Zirconium typesinglepoleconnector) . Do not usetoolswithimpactsuchas impact wrenchfor of and installation the O, sensor. removal E N- 1 4 2

ON-VEHICLE PARTS
CA18ENGINE ]

10-3

LOCKERCOVER
rlOSC

Oil Rtter cap \

\.4*
\=2

0.1- 0.3lPoinr 1] 3---'(8) Grommet 6 -_

LOCKeT COVer SCreW

fl.-r."y

Fi

l".l ks-m

Additionalwork required: . High{ension cable . AircleanerASSY

Remove& installlockercover [Point1] Removal . Removal the reverse is orderof installation seouence shown in thefigureon right. Installation . The installation sequence shownin thefigureon right. is . Whenremoving installing locker and the cover, alsoremove gasketand wipeoff the oil adhereon the gasket the cover and in the oroove.

Locker cover gasket [Point 2] . Makesurethe rockercovergasketis positioned securely in groove without twisting.

EN - 143

PARTS ON-VEHICLE
C A 1 8E N G I N E i

10-4 TIMINGBELT(CRANKPULLEYBELTCOVER) ( 1 ) Remove& installtiming belt cover

cover upper
ac!.+---:=-=+--.-

\r2,_l-_=

B o l t( 4 ) 1 . 2- 1 . 6

Lower cove(-

I
I

ts-t
oil Engine

2] pulley 12.5 13.slPoint bolt E Crank Pl

Additionalwork required: . Under cover . Fanshroud . Supplement belts . SparkPlug 1] position . No. 1 cylinder T.D.C compression [Point . Install ringgearstopper [Point2]

D.T.C compression No.1 cylinder inspection . Align crank timing pulley and mark thebeltcover the T.D.C. to indicator compression [Point1]

. No. 1 cylinder at compression stroketop deadcenter is sidecamsdo not move whenboththe intakeandexhaust thevalvelifters.

E N- 1 4 4

ON-VEHICLE PARTS
C A IB i E N G I N E

Remove& installcrank pulleybolts [Point2] . Remove starter motorand attachringgearstopper. Caution: Coatthe screwpartwithengineoilwhentightening crank the pulley bolt. Do not applyany oil on the damper areawhen installing or removing crankpulley. the

3] Remove crankpulley [Point . Loosen crank pulley the puller bolts usepulley and (steering puller wheel ST27180001) remove crank to the pulley. Caution: Donothook pulley puller thecrank the pulley groove. on

Remove& instatl belt cover [Point 4] . Do notscratch packing whenremoving installing and the beltcover. . Alwaystighten beltcoverboltusingthe rubber the washer

Installcrank pulleyplate [Point5] . Makesurethe crankpulleyplateis positioned correct in wav.

Crankpulleyside

(21 Remove& installtiming belt Timingbelt alignmentmarkverification and installation . lf painton upperbeltis unclear whendisassembly is performed, painta markon beltthat indicates rotation direction. . Position alignment the markof the cam pulleys with respective timingbeltcoveralignment marks. (No.1 cylinder T.D.C) at . Install timingbeltso the number ridges the of fromthe alignment markto crankpulley(inner) alignment markwill be as indicated below.

cA18i

43

95

EN - 145

PARTS ON-VEHICLE
CA18ENGINE r

Timing belt tensionadjustment . Remove bolt tensioner (1 & 2) sparkplugandtighten temporarily. . Hookthe tensioner spring(3) on the lowerbolt(2). . Hookthe springon the hook(4) andtighten bolt(1). the . Loosen tensioner andtighten bolt(2). (5) the the Caution: at correctly this stage Makesurethe springis positioned . Checkif thetensioner willrotate (5) by whenpushed finger. pulley . Align timing alignment markandthe belt the the to install timingbelt. mark alignment . Loosen tensioner (2). bolt the . Turnthe campulley to turnsclockwise check morethantvvo and beltmovement stopslowlyat No. 1 cylinder T. compression D.CPoint.

. Tighten bolts tensioner (1& 2). torque(kg-m): Tightening

1 . 5- 2 . O

(3) Timingbelt insPection any indicates problem. timingbeltif inspection Replace

Toothmissing Cracked tooth Cracks on rear sloe Wear and cracks on the side

@
/.Mhx t*tlt'x

Camshaft lock Crank sensor lock Tensionerlock Engine overheat with belt cover etc. Interference

.J\>
'=w!l jJlfuu/
/ A'/.4i // ///// //l

Beltmisalignment Beltplatemalfunction

Worn teeth

in Slidingmotionresistance the camshaft crank sensor and

Oilor water adhesion

Oil seal malfunction Waterleaksin waterpump

Caution: or (1) Makesurethetimingbeltis nottwisted bentsharply. is no oil film or wateron the belt. Makesurethere km every100,000 (2) Timingbeltneedto be replaced

E N- 1 4 6

ON-VEHICLE PARTS
C A ' 3 E N GN E

10.5

WATERPUMP

Waterpump[Point| 2]

,",(3),u_$\ ffiP
Springwasher \

'/:,j$t

gf.o<-spr.ins =\

*asne,

\ -Bolt(2) 16-20 E is-r p Repiace afterevery disassembly

Additional workrequired: . Drain refill and cooling water . Fanshroud . Fan . Water pump pulley . Supplementary belts . limingbeltcover Remove waterpump [Point1] . Becareful to getcoolant timing not on belt.lf anywaterdoes wipeifoffimmediately. spill, Caution: Remove gasket thewater pump old on surface using scraper. the

pumpinspection 2] Water [Point . Rotate pump hand check anyabnormal water by and for sound smooth and operation. . There must notraces water be of leaks.

E N- 1 4 7

PARTS ON-VEHICLE
C A IB i E N G I N E

10-6

THERMOSTAT

Thermostat lPoint2l Gasket

houstr Thermostat 1l t lPoint

ds\ -\-"\'t
\ ----rll./ - L l --

7r, \",4 Kg-m

dl-

( B o l t 3 )1 . 6 ' 2 . 1

everydisassembly after $ Replace

Additionalwork required: . Drainand refillcooling water . Wateroutlethose

Remove& installthermostathousing [Point1l Removal . lnsertscrewdriver housing Prylightly handleintothermostat up and downand removehouslng. lnstallation . Placethejigglevalveon topwheninstalling thermostat the housing. Caution: Removeold gasket on the water outlet surfaceusing the scraDer.

Thermostat inspection [Point 2] valve . Checkthe valveopening and temperature maximum tift. in . Hangthethermostat stringin valveand submerge by while and walled container stirwater waterin double heated it heating up. . The opening whenthe valve is temperature thetemperature fallsfromstring. opensandthermostat

String Double-wall container Thermostat

82 OverI / 95

88 Over7 / 100

E N. 1 4 8

ON-VEHICLE PARTS
]A'! E\G NE

10.7 otL PAN& OtLFILTER (1) Remove install p a n & oil

Oilstrarner nut $ oil strainel-q,
gasket

oz-oaPl=---...-. .
E

p$oit

9i,1;1'Ii'6b\e
Eoil sealgasket

El(front)\int4l

,rt')Qffi

+4eet'rt '\.)-erz-?)

:1

\u"
seaoastet

\ "
Drainplugwasher[Point4]$ pj

H, ,''0, u, - 0 85lPoint o 4]

t r , l".l Kg-m p Liquidgasket Q

Replaceafter every disassembly

Additional workrequired: . Under cover . Engine oil . Right leftengine gusset &

Drain plug washer [Point1] . Thedrainplugwasher hasinstallation direction, makesure to install the correct in direction. . Alwaysreplace drainplugwithnewoneswhenremoving andinstallino.

Oil pan side

Remove& installoil pan bolt [Point2] Removal . Remove boltsin reverse the seouence shownin floure on right. Installation . Install boltsin sequence shownin the figure right. on . Tighten boltsto correct tightening torque.

lr

Removeand installoil pan [Point3] Removal . R e m o v e t h e op la nu s i n g t h e s e a l c u t t e r ( K V 1 1 1 0 0 ) i 0 Caution: Remove liquidgasketon the blockpanflangegroove old usrng scraper. a E N- 1 4 9

PARTS ON-VEHICLE
CA18ENGINE i

lnstallation . Applysealing on or agent(SS60F equivalent) theareas oil to on shownin thefigure right install pangasket.
:.--

. Applya continuous gasket (KP510 00150) beadof liquid the and install oil tubepresser usingthe to sealingsurface panwithin5 minutes aftercoating.

. Insert two centerboltsto oil pan boltholes,makesureit is thentighten fitted correctly Caution: afterthe installation. Leave 30 minutes for

inspection 4] Oil leak& oil pressure [Point . Warm theengine check anyoilleaking the and for and up oilpressure. . Release oilpressure the and switch install oilpressure the inspection. out gauge whencarrying theoilpressure

Whenidling

2000 Approx.3

4000
4 Approx.

1 Approx.

(21 Remove& installoilfilter Removal . Useoil filterwrenchto remove oilfilter. the lnstallation . Beforeinstalling oil filter, wipeoffdust,etc.fromoil the blocksurface.Applya thincoatof engineoil to cylinder newoil filterO-ring. . Screwoil filterby handuntilit hitthe cylinder then block, wrench.After 2 an tighten additional / 3 turnwithoil filter startthe engineand checkfor oil leaks tightening, 't.5- 2.1 Tighteningtorque (kg-m): E N- 1 5 0

ON-VEHICLE PARTS
RB25DE NGINE E

10-1

AIR DUCT& AIR CLEANER I o.ts "_ Air Airhose p rilo'"" '," o.ro.1zy hose UDe L,"\..t_ ,/ ^ ,/ Rubber \ I

p 0 5 2 - 0 6 6 ( 4 )j
O-ring E

pr.: - r.o1z1

\(@ chambef

'"f"'

,,Y
. . ' - Ho s e ^ - ^

Air cleanefcase Air cleanerelement

Insutator
^ ^ ^ F i r

u^cz - uoo lv,/ r J r l " , l0 5 2 - 0 6 6 ( 4 )

( 0 . 5 2 0 . 6 6 2 )! - l

Resonator

-e/g v,

E '^^,)h '^

bracket

n c,l - necfC|l

{ as2-o66pJ

Removal . Remove negative the terminal fromthe battery. . Usean air gunto blowoff any dirtor dustbeforeremoving theairhoseandairduct. Removethe following: . 2 vacuumhosesfromthe resonator (between intake manifold canister). and Blowbyhosebetween locker coverand air duct. Air hosebetween ductandair requlator. air

. Remove airflow meterconnector.

E N- 1 5 1

PARTS ON-VEHICLE
RB2sDE NGINE E

markon eachair hosesandthe ductthen Putalignment remove. case(1 on uppercase3 on 4 Remove clipson air cleaner lowercase). element. air uppercaseto extract cleaner Remove 4 removing bolts. the Remove lowercaseby first

the by the Remove resonator firstremoving leftfender bolt. the protector thenloosening resonator

the the Remove airductbyfirstremoving frontcombination lamoandthe leftheadlampASSY or Caremustbe takennotto scratch damagethe airflow meter' the whenremoving airflow metersensor

lnstallation out . lnstallation airduct theaircleaneris carried and ofthe operation. of order removal in reverse when . Airflow use case metercircuit isnonseparable, ASSY the replacing airflowmeter. . Make and the to sure insert airhose theairductsecurely the and correctly tighten mark the byaligning alignment band theclamP. and

E N- 1 5 2

ON-VEHICLE PARTS
RB25DE NGINE E

1O.2 INTAKEMANIFOLD GOLLECTOR (1) Remove& installintakemanifoldcollector

ASSY |2i'ftt:'rti:g coirector -Y-V

\ -,-aa gasketE Collector

-[]

/l
pcoltector (2)1.8 2z.-*& boit
l-,i r<9-m E Replaceafter every disassembly

\ \ .'.
g

irlt , u22 \2)P)

. B- 2 . 2
FUELPU[,4P RELAY OFF (POS) 950 rpm CAS.RPI\,|

,/)

,,

. Select'Fuelpumprelay'in 'Active test'mode. . Selectcancel' release fuel pressure. to the . Crank2- 3 timesto consume fuelleftin the piping. the

Removal Release fuel pressure the . Warm theengine. up

:move fuel the purp frr". @ After engine the stops, crank engine twoorthree the over
timesto consume fuelleftin the pipe. the . lf the engine doesnotstart,remove pumpfuseand the crank the engine threeto fourtimesto consume fuel the leftin the pipe. Caution: The battery may becomeweakeasily, use booster cablesto connect to charged it battery necessary. if . . . . Remove negative the terminal fromthe battery. Draincooling waterfromthe radiator drainplug. Remove accelerator wire. Remove MC valveconnector, the FICDconnector the and vehicle bodyground cable

Remove hoseA between brakebooster the the andthe collector. Remove hoseB between unitandthefueldamoer. the IAA Remove hoseC between the canister the collector. and Remove hoseD between the canister the throttle and chamber.

EN- 153

PARTS ON-VEHICLE
E RB25DE NGINE

coverandthe locker RemoveblowbyhoseE befuveen collector. pressure regulator the and hoseF between Remove collector. threewaterhosesG. Remove and air the Remove hosebetween regulator the collector. the ASSYwhenremoving hosefor Liftup the collector operation. easier the fuel Remove feedandretumhoseH,thenremove clamp fromthe collector. ASSY the Loosen hoseclampto removecollector the Loosen boltsin ordershownin thefigureon right. are Checkto see everyhosesrequired removed.
11 J

. Remove gasket. collector gasket . Usea toolsuch a scraper remove leftover any to as onthesurface.

r:

lnstallation . Install collector gasket. the . Makesurethereis no dust,oil or otherforeign matteris on surface. the sealing . lnstall collector ASSY the . Tighten boltsin the ordershownin thefigureon right the tightness. stepsto uniform in Tighten gradual
. Lengfi {mm}: No. of bolls
7,10 I 105.2 65:1 40.4
1 - "9- - 5

. 1 ; " =3 - " - Y --s, . 7 . .

,2 - ' l.

't.8 - 2.2 1.8 2.2 1.8-2.2 1.8-2.2

l-

1,3,4,6
2 , 5 , 9 ,1 1

30:4

orderof eachwiringandthe pipingin the reverse Connect operation. the removal wire, the Connect accelerator wireand pull slackfor the accelerator adequate Provide usingthe of outercasein the direction the accelerator 1.5turnsfromthe position locknut 1.0to nut. Return adjust drumstartsmoving(whenthereis no play)and thethrottle tiohten. 0 . 8- 1 . 0 Tighteningtorque (kg-m): E N- 1 5 4

ON-VEHICLE PARTS
i 3 r 5 f : E N GN E

. Makesuretheradiator drainplugis closed securely and NEVER refill cooling the waterfromthe feedopening. OPEN WHEN . Release airusing airrelease the plugafter the refilling I F]OT ; a the cooling waterto prevent overheat. ... /2 ./ ) (\) Caution: Do notremove airrelease plugwhentheengine warm. the is Do notovertighten air release plugbolt. the

(21

Disassemble assemble & intakemanifoldcollector

pjBort 0.64 o (2)
Accelerator wire bracket Collector
AAC valve

(4) Bolt 0.e- 1.1 l \

lAA unit

9ts't Disassembly . Remove throttle chamber . Remove unit IAA

Water hose

E Replaceafterevery drsassembly

Assembly . Install gasket throttle chamber

lnstall iorrectdirection in

. Tighten throttle the chamber rnorder bolts shown figure in onright uniformly twostages. in Tightening torque(kg-m): Firststage 0.9- 1.1 Secondstage1.8- 2.2

. Install lMunit.

4 ' + , 0 . '0 - p .r
E N- 1 5 5

PARTS ON-VEHICLE
R B 2 s D E N GN E E

10-3

FUEL INJECTOR

ne0-I
Fi

rol-z.rtz)H

l".l k9-m

Removal process . Remove removal ASSY Fordetailed collector section. referto Collector" . Remove and connector the lamp. fuelinjector . Remove connector the Pin . The operation be carried easilyif the vehiclebody out can and connector the sensor ground watertemperature wires, are connector removed. transmitter thermal . Remove regulator connector. air . Remove fuelASSYby firstremoving bolts. the the . Replace fuel withnewoneswhenremoving injector, o-ring fromthefueltube. pressure and regulator fuelbumper . Do notpullthe connector partswhenremoving fuel the injector. when handlingO'ring Precautions . Coatthe O-ring but oil withengine (7.5W-30or equivalent) removethe oil coating. do notapplysolventas this may . AvoidusingdirtyO-rings and do not allowdirt,dustor or to objects adhereto O-rings otherequipment foreign surfaces. . Caremustbe takennotto scratch, themby twistor stretch O-rings. wheninstalling fingernails toolsor operator's Inspection . Fuelinjector resistance 13 value(f,|): Approx. - 14 Resistance . Iniector not be disassembled. can

E N- 1 5 6

ON-VEHICLE PARTS
RB25DE NGINE E

. Connect airregulator the connector. . Install fuelinjector the connector fixit inplace and using the
. ctamD. Install collector the ASSY

Installation . Do not rotate decenter partswheninstalling fuel or the the pressure in1ector, regulator fuelbumper thefueltube. and to . Tighten pressure the regulator thefuelbumper and screws uniformly twoto threestages. in Tightening torque(kg-m): 0.30- 0.39 . Install tubeASSY fuel Tightening torque (kg-m): 1 . 6- 2 . 1

10-4

INTAKEMANIFOLD p_@=---

aort o.o+o.asP 1z) Airreguraror

I

pipe oullet ASSY El Water

Intakemanifold i-,i kq-m A Liquidgasket B o l t( 6 ) 1 . 6- 2 1

p l e o it z o n - o s )

t',i

tt

Removal . Remove collector ASSY Fordetailed removal Drocess "Collector" referto section . Remove injector fuel ASSY . Remove waterhose. . Remove level gauge guidebolt. oil

Oil levelgauge

. Remove rearwaterpipeconnector bolt.

EN - 157

PARTS ON.VEHICLE
E RB25DE NGINE

ASSYboltsandnuts(1, manifold intake Remove the ordersshownin thefigureon right. gasket. the Remove intakemanifold . Remove ASS\. waterPiPe

'10'13)in

14 11

1312 10 4

lnstallation . Remove liquidgasketon the waterpipe,in the groove old with surfaces Cleanallcontact manifold. andon the intake or whitegasoline equivalent. gasket (KPs'10 50) 001 . Applya continuous beadof liquid - 3.0mmwideto sealing the using tube surface 2.0 pressor. Caution after within5 minutes shouldbe performed Installation gasket. the coating liquid enginecoolant. beforerefilling minutes Waitat least30

?,,

; -.

'3.

.jt"v,
/

:"'" - .,..''..'.-;'.|
. .ra)
,i-. ']

f-

ASSY the Install waterPiPe Tighteningtorque (kg-m):

(A)0.4 0.5 ( B )1 . 6- 2 . 1
(B) bolt(6)
1A-111o ,

gaskeL. manifold intake Install in (2. and the Install bolts nuts 10.13)uniformlyseveral on inthefigure theright. shown in stages theorder 1 . 8- 2 . 2 Tighteningtorque (kg-m):

1 4 1 3

1 4

z 3 5

. Install frontoil levelgaugeguidebolt. the

levelgauge g u i d e . 4- 0 . 5 0

. Install rearwaterpipeconnector bolt. the 0.4- 0.5 (kg'm): Tighteningtorque . lnstall waterhose. the
PrPe.l

E N- ' 1 5 8

ON-VEHICLE PARTS
RB25DE NGINE E

10-5

EXHAUST MANIFOLD
gasket $ Exhaustmanrfold

O r - s e n s4 .r1- 5 . 1 9 o

K:,
Exhaustmanifold

/:--9.

Washer
Nr,,rrto-2r\Fi

r3l

9ts-t

il;'

Exnaustmanrforo " -"

o a - - o s { 8 ) g sensor o,

tp

fr,

aftereverydisassembiy $ Reptace

Removal . Remove following: the . Under cover . Exhaust fronttube . O, sensorconnector . Exhaust manifold cover . Remove exhaust the manifold nutsin theordershownrn thefigureon right. . Remove exhaust qasket. the manifold Inspection . Lookfor anydistortion exhaust on manifold. Gas leakinspection . Afterremoving exhaust manifold,makesurethereare no tracesof gas leaksfromany partof installation. lnstallation . Install gasket. exhaust manifold . Install exhaust manifold, washer andtheVoke. Makesurenottomakemistake between 3 andNo.4 No. yokeas configurations different. are
Item No,3& Xo,i! port O$er than those above
22 24

Front

Makesurethe washeris facingthe correct waywhen installino.

Manlfold

EN - 159

PARTS ON-VEHICLE
RB2sDE NGINE

nutsin theordershownin the manifold Tighten exhaust figureon right.

cover. manifold exhaust lnstall crankengineand checkfor gas leak. Afterinstallation,

10-6

TIMINGBELT
Timingbeit cover(Upper) Timrngbelt

crommet ]

p aort r.o- z. r\ 121

t=o'
t@--- For
rrl

g N u t . 4- 5 . 9 4
Belt tensioner Conical ,'Tensioner

fo]!{a)fJ oromme

E kg-t o E Engine il aftereverydisassembly P Reptace

Removal . Remove undercover. . Draincooling enginedrainplug waterfromthe radiator . Remove belts. supplementary . Remove radiator, fan shroud fan. andthe cooling the the T.D.Cposition compression CheckNo. 1 cylinder timingmarkand beltcovertiming Alignthe crankpulley (0" At markindicator position). thistimethe No. 1 cylinder is whenthe camshaft T.D.Cposition is in the compression as locatedas described follow: top stroke deadcenter is No. 1 cylinder at thecompression sidecamsdo not and exhaust whenboththe No. 1 intake movethe valvelifters.

i'18\

EN - 160

ON-VEHICLE PARTS
RB25DE NGINE E

Remove oilfilter the camfromintake siderocker coverand checkthatthe frontend of camshaft facesthe intake side.

Remove crank angle sensor. Remove starter motor theninstall gear ring stopper. pulley Remove crank bolts.

puller remove crankpulley Usepulley to the (bolt size:M6x 1.0length below headapprox. mm) 50

. Remove crankanglesensorbracket, thenremove timing beltcover.Timingbeltcoveris separated upperand into lowersections, remove uppersection first the thenremove lowersection. Caution: Do not scratch driedliquidpacking when removing and installing timingbeltcover. the . Remove tensioner. belt . Secure tensioner the firmly witha hexagonal wrench when removing installing tensioner and bolt nuts. Caution: Do not looseninserted studat disassemblv.

lf paint timing is unclear on belt whendisassembly is performed, painta markon the beltthatindicates rotation direction. Remove timingbelt. the

EN - 161

PARTS ON-VEHICLE
RB2sDE NGINE

Timing belt insPection at . Replace are timingbeltif any problems indicated the inspection' timingbeltevery100'000km' to It is recommended replace Item
Toothmissing Cracked tooth
. '../'\

'<./

Camshaftlock Crank sensor lock

Crackson rear side

Wear and cracks on the side

lock Tensioner Engineoverheat with lnterference beltcoveretc.

Belt misalignment Belt platemalfunction In Slidingmotionresistance and the camshaft crank sensor Oil seal malfunction Water leaks in water PumP

Worn teeth

Oil or water adheston

Caution: Do nott*ist or bendthe timingbelt . Makesurethereis no oil filmor wateron the belt pulley, campulley tensioner can befoundon idlerpulley, Makesurethereis nowarnor cracks smoothly. spring.Alsocheckif theyrotates cranktimingpulleyandthetensioner

lnstallation the . Assemble tensioner springso it engages belt the pulley shownin thefigure. as tensioner withthe together . The tensioner springmustbe assembled block. pulleyin the cylinder belttensioner

sprlng . Whenthetensioner pulley free,hookthetensioner is springstud on the uppersideof the tensioner

/ A\Y] t( ' L\g)) )

{;</

-li \=o\- spring Tensioner

securinostud

-'t\t.

spring sPecifications Tensioner

pulley Tensioner

'1.8 m m

A p p r o x . 2 0 " A p p r o x1 6 3 "

Yellow-green

EN - 162

ON-VEHICLE PARTS
RB25DE NGINE E

Caremustbe takento install conical the washerin correct direction. lnstall crank the pulley theplate. timing and

]Fil
I

a l lf l r
\--J

l
. Be careful observe to frontand rearpositioning timing of beltplate, pulley cranktiming pulley plate andcranktiming wheninstallation performed. is . Alignthealignment marksof the exhaust and intake cam pulleys therespective coveralignment with belt marks(No. 1 cylinder atT,D.C). is . Alignthecranktiming pulley alignment markwiththe mark on oil pumphousing. Thegroovemustbe straight (No. up 1cylinder compression T.D.C). . Movethe belttensioner clockwise 70 - 80"Cangle, at and secure temporarily belttensioner it with nut. (Thiswill minimize offsetbetween tensioner the the shaftandthe timingbelt). . Alignthetiming beltpulley marksandinstall belt.Alignthe number ridges exhaust of of cam pulley alignment mark andcrankpulley (inner) alignment markas shownin the figureon right. . Afterloosening nutsandadjusting belttension, the the secure tensioner withhexagonal wrenchso it doesnot rotate together tighten nuts. and the Caution: At timingbeltassembly, checkthat it engages correctly with pulleyand it doesnotfloat. Timing belttensionadjustment . Remove sparkplugand aligntimingbeltalignment the markswithpulleymarksand install timingbelton to each pulley. Loosen tensioner so belttensionis applied the nut by tensioner spring. Turncrankpulley clockwise morethantwo tumsto check beltmovement stopslowlyat No. 1 cylinder and comoression T.D.C. Insert hexagonalwrench hexagonal in hole. Holdthe tensioner yourhandandtighten tensioner with the securing to specified nut tightening torque. Tightening torque (kg-m): 4.4- 5.9 At thiscondition tension belt shouldbe approximately 20 ko.

Nut

Conical

,
Crank plate

*""1"t

Crank pulleyside

Alignment mark

EN- 163

PARTS ON-VEHICLE
E RB2sDE NGINE

crankanglesensorbracket. Install Tighteningtorque (kg'm):

2 . 1- 2 . 7

Crank angle , sensor bracket

6 i z.t- z.t 1s1p)

. lnstall timingbeltcoverin orderof lowerthenupper. ( A ) 1 . 6- 2 . 1 Tighteningtorque (kg-m):

(B) 0.65 0.86

Installcrank anglesensor grease driveunitspline. to (1) Applychassis so inside driveunitspline spline the flange (2) Thereis a position.Checkthe alignment onlyhasone insertion beforeassernblY. (3) Checkthatthe crankanglesensorcan be inserted to easilyin beltcoverholesandsensormoveslightly bolts. rightand left,thentighten the loosen beltcover not lf thesensordoesn movelightly, A\ Movebeltcover inserted. withcrankanglesensor bolts center. to alignbeltcoverholecenterand camshaft crankanglesensor boltsmakingsurethe Tighten moveslightlY. 0 . 4- 0 . 5 Tighteningtorque (kg-m): the Position washerfor the crankpulleyboltsso the flat sideandthenassemble. the contacts crankpulley surface of Applyengineoil to thethreads crankpulleybolts.

torque(kg-m): Tightening

14.5 15.5

E N- 1 6 4

ON-VEHICLE PARTS
RB25DE NGINE E

10-7

OIL PAN

O-ring

Oilpanbolt(30) 0 . 5- 0 . 7 o i l strainer

l-,1kg-m g E Liquid asket after disassembly $ Repiace every

ti,

Removal . Drain engine oil. . Remove radiator fan. . Remove frontstabilizer. . Remove engineright& lefigusset.
121620 2428302622

. Remove pan boltsin orderof sequence oil shownin the figureon right.
Ti7sE272s2s2117 fi e

. Insert sealcutterbetween cylinder blockand oil pan. . Remove pan by tapping sealcutter oil the withhammer

. lf removing oil panfromthevehicle, remove the first front engine mounting nut. . Usethe hoistcraneto liftup the oil panforward. . Fromthe gap between cylinder the blockandthe oil pan, usea toolsuchas spanner remove strainer belt. to oil bolt . Pulltheoilpanout. Caution: Caremustbe takennotto strainthe hosesand the harness tootightly whenlifting the engine up usingthe hoistcrane.

EN - 165

PARTS ON-VEHICLE
RB2sDE NGINE

lnstallation from . Usea scraper remove tracesof oil liquidgasket all to blockand oil pansurface. cylinder

Caution: that material foreign and material other all Remove gasket pan. fallsintotheoil
. Cleanall contact or withwhitegasoline surfaces equivalent. . Cutoffnozzletipof gasket (KP510 atpoint 00150) liquid presser shownin thefigureon rightand insertintotube

gasket (KP51 00150) 0 . Applya continuous beadof liquid 4 surfaces mm wide. sealing to inner . lnstallation within5 minutes. be performed should Caution: gasket is application 4.0 mm wide. Be sureliquid oil engine andengine beforerefilling least30 minutes Waitat coolant.

10-8oll SEAL Valveoil seal . Remove following the Parts: . Engineundercover . Cleaning fan . Timingbeltcover, timingbelt . CamPulleY . BackPlate . Rockercover . Ornament . Camshaft . Hydraulic valvelifter . Valvespring . Useoil sealpullerto remove valveoil seal. . To prevent havethe pistonin compression valveomission position. T.D.C

Valveoil seal drift atlachment --.1' KV10111400

EN - 166

ON-VEHICLE PARTS
RB25DE NGINE E

. Valveoilsealinstallation measurement as shownin tne is figure right. on

Camshaft seal oil . Remove following parts: the . Engine undercover . Cooling fan . Crankpulley . Timing belt . Crankanglesensorbracket . Campulley . Backolate . RemoveNo. 1 camshaft thenremove camshaft seal. oil . Applyengine oilto areaaround oilseallip. the . Caremustbe takennotto scratch damageoil seal or retainer. oilsealdriftsmaller Use thanoilseal(41mm) and insertit at samelevelas frontsurface oil seal of retatner.

Oil seal drift KV40100900

Frontoil seal . Remove following parts: the . Engine undercover . Cooling fan . Crank pulley . Timing belt . Oil oan . Oilpump . Use a screwdriver removefrontoil sealfrom frontcover. to . Useoil sealdriftand insertnewfrontoil sealat samelever as frontsurface. . Facethe oil sealmarkoutside(frontside)wheninserting. Caution: Do not touchthe oil seal lip by flngeras greaseis appliedto areaaround oilseallio. the

'--_r{'@ r

Rearoil seal Remove following parts: the . Transmission A / T) (or . Flywheel driveplate) (or . Rearplate . Rearoil sealretainer

E N- 1 6 7

PARTS ON-VEHICLE
E RB25DE NGINE

grease areaaround sea oil to oil Applyengine or chassis lip. Caremustbe takennotto scratchor damageoil seal (100mm) diameter: retainer.Useoil sealdrift(External of samelevelas frontsurface oil seal and insertit at retainer. Cleaning . Usescraper removeliquidgasket. to Caution: gasketin the groove. Makesureto removeliquid . Cleanthecylinder andclean blocksideusingsamemethod withwhitegasoline. the surface

Rearoil seal installation . Installation within5 minutes. shouldbe performed . Cutoffnozzle of liquid at gasket (KPS10 00150) point tip rightand insertintotubepresser. shownin thefigureon

. Apply continuous of liquid gasket (KP510 00150) bead a - 3 mmwide 2 surfaces to rearoilsealretainer Caution: oil engine andengine refilling before 30 Wait least minutes at

v/ F\.0 64- 0.8

. Install to by rearoil sealretainer aligning dowelpin. . Tighten boltsuniformlY. 6

(R+
Rear oil seal retatner

E N- 1 6 8

ON.VEHICLE PARTS
RB25DE NGlNE E

10-9

ROCKER COVER IGNITION / COIL

Ornarnent lgnitioncoil Groundcable ?Oln^lrT-ra :aa--' -

tli

\",/ Kg-m Fillercap Rockercover O ring

Grommet
Rockercovergasket Ornament RockercovergaSket
\-.1i<9-m

Removal . Remove Rocker coverornament. . Remove ignition harness coil and removeignition coil.

. Loosen andremove rocker the bolts(intake exhaust) and in the ordershownin thefigureon right. . Remove rocker the cover.

Installation . Install rocker the mver. . Tighten rocker the coverscrewuniformly theordershown in in thefigureon rightin several stages.
8 4 2

. Install ignition bracket. the coil

Bolt0.3- 0.39 lgnition coil

. Install omament. the E N- 1 6 9

qS Vf ry rgnrtron corltacket

cv.rinder \LO

plu0 Spark

PARTS ON.VEHICLE
E RB25DE NGINE

HEAD CYLINDER 10.10 removal& installation (1) Cylinderhead

head bolt CVlinder

\J/

Leuserr

ut

o . o z1 . 2 , g l \ ^

washer g Spring -.-\o

\Y

to fl.,-(4) Tighten (5)AnSle wr II wl rorque ]|

g ,^,-^L^-

head bolt Cylinder

0.e2-1294

wasnerr'|

s/
j-Spring washer

' 0 v , /

f'-"{t

'.\) \ \ \ , \,]

/d'

H| rs-t
$

Cam pulley

Replaceafter every disassemblY

Removal . Remove fromthe radiator, watercompletely cooling drainPlug. block cylinder . Remove following; the . Connector and intakemanifold . Exhaust manifold . Timing belt . Rockercover,ignition coil . SparkPlug snown headboltsin the sequence the Remove cylinder on in thefigures right. headgasket. head,thencylinder the Remove cylinder head. on Checkfor anydistortion the cylinder blocksurface. on Checkfor any distortion the cylinder
I - 3 M6x1.0

15 4 - 1 7 | ' . , 41 .x

E N- 1 7 0

ON.VEHICLE PARTS
RB25DE NGINE E

Installation . Before installing cylinder the headASSYto cylinder block, the crankpulley andthe cam pulleymustbe positioned at No. '1cylinder compression T.D.Cposition. . Alignthecrankpulley timing markandthetiming cover belt timing indicator position). (0"

. Align intake theexhaust pulley and cam alignment mark to respective cover belt alignment marks.

Intakecam shaft Exhaust cam shafl

Makesureit is positioned No. 1 compression at T.D.C position.

Install cylinder headgasket. Install boltsin sequence the shownin thefigureon right. : The cylinder headboltsaretorqued two-step by method. llghten the boltsin two steps. ( 1 ) Tighten 3 kg-m. to (2) Tightened 10 kg-m. to (3) Loosen boltscompletely kg-m. 0 (4) Tighten 3 - 3.5 kg-m. to (5) Turnbolts80 - 90oclockwise whenanglewrenchis
USEO.

Tighten boltsto 10+15 kg-mwhentorque wrenchis used. Caution: Whenanglewrenchis not used,neverattempt to approximate tightening the anglevisually. . . . . . . Install ignition andthesparkplug. coil Install timing the belt. Install exhaust the manifold. Install collector intake and manifold. Checktheairflowof the hydraulic bulblifter. Pushthe hydraulic bulblifter crestsurface withfingerand check slump. the S l u m pl i m i tv a l u e( m m ) : 1.0

EN - 171

f O N - V E H I C L Ei R ' S
E RB25DE NGINE

hydraulic air of Thereis a possibility entrained withinthe needto be valvelifterif the slumpis over 1'0 mm Air valvelifter' fromhydraulic released at 4000rpm 10 ldlethe engineior approximately minutes cover' the afterinstalling rocker valvelifter coverandpushthe hydraulic the Remove rocKer to surface checkthe slumpof cam basecircle' if valvelifter thevalueis overthe the Replace hydraulic limit.

(2)

Cylinderheaddi"""."-bly, ""t"-bly&inspection
Valvelrfler-./ /

/u"V:f31'?'.,11''""' / 9ping seat

/ / Valve seal - o| " \<-

-'--"'" corer valve

t'd/^r/

.0.'"n**ffi" *
-t r P e o r r o . s.zj
Washer-=-3 Buffleplate---- washer/ A fp

-@-Y==--J:?"[',].",""""r"
, /Valve seat

.au^ru.

nu'o'

,{/-i

^^ -crr(@@--" O

E
I e/

B o r t o .1 2 g l e -washer

'"1::::.::"::li** *o@;*lT"ililJf""['S W KffiP*

":'">-t\
\

3:Ji9', # --.9^.#"*\
)t 6.Nr--_ F.:.t'

_ ' 4 F ^ ' " , 0 n ', sea6r[Hj::;";";:r g i l" \*tr!1liiry'""ffiy*i;ltj,tp;:;:,. r..-.'5-eo'osz-'ze ;:;:;:M,-;l*inan' ron' o
orl cam;hafttront sealE[

-$---& ri.,nso"*"o:,-a{-*?J _-\D

g..: *\..!

ffeonz.r
L",l hg'm A gasket Liquid

- z.zg

oil n Engine

aftereverydisassemblY E Replace

DisassemblY partinfrontof . Us" tne proper tooltosecurethehexagonal to camshaft removecam Pulley' . Removetimingbeltcoverbackplate shownIn to . Position cim shaftknock-pin the position the the figureon right.

