R33 - Engine Manual Ocr

~ NISSAN
R33 ENGINE MANUAL. RB20E, RB25DE, RB25DET &

RB26DETT
R33 ENGI NE
r SERVICE MANUAL
1
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GENERAL INFORMATION
SECTION GI
GENERAL INFORMATION
CONTENTS
HOW TO USE THIS MANUAL ................................................................................. GI - 2
SYMBOLS ................................................................................................................ GI - 5
GENERAL PRECAUTIONS ..................................................................................... GI - 7
VEHICLE & UNIT lDENTIFICATION LOCATION ................................................... GI -10
CONSULT ............................................................................................................... GI - 11
TIGHTENING TORQUE OF STANDARD BOLTS .................................................. GI - 12
TOWING ................................................................................................................. GI -13
GARAGE JACK & RIGID RACK SUPPORT POSITION ........................................ GI - 14
ABBREVIATION ..................................................................................................... GI -15
MAIN UNIT CONVERSION ................................................................................... GI - 16
4WD INSPECTION & REPAIR PRECAUTIONS .................................................... GI - 17
Gl-1
GENERAL INFORMATION
HOW TO USE THIS MANUAL

MAINTENANCE OPERATION EXPLANATION
This manual describes important items for installation, removal, assembly, inspection,
repair and failure diagnosis.
Caution:
A general description of a visual inspection and cleaning of disassembled parts has
generally been omitted. However, when reusing the parts, make sure to perform visual
inspection and cleaning as necessary.
CONFIGURATION COMPONENTS, OPERATION CONTENTS & PROCEDURES

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

The operations for installation, assembly and disassembly are indicated by the part name.
This description is used when the ideal procedure can not be determined or there are
many types of components.
[Point] is used to indicate the operation procedures which are necessary.
Example: Front Axle disassembly & assembly
m Outer bearing outer race

t.9J Screw (3) 0.3 - 0.4
t.9J Bolt (4) 2.5 - 3.4

Disc rotor
Spacer [Point 1]
~El Outer grease seal
Hub bolt
~ _kg-m
Knuckle
Baffle plate
El ; Should be lubricated with grease.

íX
Jr
f~
m Outer bearing
¡
J.:'P';,. : Use recommended multipurpose grease Wheel hub

~ Can not be reused
Unit definition
The unit of measure used in this manual for tightening torque is described in "SI measure
(lnternational unit)" and the units within { } is in meter unit.
Example: Tightening torque: 59 - 78 N-m {6.0 - 8.0 kg-m}
I
SI measure
Meter Jeasure
Gl-2
GENERAL INFORMATION
STRUCTURAL PARTS DIAGRAM AND OPERATIONAL SEQUENCE

The name of the parts required for the operations are shown. The operation sequen ce must
be followed in the order shown.
Assembly is the reverse of disassembly except when otherwise indicated.
Example 1: Light combination switch ASSY installation and removal
1. Steering wheel ASSY

2. Screw (1)
Light combination switch ASSY
3. Screw (5)
Connector
Shell cover
Operation where the torque should be checked and standard torque
~
value should be used.
When X to Y N.m (kg-m. ft-lb) is indicated, the standard tightening
torque índicated is the median value.
m Should be lubricated. lndicates a type of grease used.
Parts that can not be reused.
Should be lubricated with oil.
Sealing point.
* Select genuine parts.
*
Adjust parts.
Parts need to be checked visually.
Gl-3
GENERAL INFORMATION
Example 2: Fault diagnosis flow chart
A.~----------~
~3
A
CHECK POWER SUPPLY.
l 1
NG ~C_h_e_ck_t_h_e_fu-ll_o_w-in_g_~
items.
1) Turn ignition switch 1) Harness continuity
"ON". between cam shaft
2) Check voltage between position sensor and
Battery voltage should battery.
be present. 2) ECCS relay.
2 3) Fusible link.
4) Power source far
OK ECM.
B 5) lgnition switch.
B
CHECK EARTH CIRCUIT.
1) Turn ignition switch "OFF".
0
[2J ) Disconnect cam shaft
Check the following
items.
Disconnect position sensor harness 1) Harness continuity
e Eü connector. between cam shaft &
) Check resistance between earth.
terminal D and earth. 2) Earth circuit far
Resistance: Approx. O ECM.
OK
HOW TO FOLLOW THIS FLOW CHART

1. Work and diagnostic procedure
Start to diagnose a problem using procedures indicated in enclosed blocks, as shown
in the following example.
A
CHECK POWER SUPPLY. -E-- Check item being performed.
1) Turn ignition switch "ON". }
2) Check voltage between
terminal B and earth. Procedure, steps or measurement results.
Battery voltage should
exist.
2. Measurement results
Required results are indicated in bold type in the corresponding block, as shown
below.
These have the following meanings:
Battery voltage; 11 - 14V or approximately 12V
Voltage; Approximately 0V - Less than 1V
3. Cross reference of work symbols in the text and illustrations

lllustrations are provided as visual aids for work procedures.
4. Symbols used in illustrations

Symbols included in illustrations refer to measurements or procedures. Befare
diagnosing a problem, familiarize yourself with each symbol.
Gl-4
GENERAL INFORMATION
~-.
Eü Check after disconnecting the

connector to be measured. l5J Current should be measured with
an ammeter.
() Check after connecting the

connector to be measured. (j) Procedure with CONSULT
@-~ lnsert key i nto ignition switch.

® Procedure without CONSULT
~•E::() Remove key from ignition switch.

ffl A/ C switch is "ON".
~ ~
Turn ignition switch to "OFF"
position. A/ C switch is "OFF".
~-
00 Turn ignition switch to "ON"
position. ~ Fan switch is "ON".
00 Tum ignition switch to "START'

position.
~l l J 'i Fan switch is "OFF".
~
Turn ignition switch from "OFF" to Apply fused battery positive
~ce "ACC" posítion. voltage directly to components.
~
Tum ignitíon switch from "ACC"
~F to "OFF" position. Orive vehicle.
~ ~
Turn ignítion switch from "OFF" to Disconnect battery negative
"ON" position. cable.
~
Turn ignition switch from "ON" to
@~ "OFF" position. Depress brake pedal.
0 Do not start engine, ar check with

engine stopped. ~ Release brake pedal.
/ - -,
ID Start engine, or check with
engine running. ~ Depress accelerator pedal.
~ Apply parking brake.

~ Release accelerator pedal.
~ Release parking brake.

Pin terminal check for ECM and A/T control
unit connectors.
Check after engine is warmed up
cff~H sufficiently.
1 C / U Connectorl
~ Voltage should be measured with

a voltmeter.
8
~Connect
~ E)
lNJ Circuit resistance should be
LaJ measured with an ohmmeter.

-
Gl-5
GENERAL INFORMATION
CONNECTOR SYMBOL Connector symbols
A direction mark is shown to clarify the side of connector

(terminal side or harness side ).
• Connector symbols shown from the terminal side are Single line
enclosed by a single line. Direction mark
View from terminal side
iew from harness side

Connector s mbol
• Connector symbo!s shown from the harness side are

enclosed by a double line.
Double line
Direction mark
erminal side.... .
~ n e c t o r gu1de
Male & Female terminals
1 2 3
Connector guides for male terminals are shown in black 6 7 8
and female terminals in white in wiring diagrams.
5 4
10 9
Control unit
Control unit element substances

Elements such as control unit will be shown as displayed.
~ .... l
Male terminals ---~
Direction mar
2 6 7 8
11 15 16 17 (21
onnec 10n sy ol
Gl-6
GENERAL INFORMATION
GENERAL PRECAUTIONS
Follow the below precautions to ensure safe & proper servicing for your vehicle.
SRS (Supplemental Restrain System) air bag
• lnfarmation necessary to service the system safely and
correctly is included throughout this service manual.
Make sure you read 'each section carefully befare
carrying out maintenance operation.
• lmproper maintenance, including incorrect removal and
installation of the SRS air bag, can lead to personal
injuries caused by unintentional activation of the
system.
• Do not use electrical test equipment on any circuit
related to the SRS air bag.
• Ali SRS electrical wiring harnesses and connectors are
covered with yellow outer insulation.
General Precautions
• Do not operate the engine far an extended period of
time without proper exhaust ventilation.
• Keep the work area well ventilated and free of any
flammable materials.
• Care must be taken when handling any flammable or
poisonous materials.
• Befare servicing the vehicle, cover fenders, upholstery

and carpeting with appropriate covers.
• Before jacking up the vehicle, apply wheel stoppers

and only jack up the vehicle at jack up point.
• After jacking up the vehicle, support the vehicle weight
with safety stands befare workíng on the vehicle.
• When removíng heavy objects such as the engine or
transaxle / transmission, take care not to drop them. L.._-----=--=----...J
Also, do not allow them to strike other parts, especially
the brake tube and master cylínder.
Gl-7
GENERAL INFORMATION
• Befare start repairs that do not require battery power,

always turn off the engine and disconnect the earth
cable from the battery to prevent accidental short
circuit.
• Loasen the screw nut completely when removing the
earth cable from the battery.
• To prevent serious burns, avoid contact with hot metal

part such as the radiator, exhaust manifold, tail pipe
and muffler. Carry out the operation when the parts
has cooled down.
• Do not remove the radiator cap when the coolant is hot.
• An inspection may be difficult with a normal test probe Wind wire around probe
1 .
when a connector pin is extremely small. When this is ! Test pr be
the case, wind a small pin or wire around the test
probe, or sharpen the end of the probe to perform the
inspection. 1
Sharpen the end
• Use measurement equipment such as the CONSULT
electronic system diagnosis tester and an oscilloscope
to perform diagnosis operation.
• Check the vehicle damage carefully, make a careful
diagnosis of the damage and perform the correct
operation.
• Check the correct part assembly condition befare
removal or disassembly. Make alignment marks when
necessary in locations which will not interfere with the
part operation.
• When replacing parts always use correct specified
parts or tools.
• Replace oíl seals, gaskets, packing, 0-rings, !ocking
washers, cotter pins, self locking nuts, etc. with new
ones. These parts are indicated "Can not be reused"
and must be replaced with new parts.
• Always replace taper-roller bearing and the needle
bearing for inner and outer race as a set.
• Take care not to mix up the removed parts.
• When replacing parts always use genuine Nissan
replacement parts.
• Use correct lubricants specified.
• Dispose waste oil and cleaning oil in a way that is set
by the law.
Gl-8
GENERAL INFORMATION
Precautions for ECCS engine

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

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

Only use unleaded gasoline far gasoline engine vehicle.
Using a fuel other than that specified could damage the
vehicle.
Gl-9
GENERAL INFORMATION
VEHICLE & UNIT IDENTIFICATION PLATE LOCATION

Vehicle identification number (Supplement models only)
E-HR33 .......................................................HR33-000101 ~
E-ER33 .......................................................ER33-000121 ~
E-ECR33 .................................................... ECR33-000151~
umber plate
area= _ _
J',.-!1~~::~s~~~
/
~.n~Nr-~"
le identífication plata
')
Model number plate
NISSAN MOTOR CO,L TD.JAPAN
1. Type
'!fil xt iYPE
TIPO
_& 1
2. Vehicle identification number ::;!:! .
CHASSIS NO
3. Model NO DE CHASSIS
MOOEL
4. Body colour code MODELO
~
5. Trim colour code h 5 - COLOR ffiM
f ,¡ ¿ COLOR BUARIIICION
4,& &,5 ~lj o
6. Engine model ~, ENGINE
ce
;;, MOTOR 6& LD.7
7. Engine displacement h ~ ,:, TffANS AXLE
8. Transmission model 7 ?>i< THANS UE 8& &9
PLANT
9. Axle model I~ PLANTA
B ift. ~ ltJ • ~ ~ ~ +± MAOE IN JAPAN
Engine serial number
RB Vehicles: Lower rear left cylinder block
Gl-10
GENERAL INFORMATION
CONSULT
Consult is a hand-held compact type tester. lt transmits Program
card
signals to the vehicle loading control units when the
diagnoses connector is connected and can perform all
types of diagnosis and tests.
Note:
Refer to the CONSULT operation manual for further
details.
FUNCTION
Transmits commands to the electrical control unit for setting the
status suitable for required operation.
Diagnose the ECCS standard checks
Receives the self-diagnosis results from the electrical control unit
and displays malfunctioning system names and the number of
times a malfunction occurs.
Receives input and output signals from the control unit, displays
and records data used to easily determine cause of malfunction.
Sends commands to the control unit and performs the operation
inspection and verification of the output system according to
output signal changes.
Displays the part number of the electrical control unit.
APPLICATION
o o o o o
o o o o
o o o
o o o o
Gl-11
GENERAL INFORMATION
TIGHTENING TORQUE OF STANDARD BOLTS
1.25 13 1.3 15 1.5

M8 8.0
1.0 13 1.3 16 1.6
1.5 25 2.5 29 3.0
M10 10.0
1.25 25 2.6 30 3.1
1.75 42 4.3 51 5.2

M12 12.0
1.25 46 4.7 56 5.7
M14 14.0 1.5 74 7.5 88 9.0
M6 6.0 1.0 8.4 0.86 10 1.0
1.25 21 2.1 25 2.5
M8 8.0
1.0 22 2.2 26 2.7
1.5 41 4.2 48 4.9

M10 10.0
1.25 43 4.4 51 5.2
1.75 71 7.2 84 8.6
M12 12.0
1.25 77 7.9 92 9.4
M14 14.0 1.5 127 13.0 147 15.0
M6 6.0 1.0 12 1.2 15 1.5
1.25 29 3.0 35 3.6

M8 8.0
1.0 31 3.2 37 3.8
1.5 59 6.0 70 7.1
M10 10.0
1.25 62 6.3 74 7.5
1.75 98 10.0 118 12.0

M12 12.0
1.25 108 11.0 137 14.0
M14 14.0 1.5 177 18.0 206 21.0
Special parts are excluded.
This standard is applicable to bolts having the following marks embossed on the bolt head.
Grade Mark
4T 4
7T 7
9T 9
Gl-"12
GENERAL INFORMATION
TOWING
Front
After removing the front spoiler, attach a cable to the
hook in the front part of the front side member.
(
Tow
\
Rear
Attach a cable to the hook mounted at the rear part of
the rear side member.
2-POLE LIFT
Set the lift pad to side sill jack up point.
Caution:
Make sure the vehicle is empty when lifting the vehicle.
Make sure the side sill and lift arm (rear part) do not contact each other when lifting the
vehicle.
Front of the vehicle y
Side sill
Liftpad ~
Board-on Uft
Front of the vehicle
Set the board-on lift adapter (LM4086-0200) on both o
sides of the lift.
Standard set position is a jack up point located in front L
of the side sill, as the vehicle gravity point is located at
the vehicle front.
Adapter
Caution:
Make sure the vehicle is empty when lifting.
Gl-13
GENERAL INFORMATION
GARAGE JACK & RIGID RACK SUPPORT POSITION

Caution:
• When using a garage jack to jack up the vehicle, care must be taken not to damage
any pipes.
• Apply parking brake when jacking up the front of the vehicle.
• Place wheel stopper to front wheels when jacking up the rear of the vehicle.
• lf the vehicle is jacked up for prolonged period, use rigid rack to support the vehicle.
• Always set the adapter (LM4519-0000) to the rigid rack and place it to jack up point
on the side sill.
• Never place a rigid rack to the slde member on the under floor.
Riaid rack bearina
F ront of the
vehicle
y
Garage jack bearing
Gl-14
GENERAL INFORMATION
ABBREVIATION
A/C Air conditioner

A/T Automatic transmission
ABS Anti-lock brake system
ACC Accessory
ALT Alternator
ASCD Auto speed control device
ASSY Assembly
AV Audio visual
BAT Battery
BC valve Boost control valve
BPT valve Back pressure tranducer (Exhaust pressure control)
C/B Circuit breaker
C/P Crank pulley
C/U Control unit
CD Compact disc
Cyl Cylinder
DOHC Double overhead cam shaft
DSP Digital signal processor
EGR Exhaust gas circulation
ELR Emergency locking retractor
ENG Engine
EXH Exhaust
F/L Fusible link
FICD First idle control device
FPCM Fue! pump control module
GPS Global positioning system
H/B Hatch back
H/T Hard top
HEC Hybrid electronic control unit
1/p ldler pulley
IAA ldle auxiliary air unit
IAS ldle adjust screw
IGN lgnition
ILL lllumination
INT lntake
L.S.V Load sensing valve
L/U Lock up
LED Light-emitting diode
LLC Long life coolant
LSD Limited slip differential
M/T Manual transmission
Gl-15
GENERAL INFORMATION
NAVI Navigation
0/D Overdrive
OHC Overhead cam shaft
OHV Overhead valve
os Over size
P/S Power steering
P/W Power window
PBR Potensio balance resistor
PTC Potensio temp control
PTO Power take off
S/V Solenoid valve
SAS Slow adjust screw
SRS Supplemental restraint system
STO Standard
TAS Throttle adjust screw
TCS Traction control system
TCU Time control unit
Tr Transistor
TVvalve Thermal vacuum valve
us Under size
VENT Ventilation
VTC Calve timing control
VVTvalve Venturi vacuum transducer
MAIN UNITS CONVERSION
Acceleration m/s2 G 9.80665

Torque, moment N-m kgf-m 9.80665
Force N kgf 9.80665
MPa kgf/cm 2 0.0980665
Pressure
kPa mmHg 0.133322
kW PS 0.735499
Power
w kcal/h 1.16279
Volume cm 3 ce 1
Spring constant N/mm kgf/mm 9.80665
Fuel consumption rate * g/kW-h g/ps-h 1.3596
* Meter unit that can be used in SI unit
Gl-16
GENERAL INFORMATION
,,,,.,.,....--..'.
4WD INSPECTION & REPAIR PRECAUTIONS
Follow the precautions below to measure the speedometer reading and to check braking
performance in 4WD mode.
SPEEDOMETER MEASUREMENT
Two methods of measuring the speedometer are described below:
1. Measurement with front wheels jacked up
• Place the rear wheels on the roller.
• Jack up the vehicle front using the adapter and support
with rigid rack. ..---------~--____,,
• Place the transmission in 2nd gear for manual transmis- Front ~
<;S Adapter
sion vehicle and release the clutch slowly and increase __.,r=J.~
4519 0000
the speed. For automatic vehicles place the shift lever
in 2nd and increase the speed gradually.
• When the test is completed, do not apply the brakes
suddenly.
Caution:
Place the jack securely, and perform the measurement
after making sure the vehicle is stable.
Use the free rollers whenever possible.
2. Measurement using simple free roller

• Set the simple free roller the length of the wheel base
(2720 mm) forward of the centre of the measurement
roller as shown in the diagram. Wheel base
2720mm
• Place the front wheel on the free rollers and the rear
wheels on the measurement rollers.
• Place in 2nd gear for manual transmission vehicles and
<]= Front
gradually release the clutch. Far automatic vehicles place
the shift lever in 2nd and increase the speed gradually.
• When the test is completed, do not apply the brakes
suddenly. CoL~
_____ , ,: ) t :1
\
r-- \_ _j
'\""
Free roller Measurement roller
BRAKING PERFORMANCE CHECK
Measure using the low velocity type tester.
1 . Front wheel braking inspection

• Place the front wheels on the tester.
• Place change lever to neutral position.
• Measure the brake perfomance of foot brake.
2. Rear wheel braking inspection

• Orive system must be setto 2WD mode.
• Place the rear wheels on the tester.
• Place change lever to neutral position.
• Measure the brake performance of hand brake and
foot brake.
Gl-17
GENERAL INFORMATION
2WD setting
There are 2 methods to change the drive mode to 2WD lnstrument panel lower right
setting:
1. Remove airevacuation connector, and depress the brake
Pedal 5 times within 1Oseconds after placing the ignition ~ - -
switch to ON position. At the same time the 4WD warn-
ing lamp will flash in the meter panel (twice in a second)
to indicate it is in 2WD mode. To return the vehicle drive
1
\
l
Air evacuation
nnector
mode to 4WD mode, place the ignition switch to OFF

position and connect air evacuation connector.
2. Remove front propeller shaft.
4WD VEHICLE TOWING PRECAUTIONS
Towing precautions
Never tow a 4WD vehicle for a distance over 30 km and do not exceed speed limit of 30
km/ h.
Never tow a 4WD vehicle with front or rear wheels raised and opposite rear or front wheels
on the ground as this may cause serious damage to the transaxle.
Gl-18
Contents
SECTION EN
ENGINE
CONTENTS
EN1 SPECIAL SERVICE TOOLS ........................................................................ EM-8
SYSTEM DIAGRAM ................................................................................... EN-11
EN2 MAINTENANCE
1. ldle speed / lgnition timing / ldle mixture ratio inspection
(RB20E / RB25DE / RB25DET / RB26DETT) .................................... EN-15
2. Compression pressure inspection
3. Auxiliary belt tension
4. Brake hose
5. Brake fluid
6. Master cylinder cap, wheel cylinder cap, disc calliper cap & dust seal
(RB20E / RB25DE / RB25DET) ......................................................... EN-26
(RB26DETT) ...................................................................................... EN-41
7. Spark plug
(RB25DE / RB25DET) ........................................................................ EN-43
(RB26DETT) ...................................................................................... EN-45
8. Timing belt
(RB20E) ............................................................................................. EN-4 7
(RB25DE / RB25DET) ........................................................................ EN-53
(RB26DETT) ...................................................................................... EN-58
9. Engine oil
1O. Oil filter
11. Coolant
EN-1
CONTENTS
EN3 ENGINE MECHANICAL

(RB20E ENGINE)
1. Air cleaner & air duct.. ........................................................................ EN-67
2. lntake manifold col lector .................................................................... EN-68
3. Fue! injector ........................................................................................ EN-71
4. lntake manifold ................................................................................... EN-73
5. Exhaust manifold ................................................................................ EN-76
6. Rocker cover ...................................................................................... EN-78
7. Rocker shaft ....................................................................................... EN-79
8. Cam shaft ........................................................................................... EN-83
9. Cylinder head gasket ......................................................................... EN-87
1O. Oil pan & oil filter ................................................................................ EN-90
11. Collector ASSY ................................................................................... EN-92
12. Oil pump ............................................................................................. EN-94
13. Cooling fan ......................................................................................... EN-97
14. Water pump ...................................................·..................................... EN-98
15. Thermostat & water inlet .................................................................. EN-100
16. Water outlet ...................................................................................... EN-102
Refer to RB26DETT for the following:
• Fuel tank .......................................................................................... EN-240
• Fuel pump & fuel gauge ···········••n••···································••n••·········EN-245
Refer to RB25DE / RB25DET for the following:

• Exhaust system ................................................................................. EN-144
• Dual mode muffler ......................... n••··································· .. ·········· EN-146
(RB25DE / RB25DET ENGINE)

1. Air cleaner & air duct.. ...................................................................... EN-103
2. lntake manifold collector .................................................................. EN-105
3. Fuel injector ...................................................................................... EN-108
4. lntake manifold ................................................................................. EN-111
5. Exhaust manifold .............................................................................. EN-115
6. Rocker cover .................................................................................... EN-118
7. Oil pan & oil filter .............................................................................. EN-120
8. Cam shaft ......................................................................................... EN-122
9. Cylinder head gasket ..................... .................................................. EN-128
10. Oil pump ........................................................................................... EN-131
11.· Radiator ............................................................................................ EN-134
12. Cooling fan ....................................................................................... EN-136
13. Auxiliary motor fan ........................................................................... E N-137
14. Water pump ...................................................................................... EN-138
EN-2
CONTENTS
15. Thermostat & water i nlet .................................................................. EN-140

16. Accelerator control system ............................................................... EN-142
17. Exhaust system ................................................................................ EN-144
18. Dual mode muffler ............................................................................ EN-146
Refer to RB26DETT far the following:
Fuel tank .......................................................................................... EN-240
Fuel pump & fuel gauge ................................................................... EN-245
(RB25DET ENGINE)
1. lnter-cooler ....................................................................................... EN-148
2. Turbo-charger ................................................................................... EN-150
3. Oil filter bracket & oil cooler ............................................................. EN-156
(RB26DETT ENGINE)
1. Air cleaner & air duct ........................................................................ EN-158
2. lnter-cooler ....................................................................................... EN-160
3. Fuel injector ...................................................................................... EN-164
4. lntake manifold collector .................................................................. EN-166
5. lntake manifold ........................ .'........................................................ EN-174
6. Turbo-charger & Exhaust manifold ................................................... EN-178
7. Rocker cover .................................................................................... EN-188
8. Oíl pan & oil filter .............................................................................. EN-190
9. Cam shaft ......................................................................................... EN-193
10. Val ve clearance ................................................................................ EN-198
11. Cylinder head gasket ....................................................................... EN-200
12. Cylinder head ................................................................................... EN-203
,,,- ._
13. Cylinder block ................................................................................... EN-209
14. Oil pump ............................. ............................................................ .. EN-226
15. Oil filter bracket & water-cooled oil cooler ........................................ EN-228
16. Air-cooled oil cooler (N 1 ve hiele) ..................................................... EN-231
17. Radiator ............................................................................................ EN-233
18. Cooling fan ....................................................................................... EN-235
19. Auxiliary motor tan ........................................................................... EN-236
20. Water pump ...................................................................................... EN-237
21. Accel control system ........................................................................ EN-239
22. Fue! tank .... .. ..... .. .. ........................................................................... EN-240
23. Fuel pump & fuel gauge ................................................................... EN-245
24. Exhaust system .. ...................................................... ..... .. ................. EN-248
EN-3
CONTENTS
EN4 ENGINE REMOVAL

(RB20E) .................................................................................................... EN-250
(RB25DE / RB25DET) .............................................................................. EN-254
(RB26DETT) ............................................................................................. EN-259
EN5 SYSTEM OUTLINE

Circuit diagram & ECCS control unit pin layout
(RB20E) .................................................................................................... EN-263
(RB25DE / RB25DET) .............................................................................. EN-265
(RB26DETT) ............................................................................................. EN-267
EN6 ECCS (ELECTRONICALLY CONCENTRATED ENGINE CONTROL SYSTEM

1. For accurate & quick diagnosis ........................................................ EN-269
2. Diagnosis items by phenomenon ..................................................... EN-275
3. Diagnostic system ............................................................................ EN-294
4. Self-diagnosis ................................................................................... EN-296
5. Consult ............................................................................................. EN-301
6. Basic inspection
(RB20E / RB26DETT) ...................................................................... EN-307
(RB25DE / RB25DET) ...................................................................... EN-309
EN7 FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM

1. Power supply and earth circuit ......................................................... EN-312
2. Crank angle sensor system (Self-diagnosis display 11) ................... EN-314
3. Airflow meter system (Self-diagnosis display 12) ............................ EN-316
4. Water temperature sensor system (Self-diagnosis display 13) ........ EN-318
5. lgnition system (Self-diagnosis display 21) ...................................... EN-319
6. 02 sensor system (Self-diagnosis display 15) ................................. EN-321
7. Detonation sensor system (Self-diagnosis display 34) .................... EN-322
8. Throttle sensor system (Self-diagnosis display 43) .......................... EN-323
9. A/ T control system (Self-diagnosis display 54 ) ............................... EN-324
1O. Crank angle sensor system (Not in self-diagnosis) .......................... EN-325
(RB26DETT ENGINE)
1. Power supply and earth circuit ......................................................... EN-326
2. Crank angle sensor system (Self-diagnosis display 11 ) ................... EN-328
3. Air flow meter system (Self-diag nosis display 12) ............................ EN-330
EN-4
CONTENTS
4. Water temperature sensor system (Self-diagnosis display 13) ........ EN-332

--··
.
5. lgnition system (Self-diagnosis display 21) ...................................... EN-334

6. Detonation sensor system (Self-diagnosis display 34) .................... EN-336
7. lntake air temperature sensor system (Self-diagnosis display 41 ) ... EN-338
8. Throttle sensor system (Self-diagnosis display 43) .......................... EN-340
9. 02 sensor system ............................................................................ EN-342
10. Component parts inspection
1. Crank angle sensor .................................................................... EN-334
2. Air flow meter ............................................................................. EN-334
3. Water temperature sensor ......................................................... EN-334
4. Power transistor ......................................................................... EN-345
5. lntake air temperature sensor .................................................... EN-345
6. Throttle sensor .......................................................................... EN-.345
7. ECCS relay ................................................................................ EN-345
EN8 SYSTEM FAULT DIAGNOSIS

1. Fuel pump system control ................................................................ EN-346
2. lgnition signa! - 1 .............................................................................. EN-348
3. lgnition signa! - 2 .............................................................................. EN-350
4. lnjector system inspection ................................................................ EN-351
5. Vehicle speed sensor system ........................................................... EN-353
6. Air conditioner re lay system ............................................................. EN-354
7. Exhaust gas sensor heater system .................................................. EN-355
8. Throttle valve switch system ............................................................ EN-356
9. START signa! ................................................................................... EN-358
1O. AAC valve system ............................................................................ EN-389
11. Air regulator ...................................................................................... EN-360
12. Power steering oil pressure signal ................................................... EN-362
13. Components parts ínspection
1. Crank angle sensor .................................................................... EN-363
2. Air flow meter ............................................................................. EN-363
3. Water temperature sensor.......................................................... EN-363
4. lgnition coi! ................................................................................. EN-364
5. Power transistor ......................................................................... EN-364
6. Fuel pump .................................................................................. EN-364
7. Throttle valve switch ................................................................... EN-364
8. Throttle sensor ..................................................... .... .................. EN-365
9. AAC valve ...... ............................................................................. EN-365
10. FICD solenoid ....................................................................... ..... EN-365
11. Air regulator ................................................................................ EN-366
EN-5
CONTENTS
12. lnjector ..... .................................................................................. EN-366

13. lgnition relay & lnhibitor relay ..................................................... EN-366
14. Power steering hydraulic pressure inspection ............................ EN-366
(RB26DETT ENGINE)
1. Fuel pump system inspection ........................................................... EN-367
2. lnjector system inspection ................................................................ EN-370
3. lgnition system inspection ................................................................ EN-373
4. AAC val ve system ............................................................................ EN-376
5. lnjector pulse .................................................................................... EN-378
6. Boost control .................................................................................... EN-379
7. Air conditioner cut control. ................................................................ EN-381
9. 02 sensor heater system ................................................................. EN-384
1O. Vehicle speed sensor system ........................................................... EN-385
11. lgnition switch (START) signal ......................................................... EN-386
12. Power steering oil pressure signal ................................................... EN-387
13. Neutral signal ................................................................................... EN-388
14. Air conditioner operation signa! ........................................................ EN-389
15. Air regulator signa! ........................................................................... EN-390
16. Supplemental motor fan control ....................................................... EN-392
17. Component parts inspectíon
1. lgnition coil ................................................................................. EN-394
2. lgnition coil relay ........................................................................ EN-394
3. Throttle val ve switch ................................................................... EN-394
4. lnjector ....................................................................................... EN-395
5. Dropping resistor ........................................................................ EN-395
6. Fuel pump .................................................................................. EN-395
7. Fue! pump control modulator ..................................................... EN-395
8. 02 sensor heater ....................................................................... EN-395
9. Air regu lator ................................................................................ EN-396
10. AAC valve ................................................................................... EN-396
11. Boost control sol e no id ................................................................ EN-396
12. Supplementary power fan motor ................................................ EN-396
13. Power steering oil pressure switch ............................................ EN-397
14. Supplementary motor fan relay & fuel pump relay ..................... EN-397
15. Water temperature switch .......................................................... EN-397
EN-6
CONTENTS
EN9 SYSTEM DIAGNOSIS INSPECTION

(RB20E ENGINE)
1. Fuel pump system ............................................................................ EN-398
2. lnjector system ................................................................................. EN-401
3. lgnition system ................................................................................. EN-404
4. ldle speed control system ................................................................ EN-408
5. Crank angle sensor system .............................................................. EN-41 O
6. Air flow meter sensor system ........................................................... EN-413
8. Th rottle sensor system ..................................................................... EN-419
9. Engine temperature sensor system ................................................. EN-422
1O. 02 sensor heater system ................................................................. EN-424
11 . Detonation sensor system ................................................................ EN-426
12. Vehicle speed sensor system ........................................................... EN-427
EN10 ECCS CONTROL UNIT INPUT/ OUTPUT SIGNAL

(RB26DETT) .................................................................................... EN-428
(RB20E) ........................................................................................... EN-436
(RB25DE / RB25DET) ...................................................................... EN-444
EN-7
TOOLS
EN 1 SPECIAL SERVICE TOOLS
Spark plug wrench Removal & installation of

EG1740 1600 spark plug
Electronic system Program card

7.
diagnosis tester _,,- ,, Fuel pressure removal
,...· h
CONSULT Engine rev adjustment
EG1180 0000
Vacuum handy pump Recirculation valve

EG1513 0000 inspection (RB25DE)
Seat cutter
KV101 11100 Oil pan removal
Tube pressor
WS3993 Liquid gasket lubrication
Ring gear stopper

KV101 104S0
1. Adapter KV101 10410 Fly-wheel, drive plate
2. Stopper plate installation
KV101 05610 2
Pulley puller
KV111 03000 Crank pulley removal
Pulley holder Cam timing pulley removal

KV101 09900 & installation (RB20E)
Pulley holder Cam timing pulley removal

KV101 09300 & installation (RB20E)
EN-8
TOOLS
Compound gauge Turbo charger pressure

EG1508 0001 inspection (RB25DET)
Pressure gauge Turbocharger swing valve

(For LPG vaporizer inspection) controller inspection
ST1957 2000 (B25DET)
Angle wrench
lnstallation angle check
KV101 12100
Valve spring compressor Valve collet installation &

KV101 10601 removal (RB20E)
1. Valve spring
compressor
KV101 09210 Valve collet installation &
removal (RB20E)
2. Adapter
KV101 11200
Valve sprint compressor Valve collet installation &

ST1207 0000 removal (RB20E)
Valve spring compressor Valve collet installation &

KV101 089S0 removal (RB25DE / DET)
Valve oil seal puller

Valve oil seal removal
KV101 07900
Valve guide drift Valve guide ínstallation &

KV101 11000 (intake) removal (RB20E)
ST1103 3000 (exhaust)
Valve guide drift Valve guide installation &
KV101 11800 removal (RB25DE / DET)
EN-9
TOOLS
Valve guide reamer

(lntake)
KV101 07700 (<t:>11.2)
Valve guide installation
KV101 08400 (<t:>7.0)
(Exhaust) (RB20E)
ST1103 2000 (<t:>12.0)
ST1108 1000 (<t:>8.0)
Valve guide reamer set
Valve guide installation
HT5628 (<t:>9.5 ~ <f:>12)
(R825DE / RB25DET)
HT5627 (<t:>6.35 ~ <f:>9.5)
Valve oil seal drift Valve oi I seal installation

KV101 07501 (RB20E)
Valve oil seal drift

1. Body KV101 07501 Valve oil seal installation
2. Attachment (RB25DE / RB25DET)
KV101 11400
Engine stand ASSY

ST0501 S000
Engine overhaul
Engine attachment
KV101 06500
Engine sub attachment

KV101 14500 Engine overhaul
Pilot bearing puller Pilot converter, pilot bush

ST1661 0001 removal
Rear oil seal drift

1. KV401 00900 Rear oil seal installation
2. ST3002 2000
EN-10
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Air regulator *
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:lle sensor ECCS control unít tD
r,.:,
Fuel pump o
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......
......
-a?. o m
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Monitor & check m
light (red light) z
<? From fuel t~-nk J Fuel control signa! lg ~ 1~ ~ ~- ~
ru "'
,-· o, ►
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Spark plug (Q
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·ransmission·
unit "'
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Swing valve
3-way catalytic converter

Vehicle speed sensor (f)
Muffier
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' - - - - - A/ T control unit -,
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Air cleaner s::
Exhaust temperature senso1
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Q 9!.
Power transistor unit
FICD solenoid
ECCS control unit
:;o
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'hrottle va lve !'iwjtcp , , 1 "'e
UI
m m
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1 uel control signal
Fuel pump m
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I\J
Temperatul
Canister 11 tahk (!)
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light (red light) z
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3 Neutral
lgnition coil clSc;1-
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Crank angle sensor

i i l"I ! ~ -
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Transmission
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(/)
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Vehicle speed sensor
m
Muffler s:
Exhaust temperatura warning lamp
/ T control unit o
Exhaust temperatura sensor
:i.
~ IGN power ►
G)
Switching module ~
~
Air flow metér Air deaner
/
) ¡
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AAC valve control signal
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Air regulator o a.
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Power transistor :::,
~
ehicle speed signar
ECCS control unit n
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canister z m
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sensor Swilching module
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SYSTEM DIAGRAM
RB25DET ENGINE
SYSTEM DIAGRAM
RB25DET ENGINE
o.
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Engine A/í fusion control signal
·e::::,
O sensor output signal
ge lntake air mass signal
8 Knock sensor output signal
(/)
(.) 0 2 sensor output signal
ü
w
ldle control signa
Power steering signal

Variable valve timing control signal =:¡¡
o
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EN-14
MAINTENANCE
RB20E / RB25DE / RB25DET / RB26DETT ENGINE
EN2 MAINTENANCE
1. IDLE SPEED / IGNITION TIMING / IDLE MIXTURE RATIO INSPECTION
A/ T 650
20 +/- 2/600 +/- 50
M/T 600
M/T
(Approx. 800 rpm) Below 0.1 /
20 +/- 2/600 +/- 50
650 (Approx. 800 rpm) 15 +/- 2/650 +/- 50 below 50
650 (Approx. 800 rpm) 15 +/- 2/650 +/- 50
950 +/- 50 21 +/- 1/950 +/- 50
IDLE INSPECTION & ADJUSTMENT

Engine speed measurement unit ~
• Warm the engine sufficiently. ~
• Connect CONSULT to diagnosis connector on the
CONSULT • IS
vehicle (near the fuse block). Place the ignition switch ector
~
to ON position.
"
(RB20E)
(RB20E)
• Connect the measurement unit to the speed
®
detection terminal by connecting the adapter harness
far the mould coil between the coil primary terminal
and the primary terminal harness connector.
(RB25DE / RB25DET / RB26DETT)

• Connect the measurement unit to the speed
detection terminal harness connected to the
ignition coil from the power transistor.
• When the measurement is complete, always replace
®
the terminal cap on the detection terminals.
Caution:
Check the specification for the measurement unit befare
using the unit as the generation voltage is set to 6V.
lnspection
• Make sure the A/ C load, power steering oil pump load
and each electrical loads are not applied. Place the
select lever in 'N' position for automatic vehicles.
Caution:
Befare inspection when the accelerator pedal is not
depressed, make sure the throttle valve switch (idle
,,---. connection point) is turned to ON.
EN-15
MAINTENANCE
• Check "CAS.RPM (REF)" for RB20E and, ~
-~ONITORING'fl' NO FAULT [;J
"CAS.RPM (POS)" for RB25DE / RB25DET / ~ CAS.RPM (POS) 662rpm
RB26DETT engines. AIR FLOW MTR 1.12V
ENG COOLANTTEMP SEN 83°C
• Carry out the inspection using the engine speed fu'\ 02 SEN 0.37V
measurement unit. ~ 02 SEN MONITOR LEAN
VEHICLE SPEED SEN Okm/h
BATTERY VOL 14.0V
Adjustment THROTTLE SEN 0.40V
ldle adjustment is basically not necessary as the rated RECORD
value (control target value) is returned to the control unit.

lf adjustment becomes necessary, carry out the proce-
dure below.
• Select "AAC valve adjustment" in "Work support"

mode. Adjust the engine rev to set value by turning idle
00 ♦ AAC VALVE ADJ ♦O
Adjustment monitor
adjustment screw in IAA unit using a screw driver. CAS.RPM (POS) 612rpm
Engine rev set value (rpm)
Condition setting
RB20E (M / T) 600 AAC valve Guide fixed
RB20E (A/ T) / RB25DE / RB25DET 650
RB26DETT 900 Monitor
ENG TEMP SEN 83ºC
IDLE SW ON
• Return "AAC valve adjustment" screen to "DATA moni-
tor" and check if the idle speed displayed meets the
specification.
Red lamp
• Make sure the ECCS C/U idle control adjustment@ ~ RB20E

volume is turned to left completely.
Caution:
Do not turn the idle control adjustment volume with exces-
..;;;;;"'"';;;;;~J;;;;;;;;;;;~~ RB25DE /
sive force. The adjustment screw turning range is 3/4 of ~ll:;;;;;;;;;:;;;;;
.....,. r-::-.. at) @ RB25DET 1
~:~••H@A·
a turn. ~~=====1,...,=1== RB26DETT
(RB20E / RB25DE / RB25DET)

• Remove throttle sensor harness connector to stop idle ~11 I
rev feed back control (at this time, AAC valve will fix at
1/
idle set opening).
/
Throttle sensor harness connector
(RB26DETT)
(RB26DETT) IBelow intake manifold collector]
Harness connec1or AAC valve
• Remove AAC valve harness connector to stop idle rev
feedback control (at this time, AAC valve will fix at idle
set opening).
EN-16
MAINTENANCE
• Tum the IM unit idle adjustment screw using a screw
driver to adjust the engine rev.
Engine rev set value (rpm)
RB20E (M / T) 600
RB20E (A/ T) / RB25DE / RB25DET 650
RB26DETT 900
• Engine rev will increase when the idle adjust screw is
turned anticlockwise and decrease when it is turned
clockwise.
• Reconnect the throttle sensor harness connector and
make sure the idle speed is maintained at specified
value.
(RB26DETT)
• Reconnect the MC valve harness connector and
make sure the idle speed is maintaíned at specified
value.
• lf you wish to increase idle speed for any reason,

adjust the idle control adjustment volume in ECCS
control unit. Turn it clockwise to increase the engine RB20E
rev. Maximum volume is approx. 250 rpm.

Red lamp
Caution: ~w;:::-:__:=_=_~=c4-=f;:.....r1-;::¡.
rt:= RB25DE /
l ?;;¡:J~~J
The adjustment volume must be set at 40° ~ 50° away ©! RB25DET /
from the self-diagnosis position as if it is turned all the way ~-~~"""""~-""---do:;;i,,,,_ RB26DETT
to the right (self-diagnosis position), the idle speed is low-

ered (lowest rpm +50).
IGNITION TIMING INSPECTION & ADJUSTMENT (RB20E)

Timing light attachment
(RB20E)
• Connect the timing light using the mold coil adaptar
harness. The timing light collects the signal from the
primary terminal of super-tuner. (For normal timing
light, connect the sensor to the No.1 high-tension ca-
ble).

Left strut tow
(RB25DE / RB25DET / RB26DETT) imin
When using super-tuner
• Connect the super-tuner to the timing detection
terminal.
Caution:
After inspection make sure to place a hole cap on the tim-
ing detection terminal (check connector).
EN-17
MAINTENANCE
When using a primary electrical detection timing light
• Connect sensor to No. 1 cylinder primary ray when
using EG1443 0001 or EG1444 0000 (No. 1 cylinder
primary ray is longer than other cylinders).
Caution:
When using EG1444 0000 (Built-in battery type), tace the
sensor (direction of the arrow) to spark plug when connect-
ing the sensor to the primary ray.
lnspection
• Make sure the idle speed is at standard value.
• Check that ignition timing is at standard value when
Ijmin
___ , ' ) indicator
,....
idling.
RB20E (A/ T) 20º +/- 2º / 650 +/- 50rpm
RB20E (M / T) 20º +/- 2° / 600 +/- 50rpm
RB25DE / RB25DET 15º +/- 1° / 650 +/- 50rpm
o 10 20
RB26DETT 20º +/- 1° / 950 +/- 50rpm
• Make sure the ignition timing advances to correct (BlUC º)
angle when engine is raced.
Caution:
0° timing mark on the crank pulley is indicated in orange
and other points are painted in white.
Adjustment
(RB20E) (RB20E)
• lgnition timing can be adjusted by adjusting the ,.:.__ __;__B_ol-t(-se-a-lín_g_t-ap_e_p_os-it-io-n)--.
distributor installation position. Rotor rotation direction
• Remove throttle sensor connector.
• Loosen the distributor installation bolt and rotate the
distributor. Turn the distributor clockwise to advance
ignition timing.
• Connect the throttle sensor connector. To advance ignition timing
• After checking the idle rev and making sure it is at set

value, seal the distributor installation bolts with sealing
tape.
Sealing tape part No. B2235 U7410

The ignition timing adjustment is basically not necessary (RB25DE / RB25DET / RB26DETT)
as the ignition timing will not change over time. lf adjust- Sealing tape position
To advance ignition timing
ment becomes necessary, carry out the adjustment when
installing the crank angle sensor.
• Adjust the ignition timing by adjusting the crank angle
sensor installation position. I
• Remove throttle sensor connector. Cam shaft rotation
EN-18
MAINTENANCE
RB20E / RB25DE / RB25DET / RB26DETT EN GIN E
• Loosen 3 crank angle sensor installation bolts and

rotate the crank angle sensor. Turn the sensor anti-
clockwise to advance ignition timing.
• Connect the throttle sensor connector.
• After checking the idle rev and making sure it is at set
value, tighten the bolts and seal one of the crank angle
sensor installation bolt with sealing tape.
Sealing tape part No. B2235 U741 O
IDLE MIXTURE RATIO

The air-fuel ratio feedback system has a self-learning
function. CO and HC density adjustment is not necessary
as correction range is extensive.
lnspection
• Warm up the engine sufficiently and make sure the idle
speed and the ignition timing are at standard value.
Check CO and HC density with CO and HC meter.
• lf the values do not conform to standard value, perform
following procedures to inspect air-fuel feedback · ~ONITORIN~ NO FAULT W
condition: CAS.RPM (POS) 2000rpm
AIR FLOWMTR 1.61V
ENG COOLANT TEMP SEN B0ºC
•
•
In the "DATA MONITOR" mode, select "02
sensor monitor".
lncrease the engine rev to above 2000rpm and make
00 0 2 SENSOR
0 2 SENSOR MONITOR
VEHICLE SPEED SEN
0.52V
RICH
0km/h
BATTERYVOL 14.0V
sure "RICH" and "LEAN" are displayed alternatively. THROTTLE SEN 054V
RECORD
• Short-circuit the self-diagnosis connector on the fa\
vehicle side (within fuse block). OR remove the ~ r,;:¡;::::::::¡::::;::::::::::;::;;;:::==::~=;aa===:=:=:==a===;;=~5':"i'i:"':'51
Eccs COn t ro1Uíll·t an d Operate th8 8d'JUStmen t VOIUme o-c1rcu1ttesep1nsorapprox. seconsten
pen to change diagnosis mode. The mode will
on the control unit side. hange each time this operatíon is perform~
• Place the ignition switch to the ON position and use

a lead line to short-circuit the CHK and IGN pin of the
diagnosis connector for more than two seconds to re-
lease the setting. OR
Place the ignitíon switch to ON position and turn the
adjustment volume on ECCS control unit side
clockwise (self-diagnosis position) for more than two
seconds and then return to normal position.
• After warming up the engine sufficiently, raise the

engine speed until the engine warning lamp (or ECCS
control unit side red lamp) flashes (the flashing will
usually start above approx. 2000rpm).
Caution:
The accelerator pedal must be pressed lightly during idling ~
~-=~
to perform the inspection as the air-fuel ratio feed back Red lamp
// ! ""
Engine warning lamp
'--------------'
control is clamped.
EN-19
MAINTENANCE
R820E / RB25DE / RB25DET / RB26DETT ENGINE
2. COMPRESSION PRESSURE INSPECTION
1.23/300 {12.5/300} 0.93/300 {9.5/300} 0.10/300 {10./300}

1.26/300 {12.8/300} 0.96/300 {9.8/300} 0.10/300 {1.0/300}
1.20/300 {12.2/300} 0.90/300 {9.2/300} 0.10/300 {1.0/300}
1.18/300 {12.0/300} 0.88/300 {9.0/300} 0.10/300 {1.0/300}
1. Warm up the engine sufficiently.

