R32 Engine Manual PDF

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 functioning
properly.
. 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
Theinspection
shouldbeperformed
whentheenginecoldor morethanthirtyminutes
after
theengine
hasbeenstopped.
RB26DETT
/ RB2ODE,
DET/ RB2sDEENGINE
an.trs
Standard
Power steeringbelt
With HICAS
Poly-V lowmaintenancebelt
I - 10
9- 10
tc
8 - 10
10-12
16
Air corditionercompressorbelt
6-8
7-9
12
Fan belt
3-5
4-6
7.5
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
Tension limit
. llew
Powersteeringbelt
8- 10
belt
comPressor
Air conditioner
Poly-Vlowbelt
maintenance
Fan bett
9- 11
15
6-8
7-9
12
3-5
4-6
7 5
C A 1 8 iE N G I N E
Belt defction (run)
lokg of force lE appfcd at tha
'
V Po3ltionl
Adluslrnsnl
Tenrlon llnit
Power steeringpump bett
I - 11
Air conditionercomPressorbelt
6-8
7-9
12
Fan belt
4-5
4.5 - 5.5
10-12
Caution:
.1. Whenthe beltis replacedwitha newbeltincreasethetensionslightlymorethanfor the
usedbeltto allowfor wear-inof the newbelt.
"Adjustment"
value.
2. Whenthe beltdeflectionexceedsthe limit,adjustto the
installed.
belt
is
3. Makesurethe pulleygrooveis alignedcorrectlywhenthe
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 aligncrankshaft
pulleymarkwiththe beltcoverindicator.
. No. 1 cylinderis at the compression
stroketop deadcentrewhenboththe intakeand
exhaustsidecamsdo notmovethe valvelifters.
i
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
V"lu"" to be adjusted
lntake side
Exhaustside
. Rotatethecrankshaft
one revolution
(360.)andalignthemarkon thecrankshaft
pulleywith
the beltcoverindicator.
(No. 'l cylinderpistonexhaustT.D.C),
I N T A K ES I D E
C y l i n d e rN o . 3 , 5 , 6
CyiinderNo. 2, 4, 6
Valve clearancestandard value
(20+t-5C)
PART
INTAKE
Valve clearance (cold)
mm
(Reference value: warm) mm
0 4 5 + 'I r r
0.38r.1' o:,
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.
side.Selecta gauge
Insertgauge(B)fromopposite
to 0 m.
thatwillreducetheclearance
thickness
Note:
Do not use morethantwo gauges(B).
UseJIS 150A25feelergauge.
Vatveclearance= Gauge(A) + Gauge(B)
usinggauge(A)and(B):
Reasonsfor measurement
'1.The valveclearancesettingis largercomparedto
previousengines.
2. Largegaugescannotbe placedparallelto the
surface.
measurement
. Thickfeelergaugehavehighrigidityand cannotbe bent
willbe incorrect.
easily,so the measurement
. The errorfactorincreasesif a numberof thingaugesare
willbe incorrect.
layeredandthe measurement
Valve clearanceadjustment
. The valveclearanceadjustment
is performedby
selectinga shimof suitablethickness.
. Whenthe measurement
valveclearance(t)is outof
the
measure shimthickness(T)and
soecification,
replaceit witha shimthatwill producethe standard
dearance.
Shim thicknesscalculationmethod
1.
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)
the
. Measure
shimto determine
thecentreof removed
shim.
ofthecurrent
thickness
Caution:
shimsagain
Donotreusethemeasured
3. Shim selection
(T)is 2.40mm.
Currentshimthickness
2.4OF\ mm + 0.05mm = 2.450
Selectnewshimwithstampedmark124'401
--2.440-2.455).
I
valuerange+f 0.03mm.
Selecta shimwithinstandard
4. Shim types and classification
Thereare 70 typesof shims. Sizesrangefrom2.275
mmto 3.325mm in 0.05mm increments.
EN-46
T = 2.440- 2.455mm
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
levelgauge.
. The oil mustnothaveanywhiteturbidityor dirt.
BetweenL&Hmark
Lubricationoil replacementperiod
RB20DET
/ RB26DETT Every5,000kmor 6 months
CA18ii RB2OE
RB2ODE
/ RB25DE
S D . S E . S G S F c l a s so i l
Everv15.000kmor 12 months
SE,SF,SG classoil
Everv10.000km
or 6 months
SD class oil
Everv15.000km
or 12 months SE,SF,SG classoil
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
RB25DE/RB2ODE/RB2OE
:.,...L.'
4.0
3.0
Approx.3.8
Approx.4.2
3.5
Apptox.4.2
Approx.4.6
Approx.3.2
Approx.3.6
RB2ODET/RB26DETT/4WD
cA18i
1,1
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.3
Approx.3
Approx. 1 .5
Approx.3
Approx. 4
4000
Approx. 4.6
Approx.4
RB26DETT/ RB25DE/ RB2ODE
RB2OE
cA18i
ylinderbiocknghtsrde,
:
7,'
{.:
pressure"
fessureswrlcn
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
/ RB25DE
RB2ODE
or 12 months
Everv10.000km
EN.48
SE,SF,SG classoil
SD classoil
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
(RB26DETT/RB2OE/ DE / DET)
6-1 AIR CLEANERELEMENTINSPECTION
lnspection
. Removethe bandsshownin the diagramand removethe aircleanerelement.
. Thereshouldbe no excessivedirtor damaoeon the air cleanerelement.
Periodic replacementinterval
RB26DETT
Every60,000km
RB2OE
/ DE
RB2ODET
6-2 TURBOCHARGER
(RB26DETT/ RB2oDET)
tNSPECT|ON
Functioninspection
. Removethe intakemanifoldcanisterhose,and placea cap on the hose. Connecttest
hoseto intakemanifoldandattachpressuregauge(compoundgauge).
. Performthe engineoperationtestandcheckthatpressuredoesnot riseabove
approximately
0.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
TN G I N E
R B 2 6 D E T/TR B 2 O D EE
Swing valve controller inspection

. Removethe swingvalvecontrollerrubberhosefromthe vacuumtubeside.
. The controllerrod muststartoperatingwhencompressedair approx.0.7 - 0 8 kg / cm2
is forcedintothehoseby usingan
approx.0.8- 0.9kg/ cm' (RB2ODET)
(RB26DETT),
air gun. Stopblowingcompressedair as soonas controlrod operationis verified
Caution:
airpressureis applied.Usethe LPG
may be damagedif excessive
Thediaphragm
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
valvecompressor(placethe cap
. Removethe hoseon upperflowsideof the recirculation
on end of the hose)and checkif air blowsbackwhenthrottleis closedquickly.
RB2ODET
RB26DETT
Unitinspection
-400+/-150+f 30mmHg(RB26DETT)
pressure
. Usea handpumpto createnegative
muststartto liftupandthe
valvediaphragm
Therecirculation
50mmHg(RB2ODET).
willbemaintained.
vacuumoressure
EN-50
EXHAUST
SYSTEMINSPECTION
C A1 8 E N G N E
6-1 AUTOMATIC
TEMPERATURE
ADJUSTMENT
AIR CLEANERINSPECTION
Systemdiagram
Arrcleaner
Freshair ducl
When cold
n alf
-----=
lntake manifold
Freshair duct
Temperature
sensor
When warm
' @
Warma t t
SPIbody
Intakemanifold
Functioninspection
. Removethe airductandstartthe enqine.Insoectthevacuummotorooerationwhenthe
engineis coldandwarm.
When cold
Closed
Whenwarm
Open
Temperature
sensorpresettemperature:Approx.40oC.
COMPONENTPARTSINSPECTION
Temperaturesensor inspection
. Removethe hoseto the vacuummotorand connectthe
vacuumgauge.
. Startthe engineand checkthe negativepressurewhen
the temperature
of the temperature
sensorwas cooled/
warmedby the drier.
Whenwarmedup No negativepressure
Whencooled
Negativepressurecreated
Vacuummotor inspection
. Removethevacuumhosefromthevacuummotor and
mnnectvacuumhandpump.
. Usea handvacuumpumpto createnegativepressure
-150mmHg).
(approx.
. Makesurethefreshairducton the change-over
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
Temperature
sensor(whencold)
lntake
manifold
A,.'nflowfiPillL @''*'
\v
To'nta[emanifoE! _IO vdcl.rum
gauge
."-,",".'.Applynegative
Visual
cnecK
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
.
(RB25DE)
EASYINSPECTION
. Turntheignition
switchto ONposition.
. Select"Fuelpump"inthe"Function
test"mode.
F U E LP U M P.
IS THEREA PULSAT]ON
E V E R Y3 S E C O N D SW H E N
. Inspectthe pulsationby holdingthefuelhosewithhand
INt
TUEL
UI'tr
J NtrLU '
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 ?
\a/
,@\
. Holdthe fuelfilterand makesurethe hoseis hardand

pulsationcan be feltwhenthe fuelpumpis operating.
USINGTHE FUEL PRESSUREMETER

FUEL PRESSUREINSPECTION
Releasingfuel pressure(RB25DE)
OACTVETEST.O
' Revtheengine
"Activetest"mode
@
n ,,Aniivorcsr,,
. Select"Fuelpumprelay"in
mode.
RELAY OFF
FUELPUI\,4P
'STOP'to
. Press
over
engine
stoptheengine.Crankthe
CAS-RPM(POS) 950rpm
(lf the enginedoesnot startcrank3 - 4
times.
or
three
two
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.
Releasingfuel pressure(CA18i/ RB20E)

. Revtheengine.
"Operation
. Select"Releasefuelpressure"
support"mooe.
in
. 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
ruelenessuRe
I
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.
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
EE
NGINE
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
Approx.2.5
A p p r o x . 2 . 0 A p p r o x . 2 . 5 5 Approx.1.0
Approx.
3.0
Approx.2.5 Approx.3.0 Approx.

1.0
(kg/cm,)
ldlingwhenpressureregulator
vacuumhoseis removed (kg/cmr)
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
-400
. Usevacuumhandpumpto applyapproximately
pressure
mmHg(-100mmHgRB25DEengine)negative
pressure
is
maintained.
vacuum
andmakesurethe
. In thatcondition,checkthatsmallamountof aircan be
suckedfromthe manifoldvacuumpath.
FUEL TANK VACUUMRELEAFVALVE(RB2sDE)
Inspection
. Cleanthevalvehousing.
. lf thefueltankvacuum
youwillhear
releafvalveisnormal,
whenthe air is
soundfromthe valvewithsmallresistance
suckedin throughthe cap.
. Replacethe cap ASSYif the valveis closedor no
resistanceis felt.
EN-54
E G 1 5 1 30 0 0 0
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
Bol1
t . 6- 2 . 1 p ]
ts-t
Replace after every disassembly
o-'--Nut (2)i.6 - 2.19
Additionalwork requ ired:

. Undercover
. Frontbumper
Cleaningair hoses & air duct

[Point1]
. Useairgun to removeany dustand rubbishbefore
removingeachair hosesand air ducts.
Remove& installeach air hoses and tubes

[Point2]
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.
Removeand installintercooler
[Point4]
Removal
1. Removethebumperfinisher
andthebumper
reinforcement.
2. Separatethe rntercooler
inletandouflethoses.
3. Removethe mountingboltandtwo nuts. Detach
intercooler
withoutscratching
thefins.
Caution:
1. An aluminium
finsareusedandcanbe damagedeasily.
Do not placeobjectson the intercooler
or allowtoolsor
otherhardobjectsto contactthefins.
2. Themainunit(tank,fintube)cannotbedisassembled.
Installation
. Installation
operationis the reverseof the removal
operation.Performthe stepsin orderof 3, 2, 1.
Tighteningtorque (kg-m): 0.93- 1.2
..--*-t
t : i ,
Outlet
hose
"l Kq_m
E
l,4ountinq
bolt
0 . 9 3- 1 . 2
Nrounting
Removeand installrecirculationhose
[Point5]
. Removeandinstallthe recirculation
hoseandtubeas shown
in thefigureon right.
Installrecirculationhoseclamp
[Point6]
. Wheninstalling
the recirculation
hoseclap,makesureit
willnotcontactbumperfinisher.
Recirculation
valveinspection
[Point7]
Unitinspection
. Usehandvacuumpumptoapplynegative
vacuumof-150
+/-20mmHgandcheckthatrecirculation
valvediaphragm
liftsandvacuumpressure
is maintained.
[Point8]
Removeand installturbochargeroutlet
tube
. Removeand installthe turbocharqer
ou et tubeas shown
Recirculation
valve
lnlet
hose
0 . 9 3- 1 . 2
ON-VEHICLEPARTS
RB26DETTENGINE
1O-2 AIR GLEANERELEMENTASSEMBLY
To rear turbocharger
To front turbocharger
ACI
Air hose
I *n-'
-s
Arr cleanercase
OUCI
Additionalwork required:
. Removeturbocharger
outlethose
Air hose and air duct cleaning

[Point1]
. Usean air gunto blowoff any dirtand dustbefore
removingthe aircleanerelement.
Removeand installair cleanerelement
[Point2]
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

= _ \-:=
-Connector
[Point 4]
. Firstconnectthe airflowmeterconnectorfor frontturbo
charoerandtheninstallthe air cleanercover.
EN-58
,.' ll.
Arr flow meter
ON-VEHICLE
PARTS
RB26DETE
TNGINE
1O-3 CONNECTORASSY
(1)
CollectorASSYremovaland installation
No.3 Throtllecharnber
No 2 Throttlechamber
Knockpin (6)
__-/0
s;
-----
--\3nno.t
9,t1\
\,
\ur{r2,
/'/
N.o 1
o'n,e,thutb"'
1,,,ffi
""gH-= "{ y
Poinr
(12) ;:t,
ersprlnt
washer
JJ,i:*;
,ll;A,
I'i-,
.\
t"
V7,i";::;*;el
qvl
Hose
.-tt":"to"Tj,:ld' /R
Io! ,
--a
*'"-ruW,fl*6pltr==
warer
ruDe
L"","r,^,^,:."j:,-91^,^
:, :dR. i <?'- - i *_
,,",Kt$,5
Bort0.64- O.r'
F:l"i;r6,i""
l
Bort' 4)
"^,,?" - " ,m
eirtio-zrp)
ffi1.30-ouo
neptaceaftereveryd'sassembty
Fi.
\-.4 Ks''
. Releasefuelpressurein thefuellines[Point1]
. Draincoolingwater[Point2]
. Acceleration
controlwire[Point3]
. Air inlethose
. EGIharnessconnector,
harnessclamp
. Allhoses
Releasefuel pressure
[Point 1]
. 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
n"'"
ON-VEHICLEPARTS
ENGINE
R826DETT
Drainingthe coolingwater
[Point2]
. Makesureto draincoolingwatercompletelyfromthe
cylinderblockby removingthe drainplug.
Caution:
Makesurethe coolantdoesnotspillon the fronttube.
Acceleratorwire adjustment
[Point 3]
. Loosenlocknutto provideadequateslackfor the
wireand pulloutercasein the directionof the
accelerator
acceleralor.
. Returnthe locknut 1.0to 1.5turnsfromthe positionthe
throttledrumstartsmoving(whenthereis no playin cable)
andtighten.
Tighteningtorque (kg-m): 0'8 - 1.0
Removethrottle chamber links
[Point 4]
. Removethemountingnutsindicatedby arrowmarksin the
diagram.Separatethreethrottlechamberlinksfrom
side.
collector
. Removethe harnessfromthethrottlesensorandthe
throttlevalveswitch.
Fuel PiPeremoval
[Point5]
. Removethreeboltsindicatedby the arrowsand separate
the fuelpipe.
Air hose removal
[Point 6]
. Seoaratethe air hoseA, B and C fromthe collectorside.
Air hose
Booster vacuum removal

[Point 7]
. Removethe clampboltand removethe boostervacuum
tube by separatingit fromthe collectorandthe air
chamber.
Removeand installair chamberbolts

[Point8]
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
Removeand installcollectornut
[Point9]
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
A p p r o x . 9- 1 0
Resistance(20.C)O
(2)
CollectorASSYdisassemblyand assembly
(4)pl 0.64' O.B5
Bort
- 0.85
(2)gl 0.64
Bort
ag B
- Acceleralion
work unit
(w
Knockpin (2)
Intaketemperaturesensor
\,
20-3.0
Collector[Point1]
EN
o l
PARTS
ON-VEHICLE
ENGINE
R826DETT
"Throttlevalveswitch
. CollectorASSYinstallation
referto
for thethrottlevalveswitchadjustment
systeminspection"
proceoures.
CollectorinsPection
[Point1]
. Measurethe collectorinstallation
surfacefor distortionin
up,down,lefi' right'
six directions(opposingdirections,
andverticallY).
horizontally
(
m
m
)
:
0.15
Limit
10.4 SIX IN-LINETHROTTLECHAMBERREMOVALAND INSTALLATION
No. 3 Throttle No. 2 Throtfle

chamber \ chamberlPoint1,
lPornt1.2l
660-'
$
neptaceaftereverydisassembly
. CollectorASSY
removaland installation
. Canisterhose
Throttlechamberinspection
[Point1]
. Checkfor any cracksandthatsupplemental
air pathsare
notobstructed.
air
Supplemental
Installthrottlechamber
[Point2]
. lnstallNo. 1 to No.3 throttlechambers.
Caution:
the chamber.
Do not makeany mistakewheninstalling
l Throttle
-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
,,,
df'
]
Detarlof parta
\'
K:X\
.---_.. \i
sx{$r-5-i
<Y-\\1"-
/tr'
Throltle chamber f ully \\

closed stopper Fsat r- I ()\-
Detailof partb
Installacceleratorwork
unit
[Point1]
. Install
sixtn-line
throttle
chamber
andtheaccelerator
work
unitandconnect
No.1,2 and3 throttle
linkage.
=Bolt(4) 0.64- 0.85
6 in-linethrottlechamberlink adjustment
[Point2]
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
the
4. Insert 1 mm thicknessfeelergaugebetvveen
drumandfullyclosedstopperon the
accelerator
drum
work unitside. Securethe accelerator
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
whenthefullyclosedstoppercontacts
feelresistance
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:
Do notadjustfullyclosedstoppernut.
L-
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
aftereverydisassembly
E Repiace
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
on the right.Tightenin gradualstepsto uniformtightness.
30:4
60:5
1 ,4 , 1 0 ,1 2 ,1 4
6 5: 2
7,9
Air drain plug

[Point2]
. Carryoutthe operationwhenengineis cool.
Caution:
Do notremovetheairdrainplugwhentheengineis hot.
. Whentoppingup thecoolant,
alwaysremovetheairdrain
plugto allowairwithintheengineto escape(thisprevents
overheating).
EN-65
'10 6
'I
2 4
2 are nuts
ON-VEHICLEPARTS
RB26DETE
TNGINE
(21 Intakemanifolddisassembly& assembly

- o.8a
gl
Bolt(5)0.6a
Balancetube lPoint6]
B o t t( 2 ) 1 . 6- 2 . 1
6l
E o-rinsIPoint
Water temperature
FF=".;,"
"g
,-p Ffii;il
Screw(2) 0.23- 0.91---'
'.\
Fi
L-l| Eort(2) 0.64 - o.
Liquidgasket
--r.*^
-'l
\^ ,on',u - r.,
{s
lntake ml
_Waler bypassconne^to'
ro-; r
g-----5 "j,lI F.",, ptec,
Air regLrlator
outlet
5l
O-ring
ASSY[Point2]
FueltubeIntector
p ) e o r t t zr .re- z . r
;:J;id'senffi2o-30
a;
+::;;9,s

kg-m
Intakemanifoldinspection
[Point'l]
. Measurethe intakemanifoldsurfacefor distortionsin six
up,down,right'
differentdirections(atoppositedirections:
in severallocations.
andvertically)
left,horizontally
0.15
L i m i t( m m ) :
[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.
or
. CoattheO-ringwithengineoil (10W-30or equivalent)
butdo notapply
siliconoil(NUCsiliconL45or equivalent),
the
oilcoating.
remove
solventas thismay
. AvoidusingdirtyO-ringsand do not allowdirt,dustor
foreignobjectsto adhereto O-ringsor otherequipment
surfaces.
E N. 6 6
x>q)
q4,4u",F.]"
ON-VEHICLEPARTS
r 3 2 D E T TE N GN E
Do notdecenteror rotatethe fuelinlectorsandthe

pressureregulatorwheninsertingthemintothefueltube.
Do notstoreO-ringsin locationsubjectto ozone,high
temperature
or 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.
Caution:
(1) Applyliquidgasketcoating3.0mm wide.
(2) Coaton theinsideof installation
holesas shown.
Tighteningtorque (kg-m): 1.6-2.1
Water outlet elbow

[Point 5]
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
position
shownin thefigure.Usea tubepresserto apply
thegasket.
. Applythe liquidgasket(KP10 00510)to intakemanifold
surfacesin fourlocations.
theninstallwithin20 minutes
Caution:
(1) Applythe liquidgasketcoating3.0mm wrde
E N. 6 7
Tube presserWS3993
Waleroullet
PARTS
ON-VEHICLE
ENGINE
R826DETT
[Point 6] Remove and install balancetube

O-ring
Removal
. Checkthe sizeof the O-ringwhenremovingbalancetube.
lnstallation
. Alwaysreplacethe O-ringwtthnewoneswheninstalling
balancetube.
. TherearethreedifferentO-ringsizes. Makesureto install
the correctsize.
1, 2,3, 4, 5, 6
Cylinder
Cylinder1, 2, 5. 6
Cyinder3, 4
. Be carefulnotto pinchthe O-ringsduringinstallation.

ASSY
1O-7TURBOCHARGER
removal& installation
ASSY
(1) Turbocharger
REARSIDE
FRONTSIDE
*"ry:-/-----ll;at
-'-j---,.-_--,,tf:"11,%
ttose
6 q 1 q 1 z 1 o . M - l s* - -
1.+n"'1""
s'4q"*;';1+
:*,,J4_i ffis{*e
?iF.-:',',"^*
C5p-perwashe{ r-r
/ --'-
iils
Sffi\ffi;'-"
vJP,""*1,
'---ff$B"*r"*"
nipo'\=-^8
'
-H$$,
I#,2$;;?f
y's,e
#P/i:x,lr,;;:|tk#ffii;
c y l i n d eb rl o c k 1 - ,
''
\g"*9t-*l
l^
Y'^,.;}^,tfy.
t^...
o"
p:
. \"'n"i"""n
Oilpi
g:i;r:h /
nf""";n",,,
!
*
,
,",,,110,0-'',
,\F-,
s
*".n",E
F@.-!:1;,
,,?*lT,Y-
".d'Hry>-;;;';;;";--,"'"if:,"*:
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)
(10)
Removeoil returnhose.
Removethreeboltsanddetachbracket.
(11) Removefourturbocharger
nuts.
(12) Lowerturbochargercarefully.
(13) Removesix exhaustmanifoldnuts.
(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
beforeinstalling
theexhaustmanifold.
E N- 6 9
h.
-'
-:
ON-VEHICLEPARTS
R 8 2 6 D E T TE N G I N E
(3)
Rear turbochargerASSY removal & installation
. Frontturbocharger
ASSYremovaland installation
Removalsequence
andtheexhaustmanifold
(1)
Removefrontturbocharger
ASSY
Removetwo nutsand the clipsecuringbolt,and
Q\
seoaratethe tubeA.
(3)
Removethreeboltsanddetachexhaustmanifoldcover.
(4)
RemoveeyeboltB, C and E.
(5)
Removetvvoboltsand separatetube D fromcylinder
blockside.
(6)
Removethreeboltsanddetachbracket.
The sequenceafterthisstepis sameas number11to 16 of
removaland installation.
thefrontturbocharger
Installationsequence
. Installation
is reverseof removalsequence.
. Loosenthe watertubeflarenut beforeinstallingeyeboltB.
ASSYdisassembly& assembly
Turbocharger
(4)
FRONTSIDE
Air inlettube
*BeW"/.fiM
Y'1"!*q*F:i:i
/'t,"1,.,"
EGasket
tr
\
Bolt(2)g
1 . 6- 2 . 1
E GasketI _
Bolt(2)1",4
038-05'
?:J'lt'F3*'3'.# gev"oortzo-V
0.64- 0851
WasherE
xg-m
$
neptaceaftereverydtsassemblY
EN-70
ON.VEHICLE
PARTS
R3 2 6 D E T TE N G I N E
. Turbocharger
ASSYremovaland installation
Watertube inspection
[Point1]
. Aftercleaningthewaterinletandoutlettubeswithradiator
cleaner,blowwithcompressedair and checkfor rustor
anyclogging.
Oil feed tube inspection

[Point2]
. Aftercleaningtheoil feedtubewithengineconditioner,
blowwithcompressedair and checkfor any clogging.
Engine
Removeandinstalllockplate
[Point3]
. Spreadthelockplatepawlswitha screwdriver
andloosen
nuts.
. Position
lockplatesandturbocharger
mounting
nuts.
Aftertightening
thenuts,bendlockplatepawlsontothe
nuIS.
lq.)
L *
Eyeboltdetermination
[Point 4]
. Oilfeed (turbocharger
side)eye boltsare stamped'J'
(5)
Turbocharger
unit inspection
Crack inspection
Crack burn Inspectron
CoolrngwaterinlellPorntB]
Exhaustgas leak
inspectionlocation
Actuator[Point7]
-.----
SwingvalveIPoint3j
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
Compressorwheel
[Point5]
ON.VEHICLEPARTS
ENGINE
R826DETT
Rotor shaft inspection

[Point1]
. Makesurethe rotorshaftrotatessmoothlywithno
heavinessor draggingwhenturnedby finger.
shaft
:"j'^'::..
Turbinerotor inspection
lPoint2]
. Oilmustnotadhereto surface.
. Thereis nocarbonaccumulation.
. Thevanesoftheturbinemustnotbebent.
. Thereis nointerference
withturbinehousing.
or
7\ll No oenoing
r
v-.
-'-'!t-''-
No nterietence
wlh the housing
Swing valve insPection

[Point3]
. Removeactuatorrodpin and makesurethe swingvalve
or cracks.
movessmoothlywithoutdeformation
. Makesurethereare no misalignedseatingsurfacein
turbinehousing.
Rotor shaft play inspection

lPoint 4l
. 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 interference
withcompressorhoustng.
. Wheelmustnotbe bentor damaged.
Rotor shaft inspection

[Point 6l
. Theremustbe no carbonsludgeaccumulation.
EN.72
\@
No oil adhere.
No bendingor
other
d am a g e .
t No carbon
s luO0e
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 compressor
wheel,turbinewheel,compressor
=housrng
andturbinehousing
withsamemethods.
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.
MAXline,theengineoilwillflowintointake
(Wheniheengineoillevelis higherthan
may be
passandtheturbocharger
ductthroughthe blowbygas recirculation
to be malfunctioning).
determined
to deiermineif oil is cooledwhenidlingafterdriving'
customer
2. Checkwith
replacethe
in thefollowingchartis detectedin a unitinspection,
lf any malfunction
ASSY
turbocharger
sr;{tl
..r .::r,. .
Turbinerotor
Oil on rotors
l \
Carbon has accumulated
z__l
!9'
o
C
(/
There is resisianceor scraping

when rotatedby firEer
Rotationby fingeris not Possible

Corsiderable shakingbetween
rotor shafl and turbo ASSY
Carbon sludgehas accumulated

Look throLEhoil hole
(inspectintenorwithPenligm) in waste oil f|ob
@ Highlypossible
Turbimevanes are bent or folded
Turbinevanes are bent or folded
Swing valveoperation
(usearr gunor atr PumP)
o
@
Rotor scrapes agairEt the housirE
Turbineand compressor
Rotorshat play irEPection
l\
Rotor scrapes agair6t the housing
Suctioninletis dirtywithoil
Compressorwheel
z\
The valvedoes not mo\r'e

smoothlywhen pressureis
opens
applied gradually.(LlSually
at pressuregreaterthan 0.6 - 0.7
kg/cm')
O Possible
ZI
Slightlypossible
E N. 7 4
z__.\
l \
ll
A
@
ON-VEHICLE
PARTS
i 3 . al : - i
ENGTNE
1O-8 EXHAUSTMANIFOLDASSY REMOVAL& INSPECTION

FRONTSIDE
REARSIDE
Exhaustmanifoid
Exhaustmanifoldcover
B or ( 3 1 9
Bolt(3)p
0 . 3 8- 0 . 5 ' 1
lPoint4l
0 3 8- 0 . 5 1
l P o r n4t l
Exhaustmanifoldgasket
\ a
I
N u t( 6 )1 . 8- 2 . 4
lPoint21pJ
,u,,,.Iii"-r
oQ4,*,3l
2l
lPornt PJ
lPoint
l-/ kq-m
$
Additionalworkrequired:
. Turbocharger
removal
andinstallation
. Gasleakinspection
IPoint1]
Gasleakinspection
[Point1]
. Afierremoving
exhaust
manifold,
makesurethereare
notracesof gasleaksfromanyparts.
. Aftertheinstallation,
cranktheengineandcheckforany
oas teaKS.
Removeand installexhaustmanifoldnuts
[Point2]
Removal
. Removalis the reverseof installation
seouenceshowntn
the diagramon the right.
Installation
. Theinstallation
sequenceis shownin thediagramon right.
Tighteningtorque (kg-m): 1.8-2.4
Exhaustmanifoldinspection
[Point3]
. Measurethe exhaustmanifoldsurfacefor distortions
in
sixseparatedirections
(opposite
directions,
up,down.left,
right,horizontally
andvertically)
in a numberof locations.
Limit(mm):
0.3
EN-75
; REARSIDE
PARTS
ON-VEHICLE
RB26DETE
TNGINE
Install exhaust manifold cover

[Point 4]
. Attachthe exhaustmanifoldcoverboltsin thefollowing
sequence.(bothfront& rear)
tightenboltsfor positionsindicatedby A.
1 . Temporarily
2 . Tightenboltsin the positionsindicatedB.
3 . Tightenboltsin holesA to specifiedtighteningtorque.
FRONTSIDE
A
:
\'--<i
REARSIDE
fi-'-_--------, .\
.r__r1 )t/
:
SPARK PLUGS
10-9
- o.
p) eott1a;o.oa
bolt(B)
Ornament
0 . 2 3- 0 . 3 1 9
ornament
\,,.#)r-
transistor
O f n a m e nbt o l t( 2 )0 . 2 3- 0 . 3 1 9
Screw(3)
'w:
lgntion aor bracket

-i '.
:eo
*d
='v
I
5CarF.p Ug
l g n r t r o cno t l harness
le/ Kg_m
. RemoveandinstallairinletPiPe
. Removeand installblowbYhose
Removeand installignitioncoil bracket
[Point1]
Removal
. Holdthecoilbodywhenremovingthe ignitioncoilbracket.
Caution:
Do notholdthe coilconnectorwhenremovingit
lnstallation
. Makesureto attachthe ignitioncoilharnesswhen
installingthe ignitioncoilbracketto the cylinderhead
\Bolt0.23 0.31
Platinum\tip
\
Seatingmetal
SParkPlug maintenance
[Point2]
. Gapinspectionand adjustmentis not necessaryas a
platinum
tipis used.
. Replacethe plugevery'100,000
km.
. Whenusinga compressedair sparkplugcleaner,clean
the plugsat maximumpressureof 6 kg/cm2for no more
than20 seconds.
EN.76
fFt
JLT
ON.VEHICLEPARTS
R B 2 6 D E TE
TNGINE
10.10
ROCKERCOVERREMOVAL& INSTALLATION
Rockercoverscrew
(left& right10 each)
Fillercap
O-r'ng--,@
-a
Grommet
Rockercover
Rocker cover gasket 1|/
lPoint3l
.A
,.'
'/a.tt
orlamenl
s3;Tl":":.1'
Rocker
Rocker
covergasketIPoint3l
. Removeandinstallairinletpipe
. Removeand installblowbvhose
Removeand install rocker cover screw

[Point 1]
Removal
. Removethe screwsin reversesequenceshownin the
figureon the right.
Installation
. Performinstallation
in thesequenceshownin thefigureon
theright.
Rocker cover installationsurface

inspection
. Checkthatno oil,dirtor foreignmaterialadheresto the
cylinderheadinstallation
surface.
[Point2]
lnstall rocker cover gasket

[Point 3]
. Makesurethe rockercovergasketis positionedsecurely
in groovewithouttwisting,pinchingor protrusion.
EN-77
ON-VEHICLEPARTS
RB26DETE
TNGINE
TIMINGBELT REMOVAL& INSTALLATION
10-11
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|"*\-,Fiql
,,1
*ffi'Pffi
c r a n k -\n s r e s e n s\ { \ , - _ * \ l
2]
[Point
I \Al,
l;i,""?l' \ fi\f , - x - . . )
_liirQ@,"6;{ryt
\h\'10,
d"^^
:.
_#
5----J
C o n i c aw
l asher
"':]:;:,N+
t?*
qf,ffi*;,
;,,,,;['t'l \^&\
\ [::"1:N
\3\J
\ Y-
\,',,i,nno",,p,aterPo,nt.r
"rr::Jil';'"":;"'''
h
$ W\$, [*,"1J;1\::;q
\tr
, . i , . --
I r'mrn9ortcover(towerr
lpornt4]
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
(0oposition).At thistime,No. 1 cylinderis in
indicator
T.D.Cpositionwhenthecamshaftis located
compression
as describedin the followingsituations.
Timing indicator
,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
Installcrank anglesensor
[Point2]
. Applychassisgreaseto driveunit(spline)
during
installation.
. Thereis a flangeinsidethedriveunitsplineso thespline
position.Checkthealignment
hasonlyoneinsertion
visuallybeforeassembly.
. Checkthatthe crankanglesensorcan be easilyinserted
in beltcoverholesandsensormoveslightlyto rightand
left,thentightenthe bolts.
. Whenthesensordoesn'tmovelightly,loosenbeltcover
boltsto position
whenthecrankanglesensorwasinserted.
Movethebeltcoverlightlyhonzontally
andvertically
to align
it so the beltcoverholesand the camshaftcentreare
aligned.Thentightenthe boltsso the crankanglesensor
moveslightly.
[Point3]
Removal
Remove& installcrankpulleyand the bolt
. Removethe startermotorand attachthe rinooear

stopper.
. Usea pulleypuller(steering
wheelpuller)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.
Remove& installtiming belt cover
[Point4 ]
Removal
. The timingbeltcoveris separatedintoupperand lower
parts.Aftercrankanglesensoris removed,removethe
timingbeltcoverin the orderof upperandthenlower.
lnstallation
. lnstallation
is in reversesequenceof removalprocedures.
Caution:
Caremustbe takennotto scratchor damagethedriedliquid
thetimingbeltcover.
packingwhenremovingandinstalling
Remove& installbell tensionernuts

[Point5]
. Securethetensionerwithhexagonal
wrenchwhen
the belttensionernuts.
removingand installing
Caution:
Do not looseninsertedstudwhendisassembly
Tighteningtorque (kg'm): 4.4- 5.9
Installconicalwasher
[Point6]
. Payattentionto installation
directionof the conical
washers.The washershouldbe setwithfacewith
chamferedsidefacingthe tensionerpulleyside
Installtensionerspring
[Point7]
pulley
. Assemble
springto thebelttensioner
thetesioner
asshowninthefigure.
withthe
. Thetensioner
together
springmustbeassembled
pulleyinthecylinder
block.
belttensioner
. 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
Installcranktiming pulley& ptate

[Point8]
. 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
alignment
marks.(No.1 cylinder
is at T.D.C)
Cam
,;i'/5
. Positionthealignment
markon thecranktimingpulleywith
therespective
oilpumphousingalignment
marks.At this
mrng
groove
timethe
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
(, r n. Q
r aaKme )
PARTS
ON.VEHICLE
ENGINE
RB26DETT
[Point10] Timing belt tensionadjustment

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

. Do not looseninsertedstudswhendisassembly.lf studs
are loosened,coatinsertedstudwithlocktitesolution
(JapanLocktiteKK)or equivalent.
[Point12] TimingbeltinsPection
at theinspection.
. Replace
areindicated
timingbeltif anyproblems
Toothmissing
Crackedtooth
Camshaft lock
Crank sensorlock
Cracks on rear
side
Tensionerlock
E ngine overheat
lnterferencewith belt cover etc.
Wear and cracks

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

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

C,rnder headbol lvl12Y1
5l (14)
Cylinderheadbolt(M6x'1
.0)@
f,,'
II
ll
\
SpringwasherH
H
\cr
Washer'--?
0 92- i.?lpoinr
2]91
\fr
rl
l?ii:"1"..*.".
(2)Tlghten
to 11kg-m
Cylinderheadbolt(M6x1.0)
o^- 12 [Point
2]p)
v---
(3) Loosenboltscompletely o_-(4)Tighten

to 3 kg-nr
( 5 )A n g l ew r e n cB
h5 ' - 9 0 '
*,"nch 11+f 05
,.t:rlr"
>pnng wasner
headASSY
Cylinder
headbolt(1,46x'1
.0)
0.92- 1.2lPoint
2]F:
" R/'
c
{r--
Springwasher
-----J
I
$
Cam pulley
is-t
[Point3]
Replaceafter everydisassembly
69
Cylinderheadgasket[Point2]
'1]
. Drainand refillcoolingwater
[Point
. Removeand install;
. Collector
. Throttlechamber
. Intakemanifold
. Turbocharger,
exhaustmanifold
. Timingbelt
. Rockercover
. Sparkplugs
. lnstallNo. 1 cylindercompression
Drain& refillcoolingwater
[Point1]
Removal
. Removecoolingwatercompletely
fromthe cylinderblock
drainplug.
Caution:
. Makesurecoolingwaterwillnotenterexhaustfronttube.
Refill
. Referto "Coolingwaterfillingprocedures"
for details.
EN-83
.l o1
. - , ---.-^tn
-5-:!9r,"#
=:4
,;\l
I'
rl) i ,J"1 O-i
i
î-l--''
.-i@!Y
Plr
O\. . :''CLE PARTS

ENGINE
RB26DETT
Removeand installcylinderheadbolts
lPoint 2]
Removal
. Removethe boltsin reversesequenceto thefigureson
right.
lnstallation
. Installthe boltsin sequenceshownin thefigureon right.
. The cylinderheadbolt(M12xl .5)aretorquedby two-step
11 7 3
method.Tightenthe boltsin two steps.
1 - 1 4 M 1 2 x 15
(1) Tightento 3 kg-m.
(2) Tightened
to 11kg-m.
(3) Loosenboltscompletely0 kg-m.
E ".1
(4) Tightento 3 kg-m.
(5) Turnbolts85 - 90oclockwisewhenanglewrenchis
:i
useo.
Tightenboltsto 10.5 11.5 kg-mwhentorquewrench
is used.
Caution:
F
Whenanglewrenchis notused,neverattemptto
thetighteninganglevisually.
approximate
. Takecarenotto hitor scratchthegasketseatandthe bore
grommetwhenthe gasketis installed.
. Cleanthe cylinderheadlowersurfaceandthe cylinder
blockuppersurfaceto removeallwater,oil and foreign
airgun
whengasketis installed.Usecompressed
ob.iects
to blowoutthe boreholes
1 5 9 14
1 5- 1 7 M 6 x 1 . 0
:t
."f
:t
No. 1 cylindercompressionT.D'G
verification
. Beforeinstalling
thecylinderheadASSYto cylinderblock,
pulley
andthe cam pulleymustbe positionedat
the crank
T.D.Cposition
the No. 1 cylindercompression
. Alignthecrankpulleytimingmarkandthetimingbeltcover
timingindicator(0"Position).
[Point3]
mark
. Aligntheintake
campulleyalignment
andtheexhaust
marks.
beltcoveralignment
to respective
EN-84
T i m i n gi n
:^----/-dq
ON-VEHICLE
PARTS
R3 2 6 D E . i TEN G I N E
(2)
CylinderheadASSYdisassembly& assembly
va ve spflngTetarner
valveriner
lpoint14]--(>--
-)"'d
ShimlPornt6lValvecollet[P; nl 181 '-
Nut0.92- 1.2lpo]nt5r
Springwasher-, \
, vdlveorlseallpoint231
- valveguide[Pornt2a]
-,
'@d^t
w".n", - i 'P
aarreprare-J$
p J e o r r o . s- '22 = -
,.-D
washer-
17' 1s'20)
:9'": :HX':Jit
-/
valveseat lPoint25]
^-
-- Exhaustvalve[Poinl21,22]
)? 3=-r-
g
&
q-_
v=\
exnausr
valve
21 221
{Po'nt
o,o^
"tn@(E--o
O
B
Bolr
o r0r92
. s -2 -.r 22 lPoint
r p o i n5]t 5 r
g/-,Y"tJ"tL"n"o oracket
lpoint5]
!-_
^ -":1
ro'i-,zr _ q(ar
rp"i"iag
q.r !
-3t*oruJf,lJi!P!*0rpoinr13,
15,21,24,251
-*gp
";@fl<.'
camshaft,exhaust
s.oe)
ffi4pF
da5;tl
O"*\ _ P;i';.]
rei'",,si
q
Ilk
*^@-"ffi,x
fts,
P
*,;:feffi."jffi4R-g*;.
"
:;::"
."I?IT9Y\W1
" - "";"*:i;r;$
Q\2.1-2.7 -_,
12)2.1
*e
gasket
Liqurd
kg-m
,,F.\
_(N
-- *:-
e-
**
"_rJ
pr"rJ1e"'i
u""tplare
back
el;t l \
3]--.
[Point
atb-....''
@.c"..*n
pullev
uam
campurrev
2l
rl
{Point
lHornl
'".. ''
";; t - '*
t,.o*
TrEn
' ."ur
tpoint
to
'ao'r,os:--'eo'tt
._-S-.- sr,
o.gZ- r.z
,"e-, \:
*\--:
F<\
&ilJ,Y,':"rt":i1T'-1.erPo,nr2rg
crankangtesensor
bracket
1l
JPornt
iir, z., _z.rp;
Engineoil
Replaceafterevery disassembly

. Removeand installcylinderheadASSY
Instalcrank anglesensorbracket
[Point1]
. The crankanglesensorbracketis positionedontothe
cylinderheadby usingknowpins.Alignthe positions
correctlywheninstalling
the crankanglesensor.
Grankangle sensorbracketbolt tighteningtorque
(kg-m): 2.1- 2.7
Remove& installcam pulley

[Point2]
Removal
. Fixpulleywitha pulleyholderor sprocketwrenchand
removecam pulleybolts.
Pulleyholder: KV10109900or
KV10109300,
sT31520000,
sT31530000
EN-85
Crankanglesensor
Solt(2) 2.1 - 2.7

\",i
Bolt(2)2.1- 2.7
Boll (4) 1.4- 1

Pu ey holder
...\-=<:.7
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
Camshaftend play inspection

[Point4]
. Setthe dialgaugein frontof camshaftas shownin the
diagram.Readthedialgaugerun-outwidthwhenthe
camshaftmovesin frontor reardirection.
Standardvalue (mm): 0.030- 0.080
Remove& install cam bracket

[Point 5]
Removal (Exhaust and intake camshaft)
. Placemarksto indicatethe bracketpositionand its
directionbeforeremovingthe cam bracket
. Removecam bracketboltsby looseningthemgraduallyin
severalstagesin reversesequenceshownin thefigure.
lnstallation
. Alignthecrankpulleytimingindicator
andthetimingbelt
'1
covertimingindicator(0")so No. cylinderis at
T.D.Cposition.(Thisoperationis not
compression
necessarywhencylinderheadis removedas singleunit).
. Turnthe camshaftso No. '1cylinderis at compression
T.D.Cposition.(Operationis easierif the camshaftis
turned60obeforeor afterNo. 1 cylinderT D.Cpointwhen
as singleunit).
headis installed
cylinder
. Verifl/the positionof No.1 cylinderis at mmpressionT D.C
bv knockpin in frontendof camshaft.
EN-86
610
13
1l
11
12 8
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).
Valveclearanceadjustment
[Point6]
No. 1 cylindercompressionT.D.Cpoint
. Turnthe camshafts(intakeandexhaust)so No. 1 cylinder
is at thecompression
T.D.Cposition.
. Checkknockpin positionof camshaftfrontendto verify
No.1cylinder
compression
T.D.Cposition.
. No. 1 cylinderis at the compressionstroketop dead
centrewhenboththe intakeandexhaustsidecamsdo not
Valveswhich can be adJusted

lntake side
PART
ITE[I
I N T A K ES I D E
CylinderNo. 1, 2, 4
CylinderNo. 1, 3, 5
Exhaustside
Firingorder: 1 - 5 - 3 - 6 - 2 - 4
Rotatethe intakeand exhaustcamshaft'180".