E N- 1 7 2

ON-VEHICLE PARTS
RB25DE NGINE E

. Remove cambracket boltsby loosening themgradually rn several stages, reverse in sequence shownin thefigure on right. Caution: Beforeremoving camshaft bracket,paintmarksto indicate position bracket and direction. . Remove cam bracket. the

Intake exhaust and camshaft beidentified can by paint identification color presence a spline and gear of for driving crank the angle sensor.
Camshaft Intake camshaft Exhaust camshaft Purple Orange
No

Yes

I Spline gearfordriving crankangiesensoj

Remove hydraulic valvelifter. (1) Hydraulic valvelifter nonseparable. is (2) Do notstorehydraulic valvelifterup sidedownor on itsside. (3) Storehydraulic valvelifterin theengine when oil storing temporarily. . Usevalvespringcompressor (KV10108950)to remove varve spnngs.

C) V

/7^ @ K7\J

Cylinderhead inspection . Usescraper removeanytracesof oil,waterscale, to gasket, sealing agent,carbonetc.fromcylinder head surfaces. . Measure lowersurface cvlinder of headin sixdirections to

check distortion. for Limit(mm):

0.2

Whendistortion justoverthe limit, is resurface cylinder the head. lf distortion exceeds limit,replace the cylinder head.

Gamshaft visual inspection . Visually inspect camshaft anywarnor damage. for E N- 1 7 3

PARTS ON-VEHICLE
E RB25DE NGINE

Camshaftrun-out . Use V-block fixedsurface bothcamshaft and support on (No.1 & No.7). endjournals . Avoidthe oil groovein the centerof the No.4 journaland position dialgaugevertically. the . Rotate cam shaftby handto one direction and read the widthon dialgauge. the movement . The run-out equalto halfof the movement width is gauge. on indicated dial 0.05 value (mm): Standard

insPection Camnosediameter of diameter camnose. to measure Usemicrometer 39.705 39.895 value(mm): standard Intake 39.205 39.395 value(mm): standard Exhaust
valuediffers. if camshaft diameter Replace

Camshaftoil clearance . Tighten cam bracket specified torque. to the diameter' inside to micrometer measure Useinside 28.000 28.021 Standardvalue (mm): l-)

of . Usemicrometermeasure diameter camshaft outside to

JOUmal. Standard value (mm):

27.935- 27.955 ls measurement oil that Inspect the camshaft clearance value. withinsoecified = cam bracketinsidediameter Oil clearance camshaftjournal (outsidediameter) Standardvalue (mm): 0.045- 0.086

Camshaft end plaY to . Assemble cam bracket standard and camshaft tighten value. in . Seta dialgaugeat frontendof the camshaft thrust in frontand rear moves Whencamshaft direction. width. readthedualgaugerun-out direction, 0.030 0.080 value (mm): Standard

EN -

'174

ON-VEHICLE PARTS
RB25DE NGINE E

Valveguide clearance inspection D i a lg a u g e . Protrude valveapproximately mmfromvalveguidehome : 15 \ intocombustion chamber.Measure valvedeflection by swinging direction parallel dialgauge. into to . Theclearance equal is tohalfofthedialgauge reading (deflection width). Valveguide clearance (mm) Intake: 0.1 Exhaust: 0.1 . Replace valveor valveguideif clearance exceeds limit. Valveguide replacement . Usevalveguideremover andtap it fromcombustion chamber sideto removeseal.

Rectify guide cylinder head valve guide holeusing valve reamer Rectified valvestandard value(mm) Intake& exhaust: 6.000 6.018

Heatcylinder heatin an oilbathto approximately 150 160oC. Usea valveguidedriftand pressvalveguidefrom camshaft side.

. Thepress-fit dimensions shown figure right. are in on

+ 1 6 . 8 / -0 . 1

Intake Exhaust /

Ream inside theinserted ouide valve the of valve with ouide reamer. Finished internal diameter standard value(mm)
lntake& exhaust: 1 0 . 1 7- ' t 0 . 1 9 6 5
guide eamerKV101 1600) ( r 1

Valve seat inspection . Checkcontact surfaces thevalveseatandthevalve. of . Replace valveor valveseatif contacting surface too is largeor improper.

o* q"o,"

EN - 175

PARTS ON-VEHICLE
E RB25DE NGINE

Valve seat rePlacement . Cut andgrindvalveseatto remove valveseat. the . Readjust mounting holefor oversizevalveseat. the Standardvalue (mm): -0 36.5+0.016 lntake 3 2 . 0+ 0 . 0 1 6 0 Exhaust circle' . Read.just valveguidecentreandconcentric the . Heatup the cylinder oil bathto approximately headin an - 130"C. 110 . Usevalveseatdriftto tap it untilit strikethe bottom. . Whennotusingvalveseatdrift: 5 . Usedry rceto coolvalveseatfor approximatelyminutes' "C B0 headto approximately Heatup the cylinder . Insert headquickly. intocylinder valveseat cooled Caution: valveseatwithhands. touchcooled Do notdirectly

seat or . Read.lust valve using valve cutter valve seat seat the onnoer.

.\,=

is Valveseatshapeand measurement as shownin the on figures right.

* o D-'-

op,

t ,..',.,'

rg-'

.::-. . Urafe

Qa
so.o f,o'u
^^ . -0016 JO.C o

Qo, so.of,o!,'
^^ - +0113 Jb. c n o97

6o,
32.O 32.O

6o,

0D,
37.0

37.0

zs.t'.. , zs t',.,

E N- 1 7 6

ON-VEHICLE PARTS
RB25DE NGINE E

Valveinspection Outsidediameter measurement . Usemicrometer measure to eachdimension.

Valva lnlake

e
30.
'15"

Exhaust

8 5 . 3- 8 5 . 5 8 0 . 7 8- 8 ' 1 . 0 8 34.OO 34.02 5 965 - 5.980 1 . 1 5 - 1 . 4 5 2.60 - 2.90 8 7 . 3- 8 7 . 5 8 2 . 7 8- 8 3 . 0 8 2 9 0 0 - 2 9 0 7 5.960- 5.945 3 . 2- 3 . 4

Valvespring squareness inspection . Placea righfanglestraight edge(L-square) it contacts so thespring.Turnthe spring and measure maximum the clearance between upperspring surface andthe right anglesurface determine to out-of-square distance. Limit(mm): 1.8 . Replace valvespringif the oulof-square the distance is overthe limit.

Contact

Freelengthand pressureload inspection . Usea valvespringtesterto checkthe springpressure.

Freelength (mm): Installation (kg): load

43.1 24.0

Hydraulic valveliftervisualinspection . Visually inspect camshaft rotational areaon liftersideand lifterborerotational areafor anywarnor damage. . Replace thereareany abnormality. if Caution: Do notdisassemble hydraulic valvelifter.lt is nonseparabte un[.

t---.---,-'lJ

Hydraulicvalve lifter outside diameter . Usea micrometer checkthe valvelifteroutside to diameter. Standard value (mm): 30.955 30.965

EN- 177

PARTS ON-VEHICLE
RB25DE NGINE E

valvelifterhole internaldiameter Hydraulic 3 1 . 0 0- 3 1 . 0 2 0 0 Standardvalue (mm):

Hydraulic valve adjuster clearance = valveclearance Hydraulic diameter valveexterior diameter hydraulic holeinternal valveclearance HVdraulic

lnstallation . Install valveassociated Parts. . Fordetailed newvalveoilseal on information howto install "Oilsealreplacement". on referto section pitchendtowards cylinder . Install withnarrow valvespring color head(identification sidedown). . Install retainer spring . Usevalvespring valvecollet. to compressor install jelly . Applya smallcoating petroleum to the internal of of surface collet. . Usea magnetic screwdriver. (1) Uppercolletinstallation blade . Attachcolletto lowersideof magnetic screwdriver tn and install the valvestem.

(21 Lower colletinstallation

blade screwdriver Attachcolletto uppersideof magnetic in andinstall thevalvestem. . Aftervalvecolletinstallation tap lightly the stemedgewith installation. to hammer confirm a plastic

. Install valvelifter. hydraulic . Tapin camshaft knockPin pin protrusiondistance(mm): Knock

installation Gamshaft T.D.C . Turncamshaft No. 1 cylinder at compression is so No. 1 cylinder or 60o position turncamshaft before after (or . Temporarily and makesurethe tightenNo. 1 cam bracket securely. is thrustsection positioned

KnockPln

Knockpin

r.D.c).

E N- 1 7 8

ON-VEHICLE PARTS
RB25DE NGINE E

Tighten cam bracket bolts540.(1.5 turns) gradually in several stagesin the sequence shownin thefigureon

right. Tightening torque(kg-m):

0 . 9 2 -1 . 2
6 10 14 12 Ffonti

Install camshaft frontoilseal. Fordetailinformation to refer "Oil seal" section.

. Install timingbeltbackplate.

. Align pin campulley camshaft to knock to install.

Tightening torque (kg-m): 1 . 4 -1 . 9

E N- 1 7 9

ENGINE & REMOVE INSTALL

ENGINE R826DETT

E & 11 REMOVE INSTALL NGINE

[Point 1] Releasefuel Pressure . Afterstarting remove fuelpumpfuseand run the engine, fuel engineuntilit stops. Consume leftin fuellinesby two engine to threetimes. the cranking the . Whenit is not possible startthe engtne, remove fuel to fuellefiin fuellinesby cranking pumpfuseandconsume fourto fivetimes. engine Caution: booster connect weakeasily, may become The battery battery. cablesto charged Acceleratorwire adjustment [Point 2] . Loosenlocknut and provide slackfor the adequate of wire. Pulloutercasein the direction the accelerator pedaluntilthrottle to drumstarts move(noplay accelerator the in cable).Rotate locknut 1 to 1.5turnsto tighten. 0 . 8- 1 . 0 torque (kg-m): Tightening

ground line Enginemain harness, separation . Disconnect connectors for the behind battery the systems. motorandtransmission starter alternator, [Point3]

oil and Air compressor powersteering pump movement pipes . Remove Leave each to bolts securing unit brackets. withstring Care of to and connected secure side thebody the notto scratch body. be must taken 4] lPoint

!e

.iffifierr

"

ffY;"..
..-- v,r*Jo fiom betow

oil Powersteering tubebracketseparation [Point5] . Remove oiltube steering the and bolts separate power side. the towards body and bracket, move

Front enginemountingnuts removal [Point6] . Makesurethe engineslingsaresecurely hookedby nuts. mounting frontengine horst chainandremove engine

'hN4
n u t4 . 4 - 5 . 6

'6) l,----'-

rouFinlS ion-t eng,nu

E N- 1 8 0

REMOVE INSTALL & ENGINE

RB26DETENGINE T

[Point7]

. Power steering tubewillhittheright oil front engine mounting it is notpossible shift engine and to the fonvard. Therefore remove andremove engine nuts right mounting bracket. 8] Remove install & engine ASSY [Point . Operate hoist the chain, change engine and the angle gradually remove engine. to the Care must taken to be not interfere vehicle with body.

Rightfront enginemountingbracket removal

E N- ' 1 8 1

ENGINE & REMOVE INSTALL

/ R B 2 O ED E / D E T/ C A I B iE N G I N E

'11 REMOVE& INSTALLENGINE fuel Release Pressure 1] [Point . After fuse run the pump and remove fuel engine, starting
fuel engineuntilit stops. Consume leftin fuellinesby two the cranking engine to threetimes. the . Whenit is notpossible startthe engine, remove fuel to by cranking fuel pumpfuseand consume leftin fuellines to fivetimes. four engine Caution: booster connect weakeasily, may become The battery battery. cablesto charged jack set (CA18ionly) Transmission jack . Placethe transmission underthe transmission.

Acceleratorwire adjustment [Point 2] . Loosenlocknut and provide slackfor the adequate of in direction the wire. Pulloutercase accelerator pedaluntilthrottle to drumstarts move(noplay accelerator the in cable).Rotate locknut 1 to 1.5turnsto tighten. 0 . 8- 1 . 0 torque (kg-m): Tightening

[Point3]

Enginemain harness,ground line seParation for . Disconnect connectors the behind battery the systems. motorandtransmission starter alternator,

Air compressor and power steering oil pumP movement Leavepipes . Remove eachunitto brackets. boltssecuring to and connected secure sideof the bodywithstring.Care the mustbe takennotto scratch body. [Point 4l

Remove& Install propella shaft [Point 5] . Placea capon thetransmisslon sealso the oil willnot rear shaftis removed leakwhenthe propella

E N- 1 8 2

REMOVE INSTALL & ENGINE

R B 2 0 D ED t I DETT NG'NL E

Remove& installrearenginemounting [Point6] . Support transmission transmission and the jack with remove rearmember boltsandrearenqine mountino bolts andnuts.

(4) 4.4 - 5.6

Frontenginemountingnuts removal [Point7] . Makesurethe engineslingsare securely hookedby engine hoistchainandremove frontengine mounting nuts. - 5.6 Enginemountingnut tightening torque(kg-m):4.4
Front engine mounting nut

Remove& instaltengineASSY [Point8] . Operate hoist the chain, change engine and the angle gradually remove engine.Caremustbe takennotto to the interfere vehicle with bodv.

E N- 1 8 3

ENGINE & LNSTALL REI\,4OVE

E RB25DE NGINE

1 1 R E M O V E& I N S T A L LE N G I N E
Standard Points jack and and crane transmission to remove install how describes to usehoist Thissection engine. theRB25DE
. Draincooling watercompletely. . Remove bonnet. Enginebay left side: . Exhaust sensorharness disconnection gas . Groundlineconnector separatlon . Air duct,Air cleaner . Powersteering PumP removal oil . Air compressor removal Enginebay right side:

Battery /G.\ "fuel . Release pressure selecting putp rer"y" (E ) by fuel

in activetestmode,and PressSTOP.

O ncrtvgrEsr O
FUELPUMPRELAY OFF (POS) CAS-RPM 950 rpm

fuseandrun . After fuel remove pump the staring engine, fuel stops.Consurne leftinfuellinebV ffi untilit engine \Gy times. overtwotothree engine the cranking
Caution: booster connect weakeasily, may become The battery battery. cablesto charged . Accelerator wireseparation . Heater hose . Vacuum hosesseparatior
START INTERRUPT STOP

Enginemain harness& ground line separation

Enginebay front side: . Radiator radiator shroud, . Cooling fan Enginebay upPerside: . ECCSharness connectors

E N- 1 8 4

REMOVE INSTALL & ENGINE

R525lE ENGINE

Vehiclebody,lower side: . Engine undercover . Propella shaft . Transmission control lever(M/Tvehicle), linkage (A/Tvehicle) . Exhaust fronttube . Rearenginemounted bracket

\qt--l.ER)j ^
(4)4.4 5.6 bolt

xear_ rnemD:r-Rear enqinemountrn

\r,_r,_"

Uoit a.+__ s iZ;

. Right andleftengine mounted bracket.

Remove& installengineASSY . Operate hoist gradually. chain andchange engine angle Caremustbe takennotto interfere withvehicle and remove engine. the

E N- 1 8 5

OVERHAUL ENGINE
ENGINE RB26DETT

OVERHAUL 12 ENGINE
from removed assembly of disassemblytheengine the describes component Thissection of replacement the explains inspection, lt also transmission. without thevehicle and adjustments parts carry anynecessary out and orwarn damages malfunctioning, condition' engine a to in assembly order produce standard sequential

CAUTIONS OVERHAUL bly ( 1 ) Disassem out sureto carry safe and . Usecorrect suitable whenpossible make tools and procedures. to surfaces and surfaces sliding . iare must taken on withoperations mating be accuracY. prevent of surface loss detection faults for to marks organize easy . Arrange pars disassembled by making assemblY. andprecise to care mustbetaken from . Loosen andbolts a diagonal direction outside. in nuts whenindicated order the follow numerical the following inspection parts . ieplaceor repair after completing inspection parts as and forthenewparts replace sameinspection Perform orocedures. necessary.

andreplacement repair (21 lnspection,

(3) Assembly torque tightening to nuts . Always a torque to wrench tighten andbolts specific use gradually twoor in direction, diagonal . Tighten andbolts to fromcentre outside nuts whenindicated' order the Follow numeric stages. successive three in with . Replace and packing, seals O-rings newones principle' oil gasket, check air. . Clean off and ea-hpartthoroughly blown withcompressed Inparticular, or passages notclogged obstructed' are thatoilandwater cleanoffall surfaces or sliding mating . caremust taken to scratch damage or not be with surface anadequate all Lubricate sliding objects. or debris foreign dust, oil. coating

E N- 1 8 6

ENGINE OVERHAUL
RB26DETENGINE T

12.1 DISASSEMBLE ASSEMBLE & CYLINDER BLOCKASSY

Deronation sensor {211.6- 2.1rct bolt t: G-= _ Defonation _ _ - _ Rear seatlpornt sensor 7] orl 6<=

Alternator adjustment bar

"t*il;E:{ft;i;;'K)q
uon roo

*PffiffiN -A iJ:1il,8*,.",, ""S-f;ffi*

a\ (2r bolt lPornt 201 n ir""'"lil "r rn;-=-fi. l-Pn'oa D$ D$, (.4arr

Conrod bearrno r Jt bearrrg I

lt4arr oeanng lPornt captcornt 25]6;$p11 ?5]^

Flywheel [Point3, 5]

Rearplare- Mainbearing p ootr

9?i,:0":,.99-:

-\'Z

J<4*-BarnJprate

32-43

o' *'*,-ffi F Bort(2)16 _ i (/:,8!*it?-,;::;?, - r\ "d;;H (12) 2jV Bort

Fi

l',1 Kg-m

9 u.o4 - u. |[."'lTii

*n

gasket A Liquid oil fl Ensine

$ Replaceafter every disassembly

A E-r\-I Oilpanboltg . (t\r10) - 4.3 3.2 pan pt oir bo* pan (M6)/ -a.0gl 0.64- 0.85 Copper wain-e--Orain ptug:.0

a-e

Additionalwork required: . Drainand refillcooling water[Point1] . Remove and install followino the oarts: . Engine . Collector . Throttle chamber . Intake manifold . Turbocharger, exhaust manifold . Timing belt . Cylinder headASSY . Alternator

. . . . . . .

Starter motor Clutchcover, clutchdisc Oilpan,oilstrainer Waterpump Oil pump Oilcooler, strainer oil All harnesses connectors and

E N- 1 8 7

OVERHAUL ENGINE
RB26DETENGINE T

assembly Reference:Engineselection Piston (1) Piston selection

. 3
Lessthan86.010 than86.00 Greatef Lessthan85.965 than85.955 Greater Lessthan86.020 than86.010 Greater Lessthan85.975 than85.965 Greater Lessthan86.030 than86.020 Greater Lessthan85.985 than85.975 Greater

0.035 0.055

ServicesettingParts:
Pistongrade (No.1 - No.

Pistonand pistonPin

1,OOS STD 1. STD2, STD3, O.5OS,

Distinction symbol prn Prslon grade(0 1)

Mainbearing (2) Mainbearing selection

, . , ,

'

3
STD O 1.818 1.821 0.028/ 0.046 Black STD 1 1.821 -1 .824 0.028/ 0.046 Brown STD 2 1.824 - 1.827 0.028/ 0.046 NOne STD 3 1.A27- 1.830 o.028| 0.047 Yellow

l , , ' : ' . . ' . ' ' .

,.:.'.' 0
. . 1

7, :'
r ':,:l

STD1 1.821 1.824 / 0.028 0.046 Brown

STD2 1.824- 1.827 / 0.028 0.046 None

STD3 1 . 8 2- 1 . 8 3 0 7 / 0.028 0.046 Yellow

STD 4 1.830 1.833 0.028/ 0.046 Blue

STD4 1.83- 1.833 0 0.028| a.047 Blue

STD 5 1.833 1.836 0.028/ 0.047 Green

r.

2 ) '

STD 3 STD 2 1 . A 2 4 - 1 . A 2 7 1.827 - 1 -830 0.028/ 0.046 0.028/ 0.046 Yellow NOne

..3 Servicesetti

STD3 1.827 1.830 / 0.028 0.046 Yellow

STD4 1.83- 1.833 0 / 0.028 0.046

B IUE

STD6 STD5 1 . 8 3- 1 . 8 3 6 1 . 8 3 6 1 . 8 3 3 | / 0.046 90.028 0.047 0.028 Pink Green

) No.

S T D O - 6 us 0.25

EoregradeNo.

ff;:113,,".",ifl'

te! side--,-\'\l

*383".\\
r'l-lili: No 5

Iru

-5-

{,rl\
E N- 1 8 8

ENGINE OVERHAUL
R826DETT NGINE E

Pistonpin (3) Piston selection pin

(mm)

2 1 0 0 6- 2 1 . 0 0 0 20.995 20.989

2 1 . 0 1 2 2 1. 0 0 6 21.0A1- 20.995

0.005 0.017

Service parts: Piston piston setting pin S T D1 .S T D2 , S T D3 . 0 . 5 0 51 . O O S and .

Ffontmark grade Prn Cylinder No.

(0.1)

( 1- 6 )

Distinction ( 1- 3 ) Largeend grade(0.1) symbol

Con'rod bearing (4)Con'rod bearing selection

Lass tfian 51.013 Greaaer than 51.007 0
gradeNo. Bearing gradeNo. STDO Bearing STD 1 (mm) 1 . 5 0 - 1 . 5 0 3 Bearing thickness 0 Bearing (mm) 1 . 5 0 3 1 5 0 6 lhickness (mm) Oil clearance 0 . 0 2 00 . 0 3 9Oil clearance / (mm) 0.020 0.039 / ldentifcation color None ldentification coior Brown gradeNo. Bearing gradeNo. SID 1 Bearing STD2 Bearing (mm) 1 . 5 0 3 1. 5 0 6 Bearing thickness thickness (mm) 1 . 5 0 6 1 . 5 0 9 (mm) Oil clearance 0.020/ 0.040 Oil clearance (mm) 0.021 0.040 t ldentifcation color Brown ldentification color Green

parts: Service setting

journagradeNo. Upper I

us 0.08. 0.12. 0.25 us us

No.1 - No.6from

E N- 1 8 9

OVERHAUL ENGINE
ENGINE RB26DETT

Drain& refillcoolingwater [Point1] Draining from . Draincooling blockcompletely waterin the cylinder plug. thedrain Refilling "cooling instruction. . Referto thesection for water" detailed

Remove& installenginestand [Point2] . Install engine using6 boltsto engine sub attachment the on bracket rightsideof the engine. mounting

4 B o l t ( 6 )- 5 0x151=25

FlYwheelrun-out [Point 3] clutch' . Setdialgaugeto flywheelwhere contacts it . Turntheflywheel measure run-out. the and 0.10 (mm): Run-outlimit

Remove & install flywheel [Point 4] Removal . Useringgearstopper fix flywheel and remove. to lnstallation . Coatthe threadandflangeof boltswithengineoil after ra.s-)s6--\"\ the installing bolts. to . aftertightening flywheel bolts,use ringgearstopper the bolts. and flywheel tighten secure 't4.5-15.5 tighteningtorque (kg-m): Flywheelbolt

((6)
Knockpin protrusiondistance

Flywheelknock pin installation [Point5] B . Insert flyrvheel knockpinso the pin protrudes to 8 5 the mm.

Knockpin Flywheel

E N- 1 9 0

ENGINE OVERHAUL
RB26DETENGINE T

[Point6] Removal

Remove& installrearoil seal retainer

. Insert screwdriverthegapbetween a in main bearing cap rearoilseal and retainerto remove seal.

Clean ing . Usescraper removeliquidgasket to . Cleanthe cylinder blocksidein the sameway. . Wipemating surface withwhitegasoline. Caution: Also removeliquidgasketin the grooves.

lnstallation . Applyliquid gasket install within minutes. and unit 5 . Cutnozzle oftheliquid gasket (KPS10 end 00150) tubeas shownin the figureon right. Usetubepresser for aoolication. . Applyliquid gasketcontinuously rearoil sealretainer. to Caution: gasket Makesureliquid widthis 2.0- 3.0mm. Refill engineoil andstartthe engine30 minutes after assembly completed. is

. Align rearoilsealretainer dowel to install. pin the with . Tighten bolts 6 uniformly. Rear sealretainer tightening oil bolt (kg-m): torque

0.64- 0.85

7] [Point Removal

Remove install & rearoil seal

. Usea toolsuchas screwdriver remove seal. to the

Installation . Caremustbe takennotto scratch damagethe oil seal or perimeter area. Useoil sealdrift(Outside 100 diameter: mm)to install newoilseal. . Applya coatof oil or chassisgreaseto oil seal lip area. E N- 1 9 1

ENGINE OVERHAUL
ENGINE RB26DETT

inspection Con'rod side clearance [Point8] . Usethickness the gaugeto measure thrustclearance the between con'rodandthe crankarm. 0.2- 0.3 Standardvalue (mm): 0.4 Limit value(mm):

Remove& installpiston con'rodASSY [Point9] . Usea toolsuchas hammerhandle pressthe unitto to headside. cylinder

lnstallation . Setthe crankpin at B.D.C(Bottom deadcenter)position. piston oil' . Coatcylinder withengine crankpinand bore, . Assemble piston withfrontmarkon pistonheadfacingthe frontof engine. . Usea pistonringcompressor install pistonandthe the to block. in assembly cylinder con'rod Caution: Care must be taken not to strikeor deformoil jet pipe with rod largeend of connecting wheninstalling.

Gon'rodnut tightening . Applyengineoil to con'rodandthe nutsbeforeassembly. . Tighten nutsin two or threestages. '' .6 1st time Torquewrench (kg-m): 1.460 - 65 2nd time Angle wrench ( " ): Caution: torqueif anglewrench the measure tightening Do notvisually is not available. [Point10] Installcon'rod bearing con'rod . Applyengine to bearing wheninstalling surface oil of bearing.Do not applyengineoil to rearsurface thisarea. clean bearing, (left . Aligncon'rod and notches install side). retainer bearing oil . Makesurethecon'rod bearing bodyoil holeandthe holeis aligned. E N- 1 9 2

ENGINE OVERHAUL
RB26DETENGINE T

[Point11] Installoil jet . Setthe oiljet position securely and checkthatit doesnot I interfere piston.lf oiljetpipecontacts with piston oris benr,

.<

Evebort'41 3.l

replace withnewpart. it Oiljettightening torque (kg-m):

3 . 1- 4 . 1

.-.-:

_r _31 { !-\ o"* .r'-<-al -' ,''.1-l= , )*'

_=

[Point12] Remove& installpiston ring Removal . Usepistonringexpander removerings. to Caution: Caremustbe takennotto scratch oiston. Installation . Usepistonringexpander install to rings.
ldentification mark

. The stamped markson top and secondpistonring openings mustfaceup.

\
Topnng openrng

. Position pistonringsas shownin thefigureon right the to install. Caution: piston. Caremustbe takennotto scratch 'l3] [Point Removal

;",;*);^3i -" {/z--Yrr

/ ^ Decono nno ooentn0 -

Y. \ a. /l n . \

)s<-.-

OiI nno lower ra opentnq

Remove& install snap ring

. Usesnapringpliers remove to rings. Installation . Usesnapringpliers install and rings securely groove. in Caution: Always replace snap rings newones. with pistonpin & [Point14] Remove install . Usea heat to heat gun piston 60- 70"C to whenremoving piston pin. andinstalling

Placesuitable toolagainstpistonpin and pressor use plastic hammer. Applyplenty engine to pin,pin holeand con'rod of oil small note.

E N- ' 1 9 3

OVERHAUL ENGINE
ENGINE RB26DETT

Piston pin Press-fit oil . Placethe piston frontmarkso the con'rod holefaces fromfront) viewed rightsideof the engine(lefisidewhen and pressJit. Caution: to the Press-fit pistonpinfromthefrontof piston the rearside of piston.

Front

[Point15] Piston Pin inspection of diameter piston . Usethe micrometer measure outside to ptn. 20.989 21.001 Standardunit (mm):

Micrometer

[Point16] PistoninsPection piston diameter' skirt . Usemicrometer measure outside to (mm): 13 from bottom pointDistance Measuring 85.955 85.985 (mm): Standard

of insidediameter to Useinsidemicrometer measure pin piston hole.

value(mm): Standard

20.987 20.999

1.oos). 3, 2.STD o.sos,

(STD1, STD for are Fivetypesof pistons available service

inspection [Point17] Piston pin clearance by . Pistonpin clearance the figureobtained subracting is diameter the pistonpinoutside lPoint15]fromthe piston 16] diameter oinholeinside [Point normal temperature(20oC): Piston clearanceat 0 - -0.004

[Point18] Con'rod insPection Bend and torsion inspection aligner. . Measure bendand torsion withcon'rod the 0.15 Bend limit (mm): 0.3 Torsionlimit (mm): Smallend insidediameterinspection 21.000- 21.0'12 value (mm): Standard

E N- 1 9 4

ENGINE OVERHAUL
R826DETT NG]NE E

Gon'rodbearinginteriordiameter inspection . Install con'rod bearing con'rod in andcap. Tighten con'rod nutsto specified torqueand measure con'rodbearing interior diameter,
Con'rcd nut tigh!eningtorque Standardvalue
1 s tt i m e Torque wrench (kg-m) 1 . 4 - 1 . 6 2nd time Anglewrench ') ( 47.989 48.007 60-65

[Point19] Con'rodsmall end bushingclearance . The measurement difference the smallend inside of diameter 1 pin diameter piston IPoint of [Point 8] andoutside 151 the bushing is (full clearance floattype). Bush clearance standardvalue (mm):0.005- 0.017 . Thecon'rod pin smallend and piston outside diameter are separated two gradesat thefactory.Makesurethat into the grades(0.'1conform bothpartsbecause rod for the ) and pin are selected and fittedaccordino bushino to clearance.

[Point20] Gon'rodcap bolt . Con 'rodcap boltshavegrooves prevent from to it disengaging. . Forthis reasondo nottap the endsto removebolts. lPoint21] Piston ring end gap and side clearance Ring end gap inspection . Usea pistonto pressthe pistonringintothe middleof the cylinder measure gap. and the
Item Top dng
B o r eg r a d e1 , 2 , 3 : 0 . 2 4- 0 . 3 4
E

S.cond ing 0.42 0.57 0.20 0.60

Side clearance inspection . Measure clearance the between oistonrinoandthe the pistonringgroove.

0.040 0.075 0.030 0.065 0 . 0 6 5 0 . 1 3 5

Threetypesof pistonrings(STD,0.505, 1.00S)are available service. for E N- 1 9 5

ENGINE OVERHAUL
RB26DETENGINE T

inspection thrust clearance [Point22] Grankshaft . Usea thickness gaugeto measure clearance between the armwhen (No.4 bearing) the crank and thethrustbearing frontandrearof the engine. towards the crankshaft moving 0 . 0 5- 0 . 1 8 value (mm): Standard 0.3 Limit(mm):

[Point23] Remove& installpilot bushing Removal . Usea pilot pilot puller remove bushing. to bearing
Pilot bearing sr1661 0000

lnstallation . Thepilot position as shownin the is installation bushing figureon right.

[Point24] Remove& installmain bearingbolts Removal . Remove shown orderof sequence boltsin reverse bearing in thefigureon right. lnstallation . Tighten boltsto specified torquein two to threestages the shownin thefigureon the right Make in the sequence the after tightening bolts turnssmoothly surethecrankshaft torque. to specified Main bearingbolt tighteningtorque(kg-m): 4.7 - 5.3 Caution: and boltseatswhen Applyengineoil to the boltthreads bolts. the tightening

25] IPoint Removal

Remove& installmain bearingcaP

. Usetoolssuchas screwdriver prythebearing capsopen. to Caution: the Caremustbe takennotto scratch oil pan railsurface. lnstallation . Checkthefrontandrearposttion fit ontocylinder block and with of it tapping in a number locations a copper by lightly hammer E N- 1 9 6

ENGINE OVERHAUL
R B 2 6 D E TE N G I N E T

[Point26] Mainbearinginspection . The bearing shouldprotrude end whenInstalled main in

bearing or cylinder cap block Thisprotrusion called crushheight. is the

27] Crankshaft inspection [Point Out-of-round taperinspection and

Usemicrometer measure to eachjournal(No 1 - 7) and pin (No.1 - 6) in fourlocations each shownin thefigureon right. Theoufof-round valueis thedifference the dimensions of in directions andB. A Thetapervalueis the difference thedimensions of points and2. measured at 1 Out-of-round and taper limit (mm): 0.005 Pin and journal inspections . Usemicrometer measure andjournaldiameters. pin to Pin diameterstandardvalue (mm): 47.961 47.974 Journaldiameter standardvalue(mm): 54.951 54.975 Curve inspection . UseV-blocks a fixedsurface journals on andsupport on bothendsof crankshaft (No.1 and No.7). . Position dialgaugevertically middle No.4 joumal the on of as shownin thefigureon the right. . Turncrankshaft handandreaddialgaugemovement. by . The Run-out equalto halfof dialgaugemovement. is

Limit aluemm): v (

0.05

. lf the oil clearance exceeds limit,referto [Point29]and the selectthe appropriate bearing.

28] Con'rod bearing clearance oil inspection [Point (A) Usinginsidemicrometer micrometer and . Theoilclearance becalculated connecting can from rod bearing inside diameter thecrankshaft diameter pin and measured [Point and[Point in 1B] 27]. = (Oilclearance) (Bearing inside diameter)(crankshaft diameter) pin - 0.040 Standardvalue(mm): 0.020 Limit value(mm): 0.090

E N- 1 9 7

ENGINE OVERHAUL
R826DETT NGINE E

(B) Using plastigauge . Remove pins anydustfromcrankshaft and bearing surfaces. . Cutoff a pieceof plastigauge shorter thanthe slightly bearing width.Place plastigauge thecrankshaft the on in direction axis. Caremustbe takennotto olaceon the of oilhole. . Assemble connecting bearing connecting cap rod in rod rod torque. and tighten connecting nutsto specified
(kg-m) 1 . 4 - 1 . 6 1 s tt i m e Torque wrench 2 n dt i m e Anglewrench(") 60-65

. Remove plastigauge con'rod andbeanng measure cap and plastigauge scale. widthwitha Caution: or rod Never turnthe crankshaft connecting whileplastigauge is beinginserted. exceeds limitvalue,referto [Point and the 29] lf oil clearance bearing. selectthe appropriate

[Point29] Con'rod bearingselectionand engaging . Selectthe correct sizedbearing the con'rodbearing as prevents Threebearing fluctuation the oilclearance. in are to of thicknesses available fit the insidediameter the gauge. big end of the con'rodand the crankpin diameter . Whenreplacing con'rodbearing, the checkbig end inside gauge(indicated the opposite on sideof the diameter pin diameter grade(indicated on con'rodhole)and the front crankshaft 1 counterweiqht surface). No.

joumalgradeNo Upper

Con'rod bearingselectionchart
Lessthan51.@7 Grsbr tlan 51.000

gradeNo. gradeNo. STD1 STDO Bearing Bearing " . (mm) ' 1 . 5 0-3 1 . 5 0 6 (mm) 1 . 5 0 0 ' 1 5 0 3Bearing thickness Bearing thickness (mm) (mm) 0 . 0 2 00 . 0 3 9 / 0 . 0 2 0 0 . 0 3 9Oil cleararrce / Oil clearance Browl None ldentifcation colour ldentitication colour

LesstfEn 47.968 ttran Greater 47j&l.

gradeNo. gradeNo. STD 2 STD1 Bearing Bearing (mm) 1 . 5 0 6 1 . 5 0 9 (mm) ' 1 . 5 0-3 1 . 5 0 6 Bearing thickness Bearing thickness (mm) / (mm) 0.02'1 0.040 0.020 0 040 Oilclearance / Oil clearance Green Brown ldentifcation colour ldentification colour

E N- 1 9 8

ENGINE OVERHAUL
RB26DETENGINE T

. Whenusing undersize bearings, measure bearing inside diameter whenbearing installed. pin is Grind so oil clearance conforms specific to value. Bearingundersize chart
Size

R2.0jourr .p | _ R 1) ( r n l I

l'' [-J
t---4

o
1.541 1.549 1 8

us0.08 us0.12

\
\ t

i /
t /

1 . 5 6/ 1 . 5 6 9 1

12

\ \,H-l

us0.25 1.6261.634 t 25 Caution: Caremustbe takennotto scratch filletrollwhenthe crankpin is beinggrounded use undersize to bearing.

