R32 ENGINE MANUAL.

CA18i, RB20E, RB20DE,

RB20DET, RB25DE & RB26DETT
 GENERAL INFORMATION

SECTION GI
GENERAL INFORMATION

CONTENTS

HOW TO USE THIS MANUAL ................................................................................... GI- 2

GENERAL PRECAUTIONS ...................................................................................... GI- 7
VEHICLE &UNIT IDENTIFICATION PLATE LOCATION .......................................... GI - 10
CONSULT ...................................................................................................... GI-11
TIGHTENING TORQUE OF STANDARD BOLTS........... ................ GI-12
TOWING .............................................................................................................. GI- 13
4WD INSPECTION & REPAIR PRECAUTIONS ................................................... GI- 15

GI-1
 GENERAL INFORMATION

HOW TO USE THIS MANUAL

MAINTENANCE OPERATION EXPLANATION
This manual describes important items for installation removal, assembly, inspection, repair
and failure diagnosis,

Caution:
A general description of a visual inspection and cleaning of disassembled parts has
generally been omitted, However, when reusing the parts, make sure to perform visual
inspection and cleaning as necessary.

CONFIGURATION COMPONENTS, OPERATION CONTENTS & PROCEDURES

The configuration components, operation contents and procedures are shown after the title
of each operation. Preparation standards and important operation points such as parts
which can not be used again. tightening torque and lubrication locations are also indicated.

Configuration components & Operation contents

The operations for installation. assembly and disassembly are indicated by the part name.
This description is used when the ideal procedure can nol be determined or there are many
types of components.
[Point] is used to indicate the operation procedures which are necessary.

Example: Front Axle disassembly & assembly

-:lEi Inner grease seal

I
_Innerbeanng - Outer bearing outer race
; outer ~e ! (C!) Screw (3) 0.3 - 0.4

o~ ~~\.
\~ ~'
IJJ),
[I

I
(C!)
~
Bolt (4) 2.5 - 3.4
DIsc rotor
::c~ Al\;' :111" ,; ~. Spacer (POint 1)
Ell I '\L!~ i-.(.(~<, ,l.. "~'. '>:lEll Outer grease seal
Inner bearing I "'.'1_. H b b It
Knuckle
B,ffie ~,,:' I.!:(t;' '~ fJ~ 0

kg - m Ell Outer bearing ~

Should be lubricated with grease.
Use recommended mUltipurpose grease Wheel hub
Can not be reused

Unit definition
The unit of measure used in this manual for tightening torque is described in "81 measure
(International unit)" and the units within { } is in meter unit.
Example: Tightening torque: 59 78 N-m {B.O - 8.0 kg-m}

I Meter measure
SI measure

GI-2
 GENERAL INFORMATION

STRUCTURAL PARTS DIAGRAM AND OPERATIONAL SEQUENCE

The name of the parts required for the operations are shown, The operation sequence must
be followed in the order shown,
Assembly is the reverse of disassembly except when otherwise indicated,

Example 1: Light combination switch ASSY installation and removal

1, Steering wheel ASSY

2, Screw (1)
light combination switch ASSY

3. Screw (5)
Connector
Shell cover

SYMBOLS DESCRIPTION
i
Operation where the torque should be checked and the

~
standard torque value that should be used,
When X to Y N.m (kg-m, ft-Ib) is indicated, the standard
tightening torque is the mean value.

m Should be lubricated, Indicate a type of grease

~ Parts that can not be reused

~ Should be lubricated with oil

~ Sealing point

* Select proper parts

i Adjust parts
i

*~
I
, Part need to be checked visually

GI-3
 GENERAL INFORMATION

Example 2: Fault diagnosis flow chart (RB25DE VEHICLES ONLY)

/3 ,1
A ~ r . ._--,
-.- ~--...- - - - - - - - . NG . Check the following
I CHECK POWER SUPPLY.-----c items.
; 1) Turn ignition switch "OW. i 1) Harness continuity
I·

"2) Check voltage between I between camshaft

terminal B and ground. I ! position sensor and
Battery voltage should : ., battery.
~':.Xlst ..._ _ _ 1 2) ECCS relay.
, 2 I . 3) Fuslole link.
10K ; 4) Power source for

b~~~~n SWlt(;~_. __
B
:1) Turn ignition switch
;M h Disconnect camshaft . Check the following
items. :
i • PiOlcrO, Disconnect
,,-, £;!.' I pOSition sensor harness ~ 1) Harness continuity 1
, connector. between camshaft &
~,,-'
, P) Check resistance betwee ground.
, I terminal D and ground. 2) Ground circuit for
.~.~~esistance: Approx. 0 I ECM.

'--I i OK
__ ... _ ---
1
.

HOW TO FOLLOW THIS FLOW CHART

1. Work and diagnostic procedure
Start to diagnose a problem using procedures indicated in enclosed blocks. as shown
in the following example.
A
!cHECK POWER SUPPLY. <E-- Check item being performed.
·1) Turn ignition switch "ON".
2) Check voltage between
1 terminal B and ground.
. Battery voltage should
exist.

2. Measurement results
Required results are indicated in bold type in the corresponding block. as shown below.
These have the following meanings:
Battery voltage; 11 - 14V or approximately 12V
Voltage; Approximately OV - Less than 1V

3. Cross reference of work symbols in the text and illustrations

Illustrations are provided as visual aids for work procedures.

4. Symbols used in illustrations

Symbols included in illustrations refer to measurements or procedures. Before diag
nosing a problem. familiarize yourself with each symbol.

GI-4
 GENERAL INFORMATION

Symbol Symbol explanation Symbol Symbol explanation

IV Check after disconnecting the

connector to be measured. lrlJ Current should be measured with
an ammeter

() Check after connecting the

@ Procedure with CONSULT.
i
connector to be measured.

~~ Insert key into ignition switch.

® Procedure withcut CONS ULT.

(rs"c:5J Remove key from ignition switch.

E A I C switch is "ON"
I

00 Tum ignition switch to "OFF"

position. [@ A I C switch is "OFF". !

Tum ignition switch to "ON"

@) position.
_1ft' j

C::fF::':'
.. J •

:
Fan switch is "ON".

~ 'I ".
Turn ignition switch to "START"
~;
Fan switch is "OFF". !
position.

@<ce I~l
Turn ignition switch from "OFF" to Apply fused battery positive
"ACC" position. voltage directly to components.
__ TF:\
~,
Tum ignition switch from "ACC" .~~
~... ~
Drive vehicle.
to "OFF" position.

~ ~
Turn ignition switch from "OFF" to Disconnect battery negative
"ON" position. cable.

Turn ignition switch from "ON" to -ir~

~F "OFF" position. ~~ Depress brake pedal.

7?J Do not start engi ne, or check with

engine stopped. ~ Release brake pedal.

~~
Start engine, or check with
engine running. ;;a I

!
Depress accelerator pedal.

~ Apply parking brake

~ Release accelerator pedal.

~ Release parking brake.

Pin terminal check for ECM and AIT control
unit connectors.
: Check after engine is warmed up
Cf'~H suffi ci ently.
rc-;u Connecto~
~i Voltage shculd be measured with

U"ll:~i)
~---~ a voltmeter.

LzJ .

~
Circuit resistance should be

U4J measured with an ohmmeter

GI-5
 GENERAL INFORMATION

CONNECTOR SYMBOL Connector symbol

~
A direction mark is shown to clarify the side of connector 112~41SI
1617 a19i'Qj
(terminal side or harness side).
• Connector symbols shown from the terminal side are t-'" sing;e iine
enclosed by a single line. ! Direction mark
I .~
i ..
View from terminal side

iew from harness stde

Cannectorsymbol
ra
514 :1 211 ,!
• Connector symbols shown from the harness side are Ilioj9 8 7! fiJi
t
enclosed by a double line. Double line i

Direction mark

Male & Female terminals

Connector guides for male terminals are shown in black
and female terminals in white in wiring diagrams.
/ ~
) Direction mark

Control unit element substances

Element such as control unit will be shown as displayed.

GI-6
 GENERAL INFORMATION

GENERAL PRECAUTIONS
Follow the below precautions to ensure safe and proper servicing for your vehicle.
SRS (Supplemental Restrain System) air bag
• Information necessary to service the system safely and
correctly is included in the BF section of this service
manual. Make sure you read the section on "SRS air bag"
before maintenance operation.
• Improper maintenance, including incorrect removal and
installation of the SRS air bag, can lead to personal
injunes caused by unintentional activation of the system.
• Do not use electrical test equipment on any circuit related
to the SRS air bag. '-------------'
All SRS electrical wiring harnesses and connectors are
covered with yellow outer insu lation.

General Precautions
• Do not operate the engine for an extended period of time
without proper exhaust ventilation.
• Keep the work area well ventilated and free of any
flammable materials.
• Care must be taken when handling any flammable or
poisonous materials.

Seat cover
• Before servicing the vehicle. cover fenders. upholstery and
carpeting with appropriate covers.

FenCler cover

Before jacking up the vehicle, apply wheel stoppers and

only jack up the vehicle at jack up point.
• After jacking up the vehicle, support the vehicle weight with
safety stands before working on the vehicle.
• When removing heavy objects such as the engine or
transaxle I transmission, take care not to lose your
balance and drop them. Also, do not allow them to strike
parts, especially the brake tube and master cylinder. '--_ _ _ _ _ _ _ _ _....J

GI-7
 GENERAL INFORMATION

Before start repairs that do not require battery power.

always turn off the engine and disconnect the ground
cable from the battery to prevent accidental short circuit.
Loosen the screw nut completely when removing the
ground cable from the battery.

• To prevent serious burns, avoid contact with hot metal part

such as the radiator, exhaust manifold, tail pipe and
muffler. Carry out the operation when the parts has cooled
down.
• Do not remove the radiator cap when the coolant is hot.

Wind wire around probe

An inspection may be difficult with a normal test probe Test probe
when a connector pin is extremely small. When this is the
case, wind a small pin or wire around the test probe, or
sharpen the end of the probe to perform the inspection.
Use measurement equipment such as the CONSULT Sharpen the end
electronic system diagnosis tester and an oscilloscope to
perform diagnosis operation.

• Check the vehicle damage carefully, make a careful diagnosis of the damage and perform
the correct operation.
• Check the correct part assembly condition before removal or disassembly. Make
alignment marks when necessary in locations which will not interfere with the part
operation.
When replacing parts always use correct specified parts or tools.
• Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self locking
nuts, etc. with new ones. These parts are indicated "Can not be reused" and must be
replaced with new parts.
• Always replace taper-roller bearing and the needle bearing for inner and outer race as a
set.
• Take care not to mix up the removed parts.
• When replacing parts always use genuine Nissan replacement parts.
• Use correct lubricants specified.
• Dispose waste oil and cleaning oil in a way that is set by the law.

GI-8
 GENERAL INFORMATION

Precautions for ECCS engine

• Before connecting or disconnecting ECCS control
module hamess connectoL be sure to turn the ignition
switch to the "OFF" position and disconnect the negative
battery terminal.
• Release fuel pressure to eliminate danger before
disconnecting pressurized fuel line from fuel pump to
injectors.
• Do not apply any shock to the electric parts such as ECCS
control unit or Airflow metre.
• Use measurement equipment to perform diagnosis
operation.

Precautions for Catalyst converter

If a large amount of unburned fuel flows into the converter, the
temperature within the converter will become excessively ~
high. To prevent this, follow the procedure below: ~rr=""
• Only carry out the ignition spark or measuring engine
compression checks when necessary and carry out the
tests quickly.
• Do not run the engine when the fuel tank level is low,
otherwise the engine may misfire causing damage to the
converter.
• Only use gasoline specified.
Do not place burnable objects below the vehicle. Keep
flammable material off the exhaust pipe and the catalyst
converter.

Precautions for fuel

Only use unleaded gasoline for gasoline engine vehicle.
Using a fuel other than that specified could damage the
vehicle.

GI-9
 GENERAL INFORMATION

VEHICLE & UNIT IDENTIFICATION PLATE LOCATION

Vehicle identification number (Supplement models only)
E-FR32 ...................................................... FR32-000001 -
E-HR32 ...................................................... HR32-000001-
E-HCR32 ................................................... HCR32-000001-
E-ER32 ...................................................... ER32-000101-
E-ECR32 ................................................... ECR32-000101-
E-HNR32 ................................................... HNR32-000001-
E-BNR32 ................................................... BNR32-000001-

Model number plate

NISSAN MOTOR CO,LTD.JAPAN
1. Type ".. .....
,.. ""
TYPE
flPO
.&. 1
2. Vehicle identification number CHASSIS "Ie
1.0 DE Ct'ASS1S &2
3. Model
.,"'"
4.
5.
Body colour code
Trim colour code
""",,0
"., - 00L.0fI 'IlIN
''i''COl()f;~CH
&3
4& &5 •
~Ij 0
.;- EftGI!!f cc
6. Engine model ,;" YOtOA 6& &7
7. Engine displacement ""',,,.:.. TRAilS All£:
7~1," TRAitS EJE 8& &9
PtANT
8. Transmission model III ptANT"
.

9. Axle model

Engine serial number

RB26DETT engine CA18i engine RB20E I RB250E engine

GI-10
 GENERAL INFORMATION

CONSULT
Consult is a hand-held compact type tester. It transmits
signals to the vehicle loading control units when the diag-
nosis connector is connected and can perform all types of
diagnosis and tests.
Note:
Refer to the CONSULT operation manual for further details.

FUNCTION

Operation support
Transmits commands to the electrical control unit for I
setting the status suitable for required operation.

Function test Diagnose the ECCS standard checks.

Receives the self-diagnosis results from the electrical

Self-diagnosis control unit and displays malfunctioning system names !
and the number of times a malfunction occurs.

Receives input and output signals from the control unit,

Data monitor displays and records data used to easily determine
cause of malfunction. !
:
Sends commands to the control unit and performs the
i Active test operation inspection and verification of the output
system according to output signal changes.

ECU part unit Displays the part number of the electrical control unit.

APPLICATION

Engine SRS
AfT HICAS E-TS ASS
(ECCS) Air bag

Operation support 0
: Function test 0
Self diagnosis 0 0 0 0 0 0
Data monitor 0 0 0
:
Active test 0 0
ECU part number 0 0 i 0

GI-11
 GENERAL INFORMATION

TIGHTENING TORQUE OF STANDARD BOLTS

I Tightening torque (without lubricant)
Bolt
Pitch
Grade Bolt size diameter Hexagon head bolt Hexagon flange bolt
(mm)
(mm)
N-m kg-m N·m kg-m
I
M6 6.0 !
1.0 5.1 0.52 6.1 i 0.62
i

i i 125 13 1.3 15 !
15
M8 8.0
. 1.0 13 1.3 I 16 1.6
. 1.5 25 2.5 29 3.0
4T M10
i
10.0
i
1.25 25 2.6 30 3.1
i
! 1.75 42 4.3 51 i 5.2
M12 12.0
I 1.25 46 4.7 56 5.7

M14 14.0 1.5 74 7.5 88 9.0

M6 6.0 1.0 8.4 0.86 10 1.0

1.25 21 2.1 i 25 2.5

M8 8.0
i
1.0 22 2.2 26 2.7

1.5 41 4.2 48 4.9

1T M10 10.0
1.25 43 4.4 51 5.2 !

I
,
i 1.75 i
71 ! 7.2 84 8.6
M12 i
12.0
1.25 77 7.9 92 9.4
I !
M14 i 14.0 1.5 127 13.0 147 15.0

M6 6.0 1.0 12 1.2 15 1.5

1.25 29 3.0 35 3.6

M8 8.0
1.0 31 3.2 37 3.8
1.5 59 6.0 70 7.1
9T M10 10.0
125 62 6.3 74 7.5

1.75 98 10.0 118 12.0

M12 ! 12.0 ,
1.25 108 11.0 137 14.0

M14 14.0 1.5 177 18.0 206 21.0

Special parts are excluded.

This standard is applicable to bolts having the following marks embossed on the bolt head.
Grade Mark
4T 4
7T 7
9T 9

GI·12
 GENERAL INFORMATION

TOWING

Front
After removing the front spoiler, attach a cable to the hook
in the front part of the front side member.

Rear
Attach a cable to the hook mounted in the rear part of the
rear side member.

Towing hook

2-POLE LIFT
The two-pole lifting points are the same as for the right rack.
Qaution:
Make sure the vehicle is empty when lifting up the vehicle.
Make sure the side sill and lift arm (rear part) do not contact each other when lifting up the
vehicle.

Board-on Lift Front of the vehicle

The board-on lift attachment (LM4086-0200) set at the \,
front end of the vehicle should be set on the front of the \~ I

sill underthe front door opening.

Position the adapter on both sides of the board-on lift
Caution:
'I
~==-
' . .~~~~.="~.~~~~.
\
=,,!

Make sure the vehicle is empty when lifting.

Adapter
AdaDter

GI-13
 GENERAL INFORMATION

HYDRAULIC JACK LIFTING & JACK STAND SUPPORT

Caution:
• Make sure the vehicle is empty when lifting.
• When the front side is jacked up, raise the front sill edge slightly using the jack and then
jack the vehicle up.
• Use the attachment (LM4519-0000) when a vehicle is supported by jack stand.
• Take care not to allow the jack stand to crush brake tubes or fuel lines when using jack
stand.

Place jack at the centre of tlie suspension Place jack at the centre aftne dTfferenffai
member gear

GI-14
 GENERAL INFORMATION

4WD INSPECTION & REPAIR PRECAUTIONS

Follow the precautions below to measure the speedometer reading and to check breaking
performance in the 4WD mode,

SPEEDOMETER MEASUREMENT
Two methods to measure the speedometer are described below,

1. Measurement with front wheels jacked up

• Place the rear wheels on the roller.
• Support the car on jack stand with front wheels jacked
up using the attachment.
• Place the transmission in 2nd gear for the manual trans-
mission vehicle and release the clutch slowly, For
automatic vehicles place the shift lever in 2nd and
increase the speed gradually,
• When the test is completed, do not apply the brakes
suddenly,
Caution;
Place the jack securely, and perform the measurement
after making sure the vehicle is stable,
Use the free rollers whenever possible. Simple free roller
/IM24850000
" ~-'
~
2. Measurement using simple free roller , . 'vleasure,;,ent
• Set the simple free roller the length of the wheel base
(2615mm) forward ofthe centre of the measurement
.. '
.--
" roller !
/
roller as shown in the diagram, W,heelbase ~
• Place the front wheel on the simple free rollers and the 2,615mm ~
rear wheels on the measurement rollers,
Place the gear in 2nd for the manual transmission
vehicles and gradually release the gear, For automatic
vehicles place the shift lever in 2nd and increase the
<:= Front

speed gradually,
• When the test is completed, do not apply the brakes
suddenly, " ';
i",\ ... :
" ,
Simple free roller Measurement
roller

BRAKING PERFORM CHECK

Pre-Inspection preparations

The performance check must be carried out in 2WD mode,

To switch to 2WD mode, either use the front propeller shaft
removal method or remove the fusible ink from the engine
bay,

GI-15
 GENERAL INFORMATION

INSPECTION POINTS
(When fusible link in the engine bay is removed)

IRemoved the 4WD fusible link 30A from th~ engine

I bay relay box with engine turned off.

Turn on the ignition. Repeat the engine deceleration

operation from full throttle to no throttle until the 4WD
warning light on instrument panel lights.
:Note: The vehicle may not enter 2WD mode when this
Ioperation is not performed.

'---" I .
ITum the ignition switch in OFF position once the4WD I
i warning light has turned on. .

Turn on the ignition switch and make sure the 4WD i

warning light is on. i

I
Position the vehicle on rollers, set shift and range
into neutral position.

I
IPress the pedal. Release pedal when OK zone is
'reached or OK lump lights.

If the drag exceeds 10% of the axle weight when the

drag test is performed, the wheel rotation must be
checked with the vehicle jacked up. If there is no abnor-
mality, it can be assumed that the drag is caused by the
viscous torque and there is no brake abnormality.

i Place the ignition to OFF position and place the fu-I

; sible link back to its normal location.
i
I .____
. Place the ignition back to ON position and make sure i
the 4WD warning light turns off and 4WD mode is'
set.

End

GI-16
 GENERAL INFORMATION

4WD VEHICLE TOWING PRECAUTIONS

Towing precautions
Never tow a 4WD vehicle for a distance over 30
km and do not exceed speed limit of 30 km I h.
Never tow a 4WD vehicle with front or rear wheels
raised and opposite rear or front wheels on the
ground as this may cause serious damage to the
transaxle.

GI-17
 CONTENTS

SECTION EN ENGINE

CONTENTS
EN1 ENGINE SPECIFICATIONS
MAIN ENGINE SPECIFICATIONS ............................ .......... .......... EN - 6
EMISSION CONTROL EQUIPMENT SPECIFICATIONS ............................ " ........... EN - 7
SPECIAL SERVICE TOOLS..........." ... " ........... "............ EN - 8
SYSTEM DIAGRAM ...................... ............................................. .... EN - 13
VACUUM DIAGRAM ....................................... .............................. EN - 19

EN2 RB26DETT I RB20E I DE I DET I RB25DE I CA18i ENGINE

1. IDLE SPEED /IGNITION TIMING /IDLE MIXTURE RATIO INSPECTION ..... EN 23
2. COMPRESSION PRESSURE INSPECTION .............................. ............ EN - 42
3. BELT TENSION INSPECTION &ADJUSTMENT.................. ... EN - 43
4. VALVE CLEARANCE INSPECTION & ADJUSTMENT ................................. EN - 45
5. LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . ...................... EN - 47
6. EXHAUST SYSTEM INSPECTION
RB26DETT I R820DE I DET ! R820E I R825DE............ .... EN - 49
CA18i ............................................................... .. ............ EN - 51
7. FUEL PUMP SYSTEM INSPECTION ........................................................... EN - 52
8. EVAPORATIVE GAS CONTROL INSPECTION ............................................ EN - 54
9. BLOWBY GAS REDUCTION DEVICE INSPECTION ......................... EN - 55
10. ON-VEHICLE PARTS REMOVAL & INSTALLATION
RB26DETT ................................................................................ EN - 56
RB20E................................. ................ EN - 105
RB20DE, DET.. .................................................................... EN -115
CA18i ........................................................................................ EN-137
RB25DE ................................................ ....... EN -151
11. ENGINE REMOVAL & INSTALLATION
R826DETT ................................................................................ EN -180
RB20E, DE, DETT. CA18i .............................................. EN -182
RB25DE .................................................................................... EN - 184
12. ENGINE OVERHAUL
RB26DETT ................................................................................ EN - 186
RB25DE .................................................................................... EN-202
RB20E I DE I DET .......................................................... EN - 217

EN -1
 CONTENTS

EN3ECCS (ELECTRONICALLY CONCENTRATED ENGINE CONTROL SYSTEM)

1.TROUBLE DIAGNOSIS ............. " ............................................................... EN - 231
2.DIAGNOSTIC SYSTEM .............. ... ..... ........................ .......... EN 259
3.BASIC INSPECTION
RB26DETT I RB20E I DE I DET I CA 18i ...... " ......................... EN - 272
RB25DE ..... .. " .................................. " ...................... EN - 276
4. SYSTEM FIGURE & CIRCUIT DIAGRAM
RB26DETT ................................................................................ EN - 280
RB20E ... ... .............................................................................. EN - 284
RB20DE.. ........ ............... ....................................................... EN - 288
RB20DET .................................................................................. EN - 292
CA18i ......................................................................... EN - 294
RB25DE ......................... ........... ....................... .. ........... EN - 298
5. ACTUATOR SYSTEM INSPECTION (RB26DETT I CA 18i I RB20E I DE I DET)
5 1 FUEL PUMP SYSTEM INSPECTION ................... ....... .. EN - 302
5-2 INJECTOR SYSTEM INSPECTION ................................ .. EN - 314
5-3 IGNITION SYSTEM INSPECTION ............................................. EN - 328
5-4 IDLE SPEED CONTROL SYSTEM INSPECTION ...................... EN - 339
5-5 WASTEGATE VALVE CONTROL SYSTEM INSPECTION
(RB26DETT ONLy).................. .......... EN - 350
5-6 PTC HEATER CONTROL SYSTEM INSPECTION
(CA18i ONLy) ......................................................................... EN - 352
5-7 LOCK UP RELEASE CONTROL SYSTEM INSPECTION
(CA18i AIT ONLY) .................................... ....... EN - 353
6. SENSOR SYSTEM INSPECTION (RB26DETT r CA 18i I RB20E r DE r DET)
6-1 CRANK ANGLE SENSOR SYSTEM INSPECTION
(CODE No. 11 IN SELF-DIAGNOSIS) ...................................... EN - 354
6-2 AIR FLOW METER SENSOR SYSTEM INSPECTION
(CODE No. 121N SELF-DIAGNOSIS)
(RB26DETT I RB20E I DE / DET) .............................................. EN 361
6-3 THROTTLE VALVE SWITCH SYSTEM INSPECTION
(RB26DETT I RB20E I DE ! DET) .................. .................. EN - 368
6-4 THROTTLE SENSOR SYSTEM INSPECTION
(CODE No. 43 IN SELF-DIAGNOSIS)
(RB26DETT! RB20E I DE / DET) ... .... .. ................................ EN - 371
(CA18i) ................................................................................... EN - 375
6-5 INTAKE AIR TEMPERATURE SENSOR SYSTEM
(CODE No. 411N SELF-DIAGNOSIS)
(CA 18i I RB26DETT ONLY) ........... ............................ EN - 378
6-6 ENGINE TEMPERATURE SENSOR SYSTEM INSPECTION
(CODE No. 131N SELF-DIAGNOSIS) ............................. EN - 380
6 7 EXHAUST GAS SENSOR SYSTEM INSPECTION
(CODE No. 151N SELF-DIAGNOSIS) ....................................... EN 386
6-8 DETONATION SENSOR SYSTEM INSPECTION
(CODE No. 341N SELF-DIAGNOSIS)
(RB26DETT / RB20E ONLy)............................... EN - 395
6-9 VEHICLE SPEED SENSOR SYSTEM INSPECTION ................ EN - 397
6 - 10 IGNITION SWITCH (START SWITCH) SIGNAL INSPECTION ..... EN - 398
6 - 11 AIR CONDITIONER SIGNAL INSPECTION ................ ........ EN - 399
6 - 12 NEUTRAL SWITCH SIGNAL INSPECTION ............................... EN - 399

EN-2
 CONTENTS

6 - 13 POWER STEERING SWITCH SIGNAL INSPECTION ..... " .. ". EN - 400

6 -14 LIGHT SWITCH SIGNAL INSPECTION (CA18i) ................. ,...... , EN - 400
6 - 15 HEATER FAN SIGNAL INSPECTION (CA 18i) """ ..................... EN - 400
7. RB25DE DIAGNOSIS
DIAG 1 POWER SUPPLY & GROUND CIRCUIT.. ...... ,,,,,,,,..... ..... EN 401
DIAG 2 CRANK ANGLE SENSOR
(CODE NO.11 IN SELF-DIAGNOSIS) . . . . . ............ EN - 404
DIAG 3 AIR FLOW METER
(CODE No. 121N SELF-DIAGNOSIS) ... ,., .................. ,., ,...... EN - 407
DIAG 4 ENGINE TEMPERATURE SENSOR
(CODE No. 131N SELF-DIAGNOSIS) ..................................... EN - 410
DIAG 5 IGNITION SIGNAL
(CODE No, 211N SELF-DIAGNOSiS) .. ,...................... EN -412
DIAG 6 EXHAUST GAS SENSOR
(CODE No. 151N SELF-DIAGNOSIS) ....................................... EN - 415
DIAG 7 DETONATION SENSOR
(CODE No. 341N SELF-DIAGNOSIS) .... """"',, .............. EN - 417
DIAG 8 THROTILE SENSOR
(CODE No.43 IN SELF-DIAGNOSIS) ..................... . .... EN - 419
DIAG 9 A IT CONTROL
(CODE No. 54 IN SELF-DIAGNOSIS) ........ , . . . . . . . . . " . EN - 421
DIAG 10 CRANKANGLESENSOR
(NOT IN SELF-DIAGNOSIS) ...""........... EN - 442
DIAG 11 IGNITION SIGNAL 1
(NOT IN SELF-DIAGNOSIS) ,....."............... . EN - 424
IGNITIONSIGNAL2 ............... ,................................ .. EN 427
DIAG 12 INJECTOR SYSTEM INSPECTION................. .. , EN - 428
DIAG 13 VEHICLE SPEED SENSOR.... , . . . . ....... ,....... EN - 431
DIAG 14 AIR CONDITIONER RELAY SiGNAL ..... " ........................... ,. EN - 433
DIAG 15 EXHAUST GAS SENSOR HEATER .. ,.............................. ,.. ,... , EN - 434
DIAG 16 THROTILE VALVE SWITCH ..................................................... EN - 436
DIAG 17 START SIGNAL ............ ,............. ,., .............................. ,............. EN - 439
DIAG 18 FUEL PUMP CONTROL ....... ,"",., ............................................. EN - 440
DIAG 19 AAC VALVE............ ... , . . . . . . . . . . ....... EN - 443
DIAG 20 AIR REGULATOR ............. ,...... ,.............................. ,................ EN - 445
DIAG 21 POWER STEERING HYDRAULIC PRESSURE SW .................. EN - 447
DIAG 22 IDLE REV IS TOO HIGH (AFTER WARM UP) .......................... EN - 449
DIAG 23 HUNTING..................... .. ,.".......... ...... EN - 450
DIAG 24 IDLE INSTABILITY....." .. " .. ,................, ..... ," EN - 451
DIAG 25 WHEN COLD. DIFFICULT TO START OR
CAN NOT START THE ENGINE, ............................... EN - 454
DIAG 26 WHEN WARM, DIFFICULT TO START OR
CAN NOT START THE ENGINE . . .................... , EN - 456
DIAG 27 IN NORMAL CONDITION. DIFFICULT TO START OR
CAN NOT START THE ENGINE ... ,................ EN 458
DIAG 28 HESITATION AFTER WARM UP .. .......................... EN - 460
DIAG 29 HESITATION WHEN COLD ... ......... EN - 461
DIAG30 HESITATION IN NORMAL CONDITION ....... ,.. EN -462

EN-3
 CONTENTS

DIAG 31 ENGINE STALL WHILE REWING ............................................ EN - 463

DIAG 32 ENGINE STALL AFTER WARM uP................ ..... EN - 465
DIAG 33 ENGINE STALL WHEN COLD ................................................... EN - 467
DIAG 34 ENGINE STALL WHEN ACCELERATING INSTANTLy ......... EN - 469
DIAG 35 ENGINE STALL WHEN DECELERATING ................................. EN - 471
DIAG 36 ENGINE STALL WHEN ACCELERATING OR
DRIVING AT CONSTANT SPEED .............................. .. EN - 474
DIAG 37 ENGINE STALL WHEN LOADING BATTERy."........ ....... EN - 476
DIAG 38 POWER SHORTAGE AND TUMBLE (INSTANT POWER
OUTPUT SHORTAGE DURING ACCELERATION) ................ EN - 478
DIAG 39 DETONATION.............. ........................ ..................... EN - 479
DIAG40 SURGE ................................ " ..................... " ..................... EN -480
DIAG 41 BACK FIRE (SPITTING) ...... " ...... " ..... " ....................... " ........... EN - 481
DIAG 42 AFTER BURNING ......... " ........................ " ........................... " .... EN - 481
8. RB25DE COMPONENTS INSPECTION .................................................... EN - 482
9. ECCS CONTROL UNIT INPUT I OUTPUT SIGNALS
RB20DETT ................................ " ......... "" .. " .. "." ....... " .. EN - 490
RB20E I DE I DET ......................... .. " .. , ............. EN - 499
CA18i .......... ,............ ,., .............................................................. EN - 513
RB25DE .................................................................................... EN - 520
10. DECELERATION EXHAUST GAS EMISSION
CONTROL EQUIPMENT INSPECTION ...................................................... EN - 527
11. AIR CONDITIONER CUT SYSTEM INSPECTION .. ,............ ,......... ,......... EN - 528

EN4 ENGINE ELECTRICAL EQUIPMENT

SPECIFICATION .................. ,............... ,........... ,., ........................ , ...... EN - 529
1 BATTERY INSPECTION... .... "............."......" ...... " .... EN - 530
2. ALTERNATOR .................................................................... ,.................... EN-530
3. STARTER MOTOR REMOVAL & INSTALLATION ............................ ,....... EN - 531
4. SPARK PLUG INSPECTION ..................................................................... EN - 531
5. PLATINUM PLUG INSPECTION ................... ,............................................. EN - 531
6. IGNITION COILINSPECTION ........................................ ,........................... EN - 532

EN5 COOLING SYSTEM

SPECIFICATION ..... ,............................. ,.................................................... EN - 533
1. RADIATOR INSPECTION .......................................................... ,.............. EN - 534
2. RADIATOR CAP INSPECTION ................................ ,.................................. EN - 534
3. COOLING WATER FILLING PROCEDURE ................................................ EN - 534
4. RADIATOR REMOVAL & INSTALLATION .......................... ,........................ EN - 535
5. SUB ELECTRICAL FAN INSPECTION ....................................................... EN - 536
6. THERMOSTAT INSPECTION ....................................................... ' ... ,.. " .. EN - 536

EN6 FUEL SYSTEM

SPECIFICATION ......................................... " .......................................... EN - 537
1. FUEL TANK REMOVAL & INSTALLATION ............................................. "". EN - 538
2. FUEL GAUGE ,... ,.......... , ....................................................................... EN - 539
3. FUEL PUMP REMOVAL & INSTALLATION .......................... " ................... EN - 541

EN-4
 CONTENTS

EN7 EXHAUST SYSTEM

SPECiFiCATION.............................. ...... EN ~ 542
1, EXHAUST PIPE, CATALYTIC CONVERTER
&HEAT PANEL TIGHTENING TORQUES ............ .................................... EN - 543
2. EXHAUST GAS TEMPERATURE WARNING EQUIPMENT INSPECTION. EN - 545

ENS ENGINE CONTROL

1. ACCELERATOR PEDAL INSPECTION &ADJUSTMENT...... ..... EN - 546
2. ASCD .............. .................................................................... EN - 547

ENg ENGINE MOUNTING

1. FRONT ENGINE MOUNTING....... ................................................... EN - 560
2. REAR ENGINE MOUNTING ............................................................. EN - 560

EN-5
 ENGINE SPECIFICATIONS

EN1 ENGINE SPECIFICATIONS

MAIN ENGINE SPECIFICATIONS
1
I I
""_mode' E·FR32 i E-HR32, E-HCR32
E·HCR32
E·HNR32
E-ECR32
I E-8NR32 ,

Englnotype C/l.181 i R82DE R82DDE R820DET i R8250E RB26DETT :

, Displacement (ee) 1809 1998 1998 19S8 2498 2568

Semlsphere i
Pent-roof type
CombusUon chamber
type ,

!vawea~nt
!
SOHC beit dnve DOHC belt drove

; Bore x Slm,," Imm) 83.0 x 83.6 ' 780,697 78,0 x 697 78,0,697 860 x 71 ,7 860 x 73,1
Compression ratio 1~2
: 85 10,0
8,8 ~5 85

iCompression Pn>S""'" (kg I em') I (fl'm) 12,21135 '25;300 13.::: t 300 120/300 1281300 120,'300
: Maxlmtm ouIpu! (noQ (PS 1 fl'm) 91 /5200 125 I 5608
,: i 55/6400
'"-

2:.~ /~400 1- 18016000 280 j 68CC

IMal<lmum torque (nel) (kg·m il\>m) , 14$ f 3200 17.5! 4400 18815200 27.0! 32J0 23015200 36014400
•Fuel consumption ratio (9 I GS.h) I (fllm) 210 / 2400 21512400 20513200 215/2400 2CO! 3200 , 20012800
MIT 630 )( cOO x 685 845" 590 B55! 245~: 630> 660 845;,;66u;.;685 ; 845 x 630 x 660
:>: 370 x 665 x 675
I Dimensions ,. ,.-
(LxWxH) (mm)
I AIT ;:;'5x6001.685 330..:590>.:855 830;.:630~66r, 830 )( 660 x 685 830 y. 63G x 660 ,
,--'" openi~
Intake valve
.... _-
i
12 14 5 5 8 , 7
.~Ie (dogreas)

I
:VatveOPering
Intake valve closi~
a~1& (dog""'s)
48
i
52 53 !

/I closi~ cyole Exhaust valve Op.ni~ ;

54
I 54 63
(degrees) i I
:
E.nausi valv& OPeni~
i (degree.)
14
I 0
, 2 (BTDC) 7 (STOel i

Valve Intake (W31TT1) (mm) 0.30 o (Automatic adjustment typel 051

§
clearance i Exhaust (wann) (mm) 030 C (Automatic adjustment type) aM
i ,,,--'" ,

-~-:1 '" .
MIT 700 600 650 650 650 , 950
Idle speed (rpm) i
..
AIT
MIT
800
131700
l 201600
650
I' 15/650
I
650 650
15! 650 15/650 20:950 i
..... _ - - -
, 19n1tion timi~ (BTDe" I rpm)
AIT : 13! 800
'"

20 I 650 ;5! 650

! 2Q 1650 15/650
.....
151560
i ....
Preparation Idle CO d ....ll¥ (%) ,
..... __. Below 0,1
... ~ ....

'''--T :
target value Idle He density (ppm) Below 50
,
,Engine oil
.
Standard 75W·30 75W 30 7.5W" 30 7,5W· 30
•(laclllry) Cold climate ....-sion (SG gradel ,SG gcade hsbo) ,SG 9cade) I'SG gmde UxbC)
011 pan capacity (H level) (Ll . i 3.4 ; 4.0 4.0 4.5 i4WC) & 4.0 4.5

Oil ftftllr capaci1y (L) Approx 0.4

,
' Total.~lne coolant capacity il) Approx 7.0 Approx.8.0 Aoorox. 9.0 I Apprcx.9.0
'"
i APPfO)( 9 ° ApprOx. 9.0 !

EN-6
 ENGINE SPECIFICATIONS

EMISSION CONTROL EQUIPMENT SPECIFICATION

E-HCR32
. Vehicle model E·FR32 E-HR32, E·HCR32 E·ECR32 E·BNR32
i E·HNR32 !

:
Engine type CA18i RB20E : RB20DE RB20DET RB25DE I RB26DETT i
: Engine fuel sy.stem S::>i {ECCS) ECCS
•Air I fuel ratio control s}>Stem A:- f fuel ratio feedback I
Temperature control air cleaner Automatic:- - : - - -
Supplemental start equipment klle-up solenoid Bi~metal type aIr regbator
i Intake heat sy.stem Hot wafer "fMtln;j , - - !
- - :
.
: Ignition system Breakerless type {ECCS} Breakerless type (EC8S electrical distributor) i
EGROOOO"'!::>1~tem - - - - - -
1V valw operation
CO,He INCx) i temperature
-
I - !
- I
reduction eqt.ipment
' Catalyzer type Three-way catalyst (monolithic tyD6i
Catalytic COfI\ferter
size (capacity In L)
(09) X3 (17) X4 (1 3) X3 (1.7)
,
!

Deceleration exhaust
!
!
: gas reduction
, eqUIpment
Fuel cutoff eqUipment
0 -

I
- ! -
:
0 !

i E>haus\ gas temerature warning ThBr'T1ocQuple

Thermocouole (850)
I equipment (Setting temperature 'C) (940)
r Evaporative gas control system Canister system

i Blowby gas reduction system Closed system

EN-?
 TOOLS

SPECIAL SERVICE TOOLS

..
NAME USE

Spark plug wrench Removal & Installation of

EG17401600 hexagonal spark plug

Allen compression gauge /1

EG15-50000 Engine compression pressure
Adapter inspection
EG15050101

Electronic system
diagnosis tester CONSULT Idle test & adjustment
EG1180 0000

Seal cutter Oil pan removal

KV101 11100

Tube presser
Liquid gasket lubrication
WS3993

Pulley puller Removal & Installation of crank

ST2718 0001 pulley

Oil seal drift

ST0153 0000
KV401 00900 CD] )~- )) Oil seal insertion
8T30022000

Pulley holder
KV101 09300 •
~ Cam pulley bolt removal &
KV101 09900
Installation
ST3512 0000
ST3153 0000
Valve spring compressor
KV101 16200
Valve spring installation &
ST12070000
removal
KV101 08950
KV101 09210
EN-8
 TOOLS

NAME USE

Valve oil seal puller

KV101 07901 Valve seal removal
KV10107902

Valve oil seal drift

KV101 07501 0':::: 1 I)
Drift attachment
KV101 11400 2
!
1
Valve oil seal insertion

Valve guide drift Valve guide installation &

KV101 16000 removal

Engine stand ASSY

ST05015000 Engine main unit over haul

Engine attachment
Engine main unit overhaul
KV101 06500

Engine sub-attachment
KV101 10700 Engine main unit overhaul

Pilot bearing puller

Pilot bush removal
ST1661 0001

Ring gear topper Flywheel & drive plate

1, KV101 104S0 installation
2, KV101 05610

Adapter harness for mold

coil (1 poles) Ignition primary signal removal
EG1116 0000

EN-9
 TOOLS

NAME USE

Timing light
EG1443 0000 Ignition timing check
EG1443 0001

Oil filter wrench Removal & installation of oil

KV101 06250 filter

Vacuum gauge
N Automatic temperature
EG1512 0000
1) adjustment air cleaner inspection
-'i=- -"
«;:- ..:,.~
Vacuum hand pump : Automatic temperature
EG1513 0000 adjustment air cleaner inspection

Compound gauge ~~ Turbo charger pressure-charging

V
• .,. i

EG15080001 ~ inspection

Fuel pressure gauge

Measuring fuel pressure
8T1959 0000

Valve seat remover

Intake side, exhaust side Valve seat removal

Valve seat drift

Intake side, exhaust side Valve seat insertion

Valve seat cutter set Valve seat form correction

EN-10
 TOOLS

NAME USE
Valve guide reamer for guide
insertion hole correction
Exhaust side
8 iiZlAl1
Valve guide insertion hole and
Guide inner diameter
guide intemal diameter
correction
Intake side
e WZD correction

KV101 11600 (6.0 mm)

Exhaust side
KV101 07700 (7.0 mm)

Engine sub attachment ~

.... ~
~.
,'i '\J Engine main unit overhaul

~
i i
KV101 14500

Piston pin press stand Press stand

ASSY
Press stand ST1303 0020
Spring ST13030030
Drift KV101 09130
~C2J\
V~~:'
' F,C:' ...
...... ~.
,l
C
c:::~
cen;r~ shaft
Drift Remove & install piston pin
Centre shaft KV10110810
Centre cap KV101 10820 @ IWlilWiil!1
Centre cap Spring

EN -11
 TOOLS

Multipurpose tools

Valve guide reamer - Installation of the valve guide,

Valve seal cutter -Installation of the valve seal.
Piston ring compressor -Installation ofthe piston ASSY.
Piston ring expander -Installation & removal of the piston ring,

Measurement tools

V block
Dial gauge
Micrometer
Inside micrometer
Thickness gauge
Valve spring tester
Depth gauge
Protractor
Magnet stand
Plastigauge
Con'rod aligner
Bore gauge
Straight edge ruler

EN -12
 ;0(1)
ro-<
""(I)
~-I
m

AAC valve

n
~
~
~
Q
1mn Ie ~.~.
0
..J ~
(j)
n
~
c
ro :::t
m3:
~C
m»
0G')
g;:o
g
~
3
u
Vl ,~ ~

-»
~3:
ro
Air regu1ator
~.
§l.
c
'" G'>
'"" "~ rn
'0
"
"
ill
..
~I I I z
m

ECCS GQnlJOlunit
I-;) :xl

~~
OJ
Fucl pump
m valvelswitch ..
'"'"
Z
~

w
l· ap m
0
Monitor & chock
m
~
m
Z
--'
Fuel control signal '"
"'. ro
~ o. light (red light}
Gl
~
'"=r Q"
ill ~ Z
m
~
3
w
~
g 0-
m

b'~r~-;-'----,
~
S. 0
Spark plug sensor Canl~ter , ~

"
ItO' '!'. n
""- " 0
~
~L
lr,lll'.1
~

"I II fl
sensor
"
Swing v(llv19'
'" ;' )(YffJ'<). - -
(f)
converter Vehicle speed sensor -<
MutHer
AfT control unit
~
m
s:
Exhaust temper~ture warning lamp Air cleaner o
Exhaust temperature ~~nso~IGN power
Ail flow metel
~
Switching modulA ~
s:
 ;U(J)
m-(
N(J)
0-1
gm
03:
°0
:1:_
0»
mG>
(j):::O
6
~ -»
mS:
!1;
*
ro
~
0
0
C/)
~

m
Power transistor unit
z '"'"
!XI

~
<:>

Z 8:I:
m ()
m m
z !!l
~
m
()
-i'> Canister 0
!E
m
Z
Temperature 5enso~ Neutral I I G')
Ignitio!1 cOil Z
m
Crank anQlo sensor

-----.3.-~ catalytic conver\flr II l:ur==========::---:-: Vehicle Srep.tl 3eOBDr

(f)
-<
(f)
-i
~ ----- A I T control unit m
Exhaust temperature warning lamp :;;:
Exhaust tempclatur€ sensor o
~
IGN power
Switchin~ module r - ... '-----
Air flow meter
Air cleaner ?::
:;;:
 ;:O(f)
tIl-(
~(f)
C-i
mm
-13:
C
00
::x:-
Ol>
,G)
"
o
~
mAl
~ "l>
.::3: :xl
'"
~.

uel pump
m
o ~
<>
ontrol
o
Power transistor unit
lOd;J!ator
!E ~
()
~ ,LJ!!!. f:!',J~ -I
Throttle C m
G)
;:0
til m
oo ()
m
LU~~
()
I
z $
~

())
Canistor
swT[Cf)4 • t:r F- uel pump
~
;:0
<::I
:xl

~
M:naor & check
light (red I,19 hti
"'
Neutral "m
m
;:0 ~
z ~
m
T0 t nperal\;l2

~«I
:xl

I I,jllk .lilq!t, ,-;pn"l)f

"m
z ~Z
m

Vehicle speed sensor

if)

~A ; T control unit
~s:
Air c!eaflRf
Air flow meter o
Exhausl temperature sensor ~
'.1'1 power G)

~
SWitching module

s:
 O(J)
sen sur output signal l>-(
~(J)
_. -i
-m
~s:
Intake l~mperalu'8 sensor ~11.. I LTAlItnmatic temp e a 'lISlment device
~O
~~ ~~~~
m

\" II:: l. _ 'J. IIII!\

il. 'i;;»
ZG')
Revolution
Fees COlltrol umt
Cl"
z»
ms:
z cf ~
~ 2: {D
~ ~
!c~o"n; !r; ;o; ;,il (llil.l.Oil~-'-'_'__~'
-0

e ~ .:gin 53
91 I Dso!enoid ON f
v,,)lvo (NT only)
g
plug

m 1""~_ !!!
m
l!~
o
z
~

m
.! ""
$
m

· ~~J
z
PTChoater
~~-o/ serlsor Gl
:it
m
I !II EXhGust rIl8fllfoid COW;1

l~ r~~:-"
lyse!"

p~_.JJ
\
- To 50ark plug [

Transmission
From fuel tank
'--iMUftIP (J)
-<
(J)
-I
Dual ignition distribu~or f SWilCrlinQ module m
- jJ
_u, ')
~
Cmnk angle sensor
L.. 0r:r-~~ Exhoust temperature wammg lamp
o
LJ Vf!iilclc speed sensor
L-----Exhaust tf:mporaturc sensor ~
~
 ;;om
Ill-(
~m
1- 0-1
~--'.~~~
mm
mis:
z
,,0
zl>
mG')

~
is:

Ale
Power IranSrs,tor unit

FICO solenoid

;0

m I!l
z
Fuel pump
~m
~ z
-J MOllitor & check G'l
Canistor
light (red light) Z
Tplnpepitl1re., <::..n<:"r ' " m
Neutral
jgnition coil switch

~~-1i
ldn~ .llIilll~ Si'!1:<)f

&V L-;;]t
Transmissfon
I
V~ I
sensor

"t}
}:x(ax cHtalytic converter
Vehicle speed sensor OJ
i (;l
--A ! T control unit -;
Exhaust temperature warning lamp m
~
Exhaust femperatum sensor ILr--~~t- IGN power
o
.... <? j;
SWItching module Gl
~-

~
Air flow meter Air cleaner
 <gm :;O(/)
~

Ill-(
N(/)
I r,::. AAC valve control sIgna1
switch CD-i
~m
Air regulator
:p:
Recirculation vBlve
00
M~~~~~ 0-
I,Power Inmsisto __ J:»
0(;)
unit
=;;:""-t+- ~i!!:.:..--::::=::::=~~=f-~nt~~ea:r:i~rr'7"""~C
~
- r ~;¥- r~ tcmperat
sensor
e
115', ~ (i a
\r=- ,=-""''' m»::0
[!s:
:IJ
III

§'"
~~~~~~~~~~;;;=== 11 ntef COOI"~ I ~ ~ m
o
o 8

Carhon j m:m~ §I~. ,~ III{

-
(f)
'",
(')

canister :::;- :::;) :1 ~~ (

~ 9
m
~ ~ ~ z (')
m

ThroHl"r~::::~'. tC~~:: \~~~~~;~~;~~j~I~=~iffill TmntlllSSion.~

.!.t @
...._/TJl
z c:
~
Throme valve sw,tch r,' I :;0
III i
CO
nock s~ lS 1 .-. oo ~
Spark plug ("- · 1 ,I [ I ~)~"'--~ J:
l>
~
-----\,.1- :;0
G) i1i
II ~-.-.. m el

~
'T3[1=
•=F==
~-W
. ,t-L,j-, r-l :;0

~' Ve_h~I:.~speed
. _. '-::=if,'::::
. .. + !Um
l 1· m

~'.. r:::: 3-wa. • Od r--cc . ' , . '.1'1: z

liz
~,
r- y catalytic c o n v e r t e r ! J .. L ' SFmsor G)

,_ _
'"'" , " " , .. .. '"'"' ,.,.'j"'" c, I "' '"e: c><il
' , Z m

f~I!,se"S():GlJrbo:'harge~' If~';..:_~~
m
(JJ

11 C f I ~
~
_

"'~""
m
s:
sensor temperature . L_ -I" IGN power
. In 0", u ·Air.. flow meter
urbocharg
"L sensor I 1 /' L
e> o
Exhaust
,.,,""' - \ . , ,,' ~
~
s:
 VACUUM DIAGRAM
RB20 EGI (ECCS) ENGINE

VACUUM DIAGRAM
RB20 EGI (ECCS) ENGINE

.. iew B

3
Air regulator
1
View X
Pressure regUlator

,~)
Evaporation control 6 )' 4
hose ASSY I-tose - / , _ ~C'p
X. "'-,,0" Air hose
Three way connector -"",-') 5 _ '\~'
Canister \ A:rdUCl)'OO
Hose Da'ld v1'
-Ii....
" --3-5mm

~IQSS section T - T

Number Length {mmt Part I

1 Molded Intake manifold collector - Pressure regulator
:
: 2 Molded Air regulator - Intake manifold collector ,

,
3 Molded Air regulator - AAC valve
4 Molded I Three way connector - Intake manifold collector
5 160 Three way connector - Fuel damper :
,
6 Molded Air duct - Three way connector

EN -19
 VACUUM DIAGRAM
RB20 DOHC· EGI I RB20 DOHC· EGI TURBOCHARGER ENGINE

RB20 DOHC • EGI {ECCS} ENGINE

I Number Length (mm) Part

I
1 110 Intake manifold collector - Pressure regulator

RB20 DOHC . EGI (ECCS) TURBOCHARGER ENGINE

View E

0ress:.J'e regulator

1 If--~, ~' ...

Clamp {Evaporation hose Side\ \ '.~- Recirculation valve
\ White pa~nt
""-1-_ , Vacuurr gallery
I ~~ Clamp
\ ~ Hose band
,--", ''\~ \ Protector i19Cmm)
; \ ' Evaporation hose ASSY
Inter-cooler'

Number Length (mm) Part

1 110 Intake manifold collector - Pressure regulator
2 80 Throttle chamber - Vacuum gallery - ASSY
3 170 Intake manifold collector - Vacuum gallery - ASSY
4 170 Intake manifold collector - Vacuum gallery - ASSY
5 Molded Recirculation \!albe - Vacuum gallery - ASSY
------'
EN-20
 VACUUM DIAGRAM
CA18i! RB25DE ENGINE

GA18i (EGGS) ENGINE

Fue! return hose
\ / Pressure regulator
'\:, r \ (ThrOtlle/ / 3
, . body) •

1 ~.

View C
2

~/~~~L~B
Hose band Hose clamp

Radiator shroud Canister

View A
/ Front
Do not face the ramp claw towards fuel hose side

Number length (mm) Part

1 110 Intake manifold - Canister
2 80 i Throttle body - Canister
3 170 Pressure regulator - Throttle body

RB25DE ENGINE

E
1

EGGS harness

Cross section A • A. B • B Cross section C • C

Canisler ... I Purge hose
ViewE

J
@
VaclJtJm hose
2

Number I..&ngtb (mm} Part

1 110 Intake manifold collector- Pressure regulator
2 140 IIA unit connector - Fuel damper
------
EN-21
 VACUUM DIAGRAM
RB26DEIT OOHC- EGI TWIN TURBOCHARGER ENGINE

RB26DETT DOHC - EGI (ECCS) TWIN TURBOCHARGER ENGINE

Clam; -=~S;~~.:J: Turbocharged pressure control solenoid

Clamp baed r -=;;i:=~~::=. :2,-

Clamp Dar)Q---;-_~"""

Pressure regulator ~~~~h

Double vacuum tube

Clarno
Clamp

Double clamp
3
Clamp
Canister Vacuum control tube
Swing valve controller (rear)
SWing valve
Clamp coniroller
(front)

: Number I.&ngth (mm)

.. Part
..

.
..••......
. . .
:•...
! 1 580 Turbocharged pressure control solenoid - Vacuum gallery ,
2 560 , Turbocharged pressure control solenoid - Vacuum gallery
!
i 3 425 Canister - Vacuum gallery
I
4 425 Canister - Vacuum gallery

5 80 Throttle chamber - Vacuum gallery

6 290 Air chamber - Vacuum gallery

7 Molded Pressure regulator - Balance tube

8 120 Vacuum gallery - Vacuum gallery

i
9 90 : Vacuum gallery - Vacuum gallery

i 10 60 Vacuum gallery - Vacuum gallery

11 90 Vacuum gallery - Vacuum gallery

12 Molded Vacuum gallery - Swing valve controller (rear)

13 Molded Vacuum gallery - Swing valve controller (front)
14 90 Vacuum gallery - Vacuum control tube

EN-22
 IDLE SPEED; IGNITION TIMING IIDLE MIXTURE RATIO INSPECTION
RB20E {DE I DET I CA1Si I RB26DETT ENGINE

EN2 RB26DETT I RB20E I DE I DET I RB25DE I CA 18i ENGINE

1. IDLE SPEED f IGNITION TIMING I IDLE MIXTURE RATIO
INSPECTION

Idle standard value

Idle speed (rpm} Ignition timi ng CO I He density
ENGINE TRANSMISSION
. (when air condition is ON) (BTDOI rpm) (%)/(PPM)
MIT 600 (Approx. BOO) ! 20 I 600
RB20E
AIT 650 (Approx. 800) 201650
MIT
RB20DE 600 (Approx. 800) 15/650
AIT
below 0.1 f
. MIT 15/650
RB200ET 600 (Approx. 800) below 50
AIT 20/650

!
MIT 700 (Approx. 850) 13/700 ,
CA18i
AIT 800 (Approx. 850) 13/800
I RB26DETT MIT 950 (Approx. 950) 20 / 950 I

Caution:
The idle speed, ignition timing, CO and HC density are interrelated. If any adjustments are
made to one, additional inspection is required.

Diagnosis connector (inside fuse box)

ECCS control unit (inside left dash side lower finisher)

EN -23
 IDLE SPEED I IGNITION TIMING IIDLE MIXTURE RATIO INSPECTION
RB20E I DE I DET I CA 18; I RB26DETT I RB25DE ENGINE

IDLE SPEED I IGNITION TIMING / IDLE MIXTURE RATIO INSPECTION

ERE PA8.ATI ON
1.Make sure the following parts are in good condition.
• Battery
• Ignition system
• Engine oil and coolant level
• Fuses
• Control unit harness connector
• Vacuum hoses
Air intake system (Oil filler cap, oil level gauge, etc.)
Fuel pressure
• Engine compression
• Throttle valve

2. Vehicle fitted with Air conditioner should have the A I C switch in OFF position,
3, When checking idle speed, ignition timing and mixture ratio of A I T models, place the
shift lever in "N" position,
4. Insert the probe approx. 40 cm (15.7 in) into rail pipe when measuring CO percentage.
5. Turn OFF the headlight, heater blower and rear defogger.
6. Keep the steering wheel straight.
7. Recharge the CONSULT sufficiently when using consult and connect to the vehicle side
diagnosis connector.

INSPECTION SEQUENCE

INSPECTION START I

rePlace~
"It -J... NG
Self diagnosis operation 'I Repair or
OK"It
Check & adjust idle speed i'
OK ~ NG
ICheck ignition timing Adjust ignition timing I--
OK ~ Repair or replace the hamess~
NG
Check heated oxygen l1~heck heated oxygen
sensor function Check heated oxygen
sensor input signal
sensor harness cables i-
OK OKl NG J,OK
ICheck CO & HC ratio I Replace heated oxygen sensor
OK
NG .J., NG"
l;heCk emission control part~R Check heated oxygen sensor
and repair or replace 0K
\
IINSPECTION END I'
I
I

EN -24
 IDLE SPEED / IGNITI ON TIMING / IDLE MIXTURE RATIO INSPECTION
RB26DETI/CA18i ENGINE

RB26DETT Engine Idle inspection & adjustment

CA18i Engine Idle inspection & adjustment

EN - 25
 IDLE SPEED I IGNITION TIMING IIDLE MIXTURE RATIO INSPECTION
RB20E I RB20DE ENGINE

RB20E Engine Idle inspection & adjustment

• •

~.

Mold type ignition coil

~, (Engine speed measurementunit)

RB20DE Engine Idle inspection & adjustment

EN-26
 IDLE SPEED / IGNITION TIMING / IDLE MIXTURE RATIO INSPECTION
RB20DET ENGINE

RB20DET Engine Idle inspection & adjustment

EN-27
 IDLE SPEED I IGNITION TIMING I IDLE MIXTURE RATIO INSPECTION
RB26DETT I RB20DE I DET ENGINE

Idle inspection & adjustment (RB26DETT I RB20DE, DET)

Engine speed measurement unit

• Warm the engine sufficiently,
• Connect CONSULT to diagnosis Connector on vehicle
(attached to fuse block area), Place the ignition to ON
position,
• Display the "DiagnOSis mode selection",

• Connect the measurement unit to speed

detection terminal in the hamess connected to the ignition coil from the power transistor.
When the measurement is complete, always replace the terminal cap in the detection
area,
RB26DETT

Engine speed detection termmal

(Yellow & red wire)

Inspection

* MO"OO' *'0 "" ~ Dj

• Warm the engine sufficiently.
• Make sure the air conditioning load, power steering CAS-RPM (POS) 950
oil pump load and electrical loads are not applied. IDLE POSITION ON
Place the select lever in 'N' for automatic vehicles,
• Check the "IDLE POS" and "CAS-RPM" in data monitor
mode in CONSULT.
• Carry out the inspection using engine speed r<iB>\ "
measurement. ~ =========;
I
f='

Note: RECCRD
The measurement unit is limited as the speed output voltage is low (approx. 6V Vp-p).
Caution:
Before the inspection, make sure the throttle valve switch (idle connection point) is turned ON
when the accelerator pedal is not pressed.
Adjustment
The idle speed adjustment is basically not necessary as the rated • MC VALVE ADJ •
value (control target value) is returned to the control unit. If SET ENGINE RPM AT
adjustment becomes necessary, carry out the following THE SPECIFIED VALUE
UNDER THE FOLLOWING
procedures, (i:i\ CONDITION,
• Select "AAC valve adjustment" in "WORK SUPPORT" ~ • ENGINE WARMED UP
mode, Turn the AAC valve assembly idle adjustment • NO LOAD
screw with a screwdriver until idle speed is 900 rpm
(RB26DETT) 600 rpm (RB20DE, DET). START
o Return "AAe valve adjustment" screen to "DATA monitor"
and check if the idle speed shown meets the specification,
EN-28
 IDLE SPEED i IGNITION TIMING J IDLE MIXTURE RATIO INSPECTION
RB26DETI I RB20DE I DET ENGINE

• Make sure the ECCS control unit idle control Ad>\ ..-aU.lOD~
Ad,iuslment Wlttlln indicated range.
adjustment volume is turned all the way to left, ~ Do not tum with excessive force.
Caution: R~ __ ,
: j ,
Do not turn the idle control speed adjustment volume with
excessive force, The adjustment screw turning range is 3/4 i lid ~;~~eed seJ r- j~
ofa turn. i II ~diagno~
I _OWl

• Remove the 2-pin harness connector from the AAC valve to stop the idle speed feedback
control. At this time the AAC valve is completely closed and the idle speed should be
below 900 rpm (RB26DETT) 600 (RB20DE. DET) under normal condition.
RB26DETT RB20DE,DET

• Turn the AAC valve ASSY idle adjustment screw with a screw
driver to adjust engine speed to 900 rpm (26DETT).
600 rpm (20DE, DET).
• Connect the AAC valve harness connector and
make sure the idle speed is maintained at specified value.
• The engine speed increases when the adjustment screw is
turned to left (CCW) and decreases when turned to right
(CW),

• If you wish to increase idle speed for any reason, tum the ,.,au on,
idle adjustment volume in EeeS control unit to adjust the Adjustment withm :ndicated ['ange.
00 not :U!T1 with excessive force.
speed. Idle adjustment speed increases when the knob is
- - _ - - _ - - 1 -...-
Roe
turned clockwise by a maximum of 250 rpm. I
Caution:
ifd!e soeed - I
: ~Sell- r-)..,
The adjustment volume must be set 400 - 50c away from the i ~~i!,nO~
self-diagnosis position as if it is turned all the way to the right
(self-diagnosis position), the idle speed is lowered (lowest rpm '--_ _ _ _ _ _ _ _----'
+ 50 rpm).

EN-29
 IDLE SPEED I IGNITION TIMING IIDLE MIXTURE RATIO INSPEC,O~
RB26DETI I RB20DEIDET ENGINE

IGNITION TIMING CHECK & ADJUSTMENT (RB26DETI , RB20DE, DET)

1. When using "Super tuner"
Connect super tuner to timing detection terminal,
Caution:
After the operation is completed, always attach terminal cap to timing detection terminal.
RB26DETT RB20DE, DET

2. Using primary current detector timing light

• When using EG1443 0001 or EG1444 0000 connect the sensor to No, 1 cylinder primary
line, (No, 1 cylinder primary line is looped as it is longer than other cylinder primary lines),
Caution:
When using EG 1444 0000 (internal battery model), make sure that the sensor direction
(arrow direction) faces spark plug when sensor is clipped to the primary line,

RB26DETT

EG1444 0000 --"

Power transIstor umt side Spark piug side

EN-3~
 IDLE SPEED 'GNITION TIMING IIDLE MIXTURE RATIO INSPECTION
R626DETI I R620DE I DET ENGINE

Inspection
Make sure the idle speed is at standard value.
• Make sure the ignition timing at engine idle is at standard
specification.
Make sure ignition advances to correct advance angle when
the engine is raced.
Caution:
The 0° timing mark on the crank pulley is orange and other
points are painted white.

Adjustment
Since there is no variation in ignition timing, over an extended
time period, ignition adjustment is not necessary in principle. ~r ~'~- -~-~~~"-,
Sealing tape I
Adjust ignition timing when the crank angle sensor is 901 Ion
connected. .
• Set the ignition timing by adjusting the crank angle sensor
installation position. I I

• Make sure the idle speed is at standard. ! ~

• Loosen the three crank angle sensor mounting bolts and !' \}
Camshaft rotalliill
rotate crank angle sensor. Turn the sensor to left to ~~"-"-__ ,_ _~~__
advance ignition timing.
After the adjustment. attach the sealing tape to one of the
three bolts that secure the crank angle sensor.
Sealing tape part number: B2235 U7 410

EN - 31
 IDLE SPEED I IGNITION TIMING! IDLE MIXTURE RATIO INSPECTION
CA1SiI RB20E ENGINE

Idle inspection & adjustment (CA18i / RB20E)

Engine speed measurement unit (j) II"< " -,1 i / ' l
~;// d/;
i !'ell -h','
~...J / \,,-:::'
• Warm the engine sufficiently.
"'I \\
"\ \ d?' i -...;,

Connect CONSULT to diagnosis connector on vehicle .. / Consult

(attached to fuse block area). Place the ignition to ON
position.
Display the "Diagnosis mode selection".

• Connect the measurement unit to the speed detection terminal by connecting the adapter
harness for the mold coil between the coil primary terminal and the primary terminal
harness connector.
CA18i RB20E

Inspection ffi\ 1:1:

Warm the engine sufficiently. \!!J MONITOR1:I: NO FI>,IL
CAS-RPM (REFi 675'P;11
• Make sure the air conditioning load, power steering oil AIR FLOW METRE 1 04v
pump load and electrical loads are not applied. Place the WATER "EMP 79C
02 SENSOR 0.1'v
select lever in 'N' for automatic vehicles. THROTTLE SENSOR OAOV
• Check the "IDLE POS" and "CAS-RPM" in data monitor IDLE SW ON
mode in CONSULT.
Carry out the inspection using engine speed t<S\
measurement. 'aI RECORD
Caution:
Before the inspection, make sure the throttle valve switch
(idle connection point) is turned ON when the accelerator
pedal is not pressed.

Adjustment
RB20E Engine
The idle speed adjustment is basically not necessary as the
1*' AAC VALVE
I SET ENGINE RPM AT
ADJ~.l
rated value (control target value) is returned to the control unit.
i THE SPECIFIED VALUE
If adjustment becomes necessary, remove the ECCS control I UNDER THE FOLLOWING
unit and carry out the following procedures. i CONDITION. •
Select "AAC valve adjustment" in the "WORK SUPPORT" • ENGiNE WARMED UP
mode. Turn the AAC valve assembly idle adjustment screw • NO ,-OAD
with a screwdriver until idle speed is 600 rpm (M IT) 650
rpm (A IT). [ STAFrr

• Return the "AAC valve adjustment" screen to "DATA

monitor" and check if the idle speed shown meets the
specification.
EN-32
 IDLE SPEELl IGNITION TIMING I IDLE MIXTURE RATIO INSPECTION
CA 18i I R820E ENGINE

Make sure the ECCS control unit idle control Cautioli.

Adjustment Within indicated range.
adjustment volume is turned all the way to the left Do not tUT'1 'Nlth excessive force.
Caution: R!,"
... -~--/-
Do not turn the idle control speed adjustment volume with
excessive force. The adjustment screw turning range is 314
of a turn.
r Idle s~~se,L
~Zi:Jno is
((;6)"

Turn the ISS unit idle adjustment screw with a screwdriver

to adjust the engine speed to 600 rpm (M 1T), 650 (A IT).
Connect the throttle sensor harness connector. Make sure
idle speed is maintained at the specific value.

• If you wish to increase idle speed for any reason, adjust the
volume in ECCS control unit.
Caution:
The adjustment volume must be set 40° - 50° away from the
self-diagnosis position as if it is turned all the way to the right
(self-diagnosis position), the idle speed is lowered (lowest rpm
+ 50 rpm).

Adjustment
CA18i Engine
• Remove the harness connector from the intake
temperature sensor to stop the feedback system of the
ignition timing and air - fuel ratio.

• Adjust the engine revolution to 700 rpm (M / T), 800 (A I T)

by throttle adjustment screw.
• Connect the harness connector for the intake air
temperature sensor and make sure the idle speed is
maintained at the specified value.
caution:
The adjustment volume on the control unit side can not be used
for fine adjustment.

EN-33
 IDLE SPEED I IGNITION TIMING IIDLE MIXTURE RATIO INSPECTION
RB20E/CA1Si ENGINE

IGNITION TIMING CHECK & ADJUSTMENT (RB20E I CA18i)

Timing light attachment

• Connect the timing light using the adapter harness for hold coil for the timing light that
collects the signal from the super tuner.
For normal timing light connect the sensor to No, 1 Hightension cable.

CA18i RB20E

Inspection "GNITION TIMINo+

RB20E . WHILE :DLlNG PR"SS 'S-:-ART'
• Do not carry out the inspection as this may cause ignition AND STOP THE IGNITION r·v.NG
FEEDBACK CONTqOL. ROTAE
timing to become unstable.
THE CRANK ANGLE SENSOl
AND ADJUST BY USING THE
• TIMING LIGHT.

L
r '"
START
'"
_ _ _-..1
",.
'tlMONITOR'tl NO FAIL 0 1

CAS-RPM (REF) 675 'pm'

WATER TEMP 79"C
IGNITION TIMING 158TBC

RECORD
• Make sure the idle speed is at standard value. '-----
• Make sure ignition timing at engine idle is at standard r

specification.
• Make sure ignition advances to correct advance angle
when engine is raced.

Caution:
The 0° timing mark on the crank pulley is orange and nthi"rl
points are painted white.

EN-34
 IDLE SPEED I IGNITION TIMING IIDLE MIXTURE RATIO INSPECTION
RB20EI CA18i ENGINE

Inspection
CA18i engine .GNITION TIMING+
: WHILE IDLING PRESS "START
• In the "Ignition timing adjustment" in "Operation AND STOP THE IGNITION TIMING
support" mode and check the ignition timing. FEEDBACK CONTROL. ROTATE
THE CRANK ANGLE SENSO
AND ADJUST BY USING THE
TIMING LlGf-lT.

START

• Remove the harness connector for the intake temperature

sensor and fix the timing advance to inspect the ignition
timing.

• Make sure ignition timing at engine idle is at standard

specification.

Adjustment
RB20E engine
• Adjust the ignition timing by adjusting the distributor
placement position.
Seahng tape
• Make sure idle speed is standard. attachment
• Remove the throttle sensor connector.
• Loosen the crank angle sensor mounting bolts and rotate
crank angle sensor. Turn the sensor to left to advance
ignition timing.
• After the adjustment, attach sealing tape to the bolts that
secure the distributor.

CA18i engine
• Adjust the ignition timing by adjusting the distributor
placement position.
• Make sure idle speed is standard.
• Loosen the crank angle sensor mounting bolts and rotate
crank angle sensor. Tum sensor to left to advance ignition
timing.
• After adjustment, attach sealing tape to the bolts that
secure the distributor.

Sealing tape part number: 82235 U7410

EN - 35
 IDLE SPEED (IGNITION TIMING I IDLE MIXTURE RATIO INSPECTION
CA18i / RB20E/ DE/DET I RB26DEIT ENGINE

IDLE MIXTURE RATIO (CA18i I RB20E I DE I DET I RB26DETT)

INSPECTION
The air-fuel ratio feedback system which has a self-Ieaming function is used and CO and HC
density adjustment is not necessary as the correction range is wide.
Inspection
• Warm up the engine sufficiently and make sure the idle speed i:l MONITOR 1;:{ NO FAil C
and the ignition timing are at standard measure. Check CO
and HG density with GO and HG meter. CAS·RPM (POS) 95:) ro'"
EXH GAS SE'< 123\/
• If the values do not conform to standard measure, perform EXH GAS SEN.R 11 ";\'

following procedures to inspect the air I fuel feedback Mlq FC ''';;

condition: : MiR FIC MNT·R
• In the data monitor mode, select "Exhaust gas sensor ffl\
I
monitor" and "Exhaust gas sensor monitor (R)". ~ ====Re=C=ORD====
1=1

• Set the engine speed above 1000 rpm (2000 rpm for
RB26DETT engine) and make sure "RICH" and "LEAN" are
displayed alternately.
Short-circuit the self-diagnosis connector on the
vehicle side (near fuse box installation), Or
remove the ECGS control unit and operate adjustment
volume on the control unit side. --' '.
=- ,.$<2
::w:::~:K

• Place the ignition to "ON" position and use a lead line to

, ___ ~jJtIO(1;
short circuit the GHK pin and IGN pin of the diagnosis , Adjustme'1t within II)Q,cate-::: 'arv;e
connector for more than two seconds to release the i Do not turn with Clicess:ve (:)r:~n
: R
settings. (Or otherwise tum the ignition switch to "ON"
and turn the adjustment volume on the side of the EGGS
control unit to the right (CW) until it stops in the self
diagnosis mode switching position B for more than two
seconds and then return it to the original position,

• Afterwarming up the engine sufficiently, raise the engine '''---'''-1

speed until the exhaust gas temperature waming lamp (or;
the red lamp on side of the control unit) flashes (the
flashing will start above approx. 2000 rpm). The rear \ ~~.

C
exhaust
'
autIon;
gas sensor output monitor mode will be set ! ,\,,;
'. ~",
~'//,8'- " \ c="=I'
I~~'
/
"
J

'''-..
,

The accelerator pedal must be pressed intentionally during i f ,--

idling to perform the inspection as the air fuel ratio feedback 'Exhaust gas temperature warning Ilgh,
control is stopped,

EN-36
 IDLE SPEED' IGNITION TIMING IIDLE MIXTURE RATIO INSPECTION
RB26DETTENGINE

IDLE MIXTURE RATIO INSPECTION (CONT'D FOR RB26DETT)

• Use a lead to short-circuit the CHK pin and the IGN pin of I Short these pins 'or approx. 2 sees men,
the diagnosis connectorfor more than two seconds one ' opec them, the GlagnosllWIlode will then.
: change. 0 I I I I ..t.<1 (The mode:
more time to release the self-diagnosis mode. (Otherwise will change LL each time i
turn the adjustment volume of the EGGS control unit side to Ihis
the right (CW) until it stops to select the self-diagnosis mode.
8 for more than two seconds and then return it to the Fuse
block
original position).

Exhaust gas sensor monitor mode switching display

Switching the signal for
• Set the ignition switch to "ON", Use a lead line to short eXhaliS( gas sensor -
CHK pin and IGN pin of diagnosis connector for more than exhaust gas sensor (R)
two seconds to switch mode, (Otherwise tum ignition switch
to "ON" and turn adjustment volume on side of the ECGS
control unit to the right (GW) until it stops self-diagnosis
T&
U~!;l~:u :
Ext,"ust gas senson
outputmonitof

mode switching position B for more than two seconds and

then return volume to original position,
~
Appro);. 4 sees
..-- -.
.... J
Switching the Signa! for
• After warming the engine sufficiently, raise the engine speed: exhaust gas sensor (R)
until the exhaust gas temperature warning lamp (or the red: - e.,naust
lamp on the side of the control unit) flashes (the flashing will
gas senso
,.....J U L.
nn i
I
start above approx, 2000 rpm). The rear exhaust gas : I i- . ExhausIgas sensor:
, :outpU! monitor
sensor output monitor mode will be set. ~~
Caution: Approx. 4 sees
The accelerator pedal must be pressed intentionally during ~-.--....- - - - - - - -
idling to perform the inspection as the air-fuel ratio feedback
control is stopped.

Make sure the exhaust gas temperature warning lamp or

the red lamp on the side of the control unit flashes in this
condition,

• Short-circuit CHK pin and IGN pin ofthe diagnosis

connector for more than two seconds to release the mode,

• Make sure that the exhaust gas temperature warning lamp

flashes at about 2000 rpm.

EN -37
 IDLE SPEED {IGNITION TIMING! IDLE MIXTURE RATIO INSPECTION
RB25DEENGINE

IDLE SPEED {IGNITION TIMING {IDLE MIXTURE RATION INSPECTION

(RB25DE ENGINE)
INSPECTION & ADJUSTMENT

I START I
J,
Visually check the following:
• Air cleaner clogging
• Hoses and ducts for leaks A
• Electrical connectors
!· Gasket
• Throttle valve operation

A , --
~rt the engine and warm it up. I
B .J,-
Open the engine hood and run the engine at about B
2000 rpm for about 2 minutes.
\ \ , I
C " \, ' " I
.,-
~
"
Perform diagnostic test mode II (Self-diagnostic -=-'-= t.-=-
result).
OK NG
-' ~
,,0
,..

1000 r! min
Q
~, -
\V
Repair or replace components
as necessary. C
.J,-
"
~
Does the engine run smoothly? Run the engine at
about 2000 rpm.

~
OK NG
.J,-
/
~ Clean the injector. I Red lamp Exhaust temperature
warning lamp
0 ,
Race the engine for approx. 2 - 3 minutes then run o
engine at idle speed.

\V
To E

EN-38
 IDLE SPEED I IGNITION TIMING IIDLE MIXTURE RATIO INSPECTION
RB250E ENGINE

E
Stop the engine and disconnect the throttle

® , position sensor harness connector.

Restart the engine. ,E_ _ _-,--:--:=.,.,,-.,----:---.
,~

/1
/ F~~
Race engine two or three times at about 2000 If----,
- 3000 rpm then run engine at idle speed. //
/
,
OK
F
Idle speed check
(b\ Read idle speed in "IGN RPM (REF)" in
~ "DATA MONITOR" mode. F
t<ff\ Check idle speed. ?t,ONITORIN~NOFAulTD
~ Idle speed (rpm) 650 +/- 50 IGN PRM (REG) 850 rpm

OK NG
W
Race engine two or three times at about
2000 - 3000 rpm then run engine at idle I
speed.
I START
I
G
'v
Idle speed adjustment
Adjust idle speed by turning idle speed
adjusting screw (lAS).
Idle speed (rpm) 650

H ,/
Ilgnition timing check
Check the ignition timing using timing light
or su per tuner.
Ignition timing (BTO°C) 15 +/- 2

Ignition timing adjustment I

Adjust the ignition timing by adjusting crank L '

angle sensor bolt.

Ignition timing (BTOCC) 15
Attach sealing tape to crank angle sensor
bolts. Part No. B2235U7410

,/

ToJ

EN-39
 IDLE SPEED I IGNITION TIMING IIDLE MIXTURE RATION INSPECTION
RB2SOEENGINE

J J
@ Touch "BACK"
~ Stop the engine and connect throttle
position sensor harness connector.
Start the engine.

iRace engine two or three times at about:

:2000 - 3000 rpm then run engine at idle
Ispeed.
K
K ONITORIN~ 'JO FAUc TO
lGN PRM (REG! 1337 rpm I

® Idle speed check

Read idle speed in "IGN RPM (REF)"' in
AIR FLOW METRE
WATER TEMP SENSOR 80C
o SENSOR
1.SBV :

~:2'.
I
® . "DATA MON ITOR" mode.
Check idle speed.
Idle speed (rpm) 650 +/- 50
:
0: SH.. SGR ~.1C~'TCR
BATTVO ...TAG:;:
,THROTTLE SENSOR
~I'::::~,
14.0V!
8.S2V'

OK lNG
i
START
Check MC valve and replace if necessary

1
Check MC valve harness and replace if L
c--
necessary
~ONITORIN~ NO FAUL
,IGN PRM (REG)
-=1
825 rprr I·
, i O,SENSOR O.02V
: 0 SENSOR MONIT2R :::(:~
Race engine for two minutes at 2000 rpm. 1

@ 0, sensor system check

See "M / R F / C MNT" in "Data monitor" mode.
Maintain engine at 2000 rpm check the moni-
II~'OA'~T
L
tor fluctuates between "LEAN" and "RICH" more
than 5 times in 10 seconds. - ~~
1 cycle "RICH, LEAN, RICH" ~V

®
2 cycles "RICH, LEAN, RICH, LEAN"
OR
Make sure that exhaust temperature warning
,
@ I
Exhaust temperature
lamp flashes more than 5 times in 10 seconds. Red lamp
waminglamp
NG OK
,y
\ I FINISH I
TOM

EN-40
 IDLE SPEED I IGNITION TIMING I IDLE MIXTURE RATION INSPECTION
RB250E ENGINE

M M
I Check 0, sensor input signal TOl
/f' ~ONITORIN~NOF AULTD:
: See "M / R F / C MNT" in "DATA monitor" IGN PRM (REG) 837 rpm:
AIR FLOW METRE 1.S8V!
.(j)mode. WATER TEMP SENSOR aoc
I Maintaining engine at 2000 rpm and :02 SENSOR O.02V
I 02 SENSOR MONITOR RICH
check the monitor fluctuates between: : BATTERY VOLTAGE 14.0V
"LEAN" and "RICH" more than 5 times in : THROTTLE SENSOR 0.52V

I 10 seconds. I !
!

i START
N 1
Check 0, sensor harness I M
I
Turn off the engine and disconnect the
battery ground cable.
~
Disconnect harness connector from IEGGS GIU CONNECTORI
: ECCS C/U.
i Check for continuity between terminal No.

! 29 of harness connector and the term i- L~ ~"

. nal NO.2.
OK lNG
N
I Replace or repair harness
-" I r:iJEZH13
I Replace O 2 sensor I
, IEGCS C/U CONNECTO
I Carry out operation L ~
w OK NG [ill
~

FINISH]

Start the engine and warm it up I

,It /

t
Race engine then run engine at idle speed I
:
w
CO check
Check the CO measurement with CO,
HC tester.
Idle CO below 0.1 %
HC below 50%
,J.,
Fuel pressure regulator check I

J"
Air flow meter check I Check idle speed(K)
f'

'"
Check the injector and if necessary clean:

w
Replace ECCS C/U and check C/U operation I

EN - 41
 COMPRESSION PRESSURE INSPECTION
RB26::lETT i RB20DET i DE I RB20E I CA 18i I RB25DE ENG~NE

2. COMPRESSION PRESSURE INSPECTION

Compression pressure standard value

Variance limit
Standard value Limit value
Engine between cylinders
(kg I cm2) (rpm) (kg , em')(rpm)
. . (kg I em') (rpm)

RB260ETT 12.0/300 9.0/300 1.0/300

i RB200E, OET 120/300 9.0/300 1.0/300 !

CA181 1221350 10.2 1350 1.0 I 350

I
RB20E . 12.51300 9.51300 1.0. 30e
!

RB250E 12.8 i 300 9.8/300 1.0/300

I

Engine speed measurement unit installation

RB26DETT J RB20DE J DET Engine
Connect the engine speed measurement unit to the speed detection pin on the harness
connected to the ignition coil from the power transistor.
Always attach the terminal cap with rubber seal after measurement is complete.:;

RB26DETT RB20DE/DET

CA 18i I RB20E Engine

Mold type ignition coil is used for these engines. Connect the engine speed
measurement unit by connecting the adapter for mold coil between the INT side coil
primary terminal and the hamess connector primary terminal.
RB20E CA18i

EN-42
 COMPRESSION PRESSURE I BELT TENSION INSPECTION
RB26DETT! R82GE DE DET! GAlai I RB25DE ENGINE

Compression gauge installation .

• Warm up the engine and remove all 6 spark plugs. I~
• Attach the adapter to the Allen compression gauge and ! --"""'-"-Jfr
set it in a spark plug hole.

Compression pressure inspection

• Depress the acceleration pedal fully. Tum the ignition switch to START position and crank
the engine. Read compression pressure and the engine speed once the gauge needle
stops moving.
• When engine speed is out of specifications, check the specific gravity of the battery and
perform test again if the battery is functioning properly.
• If the compression pressure is still not standard, inspect the components around the
combustion chamber (valves, valve seat, hydraulic valve lifters, piston rings, cylinder bore,
cylinder head, cylinder head gasket etc.). Correct any malfunctions and repeat
compression test.

3. BELT TENSION INSPECTION AND ADJUSTMENT

Inspection
The inspection should be performed when the engine cold or more than thirty minutes after
the engine has been stopped.

RB26DETT I RB20DE, DET I RB25DE ENGINE

. . ...

~
'! . . . ! !> . Belt deft&ction (mm. ..
. . . .. 1·1. .• •

Belt speclftcation
... .• •.•. (When 10kg of fOrce llIl!PpHed at the
.' .... ..! . . ! .•.... ~Y~posIIIon)· I ..•.... .
. .. .
New !Adjustment Tension limit
PART . . . . .. I·

Standard Poly·V low· 8 - 10 9 - 10 15

Power steering be~
With HICAS maintenance bett ! 8 -10 10 -12 16
Poly·V low-
Air conditioner compressor bell 6-8 7-9 12
maintenance beft

Poly·V low-
Fan belt 3-5 4-6 7.5
maintenance belt

EN-43
 BELT TENSION INSPECTION & ADJUSTMENT
RB26DETT i RB20E I DE I OET i CA 18, i RB25DE ENGINE

RB20E ENGINE
Belt deflelltkm (!nm) -
(When 10kg of fi)rce is applied at the
• ",·;posItIon)

New Adjustment Tension Umit

Poly-V Iow-
Power steering bell 8 - 10 9 - 11
maintenance belt

Poly-V low-
Air conditioner compressor belt 6-8 7-9 12
maintenance bell
~--------------+-
POly-V low-
Fan bell 3-5 4-6 7.5
maintenance bell

CA18i ENGINE
Belt deflection (mm)
(When 10kg of force 1$ applied at the
o " • position)

New AdJuatment Tension limit :

Poly-V low-
Power steering pump bell 9 - 11 10 - 12 15
maintenance belt
;---
Poly-V low-
Air conditioner compressor belt
maintenance belt
e 8 7-9 ~ 2.

Poly-V low-
Fan belt 4-5 4.5 - 5.5 6
maintenance belt

Caution:
1. When the belt is replaced with a new belt increase the tension slightly more than for the
used belt to allow for wear-in of the new belt.
2. When the belt deflection exceeds the limit, adjust to the "Adjustment" value.
3. Make sure the pulley groove is aligned correctly when the belt is installed.

Adjustment

IT_EM
"ADJUSTMENTPosrrioN-
PART
Power steering belt Adjustment bolt in power steering pump

Air conditioner compressor belt Adjustment bolt in idler pulley

Fan belt Adjustment bolt in alternator

Fan belt
Power steering ump belt
-".

iL..._ .... _ __

EN-44
 VALVE CLEARANCE INSPECTION & ADJUSTMENT
RS260E-, '<SL"E :)E DET,' CA 181 I RB25DE ENGINE

4. VALVE CLEARANCE INSPECTION AND ADJUSTMENT

Additional work required (remove the following parts):
• Airduct
• Rocker cover

Inspection
• Inspect the valve clearance when the engine is cold.
• Remove the air duct, ornaments and the rocker cover.
• Rotate the crankshaft and align crankshaft pulley mark with the belt cover indicator.
• No.1 cylinder is at the compression stroke top dead centre when both the intake and
exhaust side cams do not move the valve lifters.

I PART VALVE CLEARANCE

.

MEASUREMENT
i ITEM , .. "

!
INTAKE SIDE Cylinder No. 1.2,4

IEXHAUST SIDE Cylinder No. 1,3,5

Firing order: 1 ·5·3·6·2·4

Rotate the crankshaft one revolution (360°) and align the mark on the crankshaft pulley with
the belt cover indicator. (No, 1 cylinder piston exhaust T.O,C),

. . . . . . Varves to be adjusted
PART VALVE CLEARANCe: Intake side
MEASUREMENT ~ ~-.

ITEM '~~7'<1

k~~- . ~. .~ ';; ,.
INTAKE SIDE Cylinder NO.3. 5, 6 I.... ;-' '. . jjH~k=;~;tJ .
EXHAUST SIDE Cylinder No.2, 4, 6 ~.
Exhaust Side

Valve clearance standard value

. ' ,.' ..
I
PART
. INTAKE EXHAUST' .....
ITEM . .

, Valve clearance (cold) mm 0.45'< 'J O.38'""uo:J

(Reference value: warm) mm 0.51',' 0.44""'3

Cau(jQn:
Always check the valves when they are cold.

EN ·45
 VALVE CLEARANCE INSPECTION & ADJUSTMENT
RB26DETT I RB20E I DE I DET I GA1811 RB25DE ENGINE

Valve clearance measurement

Insert a 0.15 - 0.20 mm gauge (A) from spark plug side.
Insert gauge (8) from opposite side. Select a gauge
thickness that will reduce the clearance to 0 m.
Note:
Do not use more than two gauges (8).
Use JIS 150A25 feeler gauge.

Valve clearance =Gauge (A) + Gauge (6)

Reasons for measurement using gauge (Aj and (8) :
1. The valve clearance setting is larger compared to
previous engines.
2. Large gauges cannot be placed parallel to the f •

II Cam : \
measurement surface. ~ I :\

• Thick feeler gauge have high rigidity and cannot be bent

easily, so the measurement will be incorrect. )J~~fter
• The error factor increases if a number of thin gauges are
layered and the measurement will be incorrect.
~D/
I. O.05Lc. / .
Imm\', / I
Valve clearance adjustment 'I Wide I !--Retainer

• The valve clearance adjustment is performed by

selecting a shim of suitable thickness.
~0
I~"n
~ I
~/
, -...
Spnng

When the measurement valve clearance (t) is out of

specification, measure the shim thickness (T) and
replace it with a shim that will produce the standard
' '-1 1
, rU- Valve

clearance.

1. Shim thickness calculation method

Example:
When the intake valve clearance (t) is 0.50 mm:
0.50 (t) - 0.45 (specified value) = 0.05 mm
• The valve clearance is 0.05 mm greater than the specified value.
• Use a shim 0.05 mm thicker than the current shim to reduce the valve clearance.

2. Current shim thickness (T)

• Measure the centre of removed shim to determine the
thickness of the current shim.
Caution:
Do not reuse the measured shims again.
,
3. Shim selection o Shim
~~o~ not ..reus~~~~~as~.~mb~~
• Current shim thickness (T) is 2.40 mm.
2.40 (T) mm + 0.05 mm = 2.450

~
• Select new shim with stamped mark [24.40]
(T = 2.440 - 2.455).

~
• Select a shim within standard value range +/- 0.03 mm.

4. Shim types and classification T = 2,440 - 2.455 mm

• There are 70 types of shims. Sizes range from 2.275
mm to 3.325 mm in 0.05 mm increments.

EN-46
 LUBRICATION SYSTEM INSPECTION
RB26DE-- ;<62:~ DE DET I CAIBi I RB25DE ENGINE

5. LUBRICATION SYSTEM INSPECTION

5-1 LUBRICATION OIL LEVEL INSPECTION

Inspection
• The engine oil level should be checked before starting the
engine or if the engine has been started, the inspection
must be carried out ten minutes after the engine has been
tumedoff.
• The oil level should be between the Hand L lines on the Between L & H mark
level gauge.
• The oil must not have any white turbidity or dirt.

Lubrication oil replacement period

. ENGINE REPLACEMENT PERIOD· ..•. ....

OIL USED .
. .
RB20DET I RB260ETT Every 5,OOOkm or 6 months SO. SE, SG, SF class oil

Every 15,OOOkm or 12 months SE, SF, SG class oil

CA181 I RB20E
Every 1O,OOOkm or 6 months SO class oil

Every 15,OOOkm or 12 months SE, SF, SG class oil

RB20DE I RB250E
Every 10,OOOkm or 12 months SO class oil

Note:
Use genuine Nissan [Turbo X (7.5W - 30)] for service for RB26DETT I RB20DET vehicles,
Use genuine Nissan SG class [Extra save X (7.5 - 3D)] for service for CA 18i I RB20E, DE I
RB25DE vehicles.

Oil quantity
- ..
(lilsupplemen,tvoiultMtllllllan ...
. - ... ....
ITEM- 011. level (L)
. . ..<replaCed(L). ._./
.
II..:. '

.-.,. !. , OnIY;9B Oil and oilftlter

..
ENGINE
.'.
• •
H ........ Hie' . t
,rep c:emen., . ,'repleoemerrt

RB25DE I RB200E I RB20E 4,0 3.0 Approx,3.8 Approx. 4.2

RB200ET I RB26DETT 14WO 4.5 3,5 Approx.4.2 Approx.4.6

GA18i 3.4 2.4 Approx.3.2 Approx. 3.6

EN -47
 LUBRICATION SYSTEM INSPECTION
RB26DEr! RB20E! DE ! DET I CA 181 I RB25DE ENGINE

5-2 OIL PRESSURE INSPECTION

• Remove the oil pressure switch and connect the oil pressure gauge.
• After warming the engine, make sure the oil pressure is appropriate to the engine speed.

(011 temperature ao"c)

. .
RB20E, DE,·'
ENGINE RB26DETT CA18i
'.
DET/RB25DE
••
Engine speed (rpm) outtet pre&&ure (kg I em")

. 600 •
- Approx.1 Approx. 1
' . 800 Approx. 1.5 - -
2000 Approx.3 Approx.3 Approx.3

.. 4000 - Approx.4
.......
.'

6000 Approx. 4.6 Approx.4

RB20E RB26DETT I RB25DE I RB20DE CA18!

~.....!"'"

5-3 OIL FILTER REPLACEMENT

Removal
• Use oil filter wrench (special service tool) to remove the filter.
Caution:
Catch any dripping oil with rag etc. when removing the filter.
Installation
• Before installing the new oil filter, clean the oil filter bracket mounting surface on the
cylinder block and coat the oil filter seal lips lightly with new engine oil.
• Screw in the oil filter until a slight resistance is felt and them tighten 213 turn.
Caution:
Make sure the oil will not leak after starting the engine.

.... .. . REPLACEMENTPERfOD . L '. OILU$ED ......•..•...•.....•

. . ENGINE .•
RB200ET/RB260ETT Every 1O,OOOkm or 12 months SO, SE, SG. SF class oil

Every 15,OOOkm or 12 months SE, SF, SG class oil

CA 18i / RB20E
Every 10,OOOkm or 12 months SO class oil

Every 15,OOOkm or 12 months SE, SF, SG class oil

RB200E / RB250E
Every 10,OOOkm or 12 months SO class oil

EN-48
 EXHAUST SYSTEM INSPECTION
RB26DETT . RB20E D~.· DET I CA 18i I RB25DE ENGINE

RB20E RB20DE I DET I RB25DE CA18i

6. EXHAUST SYSTEM INSPECTION

6·1 AIR CLEANER ELEMEN1' INSPECTION (RB26DETT I RB20E I DE I OET)

Inspection
• Remove the bands shown in the diagram and remove the air cleaner element
• There should be no excessive dirt or damage on the air cleaner element.

Periodic replacement interval Every 60,000 km

RB260ETT RB20E / DE RB20DET

6·2 TURBOCHARGER INSPECTION (RB260ETT I RB20DET)

Function inspection
• Remove the intake manifold canister hose, and place a cap on the hose. Connect test
hose to intake manifold and attach pressure gauge (compound gauge).
• Perform the engine operation test and check that pressure does not rise above
approximately 0.8 - 0.9 kg I cm'.
a. When the pressure does not reach specified level.
Check for vacuum leak in intake or exhaust system or exhaust gas leak.
b. When the pressure exceeds the maximum pressure level (approx. 0.8 - 0.9 kg I cm 2 ).
Check if swing valve controller rubber hose is disconnected or cut.
Check if swing valve controller motion malfunctions (stays closed).
RB26DETT RB20DET

EN· ..\9
 EXHAUST SYSTEM INSPECTION
RB26DETT I RB2CDET ENGINE

Swing valve controller inspection

• Remove the swing valve controller rubber hose from the vacuum tube side.
• The controlierrod must start operating when compressed air approx. 0.7 - 0.8 kg / Cm2
(RB26DETT), approx. 0.8 - 0.9 kg / cm 2 (RB20DET) is forced into the hose by using an
air gun. Stop blowing compressed air as soon as control rod operation is verified.
Caution:
The diaphragm may be damaged if excessive air pressure is applied. Use the LPG
pressure gauge (special service took for 1 kg / Cm2) to verify that the air gun pressure is
approx. 0.7 - 0.8 kg / cm 2 (RB26DETT) or 0.8 - 0.9 kg / cm 2 (RB20DET) before testing the
air hose.

RB26DETT

6·3 RECIRCUl.ATION VAl.VE INSPECTION

Function inspection
• Remove the hose on upper flow side of the recirculation valve compressor (place the cap
on end ofthe hose) and check if air blows back when throttle is closed quickly.

RB26DETT RB20DET

Unit inspection
• Use a hand pump to create negative pressure ·150 +/- 30mmHg (RB26DETT) ·400+/·
50 mmHg (RB20DET). The recirculation valve diaphragm must start to lift up and the
vacuum pressure will be maintained.
..
:~~ -~~~~ I EG1513 0000

!~~,
,~! . •.• ~j
EN·50
 EXHAUST SYSTEM INSPECTION
CA18, ENGINE

6-1 AUTOMATIC TEMPERATURE ADJUSTMENT AIR CLEANER INSPECTION

System diagram
Vacuum motof:r=======:;:
Fresn air dt..:c~ Air cleaner

When cold
\ III!,

SPI body Intake manifoid

Fresh air duct Air cleaner

rr-':ml7rilli~i!1.::...:::;:.-_....J~~=~.-r-;;:J;j---::ii--r-e-m-pe-r-a-tu-re-rr-,
When warm ___ :: sensor

~. ,",

Warm air
SPI body Intake manifold
Function inspection
• Remove the air duct and start the engine, Inspect the vacuum motor operation when the
engine is cold and warm,

Change-over valve fresh air

Condition
dud side
When cold Closed

When warm Open

Temperature sensor preset temperature: Approx.40°C.
~--,- --'--""C'--
COMPONENT PARTS INSPECTION Temperature sensor (when cold)

Temperature sensor inspection <0

• Remove the hose to the vacuum motor and connect the
, htake
l
vacuum gauge, manifold
• Start the engine and check the negative pressure when when warm)Vacuum gauge
, '-I:L
the temperature of the temperature sensor was cooled I
warmed by the drier. • Air inflow M bel ~5120000

When warmed up No negative pressure i To intake rT)8mfold 10 vacuum gauge

When cooled Negative pressure created

~
-'"''''

EG1513000Q
Vacuum motor inspection , Apply negative IT,
pressure \-- .'
• Remove the vacuum hose from the vacuum motor and
connect vacuum hand pump.
• Use a hand vacuum pump to create negative pressure
(approx. -150 mmHg).
• Make sure the fresh air duct on the change-over valve
will close when the negative pressure is applied and it will
open when there is no negative pressure applied.

6-2 AIR CLEANER ELEMENT INSPECTION

Inspection
• Remove the clips and the nuts and remove the air cleaner
element.
• There should be no excessive dirt or damage in the air
cleaner element.
EN -51
 FUEL SYSTEM INSPECTION
RB25DE I DE I CA18i ENGINE

7 FUEL SYSTEM INSPECTION

• FUEL PUMP.
EASY INSPECTION (RB25DE)
• Turn the ignition switch to ON position, IS THERE A PULSATiON!
I
• Select "Fuel pump" in the "Function test" mode. EVERY 3 SECONDS WHE'J
THE FUEL TUBE is HE"D?
I
• Inspect the pulsation by holding the fuel hose with hand. : OR CAN YOu HEAR ~HE
I OPERATION NOISE OF ~HE :
l£UEL PUMP REL"Y? ~
I II
®
• Hold the fuel filter and make sure the hose is hard and
PASS NO II YES]

pulsation can be felt when the fuel pump is operating.

• Hose is hard
• Pulsation

FUEL PRESSURE INSPECTION USING THE FUEL PRESSURE METER

Releasing fuel pressure (RB25DE)
• Rev the engine. fE\ +ACTIVE TEST.

• Select "Fuel pump relay" in "Active test" mode. \J!J FUEL PUMP RELAY OFF '1'

• Press 'STOP' to stop the engine. Crank the engine over

CAS·RPM (POS) 950 rpm ,
two or three times. (If the engine does not start crank 3 - 4
times after removing the fuse).
F===1;=="==""
• Restart the engine and remove the fuel pump fuse. ~ IOPERAT~ IINTERRu~tSTOPl
• After the engine stops, crank the engine 4 - 5 times to ~ ~.
consume the fuel in the pipe, (If the engine does not start
. ft
crank 4 - 5 times a erremovlng the fuse).
~
,J ~
j
~=-- ..-- -::-~::-
Fuel pump (use
_1,;- -~c,
!
'
' .
C au tlon, "I 'r'f~--ilijH·!l1fF.t:¥fIlt"'- !
,:' 11~~:~,\;:'~~·QJ~i:!1~iWI~;;hr'. ,
The battery may become weak easily, use booster cable t o , : : ~~~,i~~.;pl .: '
connect to another battery if n e c e s s a r y . " , = - , ~'~~~, ',,);,

• FUEL PRESSURE.
Releasing fuel pressure (CA18i I RB20E)
• Rev the engine, WHILE !DlING PRESS
"START" TO STOP THE
• Select "Release fuel pressure" in "Operation support" mode. FUEL PUMP OPERATION,
AFTER ENGINE STOPS. I
CRANK THE ENGINE OVER
TWOORTHREETIMES, ,

START

After starting the engine, remove the fuel pump fuse. After
the engine stops, crank the engine over 2 - 3 times to
consume the fuel in the pipe. (If the engine does not start
crank 3 - 4 times after removing the fuse).
Caution:
The battery may become weak easily, use booster cable
to connect to another battery if necessary.
EN ·52
 FUEL SYSTEM INSPECTION
R826DE-- R820E! DE I DET! CA18i! RB25DE ENGINE

7-1 FUEL PRESSURE INSPECTION

Releasing fuel pressure (RB20DE I DET I RB26DETT)
• After starting the engine, remove the fuel pump fuse, After
the engine stops, crank the engine over 2 - 3 times to
consume the fuel in the pipe
• If the engine does not start, remove the pump fuse and
crank the engine 3 - 4 times to consume the fuel in the
pipe,
Caution:
The battery may become weak easily, so use booster cables
to connect it to another battery if necessary,

Fuel pressure meter installation

(RB26DETT I RB20E I DE I DET I CA18i I RB25DE)
• Connect the fuel pressure meter between the fuel filter and
the fuel line,
• Attach the fuel pump fuse,

Fuel pressure inspection

Start the engine and check if the fuel pressure is at
standard value,
• If the engine does not start, check fuel pressure after 5
seconds when the ignition switch has been turned ON,

Fuel pressure measurement

. .. ." :
RB20DE,DET ,

RB20E ".', , , REl25DE

"

ITEM ENGINE I ., , RB26DETT ' , CA'I81. "

,
. III'. '"
,

: When ignition switch is ON (kg/em') Approx 3,0 Approx 2,5 Approx, 3,0 -
,
Dunng idling (kglem<) I Approx 2,5 Approx 2,0 Approx. 2,55 Approx. 1,0

klling when pressure regulator

Approx 3,0 Approx, 2,5 Approx. 3,0 Approx, 10
vacuum hose is removed (kg/em')

RB26DE!T~T~

7-2 THERMO·WAX INSPECTION (CA18i)

• Inspect the wax stroke when in following temperature,

Temperature ( ·C) 25 80

Wax.troke S (mm). Approx. 25 Approx,30

I

EN-53
 EVAPORATIVE GAS CONTROL INSPECTION
RB26DETT I RB20E I DE I DET I CAi8i / RB25DE E"<GINE

8 EVAPORATIVE GAS CONTROL SYSTEM INSPECTION

Throttle
Purge control valve

Check valve

... Evaporative gas

, <;:::; Purge air
- , ActIVe carbon
--Filter

Tray
Fresh air

8·1 PURGE CONTROL VALVE INSPECTION

CANISTER
Inspection
• Use vacuum hand pump to apply approximately ·400
mmHg (-100 mmHg RB25DE engine) negative pressure
and make sure the vacuum pressure is maintained.
In that condition. check that small amount of air can be
sucked from the manifold vacuum path.

FUEL TANK VACUUM RELEAF VALVE (RB25DE)

Inspection
o Clean the valve housing.
If the fuel tank vacuum releafvalve is normal. you will hear
sound from the valve with small resistance when the air is
()£~
sucked in through the cap.
!; '\1}
o Replace the cap ASSY if the valve is closed or no
Spring valve v\ I
resistance is felt. ave

EN-54
 BLOWBY GAS REDUCTION DEVICE INSPECTION
RB26DEF '<'lEE JE JET, CA181 i RB25DE ENGINE

9 BLOWBY GAS REDUCTION DEVICE INSPECTION

blowby control valve

~~.t. ::lEJJ
F',
,<)'\ ~I fJ~"'- Flame arrester
\ ~ '--.J
~ I 'Buffle plate
,WI.
I~LI~ Blowby path
! Fr--,o; ,
J" lV'
-"':::;;..J""
I
~
'T~

l-_:~0 (= Fresh air

.. Blowby gas

9-1 BLOWSY CONTROL VALVE INSPECTION (EXCL CA18i)

Inspection
• Check the blowby control valve flow path.

CONDITION

Air is blown Air passes

Air is drawn in No air passes

Inspection (CA18i)
• Remove the air cleaner rocker cover hose when the
engine rev is approximately 1000 rpm and check that
fresh air is drawn in.
 ON-VEHICLE PARTS
RB26DETT ENGINE

10 REMOVAL AND INSTALLATION OF ON-VEHICLE PARTS

10-1 INTERCOOLER AIR DUCT ASSEEMBLY

Front turbocharger
Hosf Qutlettube Bolt L6-2.1tqJ Air hose
Hose Air tube ,! A h f::~
.f
lntercoorer~utlet ! " ~To ~ ose~',"f.-BOlt 1.6--1". ~ '""'"

ttllBOlt(;ne6-2~\~I~V'~01l~t6Jl ~~~~~Charg~'
ReCirculation valve,,1
(211Point 7J \ /14,
/~'-./
'- --;-~
''''P' " _,
~,] Nut 1m)"oullelIUbe[PO~
&('l6 k 'I Gasket.... , ,,""e.
j, /

Air
~,.'
hos~ (2) ~@ 16 \' 21~
Bolt 12) I
! )1Ii \ \
"'V €3 }D-'"
~/as ..,
~" ",,,:' Front
"""",,,;:""
,~..J\. r~.:,.PI> Nut(2J1J5-2.1
I Air hO~ ~/ ,-,,~ '~urboharger Rearturbocnarger
[Lv I ~ tr;,.,
~-Gaskel
Il~ W
---I
"'" \
,t
Arr tube AIr heise
I
"JU'i~
I,
I
Air hos,,",
AIr tU~be \ <V"
----..J'
(~
/

" ./
! ..//:0
,. - -
,
' t" '=--,,,- ASSY

, _
AIr hose
~
(~~
ASSY

Clamp [Point 61\ ~t 51 [Pomt 5J ~ ~~ 'Air tube \,~ AI" tube ",', , )
AA> I Air hose ! , / / , Boll "i'? I taA ,,(1 / /
'~ , V' c; ~\,!
Ain,ube/
(POint 51 /
rp iI A' h
Ir os~~
~,Nut (3r~1"- \~'
~
'
~~ ~ ""
I
,
",-", /i -
, '-'-
8 1 Air hO~' -',
\ ' j~_
,/ A
/ _ lfcleaner A
SSY
'c

Clamp (PointS) ! "' --~~::'_~ !ReprculanOft tube Air tUbe __ ~-(__ It t ,:~ Air duct ?
Air hose Q;
<o\'l' ,: ' ".(! ~~ ~A"
R-! W-~! ;
ouc,/Bolt mIMI
B,olt (2) 16 - 2.1
$J 0,38 - 0 51
<I' /;' 'c'". f'lb~ ; ',..:,-.. ~
,~,~'~::-',:~i' ~---/~,I / ~ d.,i::"··~#-
Intercooler sub
bracket (RH)
!
,
J "'"~
"
_ V ~ose ~/
Air r
':::-:-- !ntercooler sub \ Ali ducl
/
~ 1 ttll
~I~j 'I,
0...bracketILH) \ , Boll 0,38 - 0,51
\. ~ Intercooler inlet hose ! \
~ I [Point 3J ,Resonator
Intercooler [POUlt 4] / ~2: Resonator tube
---~. d ;-Bolt (2)
Batt 16 - 2.1 ttll
O~Nut 12) 1,6 - 2.~ttll
ttll kg-m
. , Replace after every disassembly
--~----------------------------------~
Additional work required:
• Undercover
• Front bumper

[Point 1] Cleaning air hoses & air duct

• Use air gun to remove any dust and rubbish before
removing each air hoses and air ducts,

[Point 2] Remove & install each air hoses and tubes

Removal
Place alignment mark on each air hose and tubes before
removal.

Installation
• Align the alignment marks when installation and make
sure to tighten the clamp securely.

EN-56
 ON-VEHICLE PARTS
~320JEiT ENGINE

[Point 3J Remove and install the intercooler inlet

hose
Removal
• First remove the resonator and the tube B before removing I' ~ '~.-,--?~
hose A. ,.
Installation I,
• Attach hose A, then attach resonator and the tube B as a
single unit to install.

[Point 4] Remove and install intercooler

Removal
1. Remove the bumper finisher and the bumper
reinforcement.
2. Separate the intercooler inlet and outlet hoses.
3. Remove the mounting bolt and two nuts. Detach
intercooler without scratching the fins.
~ Inlet
Caution: Outlet Mounting bolt hose i
: hose 0.93 -1.2 ,
1. An aluminium fins are used and can be damaged easily.
~~:~_~M--,o'-.u~.!ing nu~. ?. ~~~~~J
Do not place objects on the intercooler or allow tools or
other hard objects to contact the fins.
2. The main unit (tank, fin tube) cannot be disassembled.
Installation
• Installation operation is the reverse of the removal
operation. Perform the steps in order of 3. 2, 1.
Tightening torque (kg-m): 0.93 -1.2
~
~I
[Point 5] Remove and install recirculation hose I i
Recirculation
• Remove and install the recirculation hose and tube as shown ~=;:::=:=;:::=;=~=:;;:;;:=~
in the figure on right.

[Point 6] Install recirculation hose clamp

• When installing the recirculation hose clap. make sure it
will not contact bumper finisher.

[Point 7] Recirculation valve inspection

Unit inspection
• Use hand vacuum pump to apply negative vacuum of -150
+/- 20 mmHg and check that recirculation valve diaphragm
Recirculation valve
lifts and vacuum pressure is maintained.

[Point 8] Remove and install turbocharger outlet

tube
• Remove and install the turbocharger outlet tube as shown
in the figure on right.
 ON·VEHICLE PARTS
RB26DETT ENGINE

10·2 AIR CLEANER ELEMENT ASSEMBLY

"~
A\r hose Air C\leaner e'ement
/1 BOlttoJ~;::~~-·:
/,
To rear turbocharger Air cleaner c o v e r / : c L '
To front turbocharger / /" P
t '

1
~
/,/
~\$> /
[\~
//'/(-"~~7
/:
Air hose ~~
~~
\
Air clea~e~ case
/"
Air duct
,toJ kg-m

Additional work required:

• Remove turbocharger outlet hose

[Point 1] Air hose and air duct cleaning

• Use an air gun to blow off any dirt and dust before
removing the air cleaner element

[Point 2] Remove and install air cleaner element

Removal
1. Remove turbocharger outlet hose.

2. Remove four band clips from the air cleaner. Lift air
cleaner cover and remove the air cleaner element
Installation
• Instail in reverse order of removaL

[Point 3]
• Make sure the air cleaner element is not dirty or damaged.

Periodic replacement interval: Every 60,000 km

[Point 41
• First connect the air flow meter connector for front turbo
charger and then install the air cleaner cover.

EN-58
 ON-VEHICLE PARTS
qEl26DETT ENGINE

10-3 CONNECTOR ASSY

(1) Collector ASSY removal and installation

Additional work required:

• Release fuel pressure in the fuel lines [Point 1]
• Drain cooling water [Point 2J
• Acceleration control wire [Point 3]
• Air inlet hose
• EGI harness connector, harness clamp
• All hoses

[Point 1] Release fuel pressure

• Start the engine
• After starting the engine remove the fuel pump fuse and
Fuel pump fuse
wait until the engine stops. Crank engine two or three times i'l
I ,'~~-

to consume fuel remaining in the fuel pipes.

• If the vehicle doesn't start, remove the fuel pump fuse and '\,~~f''g'#.'iti=f5~4ti;ffi¥.ic\t
crank the engine four to five times to consume f u e l ' E!fr ,~"I I , ,.'l t~~
remaining in the fuel pipes. - Remove J~'
Caution: :"i' t:::f!.
The battery may become weak easily, use booster cable to
connect to another battery if necessary.

EN - 59
 ON-VEHICLE PARTS
RB26DETT ENGINE

[Point 2] Draining the cooling water

• Make sure to drain cooling water completely from the
cylinder block by removing the drain plug.
Caution:
'~ !
Make sure the coolant does not spill on the front tube.

[Point 31 Accelerator wire adjustment

• Loosen lock nut to provide adequate slack for the
accelerator wire and pull outer case in the direction ofthe
accelerator.
• Return the lock nut 1.0 to 1.5 turns from the position the
throttle drum starts moving (when there is no play in cable)
and tighten.
Tightening torque (kg-m): 0.8 - 1.0

[Point 4] Remove throttle chamber links

• Remove the mounting nuts indicated by arrow marks in the
diagram. Separate three throttle chamber links from
collector side.
Remove the harness from the throttle sensor and the
throttle valve switch.

[Point 5] Fuel pipe removal

• Remove three bolts indicated by the arrows and separate
the fuel pipe.

[Point 6] Air hose removal

• Separate the air hose A, Band C from the collector side.

[Point 7) Booster vacuum removal

• Remove the clamp bolt and remove the booster vacuum
tube by separating it from the collector and the air
chamber.

{Point 8] Remove and install air chamber bolts

Removal
• Separate the air chamber by removing three bolts.
Installation
• Insert bolt B in air chamber bolt hole, before performing
final assembly.
Tightening torque (kg-m): 1.6 - 2.1

EN-60
 ONNEHICLE PARTS

[Point 9] Remove and install collector nut

Removal
• Remove the nuts in the reverse order of the figure on the
right.
Installation
• Install the nuts in the order shown in the figure on right
uniformly in two to three stages.
Tightening torque (kg-m): 1.6 - 2.1

[Point 10] Remove and install air chamber

Remove
• Separate the air hoses A. B, C, vacuum hoses D, F and
AAC valve connector and remove the air chamber.
Installation
• Position the air chamber in place, connect the air hoses C,
0, A, vacuum hoses F, then connect AAC valve.

[Point 11] Remove and install MC valve

Removal Gasket E3~
• Detach the AAC valve by first removing four bolts. Me valve \. ~
Caution: ~ ~ ~ir chamber.

~
(1) AAC valve cannot be disassembled.
(2) Replace gasket with a new one. Bolt(4) I
Installation !R:1064-0.85
• Install gasket and the AAC valve.
Tightening torque (kg-m) 0.64 - 0.85

[Point 12] Me valve inspection

• Measure the AAC valve resistance
Resistance (20°C) n Approx. 9 - 10

(2) Collector ASSY disassembly and assembly

Boll (4)tql 0.64 - 0.85

Throttle valve S':'~itCh
~V
.. ~
.,-"
Bolt (2) I'!"'!'I 0.64 - 0.85
/ ~
,
~ -" ~-- - Acceleration work unit
~ Bracket ""~
/t/ ~ 6_-KnOCk pin (2)

~ ~l-t;:~i .\' ~ Intake temperature sensor

. 'F '. tql20-30
"-~

./
,/
'.~ J
Collector [POint 1( '. ~~
v& :;as~£'
EN - 61
 ON-VEHICLE PARTS
RB26DETT ENGINE

Additional work required:

Collector ASSY installation refer to "Throttle valve switch
system inspection" for the throttle valve switch adjustment
procedures.

[Point 11 Collector inspection

Measure the collector installation surface for distortion in
six directions (opposing directions, up, down, left, right,
horizontally and vertically).
Limit (mm): 0.15

10-4 SIX IN-LINE THROTTLE CHAMBER REMOVAL AND INSTALLATION

('; Replace after every disassembly

Additional work required:

• Collector ASSY removal and installation
• Canister hose

[Point 1] Throttle chamber inspection

• Check for any cracks and that supplemental air paths are
not obstructed.

[Point 2] Install throttle chamber

• Install No.1 to No.3 throttle chambers.
C.aution:
Do not make any mistake when installing the chamber.

EN -62
 ON-VEHICLE PARTS

10·5 SIX IN·LlNE THROTTLE CHAMBER LINK ADJUSTMENT

Thrortie :::hamber

NutB
~""~",-
"~o. 7hrottle chamber

Nut A Detail of part a

Detail of part b

[Point 1] Install accelerator work unit

• Install six in-line throttle chamber and the accelerator work
unit and connect No.1, 2 and 3 throttle linkage.

[Point 21 6 in·line throttle chamber link adjustment

1. Loosen nuts A and B for each throttle link. Turn the
centre adjustment of each throttle link anticlockwise to
shorten the linkage.

2. Shorten each throttle link until acceleration drum contacts

fully closed stopper on the accelerator work unit side.

3. Shorten each throttle link, so the throttle cham ber lever

opens wider than fully closed stopper on the throttle
chamber side.
Caution:
(1) Do not lock the nut A and B.
(2) The throttle chamber lever opening angle should be
adequate.

EN - 63
 ON-VEHICLE PARTS
RB26DETT ENGINE

4. Insert 1 mm thickness feeler gauge between the

accelerator drum and fully closed stopper on the
accelerator work unit side. Secure the accelerator drum
so it does not move.

5. With thickness gauge inserted, turn the centre

adjustment in No.2 throttle link clockwise to lengthen the
throttle link until the throttle chamber lever contacts the
fully closed stopper on the throttle chamber side.

6. When tuming the throttle link with your fingers. You will
feel resistance when the fully closed stopper contacts
the throttle chamber lever. Shorten the throttle link to the
point just before this resistance is felt.

7. Carry out the steps 4, 5, and 6 to adjust the No.3 and 1

throttle links.

8. Tighten the lock nut A and B after the adjusting three

throttle links. After the nuts are tightened, No.1 - 3 l
throttle links must turn with the same degree of
smoothness. I
Caution:
Make sure the centre adjustment link will not rotate when the
lock nut is tightened.

9. Remove the thickness gauge from fully closed stopper

on the accelerator work unit side.
Caution:
Do not adjust fully closed stopper nut.

10. Completely open and close the six in-line throttle

chambers repeatedly and make sure that each throttle
chamber moves smoothly.

EN-64
 ON-VEHICLE PARTS
R826DETT ENGINE

10-6 INTAKE MANIFOLD ASSY

(1) Intake manifold ASSY removal and installation

Bolt (4) U 2.1 Washer

[Pomt 'I A Spnng washer Intake man;fold ASSY
Bolt (2) 1.6 - 21 Nut (3) 1 6 2.1 A
r:qJ
[Point 11 [POint 1]

o Replace after every disassembly

Akg-rn

Additional work required:

• Collector ASSY removal and installation
• Throttle chamber removal and installation
• ECCS harness connector and all hoses
• Water outlet hose
• Blowby hose

[Point 1] Remove & install Intake manifold ASSY

bolts and nuts
Removal
• Removal is the reverse order shown in the figure on the
right
Installation
~JJ ~~ ~~ 0 _
• Install the bolts and the nuts in the order shown in the figure
10 6 24 8 2 14
on the right Tighten in gradual steps to uniform tightness. 11 , 13, 2 are nuts"-_ _ _ _ _ J

. "- Length: No. of bolts lnstaHaUon loeaflon

- "

30: 4 3,5.6,8
Boft length
below head 60: 5 1,4,10,12,14
(mm)
"
""" 65: 2 7, 9

[Point 2] Air drain plug

• Carry out the operation when engine is cool.
Caution:
Do not remove the air drain plug when the engine is hot
When topping up the coolant, always remove the air drain
plug to allow air within the engine to escape !tr-is prevents : 'NEVER
: iOPi::"l
overheating). . ;",'I/.,E~ rot~?"=r-~;,;c

Tightening torque (kg-m): 0.7- 0_8

EN·
 ON-VEHICLE PARTS
RB26DETT ENGINE

(2) Intake manifold disassembly & assembly

Balance tube [Point 6J - __ '~,~ i-~-BOlt i5) 0,64 - 0,84 ~

'>,., " I
-~
,~I-~
:o:;~) 16 -
1
n
~-" t3 a-ring ;Point 6] oJJ t3 ' 1('1"-,
I '. ~

\", _o-ringl
2,

~(~~~= .~, --~-:-,~:-,~-~--;;::",,:""

Injector [Point 31
[POlntp,I
, W a t e r temperature
/ ~=iJ.l!N'" rdrum plug 0 7 - 0 8/sensor 2 0 - 30
/~-::'~J'.,,,,,P"~W t3 LJ '\/0 waSher~ ~
Fuel tube injector ASSY [Point 21 O-nng O"'''-)<') - ~water outlet elbo
I I<? ... [OOlnt51
~'
,'0
'" - Ur P:~~,
.;~ \
"" - ' •

pt""Jt
~_.. BoJt{2) 1.6-2.1 ----i
"'" Pressure
~ 'jlZ:l (poont 2] ..........l1li.4
Screw {21 023 "'" 0 3t--- ,,/
" /' ~7
~I
regUlat~ 1

Intake mamfold [POint 1]

'&€ Bolt 1 6 - 2 1

-.J , /
~
~.
1!C1
~ .......- ~ ~ Water bypass conl'lectof
Air 'eguJator ~"M ~ ~~- ;:s: ,[POint 4] ~ ~ Bolt 1.6 - 2.1

~ Boltj2) 0.64 - 085_~-~ Bolt (4) --J! vJ~ 1.6-.21~

~ Liquid gasket 1.6 - 2.1 ~ @ ~ Bort ,6 - 2.1~
( ; Replace after every disassembly

~ kg-m

[Point 1] Intake manifold inspection

• Measure the intake manifold surface for distortions in six
different directions (at opposite directions: up, down, right,
left, horizontally and vertically) in several locations.
Limit (mm): 0.15 I~-:;:;;:~:R Thickness
, gauge

I--"'---'-~
[Point 2] Fuel tube ASSY ,. Fuel tube injector ASSY I
• Replace a-ring with new ones when pressure regulator is I '
removed and installed. Pressure regulatoli

Ci3ulipn: ~crew 1

t3 o_rin7tt~1
Care must be taken not to scratch the fuel tube a-ring surface
when installing the pressure regulator.

[Point 3] Coring (for fuel injector pressure regulator)

Precautions when handling
• Never reuse a-rings.
• Coatthe a-ring with engine oil (10W -30 or equivalent) or
silicon oil (NUC silicon L45 or equivalent), but do not apply
solvent as this may remove the oil coating.
• Avoid using dirty a-rings and do not allow dirt, dust or
foreign objects to adhere to O-rings or other eqUipment
surfaces.

EN -66
 ON-VEHICLE PARTS
"326DE~T ENGINE

Do not decenter or rotate the fuel injectors and the

pressure regulator when inserting them into the fuel tube.
• Do not store O-rings in location subject to ozone. high
temperature or in the direct sunlight

[Point 4] Install and remove water bypass

connector
Removal and cleaning
• Remove eight water bypass connector bolts. Insert driver
in clearance between intake manifold and water bypass
connector and move it lightly to remove connector.
• Use a scraper and remove liquid gasket.
Caution:
Also remove liquid gasket in the grooves.
• Wipe off mounting surface with white gasoline etc. ,------.... -.~~~~- -.
.......
Installation

L~~.~
• Cutthe nozzle end of liquid gasket (KP510 00150) in the "r - /S3993: .

position shown in the figure. Use a tube presser to apply

gasket. Install bypass connector within 20 minutes of
applying liquid gasket.
• Apply liquid gasket (KP10 00510) to water bypass
connector surfaces in four locations. then install water
bypass connector within 20 minutes.
Cflution:
(1) Apply liquid gasket coating 3.0 mm wide.
(2) Coat on the inside of installation holes as shown.
Tightening torque (kg-m): 1.6 - 2.1

[Point 51 Water outlet elbow

Removal and cleaning
• Remove two water outlet elbow bolt and insert screw
driver handle as shown. Move it up and down to remove
the elbow.
• Remove liquid gasket from intake manifold and water
outlet elbow by using a scraper.
Caution:
Also remove liquid gasket in the grooves.
• Wipe off mounting surface with white gasoline etc.
Installation
• Cutthe nozzle end of liquid gasket (KP51 000150) in the
position shown in the figure. Use a tube presser to apply
the gasket.
• Apply the liquid gasket (KP1 000510) to intake manifold
surfaces in four locations, then install within 20 minutes
Caution:
(1) Apply the liquid gasket coating 3.0 mm Wide
Tightening torque (kg-m): 1.6 - 2.1
EN - 67
 ON-VEHICLE PARTS
RB26DETT ENGINE

[Point 61 Remove and install balance tube

Removal
• Check the size of the O-ring when removing balance tube.
Installation
• Always replace the O-ring with new ones when installing
balance tube.
• There are three different O-ring sizes. Make sure to install .
the correct size. ,--~~-. --~~- .. .....,~~ ....- ..~

...... ' ......... c.

.;< .. '. Number of unit Installation location
. ...
(Hjng A (.mall) 3 Cylinder 1. 2. 3. 4. 5. 6

o.nnlJ B (large) 4 Cylinder 1, 2. 5, 6

().ring C (nMldlum) 2 Cylinder 3. 4

• Be careful not to pinch the O-rings during installation.

10-7 TURBOCHARGER ASSY

(1) Turbocharger ASSY removal & installation

FRONT SIDE REAR SIDE

To cylinder block ':. ! Oil

~Gaskel-- . 80110.4 - . I Oil hose
~O ~ "-~ttl!oiltube '£J?,~~--::''''
'I

20-3f,ll
-\,J V"i 8racket~~~/ 80It1·,6--2,'1:
~I
Oil hose--\.$T I IEyebe';;;::
- "-Yoke
,g,~
ttl!
To cylinder
.racKe,<
. '. I :2.0-~';ID 9olt1.£-2.1ttl! I -""-'7
0,1 pipe I • In! ,'-41
ttl! Bolt (2) 1.3 - 19 1'-'" ;;.'"~\Washer
e-- Coppar washer 0
::qJ, Bolt (2) 1.0 - 2.1~.JA"\\~ ..... copper washer
Copp~r wash~r Oil & water tube
Eyebolt ttl! .,
°L// 2.0 - 3.0
Copper washer

I0 Replace after every disassembly

EN-68
 ON-VEHICLE PARTS
~526D:::TT ENGlNE

Additional work required:

• Remove and install undercover
• Drain cooling water
• Separate exhaust front tube
• Remove and install exhaust gas sensor connector
• Intercooler air inlet tube and hose
• Air inlet hose
f'iote:
Also remove cooling water from engine drain plug.
(If water is only drained from the radiator drain cock, the water inside cylinder block will not be
drained completely).

(2) Front turbocharger ASSY removal & installation

Removal sequence
(1) Loosen the flare nuts oftubes A and B.
(2) Remove bolts and detach tube A.
(3) Loosen flare nuts of tubes C and D on the turbo side.
(4) Remove hose B and bolts.
(5) Remove bolts and detach tube
: Exhaust manifold cover
(6) Remove three bolts, cover and ground cable. ,.
(7) Remove two bolts and detach tube H. Make sure
that bolt mounted on upper side is shorter than lower
side.
(8) Remove three bolts, cover and ground cable.

(9) Remove oil return hose.

(10) Remove three bolts and detach bracket.

(11) Remove four turbocharger nuts.

(12) Lower turbocharger ca refully.
(13) Remove six exhaust manifold nuts.
(14) Pull the exhaust manifold in direction 1 and then raise
it in direction 2 to avoid turbocharger stUd.
(15) Remove exhaust manifold.
(16) Pull out turbocharger.

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

EN - 69
 ON-VEHICLE PARTS
RB26DETT ENGiNE

(3) Rear turbocharger ASSY removal & installation

Additional work required:
• Front turbocharger ASSY removal and installation

Removal sequence
(1) Remove front turbocharger and the exhaust manifold
ASSY
(2) Remove two nuts and the clip securing bolt, and
separate the tube A.
(3) Remove three bolts and detach exhaust manifold cover.
(4) Remove eyebolt S, C and E.
(5) Remove two bolts and separate tube 0 from cylinder
block side.
(6) Remove three bolts and detach bracket.
The sequence after this step is same as number 11 to 16 of
the front turbocharger removal and installation.

Installation sequence
• Installation is reverse of removal sequence.
• Loosen the water tube flare nut before installing eyebolt S.

(4) Turbocharger ASSY disassembly & assembly

FRONT SIDE RfARSIDE
I
9-~Nut (4) 2.3 -3.0: i81-~Nut (4) 2.3 - 3.0
Lock plate (2) [Pant 3]~ ~ Lock plate (2} [PoInt 3]--4:.... Exhaust gas sensor

A/- - -
_-:~ Exhaust gas
f'\ 1 8 - 2 4
yens :
:;t:!l 'I
-<"I~
'2"::,,/,,~"">' ~~.
18 - 24
,
~
1fi'71 -C:-h' '._~ /I¥>/ '" ~:::;" \ ~ ~
)7';
1
/" I ' \
~/ t!'~~ \ I ~j ~
Turbocharger Inlet _
gasket 0
J:'ot:.. /
<:;J;::::f-" '".
:;t:!l ~ut (~) I
23- 30 Turbochal!l~e!..:~
0
gasket ~
<'-, ~
-, \
Nut \5)2.3 - 3.0

Exhaust outlet - '-0-"""-' ~ : ! Exhaust outlet ~

Front turbo charger ASSY ~-~ Rear turbo charger' ~~
l' >: AIr'nl~ltub~SSY
j

\ . ~_---"~CJ) \ --, ' ~_-~~~':J l:>

Air inlet tube ::>~-." - I \ C p~ :./'1
--, -<.;.c.c)., ~ ~/f I '
\~_,J?J,-'
~
J 'o£as(?;S~!
Jr ~ ;~ '. _~
k~\ ~
'I - J OG~Sk~~~\~/;'
, J <1J-
~yr= ' I ~ 'Exhaust ; ~ I i ~
j
I !3f' Exhaus1-I"
I, I \ ioutla~ \ :':;; / \ , \ 0 Gasket I outlet &1 \
" 0 Gasket ' cover ~Bolt (3)tc!l' \ \ cover' Bolt (3)[qJ
,Bolt (2)ttll Bolt (2)ttll 0.38-0,51' Bolt(2)ttlI Bolt (2) ~ . 0.38-0.51
1.6-2.1 0.64-0851 ttllEyebolt2.0-3.2 : 1.6-2,1 0.64-0851 ~$yaboIt2,Q-3.2

_ bit i: ~~waSharo: I ~waShero

~ye 0 ~, EyebOlt [@lo~
'./ - . I
Copper W3Shero-l:/ "'" . I: Copper waShert) ~~ 0
l.../ Watertube[Polntl j I ,, v' Water tube (Point 1]

ttll kg-m
o Replace after every disassembly
EN-70
 ON-VEHICLE PARTS
'626DETT E"IGINE

Additional work required:

• Turbocharger ASSY removal and installation
~ ~ater I ~-~water ~
[Point 1] Water tube inspection
i ~nlet tubel \~.' ---,nlet
,,~~,
tUb1
-.~, I '"<"':::5"h>_
• After cleaning the water inlet and outlet tubes with radiator
cleaner, blow with compressed air and check for rust or. I J,:'"
/
I AIr gun tv "
""

any clogging. iRacj,at2:e'an",r_l_ ~~

[Point 2] Oil feed tube inspection

• After cleaning the oil feed tube with engine conditioner,
blow with compressed air and check for any clogging.

[Point 3] Remove and install lock plate

• Spread the lock plate pawls with a screwdriver and loosen
nuts.
• Position lock plates and turbocharger mounting nuts,
After tightening the nuts, bend lock plate pawls onto the
nuts.

[Point 4] Eyebolt determination

• Oil feed (turbocharger side) eye bolts are stamped 'J'.

(5) Turbocharger unit inspection

Crack inspection
Crack burn inspection