No. 6 cylinderis at compressionstroketop deadenter
I
whenboththeintakeandtheexhaustsidecamsdo notmove
thevalvelifters.
INTAKESIDE
C y 4 i n d eNr o .3 , 5 , 6
C y i n d e rN o .2 . 4 , 6
Valveclearancespecifications
\2O+l-5C)
INTAKE
Valve clearance (cold)
mm
(Reference value: warm) mm
EXHAUST
0.45- l
0 3 8 '- ,
0 . 5 1 -l
O JJ
Caution:
Alwaysinspectwhenthe engineis cold.
EN.87
Valveswhichcan be adjusted
Intakeside
PARTS
ON-VEHICLE
RB26DETE
TNGINE
Reference: Compensationby room temperature

o+/-5
+0.02
10
20
+0.01
30 +/- 5
-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)
usinggauge(A)and(B):
Reasonsfor measurement
1. Thevalveclearancesettingis largercomparedto
previousengines.
2. Largegaugescannotbe placedparallelto the
surface.
measurement
. Thickfeelergaugehavehighrigidityand cannotbe bent
willbe incorrect.
easily,so the measurement
. The errorfactorincreasesif a numberof thingaugesare
willbe incorrect.
layeredandthe measurement
Valve clearanceadjustment
. Thevalveclearanceadjustment
is performedby selecting
thickness.
a shimof suitable
. 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:
shimsagain.
Do notreusethemeasured
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).
Selecta shimwithinstandard
valuerange+f 0.03mm.
4. Shim types and classification
. Thereare 70 typesof shims.Sizesrangefrom2.275mm
to 3.325mm in 0.05mm increments.
J = 2.440- 2.455mm
Installcamshaftfront oil seal

[Point 7]
. Caremustbe takennotto 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.
Installcamshaftrearrubberplug
[Point8]
. Beforeinstalling
the rubberplug,wipeoffanyoil,wateretc.
on thesurfaceandcleanthoroughly.
. Whenassembling
the rubberplug,coatit withadhesive
(threebond1211) or equivalent.
Intakeand exhaust camshaftclassification

[Point 9]
. Intakeand exhaustcamshaftcan be identifiedby
pointcolourand presenceof a spinegear
identification
for drivingthe crankanglesensor.
Intakecamshaft
Pink
No
Exhaustcamshafi
White
Yes
[Point10] Camshaftknock pin insertion

. Theprotrusion
distanceis 5 mm for camshaft
knockpin
insertion.
Knock pin protrusiondistance(mm):
5
EN.89
Splinegea. for dnvingcrankangle
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 micrometer
to measurethe externaldiameterof the
journal.
camshaft
No. 1 - No. 7
27.935- 27.955
[Point12] Camshaftrun-outinspection
. Supportbothcamshaftendjournals(No.1 and No.7) by
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
on thedialgauge.
indicated
Standardvalue (mm): 0.05
[Point13]
l
D i a l g a u g e\
h
)al
q.-
Cylinderheadcambracketinteriordiameterinspection
. Tightenthe cam bracketto specifiedtorque

- '1.2
Cam bracket bolt tightening torque (kg'm): 0.92
. Usethe boregaugeor insidemicrometerto measure
interiordiameter.
'l
' :--..
> ,-v,, - r:
i
r \-t-
_l
r!)/\| |
!,::>--:a
N o .1 - N o . 7
28.000- 28.O21
EN-90
mrcrometerI -,,,,-:1
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].
= (Cambracketinterior
(Oilclearance)
diameter)
(Camshafijournalexteriordiameter)
N o .1 - N o . 7
0.045- 0.086
[Point 15] Valvelifter inspection

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

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

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

When the cylinderhead is removedfrom the vehicle:
. Usethevalvespringcompressor
to removeand installthe
valves.
When the cylinderheadis installedin the vehicle:
. Usethevalvespringcompressor
to installvalvespring.
EN-91
Vaive
ON.VEHICLEPARTS
RB26DETE
TNGINE
[Point19] Remove& installvalve collet

Removal
. Usetweezersto removecollet.
lnstallation
jellyto the internal
. Applya smallcoatingof petroleum
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
distance.
out-of-souare
'1.8
Limit(mm):
[Point21] InstallvalvesPring
. Installunevenpitchtypespringwithnarrowendtowards
colourside).
cvlinderhead(identification
EN-92
ON-VEHICLEPARTS
R 3 2 6] E T T E N G I N E
[Point22] Valveguide clearanceinspection

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

c (1.2)
95
?q
+03
q
45" 30'
^ ^ 0.02c
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
150
headinanoilbathto approximately
Heatthecylinder
toolto press
to 160"Candusea valveguidedriftor press-fit
side.
valveouidefromcamshaft
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
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.
o.K
_po*"
Removal
. Minimize
thevalveseatthickness
by cuttingit,thenremove.
Installation
(1) Drivethevalveseatintocylinder
headusingthevalve
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
usingoversizevalveseats,cutand grindthe seating
recessin cvlinderto fix valveseats.
(Cutter
diameter)
Exhaust
side
--
p,
?A
JO
.^
0.5
",
fio, ffio.
+0 113
+ i - 01 s
30
0 097
^^ - -015
+0.016
36.5
+ 0 . 0 1 6 'r? _a -196
0
q +0 016
32\:::
co,
co :or
do__o (Cutter I
diameter)
::
EN-95
32
34.3
32
34.3
29.6
32.5
37.s
^ ^ 0
O,O ^r
+/-u.{J:
2 96
5.8
^ ^ 0
o o , o1
+/-u.ut
5.8
PARTS
ON.VEHICLE
ENGINE
RB26DETT
[Point27] Cylinderhead inspection

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

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

head.
cylinder
overthe limit,replace
lf the distortionexceedsexcessively
the cylinderhead.
10-13
WATERPUMPREMOVALAND INSTALLATION
Alternatoradjustbar
ton1',I o oa- o.esg'1-\
GQi,
B o l (t 2 )3 . 2- 4 . 3 I
'
t'tl''\>
r- -l r,":'.
'
peort1zy
s.z- 4 . 3
Bolt(6)1.6- 2.1pl
D Liquidgasret
kg-m

. Removeand install:
. Coolingfan,waterPumPrelaY
. Alternatoradjustmentbolt
. Timingbeltcover,timingbelt
Remove& installwater pump
[Point1]
Remove
. Caremustbe takennotto get coolanton the timingbelt.
Wipe it off immediatelyif anywaterdoesspill
. Removethewaterpumpboltsin the reverseordershown.
1 M 6( 1 )
M10 {lonq)
EN-96
EM10 (short)
11 M8
ON-VEHICLEPARTS
R826DETT
ENGINE
Installation
. Installthe boltsin the numberedsequenceshown.
7, 8 , 9 , 1 0 ,1 1, 1 2
2,3,4.5
M6
tv8
r\41
0
0.64- 0.85
't.6- 2.1
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.
Caution:
Be sureliquidgasketis 2.0to 3.0mm wide.
Installation
must be carriedout within5 minutesafterliouid
gasketapplication.
Water pump inspection

[Point 2]
. Rotatethewaterpumpby handand checkfor abnormal
soundandsmoothoperation.
. Theremustbe no tracesof waterleaks.
EN-97
Llquidgasket2.0 - 3.0 rnm

wrdealongthe groove
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
. lnsertthe screwdriver
handleintothermostathousingand
move it up anddownlightlyto removethe housing.
. Usea scraperto removethe liquidgasket.
Caution:
Makesureto removeliquidgasketin grooves.
. Wipeoffthe surfacewithwhitegasoline.
?aq't
lnstallation
. Cutnozzleendof liquidgasket(KP51000150)tubeas
snown.
. Applya continuousbeadof liquidgasketto sealingsurface
usingthetubepresser.Installthe housingwithin5 minutes
aftercoatingliquidgasket
EN-98
2.0 - 3.0 mm wideto centerof flat

matingsurfaceand innerseating
surfaces of boit holes.
ON-VEHICLE
PARTS
ia2a l:--r. ENGTNE
Installthermostat
[Point2]
. 'Top'markfiigglevalve)mustfaceup whenthermostatis
insertedin housino.
Thermostatinspection
[Point3]
. 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
. Disconnect
and connectswitchharnessconnectors
Caution:
Loosenenginedrainplugto removecoolingwaterfromcylinderblock.(lfwateris onlydrained
fromtheradiator
draincock,thecylinder
blockwillnotdraincompletely).
EN-99
PARTS
ON-VEHICLE
RB26DETE
I NG]NE
Remove& installoil filter

[Point1]
Removal
1. Removetheoillevelgauge.
pressurecontrolvacuumhose
2. Removeturbocharged
clampand movethevacuumhoseoutof theway.
3. Movemainharnessclampout of theway. (lf the oilfilter
comeloose,removethe oilfilterusingthefilterwrench)
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.
()
-@/^
Small ratchet
-V
wrench
1/
noup,".
h/
OIL PAN,OIL PUMP& OIL STRAINER

1O-16
(1) Remove& instaltoil pan,oil pump & oil strainer
g oil pannut(7)
- 4 . 3l P o i n1t ]
@-'3.2
-springwasher
f
E oil pumpgasket
Oil strainer[Point3]
p u m p , i t( B ) l
OilP
rt 4l
0 . 9t 2 - 1 . lPoint
d
2]
Eloil pan[Point
at
Ele
'11oll s
Front
Oil pump
pDrain ptug
Copper wa\sher
?7*\
\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
Remove& installoil pan bolts & nuts

[Point1]
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)
0.64- 0.8s
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)
3.2- 4.3
tv
l)Al )o
".i
Remove& installoil pan

[Point2]
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.
Installation
mustbe performed
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.
Waitat least30 minutesbeforerefillingthe engineoil
Q\
andenginecoolantafterinstallation.
Installoil strainer
[Point 3]
. Makesurethe O-ringis installedsecurelyin groovewhen
installingtheoil strainer.
Tighteningtorque (kg-m): 1.6- 2.1(Mg)
0.64- 0.85(M6)
Oil PumPbolt
[Point4]
. Thereare4 typesof bolts. Makesureto usethe correct
boltswhenthevare installed.
20
0 . 9 2- 1. 2
35
0 . 9 2- 1 . 2
45
0.92- 1.2
55
0 . 9 2- 1 . 2
Remove& install front oil seal

[Point 5l
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.
Oil leak& oil pressureinspection

[Point6l
. Afterinstallation
warmup the engineand checkfor any oil
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-'
Oil pump inspection
[Point1]
. Checkinnergear,outergearand housingfor any scratchesor wear.
. Usethicknessgaugeto measurethefollowingclearances:
Outergear and housingclearance
0.114- 0.2
Outergear and innergear clearance
B e l o w0 . 1 8 0
lnnergear and housingside clearance
0.05- 0.07
Outergear and housrngsrdeclearance
0.05- 0.11
lnnergear and housingflangeclearance
0.045- 0.091
position5 is obtainedby subtracting

Measurement
the housingflangeoutsidediameter
fromthe innergearinsidediameter.
EN- 103
PARTS
ON-VEHICLE
RB26DETTENGINE
Regulatorinspection
[Point2]
. Checkoil pressureregulatorvalveslidingsurfaceand the
springforanywearanddamage.
Valveand valve hole clearance(mm): 0.04- 0.097
Installinnergear
[Point3]
. Caremustbe takento installthe innergear in a specific
direction.
. Facethe sidewiththe grooveto the coverside.
E N- 1 0 4
Coverside
ON-VEHICLE
PARTS
I 3 2 :E E N GN E
10-1
(1)
COLLECTOR
ASSY
CollectorASSYremoval& installation
Air reieaseplug IPoint
Acceleration
wife bracket[Point2]
Collector
ASSY
IS--.-,.,^
I
Y
collector
oort(a)$l
1 . 8- 2 . 2l P o i n3t l
gasket
E Collector
g
:'j:i,i",ili'lr
?3'
ft.,
Fi.
$./.1Ks-m
E
Replace
. Releasefuelpressurein thefuel lines
[Point1]
. Drain& refillcoolingwater[Point4]
. Acceleration
wire[Point2]
. Airduct
. Harnessconnector
. All hoses
Releasefuel pressure
[Point1]
. Starttheengine.
. Afterstartingtheengineremovethefuelpumpfuseandwait
untilthe enginestops. Crankenginetwo or threetimesto
consumefuelremainingin the fuelpipes.
. lf thevehicledoesn'tstart,removethefuelpumpfuseand
crankthe enginefourto fivetimesto consumefuel
remaining
in thefuelpipes.
Caution:
[Point 3]
accelerator
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
Remove& installcollectorbolts
[Point3]
Removal
. Removethe boltsin the reverseorderof the figureon
right.
lnstallation
. Installthe boltsin theordershownin thefigureon right
uniformlyin two to threestages.
Air releasePlug
[Point4]
. Formoreinformation
referto the sectionon coolingsystem
lateron in themanual.
. Carryout the operationwhenengineis cool.
Caution:
Do not removethe air releaseplugwhenthe engineis hot.
. Removetheairreleaseplugto releasetheairwithinthe
whenrefillingcoolingwater.
enginecompletely
Caution:
Care must be taken not to over tightenthe air releaseplug
bolt.
Tighteningtorque (kg'm): 0.7- 0.8
(21
& assembly
CollectorASSYdisassembly
Throttlechambergasket
2l $
tPoint
Throttlechamber[Point1]
- Throttlechamberbolt (4)
1lpl
1.8- 2.2tPoint
p ) M c v a l v e A S SbYo l (t 4 ) 0 . 8-6 1 . 1
Fi.
lv.l Kg-m
$ neptaceafler every disassemol,

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

[Point 2]
. Checkthe installation
directionbeforeinstallinq
thethrottle
chambergasket.
I =il;10.2
(1)
INTAKEMANIFOLD
ASSY
Remove& installintakemanifoldASSY
Intakemanifoldgast<et
$
-_.4_
Fi
t-.1
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
right,
(2)
IntakemanifoldASSYdisassembly& assembly
.J
\*
Arr regulator
{4
p) Air ;egulator
bolt0.5- 0.6
FueltubA
e SSY
I P o i n1t l
Fueldamper -
;*,,i
Water outlet
7i
reguralor
Boltt-,4
1 . 8- 2.2
Bolt(2)1.6- 2.191
Replaceafter every disassemble
El Liquidsasket
Fueltubebolt1.0- 1.2
I *s-'
. RemoveandinstallintakemanifoldASSY
Fueltube ASSY
[Point1]
. Replacethe O-ringto newoneswhenremovingand
installingthe pressureregulatorandthefueldamper.
Caution:
Caremustbe takennotto scratchor damagethe fueltube
andthefuel
thepressureregulator
O-ringareawheninstalling
damoer.
E N- 1 0 8
regulator
Pressure
Fueltube injector
Fuel damper
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'sfingernails
wheninstallingO-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] ,
p ruut
z.a- s.zieornt
zj"
ri
\-/ Kg-m
Replaceafter every disassemble
. Undercover
. Assembleanddisassemble
exhaustfronttube
. O, sensorconnector
Gas leak inspection

[Point1]
. 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
Removeand installexhaustmanifoldnuts
lPoint 2l
Removal
sequenceshownin
the diagramon right.
lnstallation
. The installation
sequenceis shownin the diagramon
rioht.
10
11
Yoke
[Point 3]
. Makesure notto makemistakebetweenNo. 3 and No.4
aredifferent.
yokeas configurations
22
24
Installwasher
[Point4]
. Makesurethewasheris facingthe correctway when
installing.
10.4
+
l\4anifoldside
LOCKERCOVER
& INSTALL
REMOVE
LOCKeTCOVer
Fillercap
. Air duct
. Air duct bracket
. Blowbyhose
[Point1] Remove& installlockercover bolls

Removal
sequenceshownin
the diagi'amon right.
lnstallation
. The installation
sequenceis shownin the diagramon
rioht.
E N- 1 1 0
11
ON-VEHICLEPARTS
10-5
TIMINGBELTREMOVAL& INSTALLATION
8 e t l e " sc . e r
,.,
vvasner
Tensoner spr no fPoint7l
i
ConicatwasherI
"
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]
'121
. 3]
T i m i n gb e l tl P o i n 9
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
. Supplemental
belts
. Waterpumppulley
. Sparkplugs
. CheckNo. 1 cylindercompression
[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
wheelpuller)
[Point3] Pulleypuller(steering
. Remove
pulley
byusingthepulleypuller.
thecrank
(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
the belttensionernuts.
whenremovingand installing
[Point6] Installconicalwasher
. Paycloseattentionto the installation
directionof the
conicalwashers.The washershouldbe set withfacethe
chamferedsidefacingthe tensionerpulleyside
a
I
r I I I
-[__T--r
\_J
t
Nrt
IPoint7] Installtensionerspring
. Assemble
thebelt
springso it engages
thetensioner
pulleyasshowninthefigureonright.
tensioner
. The tensionerspringmustbe assembledtogetherwiththe

belttensionerpulleyin the cylinderblock.
EN-112
\\
Conical
washer
ON-VEHICLE
PARTS
Fixthebelttensioner
andhookthespringon topofthe
studvoltby rotatingthe springanticlockwise.
pullfy Spri
1 . 8m m
Approx.20'
Approx.227'
When free
Timingbeit pulle'
[Point8] Installcrank pulleyand plate

. Be carefulto observefrontand rearpositioning
of timing
plate,
belt
cranktimingpulleyandcranktimingpulleyplate
wheninstallation
is oerformed.
[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
---------
tar
]--lu
il
t.t
tr
- -lf--
o)o"u
E-
ll
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
4.4- 5.9
torque.Tighteningtorque (kg-m):
[ 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
marks.
alignment
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
Tensionerlock
Engineoverheat
with belt cover etc.
lnterference
Cracks on rear
stde
Wear and cracks
on the side
Worn teeth
Oil or water
adhesion
Camshaftlock
Crank sensor lock
.J.D
Beltmisalignment
Belt plate malfunction
/,ilh nn
Jary
]!lg
S lidingmotionresistancein
OIL FILTER
9.6 REMOVE& INSTALLOIL PAN,OIL STRAINER,
. 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
(1)
COLLECTOR
ASSY
Remove& installCollectorASSY
cottector
bott/2)lctl
1.8- 2.2IPoint
--{{3lrci
Accelerator
wire bracket[Point2]
Co ecrorASSI
| ,---_,--4
gasket
E Collector
Air releaseplug [Point4]

collectofbolt \2) 1 B - 2.2 lPornt31p)
&
tli
\-,i k g - m
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
remaining
in thefuelpipes.
Caution:
[Point 2] Acceleratorwire adjustment

. Loosenlocknut to provideadeouateslackfor the
accelerator
wireand oulloutercasein directionof the
accelerator.Returnthe locknut 1.0to 1.5turnsfromthe
positionthe throttledrumstartsmoving(whenthereis no
playin cable)andtighten.
Tighteningtorque (kg-m):
0.8- 1.0
E N -1 1 5
ON.VEHICLEPARTS
[Point 3] Remove & install collector bolts

Removal
. Removethe nutsin the reverseorderof thefigureon right.
Installation
. Installthe nutsin the ordershownin thefigureon right
uniformlyin tvvoto threestages.
7.10
105
65
4Q
1,3,4,6,
2 , 5 , 9 .1 1
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).
0.7- 0.8
(21 CollectorASSYdisassembly& assembly
*:;::*;l;;,'"'*>e
H41,
B o l (t a )0 . 9- 1. 19
gasketlPoint2]E
Castetq3 Throttle
chamber
Throttlechamber
a://
--..z2*)",. no""
ts-t
Repiaceaftef every disassemble
. Removeand installcollectorASSY
E N- 1 1 6
Throttlechamberbolt (4)
1 . 8- 2 . 2 [ P o i n 1t ] $ I
ON-VEHICLEPARTS
Remove& installthrottlechamberbolts
[Point1]
Removal
. Removethe boltsin the reverseorderof thefigureon right.
Installation
. Installthe boltsin the ordershownin the figureon right
uniformlyin two stages.
First stage
0.9- 1.1
Secondstage 1.8- 2.2
[Point2] Throttlechambergasket
. Checkthe installation
directionbeforeinstallino
the throttle
gasket.
chamber
.)
oVo
10-2
(1)
INTAKEMANIFOLDASSY
Remove& install intake manifold ASSY
lntakemanifoidASSY
Fi
\-.4
Replaceafter everv disassemble
. Remove& installconnectorASSY
. ECCSharnessconnector,all hoses
E N- 1 ' 1 7
ON-VEHICLEPARTS
[Point1] Remove& installintakemanifoldASSYbolts and nuts

Removal
'io I
6
. Removethe boltsand nutsin the reverseorderof thefigure
on right.
lnstallation
. lnstallthe boltsand nuts in the ordershownin thefigureon
rioht.
B
13 14
2 3
(2) Intake manifold ASSY disassembly& assembly

pl eott1r;gnt
a t"t t I t.o-
injector
lPornt,,
?_
p) aonrZtO.6a' O.SA
Air regutator
,-- 1,
Fuel tube InjectorASSY
prpenSSY
Water-outlet
lntake manifold
Liquidgasket
Fi
\",i K g - m
. Remove& installintakemanifoldASSY
[Point1] Fueltube ASSY
. Replacethe O-ringto new oneswhen removingand
installingthe pressureregulatorandthe fueldamper.
Caution:
Caremustbe takennotto scratchor damagethe fueltube
the pressureregulator'
O-ringareawheninstalling
[Point 2] O-ring (for fuel injector pressure regulator)

but
. Coatthe O-ringwithengineoil (7.5W-30or equivalent),
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
Bolt(6) 1
Bolt(2) 0.4 -
1 11 2
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
B o r t (07. i4 - o 5 I
Fi
\",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
is different.
yoke as configuration
c 0.5
P (mm)
22
24
[Point4] Installwasher
. Makesurethe washeris facingcorrectway when
installing.
Manifoldside
1O-4
REMOVE& INSTALLSPARK PLUG
Ornamentbolt(B)0.30- 0.39
F i \
l'/
narness
Ornament
\,-
Groundcable
Bolt 1.0 - '1.2 lPo]nt1l
- 3.0
Sparkplus 2 . o
fPoint3l ri
\".4
.-'--'/
Washer
L-
,/
c o i lb r a c k e t
lgnition
,,-'1
lPoint2]
\
./'/-/.
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
Installignitioncoil bracket
[Point2]
B o l t' 1 . 0. The ignitioncoilbracketthicknessdiffersbetweenRB2ODE
and RB20DETvehicles.
. Wheninstalling
ignitioncoilbracketto cylinderhead,check
ground
that
lineis connectedsecurely.
'1.2
[Point3] Sparkplugmaintenance
. TheGapinspection
andadjustment
is notnecessary
as
plat,num
tipis used.
. Change
thesparkplugevery100,000
km.
. Whenusingcompressed
airsparkplugcleaner,
cleanthe
plugsat maximum
pressure
of 6 kg/cm2for
nomorethan
20seconds.
. Donotusewirebrushto cleanplugs.
10-5
REMOVE
& INSTALL
ROCKER
COVER
9Ornamentbolt(B)0.30 0.39
F i l l e rc a p
Lockercoverbolt0.2 - 0.4 [Point'1]
e - -- ^
Grommet
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
.-4,
PARTS
ON-VEHICLE
10-6 REMOVE& INSTALLTIMINGBELT

Timingbelt cover(upper)[Pornt4]
Trmrng
b e l t[ P o i n 9t , 1 0 , 1 2 ]
"-",ffi..'
r,,'"'
i,r
j"t#
-- WW'il.
W
^,
*?tgO,S'Po;**,)H
P" r\
n,r,'*i.lvS::"fu
g*
@aS1
pl pol(31
o.o.t.
] ?ol'_,0,-9
washer
""""";'.fffi\,
,.."/b'\])D
conicar Betttensroner
9. '10.111
[Pornt
609\
I - -^6)-... llil'3E w{
\-
wasner\'
t"*t'iilln'flil3#:?lF:ill3]
SJ"P,;
Bolt44-59 ldlerpullevlPoint'111
"iE"-t,
4]
bertcover(rower)
t,
[Point
o\",.]#in
q"fl,:-';,,..""1,","iixilJ,',os-oaap)
91,n.,
Jl Ensn" oi
$
aftereverydisassemblY
Reptace

. Undercpver
. Radiator,
fan shroud
. Coolingfan
. Supplemental
belts
. WaterpumpPulleY
. Sparkplug
. No. 1 cylindercompression
No. 1 cylinderpressureT.D.C(top deadenter)inspection
[Point1]
. Alignthe crankpulleytimingmarkandthe beltcover
At thistime,the No. 1
(0"position).
timingindicator
T.D.Cpositionwhenthe
cylinderis in the compression
camshaftis locatedas describedin the following
situations.
top deadcentre
No. 1 cylinderis at the compression
whenboththe intakeandthe exhaustsidecamsdo not
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]
. 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 position
whenthecrankanglesensorwasinserted.
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)
Remove& install timing belt cover

lPoint 4]
. 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
Remove& installbelt tensionernuts

[Point5]
. Securethetensionerwithhexagonal
wrenchwhen
the belttensioner.
Caution:
Do not looseninsertedstudwhendisassembly.
n-<'( /'.)
Hexagonal wrencn
Installconicalwasher
[Point6]
. Payattentionto the installation
directionof the conical
be
setwithfacethe
should
washer
washers.The
chamferedsidefacingthetensionerpulleyside.
Installtensionerspring
[Point7]
. Assemblethetesionerspringto the belttensionerpulley
as shownin thefigure.
. Thetensionerspringmustbe assembled
togetherwiththe
belttensionerpulleyin thecylinderblock.
; iqipipnr,,.o
|,
. Hookthetensioner
springontheuppersideof thetensioner
springstudwhenthetensionerpulleyis free.
\,. "r \
/4
a Tensioner spflng
Tensionerspring sPecifications
1.8
Approx.20"
Approx.163"
Yellow
[Point8] lnstallcranktiming pulley& plate

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

[Point9]
. Painta markon thebeltthatindicates
rotation
direction
if
painton theupperbeltis unclearwhendisassembly.
Position
thealignment
markson theintakeandthe
exhaustcam pulleyswiththe respective
beltcover
alignment
marks.(No.'l cylinder
is at T.D.C)
Positionthealignment
markon thecranktimingpulleywith
the respective
oil pumphousingalignmentmarks.At this
timethe groovemustbe straightup (no. 1 cylinderis at
rD.c).
Movethe belttensionerclockwise70 - 80 degreeangle,

andsecureit temporarily
withthe belttensionernut.
. lnstallthe beltby aligningthetimingbeltandthe pulley

marks.Alignthe numberof ridgesof exhaustcam pulley
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
Cranklrmrng
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
Toothmissing
Cracked tooth
Camshaft lock
Crank sensorlock
<?
Tensionerlock
E ngine overheat
lnterferencewith belt cover etc.
Cracks on rear
side
Belt misalignment
Belt plate malfunction
Wear and cracks

on the side
Worn teeth
Oil or water
adheston

Caution:
Donottwistor bendthetimingbelt. Makesurethereis nooilfilmor wateronthebelt
10.6 REMOVE& INSTALLWATERPUMP

plaott1ryo.64-085
,t
\')/
lt
t\
Botr(2)3.2- 4
19 ns-'
ti
E
{s'

. Timingbeltcover
WaterpumplPoint1, 2]
ffih,u-,,
E N- 1 2 6
ON-VEHICLE
PARTS
Remove& installwater pump

[Point1]
Remove
. Caremustbe takennotto get coolanton the timingbelt.
Wipeit off immediately
if anywaterdoesspill.
. Removethewaterpumpboltsin the reverseordershown.
Installation
. Installthe blotsin the numberedseouenceshown.
. Wipeoffoil liquidgasketfromthe cylinderblockandon the
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.
Waterpump inspection
[Point2]
. 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
Liquidgasket2.0 - 3.0 mm
wide alongthe groove
ON-VEHICLEPARTS
R B 2 O D /ED E T E N G I N E
Remove& installthermostathousing
[Point1]
Removal
. lnsertthe screwdriver
handleintothermostathousingand
move it up anddownlightlyto removethe housing.
fzo - 3.0 mm wldeto centerof flat
lnstallation
. 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.
Installthermostat
[Point2]
. 'Top'mark(igglevalve)mustfaceup whenthermostatis
insertedin housing.
Thermostat insPection
[Point 3]
. Checkthevalveopeningtemperature
and maximumvalve
tift.
. Hangthe thermostatby stringin valveand submergein
andstirwaterwhile
heatingit up.
whenthevalve
. Theopeningtemperature
is thetemperature
opensandthermostatfallsfromstring
76.5
'10l90
E N- 1 2 8
ON.VEHICLE
PARTS
1O-8REMOVE& INSTALLOIL PAN,OIL STRAINERAND OIL FILTER
O-ring
6
Oil pan bolt (30)

0 . 5- 0 . 7
Oil strainerbolt
( 2 )1 . 6- 2 . 1
lvll Kg_m
I Engineoil
E Liquidgasket
aflereverydrsassembry
E Reolace
Additionalworkrequired
:
. Frontstabilizer
. Radiator
fan,shroud
. Right& leftenginegusset
. Enginerearplate(lower)(A/Tvehicles)
. Enoine
oil
Remove& installoilfilter
[Point1]
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
Remove& installoil panbolts
. Removethe boltsin reversesequenceof figureon right.