4,

,--nX','

il)

[Point30] Mainbearingoil clearance Using bore gaugeand micrometer (MethodA) . Install mainbearing cylinder in blockandattachbearing cap. Tighten bearing cap boltsto specified torqueand measure bearing inside diameter. Bearingcap bolt tighteningtorque (kg-m): 4.7- 5.3 . Theoil clearance distance be calculated can fromthe values outside for diameter the crankiournal of measureo in [Point 27]. (Oil clearance)= (Bearinginsidediameter) (Crankshaft outsidediameter) Standard value (mm): 0.028 0.047 Limitvalue(mm): 0.090 lf oil clearance exceeds limitvaluereferto [Point the 31]to select suitable bearing.

Using plasticgauge(MethodB) . Removeall journal dustandoilfromeachcrankshaft and bearing surfaces. . Cut a pieceof plastigauge slightly shorter thanthe gaugewidth. Placea plastigauge crankshaft bearing on in direction axis,caremustbe takennotto placeon oil of note. . Assemble mainbearing the and bearing cap and tighten cap boltsto the specified torque. Bearingcap bolt tighteningtorque (kg-m): 4.7 - 5.3 . Remove bearing cap andthe bearing.Measure plastigauge widthon plastigauge scale. Caution: Do notturncrankshaft whileplastigauge beinginserted is lf excessive bearing clearance exists, still use a thicker main bearingor undersized bearing that the specified so bearing clearance obtained is whenmeasured bygethod A as well.

SENSOR SYSTEIV INSPECTION

R826DETT NGINE E

6.6 ENGINE TEMPERATURE SENSOR SYSTEMINSPECTION CONTROL CIBCUIT DIAGRAM R826DETT ENGINE

Engrne iemperature sensor

2 " 8 "

m
O a o
f

gnrtion liming conlro

q E

dle speed control

Engine temperaturesensor system trouble diagnosis flowchart RB26DETT ENGINE

I .SELF DIAGNOSTIC FESULTS' '!: (code 13) Sel-dagnosis No.
Nonnal Abnorrna = Se f-dLagnosis

I
Abnormal

Enginetemp sensorinput signalinspection "DATA NTONITOR' t the terrninal 1 I Measure vollagebetween ano qrouno.
tempdisplay i Engine .8 3V when cold 1V atler warrn up nq

@
Olher

Enginetemp sensor inspection lvleasure reslslance the between terrnrnal and 2. 1

Apr r o x . 2 . 5 k t ) w h ec o l d n warmrng up

InspectIntakeair temperature Enginetemperature sensorand ECCS C/U connectors sensor inspeclion for faultyconnectrons defects. or l\,4easufe resistance the between lermnal 1 and 2.
Approx.2.5 Olher

up Sensorand ground inspection Measure voltagebetween the terminal and 30. 28

lnspectothe r
SVSIEMS

Replace Engine temperature sensor

sensor
Harnesscontinuityinspection Inspect ECCSC/U power l [,4easure resistance the between supplyand ground the following terminals: Engine temp ECCSC/U sen narness narness

0a InspectECCSC/U connector and engrne temp sensorconnector conlactand defects. for

c o A

Repairnarness

E N- 3 8 1

INSPECTION SYSTEM SENSOR

R B 2 O ED E / D E TE N G I N E /

SYSTEMINSPECTION SENSOR TEMPERATURE 6-6 ENGINE / DE / DET ENGINE RB2OE DIAGRAM CIRCUIT CONTROL

sensot ternperature Engine

t-*---fr -----1'

m
5128) 8 (30) o a 8 o
C

conlrol Fue injectlon

c)

=.

ldlespeedconlrol

Engine temperaturesensor system trouble diagnosis flowchad / RB2OE DE / DET ENGINE

Self-diagnosis "SELFDIAGNOSTIC RESULTS" IElcode No 13) Self-diagnosis
Normal Abnormal

i,
Abnormal

.. N.4easure voltage between termlnal l the and qround.

inspection inputsignal Enrinetempse{tsor MONITOB" E-'DATA

temp E Engrne displaY ,S 3V whencolo uP warminq ]V atter

@
Other

EiliiE-iffi

insPection sensor

EnginetemPerature Inspectintakeatr temPeralure sensorand ECCS C/U connectors sensor inspection the or N-4easure resrstance for faultyconnections defecls terminal1 and 2. between
APProx 2 aKf) wnen colo Approx 0 3K o after warn
UP

between /* f/easurethe resistance \ll-Y terminal1 and 2. 2.5kOwhencold Approx. 0.3Ko after Approx. warmrng up

Other

Sensorand ground insPection the Measure voltagebetween 5 terminal (28) and I (30). engine Beplace insPectiot continuitY Harness e beiw n Measurethe resistance termlnals: the followtng ECCSC/ ternp Engrne harness sen harness 5 (28 1 8 (30 2
Olher

other Inspect I svsrems I

Replace Engine temperature sensor

power Inspect ECCSC/U I supplyand ground

0a temp and Fnspect EcCs c/u connector engine and for connector contact delecls. sensor

cltr

[:

Repairharness

EN - 382

SENSOR SYSTEM INSPECTION

CA18ENGINF i

6.6 ENGINE TEMPERATURE SENSOR SYSTEMINSPECTION CONTBOL CIRCUIT DIAGRAM CA18iENGINE

Engrne temperature sensor

r---5f-*----+rtl t T

a o
l

m o o
gnilion mingconlrol I

q
c

Engine temperaturesensor system trouble diagnosis flowchart CA18i ENGTNE

. Se f-diagnosis .I."SELFDIAGNOSTIC BFSULTS" (codeNo. '13) 1& Self-d agnosis
Nomai

"DAIA ONITOR" M

I (Realtinrediagnosrs) |
mal

ffi--J---rono,

Enginetemp sensoroutput signalinspeclion .f,.DAIAN,4ONITOR' the :8 l\,4easure voltage between termrnal and 2. 1

fr

lempdispiay E Engrne w h e nc o i d ;3 'e V atterwarrnrng 1V up

Olher

Enginetemp sensor inspection(2) l\,4easure resistance the between termrnal and 2. 1

Approx. 2.5k',when cold Approx.0.3Kf] after warmrng up

InspectIntakeair temperature Enginetemperature sensorand ECCS C/U connectors sensor inspection(2) lor fauty connections defects. or N.4easure resistance the between terminal1 and 2. Aporo^. 2.5Kf,) when cord .+A o o , o x . 6 .r3 r n " | ' a1 o | 112l Other warmup ECCSC/U power supply and ground inspection ,F ,DATA N,4oNIToR" .& N.,1easure voltagebetween the ECCSCiU terrninal and L 5 Replace Engine temperalure sensor

Other

Inspeclolrrer

Replace engine temperature

sensor

. E ergrne r lempdrsplay 3 \ t when cold l \ ' after warm up

Olher

Harness continuityinspection Inspect CIU power l\,4easure resislance the between supplyand ground the following terminals: Engrne ternp ECCSC/U sen hafness harness

0{l

cosl

lnspectECCSC/U connector and enginetemp sensorconnector contactand detects. for

Repairnarness

EN - 383

INSPECTION SENSORSYSTEI\,4
ENGINE R826DETT

SYSTEMINSPECTION GAS SENSOR 6-7 EXHAUST ENGINE DIAGRAMR826DETT CIRCUIT CONTROL

gas Exhaust sensor

+ +r* ----T(tronl) gas Exhaust sensor

I t

r__-.0_

Air luel ratro control

2 -rH r;-T'lll 1

eallr t

+ t

(data monitor) display Cylinder,exhaust gas sensor' CONSULT

1 No. 2,3cyl No.4. 5, 6 cyl

29 ECCSC/Uterminal
55 O- sensor(rear) ECCS C/U terminal

EN - 386

SENSOR SYSTEM INSPECTION

R826DETT NGINE E

gas sensorsystemtroublediagnosisflowchartRB26DETT Exhaust engine

Air-fuel ratioteedback function inspection 'F,'DATA t40NtTOF' gas output i$ Exhaust sensor monrtor.
Normal Abnorrnal

Abnormal

gas Exhaust sensor input signal inspection lvleasure voltage the between 1. (O"sensor (F)) 2 . O . s e n s o(rR )
DeUectron belween0 - 1V Other

lTI4l

t1t2l

.-F.

(o,sensor( F ) )
(O sensor R)) t

ECCSC/U connectors faully ior contactor delects.

ECCSC/U power supply inspection ' [,4ON]TOR ! DATA D sconnecl sensorconnecior O E ano T'teasLrre taqe !et,,..'ee!o
ECCS a U ieiii,ia ;: ;i.r gj.e.i].

Baltery ,Joliaqervhe n gn 1on swrtch ON rs

Oti'er

Harness continuityinspection InspectECCSC/ Measurethe resistance between U p o w e rs u p p l y the following terminals: or replaceC/U O, sensor ECCSC/U .E;r . narness narness (R)2 Or sensor 55 (F)1 O, sensor 29 (O-,sensor sensor (O, (F)) Other (R))

@uff

the resstancebetween lowrngerminals: t O sensor(B) 1 - 3 O . s e n s o { F )2 - 3 r

Battery vo iage when gnrlron swrlch

Repairharness

Checkfor laulty conneclions or replaceexhaustgas sensor

the resistance between termrnals: Orsensorl-3 ( O , s e n s o ( R ) )2 - 3 r

oo Sl

" sensor heater oower inspection Measure the voltagebetween followrng termrnals: Or sensor(R) 1 and ground O sensor(F) 2 and
Balteryvollagewhen is 9nl on swrtch ON

ReplaceO, sensor

RepairO, sensorgroundcircuit

EN - 387

INSPECTION SYSTEM SENSOR

ENGINE R826DETT

f ratioteedback unctioninspection ,\ (1) Fuel-air items 19/ . Warm theengine check following the and up
(output GASSEN-R" with'EXHGASSEN",'EXH "M/RF/CMNT-R' (lean / M/B F/CMNT"and voltage). "DATA mode. MONITOR" in displayed rich)

CAS.RPI,4(POS) EXHGASSEN E X HG A SS E N - R M/BF/CMNT F/C I\4/R N,4NT

1975rpm 1,14V 1.03V RICH LEAN

"ACTIVE TEST"(fuelinjection . Provide valuein settrng gas exhaust sensor and quantity correction) check f unction.

AcrrvErEsr I a
0",1 937rpm 59'C 1.33V 1'35V 1 8msec 17-.

on . Using conne-ctorthevehicle diagnosis :199-^ ^ GAS to 'EXHAUST @ set tuseblock), CONSULT lneai the and MONITOR' check fuelinjection SENSOR

FUELINJECION MONITOB CAS.BPM(REF) ENGTEMPSEN EXHGASSEN EXHGASSEN'R INJPULSE AAC VALVE

Qu

UP

DWN

od

warning gas of by condition flashing exhaust temperature lampon instrument Panel.

Exhaustgas sensorlunction
lampmustflash5 times warning gas Exhaust temperature at is whenengine running interval or morein 1Oseconds rpm. approx.2,000 f Feedback unction lampmustflas warning gas Exhaust temperature at speedis running approx2'000 whenengine periodically

(2\ Input signal insPection 'lirleasu with terminals . the re the voltagebetween following connected. unit ECCScontrol harness

BEMEEN EUUD U/U ECCS C/U Between 55 29 terminal and ground terminal and ground

between Deflection 0 approx. and 1V

EN - 388

INSPECTION SYSTEM SENSOR

R B 2 O ED E / D E TE N G I N E /

INSPECTION SYSTEM GAS SENSOR 6-7 EXHAUST / BB2OE DE / DET ENGINE DIAGRAM CIRCUIT CONTROL

n
115

Air luel ratro conlrol

m
o

o a e 9,
c

EN - 390

SENSOR SYSTEM INSPECTION

R B 2 O ED E/ D E TE N G I N E /

gas sensorsystemtroublediagnosis Exhaust flowchart RB20E DE/ DETengine /

Air-tuelratioteedbacktunction . inspection !].DATAI\,4ONITOR' gas sensoroutputmonitor. Exhaust
Abnormal

Exhaustgas sensor input signalinspection Measure voltagebetween the 1 . { R B 2 0 Ea n dg r o u n d ) 2. (FB2oDE DET)and ground i
Defleclron between - lV 0 Other

1 (R820E)

( R B 2 o D/E E T ) D

ECCSC/U conneclors faulty for contact detects. or

ECCS powersupplyinspection Cru [/ONTTOF" .E DATA Or connector t' Disconnect sensor andmeasure voltage between
ECCSC/U termrnai (49)and 27
Baftery voltage when rgnrlron swrtchs ON

Harness continuityinspection Measure the resistance belween the following termlnals: O, sensor ECCSC/U harness harness RB2OE 1 6 RB2ODE/DET1 29 0a RB20DE/ DET

Inspect ECCS C/ U power supply or replace C/U

(!I?I]J
(RB2oDE/ DEr)

/-rt-\

Repairharness Checkfor laulty connections or replaceexhaustgas sensor

Batlery voltage rgnilron swilch

Checkfor laulty connections or replaceexhaust gas sensor

Measurethe resistance between termrnal and 3. 1

" sensor heater oower inspection MeasLrre voltagebetween the termrnal and ground. 1
Balteryvollagewhen ignrtron swrlchrs ON

ReplaceOrsensor

RepairO, sensorgroundcircutt

EN - 391

INSPECTION SYSTEM SENSOR

E CA18i NGINE

6-7 EXHAUSTGAS SENSORSYSTEMINSPECTION CA18iENGINE DIAGRAM CIRCUIT CONTROL

Exhauslgas sensor

'=

r---H

m o o
a
a J T o c

Engine Exhaustgas sensor systemtrouble diagnosisf lowchartCA18i

. Setldiagnosis l, "sELF-DtAGNosls FESULTS" (code Self-diagnosis No.15)
Abnormal

Abnormal

Exhaustgas sensor inPut signalinsPection 'i_ 'DATA MONITOF' ECCS6 and ground.
RICHl LEAN a Display Displayoutpul voltage0 EDrsolav0-1V

lnspectexhaustgas sensorand for ECCSC/U connectors faultY contaci or delects.

ECCSCru Power suPPlYinspection r- DATAMONITOR'' ,$ Disconnect sensorconnector 02 voltageDerween and measure 27 ECCSC/U terminal (49)and
Battery vollage wnen switchis ON ignition

insPection HarnesscontinuitY between the l\,4easure resistance 02 sensorharnesstermlnal1 and 6 ECCS C/U harnessterminal
0 {il

lnspectECcSC/ supply U power or replaceC/U

Checktor taulty conneclionsor replaceexhaust gas sensor

Repairharness

EN - 392

SENSOR SYSTEM INSPECTION

R B 2 O ED E / D E T / C A 1 8 E N G I N E /

(1) Fuel-air ratiofeedback unctioninspection f . Warm theengine check followinq with up and the items "EXH
GASSEN"and"M/RF/CMNT',0eanrich) / displayed "DATA in MONITOR" mode.

ruo rnrr fr,,lor':rroRrrufr

(POS) CAS.RPM AIRFLOWI\,ITR ENGTEMP EXHGASSEN I\,4/R I\,4NT F/C 2012em 1-54V 8O"C 0.72V RICH

RECORD

. Provide setting valuein "ACTIVE TEST"(fuelinjection quantity correction) check gas and exhaust sensor function. Note: "lNJPULSE' display RB20E 1/16. for is . Using diagnosis connector thevehicle on side (near fuseblock), CONSULTto'EXHAUST set GAS SENSOR MONlTOR" check fuelinrection and the condrtion flashing exhaust by gas temperature of warning tamp rnstrument panel. on Exhaust gas sensor function gas Exhaust temperature warning lampmustflash times 5 or morein 10seconds interval whenengine running is at approx.2,000 rpm. Feedbackf unction gas Exhaust temperature warning lampmust lash f periodically whenengine speed running approx.2.OOO is at rpm.

ncrrveresr ! |
+11o.a 1037rpm 36.C 0.87V 4.omsec 369/.

FUELINJECIION tll0NtToF CAS.RPN4iREF) ENGTEI\,4P SEN EXHGASSEN INJPULSE AAC VALVE

Ou

UP

OWN

od

(2) Inputsignatinspection . Measure voltage the between following the terminals with ECCScontrol harness unit connected.
E--r-^

RB2OE/CAt8i I
,.

nemoelo

{|l'snl kitt:i::,rir:
:-ri.i.:

Between ECCS C/U Between ECCS C/U terminai and ground termrnal and ground 1 29
Deflectronbetween approx. 0 - 1

{!pq. |!'.']r:':i:1,:

Deffection between approx. - 1 0

EN - 39s

SENSOR SYSTEI\,4 INSPECTION

B B 2 6 D E T T B 2 O ED E / D E T / C A l 8 E N G I N E iF i ]

6-9 VEHICLESPEEDSENSORSYSTEMINSPECTION CONTROL CIRCUIT DIAGRAM RB26DETT ENGINE

Fuel cut control

m o
a
o
:l

dle speedconlrol

c
l

RB2OE DE / DET ENGINE /

m
ldlespeedcontrol

o o a
o t1 O

i53)

c
l

()RB2ODE/DET

C A 1 8 iE N G I N E

EN - 397

INSPECTION SYSTEM SENSOR

:.:.:E'-T / R B 2 O ED E / D E T/ C A I B iE N G I N E

(1) Inputsignal inspection "VEHICLE in "DATA . Select SPEEDSENSOR" rtems. the modeandcheck following MONITOR"

oRNGft
( C A S . R P MR E F ) S C A RS P E E D E N

c
When drive wheelsare rotating Vehicle speed is disPlayed

terminats . Measure voltage the between following the @ connected. unit control connectors withECCS

SIGNAL SWITCH) swlTcH (START 6-10 rGNtTloN INSPECTION (1) Inputsignal insPection n perform keyoperatio the . In "DATA mode, MONITOR' "START" is signal input switch to checkif the ignition correctlv.

cAl8i

25 (45)

ECCS control unrt

terminals . Measure voltage the between following the A \@i connected. unitharness with ECCScontrol / RB26DETT RB2O
C/U C/U ECCS C/U ECCS ECCS 23 terminal 25 45 terminal and terminal ground

voltage Battery

EN - 398

SENSOR SYSTEM INSPECTION

R B 2 6 D E T/TR B 2 O ED E / D E Ti C A 1 8 E N G I N E / i

6-11 AIR CONDITIONER SIGNALINSPECTION B26DETT/ RB2O

Dua presslre switc h
4A {9) _

U) o l q

o o

(46)

( )

RB2ODE/DETiRB26DETT

(1) Inputsignalinspection . In "DATA MONITOR' pedorm airconditione mode, the I switch operation checkil theairconditioner to switch signal input is correctly. . Measure voltage the between following the terminals withECCScontrol harness unit connected.

cA18i

A/C switch

6 - 12 NEUTRAL SWITCHSIGNALINSPECTION (1) Inputsignalinspection . In "DATA MONITOR" mode,perform shiftlever operation checkif neutral to switch signal is

. ^lSililJtiS'Y;rtase the between rorowins terminars @ andground

withECCScontrol harness unit connected.

RB26DETTi RB2ODEi DET

EN - 399

INSPECTION SYSTEM SENSOR

E R B 2 6 D E T/T C A 1 8 ] N G I N E

SIGNAL SWITCH 6-13 POWERSTEERING po*"r' "t"",,nq INSPECTION tchsw inspection (1) Input signal fe .|n.,DATAMoN|ToR"mode,performpoWerSteering\g/

(ls)

switch i = oil steering pressure if to operation check power correctly. is signal rnPut terminals . Measure voltage the between following the @1 9 connected. r ,BB26DErr unit control harness withECCS

ECCS control

unit

cA18i
6-14 LIGHTSWlrcH SIGNALINSPECTION @ (1) input signal insPection lightswitchoperation . ln "DATA mode,perform MONITOR' correctly' is signal input lo checkif lightswitch terminals . Measure thefollowlng between thJvoltage @ connected. unit withECCScontrol harness
Lrghtswitch lcr_ ---6zd--{qs I

,1. I unit -

/ I control I
I

/l Eccs I

/t

FAN SIGNALINSPECTION 6-15 HEATER (1) Input signal inspection tion opera heaterfan . ln "DATA mode,perform MONITOR' correctly' is signal input fan to checkif heater switch terminals /A\ . Measure voltagebetween following the the \.f,i connected. harness withECCScontrolunit

EN - 400

R825DE DIAGNOSIS
R825DE NGINE E

DIAGNOSIS . POWERSUPPLY GROUND 1 & CIRCUTT

#21

2.1--

Components location

EN - 401

DIAGNOSIS RB25DE
E RB25DE NGINE

START Startt le engrne. Doestneengrne

CAS BAT

NG

ol
ground D. circutt Inspect OK
FINISH
STABT

A insPection PowersuPPIY to switch ONposition. ignition Place -BATTERY using voltage OK battery 1S Inspect \@ VOLTAGE"in mode. DATAMoNlToB
between the rar Usetesterto measure voltage ..1,r'ECCSC/U terminal 50 and ground. 49.
NU

f,

D circuitinsPection Ground

E in ignition switch OFF Place ECCSC/U position. Disconnect connector. harness between t ! continuity for harness Check l E C C SC / Ut e r m i n a1,0 , 2 0 ,1 0 7 '1 0 8 I ground. a n d1 1 6a n d and harness connectors lF NG: Repair
FINISH

Fle m

B
ECCS C/U terminal and ECCS relay harness continuityinsPection in switch OFFposition. ignition Place ECCSC/U and ECCSrela' harnesr t Disconnect connector. 'U al ECCSC, termin between for lnspect continuity 3. terminal 49, 59 and ECCSrelaY
OK

c
, |!l3i---\

Eer
I M qa-.'- ei--.' i
I

NG

c I Rpneirharnesso r con necto.l

Voltage inspection between ECCS C/U terminaland ground to switch ON position. rgnition Place ECCSrelay the Measure voltagebetween 2,3 terminal andground. NG voltage Voltage:Battery to switch OFF position ignition lF NG: Place l N , N o . 2 1f u s e , o . 3 N o .6 f u s i b l ei n k . and ECCSrelay between the Inspect continuity thebattery. ToE

lF
I

l l -- c c s E I :6-

or harness connector Reoair - 402 EN

FI825DE DIAGNOSIS
RB25DE NGINE E

E
Outputsignalcircuit inspection Check continuation the between ECCSC/U N G '16 terminal andterminal 1.

OK

Inspect following: the lgnition harness coil connector. Harness between ECCSC/U and ECCSrelay. lF NG: Repair harness connector. or

Component parts inspection (ECCS relay) NG Refer the section ECCSrelav to on for Inspectron. Repair ECCSrelay Checkfor anydamage the ECCSC/U on terminals ECCSC/Uconnector. and

Carry out the inspection in the lollowing order after repairs. Verifrcation inspection

Restart engine the

Doestheenoine start? Power supply inspection Check anydamage the for on ECCSC/Uterminals and ECCSC/U connector. Check anydamage the for on ECCSC/Uterminals and ECCSC/Uconnector.

Ground circurt inspection

EN - 403

DIAGNOSIS R825DE
E BB25DE NGINE

(CODENO' 11 IN SELF.DIAGNOSIS) 2 DIAGNOSIS - CRANKANGLESENSOR

16

m o
a o - c i

c
5)

Components location

"

anglesensor _CJAnk

EN - 404

RB25DE DIAGNOSIS
RB25DE NGINE E

START
Carry self-diagnosis out

NG
A

OK
To diagnosis 14

Power supplyinspection
Place ignition switch OFFposition. to Disconnect crank angle sensor harness connectors. NG Placeignition position. switch ON to Usetesterto measure voltaqe the between terminal andqround. 3 OK Inspectthe following: Checkthecontinuity between crank anglesensor terminal and ECCS 3 relayterminal 3. lF NG: Repair harness connectors. or

@
c/u

42 52 and 2 5 l a n dI

B Inputsignalcircuitinspection Placeignitron switch OFFposition. to Disconnect ECCSC/Uharness connectors. Checkthecontinuity between crankanglesensor NG terminal and ECCSC/Uterminat 52 (1"signal), 2 42, between crankanglesensor terminal andECCS 1 C/Uterminal , 5 1 (120" 41 signal).

OK

Repair harness connector or

Inputsignal inspection Connect crankanglesensor andECCSCiU harness connectors. "CRANK ANGLESEN RPM'in 'DATA ,S Use \G/ MoNlToR"to measure enqrne soeed.

Xg:Q@

/fl) Measure voltage the between ECCS C/U v t e r m i n 4 2 . 5 2 . 5 1 n dg r o u n d . al a

NG

OK

Component pans inspection (Crank angle sensor) Refer thesection crankangle to on sensor for inspection. NG: Replace lF crank angle sensor.

Check anydamage the ECCSC/U for on terminals and ECCSC/U connector. EN - 405

DIAGNOSIS RB25DE
E RB25DE NGINE

Carry out the inspection in the following order after repairs' inspection icatron Verif

f memoryromself-diagnosis Erase

by Recheck self-diagnosis

on for Check anydamage the and C/U ECCS terminals C/U ECCS connector.

EN - 406

RB25DE DIAGNOSIS
RB25DE NGINE E

DIAGNOS|S - AtR FLOWMETER 3 (CODENO.12 tN SELF-D|AGNOS|S)

A r fiow meter

o o q

SignalgroundE

26

:.

Components location

\ i \

. -,,'.1 Arrflow meter harnesscon!,eclor

EN - 407

DIAGNOSIS RB25DE
E RB25DE NGINE

Ee@

PowersupPlYinsPection to switch OFFposition. ignition Place harness flowmeter air Disconnect connectors. to switch ON position. ignition Place the Usetesterto measure voltage 3 terminal andground. between lnspect the following: air between flow the Check continuity 5 terminal andECCSrelaY meter 3. terminal or harness connectors. lF NG: Repair

%ei@

circuitinspection Ground to switch OFFposition. ignition Place connectors' C/U ECCS harness Disconnect 4 terminal andECCS between the Check continuity 26. C/Uterminal
or harness connector Repair Inputsignal insPection air between flowmeter Checkthe continuity 27 2 andECCSC/Uterminal (intake terminal signal). airquantity

Ele,@

or harness connector Bepair

EN - 408

RB25DE DIAGNOSIS
RB25DE NGINE E

D
Inputsignal inspection Connect crankarrflowmeter and ECCSC/U harness connectors.
rroRrNq\iro FAtL
(REF) cAs.RPM AIRFLOW MTR ENG TE[,4P SEN EXHSEN THROTTLE SEN INJPULSE 662rpm 1.02V 81, O.1BV O.4OV s.omsec

'AlBFLOW METERin DATA r\ Use \g/ MONITOR measure sional. to inout

,S Measure^the voltagebelweenECCSC/U :. Iermlnat andoround. z/ NG

Approx.0.3V
A p p r o x1 V

'

' ldlirq

''1'.

A p p r o x .. l V 1

ctv

OK

Component parts inspection (Crank angle sensor) Referto the sectlon crankanglesensorfor on rnspection. NG: Replace lF crankangle sensor.

Check anydamage the ECCSC/U for on terminals ECCSC/Uconnector. and

Carryout the inspection the followingorderafterrepairs. in

Verif ication inspection

Erasememory romself-diagnosis f

Recheck self-diagnosis by

Check anydamage the for on ECCSC/Uterminals and ECCSC/Uconnector.

EN - 409

DIAGNOSIS RB25DE
B 8 2 5 D EE N G I N E

SENSOR TEMPERATURE 4. DIAGNOSIS ENGINE ( c o D E N O .1 3 l N S E L F - D I A G N O S I S )

temPerature Engine sensor

conlrol Fuelinjection

a
!

m o o
o

control timrng lgnrlion

; -;

location Components

5\-

'

1 Enginelemp sen trr'l

^^nn6^t^r \'

A
Power supply insPection to switch OFFposition. Placeignition sensor temperature engine Disconnect connector. harness to switch ON position. ignition Place the to Usetester measure voltage 1 terminal andground. between or r harness connector

Ke@

E N- 4 1 0

R825DE DIAGNOSIS
F 8 2 ' D EE N G I N E

B
Groundcircuitinspection Placeignition switch OFFposition. in Check continuity between terminal andground. 2

OK

Repair harness connector or

Inputsignal inspection "ENG TEMPSENSOR Tn DATA 1S1Use : MONITOB" to checkenaine coolant NG Iemperalure. (g) Cnect the voltagebetweenECCSC/U terminal andoround. 28 Voltage: Whenigniiion switchis ON EngtempApprox. 20oC 3V Approx.80"C 1V

OK

Component parts inspection (Engine temperature sensod Refer thesection engine to on temperature sensor inspection. NG:Replace for lF crank angle sensor.

Checkfor any damageon the ECCSC/U terminals ECCSC/Uconnector. and

Carryout the inspection the followingorderafterrepairs. in

Verif ication Inspection

Erasememory fromself-diagnosis

Recheck self-diagnosis by

Check anydamage the for on ECCSC/Uterminals and ECCSC/Uconnector.

FINISH

E N- 4 1 1

D RB25DE IAGNOSIS
E RB25DE NGINE

INSPECTION SYSTEM 5 DIAGNOSIS -IGNITION (coDE NO.21 lN SELF-DIAGNOSIS)

FIL6
fi

o
ql 3

ECCSrelay

,-,tilf '3 st9-9f

-Ful

Components location

-l i",::'"u

E N- 4 1 2

RB25DE DIAGNOSIS
BB25DE NGINE E

lsrrr-onc nesO
o u ts e l f i a g n o s r s , d Toignition srgnal (ltem 1 n o tI ns e l fd i a g n o s i s )
FAILU DETECTED RE TIME I G NS I G N A L R J M A F Y P O

Circuit unction f inspection "POWER Inspect using BALANCE" in 'FUNCTION TESI-'mode. Check ifengine willdecrease to rev mome ntary

()POWER BALANCEl)

INSPECTTHE BALANCE OF EACHCYLINDER BY STOPPING INJECTOR OPERATION EACH FOR CYLINDEF,

Groundcircuitinspection Placeignition switch OFFposition. in powertransistor harness Disconnect unit connector. Checkfor harness continuity between terminal and E grouno.

FASSI
B

E err

Repair harness connector or

Outputsignalcircuitinspection Place ignition switch OFFposition. in Disconnect ECCSC/U harness connector. Inspect continuity for between following the terminals: ECCSC/Uterminal andterminal 1 2 ECCSC/Uterminal andterminal 12 2 ECCSC/Uterminal andterminal 3 3 ECCSC/Uterminal andterminal 13 4 ECCSC/Uterminal andterminal 2 s ECCSC/Uterminal andterminal 11 6 ECCSC/Uterminal andterminal 10 E ECCSC/Uterminal andtermrnal 20 E Repair harness connector or Outputsignalinspection power Connect transistor and ECCS unit C/U harness connectors. Inspect battery voltage between ECCSC/U t e r m j n a 1s 2 , 3 ,1 1 , 1 21 3a n dg r o u n d . l, , Cranking: Approx.0.2- 0.3V ldling: Approx.0.2- 0.3V 2500rpm: Approx.'lV Inputsignal systeminspection E N- 4 1 3

DIAGNOSIS RB25DE
RB25DEENGINE

Component parts inspection unit) (Power transistor for on Referto the section powertransistor power transistor Replace lF inspection. NG.

unit.
Reolace oowertranslstor on Checkfor anydamage the ECCSC/U ECCSC/Uconnector. and terminals

Carry out the inspection in the following order after repairs' insPection ication Verif

f memoryromself-diagnosis Erase

by Recheck self-diagnosis

on for Check anydamage the and ECCSC/Uterminals ECCSC/U connector.

E N- 4 1 4

R825DE DIAGNOSIS
RB2sDE NGINE

DIAGNOSIS - EXHAUST 6 GAS SENSOR (coDE NO.15 tN SELF-D|AGNOSIS)

m
2 1 5 9 ( O U' '

Components location

START
Oarry selfdiagnosis out NG OK FINISH
AIR,FUEL RAIIo TESTl HOLDTHE ENGINE SPEEDAT 2000+l200rpmAND PBESS START

Function inspection 1 Warmuotheenoine. "BASE AIR-FUEL ( l)lnspect using RAT|O" in : "FUNCTION TEST mode. NG OK To B FINISH E N- 4 1 5

DIAGNOSIS RB25DE
E RB25DE NGINE

2 Functioninspection engine. the Start

at Holdthe engine 2000rpmand inspect "O, SENSOR" and"O (output voltage using "DATA rich) MONITOR'(lean, in SENSOR mode. MONlTOR" the Measure voltagebetweenECCSCiU 29 terminal and ground. voltage) NG 0.3V(constant Approx. OK voltage) over0-6- 1V (variant Aoorox.

START

X e- 11:
Fcctc^i"""*".-i

circuitinsPection Inputsignal to switch OFFposition. ignition PIace and connector ECCS harness O, Disconnect sensor connector. C/Uharness 29 C/U ECCS terminal between continuity Check
2. terminal connector harness andO-sensor

t-;

iin

j.----.---I

Elee

or harness conneclor Repair O, Replace sensor

on Checkforanydamage the ECCSC/U and terminals ECCSC/Uconnector.

Carry out the inspection in the following order after repairs' insPectlon ication Venf

f Erasememory romself-diagnosis

by Recheck self-diagnosis

on for Check anydamage the and ECCSC/Uterminals ECCSC/Uconnector.

E N- 4 1 6

RB25DE DIAGNOSIS
RB25DE NGINE E

DIAGNOSIS - DETONATION 7 SENSOR (coDE NO.15 tN SELF-D|AGNOS|S)

tl] a

Components location
*-;:-_-.-:-"'-: Detonation sensor mid harness connector

.,:1

E N- 4 1 7

DIAGNOSIS RB25DE
RB2sDE NGINE

c/u

1 lnput signalcircuitinsPection to switch OFFposition. ignition Place and connector ECCSC/U harness Disconnect connector. sub harness 1 terminal and betvveen Checkthe continuity 2 23, ECCSC/Uterminal terminal and ECCSC/ 24. U terminal

O K Repairharness connector or 2 circuitinspection Inputsignal front connected and NG connectors harness Disconnect sensor. of rear thedetonation terminalA sub between harness continuity the Check and23. B and24.
OK or harness connector Repair

lnput signal inspection andECCSC/U sensor detonation Connect connectors. harness ECCSC/U between the Measure voltage ground. 23, terminal 24 and
location Measurement lgnition switch ON C ran king
ldling

temltnal23, 24 and ground

Approx.4V Approx.4V
Approx.4V

sensor detonatlon Replace on for Check anydamage the ECCSC/U and terminals ECCSC/Uconnector. Carry out the inspection in the following order after repairs' insPection Verification f memoryromself-diagnosis Erase

by Recheck self-diagnosis

on for Check anydamage the and C/Uterminals ECCS ECCSC/Uconnector.

RB25DE DIAGNOSIS
RB25DE NGINE E

DIAGNOS|S - THROTTLE 8 SENSOR (CODENO.43 tN SELF-D|AGNOSIS)

Throtlie sensor
'1
za 38

o
o o

:uel injection conko

fuC cutcontrol
= =

Components location

'ECCS

cortro. n,t L

START
Oarry selfdiagnosis out NG

OK
I rrRorrLeselrsonl
PFESSSTAFTWHILE P R E S S I N GH E T ACCELERATOB PEDAL FULLY

FINISH A System inspection Place ignition switch ON position. to "THROTTLE "DATA USe SENSOR'in MONITOR" inspect system. to the OK Voltage: Fully open Approx. 4.0V Fully closed Approx. 0.6V Open/ Closerange overApprox. 3.0 NG FINISH TOB

E N- 4 1 9

DIAGNOSIS RB25DE
E RB25DE NGINE

B Power supply insPection to switch ON position. ignition ffi Ptace NG : -THROTTLE SENSOB"in DATA Use inspeP!MONITOR'to to switch OFF posilion. 19 etaceignition vDisconnectthrotlle connector. harness sensor 1 terminal and between the Measure voltage

*vortrontr* (BEF) CAS.RPN,,I SEN THROTTLE

ro retr

orprn 3,94V

jll-:APProI voltage ground. Battery

OK

or harness connector Repair

r-_-._.--

circuitinsPection Inputsignal connector.NG C/Uharness ECCS Disconnect C/U ECCS between the Check continuity 2. 38 terminal andterminal

| ,,_.