2. Release the fuel pressure.
3. Place the ignition switch to OFF position.
4. Remove all six spark plugs using the spark plug
wrench.
Note:
When removing the spark plugs make sure to blow around
the spark plug with compressed air.
5. lnstall engine rev counter or CONSULT.
6. Remove injection harness connector.
7. lnstall adapter to allen compression gauge and then (RB25DE / RB25DET)
r'--------'-------,
set to engine. EG1sos 0000
8. Depress the accelerator pedal fully. Place the
ignition switch to START position and crank the
engine. Read compression pressure and engine
speed once the gauge needle stop moving. Carry out
the above operation for each cylinder.
• When the engine speed is out of specification, check
L...,____,;Li...!...~.......l.l.~-.....C:::::..--___J
the specific gravity of the battery and perform test
again.
• lf the compression pressure is still not in standard
value, inspect the components around the combustion
chamber (valve, valve seat, hydraulic valve lifter,
pistan, piston ring, cylinder bore, cylinder head,
cylinder head gasket etc.). Correct any malfunction
parts and repeat compression test.
EN-20
MAINTENANCE
3. AUXILIARY BELT TENSION
382 ~ 470
225 {23} 8 ~ 10 9 ~ 11 15
{39 ~ 48}
666 ~ 755 558 ~ 647

284 {29} 6~8 7~9 12
{68 ~ 77} {57 ~ 66}
666 ~ 775 558 ~ 647

284 {29} 3~5 4~6 7.5
{68 ~ 77} {57 ~ 66}
lnspection
Fan belt Power steering pump belt
,-·-
• The inspection should be performed when the engine
is cold or more than thirty minutes after the engine has
been stopped.
• When carrying out the inspection, apply pressure
98N{10kg} to "T" position shown in the diagram.
• When carrying out the inspection using the tension

meter set it to "T" position shown. KV9910 5600
• The operation can be done at different positions when
it is difficult to carry out the i nspection at "T" position.
Adjustment
Power steering Adjustment bolt on the power

belt steering pump
A/ C compressor
Adjustment bolt on the idler pulley
belt
Fan belt Adjustment bolt on the alternator
Caution:
• When replacing the belt with new ones, increase the
tension slightly more than used belt to allow for wear-in
of the new belt.
• When adjusting the belts, if the belt deflection exceeds
the limit, adjust to the 'Adjustment value'.
• Make sure the pulley groove is aligned correctly when
the belt is installed.
• Make sure there is no grease or water adhered to
belts.
• Do not bend or twist belts unnecessarily.
EN-21
MAINTENANCE
Removal
1 . Remove the power steering pump by loosening the
power steering bolt.
2. Remove the compressor belt by loosening the bolt
located by idler pulley.
3. Remove the tan belt by loosening the adjustment bolt
located by alternator.
4. Shift power steering pump to remove the power
steering pump belt.
lnstallation
Carry out the operation in reverse arder to install.
EN-22
MAINTENANCE
4. BRAKE HOSE
Caution:
Make sure there are no twist or fold when installing the
brake hose.
• There are no friction between parts when the steering

wheel is turned fully right or left.
• lf brake fluid leak is detected disassemble the parts
and replace with new one if there is any fault.
Replacement period: Every 4 years
Removal
1. Connect vinyl tube to air breather.
2. Depress the brake pedal to discharge brake fluid from
each air breather.
3. Place a cover so the dust or foreign objects will not
enter brake fluid line connection parts.
4. Carry out the procedures below to remove the brake

hose: Vehicle s·
[Vehicle with CL25VA & CL25VD type calliper] Brake ho
(1) Disconnect the brake hose and the brake tube by

removing the fiare nut on the brake tube using the
fiare nut wrench.
(2) Remove the union bolt to detach calliper ASSY and
brake hose.
(3) Remove lock plate.
l:[
(4) Remove brake hose from the vehicle by removing the
brake hose installation nut.
[Vehicle with OPZ25VB type calliper]

t
Calliper side
~-la--.._re~ t
(1) Remove the brake tube fiare nut on both vehicle and ~
--...____ '
calliper side using the fiare nut wrench.
(2) Remove lock plate. Vehicle sid
(3) Remove brake hose installation nut to remove brake t
Lock- ~
hose from the vehicle.
Brake hose
install ·
íl
EN-23
MAINTENANCE
[Vehicle with A09 type calliper] ¡
(1) Disconnect the brake hose and the brake tube by
removing the fiare nut on the vehicle side brake tube
using the fiare nut wrench.
(2) Remove the union bolt to detach calliper ASSY and
brake hose.
(3) Remove the lock plate and the brake hose from the
vehicle.
[Vehicle with OPZ11V type calliper]

(1) Remove the brake tube fiare nut on both vehicle and
calliper side using the fiare nut wrench.
(2) Remove lock plate.
(3) Remove brake hose installation bolt to remove brake
hose from the vehicle.
lnstallation
1 . Carry out the procedures below to install the brake
hose:
[Vehicle with CL25VA, CL25VD & AD9 type calliper]

(1) lnstall the brake hose to calliper ASSY and tighten
union bolt to specified torque.
Tightening torque (N-m{kg-m}) 17 - 20 {1.7 - 2.0}
(2) lnstall the brake hose to vehicle side brake tube and
tighten the fiare nut with your finger. Use lock plate to
fix in place and tighten bolt to specified torque.
[Vehicle with OPZ25VB & OPZ11V type calliper]

(1) lnstall the brake hose to brake tube and tighten fiare
nut with your hand to install to bracket. After fixing
with lock plate tighten bolt to specified torque.
(2) Fix the brake hose to the vehicle and tighten

installation bolt or nut to specified torque.
Tightening torque (N-m{kg-m}) 20 - 23 {2.0 ~ 2.3}
2. Release air after the operation.
EN-24
MAINTENANCE
5. BRAKE FLUID
Removal
each air breather.
Topping up brake fluid

[Vehicle without ABS device]
1. Clean inside the reservoir tank and top up with new
brake fluid.
2. Connect vinyl tube to rear left wheel cylinder air
breather to open air breather.
3. Slowly depress the brake pedal fully then release. Wait
for 2 to 3 seconds then again slowly depress the brake
pedal fully. Repeat the procedure until new brake fluid
start to emerge. Glose the air breather while depress-
ing the brake pedal.
4. Depress the brake pedal few times then hold the pedal
in depressed position. Loasen rear left wheel air
breather to release the air, then tighten quickly.
5. Tighten rear breather to specified torque.
Tightening torque (N-m{kg-m}) 6.9 ~ 8.8 {0.7 ~ 0.9}
6. Repeat procedures 2 to 5 for rear right wheel calliper,

front left wheel calliper and front right wheel calliper.
[Vehicle with ABS device]

1. Place ignition switch to OFF position and disconnect
ABS actuator connector. OR remove battery terminal.
,,,-_ 2. Top up the master cylinder reservoir tank with brake
fluid. Carry out the air release operation (procedure
2 to 5 above) making sure reservoir tank is more than
half ful! with brake fluid at all time.
EN-25
MAINTENANCE
RB20E / RB25DE / RB25DET ENGINE
6. MASTER CYLINDER CAP, WHEEL CYLINDER CAP, CISC CALLIPER CAP
& DUST SEAL
Replacement period:
Master cylinder cap & dust seal Every 2 years
Wheel cylinder cap & dust seal Every 4 years
MASTER CYLINDER (RB20E / RB25DE / RB25DET)
Oil filler
Float
a
12-18{1.2-1.8}~
Air breather
Vehicle ~th AB~'------------, /
- :rokico ~ 6.8-8.8{0.7-0.9}
n
~~,. N-m{kg-m}
Cylinder body ~O-rfng __ Napeo 5.9-9.8{0.6-1.0}
IJ Nissan brake fluid -- Proportioning valve

Tokico m, 25-34{2.5~3.5}
~ Re place after every disassembly Napeo•-~ 44-54{4.5-5.5}
Removal
Caution:
Never remove proportioning valve from the master
cylinder.
1. Extract brake fluid from the reservoir tank.
2. Remove harness connector on fluid level sensor.
3. Detach master cylinder and the brake tube using the
fiare nut wrench.
4. Remove the master cylinder ASSY from the vehicle by
removing the installation nut.
lnstallation
1. Place brake tube fiare nut on the master cylinder and
tighten by hand.
2. lnstall master cylinder to brake booster ASSY and
tighten installation nut to specified torque.
Tightening torque (N-m{kg-m}) 12 ~ 18 {1.2 ~ 1.8}
3. Tighten brake tube fiare nut to specified torque.
Tightening torque (N-m{kg-m}) 15 ~ 18 {1.5 ~ 1.8}
4. Top up with new brake fluid and release the air.
EN-26
MAINTENANCE
Disassembly
1. lnsert a screwdriver into the tab and remove the
stopper cap. Hold down the stopper cap to avoid
piston pin inside the master cylinder from jumping
out.
2. Remove the pisten stopper from the cylinder body.

Use a phillips screwdriver to push the piston inwards
to remove the pisten stopper.
3. Pull out the primary piston ASSY straight so it will not

scratch inside wall of the cylinder.
4. Lightly tap the flange with soft objects such as small
block of wood etc. so it will not damage inside wall of
the cylinder and pull out the secondary pistan ASSY.
5. Remove the reservoir tank.
Caution:
Do not remove the reservoir tank unless necessary.
lnspection
Look for any wear, damage, rust or pinhole on the inside
wall of the cy!inder. Replace the cylinder if there is any
fault.
Assembly (Vehicle without ABS)

Caution: Secondary piston
• Never use gasoline or mineral oil when cleaning or
assembling the parts.
• Make sure there is no dust or any foreign objects on
the cylinder inside wall, piston or cup seal. Care must
~IDtJ
Primary piston
be taken not to damage the parts with tools when
assembling.
• Never drop any parts. Do not use the part if it has
i•w[]C]I]
been dropped or damaged in any way.
1. Coat inside the cylinder and the piston pin ASSY

contact surface with Nissan brake fluid No. 2500 or
Nissan rubber lubricant (KRE12-00030) and insert the
secondary piston ASSY into the cylinder body. Next
insert the primary piston ASSY.
EN-27
MAINTENANCE
2. Align the secondary piston centre slit to the pistan
stopper axle and fit them together. lnspect secondary
piston slit from the cylinder body pistan stopper
installation hole to install the pistan stopper.
Caution:
Always replace pistan stopper O-rlng with new ones.
3. lnstall stopper cap.
lnsert the pistan into the cylinder until it touches the
groove by holding the pistan down with new stopper
cap. Make sure the stopper cap tab is clipped to
the cylinder groove.
Caution:
Always replace stopper cap with new ones.
4. lnstall reservoir tank seal to master cylinder.
5. lnstall new reservoir tank to master cylinder.
Caution:
Always replace reservoir tank with new ones once they
have been removed.
FRONT DISC BRAKE RB20E / RB25DE / RB25DET

CL25VA
Union bolt r:9 Brake hose
17-20{1.7-2.0}
~ Pad wear sensor
c<C.:,
El
~
2Sl1de pin
Torque member 1nstallat1on
~ El 1Pin boots bolt 72-97{7.3-9.9}r:g
ember
Brake hose CL25VD

Cylinder body
- El l lnner shim cover . El 1

lnner shim Pad retamer
~ lnner pad
2 .
Union bolt
Arr breather
17-20{1.7-2.0}r:9
--~----s,. o
o
o
A 22-31 {2 2-3.2}
~ oc
6""~==
r:9 N-m{kg-m} Outer pad
~ Nissan brake fluid No. 2500 I] Piston Outer shim
El ! Pi
~ Replace afler every disassembly Piston boots ~ El 2 Torque member
El 1 Nissan disc brake grease
El 2Nissan rubber grease (KREOO 0001 O)
MAINTENANCE
[CL25VA & CL25VO]
Removal
each air breather.
3. Disassemble brake hose from the calliper ASSY by
removing the union bolts.
4. Remove calliper ASSY from the vehicle by removing
the torque member installation bolts.
5. Remove disc rotor.
lnstallation
1. lnstall brake hose to calliper ASSY and tighten the
union bolt by hand.
2. lnstall calliper ASSY to the vehicle and tighten ).,..!_l:i;;P.tA,7:-'i nion bolt
installation bolts to specified torque.
Tightening torque (N-m{kg-m}) 72 ~ 97{7.3 ~ 9.9} t
3. Tighten union bolt to specified torque.

Tightening torque (N-m{kg-m}) 17 ~ 20{1.7 - 2.0}
4. After installing the calliper ASSY, top up with new

brake fluid and release the air.
Disassembly
1. Remove pad, shim, shim cover and pad retainer from
the calliper ASSY.
2. Remove slide pin bolt and torque member from the
ir~,.~~
cylinder body.
3. Remove slide pin and slide pin boots from the torque ~
member.
CL25VA
4. lnsert a block of wood as shown in the diagram on
the right. Blow in sorne compressed air through union
bolt installation hale then remove pistan boots. At this
time, if one side of CL25V type pistan comes off, push
in the fallen pistan a little further into the cylinder body
and then blow with compressed air again.
CL25VD
EN-29
MAINTENANCE
5. Use screwdriver to remove piston seal. CL25VA
Caution:
Care must be taken not to damage inside the cylinder.
CL25VO
lnspection
• Look for any wear, damage, rust or pinhole on the
inside wall of the cylinder. Use sandpaper to remove
any rust. lf it is damaged or warn replace it with new
cylinder body.
• Check the piston surface for any rust, wear, damage
or foreign objects. lf there is any abnormality replace
it with a new pistan.
Caution:
Only use new brake fluid far cleaning. Never use
gasoline, benzine or mineral oil.
• Look for any wear, damage ar cracks on the slide pin

and disc rotor. lf any abnormality is found replace it
with a new ones.
(1) Fix the disc rotor to wheel hub by using the wheel
nut.
(2) Check the run-out using the dial gauge.
Caution:
Befare measurement make sure the axle end play is
below 0.05mm.
(3) lf the run-out is over the limit re attach the disc rotor
and the wheel hub by changing one hale for each and
measure the mínimum run-out value.
Measurement location Measure at 10mm
inside the radial
Run-out limit (mm) 0.07
• Use micrometer to measure the thickness of the disc
rotor. Replace if not at standard measure.
CL25VA (CL25VD)
Standard thickness (mm) 22 (26)
Wear out limit (mm) 20 (24) ·
Partial wear (8 measure location) (mm) 0.02
(0.02)
EN-30
MAINTENANCE
Assembly CL25
1. Apply Nissan rubber lubricant to piston seal then
install it to the cylinder body.
'
EII Nissan rubber lubricarit (KRE12 00030)
· on seal~
E!I
2. Apply Nissan brake fluid No. 2500 or Nissan rubber

lubricant (KRE12 00030) to pistan boots and cover
pistan tip. lnstall piston cylinder side lip to cylinder
bady groave carrectly.
3. Push in the piston into cylinder bady and install piston
boats pistan side lip inta the pistan groove.
Caution:
When inserting the pistan, care must be taken nat to
damage the cylinder inside wall.
CL25VD
Piston boots ~EII
..
Piston
E!I Nissan rubber lubricant (KRE12 00030)
EN-31
MAINTENANCE
[OPZ25VB]
Removal
each air breather.
3. Remove the brake pad.
4. Remove tube bracket from knuckle spindle.
5. Disassemble calliper ASSY and the brake tube using
the fiare nut wrench.
6. Remove calliper installation bolt to disassemble cal-
liper ASSY from the vehicle.
7. Remove disc rotor.
lnstallation
1. lnstall dacro shim to calliper installation surface.
Caution:
• Care must be taken not to damage installation surface
of aluminium calliper.
• There must be no moisture or grease adhered to
installation surface of the knuckle, calliper, installation
bolts and washer.
2. Attach brake tube to calliper ASSY and tighten fiare

nut by hand.
3. lnstall calliper ASSY to the vehicle and tighten the
bolts to specified torque.
Tightening torque (N-m{kg-m}) 98-118{10~12}
4. Tighten fiare nuts to specified torque.
Tightening torque (N-m{kg-m}) 11 ~16{1.1 ~1.6}
EN-32
MAINTENANCE
5. lnstall tube bracket to knuckle spindle and tighten to
specified torque.
Tightening torque (N-m{kg-m}) 11~16{1.1~1.6}
6. lnstall brake pad.
7. After installing the calliper ASSY, top up with new
brake fluid and release air.
Disassembly
1. Remove pad and the shim from the calliper ASSY.
2. Remove the fiare nut, lock plate and calliper
installation bolt, then remove the calliper.
3. Use screwdriver as shown in the diagram on the right
to remove retaining ring.
4. lnsert a block of wood as shown in the diagram on the

right. Blow in sorne compressed air through fiare nut
installation hole to remove pistan pin and the pisten
boots. At this time, if all tour pistan does not disas-
semble equally, push in the disassembled pistan a
little further into the cylinder body and then blow with
compressed air again.
5. Remove pistan boots from the pisten.
6. Use screwdriver to remove the piston seal.

Caution:
,,,,--... Care must be taken not to damage cylinder inside
surface.
lnspection
inside wall of the cylinder. Use sand paper to remove
cylinder body.
• Check the pistan surface for any rust, wear, damage
nut.
(2) Check the runout using the dial gauge.
Caution:
Before measurement make sure the axle end play is
EN-33
MAINTENANCE
(3) lf the runout is over the limit reattach the disc rotor
and the wheel hub by changing one hale for each and
measure the minimum runout value.
inside the radial
Runout limit (mm) 0.07
• Use a micrometer to measure the thickness of the

disc rotor. Replace if not at standard measurement.
Standard thickness (mm) 30
Wear out limit (mm) 28
Partial wear (8 measurement location)(mm) 0.02
Assembly Piston seal

1. Apply Nissan rubber lubricant (KRE12 00030) to
pistan seal then install it to the cylinder body.
Pisten boots
lubricant (KRE12 00030) to pistan boots and cover
pistan tip. lnstall pistan cylinder side lip to cylinder
body groove correctly.
3. Push the pistan into cylinder body and install pistan
boot pistan side lip into the pistan groove.
Caution:
Piston IJ
When inserting the pistan, care must be taken not to
IJ Nissan brake fluid NR-3

~ Replace after every disassembly
El Nissan rubber lubrican! (KRE12-00030)
4. Fix the pistan boots using the retaining ring.

Caution:
Make sure the pistan boot is fixed in cylinder body groove
correctly.
MAINTENANCE
[AD9]
Removal
1. Connect vinyl tube to the air bleather.
each air breather.
3. Detach the brake hose connected to the calliper ASSY
by removing the union bolts.
4. Remove the calliper ASSY from the vehicle by
removing the torque member installation bolts.
5. Remove the disc rotor.
lnstallation
1. Attach the brake hose to the calliper ASSY and tighten
installation union bolts by hand.
2. Attach calliper ASSY to the vehicle and tighten the
3. Tighten the fiare nut to specified torque.
4. Top up with new brake fluid and release air.
EN-35
MAINTENANCE
Disassembly Front ~
1. Remove the pad, shim, shim cover and pad retainer
from the calliper ASSY.
2. Remove the slide pin bolt to disassemble torque
member from the cylinder body.
3. Remove slide pin and slide pin boots from the torque
member.
4. Use a screwdriver as shown in the diagram on the

right to remove retaining ring. Screwdriver

right. Blow in sorne compressed air through the union
bolt installation hole to remove pistan boots.
6. Use screwdriver to remove the pistan seal.

Caution:
Care must be taken not to damage cylinder inside
surface.
lnspection
• Look far any wear, damage, rust or pinhole on the
any rust. lf it is damaged or warn re place it with new
cylinder body.
• Check the piston surface for any rust, wear, damage
nut.
Caution:
below 0.05mm.
(3) lf the runout is over the limit re-attach the disc rotor
.and the wheel hub by changing one hale for each and
measure the mínimum runout value. OR use grinding
machine to adjust to standard value. After grinding
check the rotor thickness and replace the disc rotor if
it is not at standard value.
EN-36
MAINTENANCE
inside the radial

Assembly
1. Apply Nissan rubber lubricant to pistan seal then
install it to the cylinder body.

lubricant (KRE12 00030) to pistan baots and cover
pistan end. lnstall pisten cylinder side lip to cylinder
bady groove correctly.
3. Push in the pistan into cylinder bady and install pisten
boot pistan side lip into the piston groove.
Caution:
Retaining ring
4. Fix the piston boots using retaining.
Caution:
Make sure piston boat is fixed in cylinder body groove
correctly.
EN-37
MAINTENANCE
Pistonl]
Brake tube bracket ~ P i s t a n seal ~El 2
OPZ11V
9 7 9
B. -B.B{0. -o. }
CC!J11-16.{1.1-1-~.6} A ·___ .
p.iston boots El2~
~ 'r- . ~ . d Retaining
Y~ - ~ brea:er ~ ~~ Pistan boots El 2 ~
f '·, ~-~:::
Lock plate ---------::::: r ¡' / /
//'(}ttl}.,~
_/. Pistonseal~El2
~38-52{ . -5~}~''°--- ,C../ ~/ ' .

rp "~ •'1 Calliper
lnner shim B .1
(
ór<:,_._,_-~l~~w, -
V~ Padpmholeslill
Z',
~
PIITToof]
lnner pa~d_¡jj . ~rfrOu~ :,:;:;;;,:,hlm B Pad P~ N~{kg~}
Uf
Cross spring
Pad retainer El 1 0 IJ
~
Nissan brake fluid No. 2500
Replace after every disassembly
El 1 Nissan brake grease (KRF16-00005)
El 2 Nissan rubber lubrican! (KRE12 00030)
---
.....
[OPZ11V]
Removal
each air breather.
3. Detach brake hose connected to the calliper ASSY by
removing the fiare nut.
4. Remove the brake pad.
5. Remove calliper by removing the installation bolt.
Caution:
Do not twist the brake tube.
lnstallation
1. Attach the dacro shim to calliper installation surface lnstallation bol!
then install it to knuckle housing. le housi
Dacro sñiln
Caution: , ;.,---canip r
Do not allow grease or fluid to adhered to the knuckle
installation surface, calliper surface, bolts and washer.
2. lnstall brake tube to the calliper ASSY and tighten the

fiare nut.
3. lnstall calliper ASSY to the vehicle and tighten
4. lnstall the brake pad.
5. Tighten the fiare nut to specified torque.
6. Top up with new brake fluid and release the air.
EN-38
MAINTENANCE
Disassembly
1. Remove pad and shim from the calliper ASSY.
2. Remove the fiare nut, lock plate and installation bolts
and remove the calliper.
3. Use screwdriver as shown in the diagram on the right
to remove retaining ring.

right. Blow in sorne air from fiare nut installation hole
to remove pistan pin and pistan boots. At this time, if
two pistons do not disassemble equally, push in the
disassembled pistan a little further into the cylinder
body and then blow the air again.
5. Remove pistan boots from the pistan.
6. Use screwdriver to remove the pistan seal. · ton seal~

Caution:
Care must be taken not to damage cylinder inside
surface.
lnspection
cylinder body.
• Check the pistan surface for any rust, wear, damage
nut.
Caution:
below 0.05mm.
(3) lf the runout is over the limit re-attach the disc rotor
and the wheel hub by changing one hole for each and
measure the minimum runout value. OR use grinding
machine to adjust to standard value. After grinding
check the rotor thickness and replace the disc rotor if
it is not at standard value .
--------·
.
EN-39
MAINTENANCE
inside the radial

Assembly
1. Apply Nissan rubber lubricant to pisten seal then
install it to the cylinder bady.
2. Apply Nissan rubber lubricant (KRE12 00030) to

pistan baots and assemble to pisten groave securely.
3. Push in the pistan into cylinder body and install pistan
boot pisten side lip into the pistan groove.
Cautian:
damage the cylinder inside wall. Piston
PistonfJ
4. Fix the pistan boots using retaining ring.
Cautian:
Make sure the pistan boot is fixed in cylinder body groave
carrectly.
Piston seal~El2
fJ Nissan brake fluid NR-3
El Nissan rubber lubricant (KRE12-00030)
EN-40
MAINTENANCE
RB26DETT ENGINE
6. MASTER CYLINDER CAP, WHEEL CYLINDER CAP, DISC CALLIPER CAP
& DUSTSEAL
MASTER CYLINDER (RB26DETT ENGINE)
Reservoir cap
~ Stopper cap
Oil filter ~
I ] ~ Primary ~ · sASSY
Float--- ~ ton
_,.;,-e,
Valve stopper ~ Reservoir tank ~
Tokico
2-3.4{0.2-0.35}
Napeo . -~
~r~
1.47-2.9{0.15-0.3}
Secondary p1ston ASSYI] ~

Vehicle with ABS
Cylinder body
[t!l N-m{kg-m} 12-14.5{1.2-1.5} ~

IJ Nissan brake fluid
FRONT DISC BRAKE

OPB27V
~ N-m{kg-m}
lfJNissan brake fluid No. 2500
~ RApl¡cice after every disassembly
El N1ssan rubber lubrican! (KRE12 00030)
EN-41
MAINTENANCE
RB26DETT ENGINE
REAR DISC BRAKE
OPB13V
Shimj¡ i) lnnerpad ~
uter pad
~ N-m{kg-m}
IJ Nissan brake fluid No 2500 Cross spring
~ Replace after every disassembly Shim cover
El Nissan rubber lubricant (KRE12 00030) Pad wear se
EN-42
MAINTENANCE
RB25DE / RB25DET ENGINE
7. SPARK PLUG (RB25DE / RB25DET)
2.3-3.0{0.23-0.31}(2)~
'---?
.'9J
Bracket
gnition coil harness
l
Bracket ~-Holder
tt=!J N-m{kg-m} ~ - - S p a r k plug 20-29(2.0~3.0)(C:l
Removal
1. Disconnect negative battery terminal inside the engine
room.
2. Remove the air duct.
3. Remove blowby hose between the rocker cover intake
and the exhaust side (RB25DE).
4. Disconnect ignition coi[ harness connector.
5. Remove the rocker cover ornament.
6. Disconnect ignition coil connector.

7. Remove the ignition coil.
8. Use spark plug wrench to remove the spark plug.
lnstallation
1. Use spark plug wrench to install spark plug.
2. lnstall the ignition coil bracket.

• lnstall the ignition coil bracket with mark "F" to front
side. Make sure the arrow is facing the front.
• lnstall the ignition coil bracket with mark "R" to rear,
make sure the arrow is facing the back.
3. lnstall the ignition coil.
EN-43
MAINTENANCE
• lnstall the installation bolts at marked position shown
in the diagram.
• Tighten the installation bolts evenly in alternate turns.
Tightening torque (N-m{kg-m}) 2.3~3.0{0.23~0.31}
~ - _lL '
-,---- ' ~ ~ i _ J J
/ /-4-'
~ ' ---
4. lnstall the ignition coil harness.
• Match the distinction tape number and the cylinder
number to install.
• Fix the harness by placing the clamp near No. 2, No. 4 ~
and No. 6 connectors. l
/
s_
5. lnstall the rocker cover ornament.
_s
6. lnstall the rest in reverse arder to the installation o- .-»-....<:t.\"'--'eC:.._ /
procedure.
EN-44
MAINTENANCE
RB26DETT ENGINE
7. SPARK PLUG (RB26DETT)
lgnition coil bracket
/
/
lgnition coi! harness
~ N-m{kg-m}
Removal
1. Disconnect the negative battery terminal in the engine
room.
(1) Remove the blowby hose between right and left rock-
er cover.
(2) Remove the rear side connector and earth terminal
from the power transistor unit.
(3) Lift up the rocker cover ornament and remove power
transistor unit front connector from reverse side.
3. Remove the power transistor unit from the rocker

,,,,----.. cover ornament.
4. Disconnect the ignition coil harness connector.

6. Use the spark plug wrench to remove the spark plug.
EN-45
MAINTENANCE
RB26DETT ENGINE
lnstallation
1. Use the spark plug wrench to install spark plug.

• lnstall the ignition coil bracket with mark "F" to front
side. Make sure the arrow is facing the front.
• lnstall the ignition coil bracket with mark "R: to rear,
make sure the arrow is facing the back.
• Tighten the installation bolts evenly in alternate turns.

4. lnstall the ignition coil harness.

• Match the distinction tape number and the cylinder
number to install.
• Fix the harness by placing the clamp near No. 2, No. 4
and No. 6 connectors.
• lnstall the harness earth terminal.
5. lnstall the power transistor unit to rocker cover

ornament.
• Tighten rear right installation bolt to specified torque.

(1) Connect harness to the power transistor unit front
side connector from reverse side.
(2) Tighten the installation bolt.
7. Tighten earth terminal using the power transistor unit

rear right installation bolt.
8. lnstall the rest in reverse order to the installation

procedure.
. -----,
EN-46
MAINTENANCE
RB20E ENGINE
8. TIMING BELT (RB20E)
Wash
Conical washer
R43-58{4.4-5.\\
l
Belt tensioner
Tensioner
~ r spnng
--\
T1ming belt cover (upper
~2.9-4.9{0 3-0 5}(4
Crank pulley
Power steering pump pulley

\ Crank timing belt plate
--------------...___, Crank tíming pulley
I] Engine oil
~·
f] R142-1s2{14.s-15.5}
~lil/
\
~2.9-4.9{0.3-0.5}
Timing belt
Crank timing pulley plate
(O.l N-m{kg-m}
Replacement period: Every 100,000 km
Caution:
• Do not twist or bend the timing belt. Care must be
taken not to allow grease or water to come in contact
with the timing belt.
. Do not readjust (retension) the belt as it will shorten
the life expectancy of the tíming belt.
• lt is recommended to replace the tíming belt with a
new one, once you have removed or loosened the
timing belt during inspection or removal of other
parts.
Removal
1. Remove a negative battery terminal.
(1) Open the boot lid.
(2) Remove the boot front finisher and disconnect nega-
tive battery terminal.
2. Remove the air cleaner and the air duct.
3. Remove the under cover.
4. Extract coolant from radiator drain plug.
~
5. Remove the cooling fan.
6. Remove the radíator.
7. Remove the supplement belt. Prima,y
_.I
1
8. Remove the high-tension cord and the primary cord
from the timing belt cover (upper).
EN-47
.\~
MAINTENANCE
RB20E ENGINE
9. Remove the timing belt cover (upper).
1O.Remove the power steering pump pulley from the

crank pulley. j
1 -
l Power ey- ·
--i - )'
11. Position No. 1 cylinder at compression T.D.C (top

dead centre).
• Turn the crank pulley clockwise and align belt cover
timing indicator and the timing mark (Oº).
• At this time, the cam timing pulley alignment mark

should be in the position shown in the diagram on
right.
• lf the cam timing pulley alignment is not at correct
position, turn the crank pul/ey 360° clockwise.
• Place alignment mark on back side of the timing belt
by aligning it to the cam timing pulley alignment mark.
12. Remove the crank pulley.

( 1) Remove the starter motor.
(2) lnstall the ring gear stopper to fix the drive plate.
(3) Loasen the crank pul ley bolt and draw out approx.
1cm.
(4) 1nstall M6 x 1.0 with underhead approx. 40mm to \
-,
crank pulley screw hole. Use the crank pulley to
remove from the crankshaft.
1
1
1 1
V111 03000
EN-48
MAINTENANCE
RB20E ENGINE
13.Remove the timing belt cover (lower).
14.Remove the crank timing pulley plate (front).
15. Place alignment mark on back side af the timing belt
by aligning it to the crank timing pulley alignment
mark.
16. Remove the timing belt.

(1) Loasen the tension pulley installation nuts.
(2) lnsert the wrench into tensioner pulley hexagonal hale
and turn it to remove the timing belt.
17.Remove the tensioner pulley.

18. Remove the crank timing pulley.
19.Remove the crank timing pulley plate (rear).
lnspection
• Refer to the diagram below to inspect the timing belt.
Check for any wear or adhesíon of foreign objects.
• Replace timing belt if inspection indicates any
problem.
Missing tooth
Cracked tooth Cam shaft lock
Tensíoner lock
Cracks on rear síde Engine overheat
lnterference with belt cover etc.
Belt mis-alignment
Wear and cracks on the síde
Belt plate malfunctíon
Worn teeth
11111
·- ID
- Cam shaft rotatíon resistance
Grease or Oíl seal malfunction

water adhesion Water pump leak
• Check each pulley tooth far any wear ar cracks.

Replace with new belt if any abnormality is found.
EN-49
MAINTENANCE
RB20E ENGINE
lnstallation Crank timi
..
Timing belt plate
1. lnstall the timing belt plate (rear). pulley
plate
• Compared to front side, the rear timing pulley plate
has smaller externa! diameter.
Crank pulley
• When installing make sure the externa! diameter R is síde
facing the direction shown in the diagram on the right.
2. lnstall the crank timing pulley. Crank tíming pulley Groove
• Make sure the crankshaft key is facing the top.
3. lnstall the tensioner pulley.

(1) Fit the spring claw to the tensioner pulley groove
securely.
Stud bolt
(2) lnstall it in a way so the tensioner pulley hexagonal ~ lhole
hole and the spring claw is positioned as shown in the ~ ~==t=======~===-
diagram on the right. c
(3) Hold the tensioner pulley with your finger. Hook the
spring on top of the stud bolt by rotating the spring
anti-clockwise.
(4) Temporarily install the tensioner pul ley by installing in

the arder of washer, conical washer and installation
nut.
• Make sure the conical washer is facing the direction
shown in the diagram on the right.
Nut Conícal washer Washer
4. lnstall the timing belt. . d.,8 47 46

Allgnment m k · .• · .
(1) Check that the crank timing pulley key groove is Cam tímin ,v.,,,,="""-.. owel pin
facing up.
(2) Check that the cam timing pulley alignment mark is
Tíming
facing up.
(3) lnsert wrench to the tensioner pulley hexagonal hole
and turn it clockwise to temporarily tighten the instal-
lation nut to fix the tensioner pulley.
(4) lnstall the timing belt by aligning the crank timing
pulley and cam timing pulley alignment mark to the
Tensíoner
timing belt reverse side alignment mark. , v JP ,-~~ ove
Crank timin
• After installing make sure each pulley and the belt pulle o2 { 2
alignment mark is as shown in the diagram on the ~ ~~11' 1
0
right. A 1gnment mark
EN-50
MAINTENANCE
RB20E ENGINE
(5) Loosen the tensioner pulley installation nut to tension
the timing belt.
• Make sure the timing belt and the pulley is securely
engaged at four locations as shown in the diagram on
Cam timing pulley
the right.
5. Adjust the timing belt tension.

(1) Remove the spark plug.
(2) Remove the rocker cover.
• Crank timing pulley
(3) Loasen all rocker shaft installation bolts.
(4) lnsert the wrench to tensioner pulley hexagonal hole

and turn it anti-clockwise two to three turns to fit in the
timing belt.
• OR turn the crankshaft clockwise twice.
_,,---~.
(5) lnsert wrench to tensioner pulley hexagonal hale to fix

the tensioner pulley to tighten the installation nuts.
Tighteníng torque (N-m{kg-m}) 43~58{4.4~5.9}
l,/~
Crank tirnin pulley Timing belt plate
..
6. lnstall the crank timing pulley plate (front). plate
• Compared to rear side, the front timing pulley plate
has bigger externa! diameter.
• When installing make sure the externa! diameter R is Crank pulley
facing the direction shown in the diagram on the right. ide
Crank timing pulley

7. lnstall the timing belt cover (lower).
Tightening torque (N-m{kg-m}) 2.9-4.9{0.3~0.5}
8. lnstall the timing belt cover (upper).
• Apply gasket to reverse side of the cover.
9. lnstall the crank pulley.

• Coat crank pulley bolt and the surface with engine oil.
• lnstall the washer so the flat surface is facing the crank
pulley.
Q
Crank pulley
10.lnstall the power steering pump pulley.
Tightening torque (N-m{kg-m}) 9.8~12{1.0~1.2}
Chamfered comer
EN-51
MAINTENANCE
RB20E ENGINE
11. Timing belt replacement notification label is placed in ~ .. .
front surface of the timing belt cover (upper). Place

new label once you have replaced the timing belt.
• Write mileage and the date on the label. /t
'
12. lnstall the rest in reverse arder to the removal

procedure. --~ \ ~"'
Notific
\
EN-52
MAINTENANCE
8. TIMING BELT (RB25DE / RB25DET)
{4.4-5.9}~
Tensioner pulley
Conical Tensioner
washer spríng ,
. i
¡ ·--~ ~----~
sherr;i~~-'@• 'Tirniog plate belt
/ ·\ \ ~ Crank tíming pulley
Washer Crank timing pulley plate
Washer 43-58{4.4-5.9} ldler pulley
\ 6V
'® \ \ Timing belt cover (lower)
~ Grommet
I] ~142-152{14.5-15.5} ' 6.3-8.3{0.64-0.85}(4) ~ ~ Replace after every disassembly
Crank pulley I] Engine oil
~ N-m{kg-m}
Caution:
• Do not readjust (retension) the belt as it will shorten
the life expectancy of the timing belt.
• lt is recommended to replace the timing belt with a
new one, once you have removed or loosened the
timing belt during inspection or removal of parts.
Removal
1. Remove the negative battery terminal.
(2) Remove the boot room front finisher and disconnect
4. Remove the radiator.
5. Remove the cooling tan.
6. Remove the supplement belt.
7. Remove the crank angle sensor. ~lil

O-ring
• The crank angle sensor must be handled gently so it
will not cause any damage.
8. Remove the timing belt cover (upper). --~.. :'J J.-
Crank angle sensor
,---._
EN-53
MAINTENANCE
9. Position No. 1 cylinder at compression T.D.C (top , :::-------_ TIJ!l!ng indicator ~
1
dead centre) position. -· 0
(1) Turn the crank pulley clockwise and align timing belt /
cover indicator and the timing mark (Oº). ·