~~~~~~~=~~~--Actuator [POint 7]
Excessive pressure leak

'--'-- Compressor wheel

Sw,ng valve [POint 31 [POint 5]

Turbine rotor 1.2,4] Rotor sha1 [POint 6, 8]

[1~,~.' Oil leak inspection location

..........

EN -71
 ON-VEHICLE PARTS
RB26DETT ENGINE

[Point 1] Rotor shaft inspection

• Make sure the rotor shaft rotates smoothly with no
heaviness or dragging when turned by finger.

[Point 2} Turbine rotor inspection

• Oil must not adhere to surface.
There is no carbon accumulation.
• The vanes of the turbine must not be bent.
There is no interference with turbine housing.

[Point 3] Swing valve inspection

• Remove actuator rod pin and make sure the swing valve
moves smoothly without deformation or cracks.
• Make sure there are no misaligned seating surface in
turbine housing.

[Point 4] Rotor shaft play inspection

• Set the dial gauge and measure play and thrust clearance.
• Insert the dial gauge in oil return hole and measure rotor
shaft play.

Rotor shaft play (mm) 0.056 - 0.127

Thrust clearance (mm) 0.D13 - 0.096

[Point 5] Compressor wheel inspection

• Oil must not adhere to suction inlet.
• There must be no interference with compressor housing.
• Wheel must not be bent or damaged.

[Point 6] Rotor shaft inspection I-\-cc. , i

?,A
~.::~-S,

• There must be no carbon sludge accumulation. tt-il ,,-]I _~rm,'

, J'!} I
. ..:
L'" 'l;j \1
j-'

~ j' I c?ff!i
I I No carbon
I }II slu<lge

J~h~ I

EN-72
 ON-VEHICLE PARTS
"826DEF ENGINE

[Point 7] Swing valve controller inspection Air ,gun

• Connect the swing valve controller rubber hose on the Actuator
actuator side.
• Check the swing valve controller when the actuator rod is
installed or removed.
• Check to see if the controller rod will operates when the
compressed air pressure (approx. 0.7 - 0.8 kg I cm2) is
applied. Stop blowing air as soon as rod operates.

[Point 8] Oil & cooling water inlet and outlet

cleaning
• Use engine conditioner to clean the oil feed and return
passages.
• Use radiator cleaner to clean cooling water feed and
retum passages.

• Clean with airgun.

• Clean the compressor wheel. turbine wheel, compressor

=housing and turbine housing with same methods.

EN - 73
 ON-VEHICLE PARTS
RB26DETT ENGINE

(6) Turbocharger failure diagnosis (Oil leaks, smoke (white or blue smoke), lack
of power, poor acceleration, abnormal noise)

Points to be checked before diagnosis:

1. The engine oil level must be between the MIN and the MAX marks on the oil level gauge.
(When the engine oil level is higher than MAX line, the engine oil will flow into intake
duct through the blowby gas recirculation pass and the turbocharger may be
determined to be malfunctioning).
2. Check with customer to determine if oil is cooled when idling after driving.
If any malfunction in the following chart is detected in a unit inspection, replace the
turbocharger ASSY.
,
..... '
....•
..
....
. '. .Possil>re.~plHltiO_n .
>' ..
.......
InI!lpflCl!on lOcatIOn
...
In&pectlOrlrGsult I. ..' ••• "'Lackot
'
QllIeIIk' Smoke .Abnormal _""{Poor:
•••••
.... .
: . .. . .. ' ,..
.'.....
noise acceflndiOn" I

Oil on rotors 6 © 6 6 ,

:
Carbon has accumulated , 6 © 0 0
Turbine rotor
~'\
Rotor scrapes against the housing 6 0 © U
,
Turbime vanes are bent or folded © ©
Suction inlet IS dirty with oil 0 0 :

n I
Compressor wheel Rotor scrapes against the housing 6 'V © 0
r----
Turbine vanes are bent or folded © ©
,
i
; There is resistance or scraping
. when rotated by finger 6 6 0
i I
Turb!ne and compressor
Rotor SI18t play inspection
Rotation by finger is not possible © :

,
Considerable shaking between
rotor shaft and tlft'bo ASSY 6 6 , C 6
Look through oil hole Carbon sludge has accumulated
6 © L::. 6
(inspect intenor with pen light) in waste oil hole
I
The valve does not move i
!
smoothly when pressure is
Swing valve operation ,
(use air gun or air pump)
applied gradually. (usually opens
at pressure greater than 0.6 - 0.7
i
©
kg/em') 1

I
© Highly posslole o POSSible 6 Slightly possible

EN -74
 ON-VEHICLE PARTS

10-8 EXHAUST MANIFOLD ASSY REMOVAL & INSPECTION

FRONT SIDE REAR SIDE

Exhaust manifold cover ~ Exhaust mantfOld c o v e k

aolt (3)~
038-0.51 :
fPOlot4]
.
I

,
I
'"
, ~~
-)
/r__--.•Z,;:!
/ "J'r
\
Bolt (3),~
0.38-0.51
[PO",! 4]

Exhaust manifold Exhaust manifold

[Point 3] [Point 3]

• ~ <g-rn
I0 Replace after every disassembly

Additional work required:

• Turbocharger removal and installation
• Gas leak inspection [Point 1]

[Point 1] Gas leak inspection

• After removing exhaust manifold, make sure there are
no traces of gas leaks from any parts.
• After the installation, crank the engine and check for any
gas leaks.

[Point 2] Remove and install exhaust manifold nuts

Removal
• Removal is the reverse of installation sequence shown in
the diagram on the right.
Installation
• The installation sequence is shown in the diagram on right.
Tightening torque (kg-m): 1.8 - 2.4 4 1 3

[Point 3] Exhaust manifold inspection Straigh{ gauge"--__::::::::::::::::::~

• Measure the exhaust manifold surface for distortions in
six separate directions (opposite directions. up. down. left.
1\
right, horizontally and vertically) in a number of localions. ~
Limit (mm): 0.3 I
~S:~
I Z!
~~~
,~
~, ThicKness gauge
. '
EN 75
 ON-VEHICLE PARTS
RB26Dcr eNGINE

[Point 4] Install exhaust manifold cover FRONT SIDE A REAR SIDE A

• Attach the exhaust manifold cover bolts in the following
sequence. (both front & rear) 8\,----(
..' B . \-------_~
1. Temporarily tighten bolts for positions indicated by A.
2. Tighten bolts in the positions indicated B ~~-'
3. Tighten bolts in holes A to specified tightening torque. B B
Tightening torque (kg-m): 0.38 - 0.51 .~~- .. - -.. -._ .. __..-

10-9 SPARK PLUGS

~Bolt (4) 0.04 - O.85~1i¥ Pc;wer transistor

li / Ornament bolt (2) 0 23 - 0 31 ~
Ornament bolt (8) ~ ",/ Screw (31
:123 -.o.31~ Ornament. ~ '; <;?k ~~==-_
, \~;;:'! 'f

~\~
/'"
:gmtion coil harness

Additional work required:

• Remove and install air inlet pipe
• Remove and install blowby hose

[Point 1] Remove and install ignition coil bracket 0.23 - 0.31

Removal
• Hold the coil body when removing the ignition coil bracket
C51JJJion~
Do not hold the coil connector when removing it
~CYlinder side
Installation 'lgmtion I braCke~~ ~
• Make sure to attach the ignition coil hamess when
installing the ignition coil bracket to the cylinder head.
l Holder
Spark -plug _"

Platinum tip
Seating metal \
[Point 2] Spark plug maintenance
• Gap inspection and adjustment is not necessary as a .
\\ ~
lf~
iwrn"ll'l ~,
platinum Up is used.
• Replace the plug every 100,000 km.

I_~_. _~______~~J
• When using a compressed air spark plug cleaner, clean
the plugs at maximum pressure of 6 kg/cm2 for no more
than 20 seconds.
EN-76
 ON-VEHICLE PARTS
RB26JETT ENGINE

10-10 ROCKER COVER REMOVAL & INSTALLATION

Rocker cover screw

FiI!er cap

O-ring-,
",~ (left & fight 10 each)
0.2 - 0.4 [Point 1J A
Y
"Ciit ~,K~\
Grommet

Additional work required:

• Remove and install air inlet pipe
• Remove and install blowby hose

[Point 1] Remove and install rocker cover screw . . Front

Removal
• Remove the screws in reverse sequence shown in the 1

:
7 3 5 9
figure on the right.
~I
@ I
Installation
Perform installation in the sequence shown in the figure on
II:
8
i
4 2
it
6 10
the right.

[Point 2] Rocker cover installation surface

inspection
• Check that no oil, dirt or foreign material adheres to the
cylinder head installation surface.

[Point 3] Install rocker cover gasket

• Make sure the rocker cover gasket is positioned securely
in groove without twisting, pinching or protrusion.

EN 77
 ON-VEHICLE PARTS
RB26DETT ENGINE

10·11 TIMING BELT REMOVAL & INSTALLATION

TIming belt cover (upper)
Grommet [Paint 4) /
tt=!lBolt(2) 0 3 05 I
OOTec,Sloner spring

~
Crank angle sensor
\
W O-ring
I I
~
~'--1)\
\
[Point 7J~~--
Il}- -
I\
I,
Timing
rp a belt
' ernt -.
10 ~ 2]
. I '~--
~- M /
[Pornt 2) -~ ~- --If I . \ /' \,j/'r, \
~ ~) J \ ,~
I

Bolt (3) 16 - 2 1 Gramme,," Boit tt=!l :7 \0, ' ; :

tt=!l ~ ~5~ \ 4 14-59 1 .-:::, ~,<%D
-OJ'" Washer \ ~ y~' -
'~--Ia,ISh~er'~y~'~
~A''\1 I::: ./~_.).,_.::~'
I

•
-
tt=!lBolt 13) 0.3 - 05 Conrcal washerI ;ft\\\- -
[Point 6] \ J ~'!ll'
, -' ••_ _" -

~Nut44-5.9iPolnt51-il\\' 'If\ <" _ . /\,;V'· ___ -

I'l Crank pulley [Point 1] . I ~
Bait [Point 3] I ~ I ~ ~-..>
45.5;- 47.5 tt=!l I ~ ~ ~\ Idler pulley [Point 11]
\ Grommetk \d \ "
\ [Point ~." \ Timing belt plate [POint 8)
\ ~ Crank timing pulley [POint 8]
~ I~ I Crank timing pulley plate [Point 8]
~
\
., I Belt tensioner [POint 9.10, l1J
/ Timing b~lt cover (lower) [point 4)
tt=!l Bolt (3) 0.3 - 0.5
tt=!l kg-m
; I'l Engine oil
I ., Replace after every_d_is_a_ss_e_m_b_ly_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _---J
Additional work required:
• Drain cooling water
• Remove and install
Undercover
• Radiator, fan sh roud
Cooling fan
• Supplemental belts
• Water pump pulley
• Spark plugs
• Check No.1 cylinder compression T.D.C position [Paint 1]
• Install ring gear stopper [Point 3]

[Point 1] No.1 cylinder pressure T.D.C (top dead enter) inspection

I'··'-----'~cc·~--···~~--~
• Align crank pulley timing mark and belt cover timing
indicator (0 0 position). At this time, No, 1 cylinder is in
compression T.O. C position when the camshaft is located
as described in the following situations.
"O'~"" ,.
f"\--' I

t {broc )
.~ .. -----~-----~- ---.-~ ----)

EN -78
 ON-VEHICLE PARTS

• No, 1 cylinder is at compression top dead centre (TD,C) r;;lln;t;ta;kk;e-;;;;;;:~~·~;;itE;"u:;, carr"--;,sh,m!

when both intake and the exhaust side cams do not
move the valve lifters,

• Remove the locker cover oil filler cap from intake side
and check that front end of the camshaft faces intake
side,

[Point 2] Install crank angle sensor

• Apply chassis grease to drive unit (spline) during
installation,
• There is a flange inside the drive unit spline so the spline i

B~_elt_cover hOI"j
has only one insertion position. Check the alignment
visually before assembly, __
• Check that the crank angle sensor can be easily inserted
in belt cover holes and sensor moves lightly to right and
left, then tighten the bolts,
• When the sensor doesn't move lightly, loosen belt cover
bolts to position when the crank angle sensor was inserted,
Move the belt cover lightly horizontally and vertically to align
it so the belt cover holes and the camshaft centre are
aligned, Then tighten the bolts so the crank angle sensor
moves lightly,

[Point 3] Remove & install crank pulley and the bolt

Removal

• Remove the starter motor and attach the ring gear

stopper.

• Use a pulley puller (steering wheel puller) to remove crank

pulley (bolt size: M6 x 1,0 length below head approx.
50mm),

EN - 79
 ON-VEHICLE PARTS
RB26DETT ENG lNE

Installation
• Position the washer for the crank pulley bolts so the
surface not marked R contacts the crank pulley side and
then assemble.
• Apply engine oil to the threads of the crank pulley bolts.
Tightening torque (kg-m): 45.5 - 47.5
Not marked ,
--"'~-,-~-~
[Point 4] Remove & install timing belt cover
Removal
• The timing belt cover is separated into upper and lower
parts. After crank angle sensor is removed, remove the
timing belt cover in the order of upper and then lower.
Installation
• Installation is in reverse sequence of removal procedures.
Caution:
Care must be taken not to scratch or damage the dried liquid
packing when removing and installing the timing belt cover.
Tightening torque (kg-m): 0.3 - 0.5

[Point 5] Remove & install belt tensioner nuts

• Secure the tensioner with hexagonal wrench when
removing and installing the belt tensioner nuts.
Caution:
Do not loosen inserted stud when disassembly.
Tightening torque (kg-m): 4.4 - 5.9

[Point 6] Install conical washer

Pay attention to installation direction of the conical
washers. The washer should be set with face with
chamfered side facing the tensioner pulley side.
Nut Conical Washer
washer

[Point 7] Install tensioner spring

• Assemble the tesioner spring to the belt tensioner pulley I
as shown in the figure.
• The tensioner spring must be assembled together with the
belt tensioner pulley in the cylinder block.

• Hook the tensioner spring on the upper side of the tensioner

spring stud when the tensioner pulley is free.

EN - 80
 ON-VEHICLE PARTS

Tensioner spring specifications ff~~sioner pulley

, When set
Spring wire Classification ..

1
Set angle (a) Free angle (-)
dlalll6ter paint . 00
• •' "

• ___ J

_' L__ ,
1,8 mm ApproK 20" Approx, 163' Yellow-green
__ ..r--
--- ....

~.
'a {When free}
~~~ oo _ _ _ oo~~ __

[Point 8] Install crank timing pulley & plate

• Care must be taken ofthe rear and front positioning when
installing timing belt plate, the crank timing pulley and the
timing pulley plateo

[Point 9] Timing belt alignment mark verification

and installationo
Paint a mark on the belt that indicates rotation direction if
paint on the upper belt is unclear when disassembly,
I
• Position the alignment marks on the intake and the ~~-;;:._oo~~~~

(int~~'1' pulley (exhaust)!

exhaust cam pulleys with the respective belt cover Alignment •
alignment marks, (Noo 1 cylinder is at TDoC)
I
• Position the alignment mark on the crank timing pulley with
the respective oil pump housing alignment markso At this
time the groove must be straight up (noo 1 cylinder is at
TD,q

• Move the belt tensioner clockwise 70 - 80 degree angle,

and secure it temporarily with the belt tensioner nut

• Install the belt by aligning the timing belt and the pulley
markso Align the n umber of ridges of exhaust cam pulley bran. timing pulley Alignment mark
alignment mark and the crank pulley (inner) alignment mark '--_
as shown in the figure on right

• After loosening the nuts and adjusting the belt tension,

secure the tensioner with the hexagonal wrench so it will
not rotate together and tighten the nut
Caution:
(1) Make sure the timing belt engages correctly with the
pulley and does not float when assembling the
timing belt
(2) Replace belts whenever possible when disassembly
is performedo

EN 81
 ON-VEHICLE PARTS
RB26DE,T ENGINE

[Point 10] Timing belt tension adjustment

• Remove the spark plug and align the timing belt alignment
mark and the pulley marks and install timing belt on to each
pulley,
• Loosen the tensioner securing nut so the belt tension is
applied by the tensioner spring,
• In this condition, rotate the crank pulley clockwise more
than two turns to check the belt movement and stop slowly
at No.1 cylinder compression TD,C point. ~, _ _.'.....,.-"--"--_~_ _,:""-,,.'c
• Insert the hexagonal wrench in hexagonal hole. Hold the
tensioner by hand so the tensioner does not move, and
tighten the tensioner securing nut to specified lightening
torque,
Tightening torque (kg-m); 4.4- 5.9
• The initial tension on the belt in this condition should be
approximately 20 kg,

[Point 11] Install idler & tensioner pulley

• Do not loosen inserted studs when disassembly, If studs
are loosened, coat inserted stud with locktite solution
(Japan Locktite KK) or equivalent.

[Point 12] Timing belt inspection

• Replace timing belt if any problems are indicated at the inspection,
' "

Item Condition , , Cause "

i
Tooth missing
Cracked tooth ~~ , "(/ Camshaft lock
Crank sensor lock

Tensioner lock :

~
Cracks on rear
Engine overheat !
side
Interference with belt cover etc,

~~
Wear and cracks Belt misalignment
on the side .~ ~," Belt plate malfunction

Worn teeth
!IlJ.
- -
Sliding motion resistance in
crank sensor and the camshaft

~
Oil or water Oil seal malfunction
adhesion Water leaks in water pump

Caution:
Do not twist or bend the timing belt, Make sure there is no oil film or water on the belt.
EN - 82
 ON-VEHICLE PARTS

10-12 CYLINDER HEAD ASSY

(1) Install & remove cylinder head ASSY

CY W1 0er head bolt (M12x1.5) (14) Cylinder heac bolt (M6x1 ,0)
[Pc. n' 2] , ~ , / 0 , 9 2 - 12 [Pomt 2J ~
i,11 T:ghten to 3 Kg-m e~

CYI.lnderhead bolt IMSx1 O)~'~(3'

~ ,.2, 7ighleo '011t kg·m I I ,~., - " - Spr,ng
' h
0.92 - 1,2 [Point 2]' ~ . , L
,ooser 001 s comp etey , was er
'\ .-,. (4) Tlgh:en to 3 kg-m Washer
"'-'ft' (5: Angle wrench 85~- 90' Cylinder head ASSY
U Torque wref'lch 11 +/- c.s
Spring wa~ ~_. Washer ~~~~~£kb~~ Cylinder head bolt (M6xl.0)
Washer---= . 0,92 [Point 2J~

.. - - Spring washer

Cam pulley
~ kg-m [Point 3J
. , Rep!ace after every disassembly

Additional work required:

• Drain and refill cooling water [Point 1]
• Remove and install:
• Collector
• Throttle chamber
• Intake manifold
• Turbocharger, exhaust manifold
Timing belt
• Rocker cover
• Spark plugs
• Install No.1 cylinder compression TD.C position [Point 3)

[Point 1] Drain & refill cooling water

Removal
• Remove cooling water completely from the cylinder block
drain plug,
Caution:
• Make sure cooling water will not enter exhaust front tube.
Refill
• Refer to "Cooling water filling procedures" for details.

EN -83
 0"·. :::-'CLE PARTS
RB26DETT ENGINE

[Point 2] Remove and install cylinder head bolts

Removal
• Remove the bolts in reverse sequence to the figures on
right.
Installation
• Install the bolts in sequence shown in the figure on right.
• The cylinder head bolt (M12xl.S) are torqued by two-step
method. Tighten the bolts in two steps. L'1'~_~1-4'~""~1-c2x'1' -5--~1~5._....·~17~Mc6c-xc-1.0:-1
(1) Tighten to 3 kg-m.
(2) Tightened to 11 kg-m.
(3) Loosen bolts completely 0 kg-m.
(4) Tighten to 3 kg-m.
(S) Turn bolts 85 - 90° clockwise when angle wrench is
used. 5
TIghten bolts to 10.5 -11.5 kg-m when torque wrench
is used.
Cau.tion:
When angle wrench is not used, never attempt to
approximate the tightening angle visually.
Bore grommet
• Take care not to hit or scratch the gasket seat and the bore
grommet when the gasket is installed.
i
• Clean the cylinder head lower surface and the cylinder
block upper surface to remove all water, oil and foreign
objects when gasket is installed. Use compressed air gun
to blowout the bore holes.
Seat

[Point 3] No.1 cylinder compression T.D.C

verification
• Before installing the cylinder head ASSY to cylinder block,
the crank pulley and the cam pulley must be positioned at
the No.1 cylinder compression TD.C position.
• Align the crank pulley timing mark and the timing belt cover
timing indicator (0 0 position).

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

EN-84
 ON-VEHICLE PARTS

(2) Cylinder head ASSY disassembly & assembly

'ja:,;e spnng retalner

Vaive spring (POlli~ 17, 19. 20]
Valve hfter [POint 1 4 1 - - - - 0 " Spring seat
ShIm [POIl1! 6}-- - ___ ~~Q.... J I // _./ Valve 011 sea! [Point 23]
Valve collet [Pc;nt 18] - - / -~*,,/
Qt ~ ..,./
/ Valve guide [Point
___
24~
Valve seat tpoint 251
r.9l Nut 0,92 - 12 [Point 5]
"'"~ /
Spring washer ,._,'\~
..._.- :::xhaust valve [Poin121 ,22]

WaShe(-~
~ ~~-- Exhaust valve [Pomt 21, 22]
Baffle plate ~ 0<::::::::::. ""@

-
<lI1@~ _
tc!I Bolt 0 92 - 1.2 '& BOlt (L92 - 12 [Point 5} "'" 0 0
Washer~ : ,II"
/
Washer
V ,/"-,, Camshaft bracket [Point 5J
...- /' Ei!Rubber plugCyjirnierhead
t'.!>..-''''.,/
[Point 8]
[Point 13,15,21,24,25]
""'" e /
~~~-~'~ Camshaft (exhaust side)
'" [Point 4, 9,10,11,12]
,,/ <3 'tf-Bolt\-ll
" ~ 0,92-1,
~ 3 [PointS]

~~.
,
~'-:V'"
""""~
r
~
R~t~,~S~~~~:rJ
tc!I 801111)
1,6 _ 2.2
Timing cover ,/
back plate [P~i~J 3}/
~
fR..
\ ~
,,~
-~
'it 'fS),

='"""'-
"11>
~j
tc!I Bolt (3) , , ~/ Camshaft front oil seal [Point 7[ QIl ~~~; 092 - '2toJ
toJ 0,64 - 0.85 "" ~--'
all (2) 2,1 - 2.7 '~.-"
<S?:."t.~ Cam pulley (Poinl 2]
~ '" ~, , Cam pullev washer
~ . _. "camDUlleYOOlt1.4-1,9[POint2]toJ
~~__ Crank angle sonsor bracket [Point 1]
Liquid gasket
Bolt 2,1 - 2.7tc!1
kg-m

Engine oil
Replace after every disassembly

Additional work required:

• Remove and install cylinder head ASSY

[Point 11 Instal crank angle sensor bracket

• The crank angle sensor bracket is positioned onto the
cylinder head by using know pins. Align the positions
correctly when installing the crank angle sensor.
Crank angle sensor bracket bolt tightening torque
(kg-m): 2.1-2.7
--- ---- .... -'''''-~

[Point 2] Remove & install cam pulley

Removal
• Fix pulley with a pulley holder or sprocket wrench and
remove cam pulley bolts,
Pulley holder: KV101 09900 or
KV101 09300.
:':1'1' pulley
ST3152 0000,
ST3153 0000
EN - 85
 ON-VEHICLE PARTS
RB260ETT ENGINE

Installation
• Align the cam pulley knock pin hole and the camshaft knock
pin to install cam pulley.
• Use pulley holder or sprocket wrench to tighten cam
pulley bolt
Cam pulley bolt tightening torque (kg-m): 1.4 -1.9
• To remove and install cam pulley bolts, use the proper
tools to secure the hexagonal part in front of camshaft.

[Point 3] Remove & install timing belt cover back S.;it(2) 1.6'22 ~..~. I
Retalne( , , '"'
plate I
Grommet '~y~-""'('''''/:
~,

\. I1:\'
u...
Removal '~"' '4!_~' ~,y ,
• Remove back plate bolt and detach back plate. t--\ ~ / /K~~ ..~!i
~t , \/
~,~
~oIt D.64 • 0.851
Installation
,,\,\0;,:: . '-_ Canister tube !
• Assemble canister tube with back plate and then install \ "Grommet Timing belt cover '
back plate. \ Retainer back p!ate~'
Bolt (2) 0.64 - 0.85
1_._ _ _ _ ...___ _
Back plate bolt tightening torque (kg-m): M6 0.64 - 0.85
M81.6-2.1

[Point 4] Camshaft end play inspection

Set the dial gauge in front of camshaft as shown in the
diagram. Read the dial gauge run-out width when the
camshaft moves in front or rear direction.
Standard value (mm): 0.030 - 0.080

[Point 5] Remove & install cam bracket

Removal (Exhaust and intake camshaft)
• Place marks to indicate the bracket position and its
direction before removing the cam bracket.
• Remove cam bracket bolts by loosening them gradually in
2 6 10 ~ 12 8
several stages in reverse sequence shown in the figure.
Installation
• Align the crank pulley timing indicator and the timing belt
cover timing indicator (0°) so No.1 cylinder is at
compression TD.C position. (This operation is not
necessary when cylinder head is removed as single unit).

• Turn the camshaft so No.1 cylinder is at compression

TD.C position. (Operation is easier if the camshaft is
turned 60° before or after No.1 cylinder TD.C point when Knock pin
,
cylinder head is installed as single unit).
• Verify the position of No.1 cylinder is at compression TD.C
by knock pin in front end of camshaft.

: (intake)

EN -86
 ON-VEHICLE PARTS
RB26DETT ENG,NE

• To install camshaft, temporarily tighten No.1 cam bracket

and check that camshaft thrust section is positioned
securely. i . .- . . .. ---~

• ~~~~:r~: ~~:~~:~;~~~~~~~turns)
Cam bracket tightening torque (kg-m): 0.92 - 1.2
in the order shown in '. '5:·4::of~:.'.'
.•_.'•••=i4%-....
",._/ ) _ ._
..1

Caution:
(1) Coat the cam journals and end of the cam shaft with
engine oil before installation.
(2) Do not rotate camshaft. (The valve and pistons may
interfere).

[Point 6] Valve clearance adjustment Ilr:take ca~Sha·ft Exhaust camshaft I

I i
No.1 cylinder compression T.D.C point
• Tum the camshafts (intake and exhaust) so No.1 cylinder
is at the compression TD.C position.
• Check knock pin position of camshaft front end to verify
No.1 cylinder compression TD.C position.

PART VALVE CLEARANCE

ITEM MEASUREMENT
i INTAKE SIDE Cylinder No.1, 2, 4

EXHAUST SIDE Cylinder No.1, 3. 5 Exhaust side

FIring order: 1 - 5 - 3 - 6 - 2 4

• Rotate the intake and exhaust camshaft 180°.

• NO.6 cylinder is at compression stroke top dead enter ... Valves which can be adjusted
when both the intake and the exhaust side cams do not move
the valve lifters. fiR~~f=i'llF:i1!F~fi=:i~
.
, PART VALVE CLEARANCE
ITEM MEASUREMENT
.

INTAKE SIDE Cylinder No.3. 5, 6

EXHAUST SIDE Cylinder No, 2. 4. 6

Valve clearance specifications (20+i-5CC)

PART
INTAKE EXHAUST :
ITeM . .

• Valve clearance (cold) mm 0.45- " 0.38'

(Reference value; warm) mm 0.51-' 044

Caution:
Always inspect when the engine is cold.
EN - 87
 ON-VEHICLE PARTS
RB26DETT ENGINE

Reference: Compensation by room temperature

RClom
0+/- 5 10 +/- 5 20 +/- 5 30 +/- 5
temperature ("C) !

Compensation
+0.02
I +0.01 -0.01
0
value(mm)
I I
Valve clearance measurement
• Insert a 0.15 - 0.20 mm gauge (A) from spark plug side.
Insert gauge (8) from opposite side. Select a gauge
thickness that will reduce the clearance to 0 m.
Note:
Do not use more than two gauges for (8).
Use JIS 150A25 feeler gauge.
- - -..~---'
~- ....

Valve clearance = Gauge (A) + Gauge (8)

Reasons for measurement using gauge (A) and (8) :
1. The valve clearance setting is larger compared to
previous engines.
2. Large gauges cannot be placed parallel to the
measurement surface.
• Thick feeler gauge have high rigidity and cannot be bent
easily, so the measurement will be incorrect.
The error factor increases if a number of thin gauges are
layered and the measurement will be incorrect.

Valve clearance adjustment

• The valve clearance adjustment is performed by selecting
a shim of suitable thickness. cam1\
• When the measurement valve clearance (t) is out of
specification, measure the shim thickness (T) and replace
it with a shim that will produce the standard clearance.

1. Shim thickness calculation method

Example:
When the intake valve clearance (I) is 0.50 mm:
0.50 (t) - 0.45 (specified value) = 0.05 mm
• The valve clearance is 0.05 mm greater than the specified
value.
• Use a shim 0.05 mm thicker than the current shim to
reduce the valve clearance.

2. Current shim thickness (T)

• Measure the center of removed shim to determine the
,- "'-~~"'-l

l " , "~ ,~",~:~ ",-,

thickness of the current shim.
Caution:
Do not reuse the measured shims again.

00

EN -88
 ON-VEHICLE PARTS

3. Shim selection
• Current shim thickness (T) is 2.40mm.
2.40 (T) mm + 0,05 mm "2.450
• Select new shim with stamped mark [24.40]

~
(T" 2.440 - 2.455).
Select a shim within standard value range +/- 0.03 mm,

4. Shim types and classification

There are 70 types of shims. Sizes range from 2.275 mm
~
T =2.440 - 2455 mm
to 3.325 mm in 0.05 mm increments.

[Point 7] Install camshaft front oil seal

• Care must be taken not to scratch or make a burr in the oil
seal. Use a socket smaller than the seal (41 mm) and drive
it into same level as front surface of the oil seal retainer.
• Apply a coat of engine oil to the entire perimeter of oil seal
lip.
Caution:
Do not scratch the oil seal and lip.

[POint 81 Install camshaft rear rubber plug

• Before installing the rubber plug, wipe off any oil, water etc.
on the surface and clean thoroughly.
• When assembling the rubber plug, coat it with adhesive
(three bond 1211) or equivalent.

[Point 9] Intake and exhaust camshaft classification

• Intake and exhaust camshaft can be identified by
r "~""'~~~iniake side ...
~:.:m' WPMlI!J»
identification point colour and presence of a spine gear '~ Identification paint v:~
(~~l~lmbm>
I. "-'lin
for driving the crank angle sensor.
"-~-.z Knoc~ pin Exhaust Side
Camshaft Identification paint Spline gear

Intake camshaft Pink No

for driving crank angle senso
Exhaust camshaft White Yes

Front....
(Point 10] Camshaft knock pin insertion 5 mm
• The protrUSion distance is 5 mm for camshaft knock pin
insertion.
Knock pin protrusion distance (mm): 5
KnOCK pin

EN -89
 ON-VEHICLE PARTS
R826DETT ENGINE

[Point 11] Camshaft inspection

Cam height inspection
• Use a micrometer to measure cam height.

Intake side Exhaust side

Cam iteightstl:mdard value 40.58 40.28

Micrometer
Cam 11ft (reference) 8.58 8.28

Cam journal external diameter inspection

• Use a micrometer to measure the external diameter of the
camshaft journal.

No.1 - No.7

Standard value (mm) 27.935 - 27.955

[Point 12] Camshaft run-out inspection

Support both camshaft end journals (No.1 and No.7) by Dial gauge
using V-blocks on the fixed surface.
Avoid the oil groove in the centre of the NO.4 journal and
position the dial gauge vertically. , ,
\ :.
• Rotate the carnshaft by hand one rotation and read the , I \1
movement width on the dial gauge.
• The run-out is equal to one-half of the movement width
igJd
indicated on the dial gauge.
Standard value (mm): 0.05

[POint 13] Cylinder head cam bracket interior diameter inspection

• Tighten the cam bracket to specified torque.
Cam bracket bolt tightening torque (kg-m): 0.92 - 1.2
• Use the bore gauge or inside micrometer to measure
interior diameter.
'.'

, "
'," No.1 - No.7
,",' '"
,

.",
Standard value (mm) 28.000 - 28.021

EN-gO
 ON·VEHICLE PARTS

[Point 14] Camshaft oil clearance inspection

• The oil clearance can be calculated from the camshaft
journal outside diameter and the bracket interior diameter
measured in [Point 11] and [Point 13],
(Oil clearance) = (Cam bracket interior diameter) -
(Camshaft journal exterior diameter)

No.1 - No.7

Standard value (mm) 0.045 - 0.086

"'-l
[Point 15] Valve lifter inspection Micrometer i

• Check the contact and sliding surfaces for wear or

/ '

scratches. Replace if damaged.

• Use the micrometer to check the valve lifter outside
diameter.
Standard value (mm): 30.995 - 30.965 _._....

[Point 16] Cylinder head lifter bore inspection

• Check bore surface for wear or scratches.
• Use inside micrometer to measure valve lifter hole
diameter.
Standard value (mm): 31.0 - 31.020

[Point 17] Valve lifter-to-lifter hole clearance inspec-

tion
• Check the clearance using values for the valve lifter out
side diameter and valve lifter hole diameter measured in
[Point 15] and [POint 16].
(Clearance) = (Valve lifter hole diameter)·
(Valve lifter outside diameter)
Standard value (mm): 0.025 - 0.065

[Point 18] Remove & install valve spring

When the cylinder head is removed from the vehicle:
• Use the valve spring compressor to remove and install the ~~.-c-
valves. I
r \"~~
-""'" ~.! >;,< - \~?l
\ "\
(",1, '"' ~Jr',
\'.'" >...~
When the cylinder head is installed in the vehicle:
• Use the valve spring compressor to install valve spring.
-'"\
Val'Ve spnn~
comp'esso' ~!_));,.-
KV'Ol 1'300 '\i, .
''.-.., ~\
\.
'L'
'!lV' /"
~\
.,; \
I
I

"""'-:\"';::..-.'-///
\@')\ \~I
EN - 91
 ON-VEHICLE PARTS
RB26DETT ENGINE

[Point 19] Remove & install valve collet

Removal
• Use tweezers to remove collet.
Installation
Apply a small coating of petroleum jelly to the intemal
surface of the collet.
• Use a magnet screwdriver.
1. Upper collet installation
• Attach collet to the lower side of the magnetic
screwdriver blade and install in the valve stem.
2. Lower collet installation
• Attach the collet to upper side of the magnetic
screwdriver blade and install in the valve stem.

[Point 20] Valve spring inspection

Free length and pressure load inspection
• Use the valve spring tester to carry out the inspection.

Standard value Limityatue

· Free length (mm) 46.54 -

Installation load (kg) 240 225

identification colour White -

Caution:
Installation load is the force required to compress the spring
length to 35 mm.

Perpendicular inspection
• Place a try square by the spring so it contacts spring. Turn
the spring and measure the maximum clearance between
upper spring surface and the right angle to determine the
out-of-square distance,
Limit (mm): 1.8

[Point 21] Install valve spring

• Install uneven pitch type spring with narrow end towards
cylinder head (identification colour side).
~~~B:-Identiflcation
, paint (white)

Cylinder heae

EN -92
 ON-VEHICLE PARTS
~32cJETT ENGINE

[Point 22] Valve guide clearance inspection

• Protrude the valve approximately 15 mm towards the
combustion chamber and measure the valve deflection by'
swinging it in direction parallel to the dial gauge. ii
• The clearance is equal to half of the dial gauge reading. ,~c".'-'
~-::C~'l;?
. Intake Exhaust .

Limit (mm) 0.1 0.1

• If clearance exceeds limit, verify the valve stem diameter

and replace the valve or valve guide.

(Point 23] Valve inspection

Outside diameter measurement

"~, Y==::==:::::!Il,"
, ~-b.J. b--~--' ,
... ~~- ·a·

Valve a b e . d e f 9 ex
Intaktt 10098+/-0.1 97.45+/-0.15 345. 0
. 0 .2
60 ·(L020
. ·0.Q35 1.3 2.6 +~3 - 450 30'

300+~2 70 ·0.080 29 +0.3 60. 0 .020 45'30'+/-15'

Exhaust 99.98+/-0.1 95.48+/·0.15 . ~O.O95
(1.2)
. ° . ·0.055

Be especially careful in handling and disposal of valves as the exhaust valves are fitted with
metallic sodium.

[Point 24] Remove & install valve oil seal

Removal
• Use valve oil seal puller to remove the valve oil seal.
i Valve all --\,Y(~11;;;;
: sea! puller
. KV10l 0790
I
Installation
• Use valve oil seal drift to install the valve oil seal.
Drift KV101 07501
Drift attachment KV101 14800 .. ~-""'

Caution: I , ;<.,>~'>\ '''1.~"~

Coat inside of the valve seal with engine oil before installation. --<'VaNe oil seal drift
.,---J KV101 07501
Valve oil sea! drift attachnlent
KV101 1480 "'Y,r___ ~

EN - 93
 ON-VEHICLE PARTS
RB26DETT ENGINE

• Install valve oil seal as shown, 1--' '

I V81VC 011 :81
j
i . ... _~

i17Jn-7
I m, 1171
i.

I. L..
•
rL. 1m
--..l
I Intake . Exhaust

[Point 25) Remove & install valve guide

Removal
• Use valve guide drift and tap it from combustion chamber
side to remove,

Installation
Ream the cylinder head guide hole using the valve guide
reamer at normal temperature (when using 0,5 mm over
size service part) .
. '

Intake side 10,46 - 10.478

I. Rectified standard
value (mm) Exhaust side
. '.. 11.46-11.478

• Heat the cylinder head in an oil bath to approximately 150

to 160°C and use a valve guide drift or press-fit tool to press i

valve guide from camshaft side.

Camshaft Side

• The press-fit dimensions are shown in the figure on right.

Valve g~lde ?
,16.8+/-0.1
I .
L~
Intake

Ream inside of inserted valve guide with the valve guide

reamer.

,
,

Flni,shed inl!imal diameter Intake side 6,000 - 6.018

i
I standard value (mm)
Exhaust side 7,000 - 7,018
!

EN - 94
 ON-VEHICLE PARTS
~52ECET"'" ~NGINE

[Point 261 Valve seat

Inspection
• Inspect the condition of contacting surface of the valve seat : OOK
and the valve.
• Replace the valve seat or the valve if contacting surface is
too large or improper, or grind both surfaces and lap with
abrasive compound.
Adjustments
o
N.G
ON.G
o When surfacing valve seat due to poor contact, inspect the
valve guide clearance and valve step hole clearance.
• Use the valve seat cutter or the valve seat grinder and
finish to standard value.
Caution:
When using valve seat cutter, press firmly and cut evenly with
both hands to produce uniform cutting surface.

Removal
o Minimize the valve seat thickness by cutting it, then remove.
Installation
(1) Drive the valve seat into cylinder head using the valve
seat drifter as shown.

(2) When not using the valve seat drifter:

• Cool the valve seat for approx. 5 minutes using dry-ice.
• Heat the cylinder head to approx. 80 c C.
o Inject the valve seat into the cylinder head.
Caution:
Do not touch cooled valve seat with bare hands.
, ¢~,

Exhaust valve seats are available in 0.5 mm oversize. When LI..n... t_ak_e_si_de~.-=_·~,::.:::::....:::::..:::::.•_··=:_·=~:~o:.~.(IC~au"l1t <lter<;r)!
using oversize valve seats, cut and grind the sealing
recess in cylinder to fix valve seats.

Exhaust
side

Cylinder head
.' .... .'
Item Valve seat
finishing
.
.' .
I
Valve oyersize Id 10, 10 , 10 , 10. 10. H
+0.0 1 6 ",:::.113 30 -··0 '5 0
. Standard 36 36 o :}97: 32 343 37.5 6.6 -0.1
0
Intake +/·0.05
0.5 365+ 0 .016 36"-0113 30-- 015 . 32 34.3 - 5.8
. . 0 .., '.1 09 7 i

32 '":- '~~:: 25 - -~ 5
+0.016 0
.'
Staftdard 32 0 _ ,. 'd~ ,
1 ! 29.6 32.5 - 6.6 -0.1
ExIuwat +l-{lOt
0.5 32 5 +0.016 32 i":':'" i .~ - . -:-I 29.6 - - 5.8
. 0 5' : .:::~
v :
I i

EN - 95
 ON-VEHICLE PARTS
RB26DETT ~NGINE

[Point 27] Cylinder head inspection

• Clean and remove oil, gasket, sealing compound, carbon
and other foreign matter.

• Measure the lower surface of the cylinder head in six

directions to check for any distortion.
Limit (mm): 0.2

• When the distortion is just over the limit, resurface the

cylinder head.
• If the distortion exceeds excessively over the limit, replace
the cylinder head.

10·13 WATER PUMP REMOVAL AND INSTALLATION

Alternator adjust bar

\ Bolt (1) 0.64 - u,~"~-,,,

~/l
~<l1
~/ .
Bolt (2) 3.2 - 4.3 ~

~BOll (2) 3.2 - 4.3

~
r:I\Alo'~, pump [Point 1. 21 .

1!:3 LiqUid gasket Bolt (6) 1.6 - 2.1 ~

~ kg-m

Additional work required:

• Drain and refill cooling water
• Remove and install:
• Cooling fan, water pump relay
• Alternator adjustment bolt
• Timing belt cover, timing belt

1 6 7 8 9
[Point 1J Remove & install water pump co "'$ D I)

Remove
@l!PO@oo-O
• Care must be taken not to get coolant on the timing belt.
Q 12 1t
Wipe it off immediately if any water does spill.
• Remove the water pump bolts in the reverse order shown.
\9.

1 M6II(1)
0

III IlIM10 (short)

'4;M 10 (IO"~,,_l1_Me i6L_~.
J
EN -96
 ON-VEHICLE PARTS
RB26DETT ENGINE

Installation
• Install the bolts in the numbered sequence shown .
.. .'.
Installation Tightening
80ltslze . No. of baits
location tonwe(kg-m)
1 M6 1 0.64 - 0.85
7,8,9, 10,11,12 M8 6 1,6-2.1

2,3,4.5 M10 4 3.2 - 4.3

Removal and cleaning

• Insert stubby screwdrivers in the bolt holes and move it up
and down to remove the water pump.
C(lution:
Take care not to damage the screws in cylinder block side.
• Use a scraper to remove all liquid gasketfrom the surface.
Caution:
Also remove the liquid gasket remaining in grooves. ,

• Wipe the installation surface with white gasoline. , I

;~~S399;J
1I'·~<\.'~.
Installation Cut
• Cut the nozzle end of liquid gasket tube (KP51 000150) as
shown in the figure and use tube presser for application.
,I '
.

• Apply continuous bead of liquid gasket (KP510 00150) to L-..~.... _ _ _~... _

water pump sealing surface. liqUid gasket 2.0 - 3.0 n111
Caution: wide along the groove
Be sure liquid gasket is 2.0 to 3.0 mm wide. I
Installation must be carried out within 5 minutes after liquid ! ~o_oo@o-;;;;;;;;~.......~
gasket application,
o

[Point 2] Water pump inspection

• Rotate the water pump by hand and check for abnormal
sound and smooth operation.
• There must be no traces of water leaks.

EN -97
 ON-VEHICLE PARTS
RB26DETI ENGI"E

10-14 THERMOSTAT REMOVAL & INSTALLATION

~hermostat [Point 2]

Thermostat housing [Point 1] ~

~~~
V 0~/_'/'/_)'1
~
J/-l~~~/ /_
'~~ Bolt(3)16-21tgl
'L:i~i:;;
"~:J /';
i , 1/---
r;;J ',Iquld gasket
)
,tgl kg,m

Additional work required:

• Disconnect and connect water inlet hose
• Drain and refill cooling water
Caution:
Loosen engine drain plug to remove cooling water from
the cylinder block,

[Point 1} Remove & install thermostat housing

Removal and cleaning
• Insert the screwdriver handle into thermostat housing and
move it up and down lightly to remove the housing,
Use a scraper to remove the liquid gasket.
Caution:
Make sure to remove liquid gasket in grooves,
• Wipe off the surface with white gasoline,

Installation
• Cut nozzle end of liquid gasket (KP51 000150) tube as
shown,

I 2,0 -30 mm ~,de to ce~ter of flail

mating surface and inner seating :
Apply a continuous bead of liquid gasket to sealing surface, surfaces of bolt holes, :
using the tube presser, Install the housing within 5 minutes !

after coating liquid gasket.

EN-98
 ON·VEHICLE PARTS

[Point 2] Install thermostat Jiggle valve

I
• 'Top' mark Giggle valve) must face up when thermostat is
inserted in housing, ~
. (~~\
I~
~ e> i

[Point 3] Thermostat inspection_~~~-~ ~.~~-~ ....."

• ~ftheck the valve opening temperature and maximum valve [ Strin g ___ ,..,---t
• Hang the thermostat by string in valve and submerge in, houbie-wall oCc--~cC;~: i .
heating it up,
Thermostat
t===d
~~
• The opening temperature is the temperature when the valve ~;z
opens and thermostat falls from string. ._ _ v--"
. Standard, cold climate

Valve opening temperature (OC) 76,5

Max, valve lift mmlOC 10190

10·15 INSTALL & REMOVE OIL COOLER, OIL FILTER

Water tube ~ tUDe

Water hose

80111,6 - 2,1
~Bolt (4)
~~
O-nng 1 6 - 2 1 0-nn90

01 ~1 ~~
o ·as~t 0 ?'r-/
\
Si (0\'/>
Water rlose .' 0/,
;; ~,. /"
___ 0/ I
1
"-
'.'-,
0" pressur~wttcl:!.--..~~ \ $" Gasket 0
.:rac<eV' Oil fille' ~ \' Spring washer
/ \,,' brack1 Nul(1) 16-21~
Bolt (2) 0 64 - 0 85~ \ Oil temperature
~kg-m 011 fl,te r sensor
o Replace after every d·sassembly
Additional work required:
• Disconnect and connect switch harness connectors
• Drain and refill cooling water
Caution:
Loosen engine drain plug to remove cooling water from cylinder block, (If water is only drained
from the radiator drain cock, the cylinder block wrll not drain completely),

EN -99
 ON-VEHICLE PARTS
RB26DEF ENGINE

[Point 1] Remove & install oil filter

Removal
1. Remove the oil level gauge. f>. " Aaapter

2. Remove turbocharged pressure control vacuum hose ~ffl /

clamp and move the vacuum hose out of the way.
(;ijffflcd
3. Move main harness clamp out ofthe way. (If the oil filter Small ratcnet ;;JI
come loose, remove the oil filter using the filter wrench). wrench -~
4. Use oil filter wrench to remove oil filter. L.. .. .__._. ._ _
Installation
• Wipe off dust etc. from the oil filter mounting bracket 17~ ~ .. " <::::-~r.~
surface before installing new oil filter. Apply a thin coat of
engine oil to oil filter O-ring before installation.
16 ~W~~~I'
I~ - ; ,L-6iifiller"
• Screw the oil filter on bracket by hand until a slight I~~~ \'i': \ ,ui"J~
resistance is felt, then tighten an additional 2/3 turns using !'Ma'nifOIdCO!l;Cior,? Qr:; ')I(
the oil filter wrench. Start the engine and check for oil leaks .• ~ )~~;i'" .
Removal. .!-oi> jI ~, . '. ,
• Face lower part of all filter down and move out In the '--~...--~...---~' ...- .
direction of the arrow in figure right. Remove through
aperture behind manifold collector.

10-16 OIL PAN, OIL PUMP & OIL STRAINER

(1) Remove & install oil pan, oil pump & oil strainer

•A kg-m
~ Engine oil
o Replace after every disassembly
Additional work required:
• Engine ASSY
• Drain and refill engine oil

EN -100
 ON-VEHICLE PARTS
RB26DETT ENGINE

[Point 1] Remove & install oil pan bolts & nuts

Removal
• Remove bolts and nuts in reverse order of installation
sequence shown in the figure on right
Installation
• Install the nuts and bolts in the order of sequence shown in
the figure on right.
Caution:
Make sure there are no dirt, dust or other foreign objects on oil
installation surface.

Bolt (Nut No. of Tightening

i
:
Installation position

12:QJ~~~~
size bolts I nuts torque (kg-m)

i, 3, 12~L2.51 l2.6J
, M6 (Bolt) 9 0.64 - 0.85
Wj, lz.[ ~,1Q]
4,7,8,10,11,12,14,15,
Ml0 (Bolt) 14 3.2 - 4.3
16,17,18,19,21,22

1,2,3,5,6,9,13 Ml0 (Nut) 7 3.2 - 4.3

[Point 2] Remove & install oil pan I~A;±--;::-,:t~1/%i

Removal & cleanr'ng I'~. ~'O'!r, 0 ("'!if. ,~.'
1--'- ,-
'~(;r!
--:;C<"
,:;
\\1' ''''
• Use a seal cutter to remove and clean the oil pan. I~,,,;,:~-: ... :: ,..,\11 11\1

• Use a scraper to remove liquid gasket from mating I~, ~:;(\ I(~ \';<
surface. {KV1n1 11100M
Caution: ' " ............___1
Use a scraper to remove all liquid gasket and seal material on I
the cylinder block and oil pan flange groove. Remove all I
gasket and other foreign objects in the oil pan.
- 1

• Clean all contact surfaces with white gasoline.

Installation
• Cut off the nozzle tip of liquid gasket (KP510 00510) at '~S3993i
. )

~ .,~ .-~I
point shown in the figure on right. '"""'\. Cut
I·I ~ """"-LLL\L_'

r--- TJ.!l:>.e presser WS3993 •

• Apply liquid gasket to inner sealing surfaces on the oil pan I~~~.:::::..~
as shown in the figure on right. ,/ ~~~ ~~ ,
• Installation must be performed within 5 minutes. ~= ~I, ~-

EN - 101
[~~~- ..~._. . ----.J
 ON-VEHICLE PARTS
RB26DETT ENGINE

• Apply liquid gasket (KP510 00150) to areas 7 mm inside

from center of the oil pan bolt holes. ,mmr

~~
Caution:
(1) Make sure the liquid gasket is applied 4.0 mm wide.
(2) Wait at least 30 minutes before refilling the engine oil ,
and engine coolant after installation.
Groove Bolt role

[Point 3] Install oil strainer

• Make sure the O-ring is installed securely in groove when
installing the oil strainer.
Tightening torque (kg-m): 1.6 - 2.1 (MS)
0.64 - 0.85 (M6)

[Point 4] Oil pump bolt

There are 4 types of bolts. Make sure to use the correct
bolts when they are installed.
.

installation .Length below Tightaning

No. of bolts
I position head (mm) . torque (kg-ml

I 1 20 4 0.92 -12
2 35 ! 2 0.92 - 1.2

3 45 1 0.92 - 1.2
,

4 55 1 0.92 - 1.2

~eO!n~V5~1 Remove & install front oil seal ~~~ I

• Use a tool such as screwdriver to remove front oil seal from i ',Sj)li ( rrt,;:,::;\~'
In~;~I:~i~~ver. II' ~~~~~?~;~
iff
I
(01,
• Care must be taken not to scratch or damage the oil seal ~ ~
retainer. Use oil seal drift and insert it at same level as front L -
surface of the oil pump housing.
• Apply engine oil or chassis grease to area around the oil
C"

r-=~-~~'-'~'
I
..

~
-Oll seal drift
-
seal lip.
~~ ~

~rf!
,,~--=J.:' ",'.
[Point 6] Oil leak & oil pressure inspection l.~_..~_._
• After installation warm up the engine and check for any oil I .) \
leaks and the oil pressure. •\ \'..
f,lf_~
.1I,:c' '", {~O'j![==-
:c 1 l
• Remove oil pressure switch and attach oil pressure gauge \ : y ~ _~ /1; I
when measuring oil pressure. \~\.. :, b
I Englnt' rev (rpm) .. Idling 2000 6000 \~~~ !i! ' ..: 1('(Y:"-'J
Exhau.tPn-ure '(kg" tem') Appral<. 1.5 Approx.3 Approx 4.6
'~ ~'E~~~(
~\,~ ~L0-,Ipressure SWItchL
EN - 102
 ON-VEHICLE PARTS
;~326DE7"" ENG,NE

(2) Oil pan disassembly & assembly

Baffle plate

tgI kg-m

(3) Oil pump disassembly & assembly

~Screw (7) 0 38 - 0 51

~\,.,
['
Regulator Valvej PurPP hOUSing [POint 1 J
[Point 2] ~

RegUlato0
spring "i C 0( \
Pump cover

Inner gear [Point 2]

,
i Regulator...-Q
I washer
~
,~
L
I

Outer gear [POint 1i

Regulator plug 4,0 - 7,O~

~ kg-m

[POint 1J Oil pump inspection

• Check inner gear. outer gear and housing for any scratches or wear.
• Use thickness gauge to measure the following clearances:
"
,

Measurement position Standard value (nvn) I

I
,1 Outer gear and housing clearance 0,114-0.2

2 Outer gear and inner gear clearance Below 0,180

3 Inner gear and housing side clearance 0,05 - 0,07

4 Outer gear and housing side clearance 0,05 - 0,11 !

5 Inner gear and housing flange clearance 0,045 - 0091

Measurement position 5 is obtained by subtracting the housing flange outside diameter

from the inner gear inside diameter.

EN - 103
 ON-VEHICLE PARTS
RB26DETT ENGINE

Positior. 3 & 4 \
\

_Position
. ._--. 5
.""=

Inside micrometer

[Point 2] Regulator inspection

• Check oil pressure regulator valve sliding surface and the
spring for any wear and damage.
Valve and valve hole clearance (mm): 0.04 - 0.097

HOlJsing
[Point 31 Install inner gear sIde
• Care must be taken to install the inner gear in a specific c::::J
direction,
• Face the side with the groove to the cover side.

EN -104
 ON-VEHICLE PARTS
"32::: ~NGINE

10-1 COLLECTOR ASSY

(1) Collector ASSY removal & installation

Acceleration wire bracket [Point 2]

Collector ASSY

Collector bolt (4) ~

~
1 .8 - 22lPoint 3)

Q,.-.,,,,= II Collector bolt (3) ~ i

rJ,.// 1.8 - 2.2 IPolnt 3]

~~ !

OColiector gasket O~
~ •

~kg-m ~ I

o Replace after every disassembly

Additional work required:

• Release fuel pressure in the fuel lines [Point 1]
• Drain & refill cooling water [Point 4]
• Acceleration wire [Point 2]
• Air duct
• Harness connector
• All hoses

[Point 1] Release fuel pressure

• Start the engine.
• After starting the engine remove the fuel pump fuse and wait
until the engine stops. Crank engine two or three times to
consume fuel remaining in the fuel pipes.
• If the vehicle doesn't start, remove the fuel pump fuse and
crank the engine four to five times to consume fuel
remaining in the fuel pipes,
Caution:
The battery may become weak easily, use booster cable to
connect to another battery if necessary,

[Point 3] Accelerator wire adjustment

• Loosen lock nul to provide adequate slack for the
accelerator wire and pull outer case in the direction of the
accelerator.
• Return the lock nut 1.0 to 1.5 turns from the position the
throttle drum starts moving (when there is no play in cable)
and tighten,
Tightening torque (kg-m): 0.8 - 1.0
EN - 105
 ON-VEHICLE PARTS
RB20E ENGINE

[Point 3] Remove & install collector bolts

Removal
• Remove the bolts in the reverse order of the figure on
right.
Installation
Install the bolts in the order shown in the figure on right
uniformly in two to three stages.

[Point 4] Air release plug

For more information referto the section on cooling system
later on in the manual.
Carry out the operation when engine is cool.
Caution:
Do not remove the air release plug when the engine is hot.
• Remove the air release plug to release the air within the
engine completely when refilling cooling water.
CSljtion:
Care must be taken not to over tighten the air release plug
boll.
Tightening torque (kg·m): 0.7 - 0.8

(2) Collector ASSY disassembly & assembly

A~celeration Acceleration wire
Collector
, wire brackrt c/' bracket Dot (2)
'.., 0.64 - 0.85
Water hose .;.-
"is ~_
• .. ~W~ ~

~.. Throttle chamber bolt (4) A MC valve ASSY bolt~

(4) 0.86 -1,1
1 8 - 22 [POint 1]A
A kg-m
( ; Replace after every disassemoly

Additional work required:

• Remove and install collector ASSY

EN - 106
 ON·VEHICLE PARTS

[Point 1] Remove & install throttle chamber bolt

Removal
• Remove the bolts in the reverse order of the figure on the
right.
Installation
• Install the bolts in the order shown in the figure on right
uniformly in two stages.
Tightening torque (kg-m): First stage 0.9 - 1.1
Second stage 1.8 - 2.2

[Point 2] Throttle chamber gasket

• Check the installation direction before installing the throttle i
I
chamber gasket. I

10·2 INTAKE MANIFOLD ASSY

(1) Remove & install intake manifold ASSY

~- t I
• .:;,----'

"'<'=

Washer

~ " .",'- "". j'

~ ~" ". Washer :" Intake manifold ASSY

"'~" Intake manifoid nut (5) 1.8 - 2.2 [Point 1]A
intake mamfold body 18) 1.8 - 2.2 [POint 1] A
•A kg-m
It3 Replace after every disassembly
Additional work required:
Remove and install collector ASSY
• ECCS harness connector and all hoses

EN·107
 ONNEHICLE PARTS
RB20E ENGI\lE

[Point 1] Remove & install intake manifold ASSY bolts and nuts
Removal
• Remove the bolts and nuts in the reverse order of the figure
on right.
Installation
• Install the bolts and nuts in the order shown in the figure on
right. 11 7 5 9

(2) Intake manifold ASSY disassembly & assembly

Gasket 0
IPJ
-, Thermal transmitter 1.5 - 2.0
~,'>-;,;;",~'I~
tt=!J\\fater temperature
-~~,","'~"",Ci. sensor 1.5 - 2.0
:
Fuel tube ASSY
Fuel damper [Point 1J
gi
.~ Ia '
.4 Water outlet
~-t. Ignition coil bracket ASSY

Bolt IPJ Bolt (2) 16 - 2.1tc!l

1.8 - 2.2

(1 Replace after every disassemble

~ liquid gasket
IPJ kg-m
Additional work required:
• Remove and install intake manifold ASSY

[Point 1] Fuel tube ASSY

• Replace the O-ring to new ones when removing and
I
,Pressure regulator
i~' Fuel tube Injector i
I
. ASS'( ,
installing the pressure regulator and the fuel damper.
Caution: i _d~" Fuel damper ;
«

Care must be taken not to scratch or damage the fuel tube ,'';:.~
O-ring area when installing the pressure regulator and the fuel r;,
damper.

EN - 108
 ON-VEHICLE PARTS
RB20E ENGINE

[Point 2J a-ring (for fuel injector, pressure regulator and fuel damper)
Precautions when handling
• Coat the a-ring with engine oil (7 .5W -30 or equivalent) or ,---_ _ _ _ _ _ _ ...._.-.-,
silicon oil (NUC silicon L45 or equivalent), but do not apply ~
solvent as this may remove oil coating. ~
• Avoid using dirty a-rings and do nol allow dirt, dust or 'r(ii
foreign objects to adhere to a-rings or other equipment i ! O-flng
surfaces. ~ ,. i Insulator (i!
• Care must be taken not to scratch, twist or stretch them by ~ Inje~tor
tools or operator's fingernails when installing a-rings. Insulator (i
• Do not decenter or rotate the fuel injectors and the ........._ - -_..... . .
pressure regulator when inserting them into the fuel tube,
• Do not store a-rings in location subject to ozone, high
temperature or in direct sunlight.

10-3 REMOVE & INSTALL EXHAUST MANIFOLD ASSY

jlo
Yoke [Point 31 " / ;»
Washer [Point 41 " .
~ Nut 2.8 - 3.2 [Point 2J/

~ kg-m
(1 Reolaee after every disassemble

Additional work required:

• Under cover
• Assemble and disassemble exhaust front tube
• a 2 sensor connector

[Point 1J Gas leak inspection

• After removing the exhaust manifold, make sure there are
no traces of gas leaks from any parts,
• After the installation, crank the engine and check for any
gas leaks.

EN - 109
 ON-VEHICLE PARTS
RB20E ENGINE

[Point 2] Remove and install exhaust manifold nuts r-~~~--------'

Removal
• Removal is the r~verse of installation sequence shown in
9 Ir5
q'i' ~...
3 8 1~
'""" ~,

the diagram on right. i ~~; \;;',2

Installation ,,0 6 2 4 7 ~i ~
• The installation sequence is shown in the diagram on 'f\ .
right

[Point 3] Yoke
• Make sure not to make mistake between NO.3 and NO.4
yoke as configurations are different.
,
'.
Item D(mm)
No.3 & No.4 port 22
Other than those above 24

{
[Point 4] Install washer
• Make sure the washer is facing the correct way when
installing.
Manifold side

10-4 REMOVE & INSTALL LOCKER COVER

--~ ... ~- .. _ - - - ,

Additional work required:

• Air duct
Air duct bracket
• Blowby hose

[Point 1] Remove & install locker cover bolts

Removal
11 6 3 4 8 10
• Removal is the reverse of installation sequence shown in
the diagram on right.
~
.,J
I ,
Installation
• The installation sequence is shown in the diagram on "12
2 5 !
right.

EN -110
 ON-VEHICLE PARTS
RB20E ENGINE

10-5 TIMING BELT REMOVAL & INSTALLATION

' Belt t8:'S10ner

W asner
Conical washer ! i
Tensloner spring [Point 7]
[Point 6]
~ Nut 4.4 - 5.9 [PCI":~~ ~
\:
t,·) G . '

Timing belt cover (upper)

[POint 4]
~Bolt 0.3 - 0.5 ,
~.

Timing belt cover I

Crank pulley [POint 3]
Power steering pump
pulley

~ Bolt 10-1 timing belt olate [Point 8]

---",

'. I ~1f)

~It
Timing belt [POint 9,10,12, 13J
"\,
\ Crank timing pulley plate [Paint 8]
14.5 - 15.5
"[Pomt 1, 21~ rl ~BOlt (2) 0.3 - 0.5

~ kg·'11
rl Engine oil
• 0 Replace after every disassembly
Additional work required:
Drain and refill cooling water
• Remove and install the followings:
• Under cover
• Radiator, shroud
• Cooling fan
• Supplemental belts
• Water pump pulley
• Spark plugs
Check No.1 cylinder compression T.D,C position (Paint 1]
• Install ring gear stopper [Point 3]

[Point 1] No.1 cylinder pressure T.D.C (top dead enter) inspection

• Align the crank pulley timing mark and the belt cover timing indicator. At this time, the
distributor rotor should be in the position shown in the diagram below, or No, 1 cylinder is
in the compression T.D,C pOSition.

IDistnb~~or r~Ya~~~ f;r'ectionl--=I

, j ,I I - , ) , ,I '
I ' .

EN - 111
 ON-VEHICLE PARTS
RB20E ENGINE

[Point 3] Pulley puller (steering wheel puller)

• Remove the crank pulley by using the pulley puller.
(bolt size: M6 x 1.0 length below head 40 mm)

[Point 4] Install timing belt cover

• Attach the gasket (sponge rubber) on the timing belt cover
r 'I'~"'~' ..~-...
"..
(upper) as shown In the figure. ....::c-:::--

[Point 5] Remove & install belt tensioner nuts

• Secure the belt tensionerfirmly with a hexagonal wrench
when removing and installing the belt tensloner nuts.

[Point 6] Install conical washer

• Pay close attention to the installation direction of the
conical washers. The washer should be set with face the
chamfered side facing the tensioner pulley side.
. B-
I t?~... '
f( i
~
ut Conical Washer
washer
.. ..~~-~.

[Point 7] Install tensioner spring

• Assemble the tensioner spring so it engages the belt
tensioner pulley as shown in the figure on right.

I " ~-',S\udv(;1i-~~"--

The tensioner spring must be assembled together with the II@o) /;= ~xago~~
belt tensioner pulley in the cylinder block. . / /1, . 3)
~--~
2) .,', ;0 ~~"::..
[ , "
_ M _ _ _ _ _ _ .'__ \ _ _ ~~~~~_

EN - 112
 ON-VEHICLE PARTS
RB20E ENGINE

• Fix the belt tensioner and hook the spring on top of the
stud volt by rotating the spring anticlockwise,

'"

Spring wire
Setangle F~engle(-)
diameter ",' .
1,8 mm Approx. 20° Approx, 2270

When free

Crank"i,ming TI";i"g Qelt;;'~ley I

pulley",
[Point 8) Install crank pulley and plate plate

ii
• Be careful to observe front and rear positioning of timing -I
,[crank pulia I •
belt plate, crank timing pulley and crank timing pulley plate side.
I '
when installation is performed, I
I 7- ,
.9 rank timlf~g pulley ._ ?Foove I

• Check the number of ridges between the cam pulley and

the crank timing pulley alignment marks,

• Mark on each pulley at the alignment position with white

paint if the timing belt alignment mark (white paint) is not
clear,

Position the timing belt so the back surface arrow is facing

the engine front and align the alignment mark (white paint)
with cam pulley and the crank timing pulley alignment mark
when installing a new timing belt.
• Check the ridges after the installation,

EN - 113
 ON-VEHICLE PARTS
RB20E ENGINE

[Point 10] Install timing belt

• Assemble the tensioner spring so it engages the belt
tensioner pulley (follow point 7),
• The tensioner spring must be assembled together with the
belt tensioner pulley in the cylinder block,
• Insert hexagonal wrench into the belt tensioner hexagonal
hole and rotate clockwise to tighten the nut temporarily,
• Align the timing belt alignment marks with each pulley marks
and install timing belt on to pulley,
Tighten the tensioner securing nuts to specified tightening
torque, Tightening torque (kg-m): 4,4 - 5.9

[Point 11] Crank timing pulley r,I Alignment mark ~---~

....J!\111i1W1L.
Key groove

• Make sure to install the crank timing pulley in a correct way,

Some crank timing pulley has two key grooves and
alignment marks.

Key groove
[Point 12] Timing belt tension adjustment
• Loosen all rocker shaft tightening bolts.
• Rotate the tensioner anticlockwise two to three times
using hexagonal wrench. (it is not necessary to rotate belts).
• Fix the tensioner using hexagonal wrench and tighten the
nuts to specified tightening torque. (At this stage specific
tension will be applied to the belts automatically).

[Point 13] Timing belt inspection

• Replace timing belt if inspection indicates any problem.

. .. ' Item . Condition

•
Cause . .. .

~~
Tooth missing . Camshaft lock
C racked tooth Crank sensor lock

~
Tensioner lock
Cracks on rear
Engine overheat
side
Interference with bett cover etc.

'~~
Wear and cracks Belt misalignment
on the side ~~~/ ~\!h Belt plate malfunction

Worn teeth ~~(1@fIl}

j!. ill
Sliding motion resistance in

- - crank sensor and the camshaft

~
Oil or water Oil seal malfunction
adhesion Water leaks in water pump

9.6 REMOVE & INSTALL OIL PAN, OIL STRAINER, OIL FILTER
• Refer to RB20DE, DET section later on in the manual for detail.
EN - 114
 ONNEHICLE PARTS
R820DE! DET ENGiNE

10-1 COLLECTOR ASSY

(1) Remove & install Collector ASSY

Collector bolt (2) trll Accelerator wire bracket [POint 2J

1.8 - 2.2 [POin!2l.i

f.3 Collector gasket

i

,
Air release plug [Point 4J
."
,<:r;
': 1",\\
'>-,)' r

\1 '~
~ '"
!
Collector bolt (2) - - -..
1.8 - 2.2 [Point 3J trll /. Collector bolt (2)
\ 1B - 2.2 [Po,nt 3J
:trll kg-m trllColiector bOlt(4) trllCOliector bolt (11
1.8 - 2.2 [Point 4) 1.8 - 2.2 [POint ,,]
if.3 Rep!ace after every disassembly

Additional work required:

• Release fuel pressure in the fuel line [Point 1]
• Acceleration control wire [Point 2]
• Drain and refill cooling water
• Air duct (RB20DE). Air inlet pipe (RB20DET)
• EGI harness connector. harness clamp
• All hoses

[Point 1] Release fuel pressure

• After starting the engine remove the fuel pump fuse and
wait until the engine stops. Crank engine two or three times
to consume fuel remaining in the fuel pipes.
• If the vehicle doesn't start, remove the fuel pump fuse and
crank the engine four to five times to consume fuel
remaining in the fuel pipes.
Caution:
The battery may become weak easily, use booster cable to
connect to another battery if necessary.

[Point 2] Accelerator wire adjustment

• Loosen lock nut to provide adequate slack for the
accelerator wire and pull outer case in direction of the
accelerator. Return the lock nut 1.0 to 1.5 turns from the
position the throttle drum starts moving (when there is no
play in cable) and tighten.
Tightening torque (kg-m): 0.8 - 1.0
EN - 115
 ON-VEHICLE PARTS
RB20DE! DET ENGINE

Position . No. required Bolt length beiowhead (min)

7.10 2 105
8 1 65
1.3.4.6. 4 40
2, 5, 9, 11 4 30

[Point 4] Air release plug

• For more detail refer to cooling system later in the manual.
Caution:
Do not remove the air release plug when the engine is still
warm.
• Make sure to remove air release plug when refilling the
cooling water to release air within the engine completely
(overheat prevention).
Tightening torque (kg-m): 0.7 - 0.8

(2) Collector ASSY disassembly & assembly

AI Boit (2) 0.64 -

Accelerator wire bracket
Bolt (4) 0.9 - 11 AI
Nonseparable unit

valve:

Th,,''''o chamber gasket [POint 21 t3

Th",ttlo chamber

regulator hose-~ Tormtle chamber bolt (4)

~8 - 2.2 [Point 1J ~
""
\ ~.
Water hose
AI kg-In
+) Hepiace after every disassemble

Additional work required:

• Remove and install collector ASSY
EN - 116
 ON-VEHICLE PARTS
RB20DE I DEi ENGINE

[Point 1] Remove & install throttle chamber bolts

Removal
• Remove the bolts in the reverse order of the figure on right.
Installation
• Install the bolts in the order shown in the figure on right
uniformly in two stages.
Tightening torque (kg·m): First stage 0.9 -1.1
Second stage 1.8 - 2.2

°0
i

[POint 2] Throttle chamber gasket !

• Check the installation direction before installing the throttle I

)
chamber gasket. I
!
o 0
I
Bottom

10-2 INTAKE MANIFOLD ASSY

(1) Remove & install intake manifold ASSY

A Intake manifold bolt 18 - 2.2 [P~ A Intake <na/d nut 1.8 - 2.2 [Point 1J
~ i@4"_ Spring washer
;ntake manifold ASSY
, '. (jl~ Washer

"'''\

Akg-m
(1 Replace after every disassemble

Additional work required:

• Remove & install connector ASSY
• ECCS harness connector. all hoses

EN - 117
 ON-VEHICLE PARTS
RB20DE ! DE ENGINE

[Point 1] Remove & install intake manifold ASSY bolts and nuts
Removal
10 9 6 1 4 13 14
• Remove the bolts and nuts in the reverse order of the figure
!
on right. I ,
, !
Installation
• Install the bolts and nuts in the order shown in the figure on
!
i q:g:aj1{5
..l i
a[.';6~:oh{
right. !
f
I •! II !

8 7 2 3 5 11 12 I

(2) Intake manifold ASSY disassembly & assembly

;:;1 injector [POlot 2] i---' ~ Bolt (2) 0.64 - 0.58

.--~~;:2:::"t--=AJ-::;
...",,) -----I\i' regula!",

•
t~
80It(6) 1.6-2.1
~ 0 ! ~ Boit (2) 0.4 - O.5~ i
J::i! lIqulO gasket
~kg-m

Additional work required:

• Remove & install intake manifold ASSY

[Point 1] Fuel tube ASSY Pressure regu!at~

• Replace the O-ring to new ones when removing and
installing the pressure regulator and the fuel damper.
Caution:
Care must be taken not to scratch or damage the fuel tube
O-ring area when installing the pressure regulator.

[Point 2] O-ring (for fuel injector pressure regulator)

Precautions when handling
• Never reuse O-rings.
• Coat the O-ring with engine oil (7.5W -30 or equivalent), but ~~
do not apply solvent as this may remove the oil coating. . .
• Avoid using dirty O-rings and do not allow dirt, dust or ,"'i
....,.
i O-ring
foreign objects to adhere to O-rings or other equipment. " Insuiator~
• Care must be taken not to scratch, twist or stretch them bY~' I
Inje~tor
tools or operator's fingernails when installing O-rings.
Insulator~
• Do not decenter or rotate the fuel injectors and the pressure I_.._~_~..~~_...____ ._.~~
regulator when inserting them into the fuel tube.
EN - 118
 ON-VEHICLE PARTS
RB200E ' O"T ENGINE

10-3 REMOVE & INSTALL EXHAUST MANIFOLD ASSY

Exhaust manifold gasket

tql <g-m
t:. Replace after every dIsassemble
Additional work required:
• Under cover
• Disassemble exhaust front tube
• Exhaust sensor connector
Gas leak inspection [Point 1]
RB20DET only
• Inter cooler air inlet tube hose
• Turbocharger

[Point 1] Gas leak inspection

After removing the exhaust manifold, make sure there are
no traces of gas leaks from any parts,
• After the installation, crank the engine and check for any
gas leaks,

[Point 2] Remove and install exhaust manifold nuts

Removal
• Removal is the reverse of installation sequence shown in
the diagram on right.
Installation
• The installation sequence is shown in the diagram on right.

EN - 119
 ON-VEHICLE PARTS
RB20DE I DE, ENGINE

[Point 3] Yoke
• Make sure not to make mistake between NO.3 and NO.4 rp107 C D.5
yoke as configuration is different.

Item O(mm)
.. No.3 & No.4 port . 22 6

Other than those above 24 :

[Point 4] Install washer

• Make sure the washer is facing correct way when
installing.
Marifold side

10-4 REMOVE & INSTALL SPARK PLUG

Ornament Ignition coil harness

.----~

\
\
\
\
\
L..-

~ kg-m
Additional work required:
• Air duct (RB20DE), Air inlet pipe (RB20DET)
• Blowby hose
• Power transistor

[Point 1] Remove & install ignition coil bracket bolt

• Length of the bracket bolt between RB20DE and RB20DET
are different.
RS20DET .

25
EN -120
 ON-VEHICLE PARTS
R820DE I DET ENGINE

..
(Point 2] Install ignition coil bracket
---~-~~

• The ignition coil bracket thickness differs between RB20DE

and RB20DET vehicles.
• When installing ignition coil bracket to cylinder head, check .
that ground line is connected securely. QACyhnder side
Ignition cOil .'IfIIP "'0,.. ">:1
bracket Holder I~ •
,____~ ____.._~.._£~ri5 p~uq :

[Point 3] Spark plug maintenance Platinum

• The Gap inspection and adjustment is not necessary as Seating me!~1 ~\
platinum tip is used.
• Change the spark plug every 100,000 km.
• When using compressed air spark plug cleaner, clean the
plugs at maximum pressure of 6 kg/cm 2 for no more than
20 seconds.
• Do not use wire brush to clean plugs.

10·5 REMOVE & INSTALL ROCKER COVER

!=itIer caD

O-nng

,//
Locker cover gasket

Locker cover gasket

IRI
! Kg-rn

Additional work required:

• Air duct (RB20DE), Air inlet (RB20DET)
• Blowby hose

[Point 1] Remove & install rocker cover screws

Removal
• Perform removal in reverse order of sequence shown in the

::
7 3 1 5 9
figure on right. I
Installation
• Perform installation in sequence shown in the figure on
right.
:(8 4 2
•6 J
10

EN - 121
 ON-VEHICLE PARTS
RB20DE i DET ENGINE

10-6 REMOVE & INSTALL TIMING BELT

Timing belt cover (upper) [Point 4]

I Timing belt [Point 9. 4D. 12] ~

~ ~'~;~
~ 1~ ;1lC~~
toJ801!(2)16-2\Gr:ret '\ Nut44-S9[Pornt51toJ \

OO~rJng Tensloner~ fS'p'::~

I""Zt~.t-2?~1i9;
\ COrllcal Belt tensloner [POInt 9 11]

Crank angle sensor \ ,~

1 washer /
\ [Point 6J I spring -, ':; 3
[Point2J~.()
Q \ I
'1.{/[POlnt71
~ . 7~ ~~ ~v,/\ )I -
v""~!, \.;-_/~
\Y ~~

10""~ ~'?'\ fIDl~@ ®~~-~l%t@)~::¥~~

toJ Bot (3) I Bolt (4) .,-. Gromine r-~ ~ \\I..£..) \l)) , Crank tIming Delt plate
0.4 - 0.5 065 - 0 86 ~ I ~ \' \ I[POint 81
~ ~ 'I' ' \ Crank t1mlng pulley [Point 81
Washer . 1 ...-. '4 Washer \ Crank timing pulley plate (Point 8J

~ ®.'c'j,
\ •
\ ,"'"
,__
--- ~
'~
,
\ \
\
\
Bolt 4 - 5 9 laler pulley [POint 11]

Ti~ing belt cover (lower) [Point 4J

~f • \ Grommet
\~ t o J ! I Bolt (4) 065 - 084toJ
Bolt 145 _ 15,5 Crank puliey ~Point 1J toJ kg·m

~Engine oi'
. , Replace after every disassembly
----------------------------~---
Additional work required:
• Under cover
• Drain and refill cooling water
• Radiator. fan shroud
• Cooling fan
Supplemental belts
• Water pump pulley
• Spark plug
• No.1 cylinder compression TD.C position [Point 1]
• Install ring gear stopper [Point 2J

[Point 1] No.1 cylinder pressure T.D.C (top dead enter) inspection

-~7

• Align the crank pulley timing mark and the belt cover
timing indicator (0° position), At this time, the No.1
cylinder is in the compression T.D.C position when the
camshaft is located as described in the following
situations. \

• No, 1 cylinder is at the compression top dead centre

when both the intake and the exhaust side cams do not
move the valve lifters,

L ... _ _ ... _ _ .. _ _ _ .. _ _
EN - 122
 ON-VEHICLE PARTS
RB20DE j DET ENGINE

• Remove the locker cover oil filler cap from intake side
and check that the front end of the camshaft faces
intake side.

[Point 21 Install crank angle sensor

• Apply chassis grease to the drive unit (spline) during
installation.
• There is a flange inside the drive unit spline so the spline
has only one insertion position. Check the alignment
visually before assembly.
• Check that the crank angle sensor can be easily inserted
in belt cover holes and sensor moves lightly to right and
left, then tighten the bolts.
• When the sensor doesn't move lightly, loosen belt cover
bolts to position when the crank angle sensor was inserted.
Move the belt cover lightly hOrizontally and vertically to align
it so the belt cover holes and the camshaft centre are
aligned. Then tighten the bolts so the crank angle sensor
moves lightly.

[Point 31 Remove & install crank pulley and the bolt

• Remove the starter motor and attach the ring gear
stopper.
'?,'; KV101 05610

• Use a pulley puller (steering wheel puller) to remove crank

pulley (bolt size: M6 x 1.0 length below head approx.
50mm)

[Point 41 Remove & install timing belt cover

• The timing belt cover is separated into upper and lower
parts. After crank angle sensor is removed, remove the
timing belt cover in the order of upper and then lower.
• Installation is in reverse sequence of removal procedures.
Caution:
Care must be taken not to scratch or damage the dried
liquid packing when removing and installing the timing belt
cover.

EN - 123
 ON·VEHICLE PARTS
RB20DE I DET ENGINE

[Point 5] Remove & install belt tensioner nuts

• Secure the tensioner with hexagonal wrench when
removing and installing the belttensioner.
~autiorL
Do not loosen inserted stud when disassembly,

[Point 6] Install conical washer

18- !
Pay attention to the installation direction of the conical
washers, The washer should be set with face the
chamfered side facing the tensioner pulley side.
I
,
'Ef\-
Nut Comea, Washer
_
washer
.. _ . _ .. _ _ .. _ _--...J

[Point 7] Install tensioner spring

• Assemble the tesioner spring to the belt tensioner pulley
as shown in the figure,
• The tensioner spring must be assembled together with the
belt tensioner pulley in the cylinder block.

• Hook the tensioner spring on the upper side of the tensioner

spring stud when the tensioner pulley is free.

Tensioner spring specifications

rTenslon~;P.;;;;y Spring-stopper'
i When ", stud
I Spring wire I . CIaIlSifk:ation I

I
diameter . .
Set angle Fll1Ie. angle.. ' •. paint ~:'! ",set" ' \
[

~ Q

I 1.8 Approx.20' Approx. 163' , Yellow .L...--

• • d"
~'A,'
' /
~

'"'
When Irei!-- .
~Q~
tim in Timing belt plate i

[Point 8] Install crank timing pulley & plate Ipulley p

• Care must be taken of the rear and front positioning when

timing pulley plate,

'Crank pulley
installing timing belt plate, the crank timing pulley and the [side'"

L Crank timing pulley ~'---

"r ~

Groove
.. _ _.....J

EN·124
 ON-VEHICLE PARTS
~=2.:::: JET ENGINE

[Point 9] Timing belt alignment mark verification and installation

• Paint a mark on the belt that indicates rotation direction if
paint on the upper belt is unclear when disassembly.
• Position the alignment marks on the intake and the Cam pulley (intake)
exhaust cam pulleys with the respective belt cover I Cam pUlleYA~~;~~:~!1
alignment marks. (No.1 cylinder is at TO.C)

• Position the alignment mark on the crank timing pulley with

the respective oil pump housing alignment marks. At this'
time the groove must be straight up (no. 1 cylinder is at
TO.C).

• Move the belt tensioner clockwise 70 - 80 degree angle,

and secure it temporarily with the belt tensioner nut.

Install the belt by aligning the timing belt and the pulley lJfl/.
• marks. Align the number of ridges of exhaust cam pulley Crank timing
alignment mark and the crank pulley (inner) alignment mark 1~~. _~~~~trm11"ark..-J
as shown in the figure on right.
i

• After loosening the nuts and adjusting the belt tension,

secure the tensioner with the hexagonal wrench so it will
not rotate together and tighten the nut.
Caution:
(1) Make sure the timing belt engages correctly with the
pulley and does not flat when assembling the
timing belt.
(2) Replace belts whenever possible when disassembly
is performed.

[Point 10] Timing belt tension adjustment

• Remove the spark plug and align the timing belt alignment
mark and the pulley marks and install timing belt on to each
pulley.
• Loosen the tensioner securing nut so the belt tension is
applied by the tensioner spring.
• In this condition, rotate the crank pulley clockwise more
than two turns to check the belt movement and stop slowly
at No.1 cylinder compression TD.C point.
• Insert the hexagonal wrench in hexagonal hole. Hold the
tensioner by hand so the tensioner does not move, and
tighten the tensioner securing nut to specified tightening
torque.
Tightening torque (kg-m): 4.4 - 5.9
• The initial tension on the bell in this condition should be
approximately 20 kg.

EN 125
 ON-VEHICLE PARTS
RB20DE I DET ENGINE

[Point 11] Install idler & tensioner pulley

• Do not loosen inserted studs when disassembly. If studs are loosened, coat inserted stud
with locktite solution (Japan Locktite KK) or equivalent

[Point 12] Timing belt inspection

• Replace timing belt if any problems are indicated at the inspection .
. .
.:
.
Item Condition .... . Cause .....

~~
Tooth missing Camshaft lock
!
Cracked tooth : L.;;:: , y'~>,
Crank sensor lock
i

I Tensioner lock

~
Cracks on rear
:.{..,-
Engine overheat
side ! Interference with belt cover etc.
!

~.~~
I Wear and cracks Belt misalignment
on the side ~~;- I, Belt plate malfunction
!

I
Worn teeth 8IJ;tI/1} Sliding motion resistance in

- - crank sensor and the camshaft

!

Oil or water
adhesion .~ Oil seal malfunction
Water leaks in water pump

Calljion:
Do not twist or bend the timing belt. Make sure there is no oil film or water on the belt

10·6 REMOVE & INSTALL WATER PUMP

'tell kg-m
~ liquid gasket

Additional work required:

• Drain and refill cooling water
• Timing belt cover
EN -126
 ON-VEHICLE PARTS
RB20DE I DET ENGINE

(Point 1] Remove & install water pump 5 1 6 7 8 9

Remove
• Care must be taken not to get coolant on the timing belt.
Wipe it off immediately if any water does spill.
Remove the water pump bolts in the reverse order shown.
Installation
• Install the blots in the numbered sequence shown.

UqUld gasket 2.0 - 3.0 mm

wide along the groove
• Wipe off oil liquid gasket from the cylinder block and on the I
water pump and wipe the surface with white gasoline. I
• Apply continuous bead of liquid gasket (KP51 000150) to
water pump sealing surface.
Caution:
Be sure liquid gasket is 2.0 to 3.0 mm wide.
Installation must be carried out within 5 minutes after liquid
C;) o 0

gasket application.

(Point 2] Water pump inspection

• Rotate the water pump by hand and check for abnormal
sound and smooth operation.
• There must be no traces of water leaks.

10-7 REMOVE & INSTALL THERMOSTAT

Thermostat [Point 2]

Therm~stat housing [POint 1]~

E:I\/~ ~
~;)/~
,/ , - I

~\
Bolt (3) 1.6 - 2.1!Rl
E:I liquid gasket
!Rl kg-m

Additional work required:

• Disconnect and connect water inlet hose.
• Drain and refill cooling water
Caution:
Loosen engine drain plug to remove cooling water from
cylinder block.
EN -127
 ON-VEHICLE PARTS
RB20DE! DET ENGINE

[Point 1] Remove & install thermostat housing

Removal
• Insert the screwdriver handle into thermostat housing and
move it up and down lightly to remove the housing.
Installation 2.0 - 3.0 rr:m wide to center of
• Remove old liquid gasket on the thermostat housing and I mating surface and inner seating
. surfaces of bolt holes.
the cylinder block and wipe off the surface with white
gasoline.
• Cut nozzle end of liquid gasket (KP510 00150) tube.
Apply a continuous bead of liquid gasket to sealing surface
o
uSing the tube presser. Install the housing within 5 minutes
after coating liquid gasket. L ....~ ...~_ .. _ _ _ ~_ _ _ _ _ ---C

[Point 2] Install thermostat r--~"-~" Jiggle valve "I

• 'Top' mark (jiggle valve) must face up when thermostatis "
inserted in housing.

[Point 3] Thermostat inspection

• Check the valve opening temperature and maximum valve Ist~ng ~ -~,~~~
... ..
lift.
• Hang the thermostat by string in valve and submerge in
heated water in double walled container and stir water while
, walled
I
,,,,,,".- . . II~I
';''' 'LI '
i

heating it up.
: contamec~ :: I
!Thermostat--·-~::.,
---"if·:'J ,
• The opening temperature is the temperature when the valve -~ .""
opens and thermostat falls from string.

, ' , .
. "
'StaJ1dard,coki climate
Valve opening tempefature (OC) 76.5
. ..•. Max., valve lift rnmt OC . 10190

EN - 128
 ON·VEHICLE PARTS
R520DE I DET ENGINE

10-8 REMOVE & INSTALL OIL PAN, OIL STRAINER AND OIL FILTER

Additional work required:

• Front stabilizer
• Radiator fan, shroud
• Right & left engine gusset
• Engine rear plate (lower) (AfT vehicles)
• Engine oil

[Point 1] Remove & install oil filter

Removal
• Use oil filter wrench to remove the oil filter.
Installation
• Before installing new oil filter. wipe off dust etc. from
cylinder block mounting surface. Apply a thin coat of
engine oil to oil filter a-ring.
• Screw oil filter on bracket by hand until a slight resistance •
is felt, then tighten an additional2f3 tum with oil filter wrench .....~
After tightening, start engine and check for oil leaks.

[Point 2] Remove & install oil pan bolts

Remove
• Remove the bolls in reverse sequence of figure on right.
Installation
• Install the bolts in sequence shown in figure on right.

EN·129
 ON-VEHICLE PARTS
RB20DE I DET ENGINE

[Point 3] Remove & install oil pan

Removal
• Use seal cutter to remove the oil pan.
Caution:
(1) After removing the oil pan, remove oil liquid gasket on
the oil pan flange groove and the oil block using the
scraper. Make sure to remove liquid gasket dropped
inside the oil pan.
(2) Care must be taken not to damage the oil pan.

• Remove the engine mounting nuts (oil pan side) and use
the hoist crane to move the oil pan forward. Take off the oil
strainer bolts using the wrench before removing the oil pan.
Caution:
Care must be taken not to pull the hoses and harnesses too
r'~f~~~~J~~~~
'---_~"."--""" ~,..""-~,... ___~..__..;
much when lifting up the engine using the hoist crane.
Installation
• The following procedure must be carried out within 5 Tube presser (WS3993)i
minutes: .
Apply a continuous bead of liquid gasket(KP51 0 00150) V~ ~ '~~~~l~~~~~~)
to sealing surface uSing a tube presser. . ~;;t~ - -~,,""" -~ . "",
• Install the oil pan within 5 minutes after coating. i/ ,_-- ' .
r/"~-~~

[Point 4] OUleak and oil pressure inspection

• Start the engine and check for any oil leak and the oil
pressure. To check the oil pressure release the oil
pressure switch and use the oil pressure gauge.

[Point 5] Install oil strainer

• Check to make sure the O-ring is installed properly before
installing the oil strainer.
Tightening torque (kg-m): 1.6 - 2.1

EN -130
 ON·VEHICLE PARTS
'i920DE- ENGINE

10-9 REMOVE & INSTALL INTERCOOLER (RB20DET)

"'" To ,ntake :namfold

'-,
A"tube~ 1I'iI@ '<J1C>
t
r \ Au' hose
6"11~~~~,:;;

CI amp
Clamp •. _~

Air hose ---..u

Air tube " I'I"!! Inter~cooler
" ~ Nut (2).-..
1.3 - 1.6 ~-':~.t=;qr.~J' bracket
fl:::l''--<_.''-' Nut 0.4 - 0.5 ~

~Bolt (2) 0.38 - 0.51 ~

Bolt 2) 13 -1.6
[Point 2J ~
Air hose Bolt 0.4 - O.5~

._.J:P, Bolt (2) 1.3 - 1 ,,[Point 2J~

~
Inter~cooler bracket
!nter~cooler

~kg.m

Additional work required:

• Left front fender protector
• Fender stay
• Bonnet [Point 1]

[Point 1] Remove & install bonnet

• Remove left side bonnet bolts only (Lift up left side of the
bonnet to operate).

[Point 2] Remove & install intercooler

• Remove the fender protector then remove cooler bolts to
remove inter-cooler. Take care not to damage the fins.
Caution:
The fins are aluminium and can be damaged easily. Never
place anything on the intercooler or allow tools or other hard
objects to contact the fins.
The main unit (tank, fins, tube) cannot be disassembled.

EN - 131
 ON-VEHICLE PARTS
RS200ET ENGINE

10·10 Remove & Install turbocharger ASSY (Include fault diagnosis)

(1) Removal & installation

Additional work required:

• Under cover
• Assemble & disassemble exhaust front tube
• 0_, sensor connector
Intercooler air inlet tubes, hoses
Air inlet pipe

[Point 1] Remove water outlet tube

• Remove the water outlet tube by first removing the clamp
located on the rear side of the cylinder block.

Inspection
• After cleaning water inlet and outlet tube with radiator
cleaner, blow with compressed air and check for rust or
clogging.

EN -132
 ON-VEHICLE PARTS
R820DET ENGINE

[Point 2) Remove oil feed tube J ~

• Remove the oil feed tube by first removing the cylinder block r', I(~;~~ -"-4 '
and turbocharger eyebolts, \'<'.s;:~/,
! ), / 1)1 /
\\~I'''''
\ -' '\..0:1 feed tub
'"

Inspection
• After cleaning oil feed tube with engine conditioner, blow
with compressed air and check for clogging,

[Point 3) Remove oil return pipe

• Remove the oil return pipe by first removing the oil pan
clamp and the turbocharger bolts.

[Point 4] Remove & install lock plate

Removal
• Spread the lock plate pawls with a screwdriver and loosen
the nuts,
Installation
• Position the lock plates and turbocharger mounting nuts.
After tightening the nuts, bend lock plate pawls onto the
nuts.

[Point 5] Eyebolt determination

• Oil feed (cylinder block side and turbocharger side) eyebolts
are stamped "G".

Installation order
1. Turbocharger main unit
2, Water feed tube
3, Oil feed tube
4, Water outlet tube
5, Oil return pipe

EN .. 133
 ON-VEHICLE PARTS
RB20DET E:'-JGINc

(2) Turbocharger unit inspection

,,,,,e'dlV' [Point7J ExceSSive pressure leak

Exhaust gas leaK Inspection location

valve [Point 3]
Crack iinSI)ection-···._~_I4...;..

Crack j Turbine wheel

inspection ~-- ..---- [POint 1, 2. 4J

Compressor
[Point 5J
Cooling water Rotor shaft [Paint 6, 8J
(Point 8J

::~_~ Oil leak Inspection location I

[Point 1] Rotor shaft inspection I
• There must be no heaviness or dragging and the shaft must i
tum smoothly when rotor shaft is tumed by finger.

[Point 2] Turbine wheel inspection

• Oil must not adhere to surfaces.
• There must be no carbon accumulation,
• The vanes of the turbine rotor must not be bent.
• There must be no interference with turbine housing.

[Point 3] Swing valve inspection

• Remove actuator rod pin and make sure the swing valve
moves smoothly without deformation or cracks,
• Make sure there are no misaligned seating surfaces in
turbine housing.

[Point 4} Rotor shaft play inspection

• Position the dial gauge and measure play and thrust
clearance.
Rotor shaft play (mm): 0.084 - 0.107
Thrust clearance (mm): 0.045-0.140

EN -134
 ON-VEHICLE PARTS
RB20DET ENGINE

[Point 5] Compressor wheel inspection

• Oil must not adhere to suction inlet.
• There must be no interference with compressor housing.
• Wheel must not be bent, folded or otherwise damaged.

IZt 'J '. i

[Point 6] Rotor shaft inspection : ,'/, ( r'1'. \ !, I ,
t"
• There must be no carbon sledge accumulation.
!lJ'
fI' I j
/

mr;\\
,( : \'
~ \
I

~
. 'I ,i
i '
There must be
; ,I 1 \~ nocarbon
1": ' ~ l '/t' sledge :
in,I'j : \\' !! •
{f,aCcumUlation'
\t'\ ,~\,-r--,,"II \ 1\:
'\\' "-.:Y /' ~_~ , 7"
\\\~\ \ i\"I./ j ;
~ ..... \\\j-I!~u ! J ,,\ ' .....!
[Point 7] Swing valve controller inspection
• Remove the swing valve controlier rubber hose on the
compressor housing side.
• Check the swing valve controller whenever the actuator rod Operates smoothly
is installed or removed.
• Use the air gun to blow compressed air approx. 0.8 - 0.9 , [H.o==~=f;R~\:
kg/cm2 into hose and make sure the swing valve controlier ; ~=.;::;~~
rod operates. Stop blowing air as soon as the rod r
operates.
Caution:
Make sure to verify the air gun pressure using the LPG
pressure gauge before testing the air hose. If air pressure is
applied excessively the diaphragm may be damaged.

[Point 8] Oil and cooling water inlet and outlet

cleaning • C·,,·~
• Use engine conditioner to clean the oil feed and return i ~<;;1(2~."- _
passages. , / -;; 4?/?:tr'/ <:.'"
• Use radiator cleaner to ciean cooling water feed and retum ~~~. :~ U. 3~~.J :e.W
passages. ! 'y_/ CJ-; ~.J/..--::)
" 011 returl1:'~~
IL 1\ Ciean with enWner
conditioner

• Clean using the air gun.

• Clean the compressor wheel, turbine Wheel, compressor

housing and turbine housing with same methods.

EN - 135
 ON-VEHICLE PARTS
RB20DET ~NGINE

(3) Turbocharger failure diagnosis (Oil leaks, smoke (white or blue smoke), lack
of power, poor acceleration, abnormal noise)

Points to be checked before diagnosis:

1. The engine oil level must be between the MIN and the MAX marks on the oil level gauge.
(When the engine oil level is higher than MAX line, the engine oil will flow into the intake
duct through the blowby gas recirculation pass and the turbocharger may be
determined to be malfunctioning).
2. Check with customer to determine if oil is cooled when idling after driving.
If any malfunction in the following chart is detected in a unit inspection, replace the
turbocharger ASSY

:-:' ..... . ··t POIIIIible assoeilltlHlpnenomenon,

Inapectiontocatlon .·1 Inspection_it t.ack of ....

, OiIlUk Smoke Abnormal powerlPoor
, . nollM ace.'enatlen
. .
. ' .. I

!Oil on rotors f::" {Q'l f::" f::"

I ~" c:
~
Carbon has accumulated ".
f::" ,g;;.
i Turbine rotor
Rotor .~crapes ag.~inst the housing f::" C i
.~ \J
I•
I
. Turbime vanes are bent or folded © ©
Suction inlet.s dirty with oil 0 0
Compressor wheel : Rotor scrapes against the hosing f::" I
,~

u © 0
Turbine vanes are bent or folded © ©
There is resistance or scraping I
, when rotated by finger i
f::" f::" 0
Turbine and compresor
Rotor shet play inspection
I Rotation by finger is not possible i ©
i
Considerable shaking betvveen
i rotor shaft and turbo ASSY , f::" f::" 0 f::"
I look through oil hole Carbon sllXige has accumuiated
f::"
i (inspect interior with pen light) in waste oil hole
I © f::" f::"
The valve does not move I
! i
smoothly when pressure is
~ valve operaUon appl.ed gradually, (usually opens
(use airgun or air pump)
at pressure greater than 0.6 - 0.7
! ©
i kg/em')
I I i

© Highly possible o Possible f::" Slightly possible

EN -136
 ON-VEHICLE PARTS
CA18i ENGiNE

10,1 INTAKE MANIFOLD ASSY

(1) Remove & instal intake manifold ASSY

Throttle body bolt (4) 1.8 - 2.2 tql

"--?l ..-- Gasket.,

~!~
Water hose
~ RTC heater [Point 4] Breather hose

Throttle body ASSY ,.0;:;, _,,",~

Intake manifold ASSY 3]
:c!lBolt (2) 0.43 - 053" ..J
:c!l18 - 2,2 [Point 2J.... ~ ii :«_
Intake manifold nut ~'§) ~Ire bra~'" d~~~~·-·Gasket"

\8~ '~.
wa:~Elr,· 1
18 - 22lPo:nt 2]/c6
tqllntake manifold bOld
!

H osa ="""'~
Intake manifold gasket"
tql kg·m
. , Replace after every disassembly

Additional work required:

Release fuel pressure in the fuel lines
• Drain and refill cooling water
• Air cleaner ASSY
• Fue[ hose
• Water hose
Intake side high-tension cable
• Vacuum hoses and ECCS harness connectors
• Acceleration wire [Point 1]
• Water temperature sensor connector
• Thermal transmitter connector

[Point 1] Acceleration wire adjustment

• Loosen lock nut to provide adequate slack for the
accelerator wire and pull outer case in the direction of the
accelerator, Return the lock nut 1,0 - 1,5 turns from the
position the throttle drum starts moving (when there is no
play in cable) and tighten.
Tightening torque (kg-m): 0.8 - 1,0

[Point 2] Remove & install intake manifold

• Removal is the reverse of installation sequence shown in
the figure on the right.
• The installation sequence is shown in the figure.
Note:
Never reuse the gasket.
EN - 137
 ON-VEHICLE PARTS
CA~8; ENGINE

[Point 3] Intake manifold inspection St""ght gauge

• Measure the intake manifold surface for distortions in four \

separate directions (at opposite directions; horizontally and

vertically) in a number of locations.
Limit value (mm): 0.15

[Point 4] PTe heater inspection

• Make sure there is no crack on the PTe heater.

(2) Disassemble & assemble throttle body ASSY

Fue! injector cover screw
(2) 0.20 - 026~ ~_'"'
U ~?.-./ Fuel injector cover
. /
e.O.nng~ ~
'-c:>
Fuel injector [Point 2J '--- G
e. O·ring --c:> if//'~ Bracket
Pressure regulater [Paint 4J I ~~'f_.. ~sc,ew (4) 0.64 - O.85~
" " , e.O.ring . . .--'
~'~'.-
."7 .
~' '7"
Upperthrottlebooy
~ ___. [POint 1J r cam sprmg
P:essure ~egulator sC;:w -- -!?- ;- /1 ! Cam spnng stopper
(2) 0.39 - 052~ 'If / / '-~ ~ i'I1?ln /I,washer
/~// ~ / / J"<JJfI~(j~
B k /
rae et e.lnsulator ./
./~ /
Cam ASSY [Point 3J
Seat "'~\
/
~
Thermo wax [POint 7] . I Screw 0.20 - 0.26
Throttle adjust screw·'-. \'l' £. / . Screw 020 - o.26~
--'u 'lJI' ~O'fIOg e.
~~~'-- Bracket screw (2)~
Lower throttle body [Point 9J
"p
'-..
I~.:~'~~i
. ~." ~.
I
i/), 0-- 0.64 - 0.85
--- Throttle wire bracket
Spring \
Valve _~:~~I ,~,~.~
~",><;I '\
Screw ""'-. .
. ./~'" ,!, ~ Spnng ~ Spacer
. Washer \ \
FrCD solenoid \ \ i
1.2 - 1.6 [POiQI 8],,Jw?'" A> I I @ ~
"1\"#'"
C\ ,/
~ Colour
/ Soring retainer
~ \ ~ ~~ , \ / / ~/ / Return spring
. ~ \ ' Valve • \ ' Spacer CO ~ .. r Spnng retainer
I I
, t ' Spnng ~
I
Spnng
, ,
\ Arm ASSY .fff{jJI, . . (
CiI0,
\ 1 Washer ~J Screw __ " ____ ~ __ ._'_~
I Idle revolution adJustmlnt .... ~ " '~~. Return spring
solenoid 1 - 16 [P~t 8J l,,(':~;k , V (jfjJ-'~'" Spring retainer
Dash pot [POint 61 /
/ I ~ \
;""-...-t.?!f
S. ..- '~j" (Ij
~- / ~IJ,
Fuel Injectcr harness Dash pot bracket / \ Thro;;:~n~rum [POint 51 . / ;;1 ~
Dash pot bracket screw \ IVT tid /mV/ \
\ 4 0 ~ con ro ru / ;
(2,0.6 - .85~-. Dash pot nut [P . t 5J S' / h '.
~ kg,rn . 24 _33 n oln pnng was er \
. . .-. Nut 0.7 - 1.2~
e. Replace after every disassembly

EN -138
 ON-VEHICLE PARTS

Remove & install throttle body ASSY

• First remove four throttle body bolts to remove throttle body
ASSY.
• After the installation check the lightening torque.
Bolt tightening torque (kg-m): 1.8 - 2.2
• Always replace gasket with new ones,

[Point 1] Remove upper throttle body

• First remove the fuel injector cover then separate the fuel
injector connector.
• Loosen four upper throttle body screws to remove.