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

[Point 3]
Removal
. Usesealcutterto removethe oil pan.
Caution:
(1)
Afterremovingthe oil pan,removeoil liquidgasketon
theoilpanflangegrooveandtheoilblockusingthe
scraper.Makesureto removeliquidgasketdropped
insidetheoil Pan.
Caremustbe takennotto damagethe oil pan
Q\
. Removethe enginemountingnuts(oilpanside)and use
the hoistcraneto movetheoil panforward.Takeoffthe oil
strainerboltsusingthewrenchbeforeremovingtheoilpan.
Caution:
Caremustbe takennot to pullthe hosesand harnessestoo
muchwhenliftingup the engineusingthe hoistcrane.
lnstallation
. Thefollowingproceduremustbe carriedoutwithin5
minutes:
. Applyacontinuous
00150)
beadof liquidgasket(KPS10
to sealingsurfaceusinga tube presser'
. Installthe oil panwithin5 minutesaftercoating.
Oil leakand oil pressureinspection

[Point4]
. Startthe engineandcheckforanyoilleakandtheoil
Dressure.To checkthe oil pressurereleasethe oil
oressureswitchand usethe oil pressuregauge.
Installoil strainer
[Point 5]
. Checkto makesurethe O-ringis installedproperlybefore
the oil strainer.
installing
E N- 1 3 0
' ,
, , , i '
Tubepresser(WS3993)
Liquidgasket
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
:::=""
.*- . il"*';b,mffi3Tff;::
-'ry4e"';ol
ll-,
.o""'
u"
"^^,66;
*XgF/H
Arrrose \=/
g.
cramp-g
i";:'iF
Airn^<a
Inter-cooler
bracket
Inter-coolef
ri.
\",1Kg-m
. Leftfrontfenderprotector
. Fenderstay
. BonnetlPoint1l
Remove& installbonnet
[Point1]
. Removeleftsidebonnetboltsonly(Liftup leftsideof the
bonnetto operate).
Remove& installintercooler
[Point2]
. 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
ff"ct
^ in'"'-"nn'"'
s;il'-l
ON-VEHICLEPARTS
R B 2 O D EE
TNGINE
Remove& InstallturbochargerASSY (lncludefault diagnosis)

10-10
(1) Removal& installation
))
P5 ;::"\T'a'"^'''"'ffi"fl.
# {,*"gEK#"O:
.<=t4\
l$ -;;
leo";'o ,**"I,T::[Q'*-''
1--#r\ B"!t!TUq
\\.,1,,*
1",/ Kg-m
$ Reptaceafter every disassemblY
. Undercover
. Assemble
fronttube
exhaust
& disassemble
. O^sensorconnector
. lniercooler
airinlettubes,hoses
. Airinletoipe
Removewateroutlettube
[Point1]
theclamp
. Remove
thewateroutlettubebyfirstremoving
block.
the
cylinder
locatedontherearsideof
Inspection
. Aftercleaningwaterinletandoutlettubewith radiator
cleaner.blowwithcompressedair and checkfor rustor
clogging.
EN - 132
Water outlet
tube
ON-VEHICLEPARTS
R B 2 O D EE
TNGINE
Removeoil feed tube

[Point 2]
. Removetheoilfeedtubebyfirstremoving
thecylinderblock
andturbocharger
eyebolts.
Inspection
. Aftercleaning
oilfeedtubewithengineconditioner,
blow
withcompressed
airandcheckforclogging.
....'
:-
Removeoil returnpipe
[Point3]
. Removethe oil returnpipeby firstremovingthe oil pan
clampandthe turbocharger
bolts.
Remove& install lock plate

[Point 4]
Removal
. Spreadthe lockplatepawlswitha screwdriver
and loosen
thenuts.
Installation
. Positionthe lockplatesandturbocharger
mountingnuts.
Aftertighteningthe nuts,bendlockplatepawlsontothe
nuts.
Eyeboltdetermination
[Point 5]
. Oilfeed(cylinder
blocksideandturbocharger
side)eyebolts
arestamped"G",
Installationorder
1. Turbocharger
mainunit
2. Waterfeedtube
3. Oil feedtube
4. Wateroutlettube
5. Oil returnpipe
EN- 133
Fl
PARTS
ON-VEHICLE
R B 2 O D EE
TNGINE
(2\ Turbochargerunit insPection

Actuator[Point7]
Excessivepressureleak
Exhaustgas leak tnspectionlocation

valve[Point3]
CrackinspectionTurbinewheel
lPoin1
t ,2 , 4 l
Crack
lnspection
Compressorwheel
[Point5]
Coolingwater Rotorshaft[Pornt6, B]
[PointB]
i-
Rotor shaft insPection

[Point1]
. Theremustbe no heaviness
or draggingandtheshaftmust
turnsmoothlywhenrotorshaftis turnedby finger.
Turbinewheelinspection
[Point2]
. Oilmustnotadhereto surfaces.
. Theremustbenocarbonaccumulation.
. Thevanesoftheturbinerotormustnotbebent.
. Theremustbenointerference
withturbinehousing.
Swing valve insPection

[Point3]
. Removeactuatorrod pinand makesurethe swingvalve
or cracks
movessmoothlywithoutdeformation
. Makesurethereare no misalignedseatingsurfacesin
turbinehousing.
Rotor shaft play inspection

[Point4]
. Position
thedialgaugeandmeasureplayandthrust
clearance.
0 . 0 8 4- 0 . 1 0 7
Rotorshaftplay(mm):
(mm):
0.045- 0.140
Thrustclearance
E N- 1 3 4
) Oil leak inspectionlocation
ON-VEHICLEPARTS
R B 2 O D EE
TNGINE
Compressorwheel inspection
[Point5]
. Oil mustnotadhereto suctioninlet.
. Theremustbe no interference
withcompressor
housing.
. Wheelmustnotbe bent,foldedor otherwisedamaqed.
'qf;:l,Tiltrl
'-
d^"1,"9"a.
Rotorshaftinspection
[Point6]
. Theremustbenocarbonsledoeaccumulation.
Swing valve controller inspection

[Point 7]
. Removethe swingvalvecontrollerrubberhoseon the
compressorhousingside
. Checktheswingvalvecontroller
whenevertheactuatorrod
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
. Useengineconditioner
to cleantheoilfeedandreturn
passages.
. Useradiator
cleaner
to cleancoolinq
waterfeedandreturn
passages.
. Cleanusingtheairgun.
. Cleanthe compressor
wheel,turbinewheel,compressor
housingandturbinehousingwithsamemethods.
EN- 135
Operatessmoothly
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:
levelmustbe betweentheMINandtheMAXmarkson theolllevelgauge.
1. Theengineoil
(whentheengineoillevelis higherthanMAXline,theengineoilwillflowintotheintake
may be
passandtheturbocharger
ductthroughthe blowbygas recirculation
to be malfunctioning).
determined
2. Checkwithcustomerto determineif oil is cooledwhen idlingafierdriving'
replacethe
in thefollowingchartis detectedin a unitinspection,
lf any malfunction
ASSY
turbocharoer
1,.
Smoke
A
A
A
Or
Suctioninlet is dirty with oil
Rotor scrapes agairEt the hosing
l\
Oil on rotors
Carbonhas accumulated
Turbinerotor
Rotor scrapesagainstthe housarE
rAbnofmal
noas
Turbrmevanesare bent or folded
Compressorwheel
C
@
Turbinevanes are bent or folded

There is resistanceor scraping
when rotatedby finger
Turbineand compresor
Rotor shat play arsPection
Carbonsludgehas accumulated
Look throwh oil lrole
(inspectinteriorwith Pen light) in waste oil hole
O Highlypossible
Rotationby finger is not Possible

Cor6iderable shaking between
rotor shaft and turbo ASSY
Swing valveoperation
(usearr 9unor alr pump)
.A
Ti valvedoes rnt mo\

smoothlywhen pressureis
applied gradually.(t6uallyoPens
at pressuregreaterthan 0.6 - 0.7
kg/cm')
Possible
l\
Slightlypossible
E N- 1 3 6
z__.\
ll
^1_\
ll
ON.VEHICLE
PARTS
C A l B ]E N G I N E
10,1 INTAKEMANIFOLDASSY
(1) Remove& instalintakemanifoldASSY
T,
tn,ou,"Oody
bort(4)t.e- z.zp)
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
. Acceleration
wireIPoint1]
. Watertemperature
sensorconnector
. Thermaltransmitter
connector
Accelerationwire adjustment
[Point 1]
accelerator
accelerator.Returnthe locknut 1.0- 1.5turnsfromthe
positionthe throttledrumstartsmoving(whenthereis no
playin cable)andtighten.
Remove& installintakemanifold
[Point2]
sequenceshownin
thefigureon the right.
. The installation
sequenceis shownin thefigure.
Note:
Neverreusethe gasket.
E N- 1 3 7
PARTS
ON-VEHICLE
CA18E
i NGINE
Intakemanifoldinspection
[Point3]
. Measurethe intakemanifoldsurfacefor distortions
in four
and
horizontally
(atoppositedirections;
separatedirections
in a numberof locations.
vertically)
0.15
Limit value(mm):
Straight
PTCheaterinsPection
[Point4]
. Makesurethereis nocrackonthePTCheater.
& assemblethrottlebodyASSY
(2) Disassemble
coverscrew
Fueliniector
{2)0 20 .- 0 26I
\g
'ut'rntector
cover
,
$o-ring =----dG
-t
cl,el lnjector,0j,", ,,
$o-nng-.....-"
'egulator
Pressure
lPo,nt4l
^'
,.-
-V,a
\|g--
uT
.*?" ':"t, [l i fl
Btackel
- Sc'ew{4]OO+- OSSp)
rh,ort,"
ouuy^-_ -__
uppe.
/ s"u'
^,
eoin,
J1
^,V&d*o.
^7*ir9"" o,o- o,u
7]
Thermowax lPornt
I hrottleadtustscrew=\E
yrpo
inter_.,.
ointgt
\
--@
thro.ebod
Lower
ffi,u
S/
Screw0 20 - 0 26p
.or-n g
(2)p
screw
Bracket
E1^.<-1
=,"ref\rilff}:!,,3"il:
-,,
-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.
't.8- 2.2
Bolt tighteningtorque (kg-m):
. 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)
butdo notapplysolventto themas thismay removethe oil
coatrng.
. Do not allowdirt,dustor foreignobjectsto adhereto
O-ringsor otherequipmentsurfaces.
. 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
/--\.
l:
'..-r'\
Conneclor:rJ
rubber
\9
-lniectorcover
\^
Injector
wrflng
connector
F u e lI n i e c t o r
PARTS
ON-VEHICLE
C A ' 1 8Ei N G I N E
Cam ASSY
[Point3]
Removal
. RemovethecamASSYfromthe upperthrottlebody.
Caution:
Extracare must be taken as there are tensionon the cam
spring.
Inspection
. Lookfor anydeformationor wearon the cam spring.
24.5- 26.5
Cap spring free length(mm):
lnstallation
. Makesureto installthe cam ASSYand the cam springin
rightdirection.
. Reolacetheseatwithnewones.
Free length
I
Pressurereguator
Pressureregulator
[Point4]
Removal
. Removethepressure
fromtheupperthrottlebody'
regulator
. Carryoutthefuelpressure
inspection.
IPoint5]
Removal
Throttledrum& A / T controldrum
. Firstremovethe nutsandremovethe A / T controldrum.

. Removethrottleadjustscrewand returnspringand remove
thethrottledrumfromthe lowerthrottlebody.
Inspection
. Inspectvisually
if thereareanywarn,cracksordeformation
on springretainer,retainer,and colour.Also inspect
rotationcontactsurface.
. Checkdeformation
andwarnon thethrottleadjustment
return
spring.
screwand
19.5- 21.5
Returnspring free length(mm):
lnstallation
. Caremustbe takento installthe partsin correctdirection
the armASSY returnspring,throttledrum
wheninstalling
andA,/Tcontroldrum.
E N- 1 4 0
Springretarner
(plastrc)
f<
(plastic)
/,Retainer
Color(plastic
\0.J
\
ON-VEHICLEPARTS
C A l 8 iE N G I N E
Remove dashpot
[Point 6]
. Firstremovethe dashpotbracketto removethe dashpot.
Inspection
. Checkvisuallyfor anydeformation
or crackson the rubber
oan.
Removethermoswax
[Point7]
. Firstremovethethrottle
wirebracket
to removethermo
wax.
Inspection
. Checkifthepinwillextendwhenthethermowaxis
warmeo.
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.
'11- 12
Spring free length (mm):
lnstallation
. Checktheorientation
of thevalvewheninstallino.
Lower throttle body inspection

[Point 9]
. Checkfor any cloggingin the air passageby carryingout
air blowinspection.
. Checkfor any crackson lowerthrottlebody.
EN- 141
Thermowax
PARTS
ON-VEHICLE
10-2
EXHAUSTMANIFOLDASSY
Exhaustmanifoldqasket
- ,f4f;^
-rw--4;
ddl
V/,^-,T
Washer
t: l,aa
"*
if::'liHllli 'u'
fru
R.
o,
gl f
o,r" "-(.,:-'r.,lpoint
ExhaustmanifoldlPoint2]
Heat shieldPlate
ri.
l-/ Kq-m
$ Replaceafter everydisassembly
. Undercover
. Exhaust
fronttubenuts
. O,sensorconnector
. Exhaust
sensor
temperature
. Hotairduct
Remove& installexhaustmanifold
[Point1]
Removal
sequenceshownin
thefigure.
lnstallation
. The installation
sequenceis shownin the figureon right.
. Checkthe standardtighteningtorqueafterinstallation.
Exhaustmanifoldinspection
[Point2]
in four
. Measuretheexhaustmanifoldsurfacefor distortions
and
separatedirections(oppositedirections:horizontally
in a numberof locations).
vertically)
Remove& install O, sensor

[Point 3]
(Zirconium
typesinglepoleconnector)
. Do not usetoolswithimpactsuchas impactwrenchfor
of the O, sensor.
removaland installation
E N- 1 4 2
Straightgauge
ON-VEHICLEPARTS
CA18E
] NGINE
10-3
LOCKERCOVER
rlOSC
LOCKeT
COVerSCreW
0.1- 0.3lPoinr1]
3---'(8)
Grommet
6 -_
Oil Rttercap \
\.4*
fl.-r."y
\=2
Fi
l".l ks-m
. High{ension
cable
. AircleanerASSY
Remove& installlockercover
[Point1]
Removal
. Removalisthe reverseorderof installation
seouenceshown
Installation
. The installation
sequenceis shownin thefigureon right.
. Whenremovingandinstalling
the lockercover,alsoremove
the covergasketand wipeoff the oil adhereon the gasket
and in the oroove.
Locker cover gasket

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

[Point2]
. Removestartermotorand attachringgearstopper.
Caution:
Coatthe screwpartwithengineoilwhentighteningthe crank
pulleybolt.
Do not applyany oil on the damperareawhen installing
or
removingthecrankpulley.
Removecrankpulley
[Point3]
. Loosen
thecrankpulleyboltsandusepulleypuller
(steering
wheelpullerST27180001)
to removethecrank
pulley.
Caution:
Donothookthepulleypulleronthecrankpulleygroove.
Remove& instatl belt cover

[Point 4]
. Do notscratchpackingwhenremovingand installing
the
beltcover.
. Alwaystightenthe beltcoverboltusingthe rubberwasher
Installcrank pulleyplate
[Point5]
. 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
Crankpulleyside
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
T.D.CPoint.
compression
. 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
Engine overheat
Interferencewith belt cover etc.
Cracks on rear
sloe
Wear and cracks
on the side
.J\>
Beltmisalignment
Beltplatemalfunction
/.Mhx
Worn teeth
t*tlt'x
/ A'/.4i // ///// //l

'=w!l
jJlfuu/

Waterleaksin waterpump
Oilor water
adhesion
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]
,",(3),u_$\
ffiP
Springwasher
gf.o<-spr.ins
=\
'/:,j$t
*asne,
\ -Bolt(2)
16-20
E is-r
p Repiace
. Drainandrefillcoolingwater
. Fanshroud
. Fan
. Waterpumppulley
. Supplementary
belts
. limingbeltcover
Removewaterpump
[Point1]
. Becarefulnotto getcoolant
ontimingbelt.lf anywaterdoes
spill,wipeifoffimmediately.
Caution:
Remove
oldgasketonthewaterpumpsurfaceusingthescraper.
Waterpumpinspection
[Point2]
. 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
houstr
Thermostat
1
l
lPoint
t
ds\
-\-"\'t
\ ----rll./
---Ll
7r,
\",4 Kg-m
dl-
B o l t( 3 )1 . 6 ' 2 . 1
$ Replaceaftereverydisassembly
. Wateroutlethose
Remove& installthermostathousing
[Point1l
Removal
. lnsertscrewdriverhandleintothermostathousing Prylightly
up and downand removehouslng.
lnstallation
. Placethejigglevalveon topwheninstalling
thethermostat
housing.
Caution:
Removeold gasket on the water outlet surfaceusing the
scraDer.
Thermostat inspection
[Point 2]
. Checkthe valveopeningtemperature
and maximumvalve
tift.
. Hangthethermostatby stringin valveand submergein
andstirwaterwhile
heatingit up.
. The openingtemperatureis thetemperaturewhenthe valve
opensandthermostatfallsfromstring.
82
88
OverI / 95
Over7 / 100
E N. 1 4 8
String
Double-wall
container
Thermostat
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
Eoil sealgasket
El(front)\int4l
\u"
p$oit
+4eet'rt
'\.)-erz-?)
:1
seaoastet
,rt')Qffi
\ "
t r ,
l".l Kg-m
p Liquidgasket
Q
Drainplug washer[Point4]$ pj
H, ,''0,o u, - 0 85lPoint
4]
Replaceafter every disassembly
. Undercover
. Engine
oil
. Right& leftenginegusset
Drain plug washer

[Point1]
. Thedrainplugwasherhasinstallation
direction,
makesure
to installin the correctdirection.
. Alwaysreplacedrainplugwithnewoneswhenremoving
andinstallino.
Remove& installoil pan bolt

[Point2]
Removal
. Removethe boltsin reverseseouenceshownin floure
on right.
Installation
. Installboltsin sequenceshownin the figureon right.
. Tightenboltsto correcttighteningtorque.
Removeand installoil pan

[Point3]
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
Oil pan side
lr
ON-VEHICLEPARTS
CA18E
i NGINE
lnstallation
. Applysealingagent(SS60For equivalent)
on theareas
pan
gasket.
shownin thefigureon rightto installoil
:.--
. 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.
Oil leak& oil pressureinspection

[Point4]
. Warmuptheengineandcheckforanyoilleakingandthe
oilpressure.
. Release
switchandinstalltheoilpressure
theoilpressure
inspection.
outtheoilpressure
gaugewhencarrying
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
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
'," - o.ro.1zy
"_
Airhose
Airhose p rilo'""
UDe L,"\..t_
,/
^
,/ Rubber \ I
chambef\(@
p r . : - r . o 1 z- 1
0 5 2 - 0 6 6 ( 4p)j
'"f"'
O - r i n gE
,,Y
Air cleanefcase
. . ' - Ho s e
-
Air cleanerelement
Insutator
^ - ^
^ ^ ^
F i
u^cz - uoo lv,/

r J r l " , l0 5 2 - 0 6 6 ( 4 )
0 . 5 2- 0 . 6 6( 2 ) ! -
-e/g v,
- l
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
Resonator
bracket
E
'^'^^,)h
n c,l - necfC|l
{ as2-o66pJ
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
out
. lnstallation
carried
oftheairductandtheaircleaneris
operation.
in reverseorderof removal
. Airflowmetercircuit
useASSYwhen
caseisnonseparable,
meter.
theairflow
replacing
. Makesureto inserttheairhoseandtheairductsecurely
andtightenthe
markcorrectly
byaligningthealignment
bandandtheclamP.
E N- 1 5 2
ON-VEHICLE
PARTS
1O.2
INTAKEMANIFOLDGOLLECTOR
(1) Remove& installintakemanifoldcollector
coirector
ASSY
|2i'ftt:'rti:g
-Y-V
\ -,-aa
CollectorgasketE
-[]
/l
\ .'.
pcoltectorboit(2)1.8- 2z.-*&
l-,i r<9-m
E Replaceafter every disassembly
,/)
Removal
Releasethe fuel pressure
. Warmuptheengine.
. Select'Fuelpumprelay'in 'Activetest'mode.
. 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
,,
irlt , u- 22 \2)P)
. B- 2 . 2
FUELPU[,4PRELAY OFF
(POS) 950 rpm
CAS.RPI\,|
PARTS
ON-VEHICLE
lockercoverandthe
RemoveblowbyhoseE befuveen
collector.
RemovehoseF betweenpressureregulatorandthe
collector.
RemovethreewaterhosesG.
Removethe hosebetweenair regulatorandthe collector.
Liftup the collectorASSYwhenremovingthe hosefor
easieroperation.
RemovefuelfeedandretumhoseH,thenremovetheclamp
fromthe collector.
Loosenthe hoseclampto removecollectorASSY
11
J
Loosenthe boltsin ordershownin thefigureon right.

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
. Lengfi {mm}:
No. of bolls
"7 =3. - "1 - Y; -. -s. , .
105.2
't.8 - 2.2
65:1
1 . 8- 2 . 2
1,3,4,6
40.4
1.8-2.2
2 , 5 , 9 ,1 1
30:4
1.8-2.2
7,10
I
,2 - ' l.
Connecteachwiringandthe pipingin the reverseorderof

the removaloperation.
wire,
Connectthe accelerator
wireand pull
for
the accelerator
slack
adequate
Provide
usingthe
outercasein the directionof the accelerator
from
the position
1
.5
turns
nut
1
.0
to
lock
Return
adjustnut.
thethrottledrumstartsmoving(whenthereis no play)and
tiohten.
0 . 8- 1 . 0
E N- 1 5 4
l-
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
9ts't
Water hose
E Replaceafterevery drsassembly
Disassembly
. Removethrottlechamber
. RemoveIAAunit
Assembly
. Installthrottlechambergasket
lnstallin iorrectdirection
. Tighten
thethrottle
chamber
boltsrnordershowninfigure
onrightuniformly
intwostages.
Tightening
torque(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
FUEL INJECTOR
10-3
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
sensorconnectorandthe
groundwires,watertemperature
connectorare removed.
thermaltransmitter
. 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
value(f,|): Approx.13 - 14
Resistance
. Iniectorcan not be disassembled.
E N- 1 5 6
ON-VEHICLEPARTS
Installation
. Do not rotateor decenterthe partswheninstalling
the fuel
pressureregulator
in1ector,
andfuelbumperto thefueltube.
. Tightenthe pressureregulatorandthefuelbumperscrews
uniformlyin twoto threestages.
Tighteningtorque(kg-m):
0.30- 0.39
. InstallfueltubeASSY
1 . 6- 2 . 1
. Connect
theairregulator
connector.
. Install
thefuelinjector
connector
andfixit inplaceusingthe
.
ctamD.
Installthe collectorASSY
10-4
INTAKEMANIFOLD
p_@=---
- o.asP
aort
1z)o.o+
Airreguraror
I
El WateroulletpipeASSY
B o l t( 6 ) 1 . 6- 2 1
Intakemanifold
tt
t',i
p l e o it z o) n - o s
i-,i kq-m
A Liquidgasket
Removal
. RemovecollectorASSY FordetailedremovalDrocess
referto "Collector"
section
. RemovefuelinjectorASSY
. Removewaterhose.
. Removeoillevelgaugeguidebolt.
Oil levelgauge
. Removerearwaterpipeconnectorbolt.
EN - 157
ON.VEHICLEPARTS
RemoveintakemanifoldASSYboltsandnuts(1,
the ordersshownin thefigureon right.
Removethe intakemanifoldgasket.
'10'13)in
14 11
. RemovewaterPiPeASS\.
1312 10 4
lnstallation
. Removeold liquidgasketon the waterpipe,in the groove
andon the intakemanifold.Cleanallcontactsurfaceswith
whitegasolineor equivalent.
00150)
. Applya continuous
beadof liquidgasket(KPs'10
2.0- 3.0mmwideto sealingsurfaceusingthetube
pressor.
Caution
shouldbe performedwithin5 minutesafter
Installation
coatingthe liquidgasket.
Waitat least30 minutesbeforerefillingenginecoolant.
?,,
; -.
'3.
.jt"v,
/
Installthe waterPiPeASSY
:"'"
- .,..''..'.-;'.|
. .ra)
']
,i-.
f-
( A ) 0 . 4- 0 . 5
( B )1 . 6- 2 . 1
(B) bolt(6)
1A-111o ,
1 4 1 3
gaskeL.
Installintakemanifold
inseveral
theboltsandnuts(2.10.13)uniformly
Install
stagesintheordershowninthefigureontheright.
1 . 8- 2 . 2
z 3 5
levelgauge
g u i d e0 . 4 - 0 . 5
. Installthefrontoil levelgaugeguidebolt.
. Installthe rearwaterpipeconnectorbolt.
0.4- 0.5
Tighteningtorque (kg'm):
. lnstallthewaterhose.
PrPe.l
E N- ' 1 5 8
1 4
ON-VEHICLE
PARTS
10-5
EXHAUSTMANIFOLD
Exhaustmanrfoldgasket $
O r - s e n s4o.r1- 5 . 1 9
K:,
Exhaustmanifold
/:--9.
r3l
Washer
Nr,,rrto-2r\Fi
Exnaustmanrforo
" -"
il;'
9ts-t
fr,
tp
o a - - o s { 8 ) go, sensor
aftereverydisassembiy
$ Reptace
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
r.o- z.r\
121
t=o'
N u t4 . 4- 5 . 9g
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
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
locatedas describedas follow:
stroketopdeadcenter
No. 1 cylinderis at thecompression
whenboththe No. 1 intakeand exhaustsidecamsdo not
movethe valvelifters.
EN - 160
i'18\
ON-VEHICLEPARTS
Removetheoilfiltercamfromintakesiderockercoverand
checkthatthe frontend of camshaftfacesthe intakeside.
Remove
crankanglesensor.
Remove
startermotortheninstallringgearstopper.
Remove
crankpulleybolts.
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
bolttensionernuts.
Caution:
Do not looseninsertedstudat disassemblv.
lf painton timingbeltis unclearwhendisassembly

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

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

on the side
Worn teeth
SlidingmotionresistanceIn
Oil or water
adheston

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.
-li
\=o\Tensionerspring
securinostud
Tensionerspring sPecifications
' 1 . 8m m
Tensionerpulley
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
Nut
. Be carefulto observefrontand rearpositioning

of timing
beltplate,cranktimingpulleyandcranktimingpulleyplate
wheninstallation
is performed.
. Alignthealignmentmarksof the exhaustand intakecam
pulleyswiththerespective
beltcoveralignment
marks(No.
1 cylinder
is atT,D.C).
. Alignthecranktimingpulleyalignmentmarkwiththe mark
on oil pumphousing.Thegroovemustbe straightup (No.
1cylindercompression
T.D.C).
. Movethe belttensionerclockwiseat 70 - 80"Cangle,and
secureit temporarily
withbelttensionernut. (Thiswill
minimizetheoffsetbetweenthetensionershaftandthe
timingbelt).
. Alignthetimingbeltpulleymarksandinstallbelt.Alignthe
numberof ridgesof exhaustcam pulleyalignmentmark
andcrankpulley(inner)alignmentmarkas shownin the
figureon right.
securetensionerwithhexagonalwrenchso it doesnot
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.
4.4- 5.9
At thisconditionbelttensionshouldbe approximately
20
ko.
EN- 163
Conical
*""1"t
Crank
plate
Crank
pulleyside
Alignment
mark
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.

( A ) 1 . 6- 2 . 1
(B) 0.65- 0.86
(1)
Applychassisgreaseto driveunitspline.
(2)
Thereis a flangeinsidethedriveunitsplineso spline
onlyhasone insertionposition.Checkthe alignment
beforeassernblY.
(3)
Checkthatthe crankanglesensorcan be inserted
easilyin beltcoverholesandsensormoveslightlyto
rightand left,thentightenbolts.
lf thesensordoesnnotmovelightly,loosenthe beltcover
A\
boltswithcrankanglesensorinserted.Movebeltcover
to alignbeltcoverholecenterand camshaftcenter.
Tightenboltsmakingsurethe crankanglesensor
moveslightlY.
0 . 4- 0 . 5
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
Removal
. Drainengineoil.
. Removeradiatorfan.
. Removefrontstabilizer.
. Removeengineright& lefigusset.
121620 2428302622
. Removeoil pan boltsin orderof sequenceshownin the

figureon right.
Ti7sE272s2s2117
fi
. 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)
4 mm wide.
to innersealingsurfaces
. lnstallation
within5 minutes.
shouldbe performed
Caution:
is 4.0 mm wide.
Be sureliquidgasketapplication
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
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.
Rearoil seal
Removethefollowingparts:
. Transmission
(orA / T)
. Flywheel(ordriveplate)
. Rearplate
. Rearoil sealretainer
E N- 1 6 7
Oil seal drift

KV40100900
'--_r{'@
r
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
00150)
beadof liquidgasket(KP510
wide
3
mm
2
surfaces
to rearoilsealretainer
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
Bolt0.3- 0.39
lgnition
coil
. Installthe ignitioncoilbracket.
qS
Vf
ry
rgnrtron
corltacket
. Installtheomament.
E N- 1 6 9
cv.rinder
\LO
Sparkplu0
ON.VEHICLEPARTS
CYLINDERHEAD
10.10
(1) Cylinderhead removal& installation
CVlinderhead bolt
\J/
Leuserr
ut
fl.,-(4) Tightento
(5)AnSlewr
II
wl
rorque
]|
o . o z1- . 2 , g l
\ ^
\Y
g
Springwasher
-.-\o
Cylinderhead bolt
,^,-^L^-
0.e2-1294
wasnerr'|
s/
j-Spring
washer
f'-"{t
' 0 v , /
/d'
'.\)
\
\
\ ,
\,]
H| rs-t
$
Cam pulley
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.
E N- 1 7 0
4 - 1 7 | ' . , 411.x5
I - 3 M6x1.0
ON.VEHICLE
PARTS
Installation
. Beforeinstalling
thecylinderheadASSYto 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
of entrainedairwithinthe hydraulic
Thereis a possibility
to be
valvelifterif the slumpis over 1'0 mm Air need
releasedfromhydraulicvalvelifter'
10 minutesat 4000rpm
ldlethe engineior approximately
afterinstallingthe rockercover'
valvelifter
Removethe rocKercoverandpushthe hydraulic
surfaceto checkthe slumpof cam basecircle'
is overthe
Replacethe hydraulicvalvelifterif thevalue
limit.
(2)
Cylinderheaddi"""."-bly, ""t"-bly&inspection
Valvelrfler-
-./
valvecorer-'--"'"
/u"V:f31'?'.,11''""'
/ 9ping seat
t'd/^r/
Valve
- o| seal
.au^ru.
"
\<-
.0.'"n**ffi" *
Washer-=-3
Buffleplate----
P e o r r o . st .zrj
-@-Y==--J:?"[',].",""""r"
seat
,{/-i
A
fp
^^
-crr(@@--"
O
B o r t o .1
e2 g
-l
E
I
washer/
nu'o'
, /Valve
e/
-washer
'"1::::.::"::li**
*o@;*lT"ililJf""['S
W KffiP*
--.9-3:Ji9',
#
^.#"*\
)t 6.Nr--_
-$---&
ri.,nso"*"o:,-a{-*?J
_-\D
":'">-t\
g..:
*\..!
F.:.t'
_ ' 4 F ^ ' " , 0 n ', r g

sea6r[Hj::;";";:
i
l"
\r..-.'5-eo'osz-'ze
*tr!1liiry'""ffiy*i;ltj,tp;:;:,.
;:;:;:M,-;l*inan' ron' o
cam;hafttrontorlsealE[
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
canbeidentified
by
paintcolorandpresence
identification
of a splinegearfor
driving
thecrankanglesensor.
Camshaft
Intake
camshaft
Purple
No
Exhaust
camshaft
Orange
Yes
Removehydraulic
valvelifter.
(1)
Hydraulic
valvelifteris nonseparable.
(2)
Do notstorehydraulicvalvelifterup sidedownor on
itsside.
(3)
Storehydraulicvalvelifterin theengineoilwhen
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
I Splinegearfordrivingcrankangiesensoj
C)
V
/7^ @
K7\J
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
on dialgauge.
indicated
0.05
Standardvalue (mm):
CamnosediameterinsPection
of camnose.
diameter
to measure
Usemicrometer
(mm):
39.705- 39.895
Intakestandardvalue
39.205- 39.395
Exhauststandardvalue(mm):
Replacecamshaftif diametervaluediffers.
Camshaftoil clearance
. Tightenthe cam bracketto specifiedtorque.
to measureinsidediameter'
Useinsidemicrometer
28.000- 28.021
(mm):
value
Standard
l-)
ofcamshaft
. Usemicrometer
diameter
outside
to measure
JOUmal.
Standard value (mm):
27.935- 27.955
ls
Inspectthatthe camshaftoil clearancemeasurement
withinsoecifiedvalue.
Oil clearance= cam bracketinsidediametercamshaftjournal (outsidediameter)
Standardvalue (mm):
0.045- 0.086
Camshaft end plaY

. Assemblecamshaftandtightencam bracketto standard
value.
. Seta dialgaugeat frontendof the camshaftin thrust
direction.Whencamshaftmovesin frontand rear
direction,readthedualgaugerun-outwidth.
0.030- 0.080
Standardvalue (mm):
EN -
'174
ON-VEHICLEPARTS
Valveguide clearanceinspection
D i a lg a u g e
. Protrudevalveapproximately
15mmfromvalveguidehome :
\
intocombustionchamber.Measurevalvedeflectionby
swingingintodirection
parallel
to 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
cylinder
headvalveguideholeusingvalveguide
reamer
Rectifiedvalvestandardvalue(mm)
Intake& exhaust:
6 . 0 0 0- 6 . 0 1 8
Heatcylinder
heatin an oilbathto approximately
150160oC.Usea valveguidedriftand pressvalveguidefrom
camshaftside.
. Thepress-fit
dimensions
areshowninfigureonright.
1 6 . 8+ / -0 . 1
Intake/ Exhaust
Reamtheinside
oftheinserted
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.
EN - 175
o*
q"o,"
PARTS
ON-VEHICLE
Valve seat rePlacement

. Cut andgrindvalveseatto removethe valveseat.
. Readjustthe mountingholefor oversizevalveseat.
Standardvalue (mm):
36.5+0.016-0
lntake
3 2 . 0+ 0 . 0 1 6- 0
Exhaust
. 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
"C
B0
Heatup the cylinderheadto approximately
. Insertcooledvalveseatintocylinderheadquickly.
Caution:
Do notdirectlytouchcooledvalveseatwithhands.
. Read.lust
thevalveseatusingvalveseatcutterorvalveseat
onnoer.
.\,=
is as shownin the
Valveseatshapeand measurement
figureson right.
* o D-'-
t
,..',.,'
op,
rg-'
.::-. .
Urafe
so.of,o'u
Qo,
so.of,o!,'
^^ . -0016
JO.C o
^^ - +0113
Jb. c n o97
Qa
6o,
0D,
32.O
37.0
32.O
37.0
zs.t'.. ,
zs t',.,
E N- 1 7 6
6o,
ON-VEHICLE
PARTS
Valveinspection
Outsidediametermeasurement
. Usemicrometer
to measureeachdimension.
Valva
lnlake
Exhaust
- 34.02 5 965 - 5.980 1 . 1 5 - 1 . 4 52.60 - 2.90

8 5 . 3- 8 5 . 5 8 0 . 7 8- 8 ' 1 . 0 8 34.OO
8 7 . 3- 8 7 . 5 8 2 . 7 8- 8 3 . 0 8 2 9 0 0 - 2 9 0 7 5.960- 5.945
3 . 2- 3 . 4
Valvespring squarenessinspection
. Placea righfanglestraightedge(L-square)so it contacts
thespring.Turnthe springand measurethe maximum
clearancebetweenupperspringsurfaceandthe right
anglesurfaceto determineout-of-square
distance.
Limit(mm):
1.8
. Replacethevalvespringif the oulof-squaredistanceis
overthe limit.
Contact
Freelengthand pressureload inspection

. Usea valvespringtesterto checkthe springpressure.
Freelength(mm):
Installation
load(kg):
43.1
24.0
Hydraulicvalveliftervisualinspection
. Visuallyinspectcamshaftrotationalareaon liftersideand
lifterborerotationalareafor anywarnor damage.
. Replaceif thereareany abnormality.
Caution:
Do notdisassemblehydraulicvalvelifter.lt is nonseparabte
un[.
Hydraulicvalve lifter outside diameter

. Usea micrometerto checkthe valvelifteroutside
diameter.
Standardvalue (mm):
30.955- 30.965
EN- 177
t---.---,-'lJ
30.
'15"
ON-VEHICLEPARTS
Hydraulicvalvelifterhole internaldiameter
3 1 . 0 0-0 3 1 . 0 2 0
Standardvalue (mm):
Hydraulic valve adjuster clearance

valveclearance=
Hydraulic
valveclearanceholeinternaldiameter- hydraulicvalveexteriordiameter
HVdraulic
lnstallation
. InstallvalveassociatedParts.
. Fordetailedinformation
on howto installnewvalveoilseal
"Oilsealreplacement".
referto sectionon
. Installvalvespringwithnarrowpitchendtowardscylinder
colorsidedown).
head(identification
. 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
T.D.C
. Turncamshaftso No. 1 cylinderis at compression
position(orturncamshaft60obeforeor afterNo. 1 cylinder
r.D.c).
. Temporarily
tightenNo. 1 cam bracketand makesurethe
securely.
thrustsectionis positioned
E N- 1 7 8
KnockPln
Knockpin
ON-VEHICLE
PARTS
Tightencam bracketbolts540.(1.5 turns)graduallyin

severalstagesin the sequenceshownin thefigureon
right.
Tightening
torque(kg-m):
0 . 9 2 -1 . 2
6
Installcamshaftfrontoilseal. Fordetailinformation
referto
"Oil
seal"section.
. Installtimingbeltbackplate.
. Aligncampulleyto camshaft
knockpinto install.
1 . 4 -1 . 9
E N- 1 7 9
10 14 12
Ffonti
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.
[Point 2]
. Loosenlocknut and provideadequateslackfor the
wire. Pulloutercasein the directionof the
accelerator
pedaluntilthrottledrumstartsto move(noplay
accelerator
in cable).Rotatethe locknut 1 to 1.5turnsto tighten.
0 . 8- 1 . 0
Enginemain harness,ground line

separation
. Disconnect
the connectorsbehindthe batteryfor
systems.
startermotorandtransmission
alternator,
[Point3]
andpowersteeringoil
Air compressor
pump movement
. Remove
Leavepipes
eachunitto brackets.
boltssecuring
andsecuretosideofthebodywithstring Care
connected
thebody.
mustbetakennotto scratch
lPoint4]
!e
.iffifierr
"
ffY;"..
Powersteeringoil tubebracketseparation
[Point5]
oiltube
. Removeboltsandseparate
thepowersteering
side.
the
body
andmovetowards
bracket,
..-- v,r*Jo fiom betow
Front enginemountingnuts removal

[Point6]
. Makesurethe engineslingsaresecurelyhookedby
enginehorstchainandremovefrontenginemountingnuts.
'hN4
'6) l,----'-
ion-teng,nurouFinlS
n u t4 . 4 - 5 . 6
E N- 1 8 0
REMOVE& INSTALL
ENGINE
RB26DETE
TNGINE
[Point7]
Rightfront enginemountingbracket
removal
. Powersteering
oiltubewillhittherightfrontengine
mounting
andit is notpossible
to shifttheenginefonvard.
Therefore
removenutsandremoverightenginemounting
bracket.
Remove& installengineASSY
[Point8]
. Operate
thehoistchain,andchangetheengineangle
gradually
to 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

fuelPressure
Release
[Point1]
. 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
[Point 2]
. Loosenlocknut and provideadequateslackfor the
wire. Pulloutercasein directionof the
accelerator
pedaluntilthrottledrumstartsto move(noplay
accelerator
in cable).Rotatethe locknut 1 to 1.5turnsto tighten.
0 . 8- 1 . 0
Enginemain harness,ground line

seParation
. Disconnect
the connectorsbehindthe batteryfor
systems.
startermotorandtransmission
alternator,
[Point3]
Air compressor and power steering oil

pumP movement
. Removeboltssecuringeachunitto brackets.Leavepipes
connectedandsecureto sideof the bodywithstring.Care
mustbe takennotto scratchthe body.
[Point 4l
Remove& Install propella shaft

[Point 5]
. 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
Remove& installrearenginemounting
[Point6]
. Supportthe transmission
jack and
withtransmission
removerearmemberboltsandrearenqinemountinobolts
andnuts.
(4) 4.4 - 5.6
Frontenginemountingnuts removal
[Point7]
. Makesurethe engineslingsare securelyhookedby
enginehoistchainandremovefrontenginemountingnuts.
Enginemountingnut tighteningtorque(kg-m):4.4- 5.6
Frontenginemounting
nut
Remove& instaltengineASSY
[Point8]
. 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
engine.
theRB25DE
. Draincoolingwatercompletely.
. Removebonnet.
Enginebay left side:
. Exhaustgas sensorharnessdisconnection
. Groundlineconnectorseparatlon
. Air duct,Air cleaner
. Powersteeringoil PumPremoval
. Air compressorremoval
Enginebay right side:
Battery
/G.\
"fuelputp rer"y" (E
)
. Release
byselecting
fuelpressure
in activetestmode,and PressSTOP.
O ncrtvgrEsr O
FUELPUMPRELAY OFF
CAS-RPM(POS)
950 rpm
fuelpumpfuseandrun
. Afterstaringtheengine,remove
fuel
engineuntilitstops.Consurne leftinfuellinebV ffi
\Gy
theengineovertwotothreetimes.
cranking
Caution:
. Acceleratorwireseparation
. Heaterhose
. Vacuumhosesseparatior
Enginemain harness& ground line separation
Enginebay front side:

. Radiatorshroud,radiator
. Coolingfan
Enginebay upPerside:
. ECCSharnessconnectors
E N- 1 8 4
START INTERRUPT STOP
REMOVE& INSTALL
ENGINE
R525lE ENGINE
Vehiclebody,lower side:
. Engineundercover
. Propellashaft
. Transmission
controllever(M/Tvehicle),
linkage(A/Tvehicle)
. Exhaustfronttube
. Rearenginemountedbracket
. Rightandleftenginemountedbracket.
Remove& installengineASSY
. Operatehoistchainandchangeengineanglegradually.
Caremustbe takennotto interferewithvehicleand
removetheengine.
E N- 1 8 5
\qt--l.ER)j
^
\r,_r,_"
xear_rnemD:r-Rear
enqinemountrn
bolt(4)4.4- 5.6
UoitiZ;a.+__
s
OVERHAUL
ENGINE
RB26DETTENGINE
12 ENGINEOVERHAUL
from
removed
of theengineassembly
disassembly
thecomponent
Thissectiondescribes
of
replacement
theinspection,
lt alsoexplains
thevehiclewithouttransmission.
and
adjustments
orwarnpartsandcarryoutanynecessary
damages
malfunctioning,
enginecondition'
a standard
inorderto produce
assembly
sequential
CAUTIONS
OVERHAUL
bly
( 1 ) Disassem
andmakesureto carryoutsafe
. Usecorrectandsuitable
toolswhenpossible
procedures.
to
andslidingsurfaces
. iare mustbetakenwithoperations
on matingsurfaces
preventlossof surfaceaccuracY.
foreasyfaultsdetection
. Arrangedisassembled
parsby makingmarksto organize
andpreciseassemblY.
fromoutside.care mustbetakento
. Loosennutsandboltsin a diagonal
direction
orderwhenindicated
followthenumerical
repairandreplacement
(21 lnspection,
theinspection
following
partsinspection
. ieplaceor repairaftercompleting
forthenewpartsandreplacepartsas
sameinspection
Perform
orocedures.
necessary.
(3) Assembly
torque
tightening
. Alwaysusea torquewrenchto tightennutsandboltsto specific
gradually
intwoor
direction,
. Tightennutsandboltsfromcentreto outsidediagonal
orderwhenindicated'
stages.Followthenumeric
threesuccessive
withnewonesin principle'
. Replace
packing,
oilsealsandO-rings
gasket,
check
air. Inparticular,
. Cleanea-hpartthoroughly
andblownoffwithcompressed
arenotcloggedor obstructed'
thatoilandwaterpassages
. caremustbetakennotto scratch
ordamageslidingormatingsurfacescleanoffall
allslidingsurfacewithanadequate
dust,debrisorforeignobjects.Lubricate
oil.
coating
E N- 1 8 6
ENGINE
OVERHAUL
RB26DETE
TNGINE
12.1 DISASSEMBLE
& ASSEMBLECYLINDERBLOCKASSY
Deronation
sensorbolt{211.6- 2.1rct
t:
G-=
___-_
Defonation
sensor
Rearorlseatlpornt7]
6<=
Alternatoradjustmentbar
*PffiffiN
-A
iJ:1il,8*,.",,
""S-f;ffi*
"t*il;E:{ft;i;;'K)q
a\
bolt(2rlPornt
201
ir""'"liln "r rn;-=-fi. l-Pn'oa
D$,
D$ (.4arr
uon roo
Con
r rod bearrrg
bearrno
IJt
lt4arroeanngcaplPornt
25]6;$p11
tcornt?5]^
-\'Z
9?i,:0":,.99-:
Flywheel[Point3, 5]
Rearplare- Mainbearing
ootrp
J<4*-BarnJprate
32-43
o'*'*,-ffi F "d;;H
- r\
Bort(2)1 6 _
2jVi (/:,8!*it?-,;::;?,
Bort(12)
/
Fi
l',1 Kg-m
9 |[."'lTii
u.o4 - u.
*n
A Liquidgasket
oil
fl Ensine
$
A
E-r\-I
Oilpanboltg
.
(t\r10)
3.2- 4.3
pan
pt oirpanbo*(M6)/
0.64- 0.85 Copperwain-e--Orain ptug:.0-a.0gl
a-e
Replaceafter every disassembly
. Drainand refillcoolingwater[Point1]
. Removeand installthefollowinooarts:
. Engine
. Collector
. Throttlechamber
. Intakemanifold
. Turbocharger,
exhaustmanifold
. Timingbelt
. CylinderheadASSY
. Alternator
.
.
.
.
.
.
.
Startermotor
Clutchcover,clutchdisc
Oilpan,oilstrainer
Waterpump
Oil pump
Oilcooler,oilstrainer
All harnessesand connectors
E N- 1 8 7
ENGINEOVERHAUL
RB26DETE
TNGINE
Reference:Engineselectionassembly
Piston
(1) Piston
selection
. 3
Lessthan86.010
Greatefthan86.00
Lessthan86.020
Greaterthan86.010
Lessthan86.030
Greaterthan86.020
Lessthan85.965
Greaterthan85.955
Lessthan85.975
Greaterthan85.965
Lessthan85.985
Greaterthan85.975
0 . 0 3 5- 0 . 0 5 5
Pistonand pistonPin
ServicesettingParts:
1,OOS
STD 1. STD2, STD3, O.5OS,
Pistongrade
(No.1 - No.
Distinction
symbol
Prslonprngrade(0 1)
Mainbearing
(2) Mainbearingselection
, . , ,
'
l , , ' : ' . . ' . ' ' .
,.:.'.'
0
. . 1
7, :'
r ':,:l
r.
2 ) '
STD 1
1.821 -1 .824
0.028/ 0.046
Brown
STD 2
1.824 - 1.827
0.028/ 0.046
NOne
STD 3
1.A27- 1.830
o.028| 0.047
Yellow
STD1
1.821- 1.824
0.028/ 0.046
Brown
STD2
1.824- 1.827
0.028/ 0.046
None
STD3
1 . 8 2 -7 1 . 8 3 0
0.028/ 0.046
Yellow
STD4
1 . 8 3 -0 1 . 8 3 3
0.028| a.047
Blue
STD 3
STD 2
1 . A 2 4 - 1 . A 2 7 1.827 - 1 -830
0.028/ 0.046
0.028/ 0.046
Yellow
NOne
STD 4
1 . 8 3 0- 1 . 8 3 3
0.028/ 0.046
Blue
STD 5
1 . 8 3 3- 1 . 8 3 6
0.028/ 0.047
Green
STD3
1.827- 1.830
0.028/ 0.046
Yellow
..3
Servicesetti
STD O
1 . 8 1 8- 1 . 8 2 1
0.028/ 0.046
Black
STD4
1 . 8 3 -0 1 . 8 3 3
0.028/ 0.046
B IUE
STD6
STD5
- 1.83
1 . 8 3 -3 1 . 8 3 6 1 . 8 3 6
0.028/ 0.046 90.028| 0.047
Pink
Green
S T D O - 6 us 0.25
EoregradeNo.
ff;:113,,".",ifl'
) No.
te! side--,-\'\l
Iru
-5-
*383".\\
r'l-lili:
{,rl\
No 5
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
( 1- 3 )
Largeend grade(0.1) symbol
Con'rod bearing
(4)Con'rodbearingselection
Lass tfian 51.013
Greaaer
than 51.007
0
BearinggradeNo.
STDO
BearinggradeNo.
STD 1
Bearingthickness(mm) 1 . 5 0 -0 1 . 5 0 3Bearinglhickness(mm) 1 . 5 0 3- 1 5 0 6
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
(mm)
Oil clearance
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
Drain& refillcoolingwater
[Point1]
Draining
. Draincoolingwaterin the cylinderblockcompletelyfrom
thedrainplug.
Refilling
. Referto thesection"coolingwater"for detailedinstruction.
Remove& installenginestand
[Point2]
. Installthe enginesub attachmentusing6 boltsto engine
mountingbracketon rightsideof the engine.
B o l t ( 64)- 5
0x151=25
FlYwheelrun-out
[Point 3]
. Setdialgaugeto flywheelwhereit contactsclutch'
. Turntheflywheelandmeasuretherun-out.
0.10
Run-outlimit (mm):
Remove & install flywheel

[Point 4]
Removal
. Useringgearstopperto fix flywheeland remove.
lnstallation
. Coatthe threadandflangeof boltswithengineoil after
ra.s-)s6--\"\
bolts.
the
installing
. aftertighteningthe flywheelbolts,use ringgearstopperto
secureflywheelandtightenbolts.
't4.5-15.5
Flywheelbolt tighteningtorque (kg-m):
((6)
Flywheelknock pin installation

[Point5]
. Insertthe flyrvheelknockpinso the pin protrudesB to 8 5
mm.
Knockpin
protrusiondistance
Knockpin
Flywheel
E N- 1 9 0
ENGINE
OVERHAUL
RB26DETE
TNGINE
[Point6]
Removal
Remove& installrearoil seal retainer
. Inserta screwdriver
inthegapbetween
mainbearing
cap
andrearoilseal
retainerto
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.
. Tighten
6 boltsuniformly.
Rearoil sealretainerbolttighteningtorque(kg-m):
0.64- 0.85
[Point7]
Removal
Remove& installrearoil seal
. 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
Con'rod side clearanceinspection

[Point8]
. Usethicknessgaugeto measurethethrustclearance
betweenthe con'rodandthe crankarm.
0.2- 0.3
Standardvalue (mm):
0.4
Limit value(mm):
Remove& installpiston con'rodASSY

[Point9]
. 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): 1.460 - 65
2nd time Angle wrench ( " ):
Caution:
Do notvisuallymeasurethetighteningtorqueif anglewrench
is not available.
[Point10] Installcon'rod bearing
con'rod
. Applyengineoil to bearingsurfacewheninstalling
bearing.Do not applyengineoil to rearsurfaceof
cleanthisarea.
bearing,
. 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
interfere
withpiston.lf oiljetpipecontactspistonoris benr,
replace
itwithnewpart.
Oiljettightening
torque(kg-m):
3 . 1- 4 . 1
.<
Evebort
3.l'41
_r _31 {
!-\
o"*
.' 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.
Caution:
Caremustbe takennotto scratchpiston.
'l3]
[Point
Removal
;",;*);^3i
-"
{/z--Yrr
Y
aln
..\ \./
Remove& install snap ring
. Usesnapringpliersto removerings.
Installation
. Usesnapringpliersandinstallringssecurely
ingroove.
Caution:
Alwaysreplace
snapringswithnewones.
[Point14] Remove& installpistonpin
. Usea heatgunto heatpistonto 60- 70"Cwhenremoving
piston
pin.
andinstalling
Placesuitabletoolagainstpistonpin and pressor use

plastichammer.
Applyplentyof engineoilto pin,pin holeand con'rodsmall
note.
E N- ' 1 9 3
)s<-.-
/
^
Decononno ooentn0
-
OiI nno lower

ra opentnq
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.
[Point15] Piston Pin inspection

. Usethe micrometer
to measureoutsidediameterof piston
ptn.
20.989- 21.001
Standardunit (mm):
[Point16] PistoninsPection
. Usemicrometer
outsidepistonskirtdiameter'
to measure
from bottom(mm): 13
pointDistance
Measuring
85.955- 85.985
Standard(mm):
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.
0.15
Bend limit (mm):
0.3
(mm):
Torsionlimit
Smallend insidediameterinspection
21.000- 21.0'12
Standardvalue (mm):
E N- 1 9 4
Front
Micrometer
ENGINE
OVERHAUL
R826DETT
ENG]NE
Gon'rodbearinginteriordiameterinspection
. Installcon'rodbearingin con'rodandcap. Tightencon'rod
nutsto specifiedtorqueand measurecon'rodbearing
interiordiameter,
Con'rcd nut
tigh!eningtorque
1 s tt i m e Torquewrench(kg-m) 1 . 4 - 1 . 6
2nd time
Anglewrench( ')
60-65
4 7 . 9 8 9- 4 8 . 0 0 7
Standardvalue
[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.
lPoint21] Piston ring end gap and side clearance
Ring end gap inspection
. Usea pistonto pressthe pistonringintothe middleof the
cylinder
andmeasure
thegap.
Item
Top dng
B o r eg r a d e1 , 2 , 3 :
0 . 2 4- 0 . 3 4
S.cond ing
0.42- 0.57 0.20- 0.60
Side clearanceinspection
. Measurethe clearancebetweenthe oistonrinoandthe
pistonringgroove.
- 0.135
0.040- 0.075 0.030- 0.065 0 . 0 6 5
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
0 . 0 5- 0 . 1 8
Standardvalue (mm):
0.3
Limit(mm):
[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
thebolts
turnssmoothlyaftertightening
surethecrankshaft
to specifiedtorque.
Main bearingbolt tighteningtorque(kg-m): 4.7 - 5.3
Caution:
Applyengineoil to the boltthreadsand boltseatswhen
the bolts.
tightening
IPoint25]
Removal
Remove& installmain bearingcaP
. 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.
inspection
[Point27] Crankshaft
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
inspection
[Point28] Con'rodbearingoil clearance
(A) Usinginsidemicrometerand micrometer
. Theoilclearance
canbecalculated
fromconnecting
rod
bearinginsidediameter
pindiameter
andthecrankshaft
measured
in[Point1B]and[Point27].
=
(Oilclearance)
- (crankshaft
(Bearinginsidediameter)
pin diameter)
Standardvalue(mm):
0.020- 0.040
Limit value(mm):
0.090
. 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 plastigauge
slightlyshorterthanthe
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
scale.
widthwitha plastigauge
Caution:
or connecting
rodwhileplastigauge
Neverturnthe crankshaft
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
con'rodhole)and the pin diametergrade(indicatedon
frontsurface).
crankshaftNo. 1 counterweiqht
UpperjoumalgradeNo
Con'rod bearingselectionchart
Lessthan51.@7
Grsbr tlan 51.000
a
STD1
STDO
BearinggradeNo.
BearinggradeNo.
" ' 1. 5 0 3Bearingthickness(mm) ' 1 . 5 0-3 1 . 5 0 6
Bearingthickness(mm) 1 . 5 0 0
(mm)
0 . 0 2 0/ 0 . 0 3 9
0 . 0 2 0/ 0 . 0 3 9Oil cleararrce
Oil clearance(mm)
Browl
None
ldentifcation
colour
ldentitication
colour
LesstfEn
47.968
Greaterttran
47j&l.
STD 2
STD1
BearinggradeNo.
BearinggradeNo.
Bearingthickness(mm) ' 1 . 5 0-3 1 . 5 0 6Bearingthickness(mm) 1 . 5 0 6- 1 . 5 0 9
0.02'1/ 0.040
0.020/ 0 040 Oilclearance(mm)
Oil clearance(mm)
Green
Brown
ldentifcation
colour
ldentification
colour
E N- 1 9 8
ENGINE
OVERHAUL
RB26DETE
TNGINE
. Whenusingundersize
bearings,
measurebearinginside
diameter
whenbearingis installed.Grindpinso oil
clearanceconformsto specificvalue.
R2.0jourr
| _ R 1 ). (p r n l I
l'' [-J
Bearingundersizechart
Size
us0.08
1 . 5 4 11 1 . 5 4 9
us0.12
1 . 5 6 /11 . 5 6 9
12
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)
Standardvalue (mm):
0.028- 0.047
Limitvalue(mm):
0.090
lf oil clearanceexceedsthe limitvaluereferto [Point31]to
selectsuitablebearing.
Using plasticgauge(MethodB)
. Removealldustandoilfromeachcrankshaft
journaland
bearingsurfaces.
. Cut a pieceof plastigauge
slightlyshorterthanthe
gauge
bearing
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.
\
\ t
i /
t---4
4,
\ \,H-l
il)
,--nX','
t /
SENSORSYSTEIV
INSPECTION
R826DETT
ENGINE
6.6 ENGINETEMPERATURE
SENSORSYSTEMINSPECTION
CONTROLCIBCUITDIAGRAMR826DETTENGINE
Engrne
iemperature
sensor
m
2
"
"
O
a
o
gnrtion
limingconlro
q
E
dle speed control
Engine temperaturesensor system trouble diagnosis flowchart

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

"DATANTONITOR'
t
I Measurethe vollagebetweenterrninal1
ano qrouno.
i Enginetempdisplay
.8 3V when cold
1V atler warrnnq up
Enginetemp sensor inspection

lvleasurethe reslslancebetween
terrnrnal1 and 2.
Olher
InspectIntakeair temperature
Enginetemperature
sensorand ECCS C/U connectors sensor inspeclion
for faultyconnectrons
or defects.
l\,4easufe
the resistance
betweenlermnal 1 and 2.
Approx.2.5
Apr r o x . 2 . 5 k t ) w h ecno l d
Olher
up
Sensorand ground inspection
Measurethe voltagebetween
terminal28 and 30.
warmrngup
lnspectothe r
Replace
Engine
temperature
sensor
SVSIEMS
sensor
Harnesscontinuityinspection
Inspect ECCSC/U power
l
[,4easure
the resistancebetween supplyand ground
the followingterminals:
Enginetemp
ECCSC/U
sen narness
narness
0a
InspectECCSC/U connectorand engrnetemp
sensorconnectorfor conlactand defects.
E N- 3 8 1
c o A
Repairnarness
RB2OE
/ D E / D E TE N G I N E
6-6 ENGINETEMPERATURE
CONTROLCIRCUITDIAGRAMRB2OE/ DE / DET ENGINE
conlrol
Fue injectlon
sensot
Engineternperature
t-*---fr
-----1'
c)
o
a
8
o
5128)
8 (30)
ldlespeedconlrol
=.
Engine temperaturesensor system trouble diagnosis flowchad

RB2OE/ DE / DET ENGINE
Self-diagnosis
RESULTS"
IE-"SELFDIAGNOSTIC
lcode No 13)
Self-diagnosis
Abnormal
Normal
i,
Abnormal
Enrinetempse{tsorinputsignalinspection
MONITOB"
E-'DATA
.. N.4easure
the voltage between termlnal l
and qround.
tempdisplaY
E Engrne
,S 3V whencolo
uP
]V atterwarminq
EiliiE-iffi
sensorinsPection
EnginetemPerature
Inspectintakeatr temPeralure
sensorand ECCS C/U connectors sensor inspection
the resrstance
or defecls
N-4easure
for faultyconnections
betweenterminal1 and 2.
f/easurethe resistancebetween /*
\ll-Y
terminal1 and 2.
-
APProx 2 aKf) wnen colo

Approx 0 3K o after warn
Other
UP
Approx.2.5kOwhencold
Approx.0.3Ko after
warmrngup
other
Inspect
I
svsrems I
Other
Sensorand ground insPection

terminal5 (28) and I (30).
Beplaceengine
Replace
Engine
temperature
sensor
Olher
HarnesscontinuitYinsPectiot
Measurethe resistancebeiwe n
the followtngtermlnals:
ECCSC/
Engrneternp
harness
sen harness
5 (28
1
8 (30
2
0a
andenginetemp
Fnspect
EcCs c/u connector
for contactanddelecls.
sensorconnector
EN - 382
cltr
Inspect ECCSC/U power

I
supplyand ground
[:
Repairharness
CA18E
i NGINF
6.6 ENGINETEMPERATURE
CONTBOLCIRCUITDIAGRAMCA18iENGINE
Engrnetemperature
sensor
r---5f-*----+rt
t
T
l
m
o
o
a
o
gnilionI mingconlrol
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 "
I
(Realtinrediagnosrs)
|
ffi--J---rono,
mal
Enginetemp sensoroutput
signalinspeclion
.f,.DAIAN,4ONITOR'
the voltagebetween
:8 l\,4easure
termrnal1 and 2.
E Engrnelempdispiay
;'e3 V w h e nc o i d
1V atterwarrnrngup
Enginetemp sensor inspection(2)

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

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

CONTROLCIRCUITDIAGRAMR826DETTENGINE
gassensor
Exhaust
Air luel ratro

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

contactor delects.
(o,sensor( F ) )
( O s e n s o rt R ) )
Other
ECCSC/U power supply inspection

'
! DATA[,4ON]TOR
E D sconneclO sensorconnecior
ano T'teasLrre
!o taqe !et,,..'eeECCS a U ieiii,ia
;:
;i.r gj.e.i].
Baltery ,Joliaqervhen
gn 1on swrtchrs ON
Oti'er
InspectECCSC/
Measurethe resistancebetween
U p o w e rs u p p l y
or replaceC/U
O, sensor
ECCSC/U
.E;r .
narness
narness
Or sensor(R)2
55
O, sensor(F)1
29
(O-,sensor
(O,sensor
(F))
Other (R))
@uff
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
Repairharness
Battery vo iage when

gnrlronswrlch
Checkfor laulty conneclions

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

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

items 19/
. Warmuptheengine
andcheckthefollowing
with'EXHGASSEN",'EXHGASSEN-R"(output
"M/RF/CMNT-R'(lean/
voltage).M/B F/CMNT"and
"DATA
mode.
MONITOR"
in
rich)displayed
. Providesettrngvaluein "ACTIVETEST"(fuelinjection
andcheckexhaustgassensor
quantity
correction)
f unction.
onthevehicle
. Usingdiagnosis
conne-ctor
:199-^ ^ @
'EXHAUST
GAS
to
CONSULT
set
block),
tuse
lneai
andcheckthefuelinjection
MONITOR'
SENSOR
warning
byflashingof exhaustgastemperature
condition
lampon instrument
Panel.
Exhaustgas sensorlunction
warninglampmustflash5 times
Exhaustgastemperature
whenengineis runningat
or morein 1Osecondsinterval
rpm.
approx.2,000
Feedbackf unction
warninglampmustflas
whenenginespeedis runningat approx2'000
periodically
(2\'lirleasu
Input signal insPection
.
re the voltagebetweenthefollowingterminalswith
ECCScontrolunitharnessconnected.
BEMEEN EUUD U/U

BetweenECCS C/U
terminal29 and ground terminal55 and ground
Deflectionbetween
approx.0 and 1V
EN - 388
CAS.RPI,4(POS)
EXHGASSEN
E X HG A SS E N - R
M/BF/CMNT
I\4/RF/CN,4NT
AcrrvErEsr
a I
FUELINJECION
MONITOB
CAS.BPM(REF)
ENGTEMPSEN
EXHGASSEN
EXHGASSEN'R
INJPULSE
AAC VALVE
Qu
1975rpm
1,14V
1.03V
RICH
LEAN
UP
0",1
937rpm
59'C
1.33V
1'35V
1 8msec
17-.
DWN
od
RB2OE

CONTROLCIRCUITDIAGRAMBB2OE/ DE / DET ENGINE
n
115
Air luel ratro

conlrol
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 . { R B 2 0 Ea) n dg r o u n d
2. (FB2oDEi DET)and ground
Defleclron
between0 - lV
ECCSC/U conneclorsfor faulty

contactor detects.
1
(R820E)
( R B 2 o D/ED E T )
Other
ECCSCrupowersupplyinspection
.E DATA[/ONTTOF"
Or sensorconnector
t' Disconnect
andmeasure
voltage
between
ECCSC/U termrnai27 (49)and
Baftery voltage when
rgnrlron
swrtchs ON
Measurethe resistancebelween
the followingtermlnals:
O, sensor
ECCSC/U
harness
harness
RB2OE 1
6
RB2ODE/DET1
29
0a
InspectECCSC/
U powersupply
or replaceC/U
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

inspection
MeasLrre
the voltagebetween
termrnal1 and ground.
Balteryvollagewhen
ignrtron
swrlchrs ON
RepairO, sensorgroundcircutt
EN - 391
ReplaceOrsensor
/-rt-\
(!I?I]J
(RB2oDE/
DEr)

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

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

r- DATAMONITOR''
,$ Disconnect
02 sensorconnector
and measurevoltageDerween
ECCSC/U terminal27 (49)and
lnspectexhaustgas sensorand
for faultY
ECCSC/U connectors
contaci or delects.
Battery vollage wnen

ignitionswitchis ON
HarnesscontinuitYinsPection
l\,4easure
02 sensorharnesstermlnal1 and
ECCS C/U harnessterminal6
lnspectECcSC/
U powersupply
or replaceC/U
0 {il
Checktor taulty conneclionsor

replaceexhaust gas sensor
EN - 392
Repairharness
RB2OE
/ D E/ D E T / C A 1 8 E N G I N E
(1) Fuel-airratiofeedbackf unctioninspection

. Warmuptheengine
andcheckthefollowinq
itemswith
"EXH
GASSEN"and"M/RF/CMNT',0ean
/ rich)
displayed
in "DATAMONITOR"
mode.
ruornrr
fr,,lor':rroRrrufr
CAS.RPM(POS)
AIRFLOWI\,ITR
ENGTEMP
EXHGASSEN
I\,4/R
F/CI\,4NT
2012em
1-54V
8O"C
0.72V
RICH
RECORD
. Providesettingvaluein "ACTIVETEST"(fuelinjection
quantity
correction)
andcheckexhaustgassensor
function.
Note:
"lNJPULSE'
displayfor RB20Eis 1/16.
. Usingdiagnosis
connector
on thevehicleside
(nearfuseblock),setCONSULTto'EXHAUST
GAS
SENSORMONlTOR"
andcheckthefuelinrection
condrtionby flashingof exhaustgas temperature
warning
tampon rnstrument
panel.
Exhaust gas sensor function
warninglampmustflash5 times
or morein 10secondsinterval
whenengineis runningat
approx.2,000
rpm.
Feedbackf unction
gastemperature
Exhaust
warninglampmustf lash
periodically
whenenginespeedis runningat approx.2.OOO
rpm.
(2) Inputsignatinspection
. Measurethe voltagebetweenthefollowingterminalswith
ECCScontrolunitharnessconnected.
E--r-^
RB2OE/CAt8iI
{|l'snl
kitt:i::,rir:
:-ri.i.:
,.
{!pq.
|!'.']r:':i:1,:
nemoelo
BetweenECCS C/U
BetweenECCS C/U
terminai1 and ground termrnal29 and ground
Deflectronbetween
approx. 0 - 1
Deffection
between
approx.0 - 1
EN - 39s
ncrrveresr
| !
FUELINJECIION
tll0NtToF
CAS.RPN4iREF)
ENGTEI\,4P
SEN
EXHGASSEN
INJPULSE
AAC VALVE
Ou
UP
+11o.a
1037rpm
36.C
0.87V
4.omsec
369/.
OWN
od
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
o
t1
i53)
()RB2ODE/DET
EN - 397
ldlespeedcontrol
:.:.:E'-T
/ D E / D E T/ C A I B iE N G I N E
RB2OE
oRNGft
(1) Inputsignal inspection

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

INSPECTION
cAl8i
(1) Inputsignal insPection

n
. In "DATAMONITOR'mode,performthekeyoperatio
"START"
is
input
signal
to checkif the ignitionswitch
correctlv.
25 (45)
ECCS
control
unrt
terminalsA
. Measurethevoltagebetweenthefollowing
\@i
with ECCScontrolunitharnessconnected.
RB26DETT/ RB2O
ECCSC/U ECCSC/U ECCSC/U
23
25 terminal
45 and terminal
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
(1) Inputsignalinspection
. In "DATAMONITOR'mode,pedormtheairconditione
I
switchoperation
to checkil theairconditioner
switch
signalis inputcorrectly.
cA18i
A/C switch
. Measurethe voltagebetweenthe followingterminals

withECCScontrolunitharnessconnected.
6 - 12
NEUTRALSWITCHSIGNALINSPECTION
(1) Inputsignalinspection
. In "DATAMONITOR"mode,performshiftlever
operation
to checkif neutralswitchsignalis
. ^lSililJtiS'Y;rtase
between
therorowins
terminars
@
andgroundwithECCScontrolunitharnessconnected.
EN - 399
RB26DETTiRB2ODEiDET
R B 2 6 D E T/T C A 1 8 ]E N G I N E
6-13 POWERSTEERINGSWITCHSIGNAL
po*"r'"t"",,nq
INSPECTION
swtch(1) Input signal inspection
fe
.|n.,DATAMoN|ToR"mode,performpoWerSteering\g/
(ls)
ECCS
control
switch i =
oilpressure
tocheckif powersteering
operation
correctly.
signalisrnPut
terminals
. Measure
thefollowing
between
thevoltage
@1
9
connected.
r ,BB26DErr
unitharness
withECCScontrol
unit
cA18i
6-14 LIGHTSWlrcH SIGNALINSPECTION
@
(1) input signal insPection
"DATA
. ln
MONITOR'mode,performlightswitchoperation
lo checkif lightswitchsignalis inputcorrectly'
terminals
. MeasurethJvoltagebetweenthefollowlng
@
Lrghtswitch
lcr_ ---6zd--{qs
EN - 400
/l EccsI
/ I control
I
6-15 HEATERFAN SIGNALINSPECTION

(1) Input signal inspection
. ln "DATAMONITOR'mode,performheaterfanoperation
to checkif heaterfanswitchsignalis inputcorrectly'
. Measurethe voltagebetweenthe followingterminals /A\
\.f,i
/t
,1. I unit
-
R825DEDIAGNOSIS
R 8 2 5 D EE N G I N E
DIAGNOSIS
1 . POWERSUPPLY& GROUNDCIRCUTT
#21
2.1--
Components location
EN - 401
RB25DEDIAGNOSIS
START
Startt le engrne.
Doestneengrne
NG
CAS
BAT
ol
ground
D.
circutt
Inspect
OK
STABT
FINISH
A
A
PowersuPPIYinsPection
to ONposition.
switch
Placeignition
-BATTERY
voltageusing
OK
battery
Inspect
1S
\@ VOLTAGE"in
mode.
DATAMoNlToB
f,
rar Usetesterto measurethe voltagebetween

..1,r'ECCSC/U terminal49. 50 and ground.
NU
D
GroundcircuitinsPection
E
Placeignitionswitchin OFF
ECCSC/U
position.Disconnect
harnessconnector.
Checkfor harnesscontinuitybetween t !
E C C SC / Ut e r m i n a1l ,0 , 2 0 ,1 0 7 '1 0 8
I
a n d1 1 6a n dg r o u n d .
lF NG: Repairharnessandconnectors
FINISH
B
ECCS C/U terminal and ECCS relay harness
continuityinsPection
Placeignitionswitchin OFFposition.
DisconnectECCSC/U and ECCSrela't harnesr
connector.
'U
al
lnspectfor continuitybetweenECCSC, termin
49, 59 and ECCSrelaYterminal3.
Fle m
, |!l3i---\
I
M
qa-.'- ei--.'
i
NG
I Rpneirharnesso r connecto.lc
OK
Voltage inspection between ECCS C/U

terminaland ground
switchto ON position.
Placergnition
Measurethe voltagebetweenECCSrelay
2,3 andground.
terminal
NG
Voltage:Batteryvoltage
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
relayand
ECCS
between
thecontinuity
Inspect
thebattery.
ToE
Eer
lF
l l -Eccs
I :6-
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/Uterminals
and
ECCSC/U connector.
Groundcircurt
inspection
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
5)
Components location
"
EN - 404
anglesensor
_CJAnk
RB25DEDIAGNOSIS
START
Carryoutself-diagnosis
OK
NG
To diagnosis
14
Placeignitionswitchto OFFposition.
Disconnect
crankanglesensorharness
connectors.
NG
Placeignition
Usetesterto measurethevoltaqebetween
terminal
3 andqround.
OK
Inspectthe following:
Checkthecontinuity
betweencrank
anglesensorterminal3 and ECCS
relayterminal3.
lF NG: Repairharnessor connectors.
@
c/u
42 52 and 2
5 l a n dI
B
Inputsignalcircuitinspection
Placeignitron
switchto 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
Inputsignal inspection
ConnectcrankanglesensorandECCSCiU
harnessconnectors.
Use"CRANKANGLESEN RPM'in 'DATA
,S
\G/ MoNlToR"to measure
enqrnesoeed.
/fl) Measure
thevoltagebetweenECCSC/U
v termin4
a2
l . 5 2 . 5 1a n dg r o u n d .
OK
Xg:Q@
NG
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
byself-diagnosis
Recheck
onthe
Checkforanydamage
and
ECCSC/Uterminals
connector.
ECCSC/U
EN - 406
RB25DEDIAGNOSIS
DIAGNOS|S
3 - AtR FLOWMETER(CODENO.12 tN SELF-D|AGNOS|S)
A r fiow meter
o
o
q
SignalgroundE
26
:.
Components location
\ i \
. -,,'.1
Arrflow meter
harnesscon!,eclor
EN - 407
RB25DEDIAGNOSIS
Ee@
PowersupPlYinsPection
airflowmeterharness
Disconnect
connectors.
Placeignitionswitchto ON position.
Usetesterto measurethe voltage
3 andground.
betweenterminal
%ei@
lnspect the following:

betweenairflow
Checkthecontinuity
meterterminal5 andECCSrelaY
3.
terminal
lF NG: Repairharnessor connectors.
Groundcircuitinspection
Placeignition
connectors'
ECCSC/Uharness
Disconnect
4 andECCS
terminal
between
Checkthecontinuity
26.
C/Uterminal
Inputsignal insPection
Checkthe continuitybetweenairflowmeter
terminal2 andECCSC/Uterminal27 (intake
signal).
airquantity
Bepairharnessor connector
EN - 408
Ele,@
RB25DEDIAGNOSIS
D
Connectcrankarrflow meterand ECCSC/U
harnessconnectors.
rroRrNq\iroFAtL
cAs.RPM(REF)
AIRFLOWMTR
ENGTE[,4P
SEN
EXHSEN
THROTTLE
SEN
INJPULSE
Use 'AlBFLOWMETERin DATA

r\
\g/ MONITORtomeasure
inoutsional.
,S Measure^the
voltagebelweenECCSC/U
:. Iermlnat
z/ andoround.
NG
Approx.0.3V
A p p r o x1 V
'
OK
' ldlirq
''1'.
ctv
A p p r o x1.. l V

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

terminals
andECCSC/Uconnector.
Carryout the inspectionin the followingorderafterrepairs.

Verificationinspection
Erasememoryf romself-diagnosis
Recheckby self-diagnosis
ECCSC/Uterminals
and
ECCSC/Uconnector.
EN - 409
662rpm
1.02V
81,
O.1BV
O.4OV
s.omsec
RB25DEDIAGNOSIS
B 8 2 5 D EE N G I N E
SENSOR
DIAGNOSIS4. ENGINETEMPERATURE
( c o D E N O .1 3 l N S E L F - D I A G N O S I S )
EnginetemPerature
sensor
Fuelinjectionconlrol
a
!
m
o
o
o
timrngcontrol
lgnrlion
;
-;
Componentslocation
5\-
'
1 Enginelemp sen trr'l

^^nn6^t^r
A
Power supply insPection
sensor
enginetemperature
Disconnect
harnessconnector.
Placeignition
Usetesterto measurethe voltage
betweenterminal1 andground.
r harnessor connector
E N- 4 1 0
Ke@
\'
R825DEDIAGNOSIS
F 8 2 ' D EE N G I N E
B
Checkcontinuity
between
terminal
2 andground.
OK
Repair
harness
orconnector
Use"ENGTEMPSENSOR Tn DATA
1S1
: MONITOB"
to checkenainecoolant
NG
Iemperalure.
Cnect the voltagebetweenECCSC/U
(g)
terminal28 andoround.
Voltage: Whenigniiionswitchis ON
EngtempApprox.20oC 3V
Approx.80"C 1V
OK
Componentparts inspection
(Engine
temperature
sensod
Refertothesection
onengine
temperature
sensor
forinspection.
lF NG:Replace
crank
anglesensor.
Checkfor any damageon the ECCSC/U

terminals

VerificationInspection
ECCSC/Uterminals
and
ECCSC/Uconnector.
FINISH
E N- 4 1 1
DIAGNOSIS
RB25DE
5 -IGNITIONSYSTEMINSPECTION
DIAGNOSIS
(coDE NO.21 lN SELF-DIAGNOSIS)
FIL6
fi
o
ql
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
Inspect
using"POWER
BALANCE"
in
'FUNCTION
TESI-'mode.
Checkto ifengine
revwilldecrease
ntary
mome
Placeignition
switchin OFFposition.
powertransistorunitharnessconnector.
Disconnect
Checkfor harnesscontinuitybetweenterminalE and
grouno.
()POWER BALANCEl)
INSPECTTHE
BALANCE
OF EACHCYLINDERBY
STOPPING
INJECTOR
OPERATION
FOREACH
CYLINDEF,
FASSI
B
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
E err
RB25DEDIAGNOSIS
RB25DEENGINE

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

VerificationinsPection
and
ECCSC/Uterminals
ECCSC/U connector.
E N- 4 1 4
R825DEDIAGNOSIS
RB2sDE NGINE
DIAGNOSIS
6 - EXHAUSTGAS SENSOR
(coDE NO.15 tN SELF-D|AGNOSIS)
m
2
1
9
5
O
U'
'
Components location
START
Oarryoutselfdiagnosis
NG
OK
FINISH
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
AIR,FUEL
RAIIo TESTl
HOLDTHE
ENGINE
SPEEDAT
2000+l200rpmAND
PBESS
START
RB25DEDIAGNOSIS
Functioninspection2
Starttheengine.
Holdthe engineat 2000rpmand inspect
"O
"O,
using SENSOR"(outputvoltageand
"DATA
rich)in
SENSORMONITOR'(lean,
MONlTOR"mode.
Measurethe voltagebetweenECCSCiU
terminal29 and ground.
voltage) NG
Approx.0.3V(constant
(variant
voltage)OK
Aoorox.over0-6 1V
START
X e- 11:
Fcctcî"""*".-i
InputsignalcircuitinsPection
to OFFposition.
switch
PIaceignition
andECCS
connector
O,sensorharness
Disconnect
connector.
C/Uharness
29
betweenECCSC/Uterminal
Checkcontinuity
2.
terminal
andO-sensorharnessconnector
t-;
Elee
Repairharnessor conneclor
ReplaceO, sensor
Checkforanydamageon the ECCSC/U

terminals

VenficationinsPectlon
Checkfor anydamageon the

and
ECCSC/Uterminals
ECCSC/Uconnector.
E N- 4 1 6
iin
j.----.---I
RB25DEDIAGNOSIS
DIAGNOSIS
7 - DETONATION
SENSOR
(coDE NO.15 tN SELF-D|AGNOS|S)
tl]
a
Components location
*-;:-_-.-:-"'-:
.,:1
E N- 4 1 7
Detonationsensor mid
harness connector
RB25DEDIAGNOSIS
RB2sDE NGINE
c/u
lnput signalcircuitinsPection1
DisconnectECCSC/U harnessconnectorand
sub harnessconnector.
terminal1 and
Checkthe continuitybetvveen
ECCSC/Uterminal23, terminal2 and ECCSC/
24.
U terminal
O K Repairharnessor connector
2
frontand NG
connected
connectors
harness
Disconnect
sensor.
rearof thedetonation
terminalA
subharness
between
thecontinuity
Check
and23. B and24.
OK
lnput signal inspection

sensorandECCSC/U
Connectdetonation
harnessconnectors.
Measurethe voltagebetweenECCSC/U
23,24 andground.
terminal
Measurementlocation
temltnal23, 24 and ground
lgnition switch ON
Approx.4V
C ran king
Approx.4V
ldling
Approx.4V
Replacedetonatlonsensor
terminals
insPection
Verification
and
ECCSC/Uterminals
ECCSC/Uconnector.
RB25DEDIAGNOSIS
DIAGNOS|S
8 - THROTTLESENSOR(CODENO.43 tN SELF-D|AGNOSIS)
Throtliesensor
'1
o
o
za
fuC cutcontrol
38
:uel injectionconko
=
=
Componentslocation
'ECCS
c o r t r o .L n , t
START
OK
Oarryoutselfdiagnosis
I rrRorrLeselrsonl
NG
FINISH
A
System inspection
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
PFESSSTAFTWHILE
PRESSING
THE
ACCELERATOB
PEDAL
FULLY
RB25DEDIAGNOSIS
B
Power supply insPection
ignitionswitchto ON position.
ffi
NG
: Ptace
-THROTTLE
SENSOB"in DATA
Use
MONITOR'toinspeP!etaceignitionswitchto OFF posilion.
19
vDisconnectthrotllesensorharnessconnector.
Measurethevoltagebetweenterminal1 and
ro retr
*vortrontr*
(BEF)
CAS.RPN,,I
THROTTLESEN
orprn
3,94V
:APProIjll-voltage
ground.Battery
OK
InputsignalcircuitinsPection
connector.NG
ECCSC/Uharness
Disconnect
ECCSC/U
between
Checkthecontinuity
2.
38andterminal
terminal
r-_-._.--
| ,,_.
Ee .@,
Cornponentparts inspection (Throttlesensor)
sensorfor inspection'
Referto thesectionon throttle
unit.
sensor
throttle
lF NG: Replace
OK
terminals
Carryout the inspectionin the followingorderafterrepairs'