aligned with belt cover alignment mark.
• lf the cam timing pulley alignment is not in correct
position, turn the crank pulley 360° clockwise.
by aligning it to the cam timing pulley alignment mark. Align
Cam · (Exhaust)
~~~~ • Paint
lignment
mark ark
10.Remove the crank pulley.

(1) Remove the starter motor. Place the ring gear
stopper to fix the crankshaft.
(2) Loasen the crank pulley bolt and draw out approx.
1cm.
• lnstall M6 x 1.0 (2) with underhead approx. 50mm to
crank pulley screw holes. Use the pulley puller to
remove the crank pulley from the crankshaft.
11 . Remove the timing belt cover (lower).

• Remove the crank timing pulley plate.
mark.

(1) Loosen the tension pulley installation nuts. ;:::-'<.,.///'
r, '-..: ~
H~xag
(2) lnsert the wrench into tensioner pulley hexagonal hole
and turn it clockwise to tighten the installation nut 0
temporarily. ,,.
(3) Remove timing belt from each pulley.
13. Remove cam timing pulley.

14. Remove crank timing pulley.
EN-54
MAINTENANCE
15. Remove the timing belt pi ate.
16.Remove the tensioner pulley and the spring.
17. Remove the idler pulley.
lnspection
Timing belt
Check far any wear or adhesion of foreign objects.
• Replace timing belt if inspection indicates any
problem.
Missing tooth ~ . ~ Cam shaft lock

Cracked tooth ~ ~
~
Tensioner lock
Cracks on rear side Engine overheat
Wear and cracks on !he side ,,;;;;, ~ Belt mis-alignment

Belt plate malfunction
Worn teeth
·- 111D
- Cam shaft rotation resistance
Grease or Oil seal malfunction

• Check each pulley tooth far any wear or cracks.

Replace with new belt if any abnormality is found.
_..--.,
Timing belt cover gasket

• Check if there is any wear or damage to timing belt
cover (upper and lower) reverse side dried liquid
packing.
• Replace the cover ASSY if there is any fault or
abnormal.
EN-55
MAINTENANCE
1nstal lation Crank timi
..
Timing belt plate
1. lnstall idler pulley. pulley
plate
• After tightening with correct torque, make sure the
Crank pulley
idler pulley will turn smoothly. side
Crank timing pulley

(1) Fit the tensioner spring claw to the tensioner pulley
groove securely.
anti-clockwise.
(3) Temporarily install the tensioner pulley by installing in

the order of washer, conical washer and installation
nut.
• Make sure the conical washer is facing the direction
B -
I -
,
Nut Conical washer Washer
3. lnstall the timing belt plate (rear) and the crank timing Crank timing Timing b t plate
...
pulley. pulley plate
• Crankshaft key must be facing up.
• Rear timing belt plate has smaller exterior diameter
compared to the front timing belt plate. Crank pulley
side
• Make sure the exterior diameter 'R' is facing correct
direction.
4. lnstall the cam pulley. Cam pulley (intake)

5. lnstall the timing belt.
(1) Align the crank timing pulley alignment mark to oil
pump housing alignment mark (No. 1 cylinder T.D.C). (
(
(2) Align cam pulley alignment mark to each belt cover (l
alignment mark. (No. 1 cylinder T.D.C).

(3) lnsert the wrench to tensioner pulley hexagonal hale
and turn it clockwise to temporarily tighten the
installation nut.
(4) Align timing belt and each pulley alignment mark to
install the timíng belt.
• Make sure each timing pulley and timing belt . . ))/
e kt
p~~~Y immg Alignment mark
alignment mark is at position shown in the diagram.
EN-56
MAINTENANCE
(1) Turn the crankshaft clockwise twice with tensioner pul-
ley installation bolt in loose condition.
(2) lnsert wrench to tensioner pulley hexagonal hole to fix
the tensioner pulley to tighten the installation bolts.
Tightening torque(N-m{kg-m}) 43~58{4.4~5.9}
• The timing belt tension should be at correct tension.
7. lnstall the crank timing pulley plate.


• Fix the crankshaft using the ring gear stopper.
pulley. Q
Crank pulley
• Coat installation bolt and flange surface then tighten
the bolts.
Tightening torque (N-m{kg-m}) 142~152{14.5~15.5} Chamfered comer
10. lnstall the timing belt cover (u pper)

Tightening torque (N-m{kg-m}) Timing belt cover (upper) __
lnner hexagonal installation bolt 16~21{1.6~2.1} . --

lnstallation bolt 6.4~8.4{0.65~0.86}
~I) ') D
O-ring _,:;;-,;
_,,,
11. lnstall the crank angle sensor.
O"'
(1) Apply grease to spline parts.
Crank angle sensor
Caution:
Do not use chassis grease as it will outflow in high
temperature.
Fitting joint
(2) There is a fitting joint inside the spline. Check the \
position of the spline befare installing.
(3) Check if it can be inserted in to the crank angle sensor
Spline
belt cover hale easily, then tighten the bolt.
(4) lf it doesn't move easily, loasen the belt cover
installation bolt while the crank angle sensor is in
Belt cover hole
inserted position. Ughtly move the belt cover up,
down, right and left to align the centre of the belt cover
hole and the cam shaft centre. Tighten the bolts.
12. Place new timing belt replacement notification label on

the timing belt cover surface (upper) once you have
replaced the timing belt.
• Write mileage and the date on the label.

procedure.
EN-57
MAINTENANCE
RB26DETT ENGINE
8. TIMING BELT (RB26DETT)
I] Engíne oil
~ N-m{kg-m}
Caution:
• Do not readjust (retension) the belt as it will shorten
the life expectancy of the timing belt.
• lt is recommended to replace the timing belt with a
new ones, once you have removed or loosened the
timing belt during inspection or removal of parts.
Removal
1. Remove the negative battery terminal inside the
boot.
2. Remove the front spoiler under cover.
7. Remove the supplement belt.
8. Remove the crank angle sensor. ~11

0-ring
• The crank angle sensor must be handled gently so it
will not cause any damage. " ~
9. Remove the timing belt cover (upper). r ~ 5 ti
Crank angle sensor
EN-58
MAINTENANCE
RB26DETT ENGINE
10.Position No. 1 cylinder at compression T.D.C (top
dead centre) position.
(1) Turn the crank pulley clockwise and align timing belt
cover indicator and the timing mark (Oº).
Cam pulley
Cam pulley (intake) (exhaust)
Alignment Alignment
aligned with belt cover alignment mark. mark ~R~~ mark
• lf the cam timing pulley alignment is not at correct
position, turn the crank pulley 360° clockwise.
by aligning it to the cam timing pulley alignment mark.
11. Remove the crank pulley.

( 1) Remove the starter motor.
(2) Place the ring gear stopper to fix the crankshaft.
(3) Loasen the crank pulley bolt and draw out approx.
1cm.
• lnstall M6 x 1.0 (2) with underhead approx. 50mm to
crank pulley bolt hales. Use the pulley puller to
remove the crank pulley from the crankshaft.
12. Remove the timing belt cover (lower).

13.Remove the crank timing pulley plate.
14.Place alignment mark on back side of the timing belt
mark.
15.Remove the timing belt.

(1) Loasen the tension pul ley installation nuts.
(2) lnsert the wrench into tensioner pulley hexagonal hale
and turn it clockwise to tighten the installation nut
temporarily.
(3) Remove the timing belt from each pulley.
16.Remove the cam timing pulley.

17.Remove the crank timing pulley.
18. Remove the timing belt plate.
19.Remove the tensioner pulley and the spring.
20.Remove the idler pulley.
EN-59
MAINTENANCE
RB26DETT ENGINE
lnspection
Timíng belt
Check for any wear or adhesion of foreign objects.
• Replace tíming belt if inspection indícates any
problem.
Missing tooth ~ ~
Cracked tooth ~ ~ Cam shaft lock
~
Tensioner lock
Cracks on rear side Engine overheat
Wear and cracks on the side ,.;;;, ~ Belt mis-alignment

Belt plate malfunction
Worn teeth
IHI
- - Cam shaft rotation resistance
Grease or Oil seal malfunction

• Check each pul ley tooth for any wear or cracks.

Re place wíth new belt if any abnormality is found.
Timing belt cover gasket

• Check if there is any wear or damage to timing belt
cover (upper and lower) reverse side dríed líquid
packing.
• Re place the cover ASSY if there is any fault or
abnormal.
EN-60
MAINTENANCE
RB26DETT ENGINE
lnstallation
1. lnstall idler pulley.
• After tightening with correct torque, make sure the
idler pulley will turn smoothly.

(1) Fit the tensioner spring claw to the tensioner pulley
groove securely.
anti-clockwise.
B (
(3) Temporarily install the tensioner pulley by installing in
the arder of washer, conical washer and installation
nut. -
• Make sure the conical washer is facing the direction -
'
Nut Conical washer Washer

3. !nstall the timing belt plate (rear) and the crank timing
pulley. Crank timing Timing b t plate
• Crankshaft key must be facing up. pulley plate
• Rear timing belt plate has smaller exterior diameter

compared to the front timing belt plate. + -
Crank pulley
• Make sure the exterior diameter 'R' is facing correct
side
direction.
4. lnstall the cam pulley.

5. lnstall the timing belt. . Cam pulley
Cam pulley (1ntake) (exhaust)
(1) Align the crank timing pulley alignment mark to oil Alignment Ali nment
pump housing alignment mark (No. 1 cylinder T.D.C). mark r,;;J~~~ mark
(2) Align cam pulley alignment mark to each belt cover
alignment mark. (No. 1 cylinder T.D.C).
:ff
(3) lnsert the wrench to tensioner pulley hexagonal hole
and turn it clockwise to temporarily tighten the
installation nut.
(4) Align timing belt and each pulley alignment mark to Tensi
pulle
install the timing belt.
• Make sure each timing pulley and timing belt
alignment mark is at position shown in the diagram.
Alignment mark
EN-61
MAINTENANCE
RB26DETT ENGINE
(1) Remove all spark plugs.
(2) Turn the crankshaft clockwise twice with tensioner
pulley installation bolt in loose condition.
(3) lnsert wrench to tensioner pulley hexagonal hale to fix
the tensioner pulley to tighten the installation bolts.
• The timing belt tension should be at correct tension.
7. lnstall the crank timing pulley plate.


• Fix the crankshaft using the ring gear stopper.
pulley.
Q
• Coat installation bolt and flange surface then tighten Crank pulley
the bolts.
Chamfered comer
10.lnstall the timing belt cover (upper).

11. lnstall the crank angle sensor.

(1) Apply grease to spline parts.
Caution:
Do not use chassis grease as it will outflow in high
tempera tu re.
(2) There is a fitting joint inside the spline. Check the
position of the spline befare installing. Fitting joint
(3) Check if it can be inserted in to the crank angle sensor
belt cover hole easily, then tighten the bolt.
(4) lf it doesn't move easily, loasen the belt cover Spline
installation bolt while the crank angle sensor is in
inserted position. Lightly move the belt cover up,
Belt cover hole
down, right and left to align the centre of the belt cover
hole and the cam shaft centre. Tighten the bolts.
12. Place new timing belt replacement notification la bel

once you have replaced the timing belt.
• Write mileage and the date on the label.

procedure.
EN-62
MAINTENANCE
9. ENGINE OIL
Engine oíl replacement period
RB20E, RB25DE SE, SF, SG 15,000 km or every year

SG 10,000 km or every year
RB25DET
SE, SF 5,000 km or every 6 months
RB26DETT SE, SF, SG 5,000 km or every 6 months
H level 4.0 4.1 4.5 5.8

Oil tank capacity (L)
Lleve! 3.0 3.3 3.5 4.8
Approx. Approx.
Replacing Extracted from drain plug Approx. 3.8 Approx. 3.9
4.2 4.8
oil only
Oil replacement Extractad using oíl changer Approx. 4.0 Approx. 4.1
,--
amount (L) Approx. Approx.
Replacing Extracted from drain plug Approx. 4.2 Approx. 4.3
4.6 5.2
oil and filter
Extracted using oil changer Approx. 4.4 Approx. 4.5
Oil pressure inspection
• Check engine oil level.

• Remove oil pressure switch.
• Connect oil pressure gauge
• Check if there is adequate oil pressure far engine rev after warming up the engine.
RB25DE 0.1{1.0} 0.32{3.3} 0.52{5.3}

R825DET 0.11{1.1} 0.34{3.5} 0.55{5.6}
RB26DETT 0.15{1.5} 0.30{3.0} 0.46{4.6}
(RB20E / RB25DE) (RB25DET) (RB26DETT)
EN-63
MAINTENANCE
1O. OIL FilTER
Oil filter replacement period (RB25DET)
(When SE, SF or SG oil is used)
RB20E / RB25DE 15,000 km or every year

RB25DET 10,000 km or every year
RB26DETT 10,000 km or every year
Removal (RB26DETT)
Use oil filter wrench to remove the oil filter. \\1: \ \
KV101 15901
Caution:
Catch dripping waste oil when removing the oil filter.
\ \
---------- ----
- e,
Front
lnstallation :::::;)-
1. Wipe off any dirt or dust from surface area of the
cylinder block (oil frlter bracket: RB25DET / (RB26DETT)
RB26DETT) and coat the new filter oil seal area with
engine oil.
2. lnsert the oil filter and turn it 2/3 of a turn until it touch-
es the cylinder block (oil fotter bracket: R825DET /
RB26DETT).
Tightening torque (N-m{kg-m}) 15~21 {1.5~2.1}
Caution:
Check to make sure there are no oil leaks after starting
the engine.
4-8 FUEL FILTER
Replacement period: Every 100, 000 km
Removal
2. Loasen the hose clamp and remove the fuel hose
(RB20E / RB25DE / RB25DET), fuel feed and return ~L----
1
hose (RB26DETT) from the filter. (29 --.. m_'>li"'"'f.:- '--
A~ filter
'---11 ¡·
3. Remove the fuel filter from the bracket. \
Fuel uel filter bracket
_...W \
uel return hose
lnstallation ~\
• Carry out the removal procedures in reverse arder
noting the following points below:
• Make sure to tighten the hose clamp.
• Make sure there are no fuel leaking when the
ignition is turned to ON position.
• When installing the fuel filter, make sure the
flange is touching the holder upper end.
"ª")S(
Holder
EN-64
MAINTENANCE
11. COOLANT (RB20E / RB25DE / RB25DET)
Extracting coolant
1. Place the ignition switch to ON position and set the
vehicle temperature to 32ºC using the heater control
temperature adjustment knob.
2. Remove the under cover (RB20E / RB25DE / o
Drain plug
RB25DET).
3. Remove the radiator drain plug and remove the (RB26DETT)
radiator cap to extract the coolant.
4. Remove the exhaust front tube (RB26DETT).
5. Remove the drain plug on the left side of the cylinder
block to extract the coolant inside the cylinder block.
6. Remove the reservoir tank and discharge coolant.
Filling up coolant
1. lnstall the reservoir tank. (RB25DE)
2. lnstall the radiator drain plug and the cylinder drain ,--;:;--~
Air ralease plug
plug. NEVERO / '-..:
WH /
• Coat thread part of the cylinder block drain plug with
sealing agent (Three bond 1386B) l
3. Check each clamp to make sure it is tightened
securely.
4. Place the ignition switch to ON position and set the
vehicle temperature to 32ºC using the heater control (RB26DETT)
temperature adjustment knob.
5. Remove air release plug located at front side of the
intake manifold collector.
Note:
The bolt with copper washer is the air release plug. There
is a caution label located near the air release plug.
6. Top up the radiator with coolant at filling speed of less
than 2L / min. Clase the plug if the coolant start
spouting out from the air release plug while filling up
the radiator. Top up coolant to the top.
• Replace air release plug copper washer with a new
one.
7. Clase the radiator cap and start the engine. Keep
idling until the thermostat injection valve opens.
8. Check that the engine coolant temperature gauge
needle is pointing over mid way. Touch the radiator
lower hose and make sure warm water is flowing.
9. After checking the thermostat injection valve, race the
engine 2 to 3 times with 10 seconds interval between
each at 2500rpm.
Caution:
Do not raise the engine coolant temperature too high.
EN-65
MAi NTENANCE
10.Stop the engine.
11.After cooling down the engine, open the radiator cap
and check the level of coolant. lf the coolant leve! has
decreased repeat the steps from 7.
12.Once the coolant level has stabilised top up the
coolant to the MAX line.
13. Refill the coolant to the filler tube. Place the radiator
cap and stop the engine.
14.After cooling down the engine, refill the reservoir tank
with coolant to the MAX line.
15. Restart the engine and increase the engine speed
to 3000rpm from idling position. At this time make
sure there is no heater core water flowing sound from
the instrument panel area. lf there is a water flowing
sound, repeat steps 7 to 14 until the coolant level sta-
bilises.
Reference: LLC density.
Standard LLC 30%
Cold climate area LLC 50%
-- --,,
EN-66
AIR CLEANER &AIR DUCT ENGINE MECHANICAL
RB20E ENGINE
EN3 ENGINE MECHANICAL (RB20E)

1. AIR CLEANER & AIR DUCT
~ N-m{kg-m}
~ Replace after every dísassembly
Removal Negative terminal

1. Remove negative battery terminal. "
(2) Remove the boot front finisher and remove the
2. Befare removing, use air gun to remove any rubbish,
dust etc. to avoid foreign objects entering the duct.
3. Remove the air flow meter connector.
4. Remove the air duct, air cleaner case (upper) and air
cleaner element.
• Remove 2 air duct clips and 4 air cleaner case (upper)
clips.
5. Remove the air cleaner case (lower).
• Remove the installation bolts.
6. Remove the air duct, resonator ASSY.

• Remove 2 air hoses, and installation bolts.
lnspection
• Make suré the cleaner element is not dirty.
lnspection period: Every 60,000 km
EN-67
INTAKE MANIFOLD COLLECTOR ENGINE MECHANICAL
RB20E ENGINE
1nstal lation
1. lnstall the air duct and resonator ASSY.
• Tighten installation bolts (2).
• lnstall the air hose (2).
2. lnstall the air cleaner case (lower).

Tightening torque (N-m{kg-m}) 5.1 ~6.5{0.52~0.66}
3. lnstall the air cleaner element, air cleaner case (up-
per) and the air duct.
• lnstall 4 clips on the air cleaner case (upper) and 2
clips on the air duct clips.

procedure.
2. INTAKE MANIFOLD COLLECTOR
---....._
~ N-m{kg-m}
Removal
1. Remove the negative battery terminal. alve switch
(A/T)
ttle senso
(2) Remove the boot front finisher and remove the tor
negative battery terminal. ..._
2. Drain coolant from the radiator drain plug. r,.,
3. Remove the air duct and the resonator ASSY.
4. Remove the acceleration wire and the ASCO wire ~
from the throttle drum.
EN-68
RB20E ENGINE
5. Remove the throttle valve switch (A/ T), throttle sen-
sor and AAC valve connectors.
6. Refer to the diagram below to remove each hoses.
• The diagram refers to the reverse side of the intake
manifold collector.
• Remove the hose below the intake manifold collector
after removing the installatíon bolts.
To air duct
<;l FRONT
To canister
_Tofuel
damper
brake booster
To air regulator
To water connector
To water connect}\'.;:.,:j'.}
7. Remove the installation bolts in arder shown in the

diagram.
8. Remove the intake manifold collector.
9. Remove the intake manifold collector gasket.
lnspection
Distortion of the intake manifold collector
(1) Completely remove the gasket on reverse side of the
Straight gauge
intake manifold collector.
• Use the straight gauge and the feeler gauge to meas-
ure the distortion in six directions.
Limit value (mm) 0.1
• lf the distortion is over the limit use a surface grinder
to repair distortion. Replace the intake manifold
collector if the distortion is too excessive to fix.
lnstallation
1. lnstall the intake manifold collector gasket.
• Replace the gasket with a new one.
• Remove any fluid, grease, rubbish etc. adhered to
installation surface.
2. lnstall the intake manifold collector ASSY.
• Care must be taken to select the correct bolt.
1 100
2, 3 37
4,5 109
,_.__ 6, 7 Stud bolt + nut
EN-69
RB20E ENGINE
• lnstall the installatian balts in the arder shawn in the 2 3
diagraman the right. 6
• Make sure the gasket is fitted carrectly.
3. lnstall the rest in reverse arder to the remaval
pracedure.
• Make sure to tighten the hose clamp securely.
~ 6.3-8.3{0.64-0.85} (2) ~ r;t:!l 8.4-11(0.86-1.1} (4)

Acceleration wire bracket ,.
/
/,A
~ trb-lAAo,11
~
Air release pJug
6.9-7.8{0.7-0.8}
Copper washer '

,
\
~~ Gasket~
:!(" -'!';i
.
... ,.
/
lntake manifold collector
/
~Gasket
Replace afler every disassembly

~\
~ Refer to text below
N-m{kg-m}
Disassembly
1. Remave the throttle chamber. Front
• Remave the installatian bolts in arder shawn.
2. Remave the IAA unit.
3
Assembly
1. lnstall the IAA unit.
• Replace the gasket with a new ane.
~~
~IAA,nlt-lt~~
Gasket~
2. lnstall the throttle chamber.

• Remave old gasket and other foreign objects adhered
to installation surface.
• lnstall the bolts in two stages in the arder shown .
Tightening torque (N-m{kg-m})
1st 8.8~11 {0.9~ 1.1}
2nd 18~22{1.8~2.2}
EN-70
FUEL INJECTOR ENGINE MECHANICAL
RB20E ENGINE
3. FUEL INJECTOR
Removal
2. Remove the battery negative terminal.
3. Drain coolant from the radiator drain plug.
4. Remove the air duct and resonator ASSY.
6. Remove the fuel feed and return hose from fuel tube
side.
Caution: Fu
ho
Make sure to place a hole cap to avoid fue! leakage.
7. Remove the fue! injector harness connector.
8. Remove the intake manifold front side fuel sub tube
installation bolt.
/) v¡1 I -------- -----
9. Remove the fue! tube installation bolt to remove fue! / Fuel tube -
tube and the injector ASSY. //,..-,.-=--._'- f'"""!a:-=-.J I \ ?-
• Care must be taken not to drop insulator attached to
the injector inside the engine bay when removing the
injector ASSY. ,
10.Remove fuel injector from the fuel tube.
Caution: ~ fu~~~ub /
• Care must be taken not to damage fuel injector.
• Do not disassemble fuel injector.
11. Remove fuel pressure regulator (front side) and fuel
damper (rear side) from the fuel tube.
Caution:
The fuel inside the fuel tube may leak.
EN-71
RB20E ENGINE
lnspection
Fuel tube & fuel hose
• Look far any fuel leakage from the fuel tube and the
fuel hoses.
• Replace with new ones if there are any abnormali-
ties.
lnstallation
1. lnstall fue! pressure regulator (front side) and the fue!
damper (rear side).
• Replace O-ring with new ones.
• Read the handling note befare carrying out the
operation.
Handling note
• Always handle the O-ring with bare hands (no
gloves).
• Only apply engine oil (7.5W-30 or similar viscosity) .
and never clean or soak the o-ring in a solvent
solution.
• Avoid using dirty o-ring and devices with dust or other I
~'(O-ríng
Fuel pressure regulator
foreign objects adhered to it.
• When installing the o-ring care must be taken not to
scratch the o-ring with tools or nails. Also do not twist
or stretch them.
r1g
• When inserting fuel injector, pressure regulator or
fuel dumper into the fuel tube, do not twist or turn the
parts.
lnsulator
2. lnstall the fuel injector to fuel tube. lnjector
• Replace the insulator (up & down) with a new one.
• Replace the o-ring with a new one.
/J )1 ' ---- ----
3. lnstall the fuel tube and the injector ASSY.
Fuel tube
' \
-
-
• Tighten right and left evenly.
4. Fuel sub tube installation bolts.
~ Fue!sub /
\~
5. lnstall fuel injector harness connector.

6. lnstall fuel feed and return hose to fuel tube.
• lnstall feed hose (fuel filter síde hose) to fuel tube
bottom side and install return hose to upper side. '
Fue
7. Place the ignition switch to the ON position and apply hos
/
pressure to the fuel pipings to check for any fuel / ~~
leakage.
8. lnstall the rest in reverse order to the removal proce-
dure.
EN-72
INTAKE MANIFOLD ENGINE MECHANICAL
RB20E ENGINE
4. INTAKE MANIFOLD
lntake manifold ASSY
.----.. t:3 Rep!ace after every disassembly ~

~ 18-22{1.8-2.2} (8)
~ N-m{kg-m}
Removal
4. Drain coolant from the cylinder block drain plug.
7. Remove the fue! injector.
8. Remove the connector and primary terminal from the )s./:,_ /[ ''/1 :::----.... ~
r ~~tion coi!
ignition coil. hermal
ans
9. Disconnect the thermal transmitter and engine cool-
e?ng ·coolant temp ';,en
ant temperature sensor connector. 1.JOV
10.Remove the radiator upper hose from water outlet Earth
ont
side. /
11 . Disconnect the air regulator connector. /
12.Disconnect two earth terminals.
Nut: 1,2, 4,10,12
13. Remove water hose from the bracket below the intake Bolt: 3,5,6,7,9,11,13
manifold.
4 2
14.Remove the intake manifold.
• Remove installation bolts and nuts in the arder shown
in the diagram on the right.
15. Remove the intake manifold gasket.
5 9 13 11 7 3 1
EN-73
RB20E ENGINE
lnspection
Distortion of the intake manifold
• Use a straight gauge and the feeler gauge to measure Straight gauge
the distortion of the front and reverse surface in six
directions.
• lf the distortion is over the limit use a surface grinder
to repair distortion. Replace the intake manifold if the
distortion is too excessive to fix.
lnstallation
1. lnstall the intake manifold gasket.
• Use scraper to remove any gasket or foreign objects
etc. adhered to intake manifold and cylinder head Coolant passage
~~
• Clean the surface using white gasoline.
• Make sure the coolant passage way is facing the front Front Q
when installing the gasket.
2. lnstall the intake manifold.

Nut: 2, 4, 10, 12, 13
• Tighten the installation bolts and nuts uniformly in Bolt: 1, 3, 5, 6, 7, 8, 9, 11
severa! stages in arder shown in the diagram on the
right.
3. lnstall the water hose to the bracket below intake
manifold.
4. Connect two earth terminals.
5. lnstall the air regulator connector. r ,_;;;:. IQ!'.!_ition coil

6. lnstall the radiator upper hose to water outlet. hermal ,
tr,a
7. lnstall the engine coolant temperature sensor and e
thermal transmitter connector. '---'U O
8. lnstall the connector and primary terminal to the igni- Earth

ont
tion coil. /
/ pper ho ·'· .. / ·· • ··
9. lnstall the rest in reverse arder to the removal '-' 1
procedure.
EN-74
RB20E ENGINE
trlrhermal transmitter
15~20{1.5~2.0} ~
~ N-m{kg-m}
11!::1 Liq uid gasket
Disassembly
1. Remove the water outlet.
3. Remove the ignition coil bracket.
4. Remove the thermal transmitter and water
temperature sensor.
5. Remove the aír regulator.
Assembly
1. lnstall the air regulator.
2. lnstall the thermal transmitter and the water
temperature sensor.
• Replace the engine coolant temperature sensor
copper washer with a new one.
• Apply sealing agent to thread part and tighten to
specified torque.
Thermal transmítter
Engine coolant temperature sensor
Tightening torque (N-m{kg-m}) 8.4~11 {0.86~1.1}
5. lnstall the water outlet.
EXHAUST MANIFOLD ENGINE MECHANICAL
RB20E ENGINE
5. EXHAUST MANIFOLD
Removal
( 1) Open the boot lid.
"""'
' rur,;-,.""'-'l',N
ust sensor
ne~_for,
2. Remove air duct and resonator ASSY.
3. Remove the exhaust front tube from exhaust
r
r
manifold.
4. Remove the exhaust sensor connector.
5. Disconnect earth wire from the exhaust manifold
cover side.
6. Remove the exhaust manifold cover.
7. Remove the exhaust sensor.
• Care must be taken not to cause any damage to the
exhaust sensor.
8. Remove the exhaust manifold.
• Remove the installation nuts in the arder shown in
diagram on right.
9. Remove the exhaust manifold gasket.
lnspection
Distortion of exhaust manifold
• Use a scraper to remove gasket on the installation
Straight gauge
surface.
• Use a straight gauge and feeler gauge to measure the
installation surface distortion in tour directions.
• lf the distortion is over the limit use the surface grinder
to repair distortion. Replace the exhaust manifold if
the distortion is too excessive to fix.
EN-76
RB20E ENGINE
lnstallation
1. lnstall exhaust manifold gasket.
• Use the scraper to remove gasket and other foreign
object from exhaust manifold and cylinder head
installation area.
• Clean the installation surface with white gasoline.
Cylinder head side Q
• When installing the stud bolt, make sure the stud bolt
with shorter thread side if on the cylinder head side.
• lnstall the gasket in the correct direction shown.
2. lnstall exhaust manifold.

• There are No. 3, No.4 for port (4) and non-port (12)
yokes. Make sure to use correct yoke for each parts. 010.7 C0.5
Diameter ct>D (mm)
No. 3, No, 4 port 22
No. 1, 2, 5, 6 port 24
00
---r---t--· 6
• lnstall the washer in the direction shown.

3. lnstall the exhaust manifold cover.
4. lnstall exhaust front tube.
• Replace the installation nuts with a new one. Manifold side

• Tighten the installation nuts in the arder shown in the
diagram on the right.
Tightening torque (N-m{kg-m}) 27-31{2.8~3.2}
5. lnstall the rest in reverse order to the removal 9 ~ 1 3 8 11
~'-----"'~- ~ -e-.:-; .... .,. .. '
procedure. º · · , 12
6. lnstall exhaust sensor. 10 62 4 7 O

Exhaust sensor installation nuts 78{8.0}
Exhaust sensor 40~50{4.1 ~5.1}
EN-77
ROCKER COVER ENGJNE MECHANICAL
RB20E ENGINE
6. ROCKER COVER
Removal
1 . Remove the battery negative terminal.
3. Remove the blowby hose.
~ Replace after every dísassembly

~N-m{kg-m}
4. Remove installation screws in order shown in the

5. Remove gasket from the rocker cover.
lnspection
• Check far any cracks, damage or oil leaking from the
rocker cover.
• Replace the rocker cover if any abnormality is found.
• Make sure engine oil is not leaking from between the
rocker cover and the cylinder head.
lnstallation
1. lnstall the gasket to rocker cover.
• lnstall the gasket to rocker cover installation groove
securely.
2. lnstall the rocker cover.
• Remove any oil and rubbish etc. from cylinder head
side installation surface.
• Tighten installation screws in order shown in the
procedure.
EN-78
ROCKER SHAFT ENGINE MECHANICAL
RB20E ENGINE
7. ROCKER SHAFT
Lífter guide --~--=;; =¿......., Cylinder head
Hydraulic valv
~~!'~~~
~ N-m{kg-m}
IJ Engine oil
Removal
( 1) Open the boot lid.
3. Remove the rocker cover.
4. Remove the rocker shaft and rocker arm ASSY by
removing the rocker shaft bolt.
5. Remove the rocker arm from the rocker shaft.
• Check the installation position and store it away to
avoid confusion.
6. Remove the lifter guide together with hydraulic lifter.

• Secure each hydraulic valve lifter with wire etc. and
remove carefully without dropping.
7. Remove the hydraulic valve lifter from the lifter guide.

• Check the installation position and store it away to
avoid confusion.
• Store the hydraulic valve lifter in stand up position. lf
stored for a longer period of time, store it in clean
engine oil.
• Do not disassemble hydraulic valve lifter. 0 X
EN-79
RB20E ENGINE
lnspection
Rocker shaft visual inspection
• Visually inspect rocker arm rotational part for any
wear or damage.
• lf there are any abnormalities replace with a new
one.
Rocker arm visual inspection

• Visually inspect rocker arm and rotational part for any
wear or damage.
• lf there are any abnormalities replace with a new
one.
Rocker arm oil clearance

(Rocker shaft externa! diameter)
• Use micrometer to measure the externa! diameter
near the rocker shaft oil groove.
Standard value (mm) $17.979~18.000
(Rocker arm interna! diameter)
• Use inside micrometer to measure the interna!
diameter of the rocker arm shaft hole.
Standard value (mm) <P18.007~18.028
(Rocker arm ail clearance) =
(Rocker arm intemal diameter) -
(Racker shaft externa! diameter)
• Replace rocker arm or rocker shaft if the standard
value is incorrect. •
Hydraulic valve lifter visual inspection

• Visually inspect cam shaft warking surface, lifter
surface and guide rotatianal parts for any wear or
damage. Replace with a new one if there are any
abnarmalities.
Hydraulic valve lifter clearance

(Hydraulic valve lifter external diameter)
• Use mircrometer to measure the external diameter of
hydraulic valve lifter.
(Hydraulic valve lifter hole diameter)
• Use inside micrometer to measure the diameter of Micromeler
hydraulic valve lifter hale diameter.
(Hydraulic valve lifter clearance) =
(valve lifter hale diameter) -
(valve lifter externa! diameter)
• Replace racker arm ar racker shaft if the standard
value is incarrect.
RB20E ENGINE
Hydraulic valve lifter air interfusion inspection
• Apply engine oil to rotational surface to install.
• After installation push down on the plunger head. lf it
,..
Push with finger
moves more than 1mm carry out the air release

operation using method below. (Use same method to
check the valve lifter when abnormal sound is heard
when the engine is started).
(1) After installing the rocker cover, run the engine at
approx. 1OOOrpm with no-load far 1O minutes.
Recheck the plunger head movement.
(2) lf the air is not released by carrying out above
method, re place the hydraulic valve lifter with a new
one.
lnstallation
1. lnstall the hydraulic valve lifter to the lifter guide.
• Apply engine oil to rotational parts.
• lnstall parts back in same position as befare removal
and fix using wire etc. to avoid them falling into the
engine bey.
2. lnstall the lifter guide. .,
• The front (No. 1~3 cylindera) and the rear (No. 4~6 FRONT
".-F" mark
cylinders) can be distinct by molded mark F and R.
Make sure the molded marks are facing correct direc-
tion as shown in the diagram on the right.
3. lnstall rocker arm to the rocker shaft.
• Apply engine oil to rotational parts, the valve lifter and
o o
the valve stem contact part.
• lnstall them back in same position.
• The front (No. 1~3 cylinders) and the rear (No. 4~6
cylinders) rocker armare shaped different. Care must
Front Rear
be taken to place them correctly. (No.1-No.3 cylinder} (No. 4-No. 6 cylinder)
Distinction
• The front (No. 1~3 cylinders) and the rear (No. 4~6 mark (1 )
cylinders) rocker shaft are shaped different. They can
be distinct by distinction mark.
4. lnstall the rocker shaft and the rocker arm ASSY.

• Check the front and rear befare installing.
• When installing the rocker shaft make sure the
".-F" mark
FRONT
..
cylinder head bolt installation notch is facing out.
Caution:
Do not completely tighten the rocker shaft bolts.
EN-81
RB20E ENGINE
5. Tighten rocker shaft bolts.
• Use the following method to tighten the rocker shaft
bolts uniformly.
(1 ) Position No.1 cylinder at T.D.C (top dead centre)
position.
(2) Tighten No.4~6 cylinder locker shaft bolts.
Tightening torque (N-m{kg-m}) 18-22{1.8-2.2}
(3) Position No.6 cylinder at T.D.C by turning the crank-
shaft once.
(4) Tighten No.1 ~3 cylinder rocker shaft bolts.
..
No. 1 No.2 No.3 No.4 No.5 No.6
Front
6. Make sure there is no trapped air inside the

hydraulic valve lifter.
7. lnstall the rest in reverse order to the removal
procedure.
8. Start the engine and make sure there is no abnormal
sound from the hydraulic valve lifter.
EN-82
CAM SHAFT ENGINE MECHANICAL
RB20E ENGINE
8. CAM SHAFT
~ Rocker shaft bolt Rocke r s haft IJ
18-22{1.8-2.2} (24)
l]Rocker ar
0-ring~
Cam shaft retainer
Cam shaft retainer installation bolt
6.9-7.8{0.7-0.8} (3)toj \
IJ~cam shaft front oil eal ~-1
Distributor instaUatíon bolt

13-16 {1.3-1.6} (2) ~
r
Cam timing pulley installation bolt
16-22{1.6-2.2} (4)1J ~
0-ring
Oistributor

to] N-m{kg-m}
IJ Engine oil
Removal
6. Remove the radiator upper hose and the lower hose
from engine side.
9. Remove the fuel injector.
11. Remove the exhaust front tube.
12.Remove the exhaust manifold.
15. Remove the auxiliary belt.
18.Remove the cylinder head.
19.Remove the distributor.
20.Remove the rocker shaft and the rocker arm ASSY.
21.Remove the lifter guide.
22.Remove the cam timing pulley.
• Use pulley holder to fix the cam timing pulley to
remove the installation bolts.
,.--~ 23. Remove the cam shaft retainer.
EN-83
RB20E ENGINE
24. Remove front oil seal from the cam shaft retainer.
• Use negative driver to remove oil seal from the cam
shaft retainer.
25. Remove the cam shaft.
• Carefully remove journal and the cam from the
cylinder head , making sure they will not touch the
cam shaft bracket.
lnspection
Cam shaft visual inspection
• Check to make sure there is no damage or wear to
the cam shaft.
• Replace if any abnormalities are found.
Cam shaft run-out

• Use V-block on the fixed surface and support cam
shaft No. 1 and No. 7 journal.
• Set dial gauge vertically to No. 4 journal.
• Rotate the cam shaft in one direction and read the
movement width on the dial gauge.
• Cam shaft run-out is equal to half of movement width
indicated on dial gauge.
• lf the run-out is over the limit value replace the cam
shaft.
Cam nose height

• Use micrometer to measure cam nose height.
Standard value (mm) lntake 39.242~39.432
Exhaust 39.123~39.313
Wear out limit value (mm)
lntake 0.05
Exhaust 0.05 .......,.
• lf the value is over the limit replace the cam shaft.
Cam shaft oíl clearance

(Cam journal externa! diameter)
• Use micrometer to measure cam journal externa! di-
ameter.
Standard value (mm)
(No.1~No.6 journal) <1>46.935~<1>47 .025
(No. 7 journal) <1>46.415~<1>46.435
(Cam bracket interna! diameter}
• Use bore gauge to measure.
Standard value (mm)
(No.1~No.6 journal) <1>47.000~<1>4 7.025
(No. 7 journal) <1>46.500~<1>46.525
EN-84
RB20E ENGINE
(Cam oil clearance) =
(Cam bracket interna! diameter) -
Standard value (mm)
(No.1 ~No.6 journal) 0.045-0.090
(No.7 journal) 0.056~0.11 O
• lf the value is not within standard value, replace

cylinder head ASSY or cam shaft.
Cam shaft end play

• Set a dial gauge at front end of the cam shaft in thrust Dial gauge
direction. Move the cam shaft forwards and back-
wards and read the dial gauge run-out measurement.
Standard value (mm) 0.030~0.060
• lf the value is not within standard value, replace the
cam shaft. Re-measure and if the value is still not at
standard value, also replace the cylinder head.
lnstallation
1. lnstall the cam shaft.
• Apply engine oil to cam nose and the cam journal.
• When installing make sure the knock pin on front side
of the cam shaft is facing upwards.
• lnsert the journal and the cam straight so that it will not
interfere with cam bracket. Knock pin
2. lnstall the cam shaft retainer.

• lf the cam shaft front oil seal has been removed,
install the retainer without attaching the oil seal at this
stage.
• Replace the O-ring with a new one.
~ oo~:
Tightening torque (N-m{kg-m}) 6.9-7.8{0.7~0.8} O-ring
Cam shaft retainer
3. lnstall the cam shaft front oíl seal.

• Apply engine oil to oil seal lip area.
• Carefully tap in the oil seal using 41 mm box etc. until
level with retaíner front surface.
Caution:
Do not tap the oil seal too hard as it will block retainer oil
return. Box
RB20E ENGINE
4. lnstall cam timing pulley.
• When installing the washer tace the side with
chamfered interna! diameter to bolt side.
• Apply engine oíl to installation bolt thread part.
Face chamfered side to bolt
5. Use pulley holder to fix the cam timing pulley and

tighten the bolts.
Tightening torque (N-m{kg-m}) 16-22{1.6-2.2}
6. lnstall the distributor.

• Make sure No.1 cylinder is at compression T.D.C Housing alignment mark 2
position.
'-G-e....,ar...-a ,:.,lig._n~;;;:h
• lnstall the distributor driven gear by aligning the
distributor driven gear alignment mark to small
housing side alignment mark.
1
mari<1 H
Tightening torque (N-m{kg-m}) 13~16{1.3~1.6} Alignment Alignment mark position
mark befare distributor alter distributor is installed
is installed when first pipe is al T.D.C
procedure.
EN-86
CYLINDER HEAD GASKET ENGINE MECHANICAL
RB20E ENGINE
9. CYLINDER HEAD GASKET
i l]Cylinder head bolt (14)

Rof,c to t,e Cylinder head ASSY
1
~
Cylínder head installation bolt
6.9-7.8{0.7-0.8} (3) t°_J
1
~~~~~~-•~/
~ ·-J
..
. ~'.---·- .. ,·.--:. . _--·:·:·:~.-e:?·.-~~--

.;:.__ :>
: ..
--~
·
·-:.
. ~·::;;,:_6-~·-:··-
.. · ~Cylinder head gasket
~ Replace after every disassembl

~ N-m{kg-m}
IJ Engine oil
Removal
6. Remove the radiator upper hose and the lower hose
from engine side.
9. Remove the fuel injector.
13.Remove the cooling fan.
15.Remove the auxiliary belt.
3 1
18. Remove the cylinder head ASSY. +.... t
• Remove the cylinder head auxiliary bolts in the arder o o o o o o o
shown. o o o o o o o
•
_/ V'
Q Front 2
EN-87
RB20E ENGINE
• Remove the cylinder head bolts in the arder shown.
19. Remove the cylinder head gasket. ' .....
----.,\
""'
o o o o o
3 7 11 1°:3 9 ~ 1
4
o § 1J 1c4 w 6
o 6
_/
-
+ Front
lnspection
Cylinder head distortion
(1) Use a scraper to remove gasket.
Caution:
Care must be taken not to allow removed gasket to enter
oil and coolant passage.
(2) Measure cylinder head under surface far distortion in

Straight~~¿S:>-1
six directions.
• lf the value exceeds the limit apply compound to press o=
platen and readjust the surface. lf the value exceeds ~

_gauge
the limit greatly, replace the cylinder head with a new 1 ..J • -.., I
r-::,-3 ~
one.
~
Cylinder block top surface distortion
• Use the scraper to completely remove gasket, oil, wa-
ter stains and carbon etc. on the cylinder block front
surface.
Caution:
• Measure distortion of the block top surface in six
directions using straight gauge.
• lf the value is over the limit use a surface grinder to
correct the distortion.
• Replace the cylinder block if the distortion value is too
great.
lnstallation
1. lnstall the cylinder head gasket.
• Use a scraper to remove gasket and other foreign
objects from cylinder block side and cylinder head
side installation surface.
Caution:
Care must be taken not to allow foreign objects to enter
• Clean the surface using white gasoline.
• lnstall the gasket aligning to knock pin.
EN-88
RB20E ENGINE
2. lnstall the cylinder head.
• Make sure the No.1 cylinder head is at T.D.C
position.
• Check that No.1 cylinder intake and exhaust valve is
not raised.
• lnstall the cylinder head carefully trying not to damage
the cylinder head gasket.
3. Tighten the cylinder head bolts.

• Apply engine oil to thread part and bearing surface.
• lnstall the washer with non-chamfered side facing the
cylinder head.
Cylinder head side
4. Tighten the cylinder head bolts in arder shown in the
(1)
(2)
diagram to the right.
Tighten to 29N-m{3kg-m}
Tighten to 78N-m{8kg-m}
....
o
12
o
8
o
4
o
2
o
6
o
10
-
o
14
11
o
7
o
3
o
1
o
5
o
9
o 1J
(3) Loasen to ON-m{0kg-m} L/ ...
(4) Tighten to 25~34N-m{2.5~3.5kg-m}
. . Front
(5) Tighten to 100° ~ 105°. lf you don't have an angle
wrench tighten to 78~88N-m{8.0~9.0kg-m}
Caution:
Rotation angle should be checked using angle wrench or
protractor. Never estímate visually.
• •
5. Tighten the cylinder head auxiliary bolts in the arder 1 3
shown in the diagram to the right. .... ....

6. lnstall the rest in reverse order to the removal o o o o o o o
procedure. o o o o o o o
_/
Q Front
...
....
2
EN-89
OIL PAN & OIL FILTER ENGINE MECHANICAL
RB20E ENGINE
10. OIL PAN & OIL FILTER
~ O-ring
1
1filter ,n,
, Oil pan installation bolt ttJ.J stallation bolt ~-.,,¡
J./
1 6.3-8.3{0.64-0.85}(30) (2) 16-21 {1.6-2.1}
~ Oil filler
A N-rn{kg-m}
~ Liquid gasket
r ' Coppocw~hoc ¡:j
Drain plug 29-39{3.0~4.0} (!J_J
Removal
3. Drain engine oil from the oil pan drain plug.
4. Remove the tension rod.
5. Remove the stabilizer. OR remove stabilizer installa-
tion bolts and installation nuts located on the vehicle
.Á",,,,/2,_ : .-'.
side and lower the stabilizer to below the oil pan.
6. Remove A / T oíl cooler tube from the oil pan bracket.
7. Remove right and rear gasket.
8. Remove the lower rear plate (A/ T vehicles).
9. Remove right and left front side engine mount installa-
tion nuts. Rear
(low~ ~ ,., /
10.Attach a sling to the engine and raise using a hoist.
Front <:,
11. Remove installation bolts in the order shown in the

diagram to the right.
12. Remove oil pan from the cylinder block.

(1) lnsert seal cutter between the oil pan and the cylinder
block.
(2) Tap the sea! cutter rear surface using a hammer to
remove the oil pan.
EN-90
RB20E ENGINE
13.Remove oil pan.
• Remove the oil pan carefully making sure it will not
interfere with oil filter net area.
14.Remove the oil filter.
lnspection
Oil filter visual inspection
• Check that there are no foreign objects on the oil filter
net.
• Clean the net if there are any foreign objects.
• Replace with new one if there are any fault.
Net
lnstallation
1 . 1nstall the oil fi lter.
2. lnstall the oil pan.

7mm;ff
• Use scraper to remove any oil liquid gasket on the oil A-A B-B
pan and cylinder block installation surface.
• Clean the installation surface using white gasoline.
• Apply bond (KP51 O 00150) to specified position
•
shown in the diagram on right at approx. <P3.5~4.5.
Place the oil pan below cylinder block. Care must be

c:::J
taken not to allow liquid gasket to cone in contact with _#;-: ~- ··.
the cylinder block and other parts. ~
'
, " .
• Place 2 bolts (M6 x 1 .25) at suitable position and /
tighten temporaríly. lnstall other bolts temporarily.

~
• Tighten the bolts to specified torque in order shown in
the diagram on right.
Tlghtening torque(N-m{kg-m}) 6.3~8.3{0.64~0.85} Front Q
• No. 2 and No. 20 installation bolts will also tighten
A/ T oil cooler pipings.
Caution:
Do not over tighten the installation bolts.
3. lnstall oil pan drain plug.

• Replace the washer with a new one.
• lnstall in the direction shown. Oil pan side
4. lnstall the rest in reverse arder to the removal t
procedure.
lnspection
,,.-----. • Check the level of engine oil.
EN-91
COLLECTOR ASSY ENGINE MECHANICAL
RB20E ENGINE
11. COL LECTOR ASSY
Acceleration wíre bracket
f ' Collector bolt (4) Pn'I

18-22(1 .8 - 2.2} ~-..
Conector bolt (3) ,ni

8;22{1 8 -2.2} ,-.
(1 Collector gasket
~ N-m{kg-m}
(1 Replace after every disassembly
Removal
1 . Release the fuel pressure inside the fuel pipings.
• Start the engine.
• After starting the engine remove the fuel pump fuse
and wait until the engine stops. Crank the engine two
or three times to consume fue! remaining in the fue!
pipes.
• lf the vehicle doesn't start, remove the fuel pump and
the fuse and crank the engine four to five times to
consume fue! remaining in the fuel pipes.
Caution:
The battery may become weak, use booster cable to
connect to another battery if necessary.
2. Accelerator wire adjustment.

• Provide adequate slack for the acceleration wire and
use the lock nut to pull the outer case in the direction
of the accelerator pedal.
• Return the lock nut 1.0 ~ 1.5 turns from the position
where the throttle drum starts moving (no play at this
time) and tighten securely.
2
'
3. Remove the collector bolts.
• Remove the bolts in order shown in the figure on the
right.
EN-92
COLLECTOR ASSY ENGINE MECHANICAL
RB20E ENGINE
lnstallation
1 . lnstall the collector bolts.
• lnstall the bolts in the arder shown in the figure on the
right uniformly in two to three stages.
Disassembly
Throttle chamber
A Throttle chamber bolt (4) ~,-

A AAC valve ASSY instal abon bolt
~ -------18-22{1.8-2.2} A (4) 8.5-11{0.86-1.1}
~ (N-m{kg-m})
O Replace after every dísassembly
1 . Remove throttle chamber bolts

• Remove the bolts in the order shown in the figure on
the right.
Assembly
1. lnstall the bolts in the order shown in the figure on the
right uniformly in two stages.
Tlghtening torque (N-m{kg-m})
1st stage 9~11{0.9~1.1}
2nd stage 18~22{1.8~2.2}
2. lnstall the throttle chamber gasket. 1

• When installing the throttle chamber gasket, make Bottom
sure to instan it in the correct direction.
EN-93
OIL PUMP ENGINE MECHANICAL
RB20E ENGINE
12. OIL PUMP
.··~....
Gasket ~
rPJ 9.8-11.8{1.0-1.2} (2) Oil pump cover _
98-118{10-12}tt'.J
J¡i,@
1
'----(ll"'O)'a
~1/, lnnen~tlJ
·' ~
b~~ .
O"tenoto,IJ
•
~ ·
3 7-5.0{0.38-0.51} (7)tt'.J
~IJ Front oil sea~ ~ -~ ~0-ríng...--¡

~ - - - - Pump housing ~
Reg"latocvruve
Spring ~
¿i ~_:;,.
-----..._~ ,
_~ Oil filter
_.- i
1
~
~
©>
Washer---~
~~
~ ~9.8-11 .8{1.0-1 .2}(4)~
I
16-21{1.6~21}(2)rPj
~ 9.8-11.8{1 .0-1.2} ~
~ N-m{kg-m} Regulator plug 39.2-68.6{4.0~7.0}~
IJ Engine oíl
Removal
4. Drain the engine oil from the oil pan.
5. Remove the air duct (externa! air introduction side).
8. Remove auxiliary belt.
11. Remove the timing belt rear cover.
12.Remove the oíl pan. ·
13. Remove the oil pum p.
lnstallation
1. lnstall the oil pump.
• Use the scraper to remove old gasket from the oil
pump and the cylinder block.
• Use white gasoline to remove grease, water and
rubbish from the installation surface.
• Align to the knock pin on the cylinder block side to
install.
• There are tour types of oil pump installation bolts.
Make sure to use the correct bolts.
EN-94
RB20E ENGINE
1 4 20
2 2 35
3 1 45
4 1 55 3

procedure.
Disassembly
1. Remove the front oil seal.
• Use a tool such as a screwdriver to remove.
Caution:
Care must be taken not to damage the oil pump
housing.
2. Remove the oil pump cover.

3. Remove the inner and outer rotor.
4. Disconnect the regulator plug and remove the spring
and the regulator valve.
lnspection
Oil pump visual inspection
• Check far any wear or damage on the inner and outer
rotor and the oil pump housing.
• Replace the oil pump ASSY if there is any abnormal-
ity. Feeler
i=r...,._,~Feeler
gauge ~-~~g;uge
1-=-G
Oil pump parts clearance inspection Q
• Use the feeler gauge to check the following

clearance.
(1) Outer rotor to oil pump housing clearance ;,,-:-◊
8
Standard value (mm) 0.11 ~0.2
(2) Outer rotor and inner rotor chip clearance.
Standard value (mm) Below 0.180
(3) lnner rotor to oil pump housing side clearance
(4) Outer rotor to oil pump housing side clearance
• Replace the oil pump ASSY if any of the measure-

ments are out of standard value.
EN-95
RB20E ENGINE
(5) lnner rotor to oil pump housing inlow area clearance Position 5
• Use the method below to measure the clearance
between the inner rotor and oil pump housing inlow
area.
• Use the micrometer to measure the oil pump housing
inlow inner diameter.
(6) Use the micometer to measure the inner rotor inlow Position 6
outer diameter. Micrometer
(lnner rotor to oil pump housing inlow a rea clearance) =

(Oil pump housing inlow inner diameter) -
(Oil pump housing inlow outer diameter)
• Replace the oil pump ASSY if the measurements are
out of standard value.
Regulator valve visual inspection

• Check far any wear or damage on the regulator valve
rotational parts.
• Check the regulator spring for any abnormality.
• Replace the regulator valve or the oil pump ASSY if
there are any faults.
Assembly
1. lnstall the inner and the outer rotor.
• Apply engine oil to each rotational and moving parts.
• Position the inner rotor groove to the cover side.
Cover side
Groove
2. Tighten the oil pump cover installation screws equal-
ly.
3. lnstall the regulator valve.
Regulator valve
• Replace the regulator washer with a new one. ~
• Tighten the regulator plug.
Spring ~
Tightening torque (N-m{kg-m}) 39~69{4.0~ 7 .O} ~ Washer
~Regulator plug
4. lnstall the front oíl seal.
• Replace the oil seal with a new one.
• Check if there is any damage or deformation on oil
KV401 00900
seal periphery.
• Position the oil seal side with writing towards front.
• Use the oil seal drift to insert the oil seal in until level
with installation surface.
• Apply engine oil or chassis grease to oil seal lip sur-
face.
EN-96
COOLING FAN ENGINE MECHANICAL
RB20E ENGINE
13. COOLING FAN
Removal
1. Remove the battery negative terminal inside the
boot.
2. Remove the air duct. ~
3. Loasen the cooling fan installation nuts. é>
4. Loasen the fan belt.
5. Remove the installation nuts to remove the cooling
t°J 1
10{0.6-1.0}(4)
fan.
6. Remove the installation bolts to remove the fan from
the cup ring.
lnspection
Cup ring inspection
• Check far any silicon oil leak.
Cooling fan inspection

• Check far any damage or cut.
lnstallation
lnstall parts in the reverse arder to the removal proce-
dure.
• lnstall the fan to the cup ring making sure the front
mark is facing front.
/ -- Tightening torque (N-m{kg-m}) 6~10{0.6~1.0}
• Adjust the fan belt tension.
EN-97
WATER PUMP ENGINE MECHANICAL
RB20E ENGINE
14. WATER PUMP
fl Liquid gasket
tt=!J N-m{kg-m}
Removal
boot.
4 . Drain coolant from the radiator drain plug.
5. □ rain coolant from the cylinder block drain plug.
9. Remove the water pump pulley.
10.Remove the timing belt.
11 . Remove the tensioner pulley.
12. Remove the alternator adjust bar. ~---1 . 6 7 a 9
13. Remove the installation bolts in the arder shown.
14.Remove the water pump.
4
3 2
• lnsert a stubby driver into the installation bolt hale

