Nissan Skyline R32 Engine Manual

CON4PRESSION
PRESSURE
/ BELTTENSIONINSPECTION
R B 2 6 D E TITR B 2 0 E D E D E T/ C A 1 8/i R B 2 s D EE N G T N E
Compressiongaugeinstallation
. Warmup theengineandremoveall6 sparkplugs.
. Attachthe adapterto theAllencompression
gaugeand
setrtin a sparkplughole.
Compressionpressureinspection
' Depresstheacceleration pedalfully.Turnthe ignitionswitchto STARTpositionandcrank
the engine.Readcompression pressureand the enginespeedoncethe gaugeneedle
stopsmovrng.
. Whenenginespeedis out of specifications, checkthe specificgravityof the batteryand
performtestagainif the batteryis functioningproperly.
. lf the compression pressureis stillnotstandard,inspectthe componentsaroundthe
combustion chamber(valves,valveseat,hydraulic valvelifters,pistonrings,cylinderbore,
cylinderhead,cylinderheadgasketetc.).Correctany malfunctions and repeat
compression test.
3. BELTTENSION
INSPECTION
AND ADJUSTMENT
Inspection
shouldbeperformed
Theinspection whentheenginecoldor morethanthirtyminutes
after
theengine
hasbeenstopped.
RB26DETT
/ RB2ODE,
DET/ RB2sDEENGINE
an.trs
Standard Poly-V low- I - 10 9- 10 tc

Power steeringbelt
With HICAS maintenancebelt 8 - 10 10-12 16
Poly-V low-
Air corditionercompressorbelt 6-8 7-9 12
maintenancebelt
Poly-V low-
Fan belt 3-5 4-6 7.5
maintenancebelt
EN-43
& ADJUSTMENT
BELTTENSIONINSPECTION
/ D E / D E T/ C A 1 8 /i R B 2 s D EE N G I N E
R B 2 6 D E T/TR B 2 O E
RB2OEENGINE
. llew Tension limit
Poly-V low-
Powersteeringbelt 8- 10 9- 11 15
maintenancebelt
Poly-Vlow- 7-9 12
belt
comPressor
Air conditioner 6-8
maintenancebelt
Poly-V low- 7 5
Fan bett 3-5 4-6
maintenancebelt
C A 1 8 iE N G I N E
Belt def€ction (run)
lokg of force lE appfcd at tha
- '
V Po3ltionl
Adluslrnsnl Tenrlon llnit
Poly-V low-
Power steeringpump bett I - 11 10-12
maintenancebelt
Poly-V low- 6-8 7-9 12
Air conditionercomPressorbelt maintenancebelt
Poly-V low- 4-5 4.5 - 5.5 6
Fan belt
maintenancebelt
Caution:
.1. Whenthe beltis replacedwitha newbeltincreasethetensionslightlymorethanfor the
usedbeltto allowfor wear-inof the newbelt.
"Adjustment" value.
2. Whenthe beltdeflectionexceedsthe limit,adjustto the
3. Makesurethe pulleygrooveis alignedcorrectlywhenthe beltis installed.
Adjustment
lTEM
PART .... , ,
Power steering belt Adjustment bolt in power steering pump
Air conditioner compressor belt Adjustment bolt in idler Pulley
Fan belt Adiustment bolt in alternator
EN.44
VALVECLEARANCEINSPECTION
& ADJUSTI\,4ENT
R B 2 6 D E i i R B 2 ' E D E D E Ti C A I B i/ R B 2 5 D EE N G I N E
4 . V A L V EC L E A R A N C EI N S P E C T I O N
AND ADJUSTMENT
Additionalwork required(removethe followingparts):
. Air duct
. Rockercover
Inspection
. Inspectthevalveclearancewhenthe engineis cold.
. Removethe airduct,ornamentsandthe rockercover.
. Rotatethe crankshaft and aligncrankshaftpulleymarkwiththe beltcoverindicator.
. No. 1 cylinderis at the compression stroketop deadcentrewhenboththe intakeand
exhaustsidecamsdo notmovethe valvelifters.
i V"lu"" to be adjusted
lntake side
INTAKESIDE C y l i n d eN
r o . 1, 2 , 4
E X H A U S TS I D E Cylinder No. 1 , 3, 5
F i r i n go r d e r : 1 - 5 - 3 - 6 - 2 - 4
Exhaustside
. Rotatethecrankshaftone revolution (360.)andalignthemarkon thecrankshaft

pulleywith
(No. 'l cylinderpistonexhaustT.D.C),
the beltcoverindicator.
I N T A K ES I D E C y l i n d e rN o . 3 , 5 , 6
E X H A U S TS I D E CyiinderNo. 2, 4, 6
Valve clearancestandard value (20+t-5C)
PART
INTAKE
Valve clearance (cold) mm 0 4 5 + 'I r r 0.38r.1' o:,
(Reference value: warm) mm 0 . 5 1 ', " ' : 0 . 4 4 , ' 00 3
Caution:
Alwayscheckthe valveswhentheyarecold.
E N. 4 5
& ADJUSTMENT
VALVECLEARANCEINSPECTION
/ D E / D E T/ C A IB i/ R B 2 5 D EE N G I N E
-
Valve clearancemeasurement
. Inserta 0.15 - 0.20mm gauge(A)fromsparkplugside.
Insertgauge(B)fromopposite side.Selecta gauge
to 0 m.
thatwillreducetheclearance
thickness
Note:
Do not use morethantwo gauges(B).
UseJIS 150A25feelergauge.
Vatveclearance= Gauge(A) + Gauge(B)

Reasonsfor measurement usinggauge(A)and(B):
'1.The valveclearancesettingis largercomparedto
previousengines.
2. Largegaugescannotbe placedparallelto the
measurement surface.
. Thickfeelergaugehavehighrigidityand cannotbe bent
easily,so the measurement willbe incorrect.
. The errorfactorincreasesif a numberof thingaugesare
layeredandthe measurement willbe incorrect.
Valve clearanceadjustment
. The valveclearanceadjustment is performedby
selectinga shimof suitablethickness.
. Whenthe measurement valveclearance(t)is outof
soecification,measure shimthickness(T)and
the
replaceit witha shimthatwill producethe standard
dearance.
1. Shim thicknesscalculationmethod
Example:
Whenthe intakevalveclearance(t) is 0.50mm:
value)= 0.05mm
0.50(t)- 0.45(specified
. The valveclearanceis 0.05mm greaterthanthe specifiedvalue.
. Usea shim0.05mm thickerthanthe currentshimto reducethe valveclearance.
2. Currentshimthickness(T)
. Measure thecentreof removed the
shimto determine
ofthecurrent
thickness shim.
Caution:
Donotreusethemeasured shimsagain
3. Shim selection
Currentshimthickness (T)is 2.40mm.
2.4OF\ mm + 0.05mm = 2.450
Selectnewshimwithstampedmark124'401
--2.440-2.455).
I
Selecta shimwithinstandard valuerange+f 0.03mm.
4. Shim types and classification T = 2.440- 2.455mm

Thereare 70 typesof shims. Sizesrangefrom2.275
mmto 3.325mm in 0.05mm increments.
EN-46
LUBRICATION
SYSTEMINSPECTION
R B 2 6 D E - _ R E 2 : : D E D E T/ C A 1 8 i /R B 2 5 D EE N G I N E
5. LUBRICATION SYSTEM INSPECTION
5-1 LUBRICATION OIL LEVELINSPECTION

Inspection
. The engineoil levelshouldbe checkedbeforestartingthe
engineor if theenginehasbeenstarted, the inspection
mustbe carriedout ten minutesafterthe enqinehas been
turnedoff.
. The oil levelshouldbe betweenthe H and L lineson the
BetweenL&Hmark
levelgauge.
. The oil mustnothaveanywhiteturbidityor dirt.
Lubricationoil replacementperiod
RB20DET
/ RB26DETT Every5,000kmor 6 months S D . S E . S G S F c l a s so i l
Everv15.000kmor 12 months SE,SF,SG classoil

CA18ii RB2OE
Everv10.000km
or 6 months SD class oil
Everv15.000km
or 12 months SE,SF,SG classoil
RB2ODE
/ RB25DE
Everv10.000kmor 12 months SD classoil
Note:
UsegenuineNissan[TurboX (7.5W- 30)]for servicefor RB26DETT/ RB20DETvehictes.
UsegenuineNissanSG class[ExtrasaveX (7.5- 30)]for servicefor CAI Bi/ RB20E,DE /
RB25DEvehicles.
Oil quantity
ITEM
H :.,...L.'
RB25DE/RB2ODE/RB2OE 4.0 3.0 Approx.3.8 Approx.4.2

RB2ODET/RB26DETT/4WD 3.5 Apptox.4.2 Approx.4.6
cA18i 1,1
Approx.3.2 Approx.3.6
E N. 4 7
SYSTEMINSPECTION
LUBRICATION
/ D E / D E T/ C A I B i/ R B 2 5 D EE N G I N E
5-2 OIL PRESSUREINSPECTION

. Removethe oil pressureswitchand connectthe oil pressuregauge
to the enginespeed.
. Afterwarmingthe engine,makesurethe oil pressureis appropriate
(Oi1temperature80"C)
GA18'
Approx. 1 A p p r o x .1
Approx. 1 .5
Approx.3 Approx.3 Approx.3
4000 Approx. 4
Approx. 4.6 Approx.4
RB2OE RB26DETT/ RB25DE/ RB2ODE cA18i

ylinderbiocknghtsrde,
7,'
{-
:
.:
pressure"
fessureswrlcn
m
5.3 OIL FILTERREPLACEMENT
Removal
. Useoil filterwrench(specialservicetool)to removethe filter.
Caution:
Catchany drippingoilwithragetc.whenremovingthe filter.
lnstallation
. Beforeinstallingthe newoil filter,cleanthe oilfilterbracketmountingsurfaceon the
cylinderblockand coatthe oilfilterseallipslightlywithnewengineoil.
. Screwin the oil filteruntila slightresistanceis feltandthemtighten2l3turn'
Caution:
Makesurethe oil will notleakafterstartingthe engine.
or 12 months
/ RB26DETT Everv10.000km
RB2ODET SD.SE.SG SF classoil
or 12months SE,SF,SG classoil

Every15,000km
CA18i/ RB2OE
or 12months SD classoil
Every10,000km
Everv15.000kmor 12 months SE,SF,SG classoil
/ RB25DE
RB2ODE
or 12 months
Everv10.000km SD classoil
EN.48
EXHAUSTSYSTEI\,4
INSPECTION
R B 2 6 D E T TR B 2 C E D E ' D E T / C A I B i/ R B 2 5 D EE N G I N E
RB2OE RB2ODE/DET/RB2sDE cA18i
6.EXHAUSTSYSTEMINSPECTION
6-1 AIR CLEANERELEMENTINSPECTION (RB26DETT/RB2OE/ DE / DET)

lnspection
. Removethe bandsshownin the diagramand removethe aircleanerelement.
. Thereshouldbe no excessivedirtor damaoeon the air cleanerelement.
Periodic replacementinterval Every60,000km

RB26DETT RB2OE
/ DE RB2ODET
6-2 TURBOCHARGER tNSPECT|ON (RB26DETT/ RB2oDET)

Functioninspection
. Removethe intakemanifoldcanisterhose,and placea cap on the hose. Connecttest
hoseto intakemanifoldandattachpressuregauge(compoundgauge).
. Performthe engineoperationtestandcheckthatpressuredoesnot riseabove
approximately0.B- 0.9kg/ cm,.
a. Whenthe pressuredoesnot reachspecifiedlevel.
Checkfor vacuumleakin intakeor exhaustsystemor exhaustgas leak.
b. Whenthe pressureexceedsthe maximumpressurelevel(approx.0.8 - 0.9 kg / cm,).
Checkif swingvalvecontrollerrubberhoseis disconnected or cut.
Checkif swingvalvecontrollermotionmalfunctions(staysclosed).
RB26DETT RB2ODET
E G 1 5 0 80 0 0 1
G 1 5 0 80 0 0 9
EN--19
EXHAUSTSYSTEMINSPECTION
R B 2 6 D E T/TR B 2 O D EE
TN G I N E
Swing valve controller inspection

. Removethe swingvalvecontrollerrubberhosefromthe vacuumtubeside.
. The controllerrod muststartoperatingwhencompressedair approx.0.7 - 0 8 kg / cm2
(RB26DETT), approx.0.8- 0.9kg/ cm' (RB2ODET) is forcedintothehoseby usingan
air gun. Stopblowingcompressedair as soonas controlrod operationis verified
Caution:
Thediaphragm may be damagedif excessive airpressureis applied.Usethe LPG
pressuregauge(specialservicetook for 1 kg / cm' ) to verifythat the air gun pressurels
approx.0.7 - 0.8 kg / cm' (RB26DETT)or 0.8 - 0.9 kg / cm' (RB20DET)beforetestingthe
arrnose.
RB2ODET
6-3 RECIRCULATIONVALVEINSPECTION
Functioninspection
. Removethe hoseon upperflowsideof the recirculationvalvecompressor(placethe cap
on end of the hose)and checkif air blowsbackwhenthrottleis closedquickly.
RB26DETT RB2ODET
Unitinspection
-150+f 30mmHg(RB26DETT)
pressure
. Usea handpumpto createnegative -400+/-
50mmHg(RB2ODET). Therecirculation muststartto liftupandthe
valvediaphragm
willbemaintained.
vacuumoressure
EN-50
EXHAUST
SYSTEMINSPECTION
C A1 8 E N G N E
6-1 AUTOMATIC TEMPERATURE

ADJUSTMENT
AIR CLEANERINSPECTION
Systemdiagram
Freshair ducl Arrcleaner
When cold n alf

-----=
lntake manifold
Freshair duct
Temperature
When warm sensor
' @
Warma t t
SPIbody Intakemanifold
Functioninspection
. Removethe airductandstartthe enqine.Insoectthevacuummotorooerationwhenthe
engineis coldandwarm.
When cold Closed

Whenwarm Open
sensorpresettemperature:Approx.40oC.
Temperature
COMPONENTPARTSINSPECTION sensor(whencold)
Temperature
Temperaturesensor inspection
. Removethe hoseto the vacuummotorand connectthe
vacuumgauge. lntake
manifold
. Startthe engineand checkthe negativepressurewhen
the temperatureof the temperaturesensorwas cooled/
A,.'nflowfiP-
warmedby the drier. illL @''*'
\v
Whenwarmedup No negativepressure To'nta[emanifoE! _IO vdcl.rum
gauge
Whencooled Negativepressurecreated
F ."-,",".'.-
Vacuummotor inspection Applynegative
. Removethevacuumhosefromthevacuummotor and
mnnectvacuumhandpump.
. Usea handvacuumpumpto createnegativepressure
(approx.-150mmHg). Visual
. Makesurethefreshairducton the change-over cnecK
valve
willclosewhenthe negativepressureis appliedand it will
openwhenthereis no negativepressureapplied.
6.2 AIR CLEANERELEMENTINSPECTION

Inspection
. Removethe clipsandthe nutsand removethe aircleaner
element.
. Thereshouldbe no excessivedirtor damagein the air
cleanerelement.
EN-51
FUELSYSTEMINSPECTION
R B 2 5 D E/ D E / C A 1 8 E
i NGINE
7 F U E L S Y S T E MI N S P E C T I O N
. F U E LP U M P.
EASYINSPECTION (RB25DE)
. Turntheignition
switchto ONposition. IS THEREA PULSAT]ON
. Select"Fuelpump"inthe"Functiontest"mode. E V E R Y3 S E C O N D SW H E N
INt TUEL UI'tr J NtrLU '
. Inspectthe pulsationby holdingthefuelhosewithhand OR CANYOU HEARTHE
O P E R A T I O N O I S EO F T H E
F U E LP U M PR E L A Y ?
. Holdthe fuelfilterand makesurethe hoseis hardand

\a/
,@\
pulsationcan be feltwhenthe fuelpumpis operating.
FUEL PRESSUREINSPECTION USINGTHE FUEL PRESSUREMETER

Releasingfuel pressure(RB25DE)
' Revtheengine OACTVETEST.O
. Select"Fuelpumprelay"in "Activetest"mode
n ,,Aniivorcsr,,
mode. @ RELAY OFF
FUELPUI\,4P
. Press 'STOP'tostoptheengine.Crankthe engineover
CAS-RPM(POS) 950rpm
two or threetimes. (lf the enginedoesnot startcrank3 - 4
timesafterremovingthefuse).
. Restartthe engineand removethefuelpumpfuse. (Q\

. Afterthe enginestops,crankthe engine4 - 5 1;ts5 1e r(EV
consumethefuelin the pipe. (lf the enginedoesnotstart
crank4 - 5 timesafterremovingthe fuse).
Caution:
The batterymay becomeweak easily,use boostercableto
connectto anotherbatteryif necessary.
I ruelenessuRe
I
Releasingfuel pressure(CA18i/ RB20E)
. Revtheengine.
. Select"Releasefuelpressure"
in
"Operation
support"mooe.
@ W H I L EI D L I N GP R E S S
'START"TO STOPTHE
FUELPUMPOPERATION,
AFTERENGINESTOPS,
C R A N KT H EE N G I N EO V E R
TWOOR THREETII\,4ES.
. Afterstartingthe engine,removethefuelpumpfuse After

the enginestops,crankthe engineover2 - 3 timesto
consumethefuelin the pipe. (lf the enginedoesnotstart
crank3 - 4 timesafterremovingthefuse).
Caution:
The batterymay becomeweakeasily,use boostercable
to connectto anotherbatteryif necessary.
E N. 5 2
FUELSYSTEMINSPECTION
R B 2 6 D E - - R B 2 O ED/ E / D E T / C A 1 B i / R B 2 s D
EENGINE
7 . ' I F U E LP R E S S U R E
INSPECTION
Releasingfuel pressure(RB2ODE / DET/ RB26DETT)
. Afterstartingtheengine,removethefuelpumpfuse.After
theenginestops,cranktheengineover2 - 3 timesto
consumethefuelin theoioe.
. lf the enginedoesnotstart,removethe pumpfuseand
cranktheengine3 - 4 timesto consumethefuelrnthe
oioe.
Caution:
The batterymay becomeweakeasily,so useboostercables
to connectit to anotherbatteryif necessary.
Fuelpressuremeterinstallation
(RB26DETT / RB20E/ DE / DET/ CA18i/ RB2sDE)
. Connectthefuelpressuremeterbetweenthefuelfilterano
thefuelline.
. Attachthefuelpumpfuse.
Fuel pressureinspection
. Startthe engineand checkif the fuelpressureis at
standardvalue.
. lf the enginedoesnotstart,checkfuelpressureafter5
secondswhenthe ignitionswitchhas beenturnedON.
Fuelpressuremeasurement
Whenignitionswitchis ON (kg/cm,) Approx.

3.0 Approx.2.5 Approx.3.0
Duringidling (kg/cm,) Approx.2.5 A p p r o x . 2 . 0 A p p r o x . 2 . 5 5 Approx.1.0
ldlingwhenpressureregulator
vacuumhoseis removed (kg/cmr)
Approx.
3.0 Approx.2.5 Approx.3.0 Approx.
1.0
cA18i RB2ODE.
DET RB26DETT
r e s sur e
7-2 THERMO-WAX tNSPECT|ON (CA18i)

. Inspectthewaxstrokewhenin followingtemperature.
25 80
Approx.25 Approx.30
EN-53
GAS CONTROLINSPECTION
EVAPORATIVE
RB26DETT/ RB2OE/ DE / DET / CA18i/ RB25DEENGINE
8 EVAPORATIVEGAS CONTROLSYSTEMINSPECTION
Throttlechamber
Purgecontrolvalve
Checkvalve
gas
: Evaporative
<F Purqeair
Activecarbon
Fueltank
- Filter
fray
Freshair
8-,I PURGECONTROLVALVE INSPECTION

CANISTER
Inspection
. Usevacuumhandpumpto applyapproximately -400
mmHg(-100mmHgRB25DEengine)negative pressure
andmakesurethe vacuum pressure
is maintained.
. In thatcondition,checkthatsmallamountof aircan be E G 1 5 1 30 0 0 0
suckedfromthe manifoldvacuumpath.
FUEL TANK VACUUMRELEAFVALVE(RB2sDE)

Inspection
. Cleanthevalvehousing.
. lf thefueltankvacuum youwillhear
releafvalveisnormal,
soundfromthe valvewithsmallresistance whenthe air is
suckedin throughthe cap.
. Replacethe cap ASSYif the valveis closedor no
resistanceis felt.
EN-54
BLOWBYGASREDUCTION
DEVICEINSPECTION
R B 2 6 D E T TR B 2 iE D E D E Ti C A 1 8/i R B 2 s D EE N G I N E
BLOWBYGAS REDUCTION
D E V I C EI N S P E C T I O N
biowbycontrolvalve
9-1 BLOWBY CONTROLVALVEINSPECTION(EXCLCA18i)

Inspection
. Checkthe blowbycontrolvalveflowpath.
A i r is blown Air passes

A i r is drawn t n No air passes
Inspection(CA18i)
. Removethe aircleanerrockercoverhosewhenthe
'1000 rpm
enginerev is approximately and checkthat
freshair is drawnin.
E\
ON-VEHICLEPARTS
RB26DETE
TNGINE
OF ON-VEHICLEPARTS
1O REMOVALAND INSTALLATION
AIR DUCTASSEEMBLY
1O-1INTERCOOLER
Front tufuocharger
outlettube
,r--aolt 1.6
IntercoolerIPoint4] Resonato.lube
t . 6- 2 . 1 p ]
Bol1
o-'--Nut (2)i.6 - 2.19
I ts-t
E Replace after every disassembly
Additionalwork requ ired:

. Undercover
. Frontbumper
[Point1] Cleaningair hoses & air duct

. Useairgun to removeany dustand rubbishbefore
removingeachair hosesand air ducts.
[Point2] Remove& installeach air hoses and tubes

Removal
. Placealignmentmarkon eachair hoseand tubesbefore
removal.
lnstallation
. Alignthealignment andmake
markswheninstallation
sureto tightenthe clampsecurely.
EN-56
ON.VEHICLE
PARTS
i32' DEiT ENGINE
[Point3] Removeand installthe intercoolerinlet

hose
Removal
. FirstremovetheresonatorandthetubeB beforeremovinq
hoseA.
Installation
. AttachhoseA, thenattachresonatorandthe tubeB as a
singleunitto install.
[Point4] Removeand installintercooler

Removal ..--*-t
1. Removethebumperfinisher andthebumper
reinforcement.
2. Separatethe rntercooler inletandouflethoses.
3. Removethe mountingboltandtwo nuts. Detach
intercooler
withoutscratching thefins. t : i , E
Caution: Outlet l,4ountinq bolt
lnlet
hose
1. An aluminium finsareusedandcanbe damagedeasily. hose 0 . 9 3- 1 . 2
"l Kq_m Nrounting 0 . 9 3- 1 . 2
Do not placeobjectson the intercooler or allowtoolsor
otherhardobjectsto contactthefins.
2. Themainunit(tank,fintube)cannotbedisassembled.
Installation
. Installationoperationis the reverseof the removal
operation.Performthe stepsin orderof 3, 2, 1.
Tighteningtorque (kg-m): 0.93- 1.2
[Point5] Removeand installrecirculationhose

. Removeandinstallthe recirculation
hoseandtubeas shown
in thefigureon right.
[Point6] Installrecirculationhoseclamp
. Wheninstalling the recirculation
hoseclap,makesureit
willnotcontactbumperfinisher.
[Point7] Recirculation
valveinspection
Unitinspection
. Usehandvacuumpumptoapplynegative vacuumof-150
+/-20mmHgandcheckthatrecirculation
valvediaphragm
liftsandvacuumpressure
is maintained. Recirculation
valve
[Point8] Removeand installturbochargeroutlet

tube
. Removeand installthe turbocharqer
ou et tubeas shown
ON-VEHICLEPARTS
RB26DETTENGINE
1O-2 AIR GLEANERELEMENTASSEMBLY
To rear turbocharger
To front turbocharger
f
ACI
I *n-'
I
Air hose
-s
OUCI
Arr cleanercase
Additionalwork required:
. Removeturbocharger outlethose
[Point1] Air hose and air duct cleaning

. Usean air gunto blowoff any dirtand dustbefore
removingthe aircleanerelement.
[Point2] Removeand installair cleanerelement

Removal
outlethose.
1. Removeturbocharger
2. Removefour bandclipsfromthe air cleaner.Liftair

cleanercoverand removethe air cleanerelement.
lnstallation
. lnstallin reverseorderof removal.
[Point3]
. Makesurethe aircleanerelementis notdirtyor damaged. ),)\
Periodic replacementinterval: Every 60,000km

= _ \-:= ,.' ll.
-Connector
Arr flow meter
[Point 4]
. Firstconnectthe airflowmeterconnectorfor frontturbo
charoerandtheninstallthe air cleanercover.
EN-58
ON-VEHICLE
PARTS
RB26DETE
TNGINE
1O-3 CONNECTORASSY
(1) CollectorASSYremovaland installation
No.3 Throtllecharnber
No 2 Throttlechamber Knockpin (6)
__-/0
s;
N.o 1
----- /'/
--\3nno.t
o'n,e,thutb"'
9-
1,,,ffi
,t1\
\ur{r2,
,ll;A,
Poinr
\,
ersprlnt
.\
I'i-,
washer ""gH-= "{ y
(12) ;:t,
JJ,i:*;
- V7,i";::;*;el
.-tt":"to"Tj,:ld' /R
qvl
Io! ,
-
t"
Hose
--a
*'"-ruW,fl*6pltr== n"'"
warer
ruDe
L"","r,^,^,:."j:,-91^,^
:, :dR. i <?'- - i *_
-
,,",Kt$,5 1 F:l"i;r6,i""
Bort' 4) l
Bort0.64- O.r' eirtio-zrp)
"^,,?" - " ,m
ffi1.30-ouo
$ neptaceaftereveryd'sassembty
Fi.
\-.4 Ks''
. Releasefuelpressurein thefuellines[Point1]
. Draincoolingwater[Point2]
. Acceleration controlwire[Point3]
. Air inlethose
. EGIharnessconnector, harnessclamp
. Allhoses
[Point 1] Releasefuel pressure

. Starttheengine
. Afterstartingthe engineremovethe fuelpumpfuseand
waituntiltheenginestops.Crankenginetwoor threetimes
to consumefuelremainingin the fuelpipes.
. lf thevehicledoesn'tstart,removethefuelpumpfuseand
crankthe enginefourto fivetimesto consumefuel
remaining in thefuelpipes.
Caution:
The batterymay becomeweakeasily,use boostercableto
E N. 5 9
ON-VEHICLEPARTS
ENGINE
R826DETT
[Point2] Drainingthe coolingwater

. Makesureto draincoolingwatercompletelyfromthe
cylinderblockby removingthe drainplug.
Caution:
Makesurethe coolantdoesnotspillon the fronttube.
[Point 3] Acceleratorwire adjustment

. Loosenlocknutto provideadequateslackfor the
acceleratorwireand pulloutercasein the directionof the
acceleralor.
. Returnthe locknut 1.0to 1.5turnsfromthe positionthe
throttledrumstartsmoving(whenthereis no playin cable)
andtighten.
Tighteningtorque (kg-m): 0'8 - 1.0
[Point 4] Removethrottle chamber links

. Removethemountingnutsindicatedby arrowmarksin the
diagram.Separatethreethrottlechamberlinksfrom
collectorside.
. Removethe harnessfromthethrottlesensorandthe
throttlevalveswitch.
[Point5] Fuel PiPeremoval

. Removethreeboltsindicatedby the arrowsand separate
the fuelpipe.
[Point 6] Air hose removal

. Seoaratethe air hoseA, B and C fromthe collectorside.
Air hose
[Point 7] Booster vacuum removal

. Removethe clampboltand removethe boostervacuum
tube by separatingit fromthe collectorandthe air
chamber.
[Point8] Removeand installair chamberbolts

Removal
. Separatethe air chamberby removingthreebolts.
lnstallation
. lnsertboltB in air chamberbolthole,beforeperforming
finalassemblY.
Tighteningtorque (kg-m): 1 . 6- 2 . 1
EN-60
ON.VEHICLE
PARTS
i 3 2 6 D E T TE N G I N E
[Point9] Removeand installcollectornut

Removal
. Removethe nutsin the reverseorderof thefiqureon the
right.
Installation
. Installthe nutsin theordershownin thefigureon right
uniformlyin two to threestages.
[Point 10] Removeand installair chamber

Remove
. Separate theairhosesA, B, C, vacuumhosesD, F and
MC valveconnectorand removethe airchamber.
Installation
. Positionthe airchamberin place,connectthe air hosesC,
D, A, vacuumhosesF.E. thenconnectAAC valve.
[Point11] Removeand installAACvalve

Removal
. DetachtheAAC valveby firstremovingfourbolts.
Caution:
(1) MC valvecannotbe disassembled.
(2) Replacegasketwitha newone.
Installation
. InstallgasketandtheMC valve.
Tighteningtorque(kg-m) 0.64- 0.85
[Point 12] AAC valve inspection

. Measurethe MC valveresistance
Resistance(20.C)O A p p r o x . 9- 1 0
(2) CollectorASSYdisassemblyand assembly
(4)pl 0.64' O.B5

Bort
- 0.85
(2)gl 0.64
Bort
- Acceleralion
ag B r
work unit
(w
\,
/ Knockpin (2)
Intaketemperaturesensor
20-3.0
Collector[Point1]
EN o l
PARTS
ON-VEHICLE
ENGINE
R826DETT
. CollectorASSYinstallation "Throttlevalveswitch
referto
for thethrottlevalveswitchadjustment
systeminspection"
proceoures.
[Point1] CollectorinsPection
surfacefor distortionin
. Measurethe collectorinstallation
up,down,lefi' right'
six directions(opposingdirections,
horizontally andverticallY).
Limit ( m m ) : 0.15
10.4 SIX IN-LINETHROTTLECHAMBERREMOVALAND INSTALLATION
No. 3 Throttle No. 2 Throtfle

chamber \ chamberlPoint1,
lPornt1.2l
660-'
$ neptaceaftereverydisassembly
. CollectorASSY removaland installation
. Canisterhose
[Point1] Throttlechamberinspection
air pathsare
. Checkfor any cracksandthatsupplemental
notobstructed.
air
Supplemental
[Point2] Installthrottlechamber
. lnstallNo. 1 to No.3 throttlechambers. l Throttle
Caution:
Do not makeany mistakewheninstalling the chamber.
-t\ -
No. 3 Throttlechamber
EN-62
ON-VEHICLEPARTS
R 3 2 6f , : T T E N G I N E
10.5 SIX IN.LINETHROTTLECHAMBERLINK ADJUSTMENT
A c c e i e r a l od
r rum ful
1 ,,, df'
]
Detarlof parta
\'
K:X\
.---_.. \i
sx{$r-5-i
<Y-\\1"- /tr'
Throltle chamber f ully \\
closed stopper Fsat r- I ()\-
Detailof partb
[Point1] Installacceleratorwork unit

. Install
sixtn-line
throttle
chamberandtheaccelerator
work
unitandconnect No.1,2 and3 throttle
linkage.
=-
Bolt(4) 0.64- 0.85
[Point2] 6 in-linethrottlechamberlink adjustment

1. LoosennutsA and B for eachthrottlelink.Turnthe
centreadjustment of eachthrottlelinkanticlockwise
to
shortenthelinkage.
2. Shorteneachthrottlelinkuntilacceleration
drumcontacts
fullyclosedstopperon the accelerator
workunitside.
3. Shorteneachthrottlelink,so thethrottlechamberlever
openswiderthanfullyclosedstopperon the throttle
chamberside.
Caution:
( 1 ) D o n o tl o c k t h en u t A a n dB .
(2) Thethrottlechamberleveropeningangleshoutdbe
adeouate.
EN-63
ON.VEHICLEPARTS
RB26DETE
TNGINE
4. Insert 1 mm thicknessfeelergaugebetvveen
the
accelerator drumandfullyclosedstopperon the
accelerator drum
work unitside. Securethe accelerator
so it does not move.
Fully closed
,'-!t)
'trf
5. Withthicknessgaugeinserted,turnthe centre
adjustmentIn No.2 throttlelinkclockwiseto lengthenthe
throttlelinkuntilthethrottlechamberlevercontactsthe
fullyclosedstopperon the throttlechamberside
6. Whenturningthethrottlelinkwithyourfingers.Youwill
feelresistancewhenthefullyclosedstoppercontacts
thethrottlechamberlever.Shortenthethrottlelinkto the
pointjust beforethis resistanceis felt
7. Carryout the steps4, 5, and 6 to adjustthe No. 3 and 1

throttlelinks.
8. Tightenthe locknutA and B afterthe adjustingthree

throttlelinks.Afterthe nutsaretightened,No 1 - 3
throttlelinksmustturnwiththe samedegreeof
smoothness.
Caution:
Makesurethe centreadjustmentlinkwillnotrotatewhenthe
locknutis tightened.
9. Removethethicknessgaugefromfullyclosedstopper
workunitside.
on the accelerator
Caution:
L-
Do notadjustfullyclosedstoppernut. ca
1
10. Completelyopenandclosethe six in-linethrottle

chambersrepeatedlyand makesurethateachthrottle
chambermovessmoothly.
EN-64
ON-VEHICLEPARTS
R B 2 6 D E TE
TNGINE
10.6 INTAKEMANIFOLDASSY
(1) IntakemanifoldASSYremovaland installation
Intakemanrfoldgasket
B o l t( 5 ) 1 . 6- 2 . 1
1lp)
lPornt p,us
Airdra,n z1/ E
leornt ,fryfj
ii\ \s4!**^^'Yt-:.
B o l (t 4 )1 6 - 2 1
1]pJ
lPoint Intakemanifold
ASSY
B o l t( 2 )1 . 6-
llgl
tPoint
E Repiace
aftereverydisassembly
kg- m
. CollectorASSYremovaland installation
. Throttlechamberremovaland installation
. ECCSharnessconnector andall hoses
. Wateroutlethose
. Blowbyhose
[Point1] Remove& installIntakemanifoldASSY

bolts and nuts
Removal
. Removalis the reverseordershownin thefiqureon the
rioht.
Installation
. Installtheboltsandthenutsin theordershownin thefigure
'10 6
2 4 8
on the right.Tightenin gradualstepsto uniformtightness. 'I 2 are nuts
30:4
60:5 1 ,4 , 1 0 ,1 2 ,1 4
6 5: 2 7,9
[Point2] Air drain plug

. Carryoutthe operationwhenengineis cool.
Caution:
Do notremovetheairdrainplugwhentheengineis hot.
. Whentoppingup thecoolant, alwaysremovetheairdrain
plugto allowairwithintheengineto escape(thisprevents
overheating).
EN-65
ON-VEHICLEPARTS
RB26DETE
TNGINE
(21 Intakemanifolddisassembly& assembly
Balancetube lPoint6] - o.8a

Bolt(5)0.6a gl
B o t t( 2 ) 1 . 6- 2 . 1 6l
E o-rinsIPoint
Water temperature
;:J;id'senffi2o-30
ASSY[Point2]
FueltubeIntector
a;
O-ring outlet
5l
FF=".;,"
"g ,-p Ffii;il \^ ,on',u - r.,
p ) e o r t t zr .re- z . r
Screw(2) 0.23- 0.91---'
'.\
--r.*^
-'l lntake ml
{s
_Waler bypassconne^to'
Air regLrlator
-
ro-; r
g-----€5 "j,lI F.",, ptec,
D
Fi
L-l| Eort(2) 0.64 - o.
Liquidgasket
+::;;9,s
a Replace after every disassembly
kg-m
[Point'l] Intakemanifoldinspection
. Measurethe intakemanifoldsurfacefor distortionsin six
differentdirections(atoppositedirections: up,down,right'
left,horizontally in severallocations.
andvertically)
L i m i t( m m ) : 0.15
[Point2] FueltubeASSY
. ReplaceO-ringwithnewoneswhenpressureregulatoris
removedand installed.
Caution:
Caremustbe takennotto scratchthefueltubeo-ringsurface
the pressureregulator.
wheninstalling
[Point 3] O-ring (for fuel injector pressure regulator)

Precautionswhen handling
. NeverreuseO-rings.
. CoattheO-ringwithengineoil (10W-30or equivalent)
siliconoil(NUCsiliconL45or equivalent),
or
butdo notapply x>q)
solventas thismay remove the oilcoating.
. AvoidusingdirtyO-ringsand do not allowdirt,dustor
foreignobjectsto adhereto O-ringsor otherequipment
q4,4u",F.]"
surfaces.
E N. 6 6
ON-VEHICLEPARTS
r 3 2 €D E T TE N GN E
Do notdecenteror rotatethe fuelinlectorsandthe

pressureregulatorwheninsertingthemintothefueltube.
Do notstoreO-ringsin locationsubjectto ozone,high
temperatureor in thedirectsunlight.
[Point4] Installand removewater bypass

connector
Removaland cleaning
. Removeeightwaterbypassconnectorbolts. lnsertdriver
in clearancebetweenintakemanifoldandwaterbypass
connectorand moveit lightlyto removeconnector.
. Usea scraperandremoveliquidgasket.
Caution:
Also removeliquidgasketin the grooves.
. Wipeoff mountingsurfacewithwhitegasolineetc.
lnstallation
. Cutthenozzleendof liquidgasket(KP51000150)inthe
positionshownin the figure. Usea tubepresserto apply
gasket.Installbypassconnectorwithin20 minutesof
applying liquidgasket.
. Applyliquidgasket(KP1000510)to waterbypass
connectorsurfacesin fourlocations,theninstallwater
bypassconnectorwithin20 minutes. Tube presserWS3993
Caution:
(1) Applyliquidgasketcoating3.0mm wide.
(2) Coaton theinsideof installationholesas shown.
Tighteningtorque (kg-m): 1.6-2.1
[Point 5] Water outlet elbow

Removaland cleaning
. Removetwowateroutletelbowboltand insertscrew
driverhandleas shown. Moveit up anddownto remove
theelbow.
. Removeliquidgasketfrom intakemanifoldandwater
outletelbowby usinga scraper.
Caution:
Alsoremoveliquidgasketin thegrooves.
. Wipeoff mountingsurfacewithwhitegasolineetc.
Installation
. Cutthenozzleendof liquidgasket(KP51000'150) inthe
positionshownin thefigure.Usea tubepresserto apply Waleroullet
thegasket.
. Applythe liquidgasket(KP10 00510)to intakemanifold
surfacesin fourlocations.
theninstallwithin20 minutes
Caution:
(1) Applythe liquidgasketcoating3.0mm wrde
E N. 6 7
PARTS
ON-VEHICLE
ENGINE
R826DETT
[Point 6] Remove and install balancetube

Removal O-ring
. Checkthe sizeof the O-ringwhenremovingbalancetube.
lnstallation
. Alwaysreplacethe O-ringwtthnewoneswheninstalling
balancetube.
. TherearethreedifferentO-ringsizes. Makesureto install
the correctsize.
3 1, 2,3, 4, 5, 6
Cylinder
4 Cylinder1, 2, 5. 6
2 Cyinder3, 4
. Be carefulnotto pinchthe O-ringsduringinstallation.
1O-7TURBOCHARGER ASSY
ASSY
(1) Turbocharger removal& installation
FRONTSIDE REARSIDE
*"ry:-/-----ll;at
tf:"11,% -'-j---,.-
-_--,,-
-
ttose
s'4q"*;';1+
6 q 1 q 1 z 1 o . M - l € s* - -
:*,,J4_i ffis{*e
C5p-perwashe{ r-r
?i€F.-:',',"^*
/ --'-
Sffi\ffi;'-"
1.+n"'1""
iils
t
-H$$,
c y l i n d eb rl o c k 1 - ,
I#,2$;;?f
\g"*9t-*l '
''
y's,e
l^ Y'^,.;}^,tfy.
vJP,""*1,
'---ff$B"*r"*"
nipo'\=-^8
o"
t^... Oilpi
i:x,lr,;;:|tk#ffii;
p: g:i;r:h /
#P/- . \"'n"i"""n
, *
,",,,110,0-'', !nf""";n",,,
s *".n",E ,\F-,
".d'Hry>-;;;';;;";--,"'"if:,"*:
F@.-!:1;, ,,?*lT,Y-
F! ts-t
$ Reptaceafter every disassembly
EN-68
ON-VEHICLE
PARTS
R 3 2 6D E T TE N G I N E
Additional work required:

. Removeand installundermver
. Draincoolingwater
. Separateexhaustfronttube
. Removeand installexhaustgas sensorconnector
. Intercooler air inlettubeand hose
. Air inlethose
Note:
Alsoremovecoolingwaterfromenginedrainplug.
(lf wateris onlydrainedfromtheradiatordraincock,thewaterinsidecvlinderblockwillnotbe
drainedcompletely).
(2) FrontturbochargerASSYremoval& installation
Removal sequence
(1) LoosentheflarenutsoftubesA and B.
(2) RemoveboltsanddetachtubeA.
(3) LoosenflarenutsoftubesC and D on the turbosioe.
(4\ RemovehoseB and bolts.
(5) RemoveboltsanddetachtubeE.
(6) Removethreebolts,coverandgroundcable.
(7) Removetwo boltsanddetachtubeH. Makesure
thatboltmountedon uppersideis shorterthanlower
side.
(8) Removethreebolts,coverandgroundcable.
(9) Removeoil returnhose.

(10) Removethreeboltsanddetachbracket.
(11) Removefourturbocharger nuts.

(12) Lowerturbochargercarefully. -' -:
(13) Removesix exhaustmanifoldnuts. h. -
(14) Pullthe exhaustmanifoldin direction1 andthenrarse
it in direction2 to avoidturbocharger
stud.
(15) Removeexhaustmanifold.
(16) Pulloutturbocharger.
Installationsequence
. Installation
is the reverseof the removalsequence.
. Placeturbocharger in bottomof the engine
compartment beforeinstallingtheexhaustmanifold.
E N- 6 9
ON-VEHICLEPARTS
R 8 2 6 D E T TE N G I N E
(3) Rear turbochargerASSY removal & installation

. Frontturbocharger
ASSYremovaland installation
Removalsequence
(1) Removefrontturbocharger andtheexhaustmanifold
ASSY
Q\ Removetwo nutsand the clipsecuringbolt,and
seoaratethe tubeA.
(3) Removethreeboltsanddetachexhaustmanifoldcover.
(4) RemoveeyeboltB, C and E.
(5) Removetvvoboltsand separatetube D fromcylinder
blockside.
(6) Removethreeboltsanddetachbracket.
The sequenceafterthisstepis sameas number11to 16 of
thefrontturbochargerremovaland installation.
Installationsequence
. Installation
is reverseof removalsequence.
. Loosenthe watertubeflarenut beforeinstallingeyeboltB.
(4) ASSYdisassembly& assembly

Turbocharger
FRONTSIDE
Air inlettube
tr
\
E GasketI _
EGasket
*BeW"/.fiM
Y'1"!*q*F:i:i
/'t,"1,.,"
Bolt(2)g Bolt(2)1",4 038-05'
1 . 6- 2 . 1 0.64- 0851
?:J'lt'F3*'3'.# gev"oortzo-V
WasherE
xg-m
$ neptaceaftereverydtsassemblY
EN-70
ON.VEHICLE
PARTS
R3 2 6 D E T TE N G I N E
. Turbocharger
ASSYremovaland installation
[Point1] Watertube inspection

. Aftercleaningthewaterinletandoutlettubeswithradiator
cleaner,blowwithcompressedair and checkfor rustor
anyclogging.
[Point2] Oil feed tube inspection

. Aftercleaningtheoil feedtubewithengineconditioner, Engine
blowwithcompressedair and checkfor any clogging.
[Point3] Removeandinstalllockplate
. Spreadthelockplatepawlswitha screwdriver
andloosen
nuts.
. Positionlockplatesandturbocharger
mountingnuts.
Aftertightening
thenuts,bendlockplatepawlsontothe
nuIS.
[Point 4] Eyeboltdetermination
side)eye boltsare stamped'J'
. Oilfeed (turbocharger
lq.)
L *
(5) Turbocharger
unit inspection
Crack inspection
Crack burn Inspectron
CoolrngwaterinlellPorntB]
Exhaustgas leak
inspectionlocation
Actuator[Point7]
-.---- Compressorwheel
SwingvalveIPoint3j
[Point5]
Turbinerotor{Point1,2,4l R o t o .s h a l t P on t 6 . 8 l
rq:i,:::lOil leak inspecttontocation
E N. 7 1
ON.VEHICLEPARTS
ENGINE
R826DETT
[Point1] Rotor shaft inspection

. Makesurethe rotorshaftrotatessmoothlywithno
heavinessor draggingwhenturnedby finger.
shaft
:"j'^'::..
lPoint2] Turbinerotor inspection
. Oilmustnotadhereto surface.
. Thereis nocarbonaccumulation.
. Thevanesoftheturbinemustnotbebent. or
7\ll No oenoing
. Thereis nointerference
withturbinehousing.
r V v-. No nterietence
wlh the housing
-'-'!t-''-
[Point3] Swing valve insPection

. Removeactuatorrodpin and makesurethe swingvalve
movessmoothlywithoutdeformationor cracks.
. Makesurethereare no misalignedseatingsurfacein
turbinehousing.
lPoint 4l Rotor shaft play inspection

. Setthedialgaugeand measureplayandthrustclearance
. Insertthe dialgaugein oil returnholeand measurerotor
shaftplay.
Rotorshaftplay(mm) 0 . 0 5 6- 0 . 1 2 7
Thrustclearance(mm) 0 . 0 1 3- 0 . 0 9 6
Compressorwheel inspection
[Point5]
. Oil mustnotadhereto suctioninlet.
. Theremustbe no interferencewithcompressorhoustng.
\@ No oil adhere.
No bendingor
other
d am a g e .
. Wheelmustnotbe bentor damaged.
[Point 6l Rotor shaft inspection

. Theremustbe no carbonsludgeaccumulation. t No carbon
s luO0e
EN.72
ON-VEHICLE
PARTS
RB26DETE
TNGINE
[Point7] Swing valvecontrollerinspection

. Connectthe swingvalvecontroller rubberhoseon the
actuatorside.
. Checkthe swingvalvecontroller whenthe actuatorrodis
installedor removed.
. Checkto see if the controllerrodwilloperateswhenthe
compressed airpressure(approx. 0.7- 0.8 kg / cmr)is
applied.Stopblowingair as soonas rod operates.
[Point8] Oil & coolingwater inletand outlet

cleaning
. Useengineconditioner to cleanthe oilfeedand return
passages.
. Useradiatorcleanerto cleancoolinowaterfeedand
returnDassaoes.
. Cleanwithairgun.
. Cleanthe compressorwheel,turbinewheel,compressor
=housrngandturbinehousingwithsamemethods.
EN-73
ON-VEHICLEPARTS
R B 2 6 D E TE
TNGINE
(6) Turbochargerfailurediagnosis(Oil leaks,smoke(whiteor blue smoke),lack

of power, poor acceleration,abnormal noise)
Pointsto be checkedbeforediagnosis:
1. Theengineoillevelmustbe betweentheMINandthe MAXmarkson theoillevelgauge.
(Wheniheengineoillevelis higherthan MAXline,theengineoilwillflowintointake
ductthroughthe blowbygas recirculation passandtheturbocharger may be
determined to be malfunctioning).
2. Checkwith customer to deiermineif oil is cooledwhenidlingafterdriving'
lf any malfunctionin thefollowingchartis detectedin a unitinspection,replacethe
turbocharger ASSY
sr;{tl
..r .::r,. .
Oil on rotors l \ z\ l\
Turbinerotor
Carbon has accumulated z__l @ o o
Rotor scrapes agair6t the housing @
Turbimevanes are bent or folded @ !9'
Suctioninletis dirtywithoil o o
Compressorwheel Rotor scrapes agairEt the housirE C
Turbinevanes are bent or folded (/
There is resisianceor scraping
when rotatedby firEer
A A o
Turbineand compressor Rotationby fingeris not Possible
Rotorshat play irEPection
Corsiderable shakingbetween
rotor shafl and turbo ASSY z__.\ A o
Look throLEhoil hole Carbon sludgehas accumulated
(inspectintenorwithPenligm) in waste oil f|ob
l \ ll A
The valvedoes not mo\r'e
smoothlywhen pressureis
Swing valveoperation
(usearr gunor atr PumP)
applied gradually.(LlSually
opens @
at pressuregreaterthan 0.6 - 0.7
kg/cm')
@ Highlypossible O Possible ZI Slightlypossible
E N. 7 4
ON-VEHICLE
PARTS
i 3 . al : - i ENGTNE
1O-8 EXHAUSTMANIFOLDASSY REMOVAL& INSPECTION

FRONTSIDE REARSIDE
Exhaustmanifoldcover Exhaustmanifoid
B or ( 3 1 9 Bolt(3)p
0 3 8- 0 . 5 1 0 . 3 8- 0 . 5 ' 1
l P o r n4t l lPoint4l
Exhaustmanifoldgasket
\ a
I
v
W
N u t( 6 )1 . 8- 2 . 4
lPoint21pJ ,u,,,.Iii"-r
2l
oQ4,*,3l
lPornt PJ lPoint
l-/ kq-m
$ Replace after every disassembly
Additionalworkrequired:
. Turbocharger
removal
andinstallation
. Gasleakinspection
IPoint1]
[Point1] Gasleakinspection
. Afierremovingexhaust manifold,
makesurethereare
notracesof gasleaksfromanyparts.
. Aftertheinstallation,
cranktheengineandcheckforany
oas teaKS.
[Point2] Removeand installexhaustmanifoldnuts ; REARSIDE

Removal
. Removalis the reverseof installation
seouenceshowntn
the diagramon the right.
Installation
. Theinstallation
sequenceis shownin thediagramon right.
Tighteningtorque (kg-m): 1.8-2.4
4 1 3
[Point3] Exhaustmanifoldinspection
. Measurethe exhaustmanifoldsurfacefor distortions in
sixseparatedirections(oppositedirections,
up,down.left,
right,horizontally
andvertically)
in a numberof locations.
Limit(mm): 0.3
EN-75
PARTS
ON-VEHICLE
RB26DETE
TNGINE
[Point 4] Install exhaust manifold cover FRONTSIDE REARSIDE

A
. Attachthe exhaustmanifoldcoverboltsin thefollowing B
: L
sequence.(bothfront& rear) \'--<i
1 . Temporarilytightenboltsfor positionsindicatedby A. fi-'-_--------, .\
.r__r1 )t/
2 . Tightenboltsin the positionsindicatedB. :
B
3 . Tightenboltsin holesA to specifiedtighteningtorque.
10-9 SPARK PLUGS
- o.
p) eott1a;o.oa transistor
O f n a m e nbt o l t( 2 )0 . 2 3- 0 . 3 1 9
'w:
Ornament bolt(B) Screw(3)
0 . 2 3- 0 . 3 1 9 lgntion aor bracket
ornament -i '.
:eo
J
\,,.#)r- *d
='v
I 5CarF.p Ug
l g n r t r o cno t l harness
le/ Kg_m
. RemoveandinstallairinletPiPe
. Removeand installblowbYhose
[Point1] Removeand installignitioncoil bracket -

\Bolt0.23 0.31
Removal
. Holdthecoilbodywhenremovingthe ignitioncoilbracket.
Caution:
Do notholdthe coilconnectorwhenremovingit
lnstallation
. Makesureto attachthe ignitioncoilharnesswhen
installingthe ignitioncoilbracketto the cylinderhead
Platinum\tip
Seatingmetal \
[Point2] SParkPlug maintenance
fFt
. Gapinspectionand adjustmentis not necessaryas a , JLT
platinumtipis used.
. Replacethe plugevery'100,000km.
. Whenusinga compressedair sparkplugcleaner,clean
the plugsat maximumpressureof 6 kg/cm2for no more
than20 seconds.
EN.76
ON.VEHICLEPARTS
R B 2 6 D E TE
TNGINE
10.10 ROCKERCOVERREMOVAL& INSTALLATION
Fillercap Rockercoverscrew
(left& right10 each)
O-r'ng--,@
-a
Grommet
Rockercover
Rocker cover gasket 1|/ I
lPoint3l .A ,.' I
'/a.tt orlamenl
s3;Tl":":.1' Rocker
Rocker
covergasketIPoint3l
. Removeandinstallairinletpipe
. Removeand installblowbvhose
[Point 1] Removeand install rocker cover screw

Removal
. Removethe screwsin reversesequenceshownin the
figureon the right.
Installation
. Performinstallation in thesequenceshownin thefigureon
theright.
[Point2] Rocker cover installationsurface

inspection
. Checkthatno oil,dirtor foreignmaterialadheresto the
cylinderheadinstallationsurface.
[Point 3] lnstall rocker cover gasket

. Makesurethe rockercovergasketis positionedsecurely
in groovewithouttwisting,pinchingor protrusion.
EN-77
ON-VEHICLEPARTS
RB26DETE
TNGINE
10-11 TIMINGBELT REMOVAL& INSTALLATION

^ T t m r n gb e l l c o v e r L o o e r '
Urommer lpoint4] /
(2),,,J,,_
elBo,t --ffi<l;{:gi' :::'^^.,, _=-.:;.-"-
J
*ffi'Pffi
ffi|"*\-,Fiql ,,1 =--
c r a n k €-\n s r e s e n s\ { \ , - _ * \ l \ l;i,""?l' \ fi\f , - x - . . )
[Point2] I \Al,
_liirQ@,"6;{ryt
\h\'10,d"-
^^ :.
_# 5----J
C o n i c aw
l asher
t?* "':]:;:,N+qf,ffi*;,
;,,,,;['t'l \^&\
\ [::"1:N \3\J \ Y- \,',,i,nno",,p,aterPo,nt.r
h "rr::Jil';'"":;"'''
$ W\$, [*,"1J;1\::;q
\tr v
I r'mrn9o€rtcover(towerr
lpornt4]
, . i , . -- I g o t t , 3 to . : - o s
oil
It Engine
$ neplace after every disassembly

. Draincoolingwater
. Removeand install
. Undercover
. Radiator,fan shroud
. Coolingfan
. Supplemental belts
. WaterpumPPulleY
. Sparkplugs
. CheckNo. '1cylindercompression T.D.Cposition[Point1]
. Installringgearstopper[Point3]
inspection
[Point1] No. 1 cylinderpressureT.D.C(top dead enter)
. Aligncrankpulleytimingmarkand beltcovertiming
Timing indicator
(0oposition).At thistime,No. 1 cylinderis in
indicator
compression T.D.Cpositionwhenthecamshaftis located
as describedin the followingsituations.
,r 7\
-<-!tr
EN-78
ON-VEHICLE
PARTS
R3 : ' - - ) = - - E N G I N E
No. 1 cylinderis at compression

topdeadcentre(T.D.C)
whenbothintakeandtheexhaustsidecamsdo not
movethevalvelifters.
Removethe lockercoveroil fillercap fromintakeside

and checkthatfrontendof the camshaftfacesintake
side.
Intakeside
[Point2] Installcrank anglesensor

. Applychassisgreaseto driveunit(spline) during
installation.
. Thereis a flangeinsidethedriveunitsplineso thespline
hasonlyoneinsertion position.Checkthealignment
visuallybeforeassembly.
. Checkthatthe crankanglesensorcan be easilyinserted
in beltcoverholesandsensormoveslightlyto rightand
left,thentightenthe bolts.
. Whenthesensordoesn'tmovelightly,loosenbeltcover
boltsto positionwhenthecrankanglesensorwasinserted.
Movethebeltcoverlightlyhonzontally andvertically
to align
it so the beltcoverholesand the camshaftcentreare
aligned.Thentightenthe boltsso the crankanglesensor
moveslightly.
[Point3] Remove& installcrankpulleyand the bolt