Ee .@,

or harness connector Repair sensor) Cornponentparts inspection (Throttle for sensor inspection' on to Refer thesection throttle unit. sensor throttle lF NG: Replace

OK
on for Check anydamage the ECCSC/U andECCSC/Uconnector. terminals

in Carryout the inspection the followingorderafterrepairs'

inspection Verif ication from self-diagnosis Erasememory

by Recheck seltdiagnosis

Checkfor any damageon the and ECCSC/Uterminals connector. ECCSC/U

EN - 420

)
R825DE NGINE E

RB25DE DIAGNOSIS

D|AGNOS|S A / T CONTROL 9(CODE s4 tNSELF-DIAGNOSIS) NO.

L---i
Components location

..'''.: ,:..]

START OK Carry self out diagnosis

NG A Inputsignalcircuitinspection Place ignition switch OFFposition. to Disconnect ECCSC/U harness andA,/T C/ U harness connectors. NG Checkthe continuity between ECCSC/U terminal andA/TCiUterminat0, ECCS 14 1 C/U terminal andA"rT terminal 1. 5 C/U 1 OK Repair harness and connectors Checkforanydamage the ECCSC/U on terminals ECCSC/Uconnector. and
EN - 421

FINISH

G )@ i5

j cti lA/T connecta

DIAGNOSIS RB25DE
E RB25DE NGINE

(NOTlN SELF-DIAGNOSIS) 1O DIAGNOSIS - CRANKANGLESENSOR

FiL6 Crank angle sensor

location Components

ECCScontrolunlt

EN - 422

RB25DE DIAGNOSIS
RB25DE NGINE E

START

A Ground circuitinspection Place ignition switch OFFposition. to Disconnect angle crank NG sensor harness connector. Check continuity for between terminal 4 ground andengine harness.
OK

Xea

Repair harness or conneclor

Component parts inspection (Crank anglesensor) NG Refer thesection crank to on anqle sensor for inspection. OK Replace crank angle sensor Check anydamage the ECCSC/U for on terminals ECCSC/Uconnector. and

Carryout the inspection the followingorderafterrepairs. in

Verification inspection Ground circuit inspection Check anydamage the for on ECCSC/Uterminals and ECCSC/Uconnector.

EN - 423

DIAGNOSIS RB25DE
E BB25DE NGINE

SIGNAL1 (CODENOTlN SELF-DIAGNOSIS) 11 D|AGNOS|S - IGNIT|ON

F/16

ECCSrelay

r+/rtnt 2

!!III

Fdf4r{-d)

tElttll_lttlj

Componentslocation
unil Power tranststor

EN - 424

RB25DE DIAGNOSIS
RB25DE NG]NE E

Whole system inspection Startthe engtne. ls allcylinder ignited? To ignition signal 2 Circuitf unctioninspection "POWER Inspect using BALANCE" in "FUNCTION TEST" mode.OR power balance "ACTIVE in TEST". Check if engine willdecrease to rev momentary.

BALANCEO OPOWER INSPECT THEBATANCE OFEACH YLINDERY C B STOPPING INJECTOR OPERATION FOREACH CYLINDER. TURNOFFA/C& LIGHTS

OK

ACTIVE TEST

POWER BALANCE t\40N tToR cAS.RPr\r(POS) AIRFLOW I\,4ETER

Power supply inspection Placeignition switch OFFposition. in Disconnect ignition harness coil connector. Place ignition switch ON posrtion. to UseCONSULT thetester measure or lo the voltage between eachcoilterminalandground. 1 Power voltage: Battery voltage Inspect following: the lgnition relay lgnition switch Continuity betvveen eachcoil Harness terminal andignition 2 relavterminal 5. Ground circuit inspection Placeignition switch OFFposition. in Checkfor harness continuity between eachcoil terminal andqround. 3

rdtrILl B
e:-, f) 1% .$r

trtrtr8

c
@ 5,t,5

OK

Repair harness connector or

Outputsignalcircuitinspection powerlransislor Disconnect unit harness connector. Inspect continuity for between following the terminals: Between eachrgnition terminal and coil 1 Power transistor terminal unit 1 Powertransistor terminal unit 2 Power transistor terminal unit 3 Power transistor terminal unit 4 Power transislor terminal unit 5 Powertransistor terminal unit 6 Repair harness connector or EN - 425

iXe,@

DIAGNOSIS RB25DE
RB2sDE NGINE

Components insPection coil) (Power unit transition & lgnition coil unit transition andignition to Refer power section. inspection in inspeclion components

parts faulty Replace

Carry out the inspection in ihe lollowing order after repairs: icationinsPection Verif for ECCSC/Uterminal Recheck andcheckECCSC/U damage connection. connector harness

insPection Components

EN - 426

r 5

R825DE DIAGNOSIS
RB25DE NGINE E

DIAGNOSIS - IGNITION 11 SIGNAL2 Continuefrom ignitionsignal1

Power supply inspection Placeignition switch OFFposition. in Disconnect ignition relayconnector. coil Place ignition switch ON position. to UseCONSULT tester measure or to the voltage between terminal andground. coil 2,3 Power voltage: Battery voltage

NG

OK

F Groundcircuit inspection PIace ignition switch OFFposition. to Inspect harness continuation between eachcoil terminal and5. 2

Inspect following: the Continuation between fusible link, ignition relay coil andignition switch. Continuation between ignition coil relayandthe battery. NG

Il ee;@

OK

Repair harness / orconnector and

ECCSC/U

Outputsignalcircuit inspection Disconnect ECCSrelay. Inspect continuation the between ECCSC/U terminal 6 and ECCSrelav 1 terminal 2.

NG

OK

Inspect following: the Fusible link. Continuatron between ECCSC/Uand ECCSrelay harness. Continuation between ECCSC/U and ignition relay coil harness. lF NG: Repair harness connector. and

Components inspection (lgnition & ECCSrelay) coil NG Refer ignition and ECCSrelayinspection to coil In components inspectjon section. OK Replace faultycomponents

Inspect ECCSC/Uterminal anydamage for and ECCSC/U connector connection. for

EN - 427

DIAGNOSIS RB25DE
E RB25DE NGINE

INSPECTION SYSTEM 12 DIAGNOSIS - INJECTOR

3 Giil

4 i

m o
i o q L

:EiutttlS

-_l;la

Ftrl*".,
No-

ECCSrelav L)-IJJ -t-----1. t l/!!r l.l.l

1'-o o-+

@ @

N o .1 No.2

location Components

ECCScontrolunrt

EN - 428

RB25DE DIAGNOSIS
RB25DE NGINE E

START A
Circuit f unction inspection Inspect "POWER by BALANCEin /G\ "rurucrroN
tFowrR elLANtcEl INSPECTTHE BALANCE OF EACHCYLINDER BY STOPPING THE INJECTOR DRIVE FOR EACH CYLINDER.

fJ

"POWER Operate BALANCE" in CONSULTactive test. Make sure injector the operation noise ffi \O/ rsaudible.
NG

TEST' mooe.

OK FINISH

B Power supply inspection 1 Place ignition switch OFF. to Disconnect harness sub connector. Checkthe battery voltage between terminal 3 andground using CONSULT tester. or NG Inspect following: the Harness connector. Continuity between harness sub connector the harness. and lF NG: Repair harness connector and

ierreE

c
Power supply inspection 2 Placeignition switch OFFposition. to Disconnect harness sub connector. Inspect between following the terminals forcontinuity: between terminal and 5 3 between terminal and 6 3 belween terminal and4 3

H
No.1 No.2 No.3 No.4 No.5 No.6

OK

NG

Disconnect injector harness connector. Inspect between following the terminals forcontinuity: between terminal andNo. 1,2, 3, 109 4,5&6cylinders. To EN - 429

DIAGNOSIS RB25DE
E RB25DE NGINE

E
Out put circuit insPection connector. ECCSC/U harness Disconnect for terminals the between following Inspect continuitY: 10.1 terminal andNo. 1 cylinder between 105 terminal andNo.2 cylinder between 103 terminal andNo.3 cylinder between 112 terminal andNo.4 cylinder between 110 terminal andNo.5 cylinder between 114 terminal andNo.6 cylinder between

e:@9[
con

NG OK
or harness Flepair connector.

Component PartsinsPection (lnjector) for on to Refer theseclion injector inspection'

NG injector. Replace

for C/U ECCS terminals anY Inspect the sure connectors and damage make correctlY. areconnected in Carryout the inspection the followingorderafterrepairs:
insPection ication Verif on for Recheck anydamage the ECCSC/U and ECCSC/U connector. terminals

EN - 430

R825DE DIAGNOSIS
RB25DE NGINE E

DIAGNOSIS - VEHTCLE 13 SPEEDSENSOR

m o o a
_

3
o

Componentslocation

START
Whole system inspection UseCONSULT carry thejnspectionO K and out " u s i n g V E H l C L E P E E D E N S O Ri" S S n "FUNCTION TEST"mode. NG FINISH

Vehicle speedsensorfunctioninspection N G Inspect vehicle speed meter function

OK Vehicle speed sensor and vehicle speed sensor circuit inspection.

TOB

EN - 431

DIAGNOSIS RB25DE
RB25DEENGINE

B
InputsignalinsPection the Start engine. Rotatedriveaxles]ew]yNG

No fS,tortrontufr rnlr
(POS) CAS.RPI\, 787r7m

usingVEHICLE /a\ b-eieiltehicbspeed

u
,o' W

i'LQ4IA-NIONIIOBspeeoSENSOR"
between the to Usetester measure voltage 53andground. EccS C/Uterminal 0 aPProx. - 5V ----Voltage:
OK

Inspectthe following: ECCS between the Check continuity meterharness. C/U andcombination

c/u

orf9ple99i9M9!'-lF NG:Repair
for ECCSCiUterminals any Inspect andmakesuretheconnectors damage correctly. areconnected

in Carryout the inspection the followingorderafterrepairs'

insPection ication Verif

insPection circuit Ground

on for Check anYdamage tne and ECCSCiUterminals ECCSC/U connector.

EN - .132

R825DE DIAGNOSIS
RB25DE NGINE E

DIAGNOSIS -AIR CONDITIONER 14 RELAYSIGNAL

IGNreiay1

To FrCD rela,i Duai pressute

AC rear sw

ACC reiay ACC key SW

m o o a
o q

)-

Components location

controtunrt

Inputsignal inspection Placeignition switch ON position. to Usetesterand measure battery lhe voltage between ECCSC/Uterminal andground. I Whenblow-fan switchis OFF: battery voltage Whenblow-fan switch ON: Approx. is 1V

Inspect ECCSC/Utermrnals any for damageand makesurethe connectors areconnecled correctlv.

Carryout the inspection the followingorderafterrepairs. in

Ground circuit inspection

Check anydamage the for on ECCSC/Uterminals and ECCSC/Uconnector. EN - 433

DIAGNOSIS RB25DE
E RB25DE NGINE

HEATER GAS SENSOR 15 DIAGNOSIS - EXHAUST

Trl

o o (,
o x 9

Components location

i'

controLlntt ,,-l

EN - 434

R825DE DIAGNOSIS
FIB25DE NGINE

START A Power supplyinspection Disconnect gas exhaust sensor harness connector. G N Place ignition switch ONposition. to power Measure voltage between terminal and 1 ground. OK lnspectthe following: Harness connector. Continuity between gas exhaust sensor thefuse.lF NG: and Repair harness connector. and

Groundcircuitinspection Placeignition switch OFFposition. to Disconnect ECCSC/U harness connector. NG Check continuity for between termrnal and 3 E C C SC / Ut e r m i n a l 1 5 . 1 OK Repair harness connector. or Component parts inspection (Exhaust sensorheater) gas Referto the section exhaust on oas sensor heater inspection. for NG

OK

Replace gas exhaust sensor.

Inspect ECCSC/Uterminals any for damage andmakesuretheconnectors areconnected correctlV.

Carry out the inspection in the following order after repairs.

Verification lnspection Inspect powersupply, ground circuit Check anydamage the for on ECCSC/Uterminals and ECCSC/Uconnector.

EI\

- I+JJ

DIAGNOSIS RB25DE
E RB25DE NGINE

VALVESWITCH 16. DIAGNOSIS THROTTLE

rf o o
_

U) o q

Comoonentslocation

d--4"i6-r'
valvesw

EN - 436

RB25DE DIAGNOSIS
RB25DE NGINE E

START
] . I D L E J U D G E I V F N T' A F TW H E N C C E L E R A A OB PEDALIS FULLY OPEN.

Function inspection 1 Place ignition switch ON positron. to "IDLE Inspect using JUDGEMEN'l-' O K in "FUNCTION TEST'mode. Reference: Fully open:OFF Fully closed: ON FINISH B NG Functioninspection2 Placeignition switch ON position. to "ON-OFF" Inspect ignition switch diagnosis or measure voltage lhe between ECCSC/Uterminal O K 54 andground using tester the whenignition switch i sO N . Voltage: Accelerator pedalpressed 0V pedalnotpressed - 10V Accelerator 8 NG

START

connector

FINISH

Power supply inspection Placeignrtion switch OFFposition. to Disconnect throttle valveswitchharness connector. NG Place ignition switch ON position. to Uselesterto measure voltage lhe between terminal andground. 2 Battery voltage: Approx.8 - 10V Inspectthe following: Harness continuity between throttle valveswitch andECCSC/U. lF NG: Repair harness connector. and

D Inputsignalcircuitinspection Placeignition switch OFFposition. to NG Disconnect ECCSC/U harness connector. Disconnect throttle valveswitchharness connector. Checkthe continuity between ECCSC/Uterminal 54 andthrottle valve switch terminal 1. OK

Repair harness connector. or

Component parts inspection (Throttle valveswitch) NG Referto the section throttle on valveswitch for jon. inspect OK Replace throttle valveswitch.

Inspect ECCSC/Uterminals anydamage for and makesuretheconnectors connected are correctlv.

EN - 437

DIAGNOSIS RB25DE
E R825DE NGINE

in Carryout the inspection the followingorderafterrepairs'

insPection Verification on for Check anydamage the and ECCSCiUterminals ECCSC/U connector.

EN - 438

RB25DE DIAGNOSIS
RB25DE NGINE E

DIAGNOSIS - START 17 SIGNAL

GN SW

START
t) snRrrn srcNnrI
PLACE SHIFTLEVERTO'P'OR STARTTHE ENGINE STFAIGHT AFTER SELECTING STARI ,

Function inspection /tr\ Place ignition switch ON position. to tU "START UseCONSULT inspect and SlGNAL" in "FUNCTION TEST'mode. OK OR Place ignition switch ON position. to Inspect startsignalusing"DATA MONITOR" mode. Whenignition swrtch ON position: is OFF Whenignition position: ON switch START is

NG

FINISH
(POS) 1326rpm CAS.RPM STARTEF SIGNAL OFF

Power supply inspection ?@ Placeignition switch OFFposition. to ) Disconnect throttle valveswitchharness connector. N G Placeignition switch ON position. to Usetesterlo measure voltage the between terminal andground. 2 Battery voltage: Approx.8 - 10V OK Inspect the following: Fuse Continuity between ignition switch and ECCSC/Uharness. NG: lF Repair harness andconnector.

BECORD

'@
I ECCSC/U connector I

Inspect ECCSC/Uterminals anydamage for and makesuretheconnectors connected are correctlv.

EN - 439

DIAGNOSIS RB25DE
E RB25DE NGINE

18. DIAGNOSIS FUELPUMPCONTROL

ECCSrelay

qH,,r
F/L3 IGN SW #16

2t-

Fuel pumprelay

location Components

EN - 440

B825DE DIAGNOSIS
RB25DE NGINE E

START A

Systeminspeclion "FUEL Select PUMP" -FUNCTtON in TEST" inspect system. to the \9 Operation check "FUEL by PUMP RELAy" in 'ACTIVETEST'. OK pump operate 5 seconds the Fuel will for after ignition switch turned ONposition. is to Check if pump thefuel operation areaudible. norse B
Power inspection position. Placeignition switch "OFF" to Disconnect pumprelay. fuel Measure voltage ground between and terminal & 3 usinq tester. 2 the

.FUEL PUMP' ISTHERE PULSATION A EVEFY SECONDS 3 W H E N H EF U E L U B E T T I S H E L D ?O R C A NY O U HEARTHEOPERATION N O I S E F T H EF U E L O

I acrrvclesr I a
FUEL PUMP RELAY ON MONITOF (POS) orpm CAS. RPIV

FINISH

NG
START ON/OFF STOP

OK
Check following: the Fuse Harness connection between fuel pumprelay andthefuse. Connection between pumprelay fuel andtheignition switch. lF NG: Repair harness connector. &

c
Groundcircuit inspection Placeignition switch OFFposition. to Remove pumpharness fuel connector. Checkthe connection between fuel pumpnarness connector andthe 3 ground. NG

D Outputsignalcircuitinspection Place ignition switch OFFposition. to NG RemoveECCSC/U harness connector. Checklhe continuity between ECCSC/U& harness terminal andfuelpumprelay 18 harness lerminal 1.

Repair harness or theconnector.

Eeo

Check following: the Continuity between ECCSC/Uandfuelpumprelay. Continuity between ECCSC/U and pumprelay. lF NG: Bepair harness lhe connector. and
EN - 441

DIAGNOSIS RB25DE
E RB25DE NGINE

E Control signal insPection groundand ECCSC/U the Measure voltagebetween 18. terminal 5 seconds after ignition switch is turned ON: 1V After 5 seconds after ignition switch is turned ON: Battery voltage OK

Elee

parts inspection Component pumP relay) (Fuel for relay on to Refer thesection fuelpump rnspection. OK

NG

,Q
E9!9

relaY. fuel Replace PumP

Component PartsinsPection NG (Fuel pump) for on to Befer thesection fuelpump inspection.

OK tuel Replace pumP.

on Checkfor anydamage the ECCSC/U and ECCSC/Uconnector. terminals

Carry out the inspection in the following order after repairs' insPection ication Verif on Checkfor anydamage the ECCSC/U and terminals ECCSC/Uconnector. inspection. Fuelpressure

EN - 442

RB25DE DIAGNOSIS
RB25DE NGINE E

DIAGNOSIS AACVALVE 19.

Components location

START A Function inspection Warm engine. the Checkthe idlespeed 600 - 700 rpm. OK lF NG: Adjust speed. idle "AACVALVE in " /G\ Inspectusinq 's/ "FUNCTION TEST" mode. AAC <>, Drsconnect valveharness. W Cfreck idlerevwilldecrease. if
RN OFFA/CAND LIGHTS

FINISH

NG B Power inspection Placeignition switchto "ON"position. Measure voltage ground between andAACvalve terminal 2. TO

NG

Repair harness theconnector. or EN - 443

DIAGNOSIS RB25DE
E RB25DE NGINE

c
Output signal circuit insPection whenthe rev A Checkif theengine willchange \E/ "up" or "DOWN'is pressed AACVALVE in in .ACTIVETESI'' mode. NG ECCSC/U harness. ^ Disconnect ECCSC/U between H Cnect forcontinuity : 4 h"rn"sstermtnal andAACvalveconnector 1 terminal. OK

Ele:@

or harness conneclor. Repair

c
. N .ACTIVETEST DEG 10'6 OPENING AACAr'
MONITOR (POS) 900rpm CAS.FPM AIR FLOWI\,,ITR 1.'16V TEI,IP SEN 8O"C ENGINE

NG Component parts inspection (AACvalve) lor on to Refer the sectton AACvalve inspection'

OK

AACvalve. Beplace
Qu

UP

DWN od

on Checkfor anYdamage the ECCSC/U C/Uconnector. and terminals ECCS

Carry out the inspection in the following order after repairs'

insPection Venf ication on Checkfor anydamage the ECCSC/U and terminals ECCSCiU connector.

check. Functional

EN - 444

R825DE DIAGNOSIS
RB25DE NGINE E

DIAGNOSIS AIRREGULATOR 20.

m c) o a
o
l

Fuel pump relay

Air regulalor

Components location

control unit

f-f ,'T-

Power supply inspection Place ignition swttch OFFposition. to Disconnect pumprelay. fuel Place ignition switch ON position. to Usetesterto measure voltaqe the between terminal 3 andoround. 2. Inspect following: the Fuse. Harness continuity between fuelpumprelayandfuse. Continuity between fuel pumprelay andignition switch. lF NG: Repair harness and connector.

EN - 44s

DIAGNOSIS RB25DE
E RB25DE NGINE

B
Groundcircuit insPection to switch OFFposition. Placeignition connectors. harness air regulator Disconnect harness air between regulator for Check continuity 2 terminal andground. connector NG

OK

or harness connector. ReDair

c
circuitinsPection signal Output to switch OFFposition' ignition Place NG connector' C/U FCCS harness Disconnect C/U ECCS between continuity for Check harness 1. terminal relay 18 terminal andfuelpump OK

Eielm

the Inspect following: ECCSC/ between Continuity lF relaY. NG: U andfuelPumP andconttnuitY. harness Repair
_ t' ' _

D ControlsignalinsPection ECCSC/Uterminal between vollage Measure 18andground. NG in is switch placed ON 5 Within secwhenignition 1 position: APProx.V switchrsplacedin ON 5 sec when ignition After voltage position:Battery OK

Xc *

LEsc+r**!

Ci ECCS and Repair insPect ground and supply U power circuit.

Component Parts inspection NG (Airregulator) air Replace regulator AAC Referto the sectionon valvefor inspection. Carry out the inspection in the following order after repairs' insPection ication Verif on Checkfor anydamage the ECCSC/U and terminals ECCSC/Uconnector.

check. Functional

EN - 446

RB25DE DIAGNOSIS
RB25DE NGINE E

DIAGNOSIS . POWEBSTEERING 21 HYDRAULIC PRESSURE SWITCH

PWR hydraulic ST pressure SW

_ . - - - . - _ - _ F '\-----l | 1

*l_

Components location

Function inspection switch ON position. to fr; Placeignition : 'PWRST SlG" Inspect using in 'FUNCTION TEST"mode. OR Stopthe engine. Use "DATA MONITOR" inspectPWR to ST hydraulic pressure switch srgnal. Whenneutral: OFF Whensteered: ON Start engine. the UseCONSULT tester measure or to the voltagebetween ECCSC/U terminal19 andground. Whensteered:Approx. 0V Other:Battery voltage TOB
EN - 447

PoWEB ST SIG .

PRESSSTART WHILEFULLY STEERING STEERING THE WHEEL,

A lro frvorrroRrruqf rnt

cAS.Pr\,,t(POS) 862rpm I G N I T I O NG N A L O F F SI

HECOBD

DIAGNOSIS R825DE
E RB25DE NGINE

B
Inputsignalcircuit inspection to switch OFFposition. ignition Place connector. ECCSC/U harness Disconnect NG pressure hydraulic powersteering Disconnect connector. harness switch ECCSC/U between continuity Checkfor harness pressure hydraulic steering 19 terminal andpower 1 terminal . switch

OK

or harness connector. Repair

c
Groundcircuit insPection powersteering N G between Checkfor continuity 2 terminal andenglne pressure switch hydraulic grouno.

OK

or harness connector. Repair

Component Parts inspection pressure switch) NG hydraulic (Power steering powersteering on Referto the section pressure for switch inspection. hvdraulic powersteering Replace pressure swltch. hydraulic on tor Check anYdamage the ECCSC/U C/Uconnector. and terminals ECCS

in Carryout the inspection the followingorderafterrepairs'

insPection Verification on Checkfor anydamage the ECCSC/U ECCSC/Uconnector. and terminals

check. Functional

EN - 448

R825DE DIAGNOSIS
RB25DF NGINE E

DIAGNOSIS (Phenomenon) IDLEREV tS TOO HIGH(AFTER 22 WARMUP) 1 Throttle sensor & air regulator inspection 1
I rsnot.rue O sENson
PRESS STABTWHILE FULLY OPENING ACCELERATOB THE PEDAL.

tunction mode. tesr 5S. !.snec11n '!'/ UnecK judgement)

rlthethrottle (idle sensor is NG notturnedOFF. Makesuretheair regulator ts notrocKed untt 61 \v or electricity conducted arrrequtator. is to OK

Circuit throttle and sensor Inspectron. Airregulator circuit and inspection.

Intakeair leak inspection Warmuo the enqine. ..=. / l r \ DWN in YES flChange offsetvalueby selecting "FUEL INJECTION RATIO OFFSET VALUE" activetest mode. in Caution: Carry thetestin minimum out time required. notoperate Do during drive. Warmup lhe engine. Separate flowmeterharness air conneclor. ^ after @Cnect if the idlerevwilldecrease racing engine approx. the at below 2000rpm for 30 seconds. NO 3 Throttle linkage inspection Stop engine. the Checkif the throttle linkage movesmoothly. will Checkif thethrottle valvewillclose/ ooenfullv. NG Reoair where is leakino. air

2 I

(R o, sENsoR )
I N JP U L S E AAC VALVE Qu UP

FUEL INJECTION SET oei, OFF [40NlTOR cAS.FPr\,4(POS) 937rpm ENGTEIV1P SEN 5S'C O. SENSOB 1.33V

acrve resr a tr

1.3sV
1.8msec 17". DWN lt Od

OK
FINISH

Repair throttle linkage or Inspect throttle valve

\i _r J)"*

f Jt/*i,.

EN - 449

DIAGNOSIS RB25DE
R 8 2 5 D EE N G I N E

23 DIAGNOSIS (Phenomenon)'HUNTING

Throttle sensor insPection Warmuptheengine. when02 sen withhunting for Check anychange is connector seParated.

Power balance test ^ Startheenqine. test' ($u." PowEB BALANCE- function in time out Carry thetestin mlnimum Caution: drive during Do required. notoperate for for revwilldecrease a moment each ldle linder. for rev dl-e willdecrease a momenlwhen is connector injector eachcylinder

I serusoR O rnRorrue
FULLY STARTWHILE PRESS THEACCELERATOR OPENING PEDAL.

SparkpluginsPection the Stop engtne. for and spark Disconnect plug check dirt'
gapetc. damage. r or replace. lntake air leak insPection the Start engtne. whenblow-by rev Checkif engine willincrease is house pinched.

EN - 450

R825DE DIAGNOSIS
RB25DE NGINE E

OIAGNOSIS (Phenomenon) IDLEINSTABILITY 24 1 Operatepower balancetest ,G\ Startthe enoine.

I poweR enr.ANlce a
]NSPECTBALANCE EACH OF PIPES STOPPING BY INJECTOR OPERAT]ONAT EACHPIPES. TURNOFFALLlJCANDLIGHTS

NO '-U'operate pdwen BALANCE TESTjnfuncrion test. Caution: Operate test minimum the in time requirgd. not Do operate during drive.

for when 6ldle revwilldecrease a moment (&operating eachpipes.

YES
To No. 6

2
Injector inspection Stoptheengine. Remove crankanglesensor. (leave harness connector it is). as NO power Dlsconnect transistor connector. Place ignition switchromOFFto ON posrtion. f Can you hearoperation noisefromeachinjector whenthe crankanglesensor shaftis rotated hand. by Warning:Dependrng howthe shaftis rotated, on selfdiagnosis drsplay will abnormal, disregard display. this

YES 3

Inspect iniector circuit and

lgnition inspection Placeignition switch OFFposition. to Remove rgnition ASSY coil NG Install normai sparkplug. Facethe sparkplugrearendtowards adequate ground suchas collector crank enaine. and the Check spark. the OK Inspect ignition power coil, transistor circuits. and

ffi
\ , \

Operation noise

4 Spark plug inspection Check dirt,damage, etc.on the for gap plugremoved spark fromtheengine.

TO5

EN - 451

DIAGNOSIS RB25DE
F B 2 5 D EE N G I N E

FuelpressureinsPection the Start engine. "STOP" "ACTIVE and TEST" bring in Select to fuelpressure zero. 2 crank - 3 times. stop, engine After fuel using pressure fuel Inspect pressure gauge. x.2.5kI cm" o W h e ni d l i n q :
the Start engine. fuel fuel Remove pumpfuseandbring pressure zero. to the gaugeand inspect Attachfuel pressure and fuel Inspect pumP circuits.
': Fuel frlier:J \

la'x[\

6
to $rorrrontnqN rntr
CAS.RPI\,4(REF) 650rpm O.O2V 02 SENSOF M 02 SENSOR TR RICH

Exhaustgas sensorinsPection "BASE in RATIO" AIR-FUEL using ,6',lnspect mode. tly''ruNcrtoru TEST" "O,SENSOR in MONITOR"data Select monitor. warmup' withno load Setat 2o0orpm "LEAN'after will RlCH" repeat if Check thedisplay
for morethan5 timeswithln10 seconds fusebox) side(within ,o,Operatevehicle to and @)diaqnosis connector change O, monll0r'. sensor Set at 200orpmwith no loadafterwarm up warning temperature Checkif theexhaust lampwillf lashfor morethan5 timeswithin O, Replace sensor TO7

6
openthe 2 Ior a'pprox secsJben (rhernode /4-ff-ffF;la Ilmerhs earh Lff.ffTT-l rs -:Pedormeo)
l m o d e .s h o n - c i r c ulih e s e

EN - 452

RB25DE DIAGNOSIS
R825DE NGINE E

7 Intakeair leak inspection Start engjne. the YES Check theengine willincrease if rev when theblow-by hoseis pinched using hands.

NO
8

Repair leaks

ldle adjust screwf ixationinspection the fO Start engrne. "AAC s Operate VALVE ADJUSTMENT' N O in 'OPEBATION SUPPORT" mode. Canidlerevbe adjusted 600- TOOrpm to ("N" position A/T)by rotating idte for the adtustment screw.
r\Startthe engine. \Gr'Disconnect valveconnector. AAC Can idle rev be adjusted 600 - TOOrpm to ("N"position A/T)by rotating idle for the adjustment screw. YES AACvalveandthrottle valvefixation inspection.

AAC VALVE ADJ ' . SETTHECAS.PRI\I TO STANDARD VALUE UNDEB IHE FOLLOWING CONDITION: AFTEB WARMUP TURNOFFALL LIGHTS AND AIRCONDITIONER,

9 Compression pressure inspection Standard value:12.8i300(kgicm,)/(rpm) N G Minimum value:9.8/300 (kg/cmr)/(rpm) Eachcylinder difference Tolerance: .0/300 1 (kg/cmr)/(rpm) OK

piston, pistonring Inspect valve, valveseat,cylinder headgasket.

10

ECCSC/Uconnectorinspection Check anydamage loose for or connection on theC/Ubinterminal harness and connector.
OK 11 Tryreplacing normat with C/U.l-----.]Replace repair or FINISH

EN - 453

DIAGNOSIS RB25DE
E RB25DE NGINE

D|AGNoS|S25(Phenomenon).WHENcoLD,D|FF|CULTToSTARToRcANNoT THEENGINE START

1

motor and Oattery starter tnspect f-llsglessjljePell OK 2 inspection Fuelpressure NG in PUMP' 'FUNCTION FUEL using ,6,lnspect flltesr" mode.
withf ingers. ,o.Pinchf uelPumP 6)Cnect if thefusehoseis tensewhenf uel pumpus operatlng.

. F U E L P U M P' YOU FEELPULSATION W R Y3 S E C O N D S H E N

E FUEL TUBEIS Y E D ?O BC A N O U FUELPUMPRELAY

OK

pump circuit and Fuel inspection

Fueiiilter

insPection Air regulator NG to is thepower conducted airregulator if Check to is switch turned ONposition' the when ignition
OK 4 and air Inspect regulalor clrcull.

ThrottlesensorinsPection if pedal andcheck fully accelerator Press will theengine start.

OK

andcircuit sensor Throttle inspection. 5 lnjector inspection to switch OFFpositlon. Placeignition harness crankanglesensor(leave Remove connected). connector connector. powertransistor Remove NG to switch ON position. ignition Place noisecan be operation Checkif eachinjector heardwhenthe crankanglesensorshaftis rotated on by hand.Note:Depending howtheshaftis in will abnormal showin self-diagnosis, rolated, as thiscasedetermine normal. OK TO6 insPection and Injector circuit

4
'J5;-

Fully pen o :f lrr't

gl+uu\

,/

.\-i)

if.',{:--,!

Rolate by hand

EN - 4s4

RB25DE DIAGNOSIS
RB25DE NGINE E

6 lgnitioninspection Placeignitjon switch OFFposition. to jn Remove sub-harness eachpipptng. Install normal plug.Facethespark spark plug NG rearend towards adequate groundsuchas collector crank engine. and the Check spark. the OK Inspect ignition power coil, transistor circutt. and

7 Sparkpluginspection Check dirt, for gap damage, etc. thespark NG on plug removed theengine. from OK

Repair replace or
8 ECCS C/U connector inspection NG Checkfor any damageor looseconnection on the C/U binterminal harness and connector.

OK
o

Repair replace or

ECCSC/Upower supply andground circuit NG Inspectron. OK Repair replace or

't0
Try replacing normai with C/L. FINISH

EN- 4ss

DIAGNOSIS RB25DE
E RB25DE NGINE

DIAGNOSIS26(Phenomenon)-WHENWARM,DIFFICULTTOSTARTORCAN NOT STARTTHE ENGINE 1

FuelpressureinsPection NG in PUMP" "FUNCTION FUEL using /G Inspect !UtEST" mode. with f ,o,PinchuelPumP fingers. (SCneckifthefuse fuel when is hose tense pump operatlng. us OK 2
Vapour inspection vacuumhose O K regulator fuel Disconnect pressure hose. a Place holecapon thevacuum start? Doestheengine NG
J

1) IFUEL PUN/P YOU FEELPULSATION W 3 SECONDS HEN

E FUEL I UIJtr I-

Fuelpumpandcircuit inspection

fuel Inspect aspect

IniectorinsPection to switch OFFposition. Placeignition (leave harness sensor angle crank Remove connected). connector connector. harness powertransistor Remove NG to switch ON position. Placeignition can be noise operation Checkif eachinjector crankanglesensorshaftis rotated heardwhenthe on by hand.Note:Depending howtheshaftis in will abnormal showin self-diagnosis. rotated, as thiscasedetermine normal. OK inspection and lniector circuit

4 lgnitioninsPection to switch OFFposition. Placeignition in sub-harness eachpipping. Remove plug N G sparkplug.Facethespark normal Install groundsucnas adequate rearend towards the and collector crank engine. the Check spark. OK coil, ignition Power Inspect and transistor circult.

TO
EN - 456

RB25DE DIAGNOSIS
RB25DE NGINE E 5

Sparkplug inspection Check dirt, for gap on damage, etc. thespark N G plug removed theengine. from OK
Repair replace or 6 ECCS C/U connector inspection NG Check anydamage loose for or connection on the C/Ubinterminal harness and connector.

OK
7

Repair replace or

ECCS power C/U supply ground and circuit NG inspectron. OK

Repair replace or I Try replacing normal with C/U. FINISH

EN - 457

DIAGNOSIS RB25DE
E RB25DE NGINE

TO DIFFtCULT STABT 27 DIAGNOSIS (Phenomenon)'lN NORMALCONDITION, THE ENGINE OR CAN NOT START
t 1

motor and starter battery lnsoect

()FUEL PUI\,4P ' YOU FEELPULSATION

Fuel pressureinsPection in PUMP' "FUNCTION using 4;.,lnspect FUEL \ETEST'mooe.

withfingers fuelpumP Pinch Checkif thefusehoseis tensewhenfuel pumpus oPerating. Fuelpumpandcircuit inspection Iniectorfuel leak insPection pedal fullyan checkif the accelerator Press is switch turn whentheignition will engine staft position. to START leak. injector Inspect lniector insPection to switch OFFposition. Placeignition harness sensor angle {leave crank Remove connected). connector connector. powertransistor Remove to switch ON position. ignition Place noisecan be operation Checkif eachinjector heardwhenthe crankanglesensorshaftis rotated on by hand.Note:Depending howtheshaftis in will abnormal showin self-diagnosis, rotated, as thiscasedetermine normal. insPection and lniector circuit lgnition inspection to switch OFF position. Placeignition in sub-harness eachpipping Remove plug sparkplug.Facethespark normal Install ground suchas adequate rearendtowards the and collector crank engine. spark. the Check

W 3 S E C O N D SH E N E FUELTUBEIS ED? OR CANYOU

RELAY FUELPUI\,4P EAFI

dI?-., Fully pen o :\l rF.t ,/ ,V

TI+(f,l\

f-l

X-

Rotateby hand

OK
TO6

coil, ignition Power Inspect and transislor circuit.