and move it up and down to remove.
Caution:
Care must be taken not to damage the cylinder block
side screws.
EN-98
WATERPUMP ENGINE MECHANICAL
RB20E ENGINE
lnspection
• Check the water pump main body and the vane far
rust or foreign objects.
• Make sure the water pump is not warby.
• Replace the water pump if there is any abnormality.
lnstallation
1. lnstall the water pump.
ct>2.0~3.0mm
• Use a scraper to remove old gasket from the water
pump and the cylinder block installation surface.
• Apply sealing agent (KP71 O 00150) to the position
shown in approx. <t>2.0~3.0mm.
5 4
• Tighten the installation balts in the arder shown.
• Tighten the installation bolts 8 and 9 together with the g
alternator adjust bar.
11
• There are four types of installation bolts.

~~~~15
M6 6.3~8.3{0.64~0.85}
M8 16~21{1.6~2.1}
M10 31.4~42.1 {3.2~4.3} 1{l) M6 X 1.0 M10x15(10, 11 )
·
M8x1.25 (7,12) (8,9)
_ ..-- - . 2. 1nstall the rest in reverse arder to the removal (1~6)
procedure.
EN-99
THERMOSTAT & WATER INLET ENGINE MECHANICAL
RB20E ENGINE
15. THERMOSTAT & WATER INLET
Removal
~!stat
boot.
negative battery terminal. ~ Washer inlet rl
2. Drain coolant from the radiator drain plug. ~ Washer
16-21{1 .6-2.1}(3}~
4. Remove the alternator belt to shift the alternator
down.
5. Remove the alternator adjust bracket.
6. Remove the radiator lower hose at the thermostat
housing side.
7. Remove the water inlet.

• lnsert end of a tool such as a screwdriver into the
thermostat housing and move it up and down to
remove.
8. Remove the thermostat.
lnspection
Thermostat inspection
Check the valve opening temperature and maximum
valve lift.
• Hang the thermostat by string to the valve and sub-
merge in heated water in double walled container and
stir water while heating it up.
• The opening temperature is the temperature when
the valve opens and thermostat falls from the string.
Valve opening temperature (ºC) 76.5
Max. valve lift (mm/ºC) Over 1O/ 90
• Replace the thermostat if the value is not at standard
value.
lnstallation
Jiggle valve
1. Use a scraper to remove old liquid gasket from the
water inlet and the cylinder block installation surface.
• Use white gasoline to clean the surface.
2. lnstall the thermostat.
• Position the thermostat so the jiggle valve (TOP mark)
is on the top.
EN-100
RB20E ENGINE
3. lnstall the water inlet.
<P2.0-3.0mm
• Apply sealing agent (KP510 00150) at approx.
<t>2.0~3.0mm as shown in the figure on the right.
• lnstall in position as shown.

• Tighten the installation bolts.

procedure.
EN-101
WATER OUTLET ENGINE MECHANICAL
RB20E ENGINE
16. WATER OUTLET
Removal
boot.
3. Remove the radiator upper hose at the water outlet
side.

• lnsert end of a tool such as a screwdriver into the
water outlet and move it up and down to remove.
lnspection
Visual inspection
• Check the water outlet for any deformation or wear.
• Replace the water outlet if there is any abnormality.
lnstallation
1. Use a scraper to remove old liquid gasket on the wa-
ter outlet and intake manifold installation surface.
• Use white gasoline to clean the installation surface. <ll2.0-3.0mm
• Apply sealing agent (KP510 00150) at ct>2.0~3.0 mm

and install the water outlet.

procedure.
EN-102
A1R CLEANER & AIR OUCT ENGINE MECHANICAL
1. AIR CLEANER & AIR DUCT (RB25DE / RB25DET)
Removal N;gative terminal l

1. Remove negative battery terminal.
---
,e:_
2. Before removing, use air gun to remove any rubbish,
dust etc. to avoid foreign objects entering the duct. I Óptf /
3. Remove the air flow meter connector.
"-. ~ - Clip/ ) _____
4. Remove the air duct, air cleaner case (upper) and air Clip "'- (C
cleaner element.
• Remove 2 air duct clips and 4 air cleaner case (upper)
,t~'--i),
• 'f
clips.
5. Remove the air cleaner case (lower).
• Remove 4 installatlon bolts. >
stal]ption
lts
/ \
6. Remove the air duct, resonator ASSY (RB25DE). <e

r-:::
• Remove 2 air hoses, and installation bolts.
·0-
Front
eering uid
eserv ir t nk
7. Remove the air hose (RB25DET). rts
(1) Remove the air inlet tube.

• Remove 3 installation bolts.
(2) Remove power steering reservoir tank installation
,- bolts and shift it towards front.
EN-103
AIR CLEANER & AIR DUCT ENGINE MECHANICAL
(3) Remove air tube from the air hose.
(4) Remove air hose clamp to take out the air hose.
lnspection
• Make sure the air cleaner element is clean.
Periodic replacement period: Every 60,000km
lnstallation
1. lnstall the air hose (R825DET).
• Make sure the clamp is facing correct direction when
installing.
2. lnstall the air duct and resonator ASSY (RB25DE).

• Tighten 2 installation bolts.
• lnstall 2 air hoses.
3. lnstall the lower air cleaner case.
4. lnstall the air cleaner element, air cleaner case (up-

per) and the air duct.
• Place 4 air cleaner case (upper) clips and 2 air duct
clips.
procedure.
• When the air flow meter is removed, replace the o-ring
at installation.
EN-104
Gasket~
[g N-m{kg-m}
Removal
4. Remove the air inlet pipe.
5. Disconnect the accelerator wire and the ASCO wire.
6. Remove the throttle sensor, throttle valve switch, AAC
valve and FICD connector.
7. Disconnect the water vacuum, blow-by and air hoses
on the intake manifold collector.
8. Remove the throttle chamber ASSY.

• Remove the installatian bolts in the arder shown.
• Remave the gasket.
Front Q
9. Remave the intake manifold callectar ASSY.
• Remave the installatian nuts and balts in the arder
shown in the figure to the right.
• Check if you have removed all hoses and wires.
1O. Remove the gasket.
EN-105
lnspection
Distortion of the intake manifold collector
ure the distortion in six directions.
Limit value (mm) 0 .1
to repair distortion. Replace the intake manifold
collector if the distortion is too excessive to fix.
lnstallation
1. lnstall the gasket.
• Remove any fluid, grease, rubbish etc. adhered to
2. lnstall the intake manifold collector ASSY. Front Q
• Tighten installation nuts and bolts in several stages in
arder shown.
Caution:
lnstall 1, 4, 5, and 7 installation bolts from below intake
manifold.
No. 6 and 9 is a stud bolt and nut.
3. lnstall intake manifold collector hoses.
4. lnstall the throttle chamber.

(1) Make sure there are no grease or rubbish on the
gasket and installation surface.
(2) lnstall the gasket.
• Replace the gasket wíth a new one.
(3) lnstall the bolts in the arder shown in two stages.
1 st 8.8~11{0.9~1 .1}
2 nd 18~21 {1 .8~2.1}
5. lnstall each pipes according to the diagram on the fol-

lowing page.
• The diagram shows the reverse side of the intake
manifold collector.
procedure.
EN-106
R825DE / RB25DET ENGINE
Disassembly
1. Remove the IAA unit.
Caution:
Do not disassemble IAA unit.
Assembly
1. lnstall the IAA unit.
• Make sure there are no grease or rubbish on the
gasket and installation surface.
To canister
To rocker cover
l
. ~ .
To intake manifold - ~
. _
1
To boost sensor
To pressure (RB25DET)
regulator -
->
To heate, f e e d p,
L
, ''>
To air regulator To cylinder block
EN-107
3. FUEL INJECTOR
Removal

5. Remove air inlet pipe.
6. Remove intake manifold col!ector ASSY.
7. Remove fue! tube and fuel injector ASSY.

(1) Remove fuel feed and the return hose. e::> Front
• Place a hole cap immediately after removing the fuel
hose to avoid fuel leak.
(2) Disconnect the fuel injector harness connector.
(3) Remove fuel tube installation bolts.
(4) Remove fuel tube installation bolts in arder shown in
the diagram on right.
8. Remove the fuel pressure regulator.

Caution:
Fuel remaining in the fuel tube may leak.
EN-108
9. Remove fuel injector from the fue! tube.
(1) Remove the injector hose.
(2) Remove the fuel injector by pushing from nozzle
side. ~ lnsulator ~ rlo
~ wO-ring !-
~~ ~~oJ
• Do not hold the connector parts.
• Care must be taken not to drop them.
Caution: lnjector holder Fuel injector
Do not disassemble the fuel injector.
lnspection
Fuel tube & fuel hose
Check to make sure the fuel is not leaking from the
fuel tube and the fuel hose.
Replace the parts if there are any abnormalities.
lnstallation
1. lnstall fuel injector to the fuel tube.
(1) lnstall o-ring to fuel injector.
• Replace o-ring with a new one.
• Read the handling note befare carrying out the
operation.
Handling note
• Always handle the O-ring with bare hands (no
gloves).
• Only apply engine oil (7.5W-30 or similar viscosity)
and never clean or soak the o-ring in solvent solution.
• Avoid using dirty o-ring and devices with dust or other
or stretch them.
• When inserting the fue! injector, pressure regulator or
fuel dumper into the fuel tube, do not twist or turn the
parts.
(2) lnstall the fuel injector to fue! tube.

• Care must be taken not to damage the nozzle tip.
Note:
lf it is difficult to install the fuel injector due to o-ring
resistance, fist install the injector holder and use a screw
i
~ lnsulator
~ 0-ring .
,.,,.o,~,...
with under head approx. 30mm to tighten up alternately to

insert the fuel injector.
:l,,:~'&o~ Fuer injector
EN-109
2. lnstall the fuel pressure regulator. ~ Fuel pressure
• Replace the o-ring with a new one. wulator
3. lnstall fuel tube and fuel injector ASSY. b
(1) lnstall fuel sub tube to the fuel tube.
(2) Tighten the fue! tube installation bolts in the arder

shown in two stages. Front
Tightening torque (N-m{kg-m}) 16~21 {1.6~2.1} e;>
~
• Replace the insulator with a new one.
4. lnstall the fuel injector connectors.

5. lnstall the fuel feed and return hose.
• lnsert the hose tip up to the second bulged part of
_, . .........,_
the fue! tube and make sure to securely tighten the
clamp.
procedure.
7. Place the ignition switch to the ON position to place
fuel pressure to fuel pipings to check for any fuel
leak.
EN-110
4. INTAKE MANIFOLD
lntake m ifold ASSY

18-22{1.8-2.2} (5)
~
•
~ 18-22{1.8-2.2} (5)
~/ Gasket ~
~ 18-22{1.8-2.2}
~ Replace after ever¡ disassembly
~ N-m{kg-m}
Removal
(2) Remove the boot front finisher and remove the /j
negative battery terminal. Front /
3. Drain coolant from the radiator drain plug. /'i:::l
7. Remove the intake manifold col lector ASSY.
8. Remove the fue! injector ASSY.
9. Remove the radiator hose (upper).
10.Disconnect thermal transmitter connector.
11. Disconnect engine coolant temperature sensor
connector.
12. Disconnect VTC solenoid connector.
13.Remove ground terminals (2).
14.Disconnect air regulator connector.
15.Remove the oil level gauge guide installation bolt. Front Q
16. Remove the intake manifold ASSY. 2 6 8 12 11 5 3
(1) Remove installation bolts and nuts in order shown in
the figure on the right.
(2) Remove each water hose below intake manifold.
(RB25DET).
4 10 13 9 7 1
17.Remove the gasket.
EN-111
lnspection
• Use the straight gauge and the feeler gauge to meas- Straight gauge
ure the distortion of the front and reverse surface in
six directions.
to repair distortion. Re place the intake manifold if the
distortion is too excessive to fix.
lnstallation
• Use a scraper to remove any gasket or foreign objects
etc. adhered to intake manifold and cylinder head Coolant passage
~~
2. lnstall intake manifold ASSY.
(1) lnstall each water hoses below intake manifold Front e>
(RB25DET).
(2) lnstall the bolts and nuts in the order shown in figure
on the rig ht.
Nut: 2, 4, 10, 12, 13
Tightening torque (N-m{kg-m}) Bolt 1, 3, 5, 6, 7,8, 9, 11
Bolt 18~22{1.8~2.2}
Nut 11~13{1.1~1.3}
2,7,8,9,10 1 12, 13
40 65 95
r ,,,;;:. ~!ion coíl

3. lnstall the oil level gauge guide installation bolt.
Tightening torque (N-m{kg-m}) 3.9~4.9{0.4~0.5} ~. he
"""---...,--,,tran
sen
\__../<-.xo
4. lnstall the air regulator connector. Earth
5. lnstall the radiator hose (upper). /

/
6. Connect the earth terminal.
7. lnstall the VTC solenoid connector.
8. lnstall the engine coolant temperature sensor connec-
tor.
9. lnstall the thermal transmitter connector.
1O. lnstall the rest in reverse order to the removal
procedure.
EN-112
Disassembly
rmal transmitter
1. Remove the engine coolant temperature sensor and
thermal transmitter.
. ):¡temp
' ---J°'-
Copper washer
2. Remove each bracket and the clamps.

3. Remove the air regulator.
Caution:
• Do not disassemble and adjust the air regulator.
Care must be taken not to damage parts by dropping
tools.
4. Remove water outlet pipe.

• Place a screwdriver etc. between right and left water
outlet pipe. Move it up and down gently to remove.
5. Remove the water tube. (RB25DET)
Assembly
1. lnstall the water tube (RB25DET)
Tightening torque (N-m{kg-m}) 6.3~8.3{0;64~0.85}
EN-113
2. lnstall water outlet pipe.
(1) Use the scraper to remove gasket on water pipe in-
stallation surface and intake manifold side installation
surface.
(2) Apply sealing agent (KP51 O 00150) as shown in the
figure on the right at approx. <1>2.0 ~ 3.0 mm.
(3) lnstall the water outlet pipe to intake manifold.

• Make sure the front mark is facing the front when
installing. -
Tightening torque (N-m{kg-m}) 16~21 {1.6~2.1} {ó':
3. lnstall the air regulator. Front m
4. lnstall each bracket and the clamps as shown.
5. lnstall the engine coolant temperature sensor and

thermal transmitter.
• Apply the sealing agent to thread part.
Tlghtening torque (N-m{kg-m})
Engine coolant temperature sensor 20~29{2.0~3.0}
Thermal transmitter 15~20{1.5~2.0}
• Replace the engine coolant temperature sensor cop-
per washer with a new one.
6. lnstall each pipings following the diagram below.

To intake manifold collector
To intake manifold collector
~ /
) \::::::::=':::::!
,=-~--=:::::::::=::::::-:::
)
i J
To cylinder
To turbo-charge block
To oil cooler
To throttle chamber
To cylinder block
EN-114
5. EXHAUST MANIFOLD
----
...
RB25DE
RB25DET xhaust manifold
3.9-4.9{0.4-0.5}(3) ~
-~
vk -----® / fl ~ L J ] ~º Groundw1re
,o e @ __ -~ º -
/@ "'""~-
~27-31{2 8-3.2} (12)
1f1º
; 1,\,J
,-1 -:-l
~
º
""
, ,/ Exhaust manifold cover
~ Replace after every dísassembly 3.9-4.9{0.4-0.5} ( ? ) - - ~
~ N-m{kg-m}
Removal

4. Remove the air inlet pipe and air inlet hose
(RB25DET).
5. Remove the air hose (RB25DET)
6. Remove the exhaust front tube from exhaust manifold
(RB25DE), turbo-charger (RB25DET).
7. Disconnect the exhaust gas sensor connector.
8. Disconnect the earth wire between exhaust manifold
and the body.
9. Remove the turbo-charger (RB25DET).
1O. Remove exhaust manifold cover.
11. Remove exhaust gas sensor (RB25DE).

• Use exhaust gas sensor socket remover to remove.
EN-115
• Remove the installation nuts in the arder shown in the 4
figure on right.
13. Remove the gasket.
lnspection
• Use the scraper to remove gasket on the installation
surface.
ure the installation surface distortion in four direc-
tions.
to repair distortion . Replace the exhaust manifold if
the distortion is too excessive to fix.
Gas leak from the exhaust parts

• Look for any gas leak between the cylinder head side
installation surface and exhaust front tube, (RB25DE),
turbo-charger side installation surface (R825DET).
lnstallation
1. lnstall exhaust sensor (RB25DE).
• Use exhaust sensor installation socket to install.
Caution:
Care must be taken not to cause any damage to exhaust
gas sensor.
Exhaust sensor installation nut 78{8.0}
Exhaustsensor 40~50{4.1 ~5.1}
2. lnstall the stud bolt to cylinder head by placing the

double nut. r Loog C7
~~
1
• Remove the double nut after installation.
• Replace the stud bolt with a new one.
-ITTfilTiffl
11111 , ~ -
with shorter thread side is on the cylinder head side.
Cylinder head side Q
EN-116
• Use the scraper to remove gasket on the cylinder
head and exhaust manifold installation surface.
• Make sure to install the gasket facing correct way. +- Exhaust\anifold gasket
Tightening torque (N-m{kg-m}) 3.9~4.9{0.4~0.5} Front
4. lnstall the exhaust manifold. 010.7 C0.5

• lnstall the washer and the yoke.
• Make sure to place correct yoke when installing.
Exterior diameter CDD (mm)
No.3 & No.4 port 22
No.1, No.2, No. 5 & No.6 port 24
• lnstall the washer as shown.
Manifold side
9 5 1 3
• Tighten the installation nuts in order shown in the
~r:1~~~~ o
figure on right. 1o 6 .U 2 J 4 --,p 1
V O
Q Front
o :._o La ci'
10 6 2 4 7 12
5. lnstall exhaust manifold cover.
6. lnstall the turbo-charger (RB25DET).
7. Connect the earth wire between exhaust manifold
and the body.
8. lnstall Exhaust gas sensor connector (RB25DE).
9. lnstall exhaust front tube.
10.lnstall the rest in reverse order to the removal proce-
dure.
11 . After installation is completed , start the engine and
check for any exhaust gas leak.
EN-117
ROCKER COVER ENGINE MECHANICAL
RB25DE / R825DET ENGINE
6. ROCKER COVER
,-;:- - --------------, r,-- - - - - - - - - - - ,
•RB25DET i ,RB25DET I Ornament
1 1 1 1
r r~
n,,
~-.,¡ 2.0-3 .9
{
0.2-0.4
} l1 • \
,,,,..,.,,t 1
, ,
,.) :
1
- -
?
1
,
1
i¿c~,.. 2.0-3.9{0.2-oA} (19)
l . -
Blowby control~º met ~ - - - --- '1
valve '& Gromme
/
Filler cap
Rocker cover
Rockercove

~N-m{kg-m}
Removal
2. Remove blowby hose.
3. Remove air duct and resonator ASSY (RB25DE).
4 . Remove air inlet pipe (RB25DET).
5. Remove the canister hose (RB25DET).
6. Disconnect the power transistor unit connector.
7. Remove the ornament.
8. Disconnect ignition harness connector from the
clamp.
@~
3
,,._,
7 9
::n§ :J
(lntake side)
5 1
9. Remove the rocker cover. y.,Front (Exhaust side)
4 8 10 6 2
• Loasen the installation screw on intake and exhaust
side in order shown in the figure on right. e: 1 e=:
3 7 9
·==5 J1
lnspection
• Check for any wear or damage on the rocker cover. ·
• Replace the rocker cover if any abnormality is found.
• Make sure the oil will not leak from the rocker cover
and cylinder head alignment surface.
EN-118
lnstallation
1. lnstall the gasket to rocker cover.
2. lnstall the rocker cover. 7 3 2 5 9
~ =•nH :J
0
• Remove any oil and rubbish etc. from cylinder head
side installation surface. 8 4 1 6 10
• lntake side No.1 bolt is a hexagonal bolt. /'-1 (lntake side)
V"' Front (Exhaust side)
• Tighten the installation bolts and screws in several
C :··=: ·:
7 3 2 5 9
stages in arder shown in the figure on right.
Tightening torque (N-m{kg-m}) 2.0~3.9{0.2~0.4} 8 4 1 6
:O
10
3. Fix the ignition coil harness using the clamp.

4. lnstall the ornament.
procedure.
EN-119
~ O-ring
A N-m{kg-m}
r'Coppecwash•cl:l
,
J./
1
~
Oil pan installation bolt~
6.3~8.3{0.64~0 .85}(30)
Oil filter
Oil filter
' ~
installation bolt ~-.,1
(2) 16-21{1.6~2.1}
r;, Liquid gasket

Drain plug 29~39{3.0~4.0} A
~ Replace afler every disassembly
Removal
/ /4'
,/
negative battery terminal. '~
-~
3. Remove the under cover. .. --~v~
, z;,
rod •-,

5. Remove the stabilizer. OR remove stabilizer installa-
tion bolts and installation nuts located on the vehicle
side and lower the stabílizer to below the oil pan.
k ~ ,, - e->';¿_,, j
6. Remove A/ T oíl cooler tube from the oil pan bracket.
7. Remove right and rear gasket.
8. Remove the lower rear plate (A/ T vehicles).
9. Remove right and left front side engine mount installa-
tion nuts.
10.Attach the sling to engine and raise it up using the Rear
hoist. (low~ -- ,, /
Front <::>
11. Remove installation bolts in the arder shown in the

figure on right.
12. Remove oil pan from the cylinder block.

(1) lnsert seal cutter between the oil pan and the cylinder
block.
(2) Tap the seal cutter rear surface using the hammer to
remove the oil pan.
EN-120
OIL PAN & OIL FilTER ENGINE MECHANICAL
13.Remove the oil pan.
• Remove the oil pan carefully making sure it will not
/
-!!_.
interfere with the oil filter net area.
14. Remove the oil filter.
' /_,,,
-~ $/;'
lnspection ~-·~- >

Oil strainer visual inspection
net.
• Clean the net if there are any foreign objects.
• Replace with a new one if there is any fault.
Net
1nstal lation
1. lnstall the oil filter.
Tightening torque (N-m{kg-m}) 16~21 {1.6-2.1}

• Use scraper to remove any oil liquid gasket on the oil
pan and cylinder block installation surface.
• Clean the installation surface using white gasoline.
• Apply bond (KP51 O 00150) to specified position
shown in the figure on right at approx. <P3.5~4.5.
• Place the oil pan below cylinder block. Care must be

taken not to allow liquid gasket to come in contact with
the cylinder block and other parts.
• Place 2 bolts (M6 x 1.25) at suitable position and
tighten temporarily. lnstall other bolts temporarily.
• Tighten the bolts to specified torque in arder shown in

the figure on right.
Tightening torque(N-m{kg-m}) 6.3~8.3{0.64-0.85} Front Q
• No. 2 and No. 20 installation bolts will also tighten ¡g 15 11 7 3 1 5 9 13 17 21
~ ~, :~~
0
A/ T oil cooler pipings.
Caution: 21
-~=1'
, ' ~ --\,.,,,
)1
V
, - ~ - ·1 ·, ___ 25
2s
28 30
Do not over tighten the installation bolts. 1
_ ',---::,~.;~ .::;
24 \. ~~0_~~---- 6 -{~ 26
20 1s 12 a 4 2 6 10 14 1a 22
3. lnstall the oil pan drain plug.

• Replace the washer with a new one.
• lnstall in the direction shown.
procedure.
lnspection
• Check the leve! of engine oil.
EN-121
8. CAM SHAFT

~ N-m{kg-m}
IJ Engine oil
Removal
3. Remove air duct and resonator ASSY (RB25DE).
4. Remove air inlet pipe.
7. Remove cooling fan.
1O. Remove the timing belt.
12.Remove the cam timing pulley (intake side).
( 1) Remove the crank angle sensor installation bracket.
(2) Fix cam shaft hexagonal part using the spanner to
remove cam timing pulley installation bolts (4).
(3) Remove the cam timing pulley from the cam shaft.
EN-122
.,.-- 13. Remove cam timing pulley (intake side ) .

(1) Remove the front cover, o-ring and the spring.
(2) Remove the cam timing pulley installation bolt by

holding the cam shaft hexagonal part using the
spanner.
(3) Remove cam timing pulley from the cam shaft.
Caution:
Do not use pulley holder etc. to fix when removing the
intake side cam timing pulley as it could damage
innards.
Colla
et
14.Remove the timing belt cover (rear).
~~
v\" Timing belt cover
'\Grommet (rear)
Co!lar
15.Remove the baffle plate from No.6 and No.7 cam

shaft bracket.
1 5 13 11 7 3
16. Remove the cam bracket.
• Loasen the cam bracket installation bolts in the order
shown in severa! stages in the figure on right. "'~~¡o,µ..,-"-W-l---J ~
Caution:
Befare removal make sure to mark the installation 2 6 10 14 12 8 4
position of the cam bracket. ... Front
• lnspect the cam shaft end play befare loosening the
cam bracket installation bolts.

18.Pull out the cam shaft oil seal from the cam shaft.
19.Remove the hydraulic valve lifter.
• Check the installation position and store it to avoid
confusion.
\ J
• Store the hydraulic valve lifter in stand up position. lf
o
V
stored for a longer period of time, store it in clean X

engine oil.
• Do not disassemble the hydraulic valve lifter.
EN-123
lnspection
• Check to make sure there is no damage or wear to the Dial gauge
cam shaft.
Cam shaft run-out

• Use V-block on the fixed surface and support cam
shaft No. 1 and No. 7 journal.
movement width on the dial gauge.
Standard value (mm) 0.02
shaft.
Cam nose height

Standard value (mm)
lntake 39.705-39.895
Exhaust 39. 705~39 .895
lntake 0.05
Exhaust 0.05
• lf the val u e is over the limit replace the cam shaft.
Cam shaft oil clearance

• Use micrometer to measure cam journal externa!
di ameter.
Standard value (mm)
No.1 ~ No.6 journal <1>27. 935~<1>27 .955
No. 7 journal <1>27. 920-$27. 940
(Cam bracket interna! diameter)

• Tighten cam bracket bolt to specified torque.
• Use inside micrometer to measure.
Standard value (mm) 4>28.000~<1>28.021
lnside
micro ..,
(Cam shaft oil clearance) = ~ -::. ---
Standard value (mm)
No.1 ~ No.6 journal 4>0.045~<1>0.086
No.7 journal <t>0.061~<1>0.101
EN-124
Cam shaft end play
• Set a dial gauge at front end of the cam shaft in thrust
direction. Move the cam shaft forwards and back-
wards and read the dial gauge run-out measurement.
Standard value (mm) 0.060~0.11 O
Hydraulic valve lifter visual inspection

• Look for any wear or damage on the cam shaft
working face, lifter side surface and rotational parts.
Replace the parts if any abnormalities are found.
Hydraulic valve lifter clearance

(Hydraulic valve lifter externa! diameter)
• Use the micrometer to measure hydraulic valve lifter
externa! diameter.
Standard value (mm) $30.955~30.965
(Hydraulic valve lifter internal diameter)

• Use inside micrometer to measure hydraulic valve
lifter interna! diameter.
Standard value (mm) ct>31.000~31.020
(Hydraulic valve lifter clearance) = lnside v/
micrometer
(Hydraulic valve lifter interna[ diameter) - I"
-..ju
(Hydraulic valve lifter externa! diameter) "'-'-r

/, /,
Standard value (mm) ct>0.035-0.065 ~ &S

hydraulic valve lifter or cylinder head.
Hydraulic valve lifter air interfusion inspection

• Apply engine oil to rotational surface and install
hydraulic valve lifter to the cylinder head. Push with finger
• After the installation push down on the head. lf the

head move more than 1 mm carry out the air release
•
operation using the method below. (Use same method
to check the valve lifter when abnormal sound is heard
when the engine is started).
(1) After installing the rocker cover, run the engine at

approx. 1OOOrpm with no-load far 1O minutes.
Recheck the head movement.
(2) lf the air is not released by carrying out the above
,,,-. method, replace the hydraulic valve lifter with a new
one.
EN-125
lnstallation
1. lnstall hydraulic valve lifter.
• Apply engine oil to rotational surface.
• lnstall the hydraulic valve lifter in the position befare it
was removed. 1n
• Carry out the air interfusion inspection .
2. lnstall cam shaft to the cylinder head.
Crank angle sensor drive spline gear
• Coat the cam nose, journal and thrust parts with
engine oil.
• The distinction between the intake and the exhaust
side cam shaft can be determined by the crank angle
sensor drive spline.
Knock pin Knock pin
3. lnstall the cam shaft to the cylinder head so the knock

pin is as shown in the figure.
Cam shaft Cam shaft

(lntake) (Exhaust)
Bracket installation position
4. lnstall the cam bracket. o

~
(1) Check the engraved mark on the cam bracket
surface and the markings you have made at the
v~
removal to install the cam bracket in correct position.
ldenlification mork
1: lntake E: Exhaust
14 10 6 2 4 8 12
(2) Tighten the cam bracket installation bolts in the arder

shown in several stages.
5. lnstall the baffle plate to No. 6 and No. 7 cam shaft 13 9 5 1 3 7 11
bracket. Front . .
Tightening torque(N-m{kg-m}) 9.0~12{0.92~1 .2}
6. lnstall the timing belt cover (rear). e}:-,~ BP~lley
Tightening torque (N-m{kg-m}) Chamfered edge
M6 bolt 6.3~8.3{0.64~0.85}
M8 bolt 16~22{1.6~2.2}
7. lnstall the cam shaft front oil seal.

8. lnstall the cam timing pulley (intake side).
(1) lnstall the cam timing pulley to the cam shaft.
• Face the washer with chamfered side towards the
pulley.
(2) Apply engine oil to thread parts and the bearing
surface of the installation bolts.
EN-126
(3) Use the spanner to fix cam shaft hexagonal part to
tighten installation bolt.
Caution:
Do not use tools such as pulley holder to fix intake side
cam timing pulley as it will damage inner parts.
(4) lnsert a spring into pulley and fit the front cover.
• Care must be taken not to drop the o-ring. Spring
(5) Tighten installation bolts in opposite angles. O-ring \ ~
\~/
9. lnstall the cam timing pulley (exhaust side).

>, Front cover
( 1) lnstall the cam timing pulley to the cam shaft.

• Fix the cam shaft hexagonal part using a spanner or
use pulley holder to fix the timing pulley to tighten 4
installation bolts in opposite angle.
(2) lnstall the crank angle sensor installation bracket.

procedure.
EN-127
t ~ IJ Cylinder head bolt ( 14)

Washer
Refer to text Cylinder head installation bolt
9 0-12{\0.92-1.2} (3)~
~
! ::::-----
1 ::::.: ~~~5'3 j
. .:p
o·
·. --•;f?··t:?'
..o~· .. , .... ·-...
~p': :Afo,{~c;;,Pº ~Gasket
~ N-m{kg-m}
IJ Engine oil
Removal
1O. Remove the auxiliary belt.
11. Remove exhaust front tube.
12. Remove the turbo charger ASSY.
13.Remove exhaust manifold.
14.Remove intake manifold collector.
15. Remove the fue! injector.
18.Remove the timing belt, cam timing pulley, tíming belt
cover (rear).
19. Remove oil return tube and the top installation bolt on
the power steering pump bracket.
EN-128
20.Remove the cylinder head ASSY. 6 10 14 16 12 8 4
(1) Remove the cylinder head auxiliary bolts (1 ~3).
(2) Remove the cylinder head bolts (4~17).
• Loasen the cylinder head bolts in the arder shown in
the figure on right to remove the cylinder head ASSY.
21.Remove the cylinder head gasket. 7 11 15 17 13 9 5

1-3: M6 X 1.0 4-7: M12 X 1.5
lnspection
(1) Use a scraper to remove grease, water stain,
carbon and gasket etc.
rs--6-:::-?1
Caution:
L2SJ
t---------'
Straight gauge
""-e,
11 ¡
~
(,
(2) Measure cylinder head under surface for distortion in
ler gauge
six direction.
• lf the value exceeds the limit apply compound to press
platen and readjust the surface. lf the value exceeds
the limit greatly, replace the cylinder head with a new
one.

• Use a scraper to completely remove gasket, oil, water
stain and carbon etc. on cylinder block front surface. Straight gauge
Caution:
Care must be taken not to allow removed gasket to enter \
directions using a straight gauge.
• lf the value is over the limit use surface grinder to
• Re place the cylinder block if the distortion value is too
great.
lnstallation
• Use scraper to remove gasket on the installation
surface.
• Align the cylinder head gasket to dowel pin to install.
EN-129
2. lnstall the cylinder head ASSY.
• Check that No. 1 cylinder is at T. D. C (top dead
centre)
• Make sure each No. 1 cylinder intake and exhaust
valve is not lifted.
• Care must be taken not to damage the cylinder head
gasket when installing the cylinder head.
3. Tighten the cylinder head bolts.

• Apply engine oil to thread part of the screw. ac==II
• lnstall the washer non-chamfered side facing the
cylinder head.
•
Cylinder head side
4. Tighten the installation bolts in the order shown 12 8 4 10 14

(1 ~ 14).
(1) Tighten to 29N-m {3kg-m}
(2) Tighten to 98N-m {1 0kg-m}
(3) Loosen to 0N-m {0kg-m} -16
(4) Tighten to 25~34N-m {2.5~3.Skg-m}
(5) Tighten to 95° ~ 100° 11 7 3 1 5 9 13
(OR 93~103N-m{9.5~1 0.Skg-m} 1~4: M12x1.5 15~17: M6x1.0
• lnstall the cylinder head auxiliary bolts.
Caution:
Tightening angle should be checked using the angle
wrench or protractor. Never estímate visually.
5. lnstall the oil return tube.

6. lnstall the top installation bolts for the power steering
pump bracket.

procedure.
EN-130
10. OIL PUMP
~9.8-11.8{1.0-1.2} (2) f,;\1 Gasket~
~'J"a
~
9.8-11.8{1.0-1.2} ~
~
l"J)~
~IJ Front oíl sea~ ~0-nng-¡
~~,
~
~o
~
Regulatorvalve~i 1
SpnogL¡ OHfilte, __., i

~Washer--©
~
~~ 1@@) rt1"I
CSP-9.8-11.8{1.0-12} (4)~~..
/
15-21{1.6-21}(2)~
" 9.8-118{1.0-1.2}~
~ N-m{kg-m} Regulator plug 39.2-68.6{4.0-7.0}~
IJ Engine oil
Removal
5. Remove the air duct (externa! air introduction side).
12.Remove the oil pan.
13.Remove the oil pump.
lnstallation
1. lnstall the oil pump.
• Use a scraper to remove old gasket from the oil pump
and the cylinder block.
• Use white gasoline to remove grease, water and
rubbish from the installation surface.
• Align to the knock pin on the cylinder block side to
insta 11.
• There are four types of oil pump installation bolts.
Make sure to use the correct bolts.
EN-131
4 20 2
2 2 35
3 1 45
4 1 55 4 ~i:::::;¡~S;;~;;::::::;~~ 3

procedure.
Disassembly
1 . Remove the front oil seal.
• Use a tool such as a screwdriver to remove.
Caution:
Care must be taken not to damage the oil pump
housing.
2. Remove the oil pump cover.

3. Remove the inner and outer rotor.
4. Disconnect the regulator plug and remove the spring
and the regulator valve.
lnspection
Oil pump visual inspection
• Check for any wear or damage on the inner and outer
rotor and the oil pump housing.
• Re place the oil pump ASSY if there is any abnormal-
ity. Feeler r-r:..-,,.,,.-Feeler
gauge
gauge
Oil pump parts clearance inspection 1---:=,,;,~ 2
• Use the feeler gauge to check the following clear-

ance.
(1) Outer rotor to oil pump housing clearance
Standard value (mm) 0.11 -0.2
(2) Outer rotor and inner rotor chip clearance.
Standard value (mm) Below 0.180
(3) lnner rotor to oil pump housing side clearance
(4) Outer rotor to oil pump housing side clearance
• Replace the oil pump ASSY if any of the measure-

ments are out of standard value.
EN-132
(5) lnner rotor to oil pump housing inlow area Position 5
clearance.
• Use method below to measure the clearance between
the inner rotor and oíl pump housing inlow area.
• Use a micrometer to measure the oil pump housing
inlow inner diameter.
Position 6
(6) Use a micrometer to measure the inner rotor inlow
outer diameter. Microrneter
(lnner rotor to oil pump housing inlow area clearance) =

(Oil pump housing inlow inner diameter) -
(Oil pump housing inlow outer diameter)
• Re place the oil pump ASSY if the measurements are
out of standard value.
Regulator valve visual inspection

• Check for any wear or damage on the regulator valve
rotational parts.
• Check the regulator spring for any abnormality.
• Replace the regulator valve or the oil pump ASSY if
there is any fault.
Assembly
1. lnstall the inner and the outer rotor.
• Apply engine oil to each rotational and moving parts.
• Position the inner rotor groove to cover side.
Cover side
2. Tighten the oil pump cover ínstallation screws equal-
Groove
ly.
• Re place the regulator washer with a new one.
Regulator valve
~ --
Tightening torque (N-m{kg-m}) 39~69{4.0~ 7.0} Spring ~
~ Washer
4. lnstall the front oil seal. ~Regulator plug
• Check if there is any damage or deformation on oil
seal periphery.
• Position the oil seal side with writing towards front.
• Use the oil seal drift to insert the oil seal in until level
with installation surface.
• Apply engine oil or chassis grease to oil seal lip sur-
face.
EN-133
RADIATOR ENGINE MECHANICAL
11. RADIATOR
Removal
1 . Remove the battery negative terminal.
5. Remove the reservoir tank hose on the radiator
side.
6 . Remove the radiator upper hose.
7. Remove the radiator lower hose.
8. Remove the A/T oil cooler hose (A/T vehicle ).
• Place a hale cap on the AJT oil cooler pipe.
9. Disconnect the engine coolant temperature switch
harness connector.
10.Remove the radiator upper mount bracket (right &
left).
11. Remove the radiator ASSY.
• Care must be taken not do damage the radiator
core.
12. Remove the radiator shroud from the radiator.
13.Remove the engine coolant temperature switch from
the radiator.
EN-134
lnstallation
1. lnstall the engine coolant temperature switch to the
radiator.
2. lnstall the radiator shroud to the radiator.
• Care must be taken not to damage the radiator core.
• Only use genuine shroud installation bolts.
3. lnstall the radiator ASSY.
4. lnstall right and left radiator upper mount bracket.
5. lnstall the engine coolant temperature switch
harness.
6. lnstall NT oil cooler hose (NT vehicle).
procedure.
lnspection
• Check the level of coolant and NT fluid. Top up if
necessary.
• Start the engine and look for any coolant or NT fluid
leakage.
EN-135
12. COOLING FAN
Removal
boot.
2. Remove the air duct. ~Q>
3. Loasen the cooling fan installation nuts.
4. Loosen the fan belt.
~l
0{0.6-1.0}(4)
fan.
6. Remove the installation bolts to remove the fan from
the cup ring .
lnspection
Cup ring inspection
• Check far any silicon oíl leak and bimetal bent.
Cooling fan inspection

• Check for any damage or cut.
lnstallation
lnstall the parts in reverse order to the removal proce-
dure.
• lnstall the fan to the cup ring making sure the front
mark is facing front.
Tightening torque (N-m{kg-m}) 6~10{0.6~1 .0}
EN-136
AUXILIARY MOTOR FAN ENGINE MECHANICAL
13. AUXILIARY MOTOR FAN
Removal
boot.
~(~
2. Remove the auxiliary tan harness connector.
l~bol
3. Remove three installation bolts to remove the radiator
tan from below. , ~ onnec or '/
Caution:
Care must be taken not do damage the air conditioner
condenser.
4. Remove the fan from the fan motor.
5. Remove the fan motor trom the fan grille.
lnstallation
1. lnstall the fan motor to the fan grille.
2. lnstall the tan to the fan motor.
3. lnstall the auxiliary motor fan.
Caution:
Care must be taken not to damage the air conditioner
condenser.
4. lnstall the auxiliary motor fan harness connector.

procedure.
EN-137
14. WATER PUMP
Removal
boot.
9. Remove the water pump pulley.
1O. Remove the timing belt.
11. Remove the tensioner pulley.
12.Remove the tensioner pulley and the idler pulley.
13. Remove the alternator adjust bar.
14.Remove the installation bolts in the order shown.
15. Remove the water pump. 1, 6 7 8 9
• lnsert the stubby driver into the installation bolt hole

Caution:
side screws.
EN-138
lnspection
• Check the water pump main body and the vane for
rust ar foreign objects.
• Make sure the water pump is not warby.
• Replace the water pump if there are any abnormali-
ties.
lnstallation
G:>2.0-3.0mm
pump and the cylinder block installation surface.
• Apply sealing agent (KP71 O 00150) to the position
shown in approx. <D2.0~3.0mm.
• Tighten the installation bolts in the arder shown. 9

• Tighten the installation bolts 8 and 9 together with the
• There are four types of installation bolts.

M6 6.3~8.3{0.64~0.85}
M8 16~21 {1.6~2.1} ' ~~1 ,11 1.5
M10x15 ( º· )
M6 X 1.0 ·
M10 31.4~42.1{3.2~4.3} M8 x 1.25 (7. 12) (8, 9)
(1-6)

procedure.
EN-139
15. THERMOSTAT & WATER INLET
Removal Thermostat
boot.
Thermostat housing
rJ\ w
-~
/
1
2. Drain coolant from the radiator drain plug. 16-21{1.6-2.1}(3)~

4. Remove the alternator belt to shift the alternator
down.
5. Remove the alternator adjust bracket.
6. Remove the radiator lower hose at the thermostat
housing side.
7. Remove the water inlet.

• lnsert end of a tool such as a screwdriver into the :;::'.;J'..'ci~ J
thermostat housing and move it up and down to
remove. \
8. Remove the thermostat.
\'°""""
lnspection
Thermostat inspection
Check the valve opening temperature and maxímum
valve lift.
• Hang the thermostat by string on the valve and sub-
merge in heated water in double walled container and String
stir water while heating ít up.
• The opening temperature is the temperature when --
--
-- - -- .
the valve opens and thermostat falls from the string. Container =::: -: ·
Valve opening temperature (ºC) 76.5
Max. valve lift (mm/ºC) Over 1O / 90
• Replace the thermostat if the value is not at standard
value.
lnstallation
Jiggle valve
1. Use a scraper to remove old liquíd gasket from the
water inlet and the cylinder block installation surface.
• Use white gasoline to clean the surface.
2. lnstall the thermostat.
• Position the thermostat so the jiggle valve (TOP mark)
is on the top.
EN-140
3. lnstall the water inlet.
<ll2.0-3.0mm
• Apply sealing agent (KP510 00150) at approx.
<t:>2.0~3.0mm as shown in the figure.
• Tighten the installation bolts.


procedure.
EN-141
ACCELERATOR CONTROL SYSTEM ENGINE MECHANICAL
16. ACCELERATOR CONTROL SYSTEM
Accelerator wire bracket
.
Accelerator wire
---~_/
\. ~ ~
~7.8-12{0.8-1.2} [ •
~./ · ~ .-0 ,
ºz- ~
-
2.9-3.9(0.3-0.4}(2) ~
\!@- 2.9-J.9{0.3-0.4X2l~
Accelerator bracket'
1~
~ -Kickdown
~ switch
·-i~
e--nynamic domper
:M / T : ""/¡¡J ~2.9-3.9{0.3~0.~~ Accelerator pedal
¡Accelerator ___.\\'\) : YJ r-.mGl,...,..------
------ /
, pedal bracket ~ : \ ,_________-----
~ - - - - - - - - - - - - - -; /,-·~
E-ring~ f
Return spring IEI
'
/~CJ?(j'-
Pedal stopper 3.7-5.0(0.38-0.51}~
A N-m{kg-m}
El Nissan MP special grease No.2
Removal
1. Disconnect the accelerator wire at throttle drum side.
2. Disconnect the accelerator wire at accelerator pedal
side.
3. Remove the accelerator pedal bracket installation
bolt to remove the accelerator pedal/ bracket ASSY.
lnstallation
lnstallation is the reverse order of the removal proce-
dure.
• Apply Nissan MP special grease No. 2 to the return
spring.
Lock nut
• Replace E-ring with a new one.
• Adjust the installation position when the kickdown .---•..
switch is removed (A/T). Kickdown
• Depress the accelerator pedal so the throttle drum is . mm switch
in full open position. In this position adjust the open-

ing to approx. 0.3~1 .0mm, then tighten the lock nut.
Kickdown switch lock nut installation torque
(N-m{kg-m}) 7.8~12{0.8~1 .2}
Caution:
• Do not position the switch to fully open stopper.
• Do not damage or bend the wire.
• Make sure to apply grease to each parts except for
the inner wire at installation.
EN-142
lnspection
• Make sure the throttle drum side is fully open when
the accelerator pedal is depressed fully.
• · Make sure the parts will move smoothly.
Adjustment
• Loasen the wire and adjust the adjust nut to pull the
outer case towards the accelerator pedal until the
throttle drum starts to move.
From this position turn back the adjust nut 1.5 ~ 2.0
turns, and secure the lock nut.
_.,,..---..
EN-143
EXHAUST SYSTEM ENGINE MECHANICAL
17. EXHAUST SYSTEM
13-16tt=!] 13-16{1.3-1.6}tt=!]
{ 1 3 1 6}(2) . /Mounting rubber
Bracket
lnsulator
Brac_ket t3~16{1.3-1.6}(2) , "' ~

' ~ /
tt=!J
· - ·
Dynamic dampelJó~lrftóET)
\
13- 16{ 1.3- 1,6}(2~~---
¡f_J°f.--
--:.,\,.,
Dynam1c ~
lnsulator
\ lnsulator
"@.:
¡
lli..
(A-LSD) ¡ · __:
~
lnsulator
Mounting rubber ~4
4.3-5.9 (4)
1
¿ _' ./ -
\ l A · . ,j \ ,Q \ · 7 ~
~
7/
_413-16{1.3-1.6}(2)
..,./ Bra,cket
'
4.3-5.9{0.44-0.6}(2)~
lnsulator
~ ~ 1~ 1 0.r.<-J
·r
1 Exh cens~r
{0.44-0.6}
,---,.,. 13-16 12)

l .
l ·
~)j:-
Mounting rubljer
rn,_
51-65(5.2-6.6}(2)~-~-
-
5--·7 .
¡acket 51-65{5.2-6.6}i)~I
Catalyt1c
converter
G
askel~
'Ji~
/_ ~ \ ,
I e
!~-~tub
. - _:-
· -
~ "\,,.
1
Jj; O\
:.cr
f ::\!
Ring gaske1
jMain mufflej
-......;;
, ¡
1
,!!/
.
Dynam1c
1.3-1.6}
~s
~ ~h
Ring gasket+:i lnsulator / /Gasket \ !
5.1-6.5 7
/Jiñ0-39 . . -- 1 dlatmper
ri ~~
1
\ ~·;;:,.-::;;;::,_ ~ I . . {0.52-0.66)(2} , 3.1-4.0 nsu a or
· ~ j !
l f
~ 7 ~
¡~ Clamp/, , 13-16{1.3- 1.s} Moun1ing rubber
·Jnsulator , 5.1-6.5(0.52-0.66)(2)~
~~. ~ 1 ·¡
~ 5.1-6.5~ 5.1-6.5(0.52-0.66}(2)
~
Clamp
\
L. ' {o.52- 0·66H4) ¡RB25DE d~al;;:;od; ~;;ffi;r - - ----
lnsu ator 5_1_6_5 ~ 1
\ ~+:i
A~..
IExhaustfronttube/R\ '¡ '"1))=,.... {9,g-.Q.§fil(1L __ ~_ Controlwire
~.... 45-60 (3) . ~1 j 1RB25DE / RB20E . ~-8-9.8
1. !dual mode mufflet (O 8-1 O}
~
l Exh temp sen IRB2SDET I i(,..:::-- -~ · ·
~
,-<ft ~ i ~/"'--. : 1._ ~ V
¡ /....:¡~/.
1
-,
lnsulator:F
51 65
,ti,- ·
~ (0.52-0.66}
-
~, , 1 1
"- 1
:ire :;;r;:~:
1
Finisher
, •
[ ~ Main muffler Front
a
/ 5.1-6.5(0.52-0.66}(2) }--- - ----- - ..J __ --- ---r. ------ -- ·------
~ 5.1-6.5(0.52-0.66}(4) ~ 8.4~11(0.86-1.1}(4) / RB20E ¡RB25DE / RB25DET
RB2s'éÍET____ _ _____ ___ __ _ _______ 1/ A --~ ¡I E~:s~ulator' 1
w~~
Exhaust front,~be l n s t ~
CiRinggasket~~~ ~~
1
:
1
.
R1ng~/
V~~~-
lnsulator : tu,~._8,<
--1~_ 1
censor
\
1~1~
~-
~ : gasket ~~ ~~
~
Clamp _..-/'~ ; !·
5.1-6.5{0.52-0.6~ ],,_- ; / :
~ )f ~ - - :1 Exhaust front tube ~ InsuIator ;

1 ¡ ft
lnsulator ¡ l ~ 5 H3
5 n
· ~ : 5.1-6.5{0.52~0.66} ~ : 51-6.5 {ó.s2.:{).~J}
5.1-6.5{0.52-0.66} i {o. 52-0.66}(4)
1
~ Replace after every óisassembly
Removal
• Disconnect each parts at connection and remove.
Dual mode muffler control wire \!, __
• Remove the muffler in the following way for the
vehicle with dual mode muffier:
(1) First remove the main muffler rear mounting rubber
and lower the rear end before separating with the
rear tube.
(2) Disconnect dual mode muffier control wire from the
main muffler.
(3) Remove the main muffler.
lnstallation
• Replace or repair the heat shield pi ate with deforma-
tion. Clean and remove foreign objects.
• Make sure there is no excessive gap between
exhaust pipe and the heat shield plate when
installed.
EN-144
• Remove old gasket etc. from each sealing suriace at
the connection. Connect securely to avoid any gas
leaks.
• Replace each gasket with a new one.
• Replace the front tube installation nut with a new
one.
• lnstall each clamp by aligning the insulator projection
and the clamp hole.
• lnstall the dual mode muffier control wire.
Lock nut tightening torque (N-m{kg-m})
7.8~9.8{0.8-1.0}
• Adjust the dual mode muffler control wire on the
actuator side.
• Do not twist or pull the mount rubbera when install-
ing.
Rear muffler (other than rear parts)
t i=Jz =Ju._
y
• Offset measurements when each mount rubber is
installed correctly. QFroot D:
Rear muffler {rear parts) X
Main muffler -5~5 0~10 38~48
Centre muffler front
Centre muffler Right
-5~5
33-43
0~10
-5~5
38~48
17~27
QFroot i' ~ ~Z
rear Left 33-43 -5-5 17-27
lnspection
• Start the engine and check far any gas leaks from
each connection.
• Check for any exhaust gas leaks due to corrosion.
• Replace parts with new ones if there is a gas leak
due to corrosion.
EN-145
DUAL MODE MUFFLER ENGINE MECHANICAL
18. DUAL MODE MUFFLER
Removal
boot.
~\Wa~
,,-,/ 5.1-6.5{0.52-0.66}(3) ~
negative battery terminal. 1 .e-9.e{o.e-1.o>A
5.1- 6.5
{0.52-0.66}
(3) ~
7.8-9.8
.O}
2. Remove the control wire. Dual mode muffler control wire\!.. _

• First remove the actuator side then muffler side.
• For the muffler side control wire, first remove from the
mounting rubber then lower the rear end to remove
the wire.
3. Remove the actuator.

• Remove three installation nuts and remove the
harness connector from behind the actuator. Then
remove the actuator.
lnstallation
1. lnstall the actuator.
• Connect the harness connector behind the actuator.
• Tighten three installation nuts.
Tightening torque (N-m{kg-m}) 5.1 ~6.5{0.52~0.66}
2. lnstall the control wire to the main muffler side.
3. lnstall the main muffler to the mount.
4. Temporarily connect control wire to the actuator.
• Do not apply too much force to the wire.
5. Adjust the wire.
EN-146
DUAL MODE MUFFLER ENGINE MECHANICAL
Adjustment
• To take up the slack from the inner wire, first loasen
the wire bracket lock nut on the actuator side and
then move the outer cable in the direction of the
arrow.
• The outer cable will interfere with the wire drum if the
outer cable is positioned excessively towards the
actuator lever.
• lf the inner wire is too tight, move the outer cable in
the opposite direction to the arrow.
Caution:
The valve will be partially open if the wire it too tight.
• lnner wire adjustment.
Press down on the inner wire between the valve lever
wire bracket and the tail tube wire bracket with a fin-
ger, the wire slack should be approx. 2mm.
• Tighten the actuator side lock nut after the adjust-
ment.
Tightening torque (N-m{kg-m}) 7.8~9.8{0.8-1.0}
lnspection
• Make sure the valve is not half open when the ignition
switch is in ON position. Check for any exhaust gas
leaks from right side of the tail tube when idling.
• Check if the valve will open fully at approx. 4100rpm.
EN-147
INTER-COOLER ENGINE MECHANICAL
RB25DET ENGINE
1. INTER-COOLER (RB25DET)
~ 6.3~8.3{0.64~0.~ Aír hose

21~27{2.1~2.7}(2) ~ I~ - f ~ Vacuum hose
/. . . · / ~ - /~ ~ Front
Vacuum hoi: / Rec1rculation va~.,..,...J Air ho_se ( J _, \
J,,®-"-·-- / Í~t:,-- .
_ _ _Ai~t~ ~
63 8
To swing valve controller
" '· - ~.~---~ jr~ ~~P.1~e , ~- , J 7 ~mho!~ hose 13~16{1,3~1.6}(2)~
To íntake mani fold~ ~ i - ; - - -.../ // ] \ / A1r hose
collector
{0.86~1 .11}(2)
Air ~ose
Air hose _
Air ínlet tube- ~

~~ ~
l'T"1'!
~ .,,_____~
Bracketf
Air¡ose
w~
x ·/· .--\--r -~
8.4~11 ~~, , ~ ~ /
8 .4~11 ~ :---.! {0)6~1.11} /
t.J .
~ -r ,
-
A1r hose
21-27 ~
{2. ~- 2.7}(2)
A1r 1nlet hose
/
Air inlet hose
6.3~8.3 ~
.
{0. 64_ 0 _85} ~

~ ~
1 ~ ,. . - \\1
""\
.
~7
l
· ~'
A1r / eb 13~16{1 3- 1 6}(2)~
1 cotiar .
omn (i!,,j
~ Gasket -
•a ,
l
b
7
~'-"-..~
/ 1¡
.·_I
,/ 1 .
1
B cket
// . r),1~'v'~& / fl~~
~) <- .,.-·
-¡~ 7-C~~\
'11!.
~
racket
Turbo-charger ASSY L
'
, . ~ ,
Toair flow rfillo
meter : =1 ', . Bracket
-1 ~ . ---- - - / {otf-1~
6
,
¡· . 3~16{1.3~1 .6t-.:ii'71 , i;, - "
. \ ( ) ~ Collar-~~
2
lntercooler
A1r hose Grommet
~ N-m{kg-m}
~ Replace after every disassembfy
Removal
(1 ) Open the boot lid.
2. Remove air duct and the air cleaner case.
3. Remove air inlet pipe and the air tube.
(1) Remove vacuum hose and the air hose.
(2) Remove the canister tube installation bolt (A), air
inlet pipe installation bolt (8 ) and air tube installation
bolt (C).
(3) Loosen each clamp to remove air inlet pipe and the
air tube.
4. Remove the air inlet hose.

( 1) Remove air hose and the vacuum hose from the
boost control solenoid and air inlet hose.
(2) Place alignment marks as required and loasen each
clamp to remove air inlet hose.
5. Remove inter-cooler.
(1) Remove the front fender protector (left).
(2) Remove 4 installation bolts shown.
(3) Loosen clamps on the air hose to remove
inter-cooler.
EN-148
RB25DET ENGINE
lnspection
lnter-cooler visual inspection
• Check inter-cooler for any damage or wear.
• Replace inter-cooler if there is any fault.
Recirculation valve - (~~

v,I,Í~V--------- ----.
Recirculation
Function inspection ~•T
• Disconnect recirculation valve compressor upper end '

Place hol
hose (place a hole cap). Check if the air will blow
back when the throttle is closed.
Element inspection
• Make sure the recirculation valve diaphragm will rise
and the negative pressure is retained when the
vacuum handy pump is used to apply negative
pressure (-230+/-50mmHg).
lnstallation
1. lnstall the inter-cooler.
(1) Tighten 4 installation bolts.
(2) Tighten air hose clamps.
(3) lnstall front tender protector (left side).
2. lnstall air inlet hose.

: \
\ /
'" ,,-1
/ Boost control
(1) Align the alignment mark to install the air inlet hose.
(2) lnstall three vacuum hoses boost control solenoid and
air inlet hose. / '
Y!
/
3. lnstall the air inlet pipe. _JJ':.'. ~ acuum hose ' Air hose
Tightening torque (N-m{Kg-m}) 6.3~8.3{0.64~0.85} (J-'--1'!i ._:_. ·>• ·. .
:!Id-- 1 .. t• · .. A1rtube
..•.... '
4. lnstall the air tube. · Front
• Tighten installation bolt (C). <l◊
Tightening torque (N-m{kg-m}) 6.3~8.3{0.64~0.85} t,
5. lnstall the canister tube.

• Tighten installation bolt (A).
6. lnstall the air hose and the vacuum hose.
procedure.
EN-149
TURBO-CHARGER ENGINE MECHANICAL
RB25DET ENGINE
2. TURBO-CHARGER
. ........
a 6 .3-8.3(l)J
e ,/
x aust gas_~_ensor braeket 11 - -{0_ 64 _ 0 _85} (Z)
Eh
~Eye bolt 15-20{1.5-2.0} - - Q ~ ,- ·>\:: -·\.
~ -·1!:
~ @ - ~ W
Copper washer ~~- ~
::~ ~ ~__ ?f'-.· "-.._ ~1
;~ ·,.
Oil feed tube >¿;:;;.-- -·•· ', .
·
"-
§ - .....__
@\_,
\
Heat insulator -
~Lockplate
~
·-----,,;·~> " "-.J6.3
\ ,·•i:~;::-.:_:
o
'\
'.---~;:; : '~
., ,....
_
....-: -✓,
{0.64-0.85} (3)
•.
rr-11
8.3 ~-..
'º , ..-..•·--,
/
~Copperwasher .c- - -,,..,, / ~ \
E e bolt •- .,¡
-
,
@ ~\
\ ];?>
\.- 1
~25-29{2.5-3.0}(4) ~ ;Y
9 4 4
1, I ~ ' . \~.Ju__/. ~r -~
1
6.3-8.3 tt!J 1r20{1 .5-2.D}~ _ \ 1\ ~5-3 {Z.s- .0}( )7--- _~ ulator ~__r_:~cket
{0.64- 0.85} (2)-----.... V1 "\\. _ é i
. --~,0, _ ~ ~ ~
Jj .,.. ~
o\ JJ , , lflf
...-
"'.fü
4P'l.J' '
? ,
1
éP@
.V I!¡..... .
·
Watmerum tube ~11 _

G~ ket
~Eye bolt 33-41{3.4

~ 4.2}
0 .3 8.3
{0.64-0.85}
~
_ ~ ñ _,.- ~~~ .._j \
~
C)~ '
•
0
·
·1
'·,.
Exhaust gas sensor

Exhaust as sensor
40-50{4.~ -5.1}tt!J
~ I ___. • ( ::¡ «>~1.
•
_.-·?<\
~ /
•A- -- installation nut 78{8.0}tt!J

=~
_.-·
_._.-- · 0/ ')\ • _
\ .
G ' ~ ·L
asketw
Exhaust outlet
j
Copper washer ~
W
~ Copper washer
@. /
~ Turbo-chargerASSY
~ Gaske f
,..,,...
-~
?)º\.
\ ' •,.,
"'- ,
' --, , , ~25-29{2.5-3.0}(2)
®
, )
_r@~ @ "
Oil retum pipe - - - \ 16-2~ ·,,@ ,J/j)

~_J! .6-2.1}(2) 1~~\- \~
To cylinder ~~ ' - @ ........-,,. . . . @
~ \ Eye bolt 20-31{2.0~3.2}
/ ~Copper washer \ Water feed tube
Oil return hose Eye bolt 33-41{3.4-4.2}tt!J
toJ N-m{kg-m}
Removal
negative battery terminal. \ \
4. Remove air inlet tube.
5. Remove air hose from the turbo-charger.
6. Remove swing valve controller from the vacuum
hose.
7. Remove the earth wire.
- . ~.
8. Disconnect exhaust gas sensor connector.
9. Remove the heat insulator and exhaust gas sensor ,·. eI
-"'
bracket. l
10. Remove exhaust sensor.

• Use exhaust sensor remover socket to remove.
• Do not cause damage to exhaust sensor. -----~--- ,; ,
Eye bol! .---! _::_""\ 1 )'l.,

11. Remove water feed tube.
• Drain coolant from an eye bolt on the water feed tube
on the cylinder block side or from the cylinder block
drain plug.
• Remove two eye bolts and installation bolt. . n bolts
Ey
12. Remove water return tube.
• Remove eye bolt and two installation bolts. Wate
EN-150
RB25DET ENGINE
13. Remove oil feed tube.
• Remove two eye bolts.
14.Remove oíl return pipe.

• Loosen oíl return hose clamp to remove two ínstalla-
tion bolts.
15. Remove exhaust outlet and the insulator bracket.

16. Lift up the claw to remove four turbo-charger installa-
tion nuts.
17. Remove the turbo-charger.
Warning:
Do not disassemble turbo-charger.
lnspection
Water feed / Return tube
Check to make sure there are no blockages or rust
inside the water feed and the return tube by blowing in
air using the air gun after cleaning the tube with radiator
cleaner.
Oil feed / Return tube

Check t make sure there are no blockages or rust
inside the oíl feed and the return tube by blowing air in
using the air gun after cleaning the tube with engine
conditioner.
Turbo-charger
• Clean befare inspection.
• Clean the oil feed and the oil return with engine
conditioner.
• Clean the water inlet and outlet with radiator cleaner.
• After cleaning use the air gun to blow clean.

• Also blow air to the compressor wheel, turbine wheel,
compressor housing and turbine housing.
EN-151
RB25DET ENGINE
olant leak inspection

Swing valve ctuator rod
controller-
Exhaustgasleak
inspection
~C)
,-
e"
t
Swing valve
Compressor housin
Turbine wheel
Rotor shaft
• Make sure the rotor shaft will turn smoothly when
pushed with finger. shaftmust
moothly
• The rotor shaft must not be loase when moved right /
left.
- ~ No carbon
- sludge
• Make sure there is no carbon sludge accumulation. accumulation
• Make sure there is no change in colour with the

rotor shaft.
Rotor shaft end play

• Set end play by placing the dial gauge to the rotor
shaft end and place it to the axle direction.
Standard value (mm) 0.120 - 0.200
End play mea

Turbina wheel
• Make sure there is no grease adhesion.
• Make sure there is no carbon accumulation.
• Make sure the turbine wheel blade is not bent or
broken. rease or carbon.
• Make sure there is no interference between the o interference between
arbon housing.
turbine housing and the wheel. heel blade is not bent
Swing valve
• Remove actuator rod E-ring and check if the swing
valve will move -smoothly with no deformation or
damage.
• Check for any abnormality with the turbine housing
seat surface.
EN-152
RB25DET ENGINE
Compressor wheel
• Make sure there is no grease adhesion at
admission port.
• Check for any interference between the compressor
housing. ase adhesion.
t bent ar damaged.
• Make sure the wheel is not bent or damaged. o interference
-~
Swing valve controller
• Remove swing valve controller rubber hose at
compressor housing side.
• lnspection must be carried out when actuator rod is
installed and removed.
• Make sure the swing valve controller rod will
move when the air gun is used to blow air in (ap-
prox. 51 kPa{385mmHg} [M/T vehicle], approx.
36kPa{270mmHg} [A/T vehicle]). Stop air gun op-
eration as soon as it starts moving.
Caution:
Before blowing the air to the swing valve controller rod
make sure to check the air gun pressure using the LPG
pressure gauge (0.1 0MPa{1 kg/cm 2} ST1957 2000) so it
will not damage the diaphragm.
Turbo-charger fault diagnosis (oil leak, smoke, lack of

power, lack of acceleration, abnormal noise)
Points to be checked before diagnosis:

(1) Level of engine oil is between MIN and MAX line (lf
the level is over the MAX line, the engine oil will flow
into the intake duct causing a fault with the turbo-
charger) .
.~- (2) Enquire the customer if the oil had been cooled down
by idling the vehicle after driving.
• Referring to the table on the following page, replace
the turbo ASSY if any of the unit tests are faulty.
• lf no fault is detected there is no fault with the turbo
unit, inspect other vehicle parts.
,-------
EN-153
RB25DET ENGINE
Dirty with oil

•
Turbine wheel
Carbon accumulation
• o o
lnterference with housing o • o
Wheel is bent or broken
lnside the admission port is dirty with
• •
oil
o o
Compressor wheel lnterference with housing o • o
Wheel is bent or broken
• •
Ooesn't turn smoothly when pushed •
0
th
Rotor shaft end play 1-w_i__a_fi_in"""g_e_r- - - - - - - - - + - - - - + - - - + - - - - + - - - - - - - - - ,
checking both turbine Doesn't turn when pushed with a
•
and compressor
----------------------------------
finger
Movement of the bearing is great o
Rotor shaft and oil Carbon sludge accumulation at
return scavenge hale •
Doesn't operate smoothly when
correct air pressure is applied
Swing valve opera-
tion (use air gun)
(Approx. 51kPa{385mrnHg} [M/T
vehicle], Approx. 36kPa{270mmHg}
•
[A/T vehicle]
[ • Extremely high o High • Small J
lnstallation
1. lnstall turbo-charger to the exhaust manifold.
• After tightening the installation nut fold the lock plate
claw towards the installation nut to fix the installation
nut.
• Replace the lockplate with a new one.
2. lnstall the exhaust outlet and the insulator bracket.
T!ghtening torque (N-m{kg-m}) 25~29{2.5~3.0}
3. lnstall the oil return pipe.
• Tighten oíl return hose clamp.
4. lnstall the oil feed tube.
• Replace the copper washer with a new one.
Caution:
The eye bolts for the oil feed tube are labelled "G" as they
are different to other eye bolts.
EN-154
TURBO-CHARGER ENGINE MECHAN ICAL
RB25DET ENGINE
5. lnstall the water return tube.
lnstallation bolt 6.3~8.3{0.64-0.85}
Eye bolt 33-41 {3.4-4.2}
6. lnstall the water feed tube. Ey
bolt
• Replace the copper washer with a new one. Wate
Turbo-charger side eye bolt 33~41 {3.4~4.2}
Cylinder block side eye bolt 20~31 {2.0~3.2}
7. lnstall the exhaust sensor to exhaust outlet.
• Use the exhaust sensor installation socket to install.
Caution:
Do not cause any damage to the exhaust sensor when
installing.
Exhaust sensor installation nut 78{8.0}
Exhaust sensor 40~50{4.1 ~5.1}
8. lnstall the heat insulator and the exhaust sensor
bracket.
Tightening torque(N-m{kg-m}) 6.3~8 .3{0 .64-0.85}
9. lnstall the exhaust sensor connector and the ground
wire.
procedure.
lnspection
• Start the engine and look for any leakage from the
turbo-charger pipings such as coolant and engine oil.
Also check exhaust manifold and the turbo-charger
connection for any exhaust gas leak.
Turbo-charger function inspection

• Stop the engine after engine has warmed up.
• Connect three-way connecter to the air hose between
the air inlet pipe and the swing valve control and
install the compound gauge.
• Start the engine and increase the engine rev. Read
the maximum value on the compound gauge.
Swing valve opening pressure (kPa{mmHg})
M/T 49~54{365~405}
A/ T (when lifting 0.38mm) 33~39{250-290}
• lf the value is not within the standard value carry out
the inspection below.
• Air leak with breath system

Pressure is low / incorrect
• Faulty turbo-charger
Doesn't increase swlng valve • Disconnected / broken swing valve controller hose
opening pressure (standard value) • Non-operational swing valve controller
EN-155
OIL FILTER BRACKET & OIL COOLER ENGINE MECHANICAL
RB25DET ENGINE
3. OIL FILTER BRACKET & OIL COOLER
Water hose
r.:J Liquid gaskel
Water hose
lO.J N-m{kg-m}
Removal
6. Disconnect two water hoses on the oil cooler side.

7. Remove the oil pressure switch connector.
8. Remove the oil filter bracket and the oil cooler
ASSY.
lnstallation
1. lnstall the oil filter bracket and the oil cooler ASSY.
2. lnstall two water hoses.
procedure.
Disassembly
1. Remove the oil pressure switch.
2. Remove the oil cooler from the oil filter bracket.
EN-156
OIL FILTER BRACKET & OIL COOLER ENGINE MECHANICAL
RB25DET ENGINE
lnspection
Oil filter bracket visual inspection
• Check for any damage or wear.
• Replace the oil filter bracket if there is any abnormal-
ity.
Oil cooler inspection

• Check for any clogs in the oil cooler.
• Replace the oil cooler with a new one if there is any
abnormality.
Assembly
1. lnstall the oil cooler to the oil filter bracket.
• Align the oil cooler stopper to the oil filter bracket
--· stopper and tighten the installation bolts.
2. lnstall the oil pressure switch.
• Apply sealing agent (KP51 O 00150) to the thread part
then install.
Tightening torque (N-m{kg-m}) 12.3~17.2{1.25~1. 75}
EN-157
AIR CLEANER &AIR DUCT ENGINE MECHANICAL
RB26DETT ENGINE
1. AIR CLEANER &AIR DUCT (RB26DETT)
~lip(2)
Air duct (Fresh air introductory side)
Air duct
~ N-m{kg-m}
Removal
1. Remove negative battery terminal.
2. Use air gun to remave any rubbish, dust etc. from the
air cleaner area to avoid foreign objects entering the
duct.
3. Remove the air duct (fresh air introductory side)
clips.
4. Remave the air duct (left tender side) from the air
cleaner case (upper) and push it towards the vehicle
side.
5. Remove the air cleaner case (upper).
• Remove 4 clips and loasen the installation bolts.
6. Remave the air cleaner element.
7. Remove the air cleaner case (lower). dntc:>

8. Remove each air hose and the air tube. 0 U . .,.,Jlr--=~=~
• Disconnect each air hose and the air tube.
• Place alignment marks as necessary at each
connection part and loosen the clamps to remove. , . ___
?·~~,.1:,_,~,,T~,f--' ~D,;~
• Loasen air tube installation bolt.

lf _:j¡~-;~
cono.~gr
• Remove the air hose and the blow-by hose.

• Place alignment marks as necessary at each
connection part and loasen the clamps to remove.
,,¡
" n
n
----
tor installation bol!
EN-158
AIR CLEANER &AIR DUCT ENGlNE MECHANICAL
RB26DETT ENGINE
lnspection
• Check to make sure the air cleaner case, the air duct,
air hose, air tube and blow-by hose is not
damaged or worn in any way.
• Replace the parts with new ones if any abnormality is
found.
lnstallation
procedure.
• Align the parts to alignment marks and install each air
hoses and the air tubes.
• Tighten each clamp securely.
,,,.-.....,,
EN-159
RB26DETT ENGINE
2. INTER-COOLER
A 16~21{1 6~2.1}(right & left)

/
ttJ.l 16-21{1.6~2.1} ~
~ N-m{kg-m}
Removal
3. Remove the brake cooling duct (right and left).
4. Remove the tender protector front (ríght and left).
5. Place alignment marks on each connection part using
paint.
Caution:
Make sure to place alignment marks on the hose clamp
so to place in correct posítion at installation.
1nter-cooler
6. Remove the inter-cooler. :\
.,~. tube
.....
'\
(1) Remove the air hoses (both sides of inter-cooler).
(2) Remove the air hose (both sides of recirculatíon . ~' ... . ..
~!::!:~~!?e!~
-
tube). ~~ITTi"i ~'r hose
¡.,,\;-- ~~- ,----.., ;""'("
~"'{e\\
(3) Support the inter-cooler lower surface using a jack

etc. to avoid ínter-cooler from falling.
EN-160
RB26DETT ENGINE
(4) Remove installation bolts and two installation nuts on
lower front side of the inter-cooler.
(5) Remove right and left installation bolt and installation s .

// ~•--;,. ;/
nuts on the inter-cooler installation bracket. " -
(6) Remove right and left inter-cooler installation bracket
Front
and right and left sub bracket. ~
(7) Remove inter-cooler and the recirculation tube.

Caution:
, _})/
)
r-cooler installatíon bolt
Care must be taken not to damage inter-cooler core. , Re~irculatíon tube " '
lnter-éooler -/.,--"-., \'
7. Remove the recirculation valve. ! 1i

(1) Remove the air hoses and the air tubes between re- ~~¡;Q;-..!...; Recirculation
valve
circulation tube and the recirculation valve outlet.
(2) Remove the air hose at recirculation valve inlet.
(3) Remove the inter-cooler right side air hose.
YJ)±~I
ose & air tube
/
er-cooler
(4) Remove two vacuum hoses at recirculation valve

side.
(5) Remove three installation bolts to remove recircula-

tion valve and air tube ASSY.
~ 1 @t., Gasket
(6) Remove the recirculation valve from the air tube. ~~~
V,~ 1
Recirculation valve " \
Airtube
EN-161
RB26DETT ENGINE
lnspection
lnter-cooler visual inspection
• Check to make sure inter-cooler core is not clogged
with foreign objects.
• Check if there is any damage ar faults at joints on the
inter-cooler core and pipings.
. Clean if there are any blockages .
Replace the inter-cooler if there is any damage or
faults.
Recirculation valve function inspection

1. Remove the air hose and the air tube on recirculation
valve output side.
2. Place a hale cap on the recirculation side opening.
3. Start the engine.
4. Check the air blowout from the recirculation valve
when the throttle is closed. lt is normal if there is
blowout.
• Check the vacuum hose far any disconnection ar cut.
• lf there is no fault with the vacuum hose, carry out the
recirculation valve operation check.
Recirculation valve operation inspection

• Use a vacuum hand pump to create negative pres-
sure. Check if the valve will lift up to retain negative
pressure.
Standard value (kPa{mmHg} -16~-24{-120~-180}
• Replace the recirculation valve if there is any
abnormality.
lnstallation
Align the inter-cooler and
hose projection
Posilion white paint on top
Front
EN-162
RB26DETT ENGINE
1. lnstall the recirculation valve.
<Jhi, ~, Gasket
(1) lnstall the recirculation valve to the air tube. 1
Tightening torque(N-m{kg-m}) 16~21 {1.6~2.1}
~V~~ .~.-~
Recirculation valve \
Air tube
(2) lnstall the recirculation valve and air tube ASSY.

(3) Connect the air hose and the vacuum hose.
• Reinstall the parts by using the alignment marks.
• lnstall the clamp securely.
2. lnstall the inter-cooler.

(1) lnstall the mount rubber on upper right and left side of
_,,.---··
the inter-cooler to the bracket.
(2) Set the inter-cooler and the recirculation tube to
installation position.
• Temporarily tighten the installation bolt at lower front
side of the inter-cooler so it can be handled as a
single unit.
• Securely insert the inter-cooler upper right and left
projection to the mount rubber.
Caution:
• Care must be taken not to damage the inter-cooler
core.
• The mount rubber may fati off if the inter-cooler is
moved around excessively.
(3) lnstall the inter-cooler installation bracket (right and

left) and the sub bracket (right and left). / ~,-h. /
t,
• Temporarily tighten all installation nuts and bolts.
When the installation position is correct fully tighten Front
the nuts and bolts securely from the bracket side.
"
, 0!
er-cooler bracket
<RecirculatiOl'l tube'"
(4) Tighten installation bolt and two nuts on front lower

/ ··1nter-cooler
side of the inter-cooler.

Tightening torque (N-m{kg-m}) 16-21(1.6~2.1}
(5) Connect the air hose.
• Reinstall the parts by using the alignment marks.
• lnstall the clamp securely.

procedure.
EN-163
RB26DETT ENGINE
3. FUEL INJECTOR
~ront
2.9-3.8{0.30-0.39} (2)~
í:0-~
~ 16-21{¿~2.1} (2) " ~ '.
~ O-rii\ng
-
0
'-.'Pl
lnsulator,., /
I ~ @---------Fuel
®
)
~lnsulator
injector
~
t ,__
Fuel tube ~O-r11ng
{t!l6.3-8.3s::.64-0.85}
~ t~ -~ 0 Fuel pressure
regulator
Fuel h o s e ~ ~ .
~
Fuel feed hose /j h~
2 _3_ 3_0{0 .23 _ 0 _31 } (2)~
1 ~ ;~ .
To fuel filler---~- _ I L-i~""~
~ . Fuel hose
Fuel return hose
I
Fuel d a ~ e
j
ri
~
_1 Fuel sub tube
~ N-m{kg•m} To fuel tank - ~ ~ 6.3-8.3{0.64-0.85}M

~ Replace after every disassembly Fuel hose
Removal
3. Remove the blowby hose between the rocker cover
and the intake manifold.
4. Remove the vacuum hose for brake booster and the
clutch booster.
5. Disconnect the following:
• Throttle sensor
• Throttle valve switch
• lntake air temperature sensor
• Knock sensor
• Fuel injector
6. Remove the vacuum hose at the pressure regulator

side.
7. Remove the fuel hose for feed and return at fue! tube
side.
Caution:
Place the hole cap as soon as possible so the fue! will
not leak.
8. Remove two installation bolts to remove fue! tube and

fue! injector ASSY. Fuel injector
-Os
lnsuJator \ lnsulator
9. Remove fuel injector and the pressure regulator. -:'r \~ar

• Pull them from the fue! tube straight. t:Z-. ., iO-ring
Caution: K. e
• Place a tray to catch leaking fuel from the fuel tube. . '\.
(_ Pressure
• Do not disassemble the fuel injector. ~ regulator
• Fuel injector must be handled carefully.
EN-164
RB26DETT ENGINE
10.Remove fuel sub tube and fuel damper ASSY from
behind the intake manifold collector.
lnspection
Fuel tube and fuel hose
• Check for any fuel leaks from the fuel tube and the
fuel hose.
• Replace with new ones if there is any abnormality.
lnstallation
1. lnstall the fuel sub tube and fuel damper ASSY.
Tightening torque(N-m{kg-m}) 6.3~8.3{0.64~0.85}
2. lnstall the fuel injector to the fuel tube.
(1) lnstall o-ring and the insulator to the fuel injector.
• Replace the o-ring and the insulator with new ones.
• Read the handling note befare carrying out this lnsulator
operation.
Handling note:
• Always handle the O-ring with bare hand (no gloves).
• Only apply engine oil (7.5W-30 or similar viscosity)
and never clean or soak the o-ring in solvent
solution.
• Avoid using dirty o-ring and devices with dust or other
or stretch them.
• When inserting fuel injector, pressure regulator or