Removal
. Removethe startermotorand attachthe rinooear

stopper.
. Usea pulleypuller(steeringwheelpuller)to removecrank

pulley(boltsize:MGx '1.0lengthbelowheadapprox.
5 0m m ) .
EN-79
PARTS
ON-VEHICLE
RS26DETE
TNGlNE
lnstallation
. Positionthe washerfor the crankpulleyboltsso the
surfacenot markedR contactsthe crankpulleysideand
thenassemble.
. Applyengineoil to thethreadsof the crankpulleybolts.
[Point4 ] Remove& installtiming belt cover

Removal
. The timingbeltcoveris separatedintoupperand lower
parts.Aftercrankanglesensoris removed,removethe
timingbeltcoverin the orderof upperandthenlower.
lnstallation
is in reversesequenceof removalprocedures.
. lnstallation
Caution:
Caremustbe takennotto scratchor damagethedriedliquid
packingwhenremovingandinstalling thetimingbeltcover.
[Point5] Remove& installbell tensionernuts

. Securethetensionerwithhexagonal wrenchwhen
removingand installingthe belttensionernuts.
Caution:
Do not looseninsertedstudwhendisassembly
Tighteningtorque (kg'm): 4.4- 5.9
[Point6] Installconicalwasher
directionof the conical
. Payattentionto installation
washers.The washershouldbe setwithfacewith
chamferedsidefacingthe tensionerpulleyside
[Point7] Installtensionerspring
. Assemble thetesioner pulley
springto thebelttensioner
asshowninthefigure.
. Thetensionerspringmustbeassembled withthe
together
pulleyinthecylinder
belttensioner block.
. Hookthetensionerspring
on theuppersideofthetensioner
springstudwhenthetensionerpulleyis free.
EN-BO
ON.VEHICLE
PARTS
a i . E DE - T E N G I N E
Tensionerspring specifications puley

,Whenset
Freeangb (-)
1 . 8m m A p p r o x . 2 0 " A p p r o x1. 6 3 " Yellow-green
[Point8] Installcranktiming pulley& ptate

. Caremustbe takenof the rearandfrontpositioning when
installing
timingbeltplate,thecranktimingpulleyandthe
timingpulleyplate.
[Point9] Timingbelt alignmentmarkverification

and installation.
. Painta markon the beltthatindicatesrotationdirectionif
painton the upperbeltis unclearwhendisassembly.
. Positionthe alignmentmarkson the intakeandthe
exhaustcam pulleyswiththe respective beltcover Cam (, r n. Q
r aaKme )
alignment marks.(No.1 cylinder is at T.D.C)
. Positionthealignment ,;i'/5
markon thecranktimingpulleywith
therespective oilpumphousingalignment marks.At this
mrng
timethe groove mustbe straightup (no.1 cylinderis at
T.D.C).
. Movethe belttensionerclockwise70 - 80 degreeangre,

and secureit temporarily
withthe belttensionernut.
. Installthe beltby aligningthetimingbeltandthe pulley

marks.Alignthe numberof ridgesof exhaustcam pulley
alignment markandthecrankpulley(inner)alignment mark
as shownin the figureon right.
. Afterlooseningthe nutsandadjustingthe belttension,

securethetensionerwiththe hexagonalwrenchso it will
notrotatetogetherandtightenthe nut.
Caution.
(1) Makesurethetimingbeltengagescorrectlywiththe
pulleyanddoesnotfloatwhenassembling the
timingbelt.
(2) Replacebeltswheneverpossible whendisassembly
is performed.
EN-81
PARTS
ON.VEHICLE
ENGINE
RB26DETT
[Point10] Timing belt tensionadjustment

. Removethe sparkplugandalignthetimingbeltalignment
markandthepulleymarksandinstalltimingbelton to each
pulley.
. Loosenthe tensionersecuringnutso the belttensionis wrench
appliedby thetensioner sPring.
. In thiscondition,rotatethe crankpulleyclockwisemore
thantwoturnsto checkthe beltmovementandstopslowly
compression
at No. 1 cylinder T.D.Cpoint.
. Insertthehexagonal wrenchin hexagonalhole. Holdthe
tensionerby handso the tensionerdoesnot move,and
tightenthe tensionersecuringnutto specifiedtightening
IOrque.
. Theinitialtensionon thebeltin thiscondition
shouldbe
approximately 20 kg.
lPoint 11] Installidler & tensionerpulley

. Do not looseninsertedstudswhendisassembly.lf studs
are loosened,coatinsertedstudwithlocktitesolution
(JapanLocktiteKK)or equivalent.
[Point12] TimingbeltinsPection
. Replacetimingbeltif anyproblems at theinspection.
areindicated
Toothmissing Camshaft lock

Crackedtooth Crank sensorlock
Tensionerlock
Cracks on rear E ngine overheat
side lnterferencewith belt cover etc.
Wear and cracks Beltmisalignment

on theside Belt platemalfunction
Slidingmotionresistancein
Worn teeth crank sensor and the camshaft
Oil or water Oil seal malfunction

adhesion Water leaks in water PumP
Caution:
Do nottwistor bendthe timingbelt . Makesurethereis no oilfilmorwateron thebelt.
EN-82
ON-VEHICLE
PARTS
-=:.]:-T ENGINE
10-12 CYLINDERHEAOASSY
(1) lnstall& removecylinderheadASSY

C,rnder headbol lvl12Y1
5l (14) Cylinderheadbolt(M6x1.0)
l?ii:"1"..*.". rl o^- 12 [Point
2]p)
Cylinderheadbolt(M6x'1
.0)@ , (2)Tlghten
to 11kg-m v--- >pnng wasner
0 92- i.?lpoinr
2]91 f,,' (3) Loosenboltscompletely o_--
II (4)Tighten to 3 kg-nr
\ \fr ll ( 5 )A n g l ew r e n cB
h5 ' - 9 0 '
*,"nch 11+f 05
headASSY
SpringwasherH H ,.t:rlr"
\cr headbolt(1,46x'1
Cylinder .0)
Washer'--? 0.92- 1.2lPoint
2]F:
" R/'
c
{r-- Springwasher
-----J
I is-t
Cam pulley
[Point3]
69 Cylinderheadgasket[Point2]
$ Replaceafter everydisassembly
. Drainand refillcoolingwater '1]
[Point
. Removeand install;
. Collector
. Throttlechamber
. Intakemanifold
. Turbocharger, exhaustmanifold
. Timingbelt
. Rockercover
. Sparkplugs
. lnstallNo. 1 cylindercompression
T.D.Cposition[Point3]
[Point1] Drain& refillcoolingwater

Removal
. Removecoolingwatercompletely fromthe cylinderblock .l o1
. - , ---.-^tn
drainplug. -5-:!9r,"# I'
v
Caution: =:4 ,;\l I
. Makesurecoolingwaterwillnotenterexhaustfronttube. rl) i ,J"1 O-i
Refill
. Referto "Coolingwaterfillingprocedures" i î-l--''
for details. .-i@!Y Plr
EN-83
O\. . :''CLE PARTS
ENGINE
RB26DETT
lPoint 2] Removeand installcylinderheadbolts

Removal
. Removethe boltsin reversesequenceto thefigureson
right.
lnstallation
. Installthe boltsin sequenceshownin thefigureon right.
. The cylinderheadbolt(M12xl .5)aretorquedby two-step 11 7 3 1 5 9 14
method.Tightenthe boltsin two steps. 1 - 1 4 M 1 2 x 15 1 5- 1 7 M 6 x 1 . 0
(1) Tightento 3 kg-m.
(2) Tightened to 11kg-m.
(3) Loosenboltscompletely0 kg-m.
E ".1
(4) Tightento 3 kg-m.
(5) Turnbolts85 - 90oclockwisewhenanglewrenchis :t
:i
useo.
-
Tightenboltsto 10.5 11.5 kg-mwhentorquewrench ."f
is used.
Caution: :t
Whenanglewrenchis notused,neverattemptto F
approximate thetighteninganglevisually.
. Takecarenotto hitor scratchthegasketseatandthe bore
grommetwhenthe gasketis installed.
. Cleanthe cylinderheadlowersurfaceandthe cylinder
blockuppersurfaceto removeallwater,oil and foreign
ob.iectswhengasketis installed.Usecompressed airgun
to blowoutthe boreholes
[Point3] No. 1 cylindercompressionT.D'G

verification T i m i n gi n
. BeforeinstallingthecylinderheadASSYto cylinderblock, :^----/-dq
W
the crank pulleyandthe cam pulleymustbe positionedat
the No. 1 cylindercompressionT.D.Cposition
. Alignthecrankpulleytimingmarkandthetimingbeltcover
timingindicator(0"Position).
. Aligntheintake
andtheexhaust campulleyalignment
mark
marks.
beltcoveralignment
to respective
EN-84
ON-VEHICLE
PARTS
R3 2 6 D E . i TEN G I N E
(2) CylinderheadASSYdisassembly& assembly
va ve spflngTetarner
17' 1s'20)
valveriner
lpoint14]--(>-- -)"'d , :9'": :HX':Jit
ShimlPornt6l- -,
'@d^t , vdlveorlseallpoint231
Valvecollet[P; nl 181 '- - valveguide[Pornt2a]
-
-/ valveseat lPoint25]
g Nut0.92- 1.2lpo]nt5r \ ^-
Springwasher-, \ -- Exhaustvalve[Poinl21,22]
)? 3=-r-
w".n", - i 'P g exnausr
valve 21 221
{Po'nt
aarreprare-J$ v=\
& o,o^
"tn@(E--o
p J e o r r o . s- '22 = - € q-_
,.-D B
Bolr . s -2 -.r 22 lPoint
o r0r92 r p o i n5]t 5 r O
washer-
g/-,Y"tJ"tL"n"o oracket
lpoint5]
g -3t*oruJf,lJi!P!*0rpoinr13,
15,21,24,251
!-_ ^ -":1 ";@fl<.'
. - q.r ! -*gp camshaft,exhaust
s.oe)
ro'i-,zr _ q(ar
rp"i"iag €ffi4pF da5;tl
O"*\ €_ P;i';.]
q rei'",,si
*^@-"ffi,x
Ilk
P
"_rJ F<\
*,;:feffi."jffi4R-g*;.
:;::"
fts,"
" - "";"*:i;r;$
."I?IT9Y\W1
**
backpr"rJ1e"'i
u""tplare
atb-....''
el;t l \
3]--.
[Point
t,.o*
' ."ur TrEn
tpoint
- - o '".. ''
";; t - '*
Q\2.1-2.7 -_€,
@.c"..*n
campurrev
uampullev 2l
rl
{Point
lHornl
to 'ao'r,os:-
--'eo'tt
12)2.1 *e ,,F.\ ,"e-, \:
*\--: ._-S-.-
- s- o.gZ- r.z
r,
_(N
-- *:- - &ilJ,Y,':"rt":i1T'-1.erPo,nr2rg
e- crankangtesensor
bracket 1l
JPornt
gasket
Liqurd
iir, z., _z.rp;
kg-m
Engineoil
Replaceafterevery disassembly

. Removeand installcylinderheadASSY
Crankanglesensor
[Point1] Instalcrank anglesensorbracket
. The crankanglesensorbracketis positionedontothe
Solt(2) 2.1 - 2.7
cylinderheadby usingknowpins.Alignthe positions \",i
correctlywheninstalling
the crankanglesensor.
Grankangle sensorbracketbolt tighteningtorque
(kg-m): 2.1- 2.7 Bolt(2)2.1- 2.7
[Point2] Remove& installcam pulley Boll (4) 1.4- 1

Pu ey holder
Removal ...\-=<:.7
. Fixpulleywitha pulleyholderor sprocketwrenchand
removecam pulleybolts.
Pulleyholder: KV10109900or
KV10109300,
sT31520000,
sT31530000
EN-85
PARTS
ON-VEHICLE
RB26DETE
TNGINE
lnstallation
. Alignthecampulleyknockpinholeandthecamshaftknock
pinto installcam pulleY.
. Usepulleyholderor sprocketwrenchto tightencam
pulleybolt.
'l
Cam pulleybolt tighteningtorque (kg-m): 1.4- .9
. To removeand installcam pulleybolts.usethe proper
toolsto securethe hexagonalpartin frontof camshaft.
[Point3] Remove& installtiming belt cover back

Plate
Removal
. Removebackplateboltand detachbackplate.
lnstallation
. Assemblecanistertubewithbackplateandthen tnstal
backolate.
Backplatebolt tighteningtorque(kg-m):MO0.64- 0.85
M 8 1 . 6- 2 . 1
[Point4] Camshaftend play inspection

. Setthe dialgaugein frontof camshaftas shownin the
diagram.Readthedialgaugerun-outwidthwhenthe
camshaftmovesin frontor reardirection.
Standardvalue (mm): 0.030- 0.080
I 13 11
[Point 5] Remove& install cam bracket
Removal (Exhaust and intake camshaft)
. Placemarksto indicatethe bracketpositionand its
directionbeforeremovingthe cam bracket
. Removecam bracketboltsby looseningthemgraduallyin 12 8 4
2 610
severalstagesin reversesequenceshownin thefigure. 1l
lnstallation
. Alignthecrankpulleytimingindicator
andthetimingbelt
'1
covertimingindicator(0")so No. cylinderis at
compression T.D.Cposition.(Thisoperationis not
necessarywhencylinderheadis removedas singleunit).
. Turnthe camshaftso No. '1cylinderis at compression

T.D.Cposition.(Operationis easierif the camshaftis
turned60obeforeor afterNo. 1 cylinderT D.Cpointwhen
cylinder headis installed as singleunit).
. Verifl/the positionof No.1 cylinderis at mmpressionT D.C
bv knockpin in frontendof camshaft.
EN-86
ON-VEHICLE
PARTS
RB26DETE
TNGINE
To installcamshaft,temporarily
tightenNo. 1cam bracket
and checkthatcamshaftthrustsectionis positioned
securely.
Tightencamshaftbolt540"(1.5turns)in theordershownin
thefigureon the previouspage.
Cam brackettighteningtorque (kg-m):0.92- 1.2
Caution:
(1) Coatthe camjournalsand end of the cam shaftwith
engineoilbeforeinstallation.
(2) Do notrotatecamshaft.(Thevalveand pistonsmay
interfere).
[Point6] Valveclearanceadjustment
No. 1 cylindercompressionT.D.Cpoint
. Turnthe camshafts(intakeandexhaust)so No. 1 cylinder
is at thecompression
T.D.Cposition.
. Checkknockpin positionof camshaftfrontendto verify
No.1cylinder compressionT.D.Cposition.
. No. 1 cylinderis at the compressionstroketop dead

centrewhenboththe intakeandexhaustsidecamsdo not f Valveswhich can be adJusted
movethevalvelifters. lntake side
PART
ITE[I
I N T A K ES I D E CylinderNo. 1, 2, 4
E X H A U S TS I D E CylinderNo. 1, 3, 5 Exhaustside
Firingorder: 1 - 5 - 3 - 6 - 2 - 4
Rotatethe intakeand exhaustcamshaft'180".

No. 6 cylinderis at compressionstroketop deadenter I Valveswhichcan be adjusted
whenboththeintakeandtheexhaustsidecamsdo notmove Intakeside
thevalvelifters.
INTAKESIDE C y 4 i n d eNr o .3 , 5 , 6
E X H A U S TS I D E C y i n d e rN o .2 . 4 , 6
Valveclearancespecifications \2O+l-5C)
INTAKE EXHAUST
Valve clearance (cold) mm 0.45- l 0 3 8 '- ,

(Reference value: warm) mm 0 . 5 1 -l O JJ
Caution:
Alwaysinspectwhenthe engineis cold.
EN.87
PARTS
ON-VEHICLE
RB26DETE
TNGINE
Reference: Compensationby room temperature
o+/-5 10 J 20 q
30 +/- 5
+0.02 +0.01 o -0.01
Valve clearancemeasurement
. Inserta 0.15- 0.20mm gauge(A)fromsparkplugside.
Insertgauge(B)from oppositeside. Selecta gauge
thicknessthatwillreducethe clearanceto 0 m.
Note:
Do not use morethantwo gaugesfor (B).
UseJIS 150A25feelergauge.
Valveclearance= Gauge(A) + Gauge(B)

Reasonsfor measurement usinggauge(A)and(B):
1. Thevalveclearancesettingis largercomparedto
previousengines.
2. Largegaugescannotbe placedparallelto the
measurement surface.
. Thickfeelergaugehavehighrigidityand cannotbe bent
easily,so the measurement willbe incorrect.
. The errorfactorincreasesif a numberof thingaugesare
layeredandthe measurement willbe incorrect.
Valve clearanceadjustment
. Thevalveclearanceadjustment is performedby selecting
a shimof suitablethickness.
. Whenthe measurement valveclearance(t) is out of
measuretheshimthickness(T)and replace
specification,
it witha shimthatwill producethe standardclearance.
1. Shim thicknesscalculationmethod
Example:
Whenthe intakevalveclearance(t) is 0.50mm:
value)= 0.05mm
0.50(t)- 0.45(specified
. Thevalveclearanceis 0.05mm greaterthanthespecified
value.
. Usea shim0.05mm thickerthanthe currentshimto
reducethevalveclearance.
2. Currentshim thickness(T)
. Measurethe centerof removedshimto determinethe
thicknessof the currentshim.
Caution:
Do notreusethemeasured shimsagain.
Do not reuse after
EN-88
ON-VEHICLE
PARTS
R 3 2 6DE - i E N G I N E
3. Shim selection
. Currentshimthickness(T)is 2.40mm.
2.40I\ mm + 0,05mm = 2.450
. Selectnewshimwithstampedmark
124.401
(T =2.440-2.455).
valuerange+f 0.03mm.
Selecta shimwithinstandard
4. Shim types and classification

. Thereare 70 typesof shims.Sizesrangefrom2.275mm
J = 2.440- 2.455mm
to 3.325mm in 0.05mm increments.
[Point 7] Installcamshaftfront oil seal

. Caremustbe takennotto scratchor makea burrin the oil
seal. Usea socketsmallerthantheseal(41mm)anddnve
it intosamelevelas frontsurfaceof the oil sealretainer.
. Applya coatof engineoil to the entireperimeterof oil seal
lrD.
Caution:
Do not scratchtheoilsealandlio.
[Point8] Installcamshaftrearrubberplug
. Beforeinstalling
the rubberplug,wipeoffanyoil,wateretc.
on thesurfaceandcleanthoroughly.
. Whenassembling the rubberplug,coatit withadhesive
(threebond1211) or equivalent.
[Point 9] Intakeand exhaust camshaftclassification

. Intakeand exhaustcamshaftcan be identifiedby
identificationpointcolourand presenceof a spinegear
for drivingthe crankanglesensor.
Intakecamshaft Pink No
Splinegea. for dnvingcrankangle
Exhaustcamshafi White Yes
[Point10] Camshaftknock pin insertion

. Theprotrusiondistanceis 5 mm for camshaft
knockpin
insertion.
Knock pin protrusiondistance(mm): 5
EN.89
ON-VEHICLEPARTS
R826DETT
ENGINE
[Point'11] Camshaftinspection
Cam height inspection
. Usea micrometer camheight.
to measure
Exhau$t 3Ue
Cam.heig.ht,stt dard.value 40.58 40.28
8.58 8.28
Camjournalexternaldiameterinspection
. Usea micrometerto measurethe externaldiameterof the
journal.
camshaft
No. 1 - No. 7
27.935- 27.955
[Point12] Camshaftrun-outinspection l
. Supportbothcamshaftendjournals(No.1 and No.7) by D i a l g a u g e\ h
)al q.-
usingV-blockson thefixedsurface.
. Avoidthe oil groovein the centreof the No.4 journaland
positionthe dialgaugevertically.
. Rotatethe camshaftby handone rotationand readthe
movementwidthon thedialgauge.
. The run-outis equalto one-halfof the movementwidth
indicatedon thedialgauge.
Standardvalue (mm): 0.05
[Point13] Cylinderheadcambracketinteriordiameterinspection
. Tightenthe cam bracketto specifiedtorque
- '1.2
Cam bracket bolt tightening torque (kg'm): 0.92 -
> ,-v,, - r:
' :--..
'l
. Usethe boregaugeor insidemicrometerto measure . i
r \-t-
r!)/\-
| |
_l
!,::>--:a
interiordiameter.
N o .1 - N o . 7
28.000- 28.O21
mrcrometerI -,,,,-:1
EN-90
ON-VEHICLE
PARTS
R 3 2 ' f E * I E N GN E
[Point14] Camshaftoil clearanceinspection

. The oil clearancecan be calculatedfromthe camshaft
journaloutsidediameter andthebracketinterior
diameter
measured in [Point'l1] and[Point13].
(Oilclearance) = (Cambracketinterior -
diameter)
(Camshafijournalexteriordiameter)
N o .1 - N o . 7
0.045- 0.086
[Point 15] Valvelifter inspection

. Checkthe contactand slidingsurfacesfor wearor
scratches.Replaceif damaged.
. Usethe micrometerto checkthevalvelifteroutside
diameter.
[Point16] Cylinderheadlifter bore inspection

. Checkboresurfacefor wearor scratches.
. Useinsidemicrometerto measurevalvelifterhole
diameter.
Standardvalue(mm): 31.0- 31.020
[Point17] Valve lifter-to-lifterhole clearanceinspec-

tion
. Checkthe clearanceusingvaluesfor thevalvelifteroul
srdediameterandvalvelifterholediametermeasuredin
[Point15] and[Point16].
(Clearance) = (Valvelifterholediameter)-
(Valvelifteroutsidediameter)
[Point18] Remove& installvalve spring

When the cylinderhead is removedfrom the vehicle:
. Usethevalvespringcompressorto removeand installthe
valves.
When the cylinderheadis installedin the vehicle:

. Usethevalvespringcompressor to installvalvespring.
Vaive
EN-91
ON.VEHICLEPARTS
RB26DETE
TNGINE
[Point19] Remove& installvalve collet

Removal
. Usetweezersto removecollet.
lnstallation
. Applya smallcoatingof petroleum jellyto the internal
surfaceof the collet.
. Usea magnetscrewdriver.
1. Uopercolletinstallation
. Attachcolletto the lowersideof the magnetic
screwdriverbladeand installin the valvestem.
2. Lowercolletinstallation
. Attachthe colletto uppersideof themagnetic
screwdriverbladeand installin the valvestem.
Magnel
[Point20] Valvespring inspection

Freelengthand pressureload inspection
. Usethevalvespringtesterto carryoutthe inspection.
46.54
24.0 22.5
White
Caution:
lnstallationloadis the forcerequiredto compressthe spring
lengthto 35 mm.
PerpendicularinsPection
. Placea try squareby the springso it contactsspring Turn
the springand measurethe maximumclearancebetween
upperspringsurfaceandthe rightangleto determinethe
out-of-souaredistance.
'1.8
Limit(mm):
[Point21] InstallvalvesPring
. Installunevenpitchtypespringwithnarrowendtowards
cvlinderhead(identification
colourside).
EN-92
ON-VEHICLEPARTS
R 3 2 6] E T T E N G I N E
[Point22] Valveguide clearanceinspection D i a lg a u g e

. Protrudethe valveapproximately 15 mm towardsthe
combustion chamberand measurelhe valvedeflectionbv
swingingit in direction
parallel to thedialgauge.
. Theclearance is equalto halfof thedialgaugereading. '-J.O
Limit(mm)
Intake
0.1
Exhaust
0.1
.H.gb
. lf clearanceexceedslimit,verifythe valvestemdiameter
andreplacethe valveor valveguide.
[Point23] Valveinspection
Outsidediameter
measurement
1-e
- l --1r € o
l: '-
E
f -fli-?r-it, e q
t \ --r-;' !
c lll
| /-,i,:
L lry- -----cJ
l N
b
a
Vatue a b c d e f s q
1 0 0 . 9 8 + / - 0 .97.45+t-0.15
1 s + s - l 2o^ u^ -. 0o 0. 032! c t.J z.o ^ 45" 30'
99.98+/-0.195.48+/-0.15 7' ^" --0000 8 c (1.2) ?q
+03 ^ ^ 0.02c
95 o u - o - o s s45 30' +t-15'
Be especiallycarefulin handlingand disposalof valvesas the exhaustvalvesarefittedwith

metallic
sodium.
[Point241 Remove& installvalveoil seal

Removal
. Usevalveoil sealpullerto removethe valveoil seal.
Installation
. Usevalveoil sealdriftto installthe valveoil seal.
Drift KV10107501
Drift attachment KV10114800
Caution:
Coatinsideof thevalvesealwithenqineoilbeforeinstallation.
Valveoii sealdriftattachment
_iiaJ,
KV1011480 l
EN-93
PARTS
ON-VEHICLE
ENGINE
R826DETT
. lnstallvalveoilsealas shown.
Valveorl seal
T-
Y,
Intake
[Point 25] Remove & install valve guide

Removal
. Usevalveguidedriftandtap it fromcombustionchamber
sideto remove.
lnstallation
. Reamthe cylinderheadguideholeusingthe valveguide
(whenusing0.5 mm over
reamerat normaltemperature
sizeservicePart).
lntake side 10.46- 10.478
Exhaustside 1 1. 4 6 - 1 1. 4 7 8
headinanoilbathto approximately
Heatthecylinder 150
toolto press
to 160"Candusea valveguidedriftor press-fit
valveouidefromcamshaftside.
Camshaftside
. The press-fitdimensionsareshownin thefigureon right.

10.8+f0.1
. Reaminsideof insertedvalveguidewiththe valveguide

reamer.
Valveg0ld6.reamer
K V 1 0 11 1 6 0 0( i n t a k e l
r<V101 07700-(exhausr) _
E N. 9 4
ON-VEHICLEPARTS
I 3 2 6 C E - I . TE N G I N E
[Point26] Valveseat
Inspection
. Inspectthecondition of contacting
surfaceof thevalveseat o.K
_po*"
andthevalve.
. Replacethevalveseator thevalveif contacting surfaceis
too largeor improper,or grindbothsurfacesand lapwith
abrasivecomDound.
Adjustments
. Whensurfacingvalveseatdueto poorcontact,inspectthe
valveguideclearanceandvalvestepholeclearance.
. Usethevalveseatcutteror thevalveseatqrinderand
finishto standardvalue.
Caution:
Whenusingvalveseatcutter,pressfirmlyandcutevenlywith
bothhandsto produceuniformcuttingsurface.
Removal
. Minimize thevalveseatthickness
by cuttingit,thenremove.
Installation
(1) Drivethevalveseatintocylinderheadusingthevalve
seatdrifteras shown,
(2) Whennot usingthe valveseatdrifter:

. Coolthe valveseatfor approx.5 minutesusingdry-ice
. Heatthe cylinderheadto approx.80oC.
. Injectthevalveseatintothecylinderhead.
Caution:
Do nottouchcooledvalveseatwithbarehands.
. Exhaustvalveseatsareavailable in 0.5mmoversize.When (Cutter

diameter)
usingoversizevalveseats,cutand grindthe seating
recessin cvlinderto fix valveseats.
co,
Exhaust co :or
side -- - do__o (Cutter I
diameter)
p, fio, ffio.
+0 113 + i - 01 s ^ ^ 0
JO ?A
0 097
30 32 34.3 37.s O,O ^r
+0.016 ^^ - -015 +/-u.{J:

36.5 32 34.3 5.8
.^ + 0 . 0 1 6 'r? _a -196 ^ ^ 0
0 29.6 32.5 o o , o1
q +0 016
+/-u.ut
0.5 ", 32\::: :: 2 96 5.8
EN-95
PARTS
ON.VEHICLE
ENGINE
RB26DETT
[Point27] Cylinderhead inspection

. Cleanandremoveoil,gasket,sealingcompound,
carbon
andotherforeignmatter.
Measurethe lowersurfaceof the cylinderheadin six

directionsto checkfor any distortion.
Limit(mm): 0.2 Straightgauge
Whenthe distortionisjust overthe limit,resurfacethe

cylinder head.
lf the distortionexceedsexcessivelyoverthe limit,replace
the cylinderhead.
10-13 WATERPUMPREMOVALAND INSTALLATION

Alternatoradjustbar
\ ton1',I o oa- o.esg'1-\
GQi,
d
B o l (t 2 )3 . 2- 4 . 3 I
' t'tl''\>
r- -l r,":'.
'
\
peort1zy
s.z- 4 . 3
D Liquidgasret
M Bolt(6)1.6- 2.1pl
kg-m

. Drainand refillcoolingwater
. Removeand install:
. Coolingfan,waterPumPrelaY
. Alternatoradjustmentbolt
. Timingbeltcover,timingbelt
[Point1] Remove& installwater pump

Remove
. Caremustbe takennotto get coolanton the timingbelt.
Wipe it off immediatelyif anywaterdoesspill
. Removethewaterpumpboltsin the reverseordershown.
1 M 6( 1 ) EM10 (short)
M10 {lonq) 11 M8
EN-96
ON-VEHICLEPARTS
R826DETT
ENGINE
Installation
. Installthe boltsin the numberedsequenceshown.
M6 1 0.64- 0.85
7, 8 , 9 , 1 0 ,1 1, 1 2 tv8 6 't.6- 2.1
2,3,4.5 r\41
0 A
3.2- 4.3
Removaland cleaning
. Insertstubbyscrewdrivers in the boltholesand moveit up
anddownto removethewateroumo.
Caution:
Takecarenotto damagethe screwsin cylinderblockside.
. Usea scraperto removeall liquidgasketfromthesurface.
Caution:
Alsoremovethe liquidgasketremainingin grooves.
. Wipethe installation
surfacewithwhitegasoline.
Installation
. Cutthe nozzleendof liquidgaskettube(KP51000150)as
shownin the figureand usetubepresserfor application.
. Applycontinuous beadof liquidgasket(KP51000150)to

waterpumpsealingsurface.
Llquidgasket2.0 - 3.0 rnm
Caution: wrdealongthe groove
Be sureliquidgasketis 2.0to 3.0mm wide.
Installation
must be carriedout within5 minutesafterliouid
gasketapplication.
[Point 2] Water pump inspection

. Rotatethewaterpumpby handand checkfor abnormal
soundandsmoothoperation.
. Theremustbe no tracesof waterleaks.
EN-97
PARTS
ON-VEHICLE
RB26DETE
TNGINE
10-14 THERMOSTATREMOVAL& INSTALLATION

Thermostat[Point2]
Thermostathousrng[Pornt1]
*r,,
1 )6 - 2 . 1 F j
Borti3
EILiquidgasket
ht
t",aK g - m
. Disconnect and connectwaterinlethose
Caution:
Loosenenginedrainplugto removecoolingwaterfrom
thecylinderblock.
'l] Remove& install thermostat housing

[Point
Removaland cleaning
handleintothermostathousingand
. lnsertthe screwdriver
move it up anddownlightlyto removethe housing.
. Usea scraperto removethe liquidgasket.
Caution:
Makesureto removeliquidgasketin grooves.
. Wipeoffthe surfacewithwhitegasoline.
?aq't
lnstallation
. Cutnozzleendof liquidgasket(KP51000150)tubeas
snown.
2.0 - 3.0 mm wideto centerof flat
matingsurfaceand innerseating
. Applya continuousbeadof liquidgasketto sealingsurface surfaces of boit holes.
usingthetubepresser.Installthe housingwithin5 minutes
aftercoatingliquidgasket
EN-98
ON-VEHICLE
PARTS
ia2a l:--r. ENGTNE
[Point2] Installthermostat
. 'Top'markfiigglevalve)mustfaceup whenthermostatis
insertedin housino.
[Point3] Thermostatinspection
. Checkthevalveopeningtemperature and maximumvalve
tift.
. Hangthe thermostatby stringin valveandsubmergein
heatedwaterin doublewalledcontainer andstirwaterwhile
heatingit up.
. Theopeningtemperature isthetemperature whenthevalve
opensandthermostatfallsfromstring.
76.5
10/90
10-15 INSTALL& REMOVEOIL COOLER,OIL FILTER
. Disconnectand connectswitchharnessconnectors
Caution:
Loosenenginedrainplugto removecoolingwaterfromcylinderblock.(lfwateris onlydrained
fromtheradiatordraincock,thecylinder
blockwillnotdraincompletely).
EN-99
PARTS
ON-VEHICLE
RB26DETE
I NG]NE
[Point1] Remove& installoil filter

Removal () ^ noup,".
1. Removetheoillevelgauge.
2. Removeturbocharged pressurecontrolvacuumhose -@/^
clampand movethevacuumhoseoutof theway. h/
3. Movemainharnessclampout of theway. (lf the oilfilter Small ratchet
-V 1/
comeloose,removethe oilfilterusingthefilterwrench) wrench
4. Useoilfilterwrenchto removeoilfilter.
lnstallation
. Wipeoff dustetc.fromthe oilfiltermountingbracket
surfacebeforeinstallingnewoilfilter.Applya thincoatof
engineoil to oil filterO-ringbeforeinstallation.
. Screwthe oilfilteron bracketby handuntila slight
resistanceis felt,thentightenan additional2/3turnsusing
theoilfilterwrench.Starttheengineandcheckfor oil leaks.
Removal
. Facelowerpartof oil filterdownand moveout in the
directionof the arrowin figureright. Removethrough
aDerturebehindmanifoldcollector.
1O-16 OIL PAN,OIL PUMP& OIL STRAINER

(1) Remove& instaltoil pan,oil pump & oil strainer
g oil pannut(7)
- 4 . 3l P o i n1t ]
@-'3.2
E oil pumpgasket --
f springwasher
OilP p u m p , i t( B ) l Oil strainer[Point3]

0 . 9t 2 - 1 . lPointrt 4l
Eloil pan[Point
2]
Eleat
'11oll s
Front
Oil pump
pDrain ptug
Copper wa\sher
?7*\ t
\t\$r \
), oit panbolt(a)Fl
\ 0 . 6 4- 0 . 8 5l P o r n1t l
O i lp a nb o l t( 1 4 )3 . 2- 4 . 3t P o i n1t 1 p j
i",l Kg-m
f | E n g i n eo i t
$ neptaceafter every disassemoly
. EngineASSY
. Drainand refillengineoil
E N- 1 0 0
ON-VEHICLE
PARTS
RB26DETE
TNGINE
[Point1] Remove& installoil pan bolts & nuts

Removal
. Removeboltsand nutsin reverseorderof installation
sequenceshownin thefigureon right.
Installation
. Installthe nutsand boltsin the orderof sequenceshownin
thefigureon right.
Caution:
Makesurethereareno dirt,dustor otherforeignobjectson oil
installation
surface.
Bolt t Nut
3ize
M,E EEM N/6(Bolt) I 0.64- 0.8s
tv l)Al )o ".i
4 , 7 , 8 ,1 0 ,1 1 .1 2 .1 4 ,1 5 ,
1 6 ,1 7 ,1 8 ,1 9 . 2 1 . 2 2
M 1 0( B o l t ) 14 3.2- 4.3
1 , 2 , 3 , 5 ,6 , 9 , 1 3 lV10 (Nut) 7 3.2- 4.3
[Point2] Remove& installoil pan

Removal& cleaning
. Usea sealcutterto removeand cleanthe oil pan.
. Usea scraperto removeliquidgasketfrommating

surface.
Caution:
Usea scraperto removeall liquidgasketandsealmaterialon
the cylinderblockandoil panflangegroove.Removeall
gasketand otherforeignobjectsin the oil pan.
. Cleanall contactsurfaceswithwhiteoasoline.
Installation
. Cutoffthenozzletipof liquidgasket(KPs1000510)at
pointshownin thefigureon right.
Applyliquidgasketto innersealingsurfaceson the oil pan

as shownin the figureon right.
mustbe performed
Installation within5 minutes.
EN- 101
ON-VEHICLEPARTS
RB26DETE
TNGINE
. Applyliquidgasket(KPs1000150)to areas7 mm inside

fromcenterof the oil pan boltholes.
Caution:
(1) Makesurethe liquidgasketis applied4.0 mm wide.
Q\ Waitat least30 minutesbeforerefillingthe engineoil
andenginecoolantafterinstallation.
[Point 3] Installoil strainer

. Makesurethe O-ringis installedsecurelyin groovewhen
installingtheoil strainer.
Tighteningtorque (kg-m): 1.6- 2.1(Mg)
0.64- 0.85(M6)
[Point4] Oil PumPbolt

. Thereare4 typesof bolts. Makesureto usethe correct
boltswhenthevare installed.
20 4 0 . 9 2- 1. 2
2 35 2 0 . 9 2- 1 . 2
3 45 0.92- 1.2
4 55 0 . 9 2- 1 . 2
[Point 5l Remove& install front oil seal

Removal
. Usea toolsuchas screwdriver to removefrontoil sealfrom
the frontcover.
lnstallation
. Caremustbe takennotto scratchor damagethe oil seal
retainer.Useoilsealdriftandinsertit at samelevelasfront
surfaceof the oil PumPhousing.
. Applyengineoilor chassisgreaseto areaaroundtheoil
seallip.
[Point6l Oil leak& oil pressureinspection

warmup the engineand checkfor any oil
. Afterinstallation
leaksandtheoilPressure.
. Removeoil pressureswitchand attachoil pressuregauge
whenmeasuringoil Pressure.
ldling 2000 6000
Approx.1.5 Approx.3 A p p r o x . 4 . 6
EN - 102
ON.VEHICLEPARTS
R 3 2 6D E i T E N G ] N E
(21 Oil pan disassembly& assembly
B o l it 2 l 0 6 4 - O . ApS
Boto.6a-0.85I
t",/
Bolt(4)
74r'
ri\
\ie-".
Rrffla ^l.la
ti,
lv/ Kg_m
(3) Oil pump disassembly& assembly
Purnphousrng[Pornt
Innergear [Pornt2]
Outergear [Point1]
piuga.O- z Opl
Regulator
19*n-'
[Point1] Oil pump inspection
. Checkinnergear,outergearand housingfor any scratchesor wear.
. Usethicknessgaugeto measurethefollowingclearances:
Outergear and housingclearance 0.114- 0.2

2 Outergear and innergear clearance B e l o w0 . 1 8 0
3 lnnergear and housingside clearance 0.05- 0.07

4 Outergear and housrngsrdeclearance 0.05- 0.11
5 lnnergear and housingflangeclearance 0.045- 0.091
Measurement position5 is obtainedby subtracting

the housingflangeoutsidediameter
fromthe innergearinsidediameter.
EN- 103
PARTS
ON-VEHICLE
RB26DETTENGINE
[Point2] Regulatorinspection
. Checkoil pressureregulatorvalveslidingsurfaceand the
springforanywearanddamage.
Valveand valve hole clearance(mm): 0.04- 0.097
[Point3] Installinnergear
. Caremustbe takento installthe innergear in a specific
direction.
. Facethe sidewiththe grooveto the coverside.
Coverside
E N- 1 0 4
ON-VEHICLE
PARTS
I 3 2 :E E N GN E
10-1 COLLECTOR ASSY

(1) CollectorASSYremoval& installation
Air reieaseplug IPoint

Acceleration
wife bracket[Point2]
Collector
ASSY
IS--.-,.,^ I
Y
oort(a)$l
collector
1 . 8- 2 . 2l P o i n3t l
g
:'j:i,i",ili'lr
?3'
Fi.
gasket
E Collector
ft.,
$./.1Ks-m
E Replace
. Releasefuelpressurein thefuel lines
[Point1]
. Drain& refillcoolingwater[Point4]
. Acceleration wire[Point2]
. Airduct
. Harnessconnector
. All hoses
[Point1] Releasefuel pressure

. Starttheengine.
. Afterstartingtheengineremovethefuelpumpfuseandwait
untilthe enginestops. Crankenginetwo or threetimesto
consumefuelremainingin the fuelpipes.
. lf thevehicledoesn'tstart,removethefuelpumpfuseand
crankthe enginefourto fivetimesto consumefuel
Caution:

accelerator.
. Returnthe locknut 1.0to 1.5turnsfromthe oositionthe
throttledrumstartsmoving(whenthereis no playin cable)
andtighten.
E N- 1 0 5
PARTS
ON-VEHICLE
R B 2 O EE N G I N E
[Point3] Remove& installcollectorbolts

Removal
. Removethe boltsin the reverseorderof the figureon
right.
lnstallation
. Installthe boltsin theordershownin thefigureon right
uniformlyin two to threestages.
[Point4] Air releasePlug

. Formoreinformation referto the sectionon coolingsystem
lateron in themanual.
. Carryout the operationwhenengineis cool.
Caution:
Do not removethe air releaseplugwhenthe engineis hot.
. Removetheairreleaseplugto releasetheairwithinthe
enginecompletely whenrefillingcoolingwater.
Caution:
Care must be taken not to over tightenthe air releaseplug
bolt.
(21 & assembly

CollectorASSYdisassembly
Throttlechambergasket
2l $
tPoint
Throttlechamber[Point1]
- Throttlechamberbolt (4) p ) M c v a l v e A S SbYo l (t 4 ) 0 . 8-6 1 . 1

1.8- 2.2tPoint
1lpl
Fi.
lv.l Kg-m
$ neptaceafler every disassemol,

. Removeand installcollectorASSY
E N- 1 0 6
ON-VEHICLE
PARTS
i32]: E\GINE
[Point1] Remove& installthrottlechamberbolt

Removal
. Removethe boltsin the reverseorderof thefiqureon the
right.
Installation
. lnstallthe boltsin theordershownin thefigureon right
uniformlyin two stages.
Tighteningtorque(kg-m): Firststage 0.9- 1.1
Secondstage 1.8- 2.2
[Point 2] Throttle chamber gasket

. Checkthe installation
directionbeforeinstallinq
thethrottle
chambergasket.
I =il;-
10.2 INTAKEMANIFOLD ASSY
(1) Remove& installintakemanifoldASSY
Intakemanifoldgast<et
$
-_.4-
_
Fi
t-.1
a Replace

. RemoveandinstallcollectorASSY
. ECCSharnessconnectorand allhoses
E N- 1 0 7
PARTS
ON.VEHICLE
[Point1] Remove& installintakemanifoldASSYbolts and nuts

Removal
. Removethe boltsandnutsin the reverseorderof thefigure
on right.
lnstallation
. Installthe boltsand nuts in theordershownin thefigureon
1 17 3 1 5 I
right,
(2) IntakemanifoldASSYdisassembly& assembly
.J -
\* Arr regulator
{4
bolt0.5- 0.6
p) Air ;egulator
FueltubA
e SSY
I P o i n1t l
Fueldamper -
n
;*,,i
reguralor
Water outlet
7i
Boltt-,4
1 . 8- 2.2
Bolt(2)1.6- 2.191
$ Replaceafter every disassemble
Fueltubebolt1.0- 1.2 El Liquidsasket

I
I *s-'
. RemoveandinstallintakemanifoldASSY
[Point1] Fueltube ASSY regulator

Pressure
. Replacethe O-ringto newoneswhenremovingand Fueltube injector
installingthe pressureregulatorandthefueldamper.
Caution: Fuel damper
Caremustbe takennotto scratchor damagethe fueltube f
O-ringareawheninstalling andthefuel
thepressureregulator
damoer.
E N- 1 0 8
ON-VEHICLEPARTS
[Point 2] O-ring(for fuel injector,pressureregulatorand fuel damper)

. CoattheO-ringwithengineoil (7.5W-30or equivalent) or
siliconoil(NUCsiliconL45or equivalent),butdo notapply
solventas thismay removeoil coating.
. AvoidusingdirtyO-ringsanddo notallowdirt,dustor
surfaces.
. Caremustbe takennotto scratch,twistor stretchthemov
toolsor operator'sfingernailswheninstallingO-rings.
. Do notdecenteror rotatethefuel injectorsandthe
pressureregulatorwheninsertingthemintothefueltube.
. Do notstoreO-ringsin locationsubjectto ozone,high
temperature or in directsunlight.
10.3 REMOVE& INSTALLEXHAUSTMANIFOLD

ASSY
Exhaustmanifold plor sensor4.1 - 5.1
? ' * o i
P.P
yoke[potnt3) . P
WasherfPoint4] ,
zj"
z.a- s.zieornt
p ruut
ri
\-/ Kg-m
Replaceafter every disassemble
. Undercover
. Assembleanddisassemble exhaustfronttube
. O, sensorconnector
[Point1] Gas leak inspection

. Afterremovingthe exhaustmanifold,makesurethereare
no tracesof gas leaksfrom any parts.
. Afterthe installation,
crankthe engineand checkfor any
oas leaks.
E N- 1 0 9
PARTS
ON.VEHICLE
lPoint 2l Removeand installexhaustmanifoldnuts

Removal 8 11
sequenceshownin
the diagramon right.
10 6 2 4
lnstallation
. The installation
sequenceis shownin the diagramon
rioht.
[Point 3] Yoke
. Makesure notto makemistakebetweenNo. 3 and No.4
aredifferent.
yokeas configurations
22
24
[Point4] Installwasher
. Makesurethewasheris facingthe correctway when
installing.
+
l\4anifoldside
10.4 REMOVE LOCKERCOVER

& INSTALL
LOCKeTCOVer
Fillercap
. Air duct
. Air duct bracket
. Blowbyhose
[Point1] Remove& installlockercover bolls

Removal 11 6 3 4 8 1
sequenceshownin
the diagi'amon right.
lnstallation
. The installation
sequenceis shownin the diagramon
rioht.
E N- 1 1 0
ON-VEHICLEPARTS
10-5 TIMINGBELTREMOVAL& INSTALLATION
,., 8 e t l e " sc . e r
vvasner
ConicatwasherI i Tensoner spr no fPoint7l
"
glNur4 4 l"."il,t]",".\ i -}- dso
*
tl6'8
Timrngbelt cover(upper)
IPornl4]
Timingbeltcover
Crankpulley[Point3]
Powersteeringpump
pulrey
p a o r r. o ;t . z Cranktrrnrng beltplatelPoint
CranktimingpulleylPoint11]
T i m i n gb e l tl P o i n 9 '121
. 3]
{- t , 10,
Cranktimingpulleyplate[Point8]
ri^..
l-/ borr ( 2 )0 . 3- 0.5
I ts-.
E E n g i n eo i l
after
. Drainandrefillcooling water
. Removeand installthefollowinos:
. Undercover
. Radiator,shroud
. Coolingfan
. Waterpumppulley
. Sparkplugs
. CheckNo. 1 cylindercompression T.D.Cposition[Point1]
[Point1] No. 1 cylinderpressureT.D.C(top deadenter)inspection

. Alignthecrankpulleytimingmarkandthebeltcovertimingindicator. At thistime,the
distributorrotorshouldbe in the positionshownin the diagrambelow,or No. 1 cylinder
in thecompression T.D.Cposition.
E N- 1 1 ' l
PARTS
ON-VEHICLE
[Point2] Installring gear stopper

. Removethe startermotorand installthe ringgearstopper'
'' -*v-ror
[Point3] Pulleypuller(steeringwheelpuller)
. Remove thecrank byusingthepulleypuller.
pulley
(boltsize:M6x 1.0 lengthbelowhead40 mm)
2718
[Point4] lnstalltiming belt cover

. Attachthe gasket(spongerubber)on the timingbeltcover
(upper)as shownin the figure.
[Point5] Remove& installbelt tensionernuts

. Securethe belttensionerfirmlywitha hexagonalwrench
whenremovingand installing the belttensionernuts.
[Point6] Installconicalwasher a I
-[__T--r
r I I I
. Paycloseattentionto the installation
directionof the
conicalwashers.The washershouldbe set withfacethe \\
\_J \
chamferedsidefacingthe tensionerpulleyside t l
Nrt Conical
washer
IPoint7] Installtensionerspring
. Assemble thebelt
springso it engages
thetensioner
pulleyasshowninthefigureonright.
tensioner
. The tensionerspringmustbe assembledtogetherwiththe

belttensionerpulleyin the cylinderblock.
EN-112
ON-VEHICLE
PARTS
Fixthebelttensioner andhookthespringon topofthe

studvoltby rotatingthe springanticlockwise.
pullfy Spri
1 . 8m m Approx.20' Approx.227'
When free
Timingbeit pulle'
tar
[Point8] Installcrank pulleyand plate ---------
. Be carefulto observefrontand rearpositioning
of timing ]--lu
beltplate,
cranktimingpulleyandcranktimingpulleyplate il
wheninstallationis oerformed. t.t tr
E- ll
- -lf-- o)o"u
[Point9] Timingbelt alignmentmarkverification

. Checkif the cam pulleyalignmentmarkis alignedwiththe
cranktimingpulleyalignment markwhenNo.1 cylinder is
at compression T.D.C.
. Checkthenumberof ridgesbetweenthecampulleyand
thecranktimingpulleyalignment
marks.
Markon eachpulleyat thealignment

position
withwhite
paintif thetimingbeltalignment
mark(whitepaint)is not
clear.
Positionthe timingbeltso the backsurfacearrowis facing

the enginefrontandalignthealignmentmark(whitepaint)
withcam pulleyandthe cranktimingpulleyalignmentmark
wheninstalling a newtimingbelt.
Checkthe ridgesafterthe installation.
EN- 113
PARTS
ON-VEHICLE
[Point 10] Installtiming belt

. Assemblethe tensionerspringso it engagesthe belt
tensionerpulley(followpoint7).
. The tenstonerspringmustbe assembledtogetherwiththe
belttensionerpulleyin the cylinderblock,
. Inserthexagonalwrenchintothe belttensionerhexagonal
holeand rotateclockwiseto tightenthe nuttemporarily
. Alignthetimingbeltalignment markswitheachpulleymarks
andinstalltimingbelton to pulley.
. Tightenthe tensionersecuringnutsto specifiedtightening
torque.Tighteningtorque (kg-m): 4.4- 5.9
[ P o i n t1 1 ]C r a n kt i m i n gP u l l e Y
. Makesureto installthecranktimingpulleyin a correctway
Somecranktimingpulleyhastwo key groovesand
alignment marks.
Keygroove
[Point12]Timing belt tensionadjustment
. Loosenall rockershafttighteningbolts.
. Rotatethe tensioneranticlockwise two to threetimes
usinghexagonalwrench. (itis notnecessaryto rotatebelts)
. Fixthe tensionerusinghexagonalwrenchand tightenthe
nutsto specifiedtighteningtorque. (At thisstagespecific
tensionwill be appliedto the beltsautomatically).
[Point13]Timingbelt insPection
. Replacetimingbeltif inspectionindicatesany problem.
Toothmissing
Cracked tooth @ Camshaftlock
Crank sensor lock
Tensionerlock
Cracks on rear Engineoverheat
stde with belt cover etc.
lnterference
Wear and cracks

on the side .J.D
/,ilh nn
Beltmisalignment
Belt plate malfunction
S lidingmotionresistancein
Worn teeth Jary ]!lg crank sensor and the camshaft

adhesion Water leaks in water PumP
9.6 REMOVE& INSTALLOIL PAN,OIL STRAINER, OIL FILTER

. Referto RB20DE,DETsectionlateron in the manualfor detail
E N- 1 1 4
ON.VEHICLE
PARTS
R B 2 O D /ED E TE N G I N E
10-1 COLLECTOR ASSY

(1) Remove& installCollectorASSY
cottectorbott/2)lctl
Accelerator
wire bracket[Point2]
1.8- 2.2IPoint
--{{3lrci Co ecrorASSI
l
e | ,---_,--4
gasket
E Collector
Air releaseplug [Point4]
collectofbolt \2) - &

1 B - 2.2 lPornt31p)
tli
\-,i k g - m
a Repiaceafter every disassembly
. Releasefuelpressure in thefuelline[Point1]
. Acceleration
controlwire[Point2]
. Air duct(RB2ODE), Air inletpipe(RB20DET)
. EGIharnessconnector,harnessclamp
. All hoses
[Point1] Releasefuel pressure

. Afterstartingthe engineremovethe fuelpumpfuseand
waituntiltheenginestops.Crankenginetwoor threetimes
to consumefuel remainingin the fuel pipes.
. lf the vehicledoesn'tstart,removethe fuelpumpfuseand
crankthe enginefourto flvetimesto consumefuel
Caution:

. Loosenlocknut to provideadeouateslackfor the
accelerator wireand oulloutercasein directionof the
accelerator.Returnthe locknut 1.0to 1.5turnsfromthe
positionthe throttledrumstartsmoving(whenthereis no
playin cable)andtighten.
E N -1 1 5
ON.VEHICLEPARTS
[Point 3] Remove & install collector bolts 9 5 2 4

Removal
. Removethe nutsin the reverseorderof thefigureon right.
Installation
. Installthe nutsin the ordershownin thefigureon right
uniformlyin tvvoto threestages.
7.10 2 105
8 65
1,3,4,6, 4Q
2 , 5 , 9 .1 1 4 30
[Point4] Air releasePlug

. For moredetailreferto coolingsystemlaterin the manual.
Caution:
Do not removethe air releaseplugwhenthe engineis still
warm.
. Makesureto removeair releaseplugwhenrefillingthe
coolingwaterto releaseairwithinthe enginecompletely
(overheatprevention).
(21 CollectorASSYdisassembly& assembly
*:;::*;l;;,'"'*>e
H41,
B o l (t a )0 . 9- 1. 19
Castetq3 Throttle gasketlPoint2]E

chamber
Throttlechamber
Throttlechamberbolt (4)
z2- --..- 1 . 8- 2 . 2 [ P o i n 1t ] $ I
a:// *)",. no""

I ts-t
$ Repiaceaftef every disassemble
. Removeand installcollectorASSY
E N- 1 1 6
ON-VEHICLEPARTS
[Point1] Remove& installthrottlechamberbolts

Removal
. Removethe boltsin the reverseorderof thefigureon right.
Installation
. Installthe boltsin the ordershownin the figureon right
uniformlyin two stages.
Tighteningtorque (kg-m): First stage 0.9- 1.1
Secondstage 1.8- 2.2
[Point2] Throttlechambergasket
. Checkthe installation
directionbeforeinstallino
the throttle
chamber gasket. .)
oVo
10-2 INTAKEMANIFOLDASSY
(1) Remove& install intake manifold ASSY
lntakemanifoidASSY
Fi
\-.4
a Replaceafter everv disassemble
. Remove& installconnectorASSY
. ECCSharnessconnector,all hoses
E N- 1 ' 1 7
ON-VEHICLEPARTS
[Point1] Remove& installintakemanifoldASSYbolts and nuts

Removal 'io I 6 4 13 14
. Removethe boltsand nutsin the reverseorderof thefigure
on right.
lnstallation
. lnstallthe boltsand nuts in the ordershownin thefigureon
rioht.
B 7 2 3 5 1 11 2
(2) Intake manifold ASSY disassembly& assembly
a t"t t I t.o-
pl eott1r;gnt lPornt,,
injector p) aonrZtO.6a' O.SA
?_
Air regutator
,-- 1,
Fuel tube InjectorASSY
p prpenSSY
Water-outlet
lntake manifold Bolt(6) 1

Bolt(2) 0.4 -
a
Fi
Liquidgasket
\",i K g - m
. Remove& installintakemanifoldASSY
[Point1] Fueltube ASSY

. Replacethe O-ringto new oneswhen removingand
installingthe pressureregulatorandthe fueldamper.
Caution:
Caremustbe takennotto scratchor damagethe fueltube
O-ringareawheninstalling the pressureregulator'
[Point 2] O-ring (for fuel injector pressure regulator)

. Coatthe O-ringwithengineoil (7.5W-30or equivalent), but
do notapplysolventas this may removethe oil coating.
. AvoidusingdirtyO-ringsanddo notallowdirt,dustor
foreignobjectsto adhereto O-ringsor otherequipment.
. Caremustbe takennotto scratch,twistor stretchthemby
toolsor operator'sfingernailswheninstallingO-rings
. Do notdecenteror rotatethefuelinjectorsandthe pressure
regulatorwheninsertingthemintothefueltube
EN-118
ON.VEHICLE
PARTS
R 8 2 ,D
1 ]E D E TE N G I N E
1O-3 REMOVE& INSTALLEXHAUSTMANIFOLDASSY
Exhaustmanifoldgasket
Exhaustmanifold
Bolt(3)0.a- 0.5I
YokeIPoint3]
')@
washer potnt ti
-
| ) Nut2.8 3.2IPoint2, 3l
Fi B o r t (07. i4 - o 5 I
\",1xg-m
$ Reptaceafter every drsassemble

. Undercover
. Disassemble exhaustfronttube
. Exhaustsensorconnector
. Gasleakinspection [Point1]
RB20DETonly
. Intercoolerairinlettubehose
. Turbocharger
[Point1] Gas leakinspection

. Afterremovingthe exhaustmanifold,makesurethereare
no tracesof gas leaksfrom any parts.
. Afterthe installation,
crankthe engineand checkfor any
gas leaks.
[Point2] Removeand installexhaustmanifoldnuts

Removal
seouenceshownin
thediagramon right.
Installation
. The installation
sequenceis shownin the diagramon right.
E N- 1 1 9
PARTS
ON.VEHICLE
[Point 3] Yoke
. Makesure notto makemistakebetweenNo. 3 and No.4 c 0.5
is different.
yoke as configuration
P (mm)
22
24
[Point4] Installwasher
. Makesurethe washeris facingcorrectway when
installing.
Manifoldside
1O-4 REMOVE& INSTALLSPARK PLUG
Ornament narness
Ornamentbolt(B)0.30- 0.39
F i \
l'/ \,-
Groundcable
Bolt 1.0 - '1.2 lPo]nt1l

- 3.0
Sparkplus 2 . o
Washer fPoint3l ri
.-'--'/ \".4
\
,/
lgnitionc o i lb r a c k e t
lPoint2] ,,-'1
L- \
./'/-/.
l9l *n-'
. Air duct(RB20DE),Air inletpipe(RB20DET)
. Blowbyhose
. Powertransistor
[Point1] Remove& installignitioncoil bracketbolt

. Lengthof the bracketboltbetweenRB2ODE
and RB2ODET
are different.
22 25
E N- 1 2 0
ON.VEHICLEPARTS
[Point2] Installignitioncoil bracket B o l t' 1 . 0- '1.2

. The ignitioncoilbracketthicknessdiffersbetweenRB2ODE
and RB20DETvehicles.
. Wheninstalling ignitioncoilbracketto cylinderhead,check
thatground lineis connectedsecurely.
[Point3] Sparkplugmaintenance
. TheGapinspection andadjustment is notnecessary
as
plat,numtipis used.
. Change thesparkplugevery100,000 km.
. Whenusingcompressed airsparkplugcleaner, cleanthe
plugsat maximum pressureof 6 kg/cm2for nomorethan
20seconds.
. Donotusewirebrushto cleanplugs.
10-5 REMOVE
& INSTALL
ROCKER
COVER
-
F i l l e rc a p 9Ornamentbolt(B)0.30 0.39
Lockercoverbolt0.2 - 0.4 [Point'1]
€
e - -- ^
Grommet
- .-4,
Lockercovergasket
Orname'nt
I
Lockercovergasket
Fi
l".i xs-m
. Air duct(RB20DE),
Air inlet(RB20DET)
. Blowbyhose
[Point 1] Remove& install rocker cover screws

Removal
. Performremovalin reverseorderof seouenceshownin the
figureon right.
Installation
. Performinstallation
in sequenceshownin thefigureon
rloht.
EN- 121
PARTS
ON-VEHICLE
10-6 REMOVE& INSTALLTIMINGBELT
Timingbelt cover(upper)[Pornt4]
b e l t[ P o i n 9t , 1 0 , 1 2 ]
Trmrng
i,r"-",ffi..'
r,,'"'
g*
j"t#
-- WW'il.
@aS1 conicar Betttensroner 9. '10.111
[Pornt
P" r\
n,r,'*i.lvS::"fu
pl pol(31
W^,
*?tgO,S'Po;**,)H
o.o.t.
] ?ol'_,0,-9
I - -^6)-... llil'3E w{
609\ -
\-
washer wasner\' t"*t'iilln'flil3#:?lF:ill3]

""""";'.fffi\, SJ"P,;
Bolt44-59 ldlerpullevlPoint'111
"iE"-t,
t, bertcover(rower) 4]
[Point
,.."/b'\])D o\",.]#in
q"fl,:-';,,..""1,","iixilJ,',os-oaap)
91,n.,
Jl Ensn" oi
$ aftereverydisassemblY
Reptace

. Undercpver
. Radiator, fan shroud
. Coolingfan
. WaterpumpPulleY
. Sparkplug
. No. 1 cylindercompression T.D.Cposition[Point1]
[Point1] No. 1 cylinderpressureT.D.C(top deadenter)inspection

. Alignthe crankpulleytimingmarkandthe beltcover
timingindicator At thistime,the No. 1
(0"position).
cylinderis in the compressionT.D.Cpositionwhenthe
camshaftis locatedas describedin the following
situations.
top deadcentre
No. 1 cylinderis at the compression
whenboththe intakeandthe exhaustsidecamsdo not
movethevalvelifters.
EN - 122
ON-VEHICLEPARTS
R B 2 O D iED E TE N G I N E
. Removethe lockercoveroilfillercap fromintakeside

and checkthatthefrontendof the camshaftfaces
intakeside.
[Point2] Installcrank anglesensor

. Applychassisgreaseto the driveunit(spline)during
installation.
. Thereis a flangeinsidethedriveunitsplineso thespline
hasonlyone insertionposition.Checkthe alignment
visuallybeforeassembly.
. Checkthatthe crankanglesensorcan be easilyinserted
rnbeltcoverholesand sensormoveslightlyto rightand
left,thentightenthe bolts.
. Whenthe sensordoesn'tmovelightly,loosenbeltcover
boltsto positionwhenthecrankanglesensorwasinserted.
Movethe beltcoverlightlyhorizontally
andverticallyto align
it so the beltcoverholesand the camshaftcentreare
aligned.Thentightenthe boltsso the crankanglesensor
moveslightly.
l l rn 4 1 n
[Point3] Remove& installcrankpulleyandthe bolt
. Remove thestartermotorandattachtheringgear
stopper.
K V ' 1 0015 6 1 0
. Usea pulleypuller(steering
wheelpuller)
toremovecrank
pulley(boltsize: M6x 1.0lengthbelowheadapprox.
50mm)
lPoint 4] Remove& install timing belt cover

. The timingbeltcoveris separatedintoupperand lower
parts.Aftercrankanglesensoris removed,removethe
timingbeltcoverin the orderof upperandthen lower.
. Installation
is in reversesequenceof removalprocedures.
Caution:
Caremustbe takennot to scratchor damagethe dried
liquidpackingwhenremovingandinstalling thetimingbelt
cover.
EN- 123
PARTS
ON-VEHICLE
[Point5] Remove& installbelt tensionernuts n-<'( /'.)