[Point 2] Fuel injector

Removal
• First remove the injector cover to remove upper O-ring,
then extract fuel injector.
Care must be taken not to scratch or damage the fuel
injector and throttle body seal surface.

Cautions when handling O-ring

• Never reuse O-rings.
~....- . . . /~~'t' . !njecto; ccv~r-I
Coat the O-ring with engine oil (7.5 W - 30 or equivalent)
but do not apply solvent to them as this may remove the oil 6(~\ '
Connector. ~
coating. rubber .,--@ Injector wiring
• Do not allow dirt, dust or foreign objects to adhere to ~ ccnnector
O-rings or other equipment surfaces, ''":J l=ue1 1"'jector
• Care must be taken not to scratch, twist or stretch O-rings
l~
when installing. Do not insert it in the fuel tube by I ~/

making it stretch slightly.

• Do not store O-rings in location subjectto ozone, high
temperature or in direct sunlight.

Installation ,,--~~~----~~~~

• Replace both upper and lower O-rings to new ones.

• Coat the lower O-ring with engine oil and install to throttle
body.
• Place the fuel injector inside the throttle body and set the
injector position by placing the injector connector and the
injeclor cover,
• Use oil seal drift to insert the fuel injector (resistance must
be felt).
• Coat the upper O-ring with engine oil. Use oil seal drift to
insert the O-ring.

_._~._ _,,__-"=" ___._ ... ..J

EN - 139
 ON-VEHICLE PARTS
CA 181 ENGINE

[Point 3] Cam ASSY ~cce' ,"'ottie DOdy--j

Removal "~_ ~~'" spring ,
• Remove the cam ASSY from the upper throttle body. Cam spring
'
CautIon: , "~'
. ,. scepper
Wa'\her
Extra care must be taken as there are tension on the cam I / . ;S:>'f!!i1" . \ !
spring, Ca';"SSv . J' (~@~ i
Seat ._:~,
. _ _ ... ~crew----'~ -1
Inspection
• Look for any deformation or wear on the cam spring.
Cap spring free length (mm): 24.5 - 26.5

Installation
• Make sure to install the cam ASSY and the cam spring in Free iength I

right direction.
• Replace the seat with new ones.

Press...;re, regu'ator
[Point 4] Pressure regulator
Removal
• Remove the pressure regulator from the upper throttle body, :
• Carry out the fuel pressure inspection.

[Point 5] Throttle drum & A I T control drum r~---~" ..··-·-~~~I

: ,,--~~rm SSY Color :
Removal ;J;t:~) /
S~acer /Spnng retainer,
• First remove the nuts and remove the A I T control drum. 1~/;.-#c~,Jl./1 / Fatum spnn~
Remove throttle adjust screw and return spring and remove Iy tJ'.... ,@ -~ h, j ~:\".n:;iler •
the throttle drum from the lower throttle body, 1/ "" "", lJ) I1J Cl1I. :
"o1hThfOrtI~drurrl-_________ "I;
..J"I'(J[jf..~ Spring ~er
Inspection Return spnng / ~~ \
• Inspect visually if there are any warn, cracks or deformation spn.:0:~~;;;; drum :...W~0--Nut
on spring retainer. retainer, and colour, Also inspect i
rotation contact surface. Spring retainer ,
• Check deformation and warn on the throttle adjustment
screw and return spring,
Return spring free length (mm):

Installation
19.5 - 21.5 L (/ p./ct:(Plast'~ta,"er (plastiC)
W/
~

~
Celor (Plastlc)'1

• Care must be taken to Install the parts in correct direction

when installing the arm ASSY, return spring, throttle drum
and AIT control drum.

EN - 140
 I
ON-VEHICLE PARTS
CA 18i ENGINE

[Point 6] Remove dashpot ~-

• First remove the dashpot bracket to remove the dashpot.
Inspection .
• Check visually for any deformation or cracks on the rubber
part, !

; Rubbor
L_.~. __ ...__ _
[Point 7] Remove thermos wax
• First remove the throttle wire bracket to remove thermo
r-
wax,
Inspection
• Check if the pin will extend when the thermo wax is
warmed, Thermo wax
Caution:
Do not pull out the pin,

[Point 8] FICO solenoid & Idle revolution adjustment~.__~~~... ~~~

solenoid Va've

Removal
I Spnng !
: washen,'
• Remove FlOC solenoid and idle up solenoid from lower FICO ',! /
solenoid I I c?' /
tI1rottle body, I!~..,., ..,.,.c:f'_
Valve
; if:;! ~--- Spring
Caution:
Watch out for spring and the valve as it may jump out. r fl
I ~ --.~ Idle Washer revolution
Inspection I •••• ~l"stment s."lenoid_~

• Check that no warn orforeign matter adheres to valve head,

• Check the spring for deformation or warn,
Spring free length (mm): 11 -12
Installation
• Check the orientation ofthe valve when installing,

[Point 9] Lower throttle body inspection

• Check for any clogging in the air passage by carrying out
air blow inspection,
• Check for any cracks on lower throttle body,

EN .. 141
 ON-VEHICLE PARTS
CA18i ENGINE

10-2 EXHAUST MANIFOLD ASSY

·
Exhaust manifold gasKet
~~ ~, Washer
! ,Exhaust manifold nut (6)
O".::::,"' . //'::,.
". .
.
~
---LW..
~"I 1.8 - 2.4 [POint 1J
•
'. rfJ;/

lC
~) ~

~
r./~
/~'., r \,

/ / //:~~;~}o . 0 sensor bracket

0

I I
0, sensor 4.1 - 5.1 [Point 3] /
• \ Washer
Exhaust <'lanifold [Point 21 .....~ ,
J
//'..,..
,)
Heat shreld plate boit
Heat shield plate
(5) 0.3 - 0.5
. ~kg·m
i 0 Replace after every disassembly

Additional work required:

• Under cover
Exhaust front tube nuts
• 02 sensor connector
• Exhaust temperature sensor
• Hot air duct

[Point 1] Remove & install exhaust manifold

Removal
• Removal is the reverse of installation sequence shown in
the figure.
Installation
• The installation sequence is shown in the figure on right.
• Check the standard tightening torque after installation.

Straight
[Point 2] Exhaust manifold inspection
• Measure the exhaust manifold surface for distortions in four
separate directions (opposite directions: horizontally and
vertically) in a number of locations).

[Point 3] Remove & install O2 sensor

(Zirconium type single pole connector)
• Do not use tools with impact such as impact wrench for
removal and installation of the 0, sensor.

I
EN -142
 ON-VEHICLE PARTS
CA 1 81 ENGINE

10·3 LOCKER COVER

~
Locker Gover screw
f~(8) 0.1 - 0.3 [Palnl ~I
011 filter cap ®_Grommet
<9
I "----Tray

Locker cover
\LOCker cover gasket
[Point 21
~ kg-m

Additiona[ work required:

• High-tension cable
• Air cleaner ASSY

[Point 1] Remove & install locker cover

Removal
• Removal is the reverse order of installation sequence shown
in the figure on right.
Installation
2 4
• The installation sequence is shown in the figure on right
• When removing and installing the locker cover, also remove
the cover gasket and wipe off the oil adhere on the gasket
and in the groove.

[Point 2] Locker cover gasket

• Make sure the rocker cover gasket is positioned securely
in groove without twisting.

EN - 143
 ON-VEHICLE PARTS
CA1B; ENGINE

10-4 TIMING BELT (CRANK PULLEY, BELT COVER)

(1) Remove & install timing belt cover

Additional work required:

• Under CQver
Fan shroud
• Supplement belts
• Spark plug
• No.1 cylinder compression T.O.C position [Point 1J
• Install ring gear stopper [Point 2]

[Point 1] No.1 cylinder compression D.T.C

inspection
• Align the crank pulley mark and the belt cover timing
indicator to compression T.O.C.

• No, 1 cylinder is at compression stroke top dead center

when both the intake and exhaust side cams do not move
the valve lifters.

EN -144
 ON-VEHICLE PARTS
CA181 ENGINE

[Point 2] Remove & install crank pulley bolts ,-- l - \1-:'

• Remove starter motor and attach ring gear stopper.
Caution:
Coat the screw part with engine oil when tightening the crank
pulley bolt
Do not apply any oil on the damper area when installing or
,
I'

i/t
,., !
,j
I
~\! ;, 1i
. / +;fKV16) 1095
\ _;
-

I,
/!
.I J
, 'I
~I'
i
//!
!i,
,I

l! j
I

:
'
f I' '1/ .
removing the crank pulley. I~ I ' : I
"---_ I, I II !

[Point 3] Remove crank pulley

• Loosen the crank pulley bolts and use pulley puller
(steering wheel puller ST2718 0001) to remove the crank
pulley.
Caution:
Do not hook the pulley puller on the crank pulley groove.

~--~--

O
~
[Point 4] Remove & install belt cover
Do nol scratch packing when removing and installing the >P8ck,ng I
I' , I
belt cover.
( ""
• Always tighten the belt cover bolt using the rubber washer. i - I

I ~ ____ . _ _ ~Ir' _____ .... _ .. _ _ _ _ _ _ _ J

Crank pulley Side

[Point 5] Install crank pulley plate
• Make sure the crank pulley plate is positioned in correct
way.

II
(2) Remove & install timing belt
Timing belt alignment mark verification and installation
• If paint on upper belt is unclear when disassembly is
performed, paint a mark on belt that indicates rotation
direction.
Position the alignment mark of the cam pulleys with
respective timing belt cover alignment marks.
(No.1 cylinder at TD.C)
• Install the timing belt so the number of ridges from the
alignment mark to crank pulley (inner) alignment mark will
be as indicated below.
" No_ofrldges Total No. of
between two marks ridges
• ,

CA18i 43 95

EN -145
 ON-VEHICLE PARTS
CA :8, ENGINE

Timing belt tension adjustment

Remove spark plug and tighten tensioner bolt (1 & 2)
temporarily.
• Hook the lensioner spring (3) on the lower bolt (2).
• Hook the spring on the hook (4) and tighten the bolt (1).
• Loosen the tensioner (5) and tighten the bolt (2).
Ca[.Jtion:
Make sure the spring is positioned correctly at this stage.
• Check if the tensioner (5) will rotate when pushed by finger.
• Align the timing belt alignment mark and the pulley
alignment mark to install the timing belt.
'I~
( .,I, y/O~~~
,, \ (.:;
~ I',,' _-I1- ~I
,p~::
• Loosen the tensioner bolt (2). ' (?\, )l ,tc-
I !
• Tum the cam pulley more than two tums clockwise to check I ~: /j~~~'
((::'JI' 21L
belt moveme~t and stop slowly at NO.1 cylinder I ·:'p"".A
in~{~ '.
C?mpresslon r.o. C pOint. ::.- \\ i~ ;~~~h'\
@ I'

• TI.ghten t.ensloner bolts (1 & 2). , ,\ \S~/:~1')r'i3'''~

Tightening torque (kg-m): 1.5 - 2.0 ..
~ ,~-'-.~~~-,.~~~~

(3) Timing belt inspection

Replace timing belt if inspection indicates any problem.

Item Condition Cause

, "

'.
,
Tooth miSSing
Cracked tooth ~~
'"" '
Camshaft lock
Crank sensor lock

Tensioner lock
I
I
Cracks on rear
side :JiJ? Engine overheat
Interference with belt cover etc,

~~
Wear and cracks Belt misalignment
on the side -.~/ ,,11 Belt plate malfunction

Worn teeth
!f!J1!!J
- +-
Sliding motion resistance in
crank sensor and the camshaft

~
Oil or water Oil seal malfunction
adhesion Water leaks in water pump

Caution:
{1} Make sure the timing belt is not twisted or bent sharply.
Make sure there is no oil film or water on the belt.
(2) Timing belt need to be replaced every 100.000 km.

EN - 146
 ON-VEHICLE PARTS
CA' 5' ENGINE

10-5 WATER PUMP

Water pump [Point 1, 2]

Spring washer \

Bolt (3) 1,6 - 2,0 \ • ...-~",,~

i ~~/~""'-

o kg.",
~ Replace after every disassembly

Additional work required:

• Drain and refill cooling water
Fan shroud
• Fan
• Water pump pulley
• Supplementary belts
• liming belt cover

[Point 1] Remove water pump

• Be careful not to get coolant on timing belt. If any water does spill, wipe if off immediately,
Caution:
Remove old gasket on the water pump surface using the scraper,

[Point 2] Water pump inspection

• Rotate water pump by hand and check for any abnormal sound and smooth operation.
• There must be no traces of water leaks.

EN - 147
 ON·VEHICLE PARTS
CA181 ENGINE

10-6 THERMOSTAT

Additional work required:

Drain and refill cooling water
• Water outlet hose

[Point 1] Remove & install thermostat housing

Removal
• Insert screwdriver handle into thermostat housing, Pry lightly
up and down and remove housing,
Installation
• Place the jiggle valve on top when installing the thermostat
housing,
Caution:
Remove old gasket on the water outlet surface using the
scraper,

[Point 2] Thermostat inspection

• Check the valve opening temperature and maximum valve
~
• Hang the thermostat by string in valve and submerge in ,
I ~~~j I ~!
". , ' -~=::.:

heating it up, container '~

1;
heated water in double walled container and stir water while Double-walled . , : . , - ---=
i

• The opening temperature is the temperature when the valve Thermostat ,; " '
opens and thermostat falls from string, '"

,
, Standard climate Cold climate

ValW Opefflng
temperatwe,("C)
82 88

,Max. i/IlIliellfl
Over 8 195 Over 7 i 100
, /(mIflJ 6 C) ,'.. .
EN -148
 ON-VEHICLE PARTS

10.7 OIL PAN & OIL FILTER

(1) Remove & install oil pan

Oil strainer nut ~~

0.7 - 0,8 ~_~ r ~i:,) a,l steaner II!:! t') Oil seal gasket
t') ali strainer ~ @1'::,. / / . \ . ( r e a r ) [ P o m t 4 J
gasket --~7h

L
01 oan [Point 4111!:!
a ,;~ \

ttll Oil strainer bolt i ", ~I~' " \

(2) 1.2 -16 - _ tl ~~=-; \ \.1 \
t')0il seal gasket Ii'!I ~!\\'
_-, i !.....-
-,) I

lI!:!(front)\oint4] _,
_~I\ .'\ __ ,~. ;::~.~ ~~' ,~::;J
\ _~ '\ .~'-').,~ .,.~ I

~ ~,~~~~;'
~ ~ I,
/ c I \ Ii " &______., ~
Drain plug 3,0 - 5.0 I Oil pan bOlt (10) 0,64 - 0.85 [Point 4]
Drain plug washer [Point4it') ~
~ kg-m
II!:! liquid gasket
o Replace after every disassembly

Additional work required:

• Under cover
• Engineoi[
• Right & [eft engine gusset

[Point 1] Drain plug washer ['

Oil pan side
• The drain plug washer has installation direction, make sure
to install in the correct direction, !
• A[ways replace drain plug with new ones when removing
and installing.

[Point 2] Remove & install oil pan bolt 2

Removal 10 6
• Remove the bolts in reverse sequence shown in figure
on right.
Installation
• [nstall bolts in sequence shown in the figure on right.
• Tighten bolts to correct tightening torque, 9 5 3

[Point 3] Remove and install oil pan

Removal
• Remove the oil pan using the seal cutter (KV101 11100).
Caution:
Remove old liquid gasket on the block pan flange groove
using a scraper.
EN - 149
 ON-VEHICLE PARTS
CA18i ENGINE

Installation
• Apply sealing agent (SS60F or equivalent) on the areas
shown in the figure on right to install oil pan gasket.

• Apply a continuous bead of liquid gasket (KP51 000150) I

to sealing surface using the tube presser and install the oil
pan within 5 minutes after coating.

• Insert two center bolts to oil pan bolt holes, make sure it is
fitted correctly then tighten.
Caution:
Leave for 30 minutes after the installation.

[Point 41 Oil leak & oil pressure inspection

• Warm up the engine and check for any oil leaking and the
oil pressure.
• Release the oil pressure switch and install the oil pressure
gauge when carrying out the oil pressure inspection.

Engine. revolution (rpm) When idling 2000 4000

, Exhaust output (kg I em» Approx. 1 Approx.3 Approx. 4

(2) Remove & install oil filter

Removal
• Use oil filter wrench to remove the oil filter.
Installation
• Before installing the oil filter, wipe off dust, etc. from oil
cylinder block surface. Apply a thin coat of engine oil to
new oil filter O-ring.
• Screw oil filter by hand until it hit the cylinder block, then
tighten an additional 2/3 turn with oil filter wrench. After
tightening, start the engine and check for oil leaks.
Tightening torque (kg-m): 1.5 - 2.1

EN - 150
 ON-VEHICLE PARTS
R525DE ENGINE

10-1 AIR DUCT & AIR CLEANER

~ kg-m
r::! liquid gasket
~ Replace after every disassembly

r""""---,-~~ / // :,:-~:+ ~,~\-<. _'~; =?Z~-,~~<--~~ -I

:;,~ ,{>:J"~i:~~~"r
'>

Removal I i
• Remove the negative terminal from the battery. : K(~ ..
"~ -:?0·-./20.(
• Use an airgun to blow off any dirt or dust before removing .(~~:~ __ t'Y6<~~1 _lfti
the air hose and air duct. .-,. ~:iC_-,
IV~~,~4- ""4,' -\ Air gUI' ,
,;~. ; ,_ '

Remove the following:

2 vacuum hoses from the resonator (between intake
I(S=+~";S~~~!
--- :.
't .-
manifold and canister).
• Blowby hose between locker cover and air duct.
• Air hose between air duct and air regulator.

• Remove airflow meter connector.

EN-151
 ON-VEHICLE PARTS
RB25DE ENGiNE

• Put alignment mark on each air hoses and the duct then
remove.
• Remove 4 clips on air cleaner case (1 on upper case 3 on
lowercase).
• Remove upper case to extract air cleaner element.
• Remove the lower case by first removing 4 bolts.

• Remove the resonator by first removing the left fender

protector then loosening the resonator boll.

• Remove the air duct by first removing the front combination

lamp and the left head lamp ASSY
• Care must be taken not to scratch or damage the airflow
meter sensor when removing the airflow meter.

Installation
• Installation of the air duct and the air cleaner is carried out !

in reverse order of removal operation.

Air flow meter circuit case is nonseparable, use ASSY when

replacing the air flow meter.

• Make sure to insert the air hose and the air duct securely
by aligning the alignment mark correctly and tighten the
band and the clamp.

EN - 152
 ON-VEHICLE PARTS
R8250E ENGINE

10-2 INTAKE MANIFOLD COLLECTOR

(1) Remove & install intake manifold collector
Collector bolt ~
(2) 1.8 - Collector ASSY

t;QII'ootl)r gasket 0

~I
i

~Collector boll (2) 1.8 - 2.2·-.11.

!

1.8-2.2(2)~!

~ kg·m
o Replace after every disassembly

Removal • ACTIVE TEST • 0

Release the fuel pressure
FUEL PUMP RELAY OFF
• Warm up the engine. CAS.RPM (POS) 950 rpm i
Select 'Fuel pump relay' in 'Active test' mode. !

• Select 'cancel' to release the fuel pressure.

• Crank 2 - 3 times to consume the fuel left in the piping.

• After starting the engine remove the fuel pump fuse.

After the engine stops. crank the engine over two or three
® Fuel DUmp fuse~
times to consume the fuel left in the pipe.
• If the engine does not start, remove the pump fuse and
crank the engine three to four times to consume the fuel
left in the pipe.
Caution:
The battery may become weak easily, use booster cables to l:::=======-==~:=:=.J~
connect it to charged battery if necessary.

• Remove the negative terminal from the battery.

• Drain cooling water from the radiator drain plug.
• Remove accelerator wire.
• Remove the AAC valve connector, FICO connector and the ~
vehicle body ground cable.

• Remove the hose A between the brake booster and the

collector.
• Remove the hose B between IAA unit and the fuel damper.
• Remove the hose C between canister and the collector.
• Remove the hose 0 between canister and the throttle
chamber.

EN - 153
 ON·VEHICLE PARTS
R825DE ENGINE

• Remove blowby hose E between locker cover and the

collector.
Remove hose F between pressure regulator and the
collector.
• Remove three water hoses G.
Remove the hose between air regulator and the collector.
Lift up the collector ASSY when removing the hose for
easier operation.
• Remove fuel feed and retum hose H, then remove the clamp
from the collector.
• Loosen the hose clamp to remove collector ASSY.

• Loosen the bolts in order shown in the figure on right.

• Check to see every hoses required are removed.

Installation
• Install the collector gasket.
• Make sure there is no dust, oil or other foreign matter is on
the sealing surface.
Install the collector ASSY.
• Tighten the bolts in the order shown in the figure on right.
Tighten in gradual steps to uniform tightness.

!Installation location
Length (mm) :
No. of bolts
Tightaning torqu"
(kg-m) I
!
7.10 105: 2 1.8 - 2.2

8 65: 1 1.8 - 2.2

1,3.4.6 40 : 4 1.8-2.2

2.5.9, 11 30 :4 1.8 - 2.2

• Connect each wiring and the piping in the reverse order of

the removal operation.
• Connect the accelerator wire.
• Provide adequate slack for the accelerator wlr~ and pull
1-' -: :::.
~ ~~e=:, ¥;}%
~-=~Jusi nut u, ~;z~?Ck_n!J\:.-;_
outer case In the direction of the accelerator uSing the '. ~f'(' : : , - - ~~" "",
adjust nut. Retum lock nut 1.0 to 1.5 turns from the position:', , .""ft ~~""
the throttle drum starts moving (when there IS no play) and '~:: , :··-,-o;fc~~' "
tighten. IV~'
-y
~\I~I
Oute; cas~: \. c:y
- ~
Tightening torque (kg-m): 0.8 -1.0 -,. __ _
EN -154
 ON-VEHICLE PARTS

• Make sure the radiator drain plug is closed securely and ~~Jabel ~Tf~l
refill the cooling water from the feed opening. i OPENVVHEN" ~~~ l"
• Release the air using the air release plug after refilling thelIDT "'~' ~Air fe:ease ~IU::
cooling water to prevent overheat. , . ,. . ",.
Caution: '''"' ~ ,\ 1:" '~
Do not remove the air release plug when the engine is warm.
Do not over tighten the air release plug bolt.

(2) Disassemble & assemble intake manifold collector

~Bolt (2) 064 - 08~ Al
Accelerator wire bracket _~ ,.~/"~,, Bolt (4) 09 -11 ~
COliector ~
~,
.~/'tQ1/-lfi'1-
..... ,~
~~/~--;\..
~~
~-~~ ~

0"/
,
,/ /
",,/.
1:~
~~~:(':>
/1' ¥'il ' /~

fA
"1 :
1M unit
"'-. Gasket (+
Me valve
Throttle chamber
gasket
rT",m"f~ Chamber(+
, All regulator --~ Throttle chamber boll
hos e " (4)18-22~

~kg·m
J \
'''"
Water hose
~

(+ Replace after eveIY disassembly

Disassembly
Remove throttle chamber
• Remove IAA unit

Assembly
• Install throttle chamber gasket °d
o 0
Install In dorrect direction

• Tighten the throttle chamber bolts in order shown in figure

on right uniformly in two stages,
Tightening torque (kg·m): First stage 0.9 - 1.1
Second stage 1.8 - 2.2

I,
• InstalilAA unit.

EN - 155
 ON-VEHICLE PARTS
RB25DE ENGINE

10-3 FUEL INJECTOR

~kg.m
Removal
Remove collector ASS¥. For detailed removal process
refer to "Collector" section. 7"';. Bol;·).~:L:. . .::."·'i
Remove fuel injector connector and the lamp. ,~",~.,I~~,:gula/'tc~n:ec~[I·
Remove the connector pin. . ~ ~/'S:;S:I'2Y: k\~\ I

The operation can be carried out easily if the vehicle body ?~~{~i-. ~t::;"~\\ .
ground wires. water temperature sensor connector and the .('1",* /~~?:, \i<'~ jl
thenmal transmItter connector are removed. Wi . ·z.-.J.•~..., /.~. ~~~ i

• Remove air regulator connector. I"--f1: / ;~~v 4Bol!t:'~ •

• Remove the fuel ASSY by first removing the bolts. ,._" '-~~"'-"~

• Replace o-ring with new ones when removing fuel injector,

pressure regulator and fuel bumper from the fuel tube.
• Do not pull the connector parts when removing the fuel
injector.

Precautions when handling O-ring

• Coat the O-ring with engine oil (7.5W ·30 or equivalent) but '-~'--"-----"--'
do not apply solvent as this may remove the oil coating.
• Avoid using dirty O-rings and do not allow dirt, dust or
foreign objects to adhere to O-rings or other equipment
surfaces.
Care must be taken not to scratch, twist or stretch them by
tools or operator's fingernails when installing O-rings.

Inspection
• Fuel injector resistance
Resistance value (Q): Approx. 13 - 14
• Injector can not be disassembled.

EN - 156
 ON-VEHICLE PARTS
RB25DE ENGINE

Installation
• Do not rotate or decenter the parts when installing the fuel
injector, pressure regulator and fuel bumper to the fuel tube.
• Tighten the pressure regulator and the fuel bumper screws
uniformly in two to three stages.
Tightening torque (kg-m): 0.30 - 0.39
• Install fuel tube ASSY
Tightening torque (kg-m): 1.6 - 2.1
• Connect the air regulator connector.
• Install the fuel injector connector and fix it in place using the
clamp.
• Install the collector ASSY

10·4 INTAKE MANIFOLD

4\
!
! Bolt (6) 16 - 2 1
Intake manifold
oo9~ lOJ
I lOJ kg-m : ! tqJBoit (2) 0 4 - C 5
I C liquid gasket
Removal
• Remove collector ASSY. For detailed removal process
refer to "Collector" section.
• Remove fuel injector ASSY
• Remove water hose.

• Remove oil level gauge guide bolt

• Remove rear water pipe connector bolt

EN - 157
 ON·VEHICLE PARTS
RB25DE ENGINE

• Remove intake manifold ASSY bolts and nuts (1,10,13) in

5 6 9 14 11 2 1 .
the orders shown in the figure on right.
• Remove the intake manifold gasket. .
II I .'
",
\
: I
I I
,
'I
I
I

Remove water pipe ASSY. ')~WAA11

1]4 I I I
7 8 1312 10 4 3

Installation
• Remove old liquid gasket on the water pipe, in the groove
and on the intake manifold, Clean all contact surfaces with
white gasoline or equivalent.
• Apply a continuous bead of liquid gasket (KP51 000150)
2,0 - 3.0 mm wide to sealing surface using the tube
pressor.
Caution
Installation should be performed within 5 minutes after
coating the liquid gasket.
Wait at least 30 minutes before refilling engine coolant.

• Install the water pipe ASSY

Tightening torque (kg-m): (A)O,4-0,5
(8) 1.6-2.1

• Install intake manifold gasket. 10 9 6 1 4 13 14

i I I I I
• Install the bolts and nuts (2,10, 13) uniformly in several
stages in the order shown in the figure on the right.
Tightening torque (kg-m): 1.8 - 2,2

• Install the front oil level gauge guide bolt.

• Install the rear water pipe connector bolt.

Tightening torque (kg-m): 0.4 - 0.5
Install the water hose.

EN - 158
 ON-VEHICLE PARTS
RB25DE ENGINE

10·5 EXHAUST MANIFOLD

i trlI kg-m
i 0 Replace after every disassembly

Removal
• Remove the following:
• Under cover
• Exhaust front tube
• 02 sensor connector
• Exhaust manifold cover
• Remove the exhaust manifold nuts in the order shown in
the figure on right.
• Remove the exhaust manifold gasket.

Inspection
• Look for any distortion on exhaust manifold.
Gas leak inspection
• After removing exhaust manifold, make sure there are no
traces of gas leaks from any part of installation.

Installation ., - '': .'

• Install exhaust manifold gasket

• Install exhaust manifold, washer and the yoke. ...
Front

• Make sure not to make mistake between No, 3 and NO.4

yoke as configurations are different.

.
Item O(mm)
i
No.3 & No.4 port 22
Other than those above 24

• Make sure the washer is facing the correct way when

installing. r

Manifold side

EN - 159
 ON-VEHICLE PARTS
RB25DE ENGINE

• Tighten exhaust manifold nuts in the order shown in the

figure on right

• Install exhaust manifold cover.

• After installation, crank engine and check for gas leak.

10-6 TIMING BELT

Timing belt cover (Upper)
Timing belt ,_ ': ,,"~:_-~~::~ __
Grommet , - i .~ ""'(~.~.," 1
~ Bolt (2) 1.6. - 21\®.~.-..
~,,\..... """
Nut 44 - 5.9.-4 ,
. .-~ ~j,!~~.;U~~/·
. "".'-i!~ ,'~ ~<~ ""'~ ,
pGO-ring - '. ( ! Belt tensioner "
~
!J'~'-'~£;J.~~
/' (,/:i,/- -- - ..-L;"'~
''0' ".) .
- -;,m-'(' C 'I ;,.. . /
Crank anllie \.. . .f . .... 'j' ;1 f. Onlca ; . enSloner Ii .' . ,'''<:;;C.'.' ,.L~: ~~~.(""(!~.'('~
sensor ~ washer .,' sPrmg '/ ,,,,.',,(';- ,4"'~ )

BOlt (3) 0.65 _ 0.86 Gramme . ~." . ! \0. .

Crank timing belt plate
0.4 - 0.5 ;;;;..; \ ' Crank timing pulley

~
,(J)"'.,
Washer

\~.(p'\
J "
0)'\
.s)' \.
'. (

.
~ Washor
Bolt 4.4 - 5.9

Timing belt cover (Lower)

Crank timing pulley plate
Idler pulley

~- Grommet
I """... • i Bolt (4) 0.65 - 0.86 ~ . , kg·m
! .-. ",J Crank pullev ... Engine all
Bolt 14.5 - 1 5 . 5 ' U
~. _______________________________________~
__R_e_P_'a_C_e_a_fte_r_e_v_e~
__d_is_as_s_e_m_b~'y

Removal
• Remove under cover.
• Drain cooling water from the radiator engine drain plug.
• Remove supplementary belts.
• Remove the radiator, the fan shroud and the cooling fan.

• Check No.1 cylinder compression TD.C position.

• Align the crank pulley timing mark and belt cover timing
mark indicator (0° position). Atthis time the No.1 cylinder
is in the compression T.D.C position when the camshaft is
located as described as follow:

• No.1 cylinder is at the compression stroke top dead center r----.-.. I

when both the No.1 intake and exhaust side cams do not . Intak!" camshaft Exhaust caf'sha~
move the valve lifters. ' ~.\
.~,,\~.1All j'd.. i

I~~J ieTlXl>2
I '''{'~'' I ~ ~I ' , 'r'/'
r , ,\!" J~
I
1i

~' '~.s \. \::--='~/'~'l----~~

EN - 160
 ON-VEHICLE PARTS
RB25DE ENGINE

• Remove the oil filter cam from intake side rocker cover and
check that the front end of camshaft faces the intake side.

... : IJ
.I."take side_ _ ..

• Remove crank angle sensor.

• Remove starter motor then install ring gear stopper.
• Remove crank pulley bolts.

KV101 05610

'. I
"T071" 0001
• Use pulley puller to remove the crank pulley (bolt size: M6 x
1.0 length below head approx. 50 mm)

'; ,
, ,

• Remove crank angle sensor bracket, then remove timing

belt cover. Timing belt cover is separated into upper and
lower sections, first remove the upper section then remove
lower section.
Caution:
Do not scratch dried liquid packing when removing and
Dned liqUid
installing the timing belt cover. packing

• Remove belt tensioner.

• Secure the tensioner finmly with a hexagonal wrench when
removing and installing bolt tensioner nuts.
Caution:
Do not loosen inserted stud at disassembly.

• If paint on timing belt is unclear when disassembly is

performed, paint a mark on the belt that indicates rotation
direction.
• Remove the timing belt

EN - 161
 ON-VEHICLE PARTS
RB25DE ENGINE

Timing belt inspection

• Replace timing belt if any problems are indicated at the inspection.
It is recommended to replace timing belt every 100,000 km .
..
Item .. Condition Cause
I
,.~
~
i Tooth missing . Camshaft lock
Cracked tooth ~~ Crank sensor lock

,
Tensioner lock
!

I
Cracks on rear
side -J;;p Engine overheat
Interference with belt cover etc.
!

~~
Wear and cracks Belt misalignment
on the side - ,,~( ';/ Belt plate malfunction

Worn teeth /fIlJ

1
,,~~j) I!l/}
''i
j:'
//
,
i
; Sliding motion resistance in

i
- crank sensor and the camshaft

~
Oil or water Oil seal malfunction

l
CautioD~
adhesion Water leaks in water pump

Do not twist or bend the timing belt. Make sure there is no oil film or water on the belt.
Make sure there is no warn or cracks can be found on idler pulley, tensioner pulley, cam pulley
crank timing pulley and the tensioner spring. Also check if they rotates smoothly.

Installation
• Assemble the tensioner spring so it engages the belt
tensioner pulley as shown in the figure.
• The tensioner spring must be assem bled together with the I
belt tensioner pulley in the cylinder block. •

ic"TenSioner stud
• When the tensioner pulley is free, hook the tensioner spring 1:- .V
~J;;;;;,;;::::~ -.,;,;s~~
on the upper side of the tensioner spring stud.~. ( rT 7("r--
[. • I
~\~j

Tensioner spring specifications

EN - 162
 ON-VEHICLE PARTS
R525DE ENGINE

• Care must be taken to install the conical washer in correct

direction.
• Install the crank timing pulley and the plate.

Nul Conical Washer

washer

1
Crank timing pulley
.' '1
Timing belt

tj~~t
plate
• Be careful to observe front and rear positioning oftiming
belt plate, crank timing pulley and crank timing pulley plate
when installation is performed. ICrank.. .u. 11

I pulley Sidej :-;- '- ~roove

Crank timIng pulley
• Align the alignment marks of the exhaust and intake cam
pulleys with the respective belt cover alignment marks (No.
1 cylinder is at T.D.C).
Cam pulley
Align the crank timing pulley alignment mark with the mark
on oil pump housing. The groove must be straight up (No.
1cylinder compression T.O.C).
• Move the belt tensioner clockwise at 70 - BoaC angle, and
secure it temporarily with belt tensioner nut. (This will
minimize the offset between the tensioner shaft and the
timing belt).
• Align the timing belt pulley marks and install belt. Align the
number of ridges of exhaust cam pulley alignment mark
Bell tensioner
and crank pulley (inner) alignment mark as shown in the pulley
figure on right.
• After loosening the nuts and adjusting the belt tension, Crank timIng
secure tensionerwith hexagonal wrench so it does not I pulley
rotate together and tighten the nuts.
Caution:
At timing belt assembly, check that il engages correctly with
pulley and it does not float.

Timing belt tension adjustment

• Remove the spark plug and align timing belt alignment
marks with pulley marks and install timing belt on to each
pulley.
• Loosen the tensioner nut so belt tension is applied by
tensioner spring.
• Turn crank pulley clockwise more than two tums to check
belt movement and stop slowly at No.1 cylinder
compression T.D.C.
• Insert hexagonal wrench in hexagonal hole. Hold the
tensioner with your hand and tighten the tensioner
securing nut to specified tightening torque.
Tightening torque (kg·m): 4.4 - 5.9
• At this condition belt tension should be approximately 20
kg.

EN - 163
 ON·VEHICLE PARTS
RB25DE ENGINE

• Install crank angle sensor bracket

Tightening torque (kg-m): 2.1 - 2.7 Crank
angle
sensor
bracket

,,
,j 2.1 - 2.7 (3) Ltll[

• Install timing belt cover in order of lower then upper. 065-0.86~

Tightening torque (kg-m): (A) 1.6 - 2.1
(8) 0.65 - 0.86 t

Install crank angle sensor

(1) Apply chassis grease to drive unit spline.
(2) There is a flange inside the drive unit spline so spline
only has one insertion position. Check the alignment
before assembly.
(3) Check that the crank angle sensor can be inserted
easily in belt cover holes and sensor moves lightly to
right and left, then tighten bolts.
(4) If the sensor doesn not move lightly, loosen the belt cover
bolts with crank angle sensor inserted. Move belt cover
to align belt cover hole center and camshaft center.
Tighten bolts making sure the crank angle sensor
moves lightly.
Tightening torque (kg-m): 0.4 - 0.5

• Position the washer for the crank pulley bolts so the flat
surface contacts the crank pulley side and then assemble.
• Apply engine oil to the threads of crank pulley bolts.
Tightening torque (kg-m): 14.5 - 15.5 Curved surface

EN·164
 ON-VEHICLE PARTS
RB25DE ENGINE

10-7 OIL PAN

Oil strainer bolt (2)

1.6-2.1

tcJkg-m
!OLiquld gasket
t:1 Replace after every disassembly
Removal
• Drain engine oiL
Remove radiator fan.
• Remove front stabilizer.
• Remove engine right & left gusset.

• Remove oil pan bolts in order of sequence shown in the

figure on right.

• Insert seal cutter between cylinder block and oil pan.

• Remove oil pan by tapping the seal cutter with hammer.

If removing the oil pan from the vehicle, first remove front

• ~:~~~e~~~~tti~r;~~\o lift up the oil pan forward./i~;i~c

• From the gap between the cylinder block and the oil pan, ~~"=~~
use a tool such as spanner to remove oil strainer bolt belt.
• Pull the oil pan out.
Caution:
Care must be taken not to strain the hoses and the harness
too tightly when lifting up the engine using the hoist crane.

EN -165
 ON-VEHICLE PARTS
RB25DE ENGINE

Installation
• Use a scraper to remove aI/ traces of oil liquid gasket from
cylinder block and oil pan surface,
Caution: I ,
Remove all gasket material and other foreign material that I ""
falls into the oil pan.
• Clean all contact surfaces with white gasoline or 'Scraper
equivalent.

1~~3993
Cut off nozzle tip of liquid gasket (KP51 000150) at point Cut
shown in the figure on right and insert into tube presser.
I""~~ ~
I
I

Tube presser (WS3993)

• Apply a continuous bead of liquid gasket (KP51 0 00150) Liquid gasket
to inner sealing surfaces 4 mm wide. (KP510 00150)
• Installation should be performed within 5 minutes,
Caution:
Be sure liquid gasket application is 4,0 mm wide.
Wait at least 30 minutes before refilling engine oil and engine ,____________._.....J
coolant.

10-8 OIL SEAL

Valve oil seal
• Remove the following parts:
• Engine undercover
• Cleaning fan
• Timing belt cover, timing belt
• Cam pulley
• Back plate
• Rocker cover
• Ornament
• Camshaft
• Hydraulic valve lifter
• Valve spring
• Use oil seal puller to remove valve oil seal.
• To prevent valve omission have the piston in compression
T.D,C position.

EN - 166
 ON-VEHICLE PARTS
RB25DE ENGiNE

• Valve oil seal installation measurement is as shown in the

Valve oil seal
figure on right.

Camshaft oil seal

Intake exhaust
• Remove the following parts:
• Engine undercover
• Cooling fan
• Crank pulley
• Timing belt
• Crank angle sensor bracket
• Cam pulley
• Back plate
• Remove No.1 camshaft then remove camshaft oil seal.
• Apply engine oil to area around the oil seal lip.
• Care must be taken not to scratch or damage oil seal
retainer. Use oil seal drift smaller than oil seal (41 mm)
and insert it at same level as front surface of oil seal
retainer.

Front oil seal

• Remove the following parts:
• Engine undercover
• Cooling fan
• Crank pulley
• Timing belt
• Oil pan
Oil pump
_ _1
• Use a screwdriver to remove front oil seal from front cover.
• Use oil seal drift and insert new front oil seal at same level
as front surface.
Face the oil seal mark outside (front side) when inserting.
Caution: ;
Do not touch the oil seal lip by finger as grease is applied to i
area around the oil seal lip.

Rear oil seal

Remove the following parts:
Transmission (or A/T)
• Flywheel (or drive plate)
• Rearplate
• Rear oil seal retainer

EN - 167
 ON-VEHICLE PARTS
RB25DE ENGINE

• Apply engine oil or chassis grease to area around oil seal :I

lip.
• Care must be taken not to scratch or damage oil seal
retainer. Use oil seal drift (External diameter: (100 mm)
and insert it at same level as front surface of oil seal
retainer.

Cleaning
• Use scraper to remove liquid gasket.
Caution: I'

Make sure to remove liquid gasket in the groove. ,

• Clean the cylinder block side using same method and clean I'
the surface with while gasoline.

t:~_~----'--'-L-. ~

Rear oil seal installation

• Installation should be performed within 5 minutes.
.1!".~WS3,9,93
. I
Cut

~,
• Cut off nozzle tip of liquid gasket (KP51 000150) at point I
shown in the figure on right and insert into tube presser.

- "~--Appry a continuous
r bead of liquid gasket.
A~=~ 2-3mm'
• Apply a continuous bead of liquid gasket (KP51 000150)
to rear oil seal retainer surfaces 2 - 3 mm wide.
Cal,ltion: ." 'l
Wait at least 30 minutes before refilling engine oil and engine 1'=""-=-=-=.=,,~====-_~
start.

• Install rear oil seal retainer by aligning to dowel pin.

• Tighten 6 bolts uniformly.

EN - 168
 ON-VEHICLE PARTS
RB25DE ENGINE

10-9 ROCKER COVER I IGNITION COIL

Ornament bolt (8) or.n.a.men:_~~nltlon COii namess

030-039'~ ~~_y_C ~.~
~_
~:c'::::- - .~
~... Ground cable
, _,,---'If
~ .
,A Bolt1.3 - 16--c,,"--":~' .. -
. Washer - .~ ... ' Spark plug 2,0 - 3,0
/.~ A
Ign>lion coli bracket

Akg-m

Filler cap

Rocker cover bolt

°rDA
-Grommet

Rocker cover gasket

Ornament !
Rocker cover gasket' -'-j'.-'
i
: ~kg-m

Removal
Remove Rocker cover ornament.
- Remove ignition coil hamess and remove ignition coil.

• Loosen and remove the rocker bolts (intake and exhaust) in

the order shown in the figure on right.
• Remove the rocker cover, 3 7 9 5

Installation
• Install the rocker cover, 7 3 5 9
• TIghten the rocker cover screw uniformly in the order shown
in the figure on right in several stages, [ : :: J
8 4 2 6 10

Bolt 0,3 - 0.39

Ignition coil
• Install the ignition coil bracket.

. ,: ~ Cylinder
• Install the omament Ignition coil bracketW ~de~
Holder }fAIIt
Spark plug
EN - 169
 ON-VEHICLE PARTS
RB25DE ENGiNE

10·10 CYLINDER HEAD

(1) Cylinder head removal & installation
Cyhnder head bolt Cylinder head bolt
(1) Tighten:03kg-m.It!! 092-12 ~
(2) Tighten to 10 kg-m ~/.. •

~
Cylinder head bolt (3) Loosen bolts completely e Spring washer
:'''''/(4) Tighten to 3 .....i~ 0.5 kg-m 0»-----
0.92 - 1.2" It!! (5\ Angle wrench 85" - 90° ~ Washer
','"i ; , Torque wrench 10 +j~ 0.5 . Cylinder head ASSY
Spring washer

Washer- --~.~"'K-;'~8'1' ~~~~~~~~~~~t~!"--~;DrirlO

---.:
I§l-'~ Washer
.
.
.
Cylinder head bolt
0.92 - 1.2 It!!

washer

Cam pulley
It!! kg-m
: t3 Replace after every d~sassembly

Removal
• Remove cooling water completely from the radiator,
cylinder block drain plug.

Remove the following:

Connector and intake manifold
• Exhaust manifold
• Timing belt
• Rocker cover, ignition coil
• Spark plug

• Remove the cylinder head bolts in the sequence shown

in the figures on right.
• Remove the cylinder head, then cylinder head gasket.

Check for any distortion on the cylinder head.

Check for any distortion on the cylinder block surface. 4-17 M1x1.5 1- 3 M6x1.0

EN -170
 ON-VEHICLE PARTS
RB25DE ENGINE

Installation I~'"
• Before installing the cylinder head ASSY to cylinder block,
the crank pulley and the cam pulley must be positioned at
No.1 cylinder compression T.D.C position.
• Align the crank pulley timing mark and the timing belt cover
timing indicator (0 0 position).

• Align intake and the exhaust cam pulley alignment mark

to respective belt cover alignment marks.

• Make sure it is positioned at No.1 compression TD.C

position.

• Install cylinder head gasket

• Install the bolts in sequence shown in the figure on right 7
• The cylinder head bolls are torqued by two-step method.
lighten the bolts in two steps.
(1) Tighten to 3 kg-m.
(2) Tightened to 10 kg-m. 11
(3) Loosen bolts completely 0 kg-m.
(4) Tighten to 3 - 3.5 kg-m.
(5) Turn bolts 80 - 900 clockwise when angle wrench is
used.
• lighten bolts to 10 +1-5 kg-m when torque wrench is used.
Caution:
When angle wrench is not used, never attempt to
approximate the tightening angle visually.

• Install ignition coil and the spark plug.

• Install the timing belt.
• Install the exhaust manifold.
• Install collector and intake manifold.
• Check the air flow of the hydraulic bulb lifter.
• Push the hydraulic bulb lifter crest surface with finger and
check the slump.
Slump limit value (mm): 1.0

EN - 171
 ON-VEHICLE ?';,,-:-S
RB25DE ENGINE

• There is a possibility of entrained air within the hydraulic

valve lifter ifthe slump is over 1.0 mm. Air need to be
released from hydraulic valve lifter.
• Idle the engine for approximately 10 minutes at 4000 rpm
after installing the rocker cover.
• Remove the rocker cover and push the hydraulic valve lifter
surface to check the slump of cam base circle.
• Replace the hydraulic valve lifter if the value is over the
limit.

(2) Cylinder head disassembly, assembly & inspection

Valve sprint rera!ner
/ 'falve spring
Valve lifter-~--0 /' ~pong seat
~"'(jl I / Valve oil sea!
Valve collet .....-- ~ / / Valve guide
'"' 0' <"- / , __ Valve seat
.-~ Nut 0.92 -1.2 ~~.
· h \. ~~- Intake air valve
S pnng was e~e t?.1'\.. ____ Exhaust aif' valve
Washer----: ! ~0
Buffla plata ~ <SfV ~ ®>0r1iiW
LCJ BOlt092-1.2----ff t (J';':°CU
Washer
~I "i"

V I I
~---- :---:~~ ~
Cam shaft bra';:~.~~~;;
-"~~-u~;~;~~:~~
Cam shaft (exhaust Side)

Cam shaft (Intake S-l: "" 'ii'- 80lt LCJ

~ ~~ 0.92-1.2

.
LCJ Bolt (1
i
Timing belt cover ~ ~~.
~--~
l ""
1: ; L~"'--J
?
1.6 - 2.2 back plate ~ \ "" I
LCJ Bolt (3) 0.64 - ~/ Cam snaft fronl oil sealOIli ? ~I 0.92 -1.2 LCJ

Crank angie sensor lit ~--- Cam pulley I t-___

LCJ Bolt (2\'-<'lY e?: "-....: Cam pulley washer ~ Bolt 0.92 - 1.2 LCJ
2.1-2.7 \..~~~)) 1 "cam pulley 00111.4 - 1.9LCJ

Bolt 2.1 - 27 LCJ

tcJ kg-m
~ Liquid gasket
I l Eng;ne oil
i G Replace after every disassembly

Disassembly
• Use the proper tool to secure the hexagonal part in front of
camshaft to remove cam pulley.
• Remove timing belt cover back plate.
• Position the cam shaft knock-pin to the position shown in
the figure on right.

EN - 172
 ON-VEHICLE PARTS
RB25DE ENGII\IE

Remove cam bracket bolts by loosening them gradually in

several stages. in reverse sequence shown in the figure
on right.
Caution:
Before removing camshaft bracket, paint marks to indicate
bracket position and direction.
• Remove the cam bracket.

• Intake and exhaust camshaft can be identified by

identification paint color and presence of a spline gear for I ~DillfW~J&!)l 1
; ntificatton paInt (purplel
driving the crank angle sensor. i!~{den. tificatiOfi paint (oran
1'~lmlE'b
II

I\'~...;"..,
, Knoc~.p,nr I•
Camshaft . Identification paint Spline gear

Intake camshaft

Exhaust camshaft
Purple

Orange
No

Yes
I ~ilL
. Spline gear for driving crank angle senso1
.
Remove hydraulic valve lifter.
(1) Hydraulic valve lifter is nonseparable.
(2) Do not store hydraulic valve lifter up side down or on
its side.
(3) Store hydraulic valve lifter in the engine oil when
OK NG
storing temporarily.

• Use valve spring compressor (KV101 08950) to remove

valve springs.

Cylinder head inspection

• Use scraper to remove any traces of oil, water scale,
gasket, sealing agent, carbon etc. from cylinder head
surfaces.
• Measure lower surface of cylinder head in six directions to
check for distortion.
Limit (mm): 0.2

• When distortion is just over the limit. resurface the cylinder , ':'==,,==:'J S~aight gauge
head. r \ ..... <"'.
• If distortion exceeds the limit, replace cylinder head.

Camshaft visual inspection

• Visually inspect camshaft for any warn or damage.

EN - 173
 ON-VEHICLE PARTS
RB25DE ENGINE

Camshaft run-out
gauge
• Use V-block on fixed surface and support both camshaft
end journals (No.1 & No.7).
• Avoid the oil groove in the center of the No.4 journal and I Ii"
position the dial gauge vertically.
• Rotate the cam shaft by hand to one direction and read
Q9
the movement width on dial gauge.
• The run-out is equal to half of the movement width
indicated on dial gauge.
Standard value (mm): 0.05

Micrometer
Cam nose diameter inspection
Use micrometer to measure diameter of cam nose.
Intake standard value (mm): 39.705 - 39.895 !

Exhaust standard value (mm): 39.205 - 39.395 I

Replace camshaft if diameter value differs.

Camshaft oil clearance

• Tighten the cam bracket to specified torque.
Use inside micrometer to measure inside diameter.
Standard value (mm): 28.000 - 28.021

• Use micrometer to measure outside diameter of camshaft

joumal.
Standard value (mm): 27.935 - 27.955
Inspect that the camshaft oil clearance measurement is
within specified value.
Oil clearance = cam bracket inside diameter-
camshaft journal (outside diameter)

Standard value (mm): 0.045 - 0.086

Camshaft end play

• Assemble camshaft and tighten cam bracket to standard
value.
• Set a dial gauge at front end of the camshaft in thrust
direction. When camshaft moves in front and rear
direction, read the dual gauge run-out width.
Standard value (mm): 0.030 - 0.080

EN -174
 ON-VEHICLE PARTS
RB25DE ENGINE

Valve guide clearance inspection

• Protrude valve approximately 15 mm from valve guide home
into combustion chamber. Measure valve deflection by
swinging into direction parallel to dial gauge.
• The clearance is equal to half of the dial gauge reading
(deflection width).
Valve guide clearance (mm) Intake: 0.1
Exhaust: 0.1
• Replace valve or valve guide if clearance exceeds limit.

Valve guide replacement

• Use valve guide remover and tap it from combustion
chamber side to remove seal.

Rectify cylinder head valve guide hole using valve guide

reamer.
Rectified valve standard value (mm)
Intake & exhaust: 6.000 - 6.018

• Heat cylinder heat in an oil bath to approximately 150 -

160"C. Use a valve guide drift and press valve guide from
camshaft side.

r·· ·
.. Valve guide
C"',,shaft
'\}
,
g'de····l
i T"""--~- ---- :
• The press-fit dimensions are shown in figure on right. ! 16.9+/-0.1 I '
Intake I Exhaust
;;:====~
• Ream the inside of the inserted valve guide with valve guide
reamer.
Finished internal diameter standard value (mm)
Intake & exhaust: 10.175 -10.196

Valve seat inspection

• Check contact surfaces of the valve seat and the valve.
• Replace valve or valve seat if contacting surface is too
large or improper.

EN -175
 ON·VEHICLE PARTS
RB25DE ENGINE

~ ... ~ .. ~ ..- ~.~~.-,

Valve seat replacement

i-t~._dl~t I
o Cut and grind valve seat to remove the valve seat.
o Readjust the mounting hole for over size valve seat.
Standard value (mm):
Intake 36.5 +0.016-0 i. 'J
I. .+1!_ _. U
Exhaust 32.0 +0.016-0 !
.I I.

o Readjust the valve guide centre and concentric circle. i Valve seat
• Heat up the cylinder head in an oil bath to approximately
110 -130 oe.
• Use valve seat drift to tap it until it strike the bottom.

o When not using valve seat drift:

• Use dry ice to cool valve seat for approximately 5 minutes.
Heat up the cylinder head to approximately 80 ce.
• Insert cooled valve seat into cylinder head quickly.
Caution:
Do not directly touch cooled valve seat with hands.

.!..D,

Valve seat shape and measurement is as shown in the

figures on right.

-. .pD
-'-'"

..
.'....
'
.. .
Cylinder head . .
. .... ...,....
'

1tam
. .. ~dimensioo
.vat.e·_t.·meas....,.
. ' .

'
.!mt·.........'.'
"

"
•••
·····.v. a_Size ¢'d ¢' 0, ¢' 0, ¢' 0, ¢' 0,
+0 11:1 -0
.. Slandan:! 36.0 ~g.D16 36.0.;)097 32.0 33.8.02 37.0
Intake
......... .' O~ . 36.5~c~6 36.5 N
+{j'13
$7 32.0 33.8~2 37.0
31.5 ~:;_Ol£ +C.COO
L .Standard 31.5 -c,o'8o 29.1:;;'2 . .
Exhausf ..
.
··'.O~ 32.0~01f' 32.0;;1~ 29,1~C2 . .

EN -176
 ON-VEHICLE PARTS
R825DE ENGINE

Valve inspection
Outside diameter measurement
• Use micrometer to measure each dimension.

(mm)
Valve a 1
. b .C d e f «
IIrtake 85.3 - 85.5; 80.78 - 81.08 34.00 - 34.02 5.965 - 5.980 1.15-1.45 2.60 - 2.90 30°

Exhau. 87.3 - 87.5182.78 - 83.08 29.00 - 29.07 5.960 - 5.945 1.35 - 1.65 I 3.2 - 3.4 15°

Valve spring squareness inspection

• Place a right-angle straight edge (L-square) so it contacts
the spring, Tum the spring and measure the maximum
clearance between upper spring surface and the right
angle surface to determine out-of-square distance,
Limit (mm): 1.8
• Replace the valve spring if the out-of-square distance is
over the limit. L ~ __ ~Qnt""ar\d.t_ _ _ _ __

Free length and pressure load inspection

• Use a valve spring tester to check the spring pressure.
Free length (mm); 43.1
Installation load (kg): 24.0

Hydraulic valve lifter visual inspection

• Visually inspect camshaft rotational area on lifter side and
lifter bore rotational area for any warn or damage.
• Replace ifthere are any abnormality,
Caution:
Do not disassemble hydraulic valve lifter, It is nonseparable i

unit.

Hydraulic valve lifter outside diameter

• Use a micrometer to check the valve lifter outside
\
\
Micrometer

diameter.
Standard value (mm): 30.955 - 30.965

EN - 177
 ON-VEHICLE PARTS
RB25DE ENGINE

Hydraulic valve lifter hole internal diameter

Standard value (mm): 31.000 - 31.020

Hydraulic valve adjuster clearance

Hydraulic valve clearance =
Hydraulic valve clearance hole internal diameter - hydraulic valve exterior diameter

Installation
• Install valve associated parts.
• For detailed information on how to install new valve oil seal •
refer to section on "Oil seal replacement".
• Install valve spring with narrow pitch end towards cylinder
head (identification color side down).
• Install spring retainer.

• Use valve spring compressor to install valve collet.

• Apply a small coating of petroleum jelly to the internal
surface of collet.
Use a magnetic screwdriver.
(1) Upper collet installation
• Attach collet to lower side of magnetic screwdriver blade
and instali in the valve stem.

(2) Lower collet installation

• Attach collet to upper side of magnetic screwdriver blade
and install in the valve stem.
• After valve collet installation lightly tap the stem edge with I
a plastic hammer to confirm installation,

Front ...
• Install hydraulic valve lifter.
Tap in camshaft knock pin.
Knock pin protrusion distance (mm): 5
Knock pin

Camshaft installation
• Turn camshaft so No.1 cylinder is at compression TD.C Knock pin
'I'

position (or turn camshaft 60" before or after No.1 cylinder _

15'
TO.C). I
Temporarily tighten No.1 cam bracket and make sure the , '

thrust section is positioned securely,

Icamsh(~
I (intake)
0 0 camshaftl
(Exhaust) I
.~-.~-.~--~

EN - 178
 ON-VEHICLE PARTS
RB25DE ENGINE

• Tighten cam bracket bolts 540"(1.5 turns) gradually in

several stages in the sequence shown in the figure on
right.
Tightening torque (kg-m): 0.92 -1.2

• Install camshaft front oil seal. For detail information refer to d---~-'--::;~""~~~-li
"Oil seal" section. . i pj==F:j=;~.- I
!~...5.40,,-"-"c--"""'<-""--;/- ..._1 [
I
(2) 16 - 221PJ ~ ~I
IBolt
Retainer
I ~~ ~$~':~I
I. .
'Grommet
' cj~:/
' ~r>r"",,,,,
l./
• Install timing belt back plate.
i ~ 'I,
,,~...:.
I ..~ €,;~' ~y I;
.-
_,c'

J;. ~.' : /
~- ~

Timing belt coverl

"i~. . back plate
\ ' Grommet
\ Retamer '
Bolt (2) 0.64 - 0851PJ !

• Align cam pulley to camshaft knock pin to install.

Tightening torque (kg-m): 1.4 - 1.9

EN -179
 REMOVE & INSTALL ENGINE
RB26DETT ENGINE

11 REMOVE & INSTALL ENGINE

[Point 1] Release fuel pressure
• After starting engine, remove the fuel pump fuse and run r=:=~-~ -'----~ ,
engine until it stops. Consume fuel left in fuel lines by I ~j!lli'::~g -- pu.mp fU'S1
cranking the engine two to three times. rl:""
• When it is not possible to start the engine, remove the fuel ~;g pis 1'Jli-, ._
T'nrIDrnf[[f
~~ y,1
pump fuse and consume fuel left in fuel lines by cranking 4Qt~U!te1tJ'};I]!tt~ ~ .
engine four to five times. liliiin< f" -, ~ ~;;;'L?@;1' I
Caution: \,'~-~;;;'; ~- I

The battery may become weak easily, connect booster C---".:-,. "'~
cables to charged battery,

~P~~~;~n 10C:~~~!~~pt~~::ea~~qu::~:~:Ck for the

accelerator wire. Pull outer case in the direction of the
i~/6:~/"i\~~i~i;~~:r~~1
I~:'--ti, 'tk,
accelerator pedal until throttle drum starts to move (no play"·. Y 7f)<i<L~?
:.i!
i A~C;;~tir$ltor /;~' -"'/
in cable). Rotate the lock nut 1 to 1.5 turns to tighten. •wire 'f\\ Oul~r -c~s~'
Tightening torque (kg-m): 0.8 - 1 . 0 ' · · ' /' .
~-~--'' .. -~~~--,-----~

[Point 3] Engine main harness, ground line

separation
Disconnect the connectors behind the battery for
alternator, starter motor and transmission systems.

[Point 4] Air compressor and power steering oil

pump movement I
• Remove bolts securing each unit to brackets. Leave pipes .
connected and secure to side of the body with string. Care
must be taken not to scratch the body.
i-'{,.:;.,:- -""" Bolt 16 - 2.'~ i

,
i~-'-:~ ;.~~--.--
,\2.-/
,-' </~~i
~- ___ ---'\- "
[Point 5] Power steering oil tube bracket separation !ttll-;-''-'!;' _4 ";\, \Zt~1
• Remove bolts and separate the power steering oil tube : .. olt 1,,::::".. \ , \ ",,\;Jl:::}>:~\~\ 'r
bracket, and move towards the body side. ! From ,F,~,o.t\~':'\:P~;~nd
elf: ;\ ~i-.Y/t~,Od tube bra<*ett
f _ '_ ..._ ~~/ :yj~w;d f!.~m oelow \\ \1

[Point 6] Front engine mounting nuts removal

• Make sure the engine slings are securely hooked by
engine hoist chain and remove front engine mounting nuts.

EN - 180
 REMOVE & INSTALL ENGINE
RB26:lETT ENGINE

[Point 7] Right front engine mounting bracket

removal
• Power steering oil tube will hit the right front engine
mounting and it is not possible to shift the engine forward.
Therefore remove nuts and remove right engine mounting
bracket

[Point 8] Remove & install engine ASSY

• Operate the hoist chain, and change the engine angle
gradually to remove the engine. Care must be taken not to
interfere with vehicle body.

EN - 181
 REMOVE & INSTALL ENGINE
RB20E iDE! DET ! CA 181 ENGINE

11 REMOVE & INSTALL ENGINE

[Point 1] Release fuel pressure
After starting engine, remove the fuel pump fuse and run
engine until it stops. Consume fuel left in fuel lines by
cranking the engine two to three times.
• When it is not possible to start the engine, remove the fuel
pump fuse and consume fuel left in fuel lines by cranking
engine four to five times.
Caution:
The battery may become weak easily, connect booster
cables to charged battery.

Transmission jack set (CA18i only)

• Place the transmission jack under the transmission.

[Point 2] Accelerator wire adjustment

Loosen lock nut and provide adequate slack for the
accelerator wire. Pull outer case in direction of the
accelerator pedal until throttle drum starts to move (no play
in cable). Rotate the lock nut 1 to 1.5 turns to tighten.
Tightening torque (kg-m): 0.8 - 1.0

(Point 3] Engine main harness, ground line

separation
• Disconnect the connectors behind the battery for
alternator, starter motor and transmission systems.

[Point 4] Air compressor and power steering oil

pump movement
• Remove bolts securing each unit to brackets. Leave pipes
connected and secure to side of the body with string. Care
must be taken not to scratch the body.

[POint 5] Remove & Install propella shaft

• Place a cap on the transmission rear seal so the oil will not
leak when the propella shaft is removed.

EN - 182
 REMOVE & INSTALL ENGINE
R520DE' DET i DETT ENGINE

[Point 6] Remove & install rear engine mounting

• Support the transmission with transmission jack and
remove rear member bolts and rear engine mounting bolts
and nuts.

[Point 7] Front engine mounting nuts removal

• Make sure the engine slings are securely hooked by
engine hoist chain and remove front engine mounting nuts.
Engine mounting nut tightening torque (kg-m): 4.4 - 5.6

[Point 8] Remove & install engine ASSY

• Operate the hoist chain, and change the engine angle
gradually to remove the engine. Care must be taken not to
interfere with vehicle body.

EN - 183
 REMOVE & INSTAll ENGINE
RB25DE ENGINE

11 REMOVE & INSTALL ENGINE

Standard points
This section describes how to use hoist crane and transmission jack to remove and install
the RB25DE engine.

• Drain cooling water completely.

• Remove bonnet.

Engine bay left side:

• Exhaust gas sensor harness disconnection
• Ground line connector separation
• Air duct. Air cleaner
• Power steering oil pump removal
• Air compressor removal

Engine bay right side:

Battery (fl\, • ACTIVE TEST •

• Release fuel pressure by selecting "fuel pump relay" 'J!J FUEL PUMP RELAY OFF
in active test mode, and press STOP.
CAS· RPM (PaS) 950 rpm

• After staring the engine, remove fuel pump fuse and run
engine until it slops. Consume fuel left in fuel line by fiS\
cranking the engine over two to three times. 'aJ
Caution:
The battery may become weak easily, connect booster
cables to charged battery.

• Accelerator wire separation

Heater hose
• Vacuum hoses separation

Engine main harness & ground line separation

Engine bay front side:

• Radiator shroud, radiator
• Cooling fan

Engine bay upper side:

• ECCS harness connectors

EN·184
 REMOVE & INSTALL ENGINE
~525J::: EI\JGIr-.;E

Vehicle body. lower side:

• Engine undercover
• Propella shaft
• Transmission control lever (MfT vehicle),
linkage (AiT vehicle)
Exhaust front tube
• Rear engine mounted bracket

• Right and left engine mounted bracket.

Remove & install engine ASSY

• Operate hoist chain and change engine angle gradually,
Care must be taken not to interfere with vehicle and
remove the engine.

EN - 185
 ENGINE OVERHAUL
RB26DETT ENGiNE

12 ENGINE OVERHAUL

This section describes the component disassembly of the engine assembly removed from
the vehicle without transmission, It also explains the inspection, replacement of
malfunctioning, damages or warn parts and carry out any necessary adjustments and
sequential assembly in order to produce a standard engine condition,

OVERHAUL CAUTIONS

(1) Disassembly
o Use correct and suitable tools when possible and make sure to carry out safe
procedures,
o Care must be taken with operations on mating surfaces and Sliding surfaces to
prevent loss of surface accuracy,
o Arrange disassembled pars by making marks to organize for easy faults detection
and precise assembly.
o Loosen nuts and bolts in a diagonal direction from outside, Care must be taken to
follow the numerical order when indicated,

(2) Inspection, repair and replacement

o Replace or repair after completing parts inspection following the inspection
procedures. Perform same inspection for the new parts and replace parts as
necessary.

(3) Assembly
o Always use a torque wrench to tighten nuts and bolts to specific tightening torque,
o Tighten nuts and bolts from centre to outside diagonal direction, gradually in two or

three successive stages. Follow the numeric order when indicated,

o Replace gasket, packing, oil seals and O-rings with new ones in principle.

• Clean each part thoroughly and blown off with compressed air. In particular, check
that oil and water passages are not clogged or obstructed,
• Care must be taken not to scratch or damage sliding or mating surfaces, Clean off all
dust. debris or foreign objects. Lubricate all sliding surface with an adequate
coating oiL

EN - 186
 ENGINE OVERHAUL
RB26DEr :eNGINE

12·1 DISASSEMBLE & ASSEMBLE CYLINDER BLOCK ASSY

Detonation sensor boll (2) 1.6 - 2.1Lt!l

Alternator 8diusltment bar

".
""" !liI'_
~a~ Detonation
- - - - . ,~
sensor
~
Rear all seal [Point
0 ~
71

Water pump. bolt tlwater pump , ~~. ..oJ>

Oilpumobolt ~~"~~~~ ;" ~ tI ,- Reta~erbolt(6)~
092-12 Oilpump~;~~ 'i.:~M'~ '.0.64-0,85
Lt!l \ gasket O~ -
_
¥A, Rear ali seal retainer [Point 6]
\ ~'S: ij~ E ' ~"",CYhnder block [Point 30. 31. 32. 33]
~,:::. ,',",!J '~ yebol!
,f

' _~ ~ Y~ ~ ~ ~
:J-1 '::-4.1 [POInt 1 ra.. ---.. Oil jet [Point ,11]
" ""j::2;;'S ';
olt 5..:1.. ~ "'i::I
i313'\i - ~ PI~t buSh [Point 231
. . .... ) I rower steenng ;, - !Cl ~ ~ "" I
ILl W , I 011 pump bracke III ~ ~ V ~....,.."" 1
C) ..........
Fco~t 011 sea, )'A' bolt (6) ~

®_
d"
;r con Itlone
I Ii?/
/ . I, 1 4 .Flywheel
r. r. [P .
. 'CO<'1"reSSQr Bolt 14) 3 . 8 , 5 . 1 ' 5 - 10/ Oint 4]
Oil pump e "'/ n....J /
bracket ~ MaIO bearing" ~ ~ ~..~ ___ "
Piston ~ 00 p lnt
o 22. 21lo,31] r ~..a
[Point 9.16. 1 7. 19. 218~Pistonrin;¥D 'tU~'
P' " [Pomt12.21) ; ,,~
[~~~~~ 1~'.n'5 17, 33~_fi3 Il,., Crankshaft [POint 27 281L.,,~ . ~~
~,
..-
Can rod
[Point 8. 9.18.19: - -
&\ T ~
"Snap ring [POint 13]0
__
Con rod bolt (2) [Point 20] > \
\,
'"
Flywheel [Point 3. 5J

Con'rod beaflng~
[Point 10.18. 28. 29]~~
1
Malo beaflng cap [Point 25]
~:'.'
~~.
.
L-~ .........-~
Rear plate

Spacer 1,......--, /' Spacer M

>-Main bearing bOlt~
5.3 [POint 24]
..
Con roc cap
_11\
__ ~. .I
Baffle plate
~-.
1'n'I0li pan nut
.'$'-.. e ~
Con'rod ,nut ,Lt!l __ .1 __ . ! c;;:;::-~.J»--Baffle plate I
3.2 - 4.3
{1)1.S+!-O"1 ~ __ , ~~:.~. ~) .... __ ~ J
(2) 60'+5 [Point 10].---"""'" O/,n ,"'>--~j
g _ -~. ~C-~, _ ..,,4"~'. L
Oil strainer~~'&~;~'V~~~~~~- ~~(.~~-:;:2:j!~~~~r
~/'''' Bolt (2) 1.6 - 2.1 0~::::.":>.~-;;C'. i\
Bolt (12) ~;=~~. '~', ~:'Ii[:.' '8 ___
I ~~~\i~: Oil pan bolt~
tcJ0li strainer bolt ~ - ' . ' 1 ' ~~ (M10) 3.2-4.3
~ kg-m 0.64 - 0.85 tcJ Oil pan bolt (M6)/ ~"'...J-' MOil pan 0
0.64 - 0.85 Copper washe,&--nrain plug 3.0 -4.0~
tI Liquid gasket
~ Engine all
o Replace after every disassembly

Additional work required:

• Drain and refill cooling water [Point 1]

• Remove and install the following parts:

• Engine
• Collector • Starter motor
• Throttle chamber Clutch cover, clutch disc
• Intake manifold • Oil pan, oil strainer
• Turbocharger, exhaust manifold • Water pump
• Timing belt • Oil pump
• Cylinder head ASSY • Oil cooler, oil strainer
• Alternator • All harnesses and connectors

EN -187
 ENGINE OVERHAUL
RB260ETT ENGINE

Reference: Engine selection assembly

Piston
(1) Piston selection
.
I . Grade No: .......... .
I
. '.'
•
1 . . .2 3 .

CylindM blOckbo.... ....

".
Less than 86.010
i
Less t1lan 86.020 I Less than 86 030
diameter (min) Greater than 86.00 Greater than 86.01 0 Greater tran 86.020
. ."
.

Frsto" diametar(~)··, Less than 85.965 Less than 85.975 I Less than 85.985
I· . Greater than 85.955 Greater than 85.965 Greater than 85.975

PiSton c!ear$nC. (mml . 0.035 - 0.055

Service setting parts; Piston and piston pin sro 1, sro 2. sro 3, 0.50S. 1.00S
Piston grade Front mark
(No. t - No.

Distinction
symbol
Piston pin grade (0.1)

Main bearing
(2) Main bearing selection
C~rblocl< . less than 58.651 less \han 58.657 1.e5$ than 58.563 less than 58.670
. bearing t¥:lu$ing . Greater than Greater \han Greater \han Greater than
Inner diameter 58.645 58.651 85.657 58.$3
Cnlnk '. ·.·Grade· . . •.
'. . ..

... jQumat. Mk 0. 1 2 3 ......

dlamater·$l.amp ••. . . ' .•. .. ".
I . ....

STO 0 8m 1 ! STO 2 i sm 3 i
1.818 -1.821 1821 -1824 1.824 - 1.827 1.827 - 1.830
0.02810.046 0.028 ! 0.046 0.G28 i 0.046 0.028/0.047
Black Brown None Yellow
STD 1 sm 2 sm 3 STO 4
1.821 - 1 824 1.824 - 1827 1.827 - 1.830 1.830 -1.833 i

0.02810.046 0.028 I 0.046 0.02810.046 0.02810.047 I'

Brown None Yellow Blue

8m 2 I sm 3 STO 4 sm 5
1.824 - 1 .827 . 1.827 - 1.830 1.830 - 1.833 1.833 - 1.836
0.026 I 0.046 0.028 J 0.046 0.028 I 0.046 0.028 ! 0.047
None Yellow Blue Green
LIlS$ Ih/m. . • Be$ri~ gTat;Ie No.. STD 3 SID 4 8m 5 8TO 6
1.833 - 1.836
54.957:.3
Greater than
54.951'
0,1__..
6eaql!lickness
. • .' ldanlilicatlortCOlOl'
1.827 - 1.830
0028! 0.046
Yellow i
1.830 - 1.833
002810046
Blue !
0.028 I 0.046
Green
1.836 - 183
90.028 i 0.047
Pink
 ENGINE OVERHAUL
RB26DETT E·\jGINE

Piston pin
(3) Piston pin selection
,

I GnldIlNo•.
.' . l' 2. . .... '

Piston pin hole diameter (mm) 2, .J06 - 21.COO 21.012 - 21.006

! Piston pin extemaldiameter (mm) 20.995 - 20.989 21.001 - 20.995

I Piston pin clearance(mml .. 0.005 - 0.0' 7

Service setting parts: Piston and piston pm STD 1. STD 2, STD 3, 0.50S, 1.00S

if
Front mark
ad hole ~ j [ jPlston pin grade

'I
j' Cylinder No
!
l~/~
(01)

i 14-7--- \
Small end
,grad~ (0 1 ,,~
(1 - 6)
oa
't't ~ f)1
II ~:iF(
,{! .l): _.; ;c~tJ
I , I h' ~l..-/'
'~_J / I
I ~ DIStinction Piston grade I
I Large end grade (0.1) symbol (1-3)

Con'rod bearing
(4) Con' rod bearing selection
Connecting rod large end Leu than 51Jl07 Less than 51.013
inside diameter Greeter than 51.000 Greater than 51.007
Grede
I Crank pin diameter No. 1 I
. . stamp . .
I
.
Bearing grade No. srD i a :Bearing grade No STD 1 !

, Less than 47.974 Bearing thickness (mm) I 1.500 - '.503 Bearing thickness (mm) 1.503 - 1506 :
II I
: Greater than 47.968 Oil c1earance (mm) 0.020 i 0.039 Oil clearance (mm) 0.020 i 0.039 1
Identification color None Identification COlor Brown 1

Bearing grade No. SrD 1 Bearing grade No. STD 2 :

LU!S than 47.968 Bearing thickness (mm) i 1.503 - 1.506 Bearing thickness (mm) 1.506 -1.509!
1
Greater than 47.961 Oli clearance (mm) ! 0.020 10040 Oil clearance (mm) 0.021 10.040 I
. . .. . identification color Brown Identification color Green

Service setting parts: US 0.08, US 0.12. US 0.25

EN -189
 ENGINE OVERHAUL
RB26DETT ENGINE

[Point 1] Drain & refill cooling water

Draining
• Drain cooling water in the cylinder block completely from
the drain plug.
Refilling
• Refer to the section "cooling water"' for detailed instruction.

[Point 2] Remove & install engine stand

• Install the engine sub attachment using 6 bolts to engine
mounting bracket on right side of the engine.

~ .. -~ .. -~.-~.-~ .. ~.~

: Nut (4) (M12 x 1.5~ Engine sub.

'- attachment I

:
I Bolt (4) 4 - 5
i
:
(M12.X15~~3.CJ
\
. ?~
® i.
I " " I '. ~
•
••

~.~A ,\"r:: ~~
I "'1 .
I' .
. , ~ .. '

I, Engine attachmeni
I
: Bolt 16)4 - 5
0' =

Dial g~uge

[Point 3] Flywheel run-out

• Set dial gauge to flywheel where it contacts clutch,
• Tum the flywheel and measure the run-out.
Run-out limit (mm): 0.10

[Point 4] Remove & install flywheel

Removal IRing gear Ie bl;]l:." .
• Use ring gear stopper to fix flywheel and remove, :stopper g ~~.
Installation ! . " " I~
• ~~I;~; /;"-~"'~. ,;,.~
• Coat the thread and flange of bolts with engine oil after
installing the bolts.
• after tightening the flywheel bolts, use ring gear stopper to
I(!~/~
II , i ! /~\'
<> I I I '\ \
\ \:
\\ /1
'0/ I

secure flywheel and tighten bolts. ~._"~.'.~._:\ \E'&9-') I 1'1 i

Flywheel bolt tightening torque (kg-m): 14,5 -15.5

[Point 51 Flywheel knock pin installation

• insert the flywheel knock pin so the pin protrudes 8 to 8.5
mm.
~nock pin

Flywheel

EN ·190
 ENGINE OVERHAUL
RB26DETT ENGINE

[Point 6] Remove & install rear oil seal retainer

Removal
• Insert a screwdriver in the gap between main bearing cap
and rear oil seal retainer to remove seal.

Cleaning
• Use scraper to remove liquid gasket
• Clean the cylinder block side in the same way,
• Wipe mating surface with white gasoline,
Caution:
Also remove liquid gasket in the grooves,

Installation ~.. i
• Apply liquid gasket and install unit within 5 minutes, :S,,:'Y993
....... I
• Cut nozzle end of the liquid gasket (KP510 00150) tube as -<"'~'7 C~t , ...~ .
shown In the figure on right Use tube presser for ~ ~I
application, I
!

• Apply liquid gasket continuously to rear oil seal retainer, Apply liquid gasket tq

Caution: ~~~~~' inner surface!

~ ~ around hole I
Make sure liquid gasket width is 2,0 - 3,0 mm, area i

Refill engine oil and start the engine 30 minutes after

assembly is completed.

[Point 7] Remove & install rear oil seal

Removal
• Use a tool such as screwdriver to remove the seal.

Installation
• Care must be taken not to scratch or damage the oil seal
perimeter area. Use oil seal drift (Outside diameter: 100
mm) to install new oil seal.
• Apply a coat of oil or chassis grease to oil seal lip area,

EN - 191
 ENGINE OVERHAUL
RB26DETT ENGINE

[Point 8] Con'rod side clearance inspection

• Use thickness gauge to measure the thrust clearance
between the con'rod and the crank arm.
Standard value (mm): 0.2 - 0.3
Limit value (mm): 0.4

[Point 9] Remove & install piston con'rod ASSY

Use a tool such as hammer handle to press the unit to
cylinder head side.

~,~ -'~'~I'0"'-'-_-C--"~, '

Installation d' /C"?)
J/fU "I
I \~\ \~:J;,:,
-d'

Set the crank pin at BD.C (Bottom dead center) position. Piston ring I -~, '~},lrrd I'
~ ii1~~'5~
• Coat cylinder bore, crank pin and piston with engine oil. 'I compressor", "'I
(\'
~' /m "
Assemble piston with front mark on piston head facing the I ~) l~ /::.=*'1'
front of engine. i (i;i ;;J~(/lY; 'J
• Use a piston ring compressor to install the piston and the ; J\;\jIJ ':so LJ'::
CJ:l.:~~~d assembly in cylinder block. [ _ _.._ _ £~l
Care must be taken not to strike or deform oil jet pipe with
Front mark
large end of connecting rod when installing.
',i,'J'\
Oil hole
,:,1

~
L".
d
"
"\
- \ .
"",
.,.
\\ ~

Front

Con'rod nut tightening

Apply engine oil to con'rod and the nuts before assembly.
• TIghten nuts in two or three stages.
1st time Torque wrench (kg-m): 1.4-1.6
2nd time Angle wrench ( 0 ): 60-65
Caution:
Do not visually measure the tightening torque if angle wrench =-'-..c.c...c...'=-'-'-"-'--'c.. _ _ _ _~
e,..'

is not available.

[Point 10] Install con'rod bearing

• Apply engine oil to bearing surface when installing con'rod Notch

bearing. Do not apply engine oil to rear surface of \

bearing, clean this area.
~\
~"
• Align con'rod bearing retainer notches and install (left side).
Make sure the con'rod body oil hole and the bearing oil Notch
hole is aligned. ()

EN - 192
 ENGINE OVERHAUL
RB260ETT ENGINE

[Point11] Install oil jet . ,

• Set the oil jet position securely and check that it does not i ''''/Eyebolt
inteifere with piston, If oil jet pipe contacts piston or is bent,
replace it with new part,
Oil jettightening torque (kg-m): 3,1 - 4.1

[Point 12] Remove & install piston ring

Removal
• Use piston ring expander to remove rings,
Caution:
Care must be taken not to scratch piston,
Installation
• Use piston ring expander to install rings,
Identification mark

• The stamped marks on top and second piston ring

openings must face up,

: Oil flng spacer T,?p ,ring opening :

, Ollnng I

• Position the piston rings as shown in the figure on right , \ _ /Upper rail opening:

to install. ;""S".
i FrontUrk;J"'" ·
Caution: .
• ~~
" {C,
.
:
Care must be taken not to scratch piston,
: ./ _ 011 ring lower I
Second nng openmg rail opening
,----~-------------- ---------~ ....-
,
[Point 13] Remove & install snap ring
Removal
• Use snap ring pliers to remove rings.
Installation
• Use snap ring pliers and install rings securely in groove,
Caution:
Always replace snap rings with new ones,

[Point 14] Remove & install piston pin

• Use a heat gun to heat piston to 60 - 70nG when removing
and installing piston pin,

• Place suitable tool against piston pin and press or use

plastic hammer,
• Apply plenty of engine oil 10 pin, pin hole and con'rod small
hole,

EN - 193
 ENGINE OVERHAUL
RB26DETI ENGINE

Piston pin press-fit

Front marK
• Place the piston front mark so the con'rod oil hole faces
right side of the engine (left side when viewed from front)
and press-fit.
CautioD~
Press-fit the piston pin from the front of piston to the rear side
of piston.

[Point 15] Piston pin inspection

• Use the micrometer to measure outside diameter of piston
pin.
Standard unit (mm): 20.989 - 21.001 Micrometer

Micrometer
/
[Point 161 Piston inspection I
• Use micrometer to measure outside piston skirt diameter.
Measuring pOint Distance from bottom (mm): 13
Standard (mm): 85.955 - 85.985

-'-"---1
• Use inside micrometer to measure inside diameter of
piston pin hole.
""""'~~~ InSide I
Standard value (mm): 20.987 - 20.999
• Five types of pistons are available for service (STO 1, STO
2, STO 3. 0.50S, 1.00S).

[Point 17] Piston pin clearance inspection

• Piston pin clearance is the figure obtained by subracting
the piston pin outside diameter [Point 15) from the piston
pin hole inside diameter [Point 16].
Piston clearance at normal temperature (20°C):
0--0.004 ,
I
-

Con'rod

a:.gner
--~---

~
I
~'.)k~-
ThICkness
," gauge
J:r"--~
---.
i

I
[POint 18] Con/rod inspection
Bend and torsion inspection
• Measure the bend and torsion with con'rod aligner.
I ;,
, .---1./
Bend limit(mm): 0.15 ~-~~

Torsion limit (mm): 0.3

Small end inside diameter inspection

Standard value (mm): 21.000 - 21.012

EN - 194
 ENGINE OVERHAUL

Con'rod bearing interior diameter inspection

• Install con'rod bearing in con'rod and cap. Tighten con'rod ....~.-.:-~~~~..~....-;
nuts to specified torque and measure can 'rod bearing :! /
interior diameter. "~ y ! (

Con'rod nut 1st time Torque wrench (kg·m) 1.4-1.6

lightening torqu!r 2nd time Angle wrench ( 0) 60 - 65
I
Standard value 47.989 - 48.007 i

[Point 19] Con'rod small end bushing clearance

• The measurement difference of the small end inside ~ - - ~~ton p'n-~
. . . . . I i grade PIston grad

15]ls the bushing clearance (full f1oattype). 'Small end\ ' ~-=
Bush clearance standard value (mm); 0.005 - 0.017 Ihole rad I, .'.--1': u)
• The con'rod small end and piston pin outside diameter are (0 1) ': I

separated into two grades at the factory. Make sure that '.
Big end
"
! .
I
the grades (0,1) conform for both parts because the rod Ihole grade 10, ' ) . Identificalion symbol
and pin are selected and fitted according to bushing
clearance,

[Point 20] Con'rod cap bolt

• Can 'rod cap bolts have grooves to prevent it from
disengaging,
• For this reason do not tap the ends to remove bolts,

[Point 21] Piston ring end gap and side clearance

Ring end gap inspection ,--~- .... ~- - . _...... - .
• Use a piston to press the piston ring into the middle of the 1 7 r ~
I Thickness g\a"~~----- ,
cylinder and measure the gap,
Piston '< !

Item Top nng I Second ring I Oilnng II

Standard value Bore grade 1, 2, 3: I'
0.42 - 0,57 I: 0,20 - 0,60 I:
I
(mm) O, 24 0 34
-, • I

Side clearance inspection

• Measure the clearance between the piston ring and the
piston ring groove, -
,
···~II
Item Top ring Second ring OIll1ng
i mc. kness gauge 0'/-, I

Standard value
(mm)
0,040 - 0.D75 0,030 - 0,065 0.065 - 0,135 l~ifci"O
·1:"i'!~
Three types of piston rings (STD, 0,50S, 1 ,O~S) are I l~
..... . _ _~_...J

available for service,

EN·195
 ENGINE OVERHAUL
RB26DETT ENGINE

[Point 22] Crankshaft thrust clearance inspection/- ~" \~

• Use a thickness gauge to measure the clearance between: • O· Thickness gaulle
• - 'i
the thrust bearing (No.4 bearing) and the crank arm when ~~ \..l!;~,",
moving the crankshaft towards front and rear of the engine. ( / ' 1IIi~
Standard value (mm): 0.05 - 0.18 (q~~ .
Limit (mm): 0.3 I~ ~-?
,~....___;Y'
L2:~_ .... ,--~

[Point 23] Remove & install pilot bushing

Removal
• Use a pilot bearing puller to remove pilot bushing.

\
Pilot bearing puller
ST1661 0000

Installation
• The pilot bushing installation position is as shown in the
figure on right.

[Point 24] Remove & install main bearing bolts

Removal
• Remove bearing bolts in reverse order of sequence shown
in the figure on right.
In stallation
• Tighten the bolts to specified torque in two to three stages
in the sequence shown in the figure on the right. Make
sure the crankshaft tums smoothly after tightening the bolts
to specified torque.
Main bearing bolt tightening torque (kg·m): 4.7 - 5.3
Caution:
Apply engine oil to the bolt threads and bolt seats when
tightening the bolts.

[Point 25]
Removal
Remove & install main bearing cap

• Use tools such as screwdriver to pry the bearing caps open.

Iff
Caution:
Care must be taken not to scratch the oil pan rail surface. ',
Installation .. ~!,</ ..
• Check the front and rear pOSition and fit onto cylinder block i t:;;~.·Y:: ~ .
by lightly tapping it In a number of locations with a copper ~_""'•. ~ j ""
hammer.

EN - 196
 ENGINE OVERHAUL
RB26DETT ENGINE

[Point 26] Main bearing inspection " Crush heigrt

• The bearing end should protrude when Installed in main
", !
bearing cap or cylinder block.
This protrusion is called the crush height.

[Point 27J Crankshaft inspection - ... ~ .... ~~~

Out-of-round and taper inspection A

• Use micrometer to measure each journal (No.1 - 7) and
each pin (No.1 - 6) in four locations shown in the figure on
B '
right.
• The out-of-round value is the difference of the dimensions
in directions A and B.
• The taper value is the difference of the dimensions
measured at points 1 and 2.
Out-ot-round and taper limit (mm): 0.005

Pin and journal inspections

• Use micrometer to measure pin and journal diameters.
Pin diameter standard value (mm): 47.961 - 47.974
Journal diameter standard value (mm): 54.951 - 54.975

Curve inspection ...

~--- .. ..... - -~-- ~

• Use V-blocks on a fixed surface and support journals on Dial gauge

both ends of crankshaft (No.1 and No.7).
• Position the dial gauge vertically on middle of No.4 journal • 1~~~~PJ~~~
as shown in the figure on the right. c:
• Turn crankshaft by hand and read dial gauge movement.
• The Run-out is equal to half of dial gauge movement.
Limit value (mm): 0.05

[Point 28] Con'rod bearing oil clearance inspection

(A) Using inside micrometer and micrometer
• The oil clearance can be calculated from connecting rod
bearing inside diameter and the crankshaft pin diameter
measured in [Point 18] and [Point 27].
(Oil clearance) =
(Bearing inside diameter) - (crankshaft pin diameter)
Standard value (mm): 0.020 - 0.040
L.imit value (mm): 0.090
• If the oil clearance exceeds the limit, refer to [Point 29] and
select the appropriate bearing.

EN -197
 ENGINE OVERHAUL
RB26DETT ENGINE

(B) Using plastigauge

• Remove any dust from crankshaft pins and bearing
surfaces.
• Cut off a piece of plastigauge slightly shorter than the
bearing width. Place the plastigauge on the crankshaft
in direction of axis. Care must be taken not to place on the
oil hole.
Assemble connecting rod bearing in connecting rod cap
and tighten connecting rod nuts to specified torque.

Con'rod nut 1st time Torque wrench (kg-m) 1.4 - 1.6

tightening torque 2nd time Angle wrench (') 60 -65

• Remove con'rod cap and bearing and measure plastigauge

width with a plastigauge scale.
Caution:
Never turn the crankshaft or connecting rod while plastigauge
is being inserted.
If oil clearance exceeds the limit value, refer to [Point 29] and
select the appropriate bearing.

[Point 291 Con'rod bearing selection and engaging

• Select the correct sized bearing as the con'rod bearing
prevents fluctuation in the oil clearance. Three bearing
thicknesses are available to fit the inside diameter of the
big end of the con'rod and the crank pin diameter gauge.
• When replacing the can 'rod bearing, check big end inside ;=========~
diameter gauge (indicated on the opposite side of the
con'rod hole) and the pin diameter grade (indicated on
crankshaft No.1 counterweightfront surface). Lower pin grade
No.1 - 6 from
i left side

Con'rod bearing selection chart

Corlrpd large end inside Less than 51.007 tess tharr51.0'13
<:Iiameter Grealerthan 51.000 I31ea1er than S~ .007
Crank pin Grade
0 1
diameter No. stamp
1.;6$$ than Bearing grade No. STO 0 Bearing grade No. STD 1
47.974 Bearing thickness (mm) 1.500 - 1.503 Bearing thickness (mm) 1.503 - 1.506
0
Greater than Oil clearance (mm) 0.020 10.039 Oil clearance (mm) 0.020 I 0.039
47.968 kJentificatlOn colour None Identification colour Brown

Less than Beanng grade No. STD 1 Bearing grade No sm 2

47.968 Beanng thckness (mm) 1.503 - 1.506 Searing thickness (mm) 1.506 - 1.509
1 0.020 I 0.040 Oil clearance (mm) 0.021 10040
Greater than Oil clearance (mm)
47.961 Identification colour Brown Identification colour Green

EN - 198
 ENGINE OVERHAUL
RB26DEr ENGINE

When using undersize bearings, measure bearing inside

diameter when bearing is installed. Grind pin so oil
clearance conforms to specific value.
/
L- R2.0 journal

Bearing undersize chart L- R1.6 pin

Size

USO.OB
ThickrnHls (mm)

1.54111.549
Grade No.

8
~I
i .

USO.12 1.561 11.569 12

USO.25 1.626 11.634 25

Caution:
Care must be taken not to scratch fillet roll when the crank pin
is being grounded to use undersize bearing.

[Point 301 Main bearing oil clearance

Using bore gauge and micrometer (Method A)
• Install main bearing in cylinder block and attach bearing
cap. Tighten bearing cap boits to specified torque and
measure bearing inside diameter. . :c)"'~: i I
Bearing cap bolt tightening torque (kg-m): 4.7 - 5.3 1"-., ;«/'~_": ";&'1_ <'
• The oil clearance distance can be calculated from the '..... ~if!A\'I.:fd':':'" .~ ~ .
values for outside diameter of the crank journal measured '" _ . .r

in [Point 27]. ! • .A•.·· },.yJ'

~ ~~i'

(Oil clearance) =
" .... ¥

I ", ", J '.

(Bearing inside diameter) - (Crankshaft outside diameter) Bore gaUge~"i.I/ "~

Standard value (mm): 0.028 - 0.047
Limit value (mm): 0.090
• If oil clearance exceeds the limit value refer to [Point 31] to
select suitable bearing.

Using plastic gauge (Method B)

• Remove all dust and oil from each crankshaft journal and
bearing surfaces.
• Cut a piece of plastigauge slightly shorter than the
bearing gauge width. Place a plastigauge on crankshaft
in direction of axis, care must be taken not to place on oil
hole.
• Assemble the main bearing and bearing cap and tighten
cap bolts to the specified torque.
Bearing cap bolt tightening torque (kg-m): 4.7 - 5.3
• Remove bearing cap and the bearing. Measure
plastigauge width on plastigauge scale.
Caution:
Do not turn crankshaft while plastigauge is being inserted.
If excessive bearing clearance still exists, use a thicker main
bearing or undersized bearing so that the specified bearing
clearance is obtained when measured by method A as well.
EN - 199
 ENGINE OVERHAUL
RB26DETT ENGiNE

[Point 31] Main bearing selection and engagement

• Select correct sized bearing as the main bearing
prevents fluctuation in the oil clearance. Seven different
bearing thicknesses are available to fit the cylinder block
bearing housing and crank journal diameter grades.
f\lQte:
Selection engagement is performed only for standard size.
• Check the bearing grade (indicated on bottom face of the
cylinder block) and joumal diameter grade (indicated on
crankshaft No.1 counterweight front surface) when
replacing the main bearing.
• Select main bearing with proper thickness according to the
following table. 'I",""
! /'l
Stamp examp~

";
!' /'

.
Cylinder block Less than 58.651 Less 1I1an 58.657 Less than 58,663 Less 1I1an 58.670
bearing housing Greater than Greater 1I1an Greater than Greater 1I1an
inner diameter 58,645 58.651 85,651 58;663
Crank Grade
! journal No. 0 1 :I 3
..
diameter stamp
Bearing grade No,
, STD 1 STD 3
Less than STD 0 Sm2
54.975 Bearing thickness 1.818 - 1.821 1.821 -1.824 1.824 - 1.827 1.827 - 1.830
0 0.028 f 0046 0.028 i 0.046
Greater than Oil clearance 0.028 I 0.046 002810047
, 54.969 Identification <:O!or Black
!
Brown None Yellow
,
Less than Bearing glade No. STD 1 STD 2 STD 3 S'D 4
54.969 Bearing thickness 1.821 - 1.824 1.824 - 1.827 1.827 - 1.830 1.830 - 1.833
1
Greater than Oil Clearance 0.Q28 i 0046 002810.046 0028 10.D46 002810C47
, 54.963 ldentificallon <:O!or Brown None Yellow Blue
,Less than Bealing grade No, 8TD 2 S-:-D 3 STD 4 STD 5
54.963 Bearing thicl<nes& 1 .824 - 1.827 1.827 - 1.830 1.830 - 1.833 1.833 - 1.836 i
2
...
1

'Greater than Oil Clearance 0.028 10.046 0.028/0.046 0.028 I 0.046 0.028 i 0.047
54,957 ldentification color None Yelklw Blue Green
Less than Searing grade No, STD 3 STD 4 STD 5 STD 6
54.957 Bearing thickness 1.827 - 1.830 1.830 - 1.833 1.833 - 1.836 1.836 -1.83
3
Greater than Oil clearance 0.02810.046 0.028 I 0.046 0.D28 10046 90.02810.047
54.951 identification color Yellow Blue Green Pink

When using undersized bearings, measure bearing inside

i.r-R2.0 lournai
diameter when bearing is installed and grind journal so oil /

clearance conforms to specified clearance,

.Slze Thicknes$(mm) Grade No•

US025 1.950 i 1.958 25

C5Iution:
When crankshaft journal is being ground for use with
undersize bearings, do not scratch the fillet roll.

[Point 32] Cylinder block inspection and correction

• Remove all oil and water deposits. gasket, seal material
and carbon from cylinder block.

EN - 200
 ENGINE OVERHAUL

Upper surface distortion and wear inspection

• Clean upper face of the cylinder block and measure the
distortion in six directions.
Limit (mm): 0.1
• If the distortion exceeds the specified limit, resurface the
face with surface grinder or replace block if necessary.

Cylinder inside diameter inspection

• Use bore gauge to measure cylinder bore for bear, out-of- c -.. --~...
l' . J - - ' ' ' ' -
round and taper. Measure in three vertical locations (A, B . / (
& C) and two directions (X & Y) for a total of six locations.

~~ I. BOre3~?':~~~-1
I
Cylinder inside diameter
86.000 - 86050
standard (mm)
-,.,~(--)'---;-.~
Wear limit (mm) 0.2 ~~
:~,c;::;y
,-,CU( -
_
0-~-.;;.7-
c,,·'~~- ~
,4"i:
~,....,,~<." ( -:::w-
'.,. ____ _~,
~ \,,~' ~,~~~ _J5~ 1 l",,- ,
. Out-of-round limit (rom) 0015 0 __ • _ _ _ _ ~ __ • _ _
• _ _~ ___ • _ _ _ . . ~_ •• _ _ _

Taper limit (rom) 0.010

(1) Out-of-round measurement is the difference of
measurements in two directions (X & V).
(2) Taper is the difference of measurement at top and
bottom (A & C).

v
• Perform honing or boring when abnormality is found.
I
I_I
Cylinder honing ,-~ ..

• There are three types of oversize pistons, STD (Standard

+0.02), OS (0.5) and OS (0.1). When oversize pistons are
used, hone the cylinder so the clearance between the
piston and the cylinder conforms to the specified value
described in [Point 33]. Oversize piston rings must be used
that fit the oversize piston.

[Point 33] Piston and cylinder bore clearance

• The clearance can be calculated from the measured
values for the piston skirt outside diameter [Point 16] and
cylinder inside diameter [Point 32] (X direction B location).
(Clearance) = (Cylinder inside diameter)-
(Piston skirt outside diameter)

Standard at normal temperature (mm): 0.035 - 0.055

EN - 201
 ENGINE OVERHAUL
RB25DE ENGINE

12 ENGINE OVERHAUL
OVERHAUL CAUTIONS
(1) Disassembly
• Use correct and suitable tools when possible and make sure to carry out safe
procedures,
• Care must be taken with operations on mating surfaces and sliding surfaces to
prevent loss of surface accuracy,
• Arrange disassembled pars by making marks to organize for easy faults detection
and precise assembly,
• Loosen nuts and bolts in a diagonal direction from outside, Care must be taken to
follow the numerical order when indicated,

(2) Inspection, repair and replacement

Replace or repair after completing parts inspection following the inspection
procedures, Perform same inspection for the new parts and replace parts as
necessary,

(3) Assembly
Always use a torque wrench to tighten nuts and bolts to specific tightening torque,
Tighten nuts and bolts from centre to outside diagonal direction, gradually in two or
three successive stages, Follow the numeric order when indicated,
• Replace gasket, packing, oil seals and O-rings with new ones in principle,
• Clean each part thoroughly and blown off with compressed air, In particular, check
that oil and water passages are not clogged or obstructed,
• Care must be taken not to scratch or damage sliding or mating surfaces, Clean off all
dust, debris or foreign objects, Lubricate all sliding surface with an adequate
coating oil.

EN - 202
 ENGINE OVERHAUL
"B25:JE eNGINE

12-1 CYLINDER BLOCK DISASSEMBLE, ASSEMBLE & INSPECTION

Rear plate (NTi

/V'hl
r
,. ~ Dust Gover (lilT)
Oil pan bolt tt:u
0.64 - 0.85
Oi; pan~
OCopper washer_
tt:u Dra·n plug 3.0 - 4a-A tt:u kg-m
~ Liquid gasket
1'1 Engine oil
o Replace after every d;sasserobly

Reference: Engine selection assembly

Piston
(1) Piston selection
Grade No. 1 2 . 3
Cylinder block bore Less than 86.010 Less than 86.020 Less than 86.030
diameter (mm) Greater than 86.00 Greater than 86010 Greater than 86.Q20
Less than 85.965 Less than 85 975 Less than 85.985
Piston diameter (rom)
Greater than 85.955 Greater than 85.965 Greater than 85.975

! Piston cl&aranee (mm) 0.035 - 0.055

Servtce setting parts: Piston and piston ptn STO 1, STO 2, STO 3, 0.50S, 1.00S
Piston grade ront mark
(No.1 - No.

Distinction
symbol
Piston pin grade (O~j;
EN - 203
 ENGINE OVERHAUL
RB250E ENGINE

Main bearing
:2) Main bearing selection
I Cylinder block bealing housing Less than 58.654 Less than 58.863 u.ss than 58.672
inner diameter Greater than 58.545 Greater than 58.654 Greater !han 85.863
Crank journal Grade No.
0 1 2
diame!er stamp !

Beanng grade No. STD 0 sm 1 STD 2

less than 54.975
0
Bearing thickness 1.825/1.821 1.82911 825 1.83311 829 I
Greater than 54.967 • Oil clearance 002010045 0.02110046 0.02210.047
identification colour Black Brown None i
•
Bearing grade NCL sm 1 Sm2 sm3
Less than 54.967 1 Bearing thick"""" ~ .829/1.825 1 83311 829 1.837/1833
.Greater !han 54.959 011 clearance 0.020/0.045 0.021/0046 0.02210.047
• Identification colour Brown None Yellow .
Bearing grade No. Sm2 STD 3 STD4
less than 54959
2 Bearing thickness 183311.829 1.83711833 1.84110.837
Greall'lr than 54.951 Oil clearance 0.02010.045 0.02210046 002210.047
Identification colour None Yellow I Blue

NO.1 - No.3 No 5 - NO.7 Upper side (with groove, width 19 mm)

No.1 - NO.3 NO.5 - NO.7 Lower side (without groove, width 19 mm)
NO.4 Upper side (thrust metal, with groove, width 26.9 mm)
No.4 Lower side (thrust metal, without groove. width 26.9 mm)
Crank journal oil clearance (mm): 0.020 - 0.047
Service setting parts: SrD a - 6, US 0.25

Piston pin
(3) Piston pin selection

Grade No. 1 2
Piston pin hole diameter (mm) 20.987 - 20.993 20.993" 20.999

Piston pin extemal diameter (mm) 20.995 - 20.989 21.001 - 20.995

P-lSton pinelearanee (mm) 0 .. -0004

Service setting parts: Piston and piston pin STD 1. STO 2. STD 3. 0.50S, 1.00S

~\ Front mark I
Ojl hoie
\
wi
','f
Ip!ston pin grad. e t
~(O.l;

Srnall Emd
. i
: (1
i\ Cylinder
6\
NC'
I
lf-' '.- '\~
grade (0, 1 ~, ,-~
'/' :-d I,. \\ ~tv\1"
.1 I,.. .." ,
0
I \~/~-
/-------1
Distinction' ;=llston 'grade
(0.1) symbOl (1-3)

EN ·204
 ENGINE OVERHAUL

Con'rod bearing
(4) Con'rod bearing selection
Connecting rod large end Inside less than 51.001 less than 51.013
. diameter ~ter than 61.000 ~ter than 61.007
Measurements
Grade No.
Crank pin diameter 0 1
i· slamp

Bearng grade No STD 0 STD 1

Less than 41.974
0
Bearing thickness (mm) i 1.500 ~ 1.503 1.503 - 1.506
Greater than 47.968 Oil clearance (mm) 0.020 I 0.039 0.020 10.039
i Identification colour
i None , Brown
Bealing grade No STD 1 8TD 2
Less than 47.968 Beanng thickness (mm) i 1.503 - 1.506 1.506 - 1.509
1
Greater than 47.961 Oil clearance (mm) 0.020 I 0.040 0.021 ! 0.040
identification colour Brown Green
i
Service setting parts: us 0.08, US 0.12, US 0.25

~
n Ine sub-altachment
Disassembly '~. Engine
• Remove engine from the vehicle body with transmission. ' . ''. , attachment I
• Disassemble transmission and engine, '~;" ' I
• Remove exhaust manifold, For detailed information refer tol .~." " '
section on exhaust manifold, i '<n .'
• Install engine sub-attachment using 4 bolts on left side of. r DC< MIG x 1.5 (4) !
I . "'L 30 mm
engine, L~10 x.1c..s.f'1.~ = 2.~"m""m~_ _--,

Engine stand ASSY ST0501 SOOO

Engine attachment KV101 06500
Engine sub-attachment KV101 10700

• Drain engine oil and cooling water completely.

EN - 205
 ENGINE OVERHAUL
RB25DE ENGINE

• Remove the following in the order shown:

Intake manifold
Oil filter and oil filter bracket
• Timing belt
• Cylinder head
Oil pan
Water pump

Remove flywheel (Drive plate) bolt

• Insert stick etc, in the gap between cylinder block and
the crankshaft to secure flywheel and remove bolts,

Remove Pilot bush

• Use pilot bearing puller to remove pilot bush,

Remove rear oil retainer

• Use screwdriver to pry the bearing cap open,
Caution:
Care must be taken not to damage rear oil seal retainer.

Remove piston con'rod ASSY

Position the piston con 'rod to BDC (bottom dead center)
position.
• Use a hammer handle or similar tools to press unit to
cylinder head side.

• Disassemble piston con'rod ASSY

• Use piston ring expander to remove piston ring.
Caution:
Care must be taken not to damage piston.
Do not over expand the piston ring, Piston ring expander

• Use snap ring pliers to remove snap ring.

EN - 206
 ENGINE OVERHAUL
RB25DE ENG'NE

• Remove piston,
• Use a heat gun to heat piston to 60"C - 70°C,

Place suitable tool against piston pin and use press or

plastic hammer to tap lightly,

• Remove main bearing cap.

• Remove bearing cap bolts in the sequence shown in the
figure on right

• Use screwdriver to pry the bearing caps open.

• Care must be taken not to damage oil pan rail surface.

• Remove crankshaft.
Remove main bearing cap and main bearing from cylinder
block. _,_ .. _-=.L.l!I""'-_ _ __

Inspection
Crankshaft side clearance inspection
• Use thickness gauge or dial gauge to measure the
clearance between crank arm and the thrust bearing (No.
4 bearing) when moving the crankshaft toward front and
rear of engine.
Standard (mm): 0.05 - 0.18
Limit(mm): 0.3
• If the clearance is over the limit value replace No.4 main
bearing.

EN - 207
 ENGINE OVERHAUL
RB25DE ENGINE

Con'rod side clearance

Check that the crankshaft side clearance is within
standard value.
• Use thickness gauge to measure the side clearance
between con 'rod and the crank arm.
Standard (mm): 0.2 - 0.3
Limit (mm): 0.4
• If the clearance is overlhe limit value replace con'rod.

Piston and piston pin clearance

• Use inside micrometer 10 measure piston pin hole
diameter.
Piston pin inside diameter standard value (mm):
20.987 - 20.999

• Use micrometer to measure piston pin exterior diameter.

Piston pin exterior diameter standard value (mm):
20.989 - 21.001

• Work out the piston pin clearance.

Piston pin clearance = Piston pin hole diameter-
Piston pin exterior diameter (at 20°C)
Standard value (mm): -0.004 - 0
• Replace piston and piston pin if the piston clearance
exceeds the standard value,

Piston ring side clearance _~~ ~~~__ ~~,

• Measure the clearance between piston ring and piston ring , - (f/;;-7'
/ I r
'I

groove. ,
Side clearance st~ndard value (mm): , Thickness ga~~e
'Q c;/,
Top rmg: 0.040 - 0.073 '",~_, ')::
S~c~nd ring: 0.030 - 0.063 ". /~
all rmg: 0.20 - 0.76 ,liikCi""W"'____
Replace piston pin and piston pin ring if the piston ring side ~~~'~~~
clearance exceeds the standard value.

Ring end gap inspection

• Using a piston, press the piston ring into the middle of the
cylinder and measure the gap.
Ring end gap standard value (mm):
Top ring: 0.24 - 0.44
Second ring: 0.42 - 0.67
Oil ring: 0.20 - 0.76
• If the ring end gap measurement exceeds the standard
value with new piston ring, use oversize piston pin and
piston pin ring.

EN,208
 ENGINE OVERHAUL
R825DE c'JGINE

Con'rod inspection !----~c-C;;;;ess I

Bend and torsion inspection
• Use con'rod aligner to measure the bend and torsion.
Con'rod ~i~.~
Bend limit(mm): 0.1 to every 100 mm aligner
Torsion limit (mm): 0.3 to every 100 mm

Con'rod bush oil clearance (small end)

• Use inside micrometer to measure small end inside
diameter ~-!
i

Inside diameter standard value (mm):

Grade 1: 21.006 - 21.000
Grade 0: 21.006 - 21.012
Work out the con'rod bush oil clearance (small end).
Oil clearance =Con'rod small end inside diameter·
piston pin exterior diameter
: - - 1 ~ Front mark .,
Oil clearance standard value (mm): 0.005 - 0.017 \ !
'. \ Piston grade (1-3)'
011 hoi !, SmaUend' ~ :
\ I \' hole grad --\\ I
• Check that the con'rod small end hole grade No. and the : " :\ (0.1) ~ ;-;p :
piston pin grade No. when fitted. ;
i
';, I"
'-!'\'
(

,Large
~ ••• _
-
'P;ston p;o
,
\

l , end grade/ grade (0.1) ,

_~.~~!_nder o. (1 ,.. 6) Identifica~!9_f},rnark _,

:yt:~§~¥~;g~g~f,1~:::::::g:' ~~. ~ C

Limit (mm): 0.1 ,_ ~ I ,._>"'; .

• If the distortion exceeds the specified limit, resurface the • l . , ~. -~, .c~ •
face with surface grinder L__..:.·_. _.,_,_. ..c',_,_:t-",
Thc.:·,c:;.::kr",.e::::ss",9e=au",9:;:cel

Piston pin and cylinder bore clearance

• Check the cylinder bore for any damage and burns.
• Use bore gauge and measure cylinder bore for wear, out-
of-round and taper Measure in three vertical locations (A,
B, C) and two directions (X, Y) for a total of six locations.
Cylinder inside diameter' •
86.000 - 86.030
standard (mm)'

Wear limit (mm) 0.2

Out-of-round limit (mm) 0.015

Taper limit (mm) 0.010
• Out-af-round measurement IS difference af measurement
in two directions (X. Y).
Taper is difference of measurement at top and bottom
(A. C).
EN - 209
 ENGINE OVERHAUL
RB25DE ENGINE

• Perform honing and boring when abnormality if inspected.

Caution:
Make sure to check the bore grade No. and the piston grade
No. when replacing the cylinder block or piston.

• Use micrometer to measure outside piston skirt diameter.

• To prevent cylinder bore distortion, fix main bearing cap
and tighten to specified tightening torque.
Specified position (mm): 18 from piston lower part
Standard (mm): 85.955 - 85.985

Piston and bore clearance = .

Micrometer

Bore diameter (X, Y direction)-

Piston pin exterior diameter

• Five types of pistons are available for service.

Gradea Exterior diatmlter

Grade 1 85.975 - 85.985 (mm)

GradeZ 85.985 - 85.995
Grade 3 85.995 - 86.005
OS 0.5 86.745 - 86.775
OS 1.0 86.975 - 87.005

Crankshaft inspection
• Check for any wear and cracks on crankshaft journal and
pin.
• Use micrometer to check each journal and each pin
exterior diameter.
Journal standard diameter (mm): 47.961 - 47.974

• :~: :~c~:::e:~:::::: ~::)j:oumal (::.:~17~ :::::h • -/1!10 i21\ AAI.I

pin (No.1 - 6) in four locations shown in the figure on right. I
• The out-of-round value is the difference of the dimensions
in directions A and B.
I'
v
, : It (I .) . B

The taper value is the difference of the dimensions

measured at points 1 and 2.
Out-of-round limit value A- B (mm): 0.005
Taper limit value 1 ·2 (mm): 0.005

~ ___J
EN - 210
 ENGINE OVERHAUL
R325DE ENGINE

Main bearing oil clearance inspection

Using micrometer and bore gauge (Method A)
• Fit main bearing to cylinder block and main bearing cap.
Tighten to specified tightening torque.
• Use bore gauge to measure each main bearing inside
diameter.

Oil clearance =Main bearing inside diameter- Fu.IIjJEl.~m bearing cap

Journal exterior diameter

Standard (mm): 0.020 - 0.047
Limit (mm): 0.090

Main bearing selection chart

Con'rod large end inside Less than S8.654 Less than 58.66~; Less·than 58.en I
diameter Greater than 58.545 Greater than 58.654 Greater than 58.663 .
Crank pin Grade .'
0 1 2
i diameter No. slamp
less than Bearing grade No, i STD 0 ST::l 1 STD 2
54.975 Beanng thickness {mm) 1.825 f '.821 1.829! 1.825 ' .833 ! 1.829
0
Greater than Oil clearance (mrn) 0.02010.045 0.021 ! 0.046 0.02010.047
54.967 ldentificatio~ colour Black BroW('! None

Less than Beanng grade ·'lo. STD 1 STD 2 sm 3 i

54.967 Bearing thickness {mm} 1.829 ! 1.825 1.833 11.829 i i .837 ; 1,833
1 Oil clearance (mm) 0.02010.045 0.021 10.046 0.C22 1 0.047
Grnater than
54.959 Identification colour Brown None i Yellow I
I
Less than
54.959
Greater than
2
Bearing grade No.
Bearing thickness {mm}
Oil clearance (mm)
STD 2
1.833 - 1.829
0.02010.045
STD 3
1.837 i 1.833
0.021 10,046
I STD 4
1.841 11.837
0.02210.047
i
54.951 Identification co!our None Yellow i Blue I
Caution:
No.1 - No.3, No.5 - NO.7 Upper side (with groove, width 19 mm)
No.1 - No.3. NO.5 - NO.7 Lower side (without groove, width 19 mm)
No, 4 Upper side (with thrust metal, with groove, width 269 mm)
No.4 Lower side (with thrust metal. without groove, width 26.9 mm)

• Use undersize main bearing ifthe oil clearance can not be

adjusted using the standard main bearing.
Undersize main bearing I.r:- R2.5 journal
. ~crank pm
Size I Thickness (mm)
o
USO.25 i 1.950 11.958

• Grind the crankshaft journal if the oil clearance value is still L

not within the standard value using the undersize bearing.
Caution:
Retain fillet R when grinding the crankshaft journal.

EN - 211
 ENGINE OVERHAUL
RB25DE ENGINE

Cylinder block housing grade is imprinted on the oil pan

aligning side.

~
.Mainjourna-Ig-rad-e~..
No, 1 - 7 from ;eft
• When replacing main bearing, check the bearing grade
(indicated on bottom surface of cylinder block) and joumal Pin!ouma:

diameter grade (indicated on crankshaft No.1 counter ,No_ 1 - 6 from leif"""''!,]?;''

weight front surface). Select main bearing with proper
thickness according to the selection table.

Oil hole
Con'rod bearing oil clearance ~ '\
Install con'rod bearing to con'rod and can 'rod cap.
• .Align con'rod oil hole and bearing oil hole and install. -'fJJQ \/ 1.1
Align "otch

• Use inside micrometer to measure con'rod bearing inside

diameter.

Con'rod oil clearance =

Con'rod bearing inside diameter· Pin exterior diameter
Standard value (mm): 0.020 - 0.040
• Select correct main bearing from below chart if the con'rod
oil clearance is not within the standard value.
COn'rod !alga end inside Less tI1an 51.007 Less tI1an51.013
diameiar Greater tI1an 51.000 Greallir tI1an 51.007
Crank pin' Grade (} 1
diameiar No. stamp
less tI1an Beanng grade No. ST;) 0 I Beanng grade No. SrD 1
41.974 Beanng thickness (mmj 1.500 - 1.503 : Bearing thickness (mm) 1.503 - 1,506 :
0
Greater tI1an Oil clearance (mm) 0.020 I 0.039 • Oil clearance (mm) 0.020 10.039 '
47.968 identification coiour NOf)e Identification colour Brown

lass tI1an Beanng grade No. STD 1 Bearing grade No. STD 2
47.968 Bearing :~tckness (mm) '503 -1.506 Bearing thickness (mm) 1.506 - 1 509 i
1
Graater tI1an Oil clearance (mm) 0.020/0.040 Oil c:earance (mm) 0.021 10.040 :
47.001 identification colour Brown kJentlficaton cOIOlY Green i
• Use undersize con'rod bearing ifthe oil clearance can not
be adjusted using standard con'rod bearing.

Size Thickness (mm) Grade No.

US 0.08 1.541 j 1.549 8

US 0.12 1.561 I 1.569 12

US 0.25 1.626 / 1.634 25

EN - 212
 ENGINE OVERHAUL
R825DE E"lGINE

• Grind the crank pin if the oil clearance value is still not within ~... lft".5 cournal
the standard value using the undersize bearing. I \ Crank pin

~
• Select correct main bearing using the chart if crankshaft
con'rod is new.

Main journal grade No.

: ~ 7 from lef~ .

Pin Joumal
• Con'rod large end grade is printed on large end surface. grade No
from ieft

. Stam~,~p~~f

Using plastigauge (Method B)

• Remove all dust from crankshaft pin and bearing surfaces.

• Cut off a piece of plastigauge slightely shorter than the

gearing width. Place the plastigauge on crankshaft in
direction of axis, care must be taken not to place on oil
hole.

Assemble con'rod bearing in con'rod cap and tighten

connecting rod nuts to specified torque. Cylinde, . ~~.!J I'
No. 11-6; 81g end grad_e_(O_.1_)
Caution:
Do not turn crankshaft while plastigauge is being inserted.

• Remove cap and bearing and measure plastigauge width

with plastigauge scale.
• Standard value and bearing selection is same as method
A.

EN - 213
 ENGINE OVERHAUL
RB25DE ENGINE

Piston and con'rod installation

• Use snap ring plier to install snap ring to installation groove
I······-~ .~.--- ..
on the piston.
• Always replace snap ring with new ones.

Oii hOle

Position piston front mark so the con'rod oil hole faces right .
side of engine (left side when viewed from front).

• Use a heat gun to heat piston to 60 0 e - 70oe.

Apply plenty of oil to pin, pin hole, con'rod small hole.
• Press-fit piston pin into piston pin con'rod from the front of
piston to the rear side of piston.
• Install snap ring on piston front side. After the installation
makesure the con'rod move smoothly.

• Use piston pin expander to install piston rings in correct

position.
Caution:
«
. ' . I'
• Care must be taken not to damage or scratch piston. Piston nng expander
---.J
I
I IdentifiCjiOn marK

• The stamped marks on top and second piston ring

:(~
openings must face up.

Install crankshaft
• Install main bearing to cylinder block and main bearing cap.

• Apply plenty of engine oil on the inside surface of the 1#

bearings. F'oel I
~====F"='II.~~am bearing caPi
• Aligh the bearing notch and the block cap notch to install.
• Place crankshaft on cylinder block and tighten main
bearing cap bolts in several stages.
Tightening torque (kg-m): 4.7 - 5.3
• Apply engine oil to threaded part and flange.
• After tightening to the specified torque, check that crank
shaft turns smoothly. 4 8 12

EN - 214
 ENGINE OVERHAUL
RB25DE ENGINE

Piston & con'rod installation

o Install con'rod bearing to con'rod and con'rod cap,
o Apply engine oil to con'rod bearing exterior surface, Do
not apply engine oil to interior surface, instead clean
sufficiently,
• Make sure the con'rod main body oil hole and the bearing
oil hole is aligned correctly,

• When installing con'rod bolt make sure the bolt head with
larger chamfer of thread is on con'rod side,

• Install piston and con'rod ASSY to crankshaft. Ild"-~~c;atlon:niark Top ring ~~::i
• Position the crank pin to BDC (bottom dead centre). 1;;.::<'" ~!oilring all ricgupperraw
Coat cylinder bore, piston and crank pin with engine oiL l---'~ e\,;:der :~en",g l,
• Position the piston ring openings as shown in the figure on i Front mar1«~. '
nght. I, \,i'¥;!,
,;~
~
,""-
Second ring op~ning 011 ring lower rail i
• Check the cylinder position and con'rod cylinder No. _, ___ . _ openmo"

• Position piston front mark to engine front and use piston I Piston ring
ring compressor to install piston, !
i
compressor ',";' ,]2;
1- - - -,,'"',cc.r'

g:~!i~~st be taken not to damage crankshaft and cylinder II,~~~~,',;

Inner wall by supporting con'rod big end, '
;',\';',' ',' :"I)',J",
-, /8, .ilO"
Co_ ~_ . . _ _ :f~~~\~-~ :i~;' : r !

• Tighten con'rod nuts in the following procedures.

o Apply engine oil to con'rod bolts and nuts flange.
• Tighten the bolts and nuts.
Torque wrench (kg-m): 1.4 - 1.6
Angle wrench (0): 60· - 65°
• After installing all con'rod ASSY, rotate the crankshaft and
make sure it rotates smoothly.

• Check the con'rod side clearance.

Check the crankshaft thrust clearance.

Pilot bushing replacement

• Use a pilot bearing puller to remove pilot bushing,

P,lo! beanrg puller

,-'561 0000
--_.,--

EN - 215
 ENGINE OVERHAUL
"lB25DE ENGINE

The pilot bushing installation position is shown in the figure '

on right.
I
(~-nl

tb··
Fly-wheel installation (M I T vehicle)
• Coat bolts thread and flange with engine oil.
• After tightening the flywheel installation bolts halfway, use
the ring gear stopper to secure fly-wheel and tighten bolts.
• Tighten bolts in several stages.

8 - 8.5 mm
~nock pin
, rotrusion distanc~
Fly-wheel knock pin insertion •
• Insert the fly-wheel knowck pin so the pin protrudes 8 to 8.5 I " Knock oin
mm.
Fly-wheel

Reinforce
Reinforcement plate installation (A I T vehicle) I
• Take care with installation direction when installing
reinforcement plate for A I T vehicles.
Crankshaft

gau~e

Fly-wheel runout
• Set dial gauge to fly-wheel where it contacts clutch.
• Tum the fly-wheel and measure the run out.
Runout limit (mm) 0.10

EN - 216
 ENGINE OVERHAUL
RB20E: DE :CST ENGINE

12 ENGINE OVERHAUL

This section describes the component disassembly of the engine assembly removed from
the vehicle without transmission. It also explains the inspection, replacement of
malfunctioning, damages orwarn parts and carry out any necessary adjustments and
sequential assembly in order to produce a standard engine condition.

OVERHAUL CAUTIONS

(1) Disassembly
• Use correct and suitable tools when possible and make sure to carry out safe
procedures.
• Care must be taken with operations on mating surfaces and sliding surfaces to
prevent loss of surface accuracy.
• Arrange disassembled pars by making marks to organize for easy faults detection
and precise assembly.
• Loosen nuts and bolts in a diagonal direction from outside. Care must be taken to
follow the numerical order when indicated.

(2) Inspection, repair and replacement

• Replace or repair after completing parts inspection following the inspection
procedures. Perform same inspection for the new parts and replace parts as
necessary.

(3) Assembly
• Always use a torque wrench to tighten nuts and bolts to specific tightening torque.
• Tighten nuts and bolts from centre to outside diagonal direction, gradually in two or
three successive stages. Follow the numeric order when indicated.
• Replace gasket, packing, oil seals and O-rings with new ones in principle.
• Clean each part thoroughly and blown off with compressed air. In particular, check
that oil and water passages are not clogged or obstructed.
• Care must be taken not to scratch or damage sliding or mating surfaces. Clean off all
dust, debns or foreign objects. Lubricate all sliding surface with an adequate
coating oii.

EN·217
 ENGINE OVERHAUL
RB20E! DE i DET ENGINE

12·1 DISASSEMBLE & ASSEMBLE CYLINDER BLOCK ASSY

~ Detonation s~nsor bolt
(2) 2.5 - 3.5 ..

tqj kg-m
lei liquid gasket Main beanng cap
, I[l Engine oil [Point 23]
(RB20DE i DET)
i 0 ReOiace after every disassembly

Additional work required:

• Remove and install the following parts:
• Engine
• Exhaust manifold ASSY
• Turbocharger (RB20DET)
• Collector ESSY (RB20E)
• Intake manifold ASSY
• Timing belt
• Rocker cover, cylinderhead ASSY
• Alternator
• Walerpump

EN - 218
 ENGINE OVERHAUL
RB20E; DE; ::lET ENGINE

[Point 1] Remove & install engine stand

• Install the engine sub attachment using 4 bolts on left side
of the engine.

- - - . _ .... - _.

Dial g~uge

[Point 2] Flywheel run-out

• Set dial gauge to flywheel where it contacts clutch.
• Turn the flywheel and measure the run-out.
Run-out limit (mm): 0.10

[Point 3J Remove & install flywheel (drive plate) bolts

Removal
• Insert a stopper between cylinder block and the crank shaft
to stop crankshaft from moving.
Installation
• Coat the thread and flange of bolts with engine oil when
installing the bolts.

Reinforce
plate

[Point 4J Reinforcement plate installation (AfT vehicle)

• Take care with installation direction wen installing
Crankshaft
reinforcement plate for AiT vehicles.

[Point 5] Remove & install rear oil seal

Removal
• Use tool such as screwdriverto remove seal.

Installation
• Care must be taken not to scratch or damage the oil seal
perimeter area. Use oil seal drift (outside diameter:
110mm) to install new oil seal.
• Apply a coat of engine oil or chassis grease to oil seal lip
area.

EN - 219
 ENGINE OVERHAUL
RB20E! DE I DET ENGINE

[Point 6] Remove & install rear oil seal retainer

Removal
• Insert a screwdriver in the gap between main bearing cap
and rear oil seal retainer to remove seal.

Cleaning
F--~::--'
• Use scraper to remove liquid gasket.
• Clean the cylinder block side in the same way. , ~~~
• Wipe mating surtace with white gasoline,
Caution.: I i

c.lL~ s:raJ
Also remove liquid gasket in the grooves.
' - -_ _ _ _

Installation
• Apply liquid gasket and install unit within 5 minutes. Cut

~
.~
• Cut nozzle end of the liquid gasket (KP51 000150) tube as , I .
shown In the figure on right. Use tube presser for " ---.J
application,

• Apply liquid gasket continuously to rear oil seal retainer. Apply liquid gasKet to

Caution: ~~~o~~inner surface!

Make sure liquid gasket width is 2.0 - 3.0 mm. area
Refill engine oil and start the engine 30 minutes after
assembly is completed.

[Point 7] Con'rod side clearance inspection Thickness gaugi,c'

• Use thickness gauge to measure the thrust clearance
between the con'rod and the crank arm,
Standard value (mm): 0.2 - 0.3
Limit value (mm): 0.4

[Point 8] Con'rod nut tightening

• Tighten nuts in two stages.
(RB20E)
1st time Torque wrench (kg-m): 1.4 -1.6
2nd time Torque wrench (kg-m): 1.4 - 1.6
(RB20DE I DET)
1sttime Torque wrench (kg-m): 2.3 - 2.9
2nd time Torque wrench (kg-m): 3.9 - 4.5

EN - 220
 ENGINE OVERHAUL
R820E I DE I DET ENGINE

[Point 9] Install con'rod bearing

• Coat engine oil to beanng surface when installing con'rod
bearing. Do not apply engine oil to rear surface of the
beanng, clean this area.
• Align con'rod bearing retainer notches and Install (left side).
• Make sure the con'rod body oil hole and the bearing oil
hole is aligned.

[Point 10] Con'rod bearing oil clearance inspection

(A) Measuring basis
• Installcon'rod bearing to con'rod and con'rod cap then
tighten the con'rod nuts to specified torque. Measure
con'rod bearing inside diameter. 'inside
• Oil clearance can be calculated using the crank pin outer i micrometer" ,
die measured using points in [Point 27].
(Oil clearance) =
(Bearing inside diameter) - (Crank pin outer die)
Standard value (mm): 0.011 - 0.035
Limit value(mm): 0.090
• Select the bearing using [Point 11] as a reference if the oil
clearance is over the limit value.

(B) Using plastigauge

• Remove any dust from crankshaft pin and bearing surfaces.
• Cut off a piece of plastigauge slightly shorter than the
bearing width. Place the plastigauge on the crankshaft in
direction of axis. Care must be taken not to place it on the
oil hole.
• Assemble connecting rod bearing in connecting rod cap
and tighten connecting rod nuts to specified torque.
• Remove con'rod cap and bearing and measure plastigauge
width with a plastigauge scale.
Caution:
Never turn the crankshaft or connecting rod while plastigauge
is being inserted.
i (('\
\1
II' "
. Cylinder
; No.stamped ,I! I, I Oil hole .
[Point 11] Con'rod bearing selection I ". l i,.k Con'rod big i
• Select the correct sized bearing as the con'rod bearing \~~.
c: :.~ end grade No!
prevents fluctuation in the oil clearance. Three bearing \ \'J / stamped .
W,: .
thicknesses are available depending on inside diameter
of the big end of the con'rod and the crank pin diameter. u;OOr··;·ourna! gra(1e·~·····---

• When replacing the con'rod bearing. check big end inside 1 - 6 from left side

diameter gauge (indicated on the opposite side of the

con'rod hole) and the pin diameter grade (indicated on !e~ sine
crankshaft No.1 counterweight front surface).

EN - 221
 ENGINE OVERHAUL
RB20E I DE! DE ENGINE

Con'rod bearing selection chart

RB20E

Bearing grade No. 'Bearing grade No. sm

1 I
Bearing thickness (mm) , 1.506/1502 Bearing thickness (rnm) I 1.51011.506 I
Oil clearance (mrn) 0.014 ! 0.035 Oil clearance (mm) I ~.014!O.035 '
k:len~lflcaton colour None Identification colour Brown

Bearing grade No. STD 1 , Bearing grade No. sm 2

Bearing thickness (mm) 1.S10! 1.506 ! 8eanng thickness Imm) 1.514/1.510 .
Oil clearance (mml 0.012! 0.034 ,Oil clearance Imm) 0.011 /0.032
Brown tdentflcation colour Greep
Bearing used (Width 16mm)
RB20DE I DET

Bearing grade No. . . Beaflng grade No.

Beanng thickness (mm; , Bearing thickness (mm)
Oil cLearance (mrl) Oil clearance (mm) , 1.014/0.035
k:iet)t!ficat~on colour None lde-ntifjcatloP colour Brown
Bearrng grade No. STD 1 Beaflng grade No. STD 2
Bearing thickness (mmi 1.51011.506 I Beaflng thickness Imm); 1.514/1.510
Oil clearance (mm) 0.012 i 0.034 . Oil clearance (mm) 0.011 ! 0.032
ide-ntificatlon coiour Brown identificatIon colour Green

• When using undersize bearingsr measure bearing inside

diameter when bearing is installed. Grind pin so oil
clearance conforms to specific value.

, I
I o I',I '\\

US008 1.548 ! 1.540 8

USO.12 1 .568 / 1 .560 12

USO.25 1.633 i 1.625 25

Ci3utiQn:
Care must be taken not to scratch fillet roll when the crank pin
is being grounded to use undersize bearing.

[Point 12] Piston pin con 'rod ASSY

Removal
• Use tools such as end of hammer and push it towards the
cylinderhead side.

EN - 222
 ENGINE OVERHAUL
RB20E 8E DE" ENGINE

Removal
• Set the crank pin at B.O.C (bottom dead center) position.
• Coat engine oil to cylinder bore, crank pin and piston.
• Use piston ring compressor to install piston pin and con'rod
ASSY to the cylinder block.

• Make sure to position oil jet correctly when installing it to

~,
RB200ET engines so that the oil Jet and the piston will not
Positioning,
interfere,
. hole ~?
Oil jet

Caution: Front mark -

~~
Front mark on the piston should face engine front side when
installing, Oil hole and baffle notch of con'rod and con'rod Oil hole
cap should be on right hand side of the engine when
installing.