fuel damper into the fuel tube, do not twist or turn the
parts.
Fuel injector
(2) lnstall the fuel injector to fuel tube. lnsula\tor \ lnsulator
• Care must be taken not to damage the nozzle tip. ~&(
- o@~
3. lnstall the fuel pressure regulator.
" - ~ 0-ring
·,o/J.~
:'---.. e
4. lnstall the fuel tube and fuel injector ASSY.
• Tighten right and left fuel tube installation bolts
(_ .
~
'
Pressure
regulator
alternately.
• Re place the insulator with a new one.
• When installing the washer face the flat side towards
the fuel tube.
5. lnstall the fuel feed and the return hose.
• lnsert the hose tip up to the second bulged part of
the fuel tube and make sure to securely tighten the
clamp.
6. Connect the vacuum hose to the pressure regulator.
procedure.
EN-165
RB26DETT ENGINE
N-m{kg-m}
Replace after every disassembly
Removal
4. Remove the front strut tower bar.
5. Remove the acceleration cable.
6. Remove the oil leve! gauge.
7. Remove the air hose at intake manifold collector inlet
side.
8. Remove the blowby hose between the rocker cover
and the intake manifold. (Labelled A)
9. Remove the vacuum hoses for the brake booster and
the clutch booster. (Labelled B & C)
1O.Disconnect two vacuum hose at boost control
solenoid side. (Labelled O)
11 . Remove connectors stated below:
• Throttle sensor (Labelled E)
• Throttle valve switch (Labelled F)
• lntake air temperature sensor (Labelled G)
• Knock sensor (Labelled H)
EN-166
RB26DETT ENGINE
12.Disconnect the throttle link at the accelerator work --u--
unit side.
13.Remove the vacuum hose at No. 1 throttle chamber
side.
14.Remove both fuel hoses (feed & return) at the fuel
sub tube.
Caution:
Place a hale cap so the fuel will not leak.
15. Position the fuel filter and bracket ASSY to a position
that will not get in the way.
Reference:
Parts and installation bolts position on reverse side of the
intake manifold collector are shown in the figure below.
e;) Front Harness clamp
Vacuum tube
,.---.,.
Water lube / air Lube ASSY

Airchamber ,O, lntake manifold side
16.Remove the engine harness between the relay case

and the starter motor from the clamp after opening the
clamp.
17. Remove the fuel sub tube and fuel damper ASSY.
18. Remove the d ifferential breather hose bracket and the

harness clamp bracket.
19. Disconnect the AAC valve connector.
20.Disconnect the air hosesA, B and C at intake manifold
collector side.
EN-167
RB26DETT ENGINE
21.Remove the vacuum tube. e . ~-~ 1--11-/t
V acuum tube
22.Remove the air chamber installation bolt.

AA
cha

12 10 e;> Front ,---,
• Loasen the installation nuts in the order shown in the 1 6 2
figure on right.
Caution: ~ ....~; ,--
'\,_)'
Care must be taken not to bend the throttle link. '!
24.Remove the throttle chamber.
• First check No.2 (center} and No.3 (rear side} before
removing.
3 ll
~ AAC valve & air
25. Remove each hoses (A - F) to remove the AAC valve

and air chamber ASSY.
• Place alignment mark as necessary.
':-l
26. Remove the AAC valve from the air chamber.
Caution: Gasket
(1} Do not disassemble AAC valve. M Cvalve
(2) Care must be taken not to damage the AAC valve.
~ -f,:j: Aicchambe,
27. Disconnect each hose to remove the water tube and
air tube ASSY.
~
lnspectlon Straight gauge

Distortion of the intake manifold collector '
• Use a straight gauge and feeler gauge to measure the ~
distortion in six directions.
• lf the distortion is over the limit replace with a new
one. ~ Feeler gauge
EN-168
RB26DETT ENGINE
lnstallation
1. Connect hose to water tube and air tube ASSY. 1D paint:
None (Standar~
• Check the colour of identification paint when
Red (N1 v eI_Í
h\i
connecting the vacuum control hose to intake Vacuum .. .
manifold collector rear end. control ·. ,.,,-·
hose ·.
• Make sure the clamp is installed securely.
ID paint: . Water tube and
Reference: Red (Standard vehicle) air tube ASSY
Yellow (N1 vehicle)
(1) The vacuum control hose between the standard vehi-
cle and N 1 ve hiele is different.
(2) The vacuum control hose must be installed in the cor-
rect direction as it has an opening.
Gasket
2. lnstall AAC valve to the air chamber. MCvalve
Tightening torque (N-m{kg-m}) 6.3~8.3{0.64~0.85} ~--\) • Aicchamb,c
~
3. Connect hose to the AAC valve and air chamber --.:: A _AAC valve & air
ASSY.
• Remove old gasket from the vacuum installation
surface and clean the surface using white gasoline
befare connecting the hose.
• Make sure to install the clamp securely.
'----
º'
No. 1 Throttle chamber
4. lnstall the throttle chamber. No. 2 Throttle chamber
No 3 Throttle chamber
(1) Remove old gasket from the intake manifold and the Gasket
throttle chamber and clean the surface using white
gasoline.
• Clean the intake manifold collector side for the l
throttle chamber.
(2) lnstall dowel pin to the intake manifold lower stud
bolts (6).
• The length of the dowel pins are different for the throt-
/:::J 14mm
Dowel pin
tle chamber and the intake manifold collector.

Length of the dowel pin (mm)
For throttle chamber installation 1O
For collector installation 14
(3) 1nstall the gasket.
(4) lnstall the throttle chamber.
• Make sure all three will contact the intake manifold
when pushed.
EN-169
RB26DETT ENGINE
5. lnstall the intake manifold collector.
(1) Remove old gasket from the intake manifold and
collector and clean the surface using white gasoline.
(2) lnstall the dowel pin to six stud bolts on the throttle
chamber lower side.
• The length of the dowel pins are different for throttle
chamber and the intake manifold corrector.
Length of the dowel pin (mm)
For throttle chamber installation 1O
For collector installation 14

• Replace the gasket with new ones.
(4) lnstall the intake manifold collector.
rº
• Tighten the installation nuts in the order shown in Front
1 3
severa! stages.
7
Caution:
Care must be taken not to bend the throttle link.
1
4 8 12
6. lnstall the air chamber instaUation bolts.

• For installation bolts position, refer to a diagram on
intake manifold collector reverse side diagram on
4. lntake manifold section.
7. lnstall the vacuum tube. A ~-- 1--11-1 1-

• Replace the gasket with a new one. vacuum tube
~
8. lnstall hose A, B and C to the intake manifold

collector.
• When installing the vacuum control hose C, identi-
fication paint (red) should be on the intake manifold
collector side (N 1 vehicle ).
• Make sure the clamp is installed securely.
9. lnstall the AAC valve connector.
é, (valvEf..
'/
·
1O. lnstall the differential breather hose bracket and the
harness clamp bracket.
EN-170
RB26DETT ENGINE
11. lnstall the fuel tube and fuel damper ASSY.
12. lnstall the fuel hose.
• lnsert the hose tip up to the second bulged part then
tighten the clamp securely.
13.lnstall the throttle link to the accelerator work unit.

Tightening torque (N-m{kg-m}) 2.9-3.9{0.3~0.4} --0-
14. Carry out the method below to adjust the throttle

chamber link when you have replaced any parts which
will have affect on the way the throttle valve opening
and closing motion or when there are any abnormality
_,--..
with the throttle valve opening and closing motion.
No. 3 throttle chamber
~ Nut: B
"-. "'- · "-- No. 2. throttle chamber ·
:::::---...."-. ~ --'--~
0
~ Nut: B ~
• ~ ottle chamber
Nut: A Y in detail
\ ."-..
/
No. 3 thr
No. 2 throttle link
. \. l\
Thrott chamber ),\"-.-.._
Nut~~o. 1 thro e m
full close stopper1',i.t -~ 1 ,;>-.
Z in detail
(1) Loosen each throttle link nut A and B and turn each
throttle link centre adjustment part anti-clockwise to
shorten the links.
Ac ator d
• Shorten each throttle link until the accelerator drum
hit the full close stopper on the accelerator work unit
side.
EN-171
RB26DETT ENGINE
(2) shorten each throttle link so the throttle lever will
open from full clase stopper on the throttle chamber
side.
Caution:
Nut A and B do not lock.
F eler au e mm)
Accelerator dru
(3) lnsert 1mm feeler gauge between accelerator drum
and accelerator work unit side full stopper. Fix the
accelerator drum so it will not move.
(4) With the feeler gauge placed, turn No. 2 throttle link
centre adjustment part clockwise to extend the throt-
tle link until the full close stopper on the throttle lever
and throttle chamber side contacts.
Centre adjust
art
(5) Resistance will be felt when the full close stopper hit.
Extend the throttle link until just before this
resistance is felt.
~ ~ . 3 thr~ttle Thickness
(6) Adjust No. 3 and No. 1 throttle links as same as No.

~~
...,_
i33J_
, - _..gauge
2 throttle link adjustment.
""'
,~~
(7) Tighten lock nut A and B after centre adjustment for 3

throttle links are completed.
Caution:
Make sure the centre adjustment parts will not turn when
tightening the lock nuts.
Tightening torque(N-m{kg-m}) 2.9~3.9{0.3~0.4}
EN-172
RB26DETT ENGINE
(8) Remove the feeler gauge placed by accelerator work Locknut (not adju
Ac
unit side full close stopper.
Caution:
Do not adjust the lock nut on full close stopper side.
(9) Check that each throttle chamber will move smoothly

when the throttle chamber is fully closed and opened
repeatedly.

procedure.
~6.3~8.3{0.64~0.85}(4) ~..__.
Thrott1e valve switrf V
~ 6.3-8.5{0.64-Q.85}(2) ~~----~ !
"---vA I bl
cce erator ca e ~
il\\-- ---
Accelerator work unit
bracket
(yf
1
•
~ e,----- Dowel pin (2)

1
\(¡)C-~~~
L/ ·"''Í Íf¡ ' __, ,, . lntake air temperature
· - 1 , sensor
/ . 2>-~
/ . 1
lntake manifold collector '-~-~
~ Replace after every disassembly \ ~
W Washerr.,
~ N-m{kg-m}
Disassembly
1. Remove the accelerator work unit.
2. Remove the intake air temperature sensor.
3. Remove the accelerator cable bracket.
Assembly
1. lnstall the accelerator cable bracket.
2. lnstall the intake air temperature sensor.
3. lnstall the accelerator work unit.
• lnstall two dowel pins.
• Tighten the installation bolts alternately.
EN-173
RB26DETT ENGINE
5. INTAKE MANIFOLD
Removal
1. Release the fuel pressure .
4 . Remove the front strut tower bar.
5. Remove accelerator cable.
6. Remove the intake manifold.
7 . Remove the throttle chamber. /
8. Remove the air chamber.
~~
9. Disconnect the radiator upper hose at water outlet á.''
side. J
1O. Disconnect the water hose at water outlet side. "'<:'\

Air cha
11 . Remove all connectors and terminals extending from :--,
the harness cover to shift the harness cover. Radiator up

Front c:)
• Loosen installation bolts and nuts in the arder shown
to remove intake manifold.
lnspection
9
• Use a scraper to remove old gasket.
• Use a straight gauge and feeler gauge to measure the
distortion of the front and reverse surface in six direc-
-
~
tions. ~
~ 5-----,,/.< Feeler
• Re place the intake manifold if the distortion is over the ~---~---- ~ gauge Straight
limit. ~6~ gauge
EN-174
1NTAKE MANIFOLD ENGINE MECHANICAL
RB26DETT ENGINE
lnstallation
1. lnstall the intake manifold.
the cylinder head and clean the surface using the
white gasoline.
• Also clean the intake manifold on the throttle
chamber side.
(3) lnstall the intake manifold.
• Depending on the installation position, the bolt under
head length will differ. FrontQ
lnstallation bolt (underhead: 30mm) 3, 5, 6, 8 11 7 5 9 13
(underhead: 60mm) 1, 4, 10, 12, 14
(underhead: 65mm) 7, 9
lnstallation nut 2, 11, 13
• Tighten installation bolts and nuts in arder shown in
- -•. the figure on right in severa! stages.
10 6 2 4 8 12 14

procedure.
Disassembly
1. Remove the fuel tube and injector ASSY.
2. Remove the air regulator.
EN-175
RB26DETT ENGINE
3. Remove the water bypass connector.
• lnsert a tool such as a screwdriver between the intake
manifold and the water bypass connector and move it
lightly to remove the connector.
Caution:
Care must be taken not to damage the installation sur-
face.

• lnsert a screwdriver handle into the water outlet as
shown and move it lightly to remove.
~ ce tube
5. Remove the balance tube. ,::.,0-rin
• Check the o-ring size while removing. 0 -ring

~ ~~A
-ring B
'i;;J
Front
Assembly
1. Use the method below to caulk the clamp if the air
hose was removed from the balance tube.
(1) Make end of the end nipper as shown in the diagram.
The end nipper can be purchased commercially.
.
__ --:¡-r Caulk
7
--........:
.
dlrection
Y✓R0.5
• Caulk the clamp using the end nipper. ~
Thlckness 1.4mm
R0.5
Clamp dimension (mm)
Clamp
(2) lnstall the clamp in a way so the caulk position is as
shown in the diagram. Caulk
Caution : position
lf the non-genuine clamp is used or caulk position is in-

stalled incorrectly, the throttle valve may not clase
correctly dueto throttle lever interference.
2. lnstall the balance tube.

• Replace the o-ring with a new one. 0-ringA
Clamp
• There are three types of o-ring. Make sure to install

correct o-rings. 0-ring . A
ng
A (small): 3 positions near cylinder head -ring B
B (med): 2 centre positions near throttle chamber
C (large ): 4 outer positions near throttle chamber Front
• lnstall the o-ring to installation groove.
EN-176
RB26DETT ENGINE
Apply sealíng
(1) Remove old gasket from the intake manifold and ~....;::.~ agent approx.
the water outlet and clean the surface using the <P2.0-3.0mm
white gasoline.
(2) Apply sealing agent (KP710 00150) to position
shown with no gaps at approx. ct>2.0~3.0mm.
4. lnstall the water bypass connector. <t>2.0-3.0mm

the water bypass connector and clean the surface
using the white gasoline.
(2) Apply sealing agent (KP71 O 00150) to position
shown with no gaps at approx. ct>2.0~3.0mm.
Q Front
(3) Tighten installation bolts from the centre to outside.
• Depending on the installation position the bolt head 35 35 50 25
Fcl<--~~..-------¡¡,----~'o\
length will differ. o o__)
Tightening torque (N-m{kg-m}) 16~21 {1.6~2.1} 35 35 50 30
5. lnstall the air regulator.

6. lnstall the engine coolant temperature sensor.
• Apply sealing agent to the thread part.
7. lnstall the fuel line and injector ASSY.
EN-177
TURBO-CHARGER & EXHAUST MANIFOLD ENGINE MECHANICAL
RB26DETT ENGINE
6. TURBO-CHARGER / EXHAUST MANIFOLD
~ J
16-21 {1.6-2.1}(3)
~
Copper wastr
~
20-31{2.0-3.2}~
20-31 {2 0-3.2}~

~ N-m{kg-m}
EN-178
RB26DETT ENGINE
Removal
boot.
2. Remove the front spoiler under cover (N1 vehicle).
6. Drain coolant from the cylinder drain plug.
8. Remove the air duct, air cleaner case and the air
hose.
Caution:
Clase the turbo-charger opening to avoid foreign objects
from entering.
9. Remove the exhaust gas sensor.

• Use exhaust gas sensor removal socket to remove.
• Do not drop or cause damage to the sensor.
1O.Disconnect ali tubes and hoses shown in the figure on

hose
right. ear turbo
(1) Disconnect the exhaust gas sensor connector and arger
tlet tube
remove the harness connector from the bracket.
(2) Remove the air hose from the bracket.
y
..,
(3) Place alignment mark as necessary and remove the ensor
·\ connector
rear turb-charger outlet tube, 2 air hoses, front turbo-
./e::?
charger outlet tube and the air tube. irtube
\ ~
,,,,--
Front
Caution:
Clase the turbo-charger opening to avoid foreign objects
from entering.
11. Remove the water return tube (A).

• Remove in the arder of 1 to 4.
12.Remove the air tube.
• Remove in the arder of 5 to 7.
13.Remove the water return tube (B) and (C).

(1) Loasen the nut (8) and (9).
(2) Loosen nut (1 O) and remove the water return tube
(B).
(3) Loosen nut (11) and remove water return tube (C).
14. Remove the water connector.
15.Remove the exhaust manifold cover.
EN-179
RB26DETT ENGINE
16.Remove water feed tube eye bolt and oil feed tube rfee tube
bolt
eye bolt.
. ed ¡
17.Remove the oil feed tube installation bolt. 11
18.Remove the oil return hose and the oil return tube.
19.Remove the turbo-charger support.
~--- ~
~ : Oil fee
,
bolt - ,
\r'í'-·r<' ,< \ / . '.
Water retum luoe Turbo-charger support
20. Remove the turbo-charger ASSY from the exhaust

_(;:lFront _ _ =- ~
,,-- ~
manifold . ✓ -
(1) Open the lock plate claw and loasen the turbo-charg-
er ASSY installation nuts.
(2) Remove the turbo-charger ASSY from the exhaust

manifold and place it below the exhaust manifold.
Caution:
Do not bend the oil tube and water tube.
21.Remove the turbo-charger gasket.
22.Remove exhaust manifold . Front i Rear

1
• Remove installation bolts in the order shown.

23. Remove the exhaust manifold gasket.
24. Remove the turbo-charger ASSY.

Caution:
Care must be taken not to bend the oil tube and the wa-
3 64 : 3 64
ter tube.
25.Remove the water feed tube and the oil feed tube
from the cylinder block.
26.Remove the air tube and the water return tube ASSY
from the cylinder head rear side.
• Remove the installation bolts and the cylinder head
auxiliary bolts.
EN-180
RB26DETT ENGINE
lnspection
• Use a scraper to remove gasket on the installation
surface.
• Use a straight gauge and feeler gauge to measure
the installation surface distortion in tour directions.
• Replace the exhaust manifold if the distortion is over
the limit.
Gas leak from the exhaust parts

• Look for any gas leak from the cylinder head
installation surface, catalytic converter installation
surface and the exhaust front tube installation
surface.
,--- lnstallation
• Each pipe installation location is shown in the
figure below.
~ Front
Water r
1. lnstall the air tube / water return tube ASSY to the

cylinder head rear side.
Cylinder head auxiliary bolt 9.0~12{0.92~1.2}
lnstallation bolt 6.3-8.3{0.64~0.85}
2. lnstall the water feed tube and the oil feed tube to the
cylinder block.
• lnstall the eye bolt with ID mark 'M' to the oil feed ,,--~,, -----
~ ;' '\- --w
Front / 1-t )..e,;:
tube.
Water feed tube eye bolt 20-31 {2.0~3.2}
Oil feed tube eye bolt 15~20{1.5~2.0}
e
3. Lower the turbo-charger ASSY to the left side of the
engine making sure each tube is not bent.
EN-181
RB26DETT ENGINE
4. lnstall the stud bolt to the cylinder head by inserting
the double nut.
with the shorter thread side is installed to the cylinder
head side.
Cylinder head Q
5. lnstall the exhaust manifold gasket.
• Remove old gasket from the cylinder head and the
exhaust manifold and clean the surface using the
white gasoline.
6. lnstall the exhaust manifold.

(1) lnstall the washer with the flat surface facíng the cyl-
inder head.
..
Manifold side
Front ¡Rear
6 2 5 :6 2 5
(2) Tighten the installation nuts in the order shown in the
~~
figure.
• Replace the installation nuts with new ones.
4 1 3 l4 13
7. lnstall the turbo-charger ASSY to the exhaust mani-

fold.
• After tightening the installation nuts fold the lock plate
claw inwards.
• Replace the lock plate with a new one.
8. lnstall the turbo-charger support.

9. lnstall the oil feed tube installation bolt to the turbo-
charger support.
10.lnstall the oil return hose and the oil return tube.
11. lnstall the water feed tube eye bolt and the oil feed
tube eye bolt.
Water tube eye bolt 29~39{3.0~4.0}
Oil tube eye bolt 18~20{1.8~2.0}
EN-182
RB26DETT ENGINE
12.lnstall the exhaust manifold cover. ter connector
etum ---::i ✓.
,,..------
Attach earth wire to the front side exhaust manifold
cover.
13.lnstall the water connector.
14.lnstall the water return tube (B) and (C).
_I
,
• First temporarily tighten the nuts 8 to 11, then fully
tighten.
15. lnstall the air tube.
• lnstall the nuts in the order of 7 to 5.
Nut 7 6.3~8.3{0.64~0.85}
lnstallation bolt 6 15~20{1.5~2.0}
16. lnstall the water tube (A).
• lnstall in the order of 4 to 1.
• lnstall an eye bolt with identification mark 'N' for No. 4
eye bolt.
Eye bolt No. 4 33~41 {3.4~4.2}
Eye bolt No. 3 21~31 {2.0~3.2}
lnstallation bolt No. 2 6.3~8.3{0.64~0.85}
17.lnstall every tube and hose shown in the figure. ·r hose

ear turbo
(1) lnstall the rear turbo-charger outlet tube, two air harger
hoses, the front turbo-charger outlet tube and the air uleye
tube by aligning to the alignment mark.

(2) lnstall the bracket to the rear turbo-charger outlet
..,
,
2
nsor
tube.
e\\co:,?ºt:?
tube ~- Front
(3) lnstall the air hose to the bracket.
(4) Connect the 0 2 sensor connector and fix to the
bracket.
procedure.
,/ ,&"'~
Front
19. lnstall the 0 2 sensor. ,y"
• Use the exhaust gas sensor installation socket to A~~~
install.
• Care must be taken not to cause any damage.
• Do not drop or hit the sensor.
Tightening torque (N-m{kg-m}) 40~50{4.1 ~5.1}
lnspection
Start the engine and make sure there are no coolant
or engine oil leaks from the turbo-charger connections.
Also check the exhaust manifold and the turbo-charger
connection far any exhaust gas leak.
EN-183
RB26DETT ENGINE
~ N-mt"!:J-'"J
~ Replace after every disassemble
Disassembly
Turbo-charger
Caution:
Do not disassemble turbo-charger main body.
1. Remove the exhaust outlet cover and the turbo-
charger cover.
2. Remove the exhaust outlet.
3. Remove the air inlet tube.
4. Remove the air outlet tube (front turbo-charger
only).
5. Remove the oil feed and water feed tube.
6. Remove the oil return pipe and the oil return hose.
EN-184
RB26DETT ENGINE
Crack inspection
Actuator rod
Coolant leak inspection
Swing valve
controller
ressure charging
leak
Swing valve
~mpressor wheel
Turbine wheel Rotor shaft
- Oil leak inspection area
Water feed / Return tube

• Check to make sure there are no blockages or rust
inside the water feed and the return tube by blowing
compressed air using a air gun after cleaning the
tube with radíator cleaner.
Radiator cleaner
Airgun
Oil feed / Return tube
• Check to make sure there are no blockage or rust
inside the oil feed and the return tube by blowing com-
pressed air using a air gun after cleaning the tube
with engine conditioner.
cleaner
Oil feed tube
Oil feed tube
Turbo-charger
• Clean befare inspection.
• Clean the oil feed and the oil return with engine
conditioner.
• Clean the water feed and return with radiator clean-
er.
Airgun
• Blow compressed air using a air gun to the compres-

sor wheel, turbine wheel, compressor housing and
turbine housing.
EN-185
RB26DETT ENGINE
Rotor shaft
• Make sure the rotor shaft will turn smoothly when
pushed with finger.
• The rotor shaft must not be loose when moved right /
left.
• Make sure there are no carbon sludge accumulation.

n
• Make sure there are no change in colour with the e
rotor shaft. ulation
Rotor shaft end play

• Set end play by placing the dial gauge to the rotor
shaft end and place it to the axle direction.
Standard value (mm) 0.013 ~ 0.097
Reference:
Rotor shaft diameter direction
Clearance standard value (mm): 0.056 ~ 0.127
Turbine wheel
• Make sure there are no grease adhesion.
• Make sure there are no carbon accumulation.
• Make sure the turbine wheel blade is not bent or Turbine wheel
broken.
• Make sure there are no interference between the
turbine housing and the wheel.
Swing valve
• Remove actuator rod E-ring and check if the swing
valve will move smoothly with no deformation or
damage.
• Check for any abnormality with the turbine housing
seat surface.
Compressor wheel
• Make sure there are no grease adhesion at admis-
sion port.
• Check for any interference between the compressor
housing.
• Make sure the wheel is not bent or damaged.
EN-186
RB26DETT ENGINE
Swing valve controller Air gun
• Remove swing valve controller rubber hose on the
compressor housing side.
• lnspection must be carried out when actuator rod is
installed and removed.
• Make sure the swing valve controller rod will operate
when the air gu n is used to blow compressed air. Stop
the air gun operation as soon as it starts moving.
Actuator rod operation pressure (kPa{mmHg})
0.38mm lift 59~64{440-480}
4.00mm lift 78~84{587~627}
Caution:
Before blowing the air into the swing valve controller rod
make sure to check the air gun pressure using the LPG
pressure gauge (0.10MPa{1kg/cm2 } ST1957 2000) so it
will not damage the diaphragm.
Assembly
1. lnstall the oil return pipe and the oil return hose. Oil feed tube eye bolt B--....... Copper
2. lnstall the oil feed and water feed tube.
13~19{1.3~1.9}
Wa:ec :d Nbe,y~
'¡ /washer
• Tighten using the method below:

( 1) Temporarily tighten two bolts (A). •-Coppec washec
(2) Tighten oil feed tube eye bolt B and the water feed
tube eye bolt C. ~ Bolt (A) (2)
Tightening torque (NHm{kg-m})
Eye bolt (B) 20~29{2.0~3.0}
Eye bolt (C) 29~39{3.0~4.0}
(3) Tighten bolts (A).
Air outlet tube

3. lnstall the air outlet tube (front turbo-charger only). (front turbo-charger)..__w
• Replace the gasket with a new one. Air inlet tube Gasket .
(front turbo-charger) ~~
t~~etr~.
-~~
4. lnstall the air inlet tube.
• Replace the gasket with a new one. ...1:}
5. lnstall the exhaust outlet.
16~21{1.6~2.1} ..
ISf'
.✓-,,,."~-..C,asket
~- '
Air inlet tube (rear turbo-charqer'
Tightening torque (N-m{kgHm}) 23~29{2.3~3.0}
6. lnstall the turbo-charger cover and exhaust outlet
cover.
EN-187
ROCKER COER ENGINE MECHANICAL
RB26DETT ENGINE
7. ROCKER COVER
Rubber plugf,;l~
Blowby hose - e:r----J
~ 2.0-4.0{0.2-0.4} tg
Filler cap - e:;, (right & left 10 each)
~· Blowby hose "-~
O-ring ~ Grommet_ g
. . ,,...._
\
To blowby control valve
Rocker cover (int
~ Rocker cover gasket ~'$'.
To air duct
ocker cover (exhaust)
(g2.3-3.1{0.23-0.31} (8) ,__ ~
~ /. / ~ Rocker cov
(g N-m{kg-m} V Rocker cover ornament
fl Liquid gasket
Removal
boot.
Harness cov
4. Remove the turbo-charger outlet tube.
5. Shift the ignition coil harness.
6. Disconnect each harness and terminal and shift the Tu
harness cover. outlet
7. Disconnect right and left blowby hose on the rocker \---

cover side. \\-
4 8 10 6
o o
8. Remove the rocker cover. "
• Loosen the installation screws in order shown. 1º8@ o
4
o
9
o
7
(lntake side}
• Remove both right and left rocker cover. Q Front
(Exhaust side)
4 8 10 6
1: 8
o
o
4
o
o
9
o
o
7 3
lnspection
• Check if there are any damage or cracks on the rocker
cover.
• Re place the rocker cover if there is any fault.
• Check to make sure there is no oil leaking from be-
tween the rocker cover and the cylinder head.
EN-188
RB26DETT ENGINE
lnstallation
1. lnstall the rubber plug to the end of the cylinder
head.
(1) Remove old gasket from the cylinder head and the
exhaust manifold and clean the surface using white
gasoline.
(2) Apply sealing agent to the installation surface.
2. lnstall the gasket to the rocker cover. 7 3 1 5

o o 0
3. lnstall the rocker cover.
1 OC§) <> <> o
8 4 2 6 10
(lntake side)
• Remove grease, dust etc. from the cylinder head side QFront (Exhaust side)
installation surface. 7 3 1 5 9
• Tighten the installation screws in arder shown in

severa! stages.
1: 8
D
4
9 :
2
o
6
o
10
4. Fix the ignition coil harness with the clamp.
procedure.
EN-189
RB26DETT ENGINE
···•,,
Removal
1. Remove the engine / transmission / transfer ASSY
from the vehicle.
2. Remove the transmission / transfer ASSY from the
engine.
3. Set the engine ASSY to the engine stand.
4. Drain the engine oil from the oil pan drain plug.
5. Remove the fly-wheel.
6. Remove the rear plate.
7. Remove the oil pan from the cylinder block.
(1) Remove the oil pan installation bolts and nuts in the
order shown .
• No. 12 and 16 installation bolts will tighten the brack-
et.
(2) lnsert the seal cutter between the oil pan and the
cylinder block.
(3) Tap the seal cutter rear surface using a hammer to
remove the oil pan.
(4) Remove the oil pan carefully making sure the baffle
plate will not interfere with the oil filter.
8. Remove the baffle plate.

EN-190
RB26DETT ENGINE
lnspection
Oil filter visual inspection
net.
• Clean the filter net if there are any foreign objects.
• Replace with new one if there is any fault.
O-ring - o ~ M6 bolt
lnstallation
Tightening torque (N-m{kg-m}) M8 bolt---i
1
M6 bolt 6.3~8.3{0.64~0.35}
M8 bolt 16~21 {1.6~2.1}
2. lnstall the baffle plate.

• Make sure to install the correct installation bolts.
Bolt underhead(mm) Bolt (A) 12
Bolt (B) 30
Bolt (C) 55
Tightening torque (N-m{kg-m}) 6.3~8.3{0.64-0.85}
Baffle plate

• Use the scraper to remove old liquid gasket from the
oil pan and the cylinder block.
• Use white gasoline to clean the installation surface.
• Apply sealing agent (KP71 O00150) at <1>3.5 ~ 4.5 mm
to position shown in the figure.
• Tighten the installation bolts in the order shown. 27
Q Front
• lnstall the tightening bolts and the nuts.

(A) M6 bolt (bolt underhead 16mm)
(8) M6 bolt (bolt underhead 30mm)
(C) M10 bolt (bolt underhead 30mm)
(D) M1 O bolt (bolt underhead 50mm)
(E) M1 O nut
M6 bolt 6.3~8.3{0.64~0.85}
M10 bolt & nut 31 ~42{3.2~4.3}
EN-191
RB26DETT ENGINE
4 . lnstall the oil pan drain plug.
• Replace the washer with a new one. Oíl pan side
• Make sure the oil pan drain plug is facing in the cor-
rect direction as shown. t

procedure.
lnspection
• Check the engine oil level.
• Warm up the engine and look for any oil leak and
check the oil pressure.
. ........_
EN-192
RB26DETT ENGINE
9. CAM SHAFT
Removal
boot.
7. Remove the front turbo-charger outlet tube, the air
----
..• hose, the rear turbo-charger outlet tube (exhaust side
cam shaft).
10.Remove auxiliary belt.
11 . Remove the timing belt.
13. Remove the cam timing pulley (exhaust side ).
(1) Remove the crank angle sensor installation bracket.
(2) Use a spanner or the pulley holder to fix the hexago-
nal area of the cam timing pulley to loasen the instal-
lation bolts.
(3) Remove the cam timing pulley from the cam shaft.
EN-193
RB26DETT ENGINE
14.Remove the cam timing pulley (intake side).
• Use the spanner or the pulley holder to fix the hex- ----....
agonal area of the cam timing pulley to loosen the
installation bolts.
15.Remove the timing belt cover (rear) and the canister

tube.
16. Remove the baffle plate from No.3 and No.4 cam
shaft bracket. 1 5 9 13 11 7 3
17. Remove the cam bracket.
• Loasen the cam bracket installation bolts in the arder ~~~~~~~ ~1
shown in several stages. 1
Caution:
Make sure to mark the bracket installation position 2 6 10 14 12 8 4
before removing the cam bracket. ._ Front
• Carry out the cam shaft end play inspection befare
loosening the cam bracket installation bolts.
18.Remove the cam shaft.

19.Remove the cam shaft oil seal from the cam shaft.
20. Remove the valve lifter and the adjustment shim.
• Check the installation position and store it to avoid
confusion.
lnspection
• Check to make sure there is no damage or wear to
the cam shaft.
Cam shaft run-out

• Use V-block on a fixed surface and support cam shaft
No. 1 and No. 7 journal.
movementwidth on the dial gauge.
Standard value (mm) 0.02
shaft.
EN-194
RB26DETT ENGINE
Cam nose height
Standard value (mm)
lntake 40.58
Exhaust 40.28
lntake 0.05
Exhaust 0.05
• lf the value is over the limit replace the cam shaft.
Cam shaft oil clearance

• Use micrometer to measure cam journal externa!
diameter.
Standard value (mm) <f)27.935-<f)27.955
(Cam bracket interna! diameter)
• Tighten cam bracket bolt to specified torque.
• Use inside micrometer to measure.
Standard value (mm) <f)28.000~<f)28.021
(Cam shaft oil clearance) =
lnsid
Standard value (mm) <t>0.045-<f)0.086 micro ..., ~ -(!
.- ..._
• lf the value is not within standard value, replace :'.:)
Cam shaft end play

• Set a dial gauge to the front end of the cam shaft in
thrust direction. Move the cam shaft forwards and
backwards and read the dial gauge run-out measure-
ment.
Standard value (mm) 0.060-0.110
Valve lifter clearance

(Valve lifter externa! diameter)
• Use micrometer to measure hydraulic valve lifter ex-
terna! diameter.
Standard value (mm) <l>30.955~30.965
(Valve lifter interna! diameter)
• Use inside micrometer to measure hydraulic valve
lifter interna! diameter.
Standard value (mm) (1)31.000~31.020 .::::
(Valve lifter clearance) = lnside
(Hydraulic valve lifter interna! diameter) - /
(Hydraulic valve lifter externa! diameter) I,.,

-~? e,
Standard value (mm) <t>0.035-0.065 v /_,? /.
"'-."
• lf the value is not within standard value, replace '\/
. -"'l 0
,;r,
-
"/
V"-
\
hydraulic valve lifter or cylinder head.

EN-195
RB26DETT ENGINE
...
·fr
Valve lifter visual inspection
• Check the cam nose rotational area and the lifter sur-
face for any damage or wear. Re place if there are any Valve liftec
abnormality.
,!}
Adjustment shim visual inspection 9 Q-- Adjust shim
• Look for any damage or wear on the valve stem con- D-
tact surface. Replace if there are any abnormalities.
lnstallation
1. lnstall the valve lifter and the adjustment shim.
• Apply engine oil to the rotational area.
• lnstall it in the correct position.
2. lnstall the cam shaft to the cylinder head. 1n
• Apply engine oil to the cam nose, journal and thrust
parts.
• The distinction between the intake and the exhaust Crank angle sensor drive spline gear
side cam shaft can be determined by the crank angle

sensor drive spline. Knock pin Knock pin
3. lnstall the cam shaft to the cylinder head so the knock

pin is as shown in the figure.
Cam.shaft Cam shaft

(lntake) ,.__ __ _, (Exhaust)
Bracket installation position
4. lnstall the cam bracket.

(1) Check the engraved mark on the cam bracket surface
lntake Exhaust
and the markings you have made at the removal to side
side
install the cam bracket in correct position.
1: lntake E: Exhaust
2) Tighten the cam bracket installation bolts in the arder 14 10 6 2 4 8 12

shown in severa! stages.
Tightening torque (N-m{kg-m}) 9.0~12{0.92-1 .2}
5. lnstall the baffle plate to No.3 and No.4 cam shaft
bracket.
Tightening torque(N-m{kg-m}) 9.0~12{0.92~1.2} 13 9 5 1 3 7 11
+- Front
6. lnstall the timing belt cover (rear).

M6 bolt 6.3~8.3{0.64-0.85}
M8 bolt 16~22{1.6~2.2}
EN-196
RB26DETT ENGINE
7. lnstall the cam front oil seal.
8. lnstall the cam timing pulley (intake).
(1) Instan the cam timing pulley to the cam shaft.
• Face the washer with the chamfered side towards the
pulley.
(2) Apply engine oil to thread parts and the bearing sur-
face of the installation bolts.
(3) Use the spanner to fix cam shaft hexagonal part to
tighten installation bolt.
9. lnstall cam timing pulley (exhaust).

(1) lnstall cam timing pulley to the cam shaft.
• Fix cam shaft hexagonal part using the spanner or
pulley holder to fix the timing pulley to tighten installa-
tion bolts in opposite angle.
(2) lnstall crank angle sensor installation bracket.
1O.lnstall the rest in reverse order to the removal

procedure.
EN-197
VALVE CLEARANCE ENGINE MECHANICAL
RB26DETT ENGINE
1O. VALVE CLEARANCE
lnspection
• Measure the valve clearance when the cam shaft and
the valve associated parts are removed or replaced. lf
the value is out of standard value replace the adjust-
ment shim.
Valve clearance standard value (mm)
(When cold} lntake 0.42~0.48
Exhaust 0.35~0.41
(When hot reference only)
lntake
0.48~0.54
Exhaust 0.41~0.47
Removal
1. Remove the battery negative terminal inside the boot.
2. Remove the under plate.
4 . Drain coolant from the radiator drain plug.
ifter
6. Remove the front turbo-charger outlet tube, the air
hose, the rear turbo-charger outlet tube (exhaust side
cam shaft).
10.Remove the timing belt. e spring
11 . Remove the rocker cover.
12.Remove the cam shaft.
Valve
13. Remove the valve lifter.
14. Remove the adjustment shim from rear side of the
valve lifter.
Adjustment
• Use the method below to select the adjustment shim:
Adjustment shim thickness formula (mm).
t = t 1+ (C1 - C2)
t = Adjustment shim thickness
t 1 = Removed shim thickness
C 1 = Measured valve clearance
C2 = Standard valve clearance (when cold)
C2 : 0.45 (intake)
0 .38 (exhaust)
EN-198
VALVE CLEARANCE ENGINE MECHANICAL
R826DETT ENGINE
• Use the micrometer to measure the valve stem end
Micrometer
surface (centre area) of the removed adjustment shim
thickness (t 1).
Adjustment shim
• Refer to the engraved marks on the adjustment shim

to determine the shim thickness.
Example:
'22 2.275 mm
75'
'22 2.290 mm
90'
T = 2.440 -2.455mm
'33 3.310 mm
10'
• There are total of 70 adjustment shim thickness.
• The range far adjustment shim thickness is between
2.275 ~ 3.31 O mm.
lnstallation
1. lnstall the selected adjustment shim to the reverse
side of the valve lifter.
• Face the adjustment shim with engraved side towards
,,- the valve lifter.
2. lnstall the cam shaft and the cam timing pulley.
3. lnstall the timíng belt.
5. Turn the crank pulley twice.
6. Make sure the valve clearance is within the standard
value.
procedure.
EN-199
RB26DETT ENGINE
9.0~12{0.92-1.2} tt=!l
~
Refertotext(14)AIJf/
9.o-12{0.92-1.2}A V ®
®
~V
1
Cylinder head ASSY
/
® "'-"""'"--'°'' 9.0~12{0.92~1.2}~
'•••••--"(/,·.rl./:?C:--..1co,,,; i/
O •f.'--_'1
º~a.·o¿,.'?.
A N-m{kg-m}
"':9•\i,6º,,;§'
··••o··
'. <::):
I] Engine oil Cylinder head gasket ~

Cam tíming pulley
Removal
boot.
3. Remove the front spoiler under cover (N 1 vehicle ).
1O. Remove the radiator.
[Engine right]
11. Remove the accelerator cable from the throttle drum.
12.Remove each hoses and the connectors from the
fuel injector, intake manifold collector, intake mani-
fold, and between the vehicle body and the cylinder
block.
[Engine left]
13. Remove the air duct, air cleaner case and the air
hose.
14. Remove the turbo-charger ASSY from the exhaust
manifold side and lower it below the exhaust mani-
fold.
[Engine front]
EN-200
RB26DETT ENGINE
18. Remove the cylinder head ASSY. 6 10 14 16 12 8 4
(1) Remove the cylinder head auxiliary bolts (1 ~3}.
(2) Remove the cylinder head bolts (4~17).
• Loasen the cylinder head bolts in the order shown in
the figure to remove the cylinder head ASSY.
19. Remove the cylinder head gasket.
7 11 15 17 13 9 5
M6 X 1.0: 1-3 M12x 1.5: 4-17
lnspection
(1) Use a scraper to remove grease, water stain, Straight gauge
Caution:
oil and coolant passages.
(2) Measure cylinder head under surface for distortion in

six directions.
• lf the value exceeds the limit apply compound to
press platen and readjust the surface. lf the value
exceeds the límit greatly, replace the cylinder head
with a new one.
Cylinder block top surface distortion Straight gauge

• Use a scraperto completely remove gasket, oil, water
stain and carbon etc. on cylinder block front surface. \
Caution:
directions using straight gauge.
• lf the value is over the limit use the surface grinder to
• Re place the cylinder block if the distortion value is too
great.
EN-201
RB26DETT ENGINE
lnstallation
• Use the scraper to remove old gasket on the
• Remove any water, grease and rubbish on the
• Align the dowel pin to install.
2. lnstall the cylinder head ASSY.
• Make sure the No. 1 cylinder is at T.D.C position.
• Check No. 1 cylinder intake and exhaust valve is not
lifted.
• Care must be taken not to damage the cylinder head
gasket when installing the cylinder head.
3. Tighten cylinder head bolts.
• Coat thread parts and the bearing surface with engine Cylinder head side
oíl.
• lnstall the washer non-chamfered side facing the
cylinder head.
4. Tighten the installation bolts in the order shown 12 4 2 6 10 14

(1~14).
(1) Tighten to 29N-m {3kg-m} 15
(2) Tighten to 108N-m {11 kg-m}
Q
(3) Loosen to 0N-m {0kg-m} torque Front l\fi.~#q>~f.~~~t:::'.it1!:f----
(4) Tighten to 25~34N-m {2.5~3.5kg-m}
(5) Tighten to 85° ~ 90° 11 7 3 1 5 9 13
(OR 103~113N-m{10.5~11.5kg-m}
• lnstall the cylinder head auxiliary bolts (15~17).
Caution:
Tightening angle should be checked using the angle
wrench or protractor. Never estímate visually.
EN-202
CYLINDER HEAD ENGINE MECHANICAL
RB26DETT ENGINE
12. CYLINDER HEAD
IJ
O ~ Adjustment shim
e
Valve lifler
.~valve collet
*
~ ~Valve spring retainer
€!:\ ~ Valve spring
~ ~ /\\
::, ,o,--Valve spring seat ~
~ ~ Valve oil seal ~ liJ (J/f& (j
i rValveguide ~efffe ~&
' @-~ Valve seat¿;l(§ ~~~ Cylinder head
)1, © ¿:J
✓ ~~ Val,e ~al
liJ I]
* N-m{kg-m}
IJ Engine oil
lntake valve Exhaust valve
Removal & lnstallation

Refer to the cylinder head gasket for removal and
installation operation of the cylinder head.
Disassembly
1. Remove the cam timing pulley and the rear timing
belt cover.
3. Remove the valve lifter and the adjustment shim.
4. Remove the valve collet.
• Use the valve soring compressor to compress the
valve spring. Use magnet screwdriver to remove the
valve collet.
5. Remove the valve spring retainer.

6. Remove the valve spring.
7. Remove the valve by pushing the valve stem towards
the combustion chamber.
• Carry out the valve guide clearance inspection be-
fare removing the valve.
• Check the installation position befare removing the
valve.
8. Remove the valve oil seal.
Use the oil seal puller to remove the valve oil seal.
9. Remove the valve spring seat.
1O. Remove the valve guide.
11. Remove the valve seat.
EN-203
RB26DETT ENGINE
lnspection
(1) Use the scraper to remove grease, water stain,
Caution:
:~ :
3
5
4
Straight gauge
(2) Measure cylinder head under surface far distortion in

six directions.
• lf the value exceeds the limit apply compound to
press platen and readjust the surface. lf the value
exceeds the limit greatly, replace the cylinder head
with a new one.
Valve measurement
Standard value (lntake)
a(mm) 100.88~101 .08
b(mm) 97.3~97.6
ct>c(mm) 34.58~34.7
<l>d(mm) 5.965~5.980 d
e(mm) 1.3 e
f(mm) 2.6~2.9
a (o)
- -- - b --..._,
Standard value (Exhaust) - - -- - a - - ---<
a(mm) 99.88~100.08
b(mm) 95.33~95.63
ct>c(mm) 30.0~30.2
ct>d(mm) 6.905~6.920
e(mm) 1.2
f(mm) 2.9~3.2
a (o) 45°15'~45º45'
• Replace the valve with a new one if the exhaust valve
is out of standard value.
Valve guide clearance

• Carry out this inspection befare removing the valve
guide.
• Check if the valve stem diameter is at standard val-
ue.
• Extend the valve towards the combustion chamber
far approx. 15mm. Move the valve toread the move-
ment width on the dial gauge.
Standard value (mm) intake 0.020~0.053
exhaust 0.040~0.073
Limit value (mm) intake 0.1
exhaust 0.1
• Replace the valve guide with a new one if over the
limit value.
EN-204
RB26DETT ENGINE
Valve guide replacement
• Replace with oversize (0.5mm) valve guide when the
valve guide is removed.
(1) Use oil tank to heat up the cylinder head to approx.
150-160°.
(2) Use the valve guide drift to tap from the combustion
chamber side to remove the valve guide.
(3) Use the valve guide reamer to ream the cylinder

head guide hole.
Interna! diameter standard value (mm)
lntake $10.460 ~ 10.478
Exhaust $11.460 - 11.478
(4) Heat the cylinder head to approx. 150~160°.

(5) Use the valve guide drift to tap from the cam shaft
side to insert the valve guide.
Cam shaft
• The valve guide press-fit dimensions are shown in Valve guide v

the figure.
16.8+/-0.1
B
Exhaust
(6) Readjust the valve guide using the valve guide

reamer.
Finished standard value (mm)
lntake $6.000 ~ 6.018
Exhaust $7.000 - 7.018
HT5627 (intake)
-· .
\. ·
KV101 12300 (exhaust)
EN-205
RB26DETT ENGINE
Valve seat inspection
• Carry out this inspection after checking the valve
guide and the valve measurement.
• Check the valve seat and the valve tace contact sur-
face.
• Replace the valve seat if there is any abnormality or
faults.
Valve seat replacement

• Replace with oversize (0.5mm) valve guide when the
valve guide is removed.
d'
(1) Cut and grind the valve seat to remove the valve
seat.
(2) Readjust the mounting hale for oversize valve seat.
Valve seat diameter standard value (mm)
lntake ct:>36.500 ~ 36.516 I
Valve seat
Exhaust ct:>32.500 - 32.516
(3) Heat up the cylinder head in an oil bath to approx.

11 O~ 130°.
(4) Use dry ice to cool the valve seat. Use the valve seat
drift to tap the valve seat.
Caution:
Do not touch cooled valve seat with bare hands.
(5) Readjust the valve seat using the valve seat cutter
set and the valve seat grinder.
Standard measurement (mm)
lntake ct:>D1: 36.597~36.613
ct:>D2: 29 .85~30 .15
<t>D3: 32.0
<t>O4: 34.3 lntake side
<l>D4+1-o.1
<llDs+t-0.1
ct:>D5: 37.5 (Cutter diameter)
Exhaust <t>D1: 32.580-32.596

<t>D2: 24.85-25.15
<t>D3: 29.6
<t>D4: 32.5
<!>D2
Exhaust <!>D3+t-o.1
side
<1>D4+1-0.1 (Cutter diameter)
Caution:
When using the valve seat cutter make sure to hold the
cutter with two hands and press firmly.
(6) Use compound to adjust the valve measurement.
(7) Recheck to make sure the contact surface is
correct.
EN-206
RB26DETT ENGINE
Valve spring squareness inspection
Place a right-angle straight edge (L-square) so it is
touching the spring. Turn the spring and measure
the maximum clearance between the upper spring
surface and the right angle surface to determine out-
of-square distance.
Contact
• Replace the valve spring if over the limit value.
Free length and compression load inspection

• Use the valve spring tester.
Standard value:
Free length (mm) 46.54
Compression load (N{kg}) 24.0
Compression length (mm) 35.0
ldentification colour White
• Replace the valve spring with a new one if not at

standard value.
Assembly
1. lnstall the valve guide.
2. lnstall the valve seat.
3. lnstall the valve spring seat.
4. lnstall the valve oíl seal.
• Use the valve oil seal drift to install new valve oil
seal.
• Apply engine oil to valve guide and valve oíl seal lip KV101 0750
surface.
• lnstall as shown in the figure.
Valve oíl seal
17.7 11.7
✓'
lntake Exhaust
5. lnstall the valve.

• Apply engine oil to valve stem.
6. lnstall the valve spring.
• lnstall the valve spring with the narrow end pitch
ldentification
towards the cylinder head (identification colour side paint
down). Cylinder head
EN-207
CYLJNDER HEAD ENGINE MECHANICAL
RB26DETT ENGINE
7. lnstall the valve spring retainer.
8. 1nstall the valve collet.
• Use the valve spring compressor to compress the
valve spring. Use a magnet screwdriver to install the
valve collet.
• Use plastic hammer to tap the stem surface to check
if it is installed correctly.
9. lnstall the adjustment shim and the valve lifter.

1 O. lnstall the cam shaft.
11 . lnstall the rest in reverse order to the removal
procedure.
EN-208
CYLINDER BLOCK ENGINE MECHANICAL
RB26DETT ENGINE
13. CYLINDER BLOCK
Caution:
At disassembly
• Always make sure to use correct tools where mentioned and only carry out possible
operations.
• Place marks on the disassembled parts so it can be assembled correctly. Make sure
· they are stored correctly.
• Tighten the bolts and nuts in the corred order shown.
At inspection, repairing and replacing

• Follow the inspection points and only replace or repair where necessary. Only replace
the old parts with same types of new parts.
Atassembly
• Always use torque wrench when tightening the nuts and bolts .
• Use the angle wrench or the protractor to check the tightening angle of the conrod nut.
• Tighten installation bolts and nuts in the arder shown in several stages .
• Clean and air blow with air gun each parts especially the oil and coolant passage .
• Always replace the gasket, packing, oil seal and the o-ring with new ones after each
disassembly.
• Care must be taken not to damage alignment surface and the rotational area. Remove
all foreign objects and apply engine oil.
la Liquid gasket
*I] Engine oíl

Selectíve parts
~ N-m{kg-m}
.---- ~ Replace after every disassembly
EN-209
RB26DETT ENGINE
Disassembly
1. Remove the engine / transmission / transfer ASSY

from the vehicle.
2. Remove the transmission / transfer ASSY from the
engine.
3. Remove the engine mount from the cylinder block.
6. Remove the oil filter bracket and the cooling type oil KV101 14500
cooler. _.,.-®
7. lnstall the engine ASSY to the engine stand.
(1) Attach the engine sub attachment to the right side of
the cylinder block.
'~ :i
(2) Attach the engine attachment to the engine sub
attachment.
lightening torque (N-m{kg-m}) 39~49{4.0~5.0}
(3) Hoist the engine ASSY and attach it to the engine

stand.
9. Remove the engine slinger.
10.Remove the alternator.
11. Remove the turbo-charger ASSY.
12. Remove the air conditioner compressor bracket.
13. Remove the power steering pump bracket.
16.Remove the cylinder head.
17. Remove the oil pan and the oil filter.
18. Remove the water pump.
19. Remove the oil pump.
20. Remove the water inlet and the thermostat.
21. Remove two knock sensors from right side of the cyl-
inder block.
22. Remove the fly-wheel.
• Use the ring gear stopper to fix and remove the instal-
lation bolts.
• Carry out the wheel run-out inspection befare remov-
ing the fly-wheel.
23. Remove the baffle pi ate from the main bearing cap.
CYLINDER BLOCK ENGlNE MECHANICAL
RB26DETT ENGINE
24. Use the pilot bush puller to remove the pilot bush.
ST1661 0000
25. Remove the rear plate.

26. Remove the rear oil seal retainer.
• Use a screwdriver to remove the retainer.
-~- 27. Remove the rear oíl seal.

• Use a screwdriver to remove the oíl seal.
Caution:
Care must be taken not to damage the rear oil sea! re-
tainer.
28. Remove the baffle pi ate.

29.Remove the pistan and the conrod ASSY.
(1) Position the crankshaft pin to B.D.C (bottom dead
centre) position.
(2) Remove the conrod cap and use handle end of the
hammer to push it out to the cylinder head side.
• Carry out the conrod side clearance inspection befare
removing the pistan / conrod ASSY. Oil jet
• Push the conrod towards the left direction so it will not o o

interfere with the oíl jet.
(3) Remove the conrod bearing. o o
Caution:
Check the installation position befare removing the con- o n
rod bearing.
30.Remove the pistan ring from the pistan.

• Use the pistan ring expander.
Caution:
Care must be taken not to damage the pistan.
Do not over expand the pistan ring.
' Piston ring
expander
EN-211
RB26DETT ENGINE
31.Remove the piston from the conrod.
(1) Use the snap ring plier to remove the snap ring.
(2) Heat up the piston using a heat gun to approx.

60~70°.
(3) Push the pisten out using a round bar with diameter
<D20mm.
Caution :
Do not remove the conrod bolt from the conrod.
2 6 10 14 12 8 4
32.Remove the main bearing cap.

----
"' º•. ~.-
• Loasen and remove the installation bolts in order

shown in several stages.
• Carry out the crankshaft side clearance inspection
before loosening the main bearing cap bolts.
5 9 13 10 7 3
• Use the screwdriver to remove the main bearing

cap.
Caution:
Care must be taken not to damage the oil pan seal
surface.
33.Remove the crankshaft.
34. Remove the main bearing from the main bearing cap
and cylinder block.
Caution: (:J Front
Check installation position before removing the parts.
35.Remove the oil jet.
EN-21 2
RB26DETT ENGINE
lnspection
Crankshaft side clearance
• Use the dial gauge or the feeler gauge to measure
clearance between the thrust bearing and the crank
arm when the crankshaft is moved forwards or back-
wards.
Standard value (mm) 0.05-0.18
• lf the measurement is over the limit value replace

No.4 bearing (thrust bearing) to new one and
" -
· eeler gauge
;..,-_.,¡/Í
_,.1
remeasure the crankshaft side clearance. Replace ~

)
the crankshaft if the value is still over limit.
Conrod side clearance

• Use the feeler gauge to measure the side clearance
between the conrod and the crank arm.
Feelergau
Standard value (mm) 0.2 ~ 0.3
• lf the measurement is over the limit value replace the
conrod to new one and remeasure the conrod side
clearance. Replace the crankshaft if the value is still
over limit.
lnside micometer
Pistan and pistan pin clearance
(Pistan pin inside diameter)
• Use the inside micrometer to measure the pistan pin
inside diameter.
Standard value (mm) Grade O 4>20.987-20.993
Grade 1 4>20.993~20.999
(Pistan pin outer diameter)

• Use the micrometer to measure the pistan pin outer
diameter.
Standard value (mm) Grade O 4>20.989~20.995
Grade 1 4>20.995~21.001
(Pistan pin clearance) ::::

(Pistan pin inside diameter) - (Pistan pin outer diameter)
Standard value at room temperature (20°C) (mm)

-0.004 ~ O
EN-213
RB26DETT ENGINE
• lf the value is not at standard value, make sure the ton grade (1 -3)
· in
conrod small end inside diameter is within the 0 ,1)
standard value. Select the piston pin grade
according to the measurement range and replace the
piston pin / piston pin ASSY with new one with the
same piston pin grade.
Standard value (mm) Grade O ct:>21.000-21.006 Large enct, Cylinder No. (1-6)1D mark
Grade I ct:>21.006-21.012 raae
Piston ring side clearance

• Use the feeler gauge to measure between the piston
ring and the piston ring groove.
Standard value (mm) Top ring 0.040~0.075
Second ring 0.030~0.065
Oíl ring 0.065~0.135
Limit value (mm) Top & second ring 0.1
• lf the value is over the limit replace the piston or the
piston ring ASSY.
Pistan ring closed gap Feeler gauge

• Make sure the cylinder bore inner diameter is within
the standard value.
• Use the piston to insert the pistan ring to the cylinder
intermediate position to measure the closed gap.
Standard value (mm) Top ring 0.24~0.34
Second ring 0.42~0.57
Oil ring 0.20~0.60
• Replace the piston ring if not within the standard
value.
Conrod bend and torsion

• Use the conrod aligner to inspect.
Bend limitvalue (mm) 0.15 (every 100mm)
Torsion limit value (mm) 0.3 (every 100mm)
• Replace the conrod ASSY if over the limit value.
Conrod large end diameter

• Use the inside micrometer to measure the conrod
large end inner diameter by first placing the conrod
cap without conrod bearing and tightening the conrod
nut to standard tightening torque.
Standard value (mm) Grade O <P51 .000~51.007
Grade I ct:>51 .007~51.013
• Replace the conrod if not within standard value.
EN-214
RB26DETT ENGINE
Conrod bush clearance (small end)
(Conrod small end inner diameter)
• Use the inside micrometer to measure small end
inner diameter.
Standard value (mm) Grade O ct:>21.000~21.006
Grade 1 ct:>21.006~21.012
(Piston pin outer diameter)

• Use the micrometer to measure the piston pin outer
diameter.
Standard value (mm) Grade O ct:>20.989~20.995
Grade 1 ct:>20.995~21.001
(Conrod bush oil clearance) =

(Conrod small end inner diameter) -
(Piston pin outer diameter)
iston grade (1-3)
• lf not within the standard value recheck each Pistan pin
grade (0,1)
measurement. lf still not within the standard value
replace either conrod ASSY, piston / piston pin ASSY
or replace both.
• lf replacing both parts, make sure to match the piston
/ pistan pin ASSY pin grade and the conrod small end
Large end Cylinder No. (1-6)
grade. graae (0,1) 10 mark
• lf replacing either conrod ASSY or the piston /

piston pin ASSY, measure and use the parts with the
same grade.

• Use a scraper to completely remove gasket, grease,
Straight gauge
water stains and carbon etc. on cylinder block front
surface. \
Caution:
directions using the straight gauge.
• lf the value is over the limit use a surface grinder to
correct the distortion. Replace the cylinder block if
the distortion is too great.
EN-215
RB26DETT ENGINE
Main bearing housing inner diameter
• Place a main bearing cap without installing the main
bearing. Tighten the tightening bolts to specified
tightening torque.
• Use the bore gauge to measure main bearing
housing inner diameter.
Standard value (mm) 4>58.645-58.670
• Replace the cylinder block, the main bearing cap
ASSY if the value is not within the standard value.
Piston to cylinder bore clearance

(Cylinder bore inner diameter)
• Use the bore gauge to measure the cylinder inner
diameter in a total of six positions. Top, centre and
bottom (A, B, C) and in two directions (X, Y).
Cylinder inner diameter standard value (mm) ~e
,
4>86.000~86.030 11 º
Wear out limit value (mm) 0.2 ~

Elliptic limit value (X, Y difference )(mm) 0.015
Taper limit value (A, C difference) (mm) 0.010
• lf the measurement value is over the limit value ar the
cylinder inner wall is damaged or burnt conduct
haning ar baring.
• The piston oversize is set at 0.5 OS (0.5mm aversize)
or 1.0 OS (1.0mm oversize) at the time af service.
When using the oversize pistan conduct honing on
the cylinder, so the pistan cylinder clearance is
between 0.035~0.055mm. Also use oversize pistan
rings for oversize pistan.
Piston outer diameter

• Use the micrometer to measure the outer diameter af
the piston skirt.
Measurement position: 13mm from the pistan foot
Standard value {mm) <l>85.955~85.985
EB
(Clearance) =
{Cylinder inner diameter) - (Pistan skirt area diameter)
Standar9 value at room temperature (20°C)
0.035-0.055
• lf the clearance is not at standard value, replace the
piston by selecting the correct grade using the table
below. (mm)
85.965 85.975 85.985

85.955 85.965 85.975 ID mark
o o o Piston pin grade
EN-216
RB26DETT ENGINE
Caution: Bore grade No.
The piston is selected together with the piston pin ASSY.
When replacing the pistan refer to the conrod bush oil
clearance section to select the piston pin grade.
Reference:
Select the pistan with the same grade as the cylinder
block left upper surface bore grade engravings when us- Q Front
ing the new cylinder block.
Crankshaft journal diameter

• Use the micrometer to measure journal diameter.
Standard value (mm) ct>54.951~54.975
Crankshaft pin diameter

• Use the micrometer to measure the outer diameter of
,,,---. the pin.
Standard value (mm) ct>41.961 ~41.974
Crankshaft ellipticity and taper

• Use the micrometer to measure each journal and the 1 2 A
pins for each direction as shown in the figure.
• Ellipticity can be determined by the difference
B
between measurement A and B_
Ellipticity = A - B
• Taper can be determined by the difference between
measurement 1 and 2.
Taper = 1 - 2
Limit value for ellipticity and taper (mm) 0.05
• lf the value is over the limit replace with a new one.
Crankshaft run-out
• Use V-block on fixed surface and support the crank-
shaft journal.
• Set the dial gauge vertically to No. 4 journal.
• Crankshaft run-out is equal to half the movement
width indicated in the dial gauge.
• lf the run-out is over the limit value replace the crank-
shaft.
EN-217
RB26DETT ENGINE
Conrod bearing oil clearance
Method A
• Use the inside micrometer to measure the conrod
bearing inner diameter. First instal the conrod bear-
ing to the conrod and tighten the conrod nut to speci-
fied tightening torque.
(Oil clearance) =
(Conrod bearing inner diameter} -
(Crankshaft pin diameter}
conrod bearing.
Method B (using the plastigauge}

• Remove all dust and foreign objects from the crank-
shaft pin and the bearing surface.
• Cut off a piece of plastigauge slightly shorter than the
bearing width. Place the plastigauge on the crank-
shaft axle direction avoiding the oil hale.
• Assemble the conrod bearing to the conrod cap and
tighten the conrod nut to specified tightening torque.
Caution:
Do not turn the crankshaft.
• Remove the conrod cap and the bearing and measure
the plastigauge width using the plastigauge scale.
Conrod bearing selection

• Select the conrod bearing from the selection chart
below.
(mm)
Bearing grade No. STD0 STO 1

Bearing thickness (mm) 1.500-1.503 1.503~1.506
Oil clearance (mm) 0.020 / 0.039 0.021 / 0.039
ldentífication colour None Brown
Bearing grade No. STO 1 STD 2
Bearing thickness (mm) 1.503~1.506 1.506~1.509
Oíl clearance (mm) 0.020 / 0.040 0.021 / 0.040
fdentification colour Brown Green
EN-218
RB26DETT ENGINE
Reference:
lf the conrod is new check with the large end grade
engravings with the selection chart.
Large end
rade 0.1 Cylinder No. (1-6)
Upper journal grade

No.1 to No.7
Lower pin grade No.
lf the crank shaft is new check with the crankshaft No.1 to No.6
surface pin grade engravings with the selection chart. l
Using under size bearing

• Under size bearing can be used if oil clearance can
not be adjusted to standard value when the standard
size conrod bearing is used to measure the oil clear-
ance.
• When using the under size bearing, measure the
bearing inner diameter and grind the pin in arder to
adjust the oíl clearance to standard value.
(mm)
US0.08 1.541 / 1.549 8

US0.12 1.561 / 1.569 12
US0.25 1.626 / 1.634 25
Caution:
Care must be taken not to damage the fillet R when
grinding the crank pin to use an under size bearing.
l_5.2,0 journal
Main bearing oil clearance
Method A ~1.6 pin
• lnstall the main bearing to the cylinder block and the
conrod cap and tighten the main bearing bolt to
specified tightening torque. Measure the main
bearing inner diameter.
(Oil clearance) =
(Main bearing inner diameter) -
(Crankshaft joumal diameter)
main bearing.
EN-219
RB26DETT ENGINE
Method B (using the plastigauge)
• Remove ali dust and foreign objects from the crank-
shaft journal and the bearing surface.
• Cut off a piece of plastigauge slightly shorter than the
bearing width. Place the plastigauge on the crank-
shaft axle direction avoiding the oil hole.
• Tighten the main bearing to the specified tightening
torque.
Caution:
Do not turn the crankshaft.
• Remove the bearing cap and the bearing to measure
the plastigauge width using the plastigauge scale.
Main bearing selection

• Select the main bearing from the selection chart
below.
(mm)
Bearing grade No.

Bearing thickness (mm)
Oil clearance (mm)
ldentification colour Black Brown None Yellow
Bearing grade No. STD 1 STD2 STD 3 STD4
Bearing thickness (mm) 1.821-1.824 1.824-1.827 1.827-1 .830 1.830-1 .833
Oil clearance (mm) 0.028 / 0.046 0.028 / 0.046 0.028 / 0.046 0.028 / 0.047
ldentification colour Brown None Yellow Blue
Bearing grade No. STO 2 STD3 STD4 STDS
Bearing thickness (mm) 1.824-1.827 1.827~1.830 1.830~1.833 1.833~1.836
OH clearance (mm) 0.028 / 0.046 0.028 I 0.046 0.028 / 0.046 0.028 / 0.047
ldentification colour None Yellow Blue Green
Bearing grade No. STD3 STD4 STO 5 STO 6
Bearing thickness (mm) 1.827~1 .830 1.830~1 .833 1.833~1 .836 1.836~1.839
Oil clearance (mm) 0.028 / 0.046 0.028 / 0.046 0.028 / 0.046 0.028 / 0.047 ,•·----..,
ldentification colour Yellow Blue Green Pink
Reference:
Depending on the installation position the measurement
and the feature size will be different.
No.1 ~ No.3, No.5 ~ No.7 upper side (with groove)
No.1 ~ No.3, No.5 ~ No.7 lower side (without groove)
No.4 upper side (Thrust bearing, with groove)
No.4 lower side (Thrust bearing, without groove)
Upper journal grade No.
• lf the crank shaft is new, check the crank shaft front No.1 to No.7
surface journal grade No. engravings with the selec- Lower pin grad
No.1 to No.6
tion chart.
EN-220
RB26DETT ENGINE
• lf the cylinder block is new check the cylinder block
bottom surface housing inner diameter grade No. en-
gravings with the selection chart.
Using under size bearing

• Under size bearing can be used if oil clearance can
No.2 No.3 No.4 No.5 No.6 No.7
not be adjusted to standard value when the standard No.1 bearing
housing grade No.
size main bearing is used to measure the oil clear-
ance.
• When using the under size bearing, measure the
bearing inner diameter and grind the pin in order to
adjust the oil clearance to standard value.
l_rB2.0 journal
Bearing under size chart (mm)
l.)3.1.6 pin
US0.25 1.950 / 1.958

Caution:
Care must be taken not to damage the fillet R when
grinding the crank pin to use an under size bearing.
Crush height
Main bearing crush height
• When the main bearing is installed tighten the
bearing cap to specified tightening torque and when
the cap is removed the bearing tip is projecting.
• Replace the part when there is no main bearing crush
height.
Fly-wheel run-out
• Use a dial gauge to measure the run-out of the
fly-wheel clutch plate working face.
Limit value (mm) 0.1 O
• Replace the fly-wheel when the value is over the
limit.
Oil jet
• Check the nozzle for any deformation or damage. Nozzle
• Blow compressed air from the nozzle side and check
if there is any blockage.
• Clean or replace the oil jet if there is any abnormal-
ity.
EN-221
RB26DETT ENGINE
Oil jet eye bolt
• Use a clean stick to push the check valve inside the
eye bolt. Check if it move smoothly with moderate
resistant force.
• Re place with a new one if there is any abnormality.
Assembly
1. Use the air gun to blow compressed air through the Q Front
cylinder block coolant passage, oil passage, inside
the crank case and inside the cylinder bore to remove
any foreign objects .
2. lnstall the oil jet.
3. lnstall the main bearing.

(1) Remove any rubbish, dust, grease etc. from the
cylinder block and the main bearing cap bearing
(2) Care must be taken with the main bearing installation
direction.
• lnstall side with the oil hole and the groove to the
lllt
cylinder block side, and the side without the oil hole Front
and the groove to main cap side.
• Coat engine oil to the bearing surface (inner) when
installing the bearing. Do not apply engine oíl to the
reverse side but clean sufficiently.
• Make sure the cylinder block oil hole and the bearing
oil hole position is correct.
4. lnstall the crankshaft to the cylinder block. 13 9 5 1 3 7 11

5. lnstall the main bearing cap.
• Apply engine oil to the installation bolts thread area.
• Longer bolts are used for positions 1, 11 and 12.
• Tighten the installation bolts in the arder shown in the
figure.
Tightening torque (N-m{kg-m}) 46~52{4.7~5.3} 14 10 6 2 4
• After securing the bolts make sure the crankshaft
turns smoothly by hand.
EN-222
RB26DETT ENGINE
6. lnstall the pistan to the conrod.

(1) Use the snap ríng plier to install the snap ring to the Chamfered side
pistan rear síde installation groove.
• Use new snap ring. Pistan)_
~
º
• lnstall so the chamfered side is facing the pistan pin. pin side . . Outside
• Make sure to fit into the pistan installation groove
securely.
(2) When the pistan front mark is faced towards the

engine front, the conrod oíl hole must be on the left
side when seen from the engine frant.
~¿
Front mark
º~ Oilhole
(3) Heat up the pistan using a industrial heat gun (to

approx. 60-70°C) then insert the pistan pin into the
pistan and the conrad from the pistan front.
• At the time of insertion make sure to apply plenty of oil
to the pin, pin hale and the conrod small end parts.
(4) lnstall the snap ring to the pistan front side.

• Refer to (1) for snap ring installation direction.
• After installation make sure the conrod move
smoothly.
7. Use the pistan ring expander to install the pistan

ring.
Caution:
Care must be taken not to damage the pistan.
,
' Pistan ring
expander
• lnstall in a way so the engraved mark on the top and

the second ring alignment area will face the top.
EN-223
RB26DETT ENGINE
• Position the alignment mark as shown in the figure. Top ring opening
Oil ring (spacer) Oi1 ring opening
\ e:- (top rail)
Front mark,1'. N 45°
Second ring
J~ Oíl ring opening
opening
8. lnstall the conrod and the conrod bearing to the (bottom raíl
conrod cap.
• Coat the bearing surface (inner) with engine oil when Oil hole
installing the conrod bearing. Clean the reverse side
sufficiently.
• Align the conrod bearing projection and the conrod
rotation stopper groove to install.
• Make sure the conrod main body oil hole and the
bearing oil hole position is correct.
9. lnstall the piston and conrod ASSY to the crankshaft. ~ <lo 1

• Position the crank pin to B.D.C (bottom dead centre). t.) \
Piston ring e /
• Apply plenty of engine oil to the cylinder bore, the compressor""'-
piston and the crank pin.
• Check the cylinder position and the conrod cylinder J 1
number. @!e::- ,
• Face the piston front mark towards the engine front @,
(!fa
and use the piston ring compressor to install.
Oiljet
• Position the conrod in an angle of approx. 10~20° as
o o
shown in the figure, so it will not hit the oil jet when
inserted.
10.lnstall the conrod cap. o 10-20° o
(1) Make sure the conrod and the cap cylinder No. is on
the same side when installing. o ()
(2) Tighten the conrod nuts in the following order.

• Apply engine oil to the conrod bolts and nuts bearing
surface.
• Tighten to 14~16N0m{1.4~1.6kg-m}.
• Place alignment marks to the nuts and the conrod cap
(eg white paint etc) in one direction (if using the
protractor).
• Additionally tighten 60 ~ 65º.
Caution:
Make sure to use the angle wrench or the protractor to
tighten. Never estimate visually.
EN-224
RB26DETT ENGINE
11. lnstall the rear oil seal.
(1) Apply engine oil or chassis grease to oil seal lip
circumference.
(2) Use the oil seal drift to tap in the oil seal to level
with the oil seal retainer front surface. Care must
be taken not to cause any damage to the oíl seal
circumference.
12. lnstall the rear oil seal retainer.

(1) Use the scraper to remove liquid gasket.
(2) Apply sealing agent (KP710 00150) to the rear oil
seal retainer at approx. <l>2.0 ~ 3.0 mm.
13.Align the rear oil seal retainer to the dowel pin to

insta 11.
14.lnstall the baffle plate to the main bearing cap.
15.lnstall the pilot bush.

• Face the chamfered side towards the crankshaft and
tap the pilot bush in until it hits the end.
~
Crankshaft side
Chamfered side
16.1 nstall the fly-wheel.

• Use a ring gear stopper to fix the fly-wheel to tighten
the installation bolts.
• Apply engine oil to the installation bolts thread and
the bearing surface.
• Tighten the bolts in several stages in opposing
angle.
17.lnstall two knock sensors.
• Make sure there are no foreign objects on the
cylinder block installation surface and the knock
sensor rear surface.
Tightening torque (N-m{kg-m}) 16~21 {1 .6~2.1}
RB26DETT ENGINE
14. OIL PUMP
~ 9.8-11 .8{1.0-1.2} (2)