Hexagonal wrencn
. Securethetensionerwithhexagonal wrenchwhen
removingand installingthe belttensioner.
Caution:
Do not looseninsertedstudwhendisassembly.
[Point6] Installconicalwasher
. Payattentionto the installation
directionof the conical
washers.The washer should be setwithfacethe
chamferedsidefacingthetensionerpulleyside.
[Point7] Installtensionerspring
. Assemblethetesionerspringto the belttensionerpulley
as shownin thefigure.
. Thetensionerspringmustbe assembled togetherwiththe
belttensionerpulleyin thecylinderblock.
; iqipipnr,,.o |,
springontheuppersideof thetensioner
. Hookthetensioner
springstudwhenthetensionerpulleyis free.
/4 \,. "r \
a Tensioner spflng
Tensionerspring sPecifications
1.8 Approx.20" Approx.163" Yellow
[Point8] lnstallcranktiming pulley& plate

. Caremustbe takenof the rearandfrontpositioning when
installingtimingbeltplate,the cranktimingpulleyand the
timingpulleyplate.
EN - 124
ON-VEHICLEPARTS
i:. ]: fEi ENGINE
[Point9] Timing bettalignmentmarkverificationand installation

. Painta markon thebeltthatindicates rotationdirection
if
painton theupperbeltis unclearwhendisassembly.
Positionthealignmentmarkson theintakeandthe
exhaustcam pulleyswiththe respective beltcover
alignment marks.(No.'l cylinder
is at T.D.C)
Positionthealignment markon thecranktimingpulleywith

the respectiveoil pumphousingalignmentmarks.At this
timethe groovemustbe straightup (no. 1 cylinderis at
rD.c).
Movethe belttensionerclockwise70 - 80 degreeangle,
andsecureit temporarily
withthe belttensionernut.
. lnstallthe beltby aligningthetimingbeltandthe pulley

I marks.Alignthe numberof ridgesof exhaustcam pulley
Cranklrmrng
alignment markandthecrankpulley(inner)alignment mark
as shownin thefigureon right.

securethetensionerwiththe hexagonal wrenchso it will
notrotatetogetherandtightenthe nut.
Caution:
(1) Makesurethetimingbeltengagescorrecflywiththe
pulleyanddoesnotflatwhenassembling the
timingbelt.
(2) Replacebeltswheneverpossiblewhendisassembly
is performed.
[Point10] Timing belt tensionadjustment

. Removethesparkplugandalignthetimingbeltalignment
markandthepulleymarksandinstalltimingbelton to each
pulley.
. Loosenthe tensionersecuringnutso the belttensionis
appliedby thetensioner spring.
. In thiscondition,rotatethe crankpulleyclockwisemore
thantwoturnsto checkthe beltmovementandstopslowly
at No. 1 cylindercompression T.D.Cpoint.
. Insertthehexagonal wrenchin hexagonal hole. Holdthe
tensionerby handso the tensionerdoesnot move,and
tightenthetensionersecuringnutto specifiedtightening
toroue.
. The initialtensionon the beltin thisconditionshouldbe
approximately 20 kg.
EN- 125
ON-VEHICLEPARTS
R B 2 O D /ED E TE N G l N E
[Point11] Installidler & tensionerpulley

. Do notlooseninsertedstudswhendisassembly.lf studsareloosened,coatinsertedstud
withlocktitesolution(JapanLocktiteKK)or equivalent.
[Point12] Timing belt insPection

. Replacetimingbeltif any problemsare indicatedat the inspection
Cause
Camshaft lock
Toothmissing
Cracked tooth <? Crank sensorlock
Tensionerlock
Cracks on rear E ngine overheat
side lnterferencewith belt cover etc.
Wear and cracks Belt misalignment

on the side Belt plate malfunction

adheston Water leaks in water PumP
Caution:
Donottwistor bendthetimingbelt. Makesurethereis nooilfilmor wateronthebelt
10.6 REMOVE& INSTALLWATERPUMP
plaott1ryo.64-085
,t \')/
lt
t\
E
ti
Botr(2)3.2- 4
{s' WaterpumplPoint1, 2]
v ffih,u-,,
19 ns-'

. Timingbeltcover
E N- 1 2 6
ON-VEHICLE
PARTS
[Point1] Remove& installwater pump

Remove
. Caremustbe takennotto get coolanton the timingbelt.
Wipeit off immediately if anywaterdoesspill.
. Removethewaterpumpboltsin the reverseordershown.
Installation
. Installthe blotsin the numberedseouenceshown.
Liquidgasket2.0 - 3.0 mm
. Wipeoffoil liquidgasketfromthe cylinderblockandon the wide alongthe groove
waterpumpandwipethe surfacewithwhitegasoline.
. Applycontinuous beadof liquidgasket(KP5'10 00'l50)to
waterpumpsealingsurface.
Caution:
Be sureliquidgasketis 2.0to 3.0 mm wide.
Installation
mustbe carriedout within5 minutesafterliquid
gasketapplication.
[Point2] Waterpump inspection

. Rotatethewaterpumpby handand checkfor abnormal
. Theremustbe no tracesof waterleaks.
10-7 REMOVE& INSTALLTHERMOSTAT
Thermostat[Point2j
ThermostathousinglPoint 1
a \
ff'\,, @
t o-z lPl
p r-rquio
nr"*"?o'ttt'
Fi
!',1 ks-m
. Disconnect andconnectwaterinlethose.
Caution:
Loosenenginedrainplugto removecoolingwaterfrom
cylinderblock.
EN- 127
ON-VEHICLEPARTS
R B 2 O D /ED E T E N G I N E
[Point1] Remove& installthermostathousing

Removal
. lnsertthe screwdriverhandleintothermostathousingand
move it up anddownlightlyto removethe housing.
lnstallation fzo - 3.0 mm wldeto centerof flat
. Removeold liquidgasketon the thermostathousingand I matingsurfaceand innerseating
the cylinderblockandwipeoffthe surfacewithwhite
gasoline.
. Cutnozzleendof liquidgasket(KP51000150)tube.
. Applya continuousbeadof liquidgasketto sealingsurface
usingthe tubepresser.Installthe housingwithin5 minutes
aftercoatingliquidgasket.
[Point2] Installthermostat
. 'Top'mark(igglevalve)mustfaceup whenthermostatis
insertedin housing.
[Point 3] Thermostat insPection

. Checkthevalveopeningtemperature and maximumvalve
tift.
. Hangthe thermostatby stringin valveand submergein
heatedwaterin doublewalledcontainer andstirwaterwhile
heatingit up.
. Theopeningtemperature is thetemperaturewhenthevalve
opensandthermostatfallsfromstring
76.5
'10l90
E N- 1 2 8
ON.VEHICLE
PARTS
1O-8REMOVE& INSTALLOIL PAN,OIL STRAINERAND OIL FILTER
O-ring
Oil pan bolt (30)

0 . 5- 0 . 7 Oil strainerbolt
( 2 )1 . 6- 2 . 1
lvll Kg_m
I Engineoil
E Liquidgasket
E Reolaceaflereverydrsassembry
Additionalworkrequired :
. Frontstabilizer
. Radiatorfan,shroud
. Right& leftenginegusset
. Enginerearplate(lower)(A/Tvehicles)
. Enoineoil
[Point1] Remove& installoilfilter

Removal
. Useoil filterwrenchto removethe oilfilter.
Installation
. Beforeinstallingnewoilfilter,wipeoffdustetc.from
cylinderblockmountingsurface.Applya thincoatof
engineoilto oilfilterO-ring.
. Screwoil filteron bracketby handuntila slightresistance
isfelt,thentightenan additional
2/3turnwithoilfllterwrench.
Aftertightening,startengineand checkfor oil leaks.
[Point2] Remove& installoil panbolts

9131721
Remove 1 9 1 5 1 71 3 1 5
. Removethe boltsin reversesequenceof figureon right.
Installation
. Installthe boltsin sequenceshownin figureon right.
E N- 1 2 9
ON-VEHICLEPARTS
[Point 3] Remove & install oil Pan

Removal
. Usesealcutterto removethe oil pan.
Caution:
(1) Afterremovingthe oil pan,removeoil liquidgasketon
theoilpanflangegrooveandtheoilblockusingthe
scraper.Makesureto removeliquidgasketdropped
insidetheoil Pan.
Q\ Caremustbe takennotto damagethe oil pan
. Removethe enginemountingnuts(oilpanside)and use

the hoistcraneto movetheoil panforward.Takeoffthe oil
strainerboltsusingthewrenchbeforeremovingtheoilpan. .
' ,
, , , i '
Caution:
Caremustbe takennot to pullthe hosesand harnessestoo
muchwhenliftingup the engineusingthe hoistcrane.
lnstallation
. Thefollowingproceduremustbe carriedoutwithin5 Tubepresser(WS3993)
minutes: Liquidgasket
. Applyacontinuous beadof liquidgasket(KPS10 00150)
to sealingsurfaceusinga tube presser'
. Installthe oil panwithin5 minutesaftercoating.
[Point4] Oil leakand oil pressureinspection

. Startthe engineandcheckforanyoilleakandtheoil
Dressure.To checkthe oil pressurereleasethe oil
oressureswitchand usethe oil pressuregauge.
[Point 5] Installoil strainer

. Checkto makesurethe O-ringis installedproperlybefore
the oil strainer.
installing
E N- 1 3 0
ON.VEHICLE
PARTS
R S 2 O D EE
T N GN E
10-9REMOVE& TNSTALL
TNTERCOOLER
(RB2oDET)
"'i5=;"*3h"Sj"=@jluri""" Turbocharger
:::="" *;;"_O
M_@4p
g. Arrrose \=/
*XgF/H cramp-g Airn^<a
^ in'"'-"nn'"'
ff"ct 7
s;il'-l
.*- . il"*';b,mffi3Tff;::
i";:'iF
"^^,66;-'ry4e"';ol
ll-,
.o""'
u" Inter-cooler
bracket
Inter-coolef
ri.
\",1Kg-m
. Leftfrontfenderprotector
. Fenderstay
. BonnetlPoint1l
[Point1] Remove& installbonnet

. Removeleftsidebonnetboltsonly(Liftup leftsideof the
bonnetto operate).
[Point2] Remove& installintercooler

. Removethefenderprotectorthenremovecoolerboltsto
removeinter-cooler. Takecarenot to damagethefins.
Caution:
The finsare aluminium and can be damagedeasily.Never
placeanythingon the intercooleror allowtoolsor otherharo
objectsto contactthefins.
Themainunit(tank,fins,tube)cannotbedisassembled.
EN - 131
ON-VEHICLEPARTS
R B 2 O D EE
TNGINE
10-10 Remove& InstallturbochargerASSY (lncludefault diagnosis)

(1) Removal& installation
P5 ;::"\T'a'"^'''"'ffi"fl.
# {,*"gEK#"O: ))
l$ -;;
.<=t4\ leo";'o ,**"I,T::[- Q'*-''
1--#r\ B"!t!TUq \\.,1,,*
1",/ Kg-m
$ Reptaceafter every disassemblY
. Undercover
. Assemble & disassemble fronttube
exhaust
. O^sensorconnector
. lniercooler
airinlettubes,hoses
. Airinletoipe
[Point1] Removewateroutlettube
. Remove thewateroutlettubebyfirstremoving theclamp
locatedontherearsideof thecylinder block. Water outlet
tube
Inspection
. Aftercleaningwaterinletandoutlettubewith radiator
cleaner.blowwithcompressedair and checkfor rustor
clogging.
EN - 132
ON-VEHICLEPARTS
R B 2 O D EE
TNGINE
[Point 2] Removeoil feed tube

. Removetheoilfeedtubebyfirstremoving
thecylinderblock
andturbocharger
eyebolts.
Inspection
. Aftercleaning
oilfeedtubewithengineconditioner,
blow
withcompressed airandcheckforclogging.
....'
:-
[Point3] Removeoil returnpipe

. Removethe oil returnpipeby firstremovingthe oil pan
clampandthe turbocharger bolts.
[Point 4] Remove& install lock plate

Removal
. Spreadthe lockplatepawlswitha screwdriver and loosen
€Fl
thenuts.
Installation
. Positionthe lockplatesandturbocharger mountingnuts.
Aftertighteningthe nuts,bendlockplatepawlsontothe
nuts.
[Point 5] Eyeboltdetermination
. Oilfeed(cylinder
blocksideandturbocharger
side)eyebolts
arestamped"G",
Installationorder
1. Turbocharger mainunit
2. Waterfeedtube
3. Oil feedtube
4. Wateroutlettube
5. Oil returnpipe
EN- 133
PARTS
ON-VEHICLE
R B 2 O D EE
TNGINE
(2\ Turbochargerunit insPection
Actuator[Point7] Excessivepressureleak
Exhaustgas leak tnspectionlocation
valve[Point3]
Crackinspection-
Crack Turbinewheel
lnspection t ,2 , 4 l
lPoin1
Compressorwheel
[Point5] Coolingwater Rotorshaft[Pornt6, B]
[PointB]
i- ) Oil leak inspectionlocation
[Point1] Rotor shaft insPection

. Theremustbe no heavinessor draggingandtheshaftmust
turnsmoothlywhenrotorshaftis turnedby finger.
[Point2] Turbinewheelinspection
. Oilmustnotadhereto surfaces.
. Theremustbenocarbonaccumulation.
. Thevanesoftheturbinerotormustnotbebent.
. Theremustbenointerferencewithturbinehousing.
[Point3] Swing valve insPection

. Removeactuatorrod pinand makesurethe swingvalve
movessmoothlywithoutdeformationor cracks
. Makesurethereare no misalignedseatingsurfacesin
turbinehousing.
[Point4] Rotor shaft play inspection

thedialgaugeandmeasureplayandthrust
. Position
clearance.
Rotorshaftplay(mm): 0 . 0 8 4- 0 . 1 0 7
Thrustclearance (mm): 0.045- 0.140
E N- 1 3 4
ON-VEHICLEPARTS
R B 2 O D EE
TNGINE
[Point5] Compressorwheel inspection

. Oil mustnotadhereto suctioninlet.
. Theremustbe no interferencewithcompressor
housing.
. Wheelmustnotbe bent,foldedor otherwisedamaqed.
'qf;:l,Tiltrl
'- d^"1,"9"a.
[Point6] Rotorshaftinspection
. Theremustbenocarbonsledoeaccumulation.
[Point 7] Swing valve controller inspection

. Removethe swingvalvecontrollerrubberhoseon the
compressorhousingside
. Checktheswingvalvecontroller whenevertheactuatorrod Operatessmoothly
is installedor removed.
. Usetheairgunto blowcompressed airapprox.0.8- 0.9
kg/cm2intohoseand makesurethe swingvalvecontroller
rodoperates.Stopblowingair as soonas the rod
operates.
Caution:
Makesureto verifythe airgun pressureusingthe LPG
pressuregaugebeforetestingthe air hose. lf air pressureis
appliedexcessively the diaphragmmay be damaged.
[Point8] Oilandcoolingwaterinletandoutlet
cleaning
. Useengineconditionerto cleantheoilfeedandreturn
passages.
. Useradiator
cleaner
to cleancoolinqwaterfeedandreturn
passages.
. Cleanusingtheairgun.
. Cleanthe compressorwheel,turbinewheel,compressor
housingandturbinehousingwithsamemethods.
EN- 135
PARTS
ON-VEHICLE
R B 2 O D EE
TNGINE
(3) Turbochargerfailurediagnosis(Oil leaks,smoke(whiteor blue smoke),lack

abnormalnoise)
of power,poor acceleration,
Pointsto be checkedbeforediagnosis:
1. Theengineoil levelmustbe betweentheMINandtheMAXmarkson theolllevelgauge.
(whentheengineoillevelis higherthanMAXline,theengineoilwillflowintotheintake
ductthroughthe blowbygas recirculation passandtheturbocharger may be
determined to be malfunctioning).
2. Checkwithcustomerto determineif oil is cooledwhen idlingafierdriving'
lf any malfunction replacethe
in thefollowingchartis detectedin a unitinspection,
turbocharoer ASSY
1,. ,
, rAbnofmal
Smoke noas€
Oil on rotors A Or A
Turbinerotor
Carbonhas accumulated A a C
Rotor scrapesagainstthe housarE A
Turbrmevanesare bent or folded
Suctioninlet is dirty with oil o C

Compressorwheel Rotor scrapes agairEt the hosing l\ C
Turbinevanes are bent or folded @
There is resistanceor scraping
when rotatedby finger .A C
Turbineand compresor Rotationby finger is not Possible
Rotor shat play arsPection
Cor6iderable shaking between
rotor shaft and turbo ASSY z__.\ A o A
Look throwh oil lrole Carbonsludgehas accumulated
(inspectinteriorwith Pen light) in waste oil hole
ll ^1_\ ll
Ti€ valvedoes rnt mo\€

smoothlywhen pressureis
Swing valveoperation applied gradually.(t6uallyoPens
(usearr 9unor alr pump) @
at pressuregreaterthan 0.6 - 0.7
kg/cm')
O Highlypossible C Possible l\ Slightlypossible
E N- 1 3 6
ON.VEHICLE
PARTS
C A l B ]E N G I N E
10,1 INTAKEMANIFOLDASSY
(1) Remove& instalintakemanifoldASSY
- bort(4)t.e- z.zp)
tn,ou,"Oody
T,
G a s k e$t
RTC heater lPoint4l Breather

hose
IntakemanifoldASSYIPoint
-(
'|l
gasketE
\-,1 kg-m
$ Reptace after every disassembly
. Releasefuelpressurein thefuellines
. Air cleanerASSY
. Fuelhose
. Waterhose
. Intakesidehigh{ensioncable
. Vacuumhosesand ECCSharnessconnectors
. AccelerationwireIPoint1]
. Watertemperature sensorconnector
. Thermaltransmitter connector
[Point 1] Accelerationwire adjustment

accelerator.Returnthe locknut 1.0- 1.5turnsfromthe
positionthe throttledrumstartsmoving(whenthereis no
playin cable)andtighten.
[Point2] Remove& installintakemanifold

sequenceshownin
thefigureon the right.
. The installation
sequenceis shownin thefigure.
Note:
Neverreusethe gasket.
E N- 1 3 7
PARTS
ON-VEHICLE
CA18E
i NGINE
[Point3] Intakemanifoldinspection Straight

. Measurethe intakemanifoldsurfacefor distortions
in four
separatedirections horizontally
(atoppositedirections; and
in a numberof locations.
vertically)
Limit value(mm): 0.15
[Point4] PTCheaterinsPection
. Makesurethereis nocrackonthePTCheater.
& assemblethrottlebodyASSY
(2) Disassemble
Fueliniector coverscrew
{2)0 20 .- 0 26I \g
'ut'rntector
cover
,
$o-ring =----dG
-€t
cl,el lnjector,0j,", ,,
_
€ e ,.- Btackel
$o-nng-.....-" -V,a
'egulator \|g-- - Sc'ew{4]OO+- OSSp)
Pressure lPo,nt4l uT
.*?" ':"t, [l i fl I
^' rh,ort,"
uppe. ouuy^-_ -__
^,V&d*o.
/ s"u'
^, ^-
eoin,
J1
Thermowax lPornt 7]
7*ir9"" o,o- o,u
Screw0 20 - 0 26p
I hrottleadtustscrew=\E
S/ .or-n g
Lower inter_.,.
yrpo
thro.ebodointgt\ --@ =,"ref\rilff}:!,,3"il:
E1^.<-1 Bracket (2)p
screw
ffi,u -,, -6f"\
olo
Fuel injectorharness
ri k g - m
\-/
a ReplaceaftereverydisassernblY
E N- 1 3 8
ON-VEHICLEPARTS
.A'3 ENGNE
Remove& install throttle body ASSY

. Firstremovefour throttlebody boltsto removethrot e body
ASSY
. Afterthe installation
checkthe tighteningtorque.
Bolt tighteningtorque (kg-m): 't.8- 2.2
. Alwaysreplacegasketwith newones.
[Point1] Removeupperthrottle body

. Firstremovethe fuelinjectorcoverthenseparatethefuei
injectorconnector.
. Loosenfour upperthrottlebodyscrewsto remove.
[Point2] Fuelinjector
Removal
. Firstremovethe injectorcoverto removeupperO-ring,
thenextractfuel injector.
. Caremustbe takennotto scratchor damagethe fuel
injectorand throttlebodysealsurface.
Cautionswhen handlingO-ring
. CoattheO-ringwithengineoil (7.5W - 30 or equivalent) -lniectorcover
/--\.
'..-r'\
butdo notapplysolventto themas thismay removethe oil l:
\^
coatrng. Conneclor:rJ
rubber \9 Injector
wrflng
. Do not allowdirt,dustor foreignobjectsto adhereto connector
O-ringsor otherequipmentsurfaces. F u e lI n i e c t o r
. Caremustbe takennotto scratch,twistor stretchO-rings
wheninstalling. Do notinsertit in thefueltubeby
makingit stretchslightly.
. Do notstoreO-ringsin locationsubjectto ozone,high
temperature or in directsunlight.
Installation
Replacebothupperand lowerO-ringsto newones.
Coatthe lowerO-ringwithengineoil and installto throttle
body.
Placethefuel injectorinsidethe throttlebodyand set the
injectorpositionby placingthe injectorconnectorand the
injectorcover.
Useoil sealdriftto insertthe fuel iniector(resistance
must
be felt).
Coatthe upperO-ringwithengineoil. Useoilsealdriftto
inserttheO-ring.
E N- 1 3 9
PARTS
ON-VEHICLE
C A ' 1 8Ei N G I N E
[Point3] Cam ASSY

Removal
. RemovethecamASSYfromthe upperthrottlebody.
Caution:
Extracare must be taken as there are tensionon the cam
spring.
Inspection
. Lookfor anydeformationor wearon the cam spring.
Cap spring free length(mm): 24.5- 26.5
lnstallation
. Makesureto installthe cam ASSYand the cam springin Free length
I
rightdirection.
. Reolacetheseatwithnewones.
Pressurereguator
[Point4] Pressureregulator
Removal
. Removethepressure fromtheupperthrottlebody'
regulator
. Carryoutthefuelpressure
inspection.
IPoint5] Throttledrum& A / T controldrum

Removal
. Firstremovethe nutsandremovethe A / T controldrum.
. Removethrottleadjustscrewand returnspringand remove
thethrottledrumfromthe lowerthrottlebody.
Inspection
. Inspectvisually
if thereareanywarn,cracksordeformation
on springretainer,retainer,and colour.Also inspect
Springretarner
rotationcontactsurface. (plastrc)
. Checkdeformation andwarnon thethrottleadjustment (plastic)
/,Retainer
screwand return spring. Color(plastic
f<
Returnspring free length(mm): 19.5- 21.5 \0.J
\
lnstallation
. Caremustbe takento installthe partsin correctdirection
the armASSY returnspring,throttledrum
wheninstalling
andA,/Tcontroldrum.
E N- 1 4 0
ON-VEHICLEPARTS
C A l 8 iE N G I N E
[Point 6] Remove dashpot

. Firstremovethe dashpotbracketto removethe dashpot.
Inspection
. Checkvisuallyfor anydeformation
or crackson the rubber
oan.
[Point7] Removethermoswax
. Firstremovethethrottle
wirebracket
to removethermo
wax.
Inspection
. Checkifthepinwillextendwhenthethermowaxis
warmeo.
Thermowax
Caution:
Donotpulloutthepin.
[Point8] FIGDsolenoid& ldle revolutionadjustment

solenoid
Removal
. RemoveFIDCsolenoidand idleuo solenoidfromlower
throttlebody.
Caution:
Watchoutfor springandthe valveas it mayjumpout.
Inspection
. Checkthatno warnorforeignmatteradheresto valvehead.
. Checkthe springfor deformation or warn.
Spring free length (mm): '11- 12
lnstallation
. Checktheorientation of thevalvewheninstallino.
[Point 9] Lower throttle body inspection

. Checkfor any cloggingin the air passageby carryingout
air blowinspection.
. Checkfor any crackson lowerthrottlebody.
EN- 141
PARTS
ON-VEHICLE
10-2 EXHAUSTMANIFOLDASSY
Exhaustmanifoldqasket
- -
-rw--4; Washer
"*
if::'liHllli 'u'
,f4f;^
ddl
V/,^-,T t: l,aa
fru
R. o,
gl f
o,r" "-(.,:-'r.,lpoint
ExhaustmanifoldlPoint2]
Heat shieldPlate
ri.
l-/ Kq-m
$ Replaceafter everydisassembly
. Undercover
. Exhaustfronttubenuts
. O,sensorconnector
. Exhausttemperaturesensor
. Hotairduct
[Point1] Remove& installexhaustmanifold

Removal
sequenceshownin
thefigure.
lnstallation
. The installation
sequenceis shownin the figureon right.
. Checkthe standardtighteningtorqueafterinstallation.
Straightgauge
[Point2] Exhaustmanifoldinspection
. Measuretheexhaustmanifoldsurfacefor distortionsin four
and
separatedirections(oppositedirections:horizontally
in a numberof locations).
vertically)
[Point 3] Remove& install O, sensor

(Zirconiumtypesinglepoleconnector)
. Do not usetoolswithimpactsuchas impactwrenchfor
of the O, sensor.
removaland installation
E N- 1 4 2
ON-VEHICLEPARTS
CA18E
] NGINE
10-3 LOCKERCOVER
rlOSC LOCKeT
COVerSCreW
0.1- 0.3lPoinr1]
Oil Rttercap \ 3---'(8)
6 -_ Grommet
\.4* fl.-r."y
\=2
Fi
l".l ks-m
. High{ensioncable
. AircleanerASSY
[Point1] Remove& installlockercover

Removal
. Removalisthe reverseorderof installation
seouenceshown
Installation
. The installationsequenceis shownin thefigureon right.
. Whenremovingandinstalling the lockercover,alsoremove
the covergasketand wipeoff the oil adhereon the gasket
and in the oroove.
[Point 2] Locker cover gasket

. Makesurethe rockercovergasketis positionedsecurely
in groovewithouttwisting.
EN - 143
ON-VEHICLEPARTS
C A 1 8E
i NGINE
10-4 TIMINGBELT(CRANKPULLEYBELTCOVER)
( 1 ) Remove& installtiming belt cover
ac!.+---
-:=-=+--.-
uppercover
\r2-
,_l-_=
Lower cove(-
B o l t( 4 ) 1 . 2- 1 . 6
-
ts-t E Crankpulleybolt12.5 13.slPoint2]Pl
I
I Engineoil
. Undercover
. Fanshroud
. Supplement belts
. SparkPlug
. No. 1 cylinder
compression [Point1]
T.D.Cposition
[Point1] No.1 cylindercompression D.T.C

inspection
. Alignthecrankpulleymarkandthebeltcovertiming
T.D.C.
to compression
indicator
. No. 1 cylinderis at compressionstroketop deadcenter

whenboththe intakeandexhaustsidecamsdo not move
thevalvelifters.
E N- 1 4 4
ON-VEHICLEPARTS
C A IB i E N G I N E
[Point2] Remove& installcrank pulleybolts

. Removestartermotorand attachringgearstopper.
Caution:
Coatthe screwpartwithengineoilwhentighteningthe crank
pulleybolt.
Do not applyany oil on the damperareawhen installing
or
removingthecrankpulley.
[Point3] Removecrankpulley
. Loosen thecrankpulleyboltsandusepulleypuller
(steering
wheelpullerST27180001) to removethecrank
pulley.
Caution:
Donothookthepulleypulleronthecrankpulleygroove.
[Point 4] Remove& instatl belt cover

. Do notscratchpackingwhenremovingand installing the
beltcover.
. Alwaystightenthe beltcoverboltusingthe rubberwasher
Crankpulleyside
[Point5] Installcrank pulleyplate
. Makesurethe crankpulleyplateis positionedin correct
wav.
(21 Remove& installtiming belt

Timingbelt alignmentmarkverificationand installation
. lf painton upperbeltis unclearwhendisassembly is
performed,painta markon beltthat indicatesrotation
direction.
. Positionthe alignmentmarkof the cam pulleyswith
respective timingbeltcoveralignmentmarks.
(No.1 cylinder at T.D.C)
. Installthe timingbeltso the numberof ridgesfromthe
alignmentmarkto crankpulley(inner)alignmentmarkwill
be as indicatedbelow.
cA18i 43 95
EN - 145
ON-VEHICLEPARTS
CA18E
r NGINE
Timing belt tensionadjustment

. Removesparkplugandtightentensionerbolt(1 & 2)
temporarily.
. Hookthe tensionerspring(3) on the lowerbolt(2).
. Hookthe springon the hook(4) andtightenthe bolt(1).
. Loosenthetensioner(5)andtightenthe bolt(2).
Caution:
Makesurethe springis positionedcorrectlyat this stage
. Checkif thetensioner(5)willrotatewhenpushedby finger.
. Alignthetimingbeltalignment markandthepulley
alignmentmarkto installthetimingbelt.
. Loosenthetensionerbolt(2).
. Turnthe campulleymorethantvvoturnsclockwiseto check
beltmovementand stopslowlyat No. 1 cylinder
compression T.D.CPoint.
. Tighten bolts(1& 2).
tensioner
torque(kg-m):
Tightening 1 . 5- 2 . O
(3) Timingbelt insPection

Replacetimingbeltif inspectionindicatesany problem.
Toothmissing
Cracked tooth @ Camshaft lock
Crank sensor lock
Tensionerlock
Cracks on rear Engine overheat
sloe Interferencewith belt cover etc.
Wear and cracks

on the side .J\>
/.Mhx t*tlt'x
/ A'/.4i // ///// //l
Beltmisalignment
Beltplatemalfunction
Worn teeth '=w!l jJlfuu/ crank sensor and the camshaft
Oilor water Oil seal malfunction

adhesion Waterleaksin waterpump
Caution:
(1) Makesurethetimingbeltis nottwistedor bentsharply.
Makesurethereis no oil film or wateron the belt.
(2) Timingbeltneedto be replacedevery100,000km
E N- 1 4 6
ON-VEHICLE
PARTS
C A ' 3 E N GN E
10.5 WATERPUMP
Waterpump[Point| 2]
'/:,j$t
,",(3),u_$\
Springwasher
\
ffiP
gf.o<-spr.ins
=\ *asne,
\ -Bolt(2)
16-20
E is-r
p Repiace
. Drainandrefillcoolingwater
. Fanshroud
. Fan
. Waterpumppulley
. Supplementary belts
. limingbeltcover
[Point1] Removewaterpump
. Becarefulnotto getcoolant
ontimingbelt.lf anywaterdoes
spill,wipeifoffimmediately.
Caution:
Remove oldgasketonthewaterpumpsurfaceusingthescraper.
[Point2] Waterpumpinspection
. Rotatewaterpumpbyhandandcheckforanyabnormal
. Theremustbenotracesofwaterleaks.
E N- 1 4 7
PARTS
ON-VEHICLE
C A IB i E N G I N E
10-6 THERMOSTAT
ThermostatlPoint2l
Gasket
Thermostat houstr
1
lPoint l t
ds\
-\-"\'t
\ ----rll./
---Ll
dl- B o l t( 3 )1 . 6 ' 2 . 1
7r,
\",4 Kg-m
$ Replaceaftereverydisassembly
. Wateroutlethose
[Point1l Remove& installthermostathousing

Removal
. lnsertscrewdriverhandleintothermostathousing Prylightly
up and downand removehouslng.
lnstallation
. Placethejigglevalveon topwheninstalling thethermostat
housing.
Caution:
Removeold gasket on the water outlet surfaceusing the
scraDer.
[Point 2] Thermostat inspection

. Checkthe valveopeningtemperature and maximumvalve
tift. String
. Hangthethermostatby stringin valveand submergein
heatedwaterin doublewalledcontainerandstirwaterwhile Double-wall
container
heatingit up. Thermostat
. The openingtemperatureis thetemperaturewhenthe valve
opensandthermostatfallsfromstring.
82 88
OverI / 95 Over7 / 100
E N. 1 4 8
ON-VEHICLE
PARTS
]A'! E\G NE
10.7 otL PAN& OtLFILTER

(1) Remove& installoil p a n
Oilstrarner
nut
oz-oaPl=---...-.
$ oil strainel-q,
gasket
9i,1;1'Ii'6b\e
.
E
+4eet'rt
p$oit
:1
\u"seaoastet
Eoil sealgasket '\.-

El(front)\int4l )-erz-?)
,rt')Qffi
\ "
H, ,''0,o u, - 0 85lPoint
4]
Drainplug washer[Point4]$ pj
t r ,
l".l Kg-m
p Liquidgasket
Q Replaceafter every disassembly
. Undercover
. Engineoil
. Right& leftenginegusset
[Point1] Drain plug washer

. Thedrainplugwasherhasinstallation Oil pan side
direction,
makesure
to installin the correctdirection.
. Alwaysreplacedrainplugwithnewoneswhenremoving
andinstallino.
[Point2] Remove& installoil pan bolt

Removal
. Removethe boltsin reverseseouenceshownin floure lr
on right.
Installation
. Installboltsin sequenceshownin the figureon right.
. Tightenboltsto correcttighteningtorque.
[Point3] Removeand installoil pan

Removal
. R e m o v e t h e opi la nu s i n g t h e s e a l c u t t e r ( K V 1 1
01 0 0 )
Caution:
Removeold liquidgasketon the blockpanflangegroove
usrnga scraper.
E N- 1 4 9
ON-VEHICLEPARTS
CA18E
i NGINE
lnstallation
. Applysealingagent(SS60For equivalent) on theareas
shownin thefigureon rightto installoil pangasket.
:.--
. Applya continuous beadof liquidgasket(KP51000150)

to sealingsurfaceusingthe tubepresserand installthe oil
panwithin5 minutesaftercoating.
. Inserttwo centerboltsto oil pan boltholes,makesureit is

fittedcorrectlythentighten
Caution:
Leavefor 30 minutesafterthe installation.
[Point4] Oil leak& oil pressureinspection

. Warmuptheengineandcheckforanyoilleakingandthe
oilpressure.
. Releasetheoilpressure switchandinstalltheoilpressure
gaugewhencarrying outtheoilpressureinspection.
Whenidling 2000 4000
Approx.1 Approx.3 Approx.4
(21 Remove& installoilfilter

Removal
. Useoil filterwrenchto removethe oilfilter.
lnstallation
. Beforeinstallingthe oil filter,wipeoffdust,etc.fromoil
cylinderblocksurface.Applya thincoatof engineoil to
newoil filterO-ring.
. Screwoil filterby handuntilit hitthe cylinderblock,then
tightenan additional2 / 3 turnwithoil filterwrench.After
tightening,startthe engineand checkfor oil leaks
't.5- 2.1
Tighteningtorque (kg-m):
E N- 1 5 0
ON-VEHICLE
PARTS
R B 2 5 D EE N G I N E
10-1 AIR DUCT& AIR CLEANER
I o.ts
Airhose p rilo'"" '," - o.ro.1zy
"_ Airhose
UDe L,"\..t_ ,/ ^
,/ Rubber \ I 0 5 2 - 0 6 6 ( 4p)j
chambef\(@ '"f"'
p r . : - r . o 1 z- 1 ; O - r i n gE
,,Y Air cleanefcase
. . ' - Ho s e
Air cleanerelement
- Insutator
^ - ^ r
u^cz - uoo lv,/
^ ^ ^ F i
r J r l " , l0 5 2 - 0 6 6 ( 4 )
Resonator
0 . 5 2- 0 . 6 6( 2 ) ! - bracket n c,l - necfC|l
-e/g v,
- l
E
'^'^^,)h
{ as2-o66pJ
Removal
. Removethe negativeterminalfromthe battery.
. Usean air gunto blowoff any dirtor dustbeforeremoving
theairhoseandairduct.
Removethe following:
. 2 vacuumhosesfromthe resonator(betweenintake
manifoldandcanister).
Blowbyhosebetweenlockercoverand air duct.
Air hosebetweenair ductandair requlator.
. Removeairflowmeterconnector.
E N- 1 5 1
PARTS
ON-VEHICLE
R B 2 s D EE N G I N E
Putalignmentmarkon eachair hosesandthe ductthen

remove.
Remove4 clipson air cleanercase(1 on uppercase3 on
lowercase).
Removeuppercaseto extractaircleanerelement.
Removethe lowercaseby firstremoving4 bolts.
Removethe resonatorby firstremovingthe leftfender

protectorthenlooseningthe resonatorbolt.
Removetheairductbyfirstremovingthefrontcombination
lamoandthe leftheadlampASSY
Caremustbe takennotto scratchor damagethe airflow
metersensorwhenremovingthe airflowmeter'
lnstallation
. lnstallation out
carried
oftheairductandtheaircleaneris
in reverseorderof removal
operation.
. Airflowmetercircuit useASSYwhen
caseisnonseparable,
theairflow
replacing meter.
. Makesureto inserttheairhoseandtheairductsecurely
byaligningthealignment andtightenthe
markcorrectly
bandandtheclamP.
E N- 1 5 2
ON-VEHICLE
PARTS
1O.2 INTAKEMANIFOLDGOLLECTOR
(1) Remove& installintakemanifoldcollector
|2i'ftt:'rti:g
-Y-V coirector
ASSY
\ -,-aa
CollectorgasketE
-[]
/l
\ irl-
\ .'.
t , u- 22 \2)P)
pcoltectorboit(2)1.8- 2z.-*& g
l-,i r<9-m . B- 2 . 2
,/) ,,
E Replaceafter every disassembly
Removal
Releasethe fuel pressure
. Warmuptheengine. FUELPU[,4PRELAY OFF
(POS) 950 rpm
. Select'Fuelpumprelay'in 'Activetest'mode. CAS.RPI\,|
. Selectcancel'to releasethefuel pressure.

. Crank2- 3 timesto consumethefuelleftin the piping.
:movethefuelpurp frr". @
Aftertheengine
stops,
cranktheengine
overtwoorthree
timesto consumethefuelleftin the pipe.
. lf the enginedoesnotstart,removethe pumpfuseand
crank the enginethreeto fourtimesto consumethefuel
leftin the pipe.
Caution:
The batterymay becomeweakeasily,use boostercablesto
connectit to chargedbatteryif necessary.
. Removethe negativeterminalfromthe battery.

. Draincoolingwaterfromthe radiatordrainplug.
. Removeaccelerator wire.
. RemovetheMC valveconnector, FICDconnector andthe
vehiclebodygroundcable
Removethe hoseA betweenthe brakeboosterandthe

collector.
Removethe hoseB betweenIAAunitandthefueldamoer.
Removethe hoseC betweencanisterandthe collector.
Removethe hoseD betweencanisterandthe throttle
chamber.
EN- 153
PARTS
ON-VEHICLE
RemoveblowbyhoseE befuveen lockercoverandthe

collector.
RemovehoseF betweenpressureregulatorandthe
collector.
RemovethreewaterhosesG.
Removethe hosebetweenair regulatorandthe collector.
Liftup the collectorASSYwhenremovingthe hosefor
easieroperation.
RemovefuelfeedandretumhoseH,thenremovetheclamp
fromthe collector.
Loosenthe hoseclampto removecollectorASSY
11
Loosenthe boltsin ordershownin thefigureon right. J
Checkto see everyhosesrequiredare removed.
. Remove gasket.
collector
. Usea toolsuchasa scraper anyleftovergasket
to remove
onthesurface.
r:
lnstallation
. Installthe collectorgasket.
. Makesurethereis no dust,oil or otherforeignmatteris on
the sealingsurface.
. lnstallthe collector
ASSY
. Tightenthe boltsin the ordershownin thefigureon right
Tightenin gradualstepsto uniformtightness.
-1 "9- - 5 ,2 - ' l.
. Lengfi {mm}: "7 =3. - "1 - Y; -. -s. , .
No. of bolls
105.2
't.8 - 2.2
7,10
I 65:1 1 . 8- 2 . 2 l-
1,3,4,6 40.4 1.8-2.2
2 , 5 , 9 ,1 1 30:4 1.8-2.2
Connecteachwiringandthe pipingin the reverseorderof

the removaloperation.
Connectthe accelerator wire,
Provideadequate slack for the accelerator wireand pull
outercasein the directionof the accelerator usingthe
adjustnut. Returnlocknut 1 .0 to 1.5 turns from the position
thethrottledrumstartsmoving(whenthereis no play)and
tiohten.
E N- 1 5 4
ON-VEHICLE
PARTS
i 3 r 5 f : E N GN E
. Makesuretheradiator drainplugis closedsecurely

and
NEVER
refillthe coolingwaterfromthe feedopening. OPENWHEN
. Releasetheairusingtheairreleaseplugafterrefilling the I F]OT ; a
coolingwaterto preventoverheat. ... /2
Caution: ./ ) (\)
Do notremovetheairreleaseplugwhentheengineis warm.
Do notovertightenthe air releaseplugbolt.
(21 Disassemble& assembleintakemanifoldcollector

pjBort(2)0.64- o
Accelerator
wire bracket Bolt(4)0.e- 1.1\ l
Collector
AAC valve
lAA unit
Water hose
9ts't
E Replaceafterevery drsassembly
Disassembly
. Removethrottlechamber
. RemoveIAAunit
Assembly
. Installthrottlechambergasket
lnstallin iorrectdirection
. Tightenthethrottle
chamber
boltsrnordershowninfigure
onrightuniformly
intwostages.
Tighteningtorque(kg-m): Firststage 0.9- 1.1
Secondstage1.8- 2.2
. Install
lMunit.
4 ' + , 0 . '0. -r p
E N- 1 5 5
ON-VEHICLEPARTS
R B 2 s D EE N G N E
10-3 FUEL INJECTOR
ne0--
I
Fi
rol-z.rtz)H
l".l k9-m
Removal
. RemovecollectorASSY Fordetailedremovalprocess
referto Collector"section.
. Removefuelinjectorconnectorandthe lamp.
. Removethe connectorPin
. The operationcan be carriedout easilyif the vehiclebody
groundwires,watertemperature sensorconnectorandthe
thermaltransmitter connectorare removed.
. Removeair regulatorconnector.
. RemovethefuelASSYby firstremovingthe bolts.
. Replaceo-ringwithnewoneswhenremovingfuelinjector,
pressureregulatorandfuelbumperfromthefueltube.
. Do notpullthe connectorpartswhenremovingthefuel
injector.
Precautionswhen handlingO'ring
. Coatthe O-ringwithengineoil (7.5W-30or equivalent)but
do notapplysolventas this may removethe oil coating.
. AvoidusingdirtyO-ringsand do not allowdirt,dustor
surfaces.
. Caremustbe takennotto scratch,twistor stretchthemby
wheninstallingO-rings.
toolsor operator'sfingernails
Inspection
. Fuelinjectorresistance
Resistance value(f,|): Approx.13 - 14
. Iniectorcan not be disassembled.
E N- 1 5 6
ON-VEHICLEPARTS
Installation
. Do not rotateor decenterthe partswheninstalling the fuel
in1ector,pressureregulator
andfuelbumperto thefueltube.
. Tightenthe pressureregulatorandthefuelbumperscrews
uniformlyin twoto threestages.
Tighteningtorque(kg-m): 0.30- 0.39
. InstallfueltubeASSY
. Connect theairregulator
connector.
. Install
thefuelinjector andfixit inplaceusingthe
connector
ctamD.
. Installthe collectorASSY
10-4 INTAKEMANIFOLD
p_- aort - o.asP

1z)o.o+
@=--- Airreguraror
El WateroulletpipeASSY
B o l t( 6 ) 1 . 6- 2 1
Intakemanifold tt
t',i
i-,i kq-m p l e o it z o) n - o s
A Liquidgasket
Removal
. RemovecollectorASSY FordetailedremovalDrocess
referto "Collector"
section
. RemovefuelinjectorASSY
. Removewaterhose.
. Removeoillevelgaugeguidebolt.
Oil levelgauge
. Removerearwaterpipeconnectorbolt.
EN - 157
ON.VEHICLEPARTS
'10'13)in
RemoveintakemanifoldASSYboltsandnuts(1, I 14 11
the ordersshownin thefigureon right.
Removethe intakemanifoldgasket.
. RemovewaterPiPeASS\.
1312 10 4
lnstallation
. Removeold liquidgasketon the waterpipe,in the groove
andon the intakemanifold.Cleanallcontactsurfaceswith
whitegasolineor equivalent.
. Applya continuous beadof liquidgasket(KPs'10 00150)
2.0- 3.0mmwideto sealingsurfaceusingthetube
pressor.
Caution
shouldbe performedwithin5 minutesafter
Installation
coatingthe liquidgasket. ?,, '3.
; -. .jt"v,
Waitat least30 minutesbeforerefillingenginecoolant. :"'"
- -
/
.,..''..'.-;'.|
,i-.
']
. .ra) f-
Installthe waterPiPeASSY
Tighteningtorque (kg-m): ( A ) 0 . 4- 0 . 5
( B )1 . 6- 2 . 1
(B) bolt(6)
1A-111o ,
gaskeL. 1 4 1 3 1 4
Installintakemanifold
theboltsandnuts(2.10.13)uniformly
Install inseveral
stagesintheordershowninthefigureontheright.
Tighteningtorque (kg-m): 1 . 8- 2 . 2 z 3 5
. Installthefrontoil levelgaugeguidebolt. levelgauge

g u i d e0 . 4 - 0 . 5
. Installthe rearwaterpipeconnectorbolt.
. lnstallthewaterhose.
PrPe.l
E N- ' 1 5 8
ON-VEHICLE
PARTS
10-5 EXHAUSTMANIFOLD
Exhaustmanrfoldgasket $
O r - s e n s4o.r1- 5 . 1 9
K:,
Exhaustmanifold
/:--9.
Washer r3l
Nr,,rrto-2r\Fi
" -"
Exnaustmanrforo tp
o a - - o s { 8 ) go, sensor
fr,
9ts-t
il;'
$ Reptace
aftereverydisassembiy
Removal
. Removethefollowing:
. Undercover
. Exhaustfronttube
. O, sensorconnector
. Exhaustmanifoldcover
. Removethe exhaustmanifoldnutsin theordershownrn
thefigureon right.
. Removetheexhaustmanifoldqasket.
Inspection
. Lookfor anydistortionon exhaustmanifold.
Gas leakinspection
. Afterremovingexhaustmanifold,makesurethereare no
tracesof gas leaksfromany partof installation.
lnstallation
. Installexhaustmanifoldgasket.
. Installexhaustmanifold,
washerandtheVoke.
Front
MakesurenottomakemistakebetweenNo.3 andNo.4
yokeas configurations
aredifferent.
Item
No,3& Xo,i! port 22
O$er than those above 24
Makesurethe washeris facingthe correctwaywhen

installino.
+
Manlfold
EN - 159
PARTS
ON-VEHICLE
RB2sDE NGINE
Tightenexhaustmanifoldnutsin theordershownin the

figureon right.
lnstallexhaustmanifoldcover.
crankengineand checkfor gas leak.
Afterinstallation,
10-6 TIMINGBELT
Timingbeit cover(Upper)
Timrngbelt
crommet ]
p aort
121r.o- z.r\
N u t4 . 4- 5 . 9g
t=o' Belt tensioner
Conical ,'Tensioner
t@--- For
rrl
fo]!{a)fJ oromme
E kg-t
E E n g i n eo i l
P Reptace aftereverydisassembly
Removal
. Removeundercover.
. Draincoolingwaterfromthe radiatorenginedrainplug
. Removesupplementary belts.
. Removethe radiator,thefan shroudandthe coolingfan.
T.D.Cposition
CheckNo. 1 cylindercompression
Alignthe crankpulleytimingmarkand beltcovertiming

markindicator(0"position).At thistimethe No. 1 cylinder
T.D.Cpositionwhenthe camshaftis
is in the compression i'18\
locatedas describedas follow:
stroketopdeadcenter
z
No. 1 cylinderis at thecompression
whenboththe No. 1 intakeand exhaustsidecamsdo not
movethe valvelifters.
EN - 160
ON-VEHICLEPARTS
Removetheoilfiltercamfromintakesiderockercoverand
checkthatthe frontend of camshaftfacesthe intakeside.
Remove
crankanglesensor.
Remove
startermotortheninstallringgearstopper.
crankpulleybolts.
Remove
Usepulleypullerto removethecrankpulley(boltsize:M6x
1.0lengthbelowheadapprox.50 mm)
. Removecrankanglesensorbracket,thenremovetiming
beltcover.Timingbeltcoveris separatedintoupperand
lowersections,firstremovethe uppersectionthenremove
lowersection.
Caution:
Do not scratchdriedliquidpackingwhen removingand
installing
the timingbeltcover.
. Removebelttensioner.
. Securethetensionerfirmlywitha hexagonal wrenchwhen
removingand installingbolttensionernuts.
Caution:
Do not looseninsertedstudat disassemblv.
lf painton timingbeltis unclearwhendisassemblyis

performed,painta markon the beltthatindicatesrotation
direction.
Removethetimingbelt.
EN - 161
ON-VEHICLEPARTS
RB2sDE NGINE
Timing belt insPection

. Replacetimingbeltif any problemsare indicatedat the inspection'
It is recommendedto replacetimingbeltevery100'000km'
Item
. '../'\ Camshaftlock
Toothmissing
Cracked tooth
'<./ Crank sensor lock
Tensionerlock
Crackson rear Engine overheat
side with beltcoveretc.
lnterference
Wear and cracks Belt misalignment

on the side Belt platemalfunction
SlidingmotionresistanceIn

adheston Water leaks in water PumP
Caution:
Do nott*ist or bendthe timingbelt . Makesurethereis no oil filmor wateron the belt
pulley
Makesurethereis nowarnor crackscan befoundon idlerpulley,tensionerpulley,cam
cranktimingpulleyandthetensionerspring.Alsocheckif theyrotatessmoothly.
lnstallation
. Assemblethe tensionerspringso it engagesthe belt
tensionerpulleyas shownin thefigure.
. The tensionerspringmustbe assembledtogetherwiththe
belttensionerpulleyin the cylinderblock.
. Whenthetensionerpulleyis free,hookthetensionersprlng
on the uppersideof the tensionerspringstud / A\Y] t(
'
L\g)) )
{;</ -'t\t.
\=o\- -li
Tensionerspring
securinostud
Tensionerspring sPecifications
Tensionerpulley
' 1 . 8m m A p p r o x . 2 0 " A p p r o x1 6 3 " Yellow-green
EN - 162
ON-VEHICLE
PARTS
Caremustbe takento installthe conicalwasherin correct

direction.
lnstallthecranktimingpulleyandtheplate.
a f
r l l l
]Fil
I \--J 9
l l r
Conical
Nut
, *""1"t
Crank
plate
. Be carefulto observefrontand rearpositioning
of timing
beltplate,cranktimingpulleyandcranktimingpulleyplate
wheninstallation is performed.
+
Crank
pulleyside
. Alignthealignmentmarksof the exhaustand intakecam

pulleyswiththerespectivebeltcoveralignment marks(No.
1 cylinderis atT,D.C).
. Alignthecranktimingpulleyalignmentmarkwiththe mark
on oil pumphousing.Thegroovemustbe straightup (No.
1cylindercompression T.D.C).
. Movethe belttensionerclockwiseat 70 - 80"Cangle,and
secureit temporarilywithbelttensionernut. (Thiswill
minimizetheoffsetbetweenthetensionershaftandthe
timingbelt).
. Alignthetimingbeltpulleymarksandinstallbelt.Alignthe
numberof ridgesof exhaustcam pulleyalignmentmark
andcrankpulley(inner)alignmentmarkas shownin the
figureon right.
securetensionerwithhexagonalwrenchso it doesnot Alignment
mark
rotatetogetherandtightenthe nuts.
Caution:
At timingbeltassembly,checkthat it engagescorrectlywith
pulleyand it doesnotfloat.
Timing belttensionadjustment
. Removethe sparkplugand aligntimingbeltalignment
markswithpulleymarksand installtimingbelton to each
pulley.
Loosenthe tensionernut so belttensionis appliedby
tensionerspring.
Turncrankpulleyclockwisemorethantwo tumsto check
beltmovementandstopslowlyat No. 1 cylinder
comoression T.D.C.
Inserthexagonalwrench in hexagonalhole. Holdthe
tensionerwithyourhandandtightenthetensioner
securingnutto specifiedtighteningtorque.
At thisconditionbelttensionshouldbe approximately 20
ko.
EN- 163
PARTS
ON-VEHICLE
Installcrankanglesensorbracket.
Tighteningtorque (kg'm): 2 . 1- 2 . 7 Crank
angle
, sensor
bracket
6 i z.t- z.t 1s1p)
. lnstalltimingbeltcoverin orderof lowerthenupper.