R825DE DIAGNOSIS
RB25DE NGINE E

Sparkpluginspection Check dirt, for damage, etc.onthespark N G gap plug removed theengine. from
OK Fepar or replace ECCS C/U connector inspection NG Check anydamage loose for or connection on the C/U binterminal harness and connector,

OK

Repair replace or

I ECCSC/Upower supply andground circuit N G Inspection.

OK
Repair replace or I Tryreplacing normat with C/L. FINISH

EN - 459

DIAGNOSIS RB25DE
RB25DE NGINE E

AFTEB WARM UP 28 DIAGNOSIS (Phenomenon)- HESITATION (hesitationas throttle valve starts to open)
I

TEST' OK in'ACTIVE Gzounurtrv coRREcrtoN"

value. correction to mode change time out Carry thetestin minimum Caution: olelqle lullnggllve,Do required. not hose NG vacuum pressu regulator re nectluef ;DGcon (6)Place caponvacuum hose hole test. cruising Operate still lsthere hesitation?
NG pressure inspect lf leanhesitatlon and regulator fuelPumP.

FuelpressureinsPection 'UP'or"DWN" 'FUEL INJECTION in ,erSelect

OFF FUEL INJECTION SET 09" MONITOR 937rpm CAS.FPIV(POS) 59'C SEN ENG TEI\,4P

resr O D rcrrve

o, sENsoF (R o . S E N S OB )
iNJ PULSE AAC VALVE

1.33V 1.3sV

l.BMSEC 17'i.

Qu

UP

DWN ll Od

insPection aspect Fuel

Canisterpurge inspection nose. N G canister Disconnect Purge hose on the Purge holecap Place test. cruise Conduct still ls there hesitation? purgeandvacuum Inspect system. FINISH

EN - 460

RB25DE DIAGNOSIS
RB25DE NGINE E

DIAGNOSIS (Phenomenon) HESTTATTON 29 WHENCOLD (hesitationas throttle valve starts to open)

1

Sparkpluginspection Remove plug spark andcheck anvdirt, NG for gap damage, etc.
NG Bepair replace or

2 Fuelpressure inspection " U P ' o r D W Ni'n F U E LN J E C T I O N I rerSelect euRrurtry coRREcloN' in-ACTIVE TEST' OK mode change to correction value. Caution: Carry thetestjn minimum out time required. notoperate Do during drive. Start engine. the
rev whentheblow-by 61Does theengine increase \g/ hoseis pinched? NG 3 OK Replace normal f lowmeter. with arr NG Replace flowmeter. air Repair leaks
r.33V ACTIVE TEST
FUEL ]NJECIION OFFSET

4 Intake valve deposit inspection Remove whendeoosit Dresenr. is FINISH

EN - 461

DIAGNOSIS RB25DE
E BB25DE NGINE

lN 30 DIAGNOSIS (Phenomenon)'HESITATION NORMALCONDITION (hesitationas throttle valve starts to open) 1 Spark plug insPection for sparkplugandcheck anydirt, Remove
TE51, ItsASE FUEL RATIO AlR
REV2000+f ENGINE HOLD STARI ANDPRESS 200rpm

or Repair replace Exhaust gas sensor insPection 'BASEAIR-FUEL in RATIO" using Inspect "FUNCTION TEST"mode. "O, SENSOR NG in MONITOR" data Select monllor. with no loadafterwarm up Set at 2000rpm "LEAN, will RICH" repeat Checkif thedisplay

10 within seconds 5 than times formore

fusebox) side(within vehicle Operate to and connector change Odiagnosis monitor". sensor with 2OOOrpm no loadafterwarm up. Set at warning temperature Checkif theexhaust morethan5 timeswithin lampwillf lashfor

ttlt 7|-rl

temP Exhaust l w a r n r n ga m p I

Canister purge insPection nose. canister Disconnect Purge hose. holecaPon Purge Place test. cruise Conduct still ls there hesitation?

purge ano Inspect system vacuum

lntake air leak insPection Warmup the engine. "DWN" off Change setvalueby selecting OFFSET RATIO in "FUELINJECTION mode. in test VALUE" active Carryoutthetestin minimum Caution: drive. during Do timerequired. notoperate Warmup the enqine. connector. rateairflowmeterharness

4 O ncrtvEresr O f

OFF FUELINJECTION SET O% MONITOB s37rpm CAS.RPM(POS) 59'C SEN ENG TEI\,4P 1.33V o. SENSOR 1.35! o. sENsoR(R) 1.8msec tNLPULSE 17"h AAC VALVE

Ou

UP

owN

Qd

after @cn-.,"[ ii rn" idlerevwilldecrease

below at the racing englne approx. for 30 seconds.

any Repair leaks

RB25DE DIAGNOSIS
RB25DE NGINE E

DIAGNOSIS (Phenomenon) ENGTNE 31 STALLWHTLE REVVTNG 1 Fuel level inspection Checkthe levelof fuelin thefueltank. 1

NG

Resupply fuel

OK 2
Power balancetest operation ,ar Startthe enoine. l l l \9/ Inspect using'POWER BALANCEin 'FUNCTION TEST"mode. "POWER Operate BALANCE" "ACTIVE in TEST"mode.Caution: Carry thetestin out minimum timerequired. notoperate Do during drive. Checkif idlerevwilldecrease a moment for whenchecking eachcylinders.

I , F-rN-=
l\--l | |

'

NG
OPOWEH BALANCE' FOREACH CYLINDER STOP INJECIOR OPEMTIONAND CHECKTHEBALANCEOF EACH CYUNDER. TURN OFF,6./CAND LIGHTS

if for ,q1 Check idlerevdecrease a moment rrwhen each injector connector cylinders are disassembled.
To No. 5 OK 3 Iniector inspection Placeignition switch OFFposition. to Remove crank (leave angle sensor harness connector connected). powertransislor Remove connector. NG Placeignition switch fromOFFto ON position. Checkif eachinjector operation noisecan be heardwhenthecrankanglesensor shaftis rotated by hand.Note:Depending howtheshaft on is rotated, abnormal showin self-diagnosis, will in thiscasedetermine normal. as Injector circuit and inspectron 4 lgnition inspection Placeignition switch OFFposttion. to Remove sub-harness eachpipping. in Installnormal plug.Facethespark spark plug NG rearendlowardsadequate groundsuchas collector crank engine. and the Check spark. the
OK

/l Operationnolse

'%j,::""',,
'%!

TOs

Inspect ignition power coil, transistor circuit. and

EN - 463

DIAGNOSIS RB25DE
E RB25DE NGINE
5

Fuel pressure insPection /G\ Startthe engine. FUEL to fU'Bringfuelpressure zeroby selecting TEST". in "ACTIVE PUMPRELAY" NG stop. Crank2 to 3 timesafterengine gauge inspect: to Usefuelpressure 2.skg/cm' APProx. Whenidling. hoseis vacuum regulator Whenpressure APPToL removed:

ACTIVETEST . L--] . RELAY ON FUELPUI\.4P MONITOB (POS) 0rPm CAS.RPM

oN c

lpN/oFFll oFF

the Start engine. ,-o'' \6tlring {uel fuel by pressure zero removing to pump fuse. stop' after engine 2 Crank to 3 times gauge. pressure fuel using Inspect
OK
o

pressure Inspect diaPhragm regulator

ECCS C/U conneclor inspection NG on connection or for Check anydamage loose connector. and theC/Ubinterminal harness

OK

or Repair replace

gCCSC/Upower andground N G supply tnrpect circuit. OK 8 C/U. with Try replacing normal OK FINISH or Repair rePlace

EN - 464

RB25DE DIAGNOSIS
RB25DE NGINE E

- ENGTNE DIAGNOSIS (Phenomenon) 32 STALL AFTER WARM Up 1 1 resr O ncrrve Vapourinspection ..DWN" "FUEL correction byselecting value in ,6lChange " in"ACT|VE \E4NJECTION CORRECTTON TEST" mode. Caution: Carry thetestin mintmum required. out time Donotoperate during drive. pressure regulator vacur-rrn fG\Disconnect
\@Place hole cap on vacuum hose.

FUELINJECTION SET O'/. OFF t\,10NtToR CAS.RPI\,1(POS) 937rpm ENGTE]\IP SEN 59,C o, SENSOR 1.33V ( o " S E N S O RR ) i.35\ INJ PULSE ].8msec AAC VALVE 179L
OL/

a I

Operate cruise test. Does enaine stall? the still 2 NG

UP

DWN

od

Power balancetest operation /G\ Start the enqine. 'i -eOWeR BALANCE Inspect usirig in .FUNCTION TEST"mode. "POWER Operate BALANCE" "ACT|VE in TEST"mode.Caution: Carryoutthetestin minimum timerequired. notoperate Do during drive. Checkif tdlerevwilldecrease a moment for whencheckinq eachpippinq. Checkif idle revdecrease a moment for ,q, \r wheneachinjector pipping connector are disassembled.

NG
.POWER BALANCEO FOR EACHCYUNDERSTOP ITUECTOR OPEMTIONAND CHECKTHE BALANCEOF EACHCYUNDER. TURN OFFT/CAND LIGHTS

To No. 5 OK 3 Iniector inspection Place ignition switch OFFposition. to Remove crankanglesensor (leaveharness conneclor connected). powertransistor Remove connector. NG Place ignition switchromOFFto ON position. f Checkif eachinjector operation noisecan be heardwhenthe crankanglesensorshaftis rotated by hand.Note:Depending howtheshaft on is rotated, abnormal showin self-diagnosis, will in thiscasedetermine normal. as Injector circuit and inspection 4 lgnitioninspection Placeignitjon switch OFFposition. to Remove sub-harness eachpipping. in Install normal plug.Facethespark spark plug rearend towards groundsuchas adequate collector crank engine. and lhe Check spark. the
EN - 465

@ffr^<)
:n. =d$l}P
4

DIAGNOSIS R825DE
RB2sDE NGINE

Fuel pressure insPection rer Startthe engine. "FUEL to fUBring fuelpressure zeroby selecting TEST"mode. in "ACTIVE PUMPRELAY"

5 ILJ O ncrrverEsr
FUELPUMPRELAY OFF MONITOF

stop. after 2 Crank to3 times engine

gauge inspect: to Usefuelpressure 2.5kglcm2 APProx. Whenidling: hoseis vacuum pressure regulator When 3.0k9/cm' removed:APProx.
^ Qt. rt +ha anoina i"ul".",.

NG

(POS) 950rPn" CAS.RPI\,'1 )N/OFF OFF

ON

fuel l&Bringfuelpressure zero removing by to f o u m ou s e .

Crank2to 3 timesafterenginestop. gauge. fuelpressure using Inspect

OK

pressure Inspect diaphragm regulator

ECCS C/U connector insPection NG on connection or for Check anydamage loose connector. and harness the C/U binterminal

0oog. sT195S

OK

or Repair replace

7 ECCSC/U powersupplyandground N G tnspect circuit. OK I C/U. with Try replacing normal OK FINISH or Repair replace

EN - 466

RB25DE DIAGNOSIS
RB25DE NGINE E

DIAGNOSIS (Phenomenon) ENGINE 33 STALLWHENCOLD 't Air regulator inspection Checkif thepoweris conducted air regulatorN G to whenignition switch in ON position. is

OK

2 Throttlesensorinspection Press accelerator fully check the NG pedal and if engrne bestarted can when enqine cold. the is

Inspecl regulator air andcircuit.

Inspect regulator air andcircuit.

Fullyopen

$+@ <
.PoWER BALANcE. FOREACH CYUNDEF STOP INJECTOROPEMNONAND CHECKTHE BALANCE OF EACHCYLINDER. TURN OFFA./CAND LiGHTS

balance operation test I Power Start engine. the frt : 'POWER

Inspect using BALANCEin "FUNCTION TEST"mode. "POWER "ACT|VE Operate BALANCE'in TEST"mode.Cautton: Carryoutthetestin minjmum timerequired. notoperate Do during drive. Checklf idlerevwilldecrease a moment for whencheckinq eachcvlinders. {or @ Checkif idlerevdecrease a moment : wheneach injector connector cylinders are disassembled.

NG

oK I

T oN o . 7

Iniector inspection Placeignition switch OFF position. to Remove crankanglesensor(leave harness connector connected). power Remove transistor connector. NG Placeignition switch romOFFto ON position. f Checkif eachinjector operation noise canbe heard whenthecrank anglesensor shaftis rotated by hand.Note:Depending howtheshaftis on rotated, abnormal showin self-diagnosis, wrll in thiscasedetermrne normal. as Injector circuit and inspection TO5

@ffrX)
:Rt, >sv
/l

EN - 467

DIAGNOSIS RB25DE
RB2sDE NGINE

lgnition inspection to switch OFFposition. Placeignition in sub-harness eachcylinders' Remove plug sparkplug.Facethespark normal Install groundsuchas adequate rearendtowards the and collector crank englne. the Check spark.

coil, ignition Power 6 Inspect and transistor circult. SparkpluginsPection gap damage' etc. for Check dirt, from removed onthespark Plug

or Repair replace

insPection Fuelpressure
the '/G Start engine. FUEL l.= to fuelpressure zeroby selecting Brrnq MOdC. TEST'' in ,.ACTIVE PUMPRELAY, Crank2 to 3 timesatterenglnestop. gauge Inspect: lo UsefuelPressure 2.Skg/cm' APProx. Whenidling: hosels vacuum regulator when pressure rox.3.Okq/cm' ,6Start the engine. luel lo 6tsrinq f uelpressure zeroby removing pumpuse. f stop. Crank2 to 3 timesafterengine gauge. fueipressure using Inspect pressure lnspect diaphragm regulator ECCS C/U connector insPection on connection or for Check anydamage loose connector. and the C/U binterminal harness or Repair replace ECCSC/U powersupplyandground Insoect

rrsr O L,-i I ncrrve

FUELPUMPRELAY OFF l\,40NlToF (POS) ssorpn CAS.BP[,4 ON )N/OFF OFF

C/L. with Try replacing normal

EN - 468

RB25DE DIAGNOSIS
RB25DE NGINE E

DIAGNOSIS (Phenomenon) ENGTNE 34 STALLWHENACCELERATTNG INSTANTLY 1 AAC valve inspection

engine (f;)warm
ItrJ I l. Fl

v Inspect using'AACVALVE- FUNCTION in

"AACVALVE Select ADJ"in "ACT|VE TEST". Check theengine willchange if rev when "Qu" "Qd" or is selected change to AAC varve opentng.

NG
1

the re\Stan engine. \G/Check

if enqine willdecrease rev when AACvalveJonnector dlsconnected. ts InspectAAC valve andcircuit.

AAC/VOPENING MONITOR CAS.RPI\,{(POS) AIR FLOW['TR ENG IEI\,4P SEN

qcrrveresr t D

lOO,':

900rpm 1.16V 8O"C

Ou

UP

DWN

od

2
Power balancetest operation {Start theengine. \elnspectusing POWER BALANCEin "FUNCTION TEST"mode. OR use"POWER BALANCE" "ACT|VE in TEST"mode.Caution: Carry thetestin out minimum timerequired. notoperate Do during drive. Checkif idlerevwilldecrease a momenl for whenchecking eachcylinders.

NG

OK I ToNo.5 3 Injector inspection Placeignition switch OFFposition. to Remove crankanglesensor. powertransistor Remove connector. NG Placeignition switch fromOFFto ON position. Checkif eachinjector operation noise canbe heardwhenthe crankanglesensorshaftis rotated by hand. Injector circuit and inspection TO4

BALANCEO OPOWER FOREACHCYLINDERSTOP INJECIOR OPEMTIONAND CHECKTHE BALANCEOF EACH CYLINDEF.

2
ACTIVETEST 'f POWERBALANCE (POS) CAS. FlPl\,4 rpm AIF]FLOWMTR V q. AACVALVE . 1

2 6

r=l

3 4
START

L:]

Operatron noise

EN - 469

DIAGNOSIS RB25DE
E BB25DE NGINE

lgnition inspection to switch OFFposition. Placeignition coil. ignition Bemove plug sparkplug.Facethespark normal Install

ground as such adequate end rear lowards

the and collector crank engine. the Check sPark. coil, ignition Inspect
J

and transistor circuit.

Fuel pressure insPection the ,ar Start engine. (UBrinq fuelpressure zeroby selecting FUEL to ..ACTIVE MOdE. TEST'' in RELAY" PUNiP stop. engine Crank2to 3 timesafter gauge Inspecl: to UsefuelPressure 2.Skglcm' APProx. Whenidling: hoseis vacuum regulator Whenpressure rox.3.Okq/cm' Sta ,.,o, rt the engine. (6bring f uelpressure zeroby removing f uel to gauge. fuelpressure using Inspect

rEsr lL O ncrrve
RELAY OFF FUELPUN,IP

t\,roNtToR
(POS) 950rPrr CAS.RPN,4 ON )N/OFF OFF

pump fuseNo.B. stop. engine after 2 Crank to 3 times

ECCSC/Uconnectorinspection on connection or for Check anydamage loose connector. and theC/Ubinterminal harness
ir or replace andground supply ECCSCiU power lnspect

C/L. with Try replacing normal

EN - 470

RB25DE DIAGNOSIS
RB25DE NGINE E

DIAGNOSIS (Phenomenon) ENGTNE 35 STALLWHEN DECELERATING 1 1

AACvalveinspection /G.rWarm engine. : Inspect "AAC using VALVE- 'FUNCTION in TEST'OR "AACVALVE NG Select ADJ"in "ACTIVE TEST". Check theengine willchange if rev when "Qu" "Qd"is selected or to change AAC valve opening. r\Slarttheengine. \@/Checkengine willdecrease if rev wnen AACvalve connector disconnected. is OK 2
Adiust screw fixation inspection -AACVALVE ADJUSTMENT@,lnspectusing :in OPERATION SUPPORTmode. NG Checkif it is possible set idlespeedto to 650rpm ("N"range forA/T) turning by idte adjustment screw. sensorconnector. 6lDisconnect throttle \Gr Checkif it is possible set idlespeedto to ("N"range 650rpm forA/T) turning by idle adlustment screw. OK InspectAAC valveand throttle valvefixation.

1
A A C/ V O P E N I N G [,40NtTOR CAS.RPM(POS) AIR FLOWMTF ENGTEIV1P SEN

resr a tr O ncrrve

109:

900rpm 1 16V 80.C

Inspect valve AAC andcircuit.

Qu

UP

DWN

Qd

AAcVALVE a ADJ

ADJUSTCAS FlPM TO STANDARD VALUE UNDEF J thE FOLLOW CONDLT , NG ON AFTER WARM UP ] TURN OFFA,'CANDGHTS L

3 Power balancetest operation ,G\ Startthe enoine. \ t / "POWER v Inspect using BALANCE' in "FUNCTION rEST" mode. OR use"POWER BALANCE" "ACT|VE in TEST"mode.Caution: Carry thetestin out minjmum timerequired. notoperate Do during drive. Checkif ldlerevwilldecrease a moment for whenchecking eachcylinders. rt the engine. r,qsta \c/Check if idle revwilldecrease a moment for wheneachcylinder injector connector is disconnected.

NG

ACTIVE TES1 r f 'rcE POWERBALAI cAS.RPM(POS) rpm AIFIFLOW I\,ITF] a./" AAC VALVE .

oK I
EN - 471

T oN o . 6

1
E--l

2
--t
o l

4
STAFT

t:j

D RB25DE IAGNOSIS
E RB25DE NGINE

4 Iniector inspection to switch OFFposition. Placeignition harness crankanglesensor(leave Remove NG connected). connector connector. powertransistor Remove f romOFFto ON position. switch Placeignition noise can be operation Checkif eachinieclor shaftis rotated sensor whenthecrankangle heard by hand. insPection and Injector circuit
5

lgnitioninspection to switch OFFposition. Placeignition coil. ignition Remove plug NG sparkplug.Facethespark normal Inslall groundsucnas adequate rearend towards the crank engine. and collector the Check sPark.

resr I i--l O ncrrve

FUELPUMPRELAY OFF N,4ONITOB (POS) 950rpn CAS.RPM

OK
coil, ignition Power Inspect and transistor circuit. Fuel pressure insPection /G\ Startthe engine. -FUEL to lUBring fuelpressure zeroby selecting TEST"mode. in "ACTIVE PUMPRELAY" NG stop. 3 timesafterengine Crank2 to gauge insPect: to Usefuelpressure 2.Skg/cm' APProx. idling: When hoseis vacuum regulator when pressure 3.Okg/cm' removed:ApProx.
^ qtrrt fh6 onarina
A { f ^ " . " ' . ! I | v v i i Y l l l v .

ON

]N/OFF

OFF

lStsring f uel pressure zero by removing fuel to pumpfuseNo.8. stop. Crank2 to 3 timesafterengine gauge. fuelpressure ustng Inspect pressure regulalor Inspect ragm. diaph

,r2.
:// Fuel

TO7

EN - 472

F825DEDIAGNOSIS
RB25DE NGINE E

gas sensorinspection Exhaust "BASE usinq AIR-FUEL FATtOrn /G\ Inspect

No A,4oNrToRrNqkFA|L
(REF) CAS.RPI,4 82srpm

r-U"rurucrtoru mode. TEST

"O, Seiect SENSOR MONITOR"dara in NG mon itor. Setat2000rpm noload with after warm up. "LEAN, Check thedisplay if RICH" repeat witl formore than times 5 within seconds. 10

02 SENSOBI\,4TR RICH

vehicle side(within fusebox) re\ Operate \r' diagnosis connector change -O2 and to sensor monitor". Set at 2000rpm with no loadafterwarm up. Checkif theexhaust temperature warning lampwillf lashfor morethan5 timeswithin 10 seconds.

c h a n q e r a g n o s t c o d e s h o dc r c u t t f r e s e d m

OK
Replace sensor O, Inspect throttle sensor andvehicle speedsensor. OK
Redlarnp

Iltl
'Exhaust p tern w ar n r n q a m p

ECCSC/Uconnectorinspection NG Check anydamage loose for or connection on theC/Ubinterminal harness and connector.
OK Repair replace or

Inspect ECCSC/Upower supply ground N G and circuit. OK Tryreplacing normal with C/U. Repair replace or

OK
FINISH

EN - 473

DIAGNOSIS RB25DE
E R825DE NGINE

D|AGNoS|S36(Phenomenon)-ENGINESTALLWHENAccELERAT|NGoR SPEED AT DRIVING CONSTANT

1 Power balancetest oPeration ,/4,Startthe enqine. UInspect usin-g eOwf n BALANCE'in "FUNCTION TEST"mode. "ACTIVE "POWER BALANCE'in OR use out Carry thetestin TEST"mode.Caution: Do required. notoperate time minimum drive. during for Checkif idlerevwilldecrease a moment whenchec@ rqstart the engine. \@Checkif idlerevwilldecrease a moment for is connector iniector wheneachcylinder disconnected.
2

NG

oK I
l

ToNo'

IniectorinsPection to switch OFFposition. ignition Place (leave harness sensor crankangle Remove NG connected). connector connector. powertransistor Remove fromOFFto ON position' switch ignitron Place can be noise operation Checkif eachinjector heardwhenthe crankangiesensorshaftis rotated by hand. insPection and Injector circuit 3 lgnitioninsPection to switch OFFposition. ignition Place coil. ignition Remove plug N G plug.Face spark the spark normal Install groundsuchas adequate rearendtowards and collector crankthe engine thesPark. Check OK coil, ignition Power Inspect circult. and transistor

@ffix)
rRl' >S"/ /l
Operalionnolse

i\
.- lgntion

TO4

EN - 474

RB25DE DIAGNOSIS
RB25DE NGINE E

Fuelpressure inspection
Staftthe enqine. ua-r 'FUEL \U Aring fuelpr"essure zeroby setectrng to "ACTIVE PUMPRELAY'in TEST"mode. NG Crank to 3 timesafterengine 2 stop. Usefuelpressure gauge inspect: to Whenidling: Approx. 2.5kglcm2 Whenpressure regulator vacuum hoseis removed:Approx. 3.Okgicm,

O ecrrve rrsr I {*
FUELPUI\,4P BELAY OFF l\,lONlTOR (POS) gsorpn CAS.RPM

ON

)N/OFF O F F

6lStart theengine. \ctBring pressure zero removing fuel to by fuel pump fuseNo.B. Crank to 3 times 2 after englne stop. pressure Inspect gauge. using fuel OK pressure Inspect regulator diaphragm.

Intakeair leak inspection Start engine. the NG Checkif engine willincrease rev whenblow-by hoseis pinched. OK Repair leaks any 6

/z Fuel

ECCSC/Uconnectorinspection NG Check anydamage loose for or connection on theC/Ubinterminal harness and connector.
Repair replace or OK 7 Inspect ECCSC/Upower supply ground N G and circuit. 8 0 K Tryreplacing normal L. with Ci OK FINISH Repair replace or

EN - 475

DIAGNOSIS fr825DE
E RB25DE NGINE

BATTERY STALLWHENLOADING 37 DIAGNOSIS (Phenomenon)'ENGINE 1 and battery alternator Inspect or Repair replace

Power balance test oPeration ,6\ Startthe engine. -POWER 9lnspect using BALANCEin 'FUNCTION TEST"mode. "ACTIVE "POWER BALANCE'in OR use Carryoutthetestin TEST mode.Caution: Do timerequired' notoperate minimum drive. during for Checkif idlerevwilldecrease a moment @,Start the engine. @Check if idlerevwilldecrease a moment for ls connector injector wheneachcylinder disconnected. To No. 4 lniector insPection to switch OFFposition. ignition Place harness crankanglesensor(leave Remove connected). connector powertransistor connector. Remove f switch romOFFto ON position' Placeignition noise can be operation Checkif eachinjector heardwhenthe crankanglesensorshaftis rotated 4

I apoweR gernruce I
OPEMTION III]ECTOR STOP EACHCYLINDERTO FOR BALANCEOF CHECKTHE EACHCYLINDERS.

uUKj--l .K / .tN,,:dD/ /l
Operationnoise

tDi

rJ-

/\

ignitioncoil

insPection and Injector circuit lgnition insPection to switch OFFposition. ignition Place coil. ignition Remove plug.Facethesparkplug spark normal Install groundsuchas adequate rearendtowards the and collector crank englne. the Check spark. coil, ignition Power Inspect and transistor circuit. TO5

EN - 476

RB25DE DIAGNOSIS
RB25DE NGINE E
3

Fuelpressureinspection the ,er Start enoine. .U BringuelprLssure zero setecting.'FUEL f to by PUMP RELAY" "ACTIVE in TEST" mode. NG Crank to 3 ttmes 2 after engine stop. Usefuelpressure gauge inspect: to When idling: Approx. 2.5kglcm2 pressure When regulator vacuum hose is removed: Approx. 3.0k9/cm,
61Stad theengine. tgring fuelpressure zeroby removing to fuel pumpfuseNo.8. Crank2to 3 timesafterengjnestop. Inspect pressure gauge. using Juel

I ncrrvrresr O[
FUELPUI\,,IP RELAY OFF MONITOR (POS) 950rpn CAS.RPM ON

IDN/OFF OFF

OK
6

pressure Inspect regulator diaphragm.

ECCS C/U connector inspection NG Check anydamage loose for or connection on the C/U binterminal harness and connector. Repair replace or OK 7 Inspect ECCSC/Upower supply ground NG and circuit. 8

OK Tryreplacing normal with C/L.

OK FINISH

Repair replace or

EN - 477

DIAGNOSIS RB25DE
E BB25DE NGINE

AND STUMBLE SHORTAGE 38 DIAGNOSIS (Phenomenon)'POWER (lnstant power output shortage during acceleration) 1 Fuel pressure insPection rt /G Sta the engine. FUEL to fUBring tuelpressure zeroby selecting "ACTIVE TEST"mode. in PUMPRELAY' NG stop. Crank2to 3 timesafterengine gauge insPect: to Usefuelpressure 2.Skglcm? APProx. Whenidling: hosels vacuum regulator Whenpressure Olg&m13 removed:APProx.
^ Cr"* th6 annine

O ecrtvergst O

fuel t&Bringfuelpressure zeroby removing to pump fuseNo.8. stop. engrne after to Crank2 3 times gauge. fuelpressure using Inspect
OK pressure regulator lnspect ragm. diaph

2
Intake air leak inspection YES @Start the engine. echanqe correction DWN" valueby selecting CORRECTION iN..TUEIINJECTION "ACTIVE TEST" VALUE"in time outthetestin minimum Carry Caution: whiledriving. Do required. notoperate

the when rev it Xe treck engine willincrease is hose pinched W)blow-bv

NO

2 I

any Repair leaks

O% FUEL NJECTIONOFFSET MONITOR g37rpm CAS.RPM(POS) 59'C ENGTEMPSEN 1,33V O, SENSOR 1.35V o, sENsoR(R) l.8msec NJ PULSE 179L AAC VALVE

ncrveresr t D

pressure, timing NG ignition compression Inspect sensor. anddetonation NO FINISH or Repair replace

Ou

UP

DWN

Qd

EN - 478

RB25DE DIAGNOSIS
RB25DE NGINE E

DIAGNOSIS (Phenomenon) DETONATTON 39 1 1

Q acr veresr O f rUeL ttllecrtol Sg dl Orr
MONITOR CAS.RPI\.4(POS) 937rpm ENGTEI\,IP SEN 59'C O. SENSOR 1 33V ( o , S E N S O RR ) 1.35V INJ PULSE l.Bmsec AAC VALVE 17"i Qu UP DWN

Intake leakinspection air (l)Starttheengrne, : Change .DWN' YES correction byselecting value "FUEL in INJECTION CORRECTTON VALUE" "ACTIVE in TEST". Caution: Carry thetestinminimum out time required. notoperate Do while driving.
rev whenthe prCheck if engine willrncrease @rblow-bv hoseis oinched. NO Repalr leaks any

od

2
Combustion chamber oil leak inspection Disconnect sparkplugandlnspect oil.

NG

OK

Inspect piston. piston ring, valve, valveseat,valveoil seal,engine level oil etc.

Inspect detonation sensor svstem.

OK
FINISH

EN - 479

DIAGNOSIS RB25DE
E BB25DE NGINE

40 DIAGNOSIS (Phenomenon) S U R G E 1 Exhaust gas sensor insPection "BASE in RATIO' AIR-FUEL using /A Inspect

TESI RATIO IFASEAIR FUEL REV2000+1HOL0ENGINE PBESS START 2OOrpmAND

.-EiruructtoN mooe. TEST"

"O, NG in MONITOR" data Select SENSOR monitor. with no loadafterwarmup Set at 2000rpm "LEAN, will RICH" repeat display Checkif lhe for morethan 5 tinqllryjlllllqlegengs.-

fuse side vehicle (within box) ,o, Operate 18 diagnosis to "o. and connector change monitor". sensor warmup' with Setat 2ooorpm no loadafter warning temperature if Check theexhaust within 5 than times for will lamo flash more 10 seconds. OK
2 ECCSC/U Replace
START

O, Replace sensor

I I

:'----_-*-.,

OK
FINISH

.fi-g

Ittl

,^^':? Red la'np

EiT:1rlr lamp,
warntng

E N- 4 8 0

R825DE DIAGNOSIS
RB25DE NGINE E

DIAGNOSIS (Phenomenon) BACK FIRE(SPtTTtNG) 41 1

Sparkplug inspection NG plug. Remove spark Check anydirtonthespark for plug. OK 2

Intake air leak inspection @Start theengine. : Change -DWN' YES correction valueby selecting in "FUEL INJECTION CORBECTION VALUE'in"ACTIVE TEST"mode, Caution: Carryoutthetestin minimum time required. notoperate Do whiledriving. if enqine willincrease rev whenthe ^6.Check I ltf L
Yq/blow-bv hose ts ornched.

Repair replace or sparkplug.

2 I

FUEL ECTION INJ OFFSET O% [,4ONJTOB CAS.RPM(POS) 937rpm ENGTEI\,4P SEN 59"C O. SENSOR J.33V ( o . S E N S O RB ) 1.3sV INJ PULSE 1.8msec AAC VALVE 17"1" Qu UP DWN
Qd

ncrrve resr a n

NO Repair airleaks any

3
Intake valve deposit inspection Remove thereareanydeposlt if present.

lgnitiontiming Checkif injector clogged. is

FINISH

DIAGNOSIS (Phenomenon) AFTERBURNTNG 42 1 Engine temperaturesensor inspection Inspect engine sensor engine and sensor circuit.

NG

OK
lgnitiontiming Checkif injector clogged. is FINISH

Repair replace or

EN - 481

INSPECTION RB25DE CON,lPONENTS

F B 2 5 D EE N G I N E

(RB25DE) INSPECTION 8. coMPoNENTS

CRANKANGLESENSOR Inspection (leave fromtheengine. sensor crankangle Remove connected). connector harness sensor crankangle position. to switch ON Placeignition withhandand crankanglesensorshaftslowly Rotate 2.3 terminal andground between the inspect voltage

Xs -i
a,,fl\

I AR i X \ r q @-,p
Rotateby

sensor. angle crank lF NG: Replace afterinspection' fromCONSULT result Eraseselfdiagnosis in codeNo. 11is notdisplayed thescreen. Check Caution: f to f injectoruseor connector avoidinjectorrom Remove whileinspection. operating AIR FLOWMETER lnspection . Remove the airflowmeterfrom engine. . Applybattery air between flowmeter directly voltage 35+ terminal andterminal andblowairto hotwlre. termlnal voltagebetween in output Checkfor any change 4-. 2+ andterminal
Air is not blown Air is blown

ivl
r 1 i 2 r ? 1I4 l l

f-l .

rO lil

t t /n at,

Approx.0.8V
2V Approx.

Ee

for OR air lF NG: Replace flowmeter check anydamage withthe hotwire. inspection' after fromCONSULT result self Erase diagnosis screen. in CheckcodeNo. 12 is notdisplayed the SENSOR ENGINETEMPERATURE Inspection harness . Disconnect sensor temperature engine r. connecto . Measure resistance lemperature engine between the 1 terminal and2. harness sensor
2o"c Approx Approx 8o"c I I 2 npprox sKS) nPProx 0.3x$l

(KA
o c o

(r

(D

sensor. temperature engine lF NG: Replace inspection. after fromCONSULT result Erase self-diagnosis in codeNo.31 is notdisplayed the screen Check
EN - 482

RB25DE COMPONENTS INSPECTION

RB25DE NGINE E

IGNITION COIL Inspection . Disconnect ignition harness coil connector. . Measure resistance the between followinq terminals.
Primary resisntance (i - 2) | coil value 0.6- 0.9

lF NG: Replace ignition coil POWERTRANSISTOB Inspection . Disconnect powertransistor harness connector. . Measure resistance inserting the by analog typecircuit testerinspection - and + to powertransistor rod terminals. +/- coSJ -r* oo f,l
2-3
t - J

+ / - o o f , J > - / + 0 o r n o@ 6 1 t +/-0ornot oQ .-l* o co fl

power lF NG: Replace transistor.

F U E LP U M P Inspection . Disconnect pumpharness fuel connector. . Measure resistance the between oumoterminal fuel 1 and 3. Resistance: Approx.0.4 - 0.7 . Checkfor operation applying by battery voltagebetween thefollowing terminals directly: Connect terminal 3 to + side, terminal 1 to - side. Caution:Caremustbe takento connect battery correct to srdes. lF NG: Replace pump. fuel

Ele-,e

THROTTLEVALVE SWITCH Inspection . Warmthe engine. . Disconnect throttle valveswltchconnector measure and the resistance between throttle valveswitchterminals. (ldle contact point)

pedalis not pressed Accelerator

lF NG: Repair throttle valve switch. EN - 483

INSPECTION COI''lPONENTS RB25DE

E RB25DE NGINE

Adiustment ldle contact point touch rev (rpm): 750 - 1050 . Adjustif the touchrevis notwithinthe rangeabove the . Disconnecl and valveswitchconnector loosen throttle bolt. polntrs rev the increase engine so idlecontact Gradually 2 terminal and 1 is 0 Q ) at between ON (Resistance valveswitchunitto throttle aboveenginespeed. Move valve the touchpointandtighten bolt. Movethrottle point thebolt. andtighten unit switch to touch connector. valveswitch throttle lnstall few Racetheengine limesandcheckidlerevis within value. thestandard

fle Z*)

THROTTLESENSOR connector. sensor throttle Disconnect 2 terminal sensor throltle between lhe Measure resistance and3.
lrr p
Not pressed to Pressed halfway Completely Pressed A p p r o x0 . 4

Approx0.4- 5
Approx.5

valveswitch. throttle lF NG: Replace resultfromCONSULT eraseselfdiagnosis Afterinspection in codeNo.43 willnotdisplay thescreen' Check

AAC VALVE . Inspect resistance AAC valve. of the Resistance:APProx.9- 10 . Plunger switch insPection. and . Spring inspection. damage AACvalve. lF NG: Replace

*4-==ll u,\,9
Eei, @

v eLng", I

FICDSOLENOID . Measure resistance FICDsolenoid. of the Besistance: APProx.2 2 - 2 3

EN - 484

R825DE COMPONENTS INSPECTION

RB25DE NGINE E

Plunger switch and inspection. Spring damage inspectlon.

lF NG: Replace FICD solenoid.

tO4>d Plunger '-(L...-., / \ \ ^ Spring *9

AIR REGULATOR Static characteristicinspection . Visually check shutter the opening.