~~~
~7 Oil pump cover
9.8-11 .8(1.0-1.2}~ ~
~
l ~@) 1/, .~\
3.7-5.0{0.38- 0.51} (7) ~
~iJ Front oil seal ~ ·
~~ e 4
Pump housing
Regulator v a l v ~ ~ e::;,
. . §
Spnng g ~@)
~Washer--0 ~ ~@}
@ .. "- <SP- 9.8-11 .8(1.0-1.2}(4) ~
" ' 9.8-11 .8{1.0- 1.2}~
~ N-m{kg-m} Regulator plug 39.2-68.6{4.0~7 .O}~
I] Engine oil
Removal
1 . Remove the engine transmission ASSY.
2. Remove the transmission from the engine and attach
it to the engine stand .
4. Remove the cooling tan.
7. Remove the crank timing pulley.
9. Remove the oil pan.
1O. Remove the oíl filter.
11. Remove the oil pump ASSY.
lnstallation
Housing
1. lnstall the inner rotor and the outer rotor. side
• Apply engine oil to each rotational parts. a
• Face the inner rotor groove side towards the cover to
install.
Groove
EN-226
RB26DETT ENGINE
2. Equally tighten oil pump cover installation screw.

• Replace the regulator washer with a new one.
4. lnstall the front oil seal.

• Make sure there is no damage to the oíl seal circum-
ference.
• Position the oil seal next to the front side.
• Use the oíl seal drift to insert the oil seal to level with
the oil pump oil seal installation surface.
• Apply engine oil or the chassis grease to oil seal lip
ci rcumference.
EN-227
OIL FilTER BRACKET & WATER-COOLED OIL COOLER ENGINE MECHANICAL
RB26DETT ENGINE
15. OIL FILTER BRACKET & WATER-COOLED OIL COOLER
fl Liquid gasket
~ N-m{kg-m}
Removal
boot.
5. To create working space remove the following:
• Strut tower bar
• Accelerator cable
• Accelerator cable bracket.
6. To create working space move the following:

• Fuel filter and fuel filter bracket.
• Main harness (between the starter motor and the
relay case)

8. Remove the oil pressure switch connector and oil
temperature sensor connector.
9. Remove two water hoses on oíl cooler side.
10.Remove the oil filter bracket and oil cooler ASSY.
EN-228
OIL FILTER BRACKET & WATER-COOLED OIL COOLER ENGINE MECHANICAL
RB26DETT ENGINE
lnstallation
1. lnstall the oil filter bracket and oil cooler ASSY.
2. lnstall two water hoses.
• Tighten the clamps securely.
procedure.
5. Check the engine oil and coolant level.
6. Start the engine and check for any engine oil or
coolant leaks.
7. Cool the engine and recheck the engine oil and
coolant level. Top up if the level has decreased.
Disassembly
Alignment mark
1. Remove the oil pressure switch.
2. Remove the oíl temperature sensor.
3. Remove the oil cooler from the oil filter bracket.
• Place alignment marks on the oil filter bracket and the
oil cooler befare removal.
lnspection
• Check for oíl leak due to any damage.
• Replace the oil filter bracket with a new one if there is
any abnormality or faults.
Oíl cooler inspection

• Check for any blockages in the oil cooler.
• Replace the oíl cooler with new one if there is any
abnormality or faults.
Assembly
1. lnstall the oil cooler to the oil filter bracket.
• Align the oíl cooler and the oíl filter bracket alignment
mark and tighten the eyebolts.
2. lnstall the oil pressure switch and the oil temperature
sensor.
• Apply sealing agent (KP71 O 00150) to the thread
part.
Oil pressure switch 12.3~17.2{1.25~1.75}
Oil temperature sensor 25~29{2.5~3.0}
EN-229
OIL FILTER BRACKET & WATER-COOLED OIL COOLER ENGINE MECHANICAL
RB26DETT ENGINE
OIL FILTER BRACKET (N1 vehicle)
Removal
boot.
3. To create working space remove the following:
• Strut tower bar.
• Accelerator cable.
• Accelerator cable bracket.
4. To create working space move the following:
• Fuel filter and fuel filter bracket.
• Main harness (between the starter motor and the
relay case).
6. Remove the oil pressure switch connector and oíl
7. Remove two oil tubes from the oil filter bracket.
8. Remove the oil filter bracket.
10.Remove the oil pressure switch and the oil tempera-
ture sensor from the oil filter bracket.
lnspection
• Check for oil leaks due to any damage.
• Re place the oil filter bracket with a new one if there is
any abnormality or faults.
lnstallation
1. lnstall the oil pressure switch and the oil temperature
sensor.
• Apply sealíng agent (KP710 00150) to thread part.
Oil pressure switch 12.3~17.2{1 .25~1.75}
Oíl temperature sensor 25~29{2.5-3.0}
2. lnstall the oil filter bracket.
• Replace the gasket and the o-ring with a new one.
Tightening torque (N-m{kg-m}) 16~21{1 .6~2.1}
3. lnstall two oil tubes.
4. Connect the oíl pressure switch connector and the oil
procedure.
7. Check the leve! of engine oil and look for any oíl
leaks.
EN-230
AIR-COOLED OIL COOLER ENGINE MECHANICAL
RB26DETT ENGINE
16. AIR-COOLED OIL COOLER (N1 vehicle)
Oil filter bracket
6.3~8.3{0.64~0.85} ~
:<1/
·--.. ___
;
6.3~8.3{0.64~0.85}
/
i
Oil cooler ASSY
Stud bolts (
6.3~8.3{0.64~0. ~
~6.3~8. Front
{0.64~
·· .__ Bracket
6.3~8.3{0.64~0.85} ~
I \ rr11
6.3~8.3{0.64~0.85}(4) ~ 6 -3~ 8 -3 ..~J
Mount rubber (right & left)
~ N-m{kg-m} {0.64~0.85}
Removal
boot.
6. Remove the oil tube at oil cooler side.
• Place a hole cap on the oil tube side and the oil cooler
side.
7. Remove right and left oíl cooler mount bracket
(upper) installation bolts and nuts.
8. Remove the oil cooler from the engine bay side.
Caution:
Care must be taken not to damage the oil cooler core.
lnspection
Oil cooler visual inspection
• Make sure there is no damage or abnormality with the
oil cooler core.
• Replace the oil cooler if there is any fault.
Oil hose visual inspection