Tighteningtorque (kg-m): ( A ) 1 . 6- 2 . 1
(B) 0.65- 0.86
Installcrank anglesensor
(1) Applychassisgreaseto driveunitspline.
(2) Thereis a flangeinsidethedriveunitsplineso spline
onlyhasone insertionposition.Checkthe alignment
beforeassernblY.
(3) Checkthatthe crankanglesensorcan be inserted
easilyin beltcoverholesandsensormoveslightlyto
rightand left,thentightenbolts.
A\ lf thesensordoesnnotmovelightly,loosenthe beltcover
boltswithcrankanglesensorinserted.Movebeltcover
to alignbeltcoverholecenterand camshaftcenter.
Tightenboltsmakingsurethe crankanglesensor
moveslightlY.
Positionthe washerfor the crankpulleyboltsso the flat

surfacecontactsthe crankpulleysideandthenassemble.
Applyengineoil to thethreadsof crankpulleybolts.
torque(kg-m):
Tightening 1 4 . 5- 1 5 . 5
E N- 1 6 4
ON-VEHICLE
PARTS
10-7 OIL PAN
O-ring
Oilpanbolt(30)
0 . 5- 0 . 7
o i l strainer
ti,
l-,1kg-m
E L i q u i dg a s k e t
$ Repiace aftereverydisassembly
Removal
. Drainengineoil.
. Removeradiatorfan.
. Removefrontstabilizer.
. Removeengineright& lefigusset.
121620 2428302622
. Removeoil pan boltsin orderof sequenceshownin the
figureon right.
Ti7sE272s2s2117
fi e
. Insertsealcutterbetweencylinderblockand oil pan.

. Removeoil pan by tappingthe sealcutterwithhammer
. lf removingtheoil panfromthevehicle,firstremovefront
enginemountingnut.
. Usethe hoistcraneto liftup the oil panforward.
. Fromthe gap betweenthe cylinderblockandthe oil pan,
usea toolsuchas spannerto removeoil strainerboltbelt.
. Pulltheoilpanout.
Caution:
Caremustbe takennotto strainthe hosesand the harness
tootightlywhenliftingup the engineusingthe hoistcrane.
EN - 165
PARTS
ON-VEHICLE
RB2sDE NGINE
lnstallation
. Usea scraperto removealltracesof oil liquidgasketfrom
cylinderblockand oil pansurface.
Caution:
Removeall gasketmaterialandotherforeignmaterialthat
fallsintotheoilpan.
. Cleanall contactsurfaceswithwhitegasolineor
equivalent.
. Cutoffnozzletipofliquidgasket(KP51000150)atpoint
shownin thefigureon rightand insertintotubepresser
. Applya continuous beadof liquidgasket(KP510 00150)

to innersealingsurfaces4 mm wide.
shouldbe performed
. lnstallation within5 minutes.
Caution:
Be sureliquidgasketapplicationis 4.0 mm wide.
Waitat least30 minutesbeforerefillingengineoil andengine
coolant.
10-8oll SEAL
Valveoil seal
. RemovethefollowingParts:
. Engineundercover
. Cleaningfan
. Timingbeltcover,timingbelt
. CamPulleY
. BackPlate
. Rockercover
. Ornament
. Camshaft
. Hydraulicvalvelifter
. Valvespring
. Useoil sealpullerto removevalveoil seal.
. To preventvalveomissionhavethe pistonin compression
T.D.Cposition.
Valveoil seal drift atlachment

--.1'
KV10111400
EN - 166
ON-VEHICLE
PARTS
. Valveoilsealinstallation
measurement
is as shownin tne
figureon right.
Camshaftoil seal
. Removethefollowingparts:
. Engineundercover
. Coolingfan
. Crankpulley
. Timingbelt
. Crankanglesensorbracket
. Campulley
. Backolate
. RemoveNo. 1 camshaftthenremovecamshaftoil seal.
. Applyengineoilto areaaroundtheoilseallip.
. Caremustbe takennotto scratchor damageoil seal Oil seal drift
KV40100900
retainer.Useoilsealdriftsmallerthanoilseal(41mm)
and insertit at samelevelas frontsurfaceof oil seal
retatner.
Frontoil seal
. Removethefollowingparts:
. Engineundercover
. Coolingfan
. Crankpulley
. Timingbelt
. Oil oan
. Oilpump
. Use a screwdriverto removefrontoil sealfrom frontcover.
. Useoil sealdriftand insertnewfrontoil sealat samelever
as frontsurface.
. Facethe oil sealmarkoutside(frontside)wheninserting.
Caution:
Do not touchthe oil seal lip by flngeras greaseis appliedto
areaaroundtheoilseallio. '--_r{'@
r
Rearoil seal
Removethefollowingparts:
. Transmission (orA / T)
. Flywheel(ordriveplate)
. Rearplate
. Rearoil sealretainer
E N- 1 6 7
ON-VEHICLEPARTS
Applyengineoilor chassisgreaseto areaaroundoil sea

lip.
Caremustbe takennotto scratchor damageoil seal
retainer.Useoil sealdrift(Externaldiameter:(100mm)
and insertit at samelevelas frontsurfaceof oil seal
retainer.
Cleaning
. Usescraperto removeliquidgasket.
Caution:
Makesureto removeliquidgasketin the groove.
. Cleanthecylinderblocksideusingsamemethodandclean
the surfacewithwhitegasoline.
Rearoil seal installation

. Installation
shouldbe performedwithin5 minutes.
. Cutoffnozzletipof liquidgasket(KPS1000150)at point
shownin thefigureon rightand insertintotubepresser.
. Applya continuous beadof liquidgasket(KP510 00150)

surfaces
to rearoilsealretainer 2 - 3 mm wide
Caution:
engineoilandengine
Waitat least30minutesbeforerefilling
v/ F\.0 64- 0.8

. Installrearoil sealretainerby aligningto dowelpin.
. Tighten6 boltsuniformlY. (R+
Rear oil seal retatner
E N- 1 6 8
ON.VEHICLE
PARTS
R B 2 5 D EE N G l N E
10-9 ROCKERCOVER/ IGNITIONCOIL
Ornarnent lgnitioncoil
Groundcable
?Oln^lrT-ra
:aa--' -
tli
\",/ Kg-m
Fillercap
Rockercover
O ring
Grommet
Rockercovergasket
Ornament
RockercovergaSket
\-.1i<9-m
Removal
. RemoveRockercoverornament.
. Removeignition
coilharnessand removeignitioncoil.
. Loosenandremovetherockerbolts(intakeandexhaust)in
the ordershownin thefigureon right.
. Removethe rockercover.
Installation
. Installtherockermver.
. Tightentherockercoverscrewuniformly in theordershown
in thefigureon rightin severalstages.
8 4 2
Bolt0.3- 0.39
lgnitioncoil
. Installthe ignitioncoilbracket.
Vf qS cv.rinder
. Installtheomament. rgnrtron ry
corltacket
\LO
Sparkplu0
E N- 1 6 9
ON.VEHICLEPARTS
10.10 CYLINDERHEAD
(1) Cylinderhead removal& installation
Leuserr ut
CVlinderhead bolt @ \J/
o . o z1- . 2 , g l fl.,-(4) Tightento

(5)AnSlewr€
\ ^ II
\Y
g
]|
rorquewl
Springwasher
-.-\o
g ,^,-^L^- Cylinderhead bolt
0.e2-1294
wasnerr'|
s/
j-Spring washer
f'-"{t
' 0 v , /
'.\)€ /d'
\ \
\ ,
\,]
Cam pulley
H| rs-t
$ Replaceafter every disassemblY
Removal
. Removecoolingwatercompletely
fromthe radiator,
blockdrainPlug.
cylinder
. Removethefollowing;
. Connectorand intakemanifold
. Exhaustmanifold
. Timingbelt
. Rockercover,ignitioncoil
. SparkPlug
Removethe cylinderheadboltsin the sequencesnown

in thefigureson right.
Removethe cylinderhead,thencylinderheadgasket.
Checkfor anydistortionon the cylinderhead.

Checkfor any distortionon the cylinderblocksurface. 4 - 1 7 | ' . , 411.x5 I - 3 M6x1.0
E N- 1 7 0
ON.VEHICLE
PARTS
Installation
. BeforeinstallingthecylinderheadASSYto cylinderblock,
the crankpulleyandthe cam pulleymustbe positionedat
No. '1cylindercompression T.D.Cposition.
. Alignthecrankpulleytimingmarkandthetimingbeltcover
timingindicator(0"position).
. Alignintakeandtheexhaust campulleyalignment
mark
to respective
beltcoveralignment
marks.
Intakecam shaft Exhaustcam shafl
Makesureit is positioned
at No. 1 compression
T.D.C
position.
Installcylinderheadgasket.
Installthe boltsin sequenceshownin thefigureon right.
: The cylinderheadboltsaretorquedby two-stepmethod.
llghten the boltsin two steps.
( 1 ) Tightento 3 kg-m.
(2) Tightenedto 10 kg-m.
(3) Loosenboltscompletely0 kg-m.
(4) Tightento 3 - 3.5 kg-m.
(5) Turnbolts80 - 90oclockwisewhenanglewrenchis
USEO.
Tightenboltsto 10+15 kg-mwhentorquewrenchis used.
Caution:
Whenanglewrenchis not used,neverattemptto
approximate
thetighteninganglevisually.
. Installignition coilandthesparkplug.
. Installthetimingbelt.
. Installtheexhaustmanifold.
. Installcollectorand intakemanifold.
. Checktheairflowof the hydraulicbulblifter.
. Pushthe hydraulicbulbliftercrestsurfacewithfingerand
checktheslump.
S l u m pl i m i tv a l u e( m m ) : 1.0
EN - 171
fiR'S
ON-VEHICLE
Thereis a possibility of entrainedairwithinthe hydraulic

to be
valvelifterif the slumpis over 1'0 mm Air need
releasedfromhydraulicvalvelifter'
ldlethe engineior approximately 10 minutesat 4000rpm
afterinstallingthe rockercover'
valvelifter
Removethe rocKercoverandpushthe hydraulic
surfaceto checkthe slumpof cam basecircle'
is overthe
Replacethe hydraulicvalvelifterif thevalue
limit.
(2) Cylinderheaddi"""."-bly, ""t"-bly&inspection
/
/u"V:f31'?'.,11''""'
/ 9ping seat
Valvelrfler- -./ / / - o| seal
Valve
t'd/^r/
valvecorer-'--"'" .au^ru.
nu'o'
"
\<- -@-Y==--J:?"[',].",""""r"
, /Valve seat
.0.'"n**ffi" *
Washer-=-3 ,{/-i
A ^^
-crr(@@--"
Buffleplate----€ fp
- B o r t o .1
e2 g
-l O
P e o r r o . st .zrj E
washer/ I e/ -washer
'"1::::.::"::li**
*o@-
;*lT"ililJf""['S
W KffiP* # --.9-3:Ji9',
^.#"*\
)t 6.- F.-
Nr--_ :.t'
g
ri.,nso"*"o:,-a{-*?J
-$---& g..:
":'">-t\ _-\D
_ ' 4 F ^ ' " , 0 n ', r g \
*\..!
-
\-
sea6r[Hj::;";";:
i l" cam;hafttrontorlsealE[
*tr!1liiry'""ffiy*i;ltj,tp;:;:,.
;:;:;:- M,-;l*inan' ron' o r..-.'5-eo'osz-'ze
ffeonz.r - z.zg
L",l hg'm
gasket
A Liquid
oil
n Engine
E ReplaceaftereverydisassemblY
DisassemblY
. Us" tne propertooltosecurethehexagonalpartinfrontof
camshaftto removecam Pulley'
. Removetimingbeltcoverbackplate
. Positionthe cim shaftknock-pinto the positionshownIn
the figureon right.
E N- 1 7 2
ON-VEHICLE
PARTS
. Removecambracketboltsby loosening themgraduallyrn

severalstages,in reversesequenceshownin thefigure
on right.
Caution:
Beforeremovingcamshaftbracket,paintmarksto indicate
bracketpositionand direction.
. Removethe cam bracket.
Intakeandexhaust camshaft
canbeidentifiedby
paintcolorandpresence
identification of a splinegearfor
driving
thecrankanglesensor.
Camshaft
Intake
camshaft Purple No
Exhaust
camshaft Orange Yes I Splinegearfordrivingcrankangiesensoj
Removehydraulic
valvelifter.
(1) Hydraulicvalvelifteris nonseparable.
(2) Do notstorehydraulicvalvelifterup sidedownor on C) /7^ @
(3)
itsside.
Storehydraulicvalvelifterin theengineoilwhen
V K7\J
storingtemporarily.
. Usevalvespringcompressor(KV10108950)to remove
varvespnngs.
Cylinderhead inspection
. Usescraperto removeanytracesof oil,waterscale,
gasket,sealingagent,carbonetc.fromcylinderhead
surfaces.
. Measurelowersurfaceof cvlinderheadin sixdirections
to
checkfordistortion.
Limit(mm): 0.2
Whendistortion isjustoverthe limit,resurfacethecylinder

head.
lf distortionexceedsthe limit,replacecylinderhead.
Gamshaftvisual inspection
. Visuallyinspectcamshaftfor anywarnor damage.
E N- 1 7 3
ON-VEHICLEPARTS
Camshaftrun-out
. Use V-blockon fixedsurfaceand supportbothcamshaft
endjournals(No.1 & No.7).
. Avoidthe oil groovein the centerof the No.4 journaland
positionthe dialgaugevertically.
. Rotatethe cam shaftby handto one directionand read
the movementwidthon dialgauge.
. The run-outis equalto halfof the movementwidth
indicated on dialgauge.
Standardvalue (mm): 0.05
CamnosediameterinsPection
to measure
Usemicrometer of camnose.
diameter
Intakestandardvalue(mm): 39.705- 39.895
Exhauststandardvalue(mm): 39.205- 39.395
Replacecamshaftif diametervaluediffers.
Camshaftoil clearance
. Tightenthe cam bracketto specifiedtorque.
Useinsidemicrometer to measureinsidediameter'
Standard value (mm): 28.000- 28.021
l-)
. Usemicrometer ofcamshaft
diameter
outside
to measure
JOUmal.
Standard value (mm): 27.935- 27.955
ls
Inspectthatthe camshaftoil clearancemeasurement
withinsoecifiedvalue.
Oil clearance= cam bracketinsidediameter-
camshaftjournal (outsidediameter)
Camshaft end plaY

. Assemblecamshaftandtightencam bracketto standard
value.
. Seta dialgaugeat frontendof the camshaftin thrust
direction.Whencamshaftmovesin frontand rear
direction,readthedualgaugerun-outwidth.
'174
EN -
ON-VEHICLEPARTS
Valveguide clearanceinspection
D i a lg a u g e
. Protrudevalveapproximately15mmfromvalveguidehome : \
intocombustionchamber.Measurevalvedeflectionby
swingingintodirectionparallelto dialgauge.
. Theclearance is equaltohalfofthedialgaugereading
(deflection
width).
Valveguide clearance(mm) Intake: 0.1
Exhaust: 0.1
. Replacevalveor valveguideif clearanceexceedslimit.
Valveguide replacement
. Usevalveguideremoverandtap it fromcombustion
chambersideto removeseal.
Rectify
cylinderheadvalveguideholeusingvalveguide
reamer
Rectifiedvalvestandardvalue(mm)
Intake& exhaust: 6 . 0 0 0- 6 . 0 1 8
Heatcylinder 150-
heatin an oilbathto approximately
160oC.Usea valveguidedriftand pressvalveguidefrom
camshaftside.
. Thepress-fit
dimensions
areshowninfigureonright. 1 6 . 8+ / -0 . 1
Intake/ Exhaust
Reamtheinsideoftheinserted
valveouidewithvalveouide
reamer.
Finishedinternaldiameterstandardvalue(mm)
lntake& exhaust: 1 0 . 1 7 -5' t 0 . 1 9 6
g u i d er e a m e r( K V 1 0 11 1 6 0 0 )
Valve seat inspection

. Checkcontactsurfacesof thevalveseatandthevalve.
. Replacevalveor valveseatif contactingsurfaceis too
largeor improper.
o*
q"o,"
EN - 175
PARTS
ON-VEHICLE
Valve seat rePlacement

. Cut andgrindvalveseatto removethe valveseat.
. Readjustthe mountingholefor oversizevalveseat.
Standardvalue (mm):
lntake 36.5+0.016-0
Exhaust 3 2 . 0+ 0 . 0 1 6- 0
. Read.just the valveguidecentreandconcentriccircle'
. Heatup the cylinderheadin an oil bathto approximately
1 1 0- 1 3 0 " C .
. Usevalveseatdriftto tap it untilit strikethe bottom.
. Whennotusingvalveseatdrift:
5 minutes'
. Usedry rceto coolvalveseatfor approximately
B0 "C
Heatup the cylinderheadto approximately
. Insertcooledvalveseatintocylinderheadquickly.
Caution:
Do notdirectlytouchcooledvalveseatwithhands.
thevalveseatusingvalveseatcutterorvalveseat
. Read.lust .\,=
onnoer.
is as shownin the
Valveseatshapeand measurement
figureson right.
* o D-'-
. op,
t rg-'
,..',.,'
Qa Qo, 6o, 6o, 0D,
.::-. . so.of,o'u so.of,o!,' 32.O 37.0
Urafe ^^ . -0016 ^^ - +0113 37.0
JO.C o Jb. c n o97 32.O
zs.t'.. ,
zs t',.,
E N- 1 7 6
ON-VEHICLE
PARTS
Valveinspection
Outsidediametermeasurement
. Usemicrometer to measureeachdimension.
Valva a b c d e
lnlake 8 5 . 3- 8 5 . 5 8 0 . 7 8- 8 ' 1 . 0 8 34.OO- 34.02 5 965 - 5.980 1 . 1 5 - 1 . 4 52.60 - 2.90 30.
Exhaust 8 7 . 3- 8 7 . 5 8 2 . 7 8- 8 3 . 0 8 2 9 0 0 - 2 9 0 7 5.960- 5.945 3 . 2- 3 . 4 '15"
Valvespring squarenessinspection
. Placea righfanglestraightedge(L-square)so it contacts
thespring.Turnthe springand measurethe maximum
clearancebetweenupperspringsurfaceandthe right
anglesurfaceto determineout-of-squaredistance.
Limit(mm): 1.8
. Replacethevalvespringif the oulof-squaredistanceis
overthe limit. Contact
Freelengthand pressureload inspection

. Usea valvespringtesterto checkthe springpressure.
Freelength(mm): 43.1
Installation
load(kg): 24.0
Hydraulicvalveliftervisualinspection
. Visuallyinspectcamshaftrotationalareaon liftersideand
lifterborerotationalareafor anywarnor damage.
. Replaceif thereareany abnormality. t . )
Caution:
Do notdisassemblehydraulicvalvelifter.lt is nonseparabte
v
t---.---,-'lJ
un[.
Hydraulicvalve lifter outside diameter

. Usea micrometerto checkthe valvelifteroutside
diameter.
EN- 177
ON-VEHICLEPARTS
Hydraulicvalvelifterhole internaldiameter
Standardvalue (mm): 3 1 . 0 0-0 3 1 . 0 2 0
Hydraulic valve adjuster clearance

valveclearance=
Hydraulic
valveclearanceholeinternaldiameter- hydraulicvalveexteriordiameter
HVdraulic
lnstallation
. InstallvalveassociatedParts.
. Fordetailedinformation on howto installnewvalveoilseal
"Oilsealreplacement".
referto sectionon
. Installvalvespringwithnarrowpitchendtowardscylinder
head(identificationcolorsidedown).
. Installspringretainer
. Usevalvespringcompressor to installvalvecollet.
. Applya smallcoatingof petroleumjellyto the internal
surfaceof collet.
. Usea magneticscrewdriver.
(1) Uppercolletinstallation
. Attachcolletto lowersideof magneticscrewdriverblade
and installtnthe valvestem.
(21 Lower colletinstallation

Attachcolletto uppersideof magneticscrewdriverblade
andinstallin thevalvestem.
. Aftervalvecolletinstallationlightlytap the stemedgewith
a plastichammerto confirminstallation.
. Installhydraulic
valvelifter.
. Tapin camshaftknockPin
Knock pin protrusiondistance(mm):
Gamshaftinstallation
. Turncamshaftso No. 1 cylinderis at compressionT.D.C KnockPln Knockpin
position(orturncamshaft60obeforeor afterNo. 1 cylinder

r.D.c).
. TemporarilytightenNo. 1 cam bracketand makesurethe
thrustsectionis positioned
securely.
E N- 1 7 8
ON-VEHICLE
PARTS
Tightencam bracketbolts540.(1.5 turns)graduallyin

severalstagesin the sequenceshownin thefigureon
right.
Tightening
torque(kg-m): 0 . 9 2 -1 . 2
6 10 14 12
Ffonti
Installcamshaftfrontoilseal. Fordetailinformation
referto
"Oil
seal"section.
. Installtimingbeltbackplate.
. Aligncampulleyto camshaft
knockpinto install.
Tighteningtorque (kg-m): 1 . 4 -1 . 9
E N- 1 7 9
ENGINE
REMOVE& INSTALL
R826DETTENGINE
1 1 R E M O V E& I N S T A L LE N G I N E
[Point 1] Releasefuel Pressure
. Afterstartingengine,removethefuelpumpfuseand run
engineuntilit stops. Consumefuelleftin fuellinesby
crankingthe enginetwo to threetimes.
. Whenit is not possibleto startthe engtne,removethefuel
pumpfuseandconsumefuellefiin fuellinesby cranking
enginefourto fivetimes.
Caution:
The batterymay becomeweakeasily,connectbooster
cablesto chargedbattery.

. Loosenlocknut and provideadequateslackfor the
acceleratorwire. Pulloutercasein the directionof the
acceleratorpedaluntilthrottledrumstartsto move(noplay
in cable).Rotatethe locknut 1 to 1.5turnsto tighten.
[Point3] Enginemain harness,ground line

separation
. Disconnect the connectorsbehindthe batteryfor
startermotorandtransmission
alternator, systems.
lPoint4] Air compressor

pump movement
andpowersteeringoil !e .iffifierr "
. Remove Leavepipes
eachunitto brackets.
boltssecuring
andsecuretosideofthebodywithstring Care
connected
thebody.
mustbetakennotto scratch ffY;"..
[Point5] Powersteeringoil tubebracketseparation
. Removeboltsandseparatethepowersteeringoiltube
andmovetowards
bracket, the bodyside.
..-- v,r*Jo fiom betow
[Point6] Front enginemountingnuts removal

. Makesurethe engineslingsaresecurelyhookedby
enginehorstchainandremovefrontenginemountingnuts. '6) l,----'-
'hN4
ion-teng,nurouFinlS
n u t4 . 4 - 5 . 6
E N- 1 8 0
REMOVE& INSTALL
ENGINE
RB26DETE
TNGINE
[Point7] Rightfront enginemountingbracket

removal
. Powersteeringoiltubewillhittherightfrontengine
mountingandit is notpossibleto shifttheenginefonvard.
Thereforeremovenutsandremoverightenginemounting
bracket.
[Point8] Remove& installengineASSY

. Operate thehoistchain,andchangetheengineangle
graduallyto remove
theengine.Caremustbetakennotto
interfere
withvehiclebody.
E N- ' 1 8 1
REMOVE& INSTALLENGINE
/ D E / D E T/ C A I B iE N G I N E
RB2OE
'11 REMOVE& INSTALLENGINE

[Point1] ReleasefuelPressure
. Afterstarting thefuelpumpfuseandrun
remove
engine,
engineuntilit stops. Consumefuelleftin fuellinesby
crankingthe enginetwo to threetimes.
. Whenit is notpossibleto startthe engine,removethe fuel
pumpfuseand consumefuelleftin fuellinesby cranking
enginefourto fivetimes.
Caution:
Transmissionjack set (CA18ionly)

jack underthe transmission.
. Placethe transmission

. Loosenlocknut and provideadequateslackfor the
acceleratorwire. Pulloutercasein directionof the
acceleratorpedaluntilthrottledrumstartsto move(noplay
in cable).Rotatethe locknut 1 to 1.5turnsto tighten.
[Point3] Enginemain harness,ground line

seParation
. Disconnectthe connectorsbehindthe batteryfor
startermotorandtransmission
alternator, systems.
[Point 4l Air compressor and power steering oil

pumP movement
. Removeboltssecuringeachunitto brackets.Leavepipes
connectedandsecureto sideof the bodywithstring.Care
mustbe takennotto scratchthe body.
[Point 5] Remove& Install propella shaft

. Placea capon thetransmisslon rearsealso the oil willnot
leakwhenthe propellashaftis removed
E N- 1 8 2
REMOVE& INSTALL
ENGINE
R B 2 0 D ED t I D E T TE N G ' N L
[Point6] Remove& installrearenginemounting

. Supportthe transmission jack and
withtransmission l
removerearmemberboltsandrearenqinemountinobolts
andnuts.
(4) 4.4 - 5.6
[Point7] Frontenginemountingnuts removal

. Makesurethe engineslingsare securelyhookedby
enginehoistchainandremovefrontenginemountingnuts.
Enginemountingnut tighteningtorque(kg-m):4.4- 5.6
Frontenginemounting
nut
[Point8] Remove& instaltengineASSY

. Operatethehoistchain,andchangetheengineangle
graduallyto removethe engine.Caremustbe takennotto
interferewithvehiclebodv.
E N- 1 8 3
ENGINE
& LNSTALL
REI\,4OVE
1 1 R E M O V E& I N S T A L LE N G I N E
StandardPoints
jackto removeandinstall
howto usehoistcraneandtransmission
Thissectiondescribes
theRB25DE engine.
. Draincoolingwatercompletely.
. Removebonnet.
Enginebay left side:

. Exhaustgas sensorharnessdisconnection
. Groundlineconnectorseparatlon
. Air duct,Air cleaner
. Powersteeringoil PumPremoval
. Air compressorremoval
Enginebay right side:

Battery O ncrtvgrEsr O
/G.\
"fuelputp rer"y" (E
. Release
fuelpressure
byselecting ) FUELPUMPRELAY OFF
in activetestmode,and PressSTOP.
CAS-RPM(POS) 950 rpm
fuelpumpfuseandrun
. Afterstaringtheengine,remove
engineuntilitstops.Consurne leftinfuellinebV ffi
fuel
theengineovertwotothreetimes. \Gy
cranking
Caution: START INTERRUPT STOP
. Acceleratorwireseparation
. Heaterhose
. Vacuumhosesseparatior
Enginemain harness& ground line separation
Enginebay front side:

. Radiatorshroud,radiator
. Coolingfan
Enginebay upPerside:
. ECCSharnessconnectors
E N- 1 8 4
REMOVE& INSTALL
ENGINE
R525lE ENGINE
Vehiclebody,lower side:
. Engineundercover
. Propellashaft
. Transmission controllever(M/Tvehicle),
linkage(A/Tvehicle) \qt--l.ER)j -
. Exhaustfronttube
^ \r,_r,_"
xear_rnemD:r-Rear
enqinemountrn
. Rearenginemountedbracket bolt(4)4.4- 5.6 UoitiZ;a.+__
s
. Rightandleftenginemountedbracket.
Remove& installengineASSY
. Operatehoistchainandchangeengineanglegradually.
Caremustbe takennotto interferewithvehicleand
removetheengine.
E N- 1 8 5
OVERHAUL
ENGINE
RB26DETTENGINE
12 ENGINEOVERHAUL
Thissectiondescribesthecomponent disassemblyof theengineassemblyremovedfrom
thevehiclewithouttransmission. replacement
theinspection,
lt alsoexplains of
damages
malfunctioning, orwarnpartsandcarryoutanynecessary and
adjustments
sequentialassembly inorderto produce enginecondition'
a standard
CAUTIONS
OVERHAUL
bly
( 1 ) Disassem
. Usecorrectandsuitable toolswhenpossibleandmakesureto carryoutsafe
procedures.
. iare mustbetakenwithoperations on matingsurfaces to
andslidingsurfaces
preventlossof surfaceaccuracY.
. Arrangedisassembled foreasyfaultsdetection
parsby makingmarksto organize
andpreciseassemblY.
. Loosennutsandboltsin a diagonal fromoutside.care mustbetakento
direction
followthenumericalorderwhenindicated
repairandreplacement
(21 lnspection,
partsinspection
. ieplaceor repairaftercompleting theinspection
following
orocedures.Perform sameinspectionforthenewpartsandreplacepartsas
necessary.
(3) Assembly
. Alwaysusea torquewrenchto tightennutsandboltsto specific torque
tightening
. Tightennutsandboltsfromcentreto outsidediagonaldirection, intwoor
gradually
threesuccessivestages.Followthenumeric orderwhenindicated'
. Replace gasket, oilsealsandO-rings
packing, withnewonesin principle'
. Cleanea-hpartthoroughly andblownoffwithcompressed air. Inparticular,
check
thatoilandwaterpassages arenotcloggedor obstructed'
. caremustbetakennotto scratch ordamageslidingormatingsurfacescleanoffall
allslidingsurfacewithanadequate
dust,debrisorforeignobjects.Lubricate
coatingoil.
E N- 1 8 6
ENGINE
OVERHAUL
RB26DETE
TNGINE
12.1 DISASSEMBLE
& ASSEMBLECYLINDERBLOCKASSY
sensorbolt{211.6- 2.1rct
Deronation
t:
G-= Defonation ___-_
sensor
Alternatoradjustmentbar 6<= Rearorlseatlpornt7]
*PffiffiN -A
"t*il;E:{ft;i;;'K)q
iJ:1il,8*,.",,
""€S-f;ffi*
uon roo a\
ir""'"liln "r rn;-=-fi. l-Pn'oa
bolt(2rlPornt
201
\
Flywheel[Point3, 5]
D$,
D$ (.4arr
lt4arroeanngcaplPornt25]6;$p11 Rearplare- Mainbearing
Con
r rod bearrrg
bearrno
IJt tcornt?5]^ ootrp
9?i,:0":,.99-: -\'Z J<4*-BarnJprate 32-43
o'*'*,-ffi F "d;;H
Bort(2)1 6 _
- r\
2jVi (/:,8!*it?-,;::;?, A
Bort(12) E-r\--
/ I Oilpanboltg
9 |[."'lTii *n . 3.2- 4.3
(t\r10)
Fi
l',1 Kg-m u.o4 - u. pt oirpanbo*(M6)/ a-e pan
0.64- 0.85 Copperwain-e€--Orain ptug:.0-a.0gl
A Liquidgasket
fl Ensineoil
$ Replaceafter every disassembly
. Drainand refillcoolingwater[Point1]
. Removeand installthefollowinooarts:
. Engine
. Collector . Startermotor
. Throttlechamber . Clutchcover,clutchdisc
. Intakemanifold . Oilpan,oilstrainer
. Turbocharger,
exhaustmanifold . Waterpump
. Timingbelt . Oil pump
. CylinderheadASSY . Oilcooler,oilstrainer
. Alternator . All harnessesand connectors
E N- 1 8 7
ENGINEOVERHAUL
RB26DETE
TNGINE
Reference:Engineselectionassembly
Piston
(1) Piston
selection
. 3
Lessthan86.010 Lessthan86.020 Lessthan86.030
Greatefthan86.00 Greaterthan86.010 Greaterthan86.020
Lessthan85.965 Lessthan85.975 Lessthan85.985

Greaterthan85.955 Greaterthan85.965 Greaterthan85.975
0 . 0 3 5- 0 . 0 5 5
Pistonand pistonPin 1,OOS
STD 1. STD2, STD3, O.5OS,
ServicesettingParts:
Pistongrade
(No.1 - No.
Distinction
symbol
Prslonprngrade(0 1)
Mainbearing
(2) Mainbearingselection
'
, . , , 3
l , , ' : ' . . ' . ' ' .
STD O STD 1 STD 2 STD 3

,.:.'.' 1.821 -1 .824 1.824 - 1.827 1.A27- 1.830
1 . 8 1 8- 1 . 8 2 1
0 0.028/ 0.046 0.028/ 0.046 0.028/ 0.046 o.028| 0.047
. . 1
Black Brown NOne Yellow
STD1 STD2 STD3 STD4

1.821- 1.824 1.824- 1.827 1 . 8 2 -7 1 . 8 3 0 1 . 8 3 -0 1 . 8 3 3
7, :' 0.028/ 0.046 0.028/ 0.046 0.028/ 0.046 0.028| a.047
Brown None Yellow Blue
r.
r ':,:l STD 2 STD 3 STD 4 STD 5
1 . A 2 4 - 1 . A 2 7 1.827 - 1 -830 1 . 8 3 0- 1 . 8 3 3 1 . 8 3 3- 1 . 8 3 6
2 ) ' 0.028/ 0.046 0.028/ 0.046 0.028/ 0.046 0.028/ 0.047
NOne Yellow Blue Green
STD3 STD4 STD5 STD6

- 1.83
1 . 8 3 -3 1 . 8 3 6 1 . 8 3 6
1.827- 1.830 1 . 8 3 -0 1 . 8 3 3
..3 0.028/ 0.046 0.028/ 0.046 0.028/ 0.046 90.028| 0.047
Yellow B IUE Green Pink
Servicesetti S T D O - 6 us 0.25
) No. i
EoregradeNo. ff;:113,,".",ifl' te! side--,-\'\l
Iru -5-
*383".\\
r'l-lili: No 5
{,rl\
E N- 1 8 8
ENGINE
OVERHAUL
R826DETT
ENGINE
Pistonpin
(3) Pistonpinselection
(mm) 2 1 0 0 6- 2 1 . 0 0 0 2 1 . 0 1 2- 2 1. 0 0 6
2 0 . 9 9 5- 2 0 . 9 8 9 21.0A1- 20.995
0 . 0 0 5- 0 . 0 1 7
Servicesettingparts: Pistonandpistonpin S T D1 .S T D2 , S T D3 . 0 . 5 0 51. . O O S
Ffontmark
Prngrade
(0.1)
CylinderNo.
( 1- 6 )
Distinction
Largeend grade(0.1) symbol ( 1- 3 )
Con'rod bearing
(4)Con'rodbearingselection
Lass tfian 51.013
Greaaer than 51.007
BearinggradeNo. STDO BearinggradeNo. STD 1

Bearingthickness(mm) 1 . 5 0 -0 1 . 5 0 3Bearinglhickness(mm) 1 . 5 0 3- 1 5 0 6
0
Oil clearance(mm) 0 . 0 2 0/ 0 . 0 3 9Oil clearance(mm) 0 . 0 2 0/ 0 . 0 3 9
ldentifcation
color None ldentification
coior Brown
BearinggradeNo. SID 1 BearinggradeNo. STD2
- 1.509
Bearingthickness(mm) 1 . 5 0 3- 1. 5 0 6 Bearingthickness(mm) 1 . 5 0 6
Oil clearance(mm) 0.020/ 0.040 Oil clearance(mm) 0.021t 0.040
ldentifcation
color Brown ldentificationcolor Green
Servicesettingparts: us 0.08.
us 0.12.
us 0.25
UpperjournaI gradeNo.
No.1 - No.6from
E N- 1 8 9
OVERHAUL
ENGINE
RB26DETTENGINE
[Point1] Drain& refillcoolingwater

Draining
. Draincoolingwaterin the cylinderblockcompletelyfrom
thedrainplug.
Refilling
. Referto thesection"coolingwater"for detailedinstruction.
[Point2] Remove& installenginestand

. Installthe enginesub attachmentusing6 boltsto engine
mountingbracketon rightsideof the engine.
B o l t ( 64)- 5
0x151=25
[Point 3] FlYwheelrun-out
. Setdialgaugeto flywheelwhereit contactsclutch'
. Turntheflywheelandmeasuretherun-out.
Run-outlimit (mm): 0.10
[Point 4] Remove & install flywheel

Removal
. Useringgearstopperto fix flywheeland remove.
lnstallation
((6)
. Coatthe threadandflangeof boltswithengineoil after ra.s-)s6--\"\
the
installing bolts.
. aftertighteningthe flywheelbolts,use ringgearstopperto
secureflywheelandtightenbolts. 't4.5-15.5
Flywheelbolt tighteningtorque (kg-m):
[Point5] Flywheelknock pin installation Knockpin

protrusiondistance
. Insertthe flyrvheelknockpinso the pin protrudesB to 8 5
mm.
Knockpin
Flywheel
E N- 1 9 0
ENGINE
OVERHAUL
RB26DETE
TNGINE
[Point6] Remove& installrearoil seal retainer

Removal
. Inserta screwdriver
inthegapbetween
mainbearing
cap
andrearoilsealretainerto
remove
seal.
Cleaning
. Usescraperto removeliquidgasket
. Cleanthe cylinderblocksidein the sameway.
. Wipematingsurfacewithwhitegasoline.
Caution:
Also removeliquidgasketin the grooves.
lnstallation
. Applyliquidgasketandinstallunitwithin5 minutes.
. Cutnozzleendoftheliquidgasket(KPS10 00150)tubeas
shownin the figureon right. Usetubepresserfor
aoolication.
. Applyliquidgasketcontinuously to rearoil sealretainer.

Caution:
Makesureliquidgasketwidthis 2.0- 3.0mm.
Refillengineoil andstartthe engine30 minutesafter
assemblyis completed.
. Aligntherearoilsealretainer
withdowelpinto install.
. Tighten6 boltsuniformly.
Rearoil sealretainerbolttighteningtorque(kg-m):
0.64- 0.85
[Point7] Remove& installrearoil seal

Removal
. Usea toolsuchas screwdriver
to removethe seal.
Installation
. Caremustbe takennotto scratchor damagethe oil seal
perimeterarea. Useoil sealdrift(Outsidediameter:100
mm)to installnewoilseal.
. Applya coatof oil or chassisgreaseto oil seal lip area.
E N- 1 9 1
ENGINEOVERHAUL
RB26DETTENGINE
[Point8] Con'rod side clearanceinspection

. Usethicknessgaugeto measurethethrustclearance
betweenthe con'rodandthe crankarm.
[Point9] Remove& installpiston con'rodASSY

. Usea toolsuchas hammerhandleto pressthe unitto
headside.
cylinder
lnstallation
. Setthe crankpin at B.D.C(Bottomdeadcenter)position.
. Coatcylinderbore,crankpinandpistonwithengineoil'
. Assemblepistonwithfrontmarkon pistonheadfacingthe
frontof engine.
. Usea pistonringcompressorto installthe pistonandthe
con'rodassemblyin cylinderblock.
Caution:
Care must be taken not to strikeor deformoil jet pipe with
largeend of connectingrodwheninstalling.
Gon'rodnut tightening
. Applyengineoil to con'rodandthe nutsbeforeassembly.
. Tightennutsin two or threestages.
'' .6
1st time Torquewrench (kg-m): 1.4-
2nd time Angle wrench ( " ): 60 - 65
Caution:
Do notvisuallymeasurethetighteningtorqueif anglewrench
is not available.
[Point10] Installcon'rod bearing

. Applyengineoil to bearingsurfacewheninstallingcon'rod
bearing.Do not applyengineoil to rearsurfaceof
bearing,cleanthisarea.
. Aligncon'rodbearingretainernotchesandinstall(leftside).
. Makesurethecon'rodbodyoil holeandthe bearingoil
holeis aligned.
E N- 1 9 2
ENGINE
OVERHAUL
RB26DETE
TNGINE
[Point11] Installoil jet

. Setthe oiljet positionsecurelyand checkthatit doesnot .<
I 3.l'41
Evebort
interfere
withpiston.lf oiljetpipecontactspistonoris benr,
replace itwithnewpart.
_r _31 {
!-\ o"*
Oiljettightening torque(kg-m): 3 . 1- 4 . 1 .' r'-<-al -' ,''.1-l=
, )*-
.-.-:
_=
[Point12] Remove& installpiston ring

Removal
. Usepistonringexpanderto removerings.
Caution:
Caremustbe takennotto scratchoiston.
Installation
. Usepistonringexpanderto installrings.
ldentification
mark
. The stampedmarkson top and secondpistonring

openingsmustfaceup.
Topnng openrng
. Positionthe pistonringsas shownin thefigureon right
to install.
;",;*);^3i
-"
{/z--Yrr
Caution: Y aln
..\ \./
Caremustbe takennotto scratchpiston.
^ /
)s<-.-
Decononno ooentn0
OiI nno lower
- ra opentnq
'l3] Remove& install snap ring

[Point
Removal
. Usesnapringpliersto removerings.
Installation
. Usesnapringpliersandinstallringssecurely
ingroove.
Caution:
Alwaysreplacesnapringswithnewones.
[Point14] Remove& installpistonpin

. Usea heatgunto heatpistonto 60- 70"Cwhenremoving
piston
andinstalling pin.
Placesuitabletoolagainstpistonpin and pressor use

plastichammer.
Applyplentyof engineoilto pin,pin holeand con'rodsmall
note.
E N- ' 1 9 3
ENGINEOVERHAUL
RB26DETTENGINE
Piston pin Press-fit

. Placethe pistonfrontmarkso the con'rodoil holefaces
rightsideof the engine(lefisidewhenviewedfromfront)
and pressJit.
Caution:
Press-fitthe pistonpinfromthefrontof pistonto the rearside -
of piston. Front
[Point15] Piston Pin inspection

to measureoutsidediameterof piston
. Usethe micrometer
ptn.
Standardunit (mm): 20.989- 21.001 Micrometer
[Point16] PistoninsPection
. Usemicrometer outsidepistonskirtdiameter'
to measure
Measuring from bottom(mm): 13
pointDistance
Standard(mm): 85.955- 85.985
Useinsidemicrometerto measureinsidediameterof
pistonpinhole.
value(mm):
Standard 20.987- 20.999
Fivetypesof pistonsareavailablefor service(STD1, STD
1.oos).
2.STD3,o.sos,
[Point17] Piston pin clearanceinspection

. Pistonpin clearanceis the figureobtainedby subracting
the pistonpinoutsidediameterlPoint15]fromthe piston
oinholeinsidediameter[Point16]
Piston clearanceat normal temperature(20oC):
0 - -0.004
[Point18] Con'rod insPection

Bend and torsion inspection
. Measurethe bendand torsionwithcon'rodaligner.
Bend limit (mm): 0.15
Torsionlimit (mm): 0.3
Smallend insidediameterinspection
Standardvalue (mm): 21.000- 21.0'12
E N- 1 9 4
ENGINE
OVERHAUL
R826DETT
ENG]NE
Gon'rodbearinginteriordiameterinspection
. Installcon'rodbearingin con'rodandcap. Tightencon'rod
nutsto specifiedtorqueand measurecon'rodbearing
interiordiameter,
Con'rcd nut 1 s tt i m e Torquewrench(kg-m) 1 . 4 - 1 . 6

tigh!eningtorque 2nd time Anglewrench( ') 60-65
Standardvalue 4 7 . 9 8 9- 4 8 . 0 0 7
[Point19] Con'rodsmall end bushingclearance

. The measurement differenceof the smallend inside
diameter[Point18] andoutsidediameterof pistonpinIPoint
151is the bushingclearance(fullfloattype).
Bush clearancestandardvalue (mm):0.005- 0.017
. Thecon'rodsmallend and pistonpinoutsidediameterare
separatedintotwo gradesat thefactory.Makesurethat
the grades(0.'1) conformfor bothpartsbecausethe rod
and pin are selectedand fittedaccordinoto bushino
clearance.
[Point20] Gon'rodcap bolt

. Con 'rodcap boltshavegroovesto preventit from
disengaging.
. Forthis reasondo nottap the endsto removebolts.
E
lPoint21] Piston ring end gap and side clearance
Ring end gap inspection
. Usea pistonto pressthe pistonringintothe middleof the
cylinder
andmeasure thegap.
Item Top dng S.cond ing
B o r eg r a d e1 , 2 , 3 :
0 . 2 4- 0 . 3 4
0.42- 0.57 0.20- 0.60
Side clearanceinspection
. Measurethe clearancebetweenthe oistonrinoandthe
pistonringgroove.
0.040- 0.075 0.030- 0.065 0 . 0 6 5

- 0.135
Threetypesof pistonrings(STD,0.505, 1.00S)are

availablefor service.
E N- 1 9 5
ENGINE
OVERHAUL
RB26DETE
TNGINE
[Point22] Grankshaftthrust clearanceinspection

. Usea thicknessgaugeto measurethe clearancebetween
thethrustbearing(No.4 bearing)andthe crankarmwhen
towardsfrontandrearof the engine.
movingthe crankshaft
Standardvalue (mm): 0 . 0 5- 0 . 1 8
Limit(mm): 0.3
[Point23] Remove& installpilot bushing

Removal
. Usea pilotbearingpullerto removepilotbushing.
Pilot bearing
sr1661 0000
lnstallation
. Thepilotbushinginstallation
position
is as shownin the
figureon right.
[Point24] Remove& installmain bearingbolts

Removal
. Removebearingboltsin reverseorderof sequenceshown
lnstallation
. Tightenthe boltsto specifiedtorquein two to threestages
in the sequenceshownin thefigureon the right Make
surethecrankshaft turnssmoothlyaftertighteningthebolts
to specifiedtorque.
Main bearingbolt tighteningtorque(kg-m): 4.7 - 5.3
Caution:
Applyengineoil to the boltthreadsand boltseatswhen
tightening the bolts.
IPoint25] Remove& installmain bearingcaP

Removal
. Usetoolssuchas screwdriver to prythebearingcapsopen.
Caution:
Caremustbe takennotto scratchthe oil pan railsurface.
lnstallation
. Checkthefrontandrearposttionandfit ontocylinderblock
witha copper
by lightlytappingit in a numberof locations
hammer
E N- 1 9 6
ENGINEOVERHAUL
R B 2 6 D E TE
TNGINE
[Point26] Mainbearinginspection
. The bearingendshouldprotrudewhenInstalledin main
bearingcapor cylinder
block
Thisprotrusionis calledthe crushheight.
[Point27] Crankshaftinspection
Out-of-round
andtaperinspection
Usemicrometer to measureeachjournal(No 1 - 7) and
eachpin (No.1 - 6) in fourlocationsshownin thefigureon
right.
Theoufof-roundvalueis thedifference of the dimensions
in directions
A andB.
Thetapervalueis the differenceof thedimensions
measured at points1 and2.
Out-of-roundand taper limit (mm): 0.005
Pin and journal inspections

. Usemicrometerto measurepin andjournaldiameters.
Pin diameterstandardvalue (mm): 47.961- 47.974
Journaldiameterstandardvalue(mm): 54.951- 54.975
Curve inspection
. UseV-blockson a fixedsurfaceandsupportjournalson
bothendsof crankshaft(No.1 and No.7).
. Positionthedialgaugevertically on middleof No.4 joumal
as shownin thefigureon the right.
. Turncrankshaft by handandreaddialgaugemovement.
. The Run-outis equalto halfof dialgaugemovement.
L i m i tv a l u e( m m ) : 0.05
[Point28] Con'rodbearingoil clearance inspection

(A) Usinginsidemicrometerand micrometer
. Theoilclearancecanbecalculated fromconnectingrod
bearinginsidediameter andthecrankshaft pindiameter
measured in[Point1B]and[Point27].
(Oilclearance)=
(Bearinginsidediameter) - (crankshaftpin diameter)
Standardvalue(mm): 0.020- 0.040
. lf the oil clearanceexceedsthe limit,referto
[Point29]and
selectthe appropriatebearing.
E N- 1 9 7
ENGINEOVERHAUL
R826DETT
ENGINE
(B) Using plastigauge

. Removeanydustfromcrankshaftpinsand bearing
surfaces.
. Cutoff a pieceof plastigaugeslightlyshorterthanthe
bearingwidth.Placetheplastigauge on thecrankshaft
in directionof axis. Caremustbe takennotto olaceon the
oilhole.
. Assembleconnectingrod bearingin connectingrodcap
and tightenconnectingrod nutsto specifiedtorque.
1 s tt i m e Torquewrench(kg-m) 1 . 4 - 1 . 6
2 n dt i m e Anglewrench(") 60-65
. Removecon'rodcapandbeanngandmeasureplastigauge
widthwitha plastigaugescale.
Caution:
Neverturnthe crankshaft or connecting rodwhileplastigauge
is beinginserted.
lf oil clearanceexceedsthe limitvalue,referto [Point29] and
selectthe appropriatebearing.
[Point29] Con'rod bearingselectionand engaging

. Selectthe correctsizedbearingas the con'rodbearing
preventsfluctuation in the oilclearance.Threebearing
thicknessesare availableto fit the insidediameterof the
big end of the con'rodand the crankpin diametergauge.
. Whenreplacingthe con'rodbearing,checkbig end inside
diametergauge(indicatedon the oppositesideof the UpperjoumalgradeNo
con'rodhole)and the pin diametergrade(indicatedon
crankshaftNo. 1 counterweiqht frontsurface).
Con'rod bearingselectionchart
Lessthan51.@7
Grsbr tlan 51.000
o a .
BearinggradeNo. STDO BearinggradeNo. STD1

" ' 1. 5 0 3Bearingthickness(mm) ' 1 . 5 0-3 1 . 5 0 6
Bearingthickness(mm) 1 . 5 0 0
Oil clearance(mm) (mm)
0 . 0 2 0/ 0 . 0 3 9Oil cleararrce 0 . 0 2 0/ 0 . 0 3 9
ldentitication
colour None ldentifcation
colour Browl
LesstfEn BearinggradeNo. STD1 BearinggradeNo. STD 2
47.968 Bearingthickness(mm) ' 1 . 5 0-3 1 . 5 0 6Bearingthickness(mm) 1 . 5 0 6- 1 . 5 0 9
Greaterttran Oil clearance(mm) 0.020/ 0 040 Oilclearance(mm) 0.02'1/ 0.040
47j&l. ldentification
colour Brown ldentifcation
colour Green
E N- 1 9 8
ENGINE
OVERHAUL
RB26DETE
TNGINE
. Whenusingundersize bearings, measurebearinginside

diameter
whenbearingis installed.Grindpinso oil
clearanceconformsto specificvalue.
R2.0jourr
Bearingundersizechart
l'' [-J
| _ R 1 ). (p r n l I
t---4 I
Size o i / il)
4,
\
us0.08 1 . 5 4 11 1 . 5 4 9 8 ,--nX','
us0.12 1 . 5 6 /11 . 5 6 9 12 \ t
\ \,H-l
t /
us0.25 1 . 6 2 6t 1 . 6 3 4 25
Caution:
Caremustbe takennotto scratchfilletrollwhenthe crankpin
is beinggroundedto use undersizebearing.
[Point30] Mainbearingoil clearance

Using bore gaugeand micrometer(MethodA)
. Installmainbearingin cylinderblockandattachbearing
cap. Tightenbearingcap boltsto specifiedtorqueand
measurebearinginsidediameter.
Bearingcap bolt tighteningtorque (kg-m): 4.7- 5.3
. Theoil clearancedistancecan be calculated fromthe
valuesfor outsidediameterof the crankiournalmeasureo
in [Point27].
(Oil clearance)=
(Bearinginsidediameter)- (Crankshaftoutsidediameter)
Limitvalue(mm): 0.090
lf oil clearanceexceedsthe limitvaluereferto [Point31]to
selectsuitablebearing.
Using plasticgauge(MethodB)
. Removealldustandoilfromeachcrankshaft journaland
bearingsurfaces.
. Cut a pieceof plastigauge slightlyshorterthanthe
bearing gauge width. Placea plastigauge on crankshaft
in directionof axis,caremustbe takennotto placeon oil
note.
. Assemblethe mainbearingand bearingcap and tighten
cap boltsto the specifiedtorque.
Bearingcap bolt tighteningtorque (kg-m): 4.7 - 5.3
. Removebearingcap andthe bearing.Measure
plastigauge widthon plastigauge scale.
Caution:
Do notturncrankshaft whileplastigauge is beinginserted
lf excessivebearingclearancestillexists,use a thickermain
bearingor undersizedbearingso that the specifiedbearing
clearanceis obtainedwhenmeasuredbygethod A as well.
SENSORSYSTEIV
INSPECTION
R826DETT
ENGINE
6.6 ENGINETEMPERATURESENSORSYSTEMINSPECTION
CONTROLCIBCUITDIAGRAMR826DETTENGINE
Engrne
iemperature
sensor m
2 8 O
a
" " o gnrtion
limingconlro
f
q
E dle speed control
Engine temperaturesensor system trouble diagnosis flowchart