~~~- ...- -

[Point 12] Remove & install piston ring

Removal
• Use piston ring expander to remove rings.
Cgl,ltion:
Care must be taken not to scratch piston. Piston f'ng
expander

- - - -..... ....
Installation
~-~.~- ~

Identification mark
• The stamped marks on top and second piston ring
openings must face up.

• Position the piston rings as shown in the figure on right ,-.... - - - -.....
..... ~

. )'I"n
: Oil ring spacer Top nng opening I
to install. g
I
Caution: . " ~oer ral opemn li,
Care must be taken not to scratch piston. Ffontma~~~~
)~ ?~Oil nng Jower
Second ring open!l1g rail opening

EN - 223
 ENGINE OVERHAUL
RB20E I DE I DET ENGINE
.. ~

[Point 14] Remove & install piston pin I

(Engine number RB20 - 030511 in case of RB20E for C32) .

• Connection process for the piston and the con'rod is called
press fit method. Piston pin press stand ASSY must be
used to remove the piston pin.
Piston pin
Ipress stand
..._ .J\SSY ... _.J

(RB20DE f DEn
• Connection process is called full float method. Use a heat ,
gun to heat piston to 60 - 70 GC when removing and
installing piston pin,
• Place suitable tool against piston pin and press or use
plastic hammer.

Piston pin press-fit

Front marK
• Place the piston front mark so the con'rod oil hole faces
right side of the engine (left side when viewed from front) I
and press-fit.
Caution:
Press-fit the piston pin from the front of piston to the rear side
of piston.
.,
Front _J
Micrometer
[Point 15] Piston pin inspection I
• Use the micrometer to measure outside diameter of piston 1.___
pin skirt. '[
Measuring location from skirt bottom : ~.
(RB20E) 20mm 'l 0 ;:-)
(RB20DE f DET) 15mm I
Outside diameter standard value (mm) - . ~~.... --
(RB20E) 77.915 -77.965
(RB20E f DET) 77.925 - 77.975

• Use micrometer to measure piston pin opening diameter.

Standard value (mm):
(RB20E) 18.987 -18.999 L measurement: RB20E: 20mm
RB2QDE I DET 15mm
(RB20DE I DET) 20.987 - 20.999
Press fit type RB20E for C32 18.995 - 19.000

[Point 16] Piston pin inspection

• Use micrometer to measure outside diameter of piston pin.
Standard value (mm):
(RB20E) 18.989 - 19.001 Micrometer
(RB20DE f DET) 20.989 - 21.001
Press fit type RB20E for C32 18.995 - 19.000

EN - 224
 ENGINE OVERHAUL
RB20E; DE! DET ENGINE

• Piston pin clearance is the figure obtained by subracting

the piston pin outside diameter [Point 15] from the piston
pin hole inside diameter [Paint 16].
Piston clearance at normal temperature (20°C):
0- -0.004mm
Piston clearance at normal temperature (20°) for press
fit type RB20 for C32 is between 0.008 - 0.010mm
• Insert the piston pin as shown in the figure on the right and
check if it move smoothly.

[Point 17] Con'rod inspection

Bend and torsion inspection
• Use con'rod aligner to measure the bend and torsion.
Bend limit (1/1 00 mm): 0.025 Con'rod
aligner
Torsion limit (1/100 mm): 0.025

Small end inside diameter inspection

Standard value (mm):
(RB20E) 19.000 - 19.012
(RB20DE I DET) 21.000 - 21.012
Press fit type RB20E for C32 18.965 -18.978

[Point 19J Con'rod small end bushing clearance

• The difference between the small end inside diameter [Point !
17] and piston pin outside diameter [Point 15] is the
bushing clearance (full float type).
Bush clearance standard value (mm): 0.005 - 0.017

• The con'rod small end and piston pin outside diameter are
separated into two grades at the factory. Make sure that I.~. Insid~_ ....
m i~_r~meter
"
the grades (0.1) conform for both parts because the rod
and pin are selected and fitted according to bushing
clearance.

[Point 18] Piston ring end gap and side clearance Th!ckness gau'qw/
gap inspection
• Use a piston to press the piston ring into the middle of the
cylinder and measure the gap.

0.22 - 0.45 0.19 - 0.45 0.20 - 0.76

0.22 ·0.39 0.19-0.45 0.20 - 0.76
EN -225
 ENGINE OVERHAUL
RB20E I DE i DET ENGINE

Side clearance inspection

• Measure the clearance between the piston ring and the
piston ring groove.

tlmll'vl!duif " 0.1 0.1

(mm) I

[Point 19] Remove & install pilot bushing

Removal
• Use a pilot bearing puller to remove pilot bushing.

Installation
The pilot bushing installation position is as shown in the
figure on right

[Point 20] Remove & install pilot converter (AfT)

• Make sure to install pilot converter in correct direction .
...
I Crankshaft side

[Point 21] Crankshaft thrust clearance inspection -Thickness

.
gau.~e !~
• Use a thickness gauge to measure the clearance between (~~- / ~
the thrust bearing (No.4 bearing) and the crank arm when
moving the crankshaft forward or backward.
Standard value (mm): 0.05 - 0.18
Limit value (mm): 0.3

[Point 22] Remove & install main bearing bolts 2 6 10 14 12 S 4

• Remove bearing bolts in the roder shown in the figure on
right
• Tighten bolts to specified torque in two to three stages in
;~[r ~~~tJt~;~tl
f
,
-:-. -
-~f~)~'
,~~::,~/~, J'(L.~
'~I-~ -
reverse order shown in the figure. Make sure the crank l. . - .... :-~, ""-~")',;,
Ii
shaft turns smoothly after tightening the bolts to specified • I .
5 9 13 11 7 3
torque.
EN - 226
 ENGINE OVERHAUL
RBOE! DE ' DET ENG INE

[Point 23] Remove & install main bearing cap

(RB20E)
• Use main bearing bolt to remove bearing cap by shifting it
fOlWard and backward.

• Main bearing distinction can be checked by marks on each

main bearing.
• Make sure to face the arrow mark on the bearing to engine
front when installing No.3, 4 and 5 bearings.

(RB20DE I DET)
• Make sure to install the main bearing cap In correct
orientation when installing.

Crush height
[Point 24] Main bearing inspection
• The bearing end should protrude when installing the main
bearing to the cylinder block or main bearing cap.
This protrusion is called the crush height.

Main bearing

[Point 25] Main bearing oil clearance

Using bore gauge and micrometer (Method A)
• Install main bearing in cylinder block and attach bearing
cap. Tighten bearing cap bolts to specified torque and
measure bearing inside diameter.
• The oil clearance distance can be calculated from the
values for outside diameter of the crank journal measured
in [Point 27].
(Ojl clearance) = .
(Bearing inside diameter) - (Crankshaft outside diameter) l
Standard value (mm): 0.020 - 0.047
Limit value (mm): 0.090

• If oil clearance exceeds the limit value refer to [Point 26] to

select suitable bearing.

EN - 227
 ENGINE OVERHAUL
RB20E I DE ! DET ENGI'lE

Using plastic gauge (Method B)

• Remove all dust and oil from each crankshaft joumal and
bearing surfaces.
• Cut a piece of plastigauge slightly shorter than the
bearing gauge width. Place a plastigauge on crankshaft
in direction of axis, care must be taken not to place on oil
hole.
• Assemble the main bearing and bearing cap and tighten
cap bolts to the specified torque.
• Remove bearing cap and the bearing. Measure
plastigauge width on plastigauge scale.
Caution:
Do not turn crankshaft while plastigauge is being inserted.
If excessive bearing clearance still exists, use a thicker main
bearing or undersized bearing so that the specified bearing
clearance is obtained when measured by method A as well.

[Point 26] Main bearing selection and engagement

Select correct sized bearing as the main bearing
prevents fluctuation in the oil clearance. Five different
bearing thicknesses are available to fit the cylinder block
bearing housing and crank journal diameter grades.
Note:
Selection engagement is performed only for standard size.
• Check the bearing grade (indicated on bottom face of the
cylinder block) and journal diameter grade (indicated on
crankshaft No.1 counterweight front surface) when
replacing the main bearing.
• Select main bearing with proper thickness according to the
following table.

Black Brown None

STD 1 STD2 STD 3
1.829! 1.825 1.833 1 1.829 1.837 i 1.833
0.028! a.OdS 0.021 10.046 0.022 i 0.047
Brown None Yellow
sm 2 STD 3 8TD 4
1.833! 1.829 1.837 1 1.833 1.841 11.837
0.020! 0.045 0.021 ! 0.046 0.022 ! 0.047
None Yelkow Blue

EN - 228
 ENGINE OVERHAUL
RB20E! DE / DET ENGINE

• When uSing undersized bearings. measure bearing Inside . - ,-lr-R2 0 'ouma, f l ' I
diameter when bearing is installed and grind Journal so all r'
clearance conforms to specIfied clearance.
"I'
'.JI
I 1

v- Rl pin
'
I
~,
.I
"\ r i
USa.25 1,960 ! 1.952 2 5 ' " .-/ '

USO.50 2.085 12.077 50

CautiQ!1';
When crankshaft journal is being ground for use with
undersize bearings, do not scratch the fillet roll.

[Point 27] Crankshaft inspection ~_~_, ___ _

Out-of-round and taper inspection 1 2 A

()rt"
'\.. 'r
• Use micrometer to measure each journal (No, 1 - 7) and
e,ach pin (No, 1 - 6) in four locations shown in the figure on , 0 I \\

right II'-: • i
• The out·ol-round value is the difference of the dimensions
in directions A and B, _
-if "
,1--,1"
B I,'

• The taper value is the difference of the dimenSions __

measured at points 1 and 2,
Out-of-round and taper limit (mm): Below 0.005

Pin and journal inspections

• Use micrometer to measure pin and journal diameters,
(RB20E)
Pin diameter standard value (mm): 41.961 - 41.974
Journal diameter standard value (mm): 54.951 - 54.975 .
(RB20DE I DET) ,
Pin diameter standard value (mm): 44.961 - 44.974
Journal diameter standard value (mm): 54.951 - 54.975

Curve inspection
• Use V-blocks on a fixed surface and support journals on
both ends of crankshaft (No.1 and No, 7). i
• Position the dial gauge vertically on middle of No, 4 journal !c::1U,ijIlJ<!~'h
as shown in the figure on the right.
• Turn crankshaft by hand and read dial gauge movement.
• The Run-out is equal to half of dial gauge movement
Limit value (mm): 0.05

EN - 229
 ENGINE OVERHAUL
RB20E ! DE ' DET ENGINE

[Point 28] Cylinder block inspection and correction

• Remove all oil and water deposits, gasket, seal material
and carbon from cylinder block.

Upper surface distortion and wear inspection

• Clean upper face of the cylinder block and measure the
distortion in six directions.
Limit (mm): 0.1
• If the distortion exceeds the specified limit, resurface the
face with surface grinder or replace block il necessary.

Cylinder inside diameter inspection

• Use bore gauge to measure cylinder bore for out-of- " - - _~! / -- 1
round and taper. Measure in three vertical locations (A, B i
& C) and two directions (X & Y) for a total of six locations. I
·~i._~;(jl.~'-<
,J:aafcl·• .~t"j~2[1«!\i!,1 77 .950 - 78.000 __ --,'( ""-.:

Wear Hmlt<',·.;ttli~) 0.2 Ar~' <5~~~1

OIJt~I~'l+~ 0.015 ~._~~\_~ .~",~;';;T" ,

~iItnlt~i!~·i~;i::.~ 0.010
----'
(1) Out-ol-round measurement is the difference of
measurements in two directions (X & V).
(2) Taper is the difference of measurement at top and
bottom (A & C).
• Perform honing or boring when abnormality is found.
y

Cylinder honing
• There are three types of oversize pistons, STO (Standard
+0.02), OS (0.5) and OS (0.1). When oversize pistons are L ... ,~, __ .. __. _... _ _". ____ .i

used, hone the cylinder so the clearance between the

piston and the cylinder conforms to the specified value
described in [Point 29]. Oversize piston rings must be used
that fit the oversize piston.

[Point 29] Piston and cylinder bore clearance

• The clearance can be calculated from the measured
values for the piston skirt outside diameter [Point 151 and
cylinder inside diameter [Point 28] (X direction B location).
(Clearance) = (Cylinder inside diameter)-
(Piston skirt outside diameter)
Standard at normal temperature (mm):
(RB20E) 0.025 - 0.045
(RB20DE I DET) 0.015 - 0.035
EN·230
 TROUBLE DIAGNOSIS
RB26DETT I RB20E! DE i DET i CA1S. I RB25DE ENGINE

EN3 ECCS (ELECTRONICALLY CONCENTRATED ENGINE

CONTROL SYSTEM)
1. TROUBLE DIAGNOSIS
1-1 TROUBLE DIAGNOSIS PROCEDURE

Ask customer in detail about

I Customer interview ------- i

problem occurrence condition.

environment and the problem.

I Problem confirmation _ _ _ _ _ _ _ Check the problem and understand.

occurrence condition. i

I Self-diagnosis I}
- - - - - - - ~ Narrow down suspected systems.
I Basic inspection
'-=-------r-------' !

Spark?
Fuel? • Actuator function
• Output signal
I Inspection for individual systems • Harness
• Input signal
• Sensor
I Confirmation test I

Caution:
Engine problems are roughly divided into two types: problems relating to engine main
body and those related to control system. This section explains the trouble diagnostic
method for the control system under the assumption that the engine main body is normal.
Consequently, attention should also be paid to the condition of the engine main body and
gasoline quality.

EN - 231
 TROUBLE DIAGNOSIS
RB26DETT i RB20E IDE IDET leAISi I RB25DE ENGINE

FOR ACCURATE & QUICK DIAGNOSIS

Cautions when carrying out diagnosis

• Remove the battery terminals and place key switch in

OFF position when removing or connecting ECCS C/U
harness connector from ECCS C/U.

• Position the connector and tighten installation screw until

orange projection is level with surface when connecting
ECCS C/U harness connector.
~~I
~~!
_-:::... , , < ; JY

InstallatIOn Red proiection .

screw

Bent
//1.1
• Check the connector pin terminals for any bent or
deformation when removing or connecting ECCS C/U
harness connector.
~~~;-~.) b-~~ 1
I,~~~~ =--.J

#' :0
Broken

Check input i output !

signal before
replacing ECCS CiU
• Make sure to carry out components function check and
ECCS G/U input signal check before replacing EGGS
C/U.

• After "Diagnosis procedures" carry out the test drive and

self-diagnosis.

• Short circuit will occur if proves from same position

comes in contact when measuring battery voltage of
ECCS G/U components using circuit tester. Make sure
to connect one side of tester prove to different place.

EN - 232
 TROUBLE DIAGNOSIS
RB26DFT! RB20E ! DE 'DET ! CA 18i! RB25DE ENGINE

Cautions when handling ECCS C/U

ECCS C/U installation

• Only install EGGS C/U specified for your vehicle.
• Do not apply unnecessary power to installation bracket.

Connector installation
Keep the following points in mind when removing & installing the connector:
Bemoval
• Make sure the EGCS relay is "OFF" after turning off the key switch.
• Hold the connector body to remove connector. Never pull the hamesses to remove.
Installation
• Install connector when key switch is in "OFF" position.
• Check the ECCS C/U side connector pin for any bent or deformation before installation.
• Tighten the bolts securely until red projection is level with surface.

ECCS voltage
• Never connect the battery in reverse.
• The battery voltage should be between 10V - 16V.

Idle revolution adjustment volume

• Do not turn the knob over the lock position.
• Do not operate the adjustment volume when below 0 0 ,

Moisture & oil content

• Care must be taken to keep all rain drops and water droplets away from ECCS C/U.
• Take note of water droplets from rapid temperature change. Make sure ECCS G/U has
dried completely before installing to the vehicle.
• Do not let oil content adhered to the connector device.
• Avoid cleaning EGGS G/U using benzine or white spirit.

Dropping & strong impact

• Do not drop, tap or apply strong impact to EGCS G/U device.
• Do not use EGCS C/U unit with bent top or bottom cover.

ECCS C/U screw & cover

• Do not remove ECGS G/U cover.
• Do not rotate screws on EGGS G/U body.

EN - 233
 TROUBLE DIAGNOSIS
RB26DETI ! RB20E I DE / DET ; CA 18i I RB25DE ENGiNE

DIAGNOSIS PROCEDURE
(1) Diagnostic worksheet
• Feelings for a problem depends on each
Key points customer. It is important to fully understand
the symptoms and conditions of a vehicle
What ........... Vehicle & engine model when a customer complains.
When .......... Date, frequencies • Check with your customer in what condition
. Where ......... Road conditions problem occurs and use as a reference when
: How ............ Operation conditions, carrying out test drive.
Weather conditions, • Make a good use of a diagnostic worksheet
Symptoms such as the one shown below in order to
utilize all complaints for troubleshooting.

~': • • ~<;: • . "• ~

! Registration Initial registry i

MR I MRS I Miss I MS No. date :

I
I Vehicle type : : Chassis No.1

Manuf. ! TIM MIT,AIT I (km)

Engine Mileage
I Oate I
NO combustion Partial combusuon
Startability Hard to start (Cold climate. warm climate. constanHy)
Other ( I
No first idhng high idle Low idle
Idling Idling unstable
Other [ I
i. Symptoms 1 - - - - - . , - - - - - ' ' - - - - - - - - - - - - - - - - ' - - - - - - - - - - 1
Stumble KnocKing Spilti ng LacK of power
Driveability Lack of acceleration
Other [ I
At the time of start While Idling While driving
Engine stall Just after stopping While loading
Other [

Incident occurance Since new Recently

Frequency All the time Under certain conditions Sometimes

! Not affected

Weather Weather Fine Cloudy Raining SnoWing Others [

condition Temperature Hot V\larm Cool Cold Humid Approx. 'C
Engine conditions Cold After warm-up During warm-up V\later temperature

Road conditions In town In suburbs Highway Off road (up i down)

Not affected
At starting While Idhng At racing While accelerating
Driving conditions
While CruiSing While decelerating While tuming (right! left)
Vehicle speed. km/h, Engine rell: rpm. M! T gear

Other condition
I

EN - 234
 TROUBLE DIAGNOSIS
RB26DETT I RB20E I DE! DET I CA 18i i RB25DE ENGINE

(2) Problem confirmation

• Customer's explanation is often insufficient In clarifying
the status of the problem. Reproduction of the problem
on the actual car and its confirmation and analysis are J:f~~~
I 1 see.
this is Ihe
therefore essential. If unable to reproduce the problem,
ask the customer in detail about its occurrence
conditions and try to reproduce it under the indicated
conditions. If unable to reproduce, manually shake the
concerned harness to check for poor contacts or other
problems.
• It is also recommended to collect and analyse the data
using CONSULT while driving.
• When checking the actual vehicle, record data on normal
portions to assist in diagnosing a problem.

out adive test and !metion test

CONSULT. OR remove vacuum
and apply pressure USlf1g vacuum

crank angle sensor clockwise.

out active test and function test

CONSULT OR rotate crank angle
anti-closkwise
adive test and function test
CONSULT. OR remove O. sensor i
"
connectoL II
out active test and !metion tes!
CONSULT OR carry out sen
mode 2 In 2000
out active test and function test
CONSULT. OR rotate idle

out act.!ve test an(1 function test

CONSULT OR rotate Idle
screw clockwise.

the engine qUickly and check

contact C8l1Sed by engine torque
 TROUBLE DIAGNOSIS
RB26DETI! RB20E I DE! DET" CA18i I RB25DE ENGINE

(3) Self-diagnosis
• If problems are attributable to the ECCS signal system,
problem diagnosis should be narrowed down using the
self-diagnostic function.

I What happened up to present?

, How is the signal system at present?
Self-diagnosis
Real-time diagnosis or switch ON/OFF
diagnosis using the CONSULT "Data
monitor" function.

(4) Basic inspection

• Check to see if three elements of combustion are
functioning normally. Find out which system is faulty: Fuel
system, ignition system or idling control system.

Fuel? Are injector fuel pump operating?

Ignition? Are spark present?
Idling control? Is AAC valve operating?
Air-fuel ratio? Is air-fuel ratio feedback function normal? ''--_ _ _ _ _ _ _ _---1

EN - 236
 TROUBLE DIAGNOSIS
RB260E~ ~::: ~ - ~"'8 RB250E ENGINE

(5) Individual system inspection

• An effective method to carry Ou: S J agnosis is to check the control unit output
signal first. According to the resv:s 're output signal, continue diagnosis by checking
input signals, individual parts SccC, as acccator and sensors.
[Procedures]
Note~
The input data must be monitored 'i;st when using CONSULT.
(Only checking the output data does not provide accurate results).

( Start )

~ Output signal to NO
actuator is provided

YES Actuator is NO YES Input signal ~

, operating
I r
:'---
is provided

NO Output harness is Input sensor !

r- broken or shorted output is provided.
I
,-----'-------,
YES NO ! YES
I
YES Actuator internal
I resistance IS normal

' Actuator is seized NO

I or clogged

Check other I Actuator Harness I ! Control unit Sensor ! Harness

system! is faulty is faulty , • is faulty is faulty is faulty
L

[Analysis]
Control unit Actuator

No sensor Sensor output is Input signal IS Output signal is

output Indicates present even With provided With no controi linlt IS present but
a faulty sensor. no input signal. output signaL norrar t:ut no actuator does
It indicates ! IndIcates faiJlt ! oute",' s S nct operate,
harness is with control unit '8~c;\"ce::::: T""'€ I Fault With
! broken. i ra~"ess :: ~""',<e~ : actuator.

EN - 237
 TROUBLE DIAGNOSIS
RB26DETT I RB20E I DE I DET i CA18, I RB25DE ENGINE

(6) Trouble diagnosis using measuring instruments

(Operations in square frames I I to be periormed with CONSULT.

1, Reproducible problems
Diagnosis (Data collection)
'-----,
! "SELF·DIAG TEST' "DATA MONITOR
i

I-Input signal monitonng

• When using'_ _-1 "DATA MONITOR" 1-.-, -Monltonng of calculation resutts '-
CONSULT ' _ SWitch ON/OFF i sent to output system
- Real time diagnosis
i "ACTIVE TEST'
i (Check operation of input &

; output signal system), f-- Analysis

OSCilloscope
(Wave observation for Inlector,
ignition system, AAC valve and
I
Understanding
other output signals),
the cause
• When not uSing Self-diagnosis _ _ _ Oscilloscope
CCNSULT ---
(on-board) (or circuit tester)
(110 signal waveform observaflon)

"DATA MONITOR" f--

2, Non-reproducible r-:=" I "ACTIVE TEST'
problems ---j "FIELD TEST' ' -
(Wavelonm observation using I-- Analysis
oscilloscope)
OR
-Wave form observation using
oscilloscope, Understanding
the cause

EN -238
 TROUBLE DIAGNOSIS
RB26DETT! RB20E! DE! DET I CA 181! RB25DE ENGINE

1·2 MAJOR ECCS INPUT SIGNALS AND CONTROL ITEMS

It is important to understand the re,a:onsn,p between the Input signal and control items
(output) of ECCS to efficiently determine the cause of problems.

IlarliticlOtlming start
Engine rpm input signal
nt.

angle sensor 1G speed input

I crru"", speed input signal. 11""ili,," timing count.

air volume measuremenl

control of injector injection Ignition timing control.
width.
temperature enrichment ignition timing speed change
Water temperature
Icone,cticln. lalteraticm due to water laclcordil1g to water
sensor

I cut due to ON signal.

1I""iti"n timing change
F time enrichment
I injection interruption.
I Frm"hm,~nt correction dunng

Throttle sensor
I cut judgement during
Ispl=ed change.
alf volume measurement.

conlrol start at when

Vehicle speed sensor I cut at Okmih vehicle IvhF'i"l" speed is below 8

sift i
width control by air-fuel
gas sensor

ID,'toIMtion sensor Ilorlitieln timing change.

angle
Battery vonage width correction. rpm change.

rpm change after

if conditioner switch
warms UP
IlQrlltlCm timing change
IN€,utr,al sWitch
Ion.
of engine
Power steering switch Isp"ed reduction when
IS turned.

EN - 239
 TROUBLE DIAGNOSIS
RB26DETT i RB20E! DE i DET! CA18i I RB25DE ENGINE

1-3 DIAGNOSIS CHART ITEM BY PHENOMENON

(1) Unable to start ............ No initial combustion.

(2) Unable to start ............ Initial combustion occurs but it is not complete.
(3) Difficult to start ........... Hard to start when engine is cold.
(4) Difficult to start ........... Hard to start after engine warm up.
(5) Difficult to start ........... Hard to start when engine is hot or cold.
(6) Poor idling ................ Fast idling inoperative.
(7) Poor idling ................. Low idle rpm (after warm up).
(8) Poor idling ................. High idle rpm (after warm up).
(9) Unstable idling ........... Engine is cold.
(10) Unstable idling ........... After engine warm up.
(11) Poor driveability ......... Engine breathing.
(12) Poor driveability ......... Knocking.
(13) Poor driveability ......... Lack of output. poor acceleration, poor response.
(14) Engine stalls when start driving.
(15) Engine stalls while idling.
(16) Engine stall while driving.
(17) Engine stall when decelerating or immediately after stopping.
(18) Engine stall when electrical load or power steering load is applied.

EN - 240
 TROUBLE DIAGNOSIS
RB26DETI I RB20E I DE / DET i CA18i / RB25DE ENGINE

Diagnosis chart by phenomenon

(1) Unable to start .......... No initial combustion

[Analysis]
, Ignition spark is not generated or no fuel is injected.
, Check if the fuel pump is rotating.
• If there is no ignition spark is generated and no injector operating noise is heard, check
the control unit input (crank angle sensor signal) or control unit power supply.
, If the injector is operating but no spark is generated, control unit and crank angle sensor
can be judged as normal. Check the ignition output system (power transistor, ignition,
coil etc.)
, If ignition out spark is generated but injector is not operating, check the ignition output
system (injector power supply, harness etc.)

[Chart]

FUEL PUMP?
Operating? LCheck fuel hose for tension in CONSULT active test mode.
OR
Check if pump operating noise can be heard for five seconds after
turning ON the ignition. (If not check fuel pump system)

INJECTOR?
Operating? --r Injector noise can be heard when cranking
LOR
Check using CONSULT data monitor mode if injector pulse is output
when cranking engine.
If not correct
, Check control unit terminal voltage when cranking engine.]
• Check injector power supply circuit
[ , Check crank angle sensor input signal.

IGNITION SPARK?
Is there a
spark?
--rL
Check if tachometer needle moves during cranking.
Check using real-time diagnostic mode (CONSULT data monitor).
Check using timing light.
, Remove the plug and check for actual spark.
If not correct
' Check control unit output signal (ignition signal) ]
, Check control unit input signal (crank angle sensor)
[ , Check power transistor and ignition coil resistance value.

EN - 241
 TROUBLE DIAGNOSIS
RB26DETT I RB20E I DE I DET I CA 181 I RB25DE ENGINE

[,2: Unable to start .......... Initial combustion occurs but iUs not complete.

(Analysis]
Occurrence of initial combustion means that sparks are created. The fo~lowing three cases
are possible.
1. Initial combustion only.
• Is fuel system working? (fuel pump, injector etc.)
2. Engine fires incompletely.
• Check if fuel injection quantity is too small or large.
• Check the fuel pressure.
• Check if water temperature enrichment is provided.
• Check if start time enrichment is provided.
• Check if ignition liming is normal.
3. Engine fires completely if accelerator pedal is pressed and depressed.
• Check if AAC valve operation is normal.

(Chart]

FUEL PRESSURE?
Is pump operating? 1 Check fuel hose tension in CONSULT active test mode.
OR
Check if pump operating noise can be heard for five seconds
after tuming ON the ignition.
Is fuel pump operating during cranking?
(If not check fuel pump system)

INJECTION QUANTITY?
Water temperature ::;r
Check water temperature of CONSULT data monitor mode.
enrichment provided?L OR
Disconnect water temperature sensor and check for any
change.
• Check water temperature resistance value .
• Check water temperature sensor output voltage.
Stan lime enrichment-Check "START' signal ON/OFF (CONSULT data monitor
provided? mode).

IDLING CONTROL?
Is idling rpm [ C h e C k AAC valve operation (CONSULT active test mode).
increased? Check if AAC valve is fully closed.
Check AAC valve circuit for disconnection or loose connectors.

IGNITION SYSTEM?
Ignition timing
normal?
Is ignition correct? L
Try to advance or retard timing angle.
Check spark plugs for fouling.
Check for ignition misfiring.
(Check using a timing light or CONSULT real-time diagnostic
mode).

EN - 242
 TROUBLE DIAGNOSIS
RB26DETT! RB20E' DE DET CA18i! RB25DE ENGINE

(3) Difficult to start "".,," Hard to start when engine is cold.

[Analysis]
Inspect the system relating to water temperature as this problem only occurs when the
engine is cold.
• Fuel injection enrichment from engine temperature sensor signal is not functioning when
temperature is low.
• Idling speed control is not functioning.
• Start-time enrichment is not functioning.
• Cranking speed is too low.

[Chart]

ENGINE TEMPERATURE CORRECTION?

Engine temperatureTCheck using CONSULT data monitor mode.
sensor signal? OR L
Disconnect engine temperature sensor connector and check for
any change.
Check engine temperature sensor resistance value.
Check engine temperature sensor output voltage.
Idling control? tCheck if ACC valve for operation (CONSULT active test).
Check If ACC valve is not fully closed.
Check ACC valve circuit for disconnection, loose connector etc.

START-TIME ENRICHMENT?
'--____ Using CONSULT data monitor mode check if START signal is
provided.
CRANKING SPEED?
Is battery normal?
L -_ _ _ _ Inspect starter, starter cables (resistance, poor contact etc.)

EN·243
 TROUBLE DIAGNOSIS
RB26DETT I RB20E I DE.' DET , CA 1811 RB25DE ENGINE

I (4) Ditlicullto start ......... Hard to start after engine warm up.

[Analysis]
This problem may also be related to the water temperature control.
• Check engine temperature correction is inaccurate.
• Check if fuel pressure is correct or if air bubbles are generated in the fuel wen the
engine is hard to start, especially when water temperature is high.
• Check it engine cranking speed is low.

[Chart]

ENGINE TEMPERATURE CORRECTION?

Engine temperatureT Inspect using CONSULT data monitor.
sensor signal? OR L
Disconnect engine temperature sensor connector and check for
any change .
• Check engine sensor resistance value .
• Check engine temperature sensor output voltage.

FUEL PRESSURE?
Increase fuel --Remove vacuum hose for pressure regulator or clamp return hose.
pressure to check

CRANKING SPEED?
1 - - - - Is battery normal?
" - - - - - Inspect starting system.

EN - 244
 TROUBLE DIAGNOSIS
==~ ="8 R325DEENGINE

! (5) Difficult to start ......... Hard to start regardless of engine temperature.

[Analysis]
Spark arc is created but air-fuel ratio could be Incorrect
• Check fuel pressure.
• Check fuel injection quantity. (Is engine temperature correction accurate?)
• Check if idling speed is controlled.
• Check if cranking speed is too low.

[Chart]

FUEL PRESSURE?
Fuel pump? ~ Use CONSULT active test mode to check fuel hose tension.
LOR
Check if you can hear pump operation noise for five seconds after
tuming ignition switch ON.
• Check if you can hear pump operation noise when cranking.
• Check if fuel pressure is approx. 2,5 - 3 kg/cm'- (the value differs
depending on CA18L RB20S0HC and DOHC).
Increase fuel - - Disconnect vacuum hose for pressure regulator and check for any
pressure to check change. (or clamp retum hose)
Fuel system for Inspect fuel filter.
clogging

ENGINE TEMPERATURE CORRECTION?

Engine Inspect with CONSULT data monitor.
temperature senso{ OR
signal? Disconnect engine temperature sensor connector and check for
any change.
• Check engine temperature sensor resistance value.

Idling control? t• Check engine temperature sensor output Voltage.

Check if AAC valve operation is normal (CONSULT active test).
Check if AAC valve is not fully closed.
Check AAC valve connector circuit is disconnected, loose
connector etc.

IGNITION SYSTEM?
Ignition miSfiring CheCk in real-time diagnostic mode (CONSULT data monitor).

l
Check crank angle sensor output for missing pulses (CONSULT
data monitor mode or with oscilloscope).
Is spark plug gap normal?
Check for any leak from high-tension cable.
Is ignition timing - Check by advancing or retarding the angle.
normal?

CRANKING SPEED?
1'-_ _ _ _ Is battery normal?
r - - - - - Check charged state.
' - - - - - Check starting system.

EN - 245
 TROUBLE DIAGNOSIS
RB26DETT I RB20E ! DE! DET ! CA 18i! RB25DE ENGINE

i (6) Poor idling ............... Fast idling inoperative.

----------------------------~
[Analysis]
This problem may have been caused by abnormal control of ACC valve and air regulator
as idling speed is controlled by these device.
The air-fuel ratio and ignition timing also relate to this problem.

[Chart]

IDLE CONTROL SYSTEM?

Ai r regulator --'L-IS air regulator resistance normal?
operation Is air regulator seized?
AAC valve IsAAC valve operation signal shown?
IsAAC valve operation normal (CONSULT active test mode).
Is idle judgement ON? (CONSULT data monitor mode).
Check for ACC valve circuit for breaks or loose connectors.

signal?
ORL
Engine ----.-Check using CONSULT data monitor.
temperature
Disconnect engine temperature sensor connector and check for
any change .
• Check engine temperature sensor resistance value.
• Check water temperature sensor output voltage.

AIR-FUEL RATIO?
Enrich mixture ---Increase fuel pressure (Disconnect pressure regulator vacuum hose
to check or CONSULT active test).
Lean mixture Reduce the fuel pressure (CONSULT active test or apply negative
to check pressure greater than -500 mmHg).

EN -246
 TROUBLE DIAGNOSIS
RB26DETT I RB20E ! DE, DET i CA 181! RB25DE ENGINE

(7) Poor idling ............... Low :dle 'pm ,after warm up).

[Analysis]
Idling speed is controlled by AAC valve. A low rpm means insufficient auxiliary air volume
throughAAC valve.

[Chart]

operation?
EIS
IDLE CONTROL SYSTEM?
AAC valve ACC valve control signal issued?
IsAAC valve operation normal? (CONSULT active test mode).
Measure resistance value of ACC valve and check seizure.
CheckAAC valve circuit for disconnection or looseness.
Input signal? Is idle judgement ON?
L
Is air conditioner switch and neutral switch turned ON? (CONSULT
data monitor mode).

IS IGNITION TIMING NORMAL?

EN - 247
 TROUBLE DIAGNOSIS
RB26DETT I RB20E' DE I DET I CA18i i RB25DE ENGNE

(8) Poor idling ............ High idle rpm (after warm up)

[Analysis]
High idling can be caused by following points below:
• Low engine temperature signal.
• Throttle valve switch (Idle judgement) is OFF.
• AAC valve is seized.
• Air regulator is not energized.
• Air regulator is seized.
• Control unit adjustment volume is set to HIGH.
• Throttle valve is open.
• Air is sucked in.

[Chart]

IDLE CONTROL SYSTEM

Engine temperature [CheCk with CONSULT data monitor mode
signal? OR
Disconnect engine temperature sensor connector and check for
any change .
• Check for engine temperature sensor resistance value.
• Check for engine temperature sensor output voltage.
Throttle sensor - - Check idle judgement signal with CONSULT data monitor mode or
by using tester.
AAC valve ----;--Is AAC valve control signal present?
control Is AAC valve operation normal? (CONSULT active test mode).
Check AAC valve for seizure.
Disconnect AAC valve connector and close the valve to see if
engine rpm lowers.
Turn off air conditioner and power steering switch OFF and see if
ON signal is disconnected.
Check if neutral switch is OFF or vehicle speed signal input is OK.
Air regulator--Lr-Check air regulator circuit for breaks or loose connectors.
Check air regulator for seizure.
Control unit - - - I s adjustment knob set at HIGH position?
adjustment knob

OTHERS
Throttle valve - - - I s valve open? (Check for wire binding).
Air suction Block blow-by hose passage and check for any change.

EN - 248
 TROUBLE DIAGNOSIS
RB26DETT i RB20E! DE i DET i CA 18!1 RB25DE ENGINE

I (9) Unstable idling ......... Cold engine only.

[Analysis]
Since idling is unstable only when the engine is cold. cause of this problem can be
narrowed down to the relationship between the engine temperature and idle control
system. II also relates to the air-fuel ratio. ignition timing, misfiring etc.

[Chart]

IDLE CONTROL SYSTEM

Engine temperature-Inspect using CONSULT dala monitor mode.
sensor Signal Check engine temperature resistance value.
Check engine temperature output voltage.
AAC valve ---esee if the valve is closed completely. See if idle adjustment is
within specification.
IsAAC valve operation normal? (CONSULT active test).

AIR-FUEL RATIO?
Make the mixture Use CONSULT active test mode to make the mixture rich or lean or
rich or lean disconnect pressure regulator vacuum hose or apply additional
vacuum.

IGNITION SYSTEM
Ignition timing-......,...-Advance or retard ignition timing and check for any change.
normal?
Ignition misfiring Check crank angle sensor by real time diagnostic method
(CONSULT data monitor).
Check spark plug condition.
Check ignition system condition by real time diagnostic method
(CONSULT data monitor).

EN ·249
 TROUBLE DIAGNOSIS
RB26DETT! RB20E I DE! DET ! CA 181! RB25DE ENGINE

[EO) Unstable idling ......... Aft_e_r_w_a_rm_u_p_._ _ _ _ _ _ _ _ _ _~~_ _ _~

[Analysis]
Relates to various factors including air-fuel ratio. ignition system and compression. It is
necessary to determine factors beginning with items that are easy to check.
o Idle rpm control system .... How is MC valve operation?

• Air-fuel ration ................... Fuel pressure?

o Injection quantity? (Enriched?)

o Air suction?
o Ignition system................. Ignition timing

• Ignition misfiring (Missing signal pulse)

• Engine main unit .............. Poor compression

[Chart]

IDLE CONTROL SYSTEM

Disable control--DisconnectAAC valve connector and check for any change.
function
Control circuit---.- Check if control signal is present and check signal condition.
IsAAC valve operation normal? (CONSULT active test).
Disconnect AAC valve connector and check by adjusting with lAS.
Check AAC valve for seizure.
Check if idle judgment is ON (CONSULT data monitor).
Check circuit for breaks and connectors for looseness.

AIR·FUEL RATIO
Enrich the mixture -CONSULT active test or remove pressure regulator vacuum hose.
OR clamp return hose.
Lean the mixture --Reduce the mixture ratio by using "FUEL INJECTION" in
CONSULT active test mode, or applying vacuum greater than
-500mmHg.
Stop feedback ~Perform CONSULT active test
LOR
Disconnect engine temperature sensor connector and check for
any change .
• Check engine temperature sensor resistance value .
• Check engine temperature sensor output voltage.
Air suction - - Check vacuum line and blow-by hose.

IGNITION SYSTEM
Ignition timing
normal?
Ignition misfiring1 Advance or retard ignition timing angle and check for any change.

Check ignition system by real-time diagnosis (CONSULT data

monitor mode).
Check condition of the crank angle sensor by rea-time diagnosis.
Check condition of the spark plug.

ENGINE MAIN BODY

Compression---Measure compression pressure (Check valve timing, valve seats,
pressure piston rings etc.)
EN -250
 TROUBLE DIAGNOSIS
RB26DETT! RB20E. DE DET· CA 181 I RB25DE ENGINE

(11) Poordrivability ......... Engine breathing.

[Analysis]
It is necessary to first verify if the problem occurs during acceleration or during cruising.
1. During acceleration
• Engine breathing while accelerator pedal is depressed may be caused by
momentary misfiring or momentary occurrence of lean mixture (ie. no interrupt
injection) .
• Inclination of engine during acceleration etc. can increase tension of harness or
air duct that can cause poor contact.
• Clogging in fuel system is cause for engine breathing. Sufficient fuel pressure
cannot be maintained during acceleration.
2. During cruising
• Lean mixture and engine breathing caused by poor feedback of air-fuel ratio data.
• Misfiring of ignition system caused by leaks.
• Poor contact or malfunction of signal system, use of low quality gasoline.

[Chart]
1. During acceleration
AIR-FUEL RATIO
Stop feedback T Perform CONSULT active test
LOR
Disconnect exhaust gas sensor.
Enrich mixture - - Perform CONSULT active test or disconnect engine temperature
sensor and apply 600 0 resistance after warming up the engine.
Throttle valve - - - Check idle judgement ON/OFF operation in CONSULT data
switch monitor mode.
Throttle SenSOf-f- - Check if output voltage varies with throttle opening.
Fuel pressure - - Check if fuel pressure is maintained even while racing the engine.
Air leak Check air duct looseness.
Air flow meter - - - Check output voltage.
output

IGNITION SYSTEM
Ignition misfiring Check signal system (Ignition signal, crank angle sensor signal, air
flow meter signal) for instantaneous break by CONSULT data
monitor.
Check spark plug gap.
Check for any leak from high tension cable.
- Check if ignition coil power supply voltage is lowered.
Ignition timing Check if fail-safe mode is not set due to a detonation sensor error.

EN - 251
 TROUBLE DIAGNOSIS
RB26DETT! RB20E I DE I DET , CA 18: RB25DE ENGINE

2.

Feedback
function
D
When cruising
AIR-FUEL RATIO
Perform CONSULT active test
OR
Disconnect exhaust sensor connector.

:Perform exhaust gas sensor monitor diagnosis to see if exhaust

gas warning lamp (or control unit red lamp) is flashing or check by

LCONSULT data monitor.

Check if exhaust gas temperature waming lamp (or control unit red
lamp) is flashing more than five times in ten seconds when engine
is running at 2,000 rpm, or check by CONSULT data monitor.
Throttle valve - - - Check idling contact point revolution.
switch

IGNITION SYSTEM
Ignition misfiring - Check for instantaneous break signal system using real-time
diagnosis (ignition signal, crank angle sensor signal, airflow meter
signal) (Use CONSULT data monitor or oscilloscope).

I (12) Poor drivability ......... Knocking.

[Analysis]
This problem may be caused by lean air-fuel mixture, incorrect ignition timing or
malfunctioning or engine main unit or cooling system.
• Lean mixture ratio may be caused by fuel enrichment correction not working during
acceleration, incorrect air flow meter output. incorrect air-fuel ratio feedback correction.
• Errors in initial ignition timing or knock control system relate to the detonation caused by
incorrect ignition timing.
• Other causes can be excessively high cooling engine temperature, increased
compression ratio due to carbon deposits in combustion chamber etc.

[Chart]
AIR-FUEL RATIO?
Fuel pressure? - - Check if fuel pressure remains normal when racing.
Enrich mixture ~Enrich air-fuel ratio (CONSULT active test or disconnect pressure
L
regulator vacuum hose).

Stop feedback L Disconnect engine temperature sensor and check for any change.
Perform by CONSULT active test mode
OR
Disconnect exhaust gas sensor connector and check for change.
If any change is noted, check the fuel system (fuel pump, sensor
system or clogging in the system).
Injector clogging - - Clean with engine conditioner.
Idle judgement Is throttle sensor OFF when accelerating?

IGNITION TIMING?
I Is ignition timing normal?
Knock control----rL-check if detonation sensor error is indicated by self-diagnosis.
Check harness for disconnection or shorts-circuit
EN - 252
 TROUBLE DIAGNOSIS
RB26DETT, RB2:JE, JE :;ET CA18, , RB25DE ENGINE

I (13) Poor drivability H"H ... Lack of oLt::JuL poor acceleration, poor response.

[Analysis]
Lack of power, poor acceleration and poor responses are generally caused by insufficient
mixture quantity (lack of fuel, lack of air) or incorrect air-fuel mixture ratio.
In the injection system, these problems are caused by lack of ignition energy or incorrect
ignition timing.
Lack of compression pressure and excessive friction due to seizure in engine main body
are also causes of these conditions.

[Chart]

MIXTURE AIR QUANTITY, AIR-FUEL RATIO

Fuel pressure Check if fuel pressure drops during racing (check for clogging
with fuel pump and fuel system).
Enrich mixture - - Enrich by CONSULT active test or disconnect pressure regulator
vacuum hose.
Stop feedback - - Check for change by CONSULT active test or disconnect exhaust
sensor connector,
Injector clogging - Clean with engine conditioner (CONSULT active test or pour
conditioner into fuel filter, start engine then race engine).
Air flow meter ---Check output voltage.
output

IGNITION SYSTEM
Spark plug? Is plug gap normal?
Ignition timing ---r-Is ignition timing normal?
r
Check by advancing or retarding ignition timing angle,
' - Check detonation sensor for abnomnality (self-diagnosis for
harness disconnection and shorts).
Ignition energy? , - Check ignition coil power voltage.
L Check for any leak from high-tension cable.

ENGINE MAIN BODY

Compression - - - Measure compression pressure (Also check valve liming, valve
pressure? seat contact, piston and rings).

EN - 253
 TROUBLE DIAGNOSIS
RB26DETI i RB20E, DE ' DET ! CA 1ail RB25DE ENGINE

I (14) Engine stall when start driving,

[Analysis]
Engine stall is caused by misfiring when accelerator pedal is pressed or insufficient torque
when starting off .
• Misfiring
• Too lean or too rich air-fuel mixture ratio.
• Large error in ignition timing.
• Weak spark.
• Insufficient torque
• Lean or rich mixture.
• Insufficient intake air quantity.
• Insufficient compression pressure.

[Chart]

SELF-DIAGNOSIS
I Check if occurrence of error is stored by self-diagnosis function.

AIR·FUEL RATIO
Enrich mixture CONSULT active test or disconnect pressure regulator vacuum
hose.
Lean mixture CONSULT active test or apply vacuum greater than -500mmHg
with vacuum hand pump to pressure regulator.
Stop feedback --r- Pe rform CONSU LT active test
LOR
Disconnect exhaust sensor connector (race engine and return to
idle).
Check canister - - Check by blocking purge line.
Throttle valve Check if idle judgement is OFF when accelerator is ON (check by
switch CONSULT data monitor),
----Check engine temperature sensor.
Throttle sensor Check if accelerator opening signal is output

IGNITION
Spark Check spark plug condition (fouling, gap, electrodes).
Ignition timing--- Check if ignition timing is correct.
Ignition error Check by real-time diagnosis (Perform CONSULT data monitor)
High-tension Check resistance value and any leak.
cable

INTAKE AIR QUANTITY

f-I---
1----
Check ifthrottle valve opens normally.
Check lor any leak from turbocharger system. Duct inspection.

COMPRESSION PRESSURE
Measure ----Check valve timing, valves for incorrect timing, piston, ring for
compression damage.

EN - 254
 TROUBLE DIAGNOSIS
RB26DETT'RB20E DE JET CA,g i RB25DE ENGINE

I (15) Engine stall while idling.

[Analysis]
Engine stall during idling may be caused by one of the following conditions. (check idling
speed. and then check for misfiring).
• Improper Idling speed.
• Improper AAC valve control (Check for delayed response).
• Excessively lean or rich mixture ratio.
• Ignition error.
• Poor connector contacts etc.
• Relation to electrical load ON·OFF.

[Chart]

SELF·DIAGNOSIS
I Check if occurrence of error is stored by self-diagnosis function.

IDLING CONTROL
Proper control--,-Is idling speed normal or adjusted?

~
IsAAC valve fully closed? (Check for loose connector).
Close AAC valve fully and check for any change.
Is AAC valve control signal issued?
. (Race engine and check Voltage).
L Is AAC valve operation normal? (CONSULT active test).

t
DisconnectAAC valve connector and check by adjusting lAS.
See if idle judgement is ON.

AIR-FUEL RATIO
Air-fuel ratio ---Check if exhaust gas temperature warning lamp (control unit red
normal? lamp) will flash more than five times in ten seconds when engine is
running at 2,000 rpm, or check by CONSULT data monitor.
Enrich mixture - - - Perform CONSULT active test or disconnect pressure regulator
vacuum hose.
Lean mixture ---Perform CONSULT active test or apply vacuum greater than
-500mmHg with hand pump to pressure regulator.
Stop feedback LPerform CONSULT active test
OR
Disconnect exhaust gas sensor (Set circuit from racing mode one
time and return to idling mode).
Fuel pump ----Check for pump stop.
Fuel system Race engine and check fuel pressure for drop.
clogging

OTHER
Poor contact - - - Using real-time diagnosis mOd, check ignition signal, crank angle
sensor signal and air flow meter signal for instantaneous break and
missing pulses. (Use CONSULT data mode or oscilloscope).
Spark plug ----Check for fouling and plug gap.

EN - 255
 TROUBLE DIAGNOSIS
RB26DETT! RB20E I DE i DET I CA18i I RB25DE ENGINE

(_1_6_)_E_n_g_in_e_s_ta_ll_w_h_il_e_d_riv_in_g_,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ .~
,-I

[Analysis]
Engine stall during cruising may be caused by misfiring. If engine stalls during accelera-
tion, it may be caused by misfiring or insufficient torque.
o Too rich or lean air-fuel mixture.

o Ignition error,

o Incorrect ignition timing.

o Insufficient intake air quantity.

• Insufficient compression pressure .

• Misfinng, fuel pump stop, etc. caused by poor electrical contact.

[Chart]
SELF·DIAGNOSIS
I Check if occurrence of error is stored by self-diagnosis function.
(1) When cruising
AIR·FUEL RATIO
Throttle valve Check if idle judgement goes OFF at correct time.
switch
Feedback Check if exhaust gas temperature lamp (control unit red lamp) will
flash more than five times in ten seconds when engine is running at
2,000 rpm, or check by CONSULT data monitor.
Stop feedback -r-Perform CONSULT active test. OR
LOisconnect exhaust gas sensor connector.
Intake air quantity-Check for poor contact by CONSULT data monitor (real-time
signal diagnosis),

IGNITION
Ignition timing Is ignition timing correct?
Ignition misfiring-- Check ignition signal, crank angle sensor signal for missing pulses
in CONSULT data monitor.

(2) During acceleration

AIR·FUEL RATIO
Throttle valve switch - Check if idle judgement goes ON-OFF when acceleration pedal is
pressed and released (CONSULT data monitor),

Throttle sensor --Check if voltage output varies with throttle opening.

Feedback Check if exhaust gas temperature lamp (control unit red lamp) will
flash more than five times In ten seconds when engine is running at
2,000 rpm, or check by CONSULT data monitor.
Stop feedback -r-Perform CONSULT active test. OR
L Disconnect exhaust gas sensor connector.
Intake air Check for poor contact by CONSULT data monitor.
quantity Check for air flow or leak after turbocharger operation.

MISFIRING
Ignition timing Is ignition normal?
Ignition misfiring --Check ignition Signal and crank angle sensor signal for missing
pulses in CONSULT data monitor.
EN - 256
 TROUBLE DIAGNOSIS
RB26DETT! RB20E. DE. DET CA181! RB25DE ENGINE

(17) Engine stall when decelerating or immediately after stopping.

[Analysis]
Reduced engine rpm when releasing accelerator pedal can lead to engine stall, Another
cause is misfiring.
• Incorrect adjustment of idling control,
• Incorrect air-fuel ratio.
• Ignition error.

[Chart]

IDLE CONTROL
Idling speed - - - I s idling speed normal? Is idle adjustment correct?
Control Check if AAC valve control signal is output
Check if AAC valve operation is normal (CONSULT active test).
Check if AAC valve is OK.
Check if idle judgement is ON.
Check by disconnecting AAC valve connector (AAC fully closed).

AIR-FUEL RATIO
Stop feedbaCkLPerform CONSULT active test.
OR
Disconnect exhaust gas sensor connector.
Feedback ----Check if exhaust gas temperature lamp (control unit red lamp) will
flash more than five times in ten seconds when engine is running at
2.000 rpm, or check by CONSULT data monitor.
Enrich mixture ---CONSULT active test or disconnect regulator vacuum hose.
Lean mixture CONSULT active test or apply vacuum greaterthan -500mmHg
with hand vacuum pump to pressure regulator.
IGNITION
Ignition misfiring - - Check ignition signal, crank angle sensor signal for missing pulses
in CONSULT data monitor.

ENGINE. AfT FUSION CONTROL

Control----- Carry out self-diagnosis.

EN - 257
 TROUBLE DIAGNOSIS
RB26DETT! R820E! DE! DET i CA 18i! R825DE ENGINE

~ .. ~----~-------------------------

I (18) Engine stall when electrical load or power steering load is a_p_pl_ie_d_._ _ _ _ _-'

[Analysis]
Check if idling is increased when load switch is turned ON (AAC valve correction quantity
increases when load is applied) .
• Check If ON signal is input from each switch .
• Check if AAC valve is operating.

[Chart]

IDLE CONTROL
Idling speed ---'L-IS idling speed normal? Is idle adjustment correct?
Check if AAC valve is fully closed.
Control----,--Check if AAC valve control signal is output
Check if AAC valve operation is normal (CONSULT active test).
Check if AAC valve is OK.
Check if idle judgement is ON.
Check by disconnecting AAC valve connector (AAC fully closed).
Input signals ---Check if air conditioner switch and power steering switch signals
are provided (CONSULT data monitor).

EN -258
 DIAGNOSTIC SYSTEM
RB26DE1T, RB2GE C:;E uc, CA' 8 , RB25DE ENGINE

2. DIAGNOSTIC SYSTEM
2-1 GENERAL
The diagnostic system periormance has improved greatly concerning warning indication to
drivers, operation of the self-diagnostic system and application of the newly developed
electrical system diagnostic tester CONSULT,

(1) Enhanced fault warning items

In case when a fault occurs in the ECCS system while driving, the exhaust temperature
warning lamp will flash in the instrument panel to warn driver. At the same time, the back up
function will activate to ensure the safety of the occupants and the vehicle. The warning
items has been increased in recent years.

(2) Simplified troubleshooting strategy

The following features have been incorporated for simplifying inspection and problem
diagnosis of ECCS system,

1. Improvement of self-diagnostic function

The diagnostic modes have been rearranged and the mode shift and display
systems have been simplified.
New system

Fault warning (Same back up as

past display mode)

Exhaust gas sensor monitor

(Same as past air-fuel ratio By diagnostic connector Indicated by exhaust gas
2 feedback display) Installed near fuse block temperature warning lamp
Self,diagnosis (Also adjustable by the (Also linked with control
control unit adjustment knob) unit red lamp)
(The former ON/OFF switch diagnosis
and real-time diagnosis are included in
the operations performed by CONSULT
as explained In item 2 on the next page,

In the past

Back up display

2 Alr,fuel ratio feedback display

Indicated by red or
Adjustment by control
3 Normal self diagnoSIS green lamps on
unit adjustment knob
control unit
4 Switch ON/OFF diagnOSIs

5 ReaJ-time diagnosis

St'lort-circult these termi'la!s tor appro/(.

2 sec 1he(l open the lerr'f'uoals to change
d,agnosl,c @j I I I I EI-I mode

.
-~~~Ii
OOO"ll.Gll I (Fuse ~OO\~:c=
''..,,,-Elill°!lllO~!L , b'OCk) - -- L __ Exflaus! gas temperature
warning lamp

EN" 259
 DIAGNOSTIC SYSTEM
RB26DETI j RB20E I DE i DET i CA 18i / RB25DE ENGINE

2. Introduction of electronic system diagnostic tester for fault diagnosis

To enable use of the newly developed electronic system diagnostic tester
CONSULT the diagnostic function have been modified. It will simplify complex
diagnosis procedures.
CONSULT is a hand held type compact and lightweight type tester device
especially designed for automotive service operations. It can be used by
connecting it to the diagnostic connector installed on the vehicle, This tester can
permits data display. recording and printing.

Same no of items are

Self-
Self-diagnostie posslble as previously
, diagnostle i
I ' described 1
Used to ldentify malor causes of fault
lae,;orejinQ to results of self-diagnosis
IMonltor and print input I output data of control

Dala recording In case of eng one fault or

teneliir1e stall.
iF ormer diagncstic modes listed below are
'included in this monitor Item.
Data
Diagnostic monitor Displays exhaust gas Modes can be Displayed
mode i Exhaust gas sensor sensor output voltage selected by data can be
momtor and lean or rich touch-senSitive read on the
mixture keys on CONSULT
CONSULT screen
Same as previous
SWitch ON/OFF
function
Same as previous
Real-time dlagnosls
function
Used to examine major causes of faults
I"r.(:nrrllng to self-diagnosIs results and data
Active test momtor ~'
I Used to check actuator operatIon by giVing
driving Signal to the actuator :
Work Used to reduce additional operation when
Supplement
support checking Idling etc .

EN -260
 DIAGNOSTIC SYSTEM
RB26DETT! RB20E! DE, DET ! CA 1811 RB25DE ENGINE

~il}' ::::::::: "MOC 0 g 0

I,: . .'•.'•. •. . v~, ,,~,~ 0
speed sensor

::_.1.. '. Batle~ voltage 0

[ ' Throttle sensor 0 0 0
I,id;'">:~-------------------+--------+--=--~----~~~
;1,<)I~\jl':
;;,1 Idle position 0 0 I
Intake temperature sensor 0 0 i

1,,';1,'1,;': Detonation sensor 0

I!';~:;< ,"< ~nition switch (Start signal)
i<li'"t""~r)""" Air conditioner, neutral. power steering
. " , 011 pressure SWitch, electnc Icao switch

I. "', M iT Signal

FICO solenoid (CA18i)

'.?II"I,I'

PTC heatsr (CA 181)

EN - 261
 DIAGNOSTIC SYSTEM
RB26DETT ! RB20E! DE I DET ! GAlS,! RB25DE ENGINE

2-2 SELF-DIAGNOSIS
Self-diagnosis can be performed by indications from warning lamp (exhaust gas
temperature warning lamp) in instrument panel display and ECCS control unit red lamp
display, or by displaying data on the CONSULT screen.

(1) EXHAUST GAS TEMPERATURE WARNING LAMP DISPLAY

There are two diagnostic modes. In each mode, diagnosis is pertormed by operating the
diagnostic connector terminal installed on the vehicle. (Diagnosis can also be pertormed
using the adjustment knob on the control unit). The diagnosis results are displayed by the
exhaust gas temperature warning lamp in the combination meter and the red waming lamp
on the control unit.

Basic operation and indications

~~~~~ Alarm
Faulty system indicated by
ignition switch ON
Fau~ warning ~ i warning lamp flashing
Engine rotation . NormaL warning lamp remains OFF

Ignition SWitch ON
j i Fault. Faulty system IS indicated by
DiagnoSIS mode shift , flashing code
Self-dlagnosis . j Normal: Flashing code "55"
Engine stop
(with igninon switch ON) displayed

Se~-diagnosls status
Exhaust gas sensor I
descnbed above Lamp ON means "lean" mixture
monitor j Lamp OFF means "rich" mixture
Engine rotabon

(1) Fault warning mode (Mode 1)

Indicated by exhaust gas temerature warning lamp In instrument

panel and red lamp in control Unit (these lamps are linked together).

Engine
Display Condition
rotation

Stop ON (lamp check)

ON ON 1 sec CPU backup (Lamp .
[i(:i"~;'I:~~;:~, the se~-diagnosis OFF Of'FJLrLrL1 sec.
flashes when engine is
. OFF)
will be executed. In
this case, the self-diagnosis Warning ON ON~' r Crank angle sensor
mut be selected (see Rotating OFF OFF,J L---.J backup
" 3 sec.
(2)]
1 sec, Throttle sensor
g~F ~dLJ1Jl backup (lamp flashes
1 sec. when engine is OFF)
OFF ON (lamp check)
Nennal ~----~----~.
Rotating OFF .._ I

EN - 262
 DIAGNOSTIC SYSTEM
RB26DETT i RB20E 'DE DE" CA 18, i RB25DE ENGINE

(2) Self-diagnostic mode (Mode 2)

Turn ignition switch ON. Iinclic81ted by exhaust gas temerature wamlng

Normally fault warning mooe IS set wner. Ignition lamp in instrument panel and red lamp in
sWitch IS turned ON It is necessary to select Icemtrol unit (these lamps are linked together).
diagnostic mode.
Short circuit CHK and IGN terminals connected on
the diagnosis connector located on the vehicle Example: IndIcation of code number "43".
(near the fuse box) for approx. 2 seconds then
separate the terminals.
(Diagnosis connector)
RX TX HI-: IG~
;- 0.4 sec. x 4 ;- 0.2 sec. x 3
Ie ") LH

(The fault warmng mode and sell-diagnosis mode

:;FU~1JL~J~J ~ 0.4 sec. x 3 0.2 2
Approx. 12 sec.----i
alternate each time the operation is performed)
Stop the engine. (igmtion SWitch in ON position). ~
the engine IS operated In thIS condition the exhaust
sensor monitor win the next mode is activated.
diagnostic connector terminals
CHK: Diagnosis start (Check) RX: Control unit data reception
IGN: Ignition power supply TX: Control unit data transmission
ClK: Transmission synchronization signal (clock)
GND

Ic:!J' .·1 D~,-;"f~Cj;~'j~'E;:,~~~"i::;;~(;:l;.:~;:'j:fJ::::..,,;~, : .. ,,~ "I

~ ..:". Crank angle sensor 1'signla or 120' is not input for a certain period of time

, )"
i;'::' :.
~''''~, system
after starting the engine.
Incorrect signal waveform.
0 0
I't. Hot wire disconnection.
I j~' Disconnection or short-circuit in air flow meier power
I ;; .I·~· hi_· . supply line. ground line or signaal system.

1.t.:::'l;:.2'~;·;"'!'sMV!"",..tf,eIO'TIw meter signal •Signal output is below 0.5 V for a certain penod of time
1./ I ~lm~' i during engine operatiOn.
o
IH ; :
I Signal output is over 2 V with engine stalled. or when
ignition switch is in ON from OFF. i
'.~.
.;,
.;: ,~
temperature !Brake or stlort-circuit in engine temperature sensor
. signal system, signal system. o o
:J;i ill Air-fuel ratio learning IAir-TIJe l ratio is lean towards enrich side for a long
control of time.
Ignition signal
system
>;!'
~o, »v,
,,,,v,, signlal is not generated even though crank angle:
signal is entered. I o o
:.~
>i;... Detonation sensor
signal system
Disconnection or short-circuit in detonation sensor
signal system . o
•.;~~
.':;~
Intake temperature Disconnection or short-circuit in Intake temperature
sensor signal system senSOr Signal system. o
Throttle sensor
signal system
DisconnectIon or short-circuit in throttle sensor signal
system. o o
'.f!: IC' A i T transmiSSIon
f: "e",
DisconnectIon or short-circuit in AfT transmiSSion
system. o
iX:~~~.,"
[<;:'1ll,,1"" error
No abnonmality found in any of the above SIgnal
o o
EN - 263
 DIAGNOSTIC SYSTEM
RB26DETI! RB20E / DE! DET! CA18, F.B25DE ENGINE

How to erase memory

(a) Stop the engine in mode 2 and short-circuit terminal "CHK" and'IGN" of the
diagnostic connector for over 2 seconds. Then disconnect to erase the memories.
(the memory is also erased when the self-diagnosis mode is switched to fault
alarm mode).
(b) When method (a) is not used: If the ignition switch "START' operation is performed
successfully 50 times, the memory will be erased automatically.
(The memory will be erased automatically every 50 "START' operation of the ignition
switch).

(3) Exhaust gas sensor monitor mode 2)

ignition switch to "ON" position. Indication

IS made by tOe warolng la'11p (exhaust gas

1[l';ICt,8Ckthat self-diagnoSIS mode is set temperature warning lamp) on the instrument panel and
the red lamp on the control unit
1. Durirg air-fuel ratio seedback control:
OFF: when 8"""usl sensor output is "RICH"
ON: when exhaust sensor output is "LEAN"
I (Referencel The lamp ON and OFF indication ,s the
as that of lhe all-fuel ratio feedback correction
Icoefficent ",dicated by lhe red lamp in the former
2
I unit.
Wher. air~fuel ratio feedback control is clamped:
mode can not be changed when engine is The status immediately befo'e c!aMplng IS
maIntained,
loDel·ati.no. After warming UP the engine.
When air-fuel ratio feedback control is faulty: OFF
limore"se the engine speed until exhaust gas i I example:
:It.emperature warning lamp (or corrtrol unit lamp)
Ils,tarts flashing (approx. 2000rpm) and exhaust
gas sensor output (R) mode IS set.
ON {Lean) n n il
OFF {RICh~,-htl L...J

- - . {Lean: AiA+B x 100

1 cycle dt;ty raM Rich: 8!A+8 x 100
ai r-ruel ratio feedback control is clamped
idling. check by pressing the accelerator The status of the air-fuel ratio IS indicated by the duty
ratiO In one cycle.
pedal slightly. S·gna! thaI SWItches
In this condition check that exhaust gas Exfl.."luSi gas sensor and Exhaust gas
temperature waming lamp flashes.
nL---
Exnaust gas sensor {R; sensor output mondor

Connect terminals "CHK" and "IGN" of the

dic,on,osl:ic c,onnector for over 2 seconds then
isc()nr>ect..The exhaust gas sensor ,output
ON (Lean) I
OFF (Alctlj;
L,,-, ,
,, Iw...c,~
l
0.2 4 -;?l
nIL
is SWitched after exhaust gas
Sigrai trat switches
temperature warning lamp (or red lamp in Ext'aust gas sensor (vfd Exhaust gas ,
I unit) flashes 2 times.
g~/~ifill:~qrum:{s.nsorJtmOnljor
I I f Ct2 ~.

4 sec.
,~-.. ..-

EN - 264
 DIAGNOSTIC SYSTEM
RB26DETT I RB20E i DE! DET i CA 181 I RB25DE ENGINE

(2) CONSULT DISPLAY SCREEN

Connect CONSULT to the diagnostic connector on the vehicle (near fuse block). Data is
displayed on the CONSULT screen as touch-sensitive key. The exhaust gas sensor
monitor. switch ON/OFF operation and real-time diagnosis are performed using data
monitor mode.

connector /1
,, =TIlI
, " : !i
q

(1) "Self-diagnostic" mode

The diagnostic items are same as (1) (2). Faulty system name is indicated,

~s,'
1 Connect CONSULT to diagnostic connector r"---SELF-DIAG
, RESULTS
.,1 Numos, of times
of vehicle,
i FAiLURE DETECTED TIME the vehicle has
2 Place Ignition switch to ON.
i ENGINETH,,1P SENSOR 0 r
"
,
oeen d riven Since
detec!!rg the :as!
, problem. if same
3 Inspect wlth "Self-diagnosis' mode.
proolem is still
oresent "0·· is
4 Touch "PRINT" key to print, Touch "ERASE" i displayed.
to erase data. L ERASE ..~~.~

EN - 265
 DIAGNOSTIC SYSTEM
RB26DETT! RB20E! DE! DET i GA18i I RB25DE ENGINE

2-3 FAIL-SAFE FUNCTION AND BACKUP FUNCTION

The fail-safe function ensures the safety of the driver and the vehicle by using the control
U'lit control signals in case of an error in an important system device.
Tr,e back up function ensures normal vehicle operation when an error occurs in an
Important sensor. The control unit will ignore the signal sent from a failed sensor and
outputs prearranged control signals.
The fault alarm mode is set when the backup function is operating and exhaust gas
temperature warning lamp will flashes in the instrument panel to warn the driver.

I t:xnaUSl gas
Fix Ignition timing at warning
\Nhen detecti ng error 10
o ,0
!
CPU backup internal circuit of control
unit
specIfied value lamp ftashes in 1-sec
Fix fuel injecfion at start- interval
: time. idling and drilling i Reduce speed when
!

i : CPU IS performed

C!<I'.U>lgas
When crank angle
/ternperatUire warning
sensor Signal (1' or
. RB20E Crank angle Fix ignition timing at lamp flashes 10
! ::mly sensor backup 120') is not displayed . specified value 3-sec 1f1terval ("11" IS
: for more than 3 seconds
i i ndleated In self-
! when engme is started !
: dlagnoS! s mode)
i
~ VVhen intake aIr quantity: Fix ignItion rnjectio~
i ("12" IS Indicated In
Signal IS dIsconnected pulse v.dth at specified
0 0 Air flow meter i

engine operanon
i
value
Fuel cut at 2400rpm
. seW-diagnosls mode)

Engine snon-CirCUlt€O or I normal engine ("13" is indicated in

0 temperature se~-diagnosls mode)

! maXlmb!1m 5f! engine IS

\'Vhen Sl1Ort-Clfcuitea Of ("34" is Indicated in i

0 0 Detonation sensor in knock control

se~-dlagnosis mode)

Exhaust gas
VVhen short-clfCUlted
temperature warning
l(arJprcbx. O.2V max) or I cut at 3200rpm
o o o Throttle sensor
backup
i (approx.
5V min) dUring engine
Controlled by engine rev
and the vehicle speed
lamp flashes in
1-sec interval
("43" is indicated in '
operation
i self-diagnosis mode) I

EN - 266
 DIAGNOSTIC SYSTEM
RB26DETT! RB20E . DE DE ~ • CA 181 i RB25DE ENGINE

2·4 DATA MONITOR

The data monitor can be utilized when performing troubleshooting or trouble diagnosis
according to self-diagnosis result. GONSULTwili monitor and print the EGGS control unit
input and output signal data.
(1) Monitoring items and description

o o CAS RPM (POS)

i
rpm
El"gme rpm calculated 7rom POS (10) or
RE F <; 1800) signal sent fiorr era nK
- !

A-C-CU-",-c-.Y-S-lig-m-.I-Y-Io-we-.-re-o-a-I--'
o RB20E CAS RPM (REF)
only angle sensor
f-I

:less than Idle speed i

o o AR FLOW ~ETER V Air flow meter outp:Jt voltage

Voltage IS set at approx. OV
when engllle IS stopped
I If dlsconne-ctH)'" or srort~IrCUH i
10 1
o ENG TEMP SEN C
Engine temperature value converted occurs in sensor CI(cui:, fall-safe
from engine temperature serlsor vottage is activated and engine temp is
fixed at a cerium IelRt

o o o "XH GAS SEN

EXH GAS SEN (R)
v Exhaust gas ser.$Of outPut vortage
Sensor outpJl is fixed at OV
..vhe'l engine is s~opped

Alr-fLe! ra;IQ of exhaust gas sensor

i 51gr:a1 d\XIng air-fuel ralJo feedback
~ -RCH { comr~L
o o o f'lfR ;::!C MNT
MJR FtC :-JNT (R)
If cran:p OCCl.TeS the status iJSt
; (LEA\I) RICH Detects rich mixture and :Onlrol before clamp OCCiJrance is
,IS :::perated 10 reduce m1xtLtre ratio 1r)(lICa(eC
LEAN' Detects lean mixture and control:
is operated to Iflcrease mixture ratio

oo 0 CAR SPEED SEN

km J h Value calculated from vehicle speed
sensor signal 1

0oo BATIERYVOLT v ECGS control unit paVler supply voltage i

1 0 o o THROmE SEN
V
Th;ottle sensor output voltage
CA 18i { Throttle sensor Signal 1
o cHRomE SEN (2) : Throttle sensor (2) . S,qnal 2
I
The value converted from lf1ake Fai; safe IS activated If

I
o IN"': i A TEMP SEN 'C temperature sensor output voltage to
inake temperature
disconnection or snort-circUIt
occurs and set to this value_
I'

"OFF~ is iooicated mcspectlve

o o
i
iSTARTSG of starter signal after staftng

o 0 o IDLE POSmON 1

,i 0 v~, 0 AIR CON;:) SIG

,'--=--1---=,-1--=--1-------..., I' iON! ON I OFF se''''g IS detem1lned fcc",
OF F) each signal output
10 0 0 NEUTRAL SG

,0 0 0 PW/Si SIGNA~

o ELECT FAULT SIG

o o o lNJ PULSE msec Va:ue cOMputed by control uri!

A vaiue is indica lee '.\li1h engine
stoppeo
. BlOC
0 1
0 IGN TIMING ((.) : Value is computed by wntrol umt

Value computed by control unil : A fixed value is indicated with

Me VALVE "%" proportional soleno:d system engine stopped
~~~------~------1

o ,0 'A I F A;..FHA :rv1ear value of air-fuel rata feedback

! 0 A! F ALPHA, (R: i correction factor tor each cycle

o C' 0 AIR CO NO REi_AY i

1-0-=--+-0'-+--0'-+FU-E-L-P-U-~-1P-R-E-LA-y--1 OFF)
(ON i Icol'ltrol corx:htlon comptJI:ed by control
lu""

o ,'N I G CONTS IV ,. !
ON Corn:;ct;on"
ON! : Control condition :passag~ open
O I' FC:JS/V
i ( ,'corrtroliedbycontroliOFF,C,--,ITectlon
OFF) llnjt :passage "closed~ ___:
i
~-I--0-+---1--------1
PTe HEATER
I
toN - 267
 DIAGNOSTIC SYSTEM
RB26DETT I RB20E I DE! DET I CAtBi I RB2SDE ENGINE

(2) Operation and display

'$TEIl'
'
}:;"-; '"
.~

";'!'~ERAmN
- - ""-,---
"," ; ,"-
'~r ,'" ri.",i'OISPiJlY{El!am~~.'r: ;" ~-,

1 Connect CONSULT to diagnostic connector

on vehicle.
I"i'rMONITOR'{;; NO FAIL
; CAS. RPM (POS) 687rpm
cr
IAIRFLOWMTR t.08V
ENG TEMP SEN 70°C
EXHGASSEN 030V
2 Run the engme or drive the vehicle. EXH GAS SEN MON LEAN!
CAR SPEED SEN Okmlhi

I RECORD I
3 Select desired item on "DATA MONrTOR".
I*"ONITOR4•• \;0 FAIL
I
l:J
;CAS. RPM (POS) 685 rpm
iAIR FLOW MTR 1.06V
4 Press RECORD" key. i ENG TSMP SEN 80"e
'EXH GAS SE" O.35V !

EXC; GAS SEN MON LEAN I

,CARSPEEDSEN Okrn/h '
'BATTERY VOLT 13_8V !
I

RECORD i

(1) Exhaust gas sensor monitor

Exhaust gas sensor output voltage and RICH I LEAN status are displayed.
,~ ...~,,,,,;,·,i!!';!··'ft!1g·Ji~~~~)~~!t~!)i,
1 Connect CONSULT to diagnostic connector,
on vehicle. f1'MONITOR'{;;NO FAIL l:J
: EXH GAS SEN O.t8V
2 Run the engine.
IEXH GAS SEN MON RICH
3 : Select EXH GAS SEN, EXH GAS SEN-R,
MIR FIC MNT and MIR FIC MNT-R items L '

on "DATA MONITOR". I'

~~LP~r~e~ss~R~E~C~O~R~D~"~k=e~y. _____________ ll'__~~========;=R~E=C~O~R=D=========J~"__J

(2) Switch ON ! OFF.

The ON I OFF status of each switch is indicated.

1 Connect CONSULT to diagnostic connector

on vehicle.

2 Run the engineor drive the vehicle.

EN - 268
 DIAGNOSTIC SYSTEM
RB26DETT / RB20E' DE· DET· CA1S,! RB25DE ENGINE

Diagnosis item
(1) Ignition switch START signal system
(2) Throttle valve switch (idling connection) signal system
(3) Neutral switch signal system
(4) Power steering switch signal system
(5) Electric load signal system (CA 18i)

(3) Real-time diagnosis

Although the diagnosis items are same as those listed in 2-2 (1) (2) self-diagnosis,
and switch ON/OFF in section 2-2, this diagnostic mode provides higher detection
capability than the self-diagnosis mode (2). But it doesn't diagnose intake
temperature sensor signal system for CA 181.

.' · . !·.·~·~~iel?
STEP •••• '. .. OPERAllON .......... :) ~~i(~~~ ,:
1 Connect CONSULT to diagnostic connector
on the vehicle.
I. REAL-TIME DIAG. nl
ENGINE TEMP SENSOR .
2 Run the engine or drive the vehicle.

3 ! Select deslred items on "ACTIVE TEST

menu.
! _. ___. _J
--------1111
•.. DATA RECO~D (MEMORY1)
4 Press "START' key and input set value. ;~EM.;RY[iiATA[)ISPLAYI

EN - 269
 DIAGNOSTIC SYSTEM
RB26DETT I RB20E, DE I DET I CA1S, i RB25DE ENGINE

2-5 ACTIVE TEST

The active test mode is utilized to examine the problem diagnosis according to self-
dlag~osis results and data monitor results, CONSULT will give driving signals to the
acwators while isolating the on-board ECCS control unit, to check if the actuator is
functioning normally,

(1) Test items and description

Some test items may not apply to all vehicle modes.

Fuel-injection Changes air-fuel ratio o o

AAC valve opening Sets control value (opemng) o o
Engine teperature Sets engine temperature o o o
Ignition timing Sets delay angle correction value o o
Idle correction S I V o
FICO S IV Turns ON IOFF o
Fuel pump relay o o
Clears learned data on air-fuel ratio
Self· learning cant
feedback correction factor o o c

(2) Operation and display

1 Connect CONSULT to diagnostic connector

on the vehicle,
I. ACTIVE TEST .C;
FNGINETEMP -2'C Sating value
2 Run the engine or drive the vehicle, I
bAs, RPM (POS) 112rprrJ
,INJ PULSE 7,3 ms Data mO'litor
3 Select desired items on 'ACTIVE TEST'
~IGNTIMING 25BTDCi
menu,
Setting value
increase and
Press "START" key and inPut set value, decrease '<eys,

EN - 270
 DIAGNOSTIC SYSTEM
RB260ETI ~B20E :E CA 181 RB25DE ENGiNE

2·6 OPERATION SUPPORT

CONSULT can be used as an aid for idlng checks and other engine tune-up operations, It
issues instructions to the ECCS control unit to perform control and displays the input and
output signal data being used, Actual tune-up operations must be performed manually by
the mechanic (for example, turning adjustment screw etc),

(1) Support items and description

Fully closing idle rev correction solenoid and

Idle rev ad)
displays idle rpm speed Oi
MC valve adj Fully close MC valve and displays idle rpm o o
Idle SWad)
Displays engme rpm when Idle contact point
changes ITom OFF to ON by fully closing MC valve
o
Fix Ignition timing feedback control and displays
I Ignition timing ad)
ignition timing
o I
Fully closes thronle valve and displays throttle
Throttle sensor ad)
sensor output vonage o o
Stops fuel pump operation and stall the engine
Fuel pressure release (crank the pedal 10 release fuel pressure Within the o RB20E
fuel PIPing)

(2) Operation and display

1 Connect CONSULT to diagnostic connector +GN TiMING ADJ.

on vehicle, PRESS "START' WHEN iDLING
AND STOP IGNrTlON TIMING
FEEDBACK CONTROL
ROTATE CRANKANGLE
2 Run the engine SENSOAAND LSE TIMING
ILlGHTTOADJUST
3 Select deSired ilem on "WORK
SUPPORT' menu

+GN TiMING ADJ.

4 Press "START' key and execute operation. fGNITION TiMING FEEDBACK
FIXED

CAS, RPM (REF) S7Srpm

GNl1MING 12BTDC I
IDLE POsrriON ON

EN - 271
 BASIC INSPECTION
RB26DETT I RB20E I DE / DET / CA18, ENGINE

3 BASIC INSPECTION
Inspect three elements of combustion (1. Is fuel injected? 2. Does the spark ark? 3.
Does the AAC valve work correctly?) and determine if the faulty system is the fuel
system, ignition system or idle control system.

3-1 Injector operation inspection

• Check for injector operation noise (click, click, click)
while cranking the engine by placing stethoscope or s
crewdriver on the injector.
IF NG: Inspect injector control circuit.

3-2 Fuel pump inspection

• Connect CONSULT to the diagnosis terminal on the (if)
vehicle side (near the fuse block). I.J!!V

• ACTIVE TEST • 0
• Turn the ignition switch "ON" and select the "ACTIVE FUEL PUMP RELAY ON

TEST" mode. Press "Fuel pump relay" and check for CAS. RPM (POS) 9S0rpm
pump operation noise.

I ON "ON/OFFII OFF I

3-3 Fuel pressure inspection

(1) Simple inspection
• Pinch the hose between fuel filter and fuel gallery when
the fuel pump is operating. There must be tension and
pulsations in the hose.

EN - 272
 BASIC INSPECTION
RB26DETT I RB20E; DE! DEI! CA 181 ENGINE

• Run the engine,

• Select "FUEL PUMP RELAY" in the "ACTIVE TEST' l' • ACTIVE rEsT • q
mode, \!!J FUEL PUMP RELAY OFF I
• Press OFF switch to release fuel pressure. CAS. RPM (POS) 950rpm

(2) Inspection using fuel pressure gauge

Fuel pressure release tth
• Remove the fuel pump fuse after starting the engine. ~
Crank the engine 2 - 3 times to consume all fuel in the
fuel lines.
• When engine will not start, remove pump fuse and crank
engine 4 - 5 time to consume all fuel in the fuel lines.
Caution:
Use booster cables to connect it to another vehicle or
charged battery if the battery become weak.

Fuel pressure gauge installation

• Connect the fuel pressure gauge between the fuel
strainer and the fuel gallery.
• Install fuel pump fuse.
• Start the engine and check if the fuel pressure reaches
standard value.

Fuel pressure inspection

Approx. 3.0 Approl<. 3.0 Approx. 1.0

• For the vehicle with starting problems, turn ignition switch

ON and check fuel pressure for 5 seconds when fuel
pump is rotating.

Approx.3.0 Approx 2.5 i Approx. 1.0

I

IFNG;
Fuel pressure is abnormally high:
Fuel pressure is abnormally low:
Pressure regulator is faulty.
Return system is clogged or hose is bent.
Pressure regulator is faulty.
Fuel pump output is faulty.
Fuel supply system is clogged.

Fuel pressure should also be checked when the engine speed is increased.

EN - 273
 BASIC INSPECTION
RB260ETT I RB20E ' DE I OET i CA 18. ENGINE

3-4 Spark inspection

(1) In case of SOHC
• Disconnect one of the high tension cables connected to
the spark plug and connect it to spark plug unit. Bring
spark plug closer to engine main body (disconnect
ground cable) and crank the engine to see if the spark
arcs (check with every cylinder).
• If it doesn't spark with any of the cylinders, install spark
plug to the centre cable and carry out the spark
inspection. If the spark arcs there is a possibility of fault
with the distributor system.

(2) In case of DOHC

• Measure the voltage with a test prove at power transistor
coil side terminal for spark signal of the primary system,
Terminal 1 - 6 when cranking engine Approx. 9.SV

• Primary system check can also be performed by timing

light or tachometer needle deflection,

• To check if sparks actually arc or not, remove ignition coil

(No, 1 cylinder is easiest), Connect spark plug and
place it against collector or other part for ground, Check
if spark arcs when engine is cranked.
If NG: Inspect ignition control system,

3-5 AAC valve operation inspection

• Start the engine.
!. ACTIVE TEST •
IIMC I V OPENING 16%
MONITOR
0
'CAS,RPM (POS) 950rpm
• Set any angle in the "AAC valve opening" items in AIR FLOWMETER Q,93V
"ACTIVE TEST' mode. AIR FLOW METER(R)O,88V
• Check if idle speed at this time varies from set value, ENG TEMP SEN 87e C

lou I UP :1 OWN !Iad I

• After warming up the engine check if idle speed lowers
from specified value when AAC valve connectors are
removed.

RB26DETI RB20 (SOHC) RB20 (DOHC)

EN - 274
 BASIC INSPECTION
RB26DETI I RB20E! DE, DET I CA18! ENGINE

3·6 Air regulator operation inspection

• Start the engine when cold and check if the idle speed lowers when air regulator hose is
closed or partially pressed.
• Start the engine when cold and check if specified idle speed will increase after AAC
valve connector is removed and engine warms up.
• Connect AAC valve connector and warm up the engine sufficiently.
• After warming up the engine remove AAC valve connector again and check if idling

RB26DETT RB20 (SOHel RB20 (DOHC)

3·7 Intake manifold vacuum

• Inspect the vacuum when idling after warming up the
engine.

RB26DETT, RB20DET Approx. -480mmHg

i RB20E. DE Approx. 1510 mmHg

CA18i ·500 - . 550 mmHg

• The vacuum value will be abnormal if there are air leaks

or other problems with combustion or main engine body.
Locate and correct the cause of problem.

EN -275
 BASIC INSPECTION
RB250E ENGINE

3 BASIC INSPECTION
1 ,:.1_ _~ _ _ _ _ _ _,
Before engine start
Look for fault indication and check recent
se rvice record,
::: ~eck the following in the engine bay
IS harness connector connected
:::r:ectly?
,5 ;~ere any cracks or torsion on
vacuum hose? connected correctly? 2
Is harness connected correctly with no /' Connect

'----
disconnection,
....~."'r
'\
Diag~osls
2
'" h connector
Connect CONSULT
--
z)?( (behind fuse boxl
'I
, "
, Cornect diagnosis connector to CONSULT i CONSULT
//'
and olace Ignition switch to ON position,
. Select "ENGINE" from the item menu,
. ! ._-----' 3

"

~3~~~~~~nl~N~G- To 6
I Does the engine start?
OK
4
Idle adjustment screw primary stage 4
set up revolution inspection ®
• Select "AAC valve adjustment" ~
mode in "OPERATION SUPPORT",
. • Check that engine rpm will drop to NG
600 - 700 rpm when "START" is
pressed (N range),
• Check that engine rpm will drop to ftt'\!
600 - 700 rpm when ECCS C I U ~,
adjustment volume is turned right until
it stops, i~ONITORilNO FAUtlIJl
CAS,RPM (POS) 787rpm i
CAR SPD SEN Okm,h

OK
For engine rpm adjustment use
idle adjustment screw,
L .~
-
===
START
.. -~ .. ~"-'-----
To5

EN - 276
 BASIC INSPECTION
RB25DE ENGiNE

5
1 Ignition timing inspection

: Afterwarming up the engine, idle the engine

and inspect the ignition timing using timing
light For more information refer to "Idle rev, I NG
ignition timing, air-fuel ratio inspection" section. '
earlier in the manual. i

Ignition timing (BTDCo): 13 - 170

6 _ _ _ _---,~
OK Rotate crank angle sensor 1+ THROTILEADJ +Ci
to adjust ignition timing. ,ADJ MONITOR I
6 iTHROTILE SENS
Throttle sensor idle position inspection iMONITOR
• Select "THROTTLE SENSOR AOJ" ffJ\: ICAS. RPM (REF) Orpm'
from operation support mode. ~ IDLE ON

• Check that throttle sensor output voltage is

approx. 0.4 - O.SV (fully closed) and Idle 6
position IS ON.
• Use voltmeter to measure throttle AEt\

:~
sensor output Voltage. Make sure it ~
is between approx. 0.4 - O.SV (fully closed).

7 I •
Switches input Signal inspection 7
Select 'ollowing SWitches in "DATA MONrrOR" mode. !w10NITOR-.:NO FAUcr -,
a) Start signal
b) idling 'STARTER SiG OFF
c) A/C signal 'IDLE ON
d) Neutral SW .Ale S!G OFF

@:
e) PWRIST Signal I INEUTRAL SIG or,
Disconnect ECCS C/U and use vottmeter to mspect SWitch
ON/OFF operations.

. . . :S~ .. ljs .··.¢~~dillOri' L::-f{}fi I"

x;'.,'' -; ,:~I1I,i~iVj{.':"l' , 7
:
Ig nilion SWan
!~
:
: Start signal 0 Power supply voltage i
Ignition SW start
i l;{;
Idling after warm up
Idling Power supply volgate 0
accelerator depressed •

,A/C off
AIC signal
: A/C on
!
-
7,0 10.0 0.5 - 07 :

N. P renge !
I Neutral SW N. other than P
a 8.0 - 10.0
i
I
!
PWRIST off
PWRISTslg 8 0
PWRISTon
i i 1

OK8

EN - 277
 BASIC INSPECTION
RB250E ENGINE

8 8
Self-diagnosis result confirmation . ~-~El F::O,AG'NOS,S) U
• Operate "SELF-DIAGNOSIS RESULT" mode. ' NG IFA~LT SYSTEM
• Confirm self-diagnosis results. : ENG -EMP SENSOR 0 "
• Is there any problem?
• Set to "SELF-DIAGNOSIS MODE 2".
• Check the code number by exhaust gas
PRINT
temperature warning lamp or ECCS C/U red
lamp. a
;. Is there any problem?

OK ICarry out applicable i

iprocedure '
9
Injector operation inspe~tion I
I
. Place a stethoscope or screwdriver on the injector i NG
I, and check for injector operation noise (click, click, ' 9
! click) while cranking engine.

OK ICheck injector control

circuit
10

I"
Fuel pump operation Inspection
Inspect by "FUEL PUMP" in "FUNCTION ~;
(B\ I
TEST' mode or "FUEL PUMP RELAY" in i
10
"ACTIVE TEST' mode. Check if you can hear
NG ' . ACTIVE TEST • .'
fuel pump operation noise when "OPERATE" I
i FUEL PUMP RELAY ON!
is pressed.
MONITOR
• After turning ignition switch "ON", check
for fuel pump operation noise for 5
seconds.
®, CAS.PRM (REF) Orpm

-----o-K~I----C-h-e-ck fuel pump control i 10

'-,:.r~--<-·---····--·
circuit ' I (Operation ·L--:.:-...=.....--.....·,
(noIse A) /;Y0-,,, ""
~.J,-:~.~/ \\ .\~,
, __Q";:::-:\~~ "\"u\
r.1~1~_.____~__~.~1_____________-'1, I
; ' , , I f / f J ,g~
? --Jl-
, , '\
Fuel pressure inspection \"0 -~\;:y f
When the fuel pump is operating, press the hose NG ~ ,/'7 J
--.,--/
\\'\. ¥
i
~~ i.-'

between furl filter and fuel gallery with a finger.

There must be tension and pulsations in the hose.
11
OK;
ICheck fuel supply system I
~clog, twist orbend. I~ 'i:~W:::.::=;;:Fue~ filter I
.---~----~ U I
Finish __~
L -_ _~.=- I
has pulsation

EN - 278
 SYSTEM FIGURE & CIRCUIT DIAGRAM
RB26DETT.' RB20E I DE i DE"- . CA 181 i RB25DE ENGINE

4 SYSTEM FIGURE & CIRCUIT DIAGRAM

Wireless equipment
• When installing CB ham radio or a mobile
phone, make sure to observe the fOllowing
pOints as it may affect electronic control
system depending on its installation position.
1. Keep the antenna as far as possible away
from control unit.
2. Keep the antenna feeder line more than 20 Control unit
em away from the control unit harness. • Do not disassemble control unit.
3. Adjust the antenna and feeder line, so that • Do not turn diagnosis mode selector
the standing wave radio can be kept small. switch forcibly.
4. Make sure to ground the radio to vehicle • If a battery terminal is disconnected,
body. the memory will return to the initial
setting value.
Battery
• Only use 12V battery as power source.
• Do not disconnect battery cables while engine
is running.
• Do not disconnect injector harness connector
while engine is running.

ECCS parts handling Fuel pump

• Air flow meter must be handled with
care to avoid damages.
• Do not clean air flow meter with any
type of detergent.
• Slight leak in the air intake system
can cause serious problem.
• Do not apply shock to crank angle
sensor.
When starting
• Do not depress acceleration pedal
when starting.
• Do not rev up engine unnecessarily
immediately after starting engine.
• Do not rev up engine just prior to
shutdown.
• Do not operate fuel pump when there is no
fuel in lines.
• Make sure to tighten fuel hose clamps to the
specified torque,
Control unit harness handling
• Securely connect ECM harness connectors.
• Poor connections can cause an extremely
high (surge) VOltage to develop in coil and
condenser.
• Keep ECM harness at least 1Ocm away from
adjacent harnesses to prevent ECM system
malfunction due to receiving external noise,
degraded operation of ICs, etc.
• Make sure to place ignition switch in "OFF"
position and then disconnect battery ground
cable,

EN - 279
 .....,
,J::.

_,...~~'lb
I\
Air regulator ~:1~~=ft:~==================A~~A~C~V~"~IV:"-'~--
_ Reelle I . M
u all011 valve
- - - signal
con.rol eery
From b"U
voitage
switch
(f)
<
(f)
-f
m
Ic Ixture control $1' na! _1' 5
POWP.f lTdll"'''''V'j
"lI
Intake air I" • ___ --- :.0' - ---

_~~g~~~~~~::::::::::::;____~¢>~:: -!~;~ :r~ ECCC~'",~",". .

Unt. C')
'" pe ' - ='

I""
() - c:
§ tlal :0
() .-
r _
()
'''w' "g , roi oJ
rnA -- - - --
nt"iCool !'l
A

*: ~
"'''-'
o 2llDai
_ .. -
m
:0

ctnk:nglO~enJ '
m
N
' ,,' . . .".p en
o
Lc[®)
va~ve ..
m

~~,~~~~~~;;~~:-_~ l~' ~ MOflit~r

"".,,,,
eha b ' --
"",-,-,--_ ' ' ,!
('!) ,0 U
'
<: .
F I
:t
r- - ~"
:IJ
""',' ' ,._.. 11- ,i , ,
,.-" ' m Rlco
rn
z switch I ~~, ~ )'nnn j
-[I" & chock light
Neutral
z
!2
CJ

!\)
Q:l
z
m
9m
o ~
z
GJ
~>pal'k plug Z
m (fJ
-<
(fJ

h ___ .,'. r;-:J rr1

~-- - --- __-'1'--_ _ 1\ '~- v:.~1Ide
_____; peed
I:. sensor
5:
"T1
--r
~~' ~l~' ~ "-
SJ4 G)
C
:n
m
valv::e~l~j:~~~ ~r
3-way catalytic converter S ' I 'ltl
;- wmg va 'Ie

~::;.~---=:~~~~~ ~_
Swing ""o
:n
Muffler . (1'1"" ) I o
/ Air clealler c
Air flow meIer =i
o
Exhaust temperature 0;-, sensor ~
sensor G)
Switching module :n
»
5:
 "'"
I
r.,)

~~1i'.1T]Y."i""!
~~~~O=I.==r=J (")
Diagnosis connector :0

-t-:c
(")
c:
r-£?'::l--+1~~~~~~a~~f=~=:;,~~_~~~a~_~~nf·~~t~c~l~u~tC~h~.~l.~=_~~~~~::--~~j~ 11: f
::::j
0

. _+._ ~
u
-,( flow
;;
Automatic am~:j~~C:____ - ••- "L~--l-.-
- s . u ----~. ..~w.,~
rmtter G)
--- 0'" ront) C!11lir.ID ::0
~
'r.iiiJ2'
~~-:;:=Jt If~'"
!njt::dor ~_~__
: __ ';J
l>
{:
".
,",
j, ==
i ~W
...!..:
-- I
lrtlow ~

..J. "1--... 1 C!1~JD ::0

r-- ..1- •
~---~+-t--
*~-- .. ,) L
meter
----.!,. (Rea'i
__ - . m
r.,)

r--:-11f~.::~~=J---
."
~~f I- - - ... ~ '" l-.---1--
:: --,.----',-- l~rank ~ 0

::: pl~~====iltslsl-or
ug W1ll.lD
' ... "" s. ,----"
"-.--~.'" -_+-.. +-_ !---l- '.
m
Spark

-~
.-
DroPfl'.n 9
31
ita-
•
IUl!JI
eeon
r>olnt
"
tf·"
1101"1
-- ------r-:::-
" " .
u -
-t ,---+-,,-'" : ----~ t4
.~ f1;rt:t-"-~-~--r--" t
~_*"________
. . _ _ _ _ ..l
an9. Ie
sensul•
._____
9
m
:rJ
Rl
en
n: :
W
1. ... .-..-..-._.
z ~ e 0 Thrott~SW·- J ; O. sensor (ncar) ~ Z
0
m
=I
--~---~,-,J: . !!:
il~~::l~.·~I';
i --:~'-~.iT.·.~-'-"-'i~-
G)
I\)
CD war trallsist(;r Check pj : - Z en
~

1
~
0
\.u~.~~
I
:~~-='_
~! :
'._ t:ItV - '""'~---":=f'
~~_
,, __

-
m z
G)
Z

~~
'art~ ~ ,·-'"--·-t-itt:·:~~J··~~'· -0-'" st;-s4H- (Fr~n-t-)-·
I (") :
en

t-- --- ;.-: t::~~x:ksens:,~

(fJ
It - - ---
or
-<
(fJ
§ 1. - . __ .- --t
~b~~ock sensor m
I)
1 ;:;:
,1 - -_. • 2 t'O __
s:
",,~~-u:::=:;---]lhrottle
~'-~t,,~ t".~ __ .) I ,w~~,_, ...........,
IIG
<IMD <ifjl!l'l'l!lill} I
".. _ -n
Gl
C
:0
m
QO

~J,~_f~ ---i ---e='-8.