Verificationinspection
Erasememoryfrom self-diagnosis
Recheckby seltdiagnosis
Checkfor any damageon the

and
ECCSC/Uterminals
ECCSC/U connector.
EN - 420
RB25DEDIAGNOSIS
D|AGNOS|S
9 - A / T CONTROL
(CODENO.s4 tNSELF-DIAGNOSIS)
L---i
Componentslocation
..'''.:
,:..]
START
OK
Carryoutselfdiagnosis
NG
FINISH
A
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
G )@ i5
j
lA/Tcti connecta
RB25DEDIAGNOSIS
DIAGNOSIS1O- CRANKANGLESENSOR(NOTlN SELF-DIAGNOSIS)
FiL6
Crank angle sensor
Componentslocation
ECCScontrolunlt
EN - 422
RB25DEDIAGNOSIS
START
A
Placeignition
switch
to OFFposition.
Disconnect
crankanglesensor
harnessNG
connector.
Checkforcontinuity
between
terminal
4
andenginegroundharness.
OK
Repairharness
or
conneclor
(Crankanglesensor)
NG
Referto thesectionon crankanqlesensor
for inspection.
OK
Replacecrankanglesensor
terminals

Verification
inspection
ECCSC/Uterminals
and
ECCSC/Uconnector.
EN - 423
Xea
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
O F E A C HC Y L I N D E R
BY
STOPPING
INJECTOR
OPERATION
FOREACH
CYLINDER.
TURNOFFA/C& LIGHTS
Whole system inspection

Startthe engtne.
ls allcylinder
ignited?
To ignitionsignal2
Circuitf unctioninspection
Inspectusing"POWERBALANCE"
in
"FUNCTION
TEST"mode.OR power
balancein "ACTIVE
TEST".
Checkto if enginerevwilldecreasemomentary.
OK
Power supply inspection

Placeignition
Disconnect
ignition
coilharnessconnector.
Placeignitionswitchto ON posrtion.
UseCONSULT
or thetesterlo measurethe
voltagebetweeneachcoilterminal
1 andground.
Power voltage: Battery voltage
lgnitionrelay
lgnitionswitch
Continuitybetvveen
eachcoil
Harnessterminal
2 andignition
relavterminal5.
ACTIVE
TEST
POWER
BALANCE
t\40N
tToR
cAS.RPr\r(POS)
AIRFLOWI\,4ETER
trtrtr8
rdtrILl
B
1%e:-,.$rf)
c
@ 5,t,5
Ground circuit inspection

Checkfor harnesscontinuitybetweeneachcoil
terminal
3 andqround.
OK
Repair
harness
orconnector
powerlransislorunit harnessconnector.
Disconnect
Inspectforcontinuity
betweenthefollowingterminals:
Betweeneachrgnition
coilterminal1 and
Powertransistor
unitterminal1
Powertransistorunitterminal2
Powertransistor
unitterminal
3
Powertransistor
unitterminal
4
Powertransislor
unitterminal
5
Powertransistorunitterminal6
EN - 425
iXe,@
RB25DEDIAGNOSIS
RB2sDE NGINE
Components insPection
coil)
(Powertransition
unit& lgnition
coil
ignition
unit
and
power
transition
Referto
section.
inspection
in components
inspeclion
faultyparts
Replace
Carry out the inspection in ihe lollowing order after repairs:

ComponentsinsPection
RecheckECCSC/Uterminalfor
damageandcheckECCSC/U
harnessconnectorconnection.
EN - 426
r 5
R825DEDIAGNOSIS
DIAGNOSIS
11- IGNITION
SIGNAL2
Continuefrom ignitionsignal1

Placeignition
Disconnect
ignitioncoil relayconnector.
UseCONSULT
or testerto measurethe
voltagebetweencoilterminal
2,3 andground.
Power voltage: Battery voltage
OK
Continuation
between
fusiblelink,
ignition
coilrelayandignition
switch.
Continuation
betweenignition
coil
relayandthe battery.
F
Groundcircuit inspection
PIaceignitionswitchto OFFposition.
Inspectharnesscontinuation
betweeneachcoil
terminal2 and5.
OK
NG
ECCSC/U
NG
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
Il ee;@
Repair
harness
and/ orconnector
Outputsignalcircuit inspection
DisconnectECCSrelay.
Inspectthe continuation
betweenECCSC/U
terminal16 and ECCSrelavterminal2.
OK
NG
Replacefaultycomponents
InspectECCSC/Uterminal
for anydamage
and ECCSC/U connectorfor connection.
EN - 427
RB25DEDIAGNOSIS
DIAGNOSIS12 - INJECTORSYSTEMINSPECTION
3 Giil
m
o
i
Ftrl*".,
No-
i
o
ECCSrelav
L)-IJJ
-t-----1
l/!!r.t
l.l.l
-_l;la
:EiutttlS
1'-o o-+
@
@
N o .1
No.2
location
Components
ECCScontrolunrt
EN - 428
RB25DEDIAGNOSIS
START
A
tFowrR elLANtcEl
Circuit f unction inspection

Inspectby "POWERBALANCEin
/G\ "rurucrroN
TEST'
mooe.
fJ
"POWER
Operate
BALANCE"
in
CONSULTactive
test.
operation
noise
ffi Makesuretheinjector
\O/ rsaudible.
INSPECTTHE
BALANCE
OF EACHCYLINDERBY
STOPPING
THE
INJECTOR
DRIVE
FOR
EACHCYLINDER.
OK
NG
FINISH
B
Power supply inspection 1
Placeignition
switchto OFF.
Disconnect
Checkthe batteryvoltagebetweenterminal
3 andgroundusingCONSULT
or tester.
ierreE
NG
Harnessconnector.
Continuity
betweensub harness
connectorandthe harness.
lF NG: Repairharnessandconnector
c
Power supply inspection 2
Disconnect
Inspectbetweenthefollowingterminals
forcontinuity:
betweenterminal3 and 5
betweenterminal3 and 6
belweenterminal3 and4
OK
NG
Disconnect
injectorharnessconnector.
Inspectbetweenthefollowingterminals
forcontinuity:
betweenterminal109andNo. 1,2, 3,
4,5&6cylinders.
To
EN - 429
H
No.1
No.2
No.3
No.4
No.5
No.6
RB25DEDIAGNOSIS
E
Out put circuit insPection
Inspectbetweenthefollowingterminalsfor
continuitY:
betweenterminal10.1andNo. 1 cylinder
betweenterminal105andNo.2 cylinder
e:@9[
con
NG
OK
Flepairharnessor
connector.
ComponentPartsinsPection
(lnjector)
forinspection'
oninjector
Refertotheseclion
NG
Replaceinjector.
foranY
ECCSC/Uterminals
Inspect
connectors
damageandmakesurethe
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
"
V
E
H
l
C
L
E
using
S P E E DS E N S O Ri"n
"FUNCTION
TEST"mode.
NG
FINISH
Vehiclespeedsensorfunctioninspection N G
Inspect
vehiclespeedmeterfunction
OK
TOB
Vehiclespeedsensorand
vehiclespeedsensorcircuit
inspection.
EN - 431
RB25DEDIAGNOSIS
RB25DEENGINE
fS,tortrontufrNornlr
B
InputsignalinsPection
Startthe engine.
Rotatedriveaxles]ew]y-
NG
(POS)
CAS.RPI\,
/a\ b-eieiltehicbspeedusingVEHICLE
i'LQ4IA-NIONIIOBspeeoSENSOR"
u
,o'
W
thevoltagebetween
Usetesterto measure
53andground.
EccS C/Uterminal
0 5V ----Voltage:aPProx.
OK
betweenECCS
Checkthecontinuity
meterharness.
C/U andcombination
lF NG:Repairorf9ple99i9M9!'-forany
InspectECCSCiUterminals
connectors
damageandmakesurethe
areconnectedcorrectly.

insPection
circuit
Ground
Checkfor anYdamageon tne

and
ECCSCiUterminals
ECCSC/U connector.
EN - .132
c/u
787r7m
R825DEDIAGNOSIS
DIAGNOSIS
14 -AIR CONDITIONER
RELAYSIGNAL
To FrCDrela,i
Duai pressute
IGNreiay1
AC rear sw
ACC reiay
ACC key SW
m
o
o
a
o
)q
Components location
controtunrt
Placeignition
Usetesterand measurelhe batteryvoltage
betweenECCSC/UterminalI andground.
Whenblow-fanswitchis OFF: batteryvoltage
Whenblow-fan
switchis ON: Approx.1V
InspectECCSC/Utermrnalsfor any
damageand makesurethe connectors
areconnecledcorrectlv.
ECCSC/Uterminals
and
ECCSC/Uconnector.
EN - 433
RB25DEDIAGNOSIS
DIAGNOSIS15 - EXHAUSTGAS SENSORHEATER
Trl
o
o
(,
o
x
Components location
i'
controLlntt ,,-l
EN - 434
R825DEDIAGNOSIS
FIB25DE NGINE
START
A
Disconnect
gassensorharness
exhaust
connector.N G
Placeignition
switch
toONposition.
powervoltagebetween
Measure
terminal
1 and
ground.
OK
lnspectthe following:
Harness
connector.
Continuity
between
gas
exhaust
sensor
andthefuse.lF NG:
Repairharness
andconnector.
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)
Referto the sectionon exhaustoas sensor
heaterfor inspection.
OK
NG
Replaceexhaustgassensor.
InspectECCSC/Uterminalsfor any
damageandmakesuretheconnectors
areconnectedcorrectlV.
Carry out the inspection in the following order after repairs.
Verification
lnspection
ECCSC/Uterminals
and
ECCSC/Uconnector.
Inspectpowersupply,groundcircuit
EI\
- I+JJ
RB25DEDIAGNOSIS
DIAGNOSIS16. THROTTLEVALVESWITCH
rf
o
o
U)
o
q
Comoonentslocation
d--4"i6-r'
valvesw
EN - 436
RB25DEDIAGNOSIS
START
Function inspection 1
Placeignition
switchto ON positron.
"IDLE
Inspectusing
JUDGEMEN'l-'
in O K
"FUNCTION
TEST'mode.
Reference: Fullyopen:OFF
Fullyclosed:ON
FINISH
B
NG
Functioninspection2
Placeignition
Inspectignition
switch"ON-OFF"
diagnosis
or
measurelhe voltagebetweenECCSC/Uterminal O K
54 andgroundusingthetesterwhenignition
switch
i sO N .
Voltage: Accelerator
pedalpressed0V
pedalnotpressed8 - 10V
Accelerator
NG
FINISH

Placeignrtion
Disconnect
throttlevalveswitchharnessconnector.
NG
Placeignition
Uselesterto measurelhe voltagebetween
terminal
2 andground.
Battery voltage: Approx.8 - 10V
Harnesscontinuity
betweenthrottle
valveswitchandECCSC/U. lF NG:
Repairharnessandconnector.
D
Placeignition
NG
Disconnect
throttlevalveswitchharnessconnector.
Checkthe continuitybetweenECCSC/Uterminal
54 andthrottle
valveswitchterminal1.
OK

(Throttle
valveswitch)
NG
Referto the sectionon throttlevalveswitchfor
jon.
inspect
OK
Replacethrottlevalveswitch.
InspectECCSC/Uterminals
foranydamageand
makesuretheconnectorsareconnectedcorrectlv.
EN - 437
] . I D L E J U D G E I V F N T'
A F TW H E NA C C E L E R A OB PEDALIS FULLYOPEN.
START
connector
RB25DEDIAGNOSIS
insPection
Verification
and
ECCSCiUterminals
ECCSC/U connector.
EN - 438
RB25DEDIAGNOSIS
DIAGNOSIS
17 - STARTSIGNAL
GN SW
START
t) snRrrn srcNnrI
Function inspection
/tr\
tU
UseCONSULT
andinspect"STARTSlGNAL"in
"FUNCTION
TEST'mode.
OK
OR
Inspectstartsignalusing"DATAMONITOR"mode.
Whenignition
swrtchis ON position:
OFF
Whenignition
switchis STARTposition: ON
NG
STARTTHE
ENGINE
STFAIGHT
AFTERSELECTING
STARI,
FINISH

?@
)
Disconnect
throttlevalveswitchharnessconnector. N G
Placeignition
Usetesterlo measurethe voltagebetween
terminal
2 andground.
Battery voltage: Approx.8 - 10V
OK
PLACE
SHIFTLEVERTO'P'OR
Inspect the following:

Fuse
Continuitybetweenignitionswitch
and ECCSC/Uharness.lF NG:
Repairharnessandconnector.
InspectECCSC/Uterminals
foranydamageand
makesuretheconnectorsare connectedcorrectlv.
EN - 439
CAS.RPM(POS) 1326rpm
STARTEFSIGNAL OFF
BECORD
'@
I ECCSC/U connector
I
RB25DEDIAGNOSIS
DIAGNOSIS18. FUELPUMPCONTROL
ECCSrelay
qH,,r
F/L3
IGN SW
#16
2t-
Fuel pumprelay
Componentslocation
EN - 440
B825DEDIAGNOSIS
START
.FUEL PUMP'
ISTHEREA PULSATION
E V E F Y3 S E C O N D S
W H E NT H EF U E LT U B E
I S H E L D ?O R C A NY O U
HEARTHEOPERATION
N O I S EO F T H EF U E L
Systeminspeclion
"FUELPUMP"
Select
in-FUNCTtON
TEST"toinspect
thesystem.
\9
Operation
checkby"FUELPUMPRELAy"
in
'ACTIVETEST'.
OK
Fuelpumpwilloperate
for5 seconds
afterthe
ignition
switchisturned
to ONposition.
Checkif
thefuelpumpoperation
norse
areaudible.
I acrrvclesra I
FINISH
B
Power inspection
Placeignition
switchto "OFF"position.
Disconnect
fuelpumprelay.
Measurevoltagebetweengroundand
terminal
2 & 3 usinqthetester.
FUELPUMPRELAYON
MONITOF
CAS.RPIV(POS) orpm
NG
START ON/OFF STOP
OK
Checkthefollowing:
Fuse
Harnessconnection
betweenfuel
pumprelayandthefuse.
Connection
betweenfuelpumprelay
andtheignition
switch.
lF NG: Repairharness& connector.
c
Groundcircuit inspection
Placeignition
Removefuelpumpharnessconnector.
Checkthe connectionbetweenfuel
pumpnarnessconnector
3 andthe
ground.
NG
Repairharnessor
theconnector.
D
NG
RemoveECCSC/U harnessconnector.
Checklhe continuitybetweenECCSC/U& harness
terminal18andfuelpumprelayharnesslerminal1.
Checkthefollowing:
Continuity
betweenECCSC/Uandfuelpumprelay.
ContinuitybetweenECCSC/U and pumprelay.
lF NG: Bepairharnessandlhe connector.
EN - 441
Eeo
RB25DEDIAGNOSIS
E
Control signal insPection
Measurethe voltagebetweengroundand ECCSC/U
terminal18.
5 seconds after ignition switch is turned ON: 1V
After 5 seconds after ignition switch is turned ON:
Battery voltage
Elee
OK
Componentparts inspection
(FuelpumPrelay)
onfuelpumprelayfor
Referto thesection
rnspection.
OK
NG
,Q
E9!9
ReplacefuelPumPrelaY.
ComponentPartsinsPection
NG
(Fuelpump)
onfuelpumpforinspection.
Befertothesection
OK
tuelpumP.
Replace

terminalsand ECCSC/Uconnector.

terminals
inspection.
Fuelpressure
EN - 442
RB25DEDIAGNOSIS
DIAGNOSIS
19. AACVALVE
Components location
START
A
Function inspection
Warmtheengine.
Checkthe idlespeed600 - 700 rpm.
OK
lF NG: Adjustidlespeed.
"AAC
"
VALVE in
/G\ Inspectusinq
's/ "FUNCTION
TEST"mode.
AACvalveharness.
<>, Drsconnect
W Cfreckif idlerevwilldecrease.
RN OFFA/CAND LIGHTS
FINISH
NG
B
Power inspection
Placeignitionswitchto "ON"position.
MeasurevoltagebetweengroundandAACvalve
terminal
2.
TO
NG
Repairharnessor theconnector.
EN - 443
RB25DEDIAGNOSIS
Output signal circuit insPection

A Checkif theenginerevwillchangewhenthe
\E/ "up" or "DOWN'is pressedin AACVALVE in
.ACTIVETESI'' mode.
NG
ECCSC/U harness.
^ Disconnect
betweenECCSC/U
H: Cnect forcontinuity
4 andAACvalveconnector
h"rn"sstermtnal
t e r m i n a1l .
Ele:@
OK
orconneclor.
Repairharness
c
. N
.ACTIVETEST
10'6
DEG
OPENING
AACAr'
NG
Component parts inspection (AACvalve)
Referto the secttonon AACvalvelor inspection'
OK
MONITOR
CAS.FPM(POS) 900rpm
AIR FLOWI\,,ITR 1.'16V
ENGINETEI,IP SEN 8O"C
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
Fuel pump relay
Air regulalor
Components location
f-f ,'T-
controlunit

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

NG
(Airregulator)
Replaceair regulator
AAC
on
section
Referto the
valvefor inspection.
check.
Functional

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

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

insPection
Verification
check.
Functional

terminals
EN - 448
R825DE
DIAGNOSIS
R B 2 5 D FE N G I N E
DIAGNOSIS
22 (Phenomenon)- IDLEREV tS TOO HIGH(AFTERWARMUP)
1
Throttle sensor & air regulator inspection
1
I rsnot.rue
sENsonO
tunction
tesrmode.
5S.
!.snec11n
'!'/ UnecK
judgement)
rlthethrottlesensor(idle
is
NG
notturnedOFF.
Makesuretheair regulator
unttts notrocKed
61
\v or electricity
is conducted
to arrrequtator.
OK
PRESSSTABTWHILE
FULLY
OPENINGTHEACCELERATOB
PEDAL.
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
required.Do notoperateduringdrive.
Warmup lhe engine.
airflowmeterharnessconneclor.
^ Separate
@Cnect if the idlerevwilldecreaseafter
racingthe engineat approx.below2000rpm
for 30 seconds.
NO
2
I
acrveresr a tr
FUELINJECTION
OFFSET oei,
[40NlTOR
cAS.FPr\,4(POS)
937rpm
ENGTEIV1P
SEN
5S'C
O. SENSOB
1.33V
(R)
o, sENsoR
I N JP U L S E
AAC VALVE
Qu
UP
1.3sV
1.8msec
17".
DWN lt Od
Reoairwhereairis leakino.
3
Throttle linkage inspection
Stoptheengine.
Checkif the throttlelinkagewillmovesmoothly.
Checkif thethrottlevalvewillclose/ ooenfullv.
OK
FINISH
NG
Repairthrottlelinkage
or Inspectthrottlevalve
f Jt/*i,.
\i _r J)"*
EN - 449
RB25DEDIAGNOSIS
DIAGNOSIS23 (Phenomenon)'HUNTING
Throttle sensor insPection

Warmuptheengine.
Checkforanychangewithhuntingwhen02 sen
connectoris seParated.
Power balance test

^ Startheenqine.
($u." PowEB BALANCEin functiontest'
Caution:Carryoutthetestin mlnimumtime
required.Do notoperateduringdrive
ldlerevwilldecreasefor a momentfor each
linder.
dl-erevwilldecreasefor a momenlwhen
is
connector
eachcylinderinjector
SparkpluginsPection
Stoptheengtne.
sparkplugandcheckfordirt'
Disconnect
damage.gapetc.
r or replace.
lntake air leak insPection
Startthe engtne.
whenblow-by
Checkif enginerevwillincrease
houseis pinched.
EN - 450
I
serusoR
O rnRorrue
FULLY
PRESSSTARTWHILE
THEACCELERATOR
OPENING
PEDAL.
R825DEDIAGNOSIS
OIAGNOSIS
24 (Phenomenon)- IDLEINSTABILITY
1
Operatepower balancetest
,G\ Startthe enoine.
I poweRenr.ANlce a
NO
'-U'operate
pdwen BALANCE
TESTjnfuncrion
test.Caution:
Operate
thetestinminimum
time
requirgd.
Donotoperate
during
drive.
]NSPECTBALANCE
OF EACH
PIPESBYSTOPPING
INJECTOR
OPERAT]ONAT
EACHPIPES.
TURNOFFALLlJCANDLIGHTS
fora momentwhen
6ldle revwilldecrease
(&operating
pipes.
each
YES
To No. 6
2
Injector inspection
Stoptheengine.
Removecrankanglesensor.
(leaveharnessconnector
as it is).
NO
powertransistorconnector.
Dlsconnect
Placeignitionswitchf romOFFto ON posrtion.
Can you hearoperationnoisefromeachinjector
whenthe crankanglesensorshaftis rotatedby hand.
Warning:Dependrng
on howthe shaftis rotated,selfdiagnosis
willdrsplay
abnormal,
disregard
thisdisplay.
YES
Inspectiniector
andcircuit
3
lgnition inspection
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
ffi
\ , \
Operation
noise
RB25DEDIAGNOSIS
F B 2 5 D EE N G I N E
FuelpressureinsPection
Starttheengine.
TEST"andbring
in"ACTIVE
Select"STOP"
to zero.
fuelpressure
crank2 - 3 times.
stop,
Afterengine
usingfuelpressure
fuelpressure
Inspect
gauge.
x . 2 . 5 k Ioc m "
W h e ni d l i n q :
Startthe engine.
Removefuelpumpfuseandbringfuel
pressureto zero.
Attachfuel pressuregaugeand inspectthe
la'x[\
InspectfuelpumPand
circuits.
': Fuel frlier:J

\
6
$rorrrontnqNto rntr
CAS.RPI\,4(REF) 650rpm
O.O2V
02 SENSOF
0 2 S E N S O RM T R R I C H
Exhaustgas sensorinsPection
in
RATIO"
using"BASEAIR-FUEL
,6',lnspect
tly''ruNcrtoru TEST"mode.
indata
MONITOR"
Select"O,SENSOR
monitor.
withno loadafterwarmup'
Setat 2o0orpm
"LEAN'RlCH"willrepeat
Checkifthedisplay
for morethan5 timeswithln10 seconds
,o,Operatevehicleside(withinfusebox)
andchangeto O,
@)diaqnosis
connector
sensormonll0r'.
Set at 200orpmwith no loadafterwarm up
warning
Checkif theexhausttemperature
lampwillf lashfor morethan5 timeswithin
ReplaceO, sensor
TO7
EN - 452
6
m o d e .s h o n - c i r c ulihl e s e
openthe
Ior a'pprox2 secsJben
(rhernode
/4-ff-ffF;la
Ilmerhs
earh Lff.ffTT-l
-:rs
Pedormeo)
RB25DEDIAGNOSIS
7
Startthe engjne.
YES
Checkif theenginerevwillincrease
when
theblow-byhoseis pinchedusinghands.
NO
Repairleaks
ldle adjust screwf ixationinspection

fO Starttheengrne.
"AACVALVE
s Operate
ADJUSTMENT'
in N O
'OPEBATION
SUPPORT"
mode.
Canidlerevbe adjusted
to 600- TOOrpm
("N"position
forA/T)by rotating
theidte
adtustment
screw.
the engine.
r\Start
\Gr'Disconnect
AAC valveconnector.
Can idle rev be adjustedto 600 - TOOrpm
("N"positionforA/T)by rotating
the 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
AAC VALVEADJ '

.
SETTHECAS.PRI\ITO
STANDARD
VALUEUNDEB
IHE FOLLOWING
CONDITION:
AFTEBWARMUP
TURNOFFALLLIGHTS
AND
AIRCONDITIONER,
RB25DEDIAGNOSIS
D|AGNoS|S25(Phenomenon).WHENcoLD,D|FF|CULTToSTARToRcANNoT
STARTTHEENGINE
1
. F U E L P U M P'
YOU FEELPULSATION
WHEN
R Y3 S E C O N D S
andstartermotorf-llsglessjljePell
tnspectOattery
OK
2
E FUEL TUBEIS
E D ?O BC A NY O U
FUELPUMPRELAY
Fuelpressureinspection
'FUNCTIONNG
usingFUELPUMP'in
,6,lnspect
flltesr" mode.
,o.Pinchf uelPumPwithf ingers.
6)Cnect if thefusehoseis tensewhenf uel
pumpus operatlng.
OK
Fuelpumpandcircuit
inspection
Fueiiilter
Air regulatorinsPection
NG
to airregulator
Checkifthepowerisconducted
toONposition'
isturned
switch
whentheignition
OK
andclrcull.
Inspectairregulalor
ThrottlesensorinsPection
pedalfullyandcheckif
Pressaccelerator
theenginewillstart.
OK
Throttlesensorandcircuit
inspection.
5
lnjector inspection
Placeignitionswitchto OFFpositlon.
Removecrankanglesensor(leaveharness
connectorconnected).
Removepowertransistorconnector.
NG
Checkif eachinjectoroperationnoisecan be
heardwhenthe crankanglesensorshaftis rotated
on howtheshaftis
by hand.Note:Depending
in
rolated,abnormalwillshowin self-diagnosis,
as normal.
thiscasedetermine
OK
TO6
andcircuitinsPection
Injector
EN - 4s4
4
'J5;-
F u l l yo p e n
:f
lrr't
gl+uu\
,/
.\-i)
if.',{:--,!
Rolate by hand
RB25DEDIAGNOSIS
6
lgnitioninspection
Placeignitjon
jn eachpipptng.
Removesub-harness
Installnormalsparkplug.Facethesparkplug
NG
rearend towardsadequategroundsuchas
collector
andcranktheengine.
Checkthespark.
OK
Inspectignition
coil,power
transistorandcircutt.
7
Sparkpluginspection
Checkfordirt,damage,
gapetc.onthespark NG
plugremoved
fromtheengine.
OK
Repair
or replace
8
ECCS C/U connector inspection
NG
Checkfor any damageor looseconnectionon
the C/U binterminaland harnessconnector.
OK
Repairor replace
ECCSC/Upowersupplyandgroundcircuit NG
Inspectron.
OK
Repairor replace
't0
Try replacing
withnormaiC/L.
FINISH
EN- 4ss
RB25DEDIAGNOSIS
DIAGNOSIS26(Phenomenon)-WHENWARM,DIFFICULTTOSTARTORCAN
NOT STARTTHE ENGINE
1
in"FUNCTIONNG
usingFUELPUMP"
/G Inspect
!UtEST" mode.
withfingers.
,o,PinchfuelPumP
(SCneckifthefusehoseistensewhenfuel
pumpusoperatlng.
OK
Fuelpumpandcircuit
inspection
2
Vapour inspection
fuelpressureregulatorvacuumhose O K
Disconnect
Placea holecapon thevacuumhose.
Doestheenginestart?
NG
Inspectfuelaspect
IniectorinsPection
Removepowertransistorharnessconnector.
NG
Placeignition
noisecan be
Checkif eachinjectoroperation
on howtheshaftis
in
willshowin self-diagnosis.
abnormal
rotated,
as normal.
thiscasedetermine
OK
andcircuitinspection
lniector
4
lgnitioninsPection
in eachpipping.
Removesub-harness
plug.
Facethesparkplug N G
Installnormalspark
rearend towardsadequategroundsucnas
andcranktheengine.
collector
the
Check spark.
OK
coil,Power
Inspectignition
andcircult.
transistor
TO
EN - 456
IFUEL PUN/P1)
YOU FEELPULSATION
WHEN
3 SECONDS
E FUEL I UIJtr I-
RB25DEDIAGNOSIS
5
Sparkplug inspection
gapetc.onthespark N G
plugremoved
fromtheengine.
OK
Repairor replace
6
NG
Checkforanydamageor looseconnection
on
the C/Ubinterminaland harnessconnector.
OK
Repair
or replace
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
'
YOU FEELPULSATION
lnsoectbatteryand startermotor
Fuel pressureinsPection
"FUNCTION
usingFUELPUMP'in
4;.,lnspect
\ETEST'mooe.
SH E N
3 S E C O N DW
E FUELTUBEIS
ED? OR CANYOU
RELAY
EAFIFUELPUI\,4P
PinchfuelpumPwithfingers
Checkif thefusehoseis tensewhenfuel
pumpus oPerating.
Fuelpumpandcircuit
inspection
Iniectorfuel leak insPection
pedalfullyan checkif the
Pressaccelerator
switchisturn
enginewillstaftwhentheignition
to STARTposition.
leak.
Inspectinjector
lniector insPection
Removecrankanglesensor{leaveharness
Placeignition
on howtheshaftis
in
willshowin self-diagnosis,
abnormal
rotated,
normal.
as
thiscasedetermine
lniectorandcircuitinsPection
lgnition inspection
Placeignitionswitchto OFF position.
in eachpipping
Removesub-harness
plug.
Facethesparkplug
Installnormalspark
groundsuchas
rearendtowardsadequate
engine.
andcrankthe
collector
Checkthespark.
OK
TO6
coil,Power
Inspectignition
ci
and rcuit.
transislor
dI?-.,
F u l l yo p e n
:\l
rF.t
TI+(f,l\
,/
,V
f-l
X-
Rotateby hand
R825DEDIAGNOSIS
Sparkpluginspection
gapetc.onthespark N G
plugremoved
fromtheengine.
OK
Fepar or replace
NG
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
AFTEB WARM UP
DIAGNOSIS28 (Phenomenon)- HESITATION
(hesitationas throttle valve starts to open)
1
rcrrveresr O D
FuelpressureinsPection'FUEL
'UP'or"DWN"in
INJECTION
,erSelect
value.
correction
modeto change
time
Carryoutthetestin minimum
Caution:
required.Do notolelqle lullnggllve,vacuumhose NG
reregulator
;DGcon nectluefpressu
(6)Placeholecaponvacuum
hose
test.
cruising
Operate
lstherestillhesitation?
o, sENsoF
o . S E N S O( B
R)
TEST' OK
in'ACTIVE
GzounurtrvcoRREcrtoN"
NG
inspectpressure
lf leanhesitatlon
regulatorandfuelPumP.
FuelaspectinsPection
Canisterpurge inspection
canister
Disconnect
Purgenose. N G
Placeholecapon the Purgehose
Conductcruisetest.
ls therestillhesitation?
Inspectpurgeandvacuum
system.
FINISH
EN - 460
OFFSET 09"
FUEL INJECTION
MONITOR
937rpm
CAS.FPIV(POS)
59'C
SEN
ENG TEI\,4P
iNJ PULSE
AAC VALVE
Qu
UP
1.33V
1.3sV
l.BMSEC
17'i.
DWN ll Od
RB25DEDIAGNOSIS
DIAGNOSIS
29 (Phenomenon)- HESTTATTON
WHENCOLD
1
Sparkpluginspection
Remove
sparkplugandcheckforanvdirt, NG
gapetc.
damage,
NG
Bepairor replace
2
" U P ' o r- D W Ni'n
F U E LI N J E C T I O N
rerSelect
euRrurtry coRREcloN' in-ACTIVE
TEST' OK
modetochange
correction
value.
Caution:
Carryoutthetestjn minimum
time
required.
Donotoperate
duringdrive.
Starttheengine.
whentheblow-by
61Does theenginerevincrease
\g/ hoseis pinched?
ACTIVETEST
FUEL]NJECIION
OFFSET
NG
Repairleaks
3
OK
Replace
withnormalarrf lowmeter.
NG
Replaceairflowmeter.
4
Intake valve deposit inspection
Removewhendeoositis Dresenr.
FINISH
EN - 461
r.33V
RB25DEDIAGNOSIS
lN NORMALCONDITION
30 (Phenomenon)'HESITATION
DIAGNOSIS
1
TE51,
ItsASEAlRFUELRATIO
Spark plug insPection

Removesparkplugandcheckforanydirt,
HOLDENGINEREV2000+f
200rpmANDPRESSSTARI
Repairor replace
Exhaust gas sensor insPection
'BASEAIR-FUEL
RATIO"in
Inspectusing
"FUNCTION
TEST"mode.
"O, SENSORMONITOR"
NG
in data
Select
monllor.
Set at 2000rpmwith no loadafterwarm up
"LEAN,RICH"willrepeat
Checkif thedisplay
formorethan5 timeswithin10seconds
Operatevehicleside(withinfusebox)
andchangeto Oconnector
diagnosis
sensormonitor".
with no loadafterwarm up.
Set at 2OOOrpm
warning
Canister purge insPection

canister
Disconnect
Purgenose.
PlaceholecaPon Purgehose.
Conductcruisetest.
ls therestillhesitation?
ttlt
7|-rl
ExhausttemP
w a r n r n gl a m p I
purgeano
Inspect
system
vacuum
lntake air leak insPection

Warmup the engine.
"DWN"
Changeoffsetvalueby selecting
RATIOOFFSET
in "FUELINJECTION
mode.
in
test
active
VALUE"
Caution:Carryoutthetestin minimum
timerequired.Do notoperateduringdrive.
Warmup the enqine.
rateairflowmeterharnessconnector.
after
@cn-.,"[ ii rn" idlerevwilldecrease
racingtheenglneat approx.below
for 30 seconds.
Repairanyleaks
4
O ncrtvEresr O f
OFFSET O%
FUELINJECTION
MONITOB
s37rpm
CAS.RPM(POS)
59'C
SEN
ENG TEI\,4P
1.33V
o. SENSOR
1.35!
o. sENsoR(R)
1.8msec
tNLPULSE
17"h
AAC VALVE
Ou
UP
owN
Qd
RB25DEDIAGNOSIS
DIAGNOSIS
31 (Phenomenon)- ENGTNE
STALLWHTLEREVVTNG
1
Fuel level inspection
Checkthe levelof fuelin thefueltank.
NG
Resupply
fuel
OK
2
, F-rN-=I
l-
Power balancetest operation

,ar Startthe enoine.
l l l
\9/ Inspectusing'POWERBALANCEin
'FUNCTION
TEST"mode.
"POWER
Operate
BALANCE"in "ACTIVE
TEST"mode.Caution:Carryoutthetestin
minimumtimerequired.Do notoperate
duringdrive.
Checkif idlerevwilldecreasefor a moment
whencheckingeachcylinders.
'
\--l
NG
OPOWEHBALANCE'
FOREACHCYLINDER
STOP
INJECIOR
OPEMTIONAND
CHECKTHEBALANCEOF
EACHCYUNDER.
TURNOFF,6./CAND
LIGHTS
Checkif idlerevdecrease
fora moment
,q1
rrwheneachinjector
connector
cylinders
are
disassembled.
To No. 5
OK
3
Iniector inspection
Removepowertransislorconnector.
NG
Placeignition
switchfromOFFto ON position.
heardwhenthecrankanglesensorshaftis rotated
on howtheshaftis
rotated,
abnormal
willshowin self-diagnosis,
in
thiscasedetermine
as normal.
/l
Operationnolse
Injectorandcircuitinspectron
4
lgnition inspection
Placeignitionswitchto OFFposttion.
Removesub-harness
in eachpipping.
Installnormal
plug.
spark
Facethesparkplug
NG
rearendlowardsadequategroundsuchas
collector
andcranktheengine.
Checkthespark.
OK
TOs
Inspectignition
coil,power
transistorandcircuit.
EN - 463
'%j,::""',,
'%!
RB25DEDIAGNOSIS
5
Fuel pressure insPection

/G\ Startthe engine.
fU'Bringfuelpressureto zeroby selectingFUEL
"ACTIVETEST".
PUMPRELAY"in
NG
Crank2 to 3 timesafterenginestop.
Usefuelpressuregaugeto inspect:
2.skg/cm'
Whenidling.APProx.
vacuumhoseis
Whenpressureregulator
removed:APPToL
,-o''Starttheengine.
\6tlring {uelpressure
fuel
to zerobyremoving
pumpfuse.
Crank2 to 3 timesafterenginestop'
gauge.
usingfuelpressure
Inspect
OK
pressure
Inspect
diaPhragm
regulator
ECCS C/U conneclor inspection

NG
on
andharnessconnector.
theC/Ubinterminal
OK
Repairor replace
tnrpectgCCSC/Upowersupplyandground N G
circuit.
OK
Repairor rePlace
8
Try replacingwithnormalC/U.
OK
FINISH
EN - 464
ACTIVETEST . L--]
.
RELAY ON
FUELPUI\.4P
MONITOB
CAS.RPM(POS) 0rPm
oN
c
lpN/oFFll oFF
RB25DEDIAGNOSIS
- ENGTNE
DIAGNOSIS
32 (Phenomenon)
STALLAFTERWARMUp
1
1
resr
O ncrrve
Vapourinspection
..DWN"
correction
valuebyselecting
in"FUEL
,6lChange
"
"ACT|VE
\E4NJECTION
CORRECTTON
in
TEST"mode.
Caution:
Carryoutthetestin mintmum
timerequired.
Donotoperate
duringdrive.
pressure
regulator
vacur-rrn
fG\Disconnect
\@Place
hole cap on vacuum hose.
OL/
Operatecruisetest.
Doestheenainestillstall?
2
a I
FUELINJECTION
OFFSET O'/.
t\,10NtToR
CAS.RPI\,1(POS) 937rpm
ENGTE]\IPSEN
59,C
o, SENSOR
1.33V
o " S E N S O R( R )
i.35\
INJ PULSE
].8msec
AAC VALVE
179L
UP
DWN
od
NG

/G\ Start the enqine.
'i
Inspectusirig-eOWeR BALANCEin
.FUNCTION
TEST"mode.
"POWER
Operate
BALANCE"
in "ACT|VE
duringdrive.
Checkif tdlerevwilldecreasefor a moment
whencheckinqeachpippinq.
Checkif idle revdecreasefor a moment
,q,
\r wheneachinjector
pippingare
connector
disassembled.
NG
.POWER BALANCEO
FOREACHCYUNDERSTOP
ITUECTOR
OPEMTIONAND
CHECKTHE
BALANCEOF
EACHCYUNDER.
TURNOFFT/CANDLIGHTS
To No. 5
OK
3
Iniector inspection
Placeignition
conneclorconnected).
Removepowertransistor
connector.
NG
Placeignition
switchf romOFFto ON position.
on howtheshaftis
rotated,abnormalwillshowin self-diagnosis,
in
thiscasedetermine
as normal.
@ffr^<)
:n. =d$l}P
Injectorandcircuitinspection
4
lgnitioninspection
Placeignitjon
Removesub-harness
in eachpipping.
rearend towardsadequategroundsuchas
collector
andcranklhe engine.
Checkthespark.
EN - 465
R825DEDIAGNOSIS
RB2sDE NGINE

rer Startthe engine.
"FUEL
fUBring fuelpressureto zeroby selecting
"ACTIVETEST"mode.
PUMPRELAY"in
stop.
2 to3 timesafterengine
Crank
5
O ncrrverEsrILJ
FUELPUMPRELAY OFF
MONITOF
NG
gaugeto inspect:
Usefuelpressure
2.5kglcm2
Whenidling:APProx.
vacuumhoseis
removed:APProx.3.0k9/cm'
(POS) 950rPn"
CAS.RPI\,'1
ON
)N/OFF OFF
^ Qt. rt +ha anoina

i"ul".",.
fuel
l&Bringfuelpressure
tozerobyremoving
fuse.
oumo
Crank2to 3 timesafterenginestop.
gauge.
Inspectusingfuelpressure
OK
pressure
Inspect
diaphragm
regulator
ECCS C/U connector insPection