RB26DETTENGINE
= Se f-dLagnosis
I .SELFDIAGNOSTIC FESULTS'
'!: (codeNo.13)
Sel-dagnosis
Nonnal Abnorrna
Abnormal
Enginetemp sensorinput signalinspection

"DATANTONITOR'
t
I Measurethe vollagebetweenterrninal1
ano qrouno.
i Enginetempdisplay
.8 3V when cold @
1V atler warrnnq up Olher
InspectIntakeair temperature Enginetemperature

sensorand ECCS C/U connectors sensor inspeclion
for faultyconnectrons
or defects. l\,4easufe
the resistance
Enginetemp sensor inspection betweenlermnal 1 and 2.
lvleasurethe reslslancebetween
Approx.2.5
terrnrnal1 and 2.
Olher
Apr r o x . 2 . 5 k t ) w h ecno l d up
warmrngup Sensorand ground inspection Replace
r
lnspectothe r
Measurethe voltagebetween
terminal28 and 30.
Engine
temperature
sensor
SVSIEMS
sensor
Harnesscontinuityinspection Inspect ECCSC/U power
l
[,4easurethe resistancebetween supplyand ground
the followingterminals:
Enginetemp ECCSC/U
sen narness narness
0a c o A
InspectECCSC/U connectorand engrnetemp Repairnarness

sensorconnectorfor conlactand defects.
E N- 3 8 1
SENSORSYSTEMINSPECTION
/ D E / D E TE N G I N E
RB2OE
6-6 ENGINETEMPERATURESENSORSYSTEMINSPECTION
CONTROLCIRCUITDIAGRAMRB2OE/ DE / DET ENGINE
conlrol
Fue injectlon
sensot
Engineternperature m
c)
t-*---fr
-----1'
5128)
8 (30)
o
a
8
-
o
C ldlespeedconlrol
=.
Engine temperaturesensor system trouble diagnosis flowchad

RB2OE/ DE / DET ENGINE
Self-diagnosis
IE-"SELFDIAGNOSTIC RESULTS"
€ Self-diagnosis lcode No 13)
Normal Abnormal
i,
Abnormal
Enrinetempse{tsorinputsignalinspection
E-'DATAMONITOB"
.€. N.4easure
the voltage between termlnal l
and qround.
tempdisplaY
@
E Engrne
,S 3V whencolo
-
uP
]V atterwarminq Other
Inspectintakeatr temPeralure EnginetemPerature

sensorand ECCS C/U connectors sensor inspection
or defecls
for faultyconnections the resrstance
N-4easure
EiliiE-iffi sensorinsPection betweenterminal1 and 2.
f/easurethe resistancebetween /* APProx 2 aKf) wnen colo
terminal1 and 2. - \ll-Y Approx 0 3K o after warn Other
UP
Approx.2.5kOwhencold
Approx.0.3Ko after Sensorand ground insPection Replace
warmrngup Measurethe voltagebetween Engine
terminal5 (28) and I (30). temperature
sensor
other
Inspect Beplaceengine Olher
I
svsrems I
HarnesscontinuitYinsPectiot Inspect ECCSC/U power
I
Measurethe resistancebeiw€e n supplyand ground
the followtngtermlnals:
Engrneternp ECCSC/
sen harness harness
1 5 (28
2 8 (30
0a cltr [:
EcCs c/u connector

Fnspect andenginetemp Repairharness
for contactanddelecls.
sensorconnector
EN - 382
CA18E
i NGINF
6.6 ENGINETEMPERATURESENSORSYSTEMINSPECTION
CONTBOLCIRCUITDIAGRAMCA18iENGINE
Engrnetemperature
sensor
r---5f-*----+rt
t - T l
m
o
o
a
o gnilionI mingconlrol
l
q
c
-
Engine temperaturesensor system trouble diagnosis flowchart CA18i ENGTNE
. Se f-diagnosis
.I."SELFDIAGNOSTIC BFSULTS"
1& Self-dagnosis(codeNo. '13)
Nomai
" D A I AM O N I T O R "
t I
(Realtinrediagnosrs)
| Enginetemp sensoroutput
ffi--J---rono, mal signalinspeclion
.f,.DAIAN,4ONITOR'
:8 l\,4easure
the voltagebetween
termrnal1 and 2. fr
E Engrnelempdispiay
;'e3 V w h e nc o i d
1V atterwarrnrngup Olher
InspectIntakeair temperature Enginetemperature

sensorand ECCS C/U connectors sensor inspection(2)
lor fauty connections
or defects. N.4easure the resistance
Enginetemp sensor inspection(2) betweenterminal1 and 2.
l\,4easure
the resistancebetween .+- Aporo^. 2.5Kf,) whencord
termrnal1 and 2. | 112l A o o , o x . 6 .r3ar1no" | ' Other
warmup
Approx.2.5k',when cold
Approx.0.3Kf] after ECCSC/U power supply and Replace
warmrngup Other
ground inspection Engine
,F ,DATA
N,4oNIToR" temperalure
.& N.,1easure
the voltagebetween sensor
Inspeclolrrer Replaceengine ECCSCiU terrninal5 and L
temperature . E ergrne
r lempdrsplay
sensor € 3 \ t when cold
l \ ' after warm up Olher
Harnesscontinuityinspection Inspect CIU power

l\,4easure
the resislancebetween supplyand ground
the followingterminals:
Engrneternp ECCSC/U
sen hafness harness
0{l cosl
lnspectECCSC/U connectorand enginetemp Repairnarness

sensorconnectorfor contactand detects.
EN - 383
INSPECTION
SENSORSYSTEI\,4
R826DETTENGINE
6-7 EXHAUSTGAS SENSORSYSTEMINSPECTION

CONTROLCIRCUITDIAGRAMR826DETTENGINE
gassensor
Exhaust Air luel ratro
r__-.0_ control
It 2 lll
-rH r;-T'
1
+----T-+ r *
gassensor(tronl)
Exhaust
eallr t
+ t
Cylinder,exhaust gas sensor' CONSULT(data monitor) display
N o .1 2 , 3 c y l 29
ECCSC/Uterminal
No.4. 5, 6 cyl O- sensor(rear) ECCS C/U terminal55
EN - 386
R826DETT
ENGINE
Exhaustgas sensorsystemtroublediagnosisflowchartRB26DETT
engine
Air-fuelratioteedback
function
inspection
'F,'DATA
t40NtTOF'
i$ Exhaust gassensoroutput
monrtor.
Normal Abnorrnal
Abnormal
.-F.
Exhaustgassensorinput t1t2l
signalinspection lTI4l
lvleasure the voltagebetween (o,sensor( F ) )
1. (O"sensor(F))
2 . O . s e n s o(rR )
belween0 - 1V
DeUectron ( O s e n s o rt R ) )
Other
ECCSC/U power supply inspection

ECCSC/U connectorsior faully '
! DATA[,4ON]TOR
contactor delects.
E D sconneclO sensorconnecior
ano T'teasLrre
!o taqe !et,,..'ee-
ECCS a U ieiii,ia ;: ;i.r gj.e.i].
Baltery ,Joliaqervhen
gn 1on swrtchrs ON Oti'er
Harnesscontinuityinspection InspectECCSC/
Measurethe resistancebetween U p o w e rs u p p l y
the followingterminals: or replaceC/U
O, sensor ECCSC/U
narness narness .E;r .
Or sensor(R)2
O, sensor(F)1
55
29 (O-,sensor
@uff
(O,sensor
Other (R)) (F))
Repairharness
the resstancebetween
l o w r n gt e r m i n a l s :
O sensor(B) 1 - 3
O . s e n s o {r F )2 - 3
Battery vo iage when
gnrlronswrlch
Checkfor laulty conneclions

or replaceexhaustgas sensor the resistancebetween
termrnals:
Orsensorl-3
( O , s e n s o (r R ) )2 - 3
oo Sl
" sensor heater oower ReplaceO, sensor

inspection
Measurethe voltagebetween
followrngtermrnals:
Or sensor(R) 1 and ground
O sensor(F) 2 and
Balteryvollagewhen
9nl on swrtchis ON
RepairO, sensorgroundcircuit
EN - 387
R826DETTENGINE
(1) Fuel-airratioteedbackf unctioninspection ,€\

. Warmuptheengine andcheckthefollowingitems 19/ 1975rpm
CAS.RPI,4(POS)
with'EXHGASSEN",'EXHGASSEN-R"(output EXHGASSEN 1,14V
"M/RF/CMNT-R'(lean/
voltage).M/B F/CMNT"and E X HG A SS E N - R 1.03V
in "DATA
MONITOR"mode. M/BF/CMNT RICH
rich)displayed I\4/RF/CN,4NT LEAN
. Providesettrngvaluein "ACTIVETEST"(fuelinjection a AcrrvErEsr

a I
quantity andcheckexhaustgassensor
correction) FUELINJECION 0",1
f unction. MONITOB
CAS.BPM(REF) 937rpm
ENGTEMPSEN 59'C
EXHGASSEN 1.33V
EXHGASSEN'R 1'35V
INJPULSE 1 8msec
. Usingdiagnosis onthevehicle
conne-ctor :199-^ ^ @ AAC VALVE 17-.
CONSULT to 'EXHAUST GAS
lneaituse set
block), Qu UP DWN od
SENSOR MONITOR' andcheckthefuelinjection
warning
byflashingof exhaustgastemperature
condition
lampon instrument
Panel.
Exhaustgas sensorlunction
Exhaustgastemperature warninglampmustflash5 times
whenengineis runningat
or morein 1Osecondsinterval
approx.2,000 rpm.
Feedbackf unction
warninglampmustflas
Exhaustgastemperature
whenenginespeedis runningat approx2'000
periodically
Input signal insPection

(2\'lirleasu
. re the voltagebetweenthefollowingterminalswith
ECCScontrolunitharnessconnected.
BetweenECCS C/U BEMEEN EUUD U/U

terminal29 and ground terminal55 and ground
Deflectionbetween
approx.0 and 1V
EN - 388
RB2OE

CONTROLCIRCUITDIAGRAMBB2OE/ DE / DET ENGINE
Air luel ratro

conlrol
n
115
m
o
o
a
-
e
9,
c
EN - 390
RB2OE
/ D E/ D E TE N G I N E
Exhaustgas sensorsystemtroublediagnosisflowchart
RB20E/ DE/ DETengine
Air-tuelratioteedbacktunction
. inspection
!].DATAI\,4ONITOR'
€ Exhaustgas sensoroutputmonitor.
Abnormal
Exhaustgas sensor input

signalinspection 1
Measurethe voltagebetween (R820E)
1 . { R B 2 0 Ea) n dg r o u n d
2. (FB2oDEi DET)and ground
between0 - lV
Defleclron Other ( R B 2 o D/ED E T )
ECCSCrupowersupplyinspection
ECCSC/U conneclorsfor faulty .E DATA[/ONTTOF"
contactor detects. t' Disconnect
Or sensorconnector
andmeasurevoltage
between
ECCSC/U termrnai27 (49)and
Baftery voltage when
rgnrlron
swrtchs ON
Harnesscontinuityinspection InspectECCSC/
Measurethe resistancebelween U powersupply
the followingtermlnals: or replaceC/U
O, sensor ECCSC/U
harness harness
RB2OE 1 6 /-rt-\
(!I?I]J
RB2ODE/DET1 29 (RB2oDE/
0a DEr)
RB20DE/DET
Repairharness
Checkfor laulty connections
or replaceexhaustgas sensor
Batlery voltage
rgnilron
swilch
Checkfor laulty connections

or replaceexhaust gas sensor Measurethe resistancebetween
termrnal1 and 3.
" sensor heater oower ReplaceOrsensor

inspection
MeasLrre the voltagebetween
termrnal1 and ground.
Balteryvollagewhen
ignrtron
swrlchrs ON
RepairO, sensorgroundcircutt
EN - 391

CONTROLCIRCUITDIAGRAMCA18iENGINE
Exhauslgas sensor m
o
r---H
'=
o
a
a
J
T
o
c
:
Engine
Exhaustgas sensor systemtrouble diagnosisf lowchartCA18i
. Setldiagnosis
l, "sELF-DtAGNoslsFESULTS"
€ Self-diagnosis(codeNo.15)
Abnormal
Abnormal
Exhaustgas sensor inPut

signalinsPection
'i_ 'DATA
MONITOF'
ECCS6 and ground.
RICHl LEAN
-a Display
Displayoutpul voltage0 -
EDrsolav0-1V
lnspectexhaustgas sensorand ECCSCru Power suPPlYinspection

ECCSC/U connectors for faultY r- DATAMONITOR''
,$ Disconnect02 sensorconnector
contaci or delects.
and measurevoltageDerween
ECCSC/U terminal27 (49)and
Battery vollage wnen
ignitionswitchis ON
HarnesscontinuitYinsPection lnspectECcSC/
the resistancebetween
l\,4easure U powersupply
02 sensorharnesstermlnal1 and or replaceC/U
ECCS C/U harnessterminal6
0 {il
Repairharness
Checktor taulty conneclionsor
replaceexhaust gas sensor
EN - 392
RB2OE
/ D E/ D E T / C A 1 8 E N G I N E
(1) Fuel-airratiofeedbackf unctioninspection

. Warmuptheengine ruornrr
fr,,lor':rroRrrufr
andcheckthefollowinqitemswith
"EXH
GASSEN"and"M/RF/CMNT',0ean
/ rich) CAS.RPM(POS) 2012em
in "DATAMONITOR"
displayed mode.
AIRFLOWI\,ITR
ENGTEMP
1-54V
8O"C
EXHGASSEN 0.72V
I\,4/R
F/CI\,4NT RICH
RECORD
. Providesettingvaluein "ACTIVETEST"(fuelinjection a ncrrveresr

| !
quantity
correction)andcheckexhaustgassensor FUELINJECIION +11o.a
function. tll0NtToF
CAS.RPN4iREF) 1037rpm
ENGTEI\,4P
SEN 36.C
Note: EXHGASSEN 0.87V
"lNJPULSE' INJPULSE 4.omsec
displayfor RB20Eis 1/16. AAC VALVE 369/.
Ou UP OWN od
. Usingdiagnosis connector on thevehicleside
(nearfuseblock),setCONSULTto'EXHAUST GAS
SENSORMONlTOR" andcheckthefuelinrection
condrtionby flashingof exhaustgas temperature
warning
tampon rnstrument panel.
Exhaust gas sensor function

Exhaustgastemperature warninglampmustflash5 times
or morein 10secondsinterval
whenengineis runningat
approx.2,000 rpm.
Feedbackf unction
Exhaustgastemperature
warninglampmustf lash
periodically
whenenginespeedis runningat approx.2.OOO
rpm.
(2) Inputsignatinspection
. Measurethe voltagebetweenthefollowingterminalswith
ECCScontrolunitharnessconnected.
E--r-^
RB2OE/CAt8iI nemoelo
{|l'snl
kitt:i::,rir:
BetweenECCS C/U BetweenECCS C/U
terminai1 and ground termrnal29 and ground
:-ri.i.: ,.
{!pq. Deflectronbetween Deffection

between
|!'.']r:':i:1,: approx. 0 - 1 approx.0 - 1
EN - 39s
SENSORSYSTEI\,4
INSPECTION
B B 2 6 D E Ti TF B 2 O ED
i E/DET/CAl8E
] NGINE
6-9 VEHICLESPEEDSENSORSYSTEMINSPECTION
CONTROLCIRCUITDIAGRAM
RB26DETTENGINE
Fuel cut control

m
o
a dle speedconlrol
o
:l
c
l
RB2OE/ DE / DET ENGINE
m
o
o
a ldlespeedcontrol
o
-
t1 O
i53) c
l
()RB2ODE/DET
EN - 397
:.:.:E'-T / D E / D E T/ C A I B iE N G I N E
RB2OE
(1) Inputsignal inspection oRNGft

. Select"VEHICLESPEEDSENSOR"in "DATA CAS.RPM (REF)
MONITOR" rtems.
modeandcheckthefollowing C A RS P E E DS E N
c
When drive wheelsare rotating Vehiclespeed is disPlayed
. Measure
thevoltagebetween terminats@
thefollowing
connected.
unitconnectors
withECCScontrol
6-10 rGNtTloNswlTcH (STARTSWITCH)SIGNAL

INSPECTION cAl8i
(1) Inputsignal insPection

. In "DATAMONITOR'mode,performthekeyoperatio n
@ 25 (45)
ECCS
"START" is
signal input control
to checkif the ignitionswitch unrt
correctlv.
terminalsA
. Measurethevoltagebetweenthefollowing
with ECCScontrolunitharnessconnected. \@i
RB26DETT/ RB2O
ECCSC/U ECCSC/U ECCSC/U

45 and terminal
terminal 23
25 terminal
ground
Batteryvoltage
EN - 398
/ D E / D E Ti C A 1 8 E
i NGINE
6-11 AIR CONDITIONER

SIGNALINSPECTION
B26DETT/ RB2O
Dua presslre
s w i t ch
4A
{9) _
o
o
U)
o
l
q
(46)
( ) RB2ODE/DETiRB26DETT
cA18i
(1) Inputsignalinspection
. In "DATAMONITOR'mode,pedormtheairconditione I
@
switchoperation to checkil theairconditioner
switch A/C switch
signalis inputcorrectly.
. Measurethe voltagebetweenthe followingterminals

withECCScontrolunitharnessconnected.
6 - 12 NEUTRALSWITCHSIGNALINSPECTION
(1) Inputsignalinspection
. In "DATAMONITOR"mode,performshiftlever
operation
to checkif neutralswitchsignalis @
. ^lSililJtiS'Y;rtase
between
therorowins
terminars
@
andgroundwithECCScontrolunitharnessconnected.
I RB26DETTiRB2ODEiDET
EN - 399
R B 2 6 D E T/T C A 1 8 ]E N G I N E
6-13 POWERSTEERINGSWITCHSIGNAL -
INSPECTION po*"r'"t"",,nq
(1) Input signal inspection swtch-
fe (ls)
.|n.,DATAMoN|ToR"mode,performpoWerSteering\g/ ECCS
operationtocheckif powersteering switch i =
oilpressure control
unit
signalisrnPut
correctly.
. Measure thevoltagebetween terminals
thefollowing @1
withECCScontrol unitharness connected. 9 r ,BB26DErr
cA18i
6-14 LIGHTSWlrcH SIGNALINSPECTION
(1) input signal insPection @
"DATA Lrghtswitch
. ln MONITOR'mode,performlightswitchoperation lcr_ ---6zd--{qs I
lo checkif lightswitchsignalis inputcorrectly' /t I
. MeasurethJvoltagebetweenthefollowlng terminals /l EccsI
@ / I control
I
withECCScontrolunitharnessconnected. ,1. I unit I
t -
6-15 HEATERFAN SIGNALINSPECTION

(1) Input signal inspection
. ln "DATAMONITOR'mode,performheaterfanoperation
@
to checkif heaterfanswitchsignalis inputcorrectly'
. Measurethe voltagebetweenthe followingterminals /A\
withECCScontrolunitharnessconnected. \.f,i
EN - 400
R825DEDIAGNOSIS
R 8 2 5 D EE N G I N E
1 . POWERSUPPLY& GROUNDCIRCUTT
DIAGNOSIS
#21
2.1--
Components location
EN - 401
RB25DEDIAGNOSIS
START A
Startt le engrne. CAS

Doestneengrne BAT
NG ol
ground
Inspect D.
circutt
OK
STABT
FINISH
A A
PowersuPPIYinsPection
switch
Placeignition to ONposition. f,
-BATTERY
1S battery
Inspect voltageusing OK
\@ VOLTAGE"in DATAMoNlToB mode.
rar Usetesterto measurethe voltagebetween
..1,r'ECCSC/U terminal49. 50 and ground.
D
NU
GroundcircuitinsPection
Placeignitionswitchin OFF E
position.Disconnect ECCSC/U Fle m
harnessconnector.
Checkfor harnesscontinuitybetween t !
E C C SC / Ut e r m i n a1l ,0 , 2 0 ,1 0 7 '1 0 8
a n d1 1 6a n dg r o u n d . I
lF NG: Repairharnessandconnectors
FINISH c
B
ECCS C/U terminal and ECCS relay harness
, |!l3i---\
Eer
continuityinsPection
Placeignitionswitchin OFFposition. I
NG M
DisconnectECCSC/U and ECCSrela't harnesr qa-.'- ei--.'
connector.
i
'U al
lnspectfor continuitybetweenECCSC, termin I
49, 59 and ECCSrelaYterminal3.
I Rpneirharnesso r connecto.lc
OK
Voltage inspection between ECCS C/U lF

l l --
Eccs
terminaland ground I :6-
Placergnition switchto ON position.
Measurethe voltagebetweenECCSrelay
I
terminal 2,3 andground.
Voltage:Batteryvoltage NG
lF NG: Placeignitionswitchto OFF position
link.
, o .6 f u s i b l e
N o . 2 1f u s e ,N o . 3 N
Inspect thecontinuity between ECCS relayand
thebattery.
ToE Reoairharnessor connector

EN - 402
FI825DE
DIAGNOSIS
E
Outputsignalcircuit inspection
Checkthecontinuation betweenECCSC/U N G
terminal'16andterminal1.
OK
Inspectthefollowing:
lgnitioncoilharnessconnector.
HarnessbetweenECCSC/U and
ECCSrelay.
lF NG: Repairharnessor connector.
Component parts inspection

(ECCSrelay)
NG
Referto the sectionon ECCSrelavfor
Inspectron.
RepairECCSrelay
Checkfor anydamageon the ECCSC/U

terminals
and ECCSC/Uconnector.
Carry out the inspection in the lollowing order after repairs.
Verifrcation
inspection
Restart
theengine
Doestheenoinestart?
Powersupplyinspection Checkforanydamageon the

ECCSC/Uterminalsand
ECCSC/U connector.
Groundcircurt
inspection Checkforanydamageon the
ECCSC/Uterminals
and
ECCSC/Uconnector.
EN - 403
R825DEDIAGNOSIS
B B 2 5 D EE N G I N E
2 - CRANKANGLESENSOR(CODENO' 11 IN SELF.DIAGNOSIS)
DIAGNOSIS
16
m
o
a
o
- c i
c i
5)
Components location
" anglesensor
_CJAnk
EN - 404
RB25DEDIAGNOSIS
START
Carryoutself-diagnosis
NG OK
To diagnosis
14
A
Powersupplyinspection
Placeignitionswitchto OFFposition.
Disconnectcrankanglesensorharness
connectors. NG
Placeignition
switchto ON position.
Usetesterto measurethevoltaqebetween € @
3 andqround.
terminal c/u
OK Inspectthe following:
Checkthecontinuitybetweencrank
42 52 and 2
anglesensorterminal3 and ECCS 5 l a n dI
relayterminal3.
lF NG: Repairharnessor connectors.
B
Inputsignalcircuitinspection
Placeignitronswitchto OFFposition.
Disconnect ECCSC/Uharnessconnectors.
Checkthecontinuitybetweencrankanglesensor NG
terminal2 and ECCSC/Uterminat 42,52 (1"signal),
betweencrankanglesensorterminal1 andECCS
C/Uterminal41, 5 1 (120"signal).
OK Repairharnessor connector
c
Inputsignal inspection
ConnectcrankanglesensorandECCSCiU Xg:Q@
harnessconnectors.
,S Use"CRANKANGLESEN RPM'in 'DATA
\G/ MoNlToR"to measure
enqrnesoeed.
/fl) Measure
thevoltagebetweenECCSC/U
v termin4 a2l . 5 2 . 5 1a n dg r o u n d .
NG
OK Component pans inspection

(Crankanglesensor)
Referto thesectionon crankanglesensorfor
inspection.lF NG: Replacecrankanglesensor.

terminalsand ECCSC/U connector.
EN - 405
RB25DEDIAGNOSIS
Carry out the inspection in the following order after repairs'
Verificatroninspection
Erasememoryfromself-diagnosis
Checkforanydamageonthe
byself-diagnosis
Recheck ECCSC/Uterminalsand
ECCSC/U connector.
EN - 406
RB25DEDIAGNOSIS
3 - AtR FLOWMETER(CODENO.12 tN SELF-D|AGNOS|S)

DIAGNOS|S
€
A r fiow meter o
o
q
SignalgroundE 26 :.
Components location
\ i \
. -,,'.1
Arrflow meter
harnesscon!,eclor
EN - 407
RB25DEDIAGNOSIS
Ee@
PowersupPlYinsPection
Disconnectairflowmeterharness
connectors.
Placeignitionswitchto ON position. %ei@
Usetesterto measurethe voltage
betweenterminal 3 andground.
lnspect the following:

Checkthecontinuity betweenairflow
meterterminal5 andECCSrelaY
terminal3.
lF NG: Repairharnessor connectors.
Ele,@
Groundcircuitinspection
switchto OFFposition.
Placeignition
DisconnectECCSC/Uharness connectors'
Checkthecontinuitybetween 4 andECCS
terminal
C/Uterminal26.
Repairharnessor connector
Inputsignal insPection
Checkthe continuitybetweenairflowmeter
terminal2 andECCSC/Uterminal27 (intake
airquantitysignal).
Bepairharnessor connector
EN - 408
RB25DEDIAGNOSIS
D
Inputsignal inspection rroRrNq\iroFAtL
Connectcrankarrflow meterand ECCSC/U
cAs.RPM(REF) 662rpm
harnessconnectors. AIRFLOWMTR 1.02V
r€\ Use 'AlBFLOWMETERin DATA ENGTE[,4P
EXHSEN
SEN 81,
O.1BV
\g/ MONITORtomeasureinoutsional. THROTTLESEN O.4OV
INJPULSE s.omsec
,S Measure^the voltagebelweenECCSC/U
:. Iermlnat
z/ andoround.
NG
Approx.0.3V
A p p r o x1 V
' ' ldlirq ''1'. A p p r o x1.. l V ctv
OK Component parts inspection

(Crankanglesensor)
Referto the sectlonon crankanglesensorfor
rnspection.lF NG: Replacecrankanglesensor.

terminals
andECCSC/Uconnector.
Carryout the inspectionin the followingorderafterrepairs.
Verificationinspection
Erasememoryf romself-diagnosis
Checkforanydamageon the
Recheckby self-diagnosis ECCSC/Uterminals
and
ECCSC/Uconnector.
EN - 409
RB25DEDIAGNOSIS
B 8 2 5 D EE N G I N E
DIAGNOSIS4. ENGINETEMPERATURE SENSOR

( c o D E N O .1 3 l N S E L F - D I A G N O S I S )
EnginetemPerature Fuelinjectionconlrol
sensor m
a o
o
o timrngcontrol
lgnrlion
! o
;
-;
Componentslocation
'
. 1 Enginelemp sen trr'l
5\- ^^nn6^t^r \'
A
Ke@
Power supply insPection
Disconnectenginetemperature sensor
harnessconnector.
Placeignitionswitchto ON position.
Usetesterto measurethe voltage
betweenterminal1 andground.
r harnessor connector
E N- 4 1 0
R825DEDIAGNOSIS
F 8 2 ' D EE N G I N E
B
Placeignitionswitchin OFFposition.
Checkcontinuitybetween terminal
2 andground.
OK
c Repair
harness
orconnector
1S1 Use"ENGTEMPSENSOR Tn DATA
: MONITOB"
to checkenainecoolant
NG
Iemperalure.
(g) Cnect the voltagebetweenECCSC/U
-
terminal28 andoround.
Voltage: Whenigniiionswitchis ON
EngtempApprox.20oC 3V
Approx.80"C 1V
OK
Componentparts inspection
(Enginetemperature
sensod
Refertothesection
onenginetemperature
sensorforinspection.
lF NG:Replace
crank
anglesensor.
Checkfor any damageon the ECCSC/U

terminals
VerificationInspection
Recheckby self-diagnosis ECCSC/Uterminals
and
ECCSC/Uconnector.
FINISH
E N- 4 1 1
DIAGNOSIS
RB25DE
DIAGNOSIS5 -IGNITIONSYSTEMINSPECTION
(coDE NO.21 lN SELF-DIAGNOSIS)
FIL6
fi
o
ql 3
ECCSrelay
,-,tilf
st9-9f 3
'
-Ful
Components location
-l
i",::'"u
E N- 4 1 2
RB25DEDIAGNOSIS
lsrrr-onc nesO
o u ts e l fd i a g n o s r s , FAILURE DETECTEDTIME
I G NS I G N A LP R J M A F YO
Toignition srgnal1 (ltem

n o tI ns e l fd i a g n o s i s )
Circuitf unctioninspection
Inspectusing"POWER BALANCE"
'FUNCTION TESI-'mode.
in
@ ()POWER BALANCEl)
Checkto ifengine revwilldecrease ntary
mome INSPECTTHEBALANCE
OF EACHCYLINDERBY
STOPPINGINJECTOR
OPERATIONFOREACH
CYLINDEF,
Placeignition
switchin OFFposition. FASSI
Disconnectpowertransistorunitharnessconnector.
Checkfor harnesscontinuitybetweenterminalE and
B
grouno.
E err
Repair
harness
orconnector
Outputsignalcircuitinspection
DisconnectECCSC/U harnessconnector.
Inspectfor continuity
betweenthefollowingterminals:
ECCSC/Uterminal1 andterminal2
ECCSC/Uterminal12andterminal2
ECCSC/Uterminal3 andterminal3
ECCSC/Uterminal2 andterminals
ECCSC/Uterminal10andterminalE
ECCSC/Uterminal20 andtermrnal E
Outputsignalinspection
Connectpowertransistor unitand ECCS
C/U harnessconnectors.
InspectbatteryvoltagebetweenECCSC/U
t e r m j n a 1l s, 2 , 3 ,1 1 , 1 21, 3a n dg r o u n d .
Cranking: Approx.0.2- 0.3V
ldling: Approx.0.2- 0.3V
2500rpm: Approx.'lV
Inputsignalsysteminspection
E N- 4 1 3
RB25DEDIAGNOSIS
RB25DEENGINE

(Powertransistor unit)
Referto the sectionon powertransistorfor
inspection. lF NG. Replacepowertransistor
unit.
Reolaceoowertranslstor

terminals
VerificationinsPection
Recheckby self-diagnosis ECCSC/Uterminalsand
ECCSC/U connector.
E N- 4 1 4
R825DEDIAGNOSIS
RB2sDE NGINE
DIAGNOSIS 6 - EXHAUSTGAS SENSOR

(coDE NO.15 tN SELF-D|AGNOSIS)
m
2 9 O
U'
1 5 ( '
Components location
START
Oarryoutselfdiagnosis AIR,FUEL
RAIIo TESTl
NG HOLDTHE ENGINE
SPEEDAT
OK 2000+l200rpmAND
PBESS
FINISH START
A
Function inspection 1
Warmuotheenoine.
"BASEAIR-FUEL
( l)lnspect using RAT|O"in
: "FUNCTION
TEST mode.
NG OK
To B FINISH
E N- 4 1 5
RB25DEDIAGNOSIS
Functioninspection2
Starttheengine.
Holdthe engineat 2000rpmand inspect
"O, "O
using SENSOR"(outputvoltageand
"DATA
SENSORMONITOR'(lean, rich)in
MONlTOR"mode.
Measurethe voltagebetweenECCSCiU START
terminal29 and ground.
Approx.0.3V(constantvoltage) NG
-
Aoorox.over0-6 1V (variant
voltage)OK
X e- 11:
Fcctcî"""*".-i
InputsignalcircuitinsPection I iin
switch
PIaceignition to OFFposition. t-; j.----.---
DisconnectO,sensorharnessconnectorandECCS -I
C/Uharness connector.
betweenECCSC/Uterminal
Checkcontinuity 29
2.
terminal
andO-sensorharnessconnector
Elee
Repairharnessor conneclor
ReplaceO, sensor
Checkforanydamageon the ECCSC/U

terminals
VenficationinsPectlon
Checkfor anydamageon the

Recheckby self-diagnosis ECCSC/Uterminalsand
ECCSC/Uconnector.
E N- 4 1 6
RB25DEDIAGNOSIS
DIAGNOSIS 7 - DETONATIONSENSOR
(coDE NO.15 tN SELF-D|AGNOS|S)
tl]
Components location
*-;:-- Detonationsensor mid

_-.-:-"'-: harness connector
.,:1
E N- 4 1 7
RB25DEDIAGNOSIS
RB2sDE NGINE
c/u
lnput signalcircuitinsPection1
DisconnectECCSC/U harnessconnectorand
sub harnessconnector.
terminal1 and
Checkthe continuitybetvveen
ECCSC/Uterminal23, terminal2 and ECCSC/
U terminal24.
O K Repairharnessor connector
Inputsignalcircuitinspection2
Disconnect connectors
harness frontand NG
connected
sensor.
rearof thedetonation
Check subharness
between
thecontinuity terminalA
and23. B and24.
lnput signal inspection

Connectdetonation sensorandECCSC/U
harnessconnectors.
Measurethe voltagebetweenECCSC/U
terminal23,24 andground.
Measurementlocation temltnal23, 24 and ground
lgnition switch ON Approx.4V
C ran king Approx.4V
ldling Approx.4V
Replacedetonatlonsensor

terminals

insPection
Verification
Recheckby self-diagnosis and
ECCSC/Uterminals
ECCSC/Uconnector.
RB25DEDIAGNOSIS
8 - THROTTLESENSOR(CODENO.43 tN SELF-D|AGNOSIS)
DIAGNOS|S
m :uel injectionconko
Throtliesensor o
'1 o
za o
38 fuC cutcontrol
3 s =
=
Componentslocation
'ECCS
c o r t r o .L n , t I
START
Oarryoutselfdiagnosis
OK
I rrRorrLeselrsonl
NG
A FINISH PFESSSTAFTWHILE
PRESSING
THE
System inspection ACCELERATOB
PEDAL
Placeignitionswitchto ON position. FULLY
USe"THROTTLE SENSOR'in"DATA
MONITOR"to inspectthesystem. OK
Voltage:
Fullyopen Approx.4.0V
Fullyclosed Approx.0.6V
Open/ Closerange overApprox.3.0
NG
FINISH
TOB
E N- 4 1 9
RB25DEDIAGNOSIS
B
*vortrontr* ro retr
Power supply insPection
: Ptace
ffi ignitionswitchto ON position. NG
Use -THROTTLE SENSOB"in DATA (BEF)
CAS.RPN,,I orprn
THROTTLESEN 3,94V
MONITOR'toinspeP!-
19 etaceignitionswitchto OFF posilion.
vDisconnectthrotllesensorharnessconnector.
Measurethevoltagebetweenterminal1 and
:APProIjll--
voltage
ground.Battery
r-_-._.--
U
| ,,_. Ee .@,
InputsignalcircuitinsPection
ECCSC/Uharness
Disconnect connector.NG
Checkthecontinuity ECCSC/U
between
38andterminal
terminal 2.
l
Cornponentparts inspection (Throttlesensor)

sensorfor inspection'
Referto thesectionon throttle
lF NG: Replacethrottlesensor unit.
OK

terminals
Carryout the inspectionin the followingorderafterrepairs'
Verificationinspection
Erasememoryfrom self-diagnosis
Checkfor any damageon the

Recheckby seltdiagnosis ECCSC/Uterminals and
ECCSC/U connector.
EN - 420
)
RB25DEDIAGNOSIS
9 - A / T CONTROL
D|AGNOS|S (CODENO.s4 tNSELF-DIAGNOSIS)
-
L---i
Componentslocation
..'''.:
,:..]
START
OK
Carryoutselfdiagnosis
NG G )@ i5 j
lA/Tcti connecta
A FINISH
DisconnectECCSC/U harnessandA,/TC/
U harnessconnectors. NG
Checkthe continuitybetweenECCSC/U
terminal14 andA/TCiUterminat10, ECCS
C/U terminal5 andA"rTC/Uterminal11.
OK
Repairharnessand connectors
Checkforanydamageon the ECCSC/U

terminals
EN - 421
RB25DEDIAGNOSIS
DIAGNOSIS1O- CRANKANGLESENSOR(NOTlN SELF-DIAGNOSIS)
FiL6
Crank angle sensor
Componentslocation
ECCScontrolunlt
EN - 422
RB25DEDIAGNOSIS
START
A A
Placeignition
switch
to OFFposition.
Xea
Disconnectcrankanglesensor
harnessNG
connector.
Checkforcontinuity
betweenterminal
4
andenginegroundharness.
OK
Repairharness
or
conneclor

(Crankanglesensor) NG
Referto thesectionon crankanqlesensor
for inspection.
OK
Replacecrankanglesensor

terminals
Verification
inspection
Groundcircuitinspection ECCSC/Uterminals
and
ECCSC/Uconnector.
EN - 423
RB25DEDIAGNOSIS
D|AGNOS|S11 - IGNIT|ONSIGNAL1 (CODENOTlN SELF-DIAGNOSIS)
F/16
ECCSrelay
r+/rtnt 2
!!III
Fdf4r{-d) tElttll_lttlj
Componentslocation
Power tranststorunil
EN - 424
RB25DEDIAGNOSIS
R B 2 5 D EE N G ] N E
OPOWERBALANCEO
INSPECTTHEBATANCE
Whole system inspection O F E A C HC Y L I N D E R
BY
Startthe engtne. STOPPING INJECTOR
OPERATION FOREACH
ls allcylinder
ignited? CYLINDER.
TURNOFFA/C& LIGHTS
To ignitionsignal2
Circuitf unctioninspection
Inspectusing"POWERBALANCE" in
"FUNCTION
TEST"mode.OR power
E ACTIVE
TEST
balancein "ACTIVE TEST". OK POWER BALANCE
Checkto if enginerevwilldecreasemomentary. t\40N
tToR
cAS.RPr\r(POS)
AIRFLOWI\,4ETER
Power supply inspection trtrtr8

Placeignition
Disconnect
switchin OFFposition.
ignitioncoilharnessconnector.
B
rdtrILl
Placeignitionswitchto ON posrtion.
UseCONSULT or thetesterlo measurethe
voltagebetweeneachcoilterminal 1 andground.
1%e:-,.$rf)
Power voltage: Battery voltage
lgnitionrelay
lgnitionswitch
Continuitybetvveeneachcoil c
Harnessterminal 2 andignition
relavterminal5. @ 5,t,5
Ground circuit inspection
Checkfor harnesscontinuitybetweeneachcoil
3 andqround.
terminal
OK Repair
harness
orconnector
D
Disconnect powerlransislorunit harnessconnector. iXe,@
Inspectforcontinuity
betweenthefollowingterminals:
Betweeneachrgnition coilterminal1 and
Powertransistorunitterminal1
Powertransislorunitterminal5
EN - 425
RB25DEDIAGNOSIS
RB2sDE NGINE
Components insPection
(Powertransition coil)
unit& lgnition
Referto power transitionunitand coil
ignition
inspeclionin components inspection section.
faultyparts
Replace
Carry out the inspection in ihe lollowing order after repairs:
RecheckECCSC/Uterminalfor
ComponentsinsPection damageandcheckECCSC/U
harnessconnectorconnection.
EN - 426
r 5
R825DEDIAGNOSIS
11- IGNITION
DIAGNOSIS SIGNAL2
Continuefrom ignitionsignal1
E
Power supply inspection
Disconnectignitioncoil relayconnector.
Placeignitionswitchto ON position. NG
UseCONSULT or testerto measurethe
voltagebetweencoilterminal 2,3 andground.
Power voltage: Battery voltage
OK
Continuationbetween fusiblelink,
ignition
coilrelayandignition switch.
Il ee;@
Continuationbetweenignition coil
relayandthe battery.
F
Groundcircuit inspection
PIaceignitionswitchto OFFposition. NG
Inspectharnesscontinuation
betweeneachcoil
terminal2 and5.
OK Repair
harness
and/ orconnector
G
ECCSC/U
Outputsignalcircuit inspection
DisconnectECCSrelay. NG
Inspectthe continuation
betweenECCSC/U
terminal16 and ECCSrelavterminal2.
OK Inspectthefollowing:
Fusiblelink.
Continuatron betweenECCSC/Uand
ECCSrelayharness.
Continuation betweenECCSC/U and
ignition
coilrelayharness.
lF NG: Repairharnessandconnector.
Components inspection
(lgnition
coil& ECCSrelay) NG
Referto ignitioncoiland ECCSrelayinspection
In componentsinspectjonsection.
OK Replacefaultycomponents
InspectECCSC/Uterminal for anydamage
and ECCSC/U connectorfor connection.
EN - 427
RB25DEDIAGNOSIS
DIAGNOSIS12 - INJECTORSYSTEMINSPECTION
3 Giil
€ m
o :EiutttlS
-_l;la
Ftrl*".,
4 i i No-
o
ECCSrelav
-t-----1
l/!!r.t
1'-o o-+
L)-IJJ
l.l.l q @ N o .1
L
@ No.2
location
Components
ECCScontrolunrt
EN - 428
RB25DEDIAGNOSIS
START
A tFowrR elLANtcEl
Circuit f unction inspection
Inspectby "POWERBALANCEin
/G\ "rurucrroN
INSPECTTHEBALANCE
OF EACHCYLINDERBY
fJ TEST'
mooe. STOPPINGTHE
Operate"POWER BALANCE" in INJECTORDRIVE
FOR
CONSULTactive test. EACHCYLINDER.
ffi Makesuretheinjector
operation
noise
\O/ rsaudible.
NG OK
FINISH
B
Power supply inspection 1
Placeignition
switchto OFF. ierreE
Disconnectsub harnessconnector.
Checkthe batteryvoltagebetweenterminal
3 andgroundusingCONSULT or tester.
NG
Harnessconnector.
Continuity
betweensub harness
connectorandthe harness.
lF NG: Repairharnessandconnector
c
Power supply inspection 2
Disconnectsub harnessconnector.
Inspectbetweenthefollowingterminals
forcontinuity:
betweenterminal3 and 5
betweenterminal3 and 6
H
belweenterminal3 and4 No.1
OK NG
No.2
D No.3
No.4
Disconnectinjectorharnessconnector. No.5
Inspectbetweenthefollowingterminals No.6
forcontinuity:
betweenterminal109andNo. 1,2, 3,
4,5&6cylinders.
To
EN - 429
RB25DEDIAGNOSIS
E
Out put circuit insPection
DisconnectECCSC/U harnessconnector. e:@9[
Inspectbetweenthefollowingterminalsfor con
continuitY:
betweenterminal10.1andNo. 1 cylinder
betweenterminal105andNo.2 cylinder
NG
Flepairharnessor
OK connector.
ComponentPartsinsPection
(lnjector)
forinspection'
oninjector
Refertotheseclion
NG
Replaceinjector.
ECCSC/Uterminals
Inspect foranY
damageandmakesurethe connectors
correctlY.
areconnected
Carryout the inspectionin the followingorderafterrepairs:
Recheckfor anydamageon the ECCSC/U

terminalsand ECCSC/U connector.
EN - 430
R825DEDIAGNOSIS
DIAGNOSIS13 - VEHTCLE
SPEEDSENSOR
m
o
o
a
3
- _ o
Componentslocation
START
Whole system inspection

UseCONSULT andcarryoutthejnspectionO K
"
using V E H l C L E
S P E E DS E N S O Ri"n
"FUNCTION
TEST"mode.
NG
FINISH
Vehiclespeedsensorfunctioninspection N G
Inspect
vehiclespeedmeterfunction
OK
Vehiclespeedsensorand
vehiclespeedsensorcircuit
TOB inspection.
EN - 431
RB25DEDIAGNOSIS
RB25DEENGINE
B fS,tortrontufrNornlr
InputsignalinsPection NG
(POS)
CAS.RPI\, 787r7m
Startthe engine.
Rotatedriveaxles]ew]y-
/a\ b-eieiltehicbspeedusingVEHICLE
u i'LQ4IA-NIONIIOB-
speeoSENSOR"
,o' thevoltagebetween
Usetesterto measure
W EccS C/Uterminal 53andground.
-
0 5V -----
Voltage:aPProx.
OK
Inspectthe following: c/u
CheckthecontinuitybetweenECCS
C/U andcombination meterharness.
lF NG:Repairorf9ple99i9M9!'--
InspectECCSCiUterminals forany
damageandmakesurethe connectors
areconnectedcorrectly.
Checkfor anYdamageon tne
insPection
circuit
Ground ECCSCiUterminalsand
ECCSC/U connector.
EN - .132
R825DEDIAGNOSIS
14 -AIR CONDITIONER
DIAGNOSIS RELAYSIGNAL
IGNreiay1 To FrCDrela,i
Duai pressute
AC rear sw
m
ACC reiay o
o
ACC key SW a
o
)-
q
Components location
controtunrt
Usetesterand measurelhe batteryvoltage
betweenECCSC/UterminalI andground.
Whenblow-fanswitchis OFF: batteryvoltage
Whenblow-fan switchis ON: Approx.1V
InspectECCSC/Utermrnalsfor any
damageand makesurethe connectors
areconnecledcorrectlv.
Groundcircuitinspection ECCSC/Uterminals
and
ECCSC/Uconnector.
EN - 433
RB25DEDIAGNOSIS
DIAGNOSIS15 - EXHAUSTGAS SENSORHEATER
Trl
o
o
(,
o
x 9
Components location
t \
i' controLlntt ,,-l
EN - 434
R825DEDIAGNOSIS
FIB25DE NGINE
START
A
Powersupplyinspection
Disconnectexhaustgassensorharness
connector.N G
Placeignition
switch
toONposition.
Measurepowervoltagebetween terminal
1 and
ground.
OK
lnspectthe following:
Harnessconnector.
Continuity
between gas
exhaust
sensor
andthefuse.lF NG:
Repairharness andconnector.
B
DisconnectECCSC/U harnessconnector. NG
Checkforcontinuity between termrnal
3 and
E C C SC / Ut e r m i n a1l 1 5 .
OK
Repairharnessor connector.

(Exhaustgassensorheater) NG
Referto the sectionon exhaustoas sensor
heaterfor inspection.
OK
Replaceexhaustgassensor.
InspectECCSC/Uterminalsfor any
damageandmakesuretheconnectors
areconnectedcorrectlV.
Carry out the inspection in the following order after repairs.
Verification
lnspection
Inspectpowersupply,groundcircuit ECCSC/Uterminals
and
ECCSC/Uconnector.
EI\ - I+JJ
RB25DEDIAGNOSIS
DIAGNOSIS16. THROTTLEVALVESWITCH
rf
o
o
U)
- _ o
q
Comoonentslocation
d--4"i6-r'
valvesw
EN - 436
RB25DEDIAGNOSIS
START
A
] . I D L E J U D G E I V F N T'
Function inspection 1
Placeignitionswitchto ON positron. A F TW H E NA C C E L E R A -
"IDLE
Inspectusing JUDGEMEN'l-' in O K OB PEDALIS FULLYOPEN.
"FUNCTION
TEST'mode.
Reference: Fullyopen:OFF
Fullyclosed:ON
FINISH START
B NG
Functioninspection2
Placeignition switchto ON position.
Inspectignitionswitch"ON-OFF" diagnosis
or
measurelhe voltagebetweenECCSC/Uterminal O K connector
54 andgroundusingthetesterwhenignition switch
i sO N .
Voltage: Accelerator pedalpressed0V
Acceleratorpedalnotpressed8 - 10V
NG FINISH
c
Placeignrtionswitchto OFFposition.
Disconnect throttlevalveswitchharnessconnector.
Placeignitionswitchto ON position. NG
Uselesterto measurelhe voltagebetween
terminal2 andground.
Battery voltage: Approx.8 - 10V
Inspectthe following:
Harnesscontinuity
betweenthrottle
valveswitchandECCSC/U. lF NG:
Repairharnessandconnector.
D
Placeignition
Disconnectthrottlevalveswitchharnessconnector.
Checkthe continuitybetweenECCSC/Uterminal
54 andthrottle
valveswitchterminal1.
OK Repairharnessor connector.
(Throttle
valveswitch) NG
Referto the sectionon throttlevalveswitchfor
jon.
inspect
OK Replacethrottlevalveswitch.
InspectECCSC/Uterminalsforanydamageand
makesuretheconnectorsareconnectedcorrectlv.
EN - 437
RB25DEDIAGNOSIS
insPection
Verification
ECCSCiUterminalsand
ECCSC/U connector.
EN - 438
RB25DEDIAGNOSIS
17 - STARTSIGNAL
DIAGNOSIS
GN SW
START
A
t) snRrrn srcNnrI
Function inspection /tr\ PLACE
SHIFTLEVERTO'P'OR
Placeignitionswitchto ON position. tU
UseCONSULT andinspect"STARTSlGNAL"in
"FUNCTION STARTTHEENGINE
STFAIGHT
TEST'mode. OK AFTERSELECTING
STARI,
OR
Inspectstartsignalusing"DATAMONITOR"mode.
Whenignition swrtchis ON position: OFF
Whenignition switchis STARTposition: ON
B NG
FINISH
CAS.RPM(POS) 1326rpm
Power supply inspection STARTEFSIGNAL OFF
?@
Placeignitionswitchto OFFposition. €)
Disconnect throttlevalveswitchharnessconnector. N G
Usetesterlo measurethe voltagebetween BECORD
terminal2 andground.
Battery voltage: Approx.8 - 10V B
OK €'@
Inspect the following:
Fuse I ECCSC/U connector
I
Continuitybetweenignitionswitch
and ECCSC/Uharness.lF NG:
Repairharnessandconnector.
InspectECCSC/Uterminalsforanydamageand
makesuretheconnectorsare connectedcorrectlv.
EN - 439
RB25DEDIAGNOSIS
DIAGNOSIS18. FUELPUMPCONTROL
ECCSrelay
qH,,r
F/L3 IGN SW #16
2t-
Fuel pumprelay
Componentslocation
EN - 440
B825DEDIAGNOSIS
START
.FUEL PUMP'
A ISTHEREA PULSATION
Systeminspeclion E V E F Y3 S E C O N D S
Select"FUELPUMP" in-FUNCTtON W H E NT H EF U E LT U B E
TEST"toinspect thesystem. \9
I S H E L D ?O R C A NY O U
Operationcheckby"FUELPUMPRELAy" in HEARTHEOPERATION
'ACTIVETEST'. OK N O I S EO F T H EF U E L
Fuelpumpwilloperate for5 secondsafterthe

ignition
switchisturnedto ONposition.
Checkif
thefuelpumpoperation norseareaudible.
I acrrvclesra I
FINISH
B FUELPUMPRELAYON
Power inspection MONITOF
Placeignitionswitchto "OFF"position. CAS.RPIV(POS) orpm
Disconnectfuelpumprelay.
Measurevoltagebetweengroundand
NG
terminal
2 & 3 usinqthetester. START ON/OFF STOP
OK A
Checkthefollowing:
Fuse
Harnessconnection betweenfuel
pumprelayandthefuse.
Connectionbetweenfuelpumprelay
andtheignitionswitch.
lF NG: Repairharness& connector.
B
c
Groundcircuit inspection
Placeignition
Removefuelpumpharnessconnector. NG
Checkthe connectionbetweenfuel
pumpnarnessconnector 3 andthe
ground.
c
Repairharnessor
D
theconnector. Eeo
RemoveECCSC/U harnessconnector. NG
Checklhe continuitybetweenECCSC/U& harness
terminal18andfuelpumprelayharnesslerminal1.
Checkthefollowing:
ContinuitybetweenECCSC/Uandfuelpumprelay.
ContinuitybetweenECCSC/U and pumprelay.
lF NG: Bepairharnessandlhe connector.
EN - 441
RB25DEDIAGNOSIS
E D
Control signal insPection
Measurethe voltagebetweengroundand ECCSC/U Elee
terminal18.
5 seconds after ignition switch is turned ON: 1V
After 5 seconds after ignition switch is turned ON:
Battery voltage
OK
Componentparts inspection
(FuelpumPrelay) NG E
onfuelpumprelayfor
Referto thesection €,Q
rnspection.
E9!9
OK ReplacefuelPumPrelaY.
ComponentPartsinsPection NG
(Fuelpump)
onfuelpumpforinspection.
Befertothesection
OK
tuelpumP.
Replace

terminalsand ECCSC/Uconnector.

and ECCSC/Uconnector.
terminals
Fuelpressure
inspection.
EN - 442
RB25DEDIAGNOSIS
DIAGNOSIS
19. AACVALVE
Components location
START
A RN OFFA/CAND LIGHTS
Function inspection
Warmtheengine.
Checkthe idlespeed600 - 700 rpm.
lF NG: Adjustidlespeed. OK
"AAC " FINISH
/G\ Inspectusinq VALVE in
's/ "FUNCTION TEST"mode.
<>, Drsconnect AACvalveharness.
W Cfreckif idlerevwilldecrease.
B NG
Power inspection
Placeignitionswitchto "ON"position. NG
MeasurevoltagebetweengroundandAACvalve
terminal
2.
Repairharnessor theconnector.
TO
EN - 443
RB25DEDIAGNOSIS
c B
Output signal circuit insPection Ele:@
A Checkif theenginerevwillchangewhenthe
\E/ "up" or "DOWN'is pressedin AACVALVE in
.ACTIVETESI'' mode. NG
^ Disconnect ECCSC/U harness.
H: Cnect forcontinuity betweenECCSC/U
h"rn"sstermtnal 4 andAACvalveconnector
t e r m i n a1l .
OK c
orconneclor.
Repairharness
.ACTIVETEST . N
DEG
OPENING
AACAr' 10'6
NG MONITOR
Component parts inspection (AACvalve) CAS.FPM(POS) 900rpm
Referto the secttonon AACvalvelor inspection' AIR FLOWI\,,ITR 1.'16V
ENGINETEI,IP SEN 8O"C
OK
BeplaceAACvalve.
Qu UP DWN od
Checkfor anYdamageon the ECCSC/U

terminals
VenficationinsPection

check.
Functional andECCSCiU connector.
terminals
EN - 444
R825DEDIAGNOSIS
DIAGNOSIS
20. AIRREGULATOR
m
c)
o
a
o
l
5
Fuel pump relay Air regulalor
Components location
controlunit f-f ,'T-

Placeignitionswttchto OFFposition.
Disconnect fuelpumprelay.
Usetesterto measurethe voltaqebetween
terminal
2. 3 andoround.
Fuse.
Harnesscontinuitybetween
fuelpumprelayandfuse.
Continuity
betweenfuel
pumprelayandignition
switch.
lF NG: Repairharnessand
connector.
EN - 44s
RB25DEDIAGNOSIS
B
Groundcircuit insPection
air regulatorharnessconnectors. NG
Disconnect
Checkforcontinuitybetweenairregulatorharness
connectorterminal2 andground.
OK ReDairharnessor connector.
c
OutputsignalcircuitinsPection c
switchto OFFposition'
Placeignition NG
DisconnectFCCSC/Uharness connector' Eielm
Checkforharness betweenECCSC/U
continuity
18andfuelpumprelayterminal
terminal 1.
OK
ContinuitybetweenECCSC/
U andfuelPumPrelaY.lF NG:
RepairharnessandconttnuitY.
D
ControlsignalinsPection
_ - ' ' _
MeasurevollagebetweenECCSC/Uterminal
18andground. NG Xc *
t-
Within5 secwhenignitionswitchis placedin ON LEsc+r**!
position:
APProx. 1V
After5 sec when ignitionswitchrsplacedin ON
position:Batteryvoltage
OK
RepairandinsPectECCSCi
U power supply ground
and
circuit.
Component Parts inspection

(Airregulator) NG
Replaceair regulator
Referto the sectionon AAC
valvefor inspection.