I!::::'J Ill1ll1k
Q
,..; dlb Chec connec,m : ___.__

L~~~~f=::~:§i: i."_.,,,, '""~ :~::.'"~_ ~~::" ,,'00' ",,'"

:0
0
C
::::j
i Cl
:>
e _ _ _ _• _ _ _ w~~·· __ ~~~_._,~
Gl
:0
»
s:
 SYSTEM FIGURE & CIRCUIT DIAGRAM
RB260ETT ENGINE

ECCS CONTROL UNIT PIN LAYOUT FIGURE (RB26DETT ENGINE)

1c'1.'0)

11Q~ 111t
i()~H;11~10611iJ11Ql111

HI t1~ n111~ 11~l1!'''111

, I, • j}

1~I'JIHj1511!i
I G 1 , 6 ; 9110
17jlS 191 20 a :nlnl2Jl24ja 121>1271
~qn 331'34 l5136
26{ l'.iIJon
nl~!:w 40
4tI4zjHI.u[{d 46j HI j!1.w1 5~
11,1 lill:t'! ,,1,,1,,1,,1,,1,,1001

i renpirla' ~iPtlotK ...... ·;'1: ••.Tetmi!J81 .. " ,·-['l,I;.'.';'!;r.·'

: ... NO'.' ' ...' 1 . ....... " . .
;J!iO;!;> m .' .
1 Iqnltion timinq (Power transistor) Cyl. No.1 11 Ilgnition timing (Power transistor) Cyl. No.6
2 ignition timing (Power transistor) Cyl No 5 12 ilgnltlon timing (Power transistor) Cyl No.2
3 Ignition timing (Power transistor) Cyl No.3 13 Ignition timing (Power transistor) Cyl No.4
! 4 Me valve 14 -
i 5 - 15 -
6 Sub electrical fan relay (engine temp SW) 16 ECCS relay
7 Tachometer speed signal 17 -
, 8 - 18 iFuel pump relay
9 Air conditioner relay (A I C cut signal) 19 Power steering oil pressure sWitch
10 Ground (ignition signal system) 20 Ground (ignition signal system)

21 (RX) Recieve (control Unit data reception) 31 (eLK) Clock (synchronization signal)
I 22 (TX) Transmit (data sent from control unit) 32 Monitor and check lamp (red)
i 23 Detonation senSor 1 (cyl1 - 3) 33 -
24 Detonation sensor 1 (cyl 4 - 6) 34 ~ir flow meter ground
,
25 Wastegate valve control solenoid vaive 35 ~ir flow meter intake air signal (front)
26 Air flow meter ground 36 Intake alf temperature sensor
i 27 Air flow meter Intake air sianal (rear) 37 -
28 Engine temperature sensor 38 Throttle openlnq output
, -
i 29 Exhaust gas sensor 39
i 30 Sensor ground (throttle sen. EGN temp) 40 -
i 41 :Crank angle sensor (120' signal) 51 Crank angle sensor (120' signal)
42 Crank angle sensor (1' signal) 52 Crank angle sensor (1' signal)
43 ignition switch START signal 53 Vehicle speed sensor
44 Neutral SWitch 54 Throttle valve sWitch (Idle connection PT)
45 (IGN) Ignition switch (lGN) 55 Exhaust gas sensor (rear)
46 ~ir conditioner sWitch 56 Throttle sensor outout signal
47 (CHK) Check (Diagnosis activation) 57 :Throttle valve switch power supply
48 Throttle sensor power supply 58 Battery power supply
49 Control unit power supply 59 Control unn power supply
50 Ground (Control unit) 60 ( - ) ,Ground (control unit)
101 Injecta r No 1 109 Injector power supply
,
102 - 110 Injector No.5 :
! 103 Injector No.3 111 i -
Fuel pump ternimal volt control output
104 112 Injector No.6
FPCM) 1
105 Injector No.2 113 -
Fuel pump ternimall/Olt control output
106 : 114 Injector NoA
FPCM) 2
107 Injector ground ! 115 -
108 IlnJector ground 116 Injector ground

EN - 282
 SYSTEM FIGURE & CIRCUIT DIAGRAM
RB26DETT ENGINE

ECCS COMPONENT PARTS (RB26DETT ENGINE)

Rocker cover ornament

I (camshaft drive) front

Front left
ITtlPnTl;,;tnr type Intake manifold collector
work unit

EN - 283
 ./>0
~•

~
C/l
-<
C/l
-l
m

~~
AAC valve
s:
~ I~'" ~ ~
" -~ ."

I 8 "3 !/J
z
~
I~
Cl
C
Air reguI810r i
.il
~

~ '"!!1
Q
if>
US
~
::0
m
~

~
"
'§
c
iil '" ::0
m
'"
J
~- '" '"ai ,-i5
~ II,)
0
m
m
z
Cl
r:J ECCS control unit r~~~ ))

~
Fue~ pump Z
m • ¢!b m "'"m
z ~
0
Ii ~ '!:;'WHl.-ll
lIlli'
_J 'J
,
~

m
I\)
~ ~
Monitor & check z
~
Ol light (red lig!!!)
~ "'5 '"
z
m
"<-
~
3 I;;
:;: s,
-1 (fJ
-<

~'dflsm,~ffiJ.
Nel,tral if)
. 0
~__ _ sWitch -I
m
Spark plug sensor
- --.~ ::;.:
Power 1ranSISfOIpt\
unit
"CG)
sensol 1/-- ./ JJ
v m
Swing valve
cS~o Qo

9
converter Vehicle speed sensor JJ

q~Uft~
()
- A j T control unit c
=i
Exhaust temperature warning lamp Air cieane( 0
:P
Exhaust temperature scnsot~IGN power
Air llow meter
G>
JJ
Switching module »
s::
 Exhaust gas temperature warning lamp
f"
-----1m l\)

, , r=cJ- rurll1 n
::a
IJ
21
,
12
o
c:
40
::::j
31
" Lowl fy'
:ure SW- Air condition c
46 1----111- ! . --.~ f;:'~ 5>
'0' G)
110 ....,:. Masnct clutch -
~ - ,,-~""- ------- -,,'" t jeater control amphtier ::a
101
"2, Vehicle speed sensor »
s::
"2
'05 I ,,,"'-;;-~u1ra~;;;I ~

::a
24·----- --..--t '@-C'~ L CD
'" I .- 11' -N r relay (AlT) l\)
"'09 H1 Crank I~
2 r-:=1

<!rbA~~va;ve
j

"'
,.
9
19·---

,0
-, ~-±
"±
mangle \.!..i..llil.!)
L To HICAS controlLJOit o
m
m
z
m 1Il..f1l
Power 51 . g
I -®eenn sw 38
m
(")
(") ez JJ
ill
ru
z rt>
p'fr·-·~
p:~_".::T -eJrlflOW I~ m
o
m

rI
(")
IIDr ;~~-f;~P rela{
il .
0 er ~ n1
to. z
I\.) z
0)

~}
Gl

~
U'I

& ~
rrtm]
0
r
c:
z
=<
45
"I!
Il
j lH I To AiT conlrol unn
Z
r'1
(j)
-<
, ! Thwtlle sensor
~
- Air regulator
Fi
or
12S ,6
,,·f::----.:::.~-; 2W
lrtl
(,m;
m
s:
:!!
L-~-·~~~--g---~'----~'9
ReSistor
r- - _._ .....
I
Jl

u
51--- --
I I I
~-::i'I2 1
I ,I~
I 2. m;line telPperature
sensor ThOO"~alve SW
(;)
C
:0
.-.-j,----1 .,
1{S}- "achometor
, 23
I I 321 ToAlT control UJ1lt m
QO

I .rr:-i -+--
_______L_
=:71..; ---.- 32 " 2 Q
L~::~: - ---- ~ ;
I Staller "J 6

'6r=±=L'.~'~'_'~~~~~~~===l
:0
o
tf;6~-1 ~~ IO~ ~-
Exhaust gal5 S8ns t(
c

I =l
: : A! T control unit
j 36 108 : ; o
llli U . .1 l_____ lit> :-U- - -1=--*_ ~:0
~
 SYSTEM FIGURE & CIRCUIT DIAGRAM
RB20E ENGINE

ECCS CONTROL UNIT PIN LAYOUT FIGURE (RB20E ENGINE)

·Ttm1i,,~,
,iii•.,. . . . . " " .0eSc:ripti00.." ;t8(!l1lnal ........
De~>.i~;n .,.; .,.
I No"
; , ~"'"
•••••••••••••••••••
.'., No; •• "'.'.>;. ......
I 1 (RX) Recieve (control unit data reception) 11 (ClK) Clock (synchronization signal)
L 2 (TX) Transmit (data sent from control unit) 12 (CHK) Check (diagnosis activation)
I 3 Air flow meter intake air signal 13 Monitor and check lamp (red)
4 Sensor qround (Air flow meIer) 14 -
I 5 Engine temeerature sensor .. 15 'Intake air quantity signal (10 Aff CIU)
i 6 Exhaustgas sensor 16 Detonation sensor
7 Throttle sensor (input signal) 17 Throttle openingoutput signal (to Aff C/U)
Sensor ground (thattle sensor. Engine
8 18
tem~eralure sensor

I 9 Crank angle sensor (120' signal) 19 Crank angle sensor (120" signal)
i 10 Crank angle sensor (1 0 signal) 20 Crank angle sensor (1" signal) ,
,

21 Vehicle speed sensor 29 Air conditioner switch

I
22 Throttle valve switch (idle connecllo pornt) 30 · i

I 23 Ignition switch (START signal) 31 ·

I 24 Neutral switch 32 Throttle valve switch (power supply)
.25 (lGN) Iqnltion switch (IGN) 33 · !

26 Throttle sensor power supply 34 Battery power supply

27 Control unit power supply' 35 Control unitpower supply
I 28 Conlrol unit ground 36 ( . ) Control unit ground

37 Iqnilion signal (power transistor) 43 Tachometer speed Signal

38 Power steering switch 44 Engine AlT control input Signal
39 Ignition si(!nal chec~ 45 Engine Aff control input s'gnal
40 ECCS relay 46 lAir conditioner relay UVC cut signal)
•
41 - 47 Engine Arr control output signal
I 42 Ground (ignition signal system) 48 Ground (iqnitlon signal system)

I 101 k1J8ctor No.1 109 Injector power supply

102 - 110 k1jector No ,2
103 Injector No.3 111 ·
104 Fuel pump relay 112 Injector No.4
,
105 k1iector No ,5 113 /AAC valve
106 . 114 Injector NO.6
107 Injector ground 115 ·
108 Injector ground 116 Injector ground

EN - 286
 SYSTEM FIGURE & CIRCUIT DIAGRAM
RB20E ENGINE

ECCS COMPONENT PARTS (RB20E ENGINE)

resistor

heater)
type

EN - 287
 ....•
------- .....
~
(f)
-I
m
s:
."
Gi
c:
jJ

"
-
m
jJ
D3
11.:1
0
Power transislor unit 0
m
m
z
G)
:IJ
OJ
m Z '"
0
z m
~
0
m
rn
f\)
(» Fuel contro! signal
Fuel pump z
GO
CJ) Momtor & check
light (fed light)
Z
m
(J)
-<
(tfl Temperature
Knock
(J)
-1
m
Crank angle sensor
;;:
-n
Gi
c
JJ
m
~ cataly11c converter L':=====:===:I::I===============::t::I===========~J Vehicle speed sensor
""
()
JJ
()
,----- A! T control uni1
c
ExhalJst temperature warning lamp =i
Exhaust temperature sensor 0
jGN power );
G)
SWitching module
:0
Air cleaner l>
Air flow meter ;;:
 .j>,

Powe~sjs!or
•
(ffi]~.W1I!.D(Cojl sIde)
'"
(")
(ildil!h:ID (C i U sode) Exhaust gas temperature
warning lamn ,-----------------------, :Ii
(")

,--+--~~~,.. =.====F===~~~~~~~~~~~~~~~~----~=+~ c
=i
4~ u ,t!I;..I~.~JilJ:f~h)au~ as sens 0
t-----~~j6 ?~ ~~
Jt'
r
5>
_._~:~ ~ , .... -~ pt;. __ Diagnosis connector G)
.,--'--::--,,,---"0' z:! ~
..t--r{D~n
::.0
»
~f::==j ::: H' t+t=+'=-:-~: ': :,s~ -g:,~1i~-QL]~r~·~h:ltr--J"t... s:
~liOl
~

r--'- . +- 41 ::.0
m
~~----
~Q-~ -----:;110
I!? :;r=tt=E=~~===t~===~----J
J1r'
'"0
c· -r.'.:J+-+--r
Ale ~y Low
~
PfessuLlre-;s'"'w:-;-~
... J f
I I !"'t't
L!..l..!J
: 1111
~
n -
?G
~
~ flow
Au l r.T~
~!~
0
m :0
Cl)
", ' "!L~ .:= '- -f :11.lO/ 1- ----~ i meier 0 '"0
0
IbN coli r a Sf'Jark~ug Magnet clutch .",. Q!Y - ------- m
m
z a:l" .----1 .
. +-4_ --- '" .. 1 -I m

J#
"'-'-~ 'l~-t- Heater control amPhf'El
m j • Crank
(.-..., m t:}
I\)
CO
(0
..' ?-:;.\
r
-hnr
ITl...JJ]
~ !-_J 4-
(~l1IG!:!~Oil
-1
I
I
< ReSistor Check coonee r
-6¥d---
P<1wer
0
traJ'L~!stOf
fI ("')
~
(')
i ~ ,_ -:-~ ___ ._. p_'
-E··'-l b '
angle
sens.or
~jl12l!} Z
G)
Z
In
-;
en
Z
~I
- );·1 ,.'
__ 2 NJ"I 1
g
~ ~
'-j r - ~'" I ~
~ .'
c.
I
Powpr steering SW -:;;..-_. -- 'l To A / T control m
~
G)
Z (fJ
g- g. 0 ?'ID" I ,,,' 2 T
--- -
: •, I umt m -<
&; 3 . _ ' ',* :: c: : rThrottle sensa' . (Jl

.. ~ ~ JI : 3 • -J',' ~ ~: '-± .. ~_' : :=-!~y (<lIT]) .

-i
m
s:
fl K:i ,:=1 _, Thrott!~ valve ~W'
-.~ . '~"--l To A'..... t I
iI lil ~
"Q
; j' j iJ
~4 ;~']'~~~'ff\).-;===== I iJ~it con-ro
""T1
G)

;
i ! i
2.
_
-; .,QQIi
v f:,.--_. b
1
'"
L " ~ i C

~~.~,~= ~, Vehi~e sp;ed sensor

T JJ
I
g ..;; 6 - .. i i i f m
.L Qo
Fuel pump relay .. .-- 53 n--l (=:) I
I r~: .
I'

18 NeutraISW(M!T) 0
"}B~"- tFuelpumpcont'ol 44 'T~'-"-~-~~ JJ
rr~ i [1 t9- :0-1 ._'r:: )-- adulator '04~~~.O.: DE. Y (A T)
N.P reIaV. 7 ·t l To HICAS control unit
0
C
Jill! 'l3.
_ ttL~ R
........ l , " ,.~--.--~-. -,I, To A! T control -i
j' .j
0 l !) --.- ,.-----

~ 0
" "ll ,.--- ~()
M o _ ,. ,_~_, ____.. unit
reSIst Tachorn~ler ~
JJ
("-),1.1_ _ _ _ _ __
»
s:
 SYSTEM FIGURE & CIRCUIT DIAGRAM
RB20DE / DET ENGINE

ECCS CONTROL UNIT PIN LAYOUT FIGURE (RB20DE, DET ENGINE)

10 HI , 10 11) III HI 1

~ 11;> 11 !1 '1 11 \1 115

iT...mmaf i;,'Ii;/!:!~"";';" ·.'i·· ii

I,;,.:;;; ;'/'/.1 ~. i.'{'b'·'./
'/;N,;"!;M/ri,
,,/. ,,1.,..'.,' . ".
t_lnai
,rNb~ I' k/;}""P~~'
' 1 ' . 1 / ; 1 1 ..
."i;,
1'1 ..•, .... ,.'
1 ,lqnition timil1!l (Power transistor) Cvi. No,l : 11 IIQnitlon timing (Power transistor) CyL NO.6
, 2 Ignition timing (Power transistor) CyL No.5 12 Ilgnition timing (Power transistor) CyJ. NO.2
3 ,Ignition timing (Power tranSistor) Cyi. No.3' 13 Ilgnitlon timing (Power transistor) Cyl. No.4
4 AAC valve 14 Engine. ArT control input Sigal (BT2)
L 5 El1!line. AfT control input sigal (BTl) 15 Enqlne. ArT control input siqal (BT3)
6
. 16 ECCS relay
i
~

7 Tachometer speed signal 17 -

8 . 18 Fuel pum[)relay
9 Air comMoner relay (A I C cut signal) 19 Power steering switch
i 10 Ground (ignition signal system) 20 Ground (ignition Signal system)

.i. 22
21 (RX)
(IX)
Recleve (control unit data reception)
Transmit (data sent from control unrt) i
31 (elK) Clock (synchromzatlon signal)
32 Monitor and check lamp (red)
23 Detonation sensor 1 (cyll - 3) 33 -
24 Detonation sensor 1 (cyl4 - 6) 34 -
L 25 - 35 -
i 26 Air flow meter ground 36 ·
I 27 Air flow meter Intake air Signal (rear) L 37 -
i 28 Engine temperature sensor I 38 Throttle opening output
i
I 29 Exhaust gas sensor 39 -
I 30 Sensor grounc (throttle sen. EGNtemp) 40 ·
I 41 Crank angle sensor (120' signal) 51 Crank angle sensor (120' signal)
I
42 Crank angle sensor (1' signal) 52 Crank angle sensor IF signal)
43 ignition switch START sl.gnal 53 Vehicle s!!eed sensor
44 Neutral switch 54 Throttle valve SWitch (Idle connection Pl1
45 (IGN) IQnitlon switch (IGN) 55 · ,
46 Air conditioner switch 56 Throttle sensor output signal
47 (CHK) ,Check (Diagnosis activation) 57 .Throttle valve switch power supply
48 Throttle sensor power supely 58 Battery power supply
49 'Control unit power sUP[Jly 59 Control unit spower supply
50 Grounc (Control unitt 60 (- ) Grounc (control unit)

I 101 Injector No.1 109 Injector power supply

102 - 110 Injector No.5
I 103 Injector NO.3 111 ·
IFuel pump temimal volt control output
I
104 112 Injector No4
I FPCM) RB20DET
105 Injector No.2 113 -
106 - 114 Injector NO.6
107 Injector ground 115 Exhaust gas sensor heater grounc
108 njector flrounc 116 Injector ground

EN - 290
 SYSTEM FIGURE & CIRCUIT DIAGRAM
RB20DE ENGINE

ECCS COMPONENT PARTS (RB20DE ENGINE)

outlet
Zirconium manifold
side

EN - 291
 ..."',"
en
-<
en
....
m
s::
"11
15

['~
. .""~"
c:
1 ::JJ
m
~

::JJ
ontrol
III
I\)
-'r odulator 0
a
m
Power transistor unit
....
m :Jl
z OJ
tv
m
z !i2 0
0
.~ Z m
m .-j
m
~
~

Z
I\) Cl
z
m (f)
-<
(f)
--l
m
;:
Crank angle sensor "Gi
c
:n
m
Vehicle spee:d sensor >?'
Q
-':-"" :n
0
- A r -r conI rol unit c
=i
An cloaner 0
Exhaust temperature sensor ~~;~i"r~·~'lamp
Air flow met-er
»
G)
:n
Switching module
»
;:
 SYSTEM FIGURE & CIRCUIT DIAGRAM
RB20DET ENGINE

ECCS COMPONENT PARTS (RB20DET ENGINE)

type (Auto camshaft )

type
type

EN - 293
 't"
.....
0,,, sensor output signal

(J)

' I Intake temperature sensor AIr cleaner

-<
~
J ======'1~~~=~~~::;;;;;;tA~u~t~~~\_~l~ t_~:lr:~ustment device m
s::

RevolutIOn
_"
f:f:

Temperature s~~sor I I [il l !I)1 I

illl-,
!!
G)
c::
::D
ECCS control unit

-»
m
n
.....
~ 2!
g m
~dle rev 50leno~d ON-OFF
~

3' valve (Ai: only)

zG)
s
'"n I
Z ()
m
z ~
.-~~~
m
~ :::p
~ ___~ I Dash pot m
"
f\.) ,\6
~~ - '"(;?
'".t> lqmtiurl cuil PTChealer
------ 0 sensor
z
m
=cc( (f)
-<
(f)
!!d---------Exhaust mallifold cover -i
m
$:
-n
Gi
Noutral C
sWitch JJ
m
.-:: To spark plug

,.
Froni tue1 lank
\
Qo
Q
JJ
Transmission
o
distributor Switct~Q module C
::j
angle sensor
C1
0~f'o-- Exhaust !ernperature warning lamp
:;;
Vohlcle speed sensor
---t::xhaust temperature sensor GJ
Jl
);>
$:
 ""~
Q
:II
o

IGfIl
<>
____J [i1JZ]
Dropping
resistor
(ION)
13
I R ,I
L~~ rariP "
c:
::::j
c
);;
G')
l]TIJ" .~ --·~l n ~ relay 2 1j PTe heater relay :II
»
Stmlef
ECCS
relay
BmpcratUf
Iwaming lar
'lllPi!J.:: l -
II i( i 3
!i
01 dr0 IGN COIl
, ffi -»o....
is:

L~
0 I " I

r, • g ..., <
o
~
I ,
0 ~
lJ_ ~ m

m
z
;7:' - .. '''':j

.niior}
')Oi :!:.
.
CililV
.
b~lra()Slstor
~
z
~
z
m
o
l':
92
m
I\) IN&EXj z
<0 9?
{J1
z
m
w
T
~
.-j
ISO'
m
I s:
i~, PTe '"11
neater Gi
c
ill TIT["f11
~~ ~~ ~1~."0
-'. . 1nroI~'.seoJ
JJ
m
9<>
Q
JJ
()
~ ~ __ 1l.
~, ._,._ _ I"" "~- '.'.
3 '!...
c
9>.
>11<-l ;::
=4 ~ I · ~.
:g, 1 =i
!2
~ ~
'<
-
{§
'"
ill
Diag'J1osis connector
.. -4 11111111 :l>
Gl
JJ
:l>
s:
 SYSTEM FIGURE & CIRCUIT DIAGRAM
CA18' ENGiNE

ECCS CONTROL UNIT PIN LAYOUT FIGURE (CA18i ENGINE)

II~:~ <.: ,."", ",,,'"";'<'~1;1.f":"'0

! 1(RX)
'c_"" "":,'?5 :~
<,', """;.,,,' ,.e;', ,,' . ;;,;N~ii'~ ,>,!j'Il',j:
Recieve (control unit dara reception)
.';<~
'ie j',·i, "'"
'. ,.....c_,','" ,,',' ,?l""
11(CLK) Clock (synchronization signal)
',,,
2(TX) Transmit (data sent from control unit) • 12(CHK) Check (diagnosis activation)
I 3 Throttle sensor signal 1 13 Monitor & check lamp (red)

.
4 ,
14 -
5 Engine temperature sensor 15 -
I 6 Exhaust gas sensor 16 Tachometer speed signal
I 7 Throttle sensor signal 2 17 Throttle opening output (AfT)
i 8 Ground (sensor) 18 Ground (sensor)
9 180' signal 19 180' signal I

10 l' signal 20 1'signal I

,

21 Vehicle speed sensor 29 :Air conditioner switch i

22 30 Intake air temperature sensor I

! 23 lignitlOnswitch "START" siqnal 31 Power steering switch
i
i 24 Neutral SWitch, inhibitor switch 32 -
25(IGN) Ignition switch 'ON" 33 - I
26 Throttle sensor power suoply 34 'Control unit back up power sueply I
27 Control unit power supply 35 Control unit power supply
28( - ) Ground (circuit) 36( - ) Ground (circUit)

37 :ignition signal (Intake Side) 43 Light switch

38 ignition signal (Exhaust side) 44 -
39 Ignition primary Signal 45 Heater fan SWitch
40 ECCS relay 46 Rear defogger switch
41 'lj monitor (iniection pulse monitor) 47 -
! 42 Ground (Ignition) 48 Ground (Ignition)

101 Injector 109 -

102 Air conditioner relay 110 Injector
103 FICD solenoid 111 Idle revolution correction solenoid
104 Fuel pump relay 112 -
105 - 113 -
106 PTC heater relay 114 -
107 Injector ground 115 Lock up release solenoid (AfT only)
108 ilnjllctor ground 116 Injector ground

EN - 296
 SYSTEM FIGURE & CIRCUIT DIAGRAM
CA 18i ENGINE

ECCS COMPONENT PARTS (CA1Bi ENGINE)

- intake manifold

sensor Intake manllo,IO

Exhaust manifold

EN - 297
 ----,-l ----------,
-
f'
(f)
-<
I~~ ---~~-

I~i
m
s:
u "
0 i _
OJ
"TI
C>
c:
~ ~~ .3 ::a
n -
m

~
!
»
000 '"
~ (,Q q; - "'--
::a
,3" i!?~. III
iTT "!![ fl? I\.)
Power transistor unit
A! C signal Q
~i[~~III-llll U'I
C
FICO solenoid
m
m
ECCS contro!unit
z :JJ
C> ())

m '"'"0
z (
Fuel pump
,? Z
m
~
m
111
N rn
~ Z
cD Gl
CO "'5 Monitor & check

'-
Canister ro light (red light) , z
» m Cfl
-'1 Neutral Ii
-<
~ Ignition coil ~ ---~

i
switch . Cfl
6 -i
.. ~
--A~- I m
Crank angle sensor
"In
~ g
~(~ I :J::

~""g
~. "T1
w is
is c
~ :n
m
!lO
Vehicle speed sensor 0
q-~~f_1Ier :n
0
Exhaust temperature warning {amp
---A! T control unit c
=i
Exhaust lemperature sensor 10N power 0
SWItching module
»
Gl
:n
Air flow Ail' cleaner »
:J::
 ;t
(1
:Ii
(1
c
~
r c
:;
(1"
!
C>
:rJ
>
s:
~

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to
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U'I
C
m
m JJ
Z Rl
m C>
z Z '"om
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<0
<0
-
m m
Z
(,")
Z
m
(J)
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~
m
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::IJ
m
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()
::IJ
jc__ ()
c
..m F'(~
ITl[ill. =i
Air mg(jl"'~' lil!H! g
f;
::IJ
»
;;;:
 SYSTEM FIGURE & CIRCUIT DIAGRAM
RB25DE ENGINE

ECCS CONTROL UNIT PIN LAYOUT FIGURE (RB25DE ENGINE)

I Termt!ta.: ~;!i<i>n .••.. . :.,: . .'. i •• ' .... <i( lermlllPI .• ..••. . ...••.•.................. <.> "'(y(;.
,
,
No.:::. r1<.;· .. . . ... c · .•.• . . . . . . . . : .....No, I .................~ ........ (
1 Ignition timing (Power transistor) Cyl No.1 11 ilgn<tion tlmmg (Power transistor) CyL No.6
I 2 Ignition timing (Power transistor) Cyl. No.5 12 lignltion timing (Power transistor) Cyl No.2'
I 3 ignition timing (Power transistor) Cyl No.3 13 Ignition timing (Power transistor) Cvl No.4
4 MC valve 14 Engi~e Arr control mput slQal (BT2) !

~""
5 Engine AiT control mput sillal (BT1) 15 Engine. Arr control Input Sigal (8T3)
i 6 · 16 ECCS relay I
Tachometer speed Signal 17 (f)
.
· 7 ·
! 8 - 18 Fuel pump relax
I
9 Air conditioner relay (A I C cut Signal) 19 Power steering switch
· 10 Ground (i~nition Signal s~tem) 20 Ground (ignition signal system)
i
,
21 (RX) Receive (control unit data reception) 31 (elK)
22 (TX) Transmit (data sent from control unit)
. 32 Clock (synchromzation Si9nal)
Momtor and check lamp (red)
,
23 Detonation sensor 1 (cyl 1 - 3) 33 ·
24 .Detonation sensor 1 (CXI4 ,:.6) I 34 -
i 25 - 35 -
26 ~Ir flow meter ground 36
i
. 37 FICD solenoid mputslgnal
,
,
27 lAir flow meter intak.e air sional -
28 Engine temperature sensor 38 Throttle op_enlng output
I 29 Exhaust gas sensor 39 -
I 30 Ground (Sensor) 40 Intake alf output Signal (To Arr ClUJ

41 Crank angle sensor (120° signal) 51 .CranK angle sensor (120' signal)
42 Crank angle sensor (1' Signal) 52 Crank angle sensor (F Signal)
43 Ilgnition switch START signal 53 Vehicle speed sensor
44 Neutral switch 54 Throttle valve. SWitch (Idle connection PD
45 (IGN) ilgmtlon switch (IGN) 55 -
46 lAir condlboner switch 56 Throttle sensor output Signal (To Arr C/U)
i 47 (CHK) Check (Diagnosis activation) 57 Throttle valve SWitch power supply
48 Throttle sensor power supPly 58 Battery power supply
49 ( b ) Control unit power supply 59 Control unit spower supply
50 Ground (Control unit) 60 ( • ) Ground (control unit) i

I 101 Injector No.1 109 Injector power supply

I
102 · 110 Injector No.5 i
103 Injector No.3 111 · i
104 · 112 Injector No.4
105 Injector No.2 113 - ,

106 - 114 Injector No.6

:
101
108
Injector ground
Injector ground
115
116
Exhaust gas sensor heater ground
Injector ground
I
I

EN - 300
 SYSTEM FIGURE & CIRCUIT DIAGRAM

ECCS COMPONENT PARTS (RB25DE ENGINE)

FICD solenoid --T"'=~~==~~" valve

"~l-.lT~~~--·~-"-'-'-- P')WE;r tran~>lst()r unit

I
,;,--"'"/"-'-- Exhaus~ gas sensor

Throttle sensor &

throttle va,vo(,,,:,~;;;;,::::""

--- -

~i~·i~;~I+I~~e_c_to_r____________~Elevation
________resistor~ ____~
type Fuel tube
________________ ~
".c,,",'< Fuel pump Electronic, turbine type Fuel tank
AAC valVe Solenoid type Intake manifold collector ,

ls:miplWl FIG D solenoid Solenoid type Intake coliector manifold

0'.> Ignilion cOil Small mold type Cylinder head (above each plug)
6-channellow voltage I
Rocker cover ornament
electronic distribution
'X"li l
Crank angle sensor Photocell type Cylinder head left flint side
',i~: Air flow meter Hot wire type Front left
~L~;>~:Ji Throttle valve SWitch ON I OFF switch Throttle chamber
Throttle sensor Variable resistor type Throttle chamber
iii)).;, Engine temperature sensor ThellTlistor type ,lNater outlet
, i ' ~r; Exhaust gas sensor Zirconium type (no heater) Exhaust manifold
,dl',y, Delonation censor ,Pressure-electncal type iCylinder block

EN·301
 ACTUATOR SYSTEM INSPECTION
RB26DETT ! CA 181 i RB20E DE· DET , RB25DE ENGINE

5. ACTUATOR SYSTEM INSPECTION

Use measurement tools such as a circuit tester, CONSULT electrical system diagnosis
tester and oscilloscope to perform inspections. Refer to EN3, 1, 1-1, (6) in TROUBLE
DIAGNOSIS section for the measurement equipment operation procedures.
The following preparation must be performed when using this equipment.

(1) Using circuit tester and oscilloscope

RB20E
• Insert the testing rod from ECCS harness connector side.
• ECCS control unit and ECCS harness connector must be
connected when measurements are carried out.

RB20DE I DET I RB25DE I RB26DETT

• Always use check adapter to perform the measurement.

(2) USing CONSULT

• Connect CONSULT to the diagnostic connector on the
vehicle (near fuse block).

Nola...:
See EN3, 2, 2-2, (2) in TROUBLE DIAGNOSIS section for
details.

EN - 302
 ACTUATOR SYSTEM INSPECTION
RB26DETT cNGI~E

5·1 FUEL PUMP SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB26DETT ENGINE

Feel pump relay I:i.lo.I1l ECCS relay

IGN 2 r;:;;::; , W1l-
~I'
~~5,~2 I
1
, ~! ~
Fuel p~mp M 2
1
!
i
i

~:.
, ,
I
fPCM pin layout ....... I
' '
Pm 110, ,"
~ I I Eces contro~ uni:

1
Fiow velUMI:' control 5,g~a; i
, 4 7
5 !
:PC 1) ,

2
Flow VOlurne C:Dfl!ro' slgnal I ,::ue! pump !
(FPC 2) conlrol
3 i i modulator
4

5
6
ruel pumP! - ;
Power S;J::Joiy
Shield hne grou(l(j
I
(I:PCMi

Case
:1
I
[
1
a
Fuel pum:::> i + )
,
l ~ , 2

EN - 303
 ACTUATOR SYSTEM INSPECTION
RB26DETT ENGINE

Fuel pump system trouble diagnosis flowchart RB26DETT ENGINE

IFue: pump operation noise Inspectior, ;
Purrp sounds for 5 c-_____··~_____IL________',,"::m:t:'p::d:::o:::e:::,sn·1 sound Other
seconds when ignition
switch IS ON
riF:"u'-e-;l-p-r-:,,-:s~s-u.Lre:-7ln-;s-;p-;e-;c-;'-;io-n-s~ Fuel pump relay operation noise ~nspection I
When ignition swj~ch is ON. Relay opera1ron noise when No sound
fuel pump o~e$s~re ;$ Other ignition IS ON
ao;)rox. 3.0kg;cm~'_ _ _ _--"-_~
, ~ "DATAMONITOR'l
. ther s~stem I : ue pump va age- Inspection' ! "ACTIVETESr:
Ins ect!on ·I'lnspect .voltage between ! ~ "f"JO;;;Fm'-'-accl_ _ _ _--; Ab'lormal

.pump pinS 1 - 2 ;~

8attery vOltage When ignition switCri IS

ON 'o~ 5 sees and "ACTIVE TEST ,< is ON ~pump
! uel
Norma!

relay voltage
Replace fuse
;inspectlon. Measure voltage
or relay
IFuel pump jnspect,on :Harness contlruity inspection between re;ay lenY]inal 2, 3
! 1. Measure reSistance between !Measure resistance Detween ' and ground
. pump terminals 1 and 2 , :relay termina1 5 and pump
12. Apo:y battery voltage directly terminal 2 Battery voltage with
between terminals 1(-) and 2(+) t:::=='-o::~----"--~ ignJtion switch ON
tIti Other
L Approx, 05 $~
;;, PumQ operation , Repair
SOund is produced ' O:her arness continuity ~nspection ' Repair power
,----'-------, harness Measure resistance betweer supply circuit
relay terminal 1 ard C/U system
Connector Replace
,terr1inai 18
Check for faulty connection fuel pump
and inspect c:rcuit syslem C Q --'-_ _ _ _ _C.::'.::.th"'e.::.r_,
:FLei pump control moduiator !
;control signal inspection i
!Eces CIU
I
power inspection Repair
check voltage between FPCM : harness
1, 2 and ground 1 "DATA MONITOR"
Approx, 4 V when ignition switch is ON
.:g_ Measure voltage between C/U leminal
49 and gr:)und .
for 5 sec and engine cranks. Approx
OV at englr1e speed after warmlrg up. Other Battery voltage wnen
ig;1!tion switch is ON Other
Harness contlnu!ty inspection! ,------'------,
Measure resistance for FPCM~ Repair ECCS C/u
term;nal 1 to C/U terminal 10 power supply
ar.d input signal system
and FPCM terminal 2 and C/U! circuit system
terminal 106
OQ L Other

L RaJair
IEces contcol unit termlna~ arrangementj
:eccs CIU power inspection
harnes s
:11, "DATA MONITOR" , I, ;1'
"
'i' Measure voltage oetween C!U leml:nal
49 and ground
Battery vo!1age when
ignition SWItch is ON
I Other

I:nspect InPut, I R~pairECCS C/U

sjcr~al system powersupplY
circuit system
Fllel pump control modulato· :nspection
Check voltage between FPCM termirals
7 and 4
7 - B V: When voltage from FPCM
term!nai 1 to ground IS less than 1V
Battery voltage when;
VOl1age from FPCM 1 to ground IS IN
Voltage from FPCM 2 to ground is 4V Other
r-------~---------,I
Check for con~ector breaks and circuit sys:em I Replace FPCM
EN 304
 ACTUATOR SYSTEM INSPECTION
RB20E: DE! DET ENGINE

5·1 FUEL PUMP SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB20E I DE / DET ENGINE

(±}--~'V
?=>-- ,IGN r-4:G~~~----------l
[5~!-----L-C:+
f,'~I4~(1;8)-~\~6~~4~,~t.=ltl~~
l--:;;O-+c---r--t·----T-----,------l, EGGS
EGGS tclay

: control un;t
(1M)
I k104 ter RB2:JOET
Iilll : ')rot-
lE"'ITl L

i : RB2C0E So DET

CCS control unit pin

,,~"!
ffi
"
,
'
'
' Ililm I iI I! I =!"II

EN - 305
 ACTUATOR SYSTEM INSPECTION
RB20E I DE ' DET ENGINE

Fuel pump system trouble diagnosis flowchart RB20E I DE I DET ENGINE

F~el pump opet8tlon nOise inspection
Pump sounds for 5 _ _ _ _ _ _ _,-l_ _ _ _ _ _-'-p:::um,;.:p!::..::do;;:e;:;:;s~'t sound' \Y.her
seco'lds when ignition
sWItch is ON
r.F""':e"l-:p-:r=es::s"uc:,::le-:i'::n"sp::-e"c"t",o-:n""s Fuel pump relay operation nOise inspection
Vvnen ignition switch IS ON. fuel , Ae;ay ODeratmn noise when
pump pressure IS appro)c 3,CKg! ' Ignition :5 ON No sound
cm1 (R820DE, DET}2.5kg!cw Other
(RB20E)
~"DATArv1ONITOR"
:FL:el Dump voltage inspection;
iJrspect voltage between : 1 ". 3 ; Ncrrnal
2i£j , "ACTIVE TEST' '
Abnormal
===='-' ;pumo pins 1 - 3
Battery voltage whe~ igni1ion SWitch is ON for 5 sees;
and "ACTIVE TEST ~ IS ON. Also after engine warm
up approx. 5V fo~ RB20DET
2
!

; Other 0flrlF
5 3
,Fuel pump relay voltage
NOll11al
,
Replace fuse
Fuel pump Inspection !i!1spection. Measure voltage
or relay
1, Measure resistance between Harness continuity inspectIon Ibe-tween relay terminal 2 and
pump termi_"'Ials 1 to 3 Measure resistance between 3 and g-ew:.:ue.-n",d_ _ _r_,-,
relay termlcal 5 and pump
2. Apply battery voltage directly Battery vOltage with
terminal 1
between terminals 1H ta 3(-) Ignition swlicr ON Other
Approx. 0.5 g Other
2 Pump operatlor, i RB20E. DE
sound IS proo'r=uc:ce"dc.'_-,O_th..;,e:..,r !Connector ;Repair ; ar:1ess continuity Inspection Repair power
t l iChecK for faulty harness Measure resistance between supply circuit
Connector'
Check tor faulty
I Replace :connection apd Inspect relay ter'lilnal 1 and C!U termlfial: system
fuel pump 'eireu,t system 18 (RB20DE. DE,) 104 (RB20E) i
: cot')nect!on and
! inspect ci rcwt system
o g,_~_ _ _~.-,O_lh-,.,-r_-,
r.::IRB200ET ' - - - i uel-;;Ump-;;O":r';-,"Od~!;; il
;cont~ol signal I I r
I [9j
.31 . 24
inspection
check voitage betweer FPCM I ~ccs CIU power inspection
:i:L "DATA MONITOR"
Repair
harness
I I
IE ,,'-"'.--,:::.:..:.:.:.:..:.:.=-="-'-----=-:-:-----'"
i
2 and ground
I Approx. 0 V when ignition switch is ON I Measure vo~age betwe~,n CIU terminal.
49 and ground (RB20DE.DED 27 and I
I for 5 sec and el"gm€ cranks Battery I ground (RB20E) :
charge after waming uo. O:her
I GU"b.l' I Battery voltage when Other
I Dropping res'stor Harness continuity I \~rHtion sWItch is ON
I Inspection. Measure inspectron Measure. I
I resistance between resistance for FPCM : I Check connec;or for breaks Repair ECCS elU
terminal 1 - 2, term'nal 2 and CiU I I and Input signal system power supply
I 'terminal 106 circuit system
I Og Other I I
I
I leccs CIU pow.r Inspoction
I
Repair
I IECCS control "nit wminal arrangement I
I
I .~,' "C)ATA MONITOR" harness I (RB20E)
I : 'J!' Measure voltage between ClU temwlal ' I ~B~8 ~ :i. '",' r~
11 ;)! , i' I )
I L 49 ana ground I ::2 [.;""'5",·;1.'1 ;-j..ZlOt-W,~',;::~·ibili
Battery voltage when
I Igmtion sWltcn is ON Othe" I (RB20DE. DET)
I Repair E CS CIU power I
I supply circuit system I
log Other I
I Fue' pump control modulator Inspection Replace I
I Check VOltage belween FPCM terminals dropping I
I ,7 and 4 resistor I
I 7V when ba1tery I
I VOltage OV I
Voltage from FPCM 2
I to ground is OV Othe" I
I I I
I Check far connector i Replace FPCM I
L __b:::.a~ ~d~r~i,--=,,~'.:.i - - - - - ~ gcj6
 ACTUATOR SYSTEM INSPECTION
GA181 ENGINE

5-1 FUEL PUMP SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM CA18i ENGINE

EGGS
: control ur:it i , 2
~'
1._-' L.1

Fuel pump system trouble diagnosis flowchart CA18i ENGINE

[Fue; pump operation noise Hlspectlon!

PlJmp sounds for 5
seconds when 19rifion
r Pump doesn't sound! 01'1er

sWItch is ON I
IFuel pressure inspectlO:'1sl IFuel pump relay operation nOise inspection I
When ignition sWitch 15 ON. Re!ay operation nc:se w~en No sourd
fuel pump ;:;ressure IS
approx. i .Okg,'crn;
01hsr :gnitlon is ON I
1....-
r '~"DATAMONITOR'l

lotrer system
Inspect!on
I IInspectIon
Fuel system I r~ uel pump \/0 tage 'nspectlon
;Inspect voltage between
!
Normal
"ACTIVE -EOST'
Ab'"Iorm
1 3
,pump pins 1 ~ 3
IFese. 'ela~1
Battery voltage when igOillon swl1ct> ,$
ON tor 5 sees and "ACTIVE TEST" is ON_ Other ~ 513
IFuel pump telay vo :age
Normal
I
I A~"-~--

Replace fu se
I insoectlo~ Measure va ta~e
IFuel oump inspection !Harness continuity It"Ispect,on betwee-: re'ay te,rn'nal 2 ape
or r.lay
11. Measure resist811ce between ;Measure res:stance between 3 aod ground ,
I
pump terminals 1 ~ 3 !relay terminal 5 and pump
:2. Apply battery voltage directly Battery voltage wltr
:term:ral 1 ,,
It:;f1!.!ot. SWitch ON Other
between termlna!s 1- 3
Other .-----'L-L-L--,
1, Approx. 0,7 - 1.5U
2. Pump operatlo~ Repair
sOLnd is producoo Otner
arness continuity lospectJon: Repair power
harness Measure resistance between supply circuit
relay terminal 1 and CIU system
Connector i Replace
Check for faulty cO:1rect:on fuel pump Othe'
and inspect circuit system

Connector ECCS C/U power Inspection Repair

Check for faulty connection harness
and inspect circuit system i "DATA MONrrDR"
, 1;:' Measure voltage between C!U terminal
: 27 ana ground I
Battery voltage when
ignition switch is .---L
ON _ _ _Other
_-----,
IEces cO:itrol unit terminal arrangement!

: Check connector for creaks Repair feeS C1U

•
'1IiI~~$;I'I~?:IO
.;c:,=H''f"=+=tI,
i and input signal system power supply
circuit system
::!;n II U 1$ I i !111-\" <'II

EN - 307
 ACTUATOR SYSTEM INSPECTION
RB26DETT CRB20E, DE ClET CAIS, ENGINE

(1) Fuel pump relay operation inspection • ACTIVE TEST •

Place the 19'1IlIOn sWitch ON and select "FUEL PUMP
RELAY' in 'ACTIVE TEST' mode, Press the ON button
and cneck for pump operation noise
® I'

,
FUEL PUMP RELAY ON
MONITOR
ICAS RPM ,POS) 950m'"'11
I

OFF
3",

• When the igr,ltion sWitch IS in ON position, the relay

operation nOise ~l.ist be audibie, There must be a relay
® l Boct ~ear :inisher intedor
,.,'
Ciic
cut off nOise 5 seconds later
• After engine has stopped (stall), turn the Ignition switch to
OFF position 1.5 seconds later.

2) Fuel pump relay power inspection

Disconnect the fuel pump relay and measure the voltage
between following termnals and grourd when the ignition
sWitch is placed in ON position

Engine RB26DETT I RB20E, DE. DET I CA181

~ ~em; Between terminal 2 I:Between terminal 3

I I or fuel pLmp relay I on 'ue l pLmp relay
i r:-r.nd:tu harr-ess s:de and harness s:de and
__g_ro_u_n_d_ _.JI___,_gr_O_L;n_d_ _-I
I

C=~
I ~Ii~~~~~~'~~' I Battery votage

RB26DETT CA18i

(3) Fuel pump control signal inspection

• Select 'FUEL PUMP RELAY' in "DATA MONITOR" Mode r~'\
\ )
~
and check the following.
I
I~ONI~OR;Nctt~,O FAUc~ 0'
Kem Foel pump relay:
m;

OFFI
j F;;el pwnp relay
; When ignition switch is ON
(engine Is not running)

When cranking engine

When idUng ON ";::CORD

EN - 308
 ACTUATOR SYSTEM INSPECTION
RB26DETT! RB20E I DE! DET I CA 18i ENGINE

• Measure the voltage between the following terminals and

ground when the EGGS control unit connectors are 104
connected. 18 ( 1EC.CS I
I control I
l L@-q) ,M ~. Unit ..•

'I.Fuel pump control

modulato!

RB26DE'TT . CA18i RB20E RB20DE. DET

Belween Belween Belween Belween

lermmal18 tenninal 104 terminal 104 termmal18
and ground and ground and ground and ground

Approx. lV Approx. OV Approx. lV I Approx 1V

Batlery Battery Battery

Battery voltage I
voltage voltage vonage i

Approx. 1V I Approx OV Approx OV Approx OV

Approx. 1V Approx.OV Approx 1V ; Approx lV

(4) Fuel pump control modulator control signal

inspection (RB26DETT & RB20DET only)
• Measure voltage between the following terminals and
the ground when the EGGS control unit connectors are
connected.
RB26DETT
Belween tennmal Belween terminal
104 and ground 106 and ground
(FPCMl ) (FPCM2)

4V, OV after 5 sec 4V. OV after 5 sec I

Approx.4V Approx 4V

Approx OV Approx OV

Approx 4 Approx OV

RB20DET

Belween terminal 104 and ground

OV

OV

When cold: OV
After wann-up: Power supply voltage

EN - 309
 ACTUATOR SYSTEM INSPECTION
RB26DETT! RB20E! DE i DET i CA181 ENGINE

(5) ECCS control unit power supply inspection ftl\,

• Select "BATTERY VOLTAGE" in "DATA MONITOR" \.1!J
mode and carry out the following inspection.

!;?<L!'!; ' .• ' .• '. !elltleiy;~e", ,.

No!@.;
The same setting as ON state is maintained for a few
seconds right after the ignition switch is turned ON to OFF 'RBZ6DETI RB0::DE DET
and then ON again.

• Measure the voltage between the following terminals

and the ground when the ECCS control unit connectors
®
are connected.

Between EGGS Between EGGS Between EGCS

G/U terminal 40 GIU terminal 27 i GIU terminal 16 G/U terminal 49
and ground and ground and ground and ground

OV Battery voltage OV
OV Battery voltage OV Battery voltage i

OV Battery voHage OV Battery voltage

OV Battery voltage OV Battery voltage

(6) Harness continuity inspection

• Disconnect ECCS control unit, fuel pump relay and fuel
pump harness connectors and measure resistance
between the following terminals.

oQ oQ

OQ oQ oQ

oQ oQ

oQ i

CA18i I RB20E I DE' DET RB26DETT

- -~04~l
g(18) ~ i
(J)j
8.
L_!J
( ) RB2QDE. DET,

EN· 310
 ACTUATOR SYSTEM INSPECTION
RB26DETT ! RB20E DE' DET ! CA 181 ENGINE

[RB20DET & RB26DETI only]

• Disconnect each connector and measure the resistance
between the following terminals.
'.li .·.MulSu~nt~;!;·
,.,. ,"
''''""
. . . "'RB'tDoii;
' .. I• . , ' I , '.'

'Fuelpump :
(RB20DET onl
~l'ECCS

'r
"-ilJ\\
Between EGCS CIU terminal 104 and control i( ....-1: control unit
FPCM harness termmal 2 mOdUJatO!~~ ~_~~
~]l Fuel

~
Between dropping resistor harr""ss .c
3:
J ~
~ relay
pump
terminal 1 and FPGM harness ~ermmai 3 : ;0 ; uel ,3
, 0 g : 2 pump ....: harness Side
Between fuel pump relay harness conector ! Dropping ha m eSSr5J! F~' pum"
I, • 2:1 u~ ~
5 and FPGM harness connector 4 I
:reStstor Side 4, control modu/alo ;
iharness s!de harness Side I
Between fuel pump harness terminal 1
and FPCM harness connector 4 l
"'i~t: !h;;'~"~~r~"
.

~26PR11' .•

Between EGGS CIU terminal 1 04 and

FPCM harness terminal 1
,
Fue! pump 1 ~ 1(}1 ECCS :
control ">2, \ l contrOl:
modul.'or 7 - '''' unrt .
I Between ECCS CIU terminal 106 and
FPGM harness terminal 1 ~r~Fuel
n
, ' 'olay
pump

Between fuel pump relay harness conector

ag
HfI
I
harness Side
5 and FPCM harness connector 5 i Fuel Dumo
I : Fuel pump. :4 I 1 control modulator
l
: harness Side harness side
Between fuel pump relay harness conector I
is and FPCM harness connector 7
I Between fuel pump harness terminal 1
and FPCM harness connector 4

(7) Fuel pump voltage inspection

• Disconnect the fuel pump connector and measure the
voltage between the following terminals and ground.

~~~
Between fuel pump harness Between fuel pump harness
terminal 2 and ground terminal land grcund

Battery voltage Battery voltage

Battery voltage Battery voltage

RB26DETI RB20E I DE I DET CA18i

Fuel pump
32 "~'V-J..'
'0~~ ..
~~\ 77:~,
"C>' .. _~,'

~';~:,/- \ ,:

F~ei pump harness:

____ .... ~..conne9tor i
EN - 311
 ACTUATOR SYSTEM INSPECTION
RB26DETT! RB20E! DE! OET I CA 18i ENGINE

(8) Fuel pump inspection

• Disconnect the fuel pump connector and measure the
resistance between the following fuel pump terminals.

CA18i

• Check the fuel pump operation by disconnecting the fuel

pump connectors and apply the battery voltage directly to
the following fuel pump terminals.
Pump terminal 1 (2) to battery positive terminal (+).
Pump terminal 3 (1) to battery negative terminal (-).
( ) RB26DETI only.

RB26DETT RB20E I DE I DET CA18i

(9) Dropping resistor inspection (RB20DET only)

• Disconnect dropping resistor harness connector and
measure the resistance between the following terminals.

Between dropping resistor terminal 1 and 2 0.5

EN - 312
 ACTUATOR SYSTEM INSPECTION
RB26DETI ENGINE

(10) Fuel pump control modulator inspection

(RB26DETT only)
• When the fuel pump control modulator connector is
connected, measure the voltage between the following
terminals.

8.8 - 9.2 V Approx. 4 0-1V

Battery voltage Approx. 4 Approx.4

EN·313
 ACTUATOR SYSTEM INSPECTION
RB26DETT E'lGINE

5·2 INJECTOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB26DETT ENGINE

Air flow
'neter

/v ~Iow
i
:11eter
i rear' !
I
i
L-
Englce I
teMp
ser$or 44.~
11 _ _ _ _ _ _ _ _ _ _ ~IN;~~~hl'
i Neut.ial sw_ltchI

Throttle
sensor LftJ3§J· ~H±tTL_t--~-§:lveh~'C~.~SPd~$enl

EN - 314
 ACTUATOR SYSTEM INSPECTION
RB26D~TT ENGINE

[CONTROL DESCRIPTION]
. .
Tennlnal
Input signal
No." . f(e~rII$. ,:'
~,~ ')

Crank angle sensor

41, 51, Detennm9s injector timing
120' signal'
42, 52 i Reads engine speed
1'slgnal .
Detects 'ntake air qua~tW and detennmes
,Air flow meter Intake air, '.basle Injection quanuty (injection pulse ,Fail·safe function activated
quantity signai I 27. 35 when disconnected.
'width) based on engine load.
Increase fuel quantity when starting.
START signal 43 Determines injection quantity when starter
I
!SWisON
P e rIonns Injection Increase accord109 to
Fail-safe activated when
Engine temperature , 28
engine temperature.
short-circuit or
!Slgnal Fuel c~1 range changes according to ,
disconnection occurs.
i 'engine temperature.
i Exhaust gas sensor Injeeoon pulse width control according to According to control block
29, 55 !
'signal alf.fuel ratio feedback condition
Throttle valve SW . Activated when throttle
54
(Idle conneclion pomt) sensor damage occurs.
,Fuel cut during deceleration.
I
. Flow correction dunng acceleration or
! Throttle sensor 38 deceleration.
Interrupt inlection
i Idle judgement I
Fuel cut interrupts speed and fuel cut al 0 !
.
Vehicle speed sensor 53
kmlh vehicle speed.

i Battery vollage 49 'Injection pulse width correction

i

IntaKe ai r temperature Detects intaKe air quantity temperature .

36
,sensor ,and corrects injection pulse widtih I

EN - 315
 ACTUATOR SYSTEM INSPECTION
RB26DEH ENGINE

Injector system trouble diagnosis flowchart RB26DETT ENGINE

!ntec~or operation nOise lnspectror

Operatic" sounO "au=-d=-ib"l"e_ _ _ _ _ _ _ _ _' -_ _ _ _--'-N:.;o-'o:.::.;perat1on sound

; Injector control $ nal inspection

Measure voltage between Ir,jector connector
termlna! 2 (each cylinder) and groUflQ.

Note: Battery voltage whC'i engme is O:'lt1r

lnjector control signal
must be verified by
oscilloscope.
ana dIsconnectIon
!ECCS control Unit terrnll,a! arrangemen:
fUnj;I'lg ..
r------~ -.J------~-:::.:..::::,
Verify waveform on osc,[!oscooe
!!r.j€cto· po~ef sUPO:Y inspection
AbnonT',al
iMeasure vOltage oetween ~njectm
: connector 1 (each cylinder) and ground" '
Other than voltage
Battery voltage measurement wt;en
'#hen ignltic'l !S 0,," Ignition sWitch is ON
I
I
Injector Inspec:ion Repair injector
'Measure resistance between power supply
! lermma:s 1 - 2. circuit system

2 -30 Other

I
[DrOPPing res(,st~r inspection Replace inJectors

Resistor 3 -
4 Resistance
5 measurement
11~
6 between till!iliJ
7 terminals
8

Other

Ha r '1ess continuity inspection Replace dropping resistor

'(resistance measurement)
Injector C!U
harness harr.ess

;~~ (.i:~;
103 (#3)

( 114 (#4)
1101#5)
1121#6)

00 Other

ECGS. C/U power SLl Iv illsoectlon Repair

(8:: ·DATAMONITOR" , harness
,(b'. Voltage measurement between i
I£) terminal 49 and ground :
Battery vOl1ag·e when I
ignition switch is ON. Other

I
Inspect Input
I
Repair ECCS CIU power
51 na! s stem supply circuit system

EN - 316
 ACTUATOR SYSTEM INSPECTION
RB20E' DE. DET ENGINE

5-2 INJECTOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB20E I DE I DET ENGINE

Air 'egulator (-) 1

,..-__-, cp Air regulator (+) 2
ir=ffi(illill No.4

~ ~~N05
~~~.
ST
+)----"'<Yo_---_ _ _ _-; 23(43)
11(9)
(112)
f110}

j
41

+)---L=r\i:hf:~==r=r==j 27(49)
4.O(IGl
(114)

rt::ffiJ®ill NO.6 g
ECCS relay nOl' ....
' {IDill NO.1
--------+-1 , ~
§,'
- , 53
,
1105)t-----------W±jJ00ill No,2

~~
- 3,W
''t1
AT i
32{S7)
l1 1l3)t--
e- -------+--r2h6.Qill
f
-, No.3.

1
1 "-" 22(54)

~No,t
T hrottie vaive SW
T hrottle~ 10,j---4----!------[il'~
m 101
(1' 26(48) (") 11 ~
2 ' 2
I
,(38) g t------i ~ No.2 1
\Y "g
II t-____-L2UJ~NQ.3
c rank
J
angle sensor 10 So
[ ~
120' sional"
~al ,J.,
liB. 2 1~42) Cj!,
19(41) l11-----i=====~2Hl,[2F;i';111
1 ~ No.4 ~
I

::
Power 3;-~ !

,round 4J J:: 28(50) 105 ffi~~1

A ir flow meter
-
hlake aIr Sid
11
2: I FR 2 ' I "'t------;- ---rn~~
Pu.ver ground
S!gnalgrour:c
311111 " "t ! 1 t--- -------<0 O--'lAJ
Power supply
4T4
str h . , - - - - - - - - - - ( 3 ~- sensor ~
I
Ergine temp senso'
I
t=----;==:::::lJ.
I 2t)J~\fh
'J..r----" .
1 t
~

~2 ~2-----~~~!~.;~~~~1)
~W t """" __~t_--------~----~~~~ iS3)2 ehlde spd se

) RB20DE i DET

- -
ECCS control unit pin
[RB20Ej

103 '1 ;, , '1 ~

t=ttttj
2~! 22 : 25 26 27128

[RB20DE ! DET]

[Diagnosis connector) I
.....!"'Rx fX'J CHKIIGNI
12Jc:·'"fT"CIT'J<jTil---'-.....;:---I'["-".:.r."""-'I.

EN - 317

[CONTROL DESCRIPTION]
C ranK angle sensor
120' signal
1'5ignal
jAir flow meter intake air'
I quantity signal
ISTART signal
I .
i Engine temperature
i sensor Signal
\-
,Exhaust gas sensor
'Signal
Throttle valve SW
(Idle connection point)
.
!
IThrottle sensor
;Vehicle speed sensor
Battery voltage
( ) RB20DE I DET
ACTUATOR SYSTEM INSPECTION
RB20E i DE' DET E'JGINE
9, 19 (41, 51) Determines injector lJming
20. 10 (42. 52) ,Reads engine speed.
I
Detects intake ai r quantity and
Fall-safe function
determines baslc injection quantity
I 3 (27)
(injection pulse width) based on
engine load.
activated when
, disconnected.
I
Increase fuel quantity when starting
23 (43) Determines injection quantity when -
i
~starter SW is ON.
I;ertorms Injection increase Fail-safe activated when
. according to engine temperature
! 5 (28) short-circuit or
I Fuel cut range changes accordi ng to
disconnection occurs.
I 'engine temperature.
! Injection pulse width control Accordmg to control
6 (29)
i according to air-fuel ratio feedback. block condition.
Deceleration fuel cut according to
!
ON signal. .
32 (57)
Acceleration increase when ON
.
I . goes to OFF. I
Fiow correction dUring acceleration
7 (38) or deceleration. -
Interrupt Injection.
; Fuel cut Interrupts speed and fuel cut
21 (53)
at 0 kmlh vehicle speed
-
27 (49) Injection pulse Width correcllOn.
I
-
EN - 318
 ACTUATOR SYSTEM INSPECTION
RB20E: DE DET ENG,NE

Injector system trouble diagnosis flowchart RB20E I DE I DET ENGINE

injector operation nOIse inspectlO:1 :

Operation sOund "au:::d:::'b:::ia=--_ _ _ _ _ _ _- '_ _ _ _ _N"'C::.'::.o"'peration sound

Injector control signal inspection

;Measure voltage between Injector connector
I1e''Y11n al 2 leach cylinder) and ground.
Note: Battery voitage when engine is Ot1&r
Iniector control signal rurmng
must be verified by
oscilloscope. e,
r"V"eCC""'fy:-C:w:::a"ve"f'-oc.:rm'=-o:Cn:-:o"sc=';;-llo=s::c:::o:::p7C ,-------,\11' ,J,
InieclOr power supply Inspection
Normal Abnorma!
Measure voltage between injector connector
I 1 (each cylinder) and ground (RB20E).
Inspect connecto' lor breaks I Connector 3 and ground (RB20DE I DET).
Iand dlsconnectlo'1J
Battery vOltage Other thar: battery
when ,grlltlon ,5 ON voilage when ignition
IEces control u~it termInal arrangement I switch is ON
I
(RB20E) Injector inspection Repai; Injector
Measure resistance between power supply
terminals 1 - 2 (RB20E) circuit system
(RB20DEIDET)
(RB20DE. DET) 5 (#4)
3- 4(#6)
Ec:-:, ..........-'.• \.:; W7":~:I:i'~:: ·~:c:::;: . ·:,·:: { 6(#5)

t3 ·14 g I Other

I
Harness continuity Inspection Rep'ael i njeelors
(resistance meaSlJremer:t) If t~e va:ue is 'lot norma! at mld
Inlcctor ClU connector there is a possibll:!y
t1arness harness of faUlt With the harress, Test
the resistance measurement
~~~ i:~!

I
with injector unit
103 (#3)
1- 114 (#4)
110 (#5)
112 (#6)
(RB200E i OET)
101 (#1)

1- ;~; ;:;.~
112 (#41
( 110 (#5)
114 (#6)
I
00 I O1her
I
ECCS C:U power supply inspection I R~pair
.~ ·DATAMONITOR·· I harness
1.' Vol1age C1easurement between .
.J: terminal 27 and ground (RB20E) :
!ermmal 49 and ground (RB20DE ! DE,) i
Battery vOlta£B when
Ign:tlOn $wrtch is ON
I Other

Inspect !nput I Repair ~CCS CIU power

Is,anal svsterr supply circuit system

EN - 319
 ACTUATOR SYSTEM INSPECTION
f'B26DETI / RB20E! DE,I DET ENGINE

• Use "POWER BALANCE" in the CONSULT active • ACTIVE TEST • :::JI

test mode to check the idle speed variation and POWER BALANCE .
check the injector operation. MONITOR 1

CAS. RPM (PaS) 950rpmi

Caution: AIR FLOW METER 1.1 U
Do not perform test while driving. AACVALVE 25%1
~.~-. -.. ~

I ~ II ~Pl~ll~~;~TJ

RB26DETT
~:~ie~~~;~~~nc:C~:~1 signal and power inspection ® ~~:,,~;-,~~~::~, ~~.~'~.
• Disconnect the injector connectors and measure the '~"',:;:'~;~l::M'lY ~.
voltage between the following terminals and the ground. i& :s:~r~~~~'~ ~:~'::>
!~ ~~b":::..\'~;
!('4I' 21
~ ? '."
! S ; , . .\ ' . .
.t ""
,
,

'i'~' v~-~"y
.•• '-v~'
',",~I?l"
~"
~-~-~~-~..-~.~..~"-' ..~ :::

terminal 1 and
ground ground ground ground
H"""rv voHage Batterv voltage
Approx 10V Approx 10V Anrlrnx. 10V Approx. 10V
The voltage decreases as the engine
speed increases (apprax. O.2V decreases·
for each 2,OOOrpm of engine speed
increase)

• Inspection can be carried out at mid point connector for No.4, 5 & 6 cylinder and power
supply for RB20DE & DET engines.

BelWeen harness BelWeen harness

4, 5. 6 and ground terminal 3 and ground
Battery voltage Battery voltage
Approx. 10V Approx 10V
The voltage decreases as the engine speed
increases (approx O.2V decreases for each
2.000rpm of engine speed increase)

EN - 320
 ACTUATOR SYSTEM INSPECTION
RB26DETI! RB20E I DE I DET ENGINE

[ECCS control unit connectors)

Control CIrCUIt Power supply circuit;

Between EGCS G/U
EGCS CIU terminal i
terminals 101.103.105,
"";',", '110,112, 114 and ground 109 and ground :

Battery Battery
Approx. 10V Apprax.10V
The voltage decreases as the engine speed
increases (approl( O.2V decreases for each
2.000rpm of engine speed increase)

(2) ECCS control unit power supply inspection

• Refer to fuel pump system [EN3, 5, 5 - 1)

(3) Harness continuity inspection

• Disconnect the control unit and injector connectors and --=-1
i;~";:--''i:::-:--

measu~e th~:eSistance between the following terminals. I~~~R,;/t:~ ~Il

ECCS C/U harness Injector R820E
harness terminal 2 DET I R826DETT
I~D~Em,~ 'I~:~J;:<>~"
~>\~~~.~I;~ ~;~ ,
"" '~Y- fi: >~'" "0/ ,;-..;._ :2
Terminal 101 (101) [1011 TO No.1 cylinder '<:y' ~\ ,.,:,,,~,:~~,~=-
Termmal110 (105) [105] TO No2 cylinder ~---- ---•. _ -
Terminal 103 (103) [103J TO NO.3 cylinder 00
Terminal 112 (112) [114J TO NoA cylinder
Terminal 105 (110) [110J TO NO.5 cylinder
TermlOal114 (114) [112] TO NO.6 cylinder

( ) RB20DE I DET [ J RB26DETT

[RB26DETT]
• Disconnect the harness connector from the injector and
dropping resistor and measure the resistance between
the following terminals.

Terminal 1 TO No.1 cylinder

Terminal 4 TO No 5 cylinder
~~onnectQL_
Terminal 5 TO NO.3 cylinder oQ
Terminal 6 TO NO.6 cylinder
Terminal 7 TO No 2 cylinder
TerminalS TO NO.4 cylinder

EN - 321
 ACTUATOR SYSTEM INSPECTION
RB26DETT I RB20E I DE f DET ENGINE

• Inspection can be carned out at mid pOint connector for

No.4, 5 & 6 cylinder for RB20DE & DET engines.

ECCS CIU harness Mid point

connector harness

I Term.lnal112
Termlnal110
TO
TO
Termmal S (No 4 cylinder)
Terminal 6 (No.5 cyiinder) ; OQ
Terrnmal104 TO Terminal 4 (No 6 C'-yl_ind_er_l..LI_ _ _ _ _ _-'

(4) Injector inspection

• Disconnect the injector connector and measure the
resistance between the terminals for each injector.

Between injector terminals 1

2- 3 g 13 - 14 U
and 2 (for all cylinder)

(RB20DE I DET)
• Disconnect the injector harness mid connector and
measure the resistance between the following terminals
for resistance.

No.5 cylinder Between Injector terminals 3 and 6 13 - 14

g
No.6 cylinder Between injector terminals 3 and 4

(5) Dropping resistor

• Disconnect the dropping resistor connector and measure
the resistance between the following terminals. Dropping

Terminal 4
Dropping Terminal 5
Sg
resistor 3 - TerminalS
Terminal?
Termmal8

EN - 322
 ACTUATOR SYSTEM INSPECTION
GA181 ENGINE

5-2 INJECTOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM CA 18i ENGINE

r
ctH~' ST iii Z3

E8 ~----------~.~
3 5- , r
EGGS relay I

:~:
,-, dJI;\ Injector

T "vo:tle sensor Injection pu se (Ti) monitor

II'=p~o~w~e~,="--rI-l~----1----~
, '" 41f
, Jr'/
•
i--- Signal 1 2 -- '~, ~tl----i 3

1:::-:,;:,:1 i: I I' \'

Crank angie S€'1S0r

=-+---r--"' __-;9
II.
, 2 180"slgnai
Power I ®,'
3t 1
3. Ground . 4; 2
4. r signal
'---;.,

Engine :emp ser')sor

f---------.,
~~ 2~~­
1
2/---- ~~"'------

= fiiii [iiiiil =
101 10 ~ \: 10 1C 10 1DrlO 37 3S! 3 4
-
4; 4
l' I I 2 3 i 4 S 6 : 7 B I 9: 1C
" 22! 23 2.:.125
""I" 2B

109
" 11 11 11 1'4 "'5: 115 43 441 4 5 46
"I 4 I" I
12: 13~ '4 15 16 I 1, '~ 19: 20 29 30: 3~ 32 1 3-3 34
1
35 36

EN - 323
 ACTUATOR SYSTEM INSPECTION
CAlSi ENGINE

[CONTROL DESCRIPTION}

.>InPut~n.j
ICrank aregle sensor
, 120' signal.
l'signal
Air flow meter intake air
i quantity signal
I load
9.19.
I Reads engine speed.
20. 10
,Detects intake air quantity and
F ali-safe function
!determlnes baSIC injection quantity
3 acllvated when ,
I(injection pulse width) based on ereglne disconnected.
!

,Increase fuel quantity when startireg I

START slgr.a1
I 23 Determines Injection quantity when I -
starter SW is ON. i

Performs injection increase according to

!
Fall-safe activated when
Engine temperature ienglne temperature.
5 short-circuit or
sensor sIgnal Fuel cut range chareges according to
disconnection occurs.
engine temperature.
Exhaust gas sensor Injection pulse width control according to Accordmg to control
6
s'goal air-fuel ratio feedback. block condition.
Deceleration fuel cut according to throttle
•valve idle position signal.
Throttle sensor 3. 7 2 system type
, Acceleration Increase when ON goes to
, OFF !
Vehicle speed sensor 21 Fuel cut at prohibited vehicle speed. -
I
Battery vonage ! 27 . Injection pulse width correction .
i I

EN - 324
 ACTUATOR SYSTEM INSPECTION
CA181 ENGINE

Injector system trouble diagnosis ffowchart CA 18i ENGINE

injector mject:on S~2:8 TSCBC::C:1 I
IRemove air c!earJe' cove- '0 ::;rlBCk
Inject;;)g I No fnjectlon

I I
~
10lher system 1 IlnJector control s:gnal Inspection
i Measure voltage betwee~ Injector
j,nspection. 1
!connector terminal 3 a'1d ground.
Battery voltage when engine is running. j
\illtY
lower 05V when engine rev :S Increased Other
lO00rpm. 1

IVerify wavefor01 on oscIlloscope I

: Injector power supply inspection
Norma: I A'",norma I
I Measure voltage between injector connector

lnSpect conrector for breaks 1
j ar:d disconnection.
Note:
Injector control signal
must be vertfled by
I :6 and ground.
I Battery voltage Other than battery voltage
when IgM on IS ON
I
when jnMlon sWitch IS Of"
" •
I I
i !n;ec!or Inspection
: Measure iesistance between
i terminalS 3 - 6
0IJ1
Dropping resistor power
!

;lnspectlon
2· I,Measure voftage betwee:i
oscilloscope. connector 2 and ground.
13 ~;4 Q: i Other

I I Battery voltage I Other

fHarness con,tinJ:ty hSDsction! Replace
, ("esistance measurerre'1t) injectors IDropping res'stor
1
R . I
epalr power
I
, Injector C!U : inspection supply circuiI
'harness harness ! ~ :Measlire resistance system
3- 101 iI, 2 Ibetween connector 1
and 2.
oQ ether
1
I.SQ I Other

I R~Ptace
on Repair
harness Harness contmulty Inspection:
en Dropping Injector dropping
resistor connector resistor
6

Repair ECCS C/U power Repair

supply circuil syslem harness

IEces control U~lt ten"'\')lnal arrangement I

,
4' ,,. ,. 11.., '" "" '"

EN - 325
 ACTUATOR SYSTEM INSPECTION
CA 181 ENGINE

(1) Injector control signal and power inspection

• Disconnect the injector connectors and measure the
voltage between the following terminals and the ground.

Between injector Between injector

harness termmal 3 harness lermi nal 6 and
andground ground
OV Battery voltage

• Connect injector connector.

"".".~

Between EGGS G/U harness terminal 'cD

101 l'Intinrnl
Battery voHage
; ECGS:
,
;contro I Ii
I' ~_
-
InJElctcJr
~~.-\M-~ I
; i
Battery voltage I unit 1fl1~. .I.~
(decreases O.SV for engine speed i
'
-~~
i '~ "
increase of 1000rpm)
Note:
For accurate data use oscilloscope.

(2) ECCS control unit power supply inspection.

• Refer to fuel pump system [EN3, 5, 5 - 1]

• Measure the voltage between the following terminals

and ground with ECCS control unit connector
connected.

ov Battery voltage

Battery voltage ov

(3) Harness continuity inspection

• Disconnect ECCS control unit and injector connector
and measure the resistance between the following
terminals.

Between ECCS C/U injector

00
harness terminal 101 and 3

EN - 326
 ACTUATOR SYSTEM INSPECTION

(4) Injector inspection

• Disconnect injector connector and measure the
resistance between the following terminals,

Between injector harness

3 and 6

(5) Injection pulse monitor (Ti monitor) signal

inspection
• Measure the voltage between the following terminals with
EGGS control unit connected,

Ignition sWitch in ON position Battery vottage

Battery voltage (approx. 0.5 V

Cranking or engine running decreases for each 100rpm of
engine speed increase)

(Reference) Inspection using the Oscilloscope

• Injection pulse monitor (Ti monitor) is a result of the .
.
l
- _....
Injection
pulse width:
_-
:
injection pulse width within the EGGS control unit and it : Ti moMor
may differ slightly with actual injector waveform (about the waveform
l J --12V
OV
same for CA 18i) but the pulse width is same.
• If the waveform is abnormal and the Ti monitor is normal,
the ECGS control unit and the input system is normal and
Injector
waveform ~
L
!
t2V
OV
there is a possibility of fault with the injector circuit or the
injector main body.

EN - 327
 ACTUATOR SYSTEM INSPECTION
RB26DETT ENGINE

5-3 IGNITION SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB26DETI ENGINE

IGN

IGN
Power transistor cOil
~-4,I~ 'r'~=t.cr'~~ relay

I 2

11--+-__ 07 NO.4
I m
I---i---+ .. (')
(')
2

"'"
0
Crank argle sensor "::'2- 11

i 120' Signal ( 1 1-_+_--'/'., c:

! F signa' i 2 II 1--+---+., j!,
lPower !3I
I Ground \. 4

Engine temperature sensor

~1
~2
~
2f-'----~.,
Detonation

"t-----~~
'-----'

[Control description]

'I rank angle sensor Ignition can not be performed!

120' signal 41,51
Ignit.on liming start pomt lhere IS an instantaneous break
:-----·----,------r-------------"rnthe120"slgnal
nltion timing count IgnitlDn can not be I'H>,form<"rl I
42, 52 The Ignillon timing IS set according if there is an Instantaneous break
to the map indicated by 120" Signal
es rnjecfion timing according ail-safe is performed when there
IFrll1irlP temperature engine temperature. .s a short-circuit or disconnecting,
28
[Gelntnolfor low and high engine 20"G at slarting, gradually
conditions. to 80'G
Theettle valve sWitch, when throttle senso r
, Id Ie connection I 54 IOa,m"Qe occurs.
Idle
I cut dunng deceleration
Flow correction during acceleration
i Throttle sensor 38 deceleration

, START' Signal 43
ine.
detonation and changes 11- ail-sate is activated if short-
[D'ltolnatlon sensor 23,24
i i disconnection occurs
EN - 328
 ACTUATOR SYSTEM INSPECTION
RB26DETT ENGI."E

Ignition system trouble diagnosis flowchart RB26DETT ENGINE

I igr;ition snark inspection I
Strong spark arCS I O:'1er
I I
IInspect other system I Self-diagnosIs
~. "SELF-DIAGNOSTIC RESULT"
ell SELF-DIAGNOSIS (code No 21)
Norm.::d] Abnormal

ij'DATAMONITOR" I
(Real time dlagnosls)1
NOflllai I Abnormal

IPower transistor control signal Inspection I

I.(power tranSIstor unit) .
:
.
,Measure voltage between powef :ransistor I
i term!na~s 1.2, 3, 4, 5. 6 and ground. '
i Approx. 0.1 - O.3V
! when en :ne is runnino Other

Ignitio"" primary signa! insoection ! owe' transIstor control signa, !nspectlon :

Measure battery vOllage between : 1"'-' .(ECCS CiU unt)
•power transistor term'nals 1, 2, 3, . (E. 6! 5!4j3! 21 1) Measure Ihe voltage between CIU
4,5.6 and ground, 'terminals
, 1 P-, 3 13 2 11 and grour.d
Appro);. 14V when Approx. 0.1 - O.3V \
engine 1$ ~unnlng. when engine IS running 01her

: Power tra'1sistor
I
i ECCS C/U power inspection

Normal
; :l1spectlon I
Abn:) rmal
I ~. "DATA MONnOR"
!
:j: Measure voltage t>et\Neen CfU tennlnal
49 am grourd.
Harness contir:uity
hspectlon. Measure
Replace power
transisto r Harness cO:itinuity
Battery vOltage when
ignition switch is ON
I O~her

,resistance between :)Qwer inspection

: transistor mrrmnai 1 ar;d C;U power transistor I ECCSICIU
! ignit;on coil terminal 1, 1 .. 1 Inout signal Repair
12 .. 2 system power supply
Otrer : 3 .. 3 insoection circuit system
13 .. 4
Ignition coil power lns00ction: Repair
i 2 .. 5
Inspect voltage between COl! harnes s 11 .. 6
:terminal 2 and ground. 00 I OUier
Battery voltage wryon I I Rt .
Ignllion swrtcr is ON ' Other
Inspect connectors for i.1 epa"
I
Re~ir
faulty connect or defects harness
Ignition coH InspectIon ignition and check Circuit systems.
Measure resIStance between coil power
coli :ermnal 1 and 2. supply system

0.6 0.9 g! Other

circuit IEces contro~ Unit terminal arrangementj
I"
Ignition system secondary I R.~lac. IGN coil I '

part Inspection I

EN - 329
 ACTUATOR SYSTEM INSPECTION
RB20E i DE; DE ENGINE

5·3 IGNITION SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB20E I DE I DET ENGINE

IGN ,--......., c;!i)

~. -f--<1".O+-----+ 25(45)
~J- <SOHC+>}-_--:-H;:::au:;:::=t-_ _- .

Tachometer
)--~c(;j~f;==r==~27f49}
40i161

ECCSreiay ~

:~- : FUtL
T~rottle ~12l1-_A_._,'...:__-+ 32 (5TI \I
valve 1 }----,----<22(541 J;;P: +H
SWitch
IDLE m
g <DOHC>
Crank !II
i1)-----i----+119(41) ~ IGN
coli
a reiay

~------+;,.(501 ~ :i1:):J.;:~~~;L~~~==~~~~=ti
E:1gine temperature sensor

j I ~ ItIJ€lr-------1'!::~:;
1-~-+--_+16(23}

: Detonation se 2 1---l~--+(24)

( ) RB20DE,' DET
--------
[Control description]

,Crank angle sensor' i The Ignition can not be performed

1120' signal 19 '
i41) "'nnion timing start point
''' .1
,If there IS an Instantaneous break
r--------+-- ~---'------------~.in the 120' signal.
ilgnition timing count iThe Ignition can not be performed
ICrank angle sensor
.1'signal 10 (42) 'The Ignition timing is set according ilf there IS an instantaneous break
I i to the map Indicated by 120' signal. :in the l' signal.
! ··---r-·-----"-c-h-an-g-e-s-I-nj-e-ct-io-n-tl-m-in-g-a-c-c-o-rd-i-ng'-F-a-,I-'s-a-fe-,s""p-e-rl-o-rm-eo-'-w-h-e-n-the-re--i
Engine temperature i to engine temperature. lis a short-circuit or disconnecting,
sensor 5 (28) Control for low and high engine '20'C at starting, gradually
•temperature conditions. increaSing to 80'C
r-----------+--------r~------ --~------------~
Throttle valve switch 32 (57) Controls Ignition bmlng when idling
1-_ _ _ _ _ _ +-____ ..,:r=a.._nd=.-igniMn switch is ON
Controls ignWon timing when
"START' signal 23 (43)
cranking engme.
Detects detonation and cnanges Fail-safe is activated if short-
Detonation sensor 16 (23 24)
ignition timing. cirCUit or disconnection occurs.

EN·330
 ACTUATOR SYSTEM INSPECTION
RB2CE, DE / DET ENGINE

Ignition system trouble diagnosis flowchart RB20E I DE I DET ENGINE

I Ignition spark ,""oecllon I
!
Slrorg spark arcs Ot~er

Self-diagnosIs
'f"SELF-DIAGNOSTIC RESULT'
4 SELF·DIAGNOSIS (code No, 21)
NO(IT;a: Abnormal
RB20DE,
DET RB20E Ii, "DATA MONITOR"
(Real time d~agrosis)
Normal Abno:mal

: Ignition coil irspectlon

: Measure the reSiStanCe ~ Power transistor control signal inspection (power
befween IGN coil I1l transistor Jrir)
TIT Measure voltage betweep power trans:stor terminals
: 2 and ground (RB20E),
; Measure voltage betwee:'"\ power transistor terminal
! 1, 2, 3, 4, 5, 6 and ground (RB20DE ! DEn

Replace Approx_ 0.: 0.3V

IGN coil when en me is runnH"lC Other

IgPltlon priMary signal Inspection Power transistor control signal inspect10n

: Measure batlery voltage betweer power i (ECCS C/U Untt)
i trar;slstor terminal 1 and ground (R820E). : Measure the voltage between C/U terminals
! Measure ba~tery voltage between power i 37 and ground (RB20E)
;transistor terminals ~, 2. 3. 4. 5. 6 ar.a Measure the voltage between C;U
I ground (RB20DE / DET) lermnals 1,12,3,13,2,11 and ground,
(RB20DE i DET)
6 - 10V when engine:
IS nJnning Other Approx, C.l - Q,3V
"irem engine is r.;n:1ing : Other
RB20E
( 1-2)
~
RB200EIOET i ECCS CIU power inspection

~ I i f "DATA MONITOR"

Harness continUity Replace Harness continuity i Measure vOltage between C/U

power ;Cispectlon terminal 27 and ground (RB20E)
I
!
:nspection, Measure
transistor CiU fermlnal 37 and Termmaj 1. 12,3.13,2,11 and
;esistance between power;
groul'd IRB20DE i DEn
tra;)s'stor terminal 1 and I power transistor terminal
: ignition coil terminal 1. 2 (RB20E)
C/U power tranSis~or
Battery voltage when
Ignition switch is ON
I Other
oQ I 01her (RB20DE! DET)
I I Repair ECCSJC/U
r-----LI_ _ _---, I 1
12 -
1
2 : Inoul Signal
Ignition COil power inspection Repair ' sysle", power supply
Inspect voltage between COil harness 3 - 3
!nspectlo~ : circuit system
fermlnal 2 and ground,
13 - 4 !

2 - 5
Battery voltage when r
ignition sw!tcn IS ON: Other
11 - 6
,

~'---=:::::'I oQ Other

Ignition COli ,nspectlO'1 Repair ignition

,Inspect connectors ror Repair
Measure reSiStance coil power
'faUily connect or defects harness
o8tween COl! terminal 1 supply system
and check ClrC:Jlt s stems,
and 2, circuit
IRB2CE)
!Eces cont~ol un:t terminal arrangement!

(RB20E)

Ignition system secondary

part inspectiofl (RB20DE, DET)

EN·331
 ACTUATOR SYSTEM INSPECTION
CA 181 ENGINE

5·3 IGNITION SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM CA18i ENGINE

ThroHie sensor
I Power 1----+---...,. ,.
,1
i s.gnall~f--- , , m
0
(")
I Ground : 3 -~,
"'":1.0
i

. ~~ Irr-H---+
7
~

2-
"
~
ICrank I I
'j-'- leo
1 2
13GrClnu
angle sensor

PUIi€r
~,~;;I
''''
;
!
®
,3 1
42
j--j--......- - t
,
'0
/
s:ot'"" I
I,; -1. 1
...
--1

E')Qm8 i~rature sensor

I:
i -;;;:

i ··~m c8==·---t
L

[Control description]

I The ignition can no! be

9 Ignition timing start point. 'ilthere IS an instantaneous break i
1---=-----+---+-- ·~------·--_1in I the 180' signal.
Ignition timing count. :The Ignition can not be r"••'1onml'dl
angle sensor l'
10 The ignition timing IS set according there is an instantaneous break
Signal
to the map indicated by 180' signal. the l' i
Injection timing according
Engine temperature temperature. IF ai~safe is performed when there
5
isensor ICcmtnDlfor low and high engine a short-circuit or disconnecting.
conoilions.

3. 7 I(:rmtrnl< Ignition timing when idling

ignition timing when

Signal 23

EN - 332
 ACTUATOR SYSTEM INSPECTION
GA1SI ENGINE

Ignition system trouble diagnosis flowchart CA18i ENGINE

Othe"

Self-diagnosIs
. i"SELF-DIAGNOSTIC RESULT'
.~ SELF-DIAGNOSIS (code No. 21)
Norma! Abnormal
(EX) (IN)
~DATAMONITOR"
(Real tlr:le diagnosis)i
@ Normai Abl'ormal

!gnltion coil i:1spectlon Power transistor control Signal inspection

Measure the resIstance between (power transistor unit)
IGN cOil terminal 1 & 3. !Measure voltage between power transistor termmal
7 - 12K g ,3and ground.
Approx. O.SV when
en ina is runrm
Replace
IGNcoil
, Power transistor control slgnal insoect\on
Ignltlo"! pr:mary SIgnal insoection . (EGCS C/U unit)
Measure battery vOltage between power, ! Measure the voltage between C/U

transistor termina: 39 and ground, . terreinals 37 and ground (IN).

5 - 10V whe'l €'1iine i Measu~p the vOltage between C/U
!s runnm Other Itermlnal38 and ground (EX).
I
Approx. O.5V when
: Power tranSistor
engine IS running Olher
(IN / EX) ; 'ilspection I
(5~'3) rma! I
ECCS CJU power inspoction
Har'less continuity ,nspection, e
jj. "DATA MONffOR"
Measure res, stance between power
power transistor term'nal 5 transis tor : : jt Mea~ure voltage bet\veen C/U
,and Ignition coil terminal 1" : Harness continuity inspection' I temllnal 27 and ground
G/U tereninal 37 and power Battery voltage when
Other transistor terminal 3 (IN} :gnrMn swilch is ON Other

Ignition cod power inspection Repair

C/U terminal 36 and power
transistor termina: 3 (EX)
Input signal' Repair ECCS CIU
I . J
Inspect voltage between coil harness
terminal 2 and ground,
on
Other system , power supply
inspection] circuit system
I I
I;nspect cornectors for Repair I
faulty connect or defee:s : harness
i and check C!fcwt systems.:
Ignition co!1 l"iSpection
Repair ignition
Measure res,stance between
coil power
coil te,rrllrai 1 and 2.
supply system
circuit

lEGes contro' unit terminal arrangement I

Ignltion system secondary Replace IGN coil
patt inspection ,"• Oi_,.;,.,',,,: iii:
)aJ9ovIlU :1:_ 1:4 s" • l' 11$
'iiil
21'nf)l~ls~n~1

EN - 333
 ACTUATOR SYSTEM INSPECTION
RB26DETI! RB20E, DE! DET! CA18i ENGINE

(1) Self-diagnosis r'~·-····~·

i +SEL~'DIAG REs+
·0
LJ
• Check faulty system name in "SELF, DIAGNOSTIC rb\
RESULT' mode when the ignition switch is ON and \..!!) 'FAILuRE DETECTED TIME I
engine IS cranking, ! IGN S'GNAL PRIMARY 0 I
• When there is abnormal output, inspect assumed
locations in the following sequence, I
Power transistor (short) - ECCS harness (short) - ,.,. . .,. " . . l PRINT
J,
ECCS control unit ERASE
!_'____ ~ ________ ~~_~
i
_ _ .J'

• Place ignition switch to ON position, @

• Perform diagnosis mode selection procedure with the
diagnosis connector in the vehicle. Check the code
number of the faulty system displayed by the flashing
exhaust gas temperature warning lamp on the instrument
panel (see EN3, 2, 2-2 (2»,

(2) Power transistor control signal inspection

• Measure the battery voltage between the following
connectors and the ground when the ECCS control unit
connectors are connected,

RB26DETT

11,12.13and
2.3,
,
(i::~i; 1~
iii"313

0.2 - 03V !' ,,1#61.;'

Q (#2112 J~
~~+--+---~--O-.2---0-.3~V·-----I ~ ,<4113; v~ i
~~~----~~~~~----l' § ~,
L_:'-:'-~~~~:'-:'-2___---,A~Pil£P~ro~x::...O~.~4V~_ _ _J ,,'..-
,. -..- - . - . - -..~.
..

RB20E I DE I DET

Between EGGS G/U

terminal 37 and ground 1, 2, 3. 11. 12, 13 and

0.2 - 0.3V

0.2 - 0.3V 0.2 - 03V

Approx 1.0V Approx. OAV

CA18i

",-~_A;,cpp:".r_ox_._1_.0_V~_.l..-__A.',pp,-r_ox_._1_.0_V_---, L~, ~, .. ___ . ____ J

EN - 334
 ACTUATOR SYSTEM INSPECTION
RB26DETI! RB20E I DE I DET! CA1S; ENGINE

(3) Ignition primary voltage signal inspection

CA 18i & RB20E
• Measure the battery voltage between the following
terminals when EGGS control unit connector connected.

Between EGGS G/U terminal 39 and ground

6 - 8V 5 - 10V
Approx.l0V
Approx. 8.5V Lower than battery vo~age

RB200E I OET & RB260ETT

• Measure the primary voltage of coil side connector of
power transistor.

Between power transistor

IGN call side terminals 1, side terminal E and
2, 3, 4, 5. 6 and ground ground
Approx.l0V OV
14V OV
l4V OV

RB20E
(4) Harness continuity inspection
CA18i & RB20E
• Disconnect ECCS control unit and power transistor
connector and measure the resistance between the
following terminals.

37 and power transistor terminal 2

Between EGCS CfU harness terminal

37 and power transistor terminal 3
o
Between EGCS GIU harness terminal
38 and power transistor terminal 3

EN·335
 ACTUATOR SYSTEM INSPECTION
RB26DETI! RB20E I DE J DET I CA 181 ENGINE

RB20DE I DET & RB26DETT

• Disconnect the connectors on input side of the ECCS
C/U and power transistor unit, and measure the
resistance between the terminals.

~~~
Power transistor
harness harness side
between terminal 1 and terminal 1
between terminal 12 and terminal 2
between terminal 3 and terminal 3
o
between terminal 13 and terminal 4
between terminal 2 and terminal 5
between terminal 11 and termlOal 6

• Disconnect power transistor unit output side and ignition

coil connector and measure the resistance between the
following terminals.

~~
Ignition cOil
unit harness connector harness
(7 Polanty terminal side) (terminal 1)
between terminal 1 and terminal 1
between terminal 2 and terminal 2 o
between termlflal 3 and terminal 3
between terminal 4 and terminal 4
between terminal 5 and terminal 5
between terminal 6 and terminal 6

• Disconnect each ignition coil connector and measure the

voltage between the following terminals.

(5) Power transistor inspection

• Check the resistance value between all power transistor
terminals with an analog circuit tester probe by changing
the positive (+) and negative (-) poles.
CA18i

analog tester

EN - 336
 ACTUATOR SYSTEM INSPECTION
RB26DETT i RB20E! DE I DET! CA181 ENGINE

RB20E / DE / DET

+1- 0 or not =Q<+I- 00 Q

+1- 0 or not 00 Q =+/- G or not 00 Q

+1- 0 or not 00 Q<+I- 00 Q

RB20DE / DET
'" :1' "1\

RB26DETT

Coil side

CIU side
EEEEEE
123456
+
o or not
CX)Q +
o or not
CX)Q
r--------
I
(Coil side)

~;.e=-,
~." '~
(El'I'~2h)
2
"" ~
~

Coil side EEEEEE +

CX)Q o or not ! ~ q .,~~) ~-;
'"~ ~~~-
d _ .Le-,
COil side 123456 + CX)Q _~' ~E
~ ~

SlOtt"
Coii side 123456 +
oor not f 1121 ?4i sr~
CX)Q
CIU side 123456 CX)Q +

(6) Ignition coil inspection

• Measure primary coil resistance value.

7K - 12K 7K - 12K

RB20E RB20DE / DET I RB26DETT CA18i

EN - 337
 ACTUATOR SYSTEM INSPECTION
RB26DETT i RB20E / DE I DET / CA 181 ENGINE

(7) High tension cable resistance value

• Measure the resistance of the high tension cables.
RB20E
:~al!~~~t~n;;·qd'.;.kfNt• . . I
I No.1 cylinder 5 - 12K g
g I
No.2 eyli nder I 6 -15K
No.3 cylinder 8 -18K g
No.4 cylinder i
8 -18K g
No.5 cylinder
I 8 -19K g
No.6 cylinder I
8 -19K g
Centre cable 4 -10K g
CA18i

For No.1 cylinder Approx. 11 K g

\-------
For No 2 cylinder Approx. 11 K g

Intake side For No.3 cylinder i Approx. 13K 9 i

--------~----------~
For NO.4 cylinder Approx. 11 K g I
Centre cable Approx 8K g I
------j
For No.1 cylinder Approx. 5K g :
For No.2 cylinder Approx 7K 9
Exhaust
side
For NO.3 cylinder Approx 9K g i

For No.4 cylinder Approx 11K g I

Centre cable Approx. 7K 9 I

~------~------------------.~---

EN·338
 ACTUATOR SYSTEM INSPECTION
RB26DETT ENGINE

5-4 IDLE SPEED CONTROL SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB26DETT ENGINE

IGN
[- j.,
IJ AACvalve
El @

1
813-ill~
+
EGGS relay
.. 2 6'
7~1
2 6! AI' regulator
" 15'~~
2
E?::O:+
5 I
1
3
~ 5
----\..2.,
B 1

Throttle valve SWitch

~
'---'
18
[l--t---+sr
m

~
n 1 ,
n 5 ...-9--3

"'"0q
2 ~

Crank angle sersor Q!) Fuel puma relay

"2.
~
Fuel pump ccn1ro
r--t---i" ~ modulator

Air conditioner switcr

)-----1.,
., ~

Engine temperatve sensor

)----...,'"
j-~~"---""ll
. !
Neutrai switch

Power steering sWitch

19,

[Control description]
,{InPut.ar
", •~,.,". fl:ramiIn8l~: fl'"<," ',.', ..'. ".'C~oi.~"'~
," .' ",
..~~.1M·;-"1
' ",; .. "'.. ,,'" .. ,._,,».>.',;, ._, :,
Crank angle sensor Read engine speed and feedback control is
42. 52
1'signal I performed for speed value.
Changes Injection timing according to eng.ne
Engine temperature sensor ! 28
temperature.
'Throttle valve switch Operates when there is a fault with throttle sensor
54
(Idle connection pOint) I (idle Judgement backup)
Fuel cut Clunng deceleration.
IFlow correction dUring acceleration or deceleration
, Throttle sensor 38
I:nterrupts Injection.
I Idle Judgement.
i Vehicle speed sensor 53 IStarts idle control at vehicle speed below Bkm!h.
Air conditioner SWitch 46
IAfter engine warms up. Increase idle when air
'conditioning is turned ON. I
I
Neulra I swi tch 44 Starts idle control in neutral position.
IIncrease idle speed when power steenng oil !
PO'lrer steering switch 19
pressure is too high i
,
I 'Increase idle speed when battery voltage is low
, Batter; vonage 49
I(below 12V)
EN - 339
 ACTUATOR SYSTEM INSPECTION
RB26DETI ENGINE

Idle speed control system trouble diagnosis flowchart RB26DETI ENGINE

Me valve fLnction 'ns ect!on
:~:! Active test
'dIe ~~d changes 01her
I
!lnsoect Input system I AAC valve controi Signal Inspection I
Battery vOltage inspection between AAC I
valve terrrmal 1 and grourd.
Cranking.2 3\/
!dling 6 - 1QV I Ot'1er
I I ,.---.J-I___
, Supplemental air supply parts I
inspection !
!AAC valve power supply inspection I
Measure voltage between .",AC I
: Air regulator
!
.
Inspection (Power,
I
(Check for any disconnection. i Iterminal 1 and ground. • : maio unlt) .
. clogging etc)
f',;o disconnec:ion I
. Batteri voaage when
Ignition switch is ON I 01her
Normal I Abnorrlui
~~~---'--....,
Hose disconnected
or clogging I or clogged 1 l
~c va:ve inspectIon Repair AAc valve
IOthe r system Insoectlon I R~pair Measure reSistance between power supply
AAC valve terminal 1 and 2 circuit system
Other
Otrer system: Repair or
InSpection. i
replace air
Harness continUity inspection Replace regulator
Measure resistance between AAC haflless: AACvaive
terminal 2 and C/U harness ~ermjnal 4.
oU Other

I
ECCS CtU powor inspection Repair harness
.Il. "DATA MONITOR" Note: The output data for the
i:g:. Measure voltage between CjU terminal AAC valve system must be
49 and ground,
checked With an oscilloscope.
Battery voltage when
ignillOn sWltch is ON
r--~-'--....,

[ECCs control Unit te''71lnal arrangement I

IInput Signal syst~m Inspection I Repair ECCS
ClUpower
supply circuit

EN .. 340
 ACTUATOR SYSTEM INSPECTION
RB20E 'DE' DEi ENGiNE

5-4 IDLE SPEED CONTROL SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB20E I DE I DET ENGINE

Z5{45)
AACvalve
'27 (49}
141
4O\Hi)

Cfrdf
5 3'

m
valve J2151} ()
()
switch 22(54) III

Crank ""
0

19(41} [
10(42) c:
"""
28(00)

Air corditioner switch

Engine temoerature sensor

5 (26)

8(30)

3S{19j

Power steering switch

: 21 (53}

L
) RB20DE i DET

[Control description]

,·,c' .. i .' . .......

,,'; ...•..... '/"'i ~";ji '"rJii 'f;·j~k;' ..*
. . .' r
Crank angle sensor Read engine speea and feedback control is
10. (42)
1" signal ..,~"v, ,~u for speed value.

Changes Injection timing according to engine

Engine temperature sensor 8. (28)
temperature.
Throttle valve switch
(Idle connection pomt)
32. (57) IStarts idle control when ON at idle contact POints !

Vehicle speed sensor 21. (53) Starts idle control at veh.cle speed below 8kmlh
i
.After engine wanns up. increase idle when air
Air cond.tioner switch 29. (46)
!
conditionrng IS turned ON. i
Neutra I SWitch 24. (44) Starts idle control in neutral position .
Increase Idle soeed when power steering oi I I
Power steenng SWitch 38 (19)
pressure IS too high.
,

Increase idle speed when battery voltage is low

! Battery voltage 27. (49)
(below 12V).

EN - 341
 ACTUATOR SYSTEM INSPECTION
R820E; DE! DET ENGINE

Idle speed control system trouble diagnosis flowchart RB20E I DE I DET ENGINE

jAAC vatve control signal inspection i

II! "ACTrVE TEST' I cf0

:1j)Measure vOltage between ACC .
i valve termmal1 and ground.
OO€!t11ng (Duty) display
Cranlcng 2 ~ 3V
idlillg 6 - lGV Other

Supplemental air suppty Me valve power supply inspection I

parts inspection Measure voltage between AAC '
, (Check for any disconnection . : terrli'1al 2 and ground.
• clogging etc) Battery voltage whe'1
ignition swAch is ON O:her
No Clsconnect!on
or clogging
":-~-.L_-":::'
I
Me vaJve inspection , Repair AAC valve

=
!Other system Inspectlon
j
Repair: Measure resistance between;
I AAC valve temlnal 1 and 2 I
power supply
circuit system
9 -::-;-~ Q I O.he c

r:7"----.-~
Harness continuityIinspection I
Rep lace
Check tf-)e continuity oetween AAC harness Me valve
terminal 1 and C!U ha r '1ess termina! 4
(RB20DE. DETi. Between 1 and 27 (RB20E).
oQ I Other

I
IEGGS CIU power supply Inspection I Repair harness
r---------~~~------~
~;~ "DATA MONITOR"

'®Measure voltage between C/U Note: The output data for the
term.nal27 and ground (RB20E). AAC valve system must be
Tel111inal 49 and ground (RB20DEIDET) checked with an oscilloscope,
Battery voltage wher
ignJtion swi'lch IS ON
I Other

I I IECCS con~ro!
Iloput signal system Inspeclion I Repair ECCS unit terminal arrangement j
ClUpower
supply circuit (RB20E)

(RB20DE, DEn

EN .. 342
 ACTUATOR SYSTEM INSPECTION
RB26DETT / RB20E ; DE , DET ENGINE

(1) AAC valve control signal inspection !

• Measure the voltage between the following terminals
when ECCS control unit connector is connected,
(11~ t---i:~'ii-"'t-'--(-{f)
ECCS \
control : ~
Unit; "':"

) RB20E

6-7V 6-7V
8 - 10V 8 - 10V

OR
RB26DETT
• Measure voltage between AAC valve connector terminal
2 and middle harness connector terminal 3 and ground,

RB20E I DE I DET
RB20E I DE I DET
• Measure voltage between AAC valve connector terminal
1 and ground.

(2) AAC valve system inspection • ACTIVE TEST. 0

• Use "AAC VALVE OPENING" item in "ACTIVE @ AACN OPENING 27%
TEST' mode to set an optional angle. MONITOR
• Check that idle speed changes corresponding to setting CAS,RPM (POS) 950rpm
AIRFLOWMTR Q,93V
value at this time,
AIR FLOW MER-R Q,92V
ENG TEMP SEN 68°C

loull UP I OWN Ilod

EN - 343
 ACTUATOR SYSTEM INSPECTION
RB26DETT / RB20E I DE / DET ENGINE

(3) AAC valve power supply inspection

• Disconnect AAG valve connector and measure voltage
between the following terminals.

Between AAG valve Between AAG valve

connector harness connector harness
lerminal1 and ground i terminal 2 and ground
!
Battery voltage Battery voltage

RB26DETI
OR:
• Measure voltage between the middle harness connector
terminal 7 and the ground.