-20"C Below

Fully open
Approx halfopen Fuily closed

20"c
Over60"C

Dynamiccharacterlsticinspection . Applybattery voltage terminals inspect any to and for change withshutter opening. The shutterwill close graduallyand completely closed within 7 minutes. (areatemperature approx. 20"C). Reference: Heaterresistance value: 70 - 80 tJ (20"C) lF NG: Replace regulator air

r -1t2j

. l

ar-

INJECTOB Inspection . Disconnect injector harness connector. . Measure resistance eachiniector the of cvlinder terminal 1 and2.
Resistance between injector terminal and 1 2 (eachcylindeo 13-14Q

( __l

lF NG: Replace injector.

ECCS RELAY FUEL PUMP RELAY,RADIATOR FAN MOTORRELAY Inspection . Directly applybattery voltagebetween termin 1 and2. al . Inspecl continuity between terminal and5. 3

lF NG: Replace relay.

EN - 485

INSPECTION COMPONENTS RB25DE

E R825DE NGINE

RELAY RELAYINHIBITOR IGNITION Inspection terminal1 and 2. . Directly voitagebetween applybattery . Check continuity 3 terminal and4, 6 and7 between for

Xe ,@

relaY. lF NG:Replace

PRESSURE HYDRAULIC POWERSTEERING INSPECTION Inspection pressure switch . Remove hydraulic power steering connector. harness . c h o n k f o r c o n l i n u i t vb e t w e e n t h e t e r m i n a l s . the between terminals. for Check continuity

We:-p:-'';

pressure switch powersteering hydraulic lF NG: Replace

F .' . | tr - e _ l A . !c
f=

SPARK PLUG Inspection & Adiustment pole. . Measure gap between electric the range. . Reolace repair outof standard if or 1 . 0- 1 . 1 gap (mm): Standard

fl
lj
F]

(' FUELPUN,4P

FUEL SYSTEMINSPECTION Simpleinspection p?.ti,i?l:.,, . Turnthe ignition to switch 9N _,"Fuelpump'in the"Function \!=/ test mode. G) . Select . Inspect pulsation holding fuelhosewithhand the by the @ . Holdthefuelfilter and makesurethe hoseis hard W can andpulsation be feltwhenthefuelpumpis operating-

IS THEREA PULSATION EVEBY 3 SECONDSWHEN T H E F U E LT U B E I S H E L D ? T O B C A NY O UH E A R H E NOISEOF THE OPERATION FUEL PUMPRELAY?

EN - 486

RB25DE COMPONENTS INSPECTION

RB25DE NGINE E

Fuelpressure inspection usingthe fuel pressure meter Releasinguel pressure f . Run engine. the "Fuel . Select pump relay" "Active mode. in test" . Press'STOP'to theengine. stop Crank engine the over twoorthree times.(lftheengine doesnotstart, crank - 4 3 times after removing fuse). the Restan engine remove tuet the and pump the tuse. @ "-5 times After engine the stops, crank engine the 4 to consume fuelinthepipe.(lftheengine the does start not crank4 5 times after removing fuse). the Caution: Thebattery maybecome weakeasily. booster use cable to connect another to battery necessary. if Fuelpressure meterinstallation . Connect fuelpressure the meter between fuelfilter the and thefuelline. . Attach fuelpump the fuse. Fuelpressureinspection . Start engine check thefuelpressure at the and if is standard value.
(kg ldling / cm:, Pressure regulator vacuum hoseis (kg disconnected / cm,) Approx. 55 2 Approx.3.0

IACTIVETEST(' FUEL PUI\,4P RELAY OFF CAS-RP|\,4 {POS) 950rpm

lf theengine doesnotstart, check fuelpressure 5 seconds after ignition the switch beenturned has ON.
5 seconds afterignition switch turned ON I to Approx 3.0

I FN G :
pressure extremely Pressure Fuel is regulator notworking. is high Return system ctgged. rs hose bent
regulator notworking. is Fuelpressure extremely Pressure is Fuelpumpdischarge defect low Fr6l <\,ctam ^l^^^a.l

EN - 487

IN C R825DE OMPONENTS SPECTION

E R825DE NGINE

Fuelcut systeminspection

"lNJpulse" "DATA modeusing . Select MONITOR" in after 2000rpm the Increase enginerevto CONSULT. "lNJpulse" decrease will that Check the starting engine. pedalis whenthe accelerator to 0.6 msecfor a moment released.
ITORINg}l'lo FA L

( C A S . B P MR E F ) 1 9 5 0 r p m 0.6msec I N JP U L S E

INSPECTION SYSTEM GAS CONTROL EVAPOBATIVE

chamber Throttle

Checkvalve

f!
Tray Freshair

gas <- Evaporatlve 'F Purqeair Active carbon Filter

CANISTER lnspection negative throttle . Connect vacuumhandpumpto canister pressure ls pressure and makesurethevacuum opening maintained. -100mmHg pressure makesurethe and . Apply approx. by is pressure opening continued negative manifold air sucking f romtheoPening. FUELTANK VACUUMBELIEFVALVE Inspection . Clean valve housing. the you . lf thef ueltankvacuum valve normal, willhear is relief whenthealrls resistance withsmall fromthevalve sound the suckedin through caP or . Replace capASSYif thevalveis closed when the is resistance felt.
EN - 488

E Gl 5 13 0 0 0 0

Soflno valve . valve

R825DE COMPONENTS INSPECTION

RB25DE NGINE E

BLOWBYGAS REDUCTION DEVICE INSPECTTON

blowbycontrol valve

Flarnearrester Buffleplate Blowby path

Fresh air Blowbygas

BLOWBYCONTROL VALVEINSPECTTON Inspection . ldletheengine andremove hosefromblowby control valve. . Checkif operation noise can be heard fromtheair passage whenvalveis operating normally. . Checktheblowby control valveflowpath.

Air is blown Air is drawnin

Air passes

No arrpasses

BLOWBY HOSE Inspection . Look anyleakage thehose connection for from and area. . Remove hose clean the and using airblow. the Replace hoseifthere anyclogs. are

EN - 489

SIGNALS ECCSC/UINPUT/OUTPUT
ENGINE R826DETT

9.

SIGNALS / UNITINPUT OUTPUT ECCSCONTROL

VALUES INSPECTION 9.1 CONSULT (1) Datamonitor unit data as is signal displayed thecalculation on console so thecorrect output itlote:The disconnected' is (harness) inadvertently circuit even willdisplayed iitheoutput value ENGINE RB26DETT -olre rorron t, .IX*TTAL RETENEIGE.
loNrroREaGl'EG I

l - - - - " - '

, , .r : - t t , :

' ., . TTVALUE

,,

CAS RPM (Detecled angle speed according to srgnals) Alter wa.nrog uP engr' kjlins (N range. A/C OFF)

Ttre

m6l be no abno.mar chanqe rn sPeed

Crank adqle se.sor

slstem

AIR FLOW MTR (R)

Approt O7-l2V(2OOOrpm w hrbload 1O- 1 7V) 2 arr now meler val! Nole canvaryo-O4V Above approx 70'C

A r now meler s'1em

ENG TEMP SEN (engrne temperaure)

EXT GAS SEN EXT GAS SEN (R)

Engrre temperalure

sensor

After wa.mrng

uP ensrr

Changesbet@enO_O3V arxi06_]v 2 O O O r p mw l h n o

ErhaLrsl gas sensor system ltnake s)tem arr leak o. arr

EXT GAS SEN (RICH / LEAN) EXT GAS SEN (R) (R|cts / LEAN) (]AR SPEED SEN hrcle speed srgna ) BATTER,'VOLT THROTTLE SEN ON Thronb fully closed ! ,4rire driMng or with dn lu. ng wl'Eels

RICH. LEAN repeats 5 lrmes or more In 10 seconds Should qererally conform to speedmeter drsPlaY Vehrcle speed sensor sysiem corirol unrt Porer adjushern syslem system

ECCS

o 5

Throdle seNor ThronE semor !s

INT/A TEMP SEN aklemperaiure sensor olnPu) INJ PULSE (iryecnon pulse wdth) INJ PULSE (R) (injecrion pulse wdth)

Aner warm nq uP eng!rE (N rarEe A/C OFF)

knake arr temperatore

knaktemperature

sensor sYsrenr

14-2.2 1 4 - 2 2 2o'
Advance grealer lhan 1O' angle compared to ro|e

Air flow meter syslem Intake slstem a r leaks or ai. s@non (erlt|re InPd) hpd srgnal syslem (eture)

(N ranqe GN TIMING

A/C OFF)

Air now meter slslem

2ooorpm with m

(N rare

A/C OFF)

appro\ r5 - t5'6
Approx 30 - 5O7. AAC vaive sYsiein

Air now meter system (arr rEl rano teedback coeffciefi) corecron Aiter wa.mrng up engrre 20oo.pm wth no load 75 - 125'/. can,sler (purse) rcpecrron lntake syslem arr leak or ar.

ON START SIGNAL IOLE SW A/C SW ON AIR COND SIG ON ON

Starter SW syslem slstem SW system

ON Engine

Throttle lully closed

QN

Thronle se6or Alr co.ditiorer Nedral Po@r

NEUTRAL SW
ON PWST SIGNAL QN

SW sFlem SW syslem

sleeflrq

DLE JUDGEMENT
FUEL PUMP RELAY

Throttle sensor s!51em FLlPumP system

Otr K]N SW ON

tn

wtn

rd e ON

A/(.] QN AC-ON

ON Arr corditrorEr relay sFrem

ON WG CONT 5A/ VOLTAGE

li

POWER

orer
o ar pulse

@hage p.o\r'e measu.em

ProE measuresuremeft

PULS E

PE:6]: -

ECCSC/UINPUT/OUTPUT SIGNALS
E N GN E

(2) Activetest

' ,+rniu,,,
Perform followrng inspectionscheck1 to problem sol\d. is Setengrne ternperature or low high ENGINE Problem occurence Engine ternperature sensofsystem aar iron Do notsetextrerne values TEI\,'IPERATURE condrtion Inlector system as lnrs cancause spai*p ug burntng Air flowmetea gas exhaust sensor system
Not ellminate.l Other rtem Inspectton Flminele

Perfomr followtng tnspections checkrf to problem soived. rs

Set the airfuel ratto|ch or lean gas Exhausl sensor system Problem Ca|irnn DO |Ot Selextreme occurence valuesaS FUELINJECTION Ai. flowmetererq ne temoeratJre se-so. cono1l|on this may dan'rageengtne of catal),tic slstem ocn!enet
F limrn2ie

njeclorsystem

Nol elimin2tr.l

rtem Other inspecton

Delayignition Umrng

Perlonn followngInspecttons check11 to problern soi\d rs

GNNON TII\,1ING

F limrnrlp Problem Cer occurence r.n DOnot Setextreme valuesaS lgnrtron tirnrng adjustment conotlon thismay damageengtneor catalyt c Detonation sensor system con\rtea N.i elimlnaie.l Othef item nspeclion

AAC VALVE OPENING

Increase controlduly ratio The engtne speedshouldtncrease lf the conditron descnbedon leftcan not be Enginerunning Decreasecontrolduty reatio The lenfied ccheck AAC valve system enginespeed should decrease Set the AAC vale open to stop the specrfied injectoroperatronand the rnjector speed can be displayed this F Lm i n z t F at Enginerunning time Inlector systefir aa iion Do not perform thtsoperatton whrledriMng Turnignition swrtch ON OFF and ON so pumpoperatton makesa solnd lf the conditron descflbedon leftcan not oe lgnition switchON The fuel pressurewill nse \enfied.checkrelaysystemoffuel pomp cartion Do not perform thisoperatron and fuelpump system exceptundercondit/ons descnbedon 1eft. The air-fuelratio feedback corection coeffictentleamtnqfactor rs cleared

POWER BTALANCE

FUE PUI'P L RELAY

SELF-LEARNING CONT

EN - 491

SIGNALS OUTPUT ECCSC U INPUT

RB26DETENGINE T

EN VA I r s - 2 o s c l L L o s c o P E& C l R C U lT E S T E RN S P E C T I O N L U E ( R B 2 6 D E T T G I N E )

t"',il:"'
1 2 3 11 12 13

name I sisnar

At idle
Circuit
Sparkplug

I
Memo

rpm At APProx.2,500
Standa rd Memo

Standard

Approx.0.4V

---| t-- -r

Powertransistor signal control

---.t1

Approx.5V

AAC valvecontrol srgnal

A p p r o x1 V . Enginespeed signalfor tachometer

Approx.2.4V

0 -I

relay Air conditioner

OFF: Air condition Batteryvoltage ON: Air conditioner 1V Approx.

A i r c o n d i t i oO F F : n Batteryvoltage ON: Air conditioner 1V Approx.

ECCS relay

Approx.1V OFF. (lgnition switch Batteryvoltage)

Approx.0V

18

Fuelpumprelay

OV

OV

EN - .192

ECCS C/UINPUT/OUTPUT SIGNALS

R8 2 6 D E T T N G I N E E

R B 2 6 O E T TN G I N E E

Jnx

TX
CLK

cHl(

IGN

TeIminal No.

S i g n a ln a m e

Circuit

At idle Standard Memo

At Approx. 2,500 rpm

Standard Memo

19

Powersteerjng swtch signal

Powersteering ONI OV Powersteering OFF 5V

Powersteering ON: OV Powersteerjng OFF 5V

21 (RX)

Receive(conlrol unitdatareception)

10v

10v

(rx)

22

(data Transmit transmission from control unjt)

OV

OV

23 24

Detonation sensor srg nal

Approx. 3V 0

Approx.0.3V

25

\ hstegate valve control solenoid control stgnai

Batteryvoltage

Approx.0V

27

Air flowmeter(rear) lntake quantjty air srgnal

Approx.1.5 Approx.1V

EN - 493

SIGNALS OUTPUT ECCSC'U INPUT

ENGINE R826DETT

RR'ANFTT ENGINE

Terminal No.

S i g n a ln a m e

Circuit

At idle Standard l\ilemo

rpm 2,500 At Approx.

Standard Memo

28

temperature Engine slgnal sensor

Enginetemperature 1V Bo"C:Approx. temperature Engine 2 0 " C :A p p r o x . 3 V

temPerature Engine 1V 80"C.APProx. Enginetemperature 2 0 " C :A p p r o x . 3 V

29

gas Exhaust sensor signal(front)

0 Approx. - 1V

Deffectsbetween 0 approx. - 1V

31 (cLK)

Clock (syrchronization signal)

OV

OV

lvlotor& check lamp(redlamp)

Lampnot lit: Power voltage Lampis lit: 0V

Lampnotlit: Power\onage Lampis lit: 0V

JC

Air iow meter (lntake air (Front) quantity signal)

'1V Approx.

1.5V Approx.

36

atr lntake sensor temperature signal

C o l d A p p r o x1 . 5 V 0.8V \ hrm: Approx.

1 Cold: Approx. 5V \Abrm:Approx.0.8V

EN-494

ECCSC/UINPUT/OUTPUT SIGNALS
R826DETT NGINE E RB26DETT NGINE E

Termina I No.

S i g n a ln a m e

Circuit

At idle Standa rd

At Approx. 2.500 rpm Memo

Standard Memo

38

Throttle sensol srgna I

Approx.0.5V

0.5-4 (Voltage Increases if pedalis accelerator presseo)

03-0.7v
41

51

Crankanglesensor 1 2 0 "s r g n a l

2-3V
42 52 Crankanglesensor 1 os i g n a l

(vr 6r, dtd

2-3V

affi

43

lgnitron switch (START signal)

OV (lgnrtion switch "STARI': Battery voltage)

OV

44

NeLJtral switch srgnal

N of P range: 0V Other thanN or P range 4 - 5V

N or P range: 0V Otherthan N or P range: 4 - 5V

46

Air conditioner swjtch signal

A i r c o n d ro n e rO F F t Battery vo[age Air condrtioner ON; OV

Air conditioner OFF: Batteryvoltage Air conditioner ON: OV

EN - 495

SIGNALS ECCSC/UINPUT/OUTPUT
E B826DETT NGINE
RFI?6NFTT ENGINE

Terminal No.

At idle rd Standa Memo

: : : l l - ^ ^ lt APProx.2'500rPm

S i g n a ln a m e

C ircuit

rd Standa

Memo

48

Throttlesensor (Power suPPlY)

5V

5V

49

unit Control Power suPPlY

voltage Battery

Batteryt0ltage

53

sPeed Vehicle slgnal sensor

D range(or 1st)with rear wheelsjacked u p : 0 . 5- 1 . 5 V The valueactually deiects between0v it and 5V. However, to appears deflect around1V,accordlng sPeed. to vehicle

D range(or 1st)wlth rearwheeis iacked u p : 0 . 5- 1 . 5 V The valueactually deiects between0V lt and 5V. However, to appears defect around1V,according speed to vehicle

54

valveswtch Throttle (idle contactPoint)

10V Approx.

A p p r o x1 0 V

55

gas E*raust sensor (Rear) signal

N or P range: 0V thanN or P Other range: 4 - 5V

N or P range: 0V Otherthan N or P range:4 - 5V

56

sensor Throttle signal outprJt

Approx 0 5V

Approx.05-4V (Voltage increases as accelerator Pedal is pressed).

EN - 496

ECCSC/UINPUT/OUTPUT SIGNALS
R826DETT ENGINE RB26OETT NGINE E

Terminal No.

S i g n a ln a m e

C ircuit

At idle Standard Memo

At Approx. 2,500rpm Standard Memo

57

Throttle valveswtch (Power supply)

Batteryvollage

Battery voltage

101 103 105 110 112 114

Approx. battery voltage

Injector control sjgnal

Approx. battery vorcge

104

Fuelpumpterminal voitagecontrol s r g n a(lF P C M1 )

(affer ldling warming engrne): 0V

During middleload. 4V

106

Fuelpumpterminal voltagecordrol (FPCN4 srgnal 2)

During middleload: OV

EN - 497

SIGNALS ECCSC,UINPUTiOUTPUT
ENGINE R826DETT

CAUTIONS UNITOPERATION 9-3 ECCSCONTROL (1) Controlunit equiPment for . Never unit a install control thatis notspecified yourvehicle bracket . Do notapplyexcessive forceto the installation (2\ Connector removal and installation forceand unnecessary do . Wn"n removing installing connectors, notbendor apply and following observe Points: 1. Connector removal connectors. removing OFFbefore . Turnignition oFF andECCSrelay switch to harness' force applying . Holdconnector without to firmly disconnect lock' the loosen connector . Do notusea screworiver similar lo tool or 2. Connectorinstallation . Turnignition OFF. switch securely' then unit . Makesurepinsarenotbentor control connectorand connect of colourindicator orange reaches surface . Tighten untilinjector boltssecurely is and connector surface even. (3) Control unit Power . Nevermakea reverse to connection the battery' - 16Vrange. . Usebattery in voltage 1O (4) ldle speed adiustment knob . Do notturnPastlockPosition. lower than0"' temperature . Do notturnadlustment knobwhenambient (5) Water and oil .Caremustbetakennottoa|lowraindropsorwatertoWetthecontro|unit. in increase doesnotformdueto sudden . care mustbe takenthatcondensation in installing the before unit dry lf temperature.thereis anymoisture, control adequately vehicie. . Makesureno oiladheres connectors. to cleaners' solvent volatile . Do notclean control using unit the (6) Dropping and imPact lmpacl' it . Do notdropthecontrol or sublect to strong unit unit thecontrol whicharedented' . Do notuseupper for covers andlower (7) Control unit screws and cover . Do not remove upperand lowercoversfromthe controlunit' the . Do notturnthescrews thecontrol mainbody. unit in

EN - 498

ECCSC/UINPUT/OUTPUT SIGNALS RB2OE / DET / DE ENGINE

9. ECCSCONTROL UNITINPUT OUTPUT / STGNALS

9-1 CONSULT INSPECTION VALUES (1) Datamonitor jation Note:Theoutput signal displayed thecalcu is as dataon console so thecorrect unit value displayed will evenif theoutput (harness) inadvertentlv circuit is disconnected. RBaOE IDE / DET ENGINE

CAS RPM (Detected angte speed accordtr to signals)

Tachometer set Engine runnrng

There must be no abnormal change rn speed

Crank ange sensor slstell A r flow rneler syslera E n g r n et e m p e f a t u r es e n s o r E*lairsl gas sensor slsterf I n t a k es y s l e m a r f i e a k o r a r r lnleclor slslem V e h r ce s p e e d s e n s o r s y s l e m

AIR FLOWMTR vottage) {oLrtput

E N G T E I \ 4 PS E N ( e r E r n et e m p e r a t u r e ) EXT GAS SEN ( o u l p u tv o l i a g e ) EXT GAS SEN (RtcH / LEANI CAR SPEED SEN (\h cle speed srgnal) BATTERY VOLT
lgfllion

Aiter warmrngup engtne (N ldling range. A/C OFFI

Affer warmrng up er ne

Approx08-15V
Above appro, 70 C C h a n g e s b e t w e e nO - 0 3 V a n d 0 6 - 1 V R I C H .L E A N r e p e a t s5 t r m e s o r more In 10 seconds Should generally conform to s p e e d m e t e rd t s p l a y 11- 14V

Afterwarrning up engrne

2o00rpm wth no

While dnvrg or wlh dnve wheets turnrng

lgnrtron swrtchON Engrne stopped

swtch

Battery ECCS conlrol power unrl

T H R O T T L ES E N (odpln voflage) INJ PULSE ( r n j e c t i o n u i s ew d t h ) p N O T F 1 / 1 6 d t s p l a yf o r RB2OE

ON EngIne stopped

Throltie tully closed Throltle fully open

o 5
4 A

Throtlle sensor adlustment Throitle sensor sysiem Air iow meter s)slem I n t a k es y s t e m a r r l e a k s o r a t r sucron (en!re Input) n p L n r g n a ls y s t e m { e n t r r e ) s

b i r n g ( N r a n g e .A / C oFF) Aflerwarmrng

2 - 3 rnsec
2-3msec Mn15.. A.fi24. A d v a n c e g r e a t e rt h a n 1 0 . a n g l e comparedlo rdlepositiOn Apptax 20 - 4AY.

up engrne

200o|pm wth no
l d l i n g( N f a n q e A / C oFF)

IGNTIMING

Anerwarminq up enqrne

200orprnwjth no
hling (N .ange A/C oFF) 2000rpm wtlh no

Air flow meter system

AAC VALVE

Aner warming up eng ne

Approx30 - 50%

IAS adluslrnent AAC val\ system Arr flow meter syslem ]njeclor system C a n r s t e r( p u r g e ) r n s p e c t i o n Intake systern a r leak or a r

( a r r - t u erl a l i o f e e d b a c k correclron coeffic|ent)

A n e r w a r m r n qu p e n q i n e 200orpm wrth no load "START'

7s - 125%

START SIGNAL

ON StarlerSW system
OFF ON Throttle sensor system

lgnrlion wlch s ON E ngIne

.OFF' Throttle tully ciosed

IDLE SW

A]R COND S G

A/C SW ON A/C SW OFF

ON Arr conditroner W system S

NEUTRAL SW

N or P rarEe
NotNorP

ON
OFF ON OFF OFF Polver steenng SW system Nedral SW system

PWST SIGNAL

Sieenng
Sleeflng neLrlral

F U E LP U M P R E L A /

IGNSW ON

Slop

ON
A/C ON dling A I R C O N D I I ' I O N E RR E L A Y A/C OFF A/C ON

Fr.reipump system

ON
OFF OFF Air condrtorEr .elaysystem

SIGNALS OUTPUT ECCSC U INPUT

/ F B 2 O E D E / D E TE N G I N E

(2\ Activetest
TESr_ ACTIVE
qCT|vE TE9T DESCRIPTPI{
to Perfcrn fo lowng lnspections checkif probEri s so \ed

nlgn temperatufe or ow SetengLne system sensor ternperature Engrne occurence Problem ENGINE as values Carjtlo[ Do notsel extreme system Lnlector condrtron thrs cause TEIMPERATURE blrnlng spark can Plug gas syslem Air iow meterexhaust sensor
Nol elmrnaie.l' Orhe- rtem ,_soector

FlmLntte

l' lo check Pe'{orn'o'lowng,nspectlors problem sol\ed. rs Elimrnate ratio Settheair-fuel rlchor lean gas system Exhaust sensor as values occurence Cautoo. Do notset extreme Problem sensor temperature englne flowmeter, ALr FUELINJECTION or englne cataiytc sysrern thrsmaydamage conorllon ocn\ertet syslem Injeclor
N.t elmrnaied Other rtem Lnspection

tlmrng Lgnrtion Delay values as occurcnce Caltion: Do notset extreme Problem TIMING GNITION or engine catalytic maydamage thrs conol!on con\nel

to inspections checklt following Perform problem sol\ed. s

Flimln2lp timrngadlushenl lgnition sensorsyslem Detonation Not ehminait.l Other item Inspecton

AAC VALVE OPENING

Increasecontro duty ratio The englne descrlbedon leftcan not be lf the condition speed shouldincrease runnrng Engine venfied ccheck AAC val\ system The Decrease controlduty reatlo. decrease enginespeed should switchON. OFF and ON Turnignrtron makes a sound. so pump operatlon lf the conditiondescribed on left can not be ON The fuel pressurew11nse swrtch lgnrtion \rified. check relay system of fLlelpirmp Cado-o- Do not perform this operatron and fuel pump system Enginestop descnbedon exceptunderconditions left factorrs cleared leamlng coefficlent ratiofeedbackcorrectlon The arr-fuel

FUEL PUT,4P RELAY

SELF-LEARNING CONT

EN-500

ECCSC/UINPUT/OUTPUT SIGNALS
BB2OE NGINE E 9-2 O S C I L L O S C O P EC I R C U I T T E S T E I N S P E C T I O V A L U E & R N (RB2OE NGINE} E

Termina I No.

Signal name

Circuit

At idle Standa rd Memo

At Approx. 2,500rpm Standard Memo

Air flowmeter intake quantity arr na srg I

Appfox.1V

Approx. 1.5V

Engine temperature sensor srgnal

Engine lemperature Bo"C: Approx. 1V Engrne temperature 2 0 " C :A p p r o x . 3 V

Engine temperature 8 0 " C . A p p r o x1 V Engine temperature 2 0 " C .A p p r o x . 3 V

gas Exhaust sensor srg I na

Approx. - 1V 0

Deflectsbetween 0 - Approx '1V

Throttle sensor (lnput) srgnal

Approx 0 5V

0 . 5- 1 V (Battery voltagewill rncerase when pedaiis acceleration pressed)

0.3- 0.7v
Crankanglesensor 1 2 0 "s i g n a l

0 . 3- 0 . 7 v

2-3V
(v)
6

2-3V

10

Crankanglesensor 1 "s r g n a l

E N- s 0 1

EUUJ

\, \]

SIGNALS INPUT/OUTPUT

E RB2OE NGINE

ENGINE RB20E

Terminal No.

At idle
S i g n a ln a m e

Circuit

Standard

I Memo

rpm 2,500 At APProx'

rd Standa Memo

'13

& l\,4onitor check lamp(redlamp)

Lampnot lit; Power voltage LamPis lit: Approx.0V

Lampnot lit: Powervoltage Lampis lit: Approx.0V

'15

Intakeair quantlty signal output (ToA/T C/U)

Approx.lV

1 Approx .5V

sensor Detonation I signa

Approx.4V

Approx.4V

17

Throttleopening otjtputsignal

Approx.0.5V

0 . 5- 1 V (Battery vottagewill incerasewhen acceleration Pedalls presseo) D range(or 1st)wth jacked rearwheels u p r 0 . 5- 1 . 5 V The valueactually defrectsbetween0 lt and 5V. However, appearsto defect around1V accordlng sPeed. to vehicle

21

speed Vehicle sensorsignal

D range(or 1st)with rear wheelsjacked u p : 0 . 5- 1 . 5 V The valueactually deflectsbetween0 it and 5V. However, appearsto deflect around1V according speed. to vehicle

22

valveswitch Throttle (idle contactPornt)

l A p p r o xo v

0V when accelerator is pressed

EN 502

ECCSC/UINPUT/OUTPUT SIGNALS
RB2OE NGINE E RB2OE NGINE E

Termina I No.

S i g n a ln a m e

C ircuit

At idle Standard Memo

At Approx. 2,500 rpm

Standard Memo

23

lgnition switch (START signal)

OV (lgnition switch at START Power vonage)

OV

24

Neutralswitch srgnai

N or P range: 0V Other thanN or P range:Approx.6V

N or P range: 0V Otherthan N or P range:Approx 6V

25

lgnrtion swtch (ONsignal)

Powervoltage

Powervoltage

26

Throttlesensor srgna I (Power supply)

5V

5V

27

Controlunitpower supply

Power voltage

Powervoltage

29

Air conditioner sw'tchsignal

Air conditioner OFF: Powervoltage Air conditioner ON: Approx.0V

Air conditioner OFF: Powervoltage Air conditioner ON: Approx.0V

EN - 503

SIGNALS ECCSC/UINPUT/OUTPUT
E RB2OE NGINE

RB20E ENGINE

Terminal No.

S i g n a ln a m e

Circuit
i-;l:-*'r ilecru

At idle Standard Memo

At aPProx.2'500 rPm

rd Standa

Memo

32

valveswitch Throttle (PowersuPPlY)

l ' -

\ _.-!!r'-, |.-''

Powervoitage

Power voltage

0 . 2- 0 . 3 v

Powertranststor controlsignal

38

Powersteering signal switch

ONI Powersteering OV OFFI Powrsteenng Approx.5V

ON: Powersteering OV OFF: Powrsteering Approx.5V

n. . -

39

slgnal Tachometer (lgnition Primary coil detection signal

Disq,bul9r ' f -+-6f . reroir !_cru i-=-Po .l R6isror tranestor

Power voltage

A p p r o x1 0 V .

40

E C C Sr e l a y

1V Approx. OFF. (lgnition switch voltage) Power

OV

1V Approx.
engine Tachometer rev srgnal

Approx.3V

43

EN - 504

ECCSC/UINPUT/OUTPUT SIGNALS
RB2OE NGINE E RB2OE NGINE E

Terminal No.

S i g n a ln a m e

Circuit

At idle Standard Memo

At Approx. 2,500 rpm

Standa rd Memo

Engine A/T total controlinpLrt signal

(Dr1)

Approx. 10V

A p p r o x1 0 V

A/T control unit

45

Engine total A/l controlinputsignal (D12)

: , =:t:nsffilsfri

46

A,r conditioner relay

Air conditioner OFF Powefvoltage Air conditioner ON OV

Air conditioner OFF Pov.ier !oftage Arrcondrtroner ON OV

47

Engine A/T total contro, or.IpLlt (DT3) signal

OV

OV

101 103 105 110 112

Almostpowervoltage lnjector control srgnal

Almostpower voltage

20 0

104

Fuelpumprelay

OV

OV

EN - 505

SIGNALS ECCSC U INPUTJOUTPUT

E R82OE NGINE

E RB2OE NGINE

4 Approx - 5V

AAC valvecontrol srgnal

EN - 506

ECCSC/UINPUT/OUTPUT SIGNALS
R B 2 O D /ED E TE N G I N E 9-2 O S C I L L O S C O P E C I R C U I T E S T E R N S P E C T I OV A L U E & T I N ( R B 2 O D ED E T E N G I N E ) /

Terminal No.

Signal name

Circuit

At idle Standard Memo

At Approx. 2.500 rpm

Standard Memo

rEf-s
18 Fuelpumprelay

t g n i i i o nS W

@f'
OV OV

Qr,"r p,'p) + ,,---!)\

Powersteeflng switch stgnal

Powersteering ON: OV Powersteering OFF 5V

Powersteeflng ON: OV Powersteering OFF.

23 24

Detonation sensor signaI

Approx 4V

Approx.4V

27

Air flow meter (lntake quantity air signal)

Approx.1V

Approx.1.5V

28

Engine lemperature sensor srgnal

Engine temperature 80"C: Approx. 1V Engine temperature 2 0 " C :A p p r o x . 3 V

Engine temperature 80"C: Approx. 1V Engine temperature 2 0 " C :A p p r o x . 3 V

29

gas Exhaust sensor signaI

Approx.1V

deiect between 0 - approx. 1V

Et\

- 3U/

SIGNALS ECCSCiU INPUT/OUTPUT

R B 2 O D / D E TE N G I N E E

/ RB2ODE DET ENGINE

t"ffi:"'l

name sisnar

Ai idle
Standard Memo

Circuit

rpm 2'500 At APProx.

Standard Memo

l : : :

32

& lvlonitor check lamp(redlamP)

Lampnot lit: Powervolatge Lamplit: OV

Lamp not lit: Powervolatge Lamplit: OV

34

Engine(AfD total inpLrt signal control

'10V Approx.

10V Approx.

{Dr1)

35

Engine(AfD total signal controloutpLrt

Approx.0V

Approx.0V

(Dr3)

36

total Engine(A,/T) controloutputslgnal (D12)

10V Approx.

10V Approx.

38

Throttlesensor srgnal

Approx.0.5V

0.5 - 4V (Voltage if increases pedalis accelerator presseo)

40

Intakeair q uanttty slgnal oulput

A p p r o x1 V

Approx.1.5V

E N- 5 0 8

ECCSC/UINPUT/OUTPUT SIGNALS
R B 2 O D / D E TE N G I N E E R B 2 O D E D E TE N G I N E /

Termina I No.

S i g n a ln a m e

Circuit

At idle Standard Memo

At Approx. 2,500 rpm

Standa rd Memo

0 . 3- 0 . 7
6

41

Crankanglesensor 1 2 0 "s i g n a l

2,, 0il

2-3V
Crankanglesensor 'l'signai
-_ 0.5trr'-

2-3V

42

43

lgnation swtch (START signal)

OV (lgnition swrtch in "STARI'': Power \ cltage)

OV (lgnrtion switchn "STARI-' Power voltage)

Neutral swtch signa I

N or P range:0V Other thanN or P range:4 - 5V

N or P range: 0V Other thanN or P range:4 - 5V

46

Arr conditioner switch signal

A r rc o n o [ t o n e r F F U Powervoltage Air conditioner ON: OV

Air conditioner OFF: Powervoltage Air condilioner ONi OV

48

Throttle sensor (Power supply)

5V

trI\ - 5U9

SIGNALS ECCSC/U INPUT/OUTPUT

R B 2 O D / D E TE N G I N E E / RB2ODEDETENGINE

*il:"'l

name sisnar

At idle C ircuit Standard Memo

lt lPProx. 2,500rpm Memo rd Standa

:a:

49

unit Control Power supply

Powervollage

Power voltage

53

speed Vehicle signal sensor

D range(or 1st)wth rearwheelsjacked '1.5V u p : 0 . 5The valueactually deflectsbetween0V lt and 5V. However, to appears deflect around1V,according sPeed. to vehicle

D range(or 1st)with fearwheelsJacked up: 0.5 - 1.5V The valueactually deffectsbetween0V and 5V. Howeve(lt to appears deiect around1v, accordlng to vehiclespeed

54

valveswitch Throttle (ldle contactPoint)

A p p r o x1 0 V .

0V when accelerator pedalis pressed

56

opening Throttle signal output

Approx.0 V 5

0.5 Approx. ' 4V will (Voltage increase when acce|eralor pedalis pressed)

57

Throttlevalveswitch (Power suPPlY)

Powervoltage

Power voltage

powervoltage Alrnosl 101 103 105 110 112

Almost Powervolage

control Injector srgnal

E N- 5 1 0

ECCSC/UINPUT/OUTPUT SIGNALS
R B 2 O D iED E TE N G I N E RB2ODEDETENGINE /

Terminal No.