check.
Functional and ECCSC/Uconnector.
terminals
EN - 446
RB25DEDIAGNOSIS
DIAGNOSIS21 . POWEBSTEERINGHYDRAULICPRESSURESWITCH
PWRST hydraulic
pressure
SW
_ . - - - . - _ - _ F
'\-----l 1
|
I
*l_
Componentslocation
Function inspection
fr; Placeignitionswitchto ON position. . PoWEB ST SIG .
:
Inspectusing'PWRST SlG"in
'FUNCTION PRESSSTARTWHILEFULLY
TEST"mode. STEERING
THESTEERING
OR WHEEL,
Stopthe engine.
Use "DATAMONITOR"to inspectPWR
ST hydraulicpressure switchsrgnal.
Whenneutral:OFF
Whensteered:ON
A
Startthe engine.
UseCONSULT or testerto measurethe frvorrroRrruqflrornt
voltagebetweenECCSC/U terminal19 cAS.Pr\,,t(POS) 862rpm
andground. I G N I T I OSNI G N A L O F F
Whensteered:Approx.0V
Other:Batteryvoltage
HECOBD
TOB
EN - 447
R825DEDIAGNOSIS
B
Inputsignalcircuit inspection
Disconnectpowersteeringhydraulicpressure
switchharnessconnector.
Checkfor harnesscontinuitybetweenECCSC/U
terminal19andpowersteering pressure
hydraulic
switchterminal1.
OK orconnector.
harness
Repair
c
Groundcircuit insPection
Checkfor continuitybetweenpowersteering N G
hydraulicpressureswitchterminal2 andenglne
grouno.
OK
Repairharnessor connector.
Component Parts inspection

(Powersteeringhydraulicpressureswitch) NG
Referto the sectionon powersteering
hvdraulicpressureswitchfor inspection.
Replacepowersteering
hydraulicpressureswltch.
Checktor anYdamageon the ECCSC/U

terminals
insPection
Verification

check.
Functional and ECCSC/Uconnector.
terminals
EN - 448
R825DE
DIAGNOSIS
R B 2 5 D FE N G I N E
22 (Phenomenon)- IDLEREV tS TOO HIGH(AFTERWARMUP)

DIAGNOSIS
1 1
Throttle sensor & air regulator inspection I rsnot.rue
sENsonO
5S. tunction
!.snec11n tesrmode. PRESSSTABTWHILEFULLY
'!'/ UnecK judgement)
rlthethrottlesensor(idle is OPENINGTHEACCELERATOB
notturnedOFF. NG PEDAL.
61
Makesuretheair regulator unttts notrocKed
\€v or electricity
is conducted
to arrrequtator.
OK
Circuit
andthrottle
sensor
Inspectron.
Airregulator
andcircuit
inspection.
Intakeair leak inspection

..=.Warmuo the enqine.
/ l r \
flChange offsetvalueby selectingDWN in YES
"FUEL
INJECTION RATIOOFFSET
VALUE"in activetest mode.
Caution:Carryoutthetestin minimumtime 2
required.Do notoperateduringdrive. I acrveresr a tr
Warmup lhe engine. FUELINJECTIONOFFSET oei,
[40NlTOR
^ Separate airflowmeterharnessconneclor. cAS.FPr\,4(POS) 937rpm
ENGTEIV1P
@Cnect if the idlerevwilldecreaseafter O. SENSOB
SEN 5S'C
1.33V
racingthe engineat approx.below2000rpm (R)
o, sENsoR 1.3sV
for 30 seconds. I N JP U L S E 1.8msec
AAC VALVE 17".
NO Qu UP DWN lt Od
Reoairwhereairis leakino.
3
Throttle linkage inspection
Stoptheengine. NG
Checkif the throttlelinkagewillmovesmoothly.
Checkif thethrottlevalvewillclose/ ooenfullv.
OK
Repairthrottlelinkage
or Inspectthrottlevalve
FINISH
f Jt/*i,.
\i _r J)"*
EN - 449
RB25DEDIAGNOSIS
DIAGNOSIS23 (Phenomenon)'HUNTING
Throttle sensor insPection

Warmuptheengine.
Checkforanychangewithhuntingwhen02 sen
connectoris seParated.
Power balance test I

serusoR
O rnRorrue
^ Startheenqine.
PRESSSTARTWHILEFULLY
($u." PowEB BALANCE- in functiontest' OPENINGTHEACCELERATOR
Caution:Carryoutthetestin mlnimumtime PEDAL.
required.Do notoperateduringdrive
ldlerevwilldecreasefor a momentfor each
linder.
dl-erevwilldecreasefor a momenlwhen
eachcylinderinjectorconnector is
SparkpluginsPection
Stoptheengtne.
sparkplugandcheckfordirt'
Disconnect
damage.gapetc.
r or replace.
lntake air leak insPection

Startthe engtne.
whenblow-by
Checkif enginerevwillincrease
houseis pinched.
EN - 450
R825DEDIAGNOSIS
24 (Phenomenon)- IDLEINSTABILITY
OIAGNOSIS
1
Operatepower balancetest I poweRenr.ANlce a
,G\ Startthe enoine. ]NSPECTBALANCEOF EACH
'-U'operate
pdwen BALANCE NO PIPESBYSTOPPING
INJECTOR
TESTjnfuncrion OPERAT]ONATEACHPIPES.
test.Caution:
Operate
thetestinminimum
time TURNOFFALLlJCANDLIGHTS
requirgd.
Donotoperate
duringdrive.
6ldle revwilldecrease
fora momentwhen
(&operating pipes.
each
YES
To No. 6
2
Injector inspection
Stoptheengine.
Removecrankanglesensor.
(leaveharnessconnector as it is). NO
Dlsconnect powertransistorconnector.
Placeignitionswitchf romOFFto ON posrtion.
Can you hearoperationnoisefromeachinjector
whenthe crankanglesensorshaftis rotatedby hand.
Warning:Dependrng on howthe shaftis rotated,self-
diagnosis willdrsplay
abnormal, disregard
thisdisplay.
3
YES
lgnition inspection
Inspectiniector
andcircuit
ffi
\ , \
Operation
noise
Removergnition coilASSY NG
Installnormaisparkplug.
Facethe sparkplugrearendtowardsadequate
groundsuchas collector andcranktheenaine.
Checkthespark.
OK Inspectignition
coil,power
transistor
andcircuits.
4
Spark plug inspection
Checkfordirt,damage,gapetc.on the
sparkplugremoved fromtheengine.
TO5
EN - 451
RB25DEDIAGNOSIS
F B 2 5 D EE N G I N E
FuelpressureinsPection
Starttheengine.
Select"STOP" in"ACTIVE TEST"andbring
fuelpressure to zero.
Afterengine stop, crank2 - 3 times.
Inspect fuelpressure usingfuelpressure
gauge.
W h e ni d l i n q : x . 2 . 5 k Ioc m "
Startthe engine.
Removefuelpumpfuseandbringfuel
pressureto zero.
Attachfuel pressuregaugeand inspectthe
la'x[\
': Fuel frlier:J
InspectfuelpumPand \
circuits.
6
$rorrrontnqNto rntr
CAS.RPI\,4(REF) 650rpm
02 SENSOF O.O2V
0 2 S E N S O RM T R R I C H
Exhaustgas sensorinsPection
,6',lnspectusing"BASEAIR-FUEL RATIO"in
tly''ruNcrtoru TEST"mode.
Select"O,SENSOR MONITOR" indata
monitor. 6
Setat 2o0orpm withno loadafterwarmup' m o d e .s h o n - c i r c ulihl e s e
openthe
"LEAN'RlCH"willrepeat Ior a'pprox2 secsJben
(rhernode
Checkifthedisplay /4-ff-ffF;la
earh Lff.ffTT-l Ilmerhs
-:-
for morethan5 timeswithln10 seconds rs Pedormeo)
,o,Operatevehicleside(withinfusebox)
@)diaqnosis connector andchangeto O,
sensormonll0r'.
Set at 200orpmwith no loadafterwarm up
Checkif theexhausttemperature warning
lampwillf lashfor morethan5 timeswithin
ReplaceO, sensor
TO7
EN - 452
RB25DEDIAGNOSIS
7
Startthe engjne. YES
Checkif theenginerevwillincrease
when
theblow-byhoseis pinchedusinghands.
NO
Repairleaks
8
ldle adjust screwf ixationinspection
fO Starttheengrne.
"AACVALVE
s Operate ADJUSTMENT' in N O . AAC VALVEADJ '
'OPEBATION SETTHECAS.PRI\ITO
SUPPORT" mode. STANDARD VALUEUNDEB
Canidlerevbe adjusted to 600- TOOrpm IHE FOLLOWING
AFTEBWARMUP
CONDITION:
("N"position forA/T)by rotating
theidte TURNOFFALLLIGHTS AND
adtustment screw. AIRCONDITIONER,
r€\Startthe engine.
\Gr'DisconnectAAC valveconnector.
Can idle rev be adjustedto 600 - TOOrpm
("N"positionforA/T)by rotatingthe idle
adjustmentscrew.
YES
AACvalveandthrottle
valvefixationinspection.
9
Compression pressure inspection
Standardvalue:12.8i300(kgicm,)/(rpm) N G
Minimum value:9.8/300(kg/cmr)/(rpm)
Eachcylinderdifference
Tolerance:1.0/300(kg/cmr)/(rpm)
OK Inspectpiston,pistonring
valve,valveseat,cylinder
headgasket.
10
ECCSC/Uconnectorinspection
Checkforanydamage or looseconnection
on
theC/Ubinterminal
andharness connector.
OK
11
Tryreplacing
withnormatC/U.l-----.]Replaceor repair
FINISH
EN - 453
RB25DEDIAGNOSIS
D|AGNoS|S25(Phenomenon).WHENcoLD,D|FF|CULTToSTARToRcANNoT
STARTTHEENGINE
1
andstartermotorf-llsglessjljePell
tnspectOattery . F U E L P U M P'
YOU FEELPULSATION
OK R Y3 S E C O N D SWHEN
2 E FUEL TUBEIS
Fuelpressureinspection E D ?O BC A NY O U
'FUNCTIONNG FUELPUMPRELAY
usingFUELPUMP'in
,6,lnspect
flltesr" mode.
,o.Pinchf uelPumPwithf ingers.
6)Cnect if thefusehoseis tensewhenf uel
pumpus operatlng.
OK
Fuelpumpandcircuit Fueiiilter
inspection
Air regulatorinsPection NG
Checkifthepowerisconducted to airregulator
whentheignition isturned
switch toONposition'
OK
andclrcull.
Inspectairregulalor
4
ThrottlesensorinsPection OK
Pressacceleratorpedalfullyandcheckif
theenginewillstart.
Throttlesensorandcircuit
inspection. 4
5 'J5;-
lnjector inspection F u l l yo p e n .\-i)
Placeignitionswitchto OFFpositlon. :f lrr't ,/
Removecrankanglesensor(leaveharness
gl+uu\
connectorconnected). if.'-
,{:--,!
Removepowertransistorconnector. NG
Checkif eachinjectoroperationnoisecan be
3
heardwhenthe crankanglesensorshaftis rotated
by hand.Note:Depending on howtheshaftis
in
rolated,abnormalwillshowin self-diagnosis,
thiscasedetermine as normal.
OK
andcircuitinsPection
Injector
TO6 Rolate by hand
EN - 4s4
RB25DEDIAGNOSIS
6 6
lgnitioninspection
Placeignitjonswitchto OFFposition.
Removesub-harness jn eachpipptng.
Installnormalsparkplug.Facethesparkplug
NG
rearend towardsadequategroundsuchas
collectorandcranktheengine.
Checkthespark.
OK
Inspectignition
coil,power
transistorandcircutt.
7
Sparkpluginspection
gapetc.onthespark NG
Checkfordirt,damage,
plugremovedfromtheengine.
OK
Repair
or replace
8
ECCS C/U connector inspection
NG
Checkfor any damageor looseconnectionon
the C/U binterminaland harnessconnector.
OK Repairor replace
o
ECCSC/Upowersupplyandgroundcircuit NG
Inspectron.
OK
Repairor replace
't0
Try replacing
withnormaiC/L.
FINISH
EN- 4ss
RB25DEDIAGNOSIS
DIAGNOSIS26(Phenomenon)-WHENWARM,DIFFICULTTOSTARTORCAN
NOT STARTTHE ENGINE
1
FuelpressureinsPection IFUEL PUN/P1)
/G InspectusingFUELPUMP" in"FUNCTIONNG YOU FEELPULSATION
3 SECONDSWHEN
!UtEST" mode. E FUEL I UIJtr I-
,o,PinchfuelPumP withfingers.
(SCneckifthefusehoseistensewhenfuel
pumpusoperatlng.
OK
Fuelpumpandcircuit
inspection
2
Vapour inspection
Disconnectfuelpressureregulatorvacuumhose O K
Placea holecapon thevacuumhose.
Doestheenginestart?
NG
Inspectfuelaspect
J
IniectorinsPection
connectorconnected).
Removepowertransistorharnessconnector. NG
abnormal
rotated, in
willshowin self-diagnosis.
OK
andcircuitinspection
lniector
4
lgnitioninsPection
Removesub-harness in eachpipping.
Installnormalsparkplug. Facethesparkplug N G
rearend towardsadequategroundsucnas
Check spark.
the
OK coil,Power
Inspectignition
andcircult.
transistor
TO
EN - 456
RB25DEDIAGNOSIS
5
Sparkplug inspection
gapetc.onthespark N G
OK
Repairor replace
6
NG
Checkforanydamageor looseconnection on
the C/Ubinterminaland harnessconnector.
OK Repair
or replace
7
ECCSC/Upowersupply
andground
circuit NG
inspectron.
OK
Repairor replace
I
Try replacing
withnormalC/U.
FINISH
EN - 457
RB25DEDIAGNOSIS
TO STABT
DIFFtCULT
DIAGNOSIS27 (Phenomenon)'lN NORMALCONDITION,
OR CAN NOT STARTTHE ENGINE
t 1
()FUEL PUI\,4P
'
lnsoectbatteryand startermotor YOU FEELPULSATION
3 S E C O N DW
SH E N
E FUELTUBEIS
Fuel pressureinsPection ED? OR CANYOU
"FUNCTION RELAY
EAFIFUELPUI\,4P
usingFUELPUMP'in
4;.,lnspect
\ETEST'mooe.
PinchfuelpumPwithfingers
Checkif thefusehoseis tensewhenfuel
pumpus oPerating.
Fuelpumpandcircuit
inspection
Iniectorfuel leak insPection

Pressaccelerator pedalfullyan checkif the
enginewillstaftwhentheignition switchisturn
to STARTposition.
leak.
Inspectinjector dI?-.,
F u l l yo p e n
,V
:\l rF.t ,/
lniector insPection TI+(f,l\ f-l
Placeignitionswitchto OFFposition. X-
Removecrankanglesensor{leaveharness
Removepowertransistorconnector.
abnormal
rotated, in
willshowin self-diagnosis,
Rotateby hand
lniectorandcircuitinsPection
lgnition inspection
Placeignitionswitchto OFF position.
Removesub-harness in eachpipping
Installnormalspark plug. Facethesparkplug
rearendtowardsadequate groundsuchas
collectorandcrankthe engine.
Checkthespark.
OK
coil,Power
Inspectignition
TO6 and rcuit.
transislor ci
R825DEDIAGNOSIS
o
Sparkpluginspection
gapetc.onthespark N G
OK
Fepar or replace

NG
Checkforanydamageor looseconnection on
the C/U binterminaland harnessconnector,
OK Repair
or replace
I
ECCSC/Upowersupplyandgroundcircuit N G
Inspection.
OK
Repairor replace
I
Tryreplacing
withnormat
C/L.
FINISH
EN - 459
RB25DEDIAGNOSIS
DIAGNOSIS28 (Phenomenon)- HESITATION AFTEB WARM UP

(hesitationas throttle valve starts to open)
I 1
FuelpressureinsPection'FUEL i rcrrveresr O D
'UP'or"DWN"in INJECTION FUEL INJECTIONOFFSET 09"
,erSelect MONITOR
GzounurtrvcoRREcrtoN" TEST' OK
in'ACTIVE CAS.FPIV(POS) 937rpm
SEN
ENG TEI\,4P 59'C
modeto change correctionvalue. o, sENsoF 1.33V
Caution:Carryoutthetestin minimum time o . S E N S O( B
R) 1.3sV
iNJ PULSE l.BMSEC
required.Do notolelqle lullnggllve,- AAC VALVE 17'i.
;DGcon nectluefpressu vacuumhose NG

reregulator Qu UP DWN ll Od
(6)Placeholecaponvacuum hose
Operate cruisingtest.
lstherestillhesitation?
NG
inspectpressure
lf leanhesitatlon
regulatorandfuelPumP.
FuelaspectinsPection
Canisterpurge inspection
Disconnect Purgenose. N G
canister
Placeholecapon the Purgehose
Conductcruisetest.
ls therestillhesitation?
Inspectpurgeandvacuum
system.
FINISH
EN - 460
RB25DEDIAGNOSIS
29 (Phenomenon)- HESTTATTON
DIAGNOSIS WHENCOLD
1
Sparkpluginspection
Removesparkplugandcheckforanvdirt, NG
damage,gapetc.
NG
Bepairor replace
2
Fuelpressureinspection
" U P ' o r- D W Ni'n
rerSelect F U E LI N J E C T I O N
€euRrurtry coRREcloN' in-ACTIVE TEST' OK
modetochange correctionvalue.
Caution: Carryoutthetestjn minimum time
required. Donotoperate duringdrive.
Starttheengine.
61Does theenginerevincrease
whentheblow-by
\g/ hoseis pinched? ACTIVETEST
FUEL]NJECIION
OFFSET
NG
Repairleaks
3 r.33V
Replace
withnormalarrf lowmeter.
OK
NG
Replaceairflowmeter.
4
Intake valve deposit inspection
Removewhendeoositis Dresenr.
FINISH
EN - 461
RB25DEDIAGNOSIS
30 (Phenomenon)'HESITATION
DIAGNOSIS lN NORMALCONDITION
1 2
TE51,
ItsASEAlRFUELRATIO
Spark plug insPection
HOLDENGINEREV2000+f
Removesparkplugandcheckforanydirt, 200rpmANDPRESSSTARI
Repairor replace
Exhaust gas sensor insPection

'BASEAIR-FUEL RATIO"in
Inspectusing
"FUNCTION TEST"mode.
"O, SENSORMONITOR" in data NG
Select
monllor.
Set at 2000rpmwith no loadafterwarm up
"LEAN,RICH"willrepeat
Checkif thedisplay
formorethan5 timeswithin10seconds
Operatevehicleside(withinfusebox)
diagnosis connector andchangeto O-
sensormonitor".
Set at 2OOOrpm with no loadafterwarm up. ttlt I
lampwillf lashfor morethan5 timeswithin 7|-rl
ExhausttemP
w a r n r n gl a m p I
Canister purge insPection

Disconnect Purgenose.
canister purgeano
Inspect
PlaceholecaPon Purgehose. vacuumsystem
Conductcruisetest.
ls therestillhesitation?
4
lntake air leak insPection O ncrtvEresr O f
FUELINJECTION OFFSET O%
Warmup the engine. MONITOB
"DWN" s37rpm
Changeoffsetvalueby selecting CAS.RPM(POS)
ENG TEI\,4P
SEN 59'C
in "FUELINJECTION RATIOOFFSET o. SENSOR 1.33V
in testmode. o. sENsoR(R) 1.35!
VALUE" active 1.8msec
tNLPULSE
Caution:Carryoutthetestin minimum AAC VALVE 17"h
timerequired.Do notoperateduringdrive. Ou UP owN Qd
Warmup the enqine.

rateairflowmeterharnessconnector.
after
@cn-.,"[ ii rn" idlerevwilldecrease
racingtheenglneat approx.below
for 30 seconds.
Repairanyleaks
RB25DEDIAGNOSIS
31 (Phenomenon)- ENGTNE
DIAGNOSIS STALLWHTLEREVVTNG
1 1
Fuel level inspection
Checkthe levelof fuelin thefueltank. Resupply
fuel
, F-rN-=I
NG
OK
2 l- \--l |
|
Power balancetest operation
' _
,ar Startthe enoine.
\9/ Inspectusing'POWERBALANCEin
l l l
'FUNCTION
TEST"mode. NG
"POWER
Operate BALANCE"in "ACTIVE OPOWEHBALANCE'
TEST"mode.Caution:Carryoutthetestin FOREACHCYLINDER STOP
INJECIOR
OPEMTIONAND
minimumtimerequired.Do notoperate CHECKTHEBALANCEOF
duringdrive. EACHCYUNDER.
TURNOFF,6./CAND
LIGHTS
Checkif idlerevwilldecreasefor a moment
whencheckingeachcylinders.
,q1 Checkif idlerevdecrease
fora moment
r€rwheneachinjector connector
cylinders
are
disassembled.
3 OK To No. 5
Iniector inspection
Removepowertransislorconnector.
Placeignition NG
switchfromOFFto ON position.
heardwhenthecrankanglesensorshaftis rotated
rotated,
abnormal willshowin self-diagnosis,
in /l
thiscasedetermine as normal. Operationnolse
Injectorandcircuitinspectron
4
lgnition inspection
'%j,::""',,
Placeignitionswitchto OFFposttion.
Installnormalsparkplug. Facethesparkplug
NG
rearendlowardsadequategroundsuchas
'%!
Checkthespark.
OK
Inspectignition
coil,power
TOs transistorandcircuit.
EN - 463
RB25DEDIAGNOSIS
Fuel pressure insPection . ACTIVETEST . L--]

RELAY ON
FUELPUI\.4P
/G\ Startthe engine.
fU'Bringfuelpressureto zeroby selectingFUEL MONITOB
"ACTIVETEST".
PUMPRELAY"in
NG CAS.RPM(POS) 0rPm
Crank2 to 3 timesafterenginestop.
Usefuelpressuregaugeto inspect:
Whenidling.APProx. 2.skg/cm' oN lpN/oFFll oFF
Whenpressureregulator vacuumhoseis
c
removed:APPToL
,-o''Starttheengine.
\6tlring {uelpressure fuel
to zerobyremoving
pumpfuse.
Crank2 to 3 timesafterenginestop'
Inspect usingfuelpressuregauge.
OK pressure
Inspect
diaPhragm
regulator
o
ECCS C/U conneclor inspection NG

on
Checkforanydamageor looseconnection
andharnessconnector.
theC/Ubinterminal
OK Repairor replace
tnrpectgCCSC/Upowersupplyandground N G
circuit.
OK
Repairor rePlace
8
Try replacingwithnormalC/U.
OK
FINISH
EN - 464
RB25DEDIAGNOSIS
DIAGNOSIS - ENGTNE
32 (Phenomenon) STALLAFTERWARMUp
1 1
Vapourinspection O ncrrve
resr a I
correction
valuebyselecting..DWN" in"FUEL
FUELINJECTION OFFSET O'/.
,6lChange " "ACT|VE
t\,10NtToR
\E4NJECTION CORRECTTON in TEST"mode. CAS.RPI\,1(POS) 937rpm
ENGTE]\IPSEN 59,C
Caution:
Carryoutthetestin mintmum timerequired. o, SENSOR 1.33V
Donotoperateduringdrive. o " S E N S O R( R ) i.35\
INJ PULSE ].8msec
pressure
fG\Disconnect regulatorvacur-rrn AAC VALVE 179L
\@Place hole cap on vacuum hose. OL/ UP DWN od
Operatecruisetest.
Doestheenainestillstall?
2 NG
/G\ Start the enqine.
'€i
Inspectusirig-eOWeR BALANCEin
.FUNCTION
TEST"mode.
"POWER
Operate BALANCE" in "ACT|VE NG
TEST"mode.Caution:Carryoutthetestin
minimumtimerequired.Do notoperate .POWER BALANCEO
FOREACHCYUNDERSTOP
duringdrive. ITUECTOR
OPEMTIONAND
Checkif tdlerevwilldecreasefor a moment CHECKTHEBALANCEOF
EACHCYUNDER.
whencheckinqeachpippinq. TURNOFFT/CANDLIGHTS
Checkif idle revdecreasefor a moment
,q,
\€r wheneachinjector connector pippingare
disassembled.
3 OK To No. 5
Iniector inspection
conneclorconnected).
Removepowertransistor connector. NG
Placeignitionswitchf romOFFto ON position.
by hand.Note:Depending on howtheshaftis @ffr^<)
rotated,abnormalwillshowin self-diagnosis,
in :n. =d$l}P
Injectorandcircuitinspection
4
4
lgnitioninspection
Placeignitjonswitchto OFFposition.
rearend towardsadequategroundsuchas
collectorandcranklhe engine.
Checkthespark.
EN - 465
R825DEDIAGNOSIS
RB2sDE NGINE
5
Fuel pressure insPection O ncrrverEsrILJ
FUELPUMPRELAY OFF
rer Startthe engine. "FUEL
fUBring fuelpressureto zeroby selecting MONITOF
"ACTIVETEST"mode.
PUMPRELAY"in
stop. NG (POS) 950rPn"
CAS.RPI\,'1
2 to3 timesafterengine
Crank
gaugeto inspect:
Usefuelpressure
2.5kglcm2
Whenidling:APProx. ON )N/OFF OFF
vacuumhoseis
Whenpressureregulator
removed:APProx.3.0k9/cm'
^ Qt. rt +ha anoina
i"ul".",.
fuel
tozerobyremoving
l&Bringfuelpressure
oumo fuse.
Crank2to 3 timesafterenginestop.
Inspectusingfuelpressuregauge.
OK pressure
Inspect
diaphragm
regulator
ECCS C/U connector insPection NG

Checkfor anydamageor looseconnection on
0oog.
sT195S
OK Repairor replace
7
tnspectECCSC/U powersupplyandground N G
circuit.
OK
Repairor replace
I
Try replacingwithnormalC/U.
OK
FINISH
EN - 466
RB25DEDIAGNOSIS
33 (Phenomenon)- ENGINESTALLWHENCOLD
DIAGNOSIS
't
Air regulator inspection
Checkif thepoweris conducted to air regulatorN G
whenignitionswitchis in ON position.
OK
Inspeclair regulator
andcircuit.
2
Throttlesensorinspection
pedalfullyandcheckifthe NG
Pressaccelerator
engrnecanbestartedwhentheenqineiscold.
Fullyopen
Inspectair regulator
3
andcircuit. $ + @<
I Powerbalancetestoperation
frt Start
theengine.
:Inspectusing 'POWER BALANCEin
"FUNCTION
TEST"mode.
Operate"POWERBALANCE'in"ACT|VE NG .PoWER BALANcE.
FOREACHCYUNDEFSTOP
TEST"mode.Cautton:Carryoutthetestin INJECTOROPEMNONAND
minjmumtimerequired.Do notoperate CHECKTHEBALANCE OF
EACHCYLINDER.
duringdrive. TURNOFFA./CAND
LiGHTS
Checklf idlerevwilldecreasefor a moment
whencheckinqeachcvlinders.
@ Checkif idlerevdecrease{ora moment
: wheneach
injector
connectorcylindersare
disassembled.
4 oK I T oN o . 7
Iniector inspection
Placeignitionswitchto OFF position.
NG
Checkif eachinjectoroperation noisecanbe
heardwhenthecrankanglesensorshaftis rotated
@ffrX)
by hand.Note:Depending
rotated,
on howtheshaftis :Rt,>sv /l
abnormal wrllshowin self-diagnosis,
in
thiscasedetermrne as normal.
Injector
andcircuitinspection
TO5
EN - 467
RB25DEDIAGNOSIS
RB2sDE NGINE
lgnition inspection
Removesub-harness in eachcylinders'
Installnormalspark plug. Facethesparkplug
rearendtowardsadequategroundsuchas
collectorandcranktheenglne.
Checkthespark.
Inspect coil,Power 6
ignition
and
transistor circult.
SparkpluginsPection
gapetc.
Checkfordirt,damage'
onthesparkPlugremovedfrom Repairor replace
FuelpressureinsPection 7
'/G Startthe engine. I ncrrverrsr O L,-i
l.=Brrnqfuelpressure to zeroby selectingFUEL FUELPUMPRELAY OFF
,.ACTIVE TEST''MOdC.
PUMPRELAY,in l\,40NlToF
Crank2 to 3 timesatterenglnestop.
gaugelo Inspect: (POS) ssorpn
CAS.BP[,4
UsefuelPressure
Whenidling:APProx. 2.Skg/cm'
when pressureregulator vacuumhosels ON )N/OFF OFF
rox.3.Okq/cm'
,6Start the engine. 7
6tsrinq f uelpressure lo zeroby removingluel
p u m pf u s e .
Inspectusingfueipressure gauge.
lnspectpressure
regulatordiaphragm
ECCS C/U connector insPection

Checkfor anydamageor looseconnectionon
and
the C/U binterminal connector.
harness
Repairor replace
InsoectECCSC/U powersupplyandground
withnormalC/L.
Try replacing
EN - 468
RB25DEDIAGNOSIS
DIAGNOSIS 34 (Phenomenon)- ENGTNESTALLWHENACCELERATTNG

INSTANTLY
1
AAC valve inspection
(f;)warmengine
v Inspectusing'AACVALVE-in
FUNCTION
ItrJ I l. Fl
Select"AACVALVE ADJ"in "ACT|VE NG
TEST".
Checkiftheenginerevwillchange
when
"Qu"or "Qd"is 1
selected
tochange
AAC
varveopentng. I qcrrveresr t D
AAC/VOPENING lOO,':
theengine.
re\Stan MONITOR
\G/Checkif enqinerevwilldecrease
when CAS.RPI\,{(POS) 900rpm
AIR FLOW['TR 1.16V
AACvalveJonnectorts dlsconnected. ENG IEI\,4PSEN 8O"C
InspectAACvalve
andcircuit. Ou UP DWN od
2
{€Start theengine.
\elnspectusing POWERBALANCEin
"FUNCTION
TEST"mode.
OR use"POWERBALANCE"in "ACT|VE NG
minimumtimerequired.Do notoperate
duringdrive.
Checkif idlerevwilldecreasefor a momenl OPOWERBALANCEO
whencheckingeachcylinders. FOREACHCYLINDERSTOP
INJECIOR
OPEMTIONAND
CHECKTHE BALANCEOF
3 OK I ToNo.5 EACHCYLINDEF.
Injector inspection
Removecrankanglesensor.
Removepowertransistorconnector. 2
NG ACTIVETEST 'f
.
PlaceignitionswitchfromOFFto ON position. POWERBALANCE
Checkif eachinjectoroperation
noisecanbe (POS)
CAS.FlPl\,4 rpm
heardwhenthe crankanglesensorshaftis rotated AIF]FLOWMTR V
AACVALVE q.
by hand.
1 2 3 4
r=l START
L:] 6
Injectorandcircuitinspection
TO4
Operatronnoise
EN - 469
RB25DEDIAGNOSIS
lgnition inspection
Bemoveignition coil.
ground
adequate
rearendlowards suchas
andcranktheengine.
collector
CheckthesPark.
J
coil,
Inspectignition
andcircuit.
transistor rEsr lL
O ncrrve
RELAY OFF
FUELPUN,IP
t\,roNtToR
Fuel pressure insPection
,ar Startthe engine. (POS) 950rPrr
CAS.RPN,4
(UBrinq fuelpressureto zeroby selectingFUEL
..ACTIVETEST''MOdE.
PUNiPRELAY"in ON )N/OFF OFF
Crank2to 3 timesafter enginestop.
UsefuelPressure gaugeto Inspecl:
Whenidling:APProx. 2.Skglcm'
When pressureregulatorvacuumhoseis
rox.3.Okq/cm'
,.,o,Start the engine.
(6bring f uelpressureto zeroby removing f uel
pumpfuseNo.B.
gauge.
Inspectusingfuelpressure
Checkforanydamage on
orlooseconnection
andharness
theC/Ubinterminal connector.
ir or replace
lnspectECCSCiU powersupplyandground
withnormalC/L.
Try replacing
EN - 470
RB25DE
DIAGNOSIS
35 (Phenomenon)- ENGTNE
DIAGNOSIS STALLWHEN DECELERATING
1 1
AACvalveinspection
/G.rWarm engine.
: Inspect using"AACVALVE- in 'FUNCTION
TEST'OR
Select"AACVALVE ADJ"in "ACTIVE NG
TEST".
Checkiftheenginerevwillchange when
"Qu"or "Qd"is selected 1
to changeAAC
valveopening.
O ncrrve
resr a tr
A A C/ V O P E N I N G 109:
theengine. [,40NtTOR
r€\Slart
\@/Check CAS.RPM(POS) 900rpm
if enginerevwilldecrease wnen AIR FLOWMTF 1 16V
AACvalveconnector is disconnected. ENGTEIV1P SEN 80.C
OK Inspect
AACvalve
andcircuit. Qu UP DWN Qd
2
Adiust screw fixation inspection
@,lnspect using-AACVALVEADJUSTMENT-
:in OPERATION SUPPORTmode. NG
Checkif it is possibleto set idlespeedto
650rpm("N"rangeforA/T)by turningidte
adjustmentscrew.
6lDisconnect throttlesensorconnector.
\Gr Checkif it is possibleto set idlespeedto
650rpm("N"rangeforA/T)by turningidle
a AAcVALVE
ADJ a
adlustmentscrew. ADJUSTCAS FlPMTO
STANDARD VALUEUNDEF J
OK thE FOLLOWNGCONDLT ON ,
InspectAACvalveand AFTERWARMUP
] TURNOFFA,'CAND L GHTS
throttlevalvefixation.
3
,G\ Startthe enoine.
\ t /
v Inspectusing"POWERBALANCE'in
"FUNCTION
rEST" mode.
"POWER
OR use BALANCE"in "ACT|VE NG
minjmumtimerequired.Do notoperate
duringdrive.
Checkif ldlerevwilldecrease for a moment
whencheckingeachcylinders.
r,qsta rt the engine.
J
\c/Check if idlerevwilldecreasefor a moment . ACTIVETES1 r f
POWERBALAI'rcE
wheneachcylinderinjector connector is cAS.RPM(POS) rpm
disconnected. AIFIFLOW I\,ITF]
AAC VALVE a./"
oK I 1 2 4
T oN o . 6 E--l --t STAFT
t:j o l
EN - 471
DIAGNOSIS
RB25DE
4
Iniector inspection
connectorconnected). NG
Checkif eachiniecloroperationnoisecan be
heardwhenthecrank angle shaftis rotated
sensor
by hand.
InjectorandcircuitinsPection
5
lgnitioninspection
Removeignition coil.
NG
Inslallnormalsparkplug.Facethesparkplug 6
rearend towardsadequategroundsucnas O ncrrveresr I i--l
collectorandcranktheengine. FUELPUMPRELAY OFF
CheckthesPark. N,4ONITOB
OK CAS.RPM(POS) 950rpn
Inspectignitioncoil,Power
transistorand circuit. ON ]N/OFF OFF
Fuel pressure insPection

/G\ Startthe engine. -FUEL
lUBring fuelpressure to zeroby selecting
"ACTIVETEST"mode.
PUMPRELAY"in
NG
Usefuelpressuregaugeto insPect:
Whenidling:APProx. 2.Skg/cm'
when pressure regulatorvacuumhoseis
removed:ApProx.3.Okg/cm'
^ qtrrt fh6 onarina
A { f ^ " . " ' . ! I | v v i i Y l l l v .
lStsring f uel pressureto zero by removingfuel

pumpfuseNo.8.
Inspectustngfuelpressure gauge. ,r2.
:// Fuel
Inspectpressureregulalor
TO7 diaphragm.
EN - 472
F825DEDIAGNOSIS
7
Exhaustgas sensorinspection NoFA|L
A,4oNrToRrNqk
usinq"BASE
/G\ Inspect AIR-FUEL FATtOrn
r-U"rurucrtoru
TESTmode. (REF)
CAS.RPI,4 82srpm
"O,SENSOR
Seiect MONITOR" indara NG 02 SENSOBI\,4TR RICH
monitor.
Setat2000rpm withnoloadafterwarmup.
"LEAN,
Checkifthedisplay RICH"witlrepeat
formorethan5 timeswithin10seconds.
re\ Operatevehicleside(withinfusebox)
\€r' diagnosis
connector andchangeto -O2 c h a n q ed r a g n o s t cm o d e s h o d c r c u t t f r e s e
sensormonitor".
Set at 2000rpmwith no loadafterwarm up.
lampwillf lashfor morethan5 timeswithin
10 seconds.
OK
ReplaceO, sensor
Inspectthrottlesensorandvehicle
Iltl
speedsensor.
OK ' E x h a u stern
t p
Redlarnp w ar n r n q a m p
NG
on
theC/Ubinterminal
OK Repairor replace
InspectECCSC/Upowersupplyandground N G
circuit.
OK Repairor replace
TryreplacingwithnormalC/U.
OK
FINISH
EN - 473
RB25DEDIAGNOSIS
D|AGNoS|S36(Phenomenon)-ENGINESTALLWHENAccELERAT|NGoR
SPEED
AT CONSTANT
DRIVING
1
Power balancetest oPeration
,/4,Startthe enqine.
UInspect usin-geOwf n BALANCE'in
"FUNCTION TEST"mode.
"POWERBALANCE'in"ACTIVE NG
OR use
minimumtimerequired.Do notoperate
duringdrive.
for a moment
Checkif idlerevwilldecrease
whenchec@
rqstart the engine.
\@Checkif idlerevwilldecreasefor a moment
wheneachcylinderiniectorconnectoris
disconnected.
oK I ToNo'
2 l
IniectorinsPection
@ffix)
connectorconnected). NG rRl' >S"/
/l
Removepowertransistor connector. Operalionnolse
switchfromOFFto ON position'
Placeignitron
noisecan be
Checkif eachinjectoroperation
i\
heardwhenthe crankangiesensorshaftis rotated
by hand.
.- lgntion
3
lgnitioninsPection
NG
spark
Installnormal plug.Facethesparkplug
collectorandcrankthe engine
CheckthesPark.
OK
coil,Power
Inspectignition
transistorandcircult.
TO4
EN - 474
RB25DEDIAGNOSIS
4 4
Fuelpressureinspection O ecrrverrsr I {*
ua-rStaftthe enqine. FUELPUI\,4P
BELAY OFF
\U Aringfuelpr"essure 'FUEL
to zeroby setectrng
PUMPRELAY'in"ACTIVETEST"mode.
l\,lONlTOR
Crank2 to 3 timesafterenginestop. NG CAS.RPM(POS) gsorpn

Usefuelpressure gaugeto inspect:
Whenidling:Approx.2.5kglcm2 ON )N/OFF O F F
Whenpressure regulatorvacuumhoseis
removed:Approx.3.Okgicm, 4
6lStart theengine.
\ctBringfuelpressuretozeroby removingfuel
pumpfuseNo.B.
Crank2 to 3 timesafterenglnestop.
OK pressure
Inspect regulator
diaphragm.

Startthe engine. NG
Checkif enginerevwillincrease
hoseis pinched.
whenblow-by
z
/z Fuel
OK
Repairanyleaks
6
NG
on
theC/Ubinterminal
OK Repairor replace
7
InspectECCSC/Upowersupplyandground N G
circuit.
8 0 K Repairor replace
Tryreplacing
withnormalCiL.
OK
FINISH
EN - 475
fr825DEDIAGNOSIS
37 (Phenomenon)'ENGINESTALLWHENLOADINGBATTERY
DIAGNOSIS
1
Inspectbatteryandalternator Repairor replace
Power balance test oPeration I apoweRgernruce

I
,6\ Startthe engine.
9lnspect using-POWERBALANCEin STOPIII]ECTOROPEMTION
FOREACHCYLINDERTO
'FUNCTIONTEST"mode. CHECKTHE BALANCEOF
"POWERBALANCE'in"ACTIVE EACHCYLINDERS.
OR use
TEST mode.Caution:Carryoutthetestin
minimumtimerequired'Do notoperate
duringdrive.
Checkif idlerevwilldecreasefor a moment
@,Start the engine.

@Check if idlerevwilldecreasefor a moment
wheneachcylinderinjectorconnector ls
disconnected.
To No. 4
lniector insPection tDi rJ- /\

Placeignitionswitchto OFFposition. uUKj--l .K /
connectorconnected). .tN,,:dD/
/l
Removepowertransistorconnector. Operationnoise
Placeignitionswitchf romOFFto ON position'
Checkif eachinjector noisecan be
operation
4
ignitioncoil
lgnition insPection
collectorandcranktheenglne.
Checkthespark.
coil,Power
Inspectignition
andcircuit.
transistor
TO5
EN - 476
RB25DEDIAGNOSIS
3 c
Fuelpressureinspection I ncrrvrresr O[
,er Starttheenoine. FUELPUI\,,IP
RELAY OFF
.U BringfuelprLssure tozerobysetecting.'FUEL
in"ACTIVE
MONITOR
PUMPRELAY" TEST"mode.
Crank2 to 3 ttmesafterenginestop. NG CAS.RPM(POS) 950rpn
Usefuel pressure gaugeto inspect:
Whenidling:Approx. 2.5kglcm2 ON IDN/OFF OFF
Whenpressure regulatorvacuum hoseis
removed: Approx. 3.0k9/cm,
61Stad theengine.
tg€ring fuelpressureto zeroby removing
fuel
pumpfuseNo.8.
Crank2to 3 timesafterengjnestop.
InspectusingJuelpressuregauge.
OK Inspectpressureregulator
diaphragm.
6
Checkforanydamageor looseconnection NG
on
OK Repairor replace
7
InspectECCSC/Upowersupplyandground NG
circuit.
OK Repairor replace
8
Tryreplacing
withnormalC/L.
OK
FINISH
EN - 477
RB25DEDIAGNOSIS
38 (Phenomenon)'POWERSHORTAGEAND STUMBLE
DIAGNOSIS
(lnstant power output shortage during acceleration)
1
Fuel pressure insPection O ecrtvergst O
/G Start the engine.
fUBring tuelpressure to zeroby selectingFUEL
"ACTIVETEST"mode.
PUMPRELAY'in
Crank2to 3 timesafterenginestop. NG
Usefuelpressure gaugeto insPect:
Whenidling:APProx. 2.Skglcm?
Whenpressureregulator vacuumhosels
removed:APProx.3 Olg&m1- 1
^ Cr"* th6 annine
t&Bringfuelpressure fuel
to zeroby removing
pumpfuseNo.8.
Crank2to 3 timesafterengrnestop.
OK lnspectpressureregulator
diaphragm.
2
Intake air leak inspection
@Start the engine. YES
echanqe correction valueby selectingDWN"
iN..TUEIINJECTION CORRECTION
"ACTIVE TEST"
VALUE"in
Caution:Carryoutthetestin minimumtime
required.Do notoperatewhiledriving. 2
whenthe I ncrveresr t D
Xe treckit enginerevwillincrease FUEL NJECTIONOFFSETO%
W)blow-bv hoseis pinched MONITOR
CAS.RPM(POS) g37rpm
ENGTEMPSEN 59'C
NO O, SENSOR 1,33V
Repairanyleaks o, sENsoR(R) 1.35V
NJ PULSE l.8msec
AAC VALVE 179L
pressure,
Inspectcompression timing NG
ignition Ou UP DWN Qd
anddetonationsensor.
NO Repairor replace
FINISH
EN - 478
RB25DEDIAGNOSIS
39 (Phenomenon)- DETONATTON
DIAGNOSIS
1
1
Intakeair leakinspection
Q acr veresr O f
(l)Starttheengrne, rUeLttllecrtolOrrSg dl
: Change correction .DWN' YES MONITOR
valuebyselecting
in"FUELINJECTION
CAS.RPI\.4(POS) 937rpm
CORRECTTON ENGTEI\,IP SEN 59'C
VALUE"in "ACTIVE TEST". O. SENSOR
o , S E N S O R( R )
1 33V
1.35V
Caution:Carryoutthetestinminimum time INJ PULSE l.Bmsec
AAC VALVE 17"i
required. Donotoperatewhiledriving.
Qu UP DWN od
prCheck if enginerevwillrncrease
whenthe
@rblow-bvhoseis oinched.
NO
Repalranyleaks
2
Combustion chamber oil leak inspection NG
Disconnect
sparkplugandlnspectoil.
OK
Inspectpiston.pistonring,
valve,valveseat,valveoil
seal,engineoil leveletc.
Inspect
detonation
sensorsvstem.
OK
FINISH
EN - 479
RB25DEDIAGNOSIS
40 (Phenomenon) S U R G E
DIAGNOSIS
1
Exhaust gas sensor insPection IFASEAIR FUELRATIOTESI
"BASEAIR-FUEL RATIO'in
/A Inspectusing HOL0ENGINEREV2000+1-
.-EiruructtoNTEST"
mooe. PBESSSTART
2OOrpmAND
"O, in data NG
Select SENSORMONITOR"
monitor.
Set at 2000rpmwith no loadafterwarmup
"LEAN,RICH"willrepeat
Checkif lhe display
for morethan 5 tinqllryjlllllqlegengs.-
,o, Operatevehicleside(withinfusebox)
18 diagnosis connectorandchange to "o.
sensormonitor".
Setat 2ooorpm withno loadafterwarmup'
Checkiftheexhaust temperature warning
lamowillflashformore than 5 times within
10 seconds.
START
OK
ReplaceO, sensor
2 II
ReplaceECCSC/U :'----_-
- Ittl
.fi-
OK -*-., -g
FINISH
,^^':?
Red la'np
EiT:1rlr
lamp,
warntng
E N- 4 8 0
R825DEDIAGNOSIS
41 (Phenomenon)- BACK FIRE(SPtTTtNG)

DIAGNOSIS
1
Sparkplug inspection
Remove sparkplug. NG
Checkforanydirtonthesparkplug.
OK Repairor replacesparkplug.
2
Intake air leak inspection
@Start theengine. 2
: Changecorrection valueby selecting-DWN' YES
I ncrrve
resr a n
in "FUELINJECTION CORBECTION FUELINJECTION OFFSET O%
VALUE'in"ACTIVETEST"mode,
[,4ONJTOB
CAS.RPM(POS) 937rpm
Caution:Carryoutthetestin minimumtime ENGTEI\,4P SEN 59"C
O. SENSOR J.33V
required.Do notoperatewhiledriving. o . S E N S O R( B ) 1.3sV
^6.Checkif enqinerevwillincrease
I ltf L
whenthe INJ PULSE 1.8msec
AAC VALVE 17"1"
Yq/blow-bv hose ts ornched.
Qu UP DWN Qd
NO
Repairanyairleaks
3
Intake valve deposit inspection
Removeif thereareanydeposltpresent.
lgnitiontiming
Checkif injectoris clogged.
FINISH
42 (Phenomenon)- AFTERBURNTNG
DIAGNOSIS
1
Engine temperaturesensor inspection
Inspectenginesensorandenginesensor NG
circuit.
OK Repairor replace
lgnitiontiming
Checkif injectoris clogged.
FINISH
EN - 481
INSPECTION
RB25DECON,lPONENTS
F B 2 5 D EE N G I N E
(RB25DE)
8. coMPoNENTSINSPECTION
CRANKANGLESENSOR
Inspection
Removecrankanglesensorfromtheengine.(leave
crankanglesensorharnessconnector connected).
Placeignitionswitchto ON position. Xs -i
Rotatecrankanglesensorshaftslowlywithhandand a,,fl\
inspectthevoltagebetweenterminal 2.3 andground
I\ ARr i Xq
@-,p
Rotateby
lF NG: Replacecrankanglesensor.
EraseselfdiagnosisresultfromCONSULTafterinspection'
CheckcodeNo. 11is notdisplayed in thescreen.
Caution:
Removeinjectorf useor connectorto avoidinjectorf rom
whileinspection.
operating
AIR FLOWMETER
lnspection
. Removeairflowmeterfromtheengine. ivl
rO lil
. Applybatteryvoltagedirectlybetweenairflowmeter f-l .
terminal5+ andterminal3- andblowairto hotwlre. r 1 i 2 r ? 1I4 l l
Checkfor any changein outputvoltagebetweentermlnal t t
2+ andterminal4-.
/€n
at,
Air is not blown Approx.0.8V
Air is blown Approx.2V
Ee
lF NG: ReplaceairflowmeterOR checkfor anydamage
withthe hotwire.
Eraseselfdiagnosis resultfromCONSULT afterinspection'
CheckcodeNo. 12 is not in
displayed the screen.
ENGINETEMPERATURE SENSOR
Inspection
. Disconnect sensorharness
enginetemperature
(KA
connector.
o
. Measuretheresistancebetweenenginelemperature c
o
sensorharnessterminal1 and2. b
Approx2o"c I npprox2 sKS) (D
(r
Approx8o"c I nPProx0.3x$l
sensor.
lF NG: Replaceenginetemperature
from
result
Eraseself-diagnosis CONSULT afterinspection.
in the screen
CheckcodeNo.31 is notdisplayed
EN - 482
RB25DECOMPONENTS
INSPECTION
IGNITION COIL
Inspection
. Disconnect
ignitioncoilharnessconnector.
. Measurethe resistancebetweenfollowinq
terminals.
Primary value(i - 2) |
coilresisntance 0.6- 0.9
lF NG: Replaceignition
coil
POWERTRANSISTOB
Inspection
. Disconnectpowertransistorharnessconnector.
. Measurethe resistance by inserting
analogtypecircuit
testerinspectionrod - and + to powertransistor
terminals.
+/- coSJ -r* oo f,l
2-3 + / - o o f , J > - / + 0 o r n o@
t 61
t - J + / - 0 o r n o to o Q . - l * co fl
lF NG: Replacepowertransistor.
F U E LP U M P
Inspection Ele-,e
. Disconnect fuelpumpharnessconnector.
. Measurethe resistance
betweenfueloumoterminal1
and 3.
Resistance: Approx.0.4 - 0.7
. Checkfor operationby applyingbatteryvoltagebetween

thefollowing
terminalsdirectly:
Connect terminal 3 to + side, terminal 1 to - side.
Caution:Caremustbe takento connectbatteryto correct
srdes.
lF NG: Replace fuelpump.
THROTTLEVALVE SWITCH
Inspection
. Warmthe engine.
. Disconnect throttlevalveswltchconnectorand measure
the resistancebetweenthrottlevalveswitchterminals.
(ldle contact point)
Acceleratorpedalis not pressed
lF NG: Repairthrottle
valveswitch.
EN - 483
INSPECTION
RB25DECOI''lPONENTS
Adiustment
ldle contact point touch rev (rpm): 750 - 1050
. Adjustif the touchrevis notwithinthe rangeabove
. Disconneclthrottlevalveswitchconnectorand loosenthe fle Z*)
bolt.
Gradually increase theenginerevso idlecontactpolntrs
ON (Resistance betweenterminal2 and 1 is 0 Q ) at
aboveenginespeed. Movethrottlevalveswitchunitto
touchpointandtightenthe bolt. Movethrottlevalve
switchunitto touchpointandtightenthebolt.
lnstallthrottlevalveswitchconnector.
Racetheenginefewlimesandcheckidlerevis within
thestandard value.
THROTTLESENSOR
throttlesensorconnector.
Disconnect
betweenthroltlesensorterminal2
Measurelhe resistance
and3.
lrr p€
Not pressed A p p r o x0 . 4
Pressedto halfway Approx0.4- 5
Completely
Pressed Approx.5
lF NG: Replacethrottlevalveswitch.
AfterinspectioneraseselfdiagnosisresultfromCONSULT
CheckcodeNo.43 willnotdisplayin thescreen'
AAC VALVE
. Inspectthe resistanceof AAC valve.
Resistance:APProx.9- 10
. PlungerandswitchinsPection.
. Springdamageinspection.
*4-==ll
u,\,9
I
AACvalve.
lF NG: Replace
v eLng",
I
FICDSOLENOID Eei, @
. Measurethe resistanceof FICDsolenoid.
Besistance: APProx.2 2 - 2 3
EN - 484
R825DECOMPONENTS
INSPECTION
Plungerandswitchinspection.
Springdamageinspectlon.
tO4-
>d
Plunger '-(L...-.-
lF NG: ReplaceFICDsolenoid. , / \ \ ^
Spring *9
AIR REGULATOR
Static characteristicinspection
. Visuallychecktheshutteropening.
Below-20"C Fullyopen
20"c Approx halfopen
Over60"C Fuilyclosed
Dynamiccharacterlsticinspection
. Applybatteryvoltageto terminalsand inspectfor any
r -1t2j
changewithshutteropening. . l
The shutterwill close graduallyand completely
closed within 7 minutes. (areatemperature ar-
approx. 20"C).
Reference:Heaterresistancevalue: 70 - 80 tJ (20"C)
lF NG: Replaceairregulator
INJECTOB
Inspection
. Disconnectinjectorharnessconnector.
. Measure the resistance
of eachiniector
cvlinder
terminal (
__l
1 and2.
Resistance
betweeninjectorterminal1 and
2 (eachcylindeo 13-14Q
lF NG: Replaceinjector.
ECCS RELAY FUEL PUMP RELAY,RADIATORFAN

MOTORRELAY
Inspection
. Directlyapplybatteryvoltagebetweenterminal 1 and2.
. Inspeclcontinuity
betweenterminal3 and5.
lF NG: Replacerelay.
EN - 485
INSPECTION
RB25DECOMPONENTS
IGNITIONRELAYINHIBITOR RELAY
Inspection
. Directlyapplybatteryvoitagebetweenterminal1 and 2.
. Checkfor continuitybetweenterminal3 and4, 6 and7 Xe ,@
lF NG:ReplacerelaY.
POWERSTEERINGHYDRAULICPRESSURE
INSPECTION
Inspection
. Removepowersteeringhydraulic pressure switch We:-p:-'';
harnessconnector.
. cCheck
h o n k ffor
o r ccontinuity b e t w e e n the
o n l i n u i t v between t h e terminals.
terminals.
lF NG: Replacepowersteeringhydraulicpressureswitch
.' .. | tr -! e
c_
FlA
f=
SPARK PLUG
Inspection & Adiustment E
. Measurethe gap betweenelectricpole. fl
. Reolaceor repairif outof standardrange. lj
F]
Standardgap (mm): 1 . 0- 1 . 1
. ('
FUELPUN,4P
IS THEREA PULSATION
FUEL SYSTEMINSPECTION EVEBY 3 SECONDSWHEN
Simpleinspection T H E F U E LT U B E I S H E L D ?
. Turnthe ignitionswitchto p?.ti,i?l:.,, O B C A NY O UH E A RT H E
9N _,- G) OPERATIONNOISEOF THE
. Select"Fuelpump'in the"Function test mode. \!=/
FUEL PUMPRELAY?
. Inspectthepulsation by holdingthefuelhosewithhand
@
. Holdthefuelfilterand makesurethe hoseis hard W
andpulsation can be feltwhenthefuelpumpis operating-
EN - 486
RB25DECOMPONENTS
INSPECTION
Fuelpressureinspectionusingthe fuel
IACTIVETEST('
pressuremeter
Releasingf uel pressure FUELPUI\,4P
RELAY OFF
. Runtheengine.
"Fuelpumprelay" CAS-RP|\,4
{POS) 950rpm
. Select in"Active
test"mode.
. Press'STOP'to stoptheengine.Cranktheengine over
twoorthreetimes.(lftheenginedoesnotstart,crank3 - 4
timesafterremoving thefuse).
Restan theengine andremove thetuetpumptuse. @

Aftertheenginestops, cranktheengine4 "-5 timesto
consume thefuelinthepipe.(lftheenginedoesnotstart
-
crank4 5 timesafterremoving thefuse).
Caution:
Thebatterymaybecomeweakeasily.useboostercableto
connect toanotherbatteryif necessary.
Fuelpressuremeterinstallation
. Connect thefuelpressure
meterbetween
thefuelfilterand
thefuelline.
. Attach
thefuelpumpfuse.
Fuelpressureinspection
. Starttheengineandcheckifthefuelpressure
isat
standardvalue.
ldling(kg / cm:, Approx.2 55
Pressureregulatorvacuumhoseis
(kg / cm,) Approx.3.0
disconnected
lf theenginedoesnotstart,checkfuelpressure
5
secondsaftertheignitionswitchhasbeenturnedON.
5 secondsafterignitionswitchturnedto ON I Approx 3.0
I FN G :
Fuelpressure
is extremely Pressure
regulator
is notworking.
high Return
systemrsctgged. hosebent
Fuelpressureis extremely Pressureregulatoris notworking.