(4) Harness continuity inspection

• Disconnect the connector from EGGS control unit and
AAG valve and measure the resistance between the
following terminals.
RB20E I DE I DET

"", Between EGGS control Ul1It harness terminal

4 and AAG valve harness terminal 1
oQ
Between EGCS control unit harness termmal
113 and AAG valve hamess terminal 1

RB26DETI

Between EGGS control unit harness terminal

4 and AAe valve harness terminal 2
Between middle connector AAG valve
terminal 3 and AAe valve harness terminal 2

EN - 344
 ACTUATOR SYSTEM INSPECTION
RB26DE7I. RB20E DE, DET ENGINE

(5) AAC valve inspection RB20E I DE I DET

• Disconnect the AAC valve connector and measure the
resistance between the following MC valve terminals,

Between AAC valve termmal 1

and 2

RB26DETT
• Measurement can also be performed at middle connector
terminals,

Between AAC valve terminal

3and 7

RB260ETT ONLY
(6) Air regulator power supply inspection
• Measure the voltage between the following terminals and
ground when the air regulator middle harness is
connected,

Between middle harness connector

Measurement location
termronal 8 and ground

Ignibon switch ON Battery voltage for 5 sec

Cranking Approx 10V

kJling Battery vottage

(7) Air regulator inspection

1, Shutter opening angle inspection (static characteristic)
• Visually inspect the shutter angle

Below -20'C

Half open

2,
Above 60'C

Inspection (dynamic characteristic)

Fully closed
TI
~"',
I"'"
• Apply current from the battery to the terminals and check ~I~-'

changes in shutter opening angle, The shutter must

gradually close fully within 7 minutes,

EN - 345
 ACTUATOR SYSTEM INSPECTION
CA18' ENGINE

5-4 IDLE SPEED CONTROL SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM CA18i ENGINE

r-~~~~~----------~~

Wk;::WSS_T____---t~ ~
Idle re-v correction
solenoid
.---.---.~'lJ
ECGS 'elay
r--
~, I
1
~ 14
.I:TIil.
unJ.J i FICO solenoid ,
bU g
P-j 3

~m~-'
~ 4 I-~ 1 ;
I
Thro:tle sensor I
p~Q~w~e~r;=:::~Rl~·~==============-j3.,
lsig~
;ij.
2 Power steenng switch

riG~,o~U~nd~----t_:3~,--------~---------+~ ".-.---+w'3j+-----;
!---~-
i Signal 2 4 f-------j----.-----+ i '-- 1
29' . A'r conditioner switch
/~ 43 ~ ... Light sWItch
\tCt'
45 t----.~ Heater fan swi1Cll

46+'- Rear defogger switch

:-----------

[Control description]

engine warms up. increases idle when air

conditioner switch 29 I I Is turned ON.

31 ower steen ng sWitch ON.

43
r - - -..--------..- - - - - j - - - - - - - i Turns on Idle rev correction solenoid when switch
45 is turned ON and inceases idle (* D range for
r-----------------+-----------iAI vehicle)
defogger sWItch * 46
ilncreases Idle when air conditiOning IS turned
solenoid 103

power steenng, head lamp,

rev correction solenoid 111
d"fnn()", swltchs are ON.

EN·346
 ACTUATOR SYSTEM INSPECTION
CA 18; ENGINE

Idle speed control system trouble diagnosis flowchart CA18i ENGINE

Idle rev correction device tnspection

i ~ ACTIVE TEST
~lt ApPlY battery load and power steering
I load ect. woen Idling afrer engine warm
up, •

Idle rev stays constant

or I!'crease I :die rev decreases

I I
,Input or othe~ system! Solenoid control signal inspection
inspection Measure voltage between ECCS CIU
,:ermmal 11 and ground OR between
'mid point connector 5 and ground
No power load or power steer:ng load is
a;;::;::!ied wren Icllng: Power voltage
When cower load is apDI cd' OV Otner

I
Solenoid power inspection
Measure voltage between mid
pOint connector harness terminal 2
I and ground.
Battery voltage when :
ignition SWiiCh ,$ ON I Other

I
I~'enoid unit inspection I I Rlpair poWer

® ,Measure :esistance betv:een

: solenoid te~'1Ilnai 2 and o.
circuit

20-300 1 Other

J
WCCS CIU poiwer supply inspection Re~lace solenoid
i "DATA MONITOR"

~Measure \I()~age between EGGS

CfU terminal 27 and ground.
Battery voltage when
ign!lion switch IS ON
I Other
I
, Harness continuity inspection Re~lr ECCS C/U power
! Measure t~e res:stailce between
! supply circuit system
;1soienold harress terminal 5 and 'I·

. C/U hames$ terminal 11. .

oU Other

Inspect connector for any faults Repair harness

or bad conneciion.

IEGGS control unit terminal arrangement I

EN - 347
 ACTUATOR SYSTEM INSPECTION
CA1S; ENGINE

(1) Idle rev correction solenoid control signal i+

,
inspection !

• Use "IDLE CORRECTION S/V" in "ACTIVE TEST" . IDLE CORREC SN

mode to set the value. MONITOR
• Check that engine speed changes corresponding to
setting value. PWRSIG
;

LON :1 ON/OFF
, _.._---- ----
'I OFFl
~.---

• Measure voltage between the following terminals

when ECCS control unit connector IS connected.

ov
ov
Battery vo~age
'!:t---------i ~._._. _ _._ _ _ _ ~~

ov

(2) Idle rev correction solenoid power supply

inspection
• Disconnect idle rev correction solenoid connector and
measure voltage between the following terminals.

(3) Harness continuity inspection

• Disconnect idle rev correction solenoid connector and
measure the resistance between the following terminals.
Between EGGS GIU hamess Side
terminal 111 and idle rev correction 0 Q
solenoid harness side terminal 5

(4) Idle rev correction solenoid unit inspection

• Disconnect ECCS control unit and idle rev correction
solenoid connectors and measure the resistance
between the following terminals.

Between hamess connector termtnal 2 and 5 20 - 30 Q

EN - 348
 ACTUATOR SYSTEM INSPECTION
CA18 ENGINE

(5) FICO solenoid control signal inspection

FICD
• Use "FICO StY" in "ACTIVE TEST" mode to set solenoid .'~"'~

the value. ~ 1
1-£2'}-·-t=r--7T 103 Ii
• Check that engine speed changes corresponding to L@---(.;oi / / . ECCS .
set value.
• Measure voltage between the following terminals
when ECCS control unit connector is connected.
r~

Ale switch OFF Battery vo~age

(6) FICO solenoid power supply inspection

• Disconnect the connector and measure voltage between
the following terminals.

(7) Harness continuity inspection

• Disconnect FICO solenoid and measure the resistance
between the following terminals.
I Between ECCS C/U harness side terminal 103
i and FICD solenoid harness side terminal 4
o

(8) FICO solenoid inspection

• Disconnect ECCS control unit and FleD solenoid
connector and measure the resistance between following
terminals.
Between harness connector terminal 1 and 4 20 - 30

EN - 349
 ACTUATOR SYSTEM INSPECTION
RB26DETT ENGINE

5·5 WASTEGATE VALVE CONTROL SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB26DETT ENGINE

IGN

EGGS relay

[£D~e~to~n~a~tl~o~n=s~e~n1-----------i~ EX'1aust Inter·

irter-
manlfoid coole" Air c'eaner
IUD~e~t~on~a~t~io~n~s~en~----------i~

actuator Exhaust Airflow

tube charger tube charger meter
Wastegate
actuator

Wastegate valve control system diagnosis flowchart RB26DETT ENGINE

Wastegate valve controt solenoid contrQI signal

inspection
Measure voltage between SN terminal 2 , C/U
te'mlnal 25 and ground.
Batte'Y voltage when Idling
Without engine ,oad: OV Other
I .
! Inspect air supply: 'sOlenOid power supply Inspection.
isystem Measure voltage between SN
!

iterminaJ 1 and ground.

Battery vOltage when
Igri:ion sw\tch is ON Other
Repair air
.nspection supply system
Solenoid inspection
I
I Repair power supply
MeaSure the resistance circuit system
I
between SlY terminal 1 and 2.;
30-400 I Other

I
ECCS CIU power inspection
Re~lace
Solenold valve
j; "'JA TA MONiTOR"
ig: Measure voltage between C/U terminal
, 49 and groJnd
Batiel)' voltage when
ignition swrtcn is ON .Li_______O_t_he_r__-,

I
Harness continuity inspection
I
Repair EeCS CIU
Measure resistance between SlV i power supply
te'fT1inal 2 and C/U termlna! 25. ' circuit
oU _--'-_ _ _,
fees control unit Terminal .arrangement I
Inspect cirCUli system for connector Repair harness
break or drsconnec:iort

EN - 350
 ACTUATOR SYSTEM INSPECTION
RB26DETT ENGINE

(1) Wastegate valve control solenoid control signal

inspection
• When wastegate valve control solenoid connectors are
connected, measure voltage between the following
terminals,
OR
• When EGGS control unit connectors are connected,
measure the voltage between the following terminals,

termmal 2 and ""'linn

Approx. 0

(2) Wastegate valve control solenoid power supply

inspection
• Disconnect waste gate valve control solenoid connector
and measure the voltage between following terminals,

Between solenOld harness

terminal 1 and ground

(3) Waste gate valve control solenoid inspection

• Disconnect wastegate valve control solenoid connector
and measure the resistance between the following
terminals,
BetNeen solenoid terminals1 and 2 30 - 40 Q

(4) feeS control unit power supply inspection

• Refer to the fuel pump system section,

~alveiliil!\!
n
(')
(5) Harness continuity inspection <f)

• Disconnect the connectors from the wastegate valve ". 25 §

control solenoid and EGGS control unit and measure the ~
resistance between the following terminals,

EN - 351
 ACTUATOR SYSTEM INSPECTION
CA1SI ENGINE

5-6 PTC HEATER CONTROL SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM CA18i ENGINE

~l
, PTC heater

I, iwJ~
Crank angle sensor ,oot-- I'"
~~.
1 180" signal ,

i
2, Power
3. Ground JI r&J
~ ,2
3
4 1·) siena!_
Engine temp
sensor
PTC
heater
g]
5

10
,

~
~ relay
," ,

(1) PTC heater control signal inspection

• When EGCS control unit connectors are connected,
, fECCS! .r--'r1
measure the voltage between the following terminals.
! I~~~troi I
' ~ ~ToC heater
, I <>-t-,
! 100k-.---~
L-_: ~ PTC heater
Engine temp (below 65'C) when engine i " ,elay
Approx. OV
I
is runntng (Battery voltage over 13V) ,J.._ _ _ _ _ _ _ _ _- - '

(2) PTC heater power supply inspection

• Disconnect PTG heater connector and measure the
voltage between following terminals.

Low engine temperature when engine

Battery voltage
i IS running (Battyer voltage over 13V) ,

(3) ECCS control unit power

• When ECGS control unit connectors are connected.
measure voltage between the following terminals.

When ignition
switch is OFF :
OV Battery voltage

When Ignition
switch is ON
Battery voftage OV
Note:,
Same condition as ON will be retained for 15 seconds after
the ignition switch has been turned from ON to OFF.
EN - 352
 ACTUATOR SYSTEM INSPECTION
CAIS; ENGINE

(4) Harness continuity inspection

• Disconnect ECCS control unit; PTC heater connector
and PTC heater relay and measure the resistance
between following terminals.
Between ECCS CIU terminal 106 and i
PTC heater relay harness terminal 1 '

Between PTC relay harness terminal I

5 and PTC heater harness terminal 2 i
00
i Between PTC heater harness termmal
, 1 and ground

(5) PTC heater inspection

• Disconnect PTC healer connector and measure
resistance between the following terminals.
Between PTC heater terminia 1 and 2 Aporox. 1 0

5-7 LOCK UP RELEASE CONTROL SYSTEM INSPECTION (AfT VEHICLE)

CONTROL CIRCUIT DIAGRAM CA18i ENGINE

Lock up release
solenoid
Throttle sen SOt opening ,
(Idle position) - 115r'----t:~!j
ECCS

Eng,r.e temperature ----'L,,__---'

, control unit

(1) Lock up release solenoid control signal Lock up release

inspection $Ol~nojd ~I~~

• When ECCS control unit connectors are connected. ~1t5 !

measure the resistance between following terminals. I ~/ ; ECGS '

~" I ~~~troll
+\~)

Approx. OV
sensor in idle position

Other (apply load) Power voltage

EN - 353
 SENSOR SYSTEM INSPECTION
RB26DETT! RB20E! DE! DET I CA 181 ENGINE

6. SENSOR SYSTEM INSPECTION

Use measurement tools such as circuit tester. CONSULT electrical system diagnosis
tester and oscilloscope to test the sensor system. Refer to section EN 3, 1, 1 - 1, (6) in
TROUBLE DIAGNOSIS section for an explanation of the measurement equipment
operation procedures. Refer to section 5 for the preparation.

6-1 CRANK ANGLE SENSOR

CONTROL CIRCUIT DIAGRAM RB26DETT ENGINE

ECCS relay
r=:=-,
+ 16 i
I I I -- 49 ,Ignition timing cantrall
m
n
n
Crank angle sensor
120' signal 1
I
51
., (J)
n
I Fuel injection control I
0
1'sIgnai 2 42 a
Iidle spe~dcontrol
I
~

Power supply 3 I 52
2-
<:
, ::J
Ground 4 50 ;:;:

l-
( 11 :[31 4) i
i
~

EN" 354
 SENSOR SYSTEM INSPECTION
RB26DETT ENGiNE

Crank angle sensor system trouble diagnosis flowchart RB26DETT ENGINE

Self-diagnosis
Ii "SEL~-DIAGNOSTIC RESULT-
.:g Self-diagnosis (Code No. 11)
Normal I Abnormal
,
I
I 'DATA MONITOR" II
(real-time diagnosis)

Normal Abnorrra!
I
IInspect other Crank angle sensor input signal inspection.
sys:ems ~"DATA MONITOR"
i Measure vOltage between ECGS CiU !

term nal 41. 42 and ground

,Nhen engine IS :unnI'1g:
~ Engu;e rpm display
<fi: Approx. C.5V between terminal 41 and ground
A::::::rox, 2.5V between term',:.:::.,n:::a:::1:::42=-::a:::nd"-"'Qr:::o:::":::nd=--L_ _ _ _O:...':::he:...'_ _ _ _ _--,

: Crank angle sensor power supply

I and ground Inspection

i MeaSure :he voltage between

Crank angle sensor output signal inspection : te'mlnals 3 and 4

Measure l'1e voaage between
term'nals 1 and 4 and term;nai 2 and 4.
Battery VOltage when
ignition sWitch is ON
I Othef

When engine :s run;l'~ q !

I
Crank angle sensor inspection Repair crank
Q,5V bet~een 1errrul1al-l ard 4 !

2.5V belweer termInal 2 anc .:: Rotate shaft by hand and angle Sensor
O~her
,measure voltage between each power supply
I I :crank angle sefisor lerrr:inal and
iground.
or ground
InspeCl crank angle Harness continuity inspection
sensor and EGGS G;U ! Measure the resistance
connectOrs for breaks or; between crank angle sensor
disconnection" i
harness 1 and EGGS G;U
harness 41. crar)k angle
sensor harness 2 and EGGS
GIU harness 42
OQ I Other
I Aepair1har ness
Inspect EGGS GIU
connector for contact a d
Voltage betwee n terminal 1 and ground
defects. repeats between Q.5V and OV.
Voltage be~ween termmal 2 and ground
Other
repealS between 2.5V anrd...:O:,;v'---_ _-'--_ _ _-.

; Inspect crank angle Repair crank angle

, sensor connector for i sensor
contact and defects. !

t::!g!e:
For crank angle sensor system inspection, use CONSULT and oscilloscope to check output
waveform.

IEces control Jrit ~ermlr)al arrangement I

EN - 355
 SENSOR SYSTEM INSPECTION
RB20E ! DE! DET ENGINE

6-1 CRANK ANGLE SENSOR

CONTROL CIRCUIT DIAGRAM RB20E I DE I DET ENGINE

E~elay
40116)
I I .1 21(49) r-- _ , Ignition timin9 control
m
0
Crank angle sensor 0
120' signal 1 19 t41}
fJl
"0 I
1" signal
Power supply
,.---'~
2
3
I 10(42)
-"
~

2-
c:
\
I
I
--I Idle speed control

::l
Ground .. _- ~ ;:::

1
l' 2 3 4
) RB20DE I DET I
Crank angle sensor system trouble diagnosis flowchart
RB20E I DE I DET ENGINE
I Self-diagnosis
"Ii:, "SELF-DIAGNOSTIC RESULT"
leg Self-diagnosis (Code No, ~ 1)
Normal i Abnormal

Abnormal
~ .-~'
, Crank angle sensor input signal inspection
,~mATAMONITOR"
I
When engine:5 ,unnmg:
I
I

,:g Measure vOlt,age between EGCS C/U

terminal 19 (41).10 (42) and ground.
I
;
II Engme rorT' dISD'BY
,a Aoorox O.5V between termwal 41 and ground
I
I
Approx. 2.5\1 between terminal 42 and ground
--~~~--~
Other

r.c~m--n7k-a-n~g~le--s~en~so~r~p-o-w--e-r7su7p~P7I'v~1
Crank angle sensor output signal inspectlonl and ground inspection .
Measure the voltage between ' Measure the voitage between I
termmals 1 and 4 and terminal 2 and 4, termlna!s 3 and 4. ~
Battery voltage when
Wher engine is running: Ig'l;!ion SWitChrS,.::O;cN':""-l..__O_th_e_r___- ,
O,5V between terminal ~ ar,d 4
25V belween terminal 2 and 4 OHler Crank angle sensor in'spection I Repair crank
,Rotate s"aft by raod and I· angle sensor
'meaSIJre voltage between each power supply
Harness continuity inspection
cranK ar:gle sensor termlna; and, or ground
,Measure the res~stance
round.
connectors for breaks or, between crank angle sensor
disconnection, I harness 1 and EGGS G/U Voltage between term!!1ai ;
harness 19 (41), crank angle and ground repeats between i
sensor hamess 2 and ECGS O.5V ana OV, :
CiU harness 10 142), Voitaoe between terminal 2 ~
and ground repeats between Other
2.SV and OV.
,---
[Inspect ECCSC/U connector ·,nspect crank acgle Repair crank
Ifor contact and defects. sensor connector for angle sensor
~.. ----'
I comact and derects.

EN - 356
 SENSOR SYSTEM INSPECTION
CA1Si ENGINE

6·1 CRANK ANGLE SENSOR

CONTROL CIRCUIT DIAGRAM CA18i ENGINE

~ ___ ii.ECCSr~lay
. -J40
, tv
I J! 0 ~5 m
(")
I •
, Ignition tim:ng control
L._
(')
_3I'SL I <Jl
111""L!l It--t 9 a
Crank ancle sensor
r-us;;'"gnal
I: 2 Pcwe'
I
i
~
~4.1
1
, I 19

+~--'36
-
::l
~

2-
c
3, Ground ~~ r--_~~~--,10 ::l
~.!:).s!"gn",a"I~~
!
~ __pf---t20 ;:;: speed control

Crank angle sensor system trouble diagnosis flowchart CA 181 Engine

Self-diagnosis
i ··SELF-DIAGNOSTIC RESULT"
::g Selt-dlagnoSis (Code No. 11)
Normai Abnorma,

·'DATAMONITOW
(real-time d!agnosIS)
Abnormal

Crank angle sensor Input signal inspection.

i'DATA MONITOR"
: E Measure voltage between EGGS G;U
I terr'1l~al9. 10. 19.20 and ground.
When engine IS running:
_@_ Engine rpm display
It: A;:;;::rox, O.SV between :etminai 19,9 ana ground
Aoprox. 2.SV between terminal 10, 20 ana grouna O~her
~----~------~~-----.

eID
Crank angle sensor output signal inspection I
Crank angle sensor power supply.
and ground inspection '
Measure the voltage between : Measure the voltage between
:termina:s 1 and 3 and terminal 4 and 3, terminals 2 and 3.
8 attery vo tage wh en I Otr,er
ignition SWitch is eN
!
Whetl engine is running:
O.SV be:ween 'ermlnal 1 and 3
2.5V between terminal 4 and 3
I
Other Crank angle sensor inspection
1 Rep.: r crank
I
Inspect crank angle
sensor and ECCS C!U
! I
Harness continuity inspection
Measure the ~esls:ance
I Rota~e sha~ by hand and
measure voltage between each
crank angle sensor terrpinal and
angle sensor
pow. r supply
orgro und
I
connectors. 'or breaks or 'betwee0 crank angle sensor around.
d:sco'1'1ection. harness 1 and ECGS e/U
harness 19. crank angie
Voltage between terminal 1
and ground reoeals between :
I
sensor harress 4 and ECCS O.3V and 5V.
C/U harness 1O, Voltage between terminal 4
and ground repeats between Other
09 I Other O,3V and 5V_

Re~air
I
Itspeet ECCS GiU connector
for cor:tact and defects, '
I
harness
I
Inspec: crank angle I Rep~ir era nk
sensor connector for i angle sens or
contact and defects.
Note:
For crank angle sensor system inspection, use CONSULT and oscilloscope to check output
waveform,
EN - 357
 SENSOR SYSTEM INSPECTION
RB26DETI! RB20E! DE! DET ! CA 181 ENGINE

(1) Self-diagnosis
• If P or 1800 (1° or 1200 for RB20E I DE! DET) signal is not input within fixed period of
time, "CODE No. 11" or "FAULTY SYSTEM NAME"' will be displayed in normal self-
diagnosis operation when using CONSULT. Examine the following items carefully when
this occurs.
fE\ . When malfunction occurs again, use the real-time diagnosis (CONSULT
\.eJ "DATA MONITOR" mode) or oscilloscope to detect disconnection.
• When an abnormality is detected, consider these locations in the follOWing sequence as
there may be other malfunctions besides the crank angle sensor.
ECCS harness (faulty contact) - Crank angle sensor - ECCS control unit

(2) Input signal inspection

1* tAONITOR
CAS qpM (POS)
* NO FAIL" [;J
975rpm
• Use "CAS.RPM (POS)" item in "DATA MONITOR" to @ }!,,:R FLO'I" MTR
AIR rLOW MTR (H)
O"91V
Q,92V
determine engine speed. ENG TEMP SEN 78"C
EXH GAS SEN 1 22V
EXH GAS SEN (n) O.02V !

M/R RiC IVNT RlCH

WR FIC MNT·R RICH
GA'1 SPEED SEN Okmth
RECORD
_ _-1
• Measure the voltage between following terminals
with ECCS control unit harness connected.
RB26DETT I RB20E I DE I DET
- -...
- -.. ---

ECCS C/U terminal EGGS G/U terminal 42

41 (49) and ground
20" i
Crank 2!---c-:;/;t1O(42)
OV or approx 5V OV or approx 5V an gl € 7~,
n
1.\..:./ ontrol uni

Approx 0.5V 2 - 3V

0.3 - O.7V 2 -3V

CA18i

EGGS CIU terminal 19 i EGGS G/U terminal 10 i

and ground (180' signal): ana ground (1' signal) I

Approx. O.3V or 5V ApproK 0.3V or 5V

Note~
The voltage in above charts are average voltage values of
the pulse waveform measured by a circuit tester and these
are for reference only, The waveform must be checked by
using an oscilloscope,

EN - 358
 SENSOR SYSTEM INSPECTION
RB26DETT I RB20E ,DE I DET ! CA18i ENGINE

(3) Sensor output signal inspection RB26DETT I RB20DE I DET

• Measure the voltage between following terminals with
crank angle sensor connector connected.

OV or approx 5V Battery voltage

Approx 05V Battery voltage

Battery voltage

Approx 2 - 3V Aporox 2 - 3V Battery vo'tage

RB26DETT I RB20DE I DET

(4) Harness continuity inspection

• Disconnect ECCS control unit and crank angle sensor
connector and measure the resistance between following
terminals.

19 1
10 2
o
9 (or 19)
10 (or 20) 4

CA18i

EN - 359
 SENSOR SYSTEM INSPECTION
RB26DETT! RB20E ! DE ; DET ; CA 181 ENGINE

(5) Crank angle sensor inspection

• Disconnect crank angle sensor from engine, turn the shaft
by hand and measure the voltage using connector.

i " ' ; ". !!.ItB~}ftB~EtbE#~I~!~0J:;:~~r:~

iCrank angle sensor 2 and ground W signal) 5V

OV or approx.
: Crank angle sensor 1 and ground (120' signal)
5V
RB20E
Icrank angle sensor 3 ana ground (Battery voltage) Power voltage

: CranK angle sensor 4 and ground (ground) OV

~~-

, 03V or approx. i
Crank angle sensor 4 and ground (1' signal)
5V i
r--------~--~-\--------J I .~
O.3Vor approx!
'I L.~,_~_ _ _ _ _,_._ _ _ ._ _ .. _~
: Crank angle sensor 1 and ground (180'5Ignal) 5V'
I

Qpution:
To prevent injector from operating, remove fuse or connector
before inspection. When an apparent abnormality is
detected by self-diagnosis according to shaft rotation, be
careful as it may not be an actual abnormality in this case. /;;...

EN - 360
 SENSOR SYSTEM INSPECTION
RB26DETI ENGINE

6-2 AIR FLOW METER SENSOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB26DETT ENGINE

Air flow meter ifont)

~i~~~~~ ;~l t1Jf-:

~
---"=,...--r-----<I
m
o
o(j)
I Signal grOllt'O , :' 4 f--+-'~~::_t_+ ()

lPower G::J-"'-l--~-+ o
:::J
Air flow meter (rear) • ~
~ "'f1\ ~ --I--r'~=---t-f--+ 27 §
L!:}take~alf:J SIC ~ , 2 f-,

'"
: Power rou'ld 3 3 1"-••

l-§l.9na! cround : ., ,
LE.2.w er ... =s:iJ '='
,
! I

50

• Differs from CONSULT display (R):

Cylinder, air flow meter and CONSULT (data monitor) display items

No 4,5,6 cyi AFM (front) ECCS C/U 35 All flow meter (R)

No, 1,2,3 cyl AFM (rear) ECCS CIU 27 Air flow meter

EN - 361
 SENSOR SYSTEM INSPECTION
RB26DETT ENGINE

Air flow meter sensor system trouble diagnosis flowchart RB26DETT ENGINE

r-seTf-diagnosis .~
iii "SELF-DIAGNOSTIC RESULr I
(i Self·diagnosis (GGde Nc 12 '
I
Normal Abnormal

i Check intake system, , Air flow meter input signal inspection

, to make sure there I 'i'DATAMONITOR"
Jt Measure voltage between ECCS C/U
Air leaks present terminal 35 and 34 (front), 27 - 26 (reari,

Inspect other; Repair intake

Cranl<.ing: AP~rox.1V
Idling: Approx. 1,1V
I
i sySlerns I system 2 500rpm: Aop~ox. 2\/ Other

Air flow meter output signal inspection :Air flow meter power supply &
Measure the vOltage between ground inspection
terminais 2 and 4. Measure the voltage between
-----,---- terrr:inai 5 and 3.
Battery voltage whe~
Other
Ign:tion SWItch IS ON
~-~----~

IAir flow meter inspection

CranKing: AoorQ)c ., V
!dl'rg: Aporox. 1.1 V
2.500rpm: Approx 2V
Apply battery voltage d.rreCtiy 10 :
I Repair air flow
meter power
terminal 5 (+1 and 3 (-I and ! supply or ground
: measure the voltage between;
Other : termmal 2 and 4. While blowing
, air into meter.

Harness continuity inspection

Measure the resistance oetween
, faulty connecLon or the follOWing terr1lna!s:
detects. AI' flow meter ECCS C!U
~arness harness
Front 2 35
4 34
Rear 2 27
4 26

Inspect ECCS C/U connector Repair

for contact and defects. harness

Approx. 2V wnen blowing air in meter

Approx .• V when air is not blowmg Other
=------~.

Replace or clean
air flow meter

,Inspect air flow meier Repair intake

:cor,nectots for fau!ty system
CO'1nectlons or detects.

EN - 362
 SENSOR SYSTEM INSPECTION
RB20E' DE, DE-'- ENGINE

6·2 AIR FLOW METER SENSOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB20E I DE I DET ENGINE

E~elay !
+ 4()(161 !

I i I ... ~-.

27(491 • Fuel injection centrol

~----"I
m
(")
(")
(j) Ignition timing 8ontrol
()
0
. 1 :OJ

j intake-;ir quantlty sig 2 3 (27) ~

c:
:l
j Power ground i 3 ~ !

'"
I Signal ground 4 •
4 (26)
I Power 5

C112~ 5)4!
(Bir(E) (A) ( ) RB20DE I DET

EN - 363
 SENSOR SYSTEM INSPECTION
RB20E I DE I GET ENGINE

Air flow meter sensor system trouble diagnosis flowchart

RB20E I DE I DET ENGINE
Self-diagnosls
J!'SELF-DIAGNOSTIC RESULT"
'4 Se,/-diagnosis (Code No. 12)

rN;;;o;;;nna=i___ .1 Abnormal

ir
1Aii. flow meter input signal inspection
I·.~· 'DATA MONITOR"
: are roo air leax:s. i:i Measure vo;::age oo!ween ECCS CiU termInal!
No ai, , 3 aod 4 (RB20EI. 27 - 26 (RB20DE I DET). i
I
! Air leaks ::::reSe'11
:eaks j
I ranking:. A~prCj(.
1V
iInspect other I Repair intake
c.

Idling: Appro)(. 1,1 V

isystems' system 2.500rpm. Approx. 2V , Other

Air flow meter output signal inspection ~

MeasJre lhe voltage between I
IAir flow meter power supply &
:ground inspection
I
.
termma~s 2 and 4. !Measure the voltage between i

iterminal 5 and 3.
8attery vOltage when Other
:gnl!iDn switch is F0;CN'-_..L_ _ _ _ _ _--,

Air flow meter inspection Repair air flow

Cran"ing: Approx. 1V
Id!~ng: Approx. 1. i V
i
l
, Apply baltery voltage directiy 10
term'ral 5 1+) and 3 (-j and
meter power
supply or ground
" measure the vOitage oetween
terminal 2 and 4 whl'e blowing

[
2.::'lOOrom: A~~rox 2V

Check air flow meter and I

;=::=====L Other
1-.,._·~a=ir='O=lO=m=e~te:::r-'-·I
Harness continuity inspection
_____---1

I, ECCS C/U connectors for i Measure the resistance between

i faulty connection or tre following terminals:
de"ects. i Air flOW meter ECCS C/U
I ha;;,ess harness
FtB20E 2 3
J. 4
FtB2ODE2 27
DET 4 26
og I Other

[Inspect ECCS ~;u

connector.
jtor contact and defects. ! harness
R~air
Approx 2V wher blowlflg air in :netsr
Approx. ~ V when air IS not__
blowing
~ ~~L-
Other
______ ~

Replace or clean
air flow meter
Naair leaKS

_C Repair intake
Inspect aIr ~!ow meler
connectors for tau:ty . system
connect;ofls or ~efects·1

EN - 364
 SENSOR SYSTEM INSPECTION
RB26DETI ! RB20E DE I DET ENGINE

(1) Self-diagnosis
• Normally in a self-diagnosis operation, "CODE No.12" or "FAULTY SYSTEM - AIR
FLOW METER" (when using CONSULT) is displayed if the intake air quantity signal
voltage is abnormally high or low and disconnection or short'circuit in the signal system
should be considered.
(ff\ • When malfunction occurs again, use real-time diagnosis (CONSULT "DATA
\.eJ MON ITOR" mode) or oscilloscope to detect instantaneous breaks.
• When abnormality is detected, consider these locations in the following sequence as
there may be other malfunctions besides the air flow sensor.
When intake air quantity is low: ECCS harness (faulty contact) - air flow meter-
ECCS control unit - intake system (not airtight)
When intake air quantity is high: ECCS harness (faulty contact) - intake system
(not airtight), faultywastegate valve control-
airflow meter - ECCS control unit

(2) Input signal inspection M

• Use "AIR FLOW METER" and "AIR FLOW METER ~ 1* MONITOR *NO FAIL 0
(R)" in "DATA MONITOR" mode to check the following : CAS, RPM (POS) 950rom
items. ! AIR FLOW MTR Q,96V
!AIR FLOW MTR (R) 0 SlV

ApproK O.3V ApproK O.SV

Approx. 1.1V Approx 1.1V

Approx 1.5 - 2.0V Appro. 15 - 2V RECORD

• Measure the voltage between following terminals Ii6'\

with ECCS control unit harness connected. \..:fV

lAir flow
: meter 2t-'- - - - t
ECCS CIU iermmal4
(26) and ground
(ground I nail
Approx O.3V OV
lV
1.1 OV RB20DE:DET

EN - 365
 SENSOR SYSTEM INSPECTION
RB26DETT I RB20E I DE I DET ENGINE

(3) Air flow meter output signal inspection

• Measure the voltage between following terminals when
the air flow meter connectors connected.
~ . ,~; m" TT fZ~IHF'" L".>';
. .!.ii.·i.U.'
. ..·.• ;u.'.•:.•!.~~ io.~.•.~.~
.• ._ .•.~.,~. 2A~r~o;:u~e;i~':n::r i ~i~:~~~~~ 1~;:;'~1'
t.!.'.•.
·..... ,.1 ;." .."' ...•'!.'!!.,. quantity 51.9nal) I Signal)
19111tla1f.~i.~_f Approx 03V OV
.Tl.CrlU!\!dnjjii.~f;:; Approx V 1 OV
',>.:.. ; ~: Approx.l.1V OV

.~0~~ Air flow meter tenminal ,: Air flow meter tenminal'

B and ground (intake E and ground (ground
'",,; ':-:is!' ;";): "tf';';i,;'r elf quantity signal). signal)
.'I9!.i~~f$i~" Approx O.8V OV
Approx.1V OV
Approx 1.1V OV

(4) Air flow meter power supply inspection

• Measure the battery voltage between following terminals
with the air flow meter connector connected.
i
Ignition switch ON, Between air flow meter
. Battery voltage
and engine runnin.::g:..L-:__le_rm_in_a_1_5_a_nd-=.g_ro_u_n<l_· ....J_ _ _ _ _- l

(5) Harness continuity inspection

• Disconnect ECCS control unit and air flow meter
connector and measure the resistance between
following terminals.

--
AIrflow
harness r.arness
:T~~"'" "12 & terminal 35(27)
'T~"om"I. & termnal 34 (26)
T~rr"m'!1 3 & Body ground
harness
2 & terminal 3 (27)
4 & terminal 4 (26)
3 & Booy ground
iTo"""'i''°15 & EGGS reay : Terminal 5 & EGGS reay
harness terminal 3 r..arness terminal 3

(6) Air flow meter inspection

• Apply the battery voltage di rectly to terminal 5 (+) and 3
(-) and measure the voltage change between
terminals 2 (+) and 4 (-) while blowing airon hot wire.
No air blown Appro .. O.BV
Air blown Approx 2V
EN - 366
 SENSOR SYSTEM INSPECTION
-- ~- ::~.GiNE

6-3 THROTILE VALVE SWITCH SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB26DETI ENGINE

i~----~LI. .F u~e~lirin~je~.C;~lo~r;.c~oirn;'tr~ol ~
;
Throttle valve switch

m
(J
(J
(/) : Ignition liming control
g
a
£ .. I Idle speed cont~o!
c
:;J
riC

Throttle valve switch system trouble diagnosis flowchart RB26DETI ENGINE

I Ii 'DATA MONITOR" ;
(real-time Cllag;)051s} I
\Jorma! I AbnorMai
I I
Check Intake system i i Throttle valve switch output

~
to make Suie there signal inspection
are no air leaKS.
!
Measure the vOltage between
termInal 2 and 1.
Accele ration oedal rot
depressed: [I Acceleration ~edal not
cepra ssed: CX)O Other depressed: 8 - 10V
Acce,eration pedal
depressed: OV
: Inspect olher I Adiustlor Other
I systems replace throttle
valve switch
I I
' Inspect throttle valve switch . IThrottle valve switch I
i connectors and EGGS GiU inspection
connectors for faulty connections : Measure :he resistance
or defects_ ; tletween terminal 2 and 1.
Acceieration pedal not
depressed' 0 f.!
depressed: c::x) Q

Switch and ground Inspection Adjustor

Measure tre voltage between replace throttle
:term!nal 57 and 54. valve switch
Acceleratio;1 Dedal no: depressed: 10V
Acceleratic'l peda~ depressed: CV Olher

Harness continuity inspection Inspect EeCS CIU

Measure the resistance between power supply or
the foilowlng termlna!s: ground or replace
Throttle valve EGGS G/U control unit
SWltC'" harness harness
2 57
54
oQ I Other

I I
Inspect ECCS C L: CO:1~ector and ~ Repair harness
throttle va ve sVilich connector for !
contact and de~ecrs

EN·367
 SENSOR SVSTEMINSPECTION
RB20E ! DE i DET ENGINE

6·3 THROTTLE VALVE SWITCH SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB20E I DE I DET ENGINE

~~--.~~.,

To AfT control unit

m ~ -~---Frue! inj8ctior control)..1
mm •

,--, oo
r=o 0-
I
F~;: conUle' 3

r,-----j~p~o~w~e~r
2 IMfJr-;
3 !-

.uVl r-~--~~_+ 32157)

(f)

"
0
;;t
1·-
i
·"gM,ont,mingcortrol

Q.
~·-I 'die speed oon1<oI
~______"1ldle contac 1 j 22 (54)
~.
I
pOint I
i

I ( ) RB20DE I DET

Throttle valve switch system trouble diagnosis flowchart

RB20E I DE I DET ENGINE
, i'''DATAMONITOR·· :
: (real-time dIagnosIs)!
Normal Abnormal

Throttle valve switch inspection Throttle valve switch output

Measure the resistance between' signal inspection
terminal 2 and 1. Measure the vOltage between
I terminal 2 and 1.
Acceleration pedal rIot
depressed: 0 Acce:eration pedal not
depressed: ('X) Q: depressed: 8 - 10V
Acceleration Dedal
de:::r€ssed: OV
: Inspect other I Adjust or --- Other

I systems replace throttle

valve switch r.,----ct:-t""h-Ctt:-,
nspe ~:-,-'---:-·t:-h-----.,
ro e va ve SWI C . i Throttle valve switch
connectors and EGGS GiU . inspection
: connectors for faulty connections, Measure the resistance
i o· defects. between termInal 2 and L
Acceleration oada! not
dep~essed; 00' I Other
dep'essed:oo'" ~

Switch and ground Inspection i Adjust or

.Measure the voltage between ' replace throttle
terminal 32 (57) and 22 (54). valve switch
Acceleration oedal not depressec: 10V
AcceleratIon pedal depressed: OV

Harness continuity inspection Inspect ECCS elU

Measure the reSl$tar-ce betwe€!r1 power supply or
the followng terminals: ground or replace
Throttle valve ECGS GiU control unit
switch harness harness
2 32 (57)
1

Inspect ECCS G/U connector and Repair harness

throttle valve switch connector for
contact and defecis,

EN - 368
 SENSOR SYSTEM INSPECTION
RB26DETT PB2GE DE DET ENGINE

(1) System inspection

• Use "DATA MONITOR" to inspect idle contact point
ON-OFF signal to make sure it is operating correctly.
®

(2) Input signal inspection ::-~1---~~

i, [,jThrottle
• Measure the voltage between the following terminals with valve
:switch >_---.;+22154)
EGGS control unit connector connected.
OR
• Measure the voltage between throttle valve switch
connector terminal 2 and ground.

Bet\\'een ECGS CIU !erminal54

and ground (or bet\\'een throttle and ground (or be:ween throttle
valve switch termmal 1 and ·>J8lve switch term!ool 1 and

8 - 10V 8 - lOV

OV OV

• Measure the voltage between the following terminals

with EGGS control unit connectors connected.
OR
• Measure the voltage between throttle valve switch
connector terminal 2 and ground.

Bet\\'een EGCS CIU terminal.

57 and ground (or bet\\'een terminal 32 and ground (or i
throttle valve switch terminal 2 bet\\'een throttle va lve switch'
and terminal 1 and ground

8 -10V 8 - 10V

(3) Throttle valve switch inspection

(idle contact point)
• Disconnect throtlle valve switch connectors and measure
the resistance between throttle valve switch terminals.

Between throttle velve switch

terminals 2 and 1

con
EN - 369
 SENSOR SYSTEM INSPECTION
RB26DETT I RB20E i DE I DET ENGINE

(4) Harness continuity inspection

• Disconnect throttle valve switch and ECCS control unit
connectors and measure the resistance between the
following terminals,
Throttle
valve sWItch
1
0'1
2
'11:0''',-,'' CiU Throttle
valve sWitch
1
0'1
2

(5) Idle contact point (touch speed) inspection

• Idle SW adj •
and adjustment
• Warm up the engine sufficiently and use "IDLE SW" Lower CAS,RPM slowly
in "OPERATION SUPPORT' mode to inspect idle from 2000rpm to idle and
contact point. then check "touch RPM",
Adjustment must be done
after changing SW position, ,

• Disconnect AAC valve connector and inspect the START

unit when the AAC valve is fully open,

1200 +{- 150

850 +/- 150rpm
900 +/. 150 RB26DETT
950 +/- 150

When the tachometer speed does not conform to the

specified value, perform the adjustment as follows:
• Loosen throttle valve switch tightening volts (2),
• Remove the throllie valve switch connectors, place a test
prove between throttle valve switch terminals 1 and 2 and
measure the resistance,
• Depress the accelerator pedal and gradually release the
pedal to lower the engine speed, Rotate the throtlle valve RB20E J DE J DET
switch body and secure it in the position where the
tachometer speed conforms to the specified value and
the idle contact point is "ON" (the resistance between
terminal 1 and 2 is 0 '1),
• Tighten the throllie valve switch tightening bolts,
• Make sure the idle is ON observing by the tachometer
speed as described above,
• Connect the throttle valve switch connectors,

EN·370
 SENSOR SYSTEM INSPECTION

6-4 THROTTLE SENSOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB26DETT ENGINE

interruot i'1;ec:IOP
j control
I
m
0 - , Fuel Injection contrOl!
48
0
Power 1 1 (/)

~
c;

~[
f- c Ignition timing cortro!1
::J
Sigpal 2 2 38
~
f Ground 3
f-
3 30
c
:J
I Idle speed centroll

'--'

Throttle sensor system trouble diagnosis flowchart RB26DETT ENGINE

Self-diagnosIs I
H."SELF DIAGNOSTIC RESULTS" :
:g: Self-diagnosis (code No. 43;
Normal ,
Abnormal

I
il!'DATAMONITOR"
(real-time diagnosIs)
J
Nanna! I Abnormal

IThrottie sensor inspection Throttle sensor input signal inspection I

Measure the resistance between ~"DATAMONITOR" I

term;nal 2 and 3.
Change fro~ approx.
2kQto 10k {lwhen
accele!'ator pedal is
deoresSed
I I
!!l1soect other I
systems
'I' Measure the voltage between termina: I
: 2 and ground.
Change ~rom approx. Q,5V
to 4V when acceleration
Other
pedal is depressed Other
I
Replace throttle , Inspect throttle senSor and I:hrOtlle sensor j nspection i
sensor i ECCS C!U connectors for faulty MeasL're the re sistance
connections or defects, : oetween terrrlna! 2 and 3.
Change from approx. 2kg
to lOkQw~en accelerator Other
;::-edal IS dep:-essed
,--_---1-_---,
Sensor and ground inspection Replace
Measure the voltage between throttle
terminal 48 and 30, sensor
Other

Harness continuity inspection Inspect ECCS control unit

Measure the resistance between and ground and replace
the following termmals: control unit if necessary
Throttle ser..or ECCS CiU
i-)a:ness harness
4B
2 36
3 30

Inspect ECCS G!U connector and throttle Repair harness

sensor cor-rector for contact and defects.

EN" 371
 SENSOR SYSTEM INSPECTION
RB20E! DE I DET ENGINE

6-4 THROTILE SENSOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB20E I DE I DET ENGINE

-] Fuel injection Gcntro~

Thrott!e ser:sor m
(")
~
()
1 26(48) (fl

- n

[
0
2 1(38) "
~
r-
3
81l 0) "
::l
V '"
I

I ( RB20DE! DET

Throttle sensor system trouble diagnosis flowchart RB20E I DE I DET ENGINE

Self-diagnosIs
""SELF DIAGNOSTIC RESULTS"
i !J: Self-diagnosIs (code No. 43)
Normal Abr'lorma!

I
Abnormal
-----;
~ Throttle sensor inspection . Throttle sensor input signal inspection
Measure the resistance oetween' ·"·"DATAMONITOR" ~
terminal 2 and 3. .. ~
i :li:' Measure the voltage between terrl11n
1(1:23)
- .
Change from approx. 2 and ground
2kg to 10k Qwhe"'l
Cha'lge from approx. O.5V
accelerator pedal ;3
10 4V when accoleratiOn
depressed Other
pedal IS depressed Other

I I
Replace throttle !Inspect Ihro!tle sensor and I Throttle sensor inspection I
sensor I ECCS CIU conroctor. for faulty I Measure the resistance I
: connections or defects. i between term ina! 2 and 3.
Change trom approx, 2kQ
to lOkQwhen acce'erator
I
Other
pedal IS depressed
1.-----'----,1
Sensor and ground inspection Replace
Measure the voltage between throttle
terminal 26 (48) and 8 (30). sensor
Approx. 5V Other
1 I
Harness continuity inspection Inspect ECCS control unit
Measure the res'stance between and ground and replace
the fo'lowing terrrinals: control unit if necessary
11hrottle senso' ECCS C/U !

;- arr:ess har11ess
26 (48)
7 (38)
~.-,3'-- _ _r - _8=(3::;OL)_

Inspect ECCS C U CO~"~6':':::~ 2"'d :nro~tle! Repair harness

sensor C0'1nec1cr fe' ::~:0;::~ 2 d :Jeiects,
n

EN - 372
 SENSOR SYSTEM INSPECTION
RB26DETI' R820E ' c}E . DET ENGiNE

(1) Self-diagnosis
• There is a disconnection or short-circuit in the signal
system when "CODE 43" is displayed in normal self-
diagnosis (mode 2). When this is displayed, check the
throttle sensor resistance or harness continuity, etc.

• If the problem occurs again, use real-time diagnosis (j)

mode or an oscilloscope to check for instantaneous
break in the signal.
I~ONITORING'::r NO FAIL 01
(2) Input signal inspection :CAS.RPM (REF) O'pm
• Use 'THROTILE SENSOR" setting in "DATA MONITOR" THROTILE SEN O.50V

mode to check the following items:

Accelerator pedal not depressed Approx. O.5V

Ignition RECORD
: switch ON Accelerator f--_H_al_f-w_a....:Y'---+__O_.5_-_4_.0_V_-'.
pedal depressed Fully depressed Approx 40V c-.... --.--.--. -------.--,

• Measure the voltage between the following terminals

and ground with ECCS control unit connectors
connected.
OR
• Measure the voltage between terminal 2 and ground with

throttle sensor harness connleicfte~d~'~~~~~~~ii~~~iii~~~~~]

(3) Throttle sensor power supply inspection

• Measure the voltage between the following terminals
when throttle sensor connectors are connected.
~...."...,

Between throttle sensor terminal 1

and

Approx.5V
 SENSOR SYSTEM INSPECTION
RB26DETT I RB20E I DE I DET ENGINE

(4) Throttle sensor unit inspection

• Disconnect the throttle sensor connector and measure
the resistance between the following terminals when the
accelerator pedal is depressed and not depressed.
Between throttle sensor terminal 2 and 3 •

Approlt 2K g

Approx 2K g - 10K g (Resistance wlil,

Increase as pedal is pressed)

Approx 10Kg

(5) Harness continuity inspection

• Disconnect ECCS control unit and throttle sensor
connector and measure the resistance between the
following terminals,
ECCS C/U Throttle
harness sensor harness
26 (48) 1 oQ
7 (38) 2
8 (30) 3

.THROTTLc SEN ADJ. I

CHECKTHETHROmESEN~OR I
(6) Throttle sensor inspection (RB26DETT) SIGNALANDAOJUSTITTOTHE I
,SPECIFIED VALUE BV ROTATING •
• Warm the engine adequately and check operation of the ,THESENSORBOOYUNDERTHE'
throttle sensor by using "THROTTLE SENSOR ! FOUDWING CONDITION.

ADJUSTMENT' in "WORK SUPPORT' mode. (The '. iGN SW"ON"

• ENG NOT RUNNING
throttle sensor can not be adjusted). • ACC PEDAL KEPT OFF

~____~S~TA~R.~T______~

.THROTTLE SEN ADJ .0

AD.i MONITOR

THROTTLE SEN O,50V

MOI'.ITOR

CAS.RPM (POS) 9S0rpm

IDLE POSITION ON

EN·374
 SENSOR SYSTEM INSPECTION
CA181 ENGINE

6-4 THROTTLE SENSOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM CA18i ENGINE

I
1 - - - - -....,,' Fuel injecHon control
Power 1 2S m
0
Signal 1 I2 3
0
(f)
(")
I Grou'ld 3 36 0
::J
i
~
L:,gnaI2 14 7 3
'"
~
~

Throttle sensor system trouble diagnosis flowchart CA18i ENGINE

S"I f-dlagnosls
i i ·SELF DIAGNOSTIC RESULTS· I
I
I ~ "DATA MONITOR" ! It Self-diagnosIs Icode No. 43) i
(real-tiMe diagnosIs)! NOrTlal ! AbnOf'llal
Normal Abnormal
1

ttlB
Throttle sensor inspection
MeaSure the :es!s1ance between Throttle sensor output signallnspection~
terminal 1 & 3. 2 & 3 and 4 & 3. 3 4
.~ 'DATA MONITOR" i ~
:i Measure the voltage between :erninal !
Approx. 1.2 2.4k"
between 1 - 3. 1 & 3. 2 & 3 and 4 & 3. \I:t:D
vVren acceleraLon 3etween 1 - 3 approx. 5V
oadal is depressed: When accele~ation pedal IS depressed' i
Between 2 ~, 3 Aoprcx" 8e~ween 2 - 3 apprc;.:, 1 - 5V I'
0.3 - 2.4k Q Between 4 ~ 3 approx. 0-;:.6::..:-...:4::..5;:.:'::"_...l_ _.:.O:;th:.:;e:;,_--,
Between -4 3 A;Jcrox.
0.5 - 2.9k&..
Other I I
,-----'-- Inspect throttle senSor and Throttle sensor Inspection
I ECCS C/U connectors for faulty Measure the resistance between
Replace throttle conrtections or defects. terminal 1 & 3, 2 & 3 and 4 & 3.
sensor Berween 1 - 3 approx. ~.2 - 2.4kQ
When acceteration pedal IS de:Jressed'
8etween 2 - 3 approx. 0.3 - 2Akg
Between 4 - 3 approx. O'::>-;.,-_-.:.2;;:.9:;k:.:ll=--,_ _O:;:::.th::;:e:...r-,
I I
Throttle sensor power supply Replace
and ground inspection throttle
Measure the voltage between sensor
terminal 26 and 36.
Approx. SV I Other
I I .
Harness continuity inspection Inspect ECCS control unot
Measure the resistar:ce between and ground and replace
the fo!Jowhg terminals: control unit if necessary
Trronle sensor ECCS CiU
harress namess
1 26
2 3
I 4 7
0" I =ll

Inspect EGGS C!U conne~tor and thrott'e I Rep~ir hamess

Isensor corrector lor contact and defects. I
EN - 375
 SENSOR SYSTEM INSPECTION
RB26DETT I RB20E I DE I DET ENGINE

(1) Self-diagnosis
• There is a disconnection or short-circuit in the signal
system when "CODE 43" is displayed in normal self-
diagnosis (mode 2). When this is displayed, check the
throttle sensor resistance or harness continuity, etc.

• If the problem occurs again, use real-time diagnosis @

mode or an oscilloscope to check for instantaneous
break in the signal.
~'-"~'~"~~"~--~=n

j~ONITORINQ;'..:r NO FAIL 0:
(2) Input signal inspection
• Use "THROTTLE SENSOR" and "THROTTLE SENSOR
2" setting in "DATA MONITOR" mode to check the
following items:
[ffi"" ,'",
:CAS.RPM (REF) Orpm I

C RECORD j

Accelerator pedal not

depressed
Ignition
switch ON Accelerator
pedal depressed Fully
depressed

• Measure the voltage between following terminals and

ground with throttle sensor harness connected.

EGCS CIU terminal 3 ECCS CIU terminal 7

and ground (OR and ground (OR
throttle sensor termmal throttle sensor termlnal.
2 and 4 and ground) .

Approx.1V Approx.06V

Approx 1V - 5V

(3) Throttle sensor power supply inspection

• Measure the voltage between the following terminals
when throttle sensor connectors are connected.

Between throttle sensor terrTllnal 1 I

and ground '

Approx.5V

EN - 376
 SENSOR SYSTEM INSPECTION
CA1S, ENGINE

(4) Throttle sensor unit inspection (CA18i)

• Disconnect the throttle sensor connector and measure
the resistance between the following terminals.
Between throttle sensor
Approx. 12 - 2.4 f.l •.
I
terminal 1 and 3

Between throttle sensor. Changes between approx 0.3 - 2.4K f.l

terminal 2 and 3 . when acceleration pedal is depressed " I
Between throttle sensor Changes between approx. 05 - 2.9K f.l
terminal 3 and 4 when acceleration pedal IS depressed -,
'1 Normal I! the value IS within 0.3 - 2.4K. The value will not
change even when the accelerator pedal is depressed.
'2.3 The value is not 00 f.l and normal if the value changes when
the accelerator pedal is depressed.

(5) Harness continuity inspection (CA18i)

• Disconnect ECCS control unit and throttle sensor
connector and measure the reSistance between the
following terminals.

ECCS C/U Throttle sensor

harness harness
3 2
7 4
26

EN - 377
 SENSOR SYSTEM INSPECTION
RB26DETT ENGINE

6-5 INTAKE AIR TEMPERATURE SENSOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB26DETT ENGINE

m
0
0
Intake air temp sensor (f)
(')
Fue! injection contr;)j I
'"' 0

~'-'
36
3.
30 9.
c:
"""

Intake air temperature sensor system trouble diagnosis flowchart

RB26DETT ENGINE
• Self-diagnosIs ~
!i"SELF DIAGNOSTIC R~~U~~;S" I
I -lit Self-dlagrOSls (code No_ 411 _
Normal I Abnormal

Iintake air temp sensor inspection

;Measure tne resistance betweer
i In_take air te-inp sensor output
'signal inspection
I
Iter~mal I and 2. li-'DATAMONITOR" ~
Aoorox. 2_5kS;~ when cold -g: Measure the voltage between: \..!..l!)
Approx. 0.8 to 1.0KQ after te,enlnal 1 and 2_ !

warming up Othe;
_-~ Intake air telTlp olGolay
ll: 1.SV when cold
O.8V after warming up : 01her
Replace intake
air temperature
sensor i-Intake air temparature
Inspect :ntake air temperature
i sensor inspection
sensor and ECCS C;U connectors
Measure ~he reSistance
for faulty connections or defects.
between terrnlrial 1 and 2,
Apprex. 2.5KQ when cold
Approx 0.8 - 1.0-l\U after
warm up

ECCS CIU power supply and ground Replace

inspection intake air
j"DATAMONITOR" temperature
g Measure tne voltage between sensor
I termnal 30 - 36_
'@ Intake air temp display I
:g Battery voltage . Other
I
H7 a-r-n-es-s-c-o-n-:t7"in-u-'itC-y inL.-p-ec---Cti'"o-n-' I
r.1

Inspect ECCS C/U power

! Measure :he resistance be:ween i supply and ground
;the following ten":1inals:
Intake air te,"p ECCS CIU
sen harr,ess harness
1 36
2 30

Inspect ECCS C!U connector andctake air Repair harness

temp sensor connector for cot"\~act 8,'1d defects,

EN·378
'~ SENSOR SYSTEM INSPECTION

6-5 INTAKE AIR TEMPERATURE SENSOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM CA 18i ENGINE

Inta~mp sens~ [1.J1----......>--1 li' .. I Fuel injection co;)jrol

'--------10' .f2/-
'-
-----4 L
30

Intake air temperature sensor system trouble diagnosis flowchart CA18i ENGINE
" Self-diagnosIs ,
Ii "SELF DIAGNOSTIC RESULTS" i

i Self-d,agnosis (code No. d1) I

Normal I Abr;orrra!

I
Intake air temp sensor inspection Intake air temp sensor output
Measure the resistance betweer signal inspection
termmal 1 and 2, ~-DATAMONITOR"
Approx. 2.5kQ when c:;ld !l: Measure the voltage between
terminai 1 and 2 .
~
Approx. 0 .810 1,0>( t"J after
wafffllng up I Olher
w: 'ntake air temp display
I I 'g 1 .5V whe'l cold
0_8V after warming up Other
In speet other I Replace Intake
!sy stems air temperature
J I
sensor
Inspect intake a,r temperature- I ; Intake air temperature
sensor inspection
sensor and ECCS C/U connectors:
Measure the resistance
for faulty connectlons or defects. I
between termi'1al 1 and 2.

Approx 2.5KQ when C?ld I

Approx.0.8 1 O;{Q at:er :
warm U;J O'her
I .1
EeeS ClU power supply and ground Repl ace
inspection intak e air
i·''DATA MONITOR" tem perature
I·it Measure the voltage between sensor
term:nal 30 - 18"
~', fntake air terlp display
g Battery VOltage 01t'er
I
Harness continuity inspection Inspectehes ClU power
Measure lhe resistance between supply and ground
t;,e fol:owing :ermmals:
!ntaKe air ~emp ECGS G/U
sen harr'Jess harness
1 18
2 30
O<l 1 coil

i Ins::tect ECCS C L :C'lnector and intake air

: tem:) s\?:-:sor .::::~~ec·c:r ·or contact and defects,
[ Aep~ir harness
EN" 379
 SENSOR SYSTEM INSPECTION
RB26DETI I CA18i ENGINE

(1) Self-diagnosis
• There is a disconnection or short-circuit in the signal system when "CODE 41" is
displayed in normal self-diagnosis or "FAILURE DETECTED IN T/ATEMP SEN" (when
CONSULT is used) is displayed.

• If the problem occurs again, use real-time diagnosis mode or an oscilloscope to check
for instantaneous break in the signal.

(2) Input signal inspection I~ONITORINotr NO FAIL O[

• Use "INT/ATEMP SEN" in "DATA MONITOR" mode CAS.RPM (REF) Orpm
to check the following items: INT/A TEMP SEN 38"C

~.~lg_ni_tio_n_s_w_itc_h_i_n_O_N_-; Temperature display corresponds to i

Idling mtake air temperature. I
RECORD
• Measu re the voltage between the followi ng terminals
and ground with ECCS control unit connectors @
connected.

Ignition switch OFF OV

Ignition switch Approx20'C 1.5V

in ON Approx45'C O.BV
Approx 20"C 1.5V
Idling
Approx45'C O.8V

(3) Harness continuity inspection

• Disconnect ECCS control unit and intake air temperature
sensor connector and measure the resistance between
the following terminals. ( ) CA 18i
I
I
I
ECGS GiU hamess terminal 36 (30)
and Intake air temperature sensor 1
0Q

(4) Intake air temperature sensor inspection

• Disconnect intake air temperature sensor connector, heat ./
or cool it with a hair dryer or industrial dryer and measure
the resistance between the following terminals.

Approx. 20"G Approx 2 5K Q

Approx 50'C Approx. 0.8 - 1.0K Q

EN - 380
 SENSOR SYSTEM INSPECTION
RB26DETT ENGINE

6·6 ENGINE TEMPERATURE SENSOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB26DETT ENGINE

E,1g:ne temperature sensor

~- ·1 Fuel inject;on control
I
'
~If
()
• 28 CO
[,0
:
30
"
a
;;>.
·r Igmtion limi')g control

Q.
c
@: I
,
:diC speed control I

Engine temperature sensor system trouble diagnosis flowchart

RB26DETT ENGINE
Self -diagnosIs I
~. "SELF DIAGNOSTIC RESULTS" '
l! Sef-d:agnosis (code No. 13)
Norrr:aI Abnorma:

I~ 'DATA MONITOR"
: (Real-tIme dIagnOSIs)
NOrr'lai A.bnormal

Engine temp sensor input signal inspection

~ "DATA MONITOR"
: 'g Measure :he voltage between terminal 1
and ground.

~. Engine temp dIsplay

'Ii: 3V when cold
1V after warrring up Olher

Inspect intake air temperature : Engine temperature

sensor and EGCS C/U connectors, ; sensor inspection
i for faulty connections or defects. Measure the -res:stance
Engine temp sensor inspection between lerminal 1 and 2
Measure the resistance between Approx: 2.5K1Il when cOld
termlr':al 1 a:1d 2. Approx. O.3K g after warm
A;::-prox. 2.SkQwhen cold up
Approx. O.3K1Il after
Sensor and ground inspection Replace
vvarmln9~_u.:.p_ _ _ _--'L"::'L_ Meas~re the voltage between Engine
: terminal 28 and 30. temperature
Replace engine Engine temp display II sensor
temperature aG::.eL_....L_ _ _O_th_,e,'
Battery vco..lt..
sensor
Harness continuitylinSpeCtion Inspect Ebcs e/U power
Measure t~e resistance between supply and ground
the following terml:lals'
Engine temp EGGS C/U
sen harness harness
1 28
2 30
OQ I = Q
I
• Inspect ECCS GIU connector and engine tema: Repair harness
__
Ls~e~n~s~o r~c=o rn__ec~l=ofLfo__f~c~o..n__ta=c__t~a~n=d..d=e__ro~c~t=s__._--"
__
EN - 381
 SENSOR SYSTEM INSPECTION
RB20E i DE I DET ENGINE

6-6 ENGINE TEMPERATURE SENSOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB20E I DE I DET ENGINE

Engine tef11perature sensor

! Fue' il1jecLon ;:ontro!
m
(')

~
"....,
(')

~
5(28)

t=
(j)
BI3U)
() :gnition timing cortml
......... 0
a
9..
~.
~dle speed contrG!

I
Engine temperature sensor system trouble diagnosis flowchart
RB20E I DE I DET ENGINE

Self-diagnosIs
Q/'SELF DIAGNOSTIC RESULTS"
:g Seif-dlagnosls (code No, 13)
Abnorm;:;1

Abnormal

Engine temp sensor Input signal inspection

8 "DATA MONITOR"
,<It Measure the voltage between terminal 1
and ground,

i' Engine temp display

:g 3\/when cold
1V after warming up Other

Inspect intake air temperature Engine temperature

sensor and ECCS C/U connectors sensor inspection
'for fau,ty connect~ons or defects, : Measure the resistance
i Engine temp sensor inspection' ~ between terminal 1 and 2.
'Measure the resistance between' Approx. 2.5-Kg wnen cold
terminal 1 and 2. Approx. O.3K a:after warm
Approx. 2.5k 0: when cold up
Approx. O.3KQ after
Sensor and ground inspection Replace
warm:ng up Other
Measure the voltage between Engine
: te"nlnal 5 (281 and 8 (301, temperature
Replace engine :,~:, Er~ine temp display sensor
temperature "1. Battery vOllage Other
r-"---1~---'1
sensor
I Harness continuity inspection
MeaSUfe tne resistance between
Inspect EeeS e/u power
supply and ground
i the following terminals:
Engine lemp ECCS C:U
sen harness harness
1 5 (28)
2 8 (30)
Of.!

Inspect ECCS C:U connector and engi"e temp

sensor connector for contact a"1d defects.

EN - 382
 SENSOR SYSTEM INSPECTION
GA 181 ENGINE

6·6 ENGINE TEMPERATURE SENSOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM CA18i ENGINE

Engme temperature sensor I

~---'~'~+I------~~ ~r---------~i5 m
r-----·..,i1 Fuel H~jection
_
control

'------------'21 2.1-1--- -.,,---.,8 (")

(")
, (fJ

~'8 8 j

' - - - - -..--------: Ignition l:ming control

a
o

II ~
L,- - - -.... .,! Idle speed comro!
'---------~

Engine temperature sensor system trouble diagnosis flowchart CA16i ENGINE

Seif-diagnosis
J!SELF DIAGNOSTIC RESULTS"
:11: Self-diagnosIs (code No. 13)
Normal Abnormal

I
I .~DATAMONITOR" I :
~ (Real-t~rr:e diagr.osls) 1 I'
Engine temp senso, output
Norrr,a: Abno~mal [ signal inspection
, i

:I! "DATA MONITOR"

: -:g, Measure the voltage between
I !ermmal 1 and 2.
-~ EngIne lemp dIsplay
'" ;3V when c::>ld
,g. ~ V after WaflT'lrEg up Other
Ir----"-'---'-----'.;;...:...,I
Inspect in:ake air temperature rE=-n-g-i..lne--te-m-p-e-'-a-tu-'-e----,:
sensor and EGGS CiU connectors sensor inspection (2)
for faulty connections or defects. Measure the resistance
between terminal 1 ard 2.
Engine temp sensor inspection (2
Measu;e the resistance between Approx, 2,5KQ when cold
terminal 1 and 2.
Aoprox 0 3K Q after , ..
warm up I
Approx, 2"5kawhen cold i
I
ECCS ClU powe, supply and Repl ace
Approx. O,3K{~ after II

warming up ground inspection Engi ne

Other
,...-----'---., ~'DATAMONITOR" tern peratu,e
:g, Measure tne voltage between sen sor
Inspect other Replace engine EGGS CIU terminal 5 and 8.
systems temperature iL Engine terno display
sensor ~g, 3V when cold
1V after w;:)rrr, ,,18 01ner
I
Harness continuity inspection Inspect Ebcs CIU power
Measure :he resistance between supply and ground
the foHowing terminais:
Engl'1e temp EGGS GiU
sen ha r 1ess harness
i
1 5
2 8

Inspect ECCS C1U connector ard engire temp Repair harness

sensor connec~or for contact and defects.

EN .. 383
 SENSOR SYSTEM INSPECTION
R826DETT i R820E / DE i DET I CA 18i ENGINE

(1) Self-diagnosis
• There is a disconnection or short-circuit in the signal system when "CODE 13" is
displayed in normal self-diagnosis or "FAILURE DETECTED ENG TEMP SEN" (when
CONSULT is used) is displayed.

• If the problem reoccurs, use real-time diagnosis mode or an oscilloscope to check tor
instantaneous break in the signal.

(2) Input signal inspection

i:lMoN!T(iRlt;~NoFAIL 0:
• Use "ENG TEMP SEN" in "DATA MONITOR" mode ENG TEMP SEN lBoC ~
to check the following items:

ignition switch ON Engine temperature is displayed

RECORD

• Measure the voltage between the following terminals I

and ground with ECCS control unit connectors
connected.
®. 1 Engin~te"'2.
'ci' sen W
I ,~ .... ~~.-.~.~.'"
Between ECCS Between ECCS
Measurement locatron CIU terminal 28 CIU terminal 5 . I I RB20DE I DET ! CA' 8.
and ground and ground

Approx.
Ignition Approx.3V Approx. 3V
20'C
sWitch
ON Approx 1V Approx. 1V

zn ~o ; \: ]
Engine temperature

(3) Engine temperature sensor resistance value

inspection RB20DEI DET
• Disconnect engine temperature sensor connector and
measure the resistance between the following terminals,
Between engine temperature
sensor connector 1 and 2

CA18i RB20E RB26DETT

 SENSOR SYSTEM INSPECTION
RB26DETT! RB20E I DE IOET ' CA 18, ENGINE

(4) Harness continuity inspection

RB20E I RB26DETI
• Disconnect ECCS control unit and engine temperature
sensor hamess connector and measure the resistance
between the fOllowing terminals,
EGGS G!U Engine temp
harness sen harness
oQ
5 (28) 1
8 (30) 2

CA18i' RB20DE f DET

III

EN·385
 SENSOR SYSTEM INSPECTION
RB26DETT ENGINE

6-7 EXHAUST GAS SENSOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB26DETT ENGINE

IGN

E~xtlaus:
gas se~sor Air fuel ;'atio feedback
cO'ltrol
. 2·.
Heale' ~ 3

Cylinder, exhaust gas sensor, CONSULT (data monitor) display

.
No. 1. 2. 3 cyl O. sensor (front) ! ECCS CIU lennlnal 29 i 0, sensa r (R.c)_---1
No.4. 5, 6 cyl 0, sensor (reari I ECCS CiU tenninal 551 0_ sensor
'-----

EN - 386
 SENSOR SYSTEM INSPECTION
RB26DETI ENGINE

Exhaust gas sensor system trouble diagnosis flowchart RB26DETI engine

Air-fuei ratio feedback function!

inspection
~"DATA MONITOR'
:g Ex'1aust gas sensor output
mOnitor,
Normal Abnonnal

~" 'DATA MONITOR"

(Real"tlme diagnosIs)
Abnorma~ ;
\iorma!

Inspect other
systems Exhaust gas senSor input ~
~ si9nal inspection [!El
i Measure the voltage between (02 sersor (FJ)
1. (0. sensor {Fn
~
!

. 2 O' sensor {R}

DefiectlOn betweep 0 - 1vJ O:her (0" sensor IR1)
1,..----'---;;.......;.-,1
Inspect exhaJst gas sensor andj
EGGS GfU concectors for faulty
I ~~~---~~~--,
ECCS C/U power supply inspection
W'DAT.A MONITOR"
contact or detects. : 'J/'
,;
D'sco0r;ec; 0 sersor connec1or
and ~easl)~e '/G lcce ~el':/ee'
Er'-'''' r~ U :e~:;,.;,d. h<-; 6;-,;:: ;;:,:. ... r,c:. I
'..J\-::' y,

Battery -,;ol1a9€' '-:;!-:e,

ig ..1'tlon sw,tCh IS ON I err€"
1 I
Harness continuity inspection Inspect ECCS CI
Measure the resista:lce between U power supply
the follOWing terminals: or replace C/U
0" sersor EGGS C/U
rarness
: 0, seosor (R)2
i 0" sensor {F)1

00
harness
55
29
Other
(3m 1) tfffi
(O"sensor (0 sensor
(R)l iFf)
4 3

:Oa sensor heater inspection I

Repair harness
iMeasure :he resistarce between
follOWing termmals·
O<sensor(R) 1- 3
0, sensor IF) 2 - 3
Batte ry vOltage when
:gnitio n sWItch is ON I Other
1
Check ter ta ulty clnnectlons I~a sensor heater unit inspection
or replace e xhaust gas sensor ,Measure FIe resistance between
!followmg terminals:
0, sensor 1 - 3
,0, sensor (Ri! 2 " 3
Og 1 = {l
1
0, sensor heater power supply Replace 0zsensor
inspection
Measure the voltage between
,following termmals;
02 sensor (Ri 1 and ground
sensor (F) 2 and ground
!

°
Baltery VOltage wnen
9nitlo0 sWitch is ON I Other
I

nso( ground ctrcult I :Repair O~ sensor heat!

:power supply CirCUit
EN - 387
 SENSOR SYSTEM INSPECTION
RB26DETT ENGINE

(1) Fuel-air ratio feedback function inspection rtl\ i~ONITORIN~ NO FAII-Oi

• Warm up the engine and check the following items \1lV I ,

!CASRPM (POS) 1975rpm

with "EXH GAS SEN", "EXH GAS SEN-R" (output
iEXHGASSEN 1,14V
voltage), "M/R FIC MNT" and "M/R FIC MNT-R" (lean I EXH GAS SEN-R 1,Q3V
rich) displayed in "DATA MONITOR" mode. MiR FIC MNT RICH
MlR FIC MNT LEAN
o.~~~~~piSl!~(iIOi'*'~
,:>,;:~, ';:!(RJ')< "", ,;, :,"'rtlQrmOil~!tRl'
RECORD

Approx, 0 - 1V IS RICH, LEAN display

Engine speed at displayed, The dlspiay must be synchronized
• approx 2,000 rpm cycle is 5 times or more with output voltage
I
-.-J1___d_,s.;..p_la,;.,y_ __
in 10 sec in1e_IYa_'_,

• Provide setting value in "ACTIVE TEST" (fuel injection

quantity correction) and check exhaust gas sensor
function.
• ACTIVE TEST

"VEL INJECTION
MONITOR
CAS RPM(REFl 937rom
E"'G TEMP SEN 59'(;
EXH GAS SEN 1.33V
EXH GAS SEN-R 1,35V
• Using diagnosis connector on the vehicle side f<Eh IN.JPULSE
AAC VALVE
1,8msec
17°'0
(near fuse block), set CONSULT to "EXHAUST GAS \<S,J
SENSOR MONITOR" and check the fuel injection
condition by flashing of exhaust gas temperature warning
lamp on instrument panel.

Exhaust gas sensor function

~
Exhaust gas temperature warning lamp must flash 5 times
or more in 10 seconds interval when engine is running at
, approx. 2,000 rpm,

Feedback function
Exhaust gas temperature warning lamp must flash
periodically when engine speed is running at approx. 2,000
rpm.

(2) Input signal inspection

• Measure the voltage between the following terminals with
ECCS control unit harness connected.

i Between ECCS C/U

terminal 55 ana ground
Deflection between Deflection between
approx 0 ana 1V approx 0 and 1V

EN - 388
 SENSOR SYSTEM INSPECTION
RB26DETT ENGINE

(3) Harness continuity inspection

• Disconnect EGGS control unit and exhaust gas sensor
connectors and measure the resistance between the
following terminals.
0, sensor EGGS GIU harness terminal 29 I
(Front)
00
and 0: sensor harness terminal 1 •

0, sensor ECGS G/U harness terminal 55 •

00
(Rear) and 0, sensor harness termmal 2 I

EN - 389
 SENSOR SYSTEM INSPECTION
RB20E I DE I DET ENGINE

6-7 EXHAUST GAS SENSOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB20E / DE / DET ENGINE

(RB20DE I DET)

~"'. ,~~ r-- 1----

Htji{i) fj}-.------+~~s
Air fue! ratio teedback
control
m
o
o
(f)
g
2.
Q.
~
(RB20E)

~ &-.-----+16
+

EN - 390
 SENSOR SYSTEM INSPECTION
RB20E iDE! DET ENGINE

Exhaust gas sensor system trouble diagnosis flowchart

RB20E I DE I DEl engine
Air-fuel ratio feedback function
; inspection
I ~)"DATAMONITOR"
Exhaust gas sensor output mOnitor.
Normal Ar.ilionna!

Abnorwal
Nornai

Inspect other i

systems Ex haus gas sensor ,"pu

; signal inspection 1
Measure the voltage between (R820E)
1. (RB20E) and ground
2. IRB20DE i DET) and ground (l~h)
Oeflectlon between 0 - 1 V Other
iRB20DE ! DET)

I I
Inspect exhaust gas sensor 3'1d: IECCS C/U power supply inspection
ECCS GiU connectors lor faulty I ~ DATA MONITOR"
' ,~
,
contact or defects. ; ::i Disconnect 02 sensor con'1ector
I and measure voltago between
EGGS G/U terminal 27 (49) and ground
Batte')' voltage when
Ignition SWltch is ON I Other

ECC~
I
Harness continuity inspection Inspect CI
MeasJ:e :he resistance between U power supply
the follov'Ilng termina:s: or replace C/U
0, sensor EGGS GIU
h'arness harness
: RB20E 1 6 1 d~1)
, RB20DE ! DET 1 29 (RB20Ej (RB20DEI
0<> I Other DEl)

R820DE;DET I Ri320E I
I I Repai r harness
;0:.1; sensor neater inspection Check for faulty connections
I~easure the '€sistance between or replace exhaust g8S sensor
:ermmal 1 and 3.
Batte ry voltage when
igmtio n switch is ON Ot~er

onn~tfons
I
Check lor faulty c 02 sensor heater unit inspection
or replace exhau st gas sensor Measure the resistance between
termmal 1 and 3.
Ctf'2h)
On I =n
J I
0, sensor heater power supply Replace 0;>: sensor
inspection
(1m 3) Measure the voltage between
terminal 1 and ground.
Batt ery voltage when
igM ion sWitch IS ON Other
I
. I
IRepalr 0:; sensor ground Chewt IReoalr 0; sensor heat
:power suoply circu;t

EN - 391
 SENSOR SYSTEM INSPECTION
CA18, ENGINE

6-7 EXHAUST GAS SENSOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM CA1Si ENGINE

Exhaust gas sensor

m
;--_-W~\~! 1 ! - - - - - - + 6 o t-------""'![ A:r fuel ratio ;eedback
o(j) , control
("}
o
3-
~

2-
e:
~

Exhaust gas sensor system trouble diagnosis flowchart CA lSi Engine

i Self-diagnosis ,
:!J)·SElF-DIAGNOSIS RESULTS":
Self-d,ag10sis (Code No, 15)
Normal Abnorrr,a!

Norma!
Normal ! Abnormal Abnornal

IE,signal
"" haus!ga's sensor irip;:itl
inspection . !
·~'DATAMONITOR· i

(!i;: EGGS 6 and ground I

~ DISPlaY RICH LEAN' I
Display output vortage 0 ~ 1 V
.If Display 0 - 1V OtM'

Inspect exhaust gas sensor and EGGS CIU power supply inspection
EGeS C/U connectors for taulty If DATA MONITOR"
contact or defects, ,:I Disconnect 02 sensor connector
and measure voltage beh"Jeer ,
ECGS CfU terminal 27 (49) and ground!
Battery voltage when I
ignition S\VlICrh_'S'-O_N!-____--"O.::thc:":..r-.
I I
I Harness continuity Inspection Inspect ECGS Cf
i Measure the resistance between U power supply
02 sensor harness termiral 1 and' or replace C/U

,-
ECCS C/U harness terminal 6,
OQ

Check for faulty connections or

replace exhaust gas sensor
Repair harness

EN - 392
 SENSOR SYSTEM INSPECTION
RB20E I DE IDET I GAlS: ENGINE

(1) Fuel-air ratio feedback function inspection 1~10NITORIN~ '10 FAIL []

• Warm up the engine and check the following items with
"EXH GAS SEN" and "M/R FIC MNT' (lean I rich), ® ,
GAS,RPM (POS!
'AIRFLOWMTR
20l2rpm
L54V
displayed in "DATA MONITOR" mode, ' ENG TEMP 80'G
EXH GAS SEN OJ2V
Exhaustgaalien M!R FIC MNT RICH
mortltclr

Approx 0 - 1V is RICH I LEAN dispiay RECORD

Engine speed at displayed The display : must be synchronized
, approx 2,OOOrpm i cycle is 5 times or more with output voltage
, 10 10 seconds interval, display

,• ACTIVE TEST
• Provide selting value in "ACTIVE TEST' (fuel injection
quantity correction) and check exhaust gas sensor FUEL :NJECTIOI'< +11"\.
Mon,OR
function. CAS.RPrv1 iRE:F) 1037'pm
ENG fEMP SE.'; 36"C
EXHGASSEN 0,87V
Note:
,INJPULSE
"INJ PULSE" display for RB20E is 1/16. : MC VALVE 36%
i
, au II,--U~p~ II ad i
• Using diagnosis connector on the vehicle side
(near fuse block), set GONSULTto "EXHAUST GAS
® OWN

SENSOR MONITOR" and check the fuel injection

condition by flashing of exhaust gas temperature warning
lamp on instrument panel.

Exhaust gas sensor function

Exhaust gas temperature warning lamp must flash 5 times
: or more in 10 seconds interval when engine is running at
i approx, 2,000 rpm.

Feedback function
IExhaust gas temperature warning lamp must flash I
i periodically when engine speed is running at approx. 2,000 •
~m. i

(2) Input signal inspection

• Measure the voltage between the following terminals with rr-·-::~--='-l -~'--:,- - - I

EGGS control unit harness connected. 8 m'

I-L
I 1~... .6
~
(')
01
I /
j
(t): i (291
O,sen Q, (Jl
. ry<. c:'
Between ECCS CIU Between ECCS CJU - ~,'V . ~ I
terminal 1 am ground terminal 29 and ground :
Deflection between - Deflection between
approx_ 0 - 1 I approx. 0 - 1

EN - 393
 SENSOR SYSTEM INSPECTION
RB20E i DE,' DET I CA1B, ENGINE

(3) Harness continuity inspection RB20E

• Disconnect ECCS control Unit and exhaust gas
connectors and measure the resistance between the
1
following terminals.
·E~ib.• il",'!1 ,'.m!u~nt:IOc~ri:]···~,'.··

RB20DE I DET

RB20DE I DET

EN - 394
 SENSOR SYSTEM INSPECTION
RB26DE'f ENGINE

6-8 DETONATION SENSOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM RB26DETT ENGINE

De!onatlon
Sensor 2
1-~
24
m ~! Igmtlo(l timing cOntrol i
o :
2----123 o
(f)
41 8
o
Detonatio'1 o
::l
sensor 1
[
~14--ill
-: .. ~
c::
~

r-----------~~~------------------__1~

(1) Self-diagnosis
• There is a disconnection or short-circuit in the signal system when "CODE 34" in normal
self-diagnosis or "FAILURE DETECTED DETONATION SENSOR" (when CONSULT is
used) is displayed. If the problem occurs again, use real-time diagnosis mode
(CONSULT DATA MONITOR mode) or an oscilloscope to check for instantaneous
break in the signal.

(2) Input signal inspection

• Measure the voltage between the following terminals with
ECCS control unit harness connected.

-§'iiI
1 :::;.Q;
. ill I

Approx. O.3V Approx. O.3V ~eto~na~tio~c~se~"~50~'==j23 g::5 i ,

[QetonatiO'i sensor 24

Cranking Approx O.3V Approx. O.3V

Idling Approx. O.3V Approx.03V

.Caution:
The detonation sensor input signal must be measured by
using oscilloscope as its resistance is greater than the
circuit tester resistance. The signal should also be
checked with self-diagnosis and harness continuity
inspection.

(3) Harness continuity inspection

• Disconnect ECCS control unit and detonation censor
middle connector and measure the resistance between
the following terminals.
Between ECCS CIU terminal 23 and detonation I'

sensor middle harness terminal 2

Between ECCS CIU termmal 24 and detonatIon
sensor mIddle harness terminal 1

EN - 395
 SENSOR SYSTEM INSPECTION
RB20E! DE! DET ENGINE

6-8 DETONATION SENSOR SYSTEM INSPECTION

CONTROL. CIRCUIT DIAGRAM RB20E f DE I DET ENGINE

m
o
o(f)
()
o
"~
§
'"
Detonation sensor
)-_ _-;1.

(1) Self-diagnosis
• There is a disconnection or short-circuit in the signal system when "CODE 34" in normal
self-diagnosis or "FAILURE DETECTED DETONATION SENSOR" (when CONSULT is
used) is displayed, If the problem reoccurs, use real-time diagnosis mode (CONSULT
DATA MONITOR mode) or an oscilloscope to check for instantaneous break in the
signal.

(2) Input signal inspection

• Measure the voltage between the following terminals with
ECCS control unit harness connected. em.
(23I~g I
(f)
(24) 8
~

iOetonatlOn S€:flsor 16 g:
v

Approx 4V Approx.4V Approx. 4V '. ( ! RB20DE, DE;

~~~~~'-'-' _ _ ~ _ _ _ _ ~J

RB20E
Caution:
The detonation sensor input signal must be measured by
using oscilloscope as its resistance is greater than the circuit
tester resistance, The signal should also be checked with
self-diagnosis and harness continuity
inspection.

(3) Harness continuity inspection

• Disconnect ECCS control unit and detonation censor
middle connector and measure the resistance between
the following terminals.
RB20DE I DET
-
RB20E! I
Belween-E-C-C-S-C-'-'U-'t-e-nn-l-na-I-16 and
detonation sensor middle harness terminal 2 ,
RB20DE I Belween ECCS CIU terminal 23, 24 and
DET detonation sensor middle harness terminal 1 2
EN - 396
 SENSOR SYSTEM INSPECTION
RB26DETT! RB20E ! DE ! DET ! CA 18' ENGI NE

6-9 VEHICLE SPEED SENSOR SYSTEM INSPECTION

CONTROL CIRCUIT DIAGRAM
RB26DETT ENGINE
r !
'-:I • II Fuel cut cO'1trol
_______._---1
rn

I~
(')
()
(fl
,d:e speed C0ntro~
I ()
0 I
i~
I . ,
sel "- I
~ VehiCle sod 2.
c
:0
'"

RB20E I DE I OET ENGINE

m
I------L. Fuel cut C3ntro!

()
() ~------,

(fl
(")
1-----i Idle speed control
0
::>
~
~

Q.
1:5", ~.

( ) RB20DE ! DET

CA18i ENGINE

i VehICle speed sensorJm-----~~ Z1 1------1-L. FLel cut control

EN - 397
 SENSOR SYSTEM INSPECTION
"S~~:;=' RB20E,DE!DETIGA18iENGINE

{1) Input signal inspection r~ONITORIN~ NO FAIL :J1

• Select "VEHICLE SPEED SENSOR" in "DATA
MONITOR" mode and check tne following items. I CAS.RPM (REF}
CAQ. SPEcD SEN
787rom
Okm!h

I
When drive wheels are rotating Vehicle speed is displayed
I ,
'p================~
r''-_ _ _RECORD
_ _ _ _ _1

• Measure the VOltage between the following terminals

with ECCS control unit connectors connected.
® ,_______._____.
. ~~\r~;I··f[W2·iJij.;1'·.···.··~:~;\·~.R:s~2Il~·~oe~~1~,~I;-r-;·;.;;
Pi'~· . . ';'~'~"'~:~'~"--"'l'
I,'r;K'i >'1i,l:;.;·i ....;ii~e Ioet RB2Ot: •'. ':C~1~
. pOhle!. spd sen1---1 21 153) I
):f.,t~+;~.~~g; Between ECGS CIU Between EGGS CIU
;~;!:;\.;~?j;: terminal 45 and ground terminal 21 and ground .
,..-1/ I
. 1 , ' . control
EGCS

"""O,,-It_ _
,~i~;~~iI
. .. . . . . . • ",I

Deflection between OV and 5V (also appears .

I~i~~ as deflection around 1V)

6-10 IGNITION SWITCH (START SWITCH) SIGNAL

INSPECTION CA18i

(1) Input signal inspection

• In "DATA MONITOR" mode, perform the key operation
1+' @.
,,"L..

i .::tt-~~12~~~S i
~ r---:
to check if the ignition switch "START' signal is i n p u t ' i control I r8'
correctly. . l"n_!I==='

• Measure the voltage between the following terminals Aa>\ i,,1

with ECCS control unit harness connected. \f:!J ~._~. _~. _~ . _. __-1

~lmlm~Mi~~~~~3 !__ ~~GN_26_DE!!LRB2_0_..

ECCS CIU ECCS CIU • l±+)--fO$;-;~BI----,l. 23 I
terminal25 i termmal 23 ECCS
and and "munrl 'conlrol
-:- : unIt
OV

Battery vcltage

EN .. 398
 SENSOR SYSTEM INSPECTION
RB26DETT / RB20E! DE! DET I CAIS! ENGINE

6-11 AIR CONDITIONER SIGNAL INSPECTION

B26DETI I RB20
Dual press;Jre

Heater fail
c
switch
~,-- ___________---l29
NC switch i ""::;)
1 - . (46)
i
i (i RB20DE I DET I RB26DETI

f'fl\ CA18i
(1) Input signal inspection 1Jt)-- "" -""---"""--,
• In "DATA MONITOR" mode, perform the air conditioner ~~, 1-'-1
switch operation to check if the air conditioner switch AlC sw'tch~'i29 ECCS •
signal is input correctly, control
I Unit
AlC re,ay -'-/1 '02
• Measure the voltage between the following terminals r"
with EGGS control unit harness connected, % ~"",--'

CA18i
ECCS Gil) teml,nal
9 and ground 46 ana ground 102.29 ana grcuna
Battery voltage 8-9V
0- 1V Battery voltage

6 -12 NEUTRAL SWITCH SIGNAL INSPECTION

(1) Input signal inspection ~
• In "DATA MO NIT0 R" mode, perform shift lever (Ii)
~
operation to check if neutral switch signal is
input correctly, te\
• Measure the voltage between the following terminals '<a)
and ground with EGGS control unit harness connected.

,--'-
~
,
c=.
,.
""~24(44;
rl
~ i I ECCS
I
,I , control
C:-, L um!
4 - 5V r~-
" ( ) RB26DETI ! RB20DE; ;)",T
Approx.OV

EN"" 399
 SENSOR SYSTEM INSPECTION
RB26DETI i CA18! ENGINE

6-13 POWER STEERING SWITCH SIGNAL

INSPECTION
(1) Input signal inspection ® .,
• In "DATA MONITOR" mode. perform power steering \J!}
operation to check if power steering oil pressure switch
signal is input correctly.
• Measure the voltage between the following terminals ~
with ECCS control unit harness connected. ~ RB26DETT
~---------- - - - - - - - j

ECCS CIU terminal ECCS CIU terminal

31 and ground 19 and ground

Approx.8V Approx.5V

Approx.OV Approx OV

CA18i
6-14 LIGHT SWITCH SIGNAL INSPECTION
(1) input signal inspection
Light switch
• In "DATA MONITOR" mode, perform light switch operation
0-~43
to check if light switch signal is input correctly.
• Measure the voltage between the following terminals ~
; I
ECCS
control
l
with ECCS control unit harness connected. \S/
,-0 ~un~

19nition~llt~'I-_ _ _ _ _-t_ _A_p_p_ro_x._o_V_-I

Head lamp ON Power voltage

6-15 HEATER. FAN SIGNAL

. INSPECTION -.-;
®~'-Heater an ",
(1) Input signal inspection
• In "DATA MONITOR" mode. perform heater fan operation --I
sWllcn
• G:)---@---
' i :
-.~
45 [
to check If heater fan sWitch signal IS Input correctly.
• Measure the voltage between the following terminals
with ECCS control unit harness connected.
®I • :0
ECCS
/ i c~ntrol
U It
I

,I ~
.

Heater fan ON Power voltage

EN - 400
 RB25DE DIAGNOSIS
RB25DE ENG INE

DIAGNOSIS 1 - POWER SUPPLY & GROUND CIRCUIT

ECCS
relay

T 107
,I ID----,,
. ""
i 116 :!J
i
I
("---,}o.-4.-_ _ _ _ _ _ _ . _ __ - - - - -...- ~ !

Components location

-EC_C_S_control umt .J

EN - 401
 RB25DE DIAGNOSIS
RB25DE ENGINE

I START A

Start the engine,

'* MOr\ITORING N~ FAI~ol
1,CAS,RPM (POS) 1062,p", I'
Does the engine start? BATIERYVOL 14,QV

NG 1
0K
I Inspect ground circuitD, I
1
0K
START
I FINISH
A A
Power supply inspection
Place ignition switch to ON position, i £'~G8
;<is>I, Inspect battery voltage using "BATIERY ; OK conne",~
IIEccs'LClU
\.Bi VOLTAGE" in "DATA MONITOR" mode, I
I r6\, Use tester to measure the voltage between. v''1
:---
: ~ EGGS C/U terminal 49, 50 and ground, I ~i'.J~
NG
o
Ground circuit inspection
B
Place ignition switch in OFF
position. Disconnect ECGS G/U
harness connector,
Gheck for harness continuity between
EGGS GfU terminal, 10,20,107,108
I and 116 and ground,
IlE~ Repair harness and connectors

I FINISH I C
B
ECCS C/U terminal and ECCS relay harness It E:(\ (",.,
continuity inspection 15r,~. .'d'.)
!T~,. ~
--- ,
Place ignition switch in OFF position, .
~~~~~~~:rct EGGS G/U and EGGS relay harness ;~!
~

~1
NG
•Inspect for continuity between EGGS G/U terminal
~'4_9_,_5_9_a_nTd_E_G_G_S__re_l_aY~le_r_m_in_a_I_3_,__________~.

OK I Repair harness or connector I_C-------"'------,-,

IVoltage inspection between ECCS C/U If eli

,terminal and ground
Place ignition switch to ON position,
Measure the voltage between ECGS relay
terminal 2, 3 and ground,
! Voltage: Battery voltage
IF NG: Place ignition switch to OFF position,
No. 21 fuse, No,3, NO.6 fusible link.
, Inspect the continuity between EGGS relay and
! ry_,___..,-________________-"
the batte ....
I I Repair harness or connector I
To E
EN - 402
 RB25DE DIAGNOSIS
RB25DE ENGINE

E E
IOutput signal circuit inspection
: Check the continuation between ECCS C/U NG ~TI:E"'C:C:CS:-CC::::IU""c-on-n-eC-lo-'rI
!It eo 00 !

I terminal 16 and terminal 1. . II I

OK
Inspect the following:
I UT";)f]
i'-'!...JI
.
Ignition coil harness connectoL
: _.j ]filll1
Harness between EGCS C/U and
: ECCS relay.
I'F NG' Aepair harness or connector.

. Component parts inspection

i (EGCS relay) NG
.Aeferto the section on ECGS relay for , -
Iinspection. I

IRepair EGGS relay

. Check for any damage on the ECCS C/U I
I terminals and ECCS C/U connector.

Carry out the inspection in the following order after repairs.

Verification inspection

FINISH

I FP::.:o~w~e~r~s~u~p~pl~y~in-:s~p>.:e~c~tio~n~--i; Check for any damage on the.

L I EGCS CfU terminals and
. OK i EGGS CfU connector.

I(G~r:::o~u!2nd~cl~·rc=u~it~i!2ns~p~e=c:!iti5.:0!2n~L._Nc.:....:.G_i Check for any damage on the

L i OK EGGS G/U terminals and
I • EGCS C/U connectoL
I FINISH 1

EN - 403
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 2 - CRANK ANGLE SENSOR (CODE NO. 11 IN SELF-DIAGNOSIS)

IGN ECCS relay

~------------~~~--~~ ~t-~-4~~~
F!L6

Crank a'lgle sensor

G20~ s'gnal
, l' slgr,al
I
~
..
I·
a
.,
51

41
""
m
g
l/l
g
[
t-----i ~gnition timing contro~

~uel 'njectlon c:::mtrof J

~P~a,~"e~r~s~u~pP~I~Y~·~r-------~· .~ c
~G~ro~u~n~d____~:r---------r-----;ro
"'"
ri Idle saeed oont'ol

Components location

EN -404
 RB25DE DIAGNOSIS
RB25DE ENGINE

Carry out self-diagnosis I

NG OK

A
Power supply inspection
Place ignition switch to OFF position, ,
Disconnect crank angle sensor harness ~'
connectors, NG B
Place ignition switch to ON position, .
~-.,- ..- - - -----
Use tester to measure the voltage between i . 1~1O@1
'terminal 3 and ground, i Ifecs CIU eonnectoj
~52!41.51

OK Inspect the following:

, Check the continuity between crank
LCgJ.fl_-,
4:2, 52 and 2
angle sensor terminal 3 and ECCS
relay terminal 3,
,1E~ Repair harness or connectors,
B C
Input signal circuit inspection ~ONITORIN~O 'A1LO!
Place ignition switch to OFF position,
I?:~S.RPM :REF) 662rpm I
Disconnect ECCS CiU harness connectors, . AIR FLOW MTR '.02V I
. ENG TEMP SEN 81 .
Check the continuity between crank angle sensor NG EXHSEN C.18V
terminal 2 and ECCS C/U terminal 42, 52 (1 0 signal), THROTTLE SEN O.38V
NJ PULSE 3.0msec
between crank angle sensor terminal 1 and ECCS
C/U terminal 41 ,51 (120° signal),
START

OK Repair harness or connector

C c
Input signal inspection
Connect crank angle sensor and ECCS C/U
harness connectors,
lit £' ClB \fB
leees eM connKto~
'® Use "CRANK ANGLE SEN RPM" in "DATA

OK Component parts inspection

(Crank angle sensor)
Refer to the section on crank angle sensor for ,
,inspection, IF NG: Replace crank angle sensor,1

Check for any damage on the ECCS C/U

terminals and ECCS C/U connector,
EN - 405
 RB25DE DIAGNOSIS
RB25DE ENGINE

Carry out the inspection in the following order after repairs.

Verification Inspection

I Erase memory from self-diagnosis I

I
Test drive

r;-;;~rh.:::::k~;;;.Ji~;;-;;-;;~J-~N~G~ Check for any damage on the I

I Recheck by self-diagnosis ,EGGS G/U terminals and •I
, I EGGS G/U connector. •
1 0K
FINISH

EN - 406
 RB25DE DIAGNOSIS

DIAGNOSIS 3 - AIR FLOW METER (CODE NO. 12 IN SELF-DIAGNOSIS)

F/L3 IGN #21 ECCS relay

(j)-~ ,.
F/L6
Air flow meter
: 1
Intake air qty sig S' 2
Power ground F i3 ""

* I!gnitiCn timing control

Components location

ECCS control unIt

EN - 407
 RB25DE DIAGNOSIS
RB25DE ENGINE

Carry out self-diagnosis

NG i OK
I !FINISH
A ~I __________~
Power supply inspection I
Place ignition switch to OFF position ..
. Disconnect air flow meter harness
connectors. NG B
11 ec
t
Place ignition switch to ON position.
i Use tester to measure the voltage I I

II ~~ "l. ---~
'b,!woo" """'"," aod gm"d
OK Inspectthe following: - ,1::1 U-n-'
Check the continuity between air flow
meter termmal5 and ECCS relay
I

--~
I~-:

~--~--- --~~
I
J
terminal 3.
lfli<i: Repair harness or connectors.
c
B --~ ~,. 00
Ground circuit inspection
Place ignition switch to OFF pOSition.
Disconnect EGGS G/U harness connectors. , NG
Check the continuity between terminal 4 and ECCS 11
LC_/U_te_r_m_in_a_I..,.26_._______-_ _ _ _ _ _.-JI !

OK
Repair harness or connector
c
Input signal inspection i
Check the continuity between airflow meter I NG
terminal 2 and ECCS C/U terminal 27 (intake ~
air quantity signal). : I
OK

To 0
IRepair harness or connector

EN - 408
 RB25DE DIAGNOSIS
RB25DE ENGINE

o o
Input signal inspection I"W'MONITORIN~O FAIL '--..1
Connect crank air flow meter and ECCS C/U CAS RPM IREF) 662rpm.
hamess connectors. AIR FLOW ~TR 1 02V .

1'6\ Use "AIR FLOW METER" in "DATA I ENG TEMP SEN 8"
i EXHSEN a.18V
~ MONITOR" to measure input si nal. i THROTTLE SEN OAOV

(1'1 Measure the voltage between ECCS C/U

'iNJ PULSE 3.0msBC

\W terminal 27 and ground. .

... START

. .....
Voltaga
. ....
'.

fg!lilillnUlltl:h ON
'..
. '
'
.'

..
_1181 2'1 (in!IIlW _'" ..
•.' •. . .ntity fllllnal) .'" . .
Approx. O.3V
!

• o
;. :. Cranking •.•.... Approx. 1V :1t £H~ CIB W
.' ·····ldlIng .;; Approx. 1.1 V IECCS CIU con"ectaj

OK I Component parts inspection

. (Crank angle sensor)
Refer to the section on crank angle sensor for
inspection. IF NG: Replace crank angle sensor.

. Check for any damage on the ECCS C/U

, terminals and ECCS C/U connector.

Carry out the inspection in the following order after repairs.

Verification inspection I

Erase memory from self-diagnosis

Test drive

~;ct;;;;-kb'~~di;;;-;;~;J....!N~G~JCheCk for any damage on the

I Recheck by self-diagnosis ECCS C/U terminals and
ECCS C/U connector.

EN - 409
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 4 - ENGINE TEMPERATURE SENSOR

(CODE NO. 131N SELF-DIAGNOSIS)

Engine terrperature L_'-I---~:i

I . Fuel injection :::;ontrc!
sensor
I

~
)-------------~~

L:J-------------~l~ 1 .. t Ignition riming contro:]

~:~-'-d,-e-sp-e-ect-c-o-nt,o, I

Components location

START I

IC8rry out self-diagnosis

NG OK
A
A
Power supply inspection i
Place ignition switch to OFF position, I
; Disconnect engine temperature sensor i
hamess connector. I Ni I
Place ignition switch to ON position,
Use tester to measure the voltage
i

I ' I,-, ,., _ _ ,---1

I
between terminal 1 and ground, i

Voltage: Approx, 5V '

OK
To 8

EN - 410
 RB25DE DIAGNOSIS
R82SJE ENGINE

B B
i Ground circuit inspection

'Place ignition switch in OFF position.

ICheck continuity between terminal 2 and ground .•

OK I
IRepair harness or connector I
C
Input signal inspection
® Use "ENG TEMP SENSOR" in "DATA
i MONITOR" to check engine coolant C
temperature. 1t.\MONITofllN~O FAIL LJi
® Check the voltage between ECCS C/U ENG TEMP SEN 78" I
terminal 28 and ground.
,Voltage: When ignition switch is ON
! Eng temp Approx. 20°C 3V
I Approx. 80°C 1V I
OK START
Component parts inspection
(Engine temperature sensor)
Refer to the section on engine temperature
: sensor for inspection. lE NQ; Replace crank C 'I

Ii-a_n"'-gl_e_s_e_ns_o_r._ _ _ _ _ _ _ _ _ _ _ _ llt E ~

1
IEees CJU connectQ~

L~
Check for any damage on the ECCS C/U
terminals and ECCS C/U connector.
~"'~1

Carry out the inspection in the following order after repairs.

Verification inspection

Erase memory from self-diagnosis

Test drive

~::;:;;;;;::kh~;;;jf.k;-;:;;;~::J---.!N~G~JCheck for any damage on the

I Recheck by self-diagnosis ECCS C/U terminals and
OK IECCS C/U connector.

FINISH

EN - 411
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 5 -IGNITION SYSTEM INSPECTION

(CODE NO. 21 IN SELF-DIAGNOSIS)

@
IGN '"elay I
i Power transistor

FiL6 I I
8 ~ ~H"
i
1 2- .. +16

ECCS relay ilT3[

53
~t;"~2
---- 3
i
II
Fu'l

I
riO
>-+, ,
I

Components location

, /
i ,-' ,\ 0-.
~_tcgs con~ol<,Jn~

EN - 412
 RB25DE DIAGNOSIS

A
,"ELF-DIAG REs+"'D
Carry out self diagnosiS, lFAILURE DETECTED TIME \'
IIGNSIGNALPRIMARY 0
NG 10K , '

~.J
. To ignition signal 1 (Item
• not In se!f diagnosis)
A
Circuit function inspection ERASE I' PRINTI

Inspect using "POWER BALANCE" in

, "FUNCTION TEST' mode, \,eJ
til A
.POWER BALANCE. ;
i Gheck to if engine rev will decrease momentary, INSPECT THE BALANCE:
\ OF EACH CYLINDER BY I
FIJs~KI
STOPPING INJECTOR
OPERATION FOR EACH
I CYLINDER
B
IGround circuit inspection
•Place ignition switch in OFF position, [FiASsli START
'Disconnect power transistor unit harness connector. I NG
Check for harness continuity between terminal E and Ii B

ground, • I
OK '
i Repair harness or connect~r I
B
Output signal circuit inspection
Place ignition switch In OFF position,
Disconnect ECCS C/U harness connector,
Inspect for continuity between the following terminals:
EGGS C/U terminal 1 and terminal 2
ECGS C!U terminal 12 and terminal 2 NG
EGGS G/U terminal 3 and terminal 3 I--
ECCS C/U terminal 13 and terrninal4
,EGCS G/U terminal 2 and terminal 5
ECCS C/U terminal 11 and terminal 6
ECCS CfU terminal 10 and terminal E
ECGS C/U terminal 20 and terminal E

OK
, Repair harness or connector.

Output signal inspection

Connect power transistor unit and EGGS I
G/U harness connectors,
Inspect battery voltage between EGGS GfU NG
terminals 1, 2, 3, 11, 12, 13 and ground.
Cranking: Approx. 0.2 - 0.3V
'Idling: Approx. 0.2 - 0.3V
2500rpm: Approx.1V
OK

EN - 413
 RB25DE DIAGNOSIS
RB250E ENGINE

Component parts inspection

(Power transistor unit)
NG
. Refer to the section on powe r transistor for
inspection. IF NG: Replace power transistor
. unit.
10K I Replace power transistor!
I Check for any damage on the ECCS G/U I
terminals and EGGS C/U connector. I

Carry out the inspection in the following order after repairs.

iVerification inspection I

I E~ase memory from self-diagnosis I

Test drive
L-----rl- - - - '

r---- ~I_;;;:;;:;::~;;:;;:~l-...!N~G~-jl Check

§CheCk by self-diagnosis I •
for any damage on the
ECCS C/U terminals and
i

'
i EGGS C/U connector.
OK

EN - 414
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 6 - EXHAUST GAS SENSOR

(CODE NO. 15 IN SELF-DIAGNOSIS)

H~ater
1
r ,2
7 3
Air-fuel ratIo
feedback contro!

Components location

o
~ I:
sensor ~.

0" sensor r,arr1ess

connectqt
J
, /.//
L-.:.. "

A
~~ASE AIR-FUEL RATO TES-r+l
IHOLDTHEE'JGINESPEEDAT
j2000+1-200rpmAND PRESS
I
;
(START.
A .--~-

Function inspection 1 1800 2000 2200

, Warm up the engine.
START
@Inspect using "BASE AIR-FUEL RATIO" in
"FUNCTION TEST" mode. '
NG OK

To B

EN - 415
 RB25DE DIAGNOSIS
RB25DE ENGINE

B B
Function inspection 2 i~10NlTOR:N,*,O FAil J\•
Start the engine. .
(j) Hold the engine at 2000 rpm and inspect i OK · CAS.RPM (REF)
•
650rpm i
02 SENSOR O.02V I
using "02 SENSOR" (output voltage and "02
SENSOR MONITOR" (lean, rich) in "DATA .
I 02 SENSOR 'viTA RICH 1

MONITOR" mode.
I
M Measure the voltage between ECCS C/U
START
'4:Y terminal 29 and ground.
Approx. 0.3V (constant voltage) NG
Approx. over 0.6 - 1V (variant voltage) OK B

I FINISH § eonneeto1
c CIU

Input signal circuit inspection

'"j
I
Place ignition switch to OFF position.
Disconnect 0, sensor harness connector and ECCS NG I ' •• 1. I'
I -

C/U harness connector. _._~~_. _ _._ _._._J

.Check continuity between ECCS C/U terminal 29

C
.
and 0_ sensor harness connector terminal 2.

i
!

-----------~
: ~ e!' :1e
0K ~u connecto~
[§p",",m"so"'""'ctm ;

r~l;
1
I 32.'
[Jieplace 0, sensor
l !LJI..c.
. I
~.~

, . I
I Check for any damage on the ECCS C/U I
~erminals and ECCS C/U connector.

Carry out the inspection in the following order after repairs.

Verification inspection

~ase memory from self-diagnosis I

I
Test drive

~;;:;;;;kb~;:;jj.:;fu;-;;~iJ..~N~G~~ Check for any damage on the

I Recheck by self-diagnosis .ECCS C/U terminals and
i ECCS C/U connector.

EN - 416
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 7 - DETONATION SENSOR

(CODE NO. 15 IN SELF-DIAGNOSIS)

r------.I Zl

I
[OetonatiO:l sensor 2,

Components location

Detonation sensor
harrJess connector
I

EN - 417
 RB25DE DIAGNOSIS
RB25DE ENGINE

I START
i
I
ICarry out s~lf diagnosis ~
!NG
A [FINISH
Input signal circuit inspection 1
Place ignition switch to OFF position.
Disconnect ECCS C/U harness connector and
sub hamess connector. NG
i Check the continuity between terminal 1 a n d . B
· ECCS C/U terminal 23, terminal 2 and ECCS CI . r;,."~- . . '.
I'c GEl
I U terminal 24. •I

B . .. 10K IRepair hamess or conne~tor I i

r------' I
Input signal circuit inspection 2 I i
Disconnect hamess connectors connected front and; NG
rear of the detonation sensor.
Check the continuity between sub hamess terminal A
. and 23. Band 24.

i OK IRepair harness or connector i

'"pot "g",' '",P"'"M

Connect detonation sensor and ECCS C/U
~
harness connectors.
Measure the voltage between ECCS C/U .
i
terminal 23, 24 and ground. NG

n
Measurement location terminal 23, 24 and ground
Ignition switch ON Approx. 4V , ,
I
Cranking Appro•. 4V

L
~.
Idling Appro •. 4V 'I
i
; OK I Replace detonation sensor I
• Check for any damage on the ECCS C/U
i terminals and ECCS C/U connector.

Carry out the inspection in the following order after repairs.

[verifiCation inspection

Erase memory from self-diagnosis

Test drive

NG Check for any damage on the I

~R~e=c:..h~e:::C~k.::by~se::;l~f.:::d~ia~g~n.::os~i~sr-_-j, ECCS CIU terminals and I
OK ,ECCS C/U connector~
FINISH
EN - 418
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 8 . THROTTLE SENSOR (CODE NO. 43 IN SELF-DIAGNOSIS)

m fuel Injection controj

Throt:ie sensor (")
(")
.,
r~ 0 III
Power 1
""'- I
21 [8
0
I
l~
·1 AlC cuI control
.,"
Signal ~

Q.
, Groune 3 0 c
~
r-

Components location

"-,r:I'~«f-Ti!--'--
.- j~_,'lJ,-...:......:j
.--~ ..=--,
, ~:t.~ "

, /?""/
/. /;/
..
1 '\ -,,' ,,'

, ~- --'

, Throttle s'ensor
'-----
harness conneclo:- i

START I
A
1=-=-=-== 0 K
Irrcc:=-:-=-::::':u.:
Carry out self diagnosis I• THROTILE SENSOR.
1
NG FINISH PRESS START WHILE
A PRESSING THE
System inspection ACCELERATOR PEDAL
FULLY.
Place ignition switch to ON position.
Use "THROTTLE SENSOR" in "DATA
...~
MON ITOR" to inspect the system. OK
I--- START~
Voltage:
Fully open Approx.4.0V
: Fully closed Approx,O.6V
• Open I Close range over Approx. 3.0
NG
FINISH
TOB

EN - 419
 RB25DE DIAGNOSIS
RB25DE ENGINE

8 8
Power supply inspection !;::n~ONITORIN~ NO FML OJ
(j) Place ignition switch to ON position. NG
Use "THROTIlE SENSOR" in "DATA ICAs.RPM IREF) orprr:
MONITOR" to inc::s=e.;;;.ct:.:...._=-_ _ _ _ _-< i
,
THROTTLE SEN 3,94V'
!
eii':
Place ignition switch to OFF position. , i
is/Disconnect throttle sensor harness connector.! .J
Measure the voltage between terminal 1 and STAR.!.,T_ _---l
I ground. Battery voltage: Approx. 5V
8
C OK ] Repair harness or connector II
r21eo~

U
i2
Input signal circuit inspection I'
-~.,
Disconnect ECCS C/U harness connector. NG IL'.I:I
' ;
i Check the continuity between ECCS c/u,'i

I terminal 38 and terminal 2. ,

.~
~~-~~ . 1
~

IRepair harness or connector I

i

C
IComponent parts inspection (Throttle sensor) ,
i Refer to the section on throttle sensor for inspection./
IlENG: Replace throttle sensor unit.
I

OK
. i
Check for any damage on the ECCS C/U ,
terminals and ECCS C/U connector. '

Carry out the inspection in the following order after repairs.

'Verification inspection

Erase memory from self-diagnosis'

Test drive

NG Check for any damage on the ,

Recheck by self-dll!ia~g1.f:1n~os~i~sr-':"':"':'-jECCS C/U terminals and
OK_--,
, - -_ _ ...L.._ ECCS C/U connector.

EN - 420
 RB25DE DIAGNOSIS
R825DE ENGINE

DIAGNOSIS 9 - AIT CONTROL (CODE NO. 54 IN SELF-DIAGNOSIS)

i .I ----~--. 10

I m
(')
(') ~
"0
"'"a0
Q.
I:
I
t".....
5,
I
1" -"2-
I:
::J
::;
~

! "
~ .. - .. I

Components location

Carry out self diagnosis

A

A
Input signal circuit inspection
.NG
I
I

I"" eN ~'''"' I
I
I ~,:; 1
, 8:1(J'.\ i21IAlTcluconoectorli
10, 11, 12"

Place ignition switch to OFF position,

Disconnect ECCS C/U harness and AfT C!
U harness connectors, NG
· LF~
, Check the continuity between ECCS C/U
terminal 14 and AfT C/U terminal 10, ECCS,
C/U terminal 5 and AfT C/U terminal 11 ,

OK
I Repair harness and connectors I

, Check for any damage on the ECCS C/U

terminals and ECCS C/U connector.

EN - 421
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 10 - CRANK ANGLE SENSOR (NOT IN SELF-DIAGNOSIS)

t
F:L 3
~ ~ ~1 ECCS relay
, ,
1
~
"'---"
i8:l
,

:0 .1 1 "
F/L 6
2 L- '"'" , Ignition timing contr11

CranK angle se"'lsor

. 120" sigral 1
t% 2 1
I "
41
Pln
rJ)
r------- :--
" 0 Floel injection C()ntro~
" Q.a
1" signa; 2
Power 3 L
'" "
Ground 4
'" ~
!- r--
, Idle speed control I
( 1 I~I
2 3 4)

L _______________
Components location

EN - 422
 RB25DE DIAGNOSIS
RB25DE ENGINE

A ,----_
A
-... ... --~ .... -~

Ground circuit inspection lIerOO

Place ignition switch to OFF position. .
Disconnect crank angle sensor harness I NG
. connector . I
. Check for continuity between terminal 4
I and engine ground harness.
i

OK ,
Repair harness or
connector

Component parts inspection

(Crank angle sensor) NG
Refer to the section on crank angle sensor IL...-
for inspection.
OK ,
IReplace crank angle se nsor I
Check for any damage on the ECCS C/U
terminals and ECCS C/U connector.