NG
on
Checkfor anydamageor looseconnection
OK
Repairor replace
7
tnspectECCSC/U powersupplyandground N G
circuit.
OK
Repairor replace
I
Try replacingwithnormalC/U.
OK
FINISH
EN - 466
0oog.
sT195S
RB25DEDIAGNOSIS
DIAGNOSIS
33 (Phenomenon)- ENGINESTALLWHENCOLD
't
Air regulator inspection
Checkif thepoweris conducted
to air regulatorN G
whenignition
switchis in ON position.
OK
Inspeclair regulator
andcircuit.
2
Throttlesensorinspection
Pressaccelerator
pedalfullyandcheckifthe NG
engrne
canbestarted
whentheenqineiscold.
Inspectair regulator
andcircuit.
Fullyopen
$ + @<
I Powerbalancetestoperation
Start
theengine.
frt
:
'POWER
Inspectusing
BALANCEin
"FUNCTION
TEST"mode.
Operate"POWERBALANCE'in"ACT|VE
TEST"mode.Cautton:Carryoutthetestin
minjmumtimerequired.Do notoperate
duringdrive.
Checklf idlerevwilldecreasefor a moment
whencheckinqeachcvlinders.
Checkif idlerevdecrease{ora moment
@
: wheneach
injector
connector
cylinders
are
disassembled.
NG
.PoWER BALANcE.
FOREACHCYUNDEFSTOP
INJECTOROPEMNONAND
CHECKTHE
BALANCE
OF
EACHCYLINDER.
TURNOFFA./CAND
LiGHTS
T oN o . 7
oK I
Iniector inspection
Placeignitionswitchto OFF position.
NG
Placeignition
switchf romOFFto ON position.
noisecanbe
heardwhenthecrankanglesensorshaftis rotated
on howtheshaftis
rotated,
abnormal
wrllshowin self-diagnosis,
in
thiscasedetermrne
as normal.
Injector
andcircuitinspection
TO5
EN - 467
@ffrX)
:Rt,>sv
/l
RB25DEDIAGNOSIS
RB2sDE NGINE
lgnition inspection
Placeignition
in eachcylinders'
Removesub-harness
plug.
Facethesparkplug
Installnormalspark
rearendtowardsadequategroundsuchas
andcranktheenglne.
collector
Checkthespark.
coil,Power 6
ignition
Inspect
circult.
and
transistor
SparkpluginsPection
gapetc.
Checkfordirt,damage'
from
onthesparkPlugremoved
Repairor replace
'/G Startthe engine.
l.=Brrnqfuelpressure
to zeroby selectingFUEL
,.ACTIVE
TEST''MOdC.
PUMPRELAY,in
Crank2 to 3 timesatterenglnestop.
gaugelo Inspect:
UsefuelPressure
2.Skg/cm'
Whenidling:APProx.
vacuumhosels
when pressureregulator
rox.3.Okq/cm'
,6Start the engine.
luel
lo zeroby removing
6tsrinq f uelpressure
p u m pf u s e .
gauge.
Inspectusingfueipressure
lnspectpressure
regulatordiaphragm
ECCS C/U connector insPection
on
Checkfor anydamageor looseconnection
connector.
and
harness
the C/U binterminal
Repairor replace
InsoectECCSC/U powersupplyandground
withnormalC/L.
Try replacing
EN - 468
I ncrrverrsr O L,-i
FUELPUMPRELAY OFF
l\,40NlToF
(POS) ssorpn
CAS.BP[,4
ON
)N/OFF OFF
RB25DEDIAGNOSIS
DIAGNOSIS
STALLWHENACCELERATTNG
INSTANTLY
1
AAC valve inspection
(f;)warmengine
v Inspectusing'AACVALVE-in
FUNCTION
ItrJ I
l. Fl
Select"AACVALVE
ADJ"in "ACT|VE
TEST".
Checkiftheenginerevwillchange
when
"Qu"or "Qd"is
selected
tochange
AAC
varveopentng.
NG
1
qcrrveresr t D
AAC/VOPENING
MONITOR
CAS.RPI\,{(POS)
AIR FLOW['TR
ENG IEI\,4PSEN
theengine.
re\Stan
\G/Check
if enqinerevwilldecrease
when
AACvalveJonnector
ts dlsconnected.
InspectAACvalve
andcircuit.
Ou
UP
lOO,':
900rpm
1.16V
8O"C
DWN
od
2
{Start theengine.
\elnspectusing POWERBALANCEin
"FUNCTION
TEST"mode.
OR use"POWERBALANCE"in "ACT|VE
duringdrive.
Checkif idlerevwilldecreasefor a momenl
NG
OK I
ToNo.5
3
Injector inspection
Removecrankanglesensor.
NG
Placeignition
switchfromOFFto ON position.
noisecanbe
by hand.
OPOWERBALANCEO
FOREACHCYLINDERSTOP
INJECIOR
OPEMTIONAND
CHECKTHE
BALANCEOF
EACHCYLINDEF.
2
ACTIVETEST 'f
POWERBALANCE
(POS)
CAS.FlPl\,4
rpm
AIF]FLOWMTR
V
q.
AACVALVE
.
r=l
Injectorandcircuitinspection
L:]
2
6
3 4
START
TO4
Operatronnoise
EN - 469
RB25DEDIAGNOSIS
lgnition inspection
coil.
Bemoveignition
ground
suchas
adequate
rearendlowards
andcranktheengine.
collector
CheckthesPark.
coil,
Inspectignition
andcircuit.
transistor
,ar Startthe engine.
(UBrinq fuelpressureto zeroby selectingFUEL
..ACTIVE
TEST''MOdE.
PUNiPRELAY"in
stop.
engine
Crank2to 3 timesafter
gaugeto Inspecl:
UsefuelPressure
2.Skglcm'
Whenidling:APProx.
vacuumhoseis
pressure
regulator
When
rox.3.Okq/cm'
,.,o,Start the engine.
(6bring f uelpressureto zeroby removing
f uel
pumpfuseNo.B.
gauge.
Inspectusingfuelpressure
on
orlooseconnection
Checkforanydamage
connector.
andharness
theC/Ubinterminal
ir or replace
lnspectECCSCiU powersupplyandground
withnormalC/L.
Try replacing
EN - 470
rEsr lL
O ncrrve
RELAY OFF
FUELPUN,IP
t\,roNtToR
(POS) 950rPrr
CAS.RPN,4
ON
)N/OFF OFF
RB25DE
DIAGNOSIS
DIAGNOSIS
STALLWHEN DECELERATING
1
AACvalveinspection
/G.rWarm
engine.
: Inspect
using"AACVALVEin 'FUNCTION
TEST'OR
NG
Select"AACVALVE
ADJ"in "ACTIVE
TEST".
Checkiftheenginerevwillchange
when
"Qu"or "Qd"is selected
to changeAAC
valveopening.
theengine.
r\Slart
\@/Check
if enginerevwilldecrease
wnen
AACvalveconnector
is disconnected.
OK
resr a tr
O ncrrve
A A C/ V O P E N I N G
[,40NtTOR
CAS.RPM(POS)
AIR FLOWMTF
ENGTEIV1P
SEN
Inspect
AACvalve
andcircuit.
UP
Qu
109:
900rpm
1 16V
80.C
DWN
Qd
2
Adiust screw fixation inspection
using-AACVALVEADJUSTMENT@,lnspect
:in OPERATION
SUPPORTmode.
NG
Checkif it is possibleto set idlespeedto
650rpm("N"rangeforA/T)by turningidte
adjustmentscrew.
throttlesensorconnector.
6lDisconnect
\Gr Checkif it is possibleto set idlespeedto
650rpm("N"rangeforA/T)by turningidle
adlustmentscrew.
OK
InspectAACvalveand
throttlevalvefixation.
3
,G\ Startthe enoine.
\ t /
v Inspectusing"POWERBALANCE'in
"FUNCTION
rEST" mode.
"POWER
OR use
BALANCE"in "ACT|VE
minjmumtimerequired.Do notoperate
duringdrive.
Checkif ldlerevwilldecrease
for a moment
r,qsta rt the engine.
\c/Check
if idlerevwilldecreasefor a moment
wheneachcylinderinjector
connector
is
disconnected.
oK I
NG
ACTIVETES1 r f
POWERBALAI'rcE
cAS.RPM(POS)
rpm
AIFIFLOW I\,ITF]
a./"
AAC VALVE
.
T oN o . 6
EN - 471
AAcVALVE
ADJ a
ADJUSTCAS
FlPMTO
STANDARD
VALUEUNDEF J
thE FOLLOWNGCONDLT
ON ,
AFTERWARMUP
] TURNOFFA,'CAND
L GHTS
1
E--l
t:j
2
--t
o l
4
STAFT
DIAGNOSIS
RB25DE
4
Iniector inspection
NG
Placeignitionswitchf romOFFto ON position.
noisecan be
Checkif eachiniecloroperation
shaftis rotated
sensor
angle
heardwhenthecrank
by hand.
InjectorandcircuitinsPection
5
lgnitioninspection
coil.
Removeignition
NG
Inslallnormalsparkplug.Facethesparkplug
rearend towardsadequategroundsucnas
andcranktheengine.
collector
CheckthesPark.
OK
O ncrrveresr I i--l
FUELPUMPRELAY OFF
N,4ONITOB
CAS.RPM(POS) 950rpn
coil,Power
Inspectignition
transistorand circuit.
ON

/G\ Startthe engine.
-FUEL
to zeroby selecting
lUBring fuelpressure
"ACTIVETEST"mode.
PUMPRELAY"in
NG
Usefuelpressuregaugeto insPect:
2.Skg/cm'
Whenidling:APProx.
vacuumhoseis
regulator
when pressure
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.
gauge.
Inspectustngfuelpressure
,r2.
:// Fuel
TO7
Inspectpressureregulalor
diaphragm.
EN - 472
]N/OFF
OFF
F825DEDIAGNOSIS
Exhaustgas sensorinspection
usinq"BASE
AIR-FUEL
FATtOrn
/G\ Inspect
r-U"rurucrtoru
TESTmode.
"O,SENSOR
Seiect
MONITOR"
indara
NG
monitor.
Setat2000rpm
withnoloadafterwarmup.
"LEAN,
Checkifthedisplay
RICH"witlrepeat
formorethan5 timeswithin10seconds.
Operatevehicleside(withinfusebox)
re\
\r' diagnosis
connector
andchangeto -O2
NoFA|L
A,4oNrToRrNqk
(REF)
CAS.RPI,4
82srpm
02 SENSOBI\,4TR RICH
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.
warning
10 seconds.
OK
ReplaceO, sensor
Inspectthrottlesensorandvehicle
speedsensor.
Iltl
OK
NG
Checkforanydamage
or looseconnection
on
theC/Ubinterminal
andharness
connector.
OK
Repairor replace
InspectECCSC/Upowersupplyandground N G
circuit.
OK
Repairor replace
TryreplacingwithnormalC/U.
OK
FINISH
EN - 473
Redlarnp
' E x h a u stern
t p
w ar n r n q a m p
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
OR use
duringdrive.
for a moment
Checkif idlerevwilldecrease
whenchec@
rqstart the engine.
\@Checkif idlerevwilldecrease
for a moment
is
connector
wheneachcylinderiniector
disconnected.
2
oK I
l
NG
ToNo'
IniectorinsPection
NG
connector.
Removepowertransistor
switchfromOFFto ON position'
Placeignitron
noisecan be
heardwhenthe crankangiesensorshaftis rotated
by hand.
@ffix)
rRl' >S"/
/l
Operalionnolse
i\
.- lgntion
3
lgnitioninsPection
coil.
Removeignition
NG
plug.Facethesparkplug
spark
Installnormal
collectorandcrankthe engine
CheckthesPark.
OK
coil,Power
Inspectignition
transistorandcircult.
TO4
EN - 474
RB25DEDIAGNOSIS
O ecrrverrsr I {*
ua-rStaftthe enqine.
'FUEL
\U Aringfuelpr"essure
to zeroby setectrng
PUMPRELAY'in"ACTIVETEST"mode.
NG
Usefuelpressure
gaugeto inspect:
Whenidling:Approx.2.5kglcm2
Whenpressure
regulator
vacuumhoseis
removed:Approx.3.Okgicm,
FUELPUI\,4P
BELAY OFF
l\,lONlTOR
CAS.RPM(POS) gsorpn
ON
theengine.
6lStart
\ctBringfuelpressure
tozeroby removing
fuel
pumpfuseNo.B.
Crank2 to 3 timesafterenglnestop.
Inspect
gauge.
usingfuelpressure
OK
pressure
Inspect
regulator
diaphragm.

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

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

@Check if idlerevwilldecreasefor a moment
ls
connector
wheneachcylinderinjector
disconnected.
To No. 4
lniector insPection
switchf romOFFto ON position'
Placeignition
noisecan be
operation
Checkif eachinjector
tDi
rJ-
/\
uUKj--l .K /
.tN,,:dD/
/l
Operationnoise
4
ignitioncoil
lgnition insPection
coil.
Removeignition
andcranktheenglne.
collector
Checkthespark.
coil,Power
Inspectignition
andcircuit.
transistor
TO5
EN - 476
RB25DEDIAGNOSIS
3
,er Starttheenoine.
.U BringfuelprLssure
tozerobysetecting.'FUEL
PUMPRELAY"
in"ACTIVE
TEST"mode.
NG
Crank2 to 3 ttmesafterenginestop.
pressure
Usefuel
gaugeto inspect:
Whenidling:Approx.
2.5kglcm2
Whenpressure
regulator
vacuum
hoseis
removed:
Approx.
3.0k9/cm,
theengine.
61Stad
tgring fuelpressure
to zeroby removing
fuel
pumpfuseNo.8.
Crank2to 3 timesafterengjnestop.
InspectusingJuelpressure
gauge.
OK
Inspectpressureregulator
diaphragm.

NG
on
Repairor replace
OK
7
InspectECCSC/Upowersupplyandground NG
circuit.
8
OK
Repairor replace
Tryreplacing
withnormalC/L.
OK
FINISH
EN - 477
I ncrrvrresr O[
FUELPUI\,,IP
RELAY OFF
MONITOR
CAS.RPM(POS) 950rpn
ON
IDN/OFF OFF
RB25DEDIAGNOSIS
38 (Phenomenon)'POWERSHORTAGEAND STUMBLE
DIAGNOSIS
(lnstant power output shortage during acceleration)
1
/G Start the engine.
to zeroby selectingFUEL
fUBring tuelpressure
"ACTIVETEST"mode.
PUMPRELAY'in
NG
Crank2to 3 timesafterenginestop.
gaugeto insPect:
Usefuelpressure
2.Skglcm?
Whenidling:APProx.
vacuumhosels
removed:APProx.3 Olg&m1^
O ecrtvergst O
Cr"* th6 annine
fuel
t&Bringfuelpressure
to zeroby removing
pumpfuseNo.8.
Crank2to 3 timesafterengrnestop.
gauge.
usingfuelpressure
Inspect
OK
lnspectpressureregulator
diaphragm.
2
Intake air leak inspection
the engine.
YES
@Start
echanqe correction
valueby selectingDWN"
CORRECTION
iN..TUEIINJECTION
"ACTIVE
TEST"
VALUE"in
required.Do notoperatewhiledriving.
whenthe
Xe treckit enginerevwillincrease
hoseis pinched
W)blow-bv
NO
Repairanyleaks
pressure,
timing NG
ignition
Inspectcompression
anddetonationsensor.
NO
Repairor replace
FINISH
EN - 478
2
I
ncrveresr t D
FUEL NJECTIONOFFSETO%
MONITOR
g37rpm
CAS.RPM(POS)
59'C
ENGTEMPSEN
1,33V
O, SENSOR
1.35V
o, sENsoR(R)
l.8msec
NJ PULSE
179L
AAC VALVE
Ou
UP
DWN
Qd
RB25DEDIAGNOSIS
DIAGNOSIS
39 (Phenomenon)- DETONATTON
1
Intakeair leakinspection
(l)Starttheengrne,
: Change
.DWN' YES
correction
valuebyselecting
in"FUELINJECTION
CORRECTTON
VALUE"in "ACTIVE
TEST".
Caution:
Carryoutthetestinminimum
time
required.
Donotoperate
whiledriving.
NO
Repalranyleaks
OK
NG
Inspectpiston.pistonring,
valve,valveseat,valveoil
seal,engineoil leveletc.
Inspect
detonation
sensorsvstem.
OK
FINISH
EN - 479
Q acr veresr O f
rUeLttllecrtolOrrSg dl
MONITOR
CAS.RPI\.4(POS) 937rpm
ENGTEI\,IP
SEN
59'C
O. SENSOR
1 33V
o , S E N S O R( R )
1.35V
INJ PULSE
l.Bmsec
AAC VALVE
17"i
Qu
whenthe
prCheck if enginerevwillrncrease
@rblow-bvhoseis oinched.
Combustion chamber oil leak inspection

Disconnect
sparkplugandlnspectoil.
UP
DWN
od
RB25DEDIAGNOSIS
40 (Phenomenon) S U R G E
DIAGNOSIS
1
Exhaust gas sensor insPection
"BASEAIR-FUEL
RATIO'in
/A Inspectusing
.-EiruructtoNTEST"
mooe.
"O,
NG
in data
Select SENSORMONITOR"
monitor.
Set at 2000rpmwith no loadafterwarmup
"LEAN,RICH"willrepeat
Checkif lhe display
for morethan 5 tinqllryjlllllqlegengs.-
IFASEAIR FUELRATIOTESI
HOL0ENGINEREV2000+1PBESSSTART
2OOrpmAND
fusebox)
side(within
vehicle
,o, Operate
18 diagnosis
to "o.
andchange
connector
sensormonitor".
withno loadafterwarmup'
Setat 2ooorpm
warning
temperature
Checkiftheexhaust
within
5
times
than
lamowillflashformore
10 seconds.
OK
START
ReplaceO, sensor
II
2
ReplaceECCSC/U
:'----_-*-.,
OK
FINISH
,^^':?
Red la'np
E N- 4 8 0
Ittl
.fi-g
EiT:1rlr
lamp,
warntng
R825DEDIAGNOSIS
DIAGNOSIS
41 (Phenomenon)- BACK FIRE(SPtTTtNG)
1
Sparkplug inspection
NG
Remove
sparkplug.
Checkforanydirtonthesparkplug.
OK
Repairor replacesparkplug.
2
Intake air leak inspection
theengine.
@Start
: Changecorrection
-DWN' YES
valueby selecting
in "FUELINJECTION
CORBECTION
VALUE'in"ACTIVETEST"mode,
required.Do notoperatewhiledriving.
whenthe
^6.Checkif enqinerevwillincrease
I ltf L
Yq/blow-bv hose ts ornched.
2
I
Qu
NO
Repairanyairleaks
3
Intake valve deposit inspection
Removeif thereareanydeposltpresent.
lgnitiontiming
Checkif injectoris clogged.
FINISH
DIAGNOSIS
42 (Phenomenon)- AFTERBURNTNG
1
Engine temperaturesensor inspection
Inspectenginesensorandenginesensor
circuit.
OK
NG
Repairor replace
lgnitiontiming
Checkif injectoris clogged.
FINISH
EN - 481
ncrrve
resr a n
FUELINJECTION
OFFSET O%
[,4ONJTOB
CAS.RPM(POS)
937rpm
ENGTEI\,4P
SEN
59"C
O. SENSOR
J.33V
o . S E N S O R( B )
1.3sV
INJ PULSE
1.8msec
AAC VALVE
17"1"
UP
DWN
Qd
INSPECTION
RB25DECON,lPONENTS
F B 2 5 D EE N G I N E
(RB25DE)
8. coMPoNENTSINSPECTION
CRANKANGLESENSOR
Inspection
Removecrankanglesensorfromtheengine.(leave
connected).
crankanglesensorharnessconnector
Rotatecrankanglesensorshaftslowlywithhandand
2.3 andground
inspectthevoltagebetweenterminal
Xs -i
a,,fl\
I\ ARr i Xq
@-,p
Rotateby
crankanglesensor.
lF NG: Replace
EraseselfdiagnosisresultfromCONSULTafterinspection'
in thescreen.
CheckcodeNo. 11is notdisplayed
Caution:
Removeinjectorf useor connectorto avoidinjectorf rom
whileinspection.
operating
AIR FLOWMETER
lnspection
. Removeairflowmeterfromtheengine.
. Applybatteryvoltagedirectlybetweenairflowmeter
terminal5+ andterminal3- andblowairto hotwlre.
Checkfor any changein outputvoltagebetweentermlnal
2+ andterminal4-.
Air is not blown
Air is blown
ivl
rO lil
f-l .
r 1 i 2 r ? 1I4 l l
t t
/n
at,
Approx.0.8V
Ee
Approx.2V
lF NG: ReplaceairflowmeterOR checkfor anydamage

withthe hotwire.
afterinspection'
resultfromCONSULT
Eraseselfdiagnosis
screen.
in
the
is
not
displayed
CheckcodeNo. 12
SENSOR
ENGINETEMPERATURE
Inspection
. Disconnect
sensorharness
enginetemperature
connector.
. Measuretheresistance
betweenenginelemperature
sensorharnessterminal1 and2.
Approx2o"c
npprox2 sKS)
Approx8o"c
nPProx0.3x$l
sensor.
lF NG: Replaceenginetemperature
afterinspection.
CONSULT
from
result
Eraseself-diagnosis
in the screen
CheckcodeNo.31 is notdisplayed
EN - 482
(KA
o
c
o
b
(D
(r
RB25DECOMPONENTS
INSPECTION
IGNITION
COIL
Inspection
. Disconnect
ignition
coilharnessconnector.
. Measurethe resistance
betweenfollowinq
terminals.
Primary
coilresisntance
value(i - 2) |
0.6- 0.9
lF NG: Replaceignition
coil
POWERTRANSISTOB
Inspection
. Disconnectpowertransistorharnessconnector.
by inserting
analogtypecircuit
testerinspectionrod - and + to powertransistor
terminals.
+/- coSJ -r* oo f,l
2-3
t - J
+ / - o o f , J > - / + 0 o r n o@
t 61
+ / - 0 o r n o to o Q . - l *
co fl
lF NG: Replacepowertransistor.
F U E LP U M P
Inspection
. Disconnect
fuelpumpharnessconnector.
betweenfueloumoterminal1
and 3.
Resistance: Approx.0.4 - 0.7
. Checkfor operationby applyingbatteryvoltagebetween
thefollowing
terminals
directly:
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 resistance
betweenthrottlevalveswitchterminals.
(ldle contact point)
Acceleratorpedalis not pressed
lF NG: Repairthrottle
valveswitch.
EN - 483
Ele-,e
INSPECTION
RB25DECOI''lPONENTS
Adiustment
ldle contact point touch rev (rpm): 750 - 1050
. Adjustif the touchrevis notwithinthe rangeabove
. Disconneclthrottlevalveswitchconnectorand loosenthe
bolt.
theenginerevso idlecontactpolntrs
increase
Gradually
betweenterminal2 and 1 is 0 Q ) at
ON (Resistance
aboveenginespeed. Movethrottlevalveswitchunitto
touchpointandtightenthe bolt. Movethrottlevalve
switchunitto touchpointandtightenthebolt.
lnstallthrottlevalveswitchconnector.
Racetheenginefewlimesandcheckidlerevis within
value.
thestandard
fle Z*)
THROTTLESENSOR
throttlesensorconnector.
Disconnect
betweenthroltlesensorterminal2
Measurelhe resistance
and3.
lrr p
Not pressed
Pressedto halfway
A p p r o x0 . 4
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
*4-==ll
u,\,9
. PlungerandswitchinsPection.
. Springdamageinspection.
v eLng",
I
AACvalve.
lF NG: Replace
FICDSOLENOID
. Measurethe resistanceof FICDsolenoid.
Besistance: APProx.2 2 - 2 3
EN - 484
Eei, @
R825DECOMPONENTS
INSPECTION
Plungerandswitchinspection.
Springdamageinspectlon.
tO4>d
Plunger '-(L...-., / \ \ ^
Spring *9
lF NG: ReplaceFICDsolenoid.
AIR REGULATOR
Static characteristicinspection
. Visually
checktheshutteropening.
Below-20"C
Fullyopen
20"c
Approx halfopen
Over60"C
Fuilyclosed
Dynamiccharacterlsticinspection
. Applybatteryvoltageto terminalsand inspectfor any
changewithshutteropening.
The shutterwill close graduallyand completely
closed within 7 minutes. (areatemperature
approx. 20"C).
Reference:Heaterresistancevalue: 70 - 80 tJ (20"C)
lF NG: Replaceairregulator
INJECTOB
Inspection
. Disconnect
injector
harnessconnector.
. Measure
the resistance
of eachiniector
cvlinder
terminal
1 and2.
Resistance
betweeninjectorterminal1 and
2 (eachcylindeo
13-14Q
lF NG: Replaceinjector.
ECCS RELAY FUEL PUMP RELAY,RADIATORFAN

MOTORRELAY
Inspection
. Directlyapplybatteryvoltagebetweenterminal 1 and2.
. Inspeclcontinuity
betweenterminal
3 and5.
lF NG: Replacerelay.
EN - 485
r -1t2j
. l
ar-
(
__l
INSPECTION
RB25DECOMPONENTS
RELAY
IGNITIONRELAYINHIBITOR
Inspection
. Directlyapplybatteryvoitagebetweenterminal1 and 2.
. Checkfor continuity
betweenterminal3 and4, 6 and7
Xe ,@
lF NG:ReplacerelaY.
POWERSTEERINGHYDRAULICPRESSURE
INSPECTION
Inspection
pressure
switch
. Removepowersteeringhydraulic
harnessconnector.
. cCheck
h o n k ffor
o r ccontinuity
o n l i n u i t v between
b e t w e e n the
t h e terminals.
terminals.
We:-p:-'';
lF NG: Replacepowersteeringhydraulicpressureswitch
SPARK PLUG
Inspection & Adiustment
. Measurethe gap betweenelectricpole.
. Reolaceor repairif outof standardrange.
1 . 0- 1 . 1
Standardgap (mm):
FlA
.' .. | tr -! e
c_
fl
lj
F]
FUEL SYSTEMINSPECTION
Simpleinspection
p?.ti,i?l:.,,
. Turnthe ignitionswitchto
9N
_,G)
\!=/
test mode.
. Select"Fuelpump'in the"Function
. Inspectthepulsation
by holdingthefuelhosewithhand
@
. Holdthefuelfilterand makesurethe hoseis hard W
can be feltwhenthefuelpumpis operatingandpulsation
EN - 486
f=
('
FUELPUN,4P
IS THEREA PULSATION
EVEBY 3 SECONDSWHEN
T H E F U E LT U B E I S H E L D ?
O B C A NY O UH E A RT H E
OPERATIONNOISEOF THE
FUEL PUMPRELAY?
RB25DECOMPONENTS
INSPECTION
Fuelpressureinspectionusingthe fuel
pressuremeter
Releasingf uel pressure
. Runtheengine.
"Fuelpumprelay"
. 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.(lftheengine
doesnotstart
crank4 5 timesafterremoving
thefuse).
Caution:
Thebatterymaybecomeweakeasily.useboostercableto
connect
toanother
batteryif necessary.
Fuelpressuremeterinstallation
. Connect
thefuelpressure
meterbetween
thefuelfilterand
thefuelline.
. Attach
thefuelpumpfuse.
. Starttheengineandcheckifthefuelpressure
isat
standard
value.
ldling(kg / cm:,
Approx.2 55
Pressureregulatorvacuumhoseis
(kg / cm,)
disconnected
Approx.3.0
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
IACTIVETEST('
FUELPUI\,4P
RELAY OFF
CAS-RP|\,4
{POS) 950rpm
NSPECTION
R 8 2 5 D EC O M P O N E N TI S
Fuelcut systeminspection
modeusing
. Select"lNJpulse"in "DATAMONITOR"
after
2000rpm
rev
to
the
engine
CONSULT.Increase
"lNJ
pulse"willdecrease
theengine.Checkthat
starting
pedalis
accelerator
the
to 0.6 msecfor a momentwhen
released.
ITORINg}l'lo FA L
(REF) 1950rpm
CAS.BPM
0.6msec
I N JP U L S E
GAS CONTROLSYSTEMINSPECTION
EVAPOBATIVE
Throttlechamber
Checkvalve
f!
gas
<- Evaporatlve
'F Purqeair
Activecarbon
Filter
Tray
Freshair
CANISTER
lnspection
. Connectvacuumhandpumpto canisterthrottlenegative
pressureopeningand makesurethevacuumpressurels
maintained.
pressure
and makesurethe
. Applyapprox.-100mmHg
by
pressure
openingis continued
negative
manifold
suckingairf romtheoPening.
FUELTANK VACUUMBELIEFVALVE
Inspection
. Cleanthevalvehousing.
youwillhear
. lf thef ueltankvacuumreliefvalveis normal,
whenthealrls
soundfromthevalvewithsmallresistance
suckedin throughthecaP
. ReplacethecapASSYif thevalveis closedor when
resistanceis felt.
EN - 488
E Gl 5 13 0 0 0 0
Soflno valve . valve
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
. Lookforanyleakage
fromthehoseandconnection
area.
. Remove
thehoseandcleanusingtheairblow.Replace
hoseifthereareanyclogs.
EN - 489
SIGNALS
ECCSC/UINPUT/OUTPUT
R826DETTENGINE
9.
ECCSCONTROLUNITINPUT/ OUTPUTSIGNALS
VALUES
9.1 CONSULTINSPECTION
(1) Datamonitor
dataon consoleunitso thecorrect
as thecalculation
outputsignalis displayed
itlote:The
disconnected'
is inadvertently
eveniitheoutputcircuit(harness)
valuewilldisplayed
RB26DETTENGINE
-olre
rorron
t,
.IX*TTAL RETENEIGE.
loNrroREaGl'EG
, , .r : - t t , :
l - - - - " - '
Ttre
CAS RPM (Detecled angle

speed according to srgnals)
AIR FLOW MTR (R)
ENG TEMP SEN

(engrne temperaure)
' ., .
TTVALUE
Crank adqle se.sor
Approt O7-l2V(2OOOrpm
w hrbload 1O- 1 7V)
2 arr now meler val!
Nole
canvaryo-O4V
Alter wa.nrog uP engr'

kjlins (N range. A/C OFF)
After wa.mrng
,,
m6l be no abno.mar
chanqe rn sPeed
A r now meler s'1em
Engrre temperalure
Above approx 70'C
uP ensrr
slstem
sensor
EXT GAS SEN

Changesbet@enO_O3V
arxi06_]v
EXT GAS SEN (R)

2 O O O r p mw l h n o
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
hrcle speed srgna )
! ,4rire driMng or with dn

lu. ng
wl'Eels
Should qererally conform to

speedmeter drsPlaY
INT/A TEMP SEN

aklemperaiure sensor olnPu)
Vehrcle speed sensor sysiem
ECCS
BATTER,'VOLT
THROTTLE SEN
ErhaLrsl gas sensor system

ltnake s)tem arr leak o. arr
o 5
Thronb fully closed
ON
!s
14-2.2
INJ PULSE
(iryecnon pulse wdth)
(N rarEe A/C OFF)
1 4 - 2 2
INJ PULSE (R)

(injecrion pulse wdth)
(N ranqe
GN TIMING
(N rare
sensor sYsrenr
knaktemperature
Air flow meter syslem

Intake slstem a r leaks or ai.
s@non (erlt|re InPd)
hpd srgnal syslem (eture)
2o'
A/C OFF)
2ooorpm with m
system
adjushern
syslem
Throdle seNor
ThronE semor
knake arr temperatore
Aner warm nq uP eng!rE
corirol unrt Porer
Advance grealer lhan 1O'

angle compared to ro|e
Air now meter slslem
appro\ r5 - t5'6
A/C OFF)
Approx 30 - 5O7.
AAC
vaive sYsiein
Air now meter system

(arr rEl rano teedback
coeffciefi)
corecron
Aiter wa.mrng up engrre

20oo.pm wth no load
75 - 125'/.
ON
START SIGNAL
ON
Engine
Throttle lully closed
QN
A/C SW ON
ON
IOLE SW
AIR COND SIG
ON
NEUTRAL SW
ON
PWST
SIGNAL
QN
DLE JUDGEMENT
FUEL PUMP RELAY
Otr
tn
wtn
can,sler (purse) rcpecrron

lntake syslem arr leak or ar.
Starter SW syslem
Thronle se6or
Alr co.ditiorer
Nedral
Po@r
slstem
SW system
SW sFlem
sleeflrq
SW syslem
Throttle sensor s!51em
rd e
FLlPumP system
K]N SW ON
ON
ON
A/(.] QN
Arr corditrorEr relay sFrem

AC-ON
ON
WG
CONT 5A/
POWER
orer
VOLTAGE
PULS E
li
o ar pulse
@hage p.o\r'e measu.em

ProE
measuresuremeft
PE:6]: -
ECCSC/UINPUT/OUTPUT
SIGNALS
E N GN E
(2) Activetest
' ,+rniu,,,
Perform
followrng
inspections
to check1
problem
is sol\d.
Flminele
Setengrne
ternperature
highor low
ENGINE
Problem
occurence
Engineternperature
sensofsystem
values
TEI\,'IPERATURE condrtion aar iron Do notsetextrerne
system
as lnrscancausespai*p ug burntng Inlector
Air flowmeteaexhaust
gassensorsystem
Not ellminate.l
Other rtem Inspectton
Perfomrfollowtng
tnspections
to checkrf
problem
rs soived.
F limrn2ie
Set the airfuel ratto|ch or lean

gassensorsystem
Problem
Ca|irnn DO |Ot SelextremevaluesaS Exhausl
occurence
FUELINJECTION
se-so.
cono1l|on this may dan'rageengtne of catal),tic Ai. flowmetererq ne temoeratJre
slstem
ocn!enet
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
lgnrtron
tirnrng
adjustment
conotlon
thismay damageengtneor catalytc
Detonation
sensorsystem
con\rtea
N.i elimlnaie.l
Othef item nspeclion
AAC VALVE
OPENING
Increasecontroldulyratio The engtne

speedshouldtncrease
lf the conditrondescnbedon leftcan not be
Enginerunning
Decreasecontroldutyreatio The
lenfied ccheck AAC valve system
enginespeed shoulddecrease
POWER
BTALANCE
Set the AAC vale open to stop the

specrfied injectoroperatronand the
rnjectorspeed can be displayedat this F Lm i n z t F
Enginerunning
time
Inlector systefir
aa iion Do not performthtsoperatton
whrledriMng
FUEL PUI'P
RELAY
TurnignitionswrtchON OFF and ON

so pumpoperattonmakesa solnd
lf the conditrondescflbedon leftcan not oe
lgnitionswitchON The fuel pressurewill nse
\enfied.
checkrelaysystemoffuel pomp
cartion Do not performthisoperatron
pump system
exceptundercondit/onsdescnbedon and fuel
1eft.
SELF-LEARNING
CONT
The air-fuelratio feedback corection coeffictentleamtnqfactor rs cleared
EN - 491
ECCSC U INPUTOUTPUTSIGNALS
RB26DETE
TNGINE
VN
A L U E ( R B 2 6 D E TETN G I N E )
INSPECTIO
r ESTER
s - 2 o s c l L L o s c o P E& C l R C U lT
t"',il:"'
name
I sisnar
At idle
Circuit
Standard
Memo
rpm
At APProx.2,500
Standa rd
Approx.0.4V
Sparkplug
1
2
3
11
12
13
---| t-- -r
Powertransistor
controlsignal
---.t1
Approx.5V
AAC valvecontrol
srgnal
A p p r o x1. V
Enginespeed
signalfor
tachometer
0
--
18
Approx.2.4V
relay
Air conditioner
Air conditionOFF:
Batteryvoltage
ON:
Air conditioner
Approx.1V
A i r c o n d i t i oO
nFF:
Batteryvoltage
ON:
Air conditioner
Approx.1V
ECCS relay
Approx.1V
(lgnition
switchOFF.
Batteryvoltage)
Approx.0V
Fuelpumprelay
OV
OV
EN - .192
Memo
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
No.
S i g n a ln a m e
19
Powersteerjng
swtch signal
PowersteeringONI
OV
PowersteeringOFF
5V
PowersteeringON:
OV
PowersteerjngOFF
5V
21
(RX)
Receive(conlrol
unitdatareception)
10v
10v
(rx)
Transmit(data
transmission
from
controlunjt)
OV
OV
23
24
Detonation
sensor
srgnal
Approx.0 3V
Approx.0.3V
25
\ hstegate valve
controlsolenoid
controlstgnai
Batteryvoltage
Approx.0V
27
Air flowmeter(rear)
lntakeair quantjty
srgnal
Approx.1V
22
At idle
Circuit
Standard
At Approx.2,500rpm
Memo
Standard
Approx.1.5
EN - 493
Memo
ECCSC'U INPUTOUTPUTSIGNALS
R826DETTENGINE
RR'ANFTT ENGINE
Terminal
No.
S i g n a ln a m e
Circuit
At idle
Standard
l\ilemo
At Approx.2,500rpm
Standard
Memo
EnginetemPerature
80"C.APProx.1V
Enginetemperature
2 0 " C :A p p r o x . 3 V
28
Enginetemperature
sensorslgnal
Enginetemperature
Bo"C:Approx.1V
Enginetemperature
2 0 " C :A p p r o x . 3 V
29
Exhaustgas sensor
signal(front)
Approx.0 - 1V
Deffectsbetween
approx.0 - 1V
Clock
(syrchronization
signal)
OV
OV
lvlotor& check
lamp(redlamp)
Lampnot lit:
Power voltage
Lampis lit: 0V
Lampnotlit:
Power\onage
Lampis lit: 0V
Air iow meter