Fuelpumpdischargedefect
low Fr6l <\,ctam ^l^^â.l
EN - 487
R 8 2 5 D EC O M P O N E N TI S
NSPECTION
Fuelcut systeminspection
. Select"lNJpulse"in "DATAMONITOR" modeusing
CONSULT.Increase the enginerevto 2000rpm after
"lNJpulse"willdecrease
startingtheengine.Checkthat
to 0.6 msecfor a momentwhen the acceleratorpedalis
released.
ITORINg}l'lo FA L
CAS.BPM (REF) 1950rpm
I N JP U L S E 0.6msec
GAS CONTROLSYSTEMINSPECTION
EVAPOBATIVE
Throttlechamber
Checkvalve
f! gas
<- Evaporatlve
'F Purqeair
Activecarbon
Filter
Tray
Freshair
CANISTER
lnspection
. Connectvacuumhandpumpto canisterthrottlenegative
pressureopeningand makesurethevacuumpressurels
maintained.
. Applyapprox.-100mmHg pressureand makesurethe
manifold negative by
openingis continued
pressure E Gl 5 13 0 0 0 0
suckingairf romtheoPening.
FUELTANK VACUUMBELIEFVALVE
Inspection
. Cleanthevalvehousing.
youwillhear
. lf thef ueltankvacuumreliefvalveis normal,
soundfromthevalvewithsmallresistance whenthealrls
suckedin throughthecaP
. ReplacethecapASSYif thevalveis closedor when o . o
Soflno valve . -
resistanceis felt. valve
EN - 488
R825DECOMPONENTS
INSPECTION
BLOWBYGAS REDUCTION
DEVICEINSPECTTON
blowbycontrolvalve
Flarnearrester
Buffleplate
Blowby path
Fresh air
Blowbygas
BLOWBYCONTROLVALVEINSPECTTON
Inspection
. ldletheengineandremovehosefromblowbycontrolvalve.
. Checkif operation
noisecan be heardfromtheair
passagewhenvalveis operatingnormally.
. Checktheblowbycontrolvalveflowpath.
Air is blown Air passes

Air is drawnin No arrpasses
BLOWBYHOSE
Inspection
. Lookforanyleakagefromthehoseandconnectionarea.
. Remove thehoseandcleanusingtheairblow.Replace
hoseifthereareanyclogs.
EN - 489
SIGNALS
ECCSC/UINPUT/OUTPUT
R826DETTENGINE
9. ECCSCONTROLUNITINPUT/ OUTPUTSIGNALS
9.1 CONSULTINSPECTION VALUES
(1) Datamonitor
outputsignalis displayed
itlote:The as thecalculation dataon consoleunitso thecorrect
valuewilldisplayedeveniitheoutputcircuit(harness) disconnected'
is inadvertently
RB26DETTENGINE -olre
rorron
t- ,
loNrroREaGl'EG I .IX*TTAL RETENEIGE. , , .r : - t t , : ' ., .
TTVALUE ,,
l - - - - " - ' :
Tt€re m6l be no abno.mar Crank adqle se.sor slstem
CAS RPM (Detecled angle
chanqe rn sPeed
speed according to srgnals)
Approt O7-l2V(2OOOrpm
Alter wa.nrog uP engr'€ w hrbload 1O- 1 7V) A r now meler s'€1em
kjlins (N range. A/C OFF) Nole 2 arr now meler val!€
AIR FLOW MTR (R) canvaryo-O4V
Engrre temperalure sensor
ENG TEMP SEN After wa.mrng uP ensrr€ Above approx 70'C
(engrne temperaure)
EXT GAS SEN
Changesbet@enO_O3V
arxi06_]v ErhaLrsl gas sensor system
EXT GAS SEN (R)
2 O O O r p mw l h n o ltnake s)€tem arr leak o. arr
EXT GAS SEN

(RICH / LEAN) RICH. LEAN repeats 5 lrmes
or more In 10 seconds
EXT GAS SEN (R)
(R|cts / LEAN)
(]AR SPEED SEN ! ,4rire driMng or with dn€ wl'Eels Should qererally conform to Vehrcle speed sensor sysiem
lu. ng speedmeter drsPlaY
€hrcle speed srgna )
BATTER,'VOLT ECCS corirol unrt Porer system
Thronb fully closed o 5 Throdle seNor adjushern

THROTTLE SEN ON
ThronE semor syslem
knake arr temperatore !s sensor sYsrenr

INT/A TEMP SEN knaktemperature
Aner warm nq uP eng!rE
( aklemperaiure sensor olnPu)
14-2.2 Air flow meter syslem
INJ PULSE
(iryecnon pulse wdth) (N rarEe A/C OFF) Intake slstem a r leaks or ai.
1 4 - 2 2 s@non (erlt|re InPd)
INJ PULSE (R) hpd srgnal syslem (eture)
(injecrion pulse wdth)
2o'
(N ranqe A/C OFF)
Advance grealer lhan 1O' Air now meter slslem
GN TIMING 2ooorpm with m angle compared to ro|e
appro\ r5 - t5'6
(N rar€e A/C OFF)
AAC vaive sYsiein
Approx 30 - 5O7.
Air now meter system
Aiter wa.mrng up engrre 75 - 125'/. can,sler (purse) rcpecrron

(arr rEl rano teedback 20oo.pm wth no load lntake syslem arr leak or ar.
corecron coeffciefi)
ON
Starter SW syslem
START SIGNAL
ON
Engine Throttle lully closed QN
slstem
Thronle se6or
IOLE SW
A/C SW ON ON
Alr co.ditiorer SW system
AIR COND SIG
ON
Nedral SW sFlem
NEUTRAL SW
ON
Po@r sleeflrq SW syslem
PWST SIGNAL
QN
Throttle sensor s!51em
DLE JUDGEMENT t€n wt€n rd e
Ot€r
FL€lPumP system
FUEL PUMP RELAY K]N SW ON ON
A/(.] QN ON
Arr corditrorEr relay sFrem
AC-ON
ON
WG CONT 5A/
VOLTAGE orer @hage p.o\r'e measu.em

POWER
PULS E li o ar pulse ProE measuresuremeft
ECCSC/UINPUT/OUTPUT
SIGNALS
PE:6]: - E N GN E
(2) Activetest
' ,+rniu,,,
Perform
followrng
inspections
to check1
problem
is sol\€d.
Flminele
ENGINE Problem Setengrne ternperature
highor low
occurence Engineternperature
sensofsystem
TEI\,'IPERATURE condrtion aar iron Do notsetextrerne values
as lnrscancausespai*p ug burntng Inlectorsystem
Air flowmeteaexhaust
gassensorsystem
Not ellminate.l
Other rtem Inspectton
Perfomrfollowtng
tnspections
to checkrf
problemrs soived.
F limrn2ie
Set the airfuel ratto|ch or lean
Problem Ca|irnn DO |Ot SelextremevaluesaS Exhausl
occurence gassensorsystem
FUELINJECTION
cono1l|on this may dan'rageengtne of catal),tic Ai. flowmetererq ne temoeratJre
se-so.
ocn!enet slstem
njeclorsystem
Nol elimin2tr.l
Otherrteminspecton
PerlonnfollowngInspecttons
to check11
problern
rs soi\€d
DelayignitionUmrng
F limrnrlp
Problem Cer r.n DO not SetextremevaluesaS
occurence
GNNON TII\,1ING lgnrtrontirnrngadjustment
conotlon thismay damageengtneor catalytc
con\€rtea
Detonation sensorsystem
N.i elimlnaie.l
Othef item nspeclion
Increasecontroldulyratio The engtne
AAC VALVE speedshouldtncrease lf the conditrondescnbedon leftcan not be
Enginerunning
OPENING Decreasecontroldutyreatio The lenfied ccheck AAC valve system
enginespeed shoulddecrease
Set the AAC vale open to stop the
specrfied injectoroperatronand the
POWER rnjectorspeed can be displayedat this F Lm i n z t F
Enginerunning
BTALANCE time Inlector systefir
aa iion Do not performthtsoperatton
whrledriMng
TurnignitionswrtchON OFF and ON
so pumpoperattonmakesa solnd
FUEL PUI'P lgnitionswitchON The fuel pressurewill nse lf the conditrondescflbedon leftcan not oe
RELAY cartion Do not performthisoperatron\enfied. checkrelaysystemoffuel pomp
pump system
exceptundercondit/onsdescnbedon and fuel
1eft.
SELF-LEARNING
The air-fuelratio feedback corection coeffictentleamtnqfactor rs cleared
CONT
EN - 491
ECCSC U INPUTOUTPUTSIGNALS
RB26DETE
TNGINE
s - 2 o s c l L L o s c o P E& C l R C U lT VN
INSPECTIO
r ESTER A L U E ( R B 2 6 D E TETN G I N E )
At idle I rpm
At APProx.2,500
t"',il:"' name
I sisnar
Circuit Memo
Standard Memo Standa rd
Approx.0.4V
Sparkplug
---| t-- -r
1
2
3 Powertransistor
11 controlsignal ---.t1
12
13
Approx.5V
AAC valvecontrol
4
srgnal
A p p r o x1. V Approx.2.4V
Enginespeed
7 signalfor
tachometer 0
-- I
Air conditionOFF: A i r c o n d i t i oO
nFF:
Batteryvoltage Batteryvoltage
9 relay
Air conditioner ON:
Air conditioner Air conditioner ON:
Approx.1V Approx.1V
Approx.1V
ECCS relay switchOFF.
(lgnition Approx.0V
Batteryvoltage)
Fuelpumprelay OV OV
18
EN - .192
ECCSC/UINPUT/OUTPUT
SIGNALS
R8 2 6 D E T TE N G I N E
R B 2 6 O E TETN G I N E
Jnx TX cHl( IGN

CLK
TeIminal At idle At Approx.2,500rpm

S i g n a ln a m e Circuit
No. Standard Memo Standard Memo
PowersteeringONI PowersteeringON:
Powersteerjng OV OV
19
swtch signal PowersteeringOFF PowersteerjngOFF
5V 5V
21 Receive(conlrol
(RX) unitdatareception) 10v 10v
Transmit(data
22
(rx) transmissionfrom OV OV
controlunjt)
23 Detonation
sensor
24 srgnal Approx.0 3V Approx.0.3V
\ hstegate valve
25 controlsolenoid Batteryvoltage Approx.0V
controlstgnai
Air flowmeter(rear) Approx.1.5

27 lntakeair quantjty Approx.1V
srgnal
EN - 493
ECCSC'U INPUTOUTPUTSIGNALS
R826DETTENGINE
RR'ANFTT ENGINE
r l
At idle At Approx.2,500rpm
Terminal Circuit
S i g n a ln a m e Standard l\ilemo Standard Memo
No.
Enginetemperature EnginetemPerature
Bo"C:Approx.1V 80"C.APProx.1V
Enginetemperature
28 Enginetemperature Enginetemperature
sensorslgnal
2 0 " C :A p p r o x . 3 V 2 0 " C :A p p r o x . 3 V
Deffectsbetween
Exhaustgas sensor Approx.0 - 1V
29 approx.0 - 1V
signal(front)
Clock
31 OV OV
(syrchronization
(cLK) signal)
Lampnot lit: Lampnotlit:

lvlotor& check Power voltage Power\onage
lamp(redlamp) Lampis lit: 0V Lampis lit: 0V
Air iow meter '1V

Approx. Approx.1.5V
JC (Front)(lntakeair
quantitysignal)
lntakeatr C o l d A p p r o x1 . 5 V Cold: Approx.1 5V

36 temperaturesensor \ hrm: Approx.0.8V \Abrm:Approx.0.8V
signal
EN-494
ECCSC/UINPUT/OUTPUT
SIGNALS
R826DETT
ENGINE
R B 2 6 D E T TE N G I N E
TerminaI At idle At Approx.2.500rpm

No. Standa rd Memo Standard Memo
0.5-4
Throttlesensol (VoltageIncreasesif
38 Approx.0.5V
srgnaI acceleratorpedalis
presseo)
03-0.7v
41 Crankanglesensor
51 1 2 0 "s r g n a l
2-3V 2-3V
(vr -
6r-
, dtd
42
52
Crankanglesensor
1 os i g n a l affi
OV
lgnitron
switch (lgnrtion
switch
43 "STARI': Battery OV
(STARTsignal)
voltage)
NeLJtral
switch N of P range: 0V N or P range: 0V
44 OtherthanN or P Otherthan N or P
srgnal
range 4 - 5V range: 4 - 5V
A i r c o n d rot n e rO F F Air conditioner

OFF:
Air conditioner Batteryvo[age Batteryvoltage
46
swjtchsignal Air condrtioner ON; Air conditioner
ON:
OV OV
EN - 495
SIGNALS
ECCSC/UINPUT/OUTPUT
ENGINE
B826DETT
RFI?6NFTT ENGINE
, r i : : : l l - ^ ^ -
At idle I lt APProx.2'500rPm
Terminal S i g n a ln a m e C ircuit
Standard Memo Standard Memo
No.
Throttlesensor 5V 5V
48 (PowersuPPlY)
ControlunitPower Batteryvoltage Batteryt0ltage

49 suPPlY
D range(or 1st)with D range(or 1st)wlth

rear wheelsjacked rearwheeisiacked
u p : 0 . 5- 1 . 5 V u p : 0 . 5- 1 . 5 V
The valueactually The valueactually
VehiclesPeed deiects between0v deiects between0V
53 sensorslgnal and 5V. However,it and 5V. However,lt
appearsto deflect appearsto defect
around1V,accordlng around1V,according
to vehiclesPeed. to vehiclespeed
Throttlevalveswtch 10V
Approx. A p p r o x1 0 V
54 (idle contactPoint)
N or P range: 0V N or P range: 0V
E*raustgassensor OtherthanN or P Otherthan N or P
55
signal(Rear) range: 4 - 5V range:4 - 5V
Approx.05-4V
(Voltageincreases
Throttlesensor Approx 0 5V
56 signal as accelerator
Pedal
outprJt
is pressed).
EN - 496
ECCSC/UINPUT/OUTPUT
SIGNALS
R826DETTENGINE
R B 2 6 O E T TE N G I N E
Terminal At idle At Approx. 2,500rpm

S i g n a ln a m e C ircuit
Throttlevalveswtch
57 Batteryvollage Batteryvoltage
(Powersupply)
Approx.battery Approx.battery
101 voltage vorcge
103
105 Injectorcontrol
110 sjgnal
112
114
Fuelpumpterminal
104 voitagecontrol ldling(afferwarming Duringmiddleload.
s r g n a(lF P C M1 ) engrne):0V 4V
106
Fuelpumpterminal
voltagecordrol
t Duringmiddleload:
srgnal(FPCN4 2)
I OV
EN - 497
SIGNALS
ECCSC,UINPUTiOUTPUT
R826DETTENGINE
CAUTIONS
9-3 ECCSCONTROLUNITOPERATION
(1) Controlunit equiPment

foryourvehicle
. Neverinstalla controlunitthatis notspecified
. Do notapplyexcessiveforceto the installationbracket
(2\ Connector removal and installation

. Wn"n removingandinstalling connectors, do notbendor applyunnecessary forceand
observefollowingPoints:
1. Connector removal
switchoFF andECCSrelayOFFbeforeremoving
. Turnignition connectors.
. Holdconnector firmlyto disconnect withoutapplyingforceto harness'
. Do notusea screworiver or similartoollo loosentheconnectorlock'
2. Connectorinstallation
. Turnignition
switchOFF.
. Makesurepinsarenotbentor controlunitconnectorand thenconnectsecurely'
. Tightenboltssecurelyuntilinjectorsurfacereachesorangecolourindicatorof
connector andsurfaceis even.
(3) Control unit Power

. Nevermakea reverseconnectionto the battery'
. Usebatteryvoltagein 1O- 16Vrange.
(4) ldle speed adiustment knob

. Do notturnPastlockPosition.
lowerthan0"'
knobwhenambienttemperature
. Do notturnadlustment
(5) Water and oil

.Caremustbetakennottoa|lowraindropsorwatertoWetthecontro|unit.
. care mustbe takenthatcondensation doesnotformdueto suddenincreasein
drycontrolunitadequately
lf thereis anymoisture, in the
beforeinstalling
temperature.
vehicie.
. Makesureno oiladheresto connectors.
. Do notcleanthecontrolunitusingvolatilesolventcleaners'
(6) Dropping and imPact

. Do notdropthecontrolunitor sublectit to stronglmpacl'
. Do notuseupperandlowercoversfor thecontrolunitwhicharedented'
(7) Control unit screws and cover

. Do not removethe upperand lowercoversfromthe controlunit'
. Do notturnthescrewsin thecontrolunitmainbody.
EN - 498
ECCSC/UINPUT/OUTPUT
SIGNALS
RB2OE
/ DE/ DETENGINE
9. ECCSCONTROLUNITINPUT/ OUTPUTSTGNALS
9-1 CONSULTINSPECTION VALUES
(1) Datamonitor
Note:Theoutputsignalis displayedas thecalcujationdataon consoleunitso thecorrect
valuewilldisplayed
evenif theoutputcircuit(harness)is inadvertentlv
disconnected.
RBaOEIDE / DET ENGINE
CAS RPM (Detected angte Tachometer set There must be no abnormal

speed accordtr€ to signals) Engine runnrng Crank ange sensor slstell
change rn speed
AIR FLOWMTR Aiter warmrngup engtne
vottage)
{oLrtput ldling(N range.A/C OFFI Approx08-15V A r flow rneler syslera
E N G T E I \ 4 PS E N E n g r n et e m p e f a t u r es e n s o r
( e r E r n et e m p e r a t u r e ) Affer warmrng up er€ ne Above appro, 70 C
EXT GAS SEN C h a n g e s b e t w e e nO - 0 3 V a n d

( o u l p u tv o l i a g e ) E*lairsl gas sensor slsterf
Afterwarrning 2o00rpmwth no 0 6 - 1 V I n t a k es y s l e m a r f i e a k o r a r r
EXT GAS SEN up engrne R I C H .L E A N r e p e a t s5 t r m e s o r
(RtcH / LEANI more In 10 seconds lnleclor slslem
CAR SPEED SEN While dnvrg or wlh dnve wheets Should generally conform to
(\€h cle speed srgnal) turnrng V e h r ce s p e e d s e n s o r s y s l e m
s p e e d m e t e rd t s p l a y
lgnrtronswrtchON Battery
BATTERY VOLT 11- 14V ECCS conlrolunrlpower
Engrnestopped
lgfllion swtch
Throltie tully closed o 5
T H R O T T L ES E N ON Throtlle sensor adlustment
(odpln voflage) EngIne Throitle sensor sysiem
stopped Throltle fully open 4 A
INJ PULSE b i r n g ( N r a n g e .A / C
( r n j e c t i o np u i s e w d t h ) oFF)
2 - 3 rnsec Air iow meter s)slem
Aflerwarmrng I n t a k es y s t e m a r r l e a k s o r a t r
N O T F 1 / 1 6 d t s p l a yf o r up engrne sucron (en!re Input)
200o|pmwth no
RB2OE 2-3msec n p L ns r g n a l s y s t e m { e n t r r e )
l d l i n g( N f a n q e A / C
Mn15.. A.fi24.
IGNTIMING
Anerwarminq oFF)
up enqrne Air flow meter system
200orprnwjth no A d v a n c e g r e a t e rt h a n 1 0 . a n g l e
comparedlo rdlepositiOn
hling (N .ange A/C
Apptax 20 - 4AY.
AAC VALVE Aner warming oFF) IAS adluslrnent
up eng ne 2000rpm wtlh no AAC val\€ system
Approx30 - 50%
Arr flow meter syslem

A n e r w a r m r n qu p e n q i n e ]njeclor system
( a r r - t u erl a l i o f e e d b a c k 7s - 125% C a n r s t e r( p u r g e ) r n s p e c t i o n
correclron coeffic|ent) 200orpm wrth no load
Intake systern a r leak or a r
"START'
ON
START SIGNAL l g n r l i o ns w l c h StarlerSW system
.OFF'
ON OFF
E ngIne Throttle tully ciosed ON
IDLE SW
Throttle sensor system
A/C SW ON ON
A]R COND S G A r r c o n d i t r o n e rS W s y s t e m
A/C SW OFF
N or P rarEe ON
NEUTRALSW Nedral SW system
NotNorP OFF
Sieenng ON
PWST SIGNAL Polver steenng SW system
Sleeflng neLrlral OFF
Slop OFF
F U E LP U M P R E L A / IGNSW ON Fr.reipump system
ON
A/C ON ON
dling
A I R C O N D I I ' I O N E RR E L A Y A/C OFF OFF
Air condrtorEr .elaysystem
A/C ON OFF
ECCSC U INPUTOUTPUTSIGNALS
F B 2 O E/ D E / D E TE N G I N E
(2\ Activetest
ACTIVETESr_
qCT|vE TE9T DESCRIPTPI{
to checkif
Perfcrn fo lowng lnspections
probEri s so \ed
FlmLntte
SetengLne temperatufe nlgnor ow Engrne sensorsystem
ternperature
ENGINE occurence
Problem
Carjtlo[ Do notsel extremevaluesas Lnlector
system
TEIMPERATURE condrtron thrscancausespark
Plugblrnlng gassensorsyslem
Air iow meterexhaust
Nol elmrnaie.l'
Orhe- rtem ,_soector
Pe'{orn'o'lowng,nspectlorslo checkl'
problem rs sol\ed.
Elimrnate
ratiorlchor lean
Settheair-fuel Exhaust gassensorsystem
ProblemoccurenceCautoo. Do notset extremevaluesas ALrflowmeter, sensor
englnetemperature
FUELINJECTION conorllon thrsmaydamageenglneor cataiytc sysrern
ocn\ertet Injeclorsyslem
N.t elmrnaied
Other rtem Lnspection
to checklt
Performfollowinginspections
problems sol\ed.
tlmrng
DelayLgnrtion Flimln2lp
Problem Caltion: Do notset extremevaluesas
occurcnce lgnitiontimrngadlushenl
GNITIONTIMING conol!on thrsmaydamageengineor catalytic Detonationsensorsyslem
con\€nel Not ehminait.l
Other item Inspecton
Increasecontro duty ratio The englne
speed shouldincrease lf the conditiondescrlbedon leftcan not be
AAC VALVE Enginerunnrng Decrease controlduty reatlo. The venfied ccheck AAC val\€ system
OPENING
enginespeed shoulddecrease
TurnignrtronswitchON. OFF and ON
so pump operatlonmakes a sound. lf the conditiondescribed on left can not be
FUEL PUT,4P lgnrtionswrtchON The fuel pressurew11nse \€rified. check relay system of fLlelpirmp
RELAY Enginestop Cado-o- Do not perform this operatron and fuel pump system
exceptunderconditionsdescnbedon
left
SELF-LEARNING The arr-fuelratiofeedbackcorrectloncoefficlentleamlngfactorrs cleared

CONT
EN-500
ECCSC/UINPUT/OUTPUT
SIGNALS
B B 2 O EE N G I N E
9-2 O S C I L L O S C O P&EC I R C U I T T E S T E IRN S P E C T I OV

NA L U E ( R B 2 O EE N G I N E }
TerminaI At idle At Approx. 2,500rpm

Signal name Circuit
Air flowmeter
3 intakearrquantity Appfox.1V Approx.1.5V
srgnaI
Enginelemperature Enginetemperature
Enginetemperature Bo"C: Approx.1V 8 0 " C . A p p r o x1 V
5
sensorsrgnal Engrnetemperature Enginetemperature
2 0 " C :A p p r o x . 3 V 2 0 " C .A p p r o x . 3 V
Exhaustgas sensor Deflectsbetween

6 Approx.0 - 1V
srgnaI 0 - Approx '1V
0 . 5- 1 V
Throttlesensor (Batteryvoltagewill
7 Approx 0 5V rncerasewhen
srgnal(lnput)
acceleration pedaiis
pressed)
0.3- 0.7v 0 . 3- 0 . 7 v
Crankanglesensor
I
1 2 0 "s i g n a l
2-3V 2-3V
(v)
6
Crankanglesensor 2
10 o
1 "s r g n a l
E N- s 0 1
EUUJ \, \] SIGNALS
INPUT/OUTPUT
RB20EENGINE
At idle I At APProx'2,500rpm
Terminal Circuit
S i g n a ln a m e Memo Standard Memo
No. Standard
Lampnot lit; Lampnot lit:

& check Power voltage Powervoltage
'13 l\,4onitor
LamPis lit: Lampis lit:
lamp(redlamp)
Approx.0V Approx.0V
Intakeair quantlty
'15 Approx.lV A p p r o x1 . 5 V
outputsignal
(ToA/T C/U)
sensor
Detonation Approx.4V Approx.4V
signaI
0 . 5- 1 V
(Batteryvottagewill
Throttleopening Approx.0.5V incerasewhen
17
otjtputsignal acceleration Pedalls
presseo)
D range(or 1st)with D range(or 1st)wth

rear wheelsjacked rearwheelsjacked
u p : 0 . 5- 1 . 5 V u p r 0 . 5- 1 . 5 V
Vehiclespeed deflectsbetween0 defrectsbetween0
21 sensorsignal and 5V. However,it and 5V. However,lt
appearsto deflect appearsto defect
around1V according around1V accordlng
to vehiclespeed. to vehiclesPeed.
Throttlevalveswitch 0V when accelerator

22 A p p r o xl o v is pressed
(idle contactPornt)
EN 502
ECCSC/UINPUT/OUTPUT
SIGNALS
TerminaI At idle At Approx.2,500rpm

OV
lgnitionswitch (lgnition
switchat
23 OV
(STARTsignal) START Power
vonage)
Neutralswitch N or P range: 0V N or P range: 0V

24 OtherthanN or P Otherthan N or P
srgnai
range:Approx.6V range:Approx 6V
lgnrtion
swtch
25 Powervoltage Powervoltage
(ONsignal)
Throttlesensor
26 srgnaI 5V 5V
(Powersupply)
Controlunitpower
27 Power voltage Powervoltage
supply
Air conditioner
OFF: Air conditioner
OFF:
Air conditioner Powervoltage Powervoltage
29
sw'tchsignal Air conditioner
ON: Air conditioner
ON:
Approx.0V Approx.0V
EN - 503
SIGNALS
ECCSC/UINPUT/OUTPUT
RB20E ENGINE
At idle I At aPProx.2'500 rPm

Terminal S i g n a ln a m e Circuit
i-;l:-*'r
I il- ecru
l ' -
Throttlevalveswitch \ _.-!!r'-, Powervoitage Power voltage
32 (PowersuPPlY) |.-''
0 . 2- 0 . 3 v
Powertranststor
controlsignal
PowersteeringONI PowersteeringON:
OV OV
Powersteering
38 PowrsteenngOFFI PowrsteeringOFF:
switchsignal
Approx.5V Approx.5V
Disq,bul9r Power voltage A p p r o x1. 0 V

n f -- '
-. . -
+-6f -
reroir . !_cru
Tachometer slgnal i-=-Po€
39 (lgnition
coil Primary .l R6isror tranestor
signaldetection
Approx.1V
switchOFF.
(lgnition OV
40 E C C Sr e l a y
Powervoltage)
1V
Approx. Approx.3V
Tachometerengine
43 rev srgnal
EN - 504
ECCSC/UINPUT/OUTPUT
SIGNALS
Terminal At idle At Approx.2,500rpm

No. Standard Memo Standa rd Memo
EngineA/T total
controlinpLrt
signal Approx.
10V A p p r o x1 0 V
(Dr1)
- A/T control unit
EngineA/l total : , =:t-

45 controlinputsignal
(D12)
:nsffilsfri
Air conditioner
OFF Air conditioner
OFF
46 A,r conditioner
relay Powefvoltage Pov.ier
!oftage
Air conditioner
ON ArrcondrtronerON
OV OV
EngineA/T total
47 contro, or.IpLlt OV OV
signal(DT3)
Almostpowervoltage Almostpower voltage

101
103
105 lnjectorcontrol
20
110 srgnal 0
112
104 Fuelpumprelay OV OV
EN - 505
SIGNALS
ECCSC U INPUTJOUTPUT
R 8 2 O EE N G I N E
Approx4 - 5V
AAC valvecontrol
srgnal
EN - 506
ECCSC/UINPUT/OUTPUT
SIGNALS
9-2 O S C I L L O S C O P&E C I R C U I TT E S T E RI N S P E C T I OV
NA L U E (RB2ODE
/ D E TE N G I N E )
Terminal At idle At Approx.2.500rpm

Signal name Circuit
t g n i i i o nS W
rEf-s @f'
18 Fuelpumprelay Qr,"r p,'p- OV OV
) + ,,---!)- \
PowersteeflngON:
PowersteeringON:
Powersteeflng OV
OV
switchstgnal PowersteeringOFF.
PowersteeringOFF
5V
23 Detonation
sensor
24 signaI Approx 4V Approx.4V
Air flow meter

27 (lntakeair quantity Approx.1V Approx.1.5V
signal)
Enginetemperature Enginetemperature
Enginelemperature 80"C: Approx.1V 80"C: Approx.1V
28
sensorsrgnal Enginetemperature Enginetemperature
2 0 " C :A p p r o x . 3 V 2 0 " C :A p p r o x . 3 V
Exhaustgas sensor deiect between

29 Approx.1V
signaI 0 - approx.1V
Et\ - 3U/
SIGNALS
ECCSCiU INPUT/OUTPUT
R B 2 O D /ED E T E N G I N E
RB2ODE/ DET ENGINE
, I l : : :
Ai idle I At APProx.2'500rpm
t"ffi:"'l name
sisnar Circuit Memo
Standard Memo Standard
Lampnot lit: Lamp not lit:

& check Powervolatge Powervolatge
lvlonitor
32 Lamplit: Lamplit:
lamp(redlamP)
OV OV
Engine(AfD total '10V

Approx. 10V
Approx.
34 controlinpLrt
signal
{Dr1)
Engine(AfD total
Approx.0V Approx.0V
35 controloutpLrtsignal
(Dr3)
Engine(A,/T)total
Approx.10V 10V
Approx.
36 controloutputslgnal
(D12)
0.5 - 4V (Voltage
Throttlesensor increasesif
38 Approx.0.5V acceleratorpedalis
srgnal
presseo)
Intakeair q uanttty A p p r o x1 V Approx.1.5V

40
oulputslgnal
E N- 5 0 8
ECCSC/UINPUT/OUTPUT
SIGNALS
R B 2 O D E/ D E T E N G I N E

No.
0 . 3- 0 . 7
6
Crankanglesensor
41 2,,
1 2 0 "s i g n a l 0il
2-3V 2-3V
Crankanglesensor
42 'l'signai
-_ 0.5trr'-
OV OV
lgnation
swtch (lgnitionswrtchin (lgnrtion
switchn
43 "STARI'':
(STARTsignal) Power "STARI-' Power
\ cltage) voltage)
Neutralswtch N or P range:0V N or P range: 0V

signaI OtherthanN or P OtherthanN or P
range:4 - 5V range:4 - 5V
A r rc o n o [ t o n eUr F F Air conditioner

OFF:
46 Arr conditioner Powervoltage Powervoltage
switchsignal Air conditioner ON: Air condilioner
ONi
OV OV
48 Throttlesensor
(Powersupply) 5V
trI\ - 5U9
SIGNALS
ECCSC/U INPUT/OUTPUT
| :a:
At idle I lt lPProx. 2,500rpm
*il:"'l name
sisnar C ircuit Memo
Standard Memo Standard
ControlunitPower Powervollage Power voltage

49
supply
D range(or 1st)wth D range(or 1st)with

rearwheelsjacked fearwheelsJacked
'1.5V up: 0.5 - 1.5V
u p : 0 . 5-
Vehiclespeed deflectsbetween0V deffectsbetween0V
53
sensorsignal and 5V. However,lt and 5V. Howeve(lt
appearsto deflect appearsto deiect
around1V,according around1v, accordlng
to vehiclesPeed. to vehiclespeed
0V when accelerator
Throttlevalveswitch A p p r o x 1. 0 V
54 pedalis pressed
(ldle contactPoint)
Approx.0.5 ' 4V
Throttleopening (Voltagewillincrease
56 A p p r o x . 05 V when acce|eralor
outputsignal
pedalis pressed)
Throttlevalveswitch Powervoltage Power voltage

57 (PowersuPPlY)
Alrnoslpowervoltage Almost Powervolage

101
103
105 Injectorcontrol
110 srgnal
112
E N- 5 1 0
ECCSC/UINPUT/OUTPUT
SIGNALS
Terminal At idle At Approx.2,500rpm

Signal name Circuit
l]
r' ;".r p, p-
-- conror I
Fuelpumpterminal L mod0ralor I C o l d :0 V
I ,:\ - C o l d :0 V
104 voltagecontrol V\hrm: Power \ hrm; Power
signal(FPClvl) voltage voltage
I ECCSconlror unrr i
E N- 5 1 1
SIGNALS
ECCSC U INPUT'OUTPUT
RB2OE
CAUTIONS
9-3 ECCSCONTROLUNITOPERATION
(1) Controlunit equiPment

. Neverinstalla controlunitthatis notspecifiedforyourvehrcle'
. Do notapplyexcesstve force to the bracket
installation
(2) Connector removal and installation

. Wh"n removing andinstalling connectors, do notbendor applyunnecessary forceand
observefollowingPoints:
1. Connector removal
. TurnignitionswitchoFF andECCSrelayOFFbeforeremoving connectors.
. Holdconnector f irmlyto disconnect withoutapplyingforceto harness'
. Do notusea screwdriver or similartoolto loosentheconnectorlock'
2. Connectorinstallation
. TurnignitionswitchOFF.
.Makesurep|nsarenotbentorcontro|unitconnectorandthenconnectSecUre|y.
. Tightenboltssecurelyuntilinjectorsurlacereachesorangecolourindicatorof
connector andsurfaceis even.
(3) Control unit Power

. Nevermakea reverseconnectionto the battery.
. Usebatteryvoltagein .10- 16Vrange.
(4) ldle speed adiustment knob

. Do notturnpastlockPosition.
lowerthanOoC'
knobwhenambienttemperature
. Do notturnadjustment
(5) Waterand oil

. care mustbe takennotto allowraindropsor waterto wetthecontrolunit.
. care mustbe takenthatcondensation doesnotformdueto suddenincreasein
temperature. drycontrolunitadequately
lf thereis any moisture, in the
beforeinstalling
vehicle.
. Makesureno oil adheresto connectors.
. Do notcleanthecontrolunitusingvolatilesolventcleaners.
(6) Dropping and imPact

. Do notdropthecontrolunitor subjectit to strongimpact'
. Do notuseupperandlowercoversforthecontrolunitwhicharedented'
(7') Control unit screws and cover

. Do notremovetheupperandlowercoversf romthecontrolunit'
. Do notturnthescrewsin thecontrolunitmainbody.
E N- 5 1 2
ECCSC/UINPUT/OUTPUT
SIGNALS
C A ' 1 8Ei N G I N E
9. ECCS CONTROLUNIT INPUT/ OUTPUTSIGNALS

(1) Datamonitor
Note:Theoutputsignalis displayedas thecalculation
dataon consoleunitso thecorrecr
valuewilldisplayedevenif theoutputcircuit(harness)
is inadvertentlv
disconnected.
CAl8i ENGINE
' i
,li: , .'..,liti ..1:.1 ,.:-i
' , j..:t'.:..:i PRCiSL:ES t
cotonr !{t: . -,t t
CAS RPM (Detected angle Tachometer set There must be no abnorrnal
s p e e d a c c o r d r n gt o s r g n a l s ) Engine runnrng Crank angle sensor slstem
c n a n g eI n s p e e o
ENGTEMP SEN Engrne temperature sensor
Afrer warm,ng up engrne Abo\r'e approx 70"C
lergrne remperature)
EXT GAS SEN C h a n g e s b e M e e n 0 - 0 3 V a n d Exhaust gas sensor system
(outpLl voitage) 06 - 1V l r i a k e s y s t e ma r r e a k o r a r r
2000lpm wth no load
EXT GAS SEN up engrne R I C H .L E A N r e p e a l s 5 t m e s o r
( R I C H/ L E A N ) m o r e 1 n1 0 s e c o r d s
CAR SPEED SEN While dnvrng of wth drive whee s Should generally corform to
( v e h i c l es p e e d s r g n a l ) Vehrcle speed sensor s)€1err
tumrng s p e e d m e t e rd i s p a y
lgnrtronswitch ON Battery
BATTERY VOLI 11- 14V E C C S c o n t r o lu n r tp o \ , € r
E n g r n es l o p p e d
T H R O T T L ES E N Throtlle tully closed 1 0

lgnrlion swtch
ON 5 0 Throltle sensor adtustmenl
Engrne Thron|e tully closed Thfonle sensor system
IHROTTLE SEN (2) 06
(oLrtputvoitage)
4 5
] N T / AT E M P S E N
(rnlaktemperalure sensor I n l a k ea r r t e m p e r a l u r er s lntaktemperature sensor
Aner wannrng up engrne
ldling (N range A/C Arr now meter system

INJ PULSE I n l a k es y s l e m a r r l e a k s o r a r r
( r n j e c i o np u i s e w d t h ) sucton lennre nput)
2000rpmwith no load 1 '2 rnsec Input signal syslern (ent re)
ldlng (N range A/C
Mtf 1s. Atf20"
After warming
IGN TIMING Air flow meter system
Advance grealer fhan 10" angle
2OOOrpm wlh no oad
comparedto idle posrlron
Air llow metef system
Aner warmrng up engrrE
(arr-tuel fato feedback 75 - 125vo C a f l s t e r ( p u r g e )i n s p e c t r o n
corre.lon coeffcrent) 2 O O 0 r p mw l h n o l o a d
r{ake syslemarr leak or air
STAR']-' ON
START SIGNAL Starter SW system
ON
Engrne Throttle tully closed ON
IDLE SW
Throttle sensor syslem
A/C SW ON ON
AIR COND SIG A r r c o n d r l i o n e rS W s y s t e m
A/C SW OFF
ON
N E U T R A LS W Neutral SW system
Steenng ON
PWST SIGNAL Povt€r steenng SW slstem
Head amp heater

fan rear defogger ON
WG CONT SA/
SW ON
A/C ON ON
FICD SA/ F I C D i n p L ns y s l e m
ON AIC OFF
Eng temp cord ON
PTC healer InpLnsystem
Eng temp Hoi
Slop
FUEL PUMP RELAY IGN swtch ON Fuel pump syslem
ON
A/C ON
A I R C O N D I T I O N E RR E L A Y ldle A i r c o n d i l r o n e rs y s t e m
A/C OFF OFF
SIGNALS
ECCSC'U INPUT/OUTPUT
(2) Aciive test

r:1]U:]:.r,:r'
!*'.r.
ACTI/ETEST
ACTIVETEETDESCRIPTIO{
r,:sl,
Perfor.nfo lowrng nspectionsto check lf
problemts so \€o.
F mLn:JP
Setenginetemperature hlghor low Engnelemperatlre sensorsystem
ENGINE Problernoccurence
Cal]tion.Do notset extremevalues Inlector
system
TEIVIPERATURE condrt0n
as thiscancausesparkpLug burnlng
Arrflowmeler.exhaustgas sensorsysrem
Nol clm nated
Ot_er tem nsoeclion
Pedorm follow!nginspectionsto check if
pfoblemis sol\€d
Flimrn2te
Setthearr-fuelratronchor lean. Exhaustgas sensorsrsrem
occurenc€Calllio-rtDo notsetextremevaluesas Aif flowmeter englnetemperature
Problem sensol
FUELINJECTION condttlon or catal)'tlc
thisrnaydamageengLne system
ocn\€rter. lnlectorsystem
Not elirninaied
Other rtem Inspectlon
Performfollowlnginspectionsto check if
problemrs solt€d.
ttmrng
Delayrgnrtlon Flimrn2tt
occurenceCArdion Do not set extremevaluesas lgnitiontrmingadjustment
Problem
IGNITIONTII,IING condrtron thrsmay damageenglneor cataYlc Detonationsensor system
convefler Nol elimin2led
Other item inspectlon
TurnignitionswitchON and OFF The
Affer engrnewarm uP idle revwill change lf the condihondescribedon lell can not be
IDLE hling (N range,A/C Carxio-o.Do not pedom this operatron \€riied. checktdlecorrectlonsolenol0
CORRECTIONSA/ oFF) exceptundefcondltlondescrlbedon slstem
left
Turnrgniton swtch ON and OFF The
AfterengrnewarrnuP rdlerevwll increaseal approx200rprn lf the condrlroldescrrbedon leftcan not be
FCD SA/ ldling(N rangeA/C Ca!tjo-c|:Do not performthis operaton \€rified.checkFCD solenoldsystem
oFF) exceptunderconditiondescnbedon
lefr.
switchON OFFandON
Turnignrtron
makesa sound
so plmp operation describedon leftcannotbe
f thecondition
FUELPUMP lgnitionswitchON Thefuelpressurewillrise \€nied, checkfelaysystemof fuelpump
RELAY Do notperformthlsoperatlonandfuelPurnp
Ca!!-oxL- system
except!nderconditlonsdescnbedon
left
SELF,LEARNING coerfclentlealnlngfactorrs ceared
ralo feedbao(correctlo'1
fhe arr-fuel
CONT
EN- 514
ECCSC/UINPUT/OUTPUT
SIGNALS
9 - 2 O S C T L L O S C O p&EC t R C U t TT E S T E Rt N S P E C T I O V
NA L U E( C A l S iE N G T N E )

No, Standa rd Memo Standa rd Memo
Appfox.1V - 5V
Throttle
sensor (Voltagewillincrease
3 Approx.
1V
signal1 whenaccelerator
pedalis pressed)
Enginetemperature 80"C: 1V 80"C: 1V
5
sensorsrgnal Enginetemperature Enginetemperature
20"c 3v 20"C: 3V
Deflectbetween Deflectbelween
approx.0 - lV a p p r o x0 - 1 V
Exhaustgas sensor !"1;l-.-.,:- l

6
srgnal
Approx.06V-4.5V
Throttlesensor (Voltageincrease
7 Approx 0 6V
signal2 whenaccelerator
pedalis pressed)
Approx.0.3 - 0.7V 0.3- 0.7V

Approx.
I Crankanglesensof
'19 '180"signal
Approx.2 - 3V 2 - 3V
Approx.
(v)
6 6
10 Crankanglesensor 2
2
20 1 os r g n a l 0
E N- 5 1 s
SIGNALS
ECCSC/U INPUT/OUTPUT
' | ::::
At idle I At APProx.2,500rpm
t"',il:"'l name
sisnar Circuit
LamPnot lit: Lampnot ht:

l,4onitor& check Powervoltage Powervoltage
13
lamp(redlamp) Lamplit: APProx.0V 0V
Lamplit: APProx.
(v) '1
6 Approx. " 5V
(Cyclewill get shorter
Vehrclespeed 2
21 sensorsrgnal
0 whenvehiclesPeed
is increased)
OV OV
lgnitionswitch (lgnition
switchin switchin
(lgnition
23 "START'signal STARI Power START Power
voltage) voltage)
N or P range:0V N or P range: 0V
Neutralswitch OtherthanN or P Otherthan N or P
24
signaI range:6 - 7V range. 6 - 7V
ECCS controlunit Powervoltage Powervoltage

27 power suppty
OFF:
Air conditioner OFF:
Air conditioner
Air condittoner Powervoitage Power voltage
ta ON: ON:
Air conditioner
switchsignal Air conditioner
OV OV
E N- 5 1 6
ECCSC/UINPUT/OUTPUT
SIGNALS
CA'I8iENGINE

No. Standa rd Itdemo Standa rd Memo
lntakeatf
30 remperaturesensor Cold: Approx.1.5V C o l d :A p p r o x1. . 5 V
stgnal l brm: Approx.0.8V Wbrm: Approx.0.8V
PowersteeringON: PowersteeringON:
Powersteenng OV OV
signaI PowersteeringOFF PowersteenngOFF.
Approx.BV Approx.BV
Approx0.5V A p p r o x1. V l
(;)it-Il]l--l-t-,1 1 T
4f-:.-. -- -
Powertranststor
37
signai(lN)
control
,fltr-4- A' a''J'
't:t:t:'J't-
-- -+- 108
i r : r c ' * . . .i ,l 1
' |
-rrr:F 1 rl l l
IGN_coil Approx 0 5V :p?'.\'.

-F-:*i:= .o
oisrribu'o1 lvl-T-ttr -
I
6l-i 1 l I -. I I
Powertranslstor
38
controlsignal(EX)
J--
;iuk+irffifr
F - r t L t , I L Jl
l+iroF{':i,.1
i-i- -,--
A p p r o x 1. 1 V- 1 2 V A p p r o x 1. 0 V- 1 1 V
lgnitionprimary
39
stgnal
OV
40 ECCS relay (lgnition
swtch OFF: OV
Power voltage)
E N- 5 1 7
SIGNALS
ECCSCiU INPUT/OUTPUT
C A 1 8 ]E N G I N E
' I l : : :
At idle I at APProx.2'500rpm
t"',1::"'l sisnar
name Circuit
Powervoltage Lowef than Power
volage
FuelinjectorPUlse
41 monitorsrgnal
(ll monitor)
SwitchON: SwitchON:
Power voltage Powervoltage
43 Lightswitchsignal
SwitchOFF: 0V SwitchOFF: 0V
SwitchON: SwitchON:
Heaterfan swtch Powervonage Power voltage
45
srgnaI SwitchOFF: 0V SwitchOFF] 0V
SwitchON: SwitchON:
Reardefogger Powervoltage Power!oltage
46
switchsignal SwitchOFF] 0V SwitchOFF: 0V
Powervollage Lowerthan Po\4er

vo|tage
'101 Injectorcontrol
110 srgnal
A i r c o n d i l r o nOe rN : ON:
Air conditioner
relay
Air conditioner Powervoftage Power voltage
102 srgnal A r rc o n dt r o n eO r FF OFF:
Air conditioner
OV OV
E N- 5 1 8
ECCSC/UINPUT/OUTPUT
SIGNALS
C A ' l 8 iE N G I N E
Terminal At idle At Approx. 2,500rpm

Air condilioner
ON: Air conditioner
ON:
'103 FICDsolenoid
OV OV
Air conditioner
OFF:
Powervoltage Powervoltage
Approx.0V
(Powervoltagefor 5
104 Fuelpumprelay ,-,11t_ sec atterjgnrtion Approx.0V
swtch rs placedto
ON posrtion)
PTC heaterON: PTC heaterON:

'106 PTC heaterrelay Approx.0V Approx.0V
PTC heaterOFFr PTC heaterOFFI
Powervoltage Power \/oltage
'1. Whenign sw in
on
2. Enginerewing: Approx.0V
ldle rev correction First15 sec afrerenginestart:Approx.0V
111 Afler15 sec afterenginestarl: Powervoltage
sotenoro
Any ofthe followingsare ON (Powersteering,
laghts,
reardefoggetheaterfan switch)iApprox.
0V (D rangefor A/T)
Lockup released:
Approx.0V Lockup released:
Lock up release Lock Approx.0V
115
solenoid(Aff) Lockup appljed:
u pa p p l e o : Powervoltage
Power vottage
E N- 5 1 9
ECCSCiU INPUTOUTPUTSIGNALS
9. E C C SC O N T R O LU N I T I N P U T/ O U T P U TS I G N A L S
(1) Datamonitor
Note:Theoutputsignalis displayed dataon consoieunitso thecorrect
as thecalculation
valuewilldisplayedevenif theoutputcircuit(harness) disconnected.
is lnadvertently
RB25DEENGINE
rr,r:,r.,t,trtr',r. toR
CAS RP[,4(Detectedal.q]e set

Tacfometer Theremuslce no aonorma Crankangiesensorsyslem
speedaccordrngto srgnals) Engne runnng chaarge^ speeo
Ailerwarmng up kl lrg
AlR FLOWt'/TR engI€ Approxl0-15V A r frowmetersystem
lol,tptltvoltage) hlrg (Nrange
wthottload
2000rpm
A/COFF)
sensor
Engr€ temperaure
ENGTEMPSEN AitefwarmrngLtPenglne AboveapproxiO'C syslem
lengrnetemPerature)
Changes Detween0- 03v and
EXTGASSEN gas sensorsyslem
ExhaLrst
\oltage) 06- lv ntakesystemalr eak or alT
roLrlPut AnerwarmrngLlp 2000rpmw th rx)load
enqrie intake
RlCfl.LEANrepeats5 t mesor
EXTGASSEN nedor sysrcrn
(RICH/ LEAN) mofe n 10 seconos
C A RS P E E DS E N Shoudgene€ y conbrrnto SYsteTn

Vehrce SpeedsensoT
l\hile dfl\,1n9or w th drve wheels tLlrnlng spee0meler0 splay
(\ehcle speedsignal'
Battery
€n ttonswrtchON 11 ECCScontrolwrt Power
BATTERYVOLT Engrneslopped system
ldlrng(N range A/C A r fow metersystem
A p p r o x . 2 0 - 2 8 m s e c Inlakesystema r eaKs0r alr
IN.]PULSE Aiterwarmng !p oFF)
( nFclronpulsewldtl'r) engne sLcton{entirernpul)
2000rpfirwlthm loao A p p r o x2 0 - 2 8 m s e c npLrtsignalsystem(entlre)
tlhrg (N range A/C 15.
AJlerwamlrg up oFF) Arriow metersystem
LGNT [,4ING engrne Advancegrealerthan10"ange
2000em wrthno load comparedto tde Poston
Alterwarmng up ld r€ (N range.A/C lAS adjuslnent
AAC VALVE Approx12 - 30% AAC vaivesvstem
eng rle OFF)
Air iow metersyslem
nlectorsyslem
A/FALPHA Afterwarmrngup engr€ 75 - 125% Canrster(purge)nspeqlon
(a r-fuelratrofeedbackconeclron 2000rpmw tir m load ntakesyslemalr eak or alr
coeffcient)
slcton
STARI ON
StarterSW system
STARTSIGNAL OFF OFF
bnitionswrtchoN
Enginestopped ThrotUefLilyclosed ON
e sensorslslem
ThTott
DLE SJUDGEMENT Throttetullyopen OFF
A/C SW ON ON
Arrcondtoner SW system
AR CONDS G OFF
A/C SW OFF
N or P range ON
NeLtalSW system
NEUTRALSW OFF
NotNorP
ldle
Steenng ON
PWSTSIGNAL PowersteenngSW syslem
Steenng rcu'tral OFF
ArC ON ON
OFF OFF Arrcondtoret reay syslem
AIR CON RELAY
ACCeI A/CON OFF
Stop OFF
IGNSW ON FLE pumpsystem
FUELPUMP RELAY ON
switchON Throttlefullvc osed

lgnrtron Approx4 0
THROTTLE SEN sensorsyslem
Throttle
(ouFutvoltage) EngrnestoPPed Throttetu y open Appror0 5
POWERVOLTAGE value
Drsoav oo\r€rvoltagepro\e measurement
ls c a! oulsepro\e Tneasuresulemenl
!€lue
N-5
ECCSC/UINPUT/OUTPUT
SIGNALS
(2\ Active test

ACTIVETEST
ENTA DN! 'ECTF |TEH
JT'DGE
' Acrnrpirus'.oescnPipR,',.
Pefonn folowng Inspections 1ochecktf
problems solved.
Fliminrle
ENGINE Setengrrctemperaturehlghor low
Problemoccurence Engrnelernperature sensorslstem
IEMPERATURE Cardion Do notSetextremeValUeSaS
cono|l|on Inlectorsyslem
thrscancausesparkplugburntng
Air ilow meter exhaustgas sensofsyslem
Nai elimtneleal
Othertem inspection
Perfom foilowrngInspectionsto check lf
problemrs solved
Flimrnaie
Set the air-fuelralio rich or lean
Exhaust gas sensofsyslem
ProblemoccurenceC2r,lron DO not SetexlremevaluesaS
FUELINJECTON Arrflowrneterengrneternperature sensor
condrlion thrsmaydamageengrneor catal!,tic
systenl
ocnlener
Inlectorsystem
Nol eliminaied
Olheritem inspecton
Perfonnfollowing nspectionsto check if
probiemrs solved
Delayrgnition
umrng
Flimrn2le
Problemoccurence C2LdionDO notset exlremeva t€S aS
GNTNONTII\,IING lgnition
limingadjuslme
cono|Ilon thismaydamageeitgrneor catalytic
Detonation sensorslstem
con\€net
Nol ehmrnaled
Otherrteminspectron
Increase
conlroldutyratto.Theengtne
AAC VALVE f lhe condition
descnbedon lefican not
Enginerunning
OPENING Decreasecontroldlty ratto beverified.checkAAC valvesystem
The engrnespeedshollddecaease.
Turnrgnition
swllchON OFFandONso
pumpoperalronmakesa sound.Thefuel lf lhe condrtiondescnbedon leftcan not be
FUELPUMP lgnition
switchON
pressure
wrllnse venfed. check relaysyslem offuel pump
REtAY Engrnestop
Do nolperformlhisoperalron and fuelpumpsystenl
CaUi.o-rL
exceptunderconditi0ns
descrrbedon 1eff.
SELF-LEARNING
The air-fuelratiofeedbackcorection coefficrenllearntnqfactorts cleared.
CONT
Eng ne rev can be drsplayedwhenAAC
POWER Problemoccurencevalveopeningis flxed and set rnlector Flirnrneie
operalrons stopped.
BALANCE condition Injector systern
Car{ron Do notpedormlhis operation
whrlednMng
EN - 521
SIGNALS
ECCSC U INPUT,OUTPUT
s-2 VALUE (RB250EENGINE)

osclLLoscoPE & clRcutT TESTERINSPECTION
At idle At Approx.2,500rpm
Terminal C irc uit
S i g n a ln a m e Standard Itlemo
No. Standard Memo
0.2- 0.3v Approx.0.4V
1 (v) -
l- - ' . - . :
2 6 . _ . .
3 Powertransistor
11 controlsignal
12
13
Cold: 6 - 7V Approx.5V
Vvarm:8 - 10V
(v)-r'-:-_-_-_
l5
AAC valvecontrol 10
t|l
10 -,r1 --f|- -Ttl
4
srgnaI 5 5 - ir r'
.--'---
:+zrs ,1,.---
Afi contol un
f+
EngineA/T total i
5 controlinputsignal 10V
Approx. 10V
Approx.
(Dr1)
Approx.1V Approx.2.4V
lvt ., - - -.l
-" i ; ; ; . ; '
Tachometerengine F Tf-lTl-r-TTtf
7
speedsignal "IIilLTI]rlL
l.ih- l]]-
, t .:-_ti-
OFF:
Air conditioner OFF:
Air conditioner
Powervoltage Powervoltage
9 relay
Air conditioner ON:
Air conditioner ON:
Air conditioner
Approx.1V Approx.1V
Enginea/T total
14 controlinputsignal Approx.10V Approx.10V
(D12)
EN - 522
ECCSC/UINPUT/OUTPUT
SIGNALS
Termina
I At idle At Approx.2,500rpm
Signal name C ircuit
No. Standard Memo Stan dard Memo
EngineAff total
15 controloLrtputsrgnal Approx.0V Approx.0V
(Dr3)
Approx.1V
16 E C C Sr e l a y (lgnrtion
switch
OFF. Approx.0V
Powervoltage)
18 Fuelpumprelay OV
t v i : l!.,/erstee^ng_N
l = PowersteenngON
'19 Powersteenng OV OV
^::
swtch signal PowersteeringOFF D-\!Fr <.;.--,^
5V
----5i."",,
I rio"i""*t"**
23 Detonation
sensor i i - - - -
24 sigml
Approx.0.3V Approx.0.3V
Air iow meter