Signal name

Circuit l] r' ;".r p, p-

At idle Standard Memo

At Approx. 2,500 rpm

Standard Memo

104

pump Fuel terminal voltage control (FPClvl) signal

I

-L

,:\

conror I mod0ralor I -

C o l d :0 V V\hrm: Power voltage

C o l d :0 V \ hrm; Power voltage

ECCSconlror unrr

E N- 5 1 1

SIGNALS ECCSC U INPUT'OUTPUT

/ R B 2 O ED E / D E TE N G I N E

CAUTIONS UNITOPERATION 9-3 ECCSCONTROL (1) Controlunit equiPment for . Never unit a install control thatis notspecified yourvehrcle' bracket . Do notapplyexcesstve forceto the installation (2) Connector removal and installation forceand unnecessary . Wh"n removing installing do connectors, notbendor apply and following observe Points: 1. Connector removal connectors. removing OFFbefore . Turnignition oFF andECCSrelay switch forceto harness' applying . Holdconnector without to f irmly disconnect lock' the . Do notusea screwdriver similar to loosen connector tool or 2. Connectorinstallation . Turnignition switchOFF. .Makesurep|nsarenotbentorcontro|unitconnectorandthenconnectSecUre|y. of orangecolourindicator surlacereaches . Tighten untilinjector boltssecurely is and connector surface even. (3) Control unit Power . Nevermakea reverse to connection the battery. .10 16Vrange. . Usebattery in voltage (4) ldle speed adiustment knob . Do notturnpastlockPosition. lower thanOoC' temperature . Do notturnadjustment knobwhenambient (5) Waterand oil unit. . care mustbe takennotto allowraindropsor waterto wetthecontrol in increase . care mustbe takenthatcondensation notformdueto sudden does in installing the before unit dry lf temperature.thereis any moisture, control adequately vehicle. . Makesureno oil adheres connectors. to cleaners. solvent . Do notclean control using volatile unit the (6) Dropping and imPact impact' . Do notdropthecontrol or subject to strong it unit unit . Do notuseupper for covers thecontrol whicharedented' andlower (7') Control unit screws and cover unit' f . Do notremove upper coversromthecontrol andlower the . Do notturnthescrews thecontrol mainbody. unit in

E N- 5 1 2

ECCSC/UINPUT/OUTPUT SIGNALS
C A ' 1 8E N G I N E i

9.

ECCS CONTROLUNIT INPUT/ OUTPUTSIGNALS

9.1 CONSULT INSPECTION VALUES (1) Datamonitor Note:The output signal displayed thecalculation on console so thecorrecr is as data unit value displayed will (harness) inadvertentlv evenif theoutput circuit is disconnected. CAl8i ENGINE
,li: , .'..,liti
' ..1:.1 i ,.:-i

cotonr
CAS RPM (Detected angle s p e e d a c c o r d r n gt o s r g n a l s ) ENGTEMP SEN lergrne remperature) EXT GAS SEN (outpLl voitage) EXT GAS SEN ( R I C H/ L E A N ) CAR SPEED SEN (vehicle peed srgnal) s BATTERY VOLI T H R O T T L ES E N up engrne

' , j..:t'.:..:i !{t: . -,t

PRCiSL:ES t

Tachometer set Engine runnrng Afrer warm,ng up engrne

There must be no abnorrnal c n a n g eI n s p e e o Abo\r'e approx 70"C

Crank angle sensor slstem Engrne temperature sensor

C h a n g e s b e M e e n 0 - 0 3 V a n d Exhaust gas sensor system 06 - 1V l r i a k e s y s t e ma r r e a k o r a r r 2000lpm wth no load R I C H .L E A N r e p e a l s 5 t m e s o r m o r e 1 n1 0 s e c o r d s Should generally corform to s p e e d m e t e rd i s p a y 11- 14V 1 0 5 0 Thron|e tully closed Throltle sensor adtustmenl Thfonle sensor system Vehrcle speed sensor s)1err Battery E C C S c o n t r o lu n r tp o \ , r

While dnvrng of wth drive whee s tumrng lgnrtronswitch ON E n g r n es l o p p e d Throtlle tully closed lgnrlion swtch ON Engrne

IHROTTLE SEN (2) (oLrtput voitage) ] N T / AT E M P S E N (rnlaktemperalure sensor

06
4 5

Aner wannrng up engrne

ldling (N range A/C

I n l a k ea r r t e m p e r a l u r er s

lntaktemperature

sensor

INJ PULSE ( r n j e c i o np u i s e w d t h ) 2000rpmwith no load

ldlng (N range A/C

1 '2 Mtf 1s. Atf20"

rnsec

Arr now meter system I n l a k es y s l e m a r r l e a k s o r a r r sucton lennre nput) Input signal syslern (ent re)

IGN TIMING

After warming
2OOOrpm wlh no oad

Advance grealer fhan 10" angle comparedto idle posrlron

Air flow meter system

Air llow metef system (arr-tuel fato feedback corre.lon coeffcrent) Aner warmrng up engrrE 2OO0rpm lh no load w 75 - 125vo C a f l s t e r ( p u r g e )i n s p e c t r o n r{ake syslemarr leak or air

START SIGNAL ON Engrne IDLE SW

STAR']-'

ON Starter SW system

Throttle tully closed

ON

Throttle sensor syslem A/C SW ON A/C SW OFF ON Arr condrlioner W system S ON Neutral SW system Steenng
ON Povtr steenng SW slstem

AIR COND SIG

N E U T R A LS W

PWST SIGNAL

WG CONT SA/

Head amp heater fan rear defogger SW ON A/C ON ON AIC OFF Eng temp cord
Eng temp Hoi Slop

ON

FICD SA/

ON ON

FICD inpLn yslem s PTC healer InpLnsystem Fuel pump syslem Air condilroner ystem s

FUEL PUMP RELAY A I R C O N D I T I O N E RR E L A Y

IGN swtch ON
ldle

ON A/C ON A/C OFF OFF

SIGNALS ECCSC'U INPUT/OUTPUT

E CA18i NGINE

(2) Aciive test

ACTI/ETEST !*'.r. TEETDESCRIPTIO{ ACTIVE

r,:sl,
Perfor.nfo lowrng nspectionsto check lf problemts so \o.
F mLn:JP

r:1]U:]:.r,:r'

hlgh temperature or low Setengine system sensor Engnelemperatlre occurence Problern ENGINE values Cal]tion.Do notset extreme system Inlector condrt 0n TEIVIPERATURE pLug burnlng spark as thiscancause gas sysrem exhaust sensor Arrflowmeler.
Nol clm nated Ot_er tem nsoeclion

FUELINJECTION

Pedorm follow!nginspectionsto check if pfoblemis sol\d Flimrn2te ratro Setthearr-fuel nchor lean. gas sensorsrsrem Exhaust as values Aif flowmeter englnetemperature Calllio-rtDo notsetextreme Problem occurenc sensol

condttlon

or engLne catal)'tlc system damage thisrnay ocn\rter. lnlectorsystem

Not elirninaied Other rtem Inspectlon Performfollowlnginspectionsto check if problemrs soltd. ttmrng Delayrgnrtlon Flimrn2tt valuesas CArdion Do not set extreme Problem occurence adjustment trming lgnition thrsmay damageenglneor cataYlc condrtron Detonationsensor system convefler Nol elimin2led Other item inspectlon

TII,IING IGNITION

ON and OFF The switch Turnignition on described lell can not be lf the condihon warm uP idle revwill change Afferengrne solenol0 IDLE A/C Carxio-o.Do not pedom this operatron \riied. checktdlecorrectlon hling (N range, SA/ CORRECTION on slstem descrlbed exceptundefcondltlon oFF) left on Turnrgnit swtch ON and OFF The al warrnuP rdlerevwll increase approx200rprn lf the condrlrol Afterengrne on descrrbed leftcan not be (N ldling rangeA/C Ca!tjo-c|:Do not performthis operaton \rified.checkFCD solenold system FCD SA/ descnbedon exceptundercondition oFF) lefr.

FUELPUMP RELAY

switchON lgnition

ON ignrtron switch OFFandON Turn a makes sound so plmp operation on described leftcannotbe f thecondition will Thefuelpressure rise of \nied, checkfelaysystem fuelpump thls Do Ca!!-oxL- notperform operatlon system andfuelPurnp on descnbed except !nderconditlons left

SELF,LEARNING CONT

factorrs ceared lealnlng coerfclent ralo feedbao(correctlo'1 fhe arr-fuel

EN- 514

ECCS C/UINPUT/OUTPUT SIGNALS

C A l 8 iE N G I N E 9 - 2 O S C T L L O S C O p EC t R C U t T E S T E R N S P E C T I O V A L U E( C A l S iE N G T N E ) & T t N

Termina I No,

S i g n a ln a m e

Circuit

At idle Standa rd Memo

At Approx. 2,500 rpm

Standa rd Memo

Throttle sensor signal 1

Approx. 1V

Appfox.1V - 5V (Voltage increase will whenaccelerator pedalis pressed)

Engine temperature sensor srgnal

Engine temperature 80"C: 1V Engine temperature 20"c 3v

Engine temperature 80"C: 1V Engine temperature 20"C: 3V

Deflectbetween approx. - lV 0 6 gas Exhaust sensor srgnal

Deflectbelween a p p r o x0 - 1 V

!"1;l-.-.,:-

Throttle sensor signal2

Approx 0 6V

Approx.06V-4.5V (Voltage increase whenaccelerator pedalis pressed)

Approx. - 0.7V 0.3 I '19 Crankanglesensof '180" signal

Approx. - 0.7V 0.3

Approx. - 3V 2
(v)
6 6 2 0

Approx. - 3V 2

10 20

Crankanglesensor 1 os r g n a l

E N- 5 1 s

SIGNALS ECCSC/U INPUT/OUTPUT

C A l 8 iE N G I N E C A 1 8 iE N G I N E

'

t"',il:"'l

name sisnar

At idle Standard Memo

|
I

At APProx.2,500rpm Standard Memo

::::

Circuit

13

& l,4onitor check lamp(redlamp)

LamPnot lit: Powervoltage 0V Lamplit: APProx.

Lampnot ht: Powervoltage 0V Lamplit: APProx.

(v)
6

21

speed Vehrcle srgnal sensor

2 0

'1 Approx. " 5V (Cyclewill get shorter sPeed whenvehicle is increased)

23

lgnitionswitch "START'signal

OV (lgnition switchin STARI Power voltage)

OV in (lgnition switch START Power voltage)

24

Neutralswitch I signa

0V N or P range: thanN or P Other range:6 - 7V

N or P range: 0V Otherthan N or P range. 6 - 7V

27

unit ECCS control power suppty

Powervoltage

Powervoltage

ta

Air condittoner signal switch

OFF: Air conditioner Powervoitage ON: Air conditioner OV

OFF: Air conditioner Power voltage ON: Air conditioner OV

E N- 5 1 6

ECCSC/UINPUT/OUTPUT SIGNALS
CA18i NGINE E CA'I8iENGINE

Termina I No.

S i g n a ln a m e

C ircuit

At idle Standa rd Itdemo

At Approx. 2,500rpm Standa rd Memo

30

lntake atf remperature sensor stgnal

Cold: Approx. 1.5V l brm: Approx. 0.8V

C o l d :A p p r o x1 . 5 V . Wbrm: Approx.0.8V

Powersteenng signa I

Powersteering ON: OV Powersteering OFF Approx. BV

Powersteering ON: OV Powersteenng OFF. Approx. BV

Approx 0.5V

A p p r o x1 V .
1 T

(;)it-Il]l--l-t-,1
37

Power tranststor (lN) control signai

4f-:.-. --

,fltr-4-- -+- 108

A'

-rrr:F 1 rl
IGN_coil

't:t:t:'J'ta''J' i r : r c ' * . . .i ,l 1 l l
' |
:p?'.\'.
lvl-T-ttr I 6l-i 1 l I -. I I F - r t L t , I L Jl

oisrribu'o1

-F-:*i:=
J--

.o

Approx 0 5V

38

Powertranslstor control signal(EX)

;iuk+irffifr
l+iroF{':i,.1
i-i- -,--

A p p r o x 1 1 V- 1 2 V . primary lgnition stgnal

A p p r o x 1 0 V- 1 1 V .

39

40

ECCS relay

OV (lgnition swtch OFF: Power voltage)

OV

E N- 5 1 7

SIGNALS ECCSCiU INPUT/OUTPUT

E CA18] NGINE

C A 1 8 iE N G I N E

'

t"',1::"'l sisnar name

At idle
Standard Powervoltage Memo

Circuit

rpm 2'500 at APProx.

Standard Lowef than Power volage Memo

l : : :

41

Fuelinjector PUlse srgnal monitor (ll monitor)

43

signal Lightswitch

ON: Switch Power voltage OFF: 0V Switch

SwitchON: Powervoltage OFF: 0V Switch

45

Heaterfan swtch I srgna

ON: Switch Powervonage OFF: 0V Switch

ON: Switch Power voltage OFF] 0V Switch

46

Reardefogger switchsignal

ON: Switch Powervoltage OFF] 0V Switch

ON: Switch Power!oltage OFF: 0V Switch

Powervollage

Lowerthan Po\4er vo|tage

'101 110

control Injector srgnal

102

relay Air conditioner srgnal

e A i r c o n d i l r o n OrN : Powervoftage t r A r rc o n d r o n eO F F OV

ON: Air conditioner Power voltage OFF: Air conditioner OV

E N- 5 1 8

ECCSC/UINPUT/OUTPUT SIGNALS
C A ' l 8 iE N G I N E C A 1 8 iE N G I N E

Terminal No.

S i g n a ln a m e

Circuit

At idle Standard Memo

At Approx. 2,500rpm Standa rd Memo

'103

FICDsolenoid

Air condilioner ON: OV Air conditioner OFF: Powervoltage

Air conditioner ON: OV Air conditioner OFF: Powervoltage

104

pump Fuel relay

,-,11t_

Approx.0V (Powervoltagefor 5 sec atterjgnrtion swtch rs placedto ON posrtion)

Approx.0V

'106

PTC heater relay

PTC heater ON: Approx.0V PTC heater OFFr Powervoltage

PTC heater ON: Approx.0V PTC heater OFFI Power \/oltage

'1. Whenign sw in ldle rev correction sotenoro

111

on 2. Engine rewing: Approx.0V First15 sec afrerengine start: Approx. 0V Afler15 sec afterengine starl: Powervoltage Any ofthe followings ON (Power are steering, laghts, defoggetheater switch)iApprox. rear fan 0V (D rangefor A/T) Lockup released: Approx.0V Lock u pa p p l e o : Power vottage

115

Lock up release solenoid(Aff)

Lockup released: Approx.0V Lockup appljed: Powervoltage

E N- 5 1 9

SIGNALS OUTPUT ECCSCiU INPUT

E RB25DE NGINE

9.

S U E C C SC O N T R O L N I T I N P U T/ O U T P U T I G N A L S

VALUES INSPECTION 9.1 CONSULT (1) Datamonitor unit data as is signal displayed thecalculation on consoie so thecorrect output Note:The disconnected. (harness) lnadvertently is circuit evenif theoutput will value displayed RB25DEENGINE
rr,r:,r.,t,trtr',r.

toR

(Detected al.q]e CAS RP[,4 to speedaccordrng srgnals) AlR FLOWt'/TR voltage) lol,tptlt SEN ENGTEMP temPerature) lengrne EXTGASSEN \oltage) roLrlPut EXTGASSEN (RICH LEAN) / S C A RS P E E D E N (\ehcle speedsignal' VOLT BATTERY

set Tacfometer ng Engne runn Ailerwarmng up kl lrg engI hlrg (Nrange wthottload 2000rpm A/COFF) LtP Aitefwarmrng englne

Theremuslce no aonorma Crankangiesensor syslem ^ chaarge speeo Approxl0-15V A r frowmetersystem

AboveapproxiO'C

sensor Eng temperaure r syslem

Detween0 03v and ExhaLrst sensor Changes gas syslem 06- lv alr ntakesystem eak or alT Llp Anerwarmrng w 2000rpm th rx)load intake enqrie repeats t mesor 5 RlCfl. LEAN nedor sysrcrn mofe n 10 seconos
or l\hile dfl\,1n9 w th drve wheels tLlrnlng

Shoudgene y conbrrnto 0 spee0meler splay

11

SYsteTn sensoT Vehrc Speed e

ON n ttonswrtch slopped Engrne Aiterwarmng !p engne (N ldlrng range A/C oFF) wlth 2000rpfir m loao tlhrg (N range A/C oFF)

Battery wrt control Power ECCS system

IN.] PULSE pulse ( nFclron wldtl'r)

A r fow metersystem A p p r o x . 2 0 - 2 8 m s e c Inlake a system r eaKs0r alr rnpul) sLcton{entire 2 (entlre) Approx 0-28msec npLrt signalsystem 15. Arriow metersystem

T LGN [,4ING

AJler wamlrg up engrne Alterwarmng up eng rle

grealer than10"ange Advance 2000em wrthno load to compared tde Poston A/C ld r (N range. OFF) Approx12 - 30%

AAC VALVE A/FALPHA coneclron (a r-fuel feedback ratro coeffcient)

lAS adjuslnent svstem AAC vaive Air iow metersyslem syslem nlector (purge)nspeqlon Canrster alr ntakesyslem eak or alr slcton SW Starter system slslem ThTott sensor e Arrcondtoner SW system NeLtalSW system SW Powersteenng syslem

up Afterwarmrng engr w 2000rpm tir m load STARI

75 - 125%

ON
OFF

SIGNAL START DLE SJUDGEMENT AR CONDS G SW NEUTRAL

swrtch oN bnition stopped Engine

OFF ThrotUe fLilyclosed

ON
OFF

open Throtte tully A/C SW ON A/C SW OFF N or P range NotNorP

ldle

ON OFF ON
OFF

Steenng ng Steen rcu'tral ArC ON OFF

ON
OFF

PWSTSIGNAL

ON
OFF OFF

AIR CON RELAY

ACCeI

Arrcondtoret reay syslem

A/CON Stop

OFF ON Approx4 0 Appror0 5

FUELPUMP RELAY SEN THROTTLE (ouFutvoltage) VOLTAGE POWER

IGNSW ON

FLE pumpsystem syslem sensor Throttle

switch ON Throttlefullvc osed lgnrtron stoPPed Throttetu y open Engrne

value pro\e measurement Drso oo\rrvoltage av pro\e Tneasuresulemenl !lue ls c a! oulse

N-5

ECCSC/UINPUT/OUTPUT SIGNALS
RB25DE NGINE E

(2\

Active test
ACTIVE TEST

JT'DGE ENTA DN! 'ECTF |TEH ' Acrnrpirus'.oescnPipR,',.

Pefonn folowng Inspections checktf 1o problems solved. Fliminrle Engrne lernperature sensor slstem Inlector syslem Air ilow meter exhaust sensofsyslem gas Nai elimtneleal Othertem inspection Perfom foilowrng Inspections check lf to problem solved rs Flimrnaie gas Exhaust sensofsyslem Arrflowrneterengrne ternperature sensor systenl Inlector system Nol eliminaied Olheritem inspect on Perfonnfollowing nspections check if to probiemrs solved Flimrn2le lgnition limingadjuslme Detonation sensor slstem Nol ehmrnaled Otherrteminspectron f lhe condition descnbed lefican not on beverified. checkAAC valvesystem

Setengrrctemperature or low hlgh ENGINE Problem occurence Cardion notSet Do extreme ValUeS aS IEMPERATURE cono|l|on thrs cause plug can spark burntng

Set the air-fuelralio rich or lean

Problem occurenceC2r,lron DO not SetexlremevaluesaS FUELINJECTON condrlion thrsmaydamageengrne catal!,tic or

ocnlener

GNTNONTII\,IING

Delayrgnition umrng Problemoccurence C2LdionDO notset exlreme tS aS va cono|Ilon thismaydamageeitgrne catalytic or con\net

Increase conlrol dutyratto.Theengtne AAC VALVE OPENING Engine running Decreasecontroldlty ratto The engrne speedshollddecaease.

FUELPUMP REtAY
SELF-LEARNING CONT

lgnition switch ON Engrne stop

Turn rgnition swllch OFFandONso ON pump operalron makes sound.Thefuel lf lhe condrtion a descnbedon leftcan not be pressure nse wrll venfed. check relaysyslem offuel pump Do CaUi.o-rL nolperform operalron and fuelpump lhis systenl except under conditi0ns descrrbed 1eff. on

The air-fuelratiofeedbackcorection coefficrenl learntnq factorts cleared. Eng ne rev can be drsplayed whenAAC valveopeningis flxed and set rnlector Problem occurence operalron stopped. s condition

POWER BALANCE

Flirnrneie Injector systern

Car{ron Do notpedormlhis operation whrle dnMng

EN - 521

SIGNALS ECCSC U INPUT,OUTPUT

E RB2sDE NGINE

s-2

ENGINE) VALUE (RB250E INSPECTION osclLLoscoPE & clRcutT TESTER

Terminal No. 1 2 3 11 12 13

S i g n a ln a m e

C irc uit

At idle rd Standa Memo

rpm 2,500 At Approx.

Standard Itlemo

v 0.2 0.3
(v) 6 . _ . .

Approx.0.4V

l-

- ' . - . :

Powertransistor signal control

Cold: 6 - 7V Vvarm: - 10V 8 4 AAC valvecontrol na srg I

l5 10 5

Approx.5V
(v)-r'-:-_-_-_ t|l 10 -,r1 --f|- -Ttl 5 - ir r' .--'--:+zrs ,1,.---

f+

Afi contol un

A/T total Engine inputsignal control (Dr1)

10V Approx.

10V Approx.

1V Approx.

Approx.2.4V
lvt ., -.l

engine Tachometer speedsignal

-i; ; ; . ;' " F Tf-l Tl-r-TTtf

"IIilLTI]rlL
l.ih-

, t .:-_ti-

l]]-

relay Air conditioner

OFF: Air conditioner Powervoltage ON: Air conditioner 1V Approx.

OFF: Air conditioner Powervoltage ON: Air conditioner Approx. 1V

14

Enginea/T total inputsignal control (D12)

Approx.10V

Approx.10V

EN - 522

ECCS C/UINPUT/OUTPUT SIGNALS

RB25DE NGINE E RB25DE NGINE E

Termina I No.

Signal name

C ircuit

At idle Standard Memo

At Approx. 2,500 rpm

Stan dard Memo

15

Engine total Aff controloLrtput srgnal

(Dr3)

Approx.0V

Approx.0V

16

E C C Sr e l a y

Approx. 1V (lgnrtion switch OFF. Power voltage)

Approx.0V

18

Fuelpumprelay

OV

'19

Powersteenng swtch signal

Powersteenng ON OV Powersteering OFF

: l!.,/er stee^ng_N OV
D-\!Fr <.;.--,^ ^::

5V

----5i."",,
23 24 Detonation sensor sigml I

i i - - - -

rio"i""*t"**

Approx.0.3V

Approx.0.3V

27

Air iow meter (lntake quantity air signal)

Approx. 1V

A p p r o x1 . 5 V .

EN - 523

SIGNALS ECCSCiU INPUT,OUTPUT

ENGINF FIB25DE R B 2 5 D EE N G I N E

t"il:"'l

name sisnar

At idle Circuit
En9ire renperaturc snsor

I Memo

At APProx. 2,500 |pm Standard Memo

Standard

28

temperature Engine s!gnal sensor

Engine temperature 1V 80"C:Approx. temperature Engine 20'C: Approx.3V

temperature Engine 1V 80"C:Approx. temperature Engine 20"C:Approx.3V

29

gas Exhaust sensor nal sig

0 Approx. - 1V

Deflectbetween0 '1V approx.

32

& [,ilonitor check lamp (redlamp,exhaust temperature lamp) warning

Lampnot lit: Powervoitage Lamplit: 0V

Lampnot lit: Powervoltage Lamp lit: 0V

t-tuu sonotcl

A/C ONrov A/COFF:Power vomge

A/C ON :0V AiCOFF: Power vorcge

38

sensor Throttle nal srg

Approx.0.5V

0.5 - 4V (Vottage when increase pedalts accelerator presseo)

40

Intake quantity air sagnal oLrtput

1V Approx.

1.5V Approx.

EN - 524

ECCSC/UINPUT/OUTPUT SIGNALS
RB25DE NGINE E RB25DE NGINE E

Termina I No.

S i g n a ln a m e

Circuit

At idle Standa rd Memo

At Approx. 2,500rpm Standard Memo

03-0.7v
Crankanglesensor 1 2 0 "s i g n a l

0 . 3- 0 . 7 v

41

2-3V
lv) 6

42

Crankanglesensor 1 "s i g n a l

, ftfl{f+nnflnI , +fffHfl+HilIiI
0r!!u!Fu!uu

-r

' . -T -

. - . . , . -

43

Jgnition switch (START signai)

OV (lgnition swilch STARI Power voltage)

OV

44

Neutralswitch srgnal

N or P range: 0V Other thanN or P range:4 - 5V

N or P ranger 0V Other N or P than range: - 5V 4

46

Air conditioner switch signal

Air conditioner OFF: Powervoltage Arr conditioner ONI OV

Air conditioner OFF: Powervoltage Arr conditioner ONI OV

4A

Intake quantjty air outpLrt srgnal

EN - 525

SIGNALS ECCSC/UINPUTOUTPUT
E RB25DE NGINE RB25OEENGINE

'

t"'.,il:"'l sisnar name

Circuit

At idle Standard

I Memo

lt lPProx- 2.500rpm Standard Memo

: : : l

49

ECCS C/U powersupPlY

Powervoltage

Powervoltage

53

speed Vehicle slgnal sensor

D range(or 1st)with rearwheels iacked u p : 0 . 5" 1 . 5 V The valueactually deflectsbetween0V lt and 5V However, to appears de{lect V aroundl according speed. to vehicle

D range(or 1st)with rear wheelsJacked u p ;0 5 - l . 5 V The valueactually deflectsbetween0v rt and 5V. However, to appears deflect aroundlVaccordlng speed. to vehicle

54

valveswitch Throttle (ldlecontact Polnt)

10V Approx.

0V when accelerator pedalis pressed

56

Throttleopening srgnal oLrtput

Approx.0.5V

0.5 Approx. - 4V (Voltage increase will when accelerator pedalis pressed)

57

Throttlevalveswtch (power suPPlY)

Powervottage

Powervonage

Almostpowervoltage 101 103 105 '110 112

Almostpower voltage

control InJector srgnal

EN - 526

ENGINE ELECTRICAL EQUIPMENT

B B 2 6 D E T /TR B 2 O E D F / D E T/ C A 1 8/i R B 2 5 D E N G I N E / E

EN4

ENGINE ELECTRICAL EQUIPMENT

PREPARATION TOOLS

Hydrometer

Battery speoficgravtyinspection Resistance voltage inspections

Circuit tester

SPECIFICATION

Note: The battery capacity valueis the 5-hourratethatconforms the newJIS standard to andthevalue 80%of theformer is 2o-hour rate.

model (example) name] [New + + Terf rnallpolarity + + position

| | (rounded dimensions off) I B+tteryl.lngth qatteryl-*idth box heightclassification x Perfdffiance rank(starting function addedto 5hr capacitv)

EN - 529

EQUIPMENT ELECTRICAL ENGINE

/ R / R B 2 6 D E T T / B 2 O ED E / D E T / C A 1 B iR B 2 5 D E N GN E

INSPECTION 1. BATTERY Voltage inspection

Normal N)
12.4 12.8 1 2 . 4o r l e s s required) (V) Limit(charge (V) lrmrt) (Start

12(zo"C)

Specific gravity inspection (20"C)

Normal

1.29 1.22 1.22 less or

widthof more Thereis a variation eachcell than0.04 between

(charge required) (V) Limit

Servicelife

walerdoes not needto be addedto the batter, Additional for Whendriving driving. lile service of normal during the fluidlevel periods time in hightemperatures' of extended conditions driving to according thevehicle maydecrease (upper lower) i indicator thelevel with the Check fluidlevel andtop up to the upperlevelas necessary. to watermustbe usedto be added refi Distilled Caution: wateris used,fluidlosswillincrease the battery.lf ordinary discharge. andmaycause

2. ALTERNATOR and installation removal (1) Alternator

C A 1 8 iE N G I N E RB ENGINE

,*-*;".fr",
(21 AlternatorinsPection Output voltage insPection . Placeignition and switch ON position check thal to lamP light. will warning charge

."f'q ,",,.-.ffi i1;'5T.1

-"f;-s-'h;l

EN-530

ENGINE ELECTRICAL EOUIPMENT

BB26DETT RB20Ei DE / DET/ CAi Sr/ FiB25DE / ENGTNE

3.

STARTERMOTORREMOVAL& INSTALLATION

CAIsiENGINE
Startermotor

RBENGINE
B o l t3 . 1- 4 . 1

*-,"rt",
ll

Washe Nut

4. SPARKPLUG INSPECTION Inspection . Check anylooseness terminals. for with . Check anydamage cracks theinsulator. for or on . Usethickness gauge checkthesparkpluggap. to S p a r kp l u g g a p ( m m ) : 1 . 0- 1 . 1

5.

PLATINUM PLUG INSPECTION (BB2ODE, RB2ODET, RB26DETT) Installationprecautions Periodic replacementinterval: 100,000km Gasinspection adjustment plugcleaning and and using wirebrush, should be performed thismayscrape not as partucluate off the platinum fromthe platinum surface. tip plugs cleaned lf are withan airgun,thecleaning should be performed lessthan20 seconds an airpressure in at lessthan6.0k9 cmr. / Onlyuseparts specified Nissan, by whenreplacing the sparkplugs.

EN - 531

EQUIPMENT ELECTRICAL ENGINE

i / RB26DETT RB2OE DE / DET/ CA18i ENGINE o.

COILINSPECTION IGNITION (lntakeside) CA18iENGINE

(Exhaust side) CA18i

ENGINE RB2OE

RB2ODE/DET/RB26DETT

value. . Check primary secondary resistance coil and the

EN - 532

COOLING SYSTEM
RB26DETT RB2OE DE / DET/ CA18i / RB2sDEENGINE / /

ENs

COOLING SYSTEM

PREPARATION TOOLS

SPECIFICATIONS

Onepieceunit(owershroud)

EI\

- CJJ

SYSTEM COOLING
E i / R B 2 6 D E T/TB B 2 O E D E / D E T/ C A 1 8 / R B 2 5 D E N G I N E

INSPECTION 1. RADIATOR Cooling water leak insPection (limit Okg i 1 . Useradtator tester andapplypressure cap cm2) andcheckfor leakage. Caution: alwaysmakesureto cap Whenusingthe radiator tester, cap is notdeformed. and the connect hoseadapter filler

CAP INSPECTION 2. RADIATOR Inspection with . Cleancap rubber packing and sealsurface vacuum

drybrush. pressure ano . Attach Apply to cap radiator tester cap.

correctly. checkthatvalveoperates operation. . Pullvacuum andcheck valve withfinger

J.

WATERFILLINGPROCEDURES COOLING are hoseclamps hoseandheater 1 Makesurethe radiator securelY. tightened Setthe heatercontrolleverto HOTposition.(For first air with equipped automatic conditioners, vehicles the position remove and to placeignition switch ON connector). sensor external cap the Release radiator andairdrainplug. (RB20E: / area. RB20DE DET:Intake collector manifold lntake glovebox). areaand in frontof collector manifold than2L / graduallyilling (f speed:slower radiator Fillthe Fill withcoolant. the radiator min)to thetopof thespout the tankreaches MAXlevel in the reserve untilthe water lineindicated. cap the 5 Afterclosing radiator andairdrainplug(RB it andallow to idle. the start engine system), the to idleuntil thermostat will 6 Theengine continue f the opens.(Touch radiatorlow hoseand makesurehot the of volume airremains, lf wateris flowing). a large gauge will needle movepastthe walertemperature lf rises temperature abnormally' as middle theengine andadd it waituntil cools stoptheengine thisoccurs, above. as repeatedly described water to the radiator opens,racethe enginefor 10 Afterthe thermostat times.Checkthat two at seconds 2500rpm or three doesnot riseexcessively. watertemperature the

EN - 534

COOLING SYSTEM
RB26DETT RB2OE DE / DET/ CA18i/ RB25DE / / ENGINE

7 Stoptheengine andallowit to cool. Release radiator the capandcheck fluidlevel.lf thefluid the level lowers. return step4 and repeat process. to the OR vehicle equipped automatic conditioning, with air connect freshairsensor the connector.

4.

RADIATOR REMOVAL ANDINSTALLATION

C A l 8 iE N G I N E
- -- '' Nut0.33- 0143a.
Bolt(2) 0.33- 033 Reserver tank

Fadjator moudlng &racket (uppe.tt ,

xo __

s iff ijgj

.//-n t,! Radialor shroud ttowert I

RadiatorASSY

-/
43

R ,../
kg-m

/ /

1l

RB ENGfNES (RB20E DE I DET tRB25DE/ RB26DETT) I

(2) 0.33 - 0.43
.-|l

pao* - 0 F,?giiii,fiS:l''* o.ss . 4 3

Radiator cap Badiatorhose

Rad ator r m o unt i n g (upper)

v'

Reseryer

QnrJ
-!-'-

,afr
\-,i

- Radiator g m o un l r n (upper)

6- ,rn-- 9 -

Nut0.33 0.43

Radiatorhose (lowe4
Hose clarnp

Atf otl co(

r (A/T nose
Fladiator shroud(lower)

Radiator mo unt r n g rubber(lower)

Fi.

Badiatorshroud(upper)

lv.l Kg-m

\p*Screw ( 4 )P 0.33- 0.43

EN - 53s

FUELSYSTEM
RB26DETT F]B2OEDE / DET / CA18i/ RB25DE / / ENGINE

EN6

FUELSYSTEM

PREPARATION TOOLS

gaugeinspection FLrel

SPECIFICATIONS

EN - 537

FUELSYSTEM
E / /R F I B 2 6 D E T T B 2 O ED E / D E T/ C A l 8 i / R B 2 5 D E N G I N E

1.

FUEL TANK FEMOVAL& INSTALLATION

4] tube IPornt Filler Canister

N u t0 . 3 3- 0 . $ Q ) 2 - 7-

-Y.'/ A,, \ )

F u e itanKASSY

3] IPoint

rQ-z
d
Bolt(4) 0. 3 3- 0 . 4 3 Fueltankprotector IPoint3]

Additionalwork required: f Drainuel the Remove following: 1] vaive[Point relief Fuelpressure pressure relief Fueltankinternal tubeprotector Filler 2] holecoverIPoint Inspection connector fuel unit, pumpharness [Point3] Fuelgauge FueltankProtector Hoses 'l [Point ] Fuel pressure relief . Afterstarting engine,remove fuelpumpfuseandwait the 4 engine to 5 timesto consume stops.Crank engine until f u e li n l i n e s . fuel . Forvehicle remove pump whichcan notbe started, fuel 4 to 5 timesto consume in lines. fuse,crankengine Caution: cablesto use booster may becomeweakeasily, The battery if vehicle battery necessary. or it connect to another

[Point 2l Inspection hole cover, harness cover,fuel gauge unit harness connector removal & installation Removal . Remove the and rearfinisher detach fuelgaugeunrt connector. harness

?i..'-1 l ry 'Lcover

EN - 538

FUELSYSTEM
ENGINE / RB26DETI/ RB2OE DE / DET / CA18i/ RB2sOE

Additionalwork required: the Remove following: relief Fuelpressure pressure relief Internal hole Inspection cover Fuelgaugelimit connector Fuelpumpharness feed) Fuelhose(return, l P o i n t1 I Fuel gauge ASSY bolts installation gauge . SetO-ring fuellanksideand insert ASSYinside to figure the on in shown the the thetank.Tighten bolts right. Caution: floatandthe mustbe takennotto damage caution Extra gauge ASSY armwheninstalling ASSY f uel wheninstalling gauge ied Onlyusespecif bolts (2) Fuel pump removal& installation Removal . Loosen hoseclampon unitsideon the pumpside. pumpwiththe insulator . Liftup thepumpslightly. Flemove (PlCA) fromgaugeunitsidebracket . Remove pumpsideharness. . Detach hose. lnstallation order. . Carrvout installation in operation reverse

Handstartbolts

(3) Inspection 1. Float inspection . Place floatat the F (lever side)and E (lever upper the and downside)positions checkthe resistance.