• Check the oil hose for any cut or damage.
• Replace the oíl hose if there is any fault.
EN-231
AIR-COOLED OIL COOLER ENGINE MECHANICAL
RB26DETT ENGINE
lnstallation
1. lnstall the oil cooler.
(1) lnstall the mount bracket (upper) to the oil cooler.
(2) lnstall the oil cooler from engine bay side.
• Make sure to insert the grommet into the installation
hole securely.
(3) Tighten the mount bracket (upper) installation bolts
and nuts.
Caution:
Care must be taken not to damage the oil cooler core
parts.
2. Connect the oil tube.
procedure.
4. Check the level of engine oil.
5. Start the engine and check for any engine oil leak.
6. After cooling down the engine, recheck the leve! of
engine oil and top up if necessary.
EN-232
RB26DETT ENGINE
17. RADIATOR
3.2-4.2{0.33-0.43}(2) ~
~~~- .· ~
~ N-m{kg-m}
Removal
boot.
4. Remove the reservoir tank hose at radiator side.
5. Remove the radiator upper hose and lower hose.
Caution:
Care must be taken not to get coolant on the alternator
electrical components.
6. Remove the engine coolant temperature switch

harness connector.
7. Remove right and left radiator upper mount bracket.
8. Remove the fan shroud installation bolts and move
the fan shroud towards the cooling fan.
9. Remove the radiator ASSY.
10.Remove the fan shroud.
11. Remove the engine coolant temperature switch from
the radiator.
lnstallation
1. lnstall the engine coolant temperature switch to the
radiator.
2. Place the shroud on the cooling fan temporarily.
3. lnstall the radiator ASSY.
EN-233
RB26DETT ENGINE
4. lnstall the right and left radiator upper mount
bracket.
Tightening torque (N-m{kg-m} 3.8-4.5{0.39~0.46}
5. lnstall the engine coolant temperature switch harness
connector.
6. lnstall the radiator shroud.
• Only use genuine shroud installation bolts.
7. lnstall the radiator hose.

• Position the radiator hose so the hose end alignment
mark is as shown.
• Tighten the clamp to specified torque.

procedure. A B e
lnspection D E G F
• Check the coolant level and top up if necessary.
• Start the engine and check for any coolant leaks.
EN-234
RB26DETT ENGINE
18. COOLING FAN
Removal 6-10{0.6-1.0}(4) ~
boot.
~
3. Loasen the cooling tan installation nuts.
4. Loasen the fan belt.
tan.
~, ~
10{0.6-1.0}(4)
6. Remove the installation bolts to remove the tan from

the cup ring.
lnspection
Cup ring inspection
• Check for any silicon oil leak.
Cooling tan inspection

• Check for any damage or cut.
lnstallation
lnstall the parts in reverse arder to the removal proce-
dure.
• lnstall the tan to the cup ring making sure the front
mark is tacing front.
EN-235
AUXILIARY MOTOR FAN ENGINE MECHANICAL
RB26DETT ENGINE
19. AUXILIARY MOTOR FAN
Removal
boot.
4. Remove the hood support stay.
5. Remove the left side horn bracket ASSY.
Hood support star-------Jcistallation bolts (2) ..........

6. Remove the hood lock stay installation bolts and _ ; _......L L..w.... ' 1)
move the hood lock stay to the right side of the vehi-
cle.
7. Disconnect the auxiliary motor fan harness connec-
--
tor.
8. Remove the installation bolts (top and bottom) and -------
Hood lock stay
~-
,
Connector
------
Horn f bracket ASSY
r=--..=:;¡
the installation nuts to remove auxiliary motor fan.
Caution:
- ~-
condenser.
9. Remove the fan from the tan motor.

1O. Remove the tan motor from the fan grille.
lnstallation
1. lnstall the fan motor to the tan grille.
2. lnstall the tan to the fan motor.
3. lnstall the auxiliary motor tan.
Caution:
condenser.
4 . lnstall the auxiliary motor tan harness connector.

procedure.
EN-236
RB26DETT ENGINE
20. WATER PUMP
rl Líquid gasket
~ N-m{kg-m}
Removal
boot.
3. Remove the front spoiler under cover (N 1 vehicle ).
6. Drain coolant from the cylínder block drain plug.
7. Remove the coolíng fan.
1O. Remove the water pump pulley.
11 . Remove the timing belt.
12.Remove the tensioner pulley.
13. Remove the tensioner pulley and the idler pulley.
14. Remove the alternator adjust bar.
15.Remove the installation bolts in the arder shown.
16.Remove the water pump. 8 12, 7 6 5 4
• lnsert a stubby driver into the installation bolt hole

Caution:
side screws.
EN-237
RB26DETT ENGINE
lnspection
• Check the water pump main body and the vane for
. -....
rust or foreign objects.
• Make sure the water pump is not wobbly.
• Replace the water pump if there is any abnormality.
lnstallation
pump and the cylinder block installation surface. <l:12.0-3.0mm
• Apply sealing agent (KP710 00150) to the position
shown in approx. ct>2.0~3.0mm.
• Tighten the installation bolts in the arder shown.

• Tlghten the installation bolts 4 and 5 together with the
Reference:
No. 1 and 6 refers to retightening the same bolt twice.
• The bolt measurements are different depending on
the installation position.
4
M6 bolt: No.1
M8 bolt: No. 7, 8, 9, 10, 11, 12
M10 bolt (short) No. 2, 3
M10 bolt (long) No.4,5
• There are three types of installation bolts.

M6 6.3~8.3{0.64~0 .85}
M8 16~21 {1.6~2.1}
M10 31.4~42.1{3.2~4.3}
2. Insta!! the rest in reverse order to the removal

procedure.
3. Check the coolant level.
4. Start the engine and check for any coolant leaks.
5. After cooling down the engíne recheck the coolant
level and top up if necessary.
···--...._
EN-238
R826DETT ENGINE
21. ACCELERATOR CONTROL SYSTEM
Accelerator cable bracket
Accelerator cable
------b~aii@~ ~~\ 2.9-3.9{0.3-0.4}(2) ~
2.9-3.9{~0.4} ~ ~
¡·m@ \\
Accelerator bracket \ ~d\\
~-t··-,J(----
-.........___ "¡ _,,.. Accelerator pedal
E-ring
-~~
Adjust nut
/
~~1t
I
Return spring &
<~
/@~-"'O~
Pedal stopper 3.7-5.0{0.38-0.51}~
~ N-m{kg-m}
IE:II Nissan MP special grease No.2
Removal
1 . Remove the accelerator cable outer case from the
accelerator cable bracket.
2. Disconnect the accelerator cable at throttle drum
side.
3. Disconnect the accelerator cable at accelerator pedal
side.
4. Remove the accelerator pedal bracket installa-
tion bolts to remove the accelerator pedal / bracket
ASSY.
lnstallation
lnstallation is the reverse arder of the removal proce-
dure.
• Apply Nissan MP special grease No. 2 to the return
spring.
• Replace E-ring with a new one.
Caution:
• Do not position the switch to fully open stopper.
• Do not damage or bend the wire.
lnspection
• Make sure the throttle drum side is fully open when
the accelerator pedal is depressed fully.
• Make sure it move smoothly.
Adjustment Accelerator Q Q Throttle drum side

• Loasen the wire and adjust the adjust nut to pull the pedal síde
outer case towards the accelerator pedal until the

throttle drum starts to move.
From this position turn back the adjust nut 1.5 ~ 2.0
turns, and secure the lock nut. Accelerator cable

Lock nut
EN-239
FUEL TANK ENGINE MECHANICAL
RB26DETT ENGINE
22. FUEL TANK
Caution:
• Check the fuel tube is secured properly to the vehicle body with a clip. Make sure there
are no fuel leaks, damaged or rusty tubes. Replace parts if there is any abnormality.
• Check to make sure the evaporator system tubes are connected properly after installa-
tion.
• Check the clips for cracks and make sure they are not coming off. Replace the parts if
there is any abnormality or faults.
A4.4-ss{o.4s-o.s9}
Filler tube cover ~ -
~r
Filler cap
~ Filler tube
Grommet~ ·
11
'/ ¡
·1 /
Collar
N ,,.--
Hose
Breather ho
Fuel tan
band
Pin
~
{2.7-3.7}(2)
c.
®
!
. 4.4-5.8{0.45-0.59} ~
/ E-ring
A N-m{kg-m} Snappin ~ Clips (3)
Removal
1. Open the boot lid.
2. Remove the boot front finisher.
3. Remove the strut tower bar.
4. Remove the rear floor board.
♦ FUEL PRES RELEASE ♦
5. Ralease fuel pressure from the fuel line.
FUEL PUMP WILL STOP BY
Releasing fuel pressure TOUCHJNG START DURING
• Start the engine. IDLE.
CRANK 2 TO 3 TIMES AFTER
• Select the "Fue! pressure release" in "Work support" ENGINE STALL.
mode with CONSULT.
• Select "Start" and after engine stalls crank it 2 to 3
times.
• For the vehicles that are unable to start, crank 3 to 4
•
times.
After restarting the engine, remove the fuel @

1 START
F"ol p,mpfo,e(15A) ~
pump fuse and run the engine until it stalls. Crank 2

to 3 times to consume fuel left in the fuel pipes. -
---...
Battery
7. Open the fuel filler lid.
8. Remove the rear speaker amp and rear speaker amp
bracket.
EN-240
RB26DETT ENGINE
9. Open the inspection hale cover and remove the lnspection hole cover
connector from the fuel sender unit.
10.Extract the fuel inside the fuel tank by removing the

filler opening or the fuel sender unit.
Caution:
Keep open flames and sparks away from work area.
11 . Remove exhaust centre tube and main muffler.

12.Remove the drive shaft.
13. Remove the rear suspension member ASSY.
14.Remove the park brake wire, differential breather
hose and ABS sensor hamess.
15. Remove the filler tube cover.
16.Remove the filler tube.

• Loasen two clamps to remove the hose and then
remov installation bolts to pull out the filler tube from
the grommet on the filler opening side.
17.Remove the fuel hose on the right side of the fuel

tank.
• Place an alignment mark on the fuel hose to avoid
confusion.
18.Use transtransmission jack to support bottom of the

fuel tank.
• Place a caul etc. under the fue! tank to support
securely.
Reference:
When it is necessary to remove the fuel tank protector,
remove it before using the transmission jack to support
the fue! tank.
EN-241
RB26DETT ENGINE
19.Remove two fuel tank installation band pins at the
front and two band pins at the rear.
20.Remove the fuel tank by lowering the transmission
jack supporting the fuel tank.
21.Remove the fuel check valve.

• Remove two hoses and the clip on the bracket.
lnspection ¡j
Fuel tank visual inspection
• Look far any cuts or wear.
• Replace the fuel tank if there is any abnormality.
Fuel hose visual inspection

• Look far any cuts or wear.
• Replace the fuel tank if there is any abnormality.
lnstallation
1. lnstall the fuel check valve.
• Position the side with printing on the top.
• lnsert the hose until it touches the end then securely
fix the clamp.
\
2. When installing the fuel tank filler opening collar
position as shown in the figure. :-----
3. lnstall each fuel hose.
• Connect each hose securely. Project / V~
• Place the clamps making sure it will not touch the
bulged a rea. @~ /
4. Use the transmission jack to support the bottom and
install the fuel tank ASSY at installation position.
• Hold the filler hose and the vent hose with hands until
it is inserted into the hole on the vehicle body so it wíll
not interfere with the vehicle body.
EN-242
RB26DETT ENGINE
5. Instan the fuel tank installation band.
,,,----
• ldentification paint (R) is located on the reverse side
of the band (on the tank side}.
• lnsert front pin from outside to inside and make sure
to attach the fixing pin.
• Replace the rear side installation bolts with new
ones.
Tightening torque (N-m{kg-m}) 26~36{2. 7-3. 7}
6. lnstall the fuel tank protector.
7. Connect the fuel hose to the right side of the fuel

tank.
• Align to the alignment mark that you have placed at
the removal.
• Fix the clamp securely avoiding the bulged area.
8. Instan the filler tube.

• Align the projection on the grommet on the filler open-
i ng side to the groove on the filler tube to install.
Grommet
• Connect hoses securely.

-\~/ /
• Fix the clamp securely avoiding the bulged area. --

\
lnst /
bolt "i ;
J\ --~ert~be ·,
9. Attach the filler tube cover.

• Position the arrow on the top.
- - - - - i n s pection hole cover
1O.Connect the fue! sender unit connector.
EN-243
RB26DETT ENGlNE
11 . lnstall the inspection hole cover.
• Position so the arrow will face the front.
procedure.
lnspection
• Make sure each clamp is closed securely.
• Place the ignition switch to ON position. Check for
any fuel leaks when the fuel pressure is applied to the
fuel lines.
EN-244
FUEL PUMP & FUEL GAUGE ENGINE MECHANICAL
RB26DETT ENGINE
23. FUEL PUMP & FUEL GAUGE
~ N-m{kg-m}
Removal
1. Open the boot lid.
2. Remove the boot front finisher.
3. Remove the strut tower bar.
4. Remove the rear floor board.
5. Release fuel pressure from the fuel line.

Releasing fuel pressure
• Select the "Fuel pressure release" in "Work support"
mode with CONSULT.
• Select "Start" and after engine stalls crank it 2 to 3
times.
• For the vehicles that are unable to start, crank 3 to 4
times.
• After restarting the engine, remove the fue! @

pump fuse and run the engine until it stalls. Crank 2
to 3 times to consume fuel left in the fue! pipes.

7. Open the fuel filler lid.
8. Fully open the filler cap and release the fuel tank in-
ner pressure.
9. Remove the rear speaker amp and rear speaker amp
bracket. Fuel retum hose lnspection hole cover
/1
10.Open inspection hole cover and remove the fuel ;, n = l
hose and the fuel sender unit connector.
-
eonne
• Place alignment mark to avoid confusion at installa-

tion. ~
~-
- ,__,_. .,,.._u
Jet pump fuer hose

-~-r
Fuel feed hose
EN-245
RB26DETT ENGINE
11. Use the lock ring wrench to remove the lock wrench.
12.Lift up the fuel sender unit to remove the connector Sender uni_
t · '-✓· u__
and the fuel hose.
13. Extract fuel remaining in the tank.
/ r,...-- ",
__ , oti\'I ~ - !·,
nnect~
,...,
.....
14. Remove the fuel pump.

• Slide the fuel pump upwards to remove.
15.Remove the fuel level gauge.
,
(1) Slide the fuel level gauge towards the left side of the
vehicle and bring it to the fuel tank opening to re-
gauge
move.
Bracket ínsi~ e
ther
ankí t - j::}
l '$~
....,
"'--A '
' , , , ,}tj /
/
f
' --..
Front
........ ...,' ~
Fuel leve! gauge
(2) Disconnect the connector and remove the fuel level

gauge.
EN-246
RB26DETT ENGINE
lnstallation
dure taking note of the following points:
• Connect the fuel hose and the connectors securely.
• Make sure to connect the fuel pump wiring in the cor-
rect direction.
• Replace the seal packing with a new one.
' I ..//, 1_,,,.. - Alignment ~.t:k))
• Position the fue! sender unit so the alignment mark
will tace three centre lines on the fuel tank.
I
·
r·~hrae \\
__
lines
,,,.,,-- ' \
• Use the lock ring wrench to tighten the lock ring. KV991 04700
• Position the inspection cover so the arrow will tace

the front.
EN-247
RB26DETT ENGINE
24. EXHAUST SYSTEM
Removal
• Disconnect each parts at connection and remove.
lnstallation
• Replace or repair the heat shield plate with deforma-
tion. Clean and remove foreign objects.
• Make sure there is no excessive gap between
exhaust pipe and the heat shield plate when
installed.
• Remove old gasket etc. from each sealing surface at
the connection. Connect securely to avoid any gas
leak.
• Replace each gasket with a new one.
• Replace the front tube installation nut with a new
one.
• lnstall each clamps by aligning the insulator projec-
tion and the clamp hole.
• Do not twist or pull any mount rubber at installation.
EN-248
EXHAUST SYSTEM ENGINE MECHANlCAL
RB26DETT ENGINE
• Offset measurements when each mount rubber is
installed correctly. Rear muffier (other than rear parts)
r (i[Jz ~.
y
Exhaust centre tube O 5 43 QFmat

Rear muffler front O 5 43
Rear muffier (rear parts) X
Right 38 O 29
Rear muffler rear 1 - - - " ' - - - + - - - - - - - - + - - - - - - - ,
Left 38 O 29
◊Fmat t' ~ ~Z
lnspection
• Start the engine and check for any gas leaks from
each connection.
• Check for any exhaust gas leaks dueto corrosion.
• Replace the parts with new one if there is gas leak
due to corrosion.
EN-249
ENGINE REMOVAL
RB20E ENGINE
EN4 ENGINE REMOVAL (RB20E)

·--._
Caution:
• Extra safety precautions must be taken and do not carry out unnecessary operation.
• Do not carry out any operations until the exhaust system has cooled down.
• Make sure the vehicle is supported in the correct position when lifting up the vehicle.
rn, 43-55 43-55 ~

~- ..,¡ {4.4-5.6} {4.4-5.6}(4) A 13-16(1 .3-1.6} (2)
Bracket " - \ · /
Bolt (2 )(~~ Bracke: f
~~-
\i\i\,\ -~ ~SUU71f¡-~
r{ ~ __l/'J._ 1 8 t (AfTl•"-"" Bracket
~
~4ºJ-5.6}(2 ,@
~ ~ Nut (M/T)43~55
~ ~--rr: • 0 • {4.4-5.6}(2)rRJ
, 43-55 l9 / ' ·,
r
M°"ot brack,t
~ ) o ~ ~ {4.4-5.6}
i
Rear member 1
lnsulator ,(> f,
, ()
•
·
43-55 ~
{4 4-5 6}(4)
rRJ 43-55{4.4-5.6} ~ ' ~ a l ,nsulator 22-28{2.2~2.9} (2) rRJ . .
rRl43~55{44~5.6}(4) ~\;~
-
Mount bracket /2
'- _,,,...43-55{4.4-5.6}(0]
lnsulator ~
~ N-m{kg-m}
Removal
3. Remove the engine hood.
8. Disconnect the hose between the canister and the in-
take manifold collector at the intake manifold collector
side.
1O. Remove the radiator.
[Engine leftJ
13.Disconnect the exhaust manifold cover earth wire.
14.Remove the power steering reservoir tank installation
bolts and move it towards front side.
15.Disconnect the air conditioner compressor connector.
16. Remove the air conditioner compressor from the
bracket and use a rape to fix it to the vehicle body
side.
EN-250
ENGINE REMOVAL
RB20E ENGINE
17. Remove the power steering pump from the bracket
and use a rope to fix it to the vehicle body side.
18.Remove the power steering pump adjustment bar.
[Engine right] ring pump

19. Disconnect the engine coolant temperature sensor
and thermal transmitter connectors.
20.Disconnect the intake manifold front side earth wire.
21.Disconnect the throttle sensor and throttle valve
switch connectors.
22.Disconnect the injector harness connector at engine
rear side.
23.Disconnect the ignition coil connector.
24.Disconnect the oíl pressure sensor connector.
25.Disconnect the alternator wiring.
--··· 26.Disconnect the acceleration wire from the throttle
drum.
27.Disconnect every connector that is connected to the
engine side around the relay box area.
28. Disconnect the fuel feed and the return hose at the
fuel tube side.
Caution:
Place a hale cap so the fuel will not leak.
29. Disconnect the brake booster vacuum hose at the in-
take manifold collector side .
. 30.Disconnect the heater hose.
• Place a hale cap to avoid coolant from leaking when
the engine is lifted up and tilted.
[Lower engine]
31.Remove the exhaust front tube.
32. Remove the control lever ASSY. After the removal
place a hole cap or seal shift rod installation area with
taping to avoid wash out of transmission oil.
33. Remove the c!utch operation cylinder.
34.Disconnect A/ T control linkage.
35.Remove the drive shaft.
• Place a hole cap on rear area of the transmission to
avoid transmission oíl leakage when the engine is
lifted up.
EN-251
ENGINE REMOVAL
RB20E ENGINE
[Engine right & left]
36. lnstall engine sling to right side engine front and left
side engine rear.
37. Place the cha in block hook on to the engine sling and
support it with hoist.
Sling
(right)
38. Remove right and left gasket.
39.Support transmission with the transmission jack.
40.Remove front right and left engine mount installation

nut.
41. Remove rear member.

1/
.....
e
Rearm
l
/
-;f ... /
~/ ' , / /
~/ '-/1/v
, '-./
"'
7
42.Lift up the engine and the transmission ASSY carefully

by changing angle of the engine and the transmission
frequently.
• Check to make sure you have not forgotten to
remove or disconnect any pipes or wiring.
Extra caution must be taken not to allow any parts
to come in contact with the vehicle exterior, espe-
cially the front tip of the transmission and the oil tu bes
around the steering cylinder, crank pulley and the air
conditioner condenser.
EN-252
ENGINE REMOVAL
RB20E ENGINE
lnstallation
lnstall the parts in reverse arder to the removal
procedure.
• Tighten installation bolts and nuts making sure there
are no problems with any of the mount insulators.
• Carry out the accelerator wire adjustment.
• Adjust auxiliary belt tension.
• Carry out idle inspection and adjustment.
lnspection
• Befare starting the engine be sure to check the level
of engine oil, coolant, power steering oil and A/ T fluid
oil. Top up if the level of any fluid is inadequate.
• Start the engine and check far any abnormal noise or
movement from any parts.
• Warm up the engine sufficiently and check that cool-
ant, engine oíl, A/ T fluid, fuel and exhaust gas are not
leaking.
EN-253
ENGINE REMOVAL
ENGINE REMOVAL (RB250E / RB25DET)

Caution:
• Do not carry out any operation until the exhaust system has cooled down.
• Make sure the vehicle is supported in the correct position when lifting up the vehicle.
,rn 43-55 ,rn

~- .1 {4.4-5.6} 43-55 ~-,
\ {4.4-5.6}(4)
"="'~ ~
~'
~¡ Mount bracket
~lnsulator
©-.__,43-55{4.4-5.6} A
r.------- -- ---- - --..,,._--4-9- - --,
1
(C:?l 43 : RB2SDET 43-55 mi ¡
,RB2SDET a::,~ ~55 ' {4 4-5 6} ~-.; ,
1 43-55 ~ {4.0-5.0}(4)1 {4.4-5.6} : Mount~o--"' ~ · · ,
l {4.4-5.6 } r j ~ ,rn : \ : bracket ~ 1 Heat insulator l
¡ . ,/ ~-.. , ~ , -~ / ,
-1 . ) •~º ',\ ~ ',
4- ,{1 ~
; Bracket , ~- i " . -~ .
¡ 1 I --...___ lfj'" ¿ 1
1 / mi p , , , :=,: 1
1
lnsulator / A3~55 ~- .; <""' '~ ', "-- l
:
1
,1 (O.J
~~mi
✓- ~ /
, {4.4-5.6)(4~
o bracket , Mount bracket
~~':!i_,!
y - . \ ,' 39-49~'
1.
Jnsulator 11
1
4 0-5 0}(4)
43-55 (2) / Heat insulator .,,,, ', · · \ :
: {4.4-5.6}-@ / lnsulator , ',, 43~55{4.4~5.6} (2}(0.J ;
tt:?J N-m{kg-mt ~ · 43-55{4.4-5.6} - -~ ..._ ____ ___ ___ __ __ _ _,
Removal
1. Release the fue! pressure.
7. Remove the air duct and the air cleaner case.
8. Remove the air duct and the air ASSY (RB25DE).
9. Disconnect the air inlet pipe and the air inlet hose
(RB25DET).
10.Remove the canister hose.
EN-254
ENGINE REMOVAL
[Engine left]
14.Disconnect the exhaust manifold cover earth wire.
15.Remove the power steering reservoir tank installation
bolts and move it towards the front side.
16. Disconnect power transistor unit connector.
17.Disconnect the air conditioner compressor connec-
tor.
bracket and use rape etc. to fix it to the vehicle body.
19.Remove the power steering pump from the bracket
and use rape etc. to fix it to the vehicle body.
20.Remove the power steering pump adjustment bar. m r ssor
[Engine right]
21. Disconnect the engine coolant temperature sensor
and thermal transmitter connectors.
22.Disconnect two intake manifold front side earth wire.
23.Disconnect the throttle sensor and the throttle valve
switch connectors.
24. Disconnect the fuel injector harness connector at the
centre.
25. Disconnect the VTC solenoid connector.
26.Disconnect the AAC valve and the FICD connector.
27.Disconnect the crank angle sensor connector.
28. Disconnect the power steering pipe pressure sensor
connector.
29.Disconnect EPS solenoid connector. (Vehicle with
super HIGAS power steering vehicle)
30.Disconnect the engine earth wire.
31.Remove the acceleration wire and the ASCO wire
(vehicle with ASCO) from the throttle drum.
32.Remove every connectors connected to the engine
side around the relay box area.
33. Disconnect the relay box front side positive terminal.
34. Disconnect the fuel feed and the return hose on the
fuel tube side.
Caution:
Make sure to place a hale cap to avoid any fuel leak.
35.Disconnect the brake booster vacuum hose from the

intake manifold collector side.
36.Disconnect the vacuum hose (between intake
manifold collector and the throttle sensor).
(RB25DET)
37.Disconnect the heater hose.
• Place a hale cap so the coolant within the engine will
not leak when the engine is lifted.
EN-255
ENGINE REMOVAL
RB25DE / RB250ET ENGINE
[Lower engine]
:::!?
38.Disconnect the exhaust front tube from the exhaust -·--
manifold.
39. Disconnect the A/ T control gauge. 1 'Y'.~~ /
40.Disconnect the propeller shaft. ~
• Place a hole cap on the rear part of the transmission

....__,,, ~ nector
to avoid transmission oil from leaking when the en-
gine is lifted up.
41.Disconnect every connector behind transmission.
[Engine right & left] F ront - ~

42. lnstall the engine sling to engine front right and
'i:J ~
engine rear left.
• Place the chain block hook on to the engine sling and (ITT~(
support it with the hoist. ~~\
Sling (right)
r // "'-
43. Remove right and left gasket. Fro
_,.,, , _,...- Gas

. -~,..,_,//
44.Support the transmission using the transmission

jack.
EN-256
ENGINE REMOVAL
45. Remove the front side right and left engine mount
installation nuts. (RB25DE)
(RB25DET)
y t
46. Lift up the engine until there is no load to insulator
2
R~tfside
Ú"--
Mount bracket \
Lefts~Front\\
Mount bracket
and remove the mount bracket and the ínsulator

(RB25DET).
a or nsu a
'
~ ~: ..
47. Remove the engine rear member and the insulator. Rearm
f
'
;( <,¡ /
/
"/ '-.// ~
V/'v7"-/"
'v /4
48. Lift up the engine and the transmission ASSY
carefully by changing the angle of the engine and the
,,- - ... transmission frequently.
• Check to make sure you have not forgotten to
remove or disconnect any pipes or wiring.
• Extra caution must be taken not to allow any parts to
come in contact with the vehicle exterior especially
the front tip of the transmission and the oil tubes
EN-257
ENGINE REMOVAL
lnstallation
lnstall the parts in reverse order to the removal
procedure.
• Tighten installation bolts and nuts making sure there
are no problems with any of the mount insulators.
• Carry out the accelerator wire adjustment.
• Adjust auxiliary belt tension.
• Carry out idle inspection and adjustment.
lnspectlon
of engine oil, coolant, power steering oil and A/ T fluid
oil. Top up if leve! of any fluid is inadequate.
• Start the engine and check for any abnormal noise or
ant, engine oil, A/ T fluid, fuel and exhaust gas are not
leaking.
ENGINE REMOVAL
RB26DETT ENGINE
ENGINE REMOVAL (RB26DETT)

Caution:
• Do not carry out any operation until exhaust system has cooled down.
• Make sure to support the vehicle at correct position when lifting up the vehicle.
,,../ · ~_:./
_,,/
----~,./
---:::
--<¿, PT1'I
43-55~-.,¡
{4.4-5.6}(2)
lnsulator
/
43-55 ~ ~-¡:::..:- ----- ) \ / 43-55 ~
39-49{~-5.6}\ ~~
-~ \ ~j,.r<--·/'v ~,,,.~_v{4.4-5.6}(2)
{4.o-5t4)
"v2
® v ~)/
~
e -
43-55 ~
~/~¡
-il'1
1
l
1 ij ·1
%,,...___k, ~Bracket 4 5 5 2
-~ , Mount
{ .4- - } ( ) - - ~
Rear member /
®
1--
_.
Heat insulator
~'--M t b k t bracket ~22-28{2.2-2.9} (4) ®,
oun rae e / 43/-~5{4.4-5.6} ~ , ~ 43-55
¡ '-. {4.4-5.6} (2)
@ "- ~ ~,) Heat insulator
lnsulator ~~ ~
\
43-55
PT1'I
\ -.,j
<..
39-49 _,...,,./f()
~½'
~
{4.4-5.6}
{4 0-5.0}(4) ~ ,
/
lnsulator
,¡¡)~3-55{4.4-5.6} n
~-.,¡
~ N-m{kg-m}
Removal
9. Remove the aír duct, air cleaner case and the air
hose.
10.Remove the cooling fan.
11. Remove the radíator.
[Engine left]
13.Disconnect two canister hoses.
14.Disconnect the earth wíre between the exhaust mani-
fold cover and the vehicle body at the vehicle body
side.
15.Remove the followíng harness connectors and the
terminals at the engine side:
• 0 2 sensor
• Power transistor unit / power transistor unit earth
wire.
,..--
• air conditioner compressor
EN-259
ENGINE REMOVAL
RB26DETT ENGINE
bracket and use rope to fix it on to the vehicle body
side.
17.Remove the power steering pump from the bracket
and use rope to fix it on to the vehicle body side.
18.Remove the power steering pump adjust bar.
[Engine rightJ
19.Remove the accelerator cable from the throttle
drum.
20. Disconnect the fuel feed and the return hoses on the
fuel tube side.
Caution:
Make sure to place a hole cap to avoid any fuel leak.
21.Remove the following harness connectors and the

terminals at the engine side:
• Engine coolant temperature sensor / thermal
transmitter.
• Throttle sensor / throttle valve switch
• Fuel injector / intake air temperature sensor
• lgnition coil main harness / MC valve
• Power steering pipe pressure sensor / crank angle
sensor
• lntake manifold front side two earth wires
• Engine earth wire
22.Remove all connectors around the relay box that is

connected to the engine side.
23. Remove the relay box front side positive terminal.
24.Remove two earth terminals.
25.Disconnect the vacuum hose between the brake

booster and the intake manifold collector at intake
manifold collector side.
26.Remove the heater hoses {return and feed).
• Place a hole cap so the coolant within the engine will
not leak when the engine is lifted.
27. Disconnect two oil cooler hoses as engine side and
place a hole cap.
28. Remove two air hoses from the boost control sole-
noid.
(Interior]
29.Remove the shift rod.
• Place a hale cap on the transmission after removing
the shift rod to avoid oil leakages.
EN-260
ENGINE REMOVAL
RB26DETT ENGINE
[Lower engine]
30.Remove the exhaust front tube from the exhaust ller shaft Front
manifold.
1
31. Remove the clutch operation cylinder.
32.Remove the E-TS oil line from rear end of the trans-
fer.
33. Remove the propeller shaft.
• Place a hole cap on the rear part of the transmission
Nslme"' ....o~-<"'T'- ~
to avoid transmission oil from leaking when the en-
gine is lifted up.
34. Remove right and left front drive shaft.
[Engine right & left]

35.lnstall the engine sling to engine front right and en-
gine rear left.
36.Place the chain block hook on to the engine sling and
support it with the hoist.
37.Support the lower part of the transmission with the
transmission jack.
38. Remove the rear member and the insulator.
39. Remove right and left engine mount installation nuts.
40.Carefully remove the engine, transmission and the

transfer ASSY by frequently changing the angle.
• Check to make sure you have not forgotten to remove
or disconnect any pipes or wiring.
• Extra caution must be taken not to allow any parts to
come in contact with the vehicle exterior especially
the front top of the transmission and the oil tubes
EN-261
ENGINE REMOVAL
RB26DETT ENGINE
1nstal lation
dure.
• Tighten the installation bolts for the rear member in
the arder shown.
• Tighten bolt (A) then bolt (B) for the right and left en- A
gine mount bracket. ,,-,,;.,,,-
• Tighten each installation bolts and nuts making sure \"- ine mount
the mount insulator is fitted correctly. ' t
,
¿~
lnspection
of engine oil, coolant, power steering oil and trans-
mission fluid oil. Top up if level of any fluid is inad-
equate.
• Start the engine and check for any abnormal noise or
ant, engine oil, transmission fluid , fuel and exhaust
gas are not leaking.
EN-262
1 ')
~o
~,.ECCS relay
1 ••• 2
~
40
35
109
27
34
101
11 i--
1~
2i--
12i--
21 :speedometer!
~RX~T~
i-l
Diagnosis connector
L 1

1
r-::::'::-1
~
fH11Gj
~
0(/)
;ij
c-,(J)
c--t
m
z
01
-<
A/C relay Dual Pressure SW Gl2,\ ~ 110 24 Neutral SW(M/T) -t m
~ 1 ?r - '1
~
lnhibilator relay (A/T)
os
f-------mil
103
112
9
19 7 .:
,- -,
~
Crank ~ )>0
1 ~ 'compressor
Air cond1tíoner ',!TJ, ~ 105
10
20 __J
__ ,1 ..
~ angle
sensor
1
G> e
~ r=i
#16 '
114
!6
___J~
- lnjector 3
... .....
: :
~ ~
i..1J Air flow

~ meter
s::
_z -
F/L- 14 ~ IGN relay # 12 46 -·-~ 1 ; 2 !3
~ 5~
,,......
13
4
~m
DJ
....,
+
2 ... 11 ENG wa~ng lam~
44 - o
~
#41
Fuel pu~p rela+
?
1
000
1
~
EXH temp warning lamp
14
m 47
104 O 17
o
45-
,........._"
} ToA/T C/U
Throttle sensor
-
m
;o
~---. ..-.
CIJ
~
?
3-5 (j) 7
m o 26 1I ♦ ,3~
1\.)
o
z1
1\.)
en
~?r.:71
lAi~lator
~ ~~
--e 1
Eng coolant temp se~

¡ m
m
z
(.;.) ¡--':;""] G)
92 5
AAC valve A/Cauto amp Thermo am~ 29 z
Throttle valva sw 1~
2
1-~2 rn
.. & 113 22 ToA/T C/U
~~I~
3
25
1
~
ACC Power
QLj)
~1
o
~lm
IGN coil ? tr~nsistorHJ 32
:-- ..... , 2
1
1 Knock senj @)
~
~ 16
,?)
W212
~ ......-.,J
37
R'--- ST 1 IGN-: 8
- R~or
10 l 1 39 115
3 1 Exhaust gas sen
~ .- --- 1 ~
i 6 -----2 1
23 EXHtem sen*
10 INJ pulse sig ------,. 41 (Ground) (!'ji 2 Í1 (/)
(TI monitor) ~ 107 30
-- To starter motor ,,,. ....... ,___ 108 di'? Power steering sw -<
(/)
p~rq ,___ 116 43 To tachometer 2 -- 1 -i
-~ f 1t
't'
-
~
42
48
38
28
36
(-)-
m
~
oe
e TTTTTT (""'\
v -i
r
z
m
SYSTEM OUTLINE
RB20E ENGINE
2. ECCS CONTROL UNIT PIN LAYOUT (RB20E)
-
4 5 6 7 8910
14 15 16 17 18 19 20
-
21 22 23 24 25 2 27 28
29 30 31 32 33 34 35 36
1(RX) Receive (C / U data reception) 11(CLK) Clock (synchronization signa!)

2(TX) Transmit (data sent from C / U) 12(CHK) Check (diagnosis activation)
3 Air flow meter intake air signa! 13 Engine warning lamp
4 Air flow meter earth 14 Exhaust temperature warning lamp
5 Engine coolant temperature sensor signa! 15
6 Exhaust gas sensor signal 16 Knock sensor
7 Throttle opening output signal (to A/T C/U)

Throttle sensor opening signal 17
(A/T vehicles)
Earth (throttle sensor, engine coolant temp
8 18
sensor, exhaust temp sensor)
9 Crank angle sen 120° sig (REF) 19 Crank angle sensor (120° signal)
10 Crank angle sen 1° sig (POS) 20 Crank angle sensor (1º signal)
21 Vehicle speed sensor signal 29 Air conditioner SW
22 Throttle valve SW (ldle connection point) 30 Exhaust temperature sensor signal
23 Key SW START signal 31
24 Neutral SW 32 Throttle valve SW (Power supply)
25(1GN) Key SW IGN signal 33
26 Throttle sensor power supply 34 Battery power supply
27 C/U power supply 35 C/U power supply
28 C/U earth 36 C/U earth
37 lgnition signal (Power transistor ) 43 Tachometer engine turn signal
Engine A/T control input signal
38 Power steering oi! pressure SW 44
(DT1) (A/T vehicle)
Engine A/T control input signa!
39 lgnition signa! check (Turn signa!) 45
(DT2) (A/T vehicle)
40 ECCS relay 46 Air conditioner relay (A/C cut signal)
41 Engine A/T control input signa!

lnjection pulse (Ti monitor) signal 47
(DT3) (A/T vehicle)
42 Earth (lgnition signal) 48 Earth (lgnition signal system)
101 lnjector No.1 109 lnverse curren! feedback circuit
102 110 lnjector No.2
103 lnjector No.3 111
104 Fuel pump relay 112 lnjector No.4
105 lnjector No.5 113 AAC valve control signal
107 lnjector ground 115 Exhaust gas sensor heater ground
108 lnjector ground 116 lnjector ground
EN-264
'l ') \
...
#17
Diagnosis connector
ECCS relay 31~CLK
21
22
RX
TX
47i-CH"
87~[~J 1 ! ¡cHJ'GNI
(')
:;o
(')
+
60M----.l"""'c!'.':E~-:-:-::-:-:-::----------.-+-l------- e
101
?l-----1105
1~gt===t1.1i----:-"""'
..""'"""......1"°½_.-_ _ _ _ ____j_J ::¡
103
29 _ ___¡::::¡:lfl<
1
.__'¡:i,;~;v;;;:;l - ~ e
23f-
~
.._....;.._;...;;;.::.;c..J -
114 24--~.....P~~@ -
( )
61-------l 112 ~
s:
9
46
41
~~1
<f!)
-·
L'.t:=m Air flow
meter
-
;;o
cu
N ;::o
~
1
U1 OJ
C, N
ACC IGN 33 51 ___.B.__ ria
ToA/T C/U
m g,
lM--------t<:Y",e>)---t------_'.:=~====::~ rn
W2.L3J4) 1 L..j---~ - rn
41 ' 1
:;o --
rn R
O 42 cu ;::o
z ~
.L----~-'--- 1,-.1r,.1 - - l l
r-,._ · · - -
52 N OJ
1 U1 ~
N
O)
~ ~ 28
e o
01 ·To starter motor m ~
5·
1 l •-~l~lll ¡12
1
e 30
Throttle sensor
.:j m
.-_,.._ 1 h z
r -,
~
~r
::i'
~-1 11 ··-~lt~i,,1 38
48
l
13 EXH temp sen
G>
z
~
m
(/l
e:
"C
1 111~"~1~1, 1 113 57 (lb -nb
"C
ro ~ 111 k ~I f;',l("@l,, 1 1
12 1131
"'"'5· 1 111 kL iJ1K@I~ 1 ¡-25 111 <2I3) Vehicl~~-d sen
::,
53e--------------1Speedometer
;u
ce --.Power steering SW
~ 19 1 2 -°""1_ __
l2Jl)
UUH ~ ~ « -- ---~~--~-~~ralSW(Mm (/)
Spark plu,
-----, 17
¿
i--_ _ _ _ _ lnj pulse sig _l_i:!1!!~!9!:. ~!§IX. LA/_T_) _ .. __ -<
::i 1----- -- (TI monitor) ~RB25DE) with dual mode muffler¡ (/)
1
18 '< 141--------- } 1 To lGN relay -l
g,_____ ~;;¡
rn
~(RB25 :
I! ' - - - - - + - - - - l 104_J 1
116
108
To A/T C/U1
551---------
,
7.---...---To tachometer Dual mode

107 10 20 ~check mufflercontrolle
: L..., ; 5 -OOD2J ~
oe
I
pumpl l__~=-1-Q..EJlJ connector L - - - - - - - - - - - · - -1
r
z
rn
SYSTEM OUTLINE
2. ECCS CONTROL UNIT PIN LAYOUT (RB25DE / RB25DET)
1 IGN SIG (pwr transistor ctrl sig) Cyl. No. 1 11 IGN SIG (pwr transistor ctrl sig) Cyl. No. 6
4 MC valve control signal 14 Engine NT control input signa! (DT2)(NT)
5 Engine NT control input signal (DT1 )(NT) 15 Engine NT control input signa! (DT3)(NT)
6 16 ECCS relay
7 Engine rev signa! for tachometer 17 lnjection pulse (Ti monitor) signal
8 18 Fuet pump relay
9 Air conditioner relay (A/C cut signa!) 19 Power steering oil pressure SW signa!
10 Earth (lgnition signla system) 20 Earth (lgnition signa! system)
21(RX) Receive (C/U data reception) 31(CLK) Clock (synchronized signal )
22(TX) Transmit (Data to C/U) 32 Engine warning lamp
23 Knock sensor signa! 1 (Cyl. 1-3) 33 Exhaust temperature warning Jamp
24 Knock sensor signa! 2 (Cyl. 4-6) 34
25 Boost control solenoid sig (RB25DET only) 35
26 Air flow meter earth 36
27 Air flow meter intake air quantity signa! 37
28 Engine coolant temperature sensor signa! 38 Throttle sensor opening signa!
29 Exhaust gas sensor signa! 39
30 Earth (Sensor signal system) 40
41 Crank angle sensor 120º signa! (REF sig) 51 Crank angle sensor 120° signal (REF sig)
42 °
Crank angle sensor 1 signar (POS sig) 52 Crank angle sensor 1° signal (POS sig)
43 Key SW START signal 53 Vehicle speed sensor
44 Neutral SW 54
45(1GN) Key SW IGN signa! 55
46 Air conditioner SW signal 56 Throttle opening output signal
47(CHK) Check (diagnosis) 57 Exhaust temperatura sensor signa!
48 Throttle sensor power 58 Battery power
49 C/U power 59 C/U power
50 C/U earth 60( - ) C/U earth
101 lnjector No.1 109 Inversa current feedback circuit
102 11 O lnjector No.5
Fuel pump terminal power control output
signa! (FPCM)(RB25DET only)
105 lnjector No.2 113 Variable valve timing sotenoid
107 lnjector ground 115 Exhaust gas sensor heater ground
108 lnjector ground 116 lnjector ground
EN-266
.) )
..Jo.
IGN coil relayA

1~T
-3Cé::::'.J5 C')
Diai;inosis connector ::a
109
59
M §t i&IT!I~k l 1~HKIG1 CHK connector S ark plu
(")
e
:::¡
@'
~~f;J-t.::.::.::.::.::.::.::.::.::.::.::.::.::.::.::.::.::.::.::~~--=--=~~1~
47 CHK __ 02 sen (R) :
29 /'ffl'\ :: ..B.... §: e
Ll'=~+--:::----;;:----::;;:;::------~~75s 115 r------t----r~~~ QI7 p ·: (1l;m) s·
~ )>
Water temp sw
GJ!rr) ~~=.t@+W~fütil ~ ::¡_ G')
~
e-o
55 l. y
1, -t-t-----_r---+-'+l
12¡---H------r----+4t
'"""v,.,---,-i-
_...,._.,.~_..._. ro ~
c=..1.,
.-"~>-t..Jl>"'------¡;¡¡.,------,::;::;.¡¡:;;;;:;:--,9
-~
1e pressure S • Thro a e sw 4
ldle contac1
5
1!1=~==it+t=;;-==~-==~~7=..:::i---L;tl;
11r•--W-~ 4
-::a:s::
Ol
N
57
AJC compressor 561 1 i •ETSIABSC/U 6 crrP~---~ a,
e
r-,
·++--~,!--~ ocksenl"cll_~
..r:'I'.. m ;;o
101 m 231 -4 ro
m
105
103 8 3424 L-- üb C'iRÑrnSW
B
-
-4 N
oCJ)
m
z 114 (J)
110 o
Airflnw
(1 :2 i314 l5)
1
1\.) 112 --.
35 ~
O)
e m
-..¡ Afl..C va~ve ~ z
4 26 G)
•noid~ 27 CiT2ñFJID z
25 m
51 ,...,
#41
#3 1 43
41
42
52
' 1 GiflE,
32 50
60
48 IThrottle sen
38 m'rID
7
18
30
28
36 1·
PWRST
: ~ ~~::
~ temp sen
:i~p~~
_,.111._
íJ.J.LJ
(-)
en
oíl pressure 2@1 ~
104
106 . 11®2 llJ.12) 1L_
~ T o #16 10A fuse
-<
en
Vehicle speed sensor :! 1
~ 3=(T~he_r_m_o_a.,.,m..,.~lNC auto amp¡ -l
rn
e= fjedomete1t------~---
cimlJ s::
o
e
--i
r
z
m
SYSTEM OUTLINE
RB26DETT ENGINE
2. ECCS CONTROL UNIT PIN LAYOUT (RB26DETT)
fHKIIGNI
1
4 AAC valve control signa! 14
5 15
6 16 ECCS relay
7 Tachometer engine rev signa! 17 lnjection pulse (Ti monitor) signa!
8 18 Fuel pump relay
--,
9 Air conditioner relay (AJC cut signa!) 19 Power steering oíl pressure SW signal
10 Earth (lgnition signla system) 20 Earth (lgnition signa! system)
21 (RX) Receive (C/U data reception) 31(CLK) Clock (synchronized signa! )
22(TX) Transmit (Data to C/U) 32 Engine warning lamp
23 Knock sensor signal 1 (Cyl. 1-3) 33
24 Knock sensor signa! 2 (Cyl. 4-6) 34 Air flow meter earth
25 Boost control solenoid signal 35 Air flow meter intake air quantity signa!
26 Air flow meter (R) earth 36 lntake air temperatura sensor signal
27 Air flow meter (R) intake air quantity signa! 37
28 Engine coolant temperatura sensor signa! 38 Throttle sensor opening signa!
29 Exhaust gas sensor (R) signa! 39
30 Earth (Sensor signa! system) 40
41 Crank angle sensor 120° signa! (REF sig) 51 Crank angle sensor 120° signa! (REF sig)
42 Crank angle sensor 1° signa! (POS sig) 52 Crank angle sensor 10 signa! (POS sig)
43 Key SW START signa! 53 Vehicfe speed sensor
·-·--.
44 Neutral SW 54 Throttle valve SW (ldle contact)
45(IGN) Key SW IGN signa! 55 Exhaust gas sensor signa!
46 Air conditioner SW signa! 56 Throttle opening output signa!
47(CHK) Check (diagnosis) 57 Throttle valve SW power
48 Throttle sensor power 58 Battery power
49 C/U power 59 C/U power
50(-) C/U earth 60( - ) C/U earth
101 lnjector No.1 109 lnverse curren! feedback circuit
Fuef pump terminal power control output signa!
104 (FPCM)2 11 2 lnjector No.6
105 lnjector No.2 11 3

Fuel pump terminal power control output signal
106 (FPCM)1 114 lnjector No.4
107 lnjector ground 11 5 Exhaust gas sensor heater ground

108 lnjector ground 116 lnjector ground ~'
EN-268
ECCS
EN6 ECCS (ELECTRONICALLY CONCENTRATED

ENGINE CONTROL SYSTEM)
1. FORACCURATE & QUICK DIAGNOSIS

GENERAL OUTLINE
Main control such as fuel injection control, ignition timing, ~ Control unit {W
Sensor~~/~
idling control etc. are controlled by ECCS C/U. ECCS : ~ Actuator
C/U will receive input signal from sensors and then im-
- / 11
mediately send out output signal to the actuator.
Most faults that occurs rarely are due to bad electrical

contact or faulty wiring. In these cases it is necessary to
inspect faulty circuit carefully to avoid replacing correctly
operating parts. Use a circuit tester to diagnose a faulty
circuit as inspecting visually is not enough to diagnose
the faults.
Befare starting inspection ask your customer in detail

about the conditions of its occurrence.
OPERATION ORDER
START INSPECTION
L . . -_ _ _ ___,~------------------------------------STEP1.
IN_Q_U_I_RY
BASIC INSPECTION ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - STEP 2
ABNORMAL ITEM WITH SELF-DIAGNOSIS RESULT - - - - - - - - - - - - - - - -STEP 3

... .. ...... ..YES
... ..... ............. .... . NO
~ ~
, -....
'
-............
- - - -...........
- - - -...-.. " 4-----------,
Self-diagnosis Basic phenomenon Function test
Carry out self-diagnosis Check each phenomenon Carry out CON-
SULT function test
Any abnormal ítem in NO

self-diagnosís result STEP4
······ ...............Y.I;$ ................................................................. ........ ..
· - - - - - - ! - - - - - - - _ _ l - - - ~ ~ - - - - ' - - - - ~· Check each
~ [§_~~f-diagnosis iteml ltems other than self-diagnosis Diagnosis procedure item : faulty item
··············· ·········· ··························· ··············· ······································ ·············
Repair or replace
NG. - - - ~ - - - -· - - - - - - -
Verification check
Check if the fault has been repaired by _________ _ ________________ STEP
carrying out a basic inspection and
5
test drive
OK
lnspection end
EN-269
ECCS
STEP 1 Follow the diagnostic worksheet on the following page.

STEP2 Carry out the basic inspeciton.
STEP3 lnspect the self-diagnosis results memorised in ECCS C/U.
STEP4 According to verified faults, select inspections from below:
1. Self-diagnosis
Operate self-diagnosis mode 2 and carry out the inspection
according to the self-diagnosis result.
2. Phenomenon
This inspection is a simplified method. To inspect each parts it is
necessary to select the relevant inspection ítem from the diagnosis
procedure items.
3. Function test
This inspection is a basic inspection of the fault diagnosis. In this
inspection the CONSULT will display OK or NG after diagnosing the
faulty system .
4. Diagnosis procedure
• Carry out this inspection using the data created when faults are
detected in related circuits or when there is a fault with harness
circuit.
• lnspections for "ltems not in self-diagnosis" cannot be verified in
self-diagnosis mode.
• lf the system that comprises self diagnosis function includes the
circuit that can not be self-diagnosed, it is necessary to select "items
not in self-diagnosis" even when the self-diagnosis result shows
"OK".
Example: Crank angle sensor
STEP5 • Verification inspection must be carried out to check if the servicing
is done correctly and installation after the service has been done
correctly.
• Same fault phenomenon has reoccurred in the verification
inspection.
• Return to step 4 and carry out inspection using different method .
EN-270
ECCS
DIAGNOSTIC WORKSHEET
• Feeling for a problem depends on each KEY POINTS
customer. lt is important to fully understand the
phenomenon and conditions of a vehicle when a What ........ Vehicle & engine model
customer complains. When ....... Date, frequencies
• Check with your customer in what conditions the Where ...... Road condition
problem occurs in and use as a reference when How ......... Orive condition &
carrying out test drive. circumstances
• Make good use of a diagnostic worksheet such
as the one shown below in arder to utilize ali
complaints for troubleshooting.
Customer name Reg istration lnitial registry

MR / MRS /MISS/ MRS No. date
Vehicle type Chassis No.
Manuf. Date Engine T/M M/T,A/T Mileage (km)

• No initial combustion • Partial combustion
Starting • Hard to start (cold climate, warm climate, constantly)
• Other [
• No fast idling • High idle • Low idle
ldling • ldling unstable (cold climate, warm climate, constantly)
• Other [
Phenomenon f--------1-----=--------------------------=--1
• Stumble • Knocking • Backfire
Driving • Lack of power • Lack of acceleration
• Other [
• At start • At idle • While driving
Engine stall • After stopping • While loading (battery load, power steering)
• Other (
lnitial occurrence • Since new • Recently
Frequency • Ali the time • Under certain condition • Sometimes
Not affected
Weather Weather • Fine • Cloudy • Raining • Snowing • Other [
Temperature • Hot • Warm • Cool • Cold • Temperature ( ºC)
Engine conditions • Cold • After warm-up • During warm-up • Water temp ºC)
Road conditions • City area • In suburb • High-way • Hilly area
• Does not affect
• At start • At idle • At racing
• While driving • While accelerating • At constant speed
Driving conditions
• While decelerating
[Vehicle speed: km/h, Engine rev: rpm, M/T gear]
• At curve (• Right curve • Left curve)
Other condition
EN-271
ECCS
PHENOMENON CONFIRMATION
• Customer's explanation is often insufficient in
clarifying the status of the problem. Reproduction
of the problem on the actual car and its confirma-
tion and analysis are therefore essential. lf unable
to reproduce the problem, ask the customer in detail
about its occurrence conditions and try to reproduce
it under the indicated conditions. lf unable to repro•
duce, manually shake the concerned harness to
check for poor contacts or other problems.
• lt is also recommended to collect and analyse the
data using CONSULT whíle dríving.
• When checking the actual vehicle, record data on
normal portions to assist in diagnosing a problem.
Carry out active test and function test using

CONSULT. OR remove vacuum hose and
Lean
apply negative pressure using the vacuum
Pressure pump.
Air fuel ratio
regulator
Rich CONSULT. OR remove vacuum hose and
apply pressure using the vacuum pump.
lncrease angle Rotate the crank angle sensor clockwise.
Crank angle Carry out active test and function test using
lgnition timing
sensor Decrease angle CONSULT. OR rotate the crank angle sen-
sor anti-clockwise.
Shutdown
0 2 sensor CONSULT. OR remove 0 2 sensor harness
temporary
connector.
Air fuel ratio control
Carry out active test and function test us-
Control unit Operation check íng CONSULT. OR carry out self diagnosis
mode 2 at 2000rpm.
lncrease rev CONSULT. OR rotate idle adjust screw anti-
clockwise.
!die rev MCvalve
Carry out active test and function test
Decrease rev using CONSULT. OR rotate ídle adjust screw
clockwise.
Harness Default connector Tap or shake lightly.
Harness cables connector and contact or default Turn the engine quickly and check default
circuit circuit contact caused by engine torque movement.
Cool down using ice etc.
Cool down
(do not over cool)
Temperatura Control unít
Warm ít up using the heat gun etc.
Warm up
(do not overheat)
Electronic Moísten
Humidity Moisten
parts (Do not pour water directly on the unít)
Turn ON the headlight switch, air conditioner,
Electricity load Switch load Apply load
rear defogger etc.
!die switch conditíon Control unit ON-OFF switch Operate the acceleration (open/ close)
Check each cylinder ignítíon using timing
lgnition spark Timing light Correct ignition
light flashes.
EN-272
ECCS
CAUTIONS WHEN CARRYING OUT DIAGNOSIS
• Remove the battery terminals and place ignition
switch in the OFF position when removing or con-
necting ECCS C/U harness connector from ECCS
C/U.
• Position the conenctor and tighten the installation

screw until orange projection is at leve! with surface
when connecting ECCS C/U harness connector.
• Check the connector pin terminals far any bends or

deformities when removing or connecting ECCS C/U
harness connector.
• Be sure to carry out components function inspection

and ECCS C/U input signal inspection befare replac-
ing ECCS C/U.
• After "Diagnosis procedure" carry out the test drive

and self-diagnosis.
~--..
/ Batte
_
~ 9
\ ------~cr-:-~ · .
• Short-circuits will occur if probes from the same posi-
tion come into contact when measuring the battery
voltage of ECCS C/U components using the circuit
tester. Be sure to connect one side of tester probe to
different place.
EN-273
ECCS
CAUTIONS WHEN HANDLING ECCS C/U
ECCS C/U installation

• Only install ECCS C/U specified for your vehicle.
• Do not apply unnecessary power to installation bracket.
Connector removal
Keep the following points in mind when removing or installing the connector:
Removal:
• Make sure the ECCS relay is OFF after placing the ignition switch in the OFF position.
• Hold the connector body to remove the connector. Do not pull the harness to remove.
1nstal lati on:
• lnstall the connector when the ignition switch is in the OFF position.
• Check ECCS C/U side connector pin for any bend or deforming befare installation.
• Tighten the bolts securely until red projection is leve! with the surface.
ECCS C/U voltage

• Never connect the battery in reverse.
• The battery voltage should be between 1OV ~ 16V.
ldle rev adjustment volume

• Do not turn the knob over the lock position.
• Do not operate the adjustment volume when at below OºC.
Moisture & oil content

• Care must be taken to keep all rain drops and water droplets away from ECCS C/U.
• Take note of water droplets from rapid temperature change. Make sure ECCS C/U has
dried completely before installing in the vehicle.
• Do not allow oíl content to adhere to the connector device.
• Do not use benzine or white spirit to clean the ECCS C/U.
Dropping & strong impact

• Do not drop, hit or apply strong impact to the ECCS C/U device.
• Do not use a ECCS C/U with deformed top or bottom cover.
ECCS C/U screw & cover

• Do not remove the ECCS C/U upper and lower cover.
• Do not turn screws on ECCS C/U body.
EN-274
ECCS
2. DIAGNOSIS ITEMS BY PHENOMENON
(1) Unable to start ............ No initial combustion.

(2) Unable to start ............ lnitial combustion occurs but is not complete.
(3) Difficult to start............ Hard to start when engine is cold.
(4) Difficult to start............ Hard to start after engine warm up.
(5) Difficult to start............ Hard to start when engine is hot or cold.
(6) Poor idling .................. Fast idling inoperative.
(7) Poor idling .................. Low idle rpm (after warm up).
(8) Poor idling ..................High idle rpm (after warm up).
(9) Unstable idling ............ Engine is cold.
(10) Unstable idling ............After engine warm up.
(11) Poor driveability .......... Engine breathing.
(12) Poor driveability .......... Knocking.
(13) Poor driveability .......... Lack of output, poor acceleration, poor response.
(14) Engine stalls when starting to drive.
(15) Engine stalls while idling.
(16) Engine stalls while driving.
(17) Engine stalls when decelerating or immediately after stopping.
(18} Engine stalls when electrical loador power steering load is applied.
EN-275
ECCS
( 1) Unable to start .... ...... No initial combustion.
[Analysis]
• lgnition spark is not generated orno fuel is injected.
• Check if the fuel pump is rotating.
• lf no ignition spark is generated and no injector operating noise can be heard,
check the control unit input (crank angle sensor signal) or control unit power
supply.
• lf the injector is operating but no spark is generated, the control unit and crank
angle sensor can be considered as normal. Check the ignition output system
(power transistor, ignition, coil etc.)
• lf an ignition spark is generated but the injector is not operating, check the ignition
output system (injector power supply, harness etc.)
[Chart]
FUEL PUMP
Operating?-i-Check fuel hose tension in CONSULT active test mode.
LºR
Check if pump operating noise can be heard for five seconds after
turning ON the ignition. (lf not check fuel pump system)
INJECTOR
Operating?LCheck if injector operation noise can be heard when cranking.
OR
Check using CONSULT data monitor mode if injector pulse is output
when cranking engine.
lf not
• Check control unit terminal voltage when cranking.
• Check injector power supply circuit.
[ • Check crank angle sensor input signal.
J
IGNITION SPARK
Is there a ---C:Check if tachometer needle moves during cranking.
spark? [:Check using CONSULT real-time diagnostic mode.
Check using timing light.
• Remove the plug and check for actual spark.