27 (lntakeair quantity Approx.1V A p p r o x1. . 5 V
signal)
EN - 523
SIGNALS
ECCSCiU INPUT,OUTPUT
FIB25DEENGINF
. r t l
At idle I At APProx. 2,500 |pm
t"il:"'l name
sisnar Circuit
En9ire renperaturc s€nsor
temperature 80"C:Approx.1V 80"C:Approx.1V
Engine
28 Enginetemperature Enginetemperature
sensors!gnal
20'C: Approx.3V 20"C:Approx.3V
gassensor
Exhaust Deflectbetween0 -
29 0 - 1V
Approx. approx.
'1V
signal
[,ilonitor& check
lamp Lampnot lit: Lampnot lit:
(redlamp,exhaust Powervoitage Powervoltage
32
temperature Lamplit: 0V Lamp lit: 0V
warninglamp)
A/C ONrov A/C ON :0V

t-tuu so€notcl A/COFF:Power AiCOFF: Power
vomge vorcge
0.5 - 4V (Vottage
Throttlesensor increasewhen
38 Approx.0.5V acceleratorpedalts
srgnal
presseo)
Intakeair quantity Approx.1V Approx.1.5V

40
oLrtputsagnal
EN - 524
ECCSC/UINPUT/OUTPUT
SIGNALS

03-0.7v 0 . 3- 0 . 7 v
Crankanglesensor
41
1 2 0 "s i g n a l
2-3V
lv)
6 -r ' . -T- -
Crankanglesensor
, ftfl{f+nnflnI
42 , +fffHfl+HilIiI
1 "s i g n a l 0r!!u!Fu!uu
. - . . , . -
OV
Jgnition
switch (lgnition
swilch
43 OV
(STARTsignai) STARI Power
voltage)
Neutralswitch N or P range: 0V N or P ranger0V

44 OtherthanN or P OtherthanN or P
srgnal
range:4 - 5V range:4 - 5V
Air conditioner
OFF:
Air conditioner Powervoltage Powervoltage
46
switchsignal Arr conditioner
ONI Arr conditioner
ONI
OV OV
Intakeair quantjty
4A
outpLrtsrgnal
EN - 525
ECCSC/UINPUTOUTPUTSIGNALS
RB25OEENGINE
' t : : : l
At idle I lt lPProx- 2.500rpm
t"'.,il:"'l sisnar
name Circuit
ECCS Powervoltage Powervoltage

49
C/U powersupPlY
D range(or 1st)with D range(or 1st)with

rearwheelsiacked rear wheelsJacked
u p : 0 . 5" 1 . 5 V u p ;0 5 - l . 5 V
Vehiclespeed deflectsbetween0V deflectsbetween0v
53
sensorslgnal and 5V However,lt and 5V. However,rt
appearsto de{lect appearsto deflect
aroundlV according aroundlVaccordlng
to vehiclespeed. to vehiclespeed.
Throttlevalveswitch 0V when accelerator

54 Approx.10V pedalis pressed
(ldlecontactPolnt)
Approx.0.5 - 4V
Throttleopening (Voltagewill increase
56 Approx.0.5V when accelerator
oLrtputsrgnal
pedalis pressed)
Throttlevalveswtch Powervottage Powervonage

57 (powersuPPlY)
Almostpowervoltage Almostpower voltage

101
103
105 control
InJector
'110 srgnal
112
EN - 526
ENGINEELECTRICAL
EQUIPMENT
B B 2 6 D E T /TR B 2 O E
/ D F / D E T/ C A 1 8/i R B 2 5 D EE N G I N E
EN4 ENGINEELECTRICAL
EQUIPMENT
PREPARATION
TOOLS
Hydrometer Batteryspeoficgravtyinspection
Circuittester Resistancevoltageinspections
SPECIFICATION
Note: The batterycapacityvalueis the 5-hourratethatconformsto the newJIS standard

andthevalueis 80%of theformer2o-hourrate.
[Newmodel (example)
name]
+ + Terf
+ rnallpolarity
+ position
| |
I B+tteryl.l€ngthdimensions(roundedoff)
qatteryl-*idth
x box heightclassification
Perfdffiancerank(startingfunctionaddedto 5hr capacitv)
EN - 529
EQUIPMENT
ENGINEELECTRICAL
R B 2 6 D E T TR/ B 2 O ED/ E / D E T / C A 1 B iR/ B 2 5 D E N GN E
1. BATTERYINSPECTION
Voltage inspection
Normal N) 1 2 . 4- 1 2 . 8
Limit(chargerequired) (V) 1 2 . 4o r l e s s
(Startlrmrt) (V) 12(zo"C)
Specific gravity inspection (20"C)

Normal 1 . 2 9- 1 . 2 2
required) (V)
Limit(charge 1.22or less
Thereis a variationwidthof more
Servicelife than0.04 betweeneachcell
Additionalwalerdoes not needto be addedto the batter,

duringservicelileof normaldriving.Whendrivingfor
extendedperiodsof time in hightemperatures' the fluidlevel
maydecreaseaccording to thevehicledrivingconditions
Checkthe fluid levelwiththe (upperi lower)
levelindicator
andtop up to the upperlevelas necessary.
Caution:Distilled watermustbe usedto be addedto refi

the battery.lf ordinarywateris used,fluidlosswillincrease
andmaycausedischarge.
2. ALTERNATOR
(1) Alternatorremovaland installation
C A 1 8 iE N G I N E RB ENGINE
-"f;-s-'h;l
."f'q
,",,.-.ffi
i1;'5T.1
,*-*;".fr",
(21 AlternatorinsPection
Output voltage insPection
. Placeignitionswitchto ON positionand check thal
chargewarninglamPwilllight.
EN-530
ENGINEELECTRICAL
EOUIPMENT
BB26DETT/ RB20Ei DE / DET/ CAi Sr/ FiB25DEENGTNE
3. STARTERMOTORREMOVAL& INSTALLATION
CAIsiENGINE RBENGINE
Startermotor B o l t3 . 1- 4 . 1
*-,"rt",
ll
Washe
Nut
4. SPARKPLUG INSPECTION
Inspection
. Checkfor anylooseness withterminals.
. Checkfor anydamageor crackson theinsulator.
. Usethickness gaugeto checkthesparkpluggap.
S p a r kp l u g g a p ( m m ) : 1 . 0- 1 . 1
5. PLATINUMPLUG INSPECTION
(BB2ODE,RB2ODET, RB26DETT)
Installation precautions
Periodic replacementinterval: 100,000km
Gasinspection andadjustment andplugcleaningusing
wirebrush,shouldnotbe performed as thismayscrape
off the platinumpartucluatefromthe platinumtip surface.
lf plugsarecleanedwithan airgun,thecleaning should
be performed in lessthan20 secondsat an airpressure
lessthan6.0k9/ cmr.
Onlyusepartsspecified by Nissan,whenreplacing the
spark plugs.
EN - 531
EQUIPMENT
ENGINEELECTRICAL
RB26DETT/ RB2OEi DE / DET/ CA18i ENGINE
o. IGNITIONCOILINSPECTION
CA18iENGINE(lntakeside) CA18i(Exhaust
side)
RB2OEENGINE RB2ODE/DET/RB26DETT
. Checktheprimaryandsecondary value.
coilresistance
EN - 532
COOLING
SYSTEM
RB26DETT
/ RB2OE/ DE / DET/ CA18i / RB2sDEENGINE
ENs COOLINGSYSTEM
PREPARATIONTOOLS
SPECIFICATIONS
Onepieceunit(owershroud)
EI\ - CJJ
SYSTEM
COOLING
R B 2 6 D E T/TB B 2 O E/ D E / D E T/ C A 1 8 /i R B 2 5 D EE N G I N E
1. RADIATORINSPECTION
Cooling water leak insPection
. Useradtatorcap testerandapplypressure(limit1 Okgi
cm2)andcheckfor leakage.
Caution:
Whenusingthe radiatorcap tester,alwaysmakesureto
connectthe hoseadapterandfillercap is notdeformed.
2. RADIATORCAP INSPECTION
Inspection
. Cleancap rubberpackingsealsurfaceandvacuumwith
drybrush.
. Attachradiator
captestertocap.Applypressure
ano
checkthatvalveoperatescorrectly.
. Pullvacuumvalvewithfingerandcheckoperation.
J. COOLINGWATERFILLINGPROCEDURES
hoseandheaterhoseclampsare
1 Makesurethe radiator
tightenedsecurelY.
Setthe heatercontrolleverto HOTposition.(For
vehiclesequipped withautomatic airconditioners,first
placeignition switchto ON position andremovethe
externalsensorconnector).
Releasethe radiator capandairdrainplug. (RB20E:
lntakemanifold area. RB20DE/ DET:Intake
collector
manifoldcollectorarea and in frontof glovebox).
Filltheradiator gradually (fillingspeed:slowerthan2L /
min)to thetopof thespoutwithcoolant.Fillthe radiator
untilthe waterin the reservetankreachesthe MAXlevel
lineindicated.
5 After closingthe radiator capandairdrainplug(RB
system), starttheengineandallowit to idle.
6 Theenginewillcontinue to idleuntilthethermostat
opens.(Touchthe radiatorf low hoseand makesurehot
wateris flowing).lf a largevolumeof airremains, the
walertemperature gaugeneedlewillmove past
the
middleas theengine temperature rises abnormally' lf
thisoccurs,stoptheenginewaituntilit coolsand add
water to the radiatorrepeatedlyas describedabove.
Afterthe thermostatopens,racethe enginefor 10
secondsat 2500rpmtwoor threetimes.Checkthat
the watertemperature doesnot riseexcessively.
EN - 534
COOLING
SYSTEM
RB26DETT/ RB2OE/ DE / DET/ CA18i/ RB25DEENGINE
7 Stoptheengineandallowit to cool. Releasethe radiator

capandcheckthefluidlevel.lf thefluidlevellowers.
returnto step4 and repeatthe process.
OR vehicleequipped withautomaticairconditioning,
connectthefreshairsensorconnector.
4. RADIATOR
REMOVAL
ANDINSTALLATION
Bolt(2)
- -- '' 0.33- 033 Reservertank
Nut0.33- 0143- a.
__xo
Fadjator moudlng
&racket (uppe.tt ,
s iff ijgj
.//-n t,! Radialor

/ shroud
ttowert
I
/ A
RadiatorASSY
-/ 1l
/ /
R ,../
kg-m 43
RB ENGfNES(RB20EI DE I DET tRB25DE/ RB26DETT)
(2) 0.33 - 0.43 pao*o.ss

F,?giiii,fiS:l''* - 0.43 Re-
,afr
.-|l
seryer
Badiatorhose
R a dr a t o r
m o unt i n g
Radiatorcap
v' QnrJ
-!-'-
\-,i
(upper)
- Radiator
6- ,rn-- 9
m o un l r ng -
Nut0.33 0.43
(upper)
Radiatorhose (lowe4
Hose clarnp
Atf otl co(
r (A/T
nose
Radiator Fladiator
mo unt r n g shroud(lower)
rubber(lower)
Badiatorshroud(upper) \p*Screw ( 4 )P
Fi.
lv.l Kg-m 0.33- 0.43
EN - 53s
FUELSYSTEM
RB26DETT/ F]B2OE
/ DE / DET / CA18i/ RB25DEENGINE
EN6 FUELSYSTEM
PREPARATION
TOOLS
FLrelgaugeinspection
SPECIFICATIONS
EN - 537
FUELSYSTEM
/ D E / D E T/ C A l 8 i / R B 2 5 D EE N G I N E
F I B 2 6 D E T/ TR B 2 O E
1. FUEL TANK FEMOVAL& INSTALLATION
Fillertube IPornt4]
Canister
-Y.'/ A,, F u e itanKASSY

N u t0 . 3 3- 0 . $ Q ) 2 - 7-
IPoint3] \ )
rQ-z
d
Fueltankprotector
Bolt(4) 0. 3 3- 0 . 4 3 IPoint3]
Drainfuel
Removethefollowing:
Fuelpressure reliefvaive[Point1]
Fueltankinternalpressurerelief
Fillertubeprotector
InspectionholecoverIPoint2]
Fuelgaugeunit,fuelpumpharnessconnector
[Point3]
FueltankProtector
Hoses
'l
[Point ] Fuel pressure relief
. Afterstartingthe engine,removefuelpumpfuseandwait
untilenginestops.Crankengine4 to 5 timesto consume
f u e li n l i n e s .
. Forvehiclewhichcan notbe started,removefuelpump
fuse,crankengine4 to 5 timesto consumefuelin lines.
Caution:
The batterymay becomeweakeasily,use boostercablesto
connectit to anothervehicleor batteryif necessary.
[Point 2l Inspection hole cover, harness cover,fuel

gauge unit harness connector removal &
installation
Removal
. Removerearfinisheranddetachthefuelgaugeunrt ?i..'-1l
ry'L-
harnessconnector.
cover
EN - 538
FUELSYSTEM
RB26DETI/ RB2OE/ DE / DET / CA18i/ RB2sOEENGINE
Removethefollowing:
Fuelpressurerelief
Internalpressurerelief
Inspectionholecover
Fuel gauge limit
Fuelpumpharnessconnector
Fuelhose(return,feed)
l P o i n t1 I
Fuel gauge ASSY bolts installation
. SetO-ringto fuellanksideand insertgaugeASSYinside
thetank.Tightentheboltsshownin thefigureon the
right.
Caution:
Extracautionmustbe takennotto damagefloatandthe
armwheninstalling gaugeASSY
f uelgaugeASSY Handstartbolts
Onlyusespecif iedboltswheninstalling
(2) Fuel pump removal& installation

Removal
. Loosenhoseclampon unitsideon the pumpside.
. Liftup thepumpslightly.Flemove pumpwiththe insulator
fromgaugeunitsidebracket (PlC A)
. Removepumpsideharness.
. Detachhose.
lnstallation
operationin reverseorder.
. Carrvout installation
(3) Inspection
1. Float inspection
. Placethefloatat the F (leverupperside)and E (lever
downside)positions andcheckthe resistance.
2. Pumpinspection
. Applybatteryvoltageto harness terminal1 and
connecter
3 andcheckitsoperation.
Low fuel warning lamp sensor inspection

Connect12Vto 3.4Wtestlampor equivalent
Washsensorwithgasolineor whitegasolineandcheck
that lampdoesnotlightafterapprox.3 minuleshave
elaDSed.
Removesensorfromgasolineor whitegasolineand
checkthatlamplightswithin3 minutes.
EN 540
FUELSYSTEM
RB26DETT
/ RB2OEI DE I DEr I CA18iI RB25DEENGINE
3. FUEL PUMP REMOVAL& INSTALLATION

(1) Fuel pump disassembly

Removethefollowing:
fr ral nraqcr rro raliaf
Internalpressurerelief
Fuelgauge
Caulion:
. Caremustbe takenwhenhandling fuelpump.
. Do notreusepumpif it is dropped.
. Do not allowdirtor debristo adhereto the filter.
. Do nottwistor turnharness.
[Point 1] Fuel hose removal & installation conn*o. ;:1TF,?0"'

Removal ourlerhose\t^ ) tttar*tng
. RaisefuelgaugeASS! remove2 hosesin tank(marked Floatarm
Pump
sectionis outletsjde),fuelpumpharnessconnector
and
detachfuelgaugeASSY Band
clamp.' Approx.
160mm
Installation hose
Checkfuelhosemarking, connectfuelgaugeASSy.
Position pumpharnessandclampband160mmin from
gaugeASSYconnecting padandtightensecurely.
Caremustbe takenthatfuel hoseandfuel harnessturn
insidetankfromthe rightto frontsideof vehicleanddo not
causeanyinterference withfloatarm.
EN - 541
SYSTEM
EXHAUST
RB26DETT/ FB2OE/ DE / DET/ CA18r/ RB25DEENG NE
EN7 SYSTEM
EXHAUST
SPECIFICATIONS
Exhaust system part inspection,warning precautions

. The heatresistanceandcorrosionresistancein exhaustsystempartsand component
shapehavebeencarefully considered in thedesignprocess, so onlyusegenuine
Nissanpartsfor rePlacement.
. Cleaneachconnectlon partandconnectsecurely, makingsurethereareno gasleaks'
. Alwaysuse newgasketsin the frontand rearof catalyticconverter'
. Alwaysuse newpartsfor exhaustmanifoldconnectiongasketand nuts'
. Afteiassemblingeachpart,whenwarmengine,raisespeedto 2,000to 3,000rpmand
makesurethereare no gas leaks,sealingcompoundleaksor sealinggaps'
. Replacepartsratherthan repairingextremedeformatron in heatinsulationpanels.lf
extremeamountof dirthaveaccumulated' cleantheseareas'
. Whenattaching heatinsulationpanels,makesurethereis adequate andno
clearance
erencebelweenexhaustpipes.
interf
EN - 542
EXHAUSTSYSTEM
RB26DETT
/ RB2OE/ DE / DET/ CAI Bi / R825DEENGINE
EXHAUSTPIPE,CATALYTICCONVERTER& HEAT PANELTIGHTENING

TORQUES
(1) CAl8i ENGTNE

N u t( 3 )4 . 6 - 6 . 1
Bort{a)el
0 . 5- 0 . 7
A/T
(21 RB20EENGTNE
M / Tr t l u tt Z l+ . a- S . O P
Nut(3)4.6- 6.1gl
Bolt(6) 0.5 - 0.7

-. Bon(2)p N u t( 2 )1 . 5- 1 . 9
i
(t 6 )t"/
B o l rct
trorr gl
9 9 9 9 9 a 4 4 - 5, 6" ^1"/ - JiR
"
::- V Bo't(2)g::i'.':l; |3} gBott (2) i'"t- i;
A /ri& 44 5b
.f4
Eror l!.1
*)'l/ u'h'o
(3) RB20DE
M/T N u r( 2 )4 . 4- 5 . 6 9
Nut(3)4.6- 6.1$)
Bolt(6)0.5- 0.7g|
N u t1 6 )
1. 3 - 1 . 6 \ - /
9l ruutlt g - 't.6
View A Nut1.3-1.69
(4) RB20DET
^ N u t( 2 )4 . 4 - ---i=, A/r
) .6-6.1 M/T
Nu t ( 3 4
glBoro.5-0.7 d'i- r.s- r.sg
,r, 121
Bolt(6) 0.5 - 0.7

BoltI
Bort(2)I / 1 . 3- 1 . 6
4 . 4- 5 . 6
0 . 5- 0 . 7 Bolt(2)Pl
4 . 4- 5 . 6
Nut1.3-1.6gl
EN - 543
SYSTEM
EXHAUST
R B 2 6 D E T/TR B 2 O EI D E I D E T I C A l 1 i I R B 2 5 D EE N G I N E
(4) R826DETT E N G I N E
Nut (2) 4.4 - 5.6
N u r( 4 )4 . 6- 6 . 1I
Bolt(4)
o l t0 . 5 - 0 . 7
0 . 5- 0 . 7
Bot1.3-1.6
9lBott (2)4.4- 5.6 Nut(2)pl
Nut1.3-1.6
u'"Jo
fil'-(]ue
ry1s-16
Srp
(5) RB25DEENGINE
M/T
Insulator !9lo.s- o.ztzt-0

Insulalor
.,::p
1.3-,r.6(2)ggggg
Pta e' z '
,'::::1", $Foo,u'i) , - ' r . s-
r.oP
' *;
, ::";;*ir.9,"",,!,::it:is\ -
_-1,3 16
q/i-;-
4round ine
1 . 3- 1 6 9
.-rli,^, caôp1 .. !'1--rs-rog

rubber
N,4ounting
f,:l:r*:;',"o,'
-'
-o5:.01gl
Clamp
, ,t'i-'
i'-""*'n-'" A/T
4.6- 6.1 {3)F)
/ *' rrsu'alor
{ rrn"r.t ten'o sensor
t , . tnsutalor
I n s u l a l o r 0 . 5 - 0 7 ( 6 ) '[ q'
o.s2 0.66p:
EN - s44
EXHAUSTSYSTEM
/ D E/ D E T/ C A 1 8/i F B 2 s D EE N G I N E
2. EXHAUSTGAS TEMPERATURE
WARNING
EQUIPMENTINSPECTION
Basic inspection
. Placeignrtion switchto ON positionandcheckthat
C A 1 8E
i NGINE
exhaustgaslemperature warninglampdoesnotturnon.
. Exhaustgastemperature warninglampmustlightwhen
ignitionswitchis placedat STARTpositionandmustgo
offwhenengineis staned
Exhaust gas temperaturewarning lamp replacement i ]
and inspection
. Removevehicleharnessfromswitching module.
. Useleadlineto groundvehiclesideharnessconnecl
exhaustgastemperature warninglampterminal.
. Inspectcondition of exhaustgastemperaturewarning
lampwithignition switchturnedON.
Faultycircuitbetlveenignitionswitchingmodule.
Faultykey sensingmoduleor sensor.
Exhaust gastemperature
warning
lamp,s burned
out.
Exhaust gastemperature lamppower
warning
circuitis faulty.
EN - 545
ENGINE coNTRoL
/ D E/ D E r
R B 2 6 D E r/rB B 2 0 E / c A l B i i R B 2 5 D E N G T N E
EN8 CONTROL
ENGINE ASCDDEVICE)
(INCLUDE
cAl8i
1. ACCELERATOR PEDALINSPECTION AND
ADJUSTMENT Locl( nul
0 . 8- 1 . 0
Acceleratorpedal i nsPection
. The enginemustbe fullthrottlewhenacceleratorpedalis
pressedfully(pedallevercontactsthe stopper
completely).
Acceleratorpedal adiustment
. Loosenlocknutsso acceleratorcablehas adequate
slack.Pulloutercasein direction pedal R B 2 O E
of accelerator
trompositionwherethrottledrumstarlsoperating(there
'ThrottLe.drum
mustbe no playat thispoint),returnlocknuts1.0to 1.5 . ia--- I ,^ ^^^
turnsandtightensecurelY.
Locknut 0.8 - 1.01 F,ont
RB2ODE/DET/RB25DE
i l
Kickdown switch adiustment (RB engine A / T vehicles)

. Pressacceleratorpedalto fullyopenthrottledrum. Adjust
locknutso the gap is between0.3to 1.Omm.
0 . 3- 1 . 0
E N- 5 4 6
ASCD
RB26DETT/ RB2OE/ DE / DET/ CA18i/ FB2sDEENGINE
2. ASCD
Specification
Speedsettingrange A p p r o x5. 0 - 1 0 0 k m/ h
Constanlspeedcontrolrange Levelroad+0 I -2 km I h
Memory type Digitalmemory
Control
type.actuator
dnversource Negativeoressurecontrol.negativepressurepump
Actuator
stroke Approx.33mm
Setsystem One-touchsystem(withtap downsystem)
Resumesystem Installed
Acceleratjon
system Installed
(wrthtap up system)
Overdrivecancelsystem Installed
System
A / T VEHICLE
swltcn
Clulch Brake
s wi t c h swrlh
c
* l
|,-J
t-i
ASCDcontrolunI
Eq:T[qilil
i t l l7 t t 5 t4 t8 t l
horn retay
-------&{1*a -
ASCDrelay " *- fA
3l -. 5 illrlal
ffi iFGl Stoplamp l
#e
ASCD main d
1 4 5 3 t1
ASCD controlunit
Set,'
coas
swilr
AND ADJUSTMENT
2.1 ASCDINSPECTION
(1) FAULTDTAGNOSTS
*rl """ I r*, I R gPFhrrpsW ,,irbidir,
t l
:::i:-:t:::
il&* $iq!! 8w(!nr[ ] W:a,,:'

htdbltortlw (A/D' ierXtOf-
t|YY'
Resume/ lvlainunit lnsrdecircut [,4ainunit Faultyval\€,
set/ coasl Faultyadjustmeni
Does not operate Faulty accelefatorSW faulty faultydiaphra
SW faulty orfaultyparts faulty faulty
faulty
unit
lnsidecircurt [,,lain
Hunting FaLrlty
fespon
faulty faulty
lnsidecifcurt M a i nu n r t
Cancel Diapfgramnle
faulty faulty
Setting
u nstable lnsidecrrcurt M a i nu n i t Catchor leak
Large gap between
m set vehiclespeed faully faulty d iaphgramn
z
(n Vehiclespeed Insidecrfcuit [,4ainunrt
@ decreasewhen faully faulty
setting
lnsidecircuit Mainunit
Does not cancel laulty faulty
ASCD
RB26DETT
/ RB2OE/ DE / DET/ CA'l8 / RB25DEENGINE
INSPECTION
& MAINTENANCE
PROCEDURE
WHENIT CAN NOT BE SET
DoesmainSW lampturnON when

mainSW is restoredafterit ts
turnedOFFonce. relay,powersupplycircuit
TurnsON
Faulty
Checkcontrollergroundforany
faults(betweenterminal3 and Faultyharness,inspection
groun0).
present
Continuity
Otherthan ReplacefaultystoplampSW,
Checkforpowervoltage (approx. approx.12V SW(lV/T),
clutchrelay
12V)to controller
14 ' 3, 5 - 3 jnhibitorSW.relay
(HICASI\4/T),
(otherthaneN forA/T)l (A,T)
Approx.12V
Powervoltageis presentwhenSer
/ coastSW is ON (Approx.12V) Replacefaultyset / coastSW.
(between7 - 3)
Approx.12V
Powervollageis presentat vehtcle Otherthan
speedsensor(between7 - 3) 5V and0V lnspectvehiclespeedsensor
(Approx.5V and0V alternatively)
system.
whenwheelsare rotatedsiowly(1
Approx.5V & 0V
Donot
DisconnectASCD pump operare Removeactuatornoseandoperale
connector andappiybatteryvollage the pump. Checkif negative
betweenterminal1+ - 3-. Checkil pressureoeverop.
ASCDwirewilloperatewhen
t e r m i n a4l a n d 2 i s
Operate
Controlpowervoltagetapprox.l2\. ,
ls developed
betweenterminalI
and3, whenvehiclespeedis over
48km/hand seUcoastSW is ON.
Approx.
12V
Removecontroller connector and
checkif pumpoperateswhen12V Do not
and0V is appliedto vehicleside operate Repairiaultyharnessto the pump
harnesswhichcorresponds to or shortcircuit.
controller
terminal8+ and body
ground,terminal8+ and 9,10-.
Operate
Otherthan
Checkif set powervoltageis
OV
approx.0V betweenterminal2 and
3 whensercoastSW is released.
Approx.0V
EN - 549
ASCD
RB26DETT/ BB20E/ DE / DET i CA18r/ BB2sDEENGINE
INSPECTION& MAINTENANCE WHEN SETTINGIS UNSTABLE

PROCEDURE
(HUNTING)
SETTING
UNSTABLE
Damaged
No damage Not
smooth
Checkif ASCDwiremovementis
Smooth
Leaking ReplacefaultyASCD
for any leakor negativepressurein
pumpairvalveandreleasevalve. pump
No leakage
Cracked
Checkfor any leakor negative
in airvalveandreleasevalve.
Notcracked Removeactuatorhose
DisconnectASCD pumpconnectorand andoperatethe PUmP.
applybatteryvoltagebetweenterminal1+ - Checkif negative
3-. Checkif ASCDwirewilloperatewhen pressuredevelop.
terminal4 and2 is grounded.
Operate
PROCEDURE
& MAINTENANCE
INSPECTION IS UNSTABLE
WHENSETTING
(cANCEL)
SETTING
UNSTABLE
Thereis approx.12V
presentbetweenterminalI Voltagebetweenresume/ ReplacefaultyASCD
and 3 whenset SW is acceleratorswitchtermlnal1 switch.
placedf romON to OFF and 3 is 0V.
position.The system
with Abnormal
ls thereany abnormality vehiclespeedsensor
andmetercable.
No abnormality
Powervoltage(approx.5V and0V) is
betweenvehicle
appliedalternatively
speedsensorterminal7 and3, when
wheelsare rotatedat 1 - 2km/h.
5V & 0V
Approx.
Leaking
Checkfor leakandnegatlvepressure
Faultycontroer
EN - 5s0
ASCD
RB26DETT/ RB2OE/ DE / DET / CAl8i / RB25DEENGINE
INSPECTION
& MAINTENANCE PBOCEDUREWHEN SETTINGIS UNSTABLE
(DIFFERENT
TO SET VALUE)
SETTING
UNSTABLE
Largedifference
to settedvalue
Nocatching
Checkfor any bent,damageto Replace damagedvacuum
vacuumprprng. piping.
No damage
ASCDpump,airvalveandrelease
va,veforneoative
oressure
andleak.
Noleakage
Checkfor any leakor negativepressu ReplacefaultyASCDpu
Notcracked
Qperate
Disconnect ASCDpumpconnectorand
abnormally ReplacefaultyASCD
g r o u n dt e r m i n a1l + - 3 - 4 , 2C
. h e c ki f
pump.
Operate
normally
Faultycontroller.
INSPECTION & MAINTENANCE

PROCEDURE
WHEN SETTINGIS UNSTABLE
(Plungein vehiclespeed)
SETTING
UNSTABLE
Plungein vehicie
speedwhensetting
Notcorrect
Checkif ASCDwire playis or smooth Replaceor adjustASCD
Correctplayand smooth
Checkvacuumpipesfor bentor
damage.
Nodamage
Other
Thereis over10Vcontrolvoltage
than'12V
forcontroller
outputbetween
terminal8 and 3 justaftersetti
A p p r o x1. 2 V
DisconnectASCDpumpconnector
andgroundterminal1+ - 3-4,2.Check
if ASCDwirewilloperatenormally.
y S C Dp u m p
F a u l tA
EN - 551
ASCD
R B 2 6 D E T TB/ B 2 O E/ D E / D E T / C A 1 8 i /B B 2 s D EE N G I N E
INsPEcT|oN&MA|NTENANCEPRoCEDUREwHENAccELERAToRDEVICE
DOESNOTOPERATE
Doesnot
Checkif constantspeed
devicewilloperateusing
set/coastSW.
Operate
WhenstopptngPlace powervoltageaPProx.1
Otherthan 12V
ignitionSW in ON SW in
presentwhenresume/ accelerator
positionwith mainSW (0Vbetweenterminal1 and3)
ON Dosition
ON position.Do not
pressbrakeandclutch Otherthan
(OFFposition).lF A,/T OV
Checkif powervoltageis 0V between1
vehicle,placein D range SW is OFF
when resume/ accelerator
andapplyparkbrake.
Do not tor
Checkif speedwillincreasewhen increase urnoffthe mainswitch
resume/ acceleratorSW is Placed few secondsand turn it on
W h i l ec r u r s i nAqS C D
inONposition.
rfspeedwillincrease Do not Replacefaulty

whenresume/ accelerator tncrease controllerand
SW is turnedto ON Position vehiclespeed
sensor.
Do not Checkif vehicle Replacefaulty

Checkif lhe vehiclewillcruiseat cruise speedwillincrease and
controller
normalvehtclesPeedwhenresume to high-cutvehicle vehiclespeed
/ acceleratorSW is turnedOFF s p e e d( 1 0 0 k m/ h ) . sensor.
Do nol increase
EN - 552
ASCD
/ D E/ D E T/ C A l 8 i/ R B 2 s D EE N G I N E
INSPECTION
& MAINTENANCE
PROCEDURE
WHEN RESUMEDEVICEDO NOT
OPERATE
Besume device do
not ooerate
Doesnot
Checkif constant
speed
Inspectfollowingthe stepsof
device
willoperate
using "Can
notset".
sevcoastSW.
- r - Operate
l w h e n s l o p p r npql a c e |
| l OheckrfpOWETVoltageapprox.12Vis
SWrnoN Otherthan 12V
lrsnition I I ipresent\r r rma / a.âlar^l^|" qW in
lpositiow n i t hm a i nS W r n l | |ON positil
rn (0V betweenterminal1 and3)
'
I O Np o s i t r o nD. o n o t | |
'12V
lpressbrakeandclutch [-l Approx.
Otherthan
l(OFFpositron).
lFA/I I I r
placeinDrange oltageis 0Vbetween1- OV
lvehicle. | | |when resli m e / a Repair faultySW
parkbrake. I l! cceleratorSW is OFF
landapply
OV
Set vehiclespeedto 80km/ h
wilffi;s-_-l usingset / coastSW.
Break(l\4ake surethe vehiclespeed

w i l ln o tg e t b e l o w4 8 k m/ h ) .
Checkif the vehiclespeedwilldecreasewhen Do not

resumeSW is turnedON ([/ake surethe decrease Replacefaultycontroller.
vehiclespeedwillnotget below48km/ h)
Decrease
Otherthan
Checkif thevehicle: Otherthan
willreturnto set vehic e Speedhasde()reaseo to oerow
80km/ h 48km / h Replacefaulty
speed(80km/ h) wh 'I controller.
resumeSW is turner O F F resumeSWis t u r n e dO N
80km/ h Below48km/ h
Normal
EN - 553
ASCD
/ D E/ D E T/ C A 1 8 /i R B 2 5 D EE N G ] N E
B B 2 6 D E T /TR B 2 O E
& MAINTENANCE
INSPECTION WHEN IT CAN NOT BE
PROCEDURE
CANCELLED
SETTINGCAN NOT
BE CANCELLED
ls voltagebetweenterminal5 and3
0V whenbrakeis operated(in N
ge is presentbetween
11and3 whenbrakeis Inspectand replacestoplamPSW
outputis cut
Checkif controller
betlveen(8and3)whenbrake
pedalis pressed.
ls therean actuatorJault. Inspectand replaceactuator
ls thereharnessshortcir Inspectandreplaceharness.
(2) FUNCTIONINSPECTION
. ASCDfunctioninspection is carriedoutby drivingthevehicleandcheckingif each
functionwilloperatenormally.In thisf unctioninspectionASCDcontrolcircuitsystem
functionis inspectedusingfreeroller.
Caution:
Constantdrivecan not be achievedby ASCDas it is non-loaddriveon the free roller.Use
(1)faultdiagnosis as a referencedepending on eachproblemwhencarryingoutfault
diagnosis.
. TurnoN the mainswitchwhenignition switchis placedin oN positionandcheckthat
operation lamPwillturnon
Caution:
Thereis a faultwithmainswitchoTASCDrelayif the lampdoesnotturnon.
. checkthatthecruiselampwillturnon whendnvingat a constant speed(60kmih) and
set/ coastswitchis placedto ON position.Checkif thevehiclespeedwillincrease for
a moment,cruiselampwilllurnoffandconstant drivecan notbe achieved when
acceleratorpedalis releasedand set / coastswitchis placedto oFF position at the
sametime.
Caution:
lf ASCDcircuitis normal,huntingwilloccurandASCDwillbe cancelled as it is non-load
dnve.
. checkthatthecruiselampwillnotturnon whensetswitchis pressedwhenthebrake
pedalis pressedslightly(brakeswitch:OFF,stoplampswitch:ON)'drivingat a
constantspeed(60km/ h). Makesurethevehiclespeedwillnotincrease whenthe
acceleratorpedalis releasedand set switchis placed to OFF positionat the same
time(release function inspection).
EN - 554
ASCD
RB26DETT/ RB2OE/ DE / DET/ CA.l8J/ FIB2sDEE N G I N E
(3) COMPONENTPARTSINSPECTTON
Controller inspection
. Extractthecontrollerby removingcontrollerbolts. Inspect
ASCDcontrolsystemusingcontrollerconnectorparts.lf
diagnosis resultis faultyreplacethecontroller
unit.
Controller (ground circuit) inspection

. Checkthecontinuity betweenterminal3 andbodyground
withconnector connected
Betweentermrnal3 and booygrouno I present
Conttnutty
Controller(powercircuit)inspection
. Inspect
powervoltagebetween followrng
terminals
with
connectorsconnected.
Controller (cancel power supply input) inspection

. Measurethevoltagebetweenterminal.11and3 when
connectors areconnectec.
Controller (set / coast switch input) inspection

. Placeignitjonswitchto ON position.Measurethe
vollagebetweenterminal1 and 3 withconnectors
connected.
EN - 555
ASCD
/ F I B 2 O/ED E / D E T/ C A I B i/ R B 2 5 D EE N G i N E
FB26DETT
Controller (resume/ acceleratorswitch input)

inspection
. Placeignitionswitchto ON positionand measurethe
Renl oash srdelowerfinls
powervoltagebetweenterminal1 and 3 withconnectors
connected.
Controller(vehiclespeedsensoroutput)inspection
. Slowlyrotate
therearwheels andmeasurethevoltage
between 7 and3
terminal with connected.
connectors
I nopro, 5V and0V ahermatrvely
Controller(cruiselampoutput)inspection "" *"n.jllniil_|"'::",,"::,.,

. Measure thevoltagebetween 13and3 with
terminal / lr]]]
connected. -r- t3F-11
connectors /---2-
I
\e\
V{-
Y.
r'E--
\ \ lRr ti J)
Controller (A/T control unit control output) inspection

[A / T vehicle]
. Drive(ASCDset possiblerange)and measurethe
voltagebetweenterminal12 and 3 withconnectors
connected.
Note:
WithA/T shiftcontrol,ASCDcontrollerls prroritized
when
setat ASCDdrive.
E N- 5 5 6
ASCD
/ D E/ D E T/ C A 1 8 /i R B 2 5 D EE N G L N E
Brake,clutch & stop lamp switch inspection

. Disconnectharnessconnectorand operateeach
switchesto inspectcontinuitybetweenfollowing
terminals.
ASCD relay inspection

. RemoveASCDrelayand directlyapplybatteryvoltage
between
betweenterminal1 and2. Checkthecontinuity
terminal3 and5.
Clutch relay inspection (HICASM/Tvehicles)

. Checkthe continuitybetweenfollowingterminalswhen
batteryvoltageis directlyappliedbetweenterminal1 and
c
+ Front ]
Inhibitor (N.P)relay inspection(A/T)

. Checkthecontinuity betweenfollowing when
terminals
batteryvoltageis directlyappliedbetweenterminal1 and
2.
+Front
EN - 558
ASCD
RB26DETT/ RB2OE/ DE / DET/ CA18i/ RB25DEENGINE
ASCD pump inspection

. Removeconnector terminals.Checkthemotoroperation
by directlyapplyingbatteryvoltagebetweenterminal1
a n d4 .
Applybatteryvoltagebetweebn
Motorwilloperate
terminai1 and 4
Resistance
inspection
, ' l ' r '
r temfinak ,, :r:.1.1..
A r rv a l v e1 - 4 Approx.70
Release valve '1 - 2 Approx.70
Vacuumpumpl-3 Approx.8
Operationinspection
. Applybatteryvoltagebetweenterminal1(+)and3(-)and
checkif ASCDwirewilloperatewhenterminal4 and2 is
grounoeo. RB2OE
ASCDwire adiustment
. Loosenlocknutsso ASCDwirehasadequate
slack.Pulloutercasein directionof actuatorfrom
positionwherethrottledrumstartsoperating,returnlock
nutsapproximately1 turnsandtightensecurely.
Accele;i;;;;;
L o c kn u rt r g h t e n r nt ogr o u e{ k g - m ) | 0 . 8- 1 . 0 L o c kn u l0 . 8 - 1 0 1 F r o n r
RB20DEID E T
...''.
EN - 559
ENGINEMOUT.ITING
/ R82OE/ DE/ DET/ CAI 8I / BBASDEENGINE
RBA6DETT
ENGINEiIOUNTING
FRONTENGINEMOUNNNG
(1) CAl8r El{Gll{Es (2) RB ENGTNES

Nrt (2)
Nr, (2)
1.1
REARENGINEMOUNNNG
(1) CAl8l ENGINES FB ENGINES
Nd (2) 22 - 2.9
EN:560
lndex
Symbols E
2 - p o l lei f t. . . . . . . . . . . . . . Gl-13 E C C S. . . . . . . . . . . . . . . . . . . . . . E N- 2 3 1
4WD inspection Gl - 15 E C C SC / Ui n s t a l l a t i o n . . . . . . . . . . . . . . . . .E. N . .- 2 3 3
-
. .l.-. 1
4 W Dr e p a ipr r e c a u t i o n s . . . . . . . . . . . . . . . . . .G . 5 E C C Sr e l a y( B B 2 s D E .). . . . . . . . . . .. . . E N 4 8 5
Eccsvoltage...... , . EN-233
A -
E m i s s i ocno n t r oel q u i p m e n.t. . . . . . . . . . E N 7
Enginecontrol .... EN 46 - 5
e lq u i p m e n. t. . . . . . . . . .E N - 5 2 9
E n g i n ee l e c t r i c a
Engrnm e ounting .. . . EN- 560
E n g i noe v e r h a u. .l . . . . E N- 1 B o
-
E n g i n es p e c i f i c a t i o .n.s. . . . .. . . . . . . . . . . E N 7
. . . . . .... . . . E N 5 4 - 2
E n g i n es t a l l
Enginetemperature sensor. EN - 367. 396' 482
-
E v a p o r a t i v e g a s c o n t r o | . . .. ...... . . . E N 5 4 , 4 8 8
E x h a u s t g a s s e n s o r . . .E . .N -
. . 3 8 6 , 3 9 0 , 3 9 2 ,4 1 5
-
Exhaustgas sensorheater'.. . .. . . . . EN 434
EN -545
Exhaustgastempwarningequipment. .
. . . . E N - 159
E x h a u sm t anifold
E x h a u sm t a n i f o lA d S S Y. . E N - 7 5 , 1 0 9 , 1 1 9 '142
. E N - 543
E x h a u spti p e . . . . . . . .
EN - 4 9 , 542
E x h a u sst y s t e m . . .
B
F
B a l a n cteu b e . . . . . . . . . . . . . . .E. .N - 6 8
EN-236. 272 Frontturbocharger ASSY .. .... .. . . . . EN - 69
Basicinspection
. .. EN - 530 Fuelgauge . . . . . . . . . .E N - 5 3 9
Batteryinspection
. . EN-43 F u e li n j e c t o r ' . . . . . . . . . E N- 1 5 6
Belttension.........
- F u e lp r e s s u rien s p e c t i o n . . . . . . . . .. . . . . . E N - 5 3
B l o w b y c o n t r o l v a l v e . . . . . . ....... . . . . . .E. N 5 5 ' 4 8 9
Blowbygas reduction device... .. . .... . ... EN - 55 F u e | p u m p . . . . . . . . . . . .. . E ..- 303, 307, 440' 483
. .N
. . . . . . . . . E N- 4 8 9 Fuel system EN - 52, 486, 537
B l o w b yh o s e
....G| -13 Fueltank.............. . . . E N- 5 3 7
Board-onlift.........
B r a k i npge d o r m c h e c k. . . . . . .. . . . ... . .G|-'15 F u e tl a n kv a c u u mr e l e avf a l v e . . . . . . . . . E N - 5 4
F u e t u b eA S S y ........E . - 66
. .N
c G
Catalytic converter '. .. EN - 543 -
C i r c u idt i a g r a m . . . .. . . E N - 2 7 9 G a sl e a ki n s p e c t i o.n. . . . . . . . . . . . . . . . . . . . . . E N 7 5
CollectorASSY E N - 5 9 . 1 0 5 1 0 6 ,1 1 5 G e n e r a l p r e c a u t i o n s . . . . . . . . . . ... ....... ... ...G l - 7
Components inspectlon {RB25DE) . .. . EN - 482 H
Compression pressureinspection. .. . .... EN - 42
. . . . . . . .E. N - 8 0 Heaterpane|......... . .. EN-543
Conicalwasher.....
C o n n e c t oi nr s l a | 1 a t i o n . . . . . . . . . ... .......... . E N 2 3 3
- H o w t o u s e t h i s m a n u a | .. .. . .. .. . .. . . . . . . . G l - 2
-
Connector symbol .. .. . . . G| - 6 H y d r a u l iJca c kl i f t i n g. . . . . . . . . . . , . . . . . . .. . G l 1 4
CoNSULT . . . . . . . . .. . GI- 11
- I
C O N S U L T d i s p lsacyr e e n . . . . . . . . . . . . . . .. E N 2 6 5
Crankanglesensor...E ..N -
... 355' 356' 404' 442 ldlemixtureratio . . .. .. EN - 23
Cylinderhead . EN - 83, 85, 170 ldlespeedcontrolsystem. . .... ... EN - 339' 346
l d l es p e e di n s p e c t i o n . . . . . . . . . . . . . . EN- 23
D 1gni1ioncoi|................ . . . . . . . . E N - 4 8 3 ,5 3 2
... . .. . . EN - 267 l g n i t i o inn s p e c t i o n . . E N-328
Datamonitor
exhgas emissioncontrol . EN - 527 l g n i t i orne l a y . . . . . . . . . .. EN- 486
Deceleration
D e t o n a t i o n s e n s o r . . . . . .. E . .N. . .- .3. 8. 1 ' 3 A 2 4 1 7 l g n i t i osni g n a l . . . . . .. E N - 4 2 4
D i a g n o sci sh a r tb y p h e n o m e n o n. . . . . . E N - 2 4 0 l g n i t i o sn y s t e m . . . . . EN-330' 332' 412
-
D i a g n o s i s p r o c e d u r e . . . . . . . . .. . . . . . . E N - 2 3 4 l g n i t i o tni m i n gi n s p e c t i o .n. . . . . . . . . . . . . E N 2 3
systeminspection... .. . .. .. . EN 237 -
D i a g n o s t i c s y s t e m . . . . . ... . . . . . . . . E N - 2 5 9 Individual
- l n h i b i t or re l a y . . . . . . . . . . E N- 4 8 6
D i a g n o s t i c w o r k s h e e t . ... ... ..... . . . . . . . .E N 2 3 4 -
D O H C. . . . . . . . . . . . . . . . . . . . . E N - 274 1 n j e c t.o. .r. . . . . . . . . . . . . . . . .E. .N. . .3. .1.4. ' 3 1 7 ,3 2 3 '4 8 4
EN - 562
I n p u st i g n a l sa n dc o n t r oilt e m s . . . . . . . . . . . .E. .N. .- 2 3 9 R
l n s p e c t i op no i n t s . . . . . . . . .G. . l., 1 6
I n t a k ea i r t e m p e r a t usr e n s o r . . . . . . . . . . . . .E. .N. .-.3 7 8 R a d i a t oc ra pi n s p e c t i o n . . . . . . . . . . . . . . . . E . .N. .-.5. .3. .4. . .
lntakemani{o|d..E ..N
. . .- 6 5 , 1 O 7 ,1 1 7 . 1 3 7 , 1 5 7 Radiatorinspection ..... EN - 534
I n t a k em a n i f o lcdo | | e c t o r . . . . . . . . . . . . . . . . . E
. .N. . -. .i.5. .3 F e a rt u r b o c h a r gAeSrS Y. . . . . . . . . . . . . . . . . . . .E. N . . -. .7.0. .
I n t a k em a n i f o lvda c u u m. . . . . . . . . . . . . . . . . . . . .E. .N. .-.2. 7 5 R e c i r c u l a t ihoons e . . . . . . .E. N - 5 7
Intercooler . .N- 5 7 . 1 3 1
. . . . . . . . .E R e c r r c u l a t ivoani v ei n s p e c t i o. n
. . . . . . . . . .E
. .N. - 50. 57
Intercoola e irrd u c ta s s e m b l y. . . . . . . . . . . ..... E . N- 5 6 R e m o v ae n di n s t ael ln g i n e . . . . . . . . . . . . . . .E . .N. .-. 1. 8. .0.
l n t e r c o o li en l eht o s e. . . . . . . . . . . . . . . . . . . . . . .E. .N. -. .5. 6
r .... Rockercover EN - 76, 120, 169
J s
14 Self-diagnosis .....EN - 236. 262
S e n s osr y s t e m i n s p e c l i o n . . . . . . . . . . . . . .E. .N. .- .3. .5.4. .
S i xi n - l i nteh r o t t lceh a m b e r . . . . . . . . . . . . . . . E . .-. 6
. .N . .3. . .
S p a r ki n s p e c t i o n . . . . . . . .E. N - 2 7 4
EN - 353
1 1 0 ,1 4 3
Sparp klug............ E N - 7 6 . 1 2 1 .4 8 6
S p e c i as le r v i cteo o | s . . . . . . . . . . . . . . . . . . . . . . . .E. .N. .- .I. . . . .
EN-47
S p e e d o m e t e r m e a s u r e m e n t . . . . . . . . . . . . .G. .l.-.'.1.5. . . . . .
EN.47
S t a ns i g n a. l. . . . . . . . . . . . . . . .E. N - 4 3 6
M S t a r t emr otor........ ......E . N- 5 3 1
S u be l e c t r i c a l f ai n s p e c t j 0.n. . . . . . . . . . . . . . .E. .N. .- 5 3 6
Measurement
tools EN-12 S w i n vg a l v ec o n t r o l l.e. r. . . . . . . . . . . . . . . . . . . . .E. .N. -. .7. 3
....
Multipurpose
tools EN - 12 System diagram.. . . . . . . . .E. .N - 1 3
N S y s t e mf i g u r e . . . . . . . ......E . N- 2 7 9
T
Tensionerspring EN- 80
...........
T h e r m o - w ianxs p e c t i o n . . . . . . . . . . . . . . . . . .E. .N. .- .5. .3. . . . .
T h e r m o s t a t . . . . . . . . . . . .E . .N. . -. g
. .A. .,.1. 2 7 . 1 4 8 ,5 3 6
T h r o t r lbeo d yA S S Y . . . . . . . . . . . . . . . . . . . . . . E ..N . .-. .1.3. 9
....
Throttlesensor -
EN 371, 373. 419, 484
T h r o t t l e v a l vs ew i t c h. . . . . . . . . . . .E. .N. .- 3 6 7 , 4 3 6 . 4 8 3
T i g h t e n i nTgo r q u e . . . . . . . . .G . . .l - 1 3
T i m i n gb e l t. . . . . . .E N - 7 8 , 8 2 , 1 1 1 ,1 2 2 . 1 4 4 . 1 6 0
Towing.................. . . . . . . . .G . .l.- 1 3
T r o u b ld ei a g n o s i s . . . . . . .E. N-231
T u r b o c h a r g e r A S S Y . . . . . . . . . . . . . . . . . . .E . .N. .-.6. .8. . . . .
T u r b o c h a r g e r f a i l u r e d i a g.n. o . .s. .i .s. . . . . . . . .E. .N. .- 7 4
T u r b o c h a r gi e n rs p e c t i o. n. . . . . . . . . . . . . . . . . . . . .E. .N . .-. 4
. .9
T u r b o c h a r guenr i ti n s p e c t i o.n. . . . . . . . . .E. .N. - 7 1 , 1 3 4
U
U n a b l et o s t a r t . . . . .E. N - 2 3 9 . 4 2
. . . . . . . . . . . . . . . . . .E. .N. -. .5.3. 1 U n s t a b lied l i n g . . . . . . . . . .E. .N - 2 3 4
EN - 251
. . . . .E. N- 2 4 7 V
..EN-447,486
Vacuum diagram . .N - 1 9
. . . . . . . . .E
E N- 4 0 1 V a l v ec l e a r a n cien s p e c t i o.n. . . . . . . . . . . . . . . . . .E. .N. .-. .4 5
E N- 4 8 3 Vehicle i d e n t i t i c a t ipolna t el o c a t i o.n. . . . . . . . . . .G. .l .- 10
. . . . . . . . . . . . . .E . .N. .-. 2. 3 5
V e h i c l sep e e ds e n s o r . . . . . . . . . . . . . . . .E. .N. .-. .3.9 7 . 4 3 0
EN- 352
w
W a s t e g a tvea l v ec o n t r o.1. . . . . . . . . .. . . . . . . . . .E. .N - 3 5 0
W a t e rb y p a s sc o n n e c t o.r. . . . . . . . . . . . . . . . . . . .E . . -. .6. 7
. .N
W a t e ro u t l eet l b o w . . . . . . .E. N- 6 7
W a t e pr u m p . E N - 9 6 , 1 2 6 ,1 4 7
EN - 563

Nissan Skyline R32 Engine Manual

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Nissan Skyline R32 Engine Manual

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CON4PRESSION

Standard Poly-V low- I - 10 9- 10 tc

. llew Tension limit

Adluslrnsnl Tenrlon llnit

Air conditioner compressor belt Adjustment bolt in idler Pulley

Fan belt Adiustment bolt in alternator

. Rotatethecrankshaftone revolution (360.)andalignthemarkon thecrankshaft

Valve clearancestandard value (20+t-5C)

Valve clearance (cold) mm 0 4 5 + 'I r r 0.38r.1' o:,

(Reference value: warm) mm 0 . 5 1 ', " ' : 0 . 4 4 , ' 00 3

Vatveclearance= Gauge(A) + Gauge(B)

4. Shim types and classification T = 2.440- 2.455mm

5. LUBRICATION SYSTEM INSPECTION

5-1 LUBRICATION OIL LEVELINSPECTION

Everv15.000kmor 12 months SE,SF,SG classoil

RB25DE/RB2ODE/RB2OE 4.0 3.0 Approx.3.8 Approx.4.2

5-2 OIL PRESSUREINSPECTION

Approx. 4.6 Approx.4

RB2OE RB26DETT/ RB25DE/ RB2ODE cA18i

or 12months SE,SF,SG classoil

RB2OE RB2ODE/DET/RB2sDE cA18i

6-1 AIR CLEANERELEMENTINSPECTION (RB26DETT/RB2OE/ DE / DET)

Periodic replacementinterval Every60,000km

6-2 TURBOCHARGER tNSPECT|ON (RB26DETT/ RB2oDET)

Swing valve controller inspection

6-1 AUTOMATIC TEMPERATURE

Freshair ducl Arrcleaner

When cold n alf

When cold Closed

6.2 AIR CLEANERELEMENTINSPECTION

. Holdthe fuelfilterand makesurethe hoseis hardand

pulsationcan be feltwhenthe fuelpumpis operating.

FUEL PRESSUREINSPECTION USINGTHE FUEL PRESSUREMETER

. Restartthe engineand removethefuelpumpfuse. (Q\

. Afterstartingthe engine,removethefuelpumpfuse After

Whenignitionswitchis ON (kg/cm,) Approx.

7-2 THERMO-WAX tNSPECT|ON (CA18i)

8-,I PURGECONTROLVALVE INSPECTION

FUEL TANK VACUUMRELEAFVALVE(RB2sDE)

9-1 BLOWBY CONTROLVALVEINSPECTION(EXCLCA18i)

A i r is blown Air passes

Additionalwork requ ired:

[Point1] Cleaningair hoses & air duct

[Point2] Remove& installeach air hoses and tubes

[Point3] Removeand installthe intercoolerinlet

[Point4] Removeand installintercooler

[Point5] Removeand installrecirculationhose

[Point8] Removeand installturbochargeroutlet

1O-2 AIR GLEANERELEMENTASSEMBLY

[Point1] Air hose and air duct cleaning

[Point2] Removeand installair cleanerelement

2. Removefour bandclipsfromthe air cleaner.Liftair

Periodic replacementinterval: Every 60,000km

[Point 1] Releasefuel pressure

[Point2] Drainingthe coolingwater

[Point 3] Acceleratorwire adjustment

[Point 4] Removethrottle chamber links

[Point5] Fuel PiPeremoval

[Point 6] Air hose removal

[Point 7] Booster vacuum removal

[Point8] Removeand installair chamberbolts

[Point9] Removeand installcollectornut

[Point 10] Removeand installair chamber

[Point11] Removeand installAACvalve