Carry out the inspection in the following order after repairs.

IVerification inspection I
I NG Check for any damage on the
IGround circuit inspection ECCS C/U terminals and
I EGGS G/U connector.
I FINISH I

EN - 423
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 11 -IGNITION SIGNAL 1 (CODE NOT IN SELF-DIAGNOSIS)

IGN 'elay

Power transIstor
I
'No.1
'"
No,2
.,
I. m
(")
(")
3
No, 3
ECCS relay CD...[!) '"
(')

~2~
~_3
Full
-
~
0
"!2.
"~

~ _ _ _ _ _ _ _ _ _ _ _ _ _ _2,_ _ (_'1_21_r._4_~_~ __________________ ~

Components location

Q
._ _ _ "'~CS control cnL

EN - 424
 RB25DE DIAGNOSIS
RB25DE ENGINE

A
.POWER BALANCE.
INSPECT THE BALANCE
Whole system inspection, - OF EACH CYLINDER BY
OK STOPPING INJECTOR
Start the engine.
I Is all cylinder ignited? I I OPERATION FOR EACH
i CYLINDER,
• TURN OFF AlC & LIGHTS
A
NG I To ignition signal 2 I
ipASS]: START]
ICircuit function inspection
: Inspect using "POWER BALANCE" in
"FUNCTION TEST" mode. OR power
®! :
I

A
• ACTIVE TEST .0
balance in "ACTIVE TEST". L..Q!S, POWER BALANCE
Check to if engine rev will decrease momentary. I I MONITOR
'ICAS_RPM(POS) rpm l-

AIR FLOW METER V

NG FINISH .AAC VALVE % I
B ==ir==ir==ir=='
Power supply inspection L1 I~Jl!l[~!MONrrOR
Place ignition switch in OFF position. [iJ~nDisTART I
Disconnect ignition coil harness connector. B
•Place ignition switch to ON position. NG
: Use CONSULTor the tester to measure the
voltage between each coil terminal 1 and ground.
Power voltage: Battery voltage
--=---------'
OK Inspect the following:
Ignition relay
Ignition switch
•Continuity between each coil
i Harness terminal 2 and ignition

! relay terminal 5.
C
_ _ _ _ _ _ _- , -_ _-'---c_ _ _ _ _ _ _- - ,

Ground circuit inspection

Place ignition switch in OFF position. NG
Check for harness continuity between each coil
terminal 3 and ground,

OK IRepair harness or connector I o

0
Output Signal circuit inspection
Disconnect power transistor unit harness connector,
Inspect for continuity between the following terminals:
Between each ignition coil terminal 1 and
Power transistor unit terminal 1
Power transistor unit terminal 2 NG
Power transistor unit terminal 3
Power transistor unit terrninal4
•Power transistor unit terminal 5
i Power transistor unit terminal 6

OK I Repair harness or connector I

EN - 425
 RB25DE DIAGNOSIS
RB250E ENGINE

Components inspection
(Power transition unit & Ignition coil) NG
Refer to power transition unit and ignition coil
,inspection in components inspection section.

[§l}iace faulty parts

Carry out the inspection in the following order after repairs:

Verification inspection

I Recheck ECCS C/U terminal for

Components inspection ----j"
1-" damage and check ECCS C/U
, harness connector connection.
---~
~

EN - 426
5 RB25DE DIAGNOSIS
A825DE ENGINE

DIAGNOSIS 11 -IGNITION SIGNAL 2

Continue from ignition signal 1]

"
E
Power supply inspection
~ ~ e;! .ic2.':Jfl I
Place ignition switch in OFF position. i53r=u~ :
fT4~
'-'- ~' ,
Disconnect ignition coil relay connector.
i Place ignition switch to ON position. NG = i
L'LJ
'Use CONSULT or tester to measure the
voltage between coil terminal 2, 3 and ground.
Power voltage: Battery voltage
Ji :
OK i
i Inspect the following:
Continuation between fusible link,
ignition coil relay and ignition switch.
Continuation bel\'I'een ignition coil
i relay and the battery,
F
, Ground circuit inspection
Place ignition switch to OFF position. NG
Inspect hamess continuation between each coil
terminal 2 and 5. G

OK IRepair harness and / or connector I: !}t If'" @:)

G
'I ! IEGGS GIU connectod r~=1J i
Output signal circuit inspection I 1io- ~,
Disconnect ECCS relay.
Inspect the continuation between ECCS C/U
NG
i t ;~j i
terminal 16 and ECCS relay terminal 2.

OK Inspect the following:

Fusible link.
Continuation between ECCS C/U and
ECCS relay harness.
i Continuation between ECCS C/U and
i ignition coil relay hamess.

, IF NG: Repair harness and connector.

IComponents inspection
i
. (Ignition cOil & ECCS relay) NG
Refer to ignition coil and ECCS relay inspection I
in components inspection section. I

OK I Replace faulty components

Inspect ECCS C/U terminal for any damage
and ECCS C/U connectorforconnection.

EN - 427
 RB25DE DIAGNOSIS
R825DE ENGINE

DIAGNOSIS 12 - INJECTOR SYSTEM INSPECTION

Components location

><1·
//......
".
~

I
J

EN - 428
 RB25DE DIAGNOSIS
RB25DE ENGINE

I START I A
A I "OWER BALANCE.
Circuit function inspection
rB\ Inspect by "POWER BALANCE" in INSPECT THE BALANCE I
. OF EACH CYLINDER BY j
\eJ "FUNCTION TEST' mode. STOPPING THE i
Operate "POWER BALANCE" in INJECTOR DRIVE FOR I
CONSULT active test. i EACH CYLINDER.
fi8\ Make sure the injector operation noise I PASS [=. =S=TA=R=T="=i]
~ is audible.
A
NG 'OK
FINISH

B B
I,Power supply inspection 1
'Place ignition switch to OFF. I
Disconnect sub harness connector. ,
Check the battery voltage between terminal i
3 and ground using CONSULT or tester.

NG
i Inspect the following:
i Harness connector. C
I Continuity between sub harness
• connector and the harness.
'IFNGR
i-··· ..
~
epalr h arnessan d connector.
C
Power supply inspection 2
IFQ'j
Place ignition switch to OFF position. •
Disconnect sub harness connector.
Inspect between the following terminals
for continuity:
o
between terminal 3 and 5
between terminal 3 and 6
between terminal 3 and 4 I :IEccs c/u connectO~1
2~NO.11i
OK ING No.2.
0
Disconnect injector harness connector.
Inspect between the following terminals
U- !lilll
:.
No.3!
NoAI
No.sl
NO.6
for continuity:
I between terminal 109 and No.1. 2, 3,
4. 5 & 6 cylinders.

To E
EN - 429
 RB25DE DIAGNOSIS
RB25DE ENGINE

E
Out put circuit inspection
Disconnect EGGS G/U harness connector.
Inspect between the following terminals for
continuity: IEGGS C/U connector I 2
101,103,105,110,112,114 NO.1
between terminal 101 and NO.1 cylinder No.2
between terminal 105 and No.2 cylinder No.3
No.4
.between terminal 103 and NO.3 cylinder NO.5
between terminal 112 and NO.4 cylinder No.6

between terminal 11 0 and NO.5 cylinder

i between terminal 114 and No.6 cylinder

NG
Repair harness or
OK
. connector.

Component parts inspection

i (Injector)

I Refer to the section on injector for inspection.

NG

Inspect ECCS C/U terminals for any

damage and make sure the connectors
I
are connected correctly.
-------'

Carry out the inspection in the following order after repairs:

I Verification inspection:
I

I~~~IM;;;;clJ-~O~K~..Jj~;;-;;;'
Functional check. I Recheck for any damage on the ECGS C/U I
I

i NG IterminalS and ECGS G/U connector.

IFINisH I

EN - 430
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 13 - VEHICLE SPEED SENSOR

,
"'
(')
(')
(fl I
n .. , Fuel cut control
:)
:0

53 a _I Idle speed conirol

~.

L ..~

Components location

:.\ .
L' // ECCS ~ontrol J!"1it~

I START I

Whole system inspection i

Use CONSULT and carry out the inspection! O~
using "VEHICLE SPEED SENSOR" in ! •

"FUNCTION TEST' mode. I i

NG
1 FINISH i

I Vehicle speed sensor function inspection NG

I Inspect vehicle speed meter function

OK
IVehicle speed sensor and !
vehicle speed sensor circuit
TO B inspection,

EN - 431
 RB25DE DIAGNOSIS
RB25DE ENGINE

B
B i~ONrrORIN<tl NO FAIL 1':
Input signal inspection
NG ICAS. RPM iPOS)
VEH SDD SEN
787rp",
0 km;r.
II

Start the engine.

Rotate drive axle slowly.
Detect vehicle speed using "VEHICLE
SPEED SENSOR" in "DATA MONITOR".
Use tester to measure the voltage between START
ECCS C/U terminal 53 and ground.
Voltage: apprcx. 0 - 5V B
. .--'-----, i--
.I .ill £:-~~l
(~
~ I,
IInspect the following:
. Check the continuity between ECCS
I C/U and combination meter harness.
,
II
I EGGS G/U conneclorl
53
1
I

IIF NG: Repair or replace harness. . I ! !ool

@.Sl
•
Inspect ECCS C/U terminals for any
damage and make sure the connectors I'
are connected correct/y. .

Carry out the inspection in the following order after repairs.

Verification inspection
NG Check for any damage on the !

Ground circuit inspection f-----1ECCS C/U terminals and 1

ECCS C/U connector. •

EN - ..\32
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 14 - AIR CONDITIONER RELAY SIGNAL

• i
'----.-. .•.- - - - l

Components location

I START I

Input signal inspection

NG !21 E:' ~
Place ignition switch to ON position. II ECCS C/U connectod
• 9
Use tester and measure the battery voltage
between ECGS G/U terminal 9 and ground.
When blow-fan switch is OFF: battery voltage
I '.~..
"=J."
~···I

IWhen blow-fan switch is ON: Approx. 1V ~····1

NG
I FINISH I
Inspect ECCS G/U terminals for any
damage and make sure the connectors
are connected correctly.

Carry out the inspection in the following order after repairs.

Verification inspection
NG i Check for any damage on the
Ground circuit inspection 1 - - -.... ECCS CfU terminals and
ECGS G/U connector.

EN - 433
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 15 - EXHAUST GAS SENSOR HEATER

Components location

EN - 434
 RB25DE DIAGNOSIS
RB25DE ENGINE

I START' A
A
Power supply inspection
Disconnect exhaust gas sensor harness connector..• NG
Place ignition switch to ON position. i
IMeasure power voltage between terminal 1 and I
ground.
L_
OK
Inspect the following: B
Harness connector.
Continuity between exhaust gas
sensor and the fuse. IF NG:
Repair harness and connector.
i

iI ECCS CIU
115
,
connec!orl

'Qi]
i
3 2 ..2)

B • ilill
Ground circuit inspection •
l
~-.~
Place ignition sWitch to OFF position, !

NG
I
Disconnect ECGS G/U harness connector.
Check for continUity between termtnal3 and
IEGGS GiU terminal 115.

OK
Repair harness or connector.

IComponent parts inspection NG

i (Exhaust gas sensor heater)
! Refer to the section on exhaust gas sensor
i heater for inspection.
OK
Replace exhaust gas sensor.

,Inspect ECGS GiU terminals for any

i damage and make sure the connectors

,are con nected correctly.

Carry out the inspection in the following order after repairs.

Verification inspection'

NG •Check for any damage on the

Inspect power supply, ground circuit I-----i' EGCS C/U terminals and
OK EGGS C/U connector.
'---=F-:::IN:':-'S=-=H:-::----'

EN - 435
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 16 - THROTILE VALVE SWITCH

~-L--. --
To AfT
control unit
m Fuel injection control

i ~. . Ilgo'1'.OO 1'.mlng controll

~ ,.. . . - J l d l e speed control

~ I

Components location

Th e,nttl" ",live sw

I::
I ·~,\:1- I
~._ .. _ _ ...E.CC;L,<ontrQLymt._J

EN - 436
 RB25DE DIAGNOSIS
RB25DE ENGINE

A A
'.-::1D::C'L-=E-JU-::D::-:G:-::E::-M-=EN::-:T=--.~
,
Function inspection 1
Place ignition switch to ON position. kTART WHEN AGGELERA·
Inspect using "IDLE JUDGEMENT" in
OK ~OR PEDAL IS FULLY OPEN.
"FUNCTION TEST" mode.
: Reference: Fully open: OFF :
Fully closed: ON L - ....
FINISH I PASS I'' - - -START
-----'
B NG
Function inspection 2 B
Place ignition switch to ON position. .-'~-

Inspect ignition switch "ON-OFF" diagnosis or i ... £;00

(Idle CO'1nection poim)
OK !

measure the voltage between ECCS C/U terminal :I EGGS G!U connecto,!
: 54 and ground using the tester when ignition switch 54
jisON. I
Voltage: Accelerator pedal pressed OV
I Accelerator pedal not pressed 8 - 10V
NG
C
I FINISH I
Power supply inspection !
C
Place ignition switch to OFF position.
Disconnect throttle valve switch harness connector.
Place ignition switch to ON position. NG
,

:Use tester to measure the voltage between

terminal 2 and ground.
Battery voltage: Approx. 8 - 10V

Inspect the following:

:Harness continuity between throttle
ivalve switch and ECCS C/U. IF NG:
:Repair harness and connector
0 I
Input signal circuit inspection
Place ignition switch to OFF position.
NG
Disconnect ECCS C/U harness connector. -
Disconnect throttle valve switch harness connector.
conn.ectO~II' f~
Check the continuity between ECCS GiU terminal
'54 and throttle valve switch terminal 1.
II EGGS G1U
I
L__ ,. _:_o_ _~
r roo .
OK I Repair harness or connector.
IComponent parts inspection
, (Throttle valve switch) NG
I Refer to the section on throttle valve switch for j
Iinspection. ,

OK I IReplace throttle valve switch. I

'Inspect EGGS C/U terminals for any damage and
make sure the connectors are connected correctly.
EN - 437
 R825DE DIAGNOSIS
RB25DE ENGINE

Carry out the inspection in the following order after repairs.

. I .
%rification inspection i

NG Check for any damage on the

i Function inspection 1 - - - - - - 1 ECCS C/U terminals and
~ OK 1 ECCS C/U connector.

I
FINISH

EN - 438
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 17 - START SIGNAL

~jngcont~~

A
A
~.STARTER SIGNAL • I
Function inspection PlACE SHIFTLEVERTO ''P''OR ;
Place ignition switch to ON position. I "N' Wl1l1ACCELERATOR PEDALj
~ EULLYCLOSED :
Use CONSULT and inspect "START SIGNAL" in i START1l1E ENGINE STRAIGHT ;
"FUNCTION TEST" mode. OK ! AFTER SELECllNG START I
OR I, Ji
Place ignition switch to ON position.
START
--,
Inspect start signal using "DATA MONITOR" mode. i PASS IL'
, ,----
When ignition switch is ON position: OFF
When ignition switch is START position: ON A
iNG
I WONITORINttl: NO FAIL 01
B FINISH ! l

I
CAS, RPM (POS)
1326rpm
,STARTER SIGNAL OFF
I
Power supply inspection I ,
Place ignition switch to OFF position. ®
Disconnect throttle valve switch harness connector. ; NG
Place ignition switch to ON position. -
L I
RECORD
Use tester to measure the voltage between
terminal 2 and ground.
Battery voltage: Approx. 8 - 10V B
OK I- , I ~E)~
Inspect the following:
Fuse il ECGS CIU connector I
.Continuity between ignition switch
I and ECCS C/U harness. IF N(3~
'Repair harness and connector.

Inspect ECCS C/U terminals for any damage and

make sure the connectors are connected correctly.

EN - 439
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 18 - FUEL PUMP CONTROL

FIL6 ECCS relay

r------i~ ~~ i3 ,·-4 ..
, t 16
. I ...·-'~--
1'- L---j' .,

I FIL3 IGNSW #16 l M

!-~-(2']--i w..Lil en
0
L1.l2J 0
[J)

_1_ ~~ '""
~+':--"I-------<! 18 :>

Fue! pump relay _ rf

, ,. ""
4 5 '"
crr:Iill
UUU0i
I i to= I :L~~
J-
(-- .--------~---
Fuel pump L.. _ _ _....;i

---~-------~.L-c)
'-~
i

Components location

/
, i/.
0_'_'___-'E"'C"'"C"""'S.cy'"o'"nt"-ro""l"u~n".>.Jlt

EN - 440
 RB25DE DIAGNOSIS
RB25DE ENGINE

I START I A
, ''---+Fc--UEL PUMp+
A I ISTHERE A PULSATION
System inspection IEVERY 3 SECONDS
Select "FUEL PUMP" in "FUNCTION fIT', I WHEN THE FUEL TUBE
TEST' to inspect the system. \!J IS HELD? OR CAN YOU
HEAR THE OPERATION
Operation check by "FUEL PUMP RELAY" in
OK I NOISE OF THE FUEL
,"ACTIVE TEST'. l£I,JMP R.ELAY? =,. ==
Fuel pump will operate for 5 seconds after the
I PASS II NO II YES
ignition switch is turned to ON position. Check if
the fuel pump operation noise are audible. A
• ACTIVE TEST.0
FINISH
FUEL PUMP RELAY ON I
8
Power inspection ,
MONITOR ,II,

'Place ignition switch to "OFF" position.' CAS.RPM (POS) Orpm

,Disconnect fuel pump relay. I NG
[ ;
; Measure voltage between ground and
Iterminal 2 & 3 using the tester. I ISTART IloN/OFF[~TOP I

A
OK
Check the following:
Fuse
Harness connection between fuel
pump relay and the fuse.
Connection between fuel pump relay
,and the ignition switch.
I!EliG: Repair I-)arness & connector.
8
c
Ground circuit inspection I
Place ignition switch to OFF position.
Remove fuel pump harness connector. NG
Check the connection between fuel
pump harness connector 3 and the
'ground.
c
Repair harness or
the connector.
o
Output signal circuit inspection
Place ignition switch to OFF position.
,Remove ECCS C/U harness connector. ~
I Check the continuity between ECCS CiLi & harness

•terminal 18 and fuel pump relay harness terminal 1.

ICheck the following:

[Continuity between ECCS C/U and fuel pump relay.
'Continuity between ECCS C/U and pump relay.
lIE NG: Repair harness and the connector.
EN - 441
 RB25DE DIAGNOSIS
RB250E ENGINE

E
Control signal inspection
Measure the voltage between ground and ECCS C/U
4 o

terminal 18. ,
~
5 seconds after ignition switch is turned ON: 1V ; r9"l
After 5 seconds after ignition switch is turned ON:
Battery voltage
fOlJl T-
OK, J J I
t'----l4U.r---
I
Icomponent parts inspection
•(Fuel pump relay) E
Refer to the section on fuel pump relay for

'"'::r , Replace fuel pump relay.

Component parts inspection

(Fuel pump) n
I NG

,Refer to the section on fuel pump for inspection. , ;

OK I I
IReplace fuel pump. I

Check for any damage on the ECCS C/U

i terminals and ECGS C/U connector.

Carry out the inspection in the following order after repairs.

IVerification inspection I
I OK NG Check for any damage on the ECCS C/U
IFunctional check. r.:::.:------1 term inals and EGCS G/U connector.
I --~
r--·---'-------,NG
I
Fuel pressure inspection. ,f ------11Replace malfunctioning parts·1
0K
1
I FINISH I

EN - 442
 RB25DE DIAGNOSIS
R62SDE ENGINE

DIAGNOSIS 19 - AAC VALVE

Components location

i
,___.._-",~~CCS c:ontr.9_'u_nd

A
I . AAC VALVE •
A ITURN OFF AlC AND LIGHTS
Function inspection 'SWITCHES BEFORE
STARTiNG.
. Warm the engine.
Check the idle speed 600 - 700 rpm. OK
I,w.
IF NG: Adjust idle speed. ~~IFF~INiilISSHHI
Inspect using "AAC VALVE" in
~ "FUNCTION TEST" mode. I PASS I[ START
~ Disconnect AAC valve harness .•
~ Check if idle rev will decrease. '

B NG
Power inspection
IPlace Ignition sWitch to "ON" position. ' NG
'Measure voltage between ground and AAC valve
terminal 2.

Repair harness or the connector.

TOC
EN - 443
 RB25DE DIAGNOSIS
RB25DE ENGINE

c B
IOutput signal circuit inspection I
fb\ Check if the engine rev will change when the ;
\...!IV "UP" or "DOWN" is pressed in "AAC VALVE" in !
"ACTIVE TEST' mode,
Disconnect ECGS GiU harness.

:,® Check for continuity between ECCS C/U

harness terminal 4 and AAC valve connector
L terminal 1.

[R8j}air harness or connector. 1 c;..,-______.

'+ACTIVE TEST • cl
n
I AACN OPENING DEG 10%1'
Component parts inspection (AAC valve) NG MONITOR
Refer to the section on AAC valve for inspection,
CAS. RPM (POS) 900rpm I
AIR FLOW MTR 1.16V;

JoK
I I
IReplace AAC valve, I I
ENGINE TEMP SEN 80"CI
!

iQUI~1 OWN r!QdI

'''-C-h-e-ck-f-o-ra-n~y damage on the ECCS C/U
,
I
. terminals and EGGS C;U connector. I

1lI Ie 00
IEGGS G(U connector ~
, 4
i
[91
I

Carry out the inspection in the following order after repairs.

Functional check. r--- _ _ _ _@heck for any damage on the ECCS C/U
I
. I I . terminals and EGCS C/U connector.

i OK

[FINiISH I

EN·444
 RB25DE DIAGNOSIS
f1B25DE ENGINE

DIAGNOSIS 20 - AIR REGULATOR

F/L3

I,----~(l
-
-L
,..
i
r \
IIGNSW

i
CL.....lJU
UJjJ. >I

#8
<W
Et='~~~1B
L-~r-~3~IO +1~5~2~~' I I
Fue! ::lump relay Air reglila10r -:!:- !
L -_ _ _ »»-"!

Components location

I~I
,
,

I >/ ECCS control Unit

A
Power supply inspection A
Place ignition switch to OFF position>
lilW j£c
\.iIID ~\_..' I~I
\~ ;
Disconnect fuel pump relay. • NG I

Place ignition switch to ON position. --'---l

use tester to measure the voltage between I
iterminal 2, 3 and ground. I
OK
Inspect the following:
Fuse.
TO B Harness continuity between
fuel pump relay and fus€!>
Continuity between fuel
pump relay and ignition
switch.
IF Nft Repair harness and
connector.

EN - 445
 RB25DE DIAGNOSIS
RB25DE ENGINE

B
Ground circuit inspection
Place ignition switch to OFF position.
.Disconnect air regulator harness connectors. ~
Check for continuity between air regulator harness
/Gonnectorterminal2 and ground.
-- I
OK
IRepair harness or connector.
c
Output signal circuit inspection
Place ignition switch to OFF position. C
NG
Disconnect ECCS CIU harness connector.
Check for harness continuity between ECCS C/U I'

terminal 18 and fuel pump relay terminal 1. :I ECCS c/u connector I ~[3L
I 18 LI:!il .
OK
IInspect the following: , I .1Q1 T 1

! ContinUity between ECCS C/ L-;;'~~

U and fuel pump relay. IF NG:
Repair harness and continuity.•
D
Control signal inspection
Measure voltage between ECCS CIU terminal
18 and ground.
=l • NG
o

Within 5 sec when ignition switch is placed in ON I

n '

I @"'E""CC"'S'"'C'"iU"-cC:-on:-:n:-:ec""o""rl
position: Approx. 1V 18

~
After 5 sec when ignition switch is placed in ON i

position: Battery voltage . •

" - -_ _ _- - - ' , - _ ' -_ _ _ ~ _ _ .• I
~.~
OK
Repair and inspect ECCS C/
U power supply and ground
circuit.

Icomponent parts inspection

•(Air regulator) ~G'" . .
~ Refer to the section on AAC Replace air regulatoLI
Ivalve for inspection. .

Carry out the inspection in the following order after repairs.

Verification inspection

ICheck for any damage on the ECCS C/U I

[Functional check·t-I- - - - - 1 terminals and ECCS C/U connector. i

10K
I FINISH I

EN - 446
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 21 - POWER STEERING HYDRAULIC PRESSURE SWITCH

r--' PWR 5T hydraulic

pressure SiN

2~ , .... _ - _ ..- - - 4 19

Components location
~.~ ..- -... ..- -..
~ --~ ~I

I START I
A I
Function inspection A
(j)Place igni!ionswitch to ON position. • POWER 5T SIG •
Inspect using "PWR 8T SIG" in PRESS START WHILE FULLY
"FUNCTION TEST" mode. OK STEERING THE STEERiNG
~ WHEEL.
OR
Stop the engine.
Use "DATA MONITOR" to inspect PWR
ST hydraulic pressure switch signal. or
When neutral: OFF [ ... I
PASS i.. _ _ ~S~TA~R~T_-,
When steered: ON i
A
® Start the engine. I*,-~~ON-l-TO-R-IN-<'k--N-O-F-AI-L--"Di
Use CONSULT or tester to measure the I' i

voltage between ECCS C/U terminal 19 i CAS.PM (POS) 862rpm I

IGNITION SIGNAL OFF.
and ground.
When steered: Approx. OV
Other: Battery voltage

NG I [
L~
RECORD
____ ______ ~
I
TOB
EN - 447
 RB25DE DIAGNOSIS
RB25DE ENGINE

B A
Input signal circuit inspection
Place ignition switch to OFF position<
Disconnect ECCS C/U harness connector.
NG
Disconnect power steering hydraulic pressure
switch harness connectoL
Check for harness continuity between ECCS C/U
terminal i 9 and power steering hydraulic pressure
switch terrninal i. I

OKI Repair harness or connector<

B
c
I
Gro"O d ,',," It '0' pe",'oo
Check for continuity between power steering
I
, NG
IllI ee\ 00
,reis"'c""c,,""'c"';"'uc-o-nn-ec'""to--',Iu~'"
hydraulic pressure switch terminal 2 and engine , I 19 '

ground.
OK ~~
I
I t ~q]1
IRepair harness or connector< I I <~
--------'
Component parts inspection I

I (Power steering hydraulic pressure switch) NGI I

. Refer to the section on power steering I
hydraulic pressure switch for inspecti~ i

I
Replace power steering
hydraulic pressure switch.

•Check for any damage on the EGCS G/U I

terminals and EGCS G/U connector. i

Carry out the inspection in the following order after repairs.

ICheck for any darn age on the ECCS C/U i

'--__.,-__J------, terrninals and ECGS C/U connector. I

EN - 448
 R825DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 22 (Phenomenon) • IDLE REV IS TOO HIGH (AFTER WARM UP)

1 1
Throttle sensor & air regulator inspection I r. TH~OTTLE SENSOR •
@ Inspect in function test mode. . PRESS START WHILE FULLY
· Check i!the throttle sensor (idle judgement) is i G • OPENING THE ACCELERATOR
PEDAL.
· not turned OFF. •N
rU\ Make sure the air regulator unit is not locked
·'a' or electricity is conducted to air regulator.
OK
i Circuit and throttle sensor
: inspection. i

I Air regulator and circuit inspection .•

2
Intake air leak inspection
1;\ Warm up the engine.
(~)Change off set value by selecting "OWN" in YES
"FUEL INJECTION RATIO OFF SET
VALUE" in active test mode.
Caution: Carry out the test in minimum time 2
required. Do not operate during drive.
Warm up the engine.
I. ACTIVETES- •
' FUEL INJECTION OFF SET
DI
0°'0
MONITOR
rU\Separate air flow meter harness connector. II CAS.RPM(POS) 937rpm I'
, ENG TEMP SEN 59~C
~!Check if the idle rev will decrease after j 0, SENSOR 133V
racing the engine at approx. below 2000rpm : 0; SENSOR IR) 135V:
for 30 seconds. i I NJ PULSE : .8'11sec I
17 3 c:
NO I 1Repair where air is leaking. 1
3 2
Throttle linkage inspection
•Stop the engine. NG
Check if the throttle linkage will move smoothly.'
Check if the throttle valve will close! open fully. i

! 1 Air flow me'l:~l!-'i

OK. ; rarness

~
Repair throttle linkage j connector
L. _ _ ...... _--'~.c~_~.. __...:
or inS ect throttle valve.
3

'. \
\' II

\ \, _ ... ~~ont

EN .. 449
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 23 (Phenomenon) - HUNTING

1
Throttle sensor inspection I
Warm up the engine. : YES
Check for any change with hunting when 02 sensorr-=i
connector is separated. ~ :

NO °
-..-.. l
I. .

sensor inspection
I
I
2
2
Power balance test
i • -~.--.~
THROTTLE SENSOR •
/6'. Star the engine.
@Use "POWER BALANCE" in function test. PRESS. STAR~Wf-!ILE FULLY
OPENINGTHEACCELERATOR
Caution; Carry out the test in minimum time NO PEDAL
required. Do not operate during drive, I .I
Idle rev will decrease for a moment for each'
"i"F'=====.J
cylinder.
.'¢Idle rev will decrease for a moment when
~SS II START
L.:.:_~ '--~_
J'
~ each cylinder injector connector is
2
L..-",s;;;.:eparated.
OK I I ,
3 [TON~I
Spark plug inspection I
Stop the engine.
Disconnect spark plug and check for dirt,
,damage, gap etc. "
n NG

OK I
3
4
Intake air leak inspection
Start the engine. YES
Check if engine rev will increase when blow-by
ihouse is pinched.
i
NO;
I
FINISH

EN - 450
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 24 (Phenomenon) - IDLE INSTABILITY

1 1
Operate power balance test 1+ pOWER BALANCE
•INSPECT BALANCE OF EACH
•

/fj\Start the engine. NO PIP~S BY STOPPING I\lJECTOR

lJ!)Operate "POWER BALANCE TEST" in function iOPERA'TIONAT EACH PIPES.
.
i test. Caution: Operate the test in minimum time I iTURNOFFAlLAiCAND LIGHTS!
required. Do not operate during drive. i .
®'dle rev will decrease for a moment when
operating each pipes. 1
I PASS II START

YES
To No. 6 Ii
1
i

2
Injector inspection
Stop the engine.
Remove crank angle sensor.
(leave harness connector as it is). NO
I--
Disconnect power transistor connector.
: Place ignition switch from OFF to ON position.
Can you hear operation noise from each injector 2
when the crank angle sensor shaft is rotated by hand .
.\/yarning: Depending on how the shaft is rotated, self- i
idiagnosis will display abnormal, disregard this display.;

YES
I
~­
IInspect injector and circuit I .~:~
. ~1ll'1
\; \
;,' /{ II ;
/1 Operatio"
noise
3 "
, "-\
,iJ

Ignition inspection '.~ ,

Place ignition switch to OFF position.

Remove ignition coil ASSY. NG
Install normal spark plug.
i Face the spark plug rear end towards adequate

! ground such as collector and crank the engine.

'Check the spark.

OK

4
Spark plug inspection 4
Check for dirt, damage, gap etc. on the
spark plug removed from the engine.

105

EN - 451
 RB25DE DIAGNOSIS
RB25DE ENGINE

5 5
Fuel pressure inspection I i+r--A-c-r-Iv-ET-E-S-T---'+~a
ttl' Start the engine.
\!JSelect "STOP" in "ACTIVE TEST' and bring .
IFUEL PUMP RELAY
fuel pressure to zero. ' I. CAS.RPMMONITOR
(POS) 950rpm i
After engine stop, crank 2 - 3 times. . NG
I ~
Inspect fuel pressure using fuel pressure I , J
gauge. Q.~@~:STOPJ
When idlin : A rox.2.Sk I cm2
~Start the engine.
~Remove fuel pump fuse and bring fuel
pressure to zero.
Attach fuel pressure gauge and inspect the
pressure.

OK Inspect fuel pump and I

• circuits.

6
~ONrrORIN,* NO FAil DI
iCAS.RPM (REF) 650rpm I
6 i 02 SENSOR O.02V I
'02 SENSOR MTR RICH I
Exhaust gas sensor inspection
11J'\lnspect using "BASE AIR-FUEL RATIO" in
\.rV'FUNCTION TEST' mode.
NG START
Select "02 SENSOR MONITOR" in data
monitor.
Set at 2000rpm with no load after warm up.
Check if the display "LEAN, RICH" will repeat
for more than 5 times within 10 seco:::.n~d~s:.....--1
,~,operate vehicle side (within fuse box)
~diagnosis connector and change to "0,
sensor monitor".
Set at 2000rpm with no load after warm up.
Check if the exhaust temperature warning
lamp will flash for more than 5 times within
10 seconds. 6

T07

EN - 452
 RB25DE DIAGNOSIS
RB25DE ENGINE

7
Intake air leak inspection
Start the engine. YES
Check if the engine rev will increase when
the blow-by hose is pinched using hands.

NO i

Repair leaks
8
Idle adjust screw fixation inspection
,t'E\Start the engine. 8
\JV Operate "AAC VALVE ADJUSTMENT' in NO
--.--AAC VALVEADJ .~
SET THE CAS.PRM TO
"OPERATION SUPPORT' mode. r
,STANDARD VALUE U"JDER
'I THE FOLLOWING CONDITION'
Can idle rev be adjusted to 600 - 700rpm AFTER WARM UP,
! ("N" position for A/T) by rotating the idle TURN OFF AL~ LIGHTS AND
AIRCONDfTlONER
i adjustment screw.
®Start the engine. START
Disconnect AAC valve connector.
Can idle rev be adjusted to 600 - 700rpm
("N" position for AfT) by rotating the idle
i adjustment screw.
YES i

I AAC valve and throttle

' valve fixation inspection.
9
Compression pressure inspection
Standard value: 12.8/300 (kg/cm2)/(rpm) NG
Minimum value: 9.8/300 (kg/cm2)/(rpm)
i Each cylinder difference
9
ITolerance: 1.0/300 (kg/cm2)/(rpm)

OK Inspect piston, piston ring

i
I valve, valve seat, cylinder
I head gasket.
10
, ECCS C/U connector inspection
'Check for any damage or loose connection on
the C/U bin terminal and harness connector.

OK
11
Try replacing with normal C/U. Replace or repair

EN - 453
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 25 (Phenomenon) - WHEN COLD, DIFFICULT TO START OR CAN NOT

START THE ENGINE
1 1
Inspect battery and starter motor Replace or repair i +FUELPUMP +

~
AN YOU FEEL PULSATION
OK EVERY 3 SECONDS WHEN
2 HE FUEL TUBE IS
Fuel pressure inspection' I PINCHED? OR CAN YOU
(fl',lnspect using FUEL PUMP" in "FUNCTION ~ IHEAR FUEL PUMP RELAY ,
bPERATION NOISE?
~TEST" mode. , -.J
Minch fuel pump with fingers. jPASs i! NO!! YES i,

~Check if the fuse hose is tense when fuel

pump us operating. 2
OK
Fuel pump and circuit i
inspection .

3
Air regulator inspection i

Cneck if the power is conducted to air regulator: NG

when the ignition switch is turned to ON position.
OK
nI
!

! Inspect air regulator and circuit.!

I~hrottle sensor i:nspection'

'Press accelerator pedal fully and check if
the engine will start. ---..J
nI
: OK

i~hrottle sensor and circuit!

~spection. I
5
Injector inspection
Place ignition switch to OFF pOSition.
Remove crank angle sensor (leave harness
connector connected).
Remove power transistor connector.
i NG
Place ignition switch to ON position.
Check if each injector operation noise can be
•heard when the crank angle sensor shaft is rotated 5
.by hand. Note: Depending on how the shaft is
rotated, abnormal will show in self-diagnosis, in
,this case determine as normal. I I
OK I .....L,
!tnJector and circuit Inspection "
T06 Rotate by hand

EN·454
 RB25DE DIAGNOSIS
RB25DE ENGINE

6 6
Ignition inspection
Place ignition switch to OFF position.
Remove sub-harness in each pipping. .
Install normal spark plug. Face the spark plug· NG
rear end towards adequate ground such as
collector and crank the engine .
I•Check the spark.
OK
7
: Inspect ignition coil, power
i transistor and circuit

7
Spark plug inspection
iCheck for dirt, damage, gap etc, on the spark. NG
iPlug removed from the engine.
OK·
I Repair or replace I
8
ECCS C/U connector inspection
NG
Check for any damage or loose connection on '-----,

the C/U bin terminal and hamess connector.

I
OK I Repair or replace I
9
iECCS C/U power supply and ground circuit J:!§
Iinspection.
OK I
I Repair or replace
10
Try replacing with normal C/U.·

EN - 455
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 26 (Phenomenon) - WHEN WARM, DIFFICULT TO START OR CAN

NOT START THE ENGINE
1
· . 1
E Fuel pressure inspection
,rtt1nspect using FUEL PUMP" in "FUNCTION NG
i~TEST' mode.
.
+FUELPUMP +~1-
CAN YOU FEEL PULSATION
,EVERY 3 SECONDS WHEN
THE FUEL TUBE IS
it'<tl'FinCh fuel pump with fingers. IpINCHED? OR CAN YOU
~Check if the fuse hose is tense when fuel iHEAR FUEL PUMP RELAY
: pump us operating. bPERATION NOISE?

OK I
Fuel pump and circuit
inspection 1
2
Ivapour inspection
,Disconnect fuel pressure regulator vacuum hose. OK
;Place a hole cap on the vacuum hose.
: Does the en ine start?

NG
Inspect fuel aspect
3
2
Injector inspection
Place ignition switch to OFF position.

i
Remove crank angle sensor (leave harness
connector connected).
R,m,," pow,cI'"";'tm ham'" ",",,,tm
Place ignition switch to ON position.
I
Check if each injector operation noise can be
,heard when the crank angle sensor shaft is rotated,
:by hand. Note: Depending on how the shaft is i 3
rotated, abnormal will show in self-diagnosis, in C.-. -.--.~

£,~, I
Ithis case determine as normal.
--- i

OK
Injector and circuit inspection.
4
Ignition inspection Rotate by hand

,Place ignition switch to OFF position.

i Remove sub-harness in each pipping. 4
Install normal spark plug. Face the spark plug i NG
rear end towards adequate ground such as
collector and crank the engine.
,Check the spark.

OK Inspect ignition coil, power

transistor and circuit.
T05

EN - 456
 RB25DE DIAGNOSIS
RB25DE ENGINE

5 5
Spark plug inspection
Check for dirt, damage, gap etc, on the spark 1 - ,_ ,

plug removed from the engine.

OK'I
Repair or replace
6
•ECCS CIU connector inspection
Check for any damage or loose connection on
the C/U bin terminal and harness connector.

OK I Repai r or replace
7
ECCS CfU power supply and ground circuit NG
inspection. -

OK
I Repair or replace
8 ,
ITry replacing with normal C/U, I
i,

IFINISH I

EN - 457
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 27 (Phenomenon) - IN NORMAL CONDITION, DIFFICULT TO START

OR CAN NOT START THE ENGINE
1 1
----:---- -"'~-'

Inspect battery and starter motor' , +FUELPUMP +

bAN YOU FEEL PULSATION
OK IEVERY 3 SECONDS WHEN
2

~
HE FUEL TUBE IS
•Fuel pressure inspection i INCHED? OR CAN YOU
l,rtI'lnspect using FUEL PUMP" in "FUNCTION' NG EAR FUEL PUMP RELAY 'I'

PERATION NOISE'
iJ!VTEST' mode. , ,

'(ff\Pinch fuel pump with fingers,

\:e,;Check if the fuse hose is tense when fuel •
! PASS I~o_] YES.l

pump us operating. 2
'-~--'-'-'-"----"'1

OK I ~ / •
• Fuel pump and circuit
inspection -:;:~~~~'*~~
r
Fuel filter
f /1--1"',\/ II
3
Injector fuel leak inspection
Press accelerator pedal fully an check if the NG
engine will start. when the ignition switch is turneC\---t
to START position. : I 3
OK
[II1spect injector leak. I
4
Fully open W
I Injector inspection 4JI+OO<
Place ignition switch to OFF position.
c
n 1£
Remove crank angle sensor (leave harness
connector connected).
Remove power transistor connector. NG
4
Place ignition switch to ON position.
Check if each injector operation noise can be ~,--"-"--!
heard when the crank angle sensor shaft is rotated i
by hand. Note~ Depending on how the shaft is
rotated, abnormal will show in self-diagnosis, in
this case determine as normal.
•
U i

Rotate by hand
OK
IInjector and circuit inspection.:
5 5
Ignition inspection
Place ignition switch to OFF position.
Remove sub-harness in each pipping.
, Install normal spark plug. Face the spark plug NG
i rear end towards adequate ground such as

I collector and crank the engine.

Check the spark.
--O-K--lr-~----:~~~' ______~
TO 6
Inspect ignition coil, power
transistor and clfcuit.
I
EN·458
 RB25DE DIAGNOSIS
RB25DE ENGINE

6 6
Spark plug inspection
Check lor dirt, damage, gap etc. on the spark NG
plug removed from the engine. i

OK i
I Repair or replace
I
7
IECCS C/U connector inspection NG
ICheck for any damage or loose connection on ~

,
the C/U bin terminal and harness connector,

OK I Repair or replace I
8
ECCS C/U power supply and ground circuit NG
inspection.

OK
I Repair or replace
9
Try replacing with normal CIU, '

EN - 459
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 28 (Phenomenon) - HESITATION AFTER WARM UP

(hesitation as throttle valve starts to open)
1 1
Fuel pressure inspection
/fi',Select "UP" or "DWN" In "FUEL INJECTION
1+ AC,IVE "TEST +0
FUELINJECTION OFF SE"T 0%
MONITO"
\ibUANTITY CORRECTION" in "ACTIVE TEST' OK CAS.RPM(POSj 937rpm
ENG TEMP SEN 59'C
mode to change correction value, 0, SENSOR 1.33V,
Caution: Carry out the test in minimum time ' O. SENSOR (R) 135Vi

n
IN-J PULSE 1.8msec,
required, Do not operate dUring drive, I i AAC VALVE 17%1
~Dlsconnect fuel pressure regulator vacu~ NG [ au II UP II OWN !Lad!
'4!YPlace hole cap on vacuum hose.
Operate crUising test. I
Is there still hesitation?
NG .
If lean hesitation inspect pressure I
regu lator and fuel pump,

IFuel aspect inspection

2 I
!canister purge inspection ~i 2
!Disconnect canister purge hose. NG
'Place hole cap on the purge hose,
Conduct cruise test. '
,Is there still hesitation? , i

EN - 460
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 29 (Phenomenon) - HESITATION WHEN COLD

(hesitation as throttle valve starts to open)
1
ISpark plug inspection :
'Remove spark plug and check for any dirt, NG
damage, gap etc.

Repair or replace I 1
2
Fuel pressure inspection
(fi'oSelect "U P" or "OWN" in ;'FUEL INJECTION
CibUANTITY CORRECTION" in "ACTIVE TEST" OK
mode to change correction value.
Caution: Carry out the test in minimum time
required, Do not operate during drive.
Start the engine.
CiPoes the engine rev increase when the blow-by 2
: hose is pinched? I. ACTIVETEST • C
FUEL:NJECTIONOFFSET 0%1
MONITOR
NG·
I Repair leaks I I,CAS,RPM(POS) 937rpm
ENG TEMP SEN 59'C

3 I O. SENSOR
0', SENSOR (RI
L33V
L35V
Replace with normal air flow meter. l1NJ PULSE 1.Bmsec
~AC VALVE 17~o. '

NG I GU I[ UP I DWN {ad!

4 2
Intake valve deposit inspection .
Remove when deposit is present.

I FIN~SH I

EN·461
 RB25DE DIAGNOSIS
RB2S0E ENGINE

DIAGNOSIS 30 (Phenomenon) • HESITATION IN NORMAL CONDITION

(hesitation as throttle valve starts to open)
1 2 ..
I
--~- ---~

Spark plug inspection .... I4BASE AIR FUELRATIOTES.'

Remove spark plug and check for any dirt,' NG I HOLDENGINEREV200(.4j-

damage, gap etc.

I 2(.'Om'Tl AND PRESS START.

NG
I Repair or replace I
2
Exhaust gas sensor inspection
rtJ\ Inspect using "BASE AIR-FUEL RATIO" in
~"FUNCTION TEST' mode.
Select "0, SENSOR MONITOR" in data i NG
monitor,
Set at 2000rpm with no load after warm up.
Check if the display "LEAN, RICH" will repeat (Fuse
brock)
for more than 5 times within 10 seconds .
.4l\ Operate vehicle side (within fuse box) 2
\:a/ diagnosis connector and change to "0 0
sensor monitor".
--~~
Set at 2000rpm with no load after warm up,
Check il the exhaust temperature warning !~~;: J!lL i

lamp will flash for more than 5 times within '(~ ~

10 seconds. i ;~ , Exhaust :emp i
: Red iamp : warning lamp ;
~--- ..- - . - - . . .~

OK
3
Canister purge inspectio~
~isconnect canister purge hose. :
OK Inspect purge and
. Place hole cap on purge hose, vacuum system
Conduct cruise test.

I.
Is there still hesitation?
4 NG I 4
Intake air leak inspection ACTIVE TEST • 0
FUEL INJECTION OFF SET 0%
fh' Warm up the engine. , MONITOR
(j)Change off set value by selecting "OWN" CAS.RPM(POS) 937rpm
ENGTFMPSEN 59'C
in "FUEL INJECTION RATIO OFF SET 0, SENSOR L33V,
VALUE" in active test mode, O. SENSOR :R) 1.35
INJ PULSE 1.Bmsec
Caution.:. Carry out the test in minimum ,AAC VALVE 17,:!~
' time required, Do not operate during drive.
i Qu II UP II OWN I Qd :
I
. Warm up the engine. ,

'®~:~~~et~; t~~:r~Ve~~1 ~~;r:~~~~~:~ctor,! 4 >~<~"}~"~/T--~

raCing the engine at approx. below ' !~'i::;,,;!ll ", .
I .~~I
K .... -

2000rpm lor 30 seconds. I

~
I
.
Repair any leaks 1/
.
.;.6>', /':\0'\#
/ ' v / ~.oy
Blow-by hOSe" i

FINISH / /~\ .:::.:.:,'''~r:::rr;\ ''elf __ ..J

EN·462
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 31 (Phenomenon) - ENGINE STALL WHILE REVVING

1 1
~.-- ..- ...._. -~-.~-,

Fuel level inspection L_.fF~~~fu;~

:Check the level of fuel in the fuel tank. I NG Resupply fuel. I

Eff~F
OK i
2
Power balance test operation
"fI\ Start the engine.
~ Inspect using "POWER BALANCE" in
"FUNCTION TEST" mode. NG 2
Operate "POWER BALANCE" in "ACTIVE .POWER BALANCE.
FOR EACH CYUNDER STOP
TEST" mode. Caution: Carry out the test in INJECTOROPERAllONAND
minimum time required. Do not operate CHECK THE BALANCE OF
EACHCYUNDER
during drive. TURNOFFAlCANDLIGHTS
Check if idle rev will decrease for a moment
when checkinq each cylinders.
START
!fl>\ Check if Idle rev decrease for a moment
•~when each injector connector cylinders are 2
! disassembled.

OK To No.5
3
Injector inspection
Place ignition switch to OFF position.
Remove crank angle sensor (leave harness
connector connected).
Remove power transistor connector. 3
NG
Place ignition switch from OFF to ON position.
Check if each injector operation noise can be
heard when the crank angle sensor shaft is rotated
•by hand. Note: Depending on how the shaft is
rotated, abnormal will show in self-diagnosis, in
this case determine as normal.

Injector and circuit inspection.!

4 4
Ignition inspection
Place ignition switch to OFF position.
Remove sub-harness in each pipping.
Install normal spark plug. Face the spark plug. NG
rear end towards adequate ground such as 1 1

collector and crank the engine.

,Check the spark.

OK
,Inspect ignition coil, powerl
T05 Itransistor and circuit I

EN - 463
 RB25DE DIAGNOSIS
RB25DE ENGINE

5 5
Fuel pressure inspection I. ACTIVE TEST .Ci
(jJ\Slart the engine. : FUEL PUMP RELAY ON i
'J!/Sring fuel pressure to zero by selecting "FUEL
MONITOR
PUMP RELAY" in "ACTIVE TEST'.
Crank 2 to 3 times after engine stop. NG
- ICAS.RPM (POS) 0rpm
Use fuel pressure gauge to inspect:
When idling: Approx.2.5kg/cm 2 i ON IbN/OFFI, OFF
When pressure regulator vacuum hose is
removed: Approx. 3.0kg/c:.cm,-,-2_ _~ ___- I 5
t1\:hStart the engine.
~ring fuel pressure to zero by removing fuel I '
: 1
pump fuse.
Crank 2 to 3 times after engine stop.
I Inspect using fuel pressure gauge. I
OK IL.___-----
..__ ..__.._____ ..
I _~
Inspect pressure
regulator diaph ragm
6
ECCS C/U connector inspection I NG
I Check for any damage or loose connection on
I the C/U bin terminal and harness connector.

IRepair or replace I
7
'lnspect ECCS C/U power supply and ground I NG i

I
. circulI. :

8 OK I . .

I Try replacing with normal C/U .

. ~.
OK
FINISH

EN - 464
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 32 (Phenomenon) - ENGINE STALL AFTER WARM UP

1 1
ro----------~~.

!vapour inspection • ACTIVE TEST • 0

FUEL IN.5ECTION OF:: SET 0%
.rrfhange correction value by selecting "OWN" in "FUEL MONITOR
: CAS.RPMIPOS] 937'1'm
i ~ NJECTION CORRECTION" in "ACTIVE TEST' mode.
i ENG TEMP SEt< 59'C
Caution: Carry out the test in minimum time required. 10., SENSOR 1.33V
0; SE~SOR IRI 1.35
I Do not operate during drive. INJ PULSE 1.Bmsec
I~isconnect pressure regulator vacuum. MC VALVE
. Place hole cap on vacuum hose.
Operate cruise test. 1
i
Does the engine still stall?

NG
2
I
Power balance test operation
1" Start the engine.
iJ) Inspect using "POWER BALANCE" in
"FUNCTION TEST' mode.
Operate "POWER BALANCE" in "ACTIVE NG ---~
TEST' mode. caution: Carry out the test in 2
minimum time required. Do not operate r-+POWERBALANCE+I
:FOREACHCYUNDERSTOP
durin g drive. , ! INJECTOROPERATIONAND

Check if idle rev will decrease for a moment :CHECKTHEBAlANCEOF

i EACH CYUNDER
in .
:® Check if idle rev decrease for a moment
iTURNOFFiVCANDUGHTS

-~
I

when each injector connector pipping are [f>A~!_-~TAR!1

disassembled. I 2
OK To No. 5
3
Injector inspection
Place ignition switch to OFF position.
Remove crank angle sensor (leave hamess
connector connected). !

Remove power transistor connector. NG

Place ignition switch from OFF to ON position. I---
Check if each injector operation noise can be
heard when the crank angle sensor shaft is rotated
by hand. Note: Depending on how the shaft is
rotated, abnormal will show in self-diagnosis, in
this case determine as normal.
,
ilnjector and circuit inspection.i
4
4
Ignition inspection
Place ignition switch to OFF position.
Remove sub-harness in each pipping.
Install normal spark plug. Face the spark plug
rear end towards adequate ground such as
•collector and crank the engine.
ICheck the spark.
EN - 465
 RB25DE DIAGNOSIS
RB25DE ENGINE

5
Fuel pressure inspection·
!1ii\Start the engine.
I 5
r. ACTIVE TEST
iFUEL PUMP RELAY
.0
OFF
~Bring fuel pressure to zero by selecting "FUEL I·
• MONITOR
PUMP RELAY" in "ACTIVE TEST" mode.
Crank 2 to 3 times after engine stop. NG ICAS. RPM (POSI 950rp
Use fuel pressure gauge to inspect: I . ~
When idling: Approx.2.Skg/cm2 I ON ' 'IN/OFF:1 OFF I
When pressure regulator vacuum hose is
removed: Approx. 3.0kg/cm' 5
~Start the engine,
~ring fuel pressure to zero by removing fuel
pump fuse.
. Crank 2 to 3 times after engine stop.
~spect using fuel pressure gaug;:..e_,______

OK
rInspect pressure i

• regulator diaphragm I 5
6 ,----c----,--~c~------

!ECCS C/U connector inspection

NG
CheCk for any damage or loose connection on
)the C/U bin terminal and harness connector.

OK 1 [Repair or replace I
7 i
[Inspect ECCS C/U power supply and ground NG
i circuit.

OK 1 IRepair or replace [
8
Try replacing with normal CIU.

EN -466
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 33 (Phenomenon) - ENGINE STALL WHEN COLD

1
'Air regulator inspection •
Ch",k UIh, pp~, " ""'co'" to ." C0ge'"" ! NG
when ignition switch is in ON position.
1
OK I '
nspect air regu Iator

2
IThrottle sensor inspection
i Press accelerator pedal fully and check if the • NG
engine can be started when the engine is cold. .
h
and circuit.

,
Fuilyopen
i Inspect airregulator i
~JI
3
i and circuit. i ;;a +~
fFr:"11 /
<x
Power balance test operation I
/fi Start the engine. 1_. _
\!; Inspect using "POWER BALANCE" in 3
"FUNCTION TEST" mode.
Operate "POWER BALANCE" in "ACTIVE NG r +POWERBALANCE+
FOR EACHCYUNDER STOP
TEST" mode. caution: Carry out the test in INJECTOROPERAllONANO
CHECl< llHE BALANCE OF
minimum time required. Do not operate EACH CYLINDER. i
during drive. \llURN OFF AiCAND LIGHTS
Check if idle rev will decrease for a moment I ,_~. ___ ,,~.~~_. ._
I-"-"'~~-'~'--

whe c each c lin L.PASSj START

I ® Check if idle rev decrease for a moment
3
when each injector connector cylinders are
;l"~"'>~;~~;~'>~\ ,--T~~ ,,-,,-1
disassembled. -- - f(~l,~'---/~_-~~ _Inj-ect~/ham~;g-
, ./" ->-~~ ..n . .nect.Q~
-/-""--wo _I
To No. 7 ...>.J'~'1 ,/ ij~
4 OK I ,'c Inector / . . '.'..: ,
r:'1-nl:-'e-c-to-r:-in-s-pe-c-t:-io'-n------------, 'S:>k,~~;:\)t~
Place ignition switch to OFF position. i ' • TB' ,~ . i '.,
Remove crank angle sensor (leave harness ' \'C;~7JfJi ., !f\~~'~iy)~.--J
connector connected).
Remove power transistor connector. NG 4
"~-'----'~-"-"~~-"-,

Place ignition switch from OFF to ON position.

Check if each injector operation noise can be
heard when the crank angle sensor shaft is rotated
by hand. NOJe: Depending on how the shaft is
rotated, abnormal will show in self-diagnosis, in
this case determine as normal.

Injector and circuit inspection.

T05

EN - 467
 RB25DE DIAGNOSIS
RB25DE ENGINE

5 5
Ignition inspection
Ignition coil
Place ignition switch to OFF position.
Remove sub-harness in each cylinders.

rear end towards adequate ground such as

:collector and crank the engine.
n
Install normal spark plug. Face the spark plug: NG

I:
., Check the spark. , :

OK Inspect ignition coil, power 6

:transistor and circuit.
6
Spark plug inspection
Check for dirt, damage. gap etc, NG
on the spark plug removed from : Repair or replace I
the engine. I
7 OK
Fuel P, ressure inspection~ 7
,,~ .. _, I .01
r
fb\Start the engine. ' . ACTIVE TEST
\~Bnng fuel pressure to zero by selecting "FUEL: : FUEL PUMP RELAY OFFj
PUMP RELAY" in "ACTIVE TEST' mode. I i

Crank 2 to 3 times after engine stop.

: NG MONITOR I
Use fuel pressure gauge to inspect: ! CAS. RPM (POS) 950rp1
When idling: Approx.2.5kglcm 2 I .
When pressure regulator vacuum hose is !
=oN !PNlOFt][Qf:U
removed: Approx. 3.0kg/cm 2 ~
tWStart the engine.
7

J'
'«!YBring fuel pressure to zero by removing fuel :
I
pump fuse.
I Crank 2 to 3 times after engine stop.
~ect using fuel pressure gauge.

OK Inspect pressure :
regulator diaphragm I
8
ECCS C/U connector inspection
NG
Check for any damage or loose connection on
the C/U bin terminal and harness connector. !

.. i
OK IRepair or replace I
9
Inspect ECCS C/U power supply and ground NG
circuit.
I
10
OK I Repair or replace I
! Try replacing with normal C/U. I
OK
!F'N'SH I
EN - 468
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 34 (Phenomenon) . ENGINE STALL WHEN ACCELERATING

INSTANTLY
1 1
r-.--A-A-C-V-AL-V-E-. l
AAC valve inspection
@warmengine 'STARTINSPECTIONAFTER
~ Inspect using "AAC VALVE" in "FUNCTION TURNINGOFFAICAND
I LIGHTS
TEST' OR
Select "AAC VALVE ADJ" in "ACTIVE NG
- L____ .._
TEST".
Check if the engine rev will change when
lPASSJ
1__sT_AR_T_ _!
"Ou" or "Od" is selected to change AAC 1
• ACTIVE TEST
valve opening. AAC i V OPENING
,~Start the engine, MONITOR
~Check if engine rev will decrease when CASf'PM(POS)
AIR FLOWMTR
9CGrpM
t .16V
AAC valve connector is disconnected. ENG TEMP SEN 80 e c

1 Inspect MC valve
• and circuit. ~I UP II OWN I ad !
2
ower balance test operation
fil'ptart the engine,
~nspect using "POWER BALANCE" in
"FUNCTION TEST' mode.
OR use "POWER BALANCE" in "ACTIVE NG
TEST" mode. Caution: Carry out the test in
minimum time required, Do not operate
•
during drive .
I Check if idle rev will decrease for a moment .POWERBALANCE.
when checking each cylinders. FOREACHCYLINDERSTOP
INUECTOR OPERA1lONAND
CHECKTHEBAlANCEOF

3 OK To No. 5 EACH CYLINDER.

TURNOFFAICANDLIGHTS
Injector inspection
Place ignition switch to OFF position. li~S~i:_

n
START
Remove crank angle sensor. •
2
Remove power transistor connector.
Pia" i9 0itioo <witch 1m OFF to ON ,,,iii,"
NG!