2. Pumpinspection 1 . Apply terminal and connecter voltage harness to battery its 3 andcheck operation.
Low fuel warning lamp sensor inspection 12Vto 3.4Wtestlampor equivalent Connect and or withgasoline whitegasoline check Washsensor have 3 after approx. minules that lampdoesnotlight
elaDSed.

and or fromgasoline whitegasoline sensor Remove 3 within minutes. checkthatlamplights EN 540

FUELSYSTEM
RB26DETT RB2OE DE I DEr I CA18i RB25DE / I I ENGINE

3. FUEL PUMP REMOVAL& INSTALLATION (1) Fuel pump disassembly

Additional work required: Remove following: the

fr ral nraqcr rro raliaf

pressure Internal relief gauge Fuel Caulion: . Caremustbe taken whenhandling pump. fuel . Do notreusepumpif it is dropped. . Do not allowdirtor debristo adhereto the filter. . Do nottwistor turnharness.

[Point 1] Fuel hose removal & installation conn*o. ;:1TF,?0"' Removal ourlerhose\t^ ) tttar*tng . Raise fuelgauge ASS! remove hoses tank(marked Pump 2 in Floatarm section outlet is sjde), pumpharness fuel connector and detach gauge fuel ASSY Band
clamp.'

Installation Check fuelhosemarking, connect gauge fuel ASSy. pumpharness clampband160mm from Position and in gauge ASSYconnecting andtighten pad securely. Caremustbe takenthatfuel hoseandfuel harness turn inside tankfromthe right frontsideof vehicle do not to and cause anyinterference floatarm. with

Approx. 160mm hose

EN - 541

SYSTEM EXHAUST
ENG NE / / RB26DETT FB2OE DE / DET/ CA18r/ RB25DE

EN7

SYSTEM EXHAUST

SPECIFICATIONS

Exhaust system part inspection,warning precautions systempartsand component in . The heatresistance corrosion resistance exhaust and process, onlyusegenuine so in considered thedesign shapehavebeencarefully parts rePlacement. for Nissan surethereareno gasleaks' making part securely, . Cleaneachconnectlon andconnect converter' . Alwaysuse newgaskets the frontand rearof catalytic in gasketand nuts' connection . Alwaysuse newpartsfor exhaust manifold . Afteiassembling part,whenwarmengine,raisespeedto 2,000to 3,000rpmand each gaps' or leaks sealing compound sealing makesurethereare no gas leaks, panels.lf in . Replace deformatron heatinsulation extreme partsrather than repairing cleantheseareas' amountof dirthaveaccumulated' extreme and clearance no panels, . Whenattaching makesurethereis adequate heatinsulation pipes. exhaust belween erence interf

EN - 542

EXHAUSTSYSTEM
RB26DETT RB2OE DE / DET/ CAI Bi / R825DEENGINE / /

EXHAUSTPIPE,CATALYTIC CONVERTER HEAT PANELTIGHTENING & TORQUES (1) CAl8i ENGTNE

N u t( 3 )4 . 6 - 6 . 1

0 . 5- 0 . 7

Bort el {a)
A/T

(21 RB20E ENGTNE

M / Tr Nut(3)4.6- 6.1gl t l u tt Z l+ . a- S . O P

"

, " gl trorrrct 9 B o l ( 6 ) 9 9 9 9 a 4 4 - 5 6 ^1"/ t t"/

-. Bon (2)p

Bolt(6) 0.5 - 0.7 N u t( 2 )1 . 5- 1 . 9 JiR

::i'.':l; |3} Bo't(2)g ::- V 4 4 5 b A/ri&

gBott (2) i'"t- i;

Eror l!.1

.f4

*)'l/
(3) RB20DE
M/T Nut(3)4.6- 6.1$) ( N u r 2 )4 . 4- 5 . 6 9

u'h'o

Bolt(6)0.5- 0.7g|
N u t1 6 ) 1. 3 - 1 . 6 \ - /

lt 9l ruut g - 't.6
View A

Nut1.3-1.69

(4) RB20DET
Nu t ( 3 4 . 6 - 6 . 1 M / T )

^ N u t( 2 )4 . 4 -

---i=,

A/r

glBoro.5-0.7
Bolt(6) 0.5 - 0.7

d'i-

,r, 121 - r.sg r.s

4 . 4- 5 . 6
0 . 5- 0 . 7

(2) Bort I

BoltI /1.3 1.6

Bolt(2)Pl 4 . 4- 5 . 6 Nut1.3-1.6gl

EN - 543

SYSTEM EXHAUST
E I R B 2 6 D E T/TR B 2 O ED E I D E T I C A l 1 i I R B 2 5 D E N G I N E

(4) R826DETT E N G I N E
( N u r 4 )4 . 6- 6 . 1 I
Nut (2) 4.4 - 5.6

o l t0 . 5 - 0 . 7

9lBott (2)4.4- 5.6

Bolt(4) 0 . 5- 0 . 7

Nut(2)pl

Bot1.3-1.6 Nut1.3-1.6

u'"Jo fil'-(]ue
ENGINE (5) RB25DE
M/T
Insulator

ry1s-16

Srp
- ' r . s- 16 _-1 q/i-;-, 3 4round ine
rubber N,4ounting

Insulalor

- tzt !9lo.s o.z -0

.,::p 1.3-,r.6(2)ggggg

Pta

e' z '

' *; , ::";;*ir.9,"",,!,::it:is\ .-rli,^, ca^o p1

..
-'

,'::::1", $Foo,u'i)

r.oP

1.3 169

!'1--rs-rog

f,:l:r*:;',"o,'
, ,t'i-'
4.6- 6.1 {3)F) /
*' rrsu'alor { I n s u l a l o r 0 . 5 - 0 7 ( 6 ) '[ q '

-o5:.01gl

Clamp

rrn"r.t ten'o sensor

t , .

i'-""*'n-'"

A/T tnsutalor

o.s2 0.66p:

EN - s44

EXHAUST SYSTEM
R B 2 6 D E T/TR B 2 O E D E/ D E T/ C A 1 8/i F B 2 s D E N G I N E / E

2.

EXHAUST GAS TEMPERATURE WARNING EQUIPMENT INSPECTION

Basic inspection . Placeignrtion switch ON position check to and that gas exhaust lemperature warning lampdoesnotturnon. . Exhaust temperature gas warning lampmustlight when ignition switch placed START is position mustgo at and offwhenengine staned is Exhaust gas temperaturewarning lamp replacement and inspection . Remove vehicle harness fromswitching module. . Useleadlineto ground vehicle sideharness connecl gas exhaust temperature warning lampterminal. . Inspect condition exhaust temperature gas of warning lampwithignition switch turned ON.
Faulty circuitbetlveen ignition switching module. Faulty sensing key module sensor. or

C A 1 8E N G I N E i

gas Exhaust temperature warning lamp burned ,s out. gas Exhaust temperature power warning lamp circuit faulty. is

EN - 545

ENGINE coNTRoL / R B 2 6 D E r/rB B 2 0 ED E/ D E r / c A l B i i R B 2 5 D E N G T N E

EN8
1.

DEVICE) (INCLUDE ASCD CONTROL ENGINE

cAl8i
Locl( nul 0 . 8- 1 . 0

AND PEDALINSPECTION ACCELERATOR ADJUSTMENT Acceleratorpedal i nsPection pedalis . The engine whenaccelerator mustbe fullthrottle the pressed fully(pedallevercontacts stopper completely). Acceleratorpedal adiustment . Loosenlocknutsso accelerator cablehas adequate pedal R B 2 O E of outercasein direction accelerator slack.Pull (there drumstarlsoperating wherethrottle tromposition . ia--- I ,^ ^^^ locknuts1.0to 1.5 return mustbe no playat thispoint), securelY. andtighten turns

'ThrottLe.drum

Locknut 0.8 - 1.01 F,ont

RB2ODE/DET/RB25DE

Kickdown switch adiustment (RB engine A / T vehicles) . Pressaccelerator drum. Adjust pedalto fullyopenthrottle 0.3 locknutso the gap is between to 1.Omm.

0 . 3- 1 . 0

E N- 5 4 6

ASCD
RB26DETT RB2OE DE / DET/ CA18i/ FB2sDEENGINE / /

2.

ASCD

Specification
Speedsetting range Constanl speedcontrol range A p p r o x5 0 - 1 0 0 k m h . / Levelroad+0 I -2 km I h

Memory type Digitalmemory Control type. actuator dnver source Negative oressure control. negative pressure pump Actuator stroke Approx.33mm Setsystem (with downsystem) One-touch system tap
Resume system Acceleratjon system Overdrivecancelsystem Installed Installed (wrth up system) tap Installed

System
A / T VEHICLE

swltcn

Clulch s wi t c h

Brake swrlh c

* l
|,-J ASCDcontrol unI

Eq:T[qilil t l i t l l7 t t 5 t4 t8
horn retay

t-i

ASCDrelay
3l -. 5

-------&{1*a " *-

fA

ffi

ASCD main

#e
d

iFGl
1 4 5

illrlal

Stoplamp l

t1

ASCD controlunit

Set,' coas swilr

AND ADJUSTMENT 2.1 ASCDINSPECTION (1) FAULT DTAGNOSTS

*rl """ I r*, I R

l

il&*
Faulty adjustmeni parts orfaulty t circu lvlain unit lnsrde faulty faulty val\, Faulty [,4ain unit diaphragm faulty faulty

:::i:-:t:::

gPFhrrpsW ,,irbidir, $iq!! 8w(!nr[ ] W:a,,:' tlw htdbltor (A/D' ierXtOf-

t|YY'
wiring. harness ASCD system drsconnection, PiPtng 0lsconnectlon
I @
l\)

Does not operate

Faulty

/ Resume set/ coasl SW accelefator SW faulty faulty

Hunting

actualor Pip ng breakage, unit circurt [,,lain lnside FaLrlty fesponse meterresistancefaultysPeed faulty faulty caole meter lnside cifcurt M a i nu n r t leak Diapfgramn faulty faulty u lnside crrcurt M a i n n i t Catchor leaklng ramn d iaphg faulty faully Faulty speedmetercable

o m

Cancel

Setting u nstable

Large gap between set vehiclespeed

Actualor catcn wrre

(n

m tl m o rn *l wire actuator Faulty falltyprprngs adjustment cloggrng w Actuator re locktng

Vehiclespeed decrease when setting

unrt Inside crfcuit [,4ain faully faulty

Does not cancel

lnside circuit Mainunit faulty laulty

o = a

o m rn z

s z

TT]

ASCD
RB26DETT RB2OE DE / DET/ CA'l8 / RB25DE / / ENGINE

INSPECTION MAINTENANCE & PROCEDURE WHENIT CAN NOT BE SET

DoesmainSW lampturnON when mainSW is restored afterit ts turned OFFonce.

powersupply relay, circuit

TurnsON Faulty

Check controller ground any for faults(between terminal and 3 groun0).

Faulty harness, inspection

than Replace Other faultystoplampSW, Check power for (approx. approx. 12V voltage SW(lV/T), clutch relay 12V) controller ' 3, 5 - 3 to jnhibitor (HICAS 14 I\4/T), SW.relay (other eN forA/T)l than (A,T)
Approx. 12V Power voltage present is whenSer / coastSW is ON (Approx. 12V) (between - 3) 7 Approx. 12V Power vollage present vehtcle Otherthan is at speedsensor(between - 3) 7 5V and0V lnspect vehicle speed sensor (Approx. and0V alternatively) 5V system. whenwheels rotated (1 are siowly Replace faultyset / coastSW.

present Continuity

Approx.5V & 0V
DisconnectASCD pump operare connector appiybattery and vollage between terminal - 3-. Checkil 1+ ASCDwirewilloperate when t e r m i n a la n d 2 i s 4

Donot

Remove actuator noseandoperale the pump. Checkif negative pressure oeverop.

Operate
power Control voltage l2\. tapprox. , ls developed between terminal I and3, whenvehicle speedis over 48km/hand seUcoast is ON. SW

Approx. 12V
Remove controller connector and checkif pumpoperates when12V and0V is applied vehicle to side harness whichcorresponds to controller terminal and body 8+ ground, terminal and 9,1 8+ 0-. Operate Do not operate

Repair iaultyharness the pump to or shortcircuit.

Otherthan Checkif set power voltage is OV approx. between 0V terminal and 2 3 whensercoastSW is released. Approx.0V

EN - 549

ASCD
/ / RB26DETT BB20E/ DE / DET i CA18r BB2sDEENGINE

IS WHEN SETTING UNSTABLE PROCEDURE & INSPECTION MAINTENANCE (HUNTING) SETTING UNSTABLE
Damaged No damage is Checkif ASCDwiremovement Smooth pressure in for any leakor negative valve. pumpairvalveandrelease No leakage Checkfor any leakor negative valve. andrelease in airvalve Notcracked pumpconnector and DisconnectASCD 1 terminal + between voltage applybattery when 3-. Checkif ASCDwirewilloperate 4 terminal and2 is grounded. Operate Leaking Replace faultyASCD pump Not smooth

Cracked
hose actuator Remove the PUmP. andoperate Checkif negative pressure develop.

IS WHEN SETTING UNSTABLE PROCEDURE & INSPECTIONMAINTENANCE (cANCEL)

SETTING UNSTABLE

12V Thereis approx. I terminal present between and 3 whenset SW is placed romON to OFF f position.The system

Voltagebetweenresume/ 1 termlnal switch accelerator and 3 is 0V. with ls thereany abnormality Abnormal

ASCD faulty Replace switch.

speedsensor vehicle andmetercable.

No abnormality (approx. and0V) is 5V voltage Power vehicle between alternatively applied 7 terminal and3, when speedsensor at wheelsare rotated 1 - 2km/h.

5V Approx. & 0V
pressure Leaking Checkfor leakandnegatlve valve. in airvalve andrelease Faulty controer

EN - 5s0

ASCD
RB26DETT RB2OE DE / DET / CAl8i / RB25DEENGINE / /

INSPECTION MAINTENANCE & PBOCEDURE WHEN SETTING UNSTABLE IS (DIFFERENT SET VALUE) TO SETTING UNSTABLE
Largedifference to settedvalue Nocatching
Checkfor any bent,damage to prprng. vacuum
No damage

Replace damaged vacuum piping.

ASCDpump,airvalveandrelease

va,ve neoative for oressure leak. and Noleakage

pressu for Check any leakor negative Replace faulty ASCDpu in airvalve andrelease valve. Notcracked Qperate Disconnect ASCDpumpconnector and abnormally Replace faultyASCD g r o u n de r m i n a1 + - 3 - 4 , 2C h e c k f t l . i pump.

Operate normally
Faulty controller.

INSPECTION MAINTENANCE & PROCEDURE WHEN SETTING UNSTABLE IS (Plungein vehiclespeed)

SETTING UNSTABLE
Plunge vehicie in speedwhensetting Checkif ASCDwire playis Notcorrect or smooth Replace adjustASCD or

playand smooth Correct pipesfor bentor Checkvacuum damage. Nodamage Other Thereis over10Vcontrol voltage than'12V forcontroller output between terminal and 3 justaftersetti 8 A p p r o x1 2 V . Disconnect ASCDpumpconnector andground terminal - 3-4,2.Check 1+ if ASCDwirewilloperate normally. F a u l t A S C Dp u m p y

EN - 551

ASCD
E / R B 2 6 D E T TB B 2 O E D E / D E T / C A 1 8 i /B B 2 s D E N G I N E /

INsPEcT|oN&MA|NTENANCEPRoCEDUREwHENAccELERAToRDEVICE DOESNOTOPERATE

speed Checkif constant using will device operate set/coast SW.

Doesnot

Operate
Whenstopptng Place SW ignition in ON position with mainSW ON position.Do not pressbrakeandclutch lF (OFFposition). A,/T placein D range vehicle, andapplyparkbrake. 1 aPProx. powervoltage Otherthan 12V SW / present whenresume accelerator in (0V 1 terminal and3) ON Dosition between Otherthan OV

1 is Checkif powervoltage 0V between SW / when resume accelerator is OFF

c q W h i l e r u r s i nA S C D

Do not tor urnoffthe mainswitch when Checkif speedwillincrease increase andturn it on few seconds SW / resume accelerator is Placed

inONposition.

faulty rfspeedwillincrease Do not Replace / and whenresume accelerator tncrease controller speed vehicle SW is turnedto ON Position sensor.

Do not will Checkif lhe vehicle cruiseat cruise whenresume sPeed vehtcle normal SW / accelerator is turnedOFF

Checkif vehicle speedwillincrease vehicle to high-cut ( / speed 100kmh). Do nol increase

faulty Replace and controller speed vehicle sensor.

EN - 552

ASCD
R B 2 6 D E T/TR B 2 O E D E/ D E T/ C A l 8 i/ R B 2 s D E N G I N E / E

INSPECTION MAINTENANCE & PROCEDURE WHEN RESUMEDEVICE DO NOT OPERATE

Besume device do not ooerate
Doesnot Check constant if speed device operate will using sevcoast SW. Operate | Inspect following stepsof the "Can notset".

| l OheckrfpOWETVoltage approx. 12Vis Otherthan 12V r rma / a.^alar^l^|" qW in I I ipresent \r l p o s i t i o w i t hm a i nS W r n l | |ON positil (0V between n rn terminal and3) 1 ' . I O Np o s i t r o nD o n o t | | '12V Approx. lpressbrakeandclutch [-l Otherthan

r q l w h e n s l o p p r np l a c e

SW lrsnition rnoN

positron). lFA/I I I r l(OFF oltage 0Vbetween is 1 place Drange | | in lvehicle. | when resl m e / a i ccelerator is OFF SW park apply brake. I l! land

OV

Repa faultySW ir

wilffi;s-_-l

OV Set vehicle speedto 80km/ h usingset / coastSW.

Break(l\4ake surethe vehicle speed w i l ln o tg e t b e l o w 8 k m/ h ) . 4

Checkif the vehicle speedwilldecrease when Do not decrease Replaceaultycontroller. ([/ake surethe resume SW is turnedON f vehicle speedwillnotget below48km/ h) Otherthan Checkif thevehicle : Otherthan oerow Speedhasde( )reaseo to willreturn set vehi e to c 80km/ h 48km / h Replace faulty speed(80km/ h) wh 'I controller. resume is t u r n e d N SW O resumeSW is turner O F F Below48km/ h 80km/ h Normal Decrease

EN - 553

ASCD
E i / B B 2 6 D E T / R B 2 O E D E/ D E T/ C A 1 8 / R B 2 5 D E N G ] N E T

WHEN IT CAN NOT BE PROCEDURE & INSPECTION MAINTENANCE CANCELLED

SETTINGCAN NOT BE CANCELLED
terminal and3 5 ls voltage between (in is operated N 0V whenbrake

ge is present between 11and3 whenbrakeis

stoplamPSW Inspect and replace

is if output cut Check controller (8 brake betlveen and3)when pedal pressed. is

Jault. ls therean actuator shortcir ls thereharness actuator and Inspect replace harness. and Inspect replace

INSPECTION (2) FUNCTION if and the . ASCDfunction out is inspection carried by driving vehicle checking each circuit system ASCDcontrol inspection In normally. thisf unction will function operate usingfreeroller. is function inspected Caution: driveon the free roller.Use by drivecan not be achieved ASCDas it is non-load Constant out whencarrying fault on depending eachproblem (1)fault as diagnosis a reference diagnosis. that and in . TurnoN the mainswitch is switch placed oN position check whenignition will lamP turnon operation Caution: if relay the lampdoesnotturnon. oTASCD withmainswitch Thereis a fault speed(60kmih) and . checkthatthecruise at lampwillturnon whendnving a constant for will speed increase Checkif thevehicle is to set/ coastswitch placed ON position. when can notbe achieved drive lampwilllurnoffandconstant cruise a moment, position the at pedalis released and set / coastswitchis placedto oFF accelerator sametime. Caution: as will will hunting occurandASCD be cancelled it is non-load is lf ASCDcircuit normal, dnve. whenthebrake . checkthatthecruise is lampwillnotturnon whensetswitch pressed (brake stoplampswitch:ON)'drivingat a switch:OFF, pedalis pressed slightly whenthe will speed notincrease (60km/ h). Makesurethevehicle speed constant at pedalis released and set switchis placedto OFF position the same accelerator inspection). function time(release EN - 554

ASCD
RB26DETT RB2OE DE / DET/ CA.l8J FIB2sDE N G I N E / / / E

(3) COMPONENT PARTSINSPECTTON Controller inspection . Extract controller removing the by controller bolts. Inspect ASCDcontrol systemusingcontroller parts.lf connector diagnosis result faulty is replace controller the unit. Controller (ground circuit) inspection . Check continuity the between terminal andbodyground 3 withconnector connected
Between termrnal and booygrouno I 3 present Conttnutty

(power Controller circuit) inspection . Inspect power voltage between followrng terminals with connectors connected.

Controller (cancel power supply input) inspection .11 . Measure voltage the between terminal and3 when connectors connectec. are

Controller (set / coast switch input) inspection . Place ignitjon switch ON position. to Measure the vollagebetween terminal1 and 3 withconnectors connected.

EN - 555

ASCD
E / D F B 2 6 D E T TF I B 2 O/E E / D E T/ C A I B i/ R B 2 5 D E N G i N E

Controller (resume/ acceleratorswitch input) inspection . Placeignition the and switch ON position measure to Renl oash srdelowerfinls terminal1 and 3 withconnectors powervoltagebetween connected.

(vehicle speedsensoroutput)inspection Controller . Slowly the wheels measure voltage and the rotate rear connected. connectors 7 terminaland3 with between
I nopro, 5V and0V ahermatrvely

(cruiselampoutput)inspection Controller . Measure voltage 13 terminal and3 with between the connected. connectors

"" *"n.jllniil_|"'::",,"::,.,
\e\ \ \

/ /---2-

V{- r'E-Y.
lRr ti J)

-r-

lr]]] t3F-11

Controller (A/T control unit control output) inspection [A / T vehicle] the . Drive(ASCD possible and measure range) set terminal12 and 3 withconnectors voltagebetween connected.

Note: when ls ASCDcontroller prroritized WithA/T shiftcontrol, setat ASCDdrive.

E N- 5 5 6

ASCD
E i / R B 2 6 D E T/TR B 2 O E D E/ D E T/ C A 1 8 / R B 2 5 D E N G L N E

Brake,clutch & stop lamp switch inspection . Disconnect each and connector operate harness following between continuity to inspect switches terminals.

ASCD relay inspection . Remove voltage applybattery ASCDrelayand directly between the 1 terminal and2. Check continuity between 3 terminal and5.

Clutch relay inspection (HICASM/Tvehicles) . Checkthe continuity when terminals following between terminal1 and appliedbetween voltageis directly battery
c

Front

Inhibitor (N.P)relay inspection(A/T) . Check continuity when terminals following between the terminal1 and appliedbetween voltageis directly battery 2.

+Front

EN - 558

ASCD
RB26DETT RB2OE DE / DET/ CA18i/ RB25DE / / ENGINE

ASCD pump inspection . Remove connector terminals. Check motor the operation by directly applying battery voltage between terminal 1 a n d4 .
Applybattery voltage betweebn terminai and 4 1 Motorwilloperate

Resistance inspection
, ' l ' r '

r temfinak ,,
A r rv a l v e - 4 1
Release valve '1 - 2

:r:.1.1..
Approx.70 Approx.70

Vacuumpumpl-3

Approx.8

Operationinspection . Applybattery voltage between terminal and3(-)and 1(+) checkif ASCDwirewilloperate whenterminal and2 is 4 grounoeo. RB2OE ASCDwire adiustment . Loosen locknutsso ASCDwirehasadequate slack.Pulloutercasein direction actuator of from position wherethrottle drumstartsoperating, returnlock nutsapproximately 1 turns andtighten securely.
L o c kn u rt r g h t e n r no r o u e k g - m ) tg { | 0 . 8- 1 . 0

Accele;i;;;;; Lock ul .8-101Fronr n 0

RB20DED E T I

...''.

EN - 559

ENGINEMOUT.ITING
ENGINE / / RBA6DETT R82OE DE/ DET/ CAI 8I / BBASDE

iIOUNTING ENGINE
MOUNNNG FRONTENGINE (1) CAl8r El{Gll{Es (2) RB ENGTNES
Nrt (2) Nr, (2) 1.1

MOUNNNG REARENGINE (1) CAl8l ENGINES FB ENGINES

Nd (2) 22 - 2.9

EN:560

lndex
Symbols
Gl-13 i 2 - p o l le f t. . . . . . . . . . . . . . Gl - 15 4WD inspection . . r 4 W Dr e p a ip r e c a u t i o n s . . . . . . . . . . . . . . . . . .G.l.-. 1 5

E
. . . . E N- 2 3 1 . ECCS................. E.. . . . . . . . . N- 2 3 3 C E C C S / Ui n s t a l l a t i o n . . . . . . . . . . ( B B 2 s D E . . . . . . . . . . . .. . . E N - 4 8 5 ) r ECCS elay , . EN-233 Eccsvoltage...... l E m i s s i oc o n t r oe q u i p m e n.t. . . . . . . . . . E N 7 n -546 .... EN Enginecontrol . e l u i p m e n t. . . . . . . . . .E N - 5 2 9 q e Engine lectrica .. . . EN- 560 Engrnmounting e . . E N- 1 B o . E n g i n o v e r h a u.l . . e s n. E n g i n e p e c i f i c a t i o . .s. . . .. . . . . . . . . . . E N 7 - 254 . . . . . .... . . . E N s Engine tall sensor. EN - 367. 396' 482 temperature Engine E v a p o r a t i v e g a s c o n t r o | . . . ...... . . . E N 5 4 , 4 8 8 . - 3 8 6 , 3 9 0 , 3 9 2 ,4 1 5 E x h a u s t g a s s e n s o r . . .E.N . .. gas Exhaust sensorheater'.. . .. . . . . EN 434 equipment. . EN -545 gas Exhaust tempwarning . . . . E N- 1 5 9 E x h a u sm a n i f o l d t d E x h a u sm a n i f o lA S S Y. . E N - 7 5 , 1 0 9 , 1 1 9 ' 1 4 2 t . E N- 5 4 3 p E x h a u s ti p e . . . . . . . . EN- 49, 542 E x h a u ss y s t e m . . . t

B
. . . . . . .E.N - 6 8 . u B a l a n cte b e . . . . . . . . EN-236. 272 Basicinspection . .. EN - 530 inspection Battery . . EN-43 Belttension......... E . ...... . . . . . . . . N - 5 5 ' 4 8 9 Blowbycontrolvalve..... gas reduction device... .. . .... . ... EN - 55 Blowby . . . . . . . . . E N- 4 8 9 h Blowby ose ....G| -13 Board-onlift......... . ... . .G|-'15 . c B r a k i np e d o r mh e c k . . . . . .. . . g

F
ASSY .. .... .. . . . . EN - 69 turbocharger Front . . . . . . . . . .E N - 5 3 9 Fuelgauge ' . . . . . . . . . E N- 1 5 6 injector Fuel . n F u e lp r e s s u rie s p e c t i o n. . . . . . . .. . . . . . E N 5 3 F u e | p u m p . . . . . . . . . . . .. . E N - 3 0 3 , 3 0 7 , 4 4 0 ' 4 8 3 .... EN - 52, 486, 537 Fuel system . . . E N- 5 3 7 Fueltank.............. r f v F u e t a n k a c u u me l e av a l v e . . . . . . . . . E N - 5 4 l . . . . . . . . E N- 6 6 ... A F u et u b e S S y

c
'. .. EN - 543 converter Catalytic . . . .. . . E N - 2 7 9 C i r c u id i a g r a m t E N - 5 9 . 1 0 5 1 0 6 ,1 1 5 CollectorASSY . inspectlon {RB25DE) .. . EN - 482 Components . pressure inspection .. . .... EN - 42 Compression . . . . . . . .E N - 8 0 . Conicalwasher..... i n s l a | 1 a t i o n . . . . . . . . . ... .......... . E N - 2 3 3 Connector .. .. . . . G| - 6 symbol Connector GI- 11 . . . . . . . . .. . CoNSULT C O N S U L T d i s p ls c r e e n . . . . . . . . . . . . . . .. E N 2 6 5 ay C r a n k a n g l e s e n s o r . . . E N. 3 5 5 ' 3 5 6 ' 4 0 4 ' 4 4 2 ..... EN - 83, 85, 170 head Cylinder

G
. G a sl e a ki n s p e c t i o.n . . . . . . . . . . . . . . . . . . . . . E N 7 5 G e n e r a l p r e c a u t i o n s . . . . . . . . . . ... ....... ... ...G l - 7

H
. .. EN-543 Heaterpane|......... . .. . .. .. . .. . . . . . . . G l - 2 Howtousethismanua|. . H y d r a u l iJ a c kl i f t i n g . . . . . . . . . . , . . . . . . .. . G l 1 4 c

I
. . .. .. EN - 23 ratio ldlemixture ldlespeedcontrolsystem. . .... ... EN - 339' 346 EN- 23 i l d l es p e e d n s p e c t i o n . . . . . . . . . . . . . . 5 .. EN-483, 32 1 g n i 1 i o n c o i | . . . . . . . . .. .. .. ....... . .. EN-328 n l g n i t i o in s p e c t i o n .. EN- 486 l g n i t i or e l a y . . . . . . . . . n . . . . . .. E N - 4 2 4 l g n i t i os i g n a l n EN-330' 332' 412 lgnitiosystem..... n i n t i m i n gn s p e c t i o . . . . . . . . . . . . . . E N - 2 3 lgnition inspection... .. . .. .. . EN - 237 system Individual . . E N- 4 8 6 re lnhibitor lay........ -.3 .14. ' 3 1 7 , 2 3 '4 8 4 3 .r . . 1 n j e c t.o . . . . . . . . . . . . . . . . . .E.N. . .

D
... . .. . . EN - 267 Datamonitor control . EN - 527 exh Deceleration gas emission D e t o n a t i o n s e n s o r . . . . . . . E N . . .8 1 ' 3 A 2 4 1 7 ....-3 . . D i a g n o sc s a r t y p h e n o m e n o n . . . . . E N - 2 4 0 ih b D i a g n o s i s p r o c e d u r e . . . . . . . . .. . . . . . . E N - 2 3 4 D i a g n o s t i c s y s t e m . . . . . ... . . . . . . . . E N - 2 5 9 D i a g n o s t i c w o r k s h e e t . ... ... ..... . . . . . . . .E N 2 3 4 . . . E N- 2 7 4 . D O H C. . . . . . . . . . . . . . . . .

EN - 562

I n p u s i g n a l s n dc o n t r oilt e m s . . . . . . . . . . . .E.N. 2 3 9 t a . .po lnspection ints.. . . . . . . . G l., 1 6 .. I n t a k e i r t e m p e r a t us e n s o r . . . . . . . . . . . . .E.N.-.3 7 8 a r . . l n t a k e m a n i { o | d . . E N . 6 5 , 1 O 7 ,1 1 7 . 1 3 7 , 1 5 7 .... I n t a k e a n i f o lc o | | e c t o r . . . . . . . . . . . . . . . . . E N - .i.5.3 m d ..... . I n t a k e a n i f o lv a c u u m. . . . . . . . . . . . . . . . . . . . . . . . .2 7 5 m d . E N- . Intercooler . . . . . . . . .E N- 5 7 . 1 3 1 .. I n t e r c o o l a i rd u c ta s s e m b l y . . . . . . . . . . ..... E N - 5 6 er . . l n t e r c o o li e r eh o s e . . . . . . . . . . . . . . . . . . . . . . . . . - .5 6. . . nl t . EN. ..

R
R a d i a t o r pi n s p e c t i o n . . . . . . . . . . . . . . . . E.N.-.5.3 . . . . ca . . . .4 Radiator inspection ..... EN - 534 F e a r u r b o c h a r g e rS Y. . . . . . . . . . . . . . . . . . . . . N - . .0. t AS E...7 . R e c i r c u l a t ih o s e on . . . . . . .E N - 5 7 . R e c r r c u l a t i o n v en s p e c t i o n. . . . . . . . . E N - 5 0 . 5 7 vai i .. ... R e m o v a n di n s t ae ln g i n e . . . . . . . . . . . . . . .E.N.-. 18.0 e l . . .. . Rocker cover EN - 76, 120, 169

J
14

s
EN - 353 110, 43 1

EN-47 EN.47

M Measurement tools
Multipurpose tools N EN-12 EN - 12

Self-diagnosis ..... - 236. 262 EN S e n s os y s t e mn s p e c l i o n . . . . . . . . . . . . . .E.N. .3 . .4. r i . .- .5 . S i xi n - l i nte r o t t lce a m b e r . . . . . . . . . . . . . . . E N-. 6.3. . h h .... . . S p a r kn s p e c t i o n i . . . . . . . .E N - 2 7 4 . Sparplug............ k E N - 7 6 . 1 2 1 .4 8 6 S p e c i a le r v i cte o | s . . . . . . . . . . . . . . . . . . . . . . . .E .N. .I. . . . . s o . .S p e e d o m e t e r m e a s u r e m e n t . . . . . . . . . . . . . . .l.-.'.1 . . . . . . . G 5 -436 S t a n i g n a. l. . . . . . . . . . s . . . . . .E N . S t a r t em o t o r . . . . . . . . r . . . . . . E N- 5 3 1 . S u be l e c t r i c a l f a n s p e c t j 0.n . . . . . . . . . . . . . . . .N.- 5 3 6 i . E . S w i n v a l v e o n t r o l l.e r . . . . . . . . . . . . . . . . . . . .E .N- .7 3. . . g c .. . .. .. Systemiagram.. d . . . . . . . .E .N - 1 3 . S y s t e mi g u r e . . . . . . . f . . . . . . E N- 2 7 9 .

T Tensionerspring .... ....... - 80 EN

T h e r m o - w ia x p e c t i o n . . . . . . . . . . . . . . . . . .E .N. .5 . . . . . . ns . .- .3 - g.A.,.1 2 7 . 1 4 8 ,5 3 6 T h e r m o s t a t . . . . . . . . . . . .E N . . . . .... T h r o t r lb o d y S S Y . . . . . . . . . . . . . . . . . . . . . . E N-. . .3 9. . . e A .... 1 .. Throttle sensor EN - 371, 373. 419, 484 T h r o t t l e v a l v e i t c h . . . . . . . . . . .E.N - 3 6 7 , 4 3 6 . 4 8 3 . . .. sw Tightening rque To . . . . . . . . .G. - 1 3 .. l T i m i n g e l t. . . . . . . N - 7 8 , 8 2 , 1 1 1 ,1 2 2 . 1 4 4 . 1 6 0 E b Towing.................. . . . . . . . .G.l.- 1 3 . T r o u b ld i a g n o s i s e . . . . . . .E N - 2 3 1 . T u r b o c h a r g e r A S S Y . . . . . . . . . . . . . . . . . . .E.N.-.6.8 . . . . . . . . T u r b o c h a r g e r f a i l u r e d i a g.n o.s.i . . . . . . . . . . . . . . 7 4 .. . s ENT u r b o c h a r gi e r p e c t i o n. . . . . . . . . . . . . . . . . . . .E.N.-. 4.9 ns .. . . . T u r b o c h a r gu n i t n s p e c t i o.n. . . . . . . . . . . . - 7 1 , 1 3 4 er i . EN

U
. . . . . . . . . . . . . . . . . . . . . - . .3 1 E N. 5 . EN - 251 . . . . . E N- 2 4 7 . ..EN-447,486 E N- 4 0 1 E N- 4 8 3 . . . . . . . . . . . . . . E. N.-. 2 3 5 . . . U n a b l eo s t a r t t d U n s t a b lie l i n g . . . . .E N - 2 3 9 . 4 2 . . . . . . . . . . .E.N - 2 3 4 .

V
Vacuumiagram d . . . . . . . . .E.N - 1 9 . V a l v e l e a r a n cie s p e c t i o.n. . . . . . . . . . . . . . . . .E.N - . 5 c n . . ... 4 V e h i c l ed e n t i t i c a t ip ln t e o c a t i o.n . . . . . . . . . . . .l .- 10 i oa l . G V e h i c l s p e e d e n s o r . . . . . . . . . . . . . . . .E.N.-. . .9 7 . 4 3 0 e s . . 3

EN- 352

w
W a s t e g a tv a l v e o n t r o.1 . . . . . . . . .. . . . . . . . . .E.N - 3 5 0 e . . c W a t e r y p a s s o n n e c t o.r . . . . . . . . . . . . . . . . . . .E N - .6 7 b . ..... . c W a t e r u t l ee l b o w o t . . . . . . .E N - 6 7 . W a t ep u m p r . E N - 9 6 , 1 2 6 ,1 4 7

EN - 563