(Front)(lntakeair
quantity
signal)
'1V
Approx.
Approx.1.5V
lntakeatr
sensor
temperature
signal
C o l d A p p r o x1 . 5 V
\ hrm: Approx.0.8V
Cold: Approx.1 5V
\Abrm:Approx.0.8V
31
(cLK)
JC
36
EN-494
ECCSC/UINPUT/OUTPUT
SIGNALS
R826DETT
ENGINE
R B 2 6 D E T TE N G I N E
TerminaI
No.
S i g n a ln a m e
38
Throttlesensol
srgnaI
Circuit
At idle
Standa rd
Approx.0.5V
At Approx.2.500rpm
Memo
Standard
0.5-4
(VoltageIncreasesif
pedalis
accelerator
presseo)
03-0.7v
41
51
Crankanglesensor
1 2 0 "s r g n a l
2-3V
(vr -
2-3V
6r, dtd
affi
42
52
Crankanglesensor
1 os i g n a l
43
lgnitron
switch
(STARTsignal)
OV
(lgnrtion
switch
"STARI': Battery
voltage)
44
NeLJtral
switch
srgnal
N of P range: 0V
OtherthanN or P
range 4 - 5V
N or P range: 0V
Otherthan N or P
range: 4 - 5V
46
Air conditioner
swjtchsignal
A i r c o n d rot n e rO F F
Batteryvo[age
Air condrtioner
ON;
OV
Air conditioner
OFF:
Batteryvoltage
Air conditioner
ON:
OV
EN - 495
OV
Memo
SIGNALS
ECCSC/UINPUT/OUTPUT
ENGINE
B826DETT
RFI?6NFTT ENGINE
Terminal
No.
S i g n a ln a m e
C ircuit
At idle
Standard
I
Memo
: : :
l l - ^ ^
lt APProx.2'500rPm
Standard
Memo
48
Throttlesensor
(PowersuPPlY)
49
ControlunitPower
suPPlY
Batteryvoltage
Batteryt0ltage
53
VehiclesPeed
sensorslgnal
D range(or 1st)with
rear wheelsjacked
u p : 0 . 5- 1 . 5 V
The valueactually
deiects between0v
and 5V. However,it
appearsto deflect
around1V,accordlng
to vehiclesPeed.
D range(or 1st)wlth
rearwheeisiacked
u p : 0 . 5- 1 . 5 V
The valueactually
deiects between0V
and 5V. However,lt
appearsto defect
around1V,according
to vehiclespeed
54
Throttlevalveswtch
(idle contactPoint)
10V
Approx.
A p p r o x1 0 V
55
E*raustgassensor
signal(Rear)
N or P range: 0V
OtherthanN or P
range: 4 - 5V
N or P range: 0V
Otherthan N or P
range:4 - 5V
56
Throttlesensor
signal
outprJt
5V
Approx 0 5V
EN - 496
5V
Approx.05-4V
(Voltageincreases
as accelerator
Pedal
is pressed).
ECCSC/UINPUT/OUTPUT
SIGNALS
R826DETTENGINE
R B 2 6 O E T TE N G I N E
Terminal
No.
S i g n a ln a m e
57
Throttlevalveswtch
(Powersupply)
101
103
105
110
112
114
Injectorcontrol
sjgnal
104
Fuelpumpterminal
voitagecontrol
s r g n a(lF P C M1 )
106
Fuelpumpterminal
voltagecordrol
srgnal(FPCN4
2)
C ircuit
At idle
Standard
At Approx. 2,500rpm
Memo
Standard
Batteryvollage
Batteryvoltage
Approx.battery
voltage
Approx.battery
vorcge
ldling(afferwarming
engrne):0V
Duringmiddleload.
4V
Duringmiddleload:
OV
EN - 497
Memo
SIGNALS
ECCSC,UINPUTiOUTPUT
R826DETTENGINE
CAUTIONS
9-3 ECCSCONTROLUNITOPERATION
(1) Controlunit equiPment
foryourvehicle
. Neverinstalla controlunitthatis notspecified
bracket
. Do notapplyexcessiveforceto the installation
(2\ Connector removal and installation
forceand
do notbendor applyunnecessary
. Wn"n removing
connectors,
andinstalling
observefollowing
Points:
1. Connector removal
connectors.
. Turnignition
switchoFF andECCSrelayOFFbeforeremoving
forceto harness'
. Holdconnector
withoutapplying
firmlyto disconnect
lock'
. Do notusea screworiver
or similartoollo loosentheconnector
2. Connectorinstallation
. Turnignition
switchOFF.
thenconnectsecurely'
. Makesurepinsarenotbentor controlunitconnectorand
. Tightenboltssecurelyuntilinjectorsurfacereachesorangecolourindicatorof
andsurfaceis even.
connector
(3) Control unit Power
. Nevermakea reverseconnectionto the battery'
. Usebatteryvoltagein 1O- 16Vrange.
(4) ldle speed adiustment knob
. Do notturnPastlockPosition.
lowerthan0"'
. Do notturnadlustment
knobwhenambienttemperature
(5) Water and oil
.Caremustbetakennottoa|lowraindropsorwatertoWetthecontro|unit.
doesnotformdueto suddenincreasein
. care mustbe takenthatcondensation
in the
beforeinstalling
drycontrolunitadequately
lf thereis anymoisture,
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 displayed
as thecalcujationdataon consoleunitso thecorrect
valuewilldisplayed
evenif theoutputcircuit(harness)
is inadvertentlv
disconnected.
RBaOEIDE / DET ENGINE
CAS RPM (Detected angte

speed accordtr to signals)
Tachometer set
Engine runnrng
AIR FLOWMTR
vottage)
{oLrtput
Aiter warmrngup engtne

ldling(N range.A/C OFFI
E N G T E I \ 4 PS E N
( e r E r n et e m p e r a t u r e )
Affer warmrng up er ne
EXT GAS SEN

( o u l p u tv o l i a g e )
EXT GAS SEN
(RtcH / LEANI
CAR SPEED SEN
(\h cle speed srgnal)
lnleclor slslem
While dnvrg or wlh dnve wheets

turnrng
Should generally conform to

s p e e d m e t e rd t s p l a y
V e h r ce s p e e d s e n s o r s y s l e m
lgnrtronswrtchON
Engrnestopped
11- 14V
Battery
ECCS conlrolunrlpower
swtch
ON
EngIne
stopped
Aflerwarmrng
up engrne
IGNTIMING
Anerwarminq
up enqrne
Aner warming
up eng ne
2o00rpmwth no
Throltie tully closed
o 5
Throltle fully open
4 A
b i r n g ( N r a n g e .A / C
oFF)
l d l i n g( N f a n q e A / C
oFF)
200orprnwjth no
hling (N .ange A/C
oFF)
2000rpm wtlh no
A n e r w a r m r n qu p e n q i n e
200orpm wrth no load
l g n r l i o ns w l c h
ON
E ngIne
IDLE SW
2 - 3 rnsec
200o|pmwth no
"START'
START SIGNAL
.OFF'
Throttle tully ciosed
2-3msec
Air iow meter s)slem

I n t a k es y s t e m a r r l e a k s o r a t r
sucron (en!re Input)
n p L ns r g n a l s y s t e m { e n t r r e )
Mn15.. A.fi24.
A d v a n c e g r e a t e rt h a n 1 0 . a n g l e
comparedlo rdlepositiOn
Air flow meter system
Apptax 20 - 4AY.
Approx30 - 50%
7s - 125%
IAS adluslrnent
AAC val\ system
Arr flow meter syslem
]njeclor system
C a n r s t e r( p u r g e ) r n s p e c t i o n
Intake systern a r leak or a r
ON
StarlerSW system
OFF
ON
A/C SW ON
ON
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
NEUTRALSW
PWST SIGNAL
N or P rarEe
ON
NotNorP
OFF
Sieenng
ON
Sleeflng
IGNSW ON
neLrlral
Slop
OFF
A/C ON
ON
A/C OFF
OFF
A/C ON
OFF
dling
Nedral SW system
Polver steenng SW system
OFF
ON
A I R C O N D I I ' I O N E RR E L A Y
Throtlle sensor adlustment

Throitle sensor sysiem
Throttle sensor system
A]R COND S G
F U E LP U M P R E L A /
E n g r n et e m p e f a t u r es e n s o r
R I C H .L E A N r e p e a t s5 t r m e s o r
more In 10 seconds
INJ PULSE
( r n j e c t i o np u i s e w d t h )
N O T F 1 / 1 6 d t s p l a yf o r
RB2OE
( a r r - t u erl a l i o f e e d b a c k
correclron coeffic|ent)
Above appro, 70 C
A r flow rneler syslera
E*lairsl gas sensor slsterf

I n t a k es y s l e m a r f i e a k o r a r r
lgfllion
AAC VALVE
Approx08-15V
Crank ange sensor slstell
C h a n g e s b e t w e e nO - 0 3 V a n d
0 6 - 1 V
Afterwarrning
up engrne
BATTERY VOLT
T H R O T T L ES E N
(odpln voflage)
There must be no abnormal

change rn speed
Fr.reipump system
Air condrtorEr .elaysystem
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
nlgnor ow
temperatufe
SetengLne
sensorsystem
ternperature
Engrne
occurence
Problem
ENGINE
Carjtlo[ Do notsel extremevaluesas Lnlector
system
condrtron thrscancausespark
TEIMPERATURE
Plugblrnlng
gassensorsyslem
Air iow meterexhaust
Nol elmrnaie.l'
Orhe- rtem ,_soector
lo checkl'
Pe'{orn'o'lowng,nspectlors
problem
rs sol\ed.
Elimrnate
ratiorlchor lean
Settheair-fuel
gassensorsystem
Exhaust
ProblemoccurenceCautoo. Do notset extremevaluesas ALrflowmeter,
sensor
englnetemperature
FUELINJECTION
thrsmaydamageenglneor cataiytc sysrern
conorllon
ocn\ertet
Injeclorsyslem
N.t elmrnaied
Other rtem Lnspection
tlmrng
DelayLgnrtion
occurcnce
Caltion: Do notset extremevaluesas
Problem
GNITIONTIMING
thrsmaydamageengineor catalytic
conol!on
con\nel
to checklt
Performfollowinginspections
problems sol\ed.
Flimln2lp
lgnitiontimrngadlushenl
Detonationsensorsyslem
Not ehminait.l
Other item Inspecton
AAC VALVE
OPENING
Increasecontro duty ratio The englne

lf the conditiondescrlbedon leftcan not be
speed shouldincrease
Enginerunnrng Decrease controlduty reatlo. The
venfied ccheck AAC val\ system
enginespeed shoulddecrease
FUEL PUT,4P
RELAY
switchON. OFF and ON

Turnignrtron
so pump operatlonmakes a sound.
lf the conditiondescribed on left can not be
lgnrtionswrtchON The fuel pressurew11nse
\rified. check relay system of fLlelpirmp
Cado-o- Do not perform this operatron and fuel pump system
Enginestop
exceptunderconditionsdescnbedon
left
SELF-LEARNING
CONT
The arr-fuelratiofeedbackcorrectloncoefficlentleamlngfactorrs cleared
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
TerminaI
No.
Signal name
Air flowmeter
intakearrquantity
srgnaI
Enginetemperature
sensorsrgnal
Exhaustgas sensor
srgnaI
Throttlesensor
srgnal(lnput)
Circuit
( R B 2 O EE N G I N E }
At idle
Standard
At Approx. 2,500rpm
Memo
Standard
Appfox.1V
Enginelemperature
Bo"C: Approx.1V
Engrnetemperature
2 0 " C :A p p r o x . 3 V
Approx.1.5V
Enginetemperature
8 0 " C . A p p r o x1 V
Enginetemperature
2 0 " C .A p p r o x . 3 V
Approx.0 - 1V
Deflectsbetween
0 - Approx '1V
Approx 0 5V
0 . 5- 1 V
(Batteryvoltagewill
rncerasewhen
pedaiis
acceleration
pressed)
0.3- 0.7v
0 . 3- 0 . 7 v
Crankanglesensor
1 2 0 "s i g n a l
2-3V
2-3V
(v)
6
10
Crankanglesensor
1 "s r g n a l
E N- s 0 1
Memo
EUUJ
\, \]
SIGNALS
INPUT/OUTPUT
RB20EENGINE
Terminal
No.
At idle
S i g n a ln a m e
Circuit
Standard
I
Memo
At APProx'2,500rpm
Standard
'13
& check
l\,4onitor
lamp(redlamp)
Lampnot lit;
Power voltage
LamPis lit:
Approx.0V
Lampnot lit:
Powervoltage
Lampis lit:
Approx.0V
'15
Intakeair quantlty
outputsignal
(ToA/T C/U)
Approx.lV
A p p r o x1 . 5 V
sensor
Detonation
signaI
Approx.4V
Approx.4V
Approx.0.5V
0 . 5- 1 V
(Batteryvottagewill
incerasewhen
acceleration
Pedalls
presseo)
17
Throttleopening
otjtputsignal
21
Vehiclespeed
sensorsignal
D range(or 1st)with
rear wheelsjacked
u p : 0 . 5- 1 . 5 V
The valueactually
deflectsbetween0
and 5V. However,it
appearsto deflect
around1V according
to vehiclespeed.
22
Throttlevalveswitch
(idle contactPornt)
A p p r o xl o v
EN 502
Memo
D range(or 1st)wth
rearwheelsjacked
u p r 0 . 5- 1 . 5 V
The valueactually
defrectsbetween0
and 5V. However,lt
appearsto defect
around1V accordlng
to vehiclesPeed.
0V when accelerator
is pressed
ECCSC/UINPUT/OUTPUT
SIGNALS
TerminaI
No.
S i g n a ln a m e
23
lgnitionswitch
(STARTsignal)
OV
(lgnition
switchat
START Power
vonage)
OV
24
Neutralswitch
srgnai
N or P range: 0V
OtherthanN or P
range:Approx.6V
N or P range: 0V
Otherthan N or P
range:Approx 6V
25
lgnrtion
swtch
(ONsignal)
Powervoltage
Powervoltage
26
Throttlesensor
srgnaI
(Powersupply)
27
29
At idle
C ircuit
Standard
At Approx.2,500rpm
Memo
Standard
5V
5V
Controlunitpower
supply
Power voltage
Powervoltage
Air conditioner
sw'tchsignal
Air conditioner
OFF:
Powervoltage
Air conditioner
ON:
Approx.0V
Air conditioner
OFF:
Powervoltage
Air conditioner
ON:
Approx.0V
EN - 503
Memo
SIGNALS
ECCSC/UINPUT/OUTPUT
RB20E ENGINE
Terminal
No.
32
Throttlevalveswitch
(PowersuPPlY)
At idle
Circuit
S i g n a ln a m e
Standard
I
Memo
At aPProx.2'500 rPm
Standard
i-;l:-*'r
ilecru
l ' -
Powervoitage
\
_.-!!r'-,
|.-''
Power voltage
0 . 2- 0 . 3 v
Powertranststor
controlsignal
38
Powersteering
switchsignal
n
-. .
39
slgnal
Tachometer
(lgnition
coil Primary
signaldetection
40
E C C Sr e l a y
Disq,bul9r
'
f -+-6f reroir . !_cru
i-=-Po
.l R6isror tranestor
PowersteeringONI
OV
PowrsteenngOFFI
Approx.5V
PowersteeringON:
OV
PowrsteeringOFF:
Approx.5V
Power voltage
A p p r o x1. 0 V
Approx.1V
(lgnition
switchOFF.
Powervoltage)
OV
1V
Approx.
43
Tachometerengine
rev srgnal
EN - 504
Approx.3V
Memo
ECCSC/UINPUT/OUTPUT
SIGNALS
Terminal
No.
S i g n a ln a m e
At idle
Circuit
Standard
EngineA/T total
controlinpLrt
signal
Standa rd
Approx.
10V
(Dr1)
45
At Approx.2,500rpm
Memo
A/T control unit
A p p r o x1 0 V
: , =:t:nsffilsfri
EngineA/l total
controlinputsignal
(D12)
46
A,r conditioner
relay
Air conditioner
OFF
Powefvoltage
Air conditioner
ON
OV
47
EngineA/T total
contro, or.IpLlt
signal(DT3)
OV
OV
Almostpowervoltage
Almostpower voltage
101
103
105
110
112
104
lnjectorcontrol
srgnal
Fuelpumprelay
Air conditioner
OFF
Pov.ier
!oftage
Arrcondrtroner
ON
OV
20
0
OV
EN - 505
OV
Memo
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
Terminal
No.
Signal name
18
Fuelpumprelay
At idle
Circuit
rEf-s
(RB2ODE
/ D E TE N G I N E )
Standard
At Approx.2.500rpm
Memo
Standard
t g n i i i o nS W
@f'
Qr,"r p,'p) + ,,---!)\
OV
OV
PowersteeflngON:
OV
PowersteeringOFF.
Powersteeflng
switchstgnal
PowersteeringON:
OV
PowersteeringOFF
5V
23
24
Detonation
sensor
signaI
Approx 4V
Approx.4V
27
Air flow meter

(lntakeair quantity
signal)
Approx.1V
Approx.1.5V
28
Enginelemperature
sensorsrgnal
29
Exhaustgas sensor
signaI
Enginetemperature
80"C: Approx.1V
Enginetemperature
2 0 " C :A p p r o x . 3 V
Approx.1V
Et\
- 3U/
Enginetemperature
80"C: Approx.1V
Enginetemperature
2 0 " C :A p p r o x . 3 V
deiect between
0 - approx.1V
Memo
SIGNALS
ECCSCiU INPUT/OUTPUT
R B 2 O D /ED E T E N G I N E
RB2ODE/ DET ENGINE
t"ffi:"'l
32
34
name
sisnar
Circuit
Ai idle
Standard
I
Memo
l : : :
At APProx.2'500rpm
Standard
& check
lvlonitor
lamp(redlamP)
Lampnot lit:
Powervolatge
Lamplit:
OV
Lamp not lit:

Powervolatge
Lamplit:
OV
Engine(AfD total
signal
controlinpLrt
'10V
Approx.
10V
Approx.
{Dr1)
35
36
Engine(AfD total
controloutpLrtsignal
Approx.0V
Approx.0V
Engine(A,/T)total
controloutputslgnal
(D12)
Approx.10V
10V
Approx.
(Dr3)
38
Throttlesensor
srgnal
Approx.0.5V
0.5 - 4V (Voltage
increasesif
pedalis
accelerator
presseo)
40
Intakeair q uanttty
oulputslgnal
A p p r o x1 V
Approx.1.5V
E N- 5 0 8
Memo
ECCSC/UINPUT/OUTPUT
SIGNALS
R B 2 O D E/ D E T E N G I N E
TerminaI
No.
S i g n a ln a m e
At idle
Circuit
Standard
At Approx.2,500rpm
Memo
Standard
0 . 3- 0 . 7
6
41
Crankanglesensor
1 2 0 "s i g n a l
2,,
0il
2-3V
42
2-3V
Crankanglesensor
'l'signai
-_
0.5trr'-
lgnation
swtch
(STARTsignal)
OV
(lgnition
swrtchin
"STARI'':
Power
\ cltage)
OV
(lgnrtion
switchn
"STARI-' Power
voltage)
Neutralswtch
signaI
N or P range:0V
OtherthanN or P
range:4 - 5V
N or P range: 0V
OtherthanN or P
range:4 - 5V
46
Arr conditioner
switchsignal
A r rc o n o [ t o n eUr F F
Powervoltage
Air conditioner
ON:
OV
Air conditioner
OFF:
Powervoltage
Air condilioner
ONi
OV
48
Throttlesensor
(Powersupply)
5V
43
trI\ - 5U9
Memo
SIGNALS
ECCSC/U INPUT/OUTPUT
*il:"'l
name
sisnar
At idle
C ircuit
Standard
I
Memo
:a:
lt lPProx. 2,500rpm
Memo
Standard
ControlunitPower
supply
Powervollage
Power voltage
53
Vehiclespeed
sensorsignal
D range(or 1st)wth
rearwheelsjacked
'1.5V
u p : 0 . 5The valueactually
deflectsbetween0V
and 5V. However,lt
appearsto deflect
around1V,according
to vehiclesPeed.
D range(or 1st)with
fearwheelsJacked
up: 0.5 - 1.5V
The valueactually
deffectsbetween0V
and 5V. Howeve(lt
appearsto deiect
around1v, accordlng
to vehiclespeed
54
Throttlevalveswitch
(ldle contactPoint)
A p p r o x 1. 0 V
0V when accelerator
pedalis pressed
A p p r o x . 05 V
Approx.0.5 ' 4V
(Voltagewillincrease
when acce|eralor
pedalis pressed)
49
56
Throttleopening
outputsignal
57
Throttlevalveswitch
(PowersuPPlY)
101
103
105
110
112
Powervoltage
Power voltage
Alrnoslpowervoltage
Almost Powervolage
Injectorcontrol
srgnal
E N- 5 1 0
ECCSC/UINPUT/OUTPUT
SIGNALS
Terminal
No.
Signal name
At idle
Circuit
Standard
At Approx.2,500rpm
Memo
Standard
l]
r' ;".r p, p104
Fuelpumpterminal
voltagecontrol
signal(FPClvl)
I
-L
conror
mod0ralor
,:\ -
ECCSconlror unrr
I
I
C o l d :0 V
V\hrm: Power
voltage
E N- 5 1 1
C o l d :0 V
\ hrm; Power
voltage
Memo
SIGNALS
ECCSC U INPUT'OUTPUT
RB2OE
CAUTIONS
9-3 ECCSCONTROLUNITOPERATION
(1) Controlunit equiPment
foryourvehrcle'
. Neverinstalla controlunitthatis notspecified
bracket
. Do notapplyexcesstve
installation
to
the
force
(2) Connector removal and installation
forceand
. Wh"n removing
do notbendor applyunnecessary
connectors,
andinstalling
observefollowing
Points:
1. Connector removal
connectors.
. Turnignition
switchoFF andECCSrelayOFFbeforeremoving
forceto harness'
. Holdconnector
withoutapplying
f irmlyto disconnect
lock'
. Do notusea screwdriver
or similartoolto loosentheconnector
2. Connectorinstallation
. TurnignitionswitchOFF.
.Makesurep|nsarenotbentorcontro|unitconnectorandthenconnectSecUre|y.
. Tightenboltssecurelyuntilinjectorsurlacereachesorangecolourindicatorof
andsurfaceis even.
connector
(3) Control unit Power
. Nevermakea reverseconnectionto the battery.
. Usebatteryvoltagein .10- 16Vrange.
(4) ldle speed adiustment knob
. Do notturnpastlockPosition.
lowerthanOoC'
. Do notturnadjustment
knobwhenambienttemperature
(5) Waterand oil
. care mustbe takennotto allowraindropsor waterto wetthecontrolunit.
doesnotformdueto suddenincreasein
. care mustbe takenthatcondensation
in the
beforeinstalling
drycontrolunitadequately
lf thereis any moisture,
temperature.
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
VALUES
(1) Datamonitor
Note:The
as thecalculation
dataon consoleunitso thecorrecr
valuewilldisplayed
is inadvertentlv
disconnected.
CAl8i ENGINE
,li: , .'..,liti
cotonr
' , j..:t'.:..:i
!{t: . -,t
Tachometer set
Engine runnrng
There must be no abnorrnal

c n a n g eI n s p e e o
ENGTEMP SEN
lergrne remperature)
Afrer warm,ng up engrne
Abo\r'e approx 70"C
EXT GAS SEN

( R I C H/ L E A N )
CAR SPEED SEN
( v e h i c l es p e e d s r g n a l )
up engrne
T H R O T T L ES E N
Should generally corform to

s p e e d m e t e rd i s p a y
lgnrtronswitch ON
E n g r n es l o p p e d
11- 14V
IHROTTLE SEN (2)

(oLrtputvoitage)
] N T / AT E M P S E N
(rnlaktemperalure sensor
lgnrlion swtch
ON
Engrne
Throtlle tully closed
1 0
Thron|e tully closed
06
Crank angle sensor slstem

Engrne temperature sensor
Vehrcle speed sensor s)1err

Battery
E C C S c o n t r o lu n r tp o \ , r
5 0
Throltle sensor adtustmenl

Thfonle sensor system
4 5
I n l a k ea r r t e m p e r a l u r er s
Aner wannrng up engrne

ldling (N range
A/C
INJ PULSE
( r n j e c i o np u i s e w d t h )
1 '2
2000rpmwith no load
ldlng (N range
IGN TIMING
,.:-i
C h a n g e s b e M e e n 0 - 0 3 V a n d Exhaust gas sensor system

06 - 1V
l r i a k e s y s t e ma r r e a k o r a r r
2000lpm wth no load
R I C H .L E A N r e p e a l s 5 t m e s o r
m o r e 1 n1 0 s e c o r d s
While dnvrng of wth drive whee s

tumrng
BATTERY VOLI
PRCiSL:ES t
CAS RPM (Detected angle

s p e e d a c c o r d r n gt o s r g n a l s )
EXT GAS SEN

(outpLl voitage)
'
..1:.1
A/C
After warming
2OOOrpm wlh
no oad
rnsec
lntaktemperature
sensor
Arr now meter system

I n l a k es y s l e m a r r l e a k s o r a r r
sucton lennre nput)
Input signal syslern (ent re)
Mtf 1s. Atf20"

Advance grealer fhan 10" angle
comparedto idle posrlron
Air flow meter system
Air llow metef system

(arr-tuel fato feedback
corre.lon coeffcrent)
Aner warmrng up engrrE

2 O O 0 r p mw l h n o l o a d
STAR']-'
START SIGNAL
75 - 125vo
ON
Starter SW system
ON
Engrne
IDLE SW
Throttle tully closed
ON
Throttle sensor syslem

A/C SW ON
AIR COND SIG
ON
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
PWST SIGNAL
ON
Povtr steenng
WG CONT SA/
FICD SA/
ON
Head amp heater

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

r:1]U:]:.r,:r'
r,:sl,
ACTI/ETEST
!*'.r.
ACTIVETEETDESCRIPTIO{
Perfor.nfo lowrng nspectionsto check lf

problemts so \o.
F mLn:JP
hlghor low
Setenginetemperature
sensorsystem
Engnelemperatlre
Problernoccurence
ENGINE
Cal]tion.Do notset extremevalues Inlector
system
condrt
0n
TEIVIPERATURE
burnlng
as thiscancausesparkpLug
Arrflowmeler.exhaustgas sensorsysrem
Nol clm nated
Ot_er tem nsoeclion
FUELINJECTION
Pedorm follow!nginspectionsto check if

pfoblemis sol\d
Flimrn2te
ratronchor lean.
Setthearr-fuel
Exhaustgas sensorsrsrem
Problem
occurencCalllio-rtDo notsetextremevaluesas Aif flowmeter englnetemperature
sensol
condttlon
or catal)'tlc
thisrnaydamageengLne
system
ocn\rter.
lnlectorsystem
Not elirninaied
Other rtem Inspectlon
IGNITIONTII,IING
Performfollowlnginspectionsto check if
problemrs soltd.
ttmrng
Delayrgnrtlon
Flimrn2tt
Problem
occurenceCArdion Do not set extremevaluesas lgnitiontrmingadjustment
thrsmay damageenglneor cataYlc
condrtron
Detonationsensor system
convefler
Nol elimin2led
Other item inspectlon
TurnignitionswitchON and OFF The

lf the condihondescribedon lell can not be
idle revwill change
warm
uP
engrne
Affer
solenol0
IDLE
\riied. checktdlecorrectlon
pedom
operatron
this
hling (N range,A/C Carxio-o.Do not
SA/
CORRECTION
slstem
exceptundefcondltlondescrlbedon
oFF)
left
Turnrgniton swtch ON and OFF The
AfterengrnewarrnuP rdlerevwll increaseal approx200rprn lf the condrlroldescrrbedon leftcan not be
ldling(N rangeA/C Ca!tjo-c|:Do not performthis operaton \rified.checkFCD solenoldsystem
FCD SA/
exceptunderconditiondescnbedon
oFF)
lefr.
FUELPUMP
RELAY
SELF,LEARNING
CONT
lgnitionswitchON
switchON OFFandON
Turnignrtron
makesa sound
so plmp operation
describedon leftcannotbe
f thecondition
willrise
Thefuelpressure
\nied, checkfelaysystemof fuelpump
Do notperformthlsoperatlonandfuelPurnp
Ca!!-oxLsystem
on
descnbed
except!nderconditlons
left
coerfclentlealnlngfactorrs ceared
ralo feedbao(correctlo'1
fhe arr-fuel
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 )
TerminaI
No,
S i g n a ln a m e
Throttle
sensor
signal1
Enginetemperature
sensor
srgnal
At Approx.2,500rpm
At idle
Circuit
Standa rd
Approx.
1V
Memo
Standa rd
Appfox.1V - 5V
(Voltagewillincrease
whenaccelerator
pedalis pressed)
Enginetemperature
80"C: 1V
Enginetemperature
20"c 3v
Enginetemperature
80"C: 1V
Enginetemperature
20"C: 3V
Deflectbetween
approx.0 - lV
6
Exhaustgas sensor
srgnal
Throttlesensor
signal2
Approx.0.3 - 0.7V
I
'19
Deflectbelween
a p p r o x0 - 1 V
!"1;l-.-.,:-
Approx 0 6V
Approx.
0.3- 0.7V
Crankanglesensof
'180"signal
Approx.
2 - 3V
(v)
Crankanglesensor
1 os r g n a l
2
0
E N- 5 1 s
Approx.06V-4.5V
(Voltageincrease
whenaccelerator
pedalis pressed)
Approx.2 - 3V
10
20
Memo
SIGNALS
ECCSC/U INPUT/OUTPUT
'
t"',il:"'l
13
name
sisnar
l,4onitor& check
lamp(redlamp)
Circuit
Standard
Vehrclespeed
sensorsrgnal
I
Memo
::::
At APProx.2,500rpm
Standard
LamPnot lit:
Powervoltage
Lamplit: APProx.0V
Lampnot ht:
Powervoltage
0V
Lamplit: APProx.
(v)
'1
Approx. " 5V
get
shorter
(Cyclewill
whenvehiclesPeed
is increased)
21
At idle
2
0
OV
(lgnition
switchin
STARI Power
voltage)
OV
(lgnition
switchin
START Power
voltage)
24
Neutralswitch
signaI
N or P range:0V
OtherthanN or P
range:6 - 7V
N or P range: 0V
Otherthan N or P
range. 6 - 7V
27
ECCS controlunit
power suppty
Powervoltage
Powervoltage
OFF:
Air conditioner
Powervoitage
ON:
Air conditioner
OV
OFF:
Air conditioner
Power voltage
ON:
Air conditioner
OV
23
ta
lgnitionswitch
"START'signal
Air condittoner
switchsignal
E N- 5 1 6
Memo
ECCSC/UINPUT/OUTPUT
SIGNALS
CA'I8iENGINE
TerminaI
No.
S i g n a ln a m e
30
lntakeatf
remperaturesensor
stgnal
Cold: Approx.1.5V
l brm: Approx.0.8V
C o l d :A p p r o x1. . 5 V
Wbrm: Approx.0.8V
Powersteenng
signaI
PowersteeringON:
OV
PowersteeringOFF
Approx.BV
PowersteeringON:
OV
PowersteenngOFF.
Approx.BV
Approx0.5V
A p p r o x1. V
At idle
C ircuit
Standa rd
(;)it-Il]l--l-t-,1
37
4f-:.-. --
Powertranststor
control
signai(lN)
,fltr-4-
A'
-- -+- 108
-rrr:F 1 rl
IGN_coil
-F-:*i:=
.o
Approx 0 5V
Powertranslstor
controlsignal(EX)
Standa rd
Memo
1 T
't:t:t:'J'ta''J'
i r : r c ' * . . .i ,l 1
l l
' |
:p?'.\'.
lvl-T-ttr
I
6l-i
1 l I -. I I
oisrribu'o1
38
At Approx. 2,500rpm
Itdemo
;iuk+irffifr
J--
F - r t L t , I L Jl
l+iroF{':i,.1
i-i- -,--
39
40
A p p r o x 1. 1 V- 1 2 V
A p p r o x 1. 0 V- 1 1 V
OV
(lgnition
swtch OFF:
Power voltage)
OV
lgnitionprimary
stgnal
ECCS relay
E N- 5 1 7
SIGNALS
ECCSCiU INPUT/OUTPUT
C A 1 8 ]E N G I N E
'
t"',1::"'l sisnar
name
41
Circuit
At idle
Standard
Memo
l : : :
at APProx.2'500rpm
Standard
Powervoltage
Lowef than Power

volage
SwitchON:
Powervoltage
SwitchOFF: 0V
FuelinjectorPUlse
monitorsrgnal
(ll monitor)
43
Lightswitchsignal
SwitchON:
Power voltage
SwitchOFF: 0V
45
Heaterfan swtch
srgnaI
SwitchON:
Powervonage
SwitchOFF: 0V
SwitchON:
Power voltage
SwitchOFF] 0V
46
Reardefogger
switchsignal
SwitchON:
Powervoltage
SwitchOFF] 0V
SwitchON:
Power!oltage
SwitchOFF: 0V
Powervollage
Lowerthan Po\4er
vo|tage
e rN :
A i r c o n d i l r o nO
Powervoftage
r FF
A r rc o n dt r o n eO
OV
ON:
Air conditioner
Power voltage
OFF:
Air conditioner
OV
'101
110
Injectorcontrol
srgnal
102
relay
Air conditioner
srgnal
E N- 5 1 8
Memo
ECCSC/UINPUT/OUTPUT
SIGNALS
C A ' l 8 iE N G I N E
Terminal
No.
S i g n a ln a m e
Circuit
At idle
Standard
FICDsolenoid
Air condilioner
ON:
OV
Air conditioner
OFF:
Powervoltage
104
Fuelpumprelay
Approx.0V
(Powervoltagefor 5
sec atterjgnrtion
swtch rs placedto
ON posrtion)
'106
PTC heaterrelay
'103
,-,11t_
PTC heaterON:
Approx.0V
PTC heaterOFFr
Powervoltage
At Approx. 2,500rpm
Memo
Standard
Air conditioner
ON:
OV
Air conditioner
OFF:
Powervoltage
Approx.0V
PTC heaterON:
Approx.0V
PTC heaterOFFI
Power \/oltage
'1. Whenign sw in
111
115
ldle rev correction

sotenoro
Lock up release
solenoid(Aff)
on
2. Enginerewing: Approx.0V
First15 sec afrerenginestart:Approx.0V
Afler15 sec afterenginestarl: Powervoltage
Any ofthe followings
are ON (Powersteering,
laghts,
reardefoggetheaterfan switch)iApprox.
0V (D rangefor A/T)
Lockup released:
Approx.0V
Lock
u pa p p l e o :
Power vottage
E N- 5 1 9
Lockup released:
Approx.0V
Lockup appljed:
Powervoltage
Memo
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
VALUES
(1) Datamonitor
dataon consoieunitso thecorrect
as thecalculation
Note:The
disconnected.
is lnadvertently
valuewilldisplayed
RB25DEENGINE
toR
rr,r:,r.,t,trtr',r.
AlR FLOWt'/TR
lol,tptltvoltage)
Ailerwarmng up
kl lrg
engI
hlrg (Nrange
wthottload
2000rpm
A/COFF)
ENGTEMPSEN
lengrnetemPerature)
EXTGASSEN
\oltage)
roLrlPut
EXTGASSEN
(RICH/ LEAN)
Theremuslce no aonorma Crankangiesensorsyslem

chaarge^ speeo
set
Tacfometer
Engne runnng
al.q]e
CAS RP[,4(Detected
to srgnals)
speedaccordrng
AitefwarmrngLtPenglne
l\hile dfl\,1n9or w th drve wheels tLlrnlng
BATTERYVOLT
n ttonswrtchON
Engrneslopped
IN.]PULSE
( nFclronpulsewldtl'r)
Aiterwarmng !p
engne
LGNT [,4ING
AJlerwamlrg up
engrne
AAC VALVE
A/FALPHA
(a r-fuelratrofeedbackconeclron
coeffcient)
bnitionswrtchoN
Enginestopped
NEUTRALSW
ldle
PWSTSIGNAL
AIR CON RELAY

ACCeI
POWERVOLTAGE
sensor
Engr temperaure
syslem
ldlrng(N range A/C

oFF)
2000rpfirwlthm loao
tlhrg (N range A/C
oFF)
IGNSW ON
SYsteTn
Vehrce SpeedsensoT
Battery
ECCScontrolwrt Power
system
11
Afterwarmrngup engr
2000rpmw tir m load
AR CONDS G
SEN
THROTTLE
(ouFutvoltage)
Shoudgene y conbrrnto
spee0meler0 splay
A r fow metersystem
A p p r o x . 2 0 - 2 8 m s e c Inlakesystema r eaKs0r alr
sLcton{entirernpul)
A p p r o x2 0 - 2 8 m s e c
npLrt
signalsystem(entlre)
15.
Advancegrealerthan10"ange
2000em wrthno load
comparedto tde Poston
Alterwarmng up ld r (N range.A/C
Approx12 - 30%
OFF)
eng rle
DLE SJUDGEMENT
FUELPUMP RELAY
AboveapproxiO'C
- 03v and
Detween0
Changes
gas sensorsyslem
ExhaLrst
06- lv
ntakesystemalr eak or alT
AnerwarmrngLlp 2000rpmw th rx)load
intake
enqrie
5 t mesor
RlCfl.LEANrepeats
nedor sysrcrn
mofe n 10 seconos
C A RS P E E DS E N
(\ehcle speedsignal'
STARTSIGNAL
A r frowmetersystem
Approxl0-15V
75 - 125%
STARI
ON
OFF
OFF
ThrotUefLilyclosed
ON
Throttetullyopen
OFF
A/C SW ON
ON
A/C SW OFF
OFF
N or P range
ON
NotNorP
OFF
Steenng
ON
Steenng rcu'tral
OFF
ArC ON
ON
OFF
OFF
A/CON
OFF
Stop
OFF
Arriow metersystem
lAS adjuslnent
AAC vaivesvstem
Air iow metersyslem
nlectorsyslem
Canrster(purge)nspeqlon
ntakesyslemalr eak or alr
slcton
StarterSW system
ThTott
e sensorslslem
Arrcondtoner SW system
NeLtalSW system
PowersteenngSW syslem
Arrcondtoret reay syslem
FLE pumpsystem
ON
switchON Throttlefullvc osed

lgnrtron
EngrnestoPPed Throttetu y open
Approx4 0
Appror0 5
sensorsyslem
Throttle
value
Drsoav oo\rrvoltagepro\e measurement
!lue
ls c a! oulsepro\e Tneasuresulemenl
N-5
ECCSC/UINPUT/OUTPUT
SIGNALS
(2\
Active test
ACTIVETEST
JT'DGE
ENTA DN! 'ECTF |TEH
' Acrnrpirus'.oescnPipR,',.
Setengrrctemperature
hlghor low
ENGINE
Problemoccurence
Cardion
Do
not
Set
extreme
ValUeS
aS
IEMPERATURE
cono|l|on
thrscancausesparkplugburntng
Set the air-fuelralio rich or lean
ProblemoccurenceC2r,lron DO not SetexlremevaluesaS

FUELINJECTON
condrlion
thrsmaydamageengrneor catal!,tic
ocnlener
GNTNONTII\,IING
Delayrgnition
umrng
Problemoccurence C2LdionDO notset exlremeva tS aS
cono|Ilon
thismaydamageeitgrneor catalytic
con\net
Pefonn folowng Inspections

1ochecktf
problems solved.
Fliminrle
Engrnelernperature
sensorslstem
Inlectorsyslem
Air ilow meter exhaustgas sensofsyslem
Nai elimtneleal
Othertem inspection
Perfom foilowrngInspectionsto check lf
problemrs solved
Flimrnaie
gas sensofsyslem
Exhaust
Arrflowrneterengrneternperature
sensor
systenl
Inlectorsystem
Nol eliminaied
Olheritem inspecton
Perfonnfollowing nspectionsto check if
probiemrs solved
Flimrn2le
lgnition
limingadjuslme
Detonation
sensorslstem
Nol ehmrnaled
Otherrteminspectron
Increase
conlroldutyratto.Theengtne
AAC VALVE
OPENING
FUELPUMP
REtAY
SELF-LEARNING
CONT
POWER
BALANCE
Enginerunning
lgnition
switchON
Engrnestop
Decreasecontroldlty ratto
The engrnespeedshollddecaease.
f lhe condition
descnbedon lefican not
beverified.checkAAC valvesystem
Turnrgnition
swllchON OFFandONso
pumpoperalron
makesa sound.Thefuel lf lhe condrtiondescnbedon leftcan not be
pressure
wrllnse
venfed. check relaysyslem offuel pump
Do nolperformlhisoperalron and fuelpumpsystenl
CaUi.o-rL
exceptunderconditi0ns
descrrbed
on 1eff.
The air-fuelratiofeedbackcorection coefficrenllearntnqfactorts cleared.