I. ACTIVE TEST
POWER BALANCE
.01·
Check if each injector operation noise can be CAS. RPM (POS) rpm
AIR FLOW MTR V
heard when the crank angle sensor shaft is rotated' AACVALVE %1
~~~, . L I

Ld 21[!J[ijFoNITo~
I ITlmDI~ART ,
•Injector and circuit inspection
4
T04

I~:'~\\:; ...
~'\: ~?\\ /1 .
: ~~ Operation noise.

\~.
-_._...
\ ..-~
I
EN - 469
 RB25DE DIAGNOSIS
RB25DE ENGINE

4 4
Ignition inspection
Place ignition switch to OFF position.
Remove ignition coil.
,Install normal spark plug. Face the spark plug NG
:
I
rear end towards adequate ground such as
collector and crank the engine. -.J I

•Check the s::. I Inspect ignition coil,

transistor and circuit.

~ower 5
i+ ACTIVE TEST-. LJ\
IFUEL PUMP RELAY OFF
5 • •
Fuel pressure inspection MONITOR .
!I:J',Start the engine. CAS. RPM (POS) 950rp".j
\!)Bring fuel pressure to zero by selecting "FUEL I

PUMP RELAY" in "ACTIVE TEST" mode.

Crank 2 to 3 times after engine stop. ~N I~NI~I OFF I
Use fuel pressure gauge to inspect:
When idling: Approx. 2.5kg/cm2 5
When pressure regulator vacuum hose is
removed: Approx.3.0kg/cm2
.~Start the engine.
~ring fuel pressure to zero by removing fuel
pump fuse NO.8.
Crank 2 to 3 times after engine stop.
Inspect using fuel pressure gauge .
•

OK

ECCS C/U connector inspection

NG
Check for any damage or loose connection on
the C/U bin terminal and harness connector.
OK rRepair or replace I
I Inspect EGGS G/U power supply and ground! NG
circuil. . . 'l
OK I !Repair or replace I
[2"ry replacing with normal C/U.
OK

EN - 470
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 35 (Phenomenon) - ENGINE STALL WHEN DECELERATING

1 1
AAC valve inspection
rb\Warm engine.
• AAC VALVE .-••-~

STAATiNSPEC110NAFTER
I I!'! , TLRNINGOFF A/CAND
"""" Inspect using "AAC VALVE" in "FUNCTION UGHTS.
TEST" OR
Selecl "AAC VALVE ADJ" in "ACTIVE NG
TEST". START
Check if the engine rev will change when 1
"Qu" or "Qd" is selected to change AAC .·ACT1VE TEST .0'
valve opening. AAC ; V OPENING 10%
\>10NITOR
'r<ff\ tart t e engine. CAS.RPMIPOS} 900rom
1 ~Check if engine rev will decrease when

'
AIR FLOW MTR 116V
ENG TEMP SEN 80'C
AAC valve connector is disconnected.
I

2
OK InspectAAC valve
and circuit.
I
bau lr=u=p==i1II=D=W=N"""i"I:=Od=!!

Adjust screw fixation inspection

®Inspect using "AAC VALVE ADJUSTMENT"
in "OPERATION SUPPORT" mode. NG
c..:.=
Check if it is possible to set idle speed to
650rpm ("N" range for AfT) by turning idle
adjustment screw. ,
/iffDisconnect throttle sensor connector. I
1 Id;!J Check if it is possible to set idle speed to :
2
650rpm ("N" range for ArT) by turning idle ['
I• Me VALVE A:JJ •
adjustment screw. : ADJUST CAS RPM TO
, STANDARD VALUE lNDI=R
OK I TIiE FOLLOi;"J:NG CONO:T'ON '
IAFTER WARM lJP
lnspectAAC valve and:
Ithrottle valve fixation. I
: TJRN OFF AiCAND LIGHTS

3
Power balance test operation
r1!,Start the engine.
'§)Inspect using "POWER BALANCE" in
"FUNCTION TEST" mode.
OR use "POWER BALANCE" in "ACTIVE NG
TEST" mode. Caution: Carry out the test in
minimum time required. Do not operate
during drive.
Check if idle rev will decrease for a moment
When checkin each c linders.
(~,Start the engine.
3
'4!)Check if idle rev will decrease for a moment
----.--~--~;c;c-

i . ACTIVE TESi
: POWER BALANCE
.0'1
when each cylinder injector connector is ,CAS RPM (POS) rpm·
disconnected. 'AIR FLOW MTR ~ I
IAACVALVE ~

OK I To No.6 1~,~_1~JCj~ 4 Jr_;__

'To_Rj
EN - 471
 RB25DE DIAGNOSIS
RB25DE ENGINE

4 4
Injector inspection
Place ignition switch to OFF position,
Remove crank angle sensor (leave hamess

n
connector connected), i NG
Remove power transistor connector.
Place ignition switch from OFF to ON position,
Check if each injector operation noise can be
heard when the crank angle sensor shaft is rotated i
5
by hand. I

I Injector and circuit inspection,

5
Ignition inspection
Place ignition switch to OFF position,
Remove ignition coil. ,
Install normal spark plug, Face the spark plug I N~ 6
rear end towards adequate ground such as I i
I. ACTIVE TEST +LJ
collector and crank the engine, '" I FUEL PUMP RELAY OFF',
,Check the spark, ,
MONITOR
OK CAS, RPM (POS) 950rpni
Inspect ignition coil, power
transistor and circuit.
L "" " I
I()N IpNioFFlI OFU
6
6
Fuel pressure inspection
,1}\ Start the engine,
\!)Bring fuel pressure to zero by selecting "FUEL;
PUMP RELAY" in "ACTIVE TEST' mode, !

Crank 2 to 3 times afler engine stop. NG

Use fuel pressure gauge to inspect:
When idling: Approx, 2,5kg/cm2
When pressure regulator vacuum hose is
removed: Approx, 3,o~g",/.:::.c;:,;,m,--2_ _~_ _--l
~Start the engine,
~ring fuel pressure to zero by removing fuel
pump fuse No, 8,
Crank 2 to 3 times afler engine stop,
Inspect using fuel pressure gauge,
=--:::------'
Inspect pressure regulator
T07 diaphragm,

EN·472
 R825DE DIAGNOSIS
RB25DE ENGiNE

7 2
Exhaust gas sensor inspection IWONITORIN,* NO ~~D]
(W\ Inspect using "BASE AIR-FUEL RATIO In
~"FUNCTION TEST" mode. ICAS. RPM {REF) 825rpm \'
i 02 SENSOR O.02V
Select "02 SENSOR MONITOR" In data NG 102 SENSOR MTR RICH
monitor.
Set at 2000rpm with no load after warm up.
Check if the display "LEAN, RICH" will repeat START
for more than 5 times within 10 sec",o::...:n""ds""_-l
rfr\ Operate vehicle side (within fuse box) 2
~ diagnosis connector and change to "02
sensor monitor".
Set at 2000rpm with no load after warm up.
Check if the exhaust temperature warning
lamp will flash for more than 5 times within
10 seconds. (Fuse
block) i
.~

OK
IReplace 02 sensor I 2 '--~'------'--~""'---,

, Inspect throttle sensor and vehicle i

I speed sensor. .

OK I
.ECCS C/U connector inspection , NG
Check for any damage or loose connection on ' .
the C/U bin terminal and harness connector. I

OK I Repair or replace I
Inspect ECCS C/U power supply and ground NG
circuit.
I
OK IRepair or replace i
I Try replacing with normal C/U. I
OK i
I FINISH I

EN - 473
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 36 (Phenomenon) - ENGINE STALL WHEN ACCELERATING OR

DRIVING AT CONSTANT SPEED
1
1
Power balance test operation .~ .POWERBALANCE.
(@~,Start the engine. I
~Inspect using "POWER BALANCE" in I STOPINJECTOROPERATlON i
, FOR EACH CYUNDERTO
"FUNCTION TEST' mode. iCHECKTHEBALANCEOF
OR use "POWER BALANCE" in "ACTIVE NG , EACHCYUNDERS.
TEST' mode. Caution: Carry out the test in
minimum time required. Do not operate START
during drive.
Check if idle rev will decrease for a moment _1~--~C:~~'l9'{- -7.'--"-

when checking each c{..;.l.;;.in"'d;.;:e.:..rs:;.;.c...._ _ _ _- l

rti'\Start the engine.
\@Check if idle rev will decrease for a moment
when each cylinder injector connector is
disconnected.

OK I To No.4
2
Injector inspection
Place ignition switch to OFF position.
Remove crank angle sensor (leave harness
connector connected). NG
Remove power transistor connector.
Place ignition switch from OFF to ON position.
Check if each injector operation noise can be
heard when the crank angle sensor shaft is rotated
by hand. 3

'Injector and circuit inspection.j

3
Ignition inspection
Place ignition switch to OFF pOSition.
Remove ignition coil. j
Install normal spark plug. Face the spark plug NG n '

rear end towards adequate ground such as

. collector and crank the engine.
Check the spark. :

OK
'Inspect ignition coil, power,
!transistor and circuit.
T04

EN - 474
 RB25DE DIAGNOSIS
AB25DE ENGiNE

4 4
Fuel pressure inspection
,1:l',Start the engine. i
, + ACTIVE TEST
:1 FUEL PUMP RELAY
+ rl
o'FF
~Bring fuel pressure to zero by selecting ·'FUEL. . MONITOR I
PUMP RELAY" in "ACTIVE TEST" mode. .
Crank 2 to 3 times after engine stop. ~ : CAS.RPM (POS) 950rpml
Use fuel pressure gauge to inspect:
When idling: Approx. 2.5kg/cm 2 ON JlNlOFFI OFF i

When pressure regulator vacuum hose is

removed: Approx.3.0kg/cm2 4
riI:f,Start the engine.
~ring fuel pressure to zero by removing fuel
pump fuse NO.8.
Crank 2 to 3 times after engine stop.
Inspect using fuel pressure gauge.

OK Inspect pressure regulator

diaphragm.
5
: Intake air leak inspection
Start the engine. NG
!Check if engine rev will increase when blow-by
.hose is pinched.
OK .
IRepair any leaks
5
6
rECCS C/U connector inspection NG
.Check for any damage or loose connection on
!the C/U bin terminal and harness connector.

OK I Repair or replace I
7
Inspect ECCS C/U power supply and ground. NG
circuit. I'
OK
8
I

IRepair or replace I
I Try replacing with normal C/U.
OK
I FINISH I

EN - 475
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 37 (Phenomenon) • ENGINE STALL WHEN LOADING BATIERY

1 NG ._--
i Inspect battery and alternator : Repair or replace I
OK
2
1
I Power balance test operation i~ .POWERBftiANEE.-
t1J\Start the engine.
~Inspect using "POWER BALANCE" in ISTOPIf'<JECTOROPERATION
I FOR EACH CYLINDER TO
"FUNCTION TEST' mode. CHECKTHE BALANCE OF

n
OR use '"POWER BALANCE" in "ACTIVE ! NG EACHCYUNDERS.
TEST' mode. Caution: Carry out the test in
minimum time required. Do not operate START
during drive.
I
I

Check If Idle rev Will decrease for a moment 1

when checkln each c linders.
(W,Start the engine.
~Check if Idle rev Will decrease for a moment
when each cylinder injector connector is
disconnected.

OK i To No.4
3
Injector inspection
Place ignition switch to OFF position.
Remove crank angle sensor (leave harness
connector connected). ~
Remove power transistor connector.
Place ignition switch from OFF to ON position.
I Check if each injector operation noise can be

· heard when the crank angle sensor shaft is rotated

by hand. 4

IInjector and circuit inspection.1

4
Ignition inspection
Place ignition switch to OFF position.
· Remove ignition coil.
I Install normal spark plug. Face the spark plug. NG
rear end towards adequate ground such as i

collector and crank the engine. .

I
•Check the spark.

OK
IInspect ignition coil, power
i transistor and circuit
T05

EN - 476
 RB25DE DIAGNOSIS
RB25DE ENGINE

5 5
Fuel pressure inspection • ACTIVE TEST • C:
.ifi\Start the engine. FUEL PUMP RELAY
~8ring fuel pressure to zero by selecting "FUEL MONITOR
PUMP RELAY" in "ACTIVE TEST' mode.
Crank 2 to 3 times after engine stop. . NG CAS.RPM (POS) 950rpM
Use fuel pressu re gauge to inspect:
- I, !
.

When idling: Approx.2.5kg/cm 2 LONPN/OFFI OFF

When pressure regulator vacuum hose is
removed: Approx.3.0kg/cm_'_ _ _ _ _----1 5
fif,Start the engine .
. ~ring fuel pressure to zero by removing fuel
. pump fuse No.8.
Crank 2 to 3 times after engine slop.
Inspect uSing fuel pressure gauge.
"--::::..------"

OK

OK
7
Inspect ECCS C/U power supply and ground NG
:circuit

8
OK IRepair or replace I
Try replacing with normal C/U.

EN - 477
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 38 (Phenomenon) • POWER SHORTAGE AND STUMBLE

(Instant power output shortage during acceleration)
1 1
Fuel pressure inspection [+'~CTIVE TEST • ci
'l',Start the engine. FUEL PUMP RELAY OFF:
!
\!)Bring fuel pressure to zero by selecting "FUEL MONITOR
PUMP RELAY" in "ACTIVE TEST" mode,
Crank 2 to 3 times after engine stop.
- NG ICAS. RPM (PaS) g50rp~1
Use fuel pressure gauge to inspect: ! '
~.
When idling: Approx.2,5kg/cm2 I ON IpNlOFF]; OFF;
When pressure regulator vacuum hose is
removed: Approx.3.0kgicm 2 1
~tart the engine.
ring fuel pressure to zero by removing fuel
pump fuse NO.8.
I
Crank 2 to 3 times after engine stop,
I Inspect using fuel pressure gauge,
I
OK Inspect pressure regula
diaphragm,
2
Intake air leak inspection
@Start the engine, YES
Change correction value by selecting "DWN"
in "FUEL INJECTION CORRECTION
,
VALUE '" In "ACTIVE TEST.
Caution: Carry out the test in minimum time i
I required. Do not operate while driving. 2
!tiG'! Check if engine rev will increase when the I . ACTIVE TEST .01
\;f!,!blow-by hose is pinched. FUEL'NJECTIONOFFSET 0%1

NO
I MONITOR
CAS RPM{pOS:
\ ENG TEMP SEN
937'prn I
59'C :

I Repair any leaks I

0, SENSOR 1.33V i
0, SENSOR (Ri 1.35V:
INJ PULSE - 1.8msec \
'AAC VALVE 17";-Q :1
[Inspect compression pressure, ignition timing NG ..::u.;1 UP il OWN II Qd i
:and detonation sensor.

EN - 478
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 39 (Phenomenon) - DETONATION

1
1
Intake air leak inspection I +ACTrVE -:-EST
:FUELINJECTIONOFFSET Q%:
+ 01
rj'lstart the engine.
YES
~ Change correction value by selecting "OWN"
i MONITOR
, CAS,RPMIPOS) 937rpm
in "FUEL INJECTION CORRECTION 1 ENG TEMP SEN 59"C
0_ SENSOR 1.33V
VALUE" in "ACTIVE TEST". !0: SE4JSOR lR) 1.35VI
' Caution: Carry out the test in minimum time INJ PULSE
'I'
1.8msec'
,AAC VALVE
[~~re~q~u~i~re~d~.~D~o~n~o~t~o~p~e~ra~t~e~w~h~il~e~d~r~iv~in~g~.~~
l Qu il UP OWN il?dl

NO
! Repair any leaks I
2
Combustion chamber oil leak inspection I NG
Disconnect spark plug and inspect oil.

OK
! Inspect piston, piston ring, I
valve, valve seat, valve oil ' 2
seal, engine oil level etc, '--~"'-~-~---~~"--'

Inspect detonation sensor system.! ." , , ~ ,

OK!
i
~-~
\:::~~ .----.:-~/1
I
! FINISH! L ~:c- ~~

EN -479
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 40 (Phenomenon) . SURGE

1
1
Exhaust gas sensor inspection
«3ASEAIR FUEL RATfQ TES.
rtl', Inspect using "BASE AIR-FUEL RATIO" in
~! "FUNCTION TEST' mOde. , I-'OLD ENGINE REV 2000+;·

Select "0 2 SENSOR MONITOR" in data NG

I 200rpmAND PRESS START. I

monitor. .
r·--~-
,

1eoo 2000
Set at 2000rpm with no load after warm up. L 2200
..~_ .. ~_ .. _ _ _ .. _ _ _ J

Check if the display "LEAN, RICH" will repeat !pAsS] [ -STARTi

for more than 5 times within 10 seconds.
,41\ Operate vehicle side (within fuse box) 1
~ diagnosis connector and change to "02 ,...-.. - - - - -
sensor monitor".
·1.f.10NITORIN~ NO FAIL Dr
Set at 2000rpm with no load after warm up. ICAS.RPM (REF) 825rpm I
. 02 SENSOR O.02V I
Check if the exhaust temperature warning
lamp will flash for more than 5 times within
102 SENSOR MTR RICH.

10 seconds.

OK START

2
Replace ECCS C/U
OK
Exhaust temp
Red lamp warning lamp

EN·480
 RB25DE DIAGNOSIS
RB25DE ENGINE

DIAGNOSIS 41 (Phenomenon) - BACK FIRE (SPITTING)

1 1
Spark plug inspection
Remove spark plug. NG
Check for any dirt on the spark plug.

OK
\ Repair or replace spark plug. \
2 ~" .... -

Intake air leak inspection

yStart the engine. . : 1 YES 2
I.!JChange correction value by selecting "DWN" 1---,
in "FUEL INJECTION CORRECTION
\+ ACT'VE TES • 0
FUEL INjEC"'"ION OFF SET 0';'" i
I
I

MONITOR
VALUE" in "ACTIVE TEST' mode. ·!

CAS.RPM(pOS) 937'om
CautiQn: Carry out the test in minimum time I I
E~G TEMP SEN
0, SENSOR
59'C :
1.33V I
required Do nol operate while driving . 0'. SENSOR (RI 1.35V I
INJ PULSE 1.8ms,", :
(j:fheck if engine rev will increase when the AAC VALVE
\ blow-by hose is pinched.
~I UP

NO
I Repair any air leaks 2
3
Intake valve deposit inspection
Remove if there are any deposit present .

•Ignition timing
ICheck If Injector IS clogged. I:
I
I FINISH I

DIAGNOSIS 42 (Phenomenon) - AFTER BURNING

1
Engine temperature sensor inspection
NG
Inspect engine sensor and engine sensor
circuit

OK
IRepair or replace :

.Ignition timing
I Check if injector is clogged.

I FINISH I
EN - 481
 RB25DE COMPONENTS INSPECTION
RB25DE ENGINE

8. COMPONENTS INSPECTION (RB25DE)

CRANK ANGLE SENSOR
Inspection
• Remove crank angle sensor from the engine, (leave
crank angle sensor harness connector connected),
• Place ignition switch to ON position,
• Rotate crank angle sensor shaft slowly with hand and
inspect the voltage between terminal 2, 3 and ground,

~!~U~~~""i "'i'l,,'." <,-"-,,

" ('~' ~r.;:i
"' '--,,--
".:....n.. ang
""Z~;'
' Ie
"{:'J,~,';}':", "
Rotate by hand
Ignition sWitch in Approx, 0, 1V or Approx. OW or
ON position Approx 5V i Approx, 5V i

!ENG: Replace crank angle sensor.

Erase self diagnosis result from CONSULT after inspection,
Check code No, 11 is not displayed in the screen,
Cau!i.Qn:
Remove injector fuse or connector to avoid injector from
operating while inspection,

AIR FLOW METER

Inspection
• Remove airflow meter from the engine,
• Apply battery voltage directly between air flow meter
terminal 5+ and terminal 3- and blow air to hot wire,
Check for any change in output voltage between terminal
2+ and terminal 4-,
Air is not blown Approx, 0,8V
Blow air
Air is blown Approx,2V

IENG: Replace air flow meter OR check for any damage

with the hot wire,
Erase self diagnosis result from CONSULT after inspection,
Check code No, 12 is not displayed in the screen.

ENGINE TEMPERATURE SENSOR

Inspection
• Disconnect engine temperature sensor harness
connector,
• Measure the resistance between engine temperature
,~
KQ
( 20
('l 10
l i
sensor harness terminal 1 and 2, < 1n 2.5,:--"I,
Approx 2,5K g <in 1l
&: O<3--+~-·
•
Approx, 80'C Approx O,3K g 0,1 i
20 ---;:SO"""""'(""'''C) <

IF NG: Replace engine temperature sensor, ~<_~C()oling w<lter temperatuf"'---.J

Erase self-diagnosis result from CONSULT after inspection,
Check code No, 31 is not displayed in the screen,
EN - 482
 RB25DE COMPONENTS INSPECTION
RB25DE ENGINE

IGNITION COIL
Inspection
• Disconnect ignition coil harness connector.
• Measure the resistance between following terminals.
I Primary coil res,sntance value (1 - 2) 0.6 - 0.9

IF NG: Replace ignition coil

POWER TRANSISTOR
Inspection
• Disconnect power transistor harness connector.
• Measure the resistance by inserting analog type circuit
tester inspection rod - and + to power transistor
terminals.
1-3 1+1- 00£1 -/+ ooQ
2-3 1+1- ooQ >-I+Oor11Ot ooQ
1-3 I + / - 0 or not 00 Q < - I + 00 Q
IF NG: Replace power transistor.

FUEL PUMP
Inspection
• Disconnect fuel pump harness connector.
• Measure the resistance between fuel pump terminal 1
and3.
Resistance: Approx. 0.4 - 0.7

• Check for operation by applying battery voltage between

..
the following terminals directly:
.-~- ~----

Connect terminal 3 to + side, terminal 1 to - side.

Caution: Care must be taken to connect battery to correct
sides.
If NG: Replace fuel pump.

THROTTLE VALVE SWITCH

Inspection
• Warm the engine.
• Disconnect throttle valve switch connector and measure
the resistance between throttle valve switch terminals.
(Idle contact point)

If NG: Repair throttle valve switch.

EN - 483
 RB25DE Cm~PONENTS INSPECTION
RB25DE ENGINE

Adjustment
Idle contact point touch rev (rpm): 750 - 1050
• Adjust if the touch rev is not within the range above.
• Disconnect throttle valve switch connector and loosen the
bolt.
• Gradually increase the engine rev so idle contact point is
ON (Resistance between terminal 2 and 1 is 0 Q ) at
above engine speed. Move throttle valve switch uniT to
touch pOint and tighten the bolt. Move throttle valve
switch unit to touch paint and tighten the bolt.
• Install throttle valve switch connector.
• Race the engine few times and check idle rev is within
the standard value.

THROTTLE SENSOR
Disconnectthrottle sensor connector.
Measure the resistance between throttle sensor terminal 2
and 3.

Not pressed Approx 04

Pressed to half way Approx 04 - 5
Completely pressea I Approx.5

IF N~i Replace throttle valve switch.

After inspection erase self diagnosis result from CONSULT.
Check code No. 43 will not display in the screen.

AAC VALVE
• Inspect the resistance of AAC valve.
Resistance: Approx. 9 - 10

• Plunger and switch inspection.

• Spring damage inspection.

!ENG: Replace AAC valve.

FICO SOLENOID
• Measure the resistance of FICO solenoid.
Resistance: Approx. 22 - 23

EN - 484
 RB25DE COMPONENTS INSPECTION
RB25DE ENGiNE

• Plunger and switch inspection.

• Spring damage inspection.
o
?~
Plunger / ~~
IF NG; Replace FICD solenoid.
Spring '-':;(~

AIR REGULATOR
Static characteristic inspection
• Visually check the shutler opening.
"' ,-----." - -
Shij~rl:lPlilnifl9. '

Fully onen
20'C Approx. half open
Over60'C Fully closed

Dynamic characteristic inspection

• Apply battery voltage to terminals and inspect for any GIV
change with shutter opening. ••
The shutter will close gradually and completely
closed within 7 minutes. (area temperature
approx. 20°C).
Reference: Heater resistance value: 70 - 80 g (20°C)
IF NG; Replace air regulator.

INJECTOR
Inspection
• Disconnect injector harness connector.
• Measure the resistance of each iniector cylinder terminal
1 and 2.
i Resistance between injector tenninal 1 and
2 (each cylinder)
13 - 14 g

If NG: Replace injector.

ECCS RELAY, FUEL PUMP RELAY, RADIATOR FAN

MOTOR RELAY
Inspection
• Directly apply battery voltage between terminal 1 and 2.
• Inspect continuity between terminal 3 and 5.

Directly apply batterY voltage between

Present
terminal 1 and 2

No battery voltage Not present

IE NG: Replace relay.

EN - 485
 RB25DE COMPONENTS INSPECTION
RB25DE ENGINE

IGNITION RELAY, INHIBITOR RELAY

Inspection
• Directly apply battery voltage between terminal 1 and 2.
• Check for continuity between terminal 3 and 4.6 and 7,

Directly apply battery voltage,

Not present Present
between terminal 1 and 2

No battery
L-______ voltage
______ ~
Present
______ ~,,~,~
Not present
___
,IF .NG~ Replace relay,

POWER STEERING HYDRAULIC PRESSURE

INSPECTION
Inspection
• Remove power steering hydraulic pressure switch
harness connector.
Check for continuity between the terminals.

Steering wheel is steered Present

,L,---------------1C--------,
Steering wheelis not steered Note present
I
IF,NG: Replace power steering hydraulic pressure switch,

SPARK PLUG l..qc=~~

I, 1.1 ,-""
r=-, :"''C,"
Inspection & Adjustment I
, ,
• Measure the gap between electric pole,
I I
• Replace or repair if out of standard range. , \do
Standard gap (mm): 1.0 - 1.1

• FUEL PUMP.

IS THERE A PULSATION!
FUEL SYSTEM INSPECTION
EVERY 3 SECONDS WHEN:
Simple inspection THE FUEL TUBE IS HELD? II
• Turn the ignition switch to ON position, tj\ I
, OR CAN YOU HEAR THE
• Select "Fuel pump" in the "Function test" mode, I.J!) I
" OPERATION NOISE OF THE i
FUEL PUMP RELAY? .......J
• Inspect the pulsation by holding the fuel hose with hand.
I PASS I~~J YES!
• Hold the fuel filter and make sure the hose is hard
and pulsation can be felt when the fuel pump is operating.
®

• Hose is hard!
• Pulsation
EN - 486
 RB25DE COMPONENTS INSPECTION
RB25DE ENGINE

Fuel pressure inspection using the fuel .ACTIVE TEST.

pressure meter
FUEL PUMP RELAY OFF·
Releasing fuel pressure
• Run the englne. @ CAS-RPM {POS) 950 rpm
• Select "Fuel pump relay" in "Active test" mode. ~
• Press 'STOP' to stop the engine. Crank the engine over i
two or three times. (If the engine does not start. crank 3 - 4
times after removing the fuse).
~ERATd ~NTERRJ'[ STopml

• Restart the engine and remove the fuel pump fuse. ® , •••• ~_m _ _ ••••• _~ _ _ _ ~

• After the engine stops, crank the engine 4 - 5 times to -

~~ - "".-----~

consume the fuel in the pipe. (If the engine does not start Fuel pump 'use

crank 4 - 5 times alter removing the fuse).

Caution:
The battery may become weak easily. use booster cable to
connect to another battery if necessary.

Fuel pressure meter installation

• Connect the fuel pressure meter between the fuel fi Iter and
the fuel line.
• Attach the fuel pump fuse.

Fuel pressure inspection

• Start the engine and check if the fuel pressure is at
standard value.
kJli ng (kg I em" Approx. 2.55

Pressure regulator vacuum hose is

Approx 3.0
disconnected (kg I cm')
I ';Y_-f I\'<~'-~,
• If the engine does not start, check fuel pressure 5 l>el.•'i-~ . .'. . 1L'RerllrNe:>
'>(1"
1/ /(~~'i~~~s~~re
seconds after the ignition switch has been turned ON.
5 seconds after ignition sWItch turned to ON Approx 30
~~ '~ulator
~IF~N~G=-:- - - - - - - r - - - - - - - - - - - - - , '-_~_ . . ~)
i Fuel pressure is extremely I Pressure regulator is not working.
I high i Return system IS clgged. hose bent

Pressure regulator is not workIng.

Fuel pressure is extremely
Fuel pump discharge defect
low
: F usl system clogged

EN - 487
 RB250E COMPONENTS INSPECTION
RB25DE ENGINE

Fuel cut system inspection ~ONITORIN~NO FAIL 0

o Select "INJ pulse" in "DATA MONITOR" mode uSing
CONSULT. Increase the engine rev to 2000rpm after
® i CAS.F'PM IREF) 2000rpm
i INJ PULSE 3.1msec

starting the engine. Check that "INJ pulse" will decrease

to 0.6 msec for a moment when the accelerator pedal is
released.
START RECORDING
.
f
NiTORIN~O'FA'L
CAS.RPM (REF) 1950rpm
INJ PULSE O.6msec

L
L START RECORDING

EVAPORATIVE GAS CONTROL SYSTEM INSPECTION

Check valve

4- Evaoorative gas
<--==::::: Purge air
Fue! tanK Active carbon '
~ Fhter

Fresh air

CANISTER
Inspection
o Connect vacuum hand pump to canister throttle negative
pressure opening and make sure the vacuum pressure is
maintained.
o Apply approx. -100mmHg pressure and make sure the
manifold negative pressure opening is continued by
sucking air from the opening.
FUEL TANK VACUUM RELIEF VALVE
Inspection
o Clean the valve housing.
o If the fuel tank vacuum relief valve is normal, you will hear
sound from the valve with small resistance when the air is
sucked in through the cap.
o Replace the cap ASSY if the valve is closed or when
resistance is felt i
•
Spring valve
Valve
L -_ _..._ _._ _ .__ ~~._~
EN - 488
 RB25DE COMPONENTS INSPECTION
RB25DE ENGINE

SLOWSY GAS REDUCTION DEVICE INSPECTION

blowoy control valve

,~ Fresh air
.. Blowby gas

SLOWSY CONTROL VALVE INSPECTION

Inspection
• Idle the engine and remove hose from blowby control valve.
• Check if operation noise can be heard from the air
passage when valve is operating normally.
• Check the blowby control valve flow path.

. CONl;;ltTlOf..!
, Air is blown Air passes

Air is drawn in No air passes

Blowby control valve

BLOWSY HOSE
Inspection
I
• Look for any leakage from the hose and connection area.
• Remove the hose and clean using the air blow. Replace
hose If there are any clogs.

EN - 489
 EGGS GiU INPUT/OUTPUT SIGNALS
RB26DETT ENGINE

9. ECCS CONTROL UNIT INPUT I OUTPUT SIGNALS

9·1 CONSULT INSPECTION VALUES
(1) Data monitor
Note: The output signal is displayed as the calculation data on console unit so the correct
value will displayed even if the output circuit (harness) is inadvertently disconnected.
RB26DETT ENGINE
r:"~:jiL}b..;''';'''';'' ''r>: " : ' i •. f>A'J:A.MONn'OI't .. . '... ' .', .;;,.;.....:'
.........n.-..icir _ _•
.' ';";: .'; ; ' , " ; ;,,:L :,"'~: ..'....;: .. ,., t
<.'N.0RMAl.. R£P.EREl!ICe
.--. ',VA!'UE .: , . ' .' ';;"; .:: --re- " ,
,., ,< ,," .,', i :.
CAS RPM {Detected ang1c I "I"aChOrnel€V set ";here must oe no abnOfma' t
! Crank: angle sensor system
speed according to slgnats) Englf1e rurvl*ng change In speed
,
i
AIR FLOWMTR
(output 1I01t<lge) Alter warming up engine
Aoprox Or - l.2V C2000rpm:
with no load 1 0 - 1 7v'!
Air flow meIer system
I
idling (N range. AIC OFF) 2 air flow meter value
I AIR FLOV\j MTR {Ry
(output voltage)
:
"'"'"can vary 0 ~ GAV

i ENG TEMP SEN Errglne temperature sepSQr

After -warming up er"K;pne Above approx lO"C
(ergmc .temperature) system
, EXT GAS SEN
i
(Qutput voltage) I Changes bet\N(~n
;tinct C 6 - 1V
0 - O,3V
EXT GAS SE\I (H) ; Exhaust gas sensor system
!
I (output voltage) After eannmg 2000rprn INith no I ~ltak0 system llur leaf< or aIr
EX'" GAS SEN up erglf)€' load ! ' lintake
i
(RIC H I LEAN) ; RICH. LEAN repeats 5 times' Injector system
EX T GASSE"N(R~' ! Of more If') 10 seconds i

I ;RK>~ J LEAN) I I
CAR SPEED SEN I V\l'riiie dovlrq or wi1n drtve wheels;
i
Silou!d genEv1311y conform to
:vel1icle s p €led senser s rem
!-__,~.ve=h!Cle speed s.gnal) . tUfnlng spoedmete" display

BATTERY VOLT
ignition S\N1lch ON
~ 1 - MV Isat1erv
Engu'l6 stopped ,ECGS control Ur1It pO\l'Jer sys,em
Ignl~IQn SWITch
7>-/ROITLE SEN ON Throttle f-Jlly dosed 0,5 TlYonle sensor adjustrnenl
(output voltage) Engw!e --,------"'------,---::--------l, Throttle sensor syslerl
stoooed ThrotHe fully open 4 0

l'
INTrA 1EMP SEN
:=----+--=
After warrr<ng IIp engine Ir'rt<:!",femperature sensor system
('ntakternperulure sensor owtput)
INJ PULSE idling iAu flow meter system I
1-_..cc"c"'~e~c~"~o~n~p~ul~s=e'-"~~d~Ih=)-~i After wenning (/'i range Ate OFF) r--:--7''''':-:,--jlntake system a r leaks or air
INJ PULSE (R) , u p engJr08 ' 2000rpm VVlth no suctl0r~ 'eoftf£! .nput,
(injeclion pulse V0dlrn , o a d .!nput $191101 system (entire)
IdlirY,)

iGN ·'IMING
I
,
After warrnmg
up engH1e
,N ranqe fi,iG OFF}
p:.:.:.:::.""..:;.::=..::;:..:..'--t-",
2000rpm \filth no
load
"_-_'C-:::-::-::::::::"",-J
Advance gf£!ater than 10"
aflgle compared ~o Idle
I
AIr flow rreler systeM

, position . ,
idling
I
AAC VALVE
!After wa(rt"" ng! ':N range Ale OFF)
Approx 15 35':'cI"
! IA.S adjustment
!
up ~nglne
I 2000rpm 'Mlh no
Approx. 30 - 50%
AAC valve system

AIF ALPHA
(tHr·fuol railo feednacJ(
conecllo(1 coeffiCtent)
I
'cad
I IlAir 'flow meter system
Arter walffl,ng LIp erl\;W1e i 75 - 125".*
IflJcctor system
,Canister (plXge) Inspe!(;.iior)
I 2:JOOrpm With no load
! ; Intake svstem air leal( or air
!suctwn'

I S~ART SJGf\,AL
ON
'
19f1ltlOn sWltch-,- -..
"START"
"OFF"
0'
OFF --1 Starter SW syslem

t=
I
Engine- T'ol"Ottle fuily c,osec ON
IDLE sw I 'S~oppeO Throttle sensor system
I Throttle fulfy open OFF I
,
AIR CONO $iG
Ale S\NO .... ON I Air conditioner SW system
I I Ale SVV OFF OFF

I NEUTRALSW
'''e I Nor Prange ON I Neutrai SW system i
NotNorP OFF I .-----.J
r--- I Steenng ON
PW!8T SIGNAL Power sleerirg SW system i
I I Sleer,~ r"J!?Ulral OF~

VVhen Idle , ON
! OLE JUDGEMENT
Other than ',-..her< ,ele OFF
TIYottle sensor sys~~
P-~~l PUMP RELAY IGN SWON i Stop
\,.-Vhen rev I
OFF
ON
Fue! pump syste:n

Ale ON I ON
-Acc.e!~'"
,
AIR CON RELAY Ale Of-F OFF Ai, COno::;lltH)ner relay s'j$tem
i ..
10 sec j Ale Or-..) OFF
ON
WiG CONT SN :----O::::Fc::F----j
...L--:--_ _
POWER VOLTAGE D'SCFIY \)U'0."?' vpi'!age prow rYleasurernerrt value
PULSE :)"':;)'dY Dulse pro~ rneasuresurement value
EN .. 490
 EGCS C/U INPUT/OUTPUT SIGNALS

(2) Active test

,
~A!tI>lN$~TION~
, " " ",', '" ACTIVE TEST ,
SET ITEM,
",'"
~" CONort!Olf, ACTIVE TEST DESCRIPTION,""(, " ,,:, ...,'" ,".' . : , , '
.' ' .,:

Perform following Inspections to checK If

problem is solved.
Elirninat"'"
ENGINE Problem occurence' Set e~g!'le temperature nigh or low Engine temperature sensor system
TEMPERATURE condition :G..au.tl..:lo. Do not set extreme values Injector system
as this car) cause snark P:Jg bUrning
Air flow meter exhaust gas sensor system
Not eljminated
Other Item msoectop
Perform bi!oWIf1g ,nsoectlOns t:J check if
problem ,$ solved.
EijOOIoatw
Set the air·fuel ratio nch or lean. 'Exh , t "'.,. .
Prob~m occurence GaJJ!mn: 00 rot set extreme values as' _ aus gas .,. .... :1S0T system
FUEL INJECTION Air flow meter. eng:ne tempera:ure senso~
condition ' thiS may damage e~gme or ca:alytic
system
ocnverter,
l'ljector S;lstem
No! eltmjnated
Other Item irJspector
Perform fO!lo\W19 !nspecti<ms to check If
proble~ IS
SOlved
Delay ignition timing
Fhmna te
Problem OCCurence ~ Do not set extrer'l€ values as
, IGNmON TIMING
cOndition this may damage engine or catalyt:c
:19nition timing adjustment
i DetonatIon sersor sys'{em
i
converter I Not elloo,oater<
Oirle r ,tem inspection
Increase control du!)' rationwengine
AAC VALVE speed shOUld .ncrease If the -conditJor. descnbed on left can ret be i
Engine rUr'!nir.g
OPENING Decrease control dUty reatio The venfied. ccheck AAe vdlve system
engi!1e speed should decrease
Set the Me vale open to stop t'le
speCified inte .....ior operatIOn and the
i
POWER mjector speed can be d'splayed at mis EI mioate
i Eng I ne rU{lni n9
BLALANCE time Injector system
.~
Do not perform thiS operation
while driVlng
Turr'! igmtio1 SWitch ON. OFF ana ON
so pump operation makes a sound
If the coneitlon descnbed on left can 'lot be
FUEL PUMP ignItion switch ON The fuel pressure will nse,
venfied, check relay system 07 fuel pump
RELAY !
EngIne stoO'
= Do no! pertorm this operatIon
except urlder conditIons described on
and fuel pump system

i lelt
SELF·LEARNING i
The air-fuel rabo feedback correction coefficu,mt learr;:ng factor is cleared
! CONT !

EN - 491
 EGGS G U INPUT OUTPUT SIGNALS
RB26DETI ENGINE

9-2 OSCILLOSCOPE & CIRCUIT TESTER INSPECTION VALUE (RB26DETI ENGINE)

.--.----'--'----1

Terminal AI idle AI Appro •. 2,500 rpm

No.
Signal name I Circuit
Standard l Memo Standard Memo,

SparkOh.lg 0.2 - 0.3 V Approx, O.4V

1 PWR '--V--"~ ., !vr"~ .
6 ~"--'-'-~--1
.
2
3
11
Power tranSistor
conlrol signal
I
4 ;-- ,
~,. -r- j---I-'
i ---t~3' -.:
:
12
!
13 i

Cold: 6 - 7V Approx. 5V
i Warm: 8 - 10V

AAC V'illve control

4
Signal :
i
fees control I.lf\i!
I

Approx. 1V Approx 2.4V

Engine speed
7 signal for ,."
tachometer

r fees control umt i

Air cordition OFF: Air condition OFF

Battery voltage Battery voltage
9 Alf conditioner relay:
Air conditioner ON: Air conditioner ON:
ilpprox.1 V Approx. 1V

Appro •. 1V
16 ECGS relay (Ignition switch OFF: Appro.,OV
Battery voltage)

Fool pump relav IgmMn

~
sw;,

18
i
Fuel pump relay
-
)~, -t-,
+ OV OV

'--__-'1_______-11_, ,_c_c_s",_,o_n..'.._ffi_'00_"_·
_ ___1 _ _ _ _ _ _ _ _-LI___ ,i~______ ....L_ _.J

E~ - 492
 EGGS G!U INPUT/OUTPUT SIGNALS
RS26DETT ENGINE

RB260ETT ENGINE

r;'O"","","""051",:1O~1I>t11 11 21 ,1 ,
:"1Or1;r11~11~,d11411511'11111:!l13114!
~
19 18
• 11 8 9/10/
d 1~ 19120:
I
C 2j 2Z 2~ ,4f,,f ,alll,.! 2913011 411 ''l4;l....l''I..,f''I .. r'9I5!ll
,i "I 3~ 341 3' 3. "I ",I 391 ,.11 511 52 50' s4 5' sa "I,,!,. 601

C±Txl . elK I I I CH~ IGNI

Terminal At Idle At Approx. 2,500 rpm

Signal name Circuit
No. 1 Standard Memo Standard Memo

PWR 5T SW

~~
l_. r~
Power steeling ON: Power steenng ON:
Power steerlng OV OV ,

19 Power steenng OFF

switch signal Power steering OFF I

I E}cS'C~~".'""~' J
, 5V 5V
,
I

Qiagnows connector

(['iLL
21 Receive (control

~~ ~
10V 10V
(RX) ! unit daia reception) I
.. I
, , E'CCS control Utllt
I !

I I
Diagnosis com~ct{jr

Transmit (data
r ,"
22
,
I~
transmission from OV OV
! (TX)
control unit)
I I
!
I ECCS conirQll,mit I
!

I
!

23 Detonation sensor IAC!~: Approx.03V Approx.O.3V

I
24 !
signa! .Ih
I r ECCS control [Bllt \

r=-1 IG~-.SW

I~
'Nastegate valve C{)lItro V
v
25 control solenoid Battery vottage Approx.OV
control Signal
!
I fees ;.:omrQi unit
I ,

~---
Airflowrt'l(li't;t
! JI, S C 0 €-,F"
Air flow meter (rear) Approx. 1.5
27 Intake air quantity
Signal
,
IA I Approx. 1V
V

I ECCS co",,,, ynil I

, i i
EN - 493
 EGGS G·LJ I'<PUT OUTPUT SIGNALS
RB26DETI ENGINE

iRB260ETT ENGINE

1011 1001 1051 t01'1 1 2':L 4, 21 2 2324 2 2a 27 28' 29 301 41: 42

1 11 11V112113111 11~11 11, 1 13k 14 ~ 3- 32 3

, - . elK I
I CHKi
i
IGNI
i

I
I
: Tenninal I At idle At Approx. 2,500 rpm
Signal name Circuit
No. i Standard Memo Standard Memo
Engine lemp sensor

~ Engine temperature Engine temperature

r
(AFM ground)

28
Engine temperature ao°c: Appro" 1V 80e C. Appro•. 1V
sensor signal , Engine temperature Engine temperature
20'C: Appro .. 3V 20 c C: Appro •. 3V
! !Eees contrQI \m~:J , i
i

19n~~wllch
<+'l Exhaust gas

Exhaust gas sensor ~'GN l ~

• ,. _ Deflects between
29 signal (front)
Approx. 0 - 1V
approx. 0 - 1V
!

I fees control Illit I !

Ofagnosi$
~ COflTn
Clock
l
31
(synchronization OV OV
(ClK)
signal) , ~ , I
ECCSeontrolu~it ~J
: I
!
i I

Exhaust gas
temperature
waminglamp
Lamp not lit: Lamp not lit:
32
Motor & check
lamp (red lamp)
_~e "'N
, Power vottage
i
Power vottage

I Eees control unl!

!i
lamp IS lit: OV Lamp is lit: OV
i

Air flow meter

35 (Front) (Intake air Approx.1V Appro•. 1.5V
quantity signal)

Intake air
c;:,e",."," +
Cold. Approxt.5V Cold: Approx. 15V
36 temperature sensor i
tees control unit INarm: Approx O.8V I INanm' Approx. O.8V
Signal

EN - 494
 EGGS G/U INPUT/OUTPUT SIGNALS
R826DETI ENGINE

;RB26DETT ENGINE

1611021103 04~05100i1 1 2 3141 5: til a' 9 1 1 0 " 2 2 .2 241 22728 2930 41 4 4 45 414849 SO
1-"-31l-,",'l-",t",'t-','t-',::r37'+'",'1-""9r.:::,If",'l,,-',.+,'1,-','1-','+,.:':;';,:':,l',"'.l',".+",9
j

11~11 : 11 121131 Hi 1dle 1,' iii 1 zd,"

Terminal At idle At Approx. 2.500 rpm

Signal name Circuit
No. Standard Memo Standard ! Memo:
Throttle itensO(

0.5 - 4
Throttle sensor (Voltage Increases If
38 Approx. O.SV
signal accelerator pedal is
pressed)
ECCS control unit

03 - O.7V

41
51

2 -:lV

42 Crank angle sensor

52 1() signal

OV
Ignitton switch {!gnltion switch
43 (START signal) "START' Battery
OV
vottage)

No' Prange: OV N or Prange: OV

Neutral sWitch
44 Other than N or P Other than N or P
signal
range 4 - 5V range: 4 - 5V
Eees c<mtrol unlt

Air conditk,lnfl'r SW

"H"':~
Air condltiOr'tE:r OFF Air conditioner OFF:
Air conditioner Battery vOltage Battery voltage
46
sWltcn Signal Air conditioner ON: Air conditioner ON:
0;' '"
OV OV

EN - 495
 ECCS CiU INPUT/OUTPUT SIGNALS
RB26DETT ENGINE

iRB26DETT ENGINE

,iQ1l0<l1OJ1~1~1061Otlot111 21 31 41
11(~11Q111h1211~li4.1l~ 11411111~ 13!14!1!!
~ E4 7j 81 9! 10
1~ ,-" 18 19120
a: 212~ zsI'~ 2~ '.27!28,29 3011411'~ q «! "I .,j471 .. 14S1,,1
. 313213~ 3~ J~ ",,,,,,1,. ""II "15~'~ 54'~ ,.j 571 ,,1,.,.,,1

~ RX- i: CLKI
TX 1 I
I I CHKI IGNI
1

Terminal I At idle At Appro •. 2,500 rpm .

Signal name Circuit
No. . Standard Memo Standard Memo:

~
I Throtlle
; sensor
I I
Throttle sensor
l/0+
I
48 5V 5V
(Power supply) !

i
ECCS tOr'ltrol umt I .
i !

E~_~

~
~

Control unit power I

49
supply .r.--L~
-,
Battery voltage

I
Battery voltage

ECCS control ,,!'Ii! ! i

I

D range (or t st) With D range (or 1st) Wlth

~~
rear wheels jacked rear wheels jacked
VeflH::r:speedS!m!!Ol" "' up: 0.5 - 1.5V up: 0.5 - 1.5V

ir
The value actually The value actually
Vehicle speed
53 sensor signal
deflects between OV deflects between OV
and 5V. However, It and 5V However. it
;L ECCS control unit
appears to deflect
around tV. according
appears to deflect
around 1V. according
. •to vehicle speed . to vahicle Speed

~~
Oil

Th~atveSw .
•Throttle valva switch I
Approx. 10V
/~~-
54 Approx. lOV
(idle contact point) i
i

I Eees control unit

i
. i

19n~swik:h

I
~IGN ~ N or Prange OV N or Prange: OV
Exhaust gas sensor
55 Other \han N or P Other than N or P
i
signal (Rear)
range I 4 - 5V range: 4 - 5V .
I Eees contr~ unit -·1
I

4WAS

56 i
Throttle sensor
output signal
.

r+ I
LEecs ,om'~ "011 I
i
Approx. 0 5V
Approx. 0.5 - 4V
(Voltage Increases
' as accelerator pedal.
is pressed) !
I

I
EN - 496
 EGGS GIU INPUT/OUTPUT SIGNALS
RB26DETT ENGINE

!RB260ETT ENGINE

10 102 loll 105106 HII' 1 1

11 1
2' 3
l ' 14! 1
4'
1
Ijj 8i 9
111 1 19 20:
11) C I 21 2 ' 23 24 2
'3 3;d 3: 34 3 3
21 28 29 30
31 38 39' 40
41 42
51 S2I 5 S S
45 4148 4S'50
51585960'

Terminal I Signal name

!
! Circuit
At idle : At Appro •. 2,500 rpm
No. ; Standard I Memo Standard Memo

Throttle valve SW

Throttle valve sWltch,

57 Battery vollage Battery voltage
(Power supply) ,

InJ$ctOr
101 , "_I r..\

I/~ ~
103
105 Injector control
110 signal
112
•
; ECCS control tlnit i
114 , L -.. _ _ -.--J

~
r ruel pump
COflirol
:
,
Fuel pump terminal
104 vortage control !h~!~ Idling (afier warming.
engine): OV '
During mJOdle load:
4V
I Signal (FPCM 1)
I, '
fees control uml
I

Fuel pump termmal

Duong middle load:
106 voltage control
OV
sIgnal (FPCM 2)
L. ECCS 1;0011'01 unit \

EN - 497
 ECCS C U INPuT/OUTPUT SIGNALS
RB26DETT ENGINE

9-3 ECCS CONTROL UNIT OPERATION CAUTIONS

(1) Control unit equipment

• Never install a control unit that is not specified for your vehicle
• Do not apply excessive force to the installation bracket.

(2) Connector removal and installation

• When removing and installing connectors, do not bend or apply unnecessary force and
observe following points:
1. Connector removal
• Turn ignition switch OFF and ECCS relay OFF before removing connectors,
• Hold connector firmly to disconnect without applying force to harness,
• Do not use a screwdriver or similar tool to loosen the connector lock,
2. Connector installation
• Turn ignition switch OFF.
• Make sure pins are not bent or control unit connector and then connect securely.
• Tighten bolts securely until injector surface reaches orange colour indicator of
connector and surface is even.

(3) Control unit power

• Never make a reverse connection to the battery.
• Use battery voltage in 10- 16V range.

(4) Idle speed adjustment knob

• Do not turn past lock position.
• Do not turn adjustment knob when ambient temperature lower than 0°.

(5) Water and oil

• Care must be taken not to allow rain drops or water to wet the control unit.
• Care must be taken that condensation does not form due to sudden increase in
temperature. If there is any moisture, dry control unit adequately before installing in the
vehicle.
• Make sure no oil adheres to connectors.
• Do not clean the control unit using volatile solvent cleaners.

(6) Dropping and impact

• Do not drop the control unit or subject it to strong impact.
• Do not use upper and lower covers for the control unit which are dented.

(7) Control unit screws and cover

• Do not remove the upper and lower covers from the control unit.
• Do not turn the screws in the control unit main body.

EN - 498
 EGGS G/U INPUT/OUTPUT SIGNALS
RB20E I DE / DET ENGINE

9. ECCS CONTROL UNIT INPUT J OUTPUT SIGNALS

9-1 CONSULT INSPECTION VALUES
(1) Data monitor
Note: The output signal is displayed as the calculation data on console unit so the correct
value will displayed even if the output circuit (harness) is inadvertently disconnected,
RB20E I DE I DET ENGINE
.........••.•..•... '.':' •........•. 1 . 'i' > :. ··.·...·EDATAMClHrmR ......:...... ': ...•...••.
PROSLEMINSPECTKmI
MO
.. ' ••.•..••••• ON .••·. •
. " .:IiTE. MS...•. .
ORWG .. !'IOR
.... MA.I.REFE. ITEM
.. .... .
1iIIT.
",...,: ....' .•.L'··, ..C ••DlTlON •• :, , .• :'. VALUE.
RENCE
CAS RP1\A (Detected angle Tacho'l1eter set There ;rllJS( be no abnorma: I
Crank. ang € sensor SY1>:er~r
speed accordIng to signa,s) Engir.e fUnrllng chat1ge ;n speeC!
AIR: FLOW MTR Alter \I'/8fmlf"lg up englO8
Approx. D B - " 5V Air Row ~eter syslerr;
(output voltagei ldhrg (N range. Ale OFFl
ENG TEMP SEN I Engine temperable sensor
Above aporox_ ?O~C
(engine lemperatwre) i system
EXT GAS SEN C113,'1ges betvveen 0 - 0 3V and: ExhaliSl gas sensor system
1-_-,',:::o::ut:':Pe::L ':,:'VO:::;'' ':;:9,"e:c'_ _.Ji After \'ifarmmg 2000rprn v,.1!r no 06- 1\/ Intake system air leak Or "lit!
:::X r GAS SEN up englno load RICH, LEAN repeats 5 times or Intake
(RICd I LE.AI\o) i more In 1 0 seconds inJecto" system

CAR SPEEC SEN VVhllc drivlr"q or WIth dnve whec!S ShCI.,.Id generally conform to
Vehicle speed sensor system
(vehicle speed signal" i t.JmH'lg spe€cmeter display
Battery
Igniton sWItch C~
8ATIERYVOLT 11 ,~ 14V ECCS control unlj power
Engwe swppea
systeM
Igntion swllch
Throttle f.j!!Y closed 0.5
TH"<OTI\'E SEN ON Throttle sensor adjustment !
(mIl:plJt voltage) Engll'1£' Thro!tle sensor system
: stopped ThrottlE- fu'iy open i 40

' kl11ng (N range, Me I

!l\JJ PULSE
(mJeelio'1 pulse width) II After warming /-'_ _--.::O::,F:..F:..'_ _ -i r
2 ~ 3 msec Air 110w meter system
IfItake system air leaks or air
t:iO.IE: 1/16 dlsp'ayfor
R320E
i liP engltle i 2000:pm With no -:
Reference
2 - 3 rnsec
SlJctlOn {entlrl':; I'1Pl1!)
I"1Put signal syslem {entire)
load
Idling (N range. Ale
After warming ~._ _~O::,F_"':"_ _-I___'_1_rT_'_5_._,,"_I_T2_.,_~o_ _-4
IGN TIMING Alr flow meter system
up eng:ne 2000rpm with no Advance greater :han 10" angle
loao. compared to idle position

Idling {N range, Ale I Aporox 20.,. A.O"'/"

After warming OF:;:;'. __-1__________-..,
1--__.:::::.-.:. lAS ad:lIstrnent
I AAC VALVE
up eng'M 2000rpm With no 1- AAC valve system
Appro);, 30 - 50%
:oad
Air flow meler sysfem
Injector system
!
;
A/F ALPHA
Ailel warming liP engi'1e
(air-fuel ratio feedb.ack 75 - 125"/', Canister {pUfge} Inspection
2000:pm WIth no load
correction coeffclent) Intake system a;r leak or air
suctmn
"START' ON
START SIG!\lAL ! ~nI1io(l SWitch ~:--..::...:..:...::..---1-----..::....::..------; Starter SW system
ON "OFF" OFF

IDLE SIN
Engme
stopped
Throttle fully closed ON
TI'rottle sensor system
I
Throttle fully open OFF

~I
Ale SWON ON
Air co"ldjt!oner S'oN system
I--____A_'_R_C_O
__N_D_S_._G____ Ale S\NOFF OFF
N oc P farge ON
NEUTRAL SW Idle Neutral SW sysierl
No! N or P OFF

Steenng ON
I--"::":::::==--~"::"-----=-"::"----!:
i'
PW;ST SIGNAL Power steenng SW system
Steerirg ne"lra! OFF
i
FUEL PUMP RE:..AV I' IGN SW ON ' -___S:.:'.:,o:.p_ _ -<'-____O_"F_ _ _ _- i Fvel pump system
rev ON

Ale ON ON
i kjl!~
AIR CONOITIONER RELAY ~:_ _ _ _~..::..--A.::I.::C:..O=-F-"---I-----.::O:..F.:.F-----il Air condltlone' relay system
I When aeeel 5 Ale 01\ OFF
, sec Interval
EN - 499
 ECCS C U INPUT OUTPUT SIGNALS
RB20E! DE! DET ENGINE

(2) Active test

, ", ",,;:::<AC1"lIiETJ;!S'l'
,1.' , ," ' "
.....
::SETrrat·" JUDGEMENT ANDIlltSPE~_
.' ". ···~liIN~, '., , iAC'tI\I&IElI'I'~CRlJ>TloN ':::,':,':~):j>' ,"
:PerfcrrY' fo,lowHig Inspections to check jf
!prObJen1 :s solved_
jEllmlnate
Set engine tempera:ure high or low '
ENGINE ProbtefY' occu;ence ' ·E,,:glne :ernoerature sensor syste'1".
TEMPERATURE
ncft Cauti.on:. Do not set extreme va:ues as II
CO_ I lor ; nJector sy'Stem
thiS can cause spark plug bGmmg
, !Alf 'low f'1€!ler. exhaust gas sensor system
I~at elirmnaled-
i !
O:her Item 1I1spect,or:
'Pertorm following Inspections to check if
probiem IS solved,
E!immatg'
Set the air-fuel ratio rich or lean,
Exhaust gas sensor system
ProbleM OCCL.~nce Caufuln. 00 r:at set extreme values as
FUEL INJECTION Ar flow meter, engine temperature sensor
cOl)dition thiS may damage engl'ie or catalytic
,systeM
·ocnverter.
i injector syste'Y1
i !
: Not eliOJloa1ed
I I Other Item .nspection
Perform fe!lowing inspections to check if
I i
iDelay Ignition timing.
problem IS solved
ElimlOate'
i Problem occurence:Ca.i!tmt Do not set extreme vall.'€'s as
IGNrrlON TIMING gnition nmmg adjustment
condition IthlS may damage engine or catalytic
I Detonation ser:so r system
ccnve~er
! :~Imjnated'
I i , IOther i~m inspection
i i:'ncrease contro' duty ratio The engjne I
I AAe VALVE
OPENING
Engine 'Llnnmg
,speed shot;;d increase
i Decreas.e control duty reaM. The
; If the conditon descnbed or !eft can not be
venfied, ccheck AAe valve syster-;
! : engine speed should decrease
ITu;n Igmton sv~tch ON, OFF and ON
so oump operation "'nakes a sourd
If the condition described on left can nOT be
FUEL PUMP ignition SWitch ON , The fuel pressure WIll nse !
verified. cneck relay system of fuel pump
RELAY Engine stop ~ Do not perform this operation
and fuel pump system
except under conditions descnbed on
I left
I SELF·LEARNING
The al~-fuei 'abo feedback correction coeffiCient ieammg factor 1$ cleared
I CaNT

EN·500
 ECCS CiU INPUT/OUTPUT SIGNALS
RB20E ENGINE

9·2 OSCILLOSCOPE & CIRCUIT TESTER INSPECTION VALUE (RB20E ENGINE)

:1011 1
r_ o.i1 1 1 1 :3
_i
38:1 4 4
'iiii"
I :2 3 4 5 6 7 a !} 10
,_
21 22 2 24':2 26 211 2
'1~11 111 1 1~1 1 11 ,431, 454 4 1'1 f2 1 1 15 161 17 18 HI ;ilO: : 2 30 31 32:3 J4 35::3

Terminal At idle At Approx. 2.500 rpm

Signal name Circuit
No. Standard Memo Standard Memo:

I
.. _ ..
A!ffiowmelor
_- ..
LtiEl.'4"l .
,Air flow meter I
3 intake air quantity f';~ Approx. 1V AppfOX. 1.5V
signal
I ECCS c~~r'J
:.~.!!!L ..~~,"~.l

Engine temp sen

~-'--
:-.~ .- +
(AFM q10ulld Engine temperature Engine temperature
5
Engine temperature:
~ ao'c: Approx tV so·c. Approx tV
sensor signal 1/' Engine temperature Engine temoerature
y--.
I

20'C Approx.3V 20"C. Approx 3V

iECCScontrol unit :
L - -... _ _ _ ..

Exhaust gas sensor Deflects between

6 Approx 0 - tV
signal 0- Approx 1V

0.5 - tV
(Battery vonage Will
Throttle sensor
7 Approx 05V incerase when
signal (Input)
acceleration pedal is
ECCS control unll pressed)

03 - O.7V

Crank angle sensor

9
t20' signal

2·3V
(V):"-

"4
2
10 o

EN - 501
 EGGS G/U INPUT/OUTPUT SIGNALS
RB20E ENGINE

jRB20E ENGINE

,2122:1 24;( 2627:2

2 30; 31 32: 3 34 35 3

eBiNT I. . IC"M
I
Tanninal At idle At Approx. 2,500 rpm
Signal name Circuit
No. Standard Memo Standard , Memo

Exhawrttemp
wamI!'lglaml'
Lamp not lit: Lamp not ht:

13
Monitor & check S~'GNl Power vottage Power vottage
lamp (red lamp) Lamp is lit: Lamp is lit:
i : eccs control unit ,
.~.--~ ApproK OV Approx. OV

To AfT control unit

.~
Intake air quantity
15 output signal Approx. IV Approx 1.5V
I
(To AIT CIU) i

i
I Eccsco~u~j ,
I
I
~hOn~

!
16
Detonation sensor
signal
i ;
L ~?-I ECcs control unit
l_ _ ~._~. ___ ~
,
Approx.4V Approx 4V

,
i

010werM 05 -IV
(Battery vottage will
Throttle opening
~.
Approx.O.SV incerase when
17
output signal
i
I)- acceleration pedal is
;' Lfees control unit I pressed) ,
i

D range (or 1st) with D range (or 1st) with

~-'
rear wheels jacked rear wheels jacked
up: 0.5 - 1.5V up 0.5 - 1.5V
The value actually The value actually
Ve tucle speed
21 ,deflects between 0 deftects between 0
sensor signal ! and 5V. However. it and 5V However, it ,
i
•fees control unit appears to deflect , appears to deflect
, i
around 1V accordmg :around 1V according
i
, : to vehicle speed. ! to vehicle speed.

A~=I
, 22
Throttle valve switch r
.
Thmt1;
v
,,'~. sw I Approx. tOV i
: OV when accelerator
(Idle contact POint) i is pressed
I
" i

EN - 502
 EGGS GIU INPUT/OUTPUT SIGNALS
RB20E E~GINE

RB20E ENGINE

riiii1 ~ _
37383944412345678912.122224226272
tl 454 4~ '11~~lt 1151 i1181920, 3U31:32334353

Terminal AI idle AI Approx. 2,500 rpm

Signal name Circuil
No. Standard , Memo' Standard Memo
STAAT sw
~
OV
Ignition sWltch ? (ignition switch at
23
(START signal)
+ START Power
OV
Eees controlunil vonage)

,,=__
(MiT)
Neulra! sw

lAin N or Prange: OV N or Prange OV

Neutral switch
24 v Other than N or P Other than N or P
sIgna!
range: Approx. 6V range Approx. 6V
ECCS control unit

IgnrtJon sWItch P ower voltage

25 Power vottage
(ON signall

I I

Throttle sensor
26 signal 5V 5V
(Power supply)

ECCSr",ay

1-:==l~:':=L"J
i i
Control unit pov.;er
27
supply !~h Power voltage Power voltage

~lL:'~1
ECCS control umt ,
- .. --~

Air conditioner OFF: Air conditioner OFF:

Air conditioner Power voltage Power voltage
29 sWltch signal Air condItioner ON: Air conditioner ON:
Approx.OV I Approx.OV

I I
EN - 503
 ECCS C/U INPUT/OUTPUT SIGNALS
RB20E ENGINE

RB20E ENGINE

~1 11
- -
641 I
1112,1311141511e
1 ,1~ 3 4"
~4:::LJ"4.:J'..:.:l..:4:=
12345:6'7$91
1112 ~ 1 15 1~1~'6 191

Terminal At idle At Approx. 2.500 rpm

Signal name Circuit 1----
No. Standard Memo Standard Memo·
Throtffe valve SW
-~Aff

:t-~CiU

32
Throttle valve switch
(Power supply)
[
__/-7\.......
~ / "/ J '. . Powe r vortage Power voltage

ECCS ;onlrol unJ

~ _ _ ---l
i
i
!GNCQiI 0.2 - O.3V Approx.1V
.... ~ ..
_~ .. ~

Distributor - - -.
-"~1

-
,VI
• , .....:..'
(Vi
~

37
Power transistor ~
4
2
0
, :ririJj
o Ol1?-;"~
DG.
control sIgnal .- .
I .. ~-

!
;-~ .. --,
ECCS control unit
. -..--.
,
I
,
!
.
-
.. ""'-----. ---
...
..
.

i i

flower steenng sw

Power steering
~l ,
Power steenng ON:
OV
Power steenng ON
OV
38 i
, switch signal -~),
: -+ Powr steenng OFF: Powr steering OFF:
Approx. 5V
i
ECCS conlr'(ll unit i Approx. 5V
!

Power vortage Approx 10V

Tachometer signal
39 (Ignition cOil pnmary
sIgnal detection :
~I
!
- - i I
.c..I...:

Approx.1V
40 ECCS relay (ignition switch OFF OV
Power voltage)

Approx 3V

! Tachometer engine
43 - rev sjgnal ' o

I ,i

EN·504
 EGGS G/U INPUT/OUTPUT SIGNALS
RB20E ENGINE

RB20E ENGINE

10 1 1031041 1 101;
10911 1 12 WIt 11511,
-
1 .( 3 <1 5 6: 7 8 9 1
11 12 1 1415 1 17 18 19 2()1
r-,--rl-=I-r...,-,
21 22 23 Z4 25:26 27 2'8
29 3!}~31 32 33'34 35 36

~J II
I
i Terminal I Signal name Circuit
At idle At Approx. 2,500 rpm
, No. Standard , Memo Standard Memo

[~ Tachome!er

l/A;~
Engine AlT total
44 control input signal Approx. 10V Approx 10V
(OT1)
I ~ccs controll.:~rt I I

Engine AIT total

:..•. ~:~±. . . ..
jVj----···--···

45 control inPut s<gnal ~~

(DT2) ;:;;:_. ... !

! i

Air conditioner OFF Air condlnoner OFF·

Power voltage Power vo~age
46
Air conoitioner ON Air Condlt,oner O~
OV OV

, - - - AITcon!rm
ur'lit
Engine AlT total
47 control output OV OV
signal (DT3)
:I ECCS control l.Iflit I

Injector
101
103 C"~.......e

~~,
105 Injector control
110 signal
112
114
I ECCS ....onfr(liunit I

104 Fuel pump relay ov ov

I
EN - 505
 ECCS CU it, PUT:OUTPUT SIGNALS
RB20E ENGINE

IRB20E ENGINE
------.----------------------

Terminal At idle At Appro •. 2,500 rpm

Signal name Circuit
No. Standard Standard Memo

AAC valve control

113
signal

EN - 506
 ECCS C!U INPUT/OUTPUT SIGNALS
RB20DE! DET ENGINE

9·2 OSCilLOSCOPE & CIRCUIT TESTER INSPECTION VALUE (RB20DE I DET ENGINE)

\1O"ooI,o:i'O<lol,O<j101 HJjJ 1\" ,: 4i 5i .'

[,"""~"111~1l~11~ 11~ 11~ 11[ 12113i 111'
71.: ,1,
,~ 17i ,~
,,12 Il 2~2~ ~ 241 25; 26;
3, 3a 3~ 34j
:ni 28129
35i 56! 37j 381 :;9;
301141' 4~ 43\ 441451 46[47148! 49j501
4~ 151 j 521 53, 54) 55! 56 1 57 i 58! 591 OOJ

~ R:! ;:KI I i iI CHj IGN!

,
Terminal: At idle AI Approx, 2.500 rpm
No,
Signal name I Circuit
Standard Memo I Standard Memo

Fool pump relay

~ 19nitionSW
r~e-«'
18 Fuel pump relay ~FlWIPum~,........, OV OV
! I I './"" . . .'~..J '*
1/ ",;;]
LECCS~~~I
!

: [

POwel' steering SW

~* Power steering ON:

Power steefing ON:
OV
19
Power steenng Lm_~ OV
Power steerlng OF F,
SWItch sIgna I Power steering OFF
, 5V
i 5V
!
:
~.
_
""-

ECCS c(!ntro:i umt i I !

r---..~~t(jfi.!lti;)~~
, ,--.~

: :-'~~!.2~J

~Im
23 Detonation sensor ,
Approx 4V Approx.4V
24 signal ~ v =i }"::'T'l
m--"JL.m_'_
i i sees control unit
I
!
i
-Air,floW
-- ,-
metcr
.:TIillT·
, ~. 5 .. ) ;':':.-.J
mm ,

Air flow meter :

27 (Intake air quantity , , Approx, 1V , Approx. 15V
r-\"V~
,
, i·...------!
signal) m
~
'-'
"
~~.-,~
,
, ECCS control 1 !
I.!Di.L~ __ .---.J ,
£NG~Pl2~N
~"~
I (AFM groU:dl Engrne temperature Engine temperature

r0-~
Engine temperature 80'C Approx.1V ao°c: Approx. 1V
28 !
sensor signal Engine temperature Engme temperature

~ Eees control unil '

, 20'C Approx,3V 20'Ci Approx, 3V

~~..- -...: i

+ jg~nsw
(!J IGN O,sensor

[~
Exhaust gas sensor deflect betv'leen
29 Approx,lV
signal o- approx, lV

[---;;;;~ 0001'.' "M I I

I
[
I I i

EN·507
 ECCS C/U INPUT/OUTPUT SIGNALS
RB200E I OET ENGINE

RB20DE I DET ENGINE

2. 22 2 ;1 j 2S ;l6i 21 28 3 41'; 44.45146 47,48 49 50

~ :$ 3 35! 36j 37 JS ~ 4 $1 5~ 53 5,u 55: 56 57' 5&! 59 Ii

r± CHkllGNi
i
.--'---'------'.I

Tennina" At idle At Approx. 2,500 rpm !

Signal name Circuit

No. t

, Standard Memo Standard : Memo

Exhaust temperarure
waminglamp
Lamp not lit: Lamp not lit:

~J
Monitor & check Power volatge Power volatge
32 i
Lamp lit: :
lamp (red lamp) Lamp lit
OV OV i

i
~ _ _ AiT control
, unll

.l3~
Engine (ArT) total
34 control input signal Approx. 10V Approx.l0V
i (OT1) :
""~
,i

i ECCS "otrol i
, i

_WTconlrol
unit

ft~
Engine (ArT) total
35 control output signal I Approx.OV i Approx.OV
(OT3) ,
i L;cs 00","' un:] !
,
!

I-~ <,Ifllt
AIT oon"o'
Engine (ArT) total ,

36 cantrot output signal

(DT2)
I~ Approx 10V !
Approx. 10V

i "
:
--.~---.--.-
ECCS conlrclunil _J'ii~

0.5 - 4V (Voltage
Throttle sensor increases if
38 Approx. O.5V
signal accelerator pedal is
pressed)
tees control unit

To AJT {)ormOI umt

40 Approx. 1.5V

EN - 508
 EGGS G/U INPUT/OUTPUT SIGNALS
RB20DE ! DET ENGINE

RB20DE I DET ENGINE

~.~

~,=o~,~,~,~,~,~ooT,~o~'i'~'~'~~4~5~'~~~2c21 ~rc"t=2J~.~2~;;-~'L'5~~~~~'~2'~'·~jP.~r~~~~~~~::1~~ _ _,..L;3e.L3::<L':;L''''-':::'''':"'",,-":::',-':::"LC'l.::",,:'C.'LI5::153! 5~ ~? 56,57 55,59,6

L'='.:c':L'c:'.c"c:':L''C:'''-'c:''''''.::..c.'2'1.1;.:',-1;.:",-1:.:t3',LI.;":>...:,O:!..!.,"",·.;""n.;,1O,,,,;,'S:;'.!':L" 1

Terminal, At idle At Approx. 2,500 rpm

Signal name Circuit
No. Standard Memo Standard Memo:
0.3 - 0.7 0.3 - 0.7
\~l,~~--=-=---!

41
Crank angle sensor ,
4

120() signa! o

ECCS control unit'

2-3V 2 - 3V
\VJ~ IV)

Crank angle sensor

• •
,4
42
1" Signal L-~~l;;>~ 1JUlJUiJlJuu1J1J o

fees centro! unil

~ ___ ..- - l
1

SlAR1 SW
i-'--f:>~ OV ov
43
Ignition sv.ntch
(START signal)
I (Ignition sWitch in
'STAHT" Power
(ignition switch in
"START' Powel
voaage) voltage)

(MIT) N~~ral sw
-------:-~~_"7~

~;;ontrt)~

44
Neutral s"""tch
signal
L. --=-~,~!-' __ I
Nor Prange: OV
Ot/1er than N or P
range: 4 - 5V
Nor Prange. OV
Other than N or P
range: 4 - 5V
ECCS control unit

Air conditioner OFF: Air condihoner OFF:

Air conditioner Power voltage Power voltage
46
switcn signal Air conditioner ON: Air conditioner ON:
OV OV

Throttle sensor
48 5V 5V
(Power supply)

EN·509
 ECCS C/U INPUT/OUTPUT SIGNALS
RB20DE f DET ENGINE

RB20DE I DET ENGIN E

"
,

2 '. 212 2: :1 25 ?6,27 26; 2~ 3

3~'33.~.~.~ • • M • • U • • '
411 4 4 44;45 48147 46,49 50

~
RX
•
I ClKI
TX'
I I ICH~ IGN!
Terminall
Signal name Circuit
At idle At Appro", 2,50~
No. I I
Standard Memo! Standard i Memo

Control unit power ;

49 Power vottage Power vottage
supply

D range (or 1 st) WIth D range (or 1s1) with

rear wheels jacked rear wheels "~cked
,I GJ 1
, Vehicle speed sensor co up 0.5-1.5V UP' 0.5 - I.SV
The value actually The value actually

I/~
Vehicle speed
53 deflects between OV deftects between OV
sensor signal
l r and 5V. However, it :and 5V. However, It
appears to deftect . appears to defieci
'around IV, according I around 1V, according.
I to vehicle speed ' to vehicle speed.

OV when accelerator
54 Approx, 10V
pedal is pressed

Ie Aff control umt

56
Throttle opening
output signal

i
,C ECCS e-onlrol IIni!
Approx. O. 5V
Approx. 0,5 - 4V
(Voltage v~ II increase
when accelerator
pedal is pressed)
,

I i

Throttle valWl SW

r"""':. !
I [l..~" A'T
C/U
i

k~~+
: Throttle valve switch
57 (Power supply)
Power voltage Power vollage i
I
i
i IECCSc:::~
L_ _ _.---l !
,

101
I
i
I -- I,n~~,:~
..~;:,
Aifilost power voltage
(V,'-
- .. ~:.d
Almost power voltage

~)=-"L r-==""L~
I 103 oo~
~-----

~MJ=1~~
i .,j-- ~- --~~.

105 Injector control I, --8"l"- ,.

x.r ""' -~

i i
u . -., , ; ,
I 110 signal "~" ""
,
-, ~. -"-'--'~-~- ~-- ---'---'--I-t j-~
-""~---"" i
112
116

EN· 510
 ECCS C/U INPUT/OUTPUT SIGNALS
RB20DE i DET ENGINE

RB20DE I DET ENGINE

~-

-'011Q:i1O:1H).\1tljlO.bo1101i 1 i 2, ,: ., " 6_ 71 ., ,''O

; \OIil1(jl1~11~"~11~ H411~ 111 12! 13i 1~ 13 1£1 171 18, 19120 D 1--
211 2~ 2~ ,~ 2"'0121; 281 '" 3~i 41 ,,> 431«1 451 46<47j 4111 49! ,oj
3~ 3~ ~ ,..j ,,' "" 37' "" SCi 4lj I" L5~ 531 541 "IMi 571 ,.! 591 .01

~ RX I CT:KI !i I ICH~ IGN I

i

1
Terminal: I At idle i At Approx. 2,500 rpm
Signal name Circuit
No. i Standard Memo Standard Memo!

r "~""".----~

Fuel pump
1- CQntro! I
Fuel pump terminal i , mO<lI,!lal~.~ Cold: OV Cold: OV
'04 voltage control i D-:.. 'Warm: Power VVarm Power
signal (FPCM) c-l.:/----=
I
-,
eccs OO1ltrot urut !
voltage voltage
,

EN - 511
 ECCS C L; I!'\°UTOUTPUT SIGNALS
AB20E! DE ! DET ENGINE

9-3 ECCS CONTROL UNIT OPERATION CAUTIONS

(1) Control unit equipment

• Never install a control unit that is not specified for your vehicle.
• Do not apply excessive force to the installation bracket

(2) Connector removal and installation

• When removing and installing connectors, do not bend or apply unnecessary force and
observe following points:
1. Connector removal
• Turn ignition switch OFF and ECCS relay OFF before removing connectors.
• Hold connector firmly to disconnect without applying force to harness.
• Do not use a screwdriver or similar tool to loosen the connector lock.
2. Connector installation
• Turn ignition switch OFF.
• Make sure pins are not bent or control unit connector and then connect securely.
• Tighten bolts securely until injector surface reaches orange colour indicator of
connector and surface is even.

(3) Control unit power

• Never make a reverse connection to the battery.
• Use battery voltage in 10- 16V range.

(4) Idle speed adjustment knob

• Do not turn past lock position.
• Do not turn adjustment knob when ambient temperature lower than O°C,

(5) Water and oil

• Care must be taken not to allow rain drops or water to wet the control unit
• Care must be taken that condensation does not form due to sudden increase in
temperature, If there is any moisture, dry control unit adequately before installing in the
vehicle,
• Make sure no oil adheres to connectors.
• Do not clean the control unit using volatile solvent cleaners.

(6) Dropping and impact

• Do not drop the control unit or subject it to strong impact.
• Do not use upper and lower covers for the control unit which are dented.

(7) Control unit screws and cover

• Do not remove the upper and lower covers from the control unit.
• Do not turn the screws in the control unit main body.

EN - 512
 EGGS G/U INPUT/OUTPUT SIGNALS
CA 181 ENGINE

9. ECCS CONTROL UNIT INPUT I OUTPUT SIGNALS

9-1 CONSULT INSPECTION VALUES
(1) Data monitor
Note: The output signal is displayed as the calculation data on console unit so the correct
value will displayed even if the output circuit (harness) is inadvertently disconnected.
CA1Si ENGINE
. .' ........ ........•. r >;(D'ArA;~ITQFt ,,:·};.:i;·~R(J!IL.I!::M o.&~!!CTION i
~~INGf1'E1I!S
........ . ..•. '.'
'J'" ·.····.i·~MAl,.;~!!'.ERENe!!· .
..... ••.. ";":"(.'"0'" ''''''!'.'. ••.•••••. ': •... ··:.·~t!E;.. · •• :.:
··...ffI!M.. .
•..•..•: .•.. .. .•
.
CAS.RPM \Detec~ed angle TachOmeter set There must be no ab:1Ormal
Crank angle sensor sys:eM
soeec according :0 signals) Engine n.Jl'1rnng Change In speed I
ENG TEMP SEN Erlglfie temperature sensor
After warming up engu'le Above approx 70 C Q

{engine temperature) . system

EXT GAS SEN Charv;.;les betvJeen 0 - 0 3V ard: ExhaLst gas sensor systel'1
{output voltage! After warmirg OB -1V :In!ake syste1i al' leak Of ai'
2000rpfT 'Nlth '10 load
EXT GAS SE.~ up ergH'Ie "<:ICH ..... EAN repeats 5 Hnes or: intake
(RICH Il...EAN) more In 10 seconds i Injector system i
CAR SPEED SEN While dnvmg or WIth drive ""heels Should generally confonn to
Vehicle speed sensor system
(vehicle speed Signal) tumlng speed meter display !

! Battery
~nitlon swi:c~
0"'1
BATTERYVOL7 1" - 14V =CCS cont'oi Ur.lt PO't.'E)f
Engme stooped
systerr

THROITLE SEN TNert!€! fully closed 10

(output vor,age) Igmtion SWItch
ON Throttle fully open 5.0 Throttle sensor adlustment
Englfle Throttle sensor system
Tl-<ROTTLE SEN (2) stappen I Th~ol1le f\..!1ly dosed 0.6
;ot.1pUl voltage) Throttle fully oper 45
INTIA TE'JlP SEN
Intake air temp€rature IS :nIaktemperatum sensor
{iNsktemperafure sensor A_fter wartrllrig up englrle
displayed system
output)

Idling (6~a~e- Ale Air flow meter system

1 ~" 2 msec
INJ PULSE After warrrnng Intake sysle'i'l B'r lea.ks or i1lr
Reference
tJnject!on pulse WIdth) up englf'E Sllctlon {er,lre nput)
2000rpm WIth no load 1 ~ 2 tl'sec Irput sigr.al systeM {ef'tll"e;
ldll'lg iN range. Ale
M!T15~, Afr20 v
Afterwarmmg OF~}
lGN TllVI!NG Air flow meter syStem
up engme Advance greater lhan 10" angle
2000rpm WIth no load
compared to idle pOSitIOn I
:Alr F.ow meter system
AlF ALPHA IrljeCIOr syste!T'
After \Varm;ng L'P engine
(alr-fue! catlo feedback 75 - 125% :Canster (D~rge) inspectIOn
200Crpm With no loaa
correctIOn COeffiCHl:!rrt) ! If"take systefCl air leak or air
i , suction
"START" ON
START SIGI\IAL ~nition SWitch Starter SW systeM
ON "OFF" OFF
Engine Throttle fully closed
s~opped
0"
IDLE SW
7hrottle funyopen OFF Th:-ottle sensor system

AfCSWON ON
AIR COND SlG All conditioner SW system
Ale SWOFF ! OFF
Not Prange 0,"
NE UT::(AL SVV Neutral SW system
NotNorP OFF
klle Steenng ON I
PW/ST SIGNAL POVY'Etr steering SW system
I I , Steering r'teutral OFF !

Head :amo, heater

fan, rear cefOgger ON
WfGCONTSN SWON
Above SW OFF OFF I
• FICD SN
ignition switCh AIC ON ON
FCD input system I
ON Ale OFF OFF
Eng temp cold GN
FTC HEATEq Rewllg PTe healer mp..rt system
Eng temp HoI OFF
, Stop OFF
FUE!.. PUMP RELAY ION Sill/Itch ON Fuel pump system
I ,ov ON i

AIR CO~DITIONER RELAY Idle I Ale ON OFF

Air conditioner system
:
:
Ale OFF OFF
EN - 513
 ECCS CU iNPUT/OUTPUT SIGNALS
CA1S, ENGINE

(2) Active test

·h,li;",:.'IACTIVli:TeST.iiii' ".'. · . \ I . " i f l ' .,
I ',i>':<'p,', .••• ,.,. I.,
ISETtl'E~;?~r';""'i~.,~;....,
..., "".,': '" ,';,..;.\ON.....;..,..... ,.""".,'.•• :. e: '·:;TES:;:".;T.; ·.,be...., ""R';'II"-T-ION--I~;;~=~:~o::::!c:~
.::.=,';':AC'::",::TIV=-,' -'$c"",

ENGINE Proolerr; occurence

I
;Set engine te'i1perature high or !ow IIEE:un.wa.!e..
'191 ne TemoeratGre Se'lSOf system
TEMPERATURE
.G.au:tkul. Do net set extreme values
condItion : In)€ct:Jf system
as this can cause spark plug Durning !AI; flow meter, exhaust gas sensor system
; Nol ellm oated
Otl'1er Item Inspection
Pertonn fo;lowwtg inspections to CheCK if
problem is SONed

Set the air-fuel ratio rich 0" ~ean.

E.lirruna.te.
Problem occurenc.e ~ 00 not set extreme values as ,Exnaust gas sensor system
FUEL INJECTION :Air flow meter. engme temperature sersor
conOltion thiS may damage eng~ne or catalytiC system
ocnverter.
Iriector system
Nor elimir.ated·
Other Item inspeCTIon
! Perform following Inspections to check if

:problem is solved.
Detay 19nit:on tlmmg
Elimmate'
Problem occurence .G.a.uti.oL:. 00 not set extreme values as
IGNITION TIMING i condltwn Ignition trming adjustment
this may damage engme or catalytic
Detonation senso~ system
,converter Not eliminated
I ! Other item inspection
lTum ig1ition switch ON and OFF The
After engine warm up :'idle rev will c~ange If the conOltiOn described on left can no: ce
IDLE
idling tN range, Ale !.G..a.uti.c..n: 00 not perform thiS operation II(Hified, check Idle correcuon solenOid
CORRECTION SN
OFF) 1:~cePt 'Jnder condition aescrioed on :system

: Tum ignlt:o:\ swtch ON ana OFF The

After engi'1e warm up i1dle rev WIll ;ncrease at approx 200rpm
If ~he condItion described on left: can not be
FICO SN idling (N range Ale G.ai..ili.o.Ir Do not pertorIT' this operatlon
verified, check FICD soleroid system
OFF) except under condition described on
left,
iTurn igmtlon switch ON, OFF and ON
:50 pl.;mp operation makes a sound.
If the condition descnbed on !eft can not be
FUEL PUMP ignition SWitch ON i 1l1e fue; pressure Will rise
venfied, Cf',eCk relay system of fuel pump
RELAY E~me step .G..a.uti.oo.. 00 not oerform thiS operation
and tuel pump system
except under conditIOns descnbed on
left
SELF·LEARNINGl
CONT . The air-fuel ra~o feedbaClo( correction coefficient leammg factor is cleared.

EN - 514
 EGCS G/U INPUT/OUTPUT SIGNALS
CA 181 ENGINE

9·2 OSCILLOSCOPE & CIRCUIT TESTER INSPECTION VALUE (CA1Si ENGINE)

43 45 -
3383 <\ 414
4
'21 J 4 S!fi 769101
--
: 1111211::;t1 1511 :711fJ!19!2oJ -'
21221224251262712
2: 30313233134353

Tenninai At idle At Approx. 2,500 fpm

Signal name Circuit
I NO. Standard Memo: Standard Memo

fhrot1le sensor
Throttle
sensor r~ Approx. 1V - 5V
(Voltage will increase
I/~
3 Approx.1V
signal 1 when accelerator
pedal is pressed}
I ECCS control umt I

Engine temperature Engine temperature

5
Engme temperature ao'c: 1V 8G'C' lV
sensor signal Engine temperature ' Engine temperature
I 20'C 3V i 20'C. 3V i
i

Denee! between
approx. 0 - 1V

EXhaust gas sensor

6
signal

I
I~~'~
Approx. 06V - 4.5V

7
Throttle sensor
i Approx O.6v I i
(Voltage Increase
when accelerator
5ignal2
, , i pedal is pressed)
: ECC$ eootrot I.mit I
:

Approx. 0.3 - O. 7V Approx. 0.3 - O.7V

.
(~E ':~fCh~
,
,~

•,,
9
19 !
Crank angle sensor
18011 signal
o '~jy !
0 ~Hm
,
L , ...LJ
,

Approx. 2 - 3V

~
' fankangj~
'''''SlG~_ : (Vdlm'"
. --;;
10 Crank angle sensor r<V).-, 4.
2. '
'
J
"
20 1<) slQnal :, \.... I / v.L
- I" ": 0
" I
,--'--+.": '
" , .... ,
I II 'CC'=mum' i tm~fi i ! I ' II
EN·515
 ECCS CIU IN PUT/OUTPUT SIGNALS
CA 18i ENGINE

CA18i ENGINE

1101111~~1.~
l..!... ' -
11.1,*,' 1 1 H)' 1
11,11
-
1 2 :1 4: 5 6 7 8- 9' 1
11 12' 1 15 1 17 18 19i 2
21 22 :.I '24 2: 26 27 2
3.1 32 33;34 35 3

Terminal I Signal name Circuit

i
At idle At Approx. 2,500 rpm
No. , Standard Memo Standard Memo:

v J®-.IGN
Exhausttemp Lamp not ht Lamp nol lit:
Monitor & check wamtnglamp
,
13 " i Power voltage Power vo~age
lamp (red lamp)
i E~CS ,ontrol "m' .J; lamp lit: Approx, OV ,Lamp lit: Approx.OV
,
i

i --'--"---" !

, I
i
I

i v.L:;l + sen G ~-T-'--,

IV, , ' , ~T
; I
Approx. 1 - 5V

I~
!

21 i Vehicle speed ,,
4'

0'
", H-~ (Cycle will get shorter I
sensor signal when vehicle speed
I •

,
, I
is increased)
• r~
!

!
I
I Eees control IJl1lt
I , !

srARTSW

~ OV OV
23
Ignition switch
"START' signal I~~ (~nitionsWItch in
START: Power
(~nitionswitch in
START: Power
voltage) voltage)

r::-:::::-_Neulraf Switch
(MIT)

... N.P switct\ N or Prange: OV N or Prange: OV

Neutral switch (AI'"
24 Other than N or P Other than N or P
Signal
range: 6 -7V range: 6 -7V

ECCS control unit

27 Powervokage Power votiage
power supply

L
I L
29

2B :
: Air conditioner

s..tC_h_S_lg_na
__' __ ~
r- ECCS'"""'"oit
______________
~vOndiljOOz~ Air conditioner OFF: '
Power voltage

__r_O__ ___
Air cond.tioner OFF:
Power voltage

-L_A_'_r_c_o_nd_~_~_one N_:~ ,~_A_ir_c_o_n_d_in_'o_ne r_O_N_:~

OV __ _____

EN·516
 ECCS CiU INPUT/OUTPUT SIGNALS
CA18: ENGINE

CA18i ENGINE

:lQ11
~_,11
1
- 1 lOch
111 12 1 1.f;11 11
1 11 2 3 ,$ 51 \;
1111213111511171181112~
71 B 9: 101

, Terminal At idle At Approx. 2.500 rpm

Signal name Circuit
No. Standard Memo Standard Memoi

Intake air
Cold: Approx 1.5V COld. Approx. 1 .5V
30 temperature senSor
Warm: Approx.08V Wann: Approx. O.8V
signal

Power steenng ON Power steering ON'

Power steenng OV OV
31 Power steenng OFF
signal Power steering OFF
Approx.8V Approx.8V
l ECCS control unit

Approx.05V Approx.1V

Power transistor '11'._II.'..1,·1."1

-J~ .
37
control signal (IN) ---- --'-- ,.

: ,....--J-."~...-.
~;~F~!£~l:ii t+7"l~ ..
II
:

i fees confml Unit i

.. __ k~~

.-
.. I
I
! : I

App,ox 05V
. :.:::;: "':X I
tGNcoil
()--~ ------<B ,v
OlstrlnUl¢:1 -- - I rvf""-~ ,..
Power transistor ~----y
•4
. it i .'", J;,'T
'

38
control signal (EX) . >-"-0-. I
2
0
I

:.L,
IF : 2
01 I
tJ:-'~f
......L.... . ;
. r
,
i i E:CCS ;:;Qfl!rQ! unit l !
i L. ___~_.l

i
Distnbutor ApprOK 11V-12V Approx. IOV - llV
'~--/---:I
~~JWt..h r-:'~

IG~CJU 'V
4<)
TT~:q:
(V~
40; "-- i : i--
Ignition primary
: - I
t- .
39
signal ~
t
...:y}\ ;
Re6 !$tor
translsh)t
'"'"
10
. .

..
30;

~' ~=
,'--'

{-:- :- -(.~Ti:
1... :
. • \
~
0
~ --~~i~··L-.
E~ ~~!_ltr¢l unit: ' " . '1'+":1,~
~ . ..;_"_,~.J

~~"";~ c/u OV
40 ECCS relay (ignition SWItch OFF: OV
~i Power vottage)

l.::'cs ;M"Q,"",~ I !

I
:

EN,517
 ECCS C/U It\PUT/QUTPUT SIGNALS
CAla, ENGINE

i
;CA18i ENGINE

1:': :> 2122 242262

11 12 1 1 15 Hi 17 18 19 20' 30 31 12 3 34 35

,
,
, Tenninal ! ! At idle At Approx. 2,500 rpm
Signal name Circuit
! No. Standard Memo Standard Memo
I Power vottage Lower than power
vottage
<V)

41
F uei injector pulse
monitor signal
r0-'\" lVi~
: ;".~J-~-f' 1 • '
60
",'
..•..
1-"'-

,
(li monitor) ECCS control u~~
,
oT~-~-j-~
,. "",....·E. ; '1
2<l
o~.
.
.~. . .... '.~L I
i
r~~
F- i!!lS _!-L:_~ .,.+, . (i--
I I .~~ '1'1 •
I
!
Lrght SW

r®--®
,
43 , Light switch signal
:
ie
V0
-=ccs.contro~1
,
SWitch ON:
Power vottage
Svvtch OFF: OV
I
Switch ON:
Power vottage
Sw<tch OFF: OV
I

!
:

~
f<,- +
I

~
Switch ON: SWllch ON'
Heater fan switch
45 Signal
Power voltage Power voltage
Swllch OFF: OV Sw<tch OFF OV
i J, ECCS centrol umt
I
i

RUf detogg.l!r SW

~
,
!
46
Rear defogger
switch s<gnal I
I,
;'
v=-:
fees control UJut J
Switch ON:
Power voltage
SWItch OFF: OV
I
:
,
Switch ON:
Power voftage
SWitch OFF OV

i I
Power voHage Lower than power

~
voltage
,

:~.
<V)-1" '
I 6lJ ~'
I

101
110
Injector control
Signal '"O'L~: ' i::::::±'
20 -~, ~

~~
I
.: ~7-::':"
i 1Jfi«J i' :
ECCS control
i":""';'=:-I ::r ,

I~"
I Air co:xhtrcner ON: I Air conditioner ON:
'Air conditioner relay: Power vottage Power voltage
102 Air conCitioner OFF
signal Air conditioner OFF:
I I ECCS GOfitrof unit OV OV
!
!I I
L I i
i

EN·518
 ECCS C/U INPUT/OUTPUT SIGNALS
eAtS, ENGINE

CAt8i ENGINE

'1 H 11 1211 1 11sal1

-39 4
45 4
"
4
4 t 2 3 4 5
!1 12 13 1
is
15 1
1 8 9 101
17 16 19 201
21 22 2. '2 2. 26 21 2.
30 :)1 32! 3 J4 J5

Terminal At idle At Approx. 2,500 rpm

Signal name Circuit
No. Standard Memo Standard Memo

ACO I n1tlOn
..
oI 'd 9

~
Air condilioner ON. Air conditioner ON:
OV CV
103 FiC D solenoid
Air conditioner OFF: I Air conditioner OFF'
Power voltage P ower vo Itage I,
I ECCS Cotllro! unit I !

Fuel pump
mII.fy Igl1ihOA

104 Fuel pump relay

~i~f'
.¥ ....---rr
,"'pprox.OV
(Power vottage for 5
sec after ignition Approx.OV
I
...-.... - _'~'1"
: .;..-.-
.... sWitch IS placed to
r;.CCS coolt(ll unit' ON position)
!

I
PTe heater ON: PTe healer ON:
Approx.OV Approx.OV
t06 PTe heater relay
PTe heater OFF PTe healer OFF
Power voltage Power vonage

ldfe rlW correction 1 . VVhen ign sw in on

lIOk!:"?~ 2, Engine rewing: Approx. OV
IgnitiQtiSWlkh

~. First 15 sec after engine start: Approx. OV

Idle rev correction :
111 After 15 sec after engine start: Power vohege
solenoid !
Any of the followings are ON (Power steering.
fees control unit i
lights. rear defogger. heater fan s>Mlchl Approx
OV (D range lor AfT]

Lock up release
Lock up released:
Approx.OV
lock
I Lock up released
Approx. OV
115
solenoid (ArT) lock up applied:
: up applied: Power vo~age
i IL€_C_C_S_'O_"_"_"_"_OO_' --,I : Power voltage
I I

EN - 519
 ECCS C'U INPUT OUTPUT SIGNALS
RB25DE ENG INE

9. ECCS CONTROL UNIT INPUT I OUTPUT SIGNALS

9-1 CONSULT INSPECTION VALUES
(1) Data monitor
Note: The output signal is displayed as the calculation data on console unit so the correct
value will displayed even ilthe output circuit (harness) is iradvertently disconnected.
RB25DE ENGINE

.li~~:--G tTl
ii.i hiiiii.i i i
PRO!lI.aM~
DATA_ITO!!

" i i . : i i i i ' . ··· ..i·.iii.••.i i... /i.

"·c_o.i
i ii ii NORMAL REFERENCE
i'i i.i i·i.·' VALUE
i I1!l!.Mi "'i.i .. ii "i: ~ ,~

I Cfl.S RPM (Detected arg:e Tacrometer S€t I The:€' mus: De ro aO'>QfIT'81

era:;:'; ang'c sensor system
speed aCCordlrlg:o 519;')0,'8) Engir>::! !'tJ1I1:ng .;:~~€ ,- s:::;eec

AiR FLOil'; MTR

{outout voltage)
M€(warmlrJg
engine
(1!irg I,N range,
AJe GFF)
'Jp :
, "'i")

i 2000rJ:--:1 vlltmut load : I AJ:;:Jrox i C - 1 5V Air flow fl'IE!ter $ystem

ENG TEMP SEN Engloo tempefillue sensor

Afte~ warmi~ t.:p engine Abo\'€ approx :'C>'C
Li~pg're tefT1p~~a!J,..re)
I EXT GAS SEN
'-00!PUl voltage)
!
, Changes tlet>A'€cn C - 0 3V arc
Dj) - 1V
s.ys:em

Ex'iaiJst gas sensor system

i Ater eng!f\e 12CiiOIP
waimi") up , ,ntake system air :eak or 8!f
U rprT' w, 'Yl Ioa"j

I EXT GAS SEN

(RICH f LEAN)

CAR SPE~i) SEN

(vehicle speec signa!)
!

VVrllle dl1\i1ng at With jnvc Wlieels t\,J~r;I;;g

RICr, LE.AJ,j receats:;, times or !:-take
more In 10 seco'1ds
ShOuld gereraiiy :;omlYm Ie
speedrr-:ete; distllay
Ir~ector s't'Stem

: Vehicle speed sersor system

II;;fHtlCl switch ON
i~atter;,
BATTERY VOLT i 1~ - 14V ECCS control L:nlt oower
I Engine stopDeo
:sys!em
!dIJ~ iN railge. Ale ACt)rox.. 2 C 28msec
Air fiew meter sys:em
~'\IJPlJ ....SE Afterwarrr.rg GP OFF; lmake system a,r leaKS:Y air
('r]eCLOr' pLfse Wld~hl engine
2eDOrpr) With "lJ lead Appro); 2 0 - 2,8rnsec
suctor (entire lrout) i
Inp:.Jl: signal system (ertirel
idling {t'\ ~ange, /l,!C 15)
IGNTIMING
After v'iarrr,wg up OFF)
Ar "!low '"TI€ter syste:T!
I
enguie Advar:ce greater !har ~Oe angle'
i 200Crpm With ro load
i compared to Idle position I
AAC VALVE After :;,';';fJ up Idli 11 iN range. AF:;
OFc,
Approx. 12 - 30°::) I
tA S adjusTr1e:1t
AAC ...'B11Ie system I
!Alr flow mete, system
Air ALPHJ1.
Mter warmlllG up engine
:!r1jec:or sys~em I
(al'-fuei ratio feedback CC'TectJor:; 75 - '25% !Carns:er (purge) 'rspe::;t,on
20aOrpf'"'l Nltr, no load !
coeffiClent) i ; Irta.<.e s,.'s:em. air lea'" or air
s~b:::ifl

STARr ON
, START SIGNAL
'OF;:: OFF
,S1arter SI/V system
Ignition SWitch ON ,
EngIne stoppe<:! I Plroffie fully closed I ON
IDLE SJUOGE\1ENT Tl¥ort'e sensor sltsterr
i
-- ..
Throtj~ flJly open I OFF
I Ale SWON eN
!~$COND SIG Air cor;ci:borer SW system
i NC SWOFF
,
OFF
Nor P 'ange ON
NF~TRALSW Nel..t'ai SVV system
!
~.. t\CtN orP OFF
i Idle

L
S:eenng ON
P'vV/S"'o SIG"lAL power stee"!ng SW system
I Steeri'ig neJtrai OFF
Ale ON 0,
AR CON RE... Av OFF OFF i Air con;;toner relay system

I A.cee! Me ON OFF !
,

~i FUE~ PLMP 'oLAY IGN SWQN

Stop
\llfrlen re,.
OFF
ON
FLei pump syste'n

CHROTTLE SE\ ~["lIt101 5witcn 01\: ~~e ".JIly closed Approx 4 G

Throttle sensor system
{output voltage] Engme slopped Throttle h,jllyopen App~cx 0.5
PCV'JER VOLTAGE Dls~>ay oower ·voltage prove rneasureffiClit value
PULSE ::;<;.~Ia\' PUlse prove measuresl..rement val~

EN·520
 ECCS C/U INPUT/OUTPUT SIGNALS
RB25DE ENGINE

(2) Active test

Perfcrm foIIOV't'lrig Inspections to check if

proc!em :s solved.
EljmlM1W
Set er.gll1e temperature high or low
ENGINE Problem occurence Engine lemperature sensor system
~ Dc not set extreme values as
TEMPERATURE condition jrlJector system
i this :::an cause spark plug burning
Air flew meter. eXhaust gas sensor sysle'11
!
Not elimloaled'
Other item i~spect:on

Perforr'P foliowmg inspections to check ,f

problem IS so:ved
FljmlOare
Set t'le alr·fuel ratio rien or lean_
Exhaust gas sensor syster:1
Prob,e'TI occurence ~ Do not set extreme values as
FUEL INJECTON Air flow meter engine temperature senso:'
condition thIS malt damage eng~ne or catalytiC
sysem
t
ocnverter.
In,*Klor syster."l
Not eliminated
: : Oir;e( IteM !nspectior
Perform following inspections to check if
problem 15 solved
Delay ,gnijlon t:mmg
Eliminate
ProbleM occurence ~ Do not set extreme values as
iG Nrno N TIMING ilg:nilion timitlg adjus1rnem
conditon tbs may damage eng we or cataly:jc
IDetonatlOn sensor system
ccrverter.
: Not eliminated' !
:Other itel!' inspection
Inc'ease controi dUty ratio, The engine
Me VALVE Engl1e running
speed s"'Iould Increase. If the condition descnbed on left can not
OPENING Decrease contrOl dLly ratio bevenfied. check AAe valve syste:-n
The engine speed ShOJId decrease.
Tum ignition switch ON OFF and ON so
pump ope~ation rr.akes a so~nd" The fuel If the conditIOn descnbed on :et can not be
FUEL PUMP ¥J0mor, switch ON
pressure Will nse venDed, CheCK relay system of foo, Dump
RELAY Engine stop
.cauti.orL Do rot perform thiS operation ar:d rue: pump system
exceot under conditions descnbed on left.
SELF-LEARNING
The alr~fuel ratio feedback correction coeffiCIent !earning factor IS cleared.
CONT :
En~:.l't1e
rev can be d:splayed when AAC
valve openiflg is fixed and set injector
POINER Prob!em occurence :Elimmate
operation:5 stopped.
BALANCE condition Injector system
.G.a..ul.k:n. Do net perform thiS ooeratior~
while drlvmg

EN - 52i
 ECCS CU INPUTOUTPUT SIGNALS
RB25DE ENGINE

9·2 OSCILLOSCOPE & CIRCUIT TESTER INSPECTION VALUE (RB25DE ENGINE)

: ~ AXl ;:K!
I

I :
I Terminal I Signal name Circuit
At idle At Approx. 2,500 rpm
: No. . Standard Memo Standard Memo
0.2 - 0.3 V Approx. DAV
1 ~V} .... c ~ e_'" )

2 6 ~~," "
41~·· . <-r-«
3
11
i Power transistor
control signal
! 1." -;----r:----
12
13

COld: 6 -7V Approx.5V

VVarm: 8 - 10V

4
AAC valve control
signal
Yi=;.t~ ~y=t.j±
s-·--
(I • t
+-,~-
--
, ,-;-
~ ~
f~-' ~

ECCS contr<ri VI'II!

Engine AIT total i

5 control input signal: Approx. 10V Approx 10V
j ..

Il"<'--'
(DT1) :

J Approx. IV Approx. 2.4V

-.... Taehometo¥
.
i
i
(V)_,~,

:-:-r~-~"";~
_
!
IVI
~-.-- .- . ..

:
7
Tachometer engine i
'1 - *1·~
o>~r-----' ~ -I 'ffutil1
~ "- "- ~ J
speed signal '
.~:~ ... '.~ . o~+ _~~_~ 4-.j.~J
.
I ECCS control unit L •• !-=:_-~k~~~ i
...~ .< .. -
i
Lowpressum
AlCrefay sw
i-f'iii'i~:!)1'iSJe
Air conditioner OFF: ' Air conditioner OFF:
I~- :

!l~pressor , Power vonage Power voltage

9
:
Air conditioner relay
--
L -..
...-~.---
ECCS control umt
.J
Air conditioner ON'
Approx.1V
Air COndiTIOner ON
Approx. 1V
:
i i

I A/Tcomroi
I,jl'l:ll ! .
l
i Engine alT total
14 control ,nout signal Approx 10V I Approx.10V
(DT2)
ECCS cootro! lIflil 1 i

i I i

EN·522
 EGGS GiU INPUT/OUTPUT SIGNALS
RB25DE ENGINE

RB25DE ENGINE

i'ol'o:l ",iiOiioo"lO lOJ,,>ii 1 2, 314' ': &[71 8 '.10

110411Ql1~112tl~1141l:(1'1~ 11 12: 13 .. 141'.ill~ 1]1 1S! 191 2Q
D 72~2·3~ 241251261 27! ui 2f3t'IT4·1: 42143!44!4S!46!47!481.i9I501
: 311 32133 341 351361 37 ~ 391 4~ 1 51\ 521S3! 54155~i s7i 581 591601
!

~ ~XI':KI CHKIIG~J
i ! I

Tenninal! At idle At Approx. 2.500 rpm

Signal name Circuit
No. Standard Memo i Standard Memo
! I
AfT comrol Unit

Engine Arr total i

~5 control output signal Approx.OV , Approx.OV !

(DT3)
•
ECCS cOrltrol urn1

,
ECC$rclay
-~ ~
! L--....: ±: i

•
ClU
Approx.1V
16 EGGS relay (~mtion sw!!ch OFF. Approx.OV
Power voltage) !
I
Fuel pump rniay

•
~
, "
' 't : , •
18 Fuel pump relay j ~ Fuel pump OV
I •
,. - I •
, EeeS control Unit: i
! I I I
POwttr sl~in9 SW ,
~+ :1'. !
Power stee:vig ON ;: :we' stef"ng
Pmver steenng ov OV I
. 19
sWltch signal
~

Power steering OFF P:,·,e~ 5:£-'0---': ---

--
!
I 5V 5V
ECCS eomrm umt
•

---:O~tonat<ofl.ef!l

23 Detonation sensor ! Ji Oeto,!!tII!~.~ ! .

Approx. O. 3V Approx. 0 3V
24 signal
•
I I .. _-- ..
.
1 ECCS c-ontt-ol unit
, ... ~
~----

,
I
AJtffowmeler
-$r~~1~'''''''-;-;,
1
~~
Air flow meter
27 (Intake alf quantity
~v>-~ .. _.J i Approx.1V Approx. 1.5V
signal) "'"',- i
! -,...
i ECCS control '"
!
!
i !mil
I • i

EN .. 523
 ECCS C/U INPUT,OUTPUT SIGNALS
RB25DE ENGINE

RB25DE ENGINE

I
; Tenninal At idle At Approx. 2,500 rpm
Signal name Circuil
No, Standard Memo Standard Memo
Engine temperature sen&or

b
~;J. Engine temperature , Eng Ine tempe rature
Engine temperature, ,'ground,
I'M ao'c, Approx. 1V !
80'C. Approx. lV
28 Eng",e temperature
sensor signal Engine temperature
20ce: Approx. 3V 20"C: Appmx. 3V
E~~.~ e;~·~~

IGNSW

~,'
~: ~:o'
!

29
Exhaust gas senSor ~.
__ .' Approx. 0 - 1V
Deflect between a- :
signal approx. lV
i

: :
ECCS C¢lltrof unit

Morutor & check

Exhl!lusttemp
wa~mi
lamp
I
tamp !GN Lamp not lit: Lamp not lit:
i
32 (red lamp, exhaust Power vottage Power vottage

~:~f~ra~:) • ~.ECC.,on":'=l i
Lamp lit: OV Lamp lit: OV

AIC ON :OV ' Ale ON :ov

36 FICO solenoid AIC OFF: Power i Ale OFF Power
vottage voltage

To A/Tconlrol unit
0.5 - 4V (Vottage
Throttle sensor Increase when
38 Approx. O.5V
signal accelerator pedal is
r--/.--~ '~-
I ECCS control unit i : pressed)

To IVT control urnt

40 Intake alf quantity Approx. lV Approx. 1.5V

L-____ ~_~_S_'_g_n_a_I ~ _-_E~C~C·S_-'_'~O-'_~_·'_"O_"___'~________________~____~________________~____~

__

EN .. 524
 ECCSC/U INPUT/OUTPUTSIGNALS
RB25DE ENGINE

RB25DE ENGINE

: Tenninal At idle At Approx. 2,500 rpm

Signal name Circuit
No. Standard Memo: Standard Memo!
03 - 07V 0.3 -O.7V

Crank angle sensor'

41
120' signal

control unil

2 -3V

Crank angle sensor

42
l'signal

IGN

OV
Ignition switch (ignition switch
43
(START signal) START Power
OV
voltage)
..fces ca(molumt i

44
Neutral swilch
signal l__
---- .. ~
1
Nor Prange. OV
Other then N or P
range 4 - 5V
Nor Prange' OV
Other than N or P
range: 4 - 5V
I
~--
ECCS et.lnlrol unit
...- - - '
'

AlCSW

~
He~r fan SW ~
Air conditioner OFF:
Power vo~age
Air conditioner OFF:
Power vo~age

1
Air conditioner
46 Air conditioner ON:
switch signal Air conditioner ON:
. --_._-- OV OV
teeS eontrOI unrl
.--_
i
...- - - '

Intake air quantity

48 5V 5V
output signal

EN - 525
 ECCS C/U INPUT OUTPUT SIGNALS
RB25DE ENGINE

RB25DE ENGINE

Terminal
No.
Signal name I Circuit
, At idle i At Approx. 2,500 rpm I
i Standard Memo Standard Memo!

ECCSn:!lev
c-
~~~

~~
EGGS
49 Power voltage Power voltage i
GIU power supply :
i
i I

L:~cs cOntlol unit ! !

, ' .-------~

i
•
D range (or 151) with D range (or 151) with
rear wheeis jacked rear wheels jacked
1 v;S~
""",m
+ up' 0.5 - t.5V up 05 -1.5V
The value actually The value actually
Vehicle speed
53
sensor signal I deflects between OV
and 5V However, it
deftects between OV
and 5V However. it
, 1 ECCS conttOil.lnit ! :appears to deflect appears to deflect
!around1Vaccording around1V according
, i
•to vehicle speed to vehicle speed.

wrCIIJ

-
•. ~
~
.

,
,Throttle valve switch OV when accelerator
54 Approx tOY
(Idle contact pOint) : ! : pedal is pressed
I
: !

I[ ECCS'Q;';~~ !
--.---~
i

I
, To A/T control Oinil
Approx. 05 - 4V
Throttle opening • (Voltage will increase
56 ! Approx. O.5V ,
output SIgnal when accelerator
, :
pedal IS pressed)
I
t ECCS coou," uflit
I i
,i

Throttle \'~ $W

, i I Lc::j::~ i ,
Throttle valve switch
57 Power voltage Power vottage
-_
!
(power supply) !
!
i ...
ECCS oomrollJnit

Almost power vollage Almost power vottage

101
103
105 Injector contrOl
110 signal
112
114

EN - 526
 DEcELER~TIC" EXH GAS EMISSION CONTROL EQUIP INSP
RB26DE~ ""c:=« =~- CA181 ENGINE

10. DECELERATION EXHAUST GAS EMISSION CONTROL

EQUIPMENT INSPECTION
10-1 THROTILE VALVE SWITCH SHORT-CIRCUIT
(RB26DETI I RB20E I DE I DET ENGINE)
• Remove the throttle valve switch harness connector and
use a lead line to connect harness connector terminals
(2) and (3).
• The throttle valve sequence power and idle connection
points are set ON.

10-2 FUEL CUT INSPECTION

(RB26DETI I RB20E I DE I DET ENGINE)
• After warming the engine, place the transmission in to
neutral and run engine at 2000rpm.
• Lower the speed to approx. 1000 rpm and then raise the
speed to 2000rpm again and check for fuel cut.
• If the accelerator opening angle is fixed, the procedures
described above will be repeated,

(CA18i ENGINE)
• After warming the engine, lift up the rear wheels and
remove air cleaner case cover.
• Place wheel stopper, hand brake and apply foot brake.
• Start the engine and place the gear into D range (Arr
vehicles) or 4 or 5th gear (MfT vehicles). Run engine at
over 2000rprn,
• Check if the injector fuel injection will stop operating
when the accelerator pedal is released, and start again
when the engine speed decrease to below approx,
1600rpm,

10-3 DASH POT INSPECTION AND ADJUSTMENT

System inspection (CA18i ENGINE)
o Warm the engine and set the engine rev counter,
o Increase the engine speed to extend dash pot stern,
o Close the throttle valve slowly and check the engine
speed when tip of the dash pot stem and the Ihrottle lever
contacts,
<:(' "\ ; ;" ,,<> '
i~~~ ~~j'" M!T Approx. 3000
;:;, ·····1·· A iT I Appro .. 2200

• Check if the dash pot will move and resistance can be fell
when the dash pot stem is pushed, Also check if it will
relurn to normai pOSition when hand is removed.
Adjustment
o Adjust using adjustment knob on the throttle lever side
when contact speed is not at standard value.

EN - 527
 AIR CONDITIONER CUT SYSTEM INSPECTION
RB26DETT ! RB20E / DE / DET / CA 18, ENGINE

10-4 AB VALVE INSPECTION (A I T VEHICLE)

• Remove hose connected to A and place your finger to A.
• Increase engine speed to 3000rpm and close the throttle
valve suddenly. At this time check if your finger will feel
any suction for 1 to 2 seconds.

11. AIR CONDITIONER CUT SYSTEM INSPECTION

11-1 AIR CONDITIONER CUT SYSTEM FUNCTION INSPECTION
• Turn the air conditioner switch to ON position when the
engine is idling. Check that the air conditioner
compressor will turn ON and then OFF.

EN - 528
 ENGINE ELECTRICAL EQUIPMENT
RB26DEIT! RB20E I DE I DET I CA18i I RB25DE ENGINE

EN4 ENGINE ELECTRICAL EQUIPMENT

PREPARATION TOOLS

Hydrometer Batter! specific graVIty Inspection

CircUit tester Resistance, voltage inspections

SPECIFICATION

S114-445 S114-445 S114-505

(LO) (1,0) (1
Mff:M3T27686D,
(0,8) I M3T-41185 M3T-41185 M3T-41185 M1T-70685 I
AfTM3T27686H, (1.01 (1.0) (10) 114)
(1,0)
S114,505 S114,505
(14) (1 4)
MiT-70685 M1T-70685

IN sfde:
SMC-102
SMC-200 MPC,302 MPC,302 MPC,302
EX side,
SMC-152
06188-01 D6188,01
D4P82-08 (crank angle (crank angle
sensor)
T2T49171 T2T49171 TOT49171
TOT61271A TOT42071 (crank angle (crank angle (crank angle

BCPR5ES,11 PFR5A,11 PFR5A-11 PFR6A-11

PFR4A-11 PFR4A-l1
BCPR4ES-11 BCPR4ES-11 PFR5A-l1
PFR6A-l1 PFR6A-11
BCPR6ES-11 BCPR6ES,11 PFR7A-l1
PFR7A,11 PFR7A-l1

1,1 1,1 11 1,1 1,1

Note: The battery capacity value is the 5-hour rate that conforms to the new JIS standard
and the value is 80% of the former 20-hour rate,
[New model name] (example) 34 B 19 A

~t
eJ';lna~laritY position
B tteCJ'~ngth dimensions (rounded off)
atte Idth x box height classification
Perf ance rank (starting function added to 5hr capacity)
EN - 529
 ENGINE ELECTRICAL EQUIPMENT
RB26DETT! RB20E i DE i DET i CA1S; I RB25DE E~,GINE

1. BATTERY INSPECTION
Voltage inspection
Normal (V) I 124 - 128
L,mlt (charge required)
I(Start limit)
(V)
(V)
'. l___
.
12_A_,or I_es_s_ _-..;
12 (20°C)

Specific gravity inspection (20°C)

I
:Normal 1.29-1.22
:limlt (charge required) (V) 1.22 or less
i
· There is a vanation width of more
Iservice life
I than 0.04 between each cell
Additional water does not need to be added to the battery
during service life of normal driving. When driving for
extended periods of time in high temperatures, the fluid level
may decrease according to the vehicle driving conditions.
Check the fluid level with the level indicator (upper flower)
and top up to the upper level as necessary,

Caution: Distilled water must be used to be added to refill

the battery. If ordinary water is used, fluid loss will increase
and may cause discharge,

2. ALTERNATOR
(1) Alternator removal and installation

CA18i ENGINE RB ENGINE

wasner~ ...."';~'~
.I
,---- "'-~

"M
1.0-:-.2 Bolt
I Bolt 1.4 - 1.7 . ' . ' Nutt'll' I Allern~tor..
..~

J 'c1' t'll
I ,jf"
.
0.4 - 0.5 :
, ,,, '
,i!,J ! Ii . ,,\washer
, 0.4· nuti
o.S
,
.,~, I

~,. ~~~ppe, I
I

I8011 5.0 • 6.0' ~Olt,

, t'll~,,,, ~. Stopper nut;
Washer ! ~ ,::':
Seacer 0.4 • 0,5 I
'Bolt 5,0 - 6,Ot'll L~' "'8'''' Washer_ _ __

(2) Alternator inspection

Output voltage inspection
• Place ignition switch to ON position and check that
charge warning lamp will light.
Standard (V 1 rpm) 13.9 - 14.9 12000 (accessories OFF)

EN·530
 ENGINE ELECTRICAL EQUIPMENT
RB26DETT i RB20E i DE! DET I CA181! RB25DE ENGINE

3. STARTER MOTOR REMOVAL & INSTALLATION

CA18i ENGINE RS ENGINE

Bol: 3.1 - 4.1

-"st,,,ter motor

- _ .... -_ __
......... ...

4. SPARK PLUG INSPECTION

Inspection
• Check for any looseness with terminals.
• Check for any damage or cracks on the insulator
• Use thickness gauge to check the spark plug gap.
Spark plug gap (mm): 1.0 -1.1

5. PLATINUM PLUG INSPECTION

(RB20DE, RB20DET, RB26DETT)
Installation precautions
Periodic replacement interval: 100,000km -----Platinum lip~
• Gas inspection and adjustment and plug cleaning using Seating m<'(tal \.
~." ,
wire brush. should not be performed as this may scrape
~
'!:it I
off the platinum partucluate from the platinum tip surface.
If plugs are cleaned with an air gun, the cleaning should
be performed in less than 20 seconds at an air pressure
less than 6. Okg I cm 2 •
• Only use parts specified by Nissan, when replacing the
spark plugs.

EN .. 531
 ENGINE ELECTRICAL EQUIPMENT
R626DETI ! RB20E j DE i DET I CA 18i ENGINE

6. IGNITION COIL INSPECTION

RB20E ENGINE RB20DE I DET I RB26DETT

.~~~ Seeo ry Side ~~- ... ..-
-~~

Q
! Primary ~
..
, sIde j __ -
i '.---

· t=
! ~
• Check the primary and secondary coil resistance value.

Primary resistance 0.7-1.2 0.8 - 12 06 - 0.9

Secondary resistance 7 - 12 7 - 12

EN - 532
 COOLING SYSTEM
RB26DETT! RB20E I DE I DET I CA 18i I RB25DE ENGINE

ENS COOLING SYSTEM

PREPARATION TOOLS
~H<~~,
Radiator cap tester
EG1765 0000
Radiator and cap pressure test I
Radiator cap hose adapter
Small cap adapter
EG1765 0301

SPECIFICATIONS

1.9 1.9 1.5 15 L5

0.9 0.9 0.9 09 0.9

650 650 815 1080 1380

'Nith (AlT) With (AfT) With (AiT) With (AfT)

Plastic Plastic PlastiC PlastiC :?Iasti:

Alumium AJumium All.llium ,A IUiTllurr :., UrT',~rr

One piece unit (lower shroUd)

410 x 7 420 x 8 420:i 5 42-::' 'i :: .!: ,- ;

~

2 levels 31e\f€1$ 3 :evels 3 !e'v'€-,s 3 levels

~BC x5 320 'X 4

80 160

90 90

82 - 88 76.5 76.5 76.5 76.5

30 - 50 30 -50 30 - 50 30 - 50 30

Appro" 0.7 Approx.O.7 Appc"'( 0.7 Approx 0.7 App'C" 0.7

Approx. 7 Approx.8 Approx 9 Appro" 9 Approx.8.7

EN - 533
 COOLING SYSTEM
RB260ETT i RB20E ! DE ! DET ! CA 181 I RB25DE ENGI i'lE

1. RADIATOR INSPECTION
Cooling water teak inspection
• Use radiator cap tester and apply pressure (limit 1.0kg!
cm2) and check for leakage.
Caution:
When using the radiator cap tester, always make sure to \
'\
connect the hose adapter and filler cap is not deformed. ,
\
,

2. RADIATOR CAP INSPECTION

Inspection
• Clean cap rubber packing seal surface and vacuum with
dry brush.
• Attach radiator cap tester to cap. Apply pressure and
check that valve operates correctly.
RaCllator cap relief pressure (kg/erne) I 06 - 1.0

• Pull vacuum valve with finger and check operation.

3. COOLING WATER FILLING PROCEDURES

1 Make sure the radiator hose and heater hose clamps are
lightened securely.
2 Set the heatercontrolleverto HOT position. (For
vehicles equipped with automatic air conditioners, first
place ignition switch to ON pOSition and remove the
extemal sensor connector).
3 Release the radiator cap and air drain plug. (RB20E:
Intake manifold collector area. RB20DE / DET: Intake
manifold collector area and in front of glove box).
4 Fill the radiator gradually (filling speed: slower than 2L I
min) to the top of the spout with coolant Fill the radiator
until the water in the reserve tank reaches the MAX level
line indicated.
5 After closing the radiator cap and air drain plug (RB
system), start the engine and allow it to idle.
6 The engine will continue to idle until the thermostat
opens. (Touch the radiator flow hose and make sure hot
water is flowing). If a large volume of air remains. the
water temperature gauge needle will move past the
middle as the engine temperature rises abnormally. If
this occurs, stop the engine wait until it cools and add
water to the radiator repeatedly as described above.
Atter the thermostat opens, race the engine for 10
seconds at 2500rpm two or three times. Check that
the water temperature does not rise excessively.

EN - 534
 COOLING SYSTEM
RB26DETT! RB20E! DE! DET! CA18i! RB25DE ENGINE

7 Stop the engine and allow it to cool, Release the radiator

cap and check the fluid level. If the fluid level lowers,
return to step 4 and repeat the process,
OR vehicle equipped with automatic air conditioning,
connect the fresh air sensor connector,

4. RADIATOR REMOVAL AND INSTALLATION

CA18i ENGINE

IRl kg-m
RB ENGINES (RB20E I DE I OET I RB250E I RB26DETT)
AB20E
Net· (2) 0 .33 - 043
,
Radiator mounting
bracket (uppen ~ Bolt 0,33 - 0,43
Re-
A ~
--a /"
Radiator cap
'. .
Radla,or hose
\
\ /1 server
tank/
R.adlator I I (cpper)~~
mounting --1' "~_~~B200E. D ~I

(upper) " Radiator • ~ i/J,~~ fit ." - rPJ HoseclamD

, !
'fIountmg,
Thermo
--SWJtch
,,- / O~251
, / Nut 0,33 - OA3.
0.26 Radiator
hose
(upper) ~ Ho~e clamp . ~Radlator (upper)
'I . '~do 0.2. - hose
~lf}.~ ~ ~ (lower)
.... ..... Radiator hose I'lower)·
~..-s;Y-", I . = '''" V/ rPJ ~~~I" L-===--=~=4
I /rli"":,,, /"t-~' .~\ Hose clamp /
. /
t
f Y I )'..."'-'\ r, ~ 025~02
Radiator ., i '..... AIT 011 cooler' .
ASSY I
Radiator
\'
Hose ! IJ ~ose (AlT)
I Hose ci r~
'~AO·<c""r,'·1T
/
· k \, ,
d r~lIn COC \ clamp ;; /
Radiator ~,_ !C~-?
mounting
rubber (lower)

Radiator shroL.d (upper)

IRl kg·m
EN·535
 COOLING SYSTEM
RB260ETT! RB20E I DE I DET 1 CA18i! RB250E ENGINE

Additional work required:

• Drain and fill cooling water
• Remove AfT oil cooler hose (AfT vehicle)
• Remove supplementary electrical fan connector r-;:;::' --'-.. I

, Radlato.'
B S.hro.1 1 : : 1
' -. .
n "" /
. IUP;?1P I.
~-~c::-,' Hook Pusn,
[Point 1] Radiator shroud (lower) removal .'«"",12 I

~
• While pushing hooks (left and right 2 locations) to '~l~awls. IIrr
.....;.;... .
release, remove pawls and detach shroud. .j ~/ 1/

~ ~diator
- /'.'-Pusfi
-': C .--<
"-
{lower)
shroud
,

5. SUB ELECTRICAL FAN INSPECTION

(RB20DET I RB26DETT I RB25DE)

Operation
I
1 Thermoswltch ON
Radiator fan ON condition
~______________~(~e~ng~i~ne~.t=e~m=p~er=a=tu=~=o~v=e=r~90=o=C~)
'1

Function inspection FUSClf18

Radlatcr
• Place ignition switch to OFF position and remove switch tan relay SW .".

harness connectors and short·circuit harness connector.

• Check that fan motor operates correctly when ignition
switch is placed to ON position.
Thermoswitch inspection
• Heat thermoswitch with high~temperatu re water or oil
(heat with heat gun, for example) and check if it conforms
to values in chart below:
Valve rised Valve rised:
90 +/- 3 max 90 +1- 3 min.
Valve lowered: Valve lowered:
83 +/- 3 max. 83 +/- 3 min.

Non-continuity Continuity

0.3 - 0.5

6. THERMOSTAT INSPECTION
Inspection
• Check that valve opening temperature and maximum
valve lift conform to specified val ue.
• Place a string in thermostat valve and inset it in container
of water. While holding thermostat heat the water.
• The valve opening temperature is the temperature when
the thermostat falls off the

EN - 536
 FUEL SYSTEM
RB26DETT I RB20E I DE I DET I CA 18i I RB25DE ENGINE

EN6 FUEL SYSTEM

PREPARATION TOOLS

Name

Clrc~lt tester Fuel gauge inspection

SPECIFICATIONS
..... RB26DETT

None

EN - 537
 FUEL SYSTEM
RB26DETT I RB20E I DE i DET i CA 18i i RB25DE ENG~~JE

1. FUEL TANK REMOVAL & INSTALLATION

Filler tube [Point 4J

y/

:...1c~'L-- Fuel tank protector

Bolt (4) 0.33 - 0.43 (Point 3J

Additional work required:

Drain fuel
Remove the following:
Fuel pressure relief valve [Point 1]
Fuel tank internal pressure relief
Filler tube protector
Inspection hole cover [Point 2]
Fuel gauge unit. fuel pump harness connector [Point3]
Fuel tank protector
Hoses

[Point 1) Fuel pressure relief

• After starting the engine. remove fuel pump fuse and wait
until engine stops. Crank engine 410 5 times to consume
fuel in lines.
• For vehicle which can not be started, remove fuel pump
fuse, crank engine 4 to 5 times to consume fuel in lines.
CaUjiQJ1
The battery may become weak easily, use booster cables to
connect it to another vehicle or battery if necessary.

[Point 2] Inspection hole cover, harness cover, fuel

gauge unit harness connector removal &
installation
Removal
Remove rear finisher and detach the fuel gauge unit
harness connector.

EN - 538
 FUEL SYSTEM
RB26DETT! RB20E! DE! DET / GAl 8; i RB25DE ENGINE

Installation
• Check that fuel gauge unit and fuel pump harness
connectors are connected securely.
• Check that fuel hose connections are secure.
Bolt tightening torque 0.33 - 045

[Point 3] Fuel tank removal & installation

Removal
• Remove feeler tube protector and detach bolt shown in
the figure on right.
• Remove feeler tube grommet from the body.
• Remove fuel tank protector, fuel tank band mount bolts
and detach fuel tank.
Installation
• Attach tank and secure by tightening mount bolt on front
side of right member to specified torque.
Band mount bolt tightening torque 28 - 36 kg-m

Protector nut tightening torque 0.33 - 043 kg-m

f!~~~-"'-

[POINT 4] Feeler tube installation ~ Tube, Fuel tank

• Use specified feeler tube bolt to install feeler tube. Feel;j'\ 't!J ) ~
tube ~'O ~!;.,.r
Screw(6~t:O I ~"O
033-043 I ,
"
'
JOint plate O-nng ~

2. FUEL GAUGE
(1) Fuel gauge ASSY removal & installation

rover

~ Fuel gauge
ASSY

EN 539
 FUEL SYSTEM
RB26DETI I RB20E! DE! DET ! CA18i! RB25DE ENGINE

Additional work required:

Remove the following:
Fuel pressure relief
Internal pressure relief
Inspection hole cover
Fuel gauge limit
Fuel pump harness connector
Fuel hose (return, feed)

[Point 1]
Fuel gauge ASSV bolts installation
• Set O-ring to fuel tank side and insert gauge ASSY inside
the tank. Tighten the bolts shown in the figure on the
right.
gaution~
Extra caution must be taken not to damage float and the
arm when installing gauge ASSY.
Only use specified bolts when installing fuel gauge ASSY. Hand start bolls

(2) Fuel pump removal & installation

Removal
• Loosen hose clamp on unit side on the pump side.
• Lift up the purnp slightly. Remove pump with the insulator
from gauge unit side bracket (PIC A).
• Remove pump side harness.
• Detach hose.
Installation
• Carry out installation operation in reverse order.

(3) Inspection
1. Float inspection
• Place the floal al the F (lever upper side) and E (lever
down side and check the resistance.

4-5 Approx.6 Approx.80

2. Pump inspection
• Apply battery voltage to harness connecter terminal 1 and
3 and check its operation.

3. Low fuel warning lamp sensor inspection

• Connect 12V to 3AW lest lamp or equivalent.
Test lamp .1
----cc'-~--:--,I r--@--, 01
• Wash sensor with gasoline or white gasoline and check . r"---~.. C2LJ
that lamp does not light after approx. 3 minutes have
elapsed.
• Remove sensor from gasoline or white gasoline and
check that lamp lights within 3 minutes.
EN - 540
 FUEL SYSTEM
RB26DETI I RB20E I DE I DET! CA18i I RB25DE ENGINE

3. FUEL PUMP REMOVAL & INSTALLATION

(1) Fuel pump disassembly

C-~~

I Y (,
~
~.~ ~~~
~-~
I ~
I ~())

~
~
/
__~_" J !

Additional work required:

Remove the following:
fuel pressure relief
Internal pressure relief
Fuel gauge

CatJtion:
• Care must be taken when handling fuel pump.
• Do not reuse pump if it is dropped.
• Do not allow dirt or debris to adhere to the filter.
• Do nottwist orturn harness.

[Point 1] Fuel hose removal & installation

Removal
• Raise fuel gauge ASSY, remove 2 hoses in tank (marked
section is outlet side), fuel pump harness connector and
detach fuel gauge ASSY.

Installation
• Check fuel hose marking, connect fuel gauge ASSY.
Position pump harness and clamp band 160mm in from
gauge ASSY connecting part and tighten securely.
• Care must be taken that fuel hose and fuel harness turn
inside tank from the right to front side of vehicle and do not
cause any interierence with float arm.

EN - 541
 EXHAUST SYSTEM
RB26DETT! RB20E I DE WET! CA 1811 RB25DE E',G!I';E

EN7 EXHAUST SYSTEM

SPECIFICATIONS

RB20DE

45 50.8 50.8 63.5 70

modium rhodium modium

Appro, 850 Approx. 850 Approx. 85C Approx. 850

Exhaust system part inspection, warning precautions

• The heat resistance and corrosion resistance in exhaust system parts and component
shape have been carefully considered in the design process, so only use genuine
Nissan parts for replacement
• Clean each connection part and connect securely, making sure there are no gas leaks.
• Always use new gaskets in the front and rear of catalytic converter.
• Always use new parts for exhaust manifold connection gasket and nuts.
• After assembling each part, when warm engine, raise speed to 2,000 to 3,000 rpm and
make sure there are no gas leaks, sealing compound leaks or sealing gaps.
• Replace parts rather than repairing extreme deformation in heat insulation panels. If
extreme amount of dirt have accumulated, clean these areas.
• When attaching heat insulation panels, make sure there is adequate clearance and no
interference between exhaust pipes.

EN - 542
 EXHAUST SYSTEM
RB26DETT i RB20E I DE i DET I CA1Si i RB2SDE ENGINE

1 EXHAUST PIPE, CATALYTIC CONVERTER & HEAT PANEL TIGHTENING

TORQUES

(1) CA18i ENGINE

Nul (3) 4.6 - 6.1 MIT l- A
t'.:lJ1
~
'l
_ . / i.:lJ\ \
Bolt ,~ , Nut (6) ~
Nut (2) 15 - 1.9 \.
Bo't' (4) ~
0.5 - 0.7
t
Bolt 121 i.:lJ
r:;.
13 - 16 8011(2) /
o5 - 0 7
AIT 1 4.4 - 5 6

...... 44-56
Boll (2) i.:lJ V'
'1l
lew
A
1 3 - 1 6i.:lJGjOlt

i.:lJ Nut 13 - 1
~
6'
__________~====~V~ie~w~B__
\
1 3 - 1.6\
Q'
~
N
ut 1 3 ~ 1 6""
~-..
- Bi

-1
I,
i

(2) RB20E ENGINE

MIT, _ A Nut (21 4 .4 - S.6i.:lJ ~ Nut 1.3 - 1" ~

F~~'"'''~W
N~t (3) 4.6 - 6.1 i.:lJ . ~ !

~~, BO·1(6)O.5-0.7~ \,13-16 Q I

!
Boll'(6) ~
0.5 - 0.7

A/~,J .44-56
l
'f'
'. Bolt !2)~
4.4- 5.6
Bolt (2) ~
~
Bolt (6) "
1.3 _ 1.6
~
•

~
\' ' Nut
i.:lJBolt 12)
~

1 3 _ 1'6
1.3 - 1 6 ,
i.:lJ

~ "I
\

\0
Nut(2! 1 5 _ 1 9\ \ View B

. ~
_ B
I
!
,
Bolt t'.:lJ
.J)l\/ View A 1.3 1.6

(3) RB20DE

A Nut (2) 4.4 - 5.6~

Nul (3) 4.6 - 6.1 toJMIT,... -
, I A Bolt 0.5 - Q.
\ ,

Bo!t (6)
0.5 - 07
,

A
~
IsL 0.6 .'-l
....
'BO.II (2).-.
4.4 -
Be,t (2) ~
4.4 - 5.6
Boll(6)05-0.7~
,.."
~-
Nut (6)
1.3 - 16~
_.

Bolt (2) -
A
/,7

1.3 - 1.6 ~,
(5011
,/ ,
MIT Bolt

'
~'! i
1.3 - I 6~1'
\

1.3 - 1.6' .. '

, l
J B
.
'
ii,
I'
.
I'.
j "\\ I ..:.J ~Nut1.3-1_6 ~ \. •
"='
l , ----- ,-~,-- ' . - -..•
View A
- - - - - , - - - , - - --,,'-,--,----,,---,-----
ViewB Nu,1.3 1.6i.:lJ

(4) RB20DET
, ~ .. --~. "-- ,.,--~ -- .::::::,,-;:--..AiT-- ------1
I' Nut(3)46-6l ~IT A Nut(2)44-5~~~1 K
ABo'1 I 0.5,07
""'Ie'
~ L_ ~ Nut (2) 1 5 - 1 9 A
I!
i .t-=Jl=' " ~..
~Bolt(6)05-07'
"-JI
M/T~
I

i
"

Bolt 12)/ ~
0.5 - 0 7
A IT ''br 4
. 4
'\ Go't (2) ~
- 56
Bolt (2) toJ
~-~ - 1 6(2) '/~;ml
• 1 3 Bo,t
13 _ 16
A' 'Boll
1.3
Nut (6) ~
Bolt ~ \'
13_16 '

~
\, I
1 E7\
'
_ B

! ~ 4.4-5,6 :..c; ANull 3- ;.6 0 '-Nut 13-16~

l.____. _____~____ "_ Vlew_!?_",,_ '_'"'_ _

EN - 543
 EXHAUST SYSTEM
RB26DETT I RB20E i DE! DET I CA18;! RB25DE ENGINE

(4) RB26DETT ENGINE

(5) RB25DE ENGINE

MIT

Mounting rubber

AIT

EN - 544
 EXHAUST SYSTEM
RB26DETT j RB20E! DE j DET I GA1SI j HB25DE ENGINE

2. EXHAUST GAS TEMPERATURE WARNING

EQUIPMENT INSPECTION

Basic inspection
• Place ignition switch to ON position and check that
exhaust gas temperature warning lamp does not turn on.
• Exhaust gas temperature warning lamp must light when
ignition switch is placed at START position and must go
off when engine is started.
Exhaust gas temperature warning lamp replacement
and inspection
• Remove vehicle harness from switching module.
• Use lead line to ground vehicle side harness connect
exhaust gas temperature warning lamp terminal.
• Inspect condition of exhaust gas temperature warning
lamp with ignition switch turned ON.
I..ampJlQnt. . Faufty circuit between ignition switching module.
..•.• •.•• ..••. . • • Faulty key sensing module or sensor.
••. ..•.. •.•.•.. Exhaust gas temperature warning lamp is burned
l...~p~notout
···lIght· ..•• Exhaust gas temperature warning lamp power
•.•..." ... . '. CirCUit is faulty.

EN - 545
 ENGINE CONTROL
RB26DETT I RB20E / DE I OET I CA 181 i RB25DE ENGINE

EN8 ENGINE CONTROL (INCLUDE ASCD DEVICE)

CA18i ~-~-~~,--.~

1. ACCELERATOR PEDAL INSPECTION AND . , ,~

ADJUSTMENT $ Locknut
Accelerator pedal inspection rl~Z . 0.8 ~ 1.0
• The engine must be full throttle when accelerator pedal is ,-->~"'l:;--~ ", . ,: 1'1'

pressed fully (pedal lever contacts the stopper

completely).
iA~c~~e;ator~'~,'
·Wlrt:. ~,
Accelerator pedal adjustment
• loosen lock nuts so accelerator cable has adequate
slack. Pull outer case in direction of accelerator pedal
RB20E
from position where throttle drum starts operating (there
must be no play at this point), return lock nuts 1.0 to 1.5
turns and tighten securely.

Tightening torque (kg-m) 0.8-1.0

RB20DE I DET / RB25DE

. - 1.0 I
l Torottle drum
i ASC£tWI're
. / ---'- I

Kickdown switch adjustment (RB engine A I T vehicles) . II Ii Lock nUl 0.8 - 121
• Press accelerator pedal to fully open throttle drum. Adjust i , ,rI fItl
lock nut so the gap is between 0.3 to 1.0mm. I
I !'. ,
..,:d... •. Kickdown
I
~
. 0.3 - 1.0 switch
o m'n
\ I

EN - 546
 ASCD
RB26DETT! RB20E! DE! DEI! CAlSI ; RB25DE ENGINE

2. AseD

Specification
Speed setting range Approx. 50 - 1OOkm I h
Constant speed control range Level road +0 I ·2 km i h
IMemory type 'Digital memory
Control type. actuator dnver source Negative pressure control. negative pressure pump
IActuator stroke Approx 33mm
ISet system One·touch system (with tap down system)
.
Resume system Installed
Acceleration system ,Installed (with tap up system)
Over drive cancel system Installed

System
AITVEHICLE

Ignition switch
IHICAS'
t':::, vehiCleil
\..;.<"

~~--~tt, Horn relay (coil)

r~'::""H"'v ' •
Small
.
:
Vacuum: :
. :
'I ( .;t=:-
- ' I 'Cruise
,'123(:::}* "Iamp
Ughl : Air valve :Set: 1 ReS;Jme~/' Cancel ~
SWitch , ~.
-,,,.--.r- !
lena - I cceler -""
: SIN!' , ';!
C '
~I ~ Horn
"9,,., ...
~~~!~a~l?ELy~I:t~SWltc Switch J SWltc"

M/TVEHICLE

Igmtior, swi~ch
_~
~I !
_____---+
I a i,i ~~ -+1 Ii! II I
EB A ! T control unit

FUS{J

Ll ASCD control unit

Small

EN - 547
 2·1 AseD INSPECTION AND ADJUSTMENT
(1) FAULT DIAGNOSIS

Does not operate Faulty I

set / coast
SW faulty
Resume i
accelerator SW
FauKy adjustment
parts
Main unit I Inside circuit
faulty
I Mafn unit
iaulty
Faulty val"",
faulty diaphragm
ASCD system Wiring. harness
disconnection, piPing
faulty disconnection
:IJ

Piping breakage, actuator Rl

Hunting
Inside drcult
faulty
I Main unit
Faulty response meter reSistance faulty speed '"om
meter cable :::j
:IJ
Cancel Inside CirCUit I Ma", Unit I Diaphgramn leak I faulty speed meter cable OJ
Setting
faulty '"
o
m
unstable
Large gap between h1Side CHcuit Mam umt Catch or leaK"'g o
m set vehicle speed
Actuator wire catch m
z faulty faulty dlaphgramn
.,' -- o
<.n Vehicle speed Faulty actuator Wire ~
~ inSide circuit Main Unit
()O decrease when adjustment faulty pipings ()
setting
faully fautty
clogging :::
Does not cancel
Inside CirCUit I Main unit Actuator wife locking
'"
:0
faulty Rien
o
m
m
.'
Cl
L
m

}>
(fJ
o
o
 ASCD
RB26DETT I RB20E! DE I DET I CA 18 ! RB25DE ENGINE

INSPECTION & MAINTENANCE PROCEDURE WHEN IT CAN NOT BE SET

Does not
Does main SW lamp turn ON when. turn ON
'----1 main SW IS restored after it is - - - - - I Replace faulty main SW, ASCD
i-'

!tumed OFF once. relay, power supply circuit

Turns ON
CheCK piping connection for any Faulty
faults,
I Repair piping I
NOl111al
No
Check controller ground for any continuity
faults (between terminal 3 and body, Faulty harness, inspection
ground),

i
c
ontinUity present Other than Replace faulty stop lamp SW,
Check for power votage (approx, approx,12V clutch SW (MiT). clutch relay
12V) to controller [4 - 3, 5 - 3 (HICAS MIT), inhibitor SW, relay,
; (other than P,N for AlT») ,(AlT) ;
I Approx 12V Other than
Power voltage is present when Set : approx, 12V
I coast SW is ON (Approx, 12V)
(between 7 ,3)
I I
Replace faulty set! coast SW, I
I Approx, 12V
1Power voltage is present at vehicle Other than
! speed sensor (between 7 - 3) 5V and OV Inspect vehicle speed sensor
; (Approx, 5V and OV alternatively) system,
i when wheels are rotated slowl 1
2km i h)
Approx, 5V & OV
Do not
Disconnect ASCD pump operate ; Remove actuator hose and operate i
connector and apply battery voltagel----.....,' the pump, Check if negative
,between terminal 1+ - 3', Check if pressure develop.
: ASCD wire will operate when L-----r----'----,----'
i terminal 4 and 2 is grounded,

, Operate
Control power voltage (approx, 12V) Olherthan
is developed between tel111inal8 12V
and 3, when vehicle speed ''s over
Replace faulty controller, I
48kmih and seVcoast SW is ON,
I Approx,12V
Remove controller connector and
check il pump operates when 12V Donat
and OV IS applied 10 vehicle side operate I Repalrfaulty harness to the pump I
harness which corresponds to lor short oircuit
,controller termInal 8+ and body
; ground, terminal 8+ and 9,10-,
I Operate
Other than
Check if set power voltage is OV
approx, OV between terminal 2 and Replace faulty seVcoast SWI
3 when seVcoast SW is released,

I Approx.OV

EN - 549
 AseD
f1826DETT i R820E i DE f on I CAtSI f RB25DE ENGINE
INSPECTION & MAINTENANCE PROCEDURE WHEN SETIING IS UNSTABLE
(HUNTING)

I ~~~~~NB~E I
~
.... ' - : - 1

Hunting
L---1~~~~l----1
Setting OK Check for bent or any damage 1--"--;
with vacuum piping. ' -_ _ _--'
No damage Not
smooth
Check if ASCD wire movement is smooth Repair or replace
Smooth
Check for any leak or negative pressure in f---i
ASCD pump air valve and release valve. t.:.p_u_
m.:..p_ _ _._ _-,
No leakage
r-----·...L-------,Cracked
Check for any leak or negative pressureL:==-ER~ep~l~ac~e~f~a~ul§tY~it~e~m~
in air valve and release valve I
Not cracked ; Remove actuator hose
I DlsconnectASCDpu;;'p connector-an-a--! Do not and operate the pump.
i apply battery voltage between terminal 1+ _ ; operate Check if negative
; 3-. Check if ASCD wire will operate when pressure develop.
• terminal 4 and 2 is grounded.

Operate

Replace controller

INSPECTION & MAINTENANCE PROCEDURE WHEN SETIING IS UNSTABLE

(CANCEL)

I
~ There is approx. 12V
. ; present between terminalS f
! and 3 when set SW is
; placed from ON to OFF
position. The system
automatically cancel itself.
i
Other
Voltage between resume I
I thanOV Replace faulty ASCD I
:accelerator switch termrnal1
I switch.
and 3 is OV.
I OV
Abnof111al Inspect & repiace
/IS there any abnormality with vehicle speed sensor
speed meter needle movement?
and meter cable.
I No abnormality
Power voltage (approx. 5V and OV) is Other than
applied alternatively between vehicle 5V & OV 1r:I-ns-pe~ct-:-v-e7h-;-ic7Ie-s-p-e-ed""jI
speed sensor terminal? and 3. when system. I
wheels are rotated at 1 _ 2kmfh. .. ______........J

1 Aoprox. 5V & OV
1r;:'Cc-h-ec-:k-:f-or-:le-a-:-k-a-n-:d ~egatlve pressure Leaking Iinspect & replace faultyl
lin air valve and release valve. lASeD pump I
I
[R,uity cont'o:er I Replace I
EN - 550
 ASCD
RB26DETT I RB20E / DE I DET I CA18t I RB25DE ENGINE

INSPECTION & MAINTENANCE PROCEDURE WHEN SETTING IS UNSTABLE

(DIFFERENT TO SET VALUE)

I SETTING I
UNSTABLE
I Catching
ILarge difference I Any abnormal catch to actuator I present
Replace I
to setted value or ASCD wire. I
I No catching
• Check for any bent. damage to I Damaged I Replace damaged vacuum
. vacuum piping, I I piping,
I Nodamage
" Leaking
Check ASCD pump, alf valve and release Replace faulty ASCD pumpl
valve for negative pressure and leak, I'
I No leakage
Check for any leak or negative pressurel Leaking
Replace faulty ASCD pumpl
in air valve and release valve, I
I Not cracked
Operate
Disconnect ASCD pump connector and abnormally
ground terminal 1 + - 3-4,2, Check If
I Re
p
lace faulty ASCD I
ASCD wire wiil operate normally, I pump,
I Operate normally
I Faulty controller, Replace cantrolier.1

INSPECTION & MAINTENANCE PROCEDURE WHEN SETTING IS UNSTABLE

(Plunge in vehicle speed)

SETTING
UNSTABLE

Plunge in vehicle
speed when selling
I rPlunge in vehicle
y speed after selling
Not correct
Check if ASCD wire play is I or smooth I Replace or adjust ASCD I
normal and move smoothly, I I wire play, !
i Correct play and smooth

Check vacuum pipes for bent orl Damaged Repair. I

damage, '---':--L~~:...J
INodamage
=--,----':=--,-",-'-,.",---, Other
There is over 1OV control voltage than 12V
for controller output between ~~2.:.::"~R~e~p~la~c~e~fa~u~lt~y~CO~n~t~ro~lIe~rJI
terminal 8 and 3 Just after setting, I
I Approx, 12V
Disconnect ASCD pump connector
and ground terminal 1 .. - 3-4.2, Check
NG Replace faulty ASCD I
pump,
if ASCD wire will operate normally, .
I OK
I Faulty ASCD pump Replace, I
EN - 551
 ASCD
RB26DETT I RB20E I DE I DET! CA1811 RB25DE ENGINE

INSPECTION & MAINTENANCE PROCEDURE WHEN ACCELERATOR DEVICE

DOES NOT OPERATE

Acceleration device
do not operate

l I' Check 'f constant speed I Does tnot

I ~evice will operate using f opera e
IlnSpeCtfollowmg the steps of
"Can not set', I
seticoast Sw.
- I Operate
When stopping place Check if power voltage approx. 12V is 1 V
ignition SW in ON present when resume I accelerator SW in hher than 2
position with main SW in ON position (OV between terminal! and 3). I
ON pOSition. Do nol
l-
•press brake and clutch I Approx. 12V
. (OFF position). IF AfT
ICheck if po~er voltage is OV between 1 - 31 I Other than
vehicle, place in D range
and apply park brake. when resume i accelerator SW Is OFF.
OV
IRepairfaulty SW I
.

OV
Do not
Check If speed will Increase when Turn off the main switch for
increase
Ehlle crUising ASCD resume I accelerator SW Is placed few seconds and turn it on
in ON position. again.

lr
i
r
Check If speed will increase
I
Replace faulty
~.
Donat
. when resume J accelerator increase controller and
i SW is turned to ON pOSition. vehicle speed
t

; sensor,

Do not Check If vehlcie i ; Replace faulty I

Check if the vehicle will crUise at speed will increase: Increase controller and •
normal vehicle speed when resume -==~ r'
; to high-cut vehicle vehicle speed
:i accelerator SW is turned OFF. speed (100km I hJ. sensor.
! Cruise
Do not increase

I No~al I Replace faUlty controller

EN - 552
 AseD
AB26DETT i AB20E I DE! DET i CA18i / AB25DE ENGINE

INSPECTION & MAINTENANCE PROCEDURE WHEN RESUME DEVICE DO NOT

OPERATE

!Resume device do
•not operate
Does not
I Check If constant speed
device will operate USing
operate I Inspect follOWing the steps of
set/coast sw.
I "Can no! set". I
r- I Operate
When stoPPing piace Check if power voltage approx. l2Vis Otherthan l2V
ignition SW in ON present when resume / accelerator SW in I -
position with main SW In ON position (OV between terminal 1 and 3).
ON position. Do not
press brake and clutch
(OFF position). IF AfT
- T Approx. l2V
Other than
vehicle. place In D range •Check if power voltage is OV between 1 - 3\. OV
I
Repair faulty SW
i when resume / accelerator SW is OFF. .
!and apply park brake.
'-
I OV
: While cruising
rI
Set vehicle speed to 80km
using set i coast Sw.
i hi
T
I Break (Make sure the vehicle speed I
will not get below 48km i h).

I
ICheck if the vehicle speed will decrease when, Do not
decrease
.resume SW IS turned ON ( Make sure the ' Replace faulty controlier.
:vehicle speed will not get below 48km / h)
Decrease
Other than

~~Ier~~~fr~ht~ ~~~~~~~:ed f-.: :~",~ ,-, ~, -,r.'. ;h.: ~ n;!;r-e-~-o~-d-:-:-:-~-~-~-r~-~-~-~-d-tO"""'L.:.:=':':"':':""; Replace faulty
speed (60km j h) when controller.
resume SW IS turned OFF.: resume SW is turned ON.'
80km ! h _ _ _ _ _ _ _ _ _ _---" Below 48km! h

Normal

EN - 553
 ASCD
RB26DETI I R820E! DE i DET ! CA181 i RB25DE ENGINE

INSPECTION & MAINTENANCE PROCEDURE WHEN IT CAN NOT BE

CANCELLED

SETTING CAN NOT

BE CANCELLED
,
i
Is voltage between terminal 5 and 3 '
OV when brake is operated (in N
range)?
NG I Reolace faulty orake SW
lor N,P SW
I
I

I
OK

Check if voltage IS present between ~~N~G~_~~~~~~~~~§~~

terminal!! and 3 when brake is Inspect and replace stop lamp SW I
operated,

I OK
'-=:--:-::c---
'Check If controller output IS cut
i NG
between (8 and 3) when brake Replace faulty contrOller
pedal is pressed,
OK
NG
Is there an actuator fault. Inspect and replace actuator i
OK
lis there harness short circuit.1 NG
I Inspect and replace harness, I

(2) FUNCTION INSPECTION

• ASCD function inspection is carried out by driving the vehicle and checking if each
function will operate normally, In this function inspection ASCD control circuit system
function is inspected using free roller,
Qautio!];
Constant drive can not be achieved by ASCD as it is non-load drive on the free roller, Use
(1) fault diagnosis as a reference depending on each problem when carrying out fault
diagnosis,
• Turn ON the main switch when ignition switch is placed in ON position and check that
operation lamp will turn on,
Caution:
There is a fault with main switch or ASCD relay if the lamp does not turn on,
• Check that the cruise lamp will turn on when driving at a constant speed (60 km/h) and
set I coast switch is placed to ON position. Check if the vehicle speed will increase for
a moment. crUise lamp will turn off and constant drive can not be achieved when
accelerator pedal is released and set I coast switch is placed to OFF position at the
same time,
Caution:
If ASeD circuit is normal, hunting will occur andASCD will be cancelled as it is non-load
drive.
• Check that the cruise lamp will not turn on when set switch is pressed when the brake
pedal is pressed slightly (brake switch: OFF, stop lamp switch: ON), driving at a
constant speed (60 km! h), Make sure the vehicle speed will not increase when the
accelerator pedal is released and set switch is placed to OFF position at the same
time (release function inspection),

EN" 554
 ASCD
RB26DETT I RB20E I DE! DET ! CA 181! RB25DE ENGINE

(3) COMPONENT PARTS INSPECTION

Controller inspection
• Extract the controller by removing controller bolts. Inspect
ASCD control system using controller connector parts. If
diagnosis result is faulty replace the controller unit.

Controller (ground circuit) inspection

• Check the continuity between terminal 3 and body ground
with connector connected.
Between terminal 3 and body ground ContinUity present

Controller (power circuit) inspection

• Inspect power voltage between following terminals with
connectors connected.
.,
finisher interior

OV Approx.12V OV

Controller (cancel power supply input) inspection

• Measure the voltage between terminal 11 and 3 when
connectors are connected.

Controller (set I coast switch input) inspection

• Place ignition switch to ON position. Measure the
voltage between terminal 1 and 3 with connectors
connected.

EN - 555
 AseD
RB26DETT ! RB20E! DE I DET! GA18;! RB25DE ENGiNE

Controller (resume I accelerator switch input)

inspection
• Place ignition switch to ON position and measure the -- ----~ ... --~

Jasr: sloe :Qwer finisher interim 1

power voltage between terminal 1 and 3 with connectors
connected,
MaId_ftcti l ;! •

- - - ---
RighI dash side
.-.--~ .---c-......,
finlsh(f interior
Controller (vehicle speed sensor output) inspection
• Slowly rotate the rear wheels and measure the voltage
between terminal 7 and 3 with connectors connected,
1{:"j~3{") . i-I Approx. 5V and OV altermallvely

Controller (cruise lamp output) inspection Right dash side lower .fim$her intenor
. >"'p"o '
• Measure the voltage between terminal 13 and 3 with
connectors connected,

.~--- - ..- .. ------'-~.- -~~-

Controller (AfT control unit control output) inspection

[A/Tvehicle]
• Drive (ASeD set possible range) and measure the
voltage between terminal 12 and 3 with connectors
connected,

Note:
With AfT shift control, ASeD controller is prioritized when
set at ASeD drive,

EN - 556
 ASCD
RB26DETT R320E / DE:; DET ! CA18i! RB25DE ENGINE

Controller (valve output) inspection

• Drive (ASCD set possible range) and measure the das~ side
I,R!cht
~
ii'1istler :n1enQr
,:
voltage between terminal 8 and 3 with connectors ,
I
connected.

a(+j - 3(-) Approx 12V OV

Main switch inspection

• Remove harness connectors and check the continuity
between following terminals on main switch side
connectors.

Continuity
No continUity
present
Continuity
No continuity
present
Continuity
No continuity
present
ContinUity
No continuity No continuity •
present
Continuity ContinUity
No COn!inUlty ;
present present
ContinUity Continuity Continuity
present present present
Continuity ContinUity ContinUity
present present present

Set I coast, resume I accelerator & cancel switch

inspection
• Remove horn pad and harness connector. Operate each
switch and check continuity between following terminals.

ContinUity

Contmuity
present
Continuity
No contrnUity

EN·557
 ASCD
RB26DETT! RB20E I DE! DET! CA 1811 RB25DE ENGiNE

Brake, clutch & stop lamp switch inspection

• Disconnect harness connector and operate each
switches to inspect continuity between following
terminals.

ASCD relay inspection

• Remove ASCD relay and directly apply battery voltage
between terminal 1 and 2. Check the continuity between
terminal 3 and 5.

Clutch relay inspection (HICAS MfT vehicles)

• Check the continuity between following terminals when
battery voltage is directly applied between terminal 1 and
2.

3-5 Contmulty present

3-4 Continuity present No continuity

Inhibitor (N.P) relay inspection (AfT)

• Check the continuity between following terminals when
battery voltage is directly applied between terminal 1 and
2.

6-7 No continuity Continuity present ,

Continuity present No continUity

EN - 558
 ASCD
RB260ETT I RB20E i DE! DET /CA18i i RB25DE ENGINE

AseD pump inspection

• Remove connector terminals. Check the motor operation
by directly applying battery voltage between terminal 1
and4.
Apply battery voltage betweebn
Motor will operate
termlnai 1 and 4

Resistance inspection

..••.. TeFlllirlais ..•. . ..••.. . ; . >!. /t~I8ta~~~ ,a

Alf valve 1 - 4 Approx. 70
Release valve 1 - 2 Approx. 70
Vacuum pump ~ - 3 Approx. 8

Operation inspection
• Apply battery voltage between terminal 1(+) and 3(-) and
check if ASCD wire will operate when terminal 4 and 2 is
grounded. RB20E

AseD wire adjustment

• Loosen lock nuts so ASCD wire has adequate
slack. Pull outer case in direction of actuator from
position where throttle drum starts operating. return lock
nuts approximately 1 turns and tighten securely.
Lock nut tightening torque (kg·m) 0.8 -1.0

RB20DE I DET
,--- Tcck-nut
i Throttle

Front

EN - 559
 ENGINE MOUNTING
RB260EIT I RB20E 1 DE 1 DET I CA1811 RB2SDE ENGINE

ENGINE MOUNTING
FRONT ENGINE MOUNnNG

(1) CA181 ENGINES (2) AS ENGINES

fi Bolt (3) ".4 - 5.8
I» ,Nut (2) 4.4 -
2.2 -
2.9

REAR ENGINE MOUNnNG

(1) CA181 ENGINES (2) RS ENGINES

)-,
/~\ Ir Nul (2) 4.4 - 5.8
Bolt (2) Bolt (4) ( 0 \1•• (1)
4.4 - 5.8
801(2) I } 4.4 _ 5.8 4.4 - &..8 . , •

~_5~frl<-
~ (ot)
4.4 - 5.8
Nut (2) 2.2 - 2.9 Nut (4) 2.2 - 2.9

EN·.. 560-
 Index
Symbols
2-pole lift ..................................... . . .. G! -13
4WD inspection ....................... .. ". GI 15
4WD repair precautions ..................... . . GI - 15
A Emission control equipment ........................ EN - 7
A / T control (RB25DE) ............................ EN - 421
MCvalve ................................ EN 274. 443. 484
Active test ................................................ EN - 270
Actuator system inspection ...................... EN - 302
Air cleaner element ..................... EN - 49, 58. 151
Air conditioner relay ................................. EN - 433
Air conditioner signal ................................ EN - 399
Air duct & air cleaner ............................... EN - 151
Airflow meter ................................... EN - 407, 482
Air flow meter sensor (RB20) ............ EN - 361. 363
Air regulator ............................ EN - 275, 445. 485
Alternator ................................................. EN - 530
ASCD ...................................................... EN - 547
Automatic temperature adjustment ............. EN - 51
B
Balance tube .............................................. EN - 68
Basic inspection .............................. EN - 236. 272
Battery inspection .................................... EN - 530
Belt tension................................................ EN - 43
Blowby control valve ........................... EN - 55. 489
Blowby gas reduction device ...................... EN - 55
Blowby hose ............................................ EN - 489
Board-on Lift ......................... '" ..................... GI - 13
Braking periorm check ................................. G I - 15
C
Catalytic converter ................................... EN - 543
Circuit diagram ......................................... EN 279
Collector ASSV ................ EN - 59. 105. 106, 115
Components inspection (RB25DE) ........... EN - 482
Compression pressure inspection .......... ' ... EN - 42
Conical washer ........................................... EN - 80
Connector installation............................... EN - 233
Connector symbol .......................................... GI - 6
CONSULT .................................................... GI - 11
CONSULT display screen......................... EN· 265
Crank angle sensor ........ EN - 355, 356, 404, 442
Cylinder head .............................. EN - 83. 85, 170
o Idle speed inspection ................................ EN 23
Data monitor ........................................... EN - 267
Deceleration exh gas emission control ... EN - 527
Detonation sensor .................. EN - 381, 382, 417
Diagnosis chart by phenomenon ............ EN - 240
Diagnosis procedure ................................ EN - 234
Diagnostic system .................................. EN - 259
Diagnostic worksheet .............................. EN - 234
OOHC ..................................................... EN - 274
EN - 562
E
ECCS ..................................................... EN 231
ECCS C/U installation ............................. EN - 233
ECCS relay (RB25DE) ............................ EN - 485
ECCS voltage .......................................... EN - 233
Engine control ......................................... EN - 546
Engine electrical equipment .................... EN - 529
Engine mounting ..................................... EN - 560
Engine overhaul....................................... EN - 186
Engine specifications .................................. EN - 7
Engine stall ............................................. EN - 254
Engine temperature sensor .... EN - 367, 396. 482
Evaporative gas control ..................... EN 54, 488
Exhaust gas sensor ....... EN - 386, 390, 392, 415
Exhaust gas sensor heater ..................... EN - 434
Exhaust gas temp warning equipment ..... EN - 545
Exhaust manifold .................................... EN - 159
Exhaust manifold ASSY ... EN - 75, 109, 119, 142
Exhaust pipe ........................................... EN - 543
Exhaust system ............................... EN - 49, 542
F
Frontturbocharger ASSY .......................... EN 69
Fuel gauge .............................................. EN - 539
Fuel injector ............................................ EN - 156
Fuel pressure inspection ........................... EN - 53
Fuel pump ..................... EN - 303, 307, 440, 483
Fuel system ............................. EN - 52, 486, 537
Fuel tank ................................................ EN - 537
Fuel tank vacuum releaf valve .................... EN - 54
Fuel tube ASSV ........................................ EN 66
G
Gas leak inspection .................................. EN - 75
General precautions ...................................... GI - 7
H
Heater panel ............................................ EN - 543
How to use this manual ................................. GI - 2
Hydraulic Jack lifting ................................... GI - 14
Idle mixture ratio ....................................... EN 23
Idle speed control system ............... EN - 339, 346
Ignition coil ...................................... EN· 483, 532
Ignition inspection ................................... EN - 328
Ignition relay ............................................ EN - 486
Ignition signal .......................................... EN - 424
Ignition system ....................... EN - 330. 332, 412
Ignition timing inspection ........................... EN 23
Individual system inspection .................... EN - 237
Inhibiforrelay ........................................... EN - 486
Injector ............................. EN - 314,317.323,484
Input signals and control items............. EN - 239
Inspection pOints ......................................... GI - 16
Intake air temperature sensor........... EN - 378
Intake manifold ....... EN - 65, 107, 117, 137, 157
Intake manifold collector .......................... EN - 153
Intake manifold vacuum.................... .. .. EN - 275
Intercooler ...... ............................... EN - 57. 131
Intercooler air duct assembly .................... EN - 56
Intercooler in let hose ................................. EN - 56
J s
Jack stand support ...................................... GI - 14
L Six in~line throttle chamber ......................... EN - 63
Lock up release control system .............. EN ~ 353
Locker cover .................................... EN 110, 143
Lubrication oil level................................. EN - 47
Lubrication system inspection ................... EN - 47
M Starter motor ............................................ EN - 531
Measurement tools ................................... EN - 12
Multipurpose tools ..................................... EN - 12
N System figure ........................................... EN - 279
Neutral switch signal ............................... EN - 399
No.1 cylinder pressure T.D.C .................... EN - 78
o Thermo-wax inspection ............................... EN - 53
O-ring ........................................................ EN - 66
Oil & cooling water inlet and outlet ............ EN - 73
Oil cooler .................................................. EN - 99
Oil filter .......... .. ............ EN - 48, 99, 129, 149
Oil pan ................................... EN - 129. 149, 165
Oil pressure .............................................. EN - 48
Oil pump bolL. ......................................... EN -102
Oil seal................................................. EN -166
Oil strainer ...................................... EN 100, 129
On-vehicle parts ........................................ EN - 56
Operation support .................................... EN - 271
Operational sequence ................................... GI- 3
p
Platinum plug inspection ......................... EN - 531
Poor drivability ......................................... EN - 251
Poor idling ............................................... EN - 247
Power steering hydraulic pressure ... EN - 447, 486
Power supply & ground circuit ................. EN - 401
Power transistor ...................................... EN - 483
Problem confirmation .............................. EN - 235
PTe heater control system ...................... EN - 352
Purge control valve .................................... EN - 54
EN - 563
R
Radiator cap inspection ............................ EN - 534
Radiator inspection ........... .. ................ EN - 534
Rear turbocharger ASSY ...................... EN - 70
Recirculation hose ..................................... EN - 57
Recirculation valve inspection .............. EN - 50. 57
Remove and install engine ........................ EN - 180
Rocker cover ............................. EN - 76. 120, 169
Self-diagnosis .................... ,............. EN - 236. 262
Sensor system inspection ..... .. .............. EN - 354
Spark inspection ...................................... EN - 274
Spark plug ................................. EN - 76, 121, 486
Special service tools.................... .. ....... EN - 8
Speedometer measurement.. .................. G I - 15
Start signal ............................................... EN - 436
Sub electrical fan inspection .................... EN - 536
Swing valve controller ................................. EN - 73
System diagram ......................................... EN -13
T
Tensioner spring ......................................... EN - 80
Thermostat. ...................... EN - 98. 127, 148. 536
Throttle body ASSY .................................. EN - 139
Throttle sensor ............... EN - 371, 373, 419. 484
Throttle valve switch ................ EN «367, 436. 483
Tightening Torque ......................................... GI - 13
Timing belt ........ EN - 78, 82. 111, 122, 144, 160
Towing............................................ ........... G I - 13
Trouble diagnosis ..................................... EN - 231
Turbocharger ASSY .................................... EN - 68
Turbocharger failure diagnosis .................... EN - 74
Turbocharger inspection ............................. EN - 49
Turbocharger unit inspection .............. EN - 71. 134
u
Unable to start ................................... EN - 239. 42
Unstable idling ......................................... EN - 234
V
Vacuum diagram ........................................ EN - 19
Valve clearance inspection ......................... EN - 45
Vehicle identification plate location ............... GI - 10
Vehicle speed sensor ....................... EN - 397, 430
W
Wastegate valve control ........................... EN - 350
Water bypass connector ............................ EN - 67
Water outlet elbow ..................................... EN - 67
Waterpump .............................. EN-96, 126,147