Eng ne rev can be drsplayedwhenAAC
Problemoccurencevalveopeningis flxed and set rnlector
operalrons stopped.
condition
Car{ron Do notpedormlhis operation
whrlednMng
EN - 521
Flirnrneie
Injector systern
SIGNALS
ECCSC U INPUT,OUTPUT
VALUE (RB250EENGINE)
osclLLoscoPE & clRcutT TESTERINSPECTION
s-2
Terminal
No.
Standard
0.2- 0.3v
1
2
3
11
12
13
At Approx.2,500rpm
At idle
C irc uit
S i g n a ln a m e
(v)
6 . _ . .
l-
Approx.0.4V
- ' . - . :
Powertransistor
controlsignal
Cold: 6 - 7V
Vvarm:8 - 10V
4
AAC valvecontrol
srgnaI
EngineA/T total
controlinputsignal
(Dr1)
Approx.5V
(v)-r'-:-_-_-_
t|l
10 -,r1 --f|- -Ttl
5 - ir
r'
.--'--:+zrs ,1,.---
l5
10
5
f+
Afi contol un
10V
Approx.
10V
Approx.
Approx.1V
Approx.2.4V
lvt
Itlemo
Standard
Memo
.,
-.l
-" i ; ; ; . ; '
F Tf-lTl-r-TTtf
Tachometerengine
speedsignal
"IIilLTI]rlL
l.ih-
l]]-
, t .:-_ti-
relay
Air conditioner
OFF:
Air conditioner
Powervoltage
ON:
Air conditioner
Approx.1V
14
Enginea/T total
controlinputsignal
(D12)
Approx.10V
EN - 522
OFF:
Air conditioner
Powervoltage
ON:
Air conditioner
Approx.1V
Approx.10V
ECCSC/UINPUT/OUTPUT
SIGNALS
Termina
I
No.
15
Signal name
C ircuit
EngineAff total
controloLrtputsrgnal
At Approx.2,500rpm
At idle
Standard
Memo
Stan dard
Approx.0V
(Dr3)
16
E C C Sr e l a y
Approx.1V
(lgnrtion
switch
OFF.
Powervoltage)
18
Fuelpumprelay
OV
'19
Powersteenng
swtch signal
PowersteenngON
OV
PowersteeringOFF
Memo
Approx.0V
Approx.0V
: l!.,/erstee^ng_N
OV
D-\!Fr
<.;.--,^
^::
5V
----5i."",,
23
24
Detonation
sensor
sigml
27
Air iow meter

(lntakeair quantity
signal)
rio"i""*t"**
i i - - - -
Approx.0.3V
Approx.1V
EN - 523
Approx.0.3V
A p p r o x1. . 5 V
SIGNALS
ECCSCiU INPUT,OUTPUT
FIB25DEENGINF
t"il:"'l
name
sisnar
At idle
Circuit
Standard
I
Memo
At APProx. 2,500 |pm

Standard
Memo
En9ire renperaturc snsor
Enginetemperature
1V
80"C:Approx.
Enginetemperature
20'C: Approx.3V
temperature
Engine
1V
80"C:Approx.
Enginetemperature
20"C:Approx.3V
28
temperature
Engine
sensors!gnal
29
gassensor
Exhaust
signal
0 - 1V
Approx.
32
[,ilonitor& check
lamp
(redlamp,exhaust
temperature
warninglamp)
Lampnot lit:
Powervoitage
Lamplit: 0V
Lampnot lit:
Powervoltage
Lamp lit: 0V
t-tuu sonotcl
A/C ONrov
A/COFF:Power
vomge
A/C ON :0V
AiCOFF: Power
vorcge
Approx.0.5V
0.5 - 4V (Vottage
increasewhen
pedalts
accelerator
presseo)
38
40
Throttlesensor
srgnal
Intakeair quantity
oLrtputsagnal
Approx.1V
EN - 524
Deflectbetween0 '1V
approx.
Approx.1.5V
ECCSC/UINPUT/OUTPUT
SIGNALS
TerminaI
No.
S i g n a ln a m e
At idle
Circuit
Standard
03-0.7v
41
At Approx. 2,500rpm
Memo
Standard
0 . 3- 0 . 7 v
Crankanglesensor
1 2 0 "s i g n a l
2-3V
lv)
6
42
Crankanglesensor
1 "s i g n a l
-r
' . -T- -
, ftfl{f+nnflnI
, +fffHfl+HilIiI
0r!!u!Fu!uu
. - . . , . -
43
Jgnition
switch
(STARTsignai)
OV
(lgnition
swilch
STARI Power
voltage)
OV
44
Neutralswitch
srgnal
N or P range: 0V
OtherthanN or P
range:4 - 5V
N or P ranger0V
OtherthanN or P
range:4 - 5V
46
Air conditioner
switchsignal
Air conditioner
OFF:
Powervoltage
Arr conditioner
ONI
OV
Air conditioner
OFF:
Powervoltage
Arr conditioner
ONI
OV
4A
Intakeair quantjty
outpLrtsrgnal
EN - 525
Memo
ECCSC/UINPUTOUTPUTSIGNALS
RB25OEENGINE
'
t"'.,il:"'l sisnar
name
Circuit
At idle
Standard
I
Memo
: : : l
lt lPProx- 2.500rpm
Standard
ECCS
C/U powersupPlY
Powervoltage
Powervoltage
53
Vehiclespeed
sensorslgnal
D range(or 1st)with
rearwheelsiacked
u p : 0 . 5" 1 . 5 V
The valueactually
deflectsbetween0V
and 5V However,lt
appearsto de{lect
aroundlV according
to vehiclespeed.
D range(or 1st)with
rear wheelsJacked
u p ;0 5 - l . 5 V
The valueactually
deflectsbetween0v
and 5V. However,rt
appearsto deflect
aroundlVaccordlng
to vehiclespeed.
54
Throttlevalveswitch
(ldlecontactPolnt)
49
Approx.10V
0V when accelerator
pedalis pressed
Memo
56
Throttleopening
oLrtputsrgnal
Approx.0.5V
Approx.0.5 - 4V
(Voltagewill increase
when accelerator
pedalis pressed)
57
Throttlevalveswtch
(powersuPPlY)
Powervottage
Powervonage
Almostpowervoltage
Almostpower voltage
101
103
105
'110
control
InJector
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.
(example)
name]
[Newmodel
+ + Terf
+ rnallpolarity
+
position
|
|
dimensions(roundedoff)
I B+tteryl.lngth
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
1 2 . 4- 1 2 . 8
N)
1 2 . 4o r l e s s
Limit(chargerequired) (V)
(V)
(Startlrmrt)
12(zo"C)
Specific gravity inspection (20"C)

Normal
1 . 2 9- 1 . 2 2
required) (V)
Limit(charge
1.22or less
Servicelife
Thereis a variationwidthof more

than0.04 betweeneachcell
Additionalwalerdoes not needto be addedto the batter,

duringservicelileof normaldriving.Whendrivingfor
the fluidlevel
extendedperiodsof time in hightemperatures'
to thevehicledrivingconditions
maydecreaseaccording
(upperi lower)
levelindicator
the
level
with
fluid
Checkthe
andtop up to the upperlevelas necessary.
watermustbe usedto be addedto refi
Caution:Distilled
the battery.lf ordinarywateris used,fluidlosswillincrease
andmaycausedischarge.
2. ALTERNATOR
(1) Alternatorremovaland installation
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
B o l t3 . 1- 4 . 1
Startermotor
*-,"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)
precautions
Installation
Periodic replacementinterval: 100,000km
Gasinspection
andadjustment
andplugcleaningusing
wirebrush,shouldnotbe performed
as thismayscrape
off the platinumpartucluate
fromthe platinumtip surface.
lf plugsarecleanedwithan airgun,thecleaning
should
be performed
in lessthan20 secondsat an airpressure
lessthan6.0k9/ cmr.
Onlyusepartsspecified
by Nissan,whenreplacing
the
plugs.
spark
EN - 531
EQUIPMENT
ENGINEELECTRICAL
RB26DETT/ RB2OEi DE / DET/ CA18i ENGINE
o.
IGNITIONCOILINSPECTION
side)
CA18i(Exhaust
CA18iENGINE(lntakeside)
RB2ODE/DET/RB26DETT
RB2OEENGINE
value.
. Checktheprimaryandsecondary
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
. Useradtator
cap testerandapplypressure(limit1 Okgi
cm2)andcheckfor leakage.
Caution:
Whenusingthe radiatorcap tester,alwaysmakesureto
connectthe hoseadapterandfillercap is notdeformed.
2. RADIATORCAP INSPECTION
Inspection
. Cleancap rubberpackingsealsurfaceandvacuumwith
drybrush.
ano
. Attachradiator
captestertocap.Applypressure
checkthatvalveoperatescorrectly.
. Pullvacuumvalvewithfingerandcheckoperation.
J.
COOLINGWATERFILLINGPROCEDURES
hoseandheaterhoseclampsare
1 Makesurethe radiator
tightenedsecurelY.
Setthe heatercontrolleverto HOTposition.(For
first
airconditioners,
withautomatic
vehiclesequipped
andremovethe
placeignition
switchto ON position
externalsensorconnector).
capandairdrainplug. (RB20E:
Releasethe radiator
area. RB20DE/ DET:Intake
collector
lntakemanifold
in frontof glovebox).
and
manifoldcollectorarea
gradually
(fillingspeed:slowerthan2L /
Filltheradiator
min)to thetopof thespoutwithcoolant.Fillthe radiator
untilthe waterin the reservetankreachesthe MAXlevel
lineindicated.
capandairdrainplug(RB
closingthe radiator
After
5
starttheengineandallowit to idle.
system),
to idleuntilthethermostat
6 Theenginewillcontinue
opens.(Touchthe radiatorf low hoseand makesurehot
the
wateris flowing).lf a largevolumeof airremains,
past
the
gaugeneedlewillmove
walertemperature
lf
abnormally'
rises
temperature
middleas theengine
add
thisoccurs,stoptheenginewaituntilit coolsand
water to the radiatorrepeatedlyas describedabove.
Afterthe thermostatopens,racethe enginefor 10
secondsat 2500rpmtwoor threetimes.Checkthat
doesnot riseexcessively.
watertemperature
the
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
withautomatic
airconditioning,
connectthefreshairsensorconnector.
4.
RADIATOR
REMOVAL
ANDINSTALLATION
Bolt(2)
0.33- 033
- -- ''
Nut0.33- 0143a.
Reservertank
__xo
Fadjator moudlng
&racket (uppe.tt ,
s iff ijgj
.//-n t,! Radialor

shroud
ttowert
I
-/
RadiatorASSY
1l
/ /
R ,../
43
kg-m
RB ENGfNES(RB20EI DE I DET tRB25DE/ RB26DETT)

(2) 0.33 - 0.43
.-|l
R a dr a t o r
m o unt i n g
(upper)
pao*o.ss
- 0.43
F,?giiii,fiS:l''*
Radiatorcap
Badiatorhose
- Radiator
m o un l r ng
(upper)
v'
Reseryer
QnrJ
,afr
\-,i
-!-'-
6- ,rn-- 9
-
Nut0.33 0.43
Radiatorhose (lowe4
Hose clarnp
Atf otl co(
r (A/T
nose
Fladiator
shroud(lower)
Radiator
mo unt r n g
rubber(lower)
Fi.
lv.l Kg-m
Badiatorshroud(upper)
\p*Screw
( 4 )P
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
N u t0 . 3 3- 0 . $ Q ) 2 - 7-
IPoint3]
-Y.'/ A,,
F u e itanKASSY
\ )
rQ-z
d
Fueltankprotector
IPoint3]
Bolt(4) 0. 3 3- 0 . 4 3
Drainfuel
Removethefollowing:
reliefvaive[Point1]
Fuelpressure
Fueltankinternalpressurerelief
Fillertubeprotector
holecoverIPoint2]
Inspection
[Point3]
Fuelgaugeunit,fuelpumpharnessconnector
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
harnessconnector.
?i..'-1l
ry'Lcover
EN - 538
FUELSYSTEM
RB26DETI/ RB2OE/ DE / DET / CA18i/ RB2sOEENGINE
Removethefollowing:
Fuelpressurerelief
Internalpressurerelief
holecover
Inspection
gauge
limit
Fuel
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
gaugeASSY
armwheninstalling
f uelgaugeASSY
iedboltswheninstalling
Onlyusespecif
(2) Fuel pump removal& installation
Removal
. Loosenhoseclampon unitsideon the pumpside.
pumpwiththe insulator
. Liftup thepumpslightly.Flemove
(PlC
A)
fromgaugeunitsidebracket
. Removepumpsideharness.
. Detachhose.
lnstallation
. Carrvout installation
operationin reverseorder.
(3) Inspection
1. Float inspection
. Placethefloatat the F (leverupperside)and E (lever
andcheckthe resistance.
downside)positions
2. Pumpinspection
terminal1 and
. Applybatteryvoltageto harness
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
Handstartbolts
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.'
Installation
Checkfuelhosemarking,
connectfuelgaugeASSy.
pump
Position
harnessandclampband160mmin from
gaugeASSYconnecting
padandtightensecurely.
Caremustbe takenthatfuel hoseandfuel harnessturn
insidetankfromthe rightto frontsideof vehicleanddo not
causeanyinterference
withfloatarm.
EN - 541
Approx.
160mm
hose
SYSTEM
EXHAUST
RB26DETT/ FB2OE/ DE / DET/ CA18r/ RB25DEENG NE
EN7
SYSTEM
EXHAUST
SPECIFICATIONS
Exhaust system part inspection,warning precautions

. The heatresistanceandcorrosionresistancein exhaustsystempartsand component
so onlyusegenuine
in thedesignprocess,
considered
shapehavebeencarefully
Nissanpartsfor rePlacement.
makingsurethereareno gasleaks'
partandconnectsecurely,
. Cleaneachconnectlon
. Alwaysuse newgasketsin the frontand rearof catalyticconverter'
. Alwaysuse newpartsfor exhaustmanifoldconnectiongasketand nuts'
. Afteiassemblingeachpart,whenwarmengine,raisespeedto 2,000to 3,000rpmand
makesurethereare no gas leaks,sealingcompoundleaksor sealinggaps'
in heatinsulationpanels.lf
. Replacepartsratherthan repairingextremedeformatron
cleantheseareas'
extremeamountof dirthaveaccumulated'
andno
clearance
panels,makesurethereis adequate
. Whenattaching
heatinsulation
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
Nut(3)4.6- 6.1gl
t l u tt Z l+ . a- S . O P
Bolt(6) 0.5 - 0.7
-. Bon(2)p
N u t( 2 )1 . 5- 1 . 9
gl
(t 6 )t"/
B o l rct
trorr
9 9 9 9 9 a 4 4 - 5, 6" ^1"/
-
"
JiR
V Bo't(2)g::i'.':l; |3}
::A
/ri&
44 5b
gBott (2) i'"t- i;
.f4
*)'l/
Eror l!.1
u'h'o
(3) RB20DE
M/T
Nut(3)4.6- 6.1$)
N u r( 2 )4 . 4- 5 . 6 9
Bolt(6)0.5- 0.7g|
N u t1 6 )
1. 3 - 1 . 6 \ - /
9l ruutlt g - 't.6
Nut1.3-1.69
View A
(4) RB20DET
Nu t ( 3 4
) .6-6.1 M/T
A/r
---i=,
^ N u t( 2 )4 . 4 -
d'i-
glBoro.5-0.7
,r, 121
r.s- r.sg
Bolt(6) 0.5 - 0.7
BoltI
/ 1 . 3- 1 . 6
Bort(2)I
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)
0 . 5- 0 . 7
o l t0 . 5 - 0 . 7
9lBott (2)4.4- 5.6
Bot1.3-1.6
Nut(2)pl
ry1s-16
Nut1.3-1.6
Srp
u'"Jo
fil'-(]ue
(5) RB25DEENGINE
M/T
!9lo.s- o.ztzt-0
Insulator
Insulalor
.,::p
1.3-,r.6(2)ggggg
Pta
e' z '
,'::::1", $Foo,u'i)
- ' r . s-
' *;
, ::";;*ir.9,"",,!,::it:is\
.-rli,^, caôp1
..
_-1,3 16
q/i-;4round ine
r.oP
1 . 3- 1 6 9
!'1--rs-rog
rubber
N,4ounting
f,:l:r*:;',"o,'
-'
, ,t'i-'
4.6- 6.1 {3)F)
/
*'
i'-""*'n-'"
rrsu'alor
I n s u l a l o r 0 . 5 - 0 7 ( 6 ) '[ q'
Clamp
-o5:.01gl
t , .
rrn"r.t ten'o sensor
o.s2 0.66p:
EN - s44
A/T
tnsutalor
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 position
andcheckthat
exhaustgaslemperature
warninglampdoesnotturnon.
. Exhaustgastemperature
warninglampmustlightwhen
ignitionswitchis placedat STARTpositionandmustgo
offwhenengineis staned
Exhaust gas temperaturewarning lamp replacement
and inspection
. Removevehicleharnessfromswitching
module.
. Useleadlineto groundvehiclesideharnessconnecl
exhaustgastemperature
warninglampterminal.
. Inspectcondition
of exhaustgastemperature
warning
lampwithignition
switchturnedON.
Faultycircuitbetlveenignitionswitchingmodule.
Faultykey sensingmoduleor sensor.
gastemperature
Exhaust
warning
lamp,s burned
out.
gastemperature
Exhaust
warning
lamppower
circuitis faulty.
EN - 545
C A 1 8E
i NGINE
ENGINE coNTRoL
E
N
G
T
N
E
/
c
A
l
B
i
i
R
B
2
5
D
/ D E/ D E r
R B 2 6 D E r/rB B 2 0 E
EN8
(INCLUDE
ASCDDEVICE)
CONTROL
ENGINE
cAl8i
AND
PEDALINSPECTION
1. ACCELERATOR
ADJUSTMENT
Acceleratorpedal i nsPection
pedalis
. The enginemustbe fullthrottlewhenaccelerator
pressedfully(pedallevercontactsthe stopper
completely).
Acceleratorpedal adiustment
. Loosenlocknutsso acceleratorcablehas adequate
pedal R B 2 O E
of accelerator
slack.Pulloutercasein direction
trompositionwherethrottledrumstarlsoperating(there
. ia--- I ,^ ^^^
mustbe no playat thispoint),returnlocknuts1.0to 1.5
turnsandtightensecurelY.
Locl( nul
0 . 8- 1 . 0
'ThrottLe.drum
Locknut 0.8 - 1.01 F,ont
RB2ODE/DET/RB25DE
Kickdown switch adiustment (RB engine A / T vehicles)

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

t
Does not operate
Setting
u nstable
(n
@
Faulty
:::i:-:t:::
il&*
Resume/
set/ coasl
accelefatorSW
SW faulty
faulty
gPFhrrpsW ,,irbidir,
$iq!! 8w(!nr[ ] W:a,,:'
htdbltortlw (A/D' ierXtOf-
t|YY'
Faultyadjustmeni
orfaultyparts
lvlainunit lnsrdecircut
faulty
faulty
Faultyval\,
[,4ainunit
faulty
faultydiaphra
Hunting
unit
lnsidecircurt [,,lain
FaLrlty
fespon
faulty
faulty
Cancel
lnsidecifcurt M a i nu n r t
Diapfgramnle
faulty
faulty
Large gap between

set vehiclespeed
lnsidecrrcurt M a i nu n i t Catchor leak

d iaphgramn
faulty
faully
Vehiclespeed
decreasewhen
setting
Does not cancel
Insidecrfcuit [,4ainunrt
faully
faulty
lnsidecircuit Mainunit
faulty
laulty
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
Checkcontroller
groundforany
faults(betweenterminal3 and
groun0).
Faultyharness,inspection
present
Continuity
Otherthan ReplacefaultystoplampSW,
(approx. approx.
Checkforpowervoltage
12V
SW(lV/T),
clutchrelay
'
12V)to controller
jnhibitorSW.relay
3,
5
3
(HICASI\4/T),
14
(otherthaneN forA/T)l
(A,T)
Approx.12V
Powervoltageis presentwhenSer
/ coastSW is ON (Approx.12V)
(between7 - 3)
Replacefaultyset / coastSW.
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
connector
andappiybatteryvollage
betweenterminal1+ - 3-. Checkil
ASCDwirewilloperatewhen
t e r m i n a4l a n d 2 i s
Removeactuatornoseandoperale
the pump. Checkif negative
pressureoeverop.
Operate
Controlpowervoltagetapprox.l2\. ,
ls developed
betweenterminalI
and3, whenvehiclespeedis over
48km/hand seUcoastSW is ON.
Approx.
12V
Removecontroller
connector
and
checkif pumpoperateswhen12V
and0V is appliedto vehicleside
harnesswhichcorresponds
to
controller
terminal8+ and body
ground,terminal8+ and 9,10-.
Do not
operate
Operate
Otherthan
Checkif set powervoltageis
OV
approx.0V betweenterminal2 and
3 whensercoastSW is released.
Approx.0V
EN - 549
Repairiaultyharnessto the pump

or shortcircuit.
ASCD
RB26DETT/ BB20E/ DE / DET i CA18r/ BB2sDEENGINE
WHEN SETTINGIS UNSTABLE

PROCEDURE
& MAINTENANCE
INSPECTION
(HUNTING)
SETTING
UNSTABLE
Damaged
No damage
Checkif ASCDwiremovementis
Not
smooth
Smooth
for any leakor negativepressurein
pumpairvalveandreleasevalve.
Leaking ReplacefaultyASCD
pump
No leakage
Checkfor any leakor negative
in airvalveandreleasevalve.
Notcracked
Cracked
Removeactuatorhose
andoperatethe PUmP.
Checkif negative
pressure
develop.
pumpconnectorand
DisconnectASCD
applybatteryvoltagebetweenterminal1+ 3-. Checkif ASCDwirewilloperatewhen
terminal4 and2 is grounded.
Operate
IS UNSTABLE
WHENSETTING
PROCEDURE
& MAINTENANCE
INSPECTION
(cANCEL)
SETTING
UNSTABLE
Thereis approx.12V
presentbetweenterminalI
and 3 whenset SW is
placedf romON to OFF
position.The system
Voltagebetweenresume/
switchtermlnal1
accelerator
and 3 is 0V.
with
ls thereany abnormality
ReplacefaultyASCD
switch.
Abnormal
vehiclespeedsensor
andmetercable.
No abnormality
Powervoltage(approx.5V and0V) is
betweenvehicle
appliedalternatively
speedsensorterminal7 and3, when
wheelsare rotatedat 1 - 2km/h.
5V & 0V
Approx.
Checkfor leakandnegatlvepressure
Faultycontroer
EN - 5s0
Leaking
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
vacuumprprng.
Replace
damagedvacuum
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
Checkif ASCDwire playis
Notcorrect
or smooth
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
Disconnect
ASCDpumpconnector
andgroundterminal1+ - 3-4,2.Check
if ASCDwirewilloperatenormally.
F a u l tA
y S C Dp u m p
EN - 551
Replaceor adjustASCD
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
ignitionSW in ON
positionwith mainSW
ON position.Do not
pressbrakeandclutch
(OFFposition).lF A,/T
vehicle,placein D range
andapplyparkbrake.
W h i l ec r u r s i nAqS C D
powervoltageaPProx.1
Otherthan 12V
SW in
presentwhenresume/ accelerator
(0Vbetweenterminal1 and3)
ON Dosition
Checkif powervoltageis 0V between1

SW is OFF
when resume/ accelerator
Otherthan
OV
Do not
tor
Checkif speedwillincreasewhen increase urnoffthe mainswitch
it
on
turn
and
seconds
few
SW is Placed
resume/ accelerator
inONposition.
rfspeedwillincrease Do not
Replacefaulty
and
whenresume/ accelerator tncrease controller
vehiclespeed
SW is turnedto ON Position
sensor.
Do not
Checkif lhe vehiclewillcruiseat
cruise
normalvehtclesPeedwhenresume
SW is turnedOFF
/ accelerator
Checkif vehicle
speedwillincrease
to high-cutvehicle
s p e e d( 1 0 0 k m/ h ) .
Do nol increase
EN - 552
Replacefaulty
and
controller
vehiclespeed
sensor.
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
r
l w h e n s l o p p r npql a c e
Doesnot
Checkif constant
speed
device
willoperate
using
sevcoastSW.
Operate
Inspectfollowingthe stepsof
"Can
notset".
| l OheckrfpOWETVoltageapprox.12Vis
Otherthan 12V
r rma / a.âlar^l^|" qW in
I I ipresent\r
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
Approx.
lpressbrakeandclutch [-l
Otherthan
SWrnoN
lrsnition
positron).
lFA/I I I r
l(OFF
oltageis 0Vbetween
1place
inDrange
lvehicle.
| | |when resli m e / a
cceleratorSW is OFF
parkbrake. I l!
landapply
wilffi;s-_-l
OV
Repair faultySW
OV
Set vehiclespeedto 80km/ h
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

decrease Replacefaultycontroller.
resumeSW is turnedON ([/ake surethe
vehiclespeedwillnotget below48km/ h)
Decrease
Otherthan
Checkif thevehicle:
Otherthan
Speedhasde()reaseo to oerow
willreturnto set vehic e
80km/ h
48km / h Replacefaulty
speed(80km/ h) wh 'I
controller.
resumeSWis t u r n e dO N
resumeSW is turner O F F
Below48km/ h
80km/ 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
WHEN IT CAN NOT BE

PROCEDURE
& MAINTENANCE
INSPECTION
CANCELLED
SETTINGCAN NOT
BE CANCELLED
ls voltagebetweenterminal5 and3
0V whenbrakeis operated(in N
ge is presentbetween
11and3 whenbrakeis
Inspectand replacestoplamPSW
outputis cut
Checkif controller
(8and3)whenbrake
betlveen
pedalis pressed.
ls therean actuatorJault.
Inspectand replaceactuator
ls thereharnessshortcir
Inspectandreplaceharness.
(2) FUNCTIONINSPECTION
. ASCDfunctioninspection
is carriedoutby drivingthevehicleandcheckingif each
ASCDcontrolcircuitsystem
functionwilloperatenormally.In thisf unctioninspection
functionis inspectedusingfreeroller.
Caution:
Constantdrivecan not be achievedby ASCDas it is non-loaddriveon the free roller.Use
on eachproblemwhencarryingoutfault
depending
(1)faultdiagnosis
as a reference
diagnosis.
andcheckthat
. TurnoN the mainswitchwhenignition
switchis placedin oN position
lamPwillturnon
operation
Caution:
Thereis a faultwithmainswitchoTASCDrelayif the lampdoesnotturnon.
speed(60kmih) and
. checkthatthecruiselampwillturnon whendnvingat a constant
for
set/ coastswitchis placedto ON position.Checkif thevehiclespeedwillincrease
when
drivecan notbe achieved
a moment,cruiselampwilllurnoffandconstant
position
at the
placed
to
oFF
acceleratorpedalis releasedand set / coastswitchis
sametime.
Caution:
as it is non-load
lf ASCDcircuitis normal,huntingwilloccurandASCDwillbe cancelled
dnve.
. checkthatthecruiselampwillnotturnon whensetswitchis pressedwhenthebrake
pedalis pressedslightly(brakeswitch:OFF,stoplampswitch:ON)'drivingat a
whenthe
constantspeed(60km/ h). Makesurethevehiclespeedwillnotincrease
position
same
placed
at
the
to OFF
acceleratorpedalis releasedand set switchis
inspection).
function
time(release
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
(powercircuit)inspection
Controller
. Inspect
powervoltagebetween
followrng
terminals
with
connectors
connected.
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
thevoltage
. Slowlyrotate
andmeasure
therearwheels
connected.
with
connectors
7 and3
terminal
between
I nopro, 5V and0V ahermatrvely
Controller(cruiselampoutput)inspection
13and3 with
. Measure
terminal
between
thevoltage
connected.
connectors
"" *"n.jllniil_|"'::",,"::,.,
/
/---2-
\e\
\ \
Controller (A/T control unit control output) inspection

[A / T vehicle]
. Drive(ASCDset possiblerange)and measurethe
voltagebetweenterminal12 and 3 withconnectors
connected.
Note:
when
WithA/T shiftcontrol,ASCDcontrollerls prroritized
setat ASCDdrive.
E N- 5 5 6
lr]]]
t3F-11
-r-
r'E-V{Y.
lRr
ti
J)
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
when
terminals
betweenfollowing
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
terminai1 and 4
Motorwilloperate
Resistance
inspection
,
'
'
'
r temfinak ,,
:r:.1.1..
A r rv a l v e1 - 4
Release valve '1 - 2
Approx.70
Approx.70
Vacuumpumpl-3
Approx.8
Operationinspection
. Applybatteryvoltagebetweenterminal1(+)and3(-)and
checkif ASCDwirewilloperatewhenterminal4 and2 is
grounoeo.
RB2OE
ASCDwire adiustment
. Loosenlocknutsso ASCDwirehasadequate
slack.Pulloutercasein direction
of actuatorfrom
positionwherethrottledrumstartsoperating,returnlock
nutsapproximately
1 turnsandtightensecurely.
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
Accele;i;;;;;
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
Gl-13
2 - p o l lei f t. . . . . . . . . . . . . .
Gl - 15
4WD inspection
. .l.-. 1
. 5
4 W Dr e p a ipr r e c a u t i o n s . . . . . . . . . . . . . . . . . .G
. . . . E N- 2 3 1
E C C S. . . . . . . . . . . . . . . . . .
. .- 2 3 3
E C C SC / Ui n s t a l l a t i o n . . . . . . . . . . . . . . . . .E. N
E C C Sr e l a y( B B 2 s D E .). . . . . . . . . . .. . . E N 4 8 5
, . EN-233
Eccsvoltage......
E m i s s i ocno n t r oel q u i p m e n.t. . . . . . . . . . E N 7
5
.... EN 46
Enginecontrol
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
.. . . EN- 560
Engrnm
e ounting
. . E N- 1 B o
E n g i no
e v e r h a u. .l . .
E n g i n es p e c i f i c a t i o .n.s. . . . .. . . . . . . . . . . E N 7
2
. . . . . .... . . . E N 5 4
E n g i n es t a l l
sensor. EN - 367. 396' 482
Enginetemperature
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
-545
EN
Exhaustgastempwarningequipment. .
- 159
.
.
.
E
N
.
E x h a u sm
t anifold
1
1
9
'142
d S S Y. . E N - 7 5 , 1 0 9 ,
E x h a u sm
t a n i f o lA
E
N
543
.
E x h a u spti p e . . . . . . . .
4
9
,
542
EN
E x h a u sst y s t e m . . .
B
. . . . . . .E. .N - 6 8
B a l a n cteu b e . . . . . . . .
EN-236. 272
Basicinspection
. .. EN - 530
Batteryinspection
. . EN-43
Belttension.........
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
device... .. . .... . ... EN - 55
Blowbygas reduction
. . . . . . . . . E N- 4 8 9
B l o w b yh o s e
....G| -13
Board-onlift.........
. ... . .G|-'15
c h e c k. . . . . . .. . .
B r a k i npge d o r m
c
'. .. EN - 543
converter
Catalytic
. . . .. . . E N - 2 7 9
C i r c u idt i a g r a m
E N - 5 9 . 1 0 5 1 0 6 ,1 1 5
CollectorASSY
. .. . EN - 482
inspectlon
{RB25DE)
Components
pressureinspection. .. . .... EN - 42
Compression
. . . . . . . .E. N - 8 0
Conicalwasher.....
C o n n e c t oi nr s l a | 1 a t i o n . . . . . . . . . ... .......... . E N 2 3 3
.. .. . . . G| - 6
symbol
Connector
GI- 11
. . . . . . . . .. .
CoNSULT
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
. EN - 83, 85, 170
Cylinderhead
D
... . .. . . EN - 267
Datamonitor
exhgas emissioncontrol . EN - 527
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
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
D i a g n o s i s p r o c e d u r e . . . . . . . . .. . . . . . . E N - 2 3 4
D i a g n o s t i c s y s t e m . . . . . ... . . . . . . . . E N - 2 5 9
D i a g n o s t i c w o r k s h e e t . ... ... ..... . . . . . . . .E N 2 3 4
- 274
.
.
.
E
N
D O H C. . . . . . . . . . . . . . . . . .
F
ASSY .. .... .. . . . . EN - 69
Frontturbocharger
. . . . . . . . . .E N - 5 3 9
Fuelgauge
' . . . . . . . . . E N- 1 5 6
F u e li n j e c t o r
. . . . . . . . .. . . . . . E N - 5 3
F u e lp r e s s u rien s p e c t i o n
F u e | p u m p . . . . . . . . . . . .. . E
. .N
..- 303, 307, 440' 483
EN - 52, 486, 537
Fuel system
. . . E N- 5 3 7
Fueltank..............
F u e tl a n kv a c u u mr e l e avf a l v e . . . . . . . . . E N - 5 4
........E
. .N
. - 66
F u e t u b eA S S y
G
G a sl e a ki n s p e c t i o.n. . . . . . . . . . . . . . . . . . . . . . E N 7 5
G e n e r a l p r e c a u t i o n s . . . . . . . . . . ... ....... ... ...G l - 7
H
. .. EN-543
Heaterpane|.........
H o w t o u s e t h i s m a n u a | .. .. . .. .. . .. . . . . . . . G l - 2
H y d r a u l iJca c kl i f t i n g. . . . . . . . . . . , . . . . . . .. . G l 1 4
I
. . .. .. EN - 23
ldlemixtureratio
EN - 339' 346
.
....
...
ldlespeedcontrolsystem.
EN- 23
. .
.
.
.
.
.
.
.
.
.
.
l d l es p e e di n s p e c t i o n . .
.
.
E
N
4
8 3 ,5 3 2
.
.
.
.
.
.
1gni1ioncoi|................
E
N-328
.
.
l g n i t i o inn s p e c t i o n
.. EN- 486
l g n i t i orne l a y . . . . . . . . .
. . . . . .. E N - 4 2 4
l g n i t i osni g n a l
EN-330' 332' 412
l g n i t i o sn y s t e m . . . . .
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
Individual
. . E N- 4 8 6
l n h i b i t or re l a y . . . . . . . .
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

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
lntakemani{o|d..E
..N
. . .- 6 5 , 1 O 7 ,1 1 7 . 1 3 7 , 1 5 7
I n t a k em a n i f o lcdo | | e c t o r . . . . . . . . . . . . . . . . . E
. .N
. . -. .i.5. .3
I n t a k em a n i f o lvda c u u m. . . . . . . . . . . . . . . . . . . . .E. .N. .-.2. 7 5
Intercooler
. . . . . . . . .E
. .N- 5 7 . 1 3 1
Intercoola
e irrd u c ta s s e m b l y. . . . . . . . . . . ..... E
. N- 5 6
l n t e r c o o li e
r
n l eht o s e. . . . . . . . . . . . . . . . . . . . . . .E. .N. -. .5. 6
....
R a d i a t oc ra pi n s p e c t i o n . . . . . . . . . . . . . . . . E
. .N
. .-.5. .3. .4. . .
Radiatorinspection
..... EN - 534
F e a rt u r b o c h a r gAeSrS Y. . . . . . . . . . . . . . . . . . . .E. N
. . -. .7.0. .
R e c i r c u l a t ihoons e
. . . . . . .E. N - 5 7
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
R e m o v ae n di n s t ael ln g i n e . . . . . . . . . . . . . . .E
. .N
. .-. 1. 8
. .0.
Rockercover
EN - 76, 120, 169
s
14
EN - 353
1 1 0 ,1 4 3
EN-47
EN.47
M
Measurement
tools
Multipurpose
tools
EN-12
EN - 12
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
. .N
. .-. 6
. .3. . .
S p a r ki n s p e c t i o n
. . . . . . . .E. N - 2 7 4
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. . . . .
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. . . . . .
S t a ns i g n a. l. . . . . . . . . .
. . . . . .E. N - 4 3 6
S t a r t em
r 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
S w i n vg a l v e
c o n t r o l l.e. r. . . . . . . . . . . . . . . . . . . . .E. .N. -. .7. 3
....
System
diagram..
. . . . . . . .E. .N - 1 3
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 e
. .N
. .- 3 6 7 , 4 3 6 . 4 8 3
w i t c h. . . . . . . . . . . .E
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
. . . . . . . . . . . . . . . . . .E. .N. -. .5.3. 1
EN - 251
. . . . .E
. N- 2 4 7
..EN-447,486
E N- 4 0 1
E N- 4 8 3
. . . . . . . . . . . . . .E
. .N
. .-. 2. 3 5
EN- 352
U n a b l et o s t a r t
U n s t a b lied l i n g
. . . . .E. N - 2 3 9 . 4 2
. . . . . . . . . .E. .N - 2 3 4
V
Vacuum
diagram
. . . . . . . . .E
. .N - 1 9
V a l v ec l e a r a n cien s p e c t i o.n. . . . . . . . . . . . . . . . . .E
. .N
. .-. .4 5
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
V e h i c l sep e e ds e n s o r . . . . . . . . . . . . . . . .E. .N
. .-. .3.9 7 . 4 3 0
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
. .N
. . -. .6. 7
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

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CON4PRESSION

Power steeringpump bett

Power steering belt

Adjustment bolt in power steering pump

Air conditioner compressor belt

Adjustment bolt in idler Pulley

Adiustment bolt in alternator

Valve clearancestandard value

(Reference value: warm) mm

0 . 5 1 ', " ' :

5. LUBRICATION SYSTEM INSPECTION

5-2 OIL PRESSUREINSPECTION

RB26DETT/ RB25DE/ RB2ODE

5.3 OIL FILTERREPLACEMENT

or 12months SE,SF,SG classoil

Swing valve controller inspection

. Inspectthe pulsationby holdingthefuelhosewithhand

. Holdthe fuelfilterand makesurethe hoseis hardand

USINGTHE FUEL PRESSUREMETER

Releasingfuel pressure(CA18i/ RB20E)

. Afterstartingthe engine,removethefuelpumpfuse After

Approx.2.5 Approx.3.0 Approx.

8-,I PURGECONTROLVALVE INSPECTION

9-1 BLOWBY CONTROLVALVEINSPECTION(EXCLCA18i)

Replace after every disassembly

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

Additionalwork requ ired:

Cleaningair hoses & air duct

Remove& installeach air hoses and tubes

Removeand installthe intercoolerinlet

1O-2 AIR GLEANERELEMENTASSEMBLY

Air hose and air duct cleaning

2. Removefour bandclipsfromthe air cleaner.Liftair

Periodic replacementinterval: Every 60,000km

Booster vacuum removal

Removeand installair chamberbolts

[Point 10] Removeand installair chamber

[Point11] Removeand installAACvalve

10.4 SIX IN-LINETHROTTLECHAMBERREMOVALAND INSTALLATION

No. 3 Throttle No. 2 Throtfle

10.5 SIX IN.LINETHROTTLECHAMBERLINK ADJUSTMENT

Throltle chamber f ully \\

=Bolt(4) 0.64- 0.85

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

8. Tightenthe locknutA and B afterthe adjustingthree

10. Completelyopenandclosethe six in-linethrottle

Air drain plug

(21 Intakemanifolddisassembly& assembly

Replace after every disassembly

Do notdecenteror rotatethe fuelinlectorsandthe

Installand removewater bypass

Water outlet elbow

[Point 6] Remove and install balancetube

. Be carefulnotto pinchthe O-ringsduringinstallation.

Reptaceafter every disassembly

Additional work required:

Oil feed tube inspection

Crack burn Inspectron

rq:i,:::lOil leak inspecttontocation

Rotor shaft inspection

Swing valve insPection

Rotor shaft play inspection

Rotor shaft inspection