• Check if leaking from high-tension cable.
lf not correct
• Check control unit output ignition signa!. ]
• Check control unit input crank angle sensor signal.
[ • Check power transistor and ignition coil resistance value.
EN-276
ECCS
(2) Unable to start .......... lnitial combustion occurs but is not complete.
[Analysis]
Occurrence of initial combustion means that sparks are created. The following three
cases are possible:
1. lnitial combustion only.
• Is fuel system working? (fuel pump, injector etc.)
2. Engine fires incompletely.
• Check if fuel injection quantity is too small or too large.
• Check the fuel pressure.
• Check if water temperature enrichment is provided.
• Check if start time enrichment is provided.
• Check if ignition timing is normal.
3. Engine tires completely if accelerator pedal is depressed.
• Check íf MC valve is operating normally.
[Chart]
FUEL PRESSURE
Is pump ~ Check fuel hose tension in CONSULT active test mode.
operating? OR
Check if pump operating noise can be heard for five seconds
afler turning ON the ignition.
Is fue! pump operating during cranking?
(lf not check fuel pump system)
INJECTION QUANTITY
Water temp T
Check water temperature in CONSULT data monitor mode.
enrichment OR L
provided? Disconnect water temperature sensor and check far any change.
• Check water temperature resistance value.
Start time • Check water temperature sensor output voltage.
enrichment--Check "START" signa! ON/OFF (CONSULT data monitor mode).
provided?
IDLING CONTROL
Is idling rpmt CheckAAC valve operation (CONSULT active test mode).
increased? Check if MC valve is fully closed.
Check AAC valve circuit for disconnection or loase connectors.
IGNITION SYSTEM
lgnition timing -Try to advance or retard timing angle.
normal?
Is ignition -~L-Check spark plugs for fouling.
correct? Check for ignition misfiring.
(Check using a tíming light or CONSULT real-time diagnostíc mode).
EN-277
ECCS
(3) Difficult to start............Hard to start when engine is cold.
[Analysis]
lnspect the system relating to the engine coolant temperature as this problem only occurs
when the engine is cold.
• Fue! injection enrichment from the engine temperature sensor signa! is not functioning
when temperature is low.
• ldling speed control is not functioning.
• Start-time enrichment is not functioning.
• Cranking speed is too low.
[Chart]
ENGINE TEMPERATURE CORRECTION

Engine ~ Check using CONSULT data monitor mode.
temperature L
OR
sensor sig? Disconnect engine temperature sensor connector and check for any --.
change.
• Check engine temperature sensor resistance value.
• Check engine temperature sensor output voltage.
ldling control?LCheck if AAC valve for operation (CONSULT active test).
L
Check if AAC valve is not fully closed.
Check AAC valve circuit for disconnection, loase connector etc.
START-TIME ENRICHMENT
~ - - - Using CONSULT data monitor mode check if START signal is
provided.
CRANKING SPEED
.____ _ _ Is battery normal?
lnspect starter, starter cables (resistance, poor contact etc.)
EN-278
ECCS
(4) Difficult to start................ Hard to start after engine warm up.
[Analysis]
This problem may also be related to the water temperature control.
• Check if the engine temperature correction is inaccurate.
• Check if the fuel pressure is corrector if air bubbles are generated in the fuel when the
engine is hard to start, especially when water temperature is high.
• Check if the engine cranking speed is low.
[Chart]

Engine temp 1nspect using CONSULT data monitor.
sensor OR
1L
signal? Disconnect engine temperature sensor connector and check for any
change.
--- • Check engine sensor resistance value.
FUEL PRESSURE
lncrease fuel--Remove vacuum hose from pressure regulator or clamp return hose.
pressure to
check
CRANKING SPEED
~ Is battery normal?
L__ lnspect starting system.
EN-279
ECCS
(5) Difficult to start.. ............ Hard to start regardless of engine temperature.
[Analysis]
Spark are is created but air-fuel ratio could be incorrect.
• Check fuel pressure.
• Check fuel injection quantity. (Is engine temperature correction accurate?)
• Check if idling speed is controlled.
• Check if cranking speed is too low.
[Chart]
FUEL PRESSURE
Fuel pump LUse CONSULT active test mode to check fuel hose tension.
OR
Check if you can hear pump operation noise for five seconds after
turning ignition switch ON.
• Check if you can hear pump operation noise when cranking. -..___
In crease fuel-- Disconnect vacuum hose from pressure regulator and check for any
pressure change. (or clamp return hose)
Check for - --lnspect fuel filter for any clogging.

clogging

Engine ~ lnspect using CONSULT data monitor.
coolant te~~. L
OR
sensor signa! Disconnect engine temperature sensor connector and check for
any change.
ldling controlt • Check engine temperature sensor output voltage.

Check if AAC valve operation is normal (CONSULT active test).
Check if AAC valve is not fully closed.
Check AAC valve connector circuit for disconnection, loose
connectors.
IGNITION SYSTEM
lgnition l C h e c k in real-time diagnostic mode (CONSULT data monitor).
misfiring Check crank angle sensor output for missing pulses (CONSULT
data monitor mode or with oscilloscope ).
Is spark plug gap correct?
Check for any leak from high-tension cable.
lgnition timing-Check by advancing or retarding the angle.
normal
CRANKING SPEED
Check the battery.
É Check charged state.

Check starting system.
EN-280
ECCS
(6) Poor idling ............... Fast idling inoperative.
[Analysis]
This problem may have been caused by abnormal control of AAC valve and air regulator
as idling speed is controlled by these devices.
The air-fuel ratio and ignition timing also relate to thís problem.
(Chart]
IDLE CONTROL SYSTEM

Air regulator L
Is air regulator resistan ce normal?
operation Is air regulator seized?
AAC valve ~ Is AAC valve operation signa] shown?
Is AAC valve operation normal (CONSULT active test mode).
Is idle judgement ON? (CONSULT data monitor mode).
En gin e ---~L-
coolant temp
Check AAC valve circuit for breaks or loase connectors.
Check using CONSULT data monitor.
OR
signal? Disconnect engine temperature sensor connector and check for
any change.
• Check water temperature sensor output voltage.
AIR-FUEL RATIO
Enrich mixture - - lncrease fuel pressure (Disconnect pressure regulator vacuum
hose or CONSULT active test).
Lean mixture - - - Reduce the fuel pressure (CONSULT active test or apply negative
pressure greater than -500 mmHg).
EN-281
ECCS
(7) Poor idling .............Low idle rpm (after warm up).
[Analysis]
ldling speed is controlled by AAC valve. A low rpm means insufficient auxiliary air volume
through AAC valve.
[Chart]
IDLE CONTROL SYSTEM

AAC valve E l s AAC valve control signal issued?
operation Is MC valve operation normal? (CONSULT active test mode).
Measure resistance value of AAC valve and check seizure.
Check MC valve circuit for disconnection or looseness.
Input signa~ls idle judgement ON?
Lis air conditioner switch and neutral switch turned ON? (CONSULT
data monitor mode).
CHECK IGNITION TIMING FOR CORRECTION
EN-282
ECCS
(8) Poor idling .............. High idle rpm (after warm up).
[Analysis]
High idling can be caused by the following points:
• Low engine coolant temperature signal.
• Throttle valve switch (!die judgement) is OFF.
• Air conditioner switch or power steering switch is constantly in ON position.
• AAC valve is seized.
• Electricity is not conducted to air regulator.
• Air regulator is seized.
• Control unit adjustment volume is set to HIGH.
• Throttle valve is open.
• Air is sucked in.
[Chart]
coolant temp
;-e
IDLE CONTROL SYSTEM
Engine Check with CONSULT data monitor mode
OR
signal Disconnect engine temperature sensor connector and check for
any change.
• Check for engine temperature sensor resistance value.
• Check for engine temperature sensor output voltage.
Throttle sen--Check idle judgement signal with CONSULT data monitor mode or
valve sw by using tester.
AAC valve ---Is AAC valve control signa! present?

control Is AAC valve operation normal? (CONSULT active test mode).
Check AAC valve for seizure.
Disconnect AAC valve connector and clase the valve to see if
engine rpm lowers.
Turn off air conditíoner and power steering switch OFF and see if
ON signal is disconnected.
Check íf neutral switch is OFF or vehicle speed signal input is OK.
Air regulatorLCheck air regulator circuit far break or loose connectors.

Check air regulator for seizure.
C/U - - - Is adjustment knob set at HIGH position?

adj knob
OTHERS
Throttle valve --Is valve open? (Check for bent wiring).
Air suction - - - Block blow-by hose passage and check for any change.
EN-283
ECCS
·--......
(9) Unstable idling ............. Cold engine only.
[Analysis]
Since idling is unstable only when the engine is cold, the cause of this problem can be nar-
rowed down to the relationship between the engine temperature and idle control system.
lt also relates to the air-fuel ratio, ignition timing, misfiring etc.
[Chart]
IDLE CONTROL SYSTEM

Eng temp ---lnspect using CONSULT data monitor mode.
sen signa! • Check engine temperature resistance value.
• Check engine temperature output voltage.
MC valve~ Check that the valve is closed completely. Check that idle
L
adjustment is within specification.
Is MC valve operation normal? (CONSULT active test).
--......
AIR-FUEL RATIO
Adj the mixture- Use CONSULT active test mode to make the mixture rich or lean or
rich or lean disconnect pressure regulator vacuum hose or apply additional
vacuum.
IGNITION SYSTEM
Correct ign-----Advance or retard ignition timing and check for any change.
timing
lgnition Check crank angle sensor by real time diagnostic method
misfiring (CONSULT data monitor).
Check spark plug condition.
Check ignition system condition by real time diagnostic method
(CONSULT data monitor).
.·- ...
EN-284
ECCS
(10) Unstable idling .................After warm up.
[Analysis]
Relates to various factors including air-fuel ratio, ignition system and compression. lt is
necessary to determine factors, begínning with items that are easy to check.
• ldle rpm control system Check far AAC valve operation
• Air-fuel ration Check for fuel pressure
Check for injection quantity (Enriched?)
Check far air suction
• lgnition system Check ignition timing
lgnition misfiring (Missing signal pulse)
• Engine main unit Check for poor compression
[Chart]
IDLE CONTROL SYSTEM

,,,--. Disable ctrl - - Disconnect AAC valve connector and check for any change.
function
Control circuit Check if control signa! is present and check signa! condition.
Is AAC valve operation normal? (CONSULT active test).
Disconnect AAC valve connector and check by adjusting with IAS.
Check AAC valve for seizure.
Check if idle judgment is ON (CONSULT data monitor).
Check circuit for breaks and connectors for looseness.
AIR-FUEL RATIO
Enrich the---CONSULT active test or remove pressure regulator vacuum hose.
mixture OR clamp return hose.
Lean the ---Reduce the mixture ratio by using "FUEL INJECTION" in CONSULT
mixture active test mode, or applying vacuum greater than -500mmHg.
Stop ~ Perform CONSULT active test.
feedback ORL
Disconnect engine temperature sensor connector and check for
any change.
Air suction---Check vacuum line and blow-by hose.
IGNITION SYSTEM
lgnition timing--Advance or retard the ignition timing angle and check for any
change.
lgnition -iCheck ignition system by real-time diagnosis (CONSULT data
misfiring monitor mode ).
Check condition of the crank angle sensor by real-time diagnosis.
Check condition of the spark plug.
ENGINE MAIN BODY

Compression--Measure compression pressure (check valve timing, valve seats,
pressure piston rings etc.)
EN-285
ECCS
RB20E / RB25DE / R825DET / RB26DETT ENGINE
(11) Poor driveability............... Engine breathing.
[Analysis]
lt is necessary to first verify if the problem occurs during acceleration or during cruising.
1. During acceleration
• Engine breathing while accelerator pedal is depressed may be caused by
momentary misfiring or momentary occurrence of lean mixture (ie. no interrupt
injection).
• lnclination of engine during acceleration etc. can increase tension of harness or
air duct that can cause poor contact.
• Clogging in fuel system is cause far engine breathing. Sufficient fuel pressure
cannot be maintained during acceleratíon.
2. During cruising
• Lean mixture and engine breathing caused by poor feedback of air-fuel ratio data.
• Misfiring of ignition system caused by leaks.
• Poor contact or malfunction of signar system, use of low quality gasoline.
[Chart]
1. During acceleration
AIR-FUEL RATIO
Stop feedback1Perform CONSULT active test.
OR
Disconnect exhaust gas sensor.
Enrich mixture-Perform CONSULT active test or disconnect engine temperature
sensor and apply 600 O resistance after warming up the engine.
Throttle valve-Check idle judgement ON/OFF operation in CONSULT data
switch monitor mode.
Throttle sen --Check if output voltage varíes with throttle opening.
Fuel pressure-Check if fue! pressure is maintained even while racing the engine.
Air leak - - - - Check air duct looseness.
Air flow mtr - - Check output voltage.
output
IGNITION SYSTEM
lgnition----Check signal system (lgnition signal, crank angle sensor signar, air
misfiring flow meter signal) far instantaneous break by CONSULT data
monitor.
Check spark plug gap.
Check for any leak from high tension cable.
Check if ignition coi! power supply voltage is lowered.
lgnition _ _.....___ Check if fail-safe mode is not set due to a detonation sensor error.
timing
EN-286
ECCS
2. When cruising
AIR-FUEL RATIO
Feedback---Perform CONSULT active test.
function OR
Disconnect exhaust sensor connector.
.___ Perform exhaust gas sensor monitor diagnosis to see if exhaust gas
warning lamp (or control unit red lamp) is flashing or check by
CONSULT data monitor.
Check if exhaust gas temperature warning lamp (or control unit red
lamp) is flashing more than five times in ten seconds when engine
is running at 2,000 rpm, or check by CONSULT data monitor.
Throttle valve - Check idling contact point revolution.
switch
IGNITION SYSTEM
lgnition misfiring-Check for instantaneous break signal system using real-time
diagnosis (ignition signal, crank angle sensor signal, air flow meter
signa!) (Use CONSULT data monitor or oscilloscope).
1 ( 12) Poor driveability.............. Knocking.
[Analysis]
This problem may be caused by lean air-fuel mixture, incorrect ignition timing or
malfunctioning or engine main unit or cooling system.
• Lean mixture ratio may be caused by fuel enrichment correction not working during
acceleration, incorrect air flow meter output, incorrect air-fuel ratio feedback
correction.
• Errors in initial ignition timing or knock control system relate to the detonation caused
by incorrect ignition timing.
• Other causes can be excessively high cooling engine temperature, increased
compression ratio due to carbon deposits in combustion chamber etc.
[Chart]
AIR-FUEL RATIO
Fuel pressure- Check if fuel pressure remains normal when racing.
Enrich mixture [Enrich air-fuel ratio (CONSULT active test or disconnect pressure
regulator vacuum hose).
Disconnect engine temperature sensor and check for any change.
Stop feedbacklPerform by CONSULT active test mode
OR
Disconnect exhaust gas sensor connector and check fer change.
• lf any change is noted, check the fuel system (fuel pump, sensor system or clogging
in the system).
lnj clogging --Clean with engine conditioner.
ldle judgement - I s throttle sensor OFF when accelerating?
IGNITION TIMING
' - - - - - I s ignition timing normal?
Knock control -Check if detonation sensor error is indicated by self-diagnosis.
EN-287
ECCS
(13) Poor driveability............. Lack of output, poor acceleration, poor response.
[Analysis]
Lack of power, poor acceleration and poor responses are generally caused by insufficient
mixture quantity (lack of fuel, lack of air) ar incorrect air-fuel mixture ratio.
In the injection system, these problems are caused by lack of ignition energy or incorrect
ignition timing.
Lack of compression pressure and excessive friction dueto seizure in engine main body
are also causes of these conditions.
[Chart]
MIXTURE AIR QUANTITY, AIR-FUEL RATIO

Fuel pressure-Check if fuel pressure drops during racing (check for clogging
with fuel pump and fuel system).
Enrich mixture-Enrich by CONSULT active test or disconnect pressure regulator
vacuum hose.
Stop feedback-Check for change by CONSULT active test or disconnect exhaust
sensor connector.
lnjector clogging-Clean with engine conditioner (CONSULT active test or pour
conditioner into fuel filter, start engine then race engine).
Air flow meter-- Check output voltage.
output
IGNITION SYSTEM
Spark plug - - I s plug gap normal?
lgnition timing1 Is ignition timing normal?
Check by advancing or retarding ignition timing angle.
Check detonation sensor for abnormality (self-diagnosis for harness
disconnection and shorts).
lgnition energy LCheck ignition coil power voltage.
Check for any leak from high-tension cable.
ENGINE MAIN BODY

Compression - -Measure compression pressure (Also check valve timing, valve
pressure seat contact, pisten and rings).
EN-288
ECCS
1 (14) Engine stall when start driving.
[Analysis]
Engine stall is caused by misfiring when accelerator pedal is pressed or insufficient torque
when starting off.
• Misfiring
• Too lean or too rich air-fuel mixture ratio.
• Large error in ignition timing.
• Weak spark.
• lnsufficient torque
• Lean or rich mixture.
• 1nsufficient intake air quantity.
• lnsufficient compression pressure.
[Chart]
SELF-DIAGNOSIS
1 Check if occurrence of error is stored by self-diagnosis function.
AIR-FUEL RATIO
Enrich mixture-CONSULT active test or disconnect pressure regulator vacuum
hose.
Lean mixture - CONSULT active test or apply vacuum greater than -500mmHg
with vacuum hand pump to pressure regulator.
Stop feedbackTPerform CONSULT active test.
LºR
Disconnect exhaust sensor connector (race engine and back to
idle).
Check canister-Check by blocking purge line.
Throttle valve-Check if idle judgement is OFF when accelerator is ON (check by
switch CONSULT data monitor).
Check engine temperature sensor.
Throttle sensor -Check if accelerator opening signal is output.
IGNITION
Spark----Check spark plug condition (fouling, gap, electrodes).
lgn timing---Check if ignition timing is correct.
lgn error ---Check by real-time diagnosis (Perform CONSULT data monitor)
High-tension --Check resistance value and any leak.
cable
INTAKE AIR QUANTITY

1-I
-Check if throttle valve opens normally.
- -
Check far any leak from turbocharger system. Duct inspection.
COMPRESSION PRESSURE
Measure ---Check valve timing, valves for incorrect timing, pistan, ring for
compression damage.
EN-289
ECCS
1 (15) Engine stall while idling.
[Analysis]
Engine stall during idling may be caused by one of the fallowing conditions. (check idling
speed, and then check far misfiring).
• lmproper idling speed.
• lmproper AAC valve control (Check far delayed response).
• Excessively lean or rich mixture ratio.
• lgnition error.
• Poor connector contacts etc.
• Relation to electrical load ON-OFF.
[Chart]
SELF-DIAGNOSIS
,____---Check if occurrence of error is stored by self-diagnosis function.
IDLING CONTROL
Correct - - ~ Is idling speed normal or adjusted?
control Is AAC valve fully closed? (Check far loose connector).
Glose AAC valve fully and check for any change.
Is AAC valve control signa! issued?
(Race engine and check voltage ).
ls AAC valve operation normal? (CONSULT active test).
Disconnect AAC valve connector and check by adjusting IAS.
Check if idle judgement is ON.
AIR-FUEL RATIO
Air-fuel ratio - - Check if exhaust gas temperature warning lamp (control unit red
lamp) will flash more than five times in ten seconds when engine is
running at 2,000 rpm, or check by CONSULT data monitor.
Enrich mixture-Perform CONSULT active test or disconnect pressure regulator
vacuum hose.
Lean mixture--Perform CONSULT active test or apply vacuum greater than
-S00mmHg with hand pump to pressure regulator.
Stop feedback1 Perform CONSULT active test.
OR
Disconnect exhaust gas sensor (Set circuit from racing mode one
time and return to idling mode ).
Fuel pump---Check for pump stop.
Fuel system Race engine and check fuel pressure for drop.
clogging
OTHER
Poor contact --Using real-time diagnosis mode, check ignition signal, crank angle
sensor signal and air flow meter signal far instantaneous break and
missing pulses. (Use CONSULT data mode or oscilloscope ).
Spark plug --Check for fouling and plug gap.
EN-290
ECCS
1 (16) Engine stall while driving.
[Analysis]
Engine stall during cruising may be caused by misfiring. lf engine stalls during accel-
eration, it may be caused by misfiring or insufficient torque.
• Too rich or lean air-fuel mixture.
• lgnition error.
• lncorrect ignition timing.
• lnsufficient intake air quantity.
• lnsufficient compression pressure.
• Misfiring, fuel pump stop, etc. caused by poor electrícal contact.
[Chart]
SELF-DIAGNOSIS
~---Check if occurrence of error is stored by self-diagnosis function.
(1) When cruising
AIR-FUEL RATIO
Throttle valve-Check if idle judgement goes OFF at correct time.
switch
Feedback---Check if exhaust gas temperature lamp (control unit red lamp) wíll
flash more than five times in ten seconds when engine is running at
2,000 rpm, or check by CONSULT data monitor.
Stop feedbackLPerform CONSULT active test. OR
Disconnect exhaust gas sensor connector.
lntake air---Check for poor contact by CONSULT data monitor (real-time
quantity sig diagnosis).
IGNITION
lgnition timing-ls ignition timing correct?
lgnition - - - - Check ignition signal, crank angle sensor signal for missing pulses
misfiring in CONSULT data monitor.
(2) During acceleration

AIR-FUEL RATIO
Throttle valve-Check if idle judgement goes ON-OFF when acceleration pedal is
switch pressed and released (CONSULT data monitor).
Throttle sensor-Check if voltage output varies with throttle opening.

Feedback·---Check if exhaust gas temperature lamp (control unit red lamp) will
2,000 rpm, or check by CONSULT data monitor.
Stop feedback LPerform CONSULT active test. OR
lntake air L Check for poor contact by CONSULT data monitor.
quantity Check for air flow or leak after turbocharger operation.
MISFIRING
lgnition timing--Check if ignition timing is normal.
lgnition misfiring-Check ignition signal and crank angle sensor signal for missing
pulses in CONSULT data monitor.
EN-291
ECCS
(17) Engine stall when decelerating or immediately after stopping. ----.
[Analysis]
Reduced engine rpm when releasing accelerator pedal can lead to engine stall. Another
cause is misfiring.
• lncorrect adjustment of idling control.
• lncorrect air-fuel ratio.
• lgnition error.
[Chart]
IDLE CONTROL
ldling speedL Is idling speed normal? Is idle adjustment correct?
Check if AAC valve is fully closed.
Control ---r---Check if AAC valve control signal is output.
Check if AAC valve is OK.
Check if idle judgement is ON .
Check by disconnecting AAC valve connector (AAC fully closed).
AIR-FUEL RATIO
Stop feedbackIPerform CONSULT active test.
OR
Feedback - --Check if exhaust gas temperature lamp (control unit red lamp) will
2,000 rpm , or check by CONSULT data monitor.
Enrich mixture-CONSULT active test or disconnect regulator vacuum hose.
Lean mixture --CONSULT active test or apply vacuum greater than -500mmHg
with hand vacuum pump to pressure regulator.
IGNITION
lgnition ----Check ignition signal, crank angle sensor signal for missing pulses
misfiring in CONSULT data monitor.
ENGINE . A/T FUSION CONTROL

Control---- Carry out self-diagnosis.
EN-292
ECCS
(18) Engine stall when electrical loador power steering load is applied.
[Analysis]
Check if idling is increased when load switch is turned ON (AAC valve correction quantity
increases when load is applied).
• Check if ON signal is input from each switch.
• Check if AAC valve is operating.
[Chart]
IDLE CONTROL
ldling speed LIs idling speed normal? Is idle adjustment correct?
Check if AAC valve is fully closed.
Control É C h e c k íf AAC valve control signal is output.
Check if AAC valve is OK.
Check if idle judgement is ON.
Check by disconnecting AAC valve connector (AAC fully closed).
Input signals--Check if air conditioner switch and power steering switch signals are
provided (CONSULT data monitor).
EN-293
ECCS
3. DIAGNOSTIC SYSTEM
General
The performance of the diagnostic system has improved greatly with warning indication
to drivers, operation of the self-diagnostic system and application of the newly developed
electrical system diagnostic tester CONSULT.
Enhanced fault warning items

In cases when a fault occurs in the ECCS system while driving, the exhaust temperature
warning lamp will flash in the instrument panel to warn a driver. At the same time, the back
up function will actívate to ensure the safety of occupants and the vehicle.
Simplified trouble-shooting strategy

The following features have been incorporated for simplifying inspection and problem
diagnosis of the ECCS system. ----
lmprovement of self-diagnostic function

The diagnostic modes have been rearranged and the mode shift and display system have
been simplified.
1 Fault warning
0 2 sensor monitor By diagnostic connector lndicated by exhaust gas
2
Self-diagnosis installed near the fuse box temperature
-S-w-
it-ch-"O_N........_
/0 -F-,-,d-ia"""'g"-n-o-s-is_a_n_d_re_a_l_ti_m_e-l (also adjustable by ECCS warning lamp
diagnosis are included in the operations C/U adjustment volume (Also linked with
performed by CONSULT as explaíned in knob) ECCS C/U red lamp)
ítem 2 on the following page.
ª~ª ~- le/)
Short-circuit these ~ ...___.,.... i
terminals for
approx.2 seconds H
i- - - ---. then open the
~ :::;::;::;__,~2m/
terminals to
l;;!)( . )
~ ,1I11 change diagnostic
llt:::::-i:;¡:;;¡:;;::;::== =====
mode.
{Fuse block)
,M~oo
Exhaust gas temperature warning lamp
EN-294
ECCS
lntroduction of electronic system diagnostic tester for fault diagnosis
To enable use of newly developed electronic system diagnostic tester CONSULT, the
diagnostic function have been modified. Using the CONSULT will simplify complex diag-
nostic procedures.
CONSULT is a hand held type compact and light weight type tester device especially
designed for automotive service operations. lt can be used by connecting it to the diag-
nostic connector installed on the vehicle. This tester can permit data display, recording
and printing.
• OK or NG can be determined far each

Function test
system as a basic inspection
Self-d iagnosis • Self-diagnosis
• U sed to identify majar causes of fault
according to result from self-diagnosis.
• Input and output data from ECCS C/U
can be monitored and printed.
• Data can be recorded at the time of
Data monitor engine faults or stall. Modes can be Displayed data
• The following items are included in selected by can be read
this monitor item: touch-sensitive on
02 sensor monitor keys on the CONSULT
Switch ON/OFF CONSULT screen
Real time diagnosis
• Used to examine majar causes of
faults from self-diagnosis result and
Active test data monitor.
• Used to check actuator operation by
giving drive signal to actuator.
• Used to reduce additional operation
Operation support
when checking idling etc.
EN-295
ECCS
4. SELF-DIAGNOSIS
Self-diagnosis can be performed by indications from warning lamp (exhaust gas temperature
warning lamp) in the instrument panel display and ECCS control unit red lamp display or
by displaying data on the CONSULT screen.
Engine warning lamp display

There are two diagnostic modes. 1n each mode diagnosis is performed by operating the
diagnostic connector terminal installed on the vehicle. (Diagnosis can also be performed
by using the adjustment knob on the control unit). The diagnosis results are displayed by
exhaust gas temperature warning lamp in the combination meter and the red warning lamp
on the control unit.
Alarm: Faulty system indicated

lgnition switch "ON"
Mode 1 Fault warning by warning lamp flashing
! Normal: Warning lamp remains
Engine rev
OFF
lgnition switch "ON"
! Faulty: Faulty system is
Diagnosis mode shift indicated by flashing
Self-diagnosis ! code
Engine stop Normal: Flashing code "55"
Mode2 (with ignition switch displayed
"ON" position)
Self-diagnosis status
described above Lamp ON: Lean
0 2 sensor monitor
! Lamp OFF: Rich
Engine rev
(1) Fault warning mode (mode 1)

Operation and display
• Place ignition switch to ON position. lndicated by exhaust gas temperature warning lamp
Mode 1 is usually set by this operation. and ECCS C/U red lamp (these lamps are connect-
[Pay attention to the following as the ed).
following can also happen: Engine
lf the ignition switch is turned OFF in Display Condition
rev
the self-diagnosis mode and then
ON (lamp
turned ON few seconds later, the Stop
check)
self-diagnosis mode will be selected. In
Warning CPU back up
this case, the diagnosis mode must be
(lamp flashes
changed (see item (2}] Rev Flashing
when engine has
stopped)
Stop ON (lamp
Normal check)
Rev OFF
EN-296
ECCS
(2) Fault warning mode (mode 2)
• Place ignition switch to ON position. lndicated by exhaust gas temperature

Normally fault warning mode is set when ignition warning lamp in instrument panel and red
switch is turned ON. lt is necessary to select lamp in control unit (these lamps are linked
diagnostic mode. together).
Short-circuit. "CHK" and "IGN" terminals
connected on the diagnosis connector located on
the vehicle (inside fuse box) far approx. 2 sec.
then separate the terminals. Example: lndication of code number "43".
(Diagnosis connector)
0.4 sec x 3 0.2 sec x 4
íle~ 11 ttl
(The fault warning mode and self-diagnosis mode
ON~~
OFF ~ A p p r o x . 1 2 s e c ~
alternate each time the operation is performed).
• Stop the engine (lgnition switch in ON position).
lf the engine is operated in this condition the
monitor will change to next mode 0 2 sensor
monitor.
(Reference) Name of diagnosis connector terminals
CHK: Diagnosis start (Check)
JGN: lgnition power supply
CLK: Transmíssion synchronízation signal (clock)
RX: ECCS C/U data reception
TX: ECCS C/U data transmission
Earth
Diagnosis item
• 1° and 120° signal is not input far a certain period

Crank angle sensor signa! of time after starting the engine.
11
system • lncorrect signal waveform
(abnormal linkage between 1° and 120° signal).
• Hot wire dísconnection.
• Disconnection or short-circuit in air flow meter
power supply, earth or signal system.
• Signal output is below 1V far a certain period of
12 Air flow meter signal system
time during engine operation.
• Signal output is over 2V far a certain period of
time at engine stall or when ignition switch is in
OFF to ON.
Engine coolant temperature • Disconnection ar short-circuit in engine coolant
13
sensor signal system temperature sensor signal system.
• lgnition signa! is not generated even though the
21 lgnition signal system
crank angle sensor signal is entered.
34 Knock sensor signal system • Disconnection or short-circuit in knock sensor.
43 Throttle sensor signal system • Disconnection or short-circuit in throttle sensor.
• Disconnection or short-circuit in A/T transmission
54 A/T transmission system
system.
-- 55 No error
• No abnormality found in any of above signa!
system.
EN-297
ECCS
R820E / RB25DE / RB25DET / RB26DETT ENGINE
To erase memory
Stop the engine in mode 2 and short-circuit the terminal "CHK" and "IGN" of the diagnostic ·-
connector for over 2 seconds. Then OPEN to erase every diagnosis ítem.
(3) 0 2 sensor monitor mode (mode 2)

• Place ignition switch in the "ON" position. lndication is made by the warning lamp
At this time check the mode is in (exhaust temperature warning lamp) and
"Self-diagnosis" mode. lf in "Fault warning"ECCS C/U red lamp.
mode, short-circuit "CHK" and "IGN" terminals
• During air-fuel ratio feedback control.
for approx. 2 seconds then OPEN to change the OFF: 02 sensor output is 'RICH'
mode. ON: 02 sensor output is 'LEAN '
(Reference) The lamp ON and OFF indica-
• Rev the engine. tion is the same as that of the air-fuel ratio
Caution: feed back correction coefficient indicated by
The mode cannot be changed when the engine is the red lamp in the former control unit.
running.
• Air-fuel ratio feedback control is clamped:
Status immediately befare clamping is
maintained.
• Air-fuel ratio feedback control is faulty:
OFF
Example:
ON (lean) n ílfL
OFF (rich) ~ ~
. { Lean: A/A+Bx100
1 cycle duty ratio Rich: B/A+Bx 100
The status of air-fuel ratio is indicated by the

duty ratio in one cycle.
EN-298
ECCS
FAIL-SAFE FUNCTION AND BACK UP FUNCTION
Fail-safe function ensures the safety of the driver and the vehicle by using the control unit
control signals in case of an error in an important system device.
The back up function ensures normal vehicle operation when an error occurs in an impor-
tant sensor. The control unit will ignore the signal sent from a failed sensor and outputs
prearranged control signals.
The fault alarm mode is set when the back up function is operating, and the exhaust gas
temperature warning lamp will flash in the instrument panel to warn the driver.
• Fix ignition timing at set • Exhaust temperature

Error detected in ECCS C/U value warning lamp turns on
CPU back up • Decrease vehicle
internal circuit • Fix fuel injection at start,
idling and driving speed at CPU back up
When crank angle sensor
_,,...-. Crank angle sensor signal ( 1° or 120°) is not • Fix ignitíon timing at set ('11' is indicated in
back (RB20E only) displayed for over 3 seconds value self-diagnosis mode)
when engine is started
lntake air quantity signal is • Fix fuel injection pulse
('12' is indicated in
Air flow meter disconnected during engine width at set value
self-diagnosis mode)
operation • Fuel cut at 2000rpm
Engine coolant ('13' is indicated in
Short-circuit or disconnected • Enable normal driving
temperature sensor self-diagnosis mode)
• Maximum 5° engine is
Knock sensor Short-circuit or disconnected delayed in knock control
area.
Throttle sensor Short-circuit or dísconnected • Enable normal driving
At idling condition (ídle sw
'ON', neutral SW 'ON', vehi- • Fuel cut (Cut and
AAC valve ele speed below 8km/h) the recovery, idle hunting is
engine rev is extremely high repeated}
(target rev + over 700rpm)
EN-299
ECCS
ECCS C/U INPUT AND OUTPUT SIGNAL MODE APPLICATION
Air flow meter

Engine coolant temp sensor
• • •
• •
Battery voltage
•
ldleSW
• • •
Throttle sensor
ldle determination
• •
(Throttle sensor) • • •
•
lgnition (START) signa!
Air conditioner, neutral, power
• •
steering oil pressure SW • •
•
•
. lgnition signa! •
(lgnition
tíming) • •
(lgnition
timing)
•
(lgnition
timing)
• • • •
Air conditioner relay
•
Fuel pump relay
• • • •
Power balance
• •
EN-300
ECCS
R820E / RB25DE / R825DET / RB26DETT ENGINE
5. CONSULT
Connect CONSULT to diagnosis connector on the
vehicle (inside the fuse box). Data is displayed on the
CONSULT screen as touch-sensitive keys. The exhaust
gas sensor monitor, switch ON / OFF operation and
real-time diagnosis are performed using data monitor
mode.
FUNCTION TEST
This is a basic fault diagnosis. CONSULT will diagnose each system and displays OK or
NG in the monitor.
Self-diagnosis result Output self-diagnosis result

ldle determination Diagnose ídle switch by fully opening or closing the accelerator pedal
Diagnose throttle sensor system by fully opening or closing the accel
Throttle sensor
erator pedal
Neutral SW Diagnose neutral switch system by moving the select lever
Diagnose fuel pump system by checking the fuel pressure pulsation
Fuel pump
when the fuel tube is connected
Diagnose starter signal system by starting the engine. Also displays
Starter signal the battery voltage, average battery voltage while cranking, engine
coolant temperature, cranking rev and air flow meter output voltage.
Diagnose power steering signal system by rotating and straightening
the steering wheel.
Diagnose vehicle speed sensor system when the vehicle speed is
o ver 1O km/h.
Reads ignition timing using timing light. lgnition timing is diagnosed by
lgnition timing test
corresponding read value with set value.
Diagnose air-fuel ratio from 0 2 sensor output and feed back system
Base air-fuel ratio test (fuel ínjection control, ignition timing control, vacuum system etc.)
when at 2000rpm wíth no load.
Diagnose combustion condition of each pipes by stopping each injec-
Power balance
tor pipes one at a time and checking the change in engine rev.
Diagnose AAC valve system by checking the change in engine rev
AAC valve
when AAC valve opening is 0%, 20% and 80%.
Caution:
There is no OK or NG display far the fue! pump and ignition timing diagnosis. lt is the
checker's decision to determine OK or NG.
EN-301
ECCS
• Connect CONSULT to vehicle diagnosis

connector.
ll'., TEST MODE SELECT Oj
• Place ignition switch to ON position or rev the 1 PROGRAM MODE 1
engine. 1 MANUAL MODE 1
• Select "Function test" on touch-sensitive
screen.
• Select "Program mode" or "Manual mode"
and carry out diagnosis.
Follow the procedure on the CONSULT
screen.
♦IDLE DETERMINATION♦
PRESS 'START' WHILE

"FULLY OPENING" THE
ACCEL PEDAL.
[ PASS l~I__ST_A_R_T_ _
Caution:
lf diagnosis connector is removed while carrying out the function test, the mode will remain
in 'Function test mode' until the ignition switch is placed in OFF position.
SELF-DIAGNOSIS MODE
Diagnosis item is same for (1) and (2). lt will be displayed in faulty system name.

connector. ◊ SELF-DIAGNOSIS ◊ □
• Place ignition switch to ON position (engine RESU LT
stopped). FAULTY SYSTEM TIME Displays how

• lnspect in "Self-diagnosis result". ENG COOLANT TEMP SEN 0
many time the
vehicle has
• To print touch 'Print' key.
travelled since last
• To erase memory touch 'Erase' key. faults has been
detected.
lf fault is currently
::==E=R
=A=S
= E=::;,11=== =A=R
=T= ~¡ detected, it will
31
'--- -,--- ~-~--- - - ~-show 'O'.
EN-302
ECCS
DATA MONITOR
The data monitor can be utilized when performing troubleshooting or trouble diagnosis ac-
cording to self-diagnosis result. CONSULT will monitor and print the ECCS C/U input and
output signal data.
Monitoring items and description

11-llíttlltlifflltl~'! ~!illt.t1ffi fl11f~it~1ililii8111ilt'-il11;imtlitffl •••i• 1111rtümmt~~llj~t~l
Engine rev calculated from crank System decrease when
CAS.RPM (POS) rpm
angle sensor signal below idle rev
Voltage is set at approx. 0V
AIR FLOWMTR V Air flow meter output voltage
when engine is stopped
Fail-safe is activated when
Converted into temperature from
ENG COOLANT short-circuited or disconnect-
ºC engine coolant temperature sensor
TEMP SEN ed and temperature is set at
output voltage
set value
Set at 0V when engine is
0 2 SENSOR V 0 2 sensor output voltage
stopped
A/F ratio of 02 sensor signal during
A/F ratio feedback control
RICH: Detects rich mixture and con-
When clamped, the status
(RICH/ trol is operated to reduce mixture
0 2 SEN MTR just befare clamping is
LEAN) ratio
indicated
LEAN: Detects lean mixture and
control is operated to increase mix-
ture ratio
Value calculated from vehicte speed
VEHICLE SPEED SEN km/h
sensor signal
-
BATTERY VOLT ECCS C/U power voltage -
V
THROTTLE SEN Throttle sensor output voltage -
OFF is displayed irrespective
STARTERSIG of starter signal after starting
engine
(ON / ON/OFF setting is determined from Determined by throttle
IDLE DETERMINATION
OFF) each signal output sensor output
AIRCON SIG
NEUTRALSW -
POWER STEERING SIG
INJ PULSE msec
Value computed by control unit
IGNITION TIMING BTDC Set value is displayed when
Value computed by control unit '%': engine is stopped
MCVALVE step
proportional solenoid system
Mean value of A/F ratio feedback Set value is displayed when
A/F RATIO CORRECTION %
correction factor for each cycle engine is stopped
AIR CON RELAY (ON / Control condition computed by
FUEL PUMP RELAY OFF) ECCS control unit
PWRVOLTAGE Displays measured value of probe voltage
PULSE Displays measured value of pulse probe
EN-303
ECCS
• Connect C0NSULT to vehicle diagnosis

connector. ~ONITORIN~ NO FAULT □
CAS.RPM(REF) 850rpm
• Run the engine or drive the vehicle. AIR FLOW MTR 1.58v
• Select item in "Data monitor". ENG COOLANT TEMP SEN 68ºC
02 SEN 1.17V
• Select "START monitoring" key. 02 SEN MONITOR RICH
VEH SPEED SEN Okm/h
BATTERYVOL 14.0V
STARTER SIG OFF
1 START MONITORING 1
#v1EMORIZING 5/it{NO FAULT □

CAS.RPM (REF) 850rpm
AIRFLOWMTR 1.57V
ENG COOLANT TEMP SEN 69ºC
O2SEN 1.18V
02 SEN MONITOR RICH
VEH SPEED SEN Okm/h
BATTERYVOL 14.0V
STARTERSIG OFF
STOP MONITORING
0 2 SENSOR MONITOR
0 2 sensor output voltage and "RICH" or "LEAN" is displayed.
• Connect C0NSULT to vehicle diagnosis

connector. *MONITORIN~O FAUL-0
• Run the engine or drive the vehicle. 02 SENSOR 1.19V
• Select '02 sensor monitor' or '02 sensor' in 02 SENSOR MONITOR RICH
"Data monitor" to carry out inspection.
• Select "STAR MEM0RIZING" key to
memorize.
START MONITORING
EN-304
ECCS
SWITCH ON / OFF
The ON / OFF status of each switch is indicated.

connector. ~ONITORING#-JO FAUL"{]
• Run the engine or drive the vehicle. STARTER SIGNAL OFF
• Select each switches in "Data monitor". IDLE DETERMINATION ON
AIR CONO SIGNAL OFF
• Set operating condition far applicable switch NEUTRALSW ON
and check ON / OFF display. POWER STEERING SIG OFF
START MONITORING
Diagnosis items
• lgnition switch "start" signa! system
• Throttle sensor signal system
• Neutral switch signal system
• Power steering switch signal system
• Air conditioner switch signal system
• Fuel pump signal system
REAL - TIME DIAGNOSIS

Although the diagnosis items are the same as those listed in self-diagnosis switch ON /
OFF mode, this diagnostic mode provides higher detection capability than self-diagnosis
mode for the crank angle sensor, air flow meter, ignition primary signal and the fuel pump.

connector. ♦ REAL-TIME DIAG ♦ Q
• lnspect using the "DATA MONITOR" real-time ENG COOLANT TEMP SENS ~
diagnosis mode.
1 DATA MEMORIZED
~EMORY 21~ATA DISPLAY
EN-305
ECCS
ACTIVE TEST
The active test mode is used to examine the problem diagnosis according to self-diagnosis
results and data monitor results. CONSULT will give driving signals to the actuator while
isolating the on-board ECCS C/U to check if the actuator is functioning properly.
Monitoring items and description
Fuel injection Changes air - fuel ratio

AAC valve opening Sets control value (opening)
Engine coolant temperature Sets engine coolant temperature
lgnition timing Sets delay angle correction value
Fixes AAC valve opening degree and stops specified injector op-
Power balance
eration. lt will display the current engine rev.
Fuel pump relay Turns ON / OFF
Self-learning cont Clears leaned air-fuel ratio feedback correction factor.

connector. ♦ ACTIVE TEST ♦□
• Run the engine or drive the vehicle. ENG COOLANT TEMP SEN 20ºC
• Select item in "Active test".

• Touch "START" key to set the value.
CAS.RPM(POS) 800rpm
INJ PULSE 3.7msec
IGN timing 15BTDC
1Qu 11 UP 11 DOWN 1§:J
OPERATION SUPPORT
CONSULT can be used as an aid far idling checks and other engine tune-up operations. lf .·---..
an instruction is sent to ECCS C/U, it will perform control and displays the input and output
signal data being used. The actual tune-up operation must be performed manually by a
mechanic (far example, tuning adjustment screw etc.)
Support items and description
AAC valve adjustment Fully clases AAC valve and display idle rev
Throttle sensor (installation position) Displays throttle sensor output voltage when the throttle
adjustment valve is fully closed
EN-306
ECCS
RB20E / RB26DETT ENGlNE
6. BASIC INSPECTION (RB20E / RB26DETT)
A A
Switches input sh:mal insoection *MONITORIN~O FAULg]
• Select the following switches in the
"DATA MONITOR" mode. 00 STARTERSIG
IDLING
OFF
OFF
a) Start signal Replace or
AIR CON SIG OFF
b) ldling NG repair if fault NEUTRALSW ON
c) Air conditioner signal is detected. POWER ST SIG OFF
d) Neutral switch PWR LOAD SIG OFF
e) Power steering signal
• Check ON / OFF switch operation. START MONITORING
• Connect a check adapter between
ECCS C/U and the harness A
connector and use volt meter to
inspect ON / OFF switch opera-
tion.
Start signal
® § ©i]
lgnition sw ON: Approx. OV
lgnition sw START:
ldling:
Power vol
ldling (after engine warm up)
Approx. 0.4V
Accel fully open: Approx. 3.8V
Air conditioner signal B
d J
A/C OFF: Power voltage ♦ SELF-DIAGNOSIS ♦ □
A/CON: Approx. OV RESULT
Neutral SW FAULTY SYSTEM TIME
ENG COOLANT TEMP SEN O
Neutral: OV
Not neutral: Approx. 4.5V
Not steered Approx. 4.5V
Steered Approx. OV
ERASE 11 PRINT
B 1 OK
Self-diagnosis r~sult c~nfirmation Carry out B
• Operate self-d_1agnos_1s mode (!) NG necessary \ 1 /
• Confirm self-d1agnos1s result. inspection
• Set to "Self diagnosis mode"
(mode 2).
@ "CHECK-
-~/
'
• Check the code number using
engine warning lamp flashes.
/
/1 ¡ \
Engine warning lamp
e 1 OK e
lnjector operation inspection
Place a sound scope or screwdriver t. .
. . d h k f . . t Inspec mJ
on t he mJector an c ec or 1nJec or , - t • •t
.
operat 10n .
nrnse . k) w h'II e NG con ro 1 c1rcu1
(t·1ck , t·1ck , 11c
cranking.
1 OK
TOD
EN-307
ECCS
RB20E / RB26DETT ENGINE
o D
Fuel pump operation inspection@ lnspect fuel ♦ ACTIVE TEST ♦0
• Select "Fuel pump relay" in fm ~
pump control
NG
active test. Check for operation circuit FUEL PUMP RELAY ON
noise when "START" is selected.
• Check for fuel pump operation@ MONITORING
noise for 5 sec after turning CAS.RPM (POS) Orpm .
ignition switch to ON position.
E OK
1
1 START l[1NTERM1rll STOP
Fuel pressure inspection
• Select "Fuel pump" in function00 lnspect fuel D
test. Check for pulsation on the
fuel hose.
- NG
hose for clogs,
bent or torsion
• Pinch the hose between fuel filter
and the fuel gallery while fuel pump
is operating and check for tension
or pulsation.
® / I
OK
1 E
FINISH
♦ FUELPUMP ♦
CAN YOU FEEL A PULSE

EVERY 3 SECONDS OR CAN
YOU HEAR FUEL PUMP RE-
LAY OPERATION NOISE?
¡ PASS ll NO t1 YES
EN-308
ECCS
6. BASIC INSPECTION (RB25DE / RB25DET)
A A
Before engine start

• Look for fault indication and check recent
service record.
• Check the following in the engine bay:
• Is hamess connector connected?
• Are there any cracks or torsion on
vacuum hose? connected correctly? B
• Is harness connected correctly with no Connect
'✓
disconnection.
\
B Diagnosis
""-. connector
Connect CONSULT ""- (behind fuse box)
Connect diagnosis connector to CONSULT CONSULT
and place ignition switch to ON position.

Select "ENGINE" from the item menu.
e
e
NG
1 Does the engine start? : To E
D OK
ldle adjustment screw primary stage set

up revolution inspection
• Select "AAC valve adjustment" in
(j)
NG
- ~~-~-
D
~
- - -
~
ing indicator : -
\,,..::::.:_--:.-.-:.--
-~- ·- '; ,,
"Operation support" mode.
• Check that engine rpm will drop to 600
~ 700 rpm when "START" is pressed (N
range). 'º 20 30
0 , 1
• Check that engine rpm will drop to ~ (BTOC~)

600 ~ 700 rpm when ECCS C / U '&
adjustment volume is turned right until it o
stops. *MONITORINGi:¡,NO FAULrn
OK CAS.RPM (POS) 787rpm

For engine rpm adjustment
use idle adjustment screw. CAR SPD SEN 0km/h
E
lgnition timing inspection
After warming up the engine, idle the engine
and inspect the ignition timing using timing START MONITORING
light. For more information refer to "ldle rev, NG E
ignition timing, air-fuel ratio inspection" ..__
section earlier in the manual.
lgnition timing (BTDCº) : 13 - 17°
1
Rotate crank angle sensor
TO F
to adjust ignition timing.
EN-309
ECCS
RB25DE / RB25DET ENGlNE
F F
Throttle sensor idle position inspection ♦HROTTLE ADJ♦
• Select "THROTTLE SENSOR ADJ"
ADJ MONITOR
from operation support mode.
THROTTLE SENS 0.40V
• Check that throttle sensor output voltage is
approx. 0.4 - 0.5V (fully closed) and ldle MONITOR
position is ON. CAS.RPM {REF) Orpm
• Use voltmeter to measure throttle sensor fa>\ IDLE ON
output voltage. Make sure it is between '&
approx. 0.4 - 0.5V (fully closed).
F
G
Switches input signal inspection
• Select the following switches in the "DATA
MONITOR" mode. ~
a) Start signal ~
b) ldling
e) Air conditioner signal
d) Neutral switch
e) Power steering signal G
• Check ON / OFF switch operation.
* MONITOR *No FAULTD
• Connect a check adapter between
ECCS C/U and the harness connector STARTER SIG OFF
and use volt meter to inspect ON / OFF IDLE ON
switch operation. ® A/C SIG
NEUTRAL SIG
OFF
ON
Start signa! P/S SIG OFF
lgnition sw ON: Approx. OV
lgnition sw START: Power voltage
ldling (after engine warm up)
START MONITORING
ldling: Power voltage
Accelerator fully open: Approx. OV G
Air conditioner signal
NC OFF: 7.0-10.0V
NCON: 0.5~0.7V
Neutral SW
Neutral: ov
Not neutral: 8.0~10.0V
Power steering signa!
Not steered Approx. 8V
Steered Approx. OV
H H
Self-diagnosis result confirmation
• Operate self-diagnosis mode.
• Confirm self-diagnosis result. NG
• Set to "Self diagnosis mode" (mode 2),
-
• Check the code number using engine
warning lamp flashes.
IOK Carry out necessary
TO 1 procedure
EN-310
ECCS
H
lnjector operation inspection NG 0sELF-DIAGNOSIS ◊ □
Place a stethoscope or screwdriver on the
FAULT SYSTEM TIME
injector and check for injector operation
ENG COOLANT TEMP SEN O
noise (tick, tick, tick) while cranking.
OK Check injector
control circuit
J
Fuel pressure inspection @ NG
_IL-1_P_R_IN_T_
,.____ERA_S_E
• Select "Fuel pump" in function test.
Check for pulsation on the fuel hose.
• Pinch the hose between fuel filter and
the fuel gallery while fuel pump is
operating and check for tension or®
pulsation.
OK
Check fuel supply system
for clogs, twists or bends.
J
Finish
J
POWER SUPPLY & EARTH CIRCUIT FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM

1. POWER SUPPLY ANO EARTH CIRCUIT
F/L-6 ECCS relay

¡------ - - - -- - - --~,-~3 -fg
1191w"""2--..-[=--j-1'1::
[ 5 3, !
m
o
o
(/)
:~ "L
116
__J
20 t------t
.
A A
Power supply inspection @ '¡.:'.¡ MONITORING*NO FAULT
• Place ignítion switch in the ON position. OK
CAS.RPM (POS) 1062rpm
• Check power voltage using "battery voltage" - POWER VOL 14.0V
in data monitor mode.
• Use tester to measure power voltage
between ECCS C/U terminal 49, 50
and body earth.
START MONITORING
B
Ground circuit inspection A
• Place ignition switch to OFF position.
NG Remove ECCS C/U harness con-
I ECCS C/U connector 1
nector. 9 59
• Check far harness continuity between
ECCS C/U terminal 1O, 20, 107, 108,
116 and body earth.
lf NG repair faulty harness or connectors.
B
1
FINISH
e
Harness continuity inspection
!ECCS C/U connector !
• Place ignition switch to OFF position. ,,,u ~
• Disconnect ECCS C/U and ECCS relay har- NG f-----
ness connector.
• Check far continuity between ECCS C/U termi-
nal 49, 59 and ECCS relay terminal 3.
OK 1 Faulty harness or connector.

TOO
EN-312
POWER SUPPLY & EARTH CIRCUIT FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
D e
Voltage inspection between ECCS C/U
terminal and earth
• Place ignition switch to ON position .
IECCS C/U connector I
• Measure power voltage between ECCS
relay terminal 2, 3 and earth.
lf NG place ignition switch to OFF position.
NG
-"L 1~1 ~
5 3
lnspect the continuity between ECCS relay
and the battery.
l 1 2
D
OK
1 Repair faulty harness or connector. 15 3,t-----,
[i 2'+-->----,j
E
Output signal circuit inspection
Check for continuation between ECCS NG
C/U terminal 16 and terminal 1.
OK
lnspect the following: E
lgnition coi! harness connector.
Harness between ECCS C/U and
~I
[lt ID 00
E-CC_S_C_/U_co_n_n-ec-to~r1
ECCS relay. 16
lf NG repair faulty harness or con-
nector.
lliJ
Component parts inspection NG
,___
• Check ECCS relay.
OK
1 Repair ECCS relay
lnspect ECCS C/U terminal for any damage

and ECCS C/U connector connections.
EN-313
CRANKANGLESENSORSYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
2. CRANKANGLE SENSOR SYSTEM (SELF-DIAGNOSIS DISPLAY 11)
- ---------
IGN ECCS relay
1 2 16
49
5 - 3 IGN TIMING CTRL
59
Crank an le sensor
120° sígnal
~ 1 51
41 m
(")
(")
1º signal 2 42 (1) FUEL INJ CTRL
Power supply 3 52 Q
e
Earth 4 50
, . - - - - [ IDLE SPEED CTRL
A A
Power supply inspection
• Place ignition switch to OFF position. lit €)
• Remove crank angle sensor harness con-
~
nectors. NG
• Place ignition switch in the ON position.
• Use tester to measure the voltage
between terminal 3 and body earth.
OK
B
lnspect the following:
Check the continuity between crank [:it eJ (00
angle sensor terminal 3 and ECCS relay 1 ECCS C/U connector 1
terminal 3. 42, 52, 41 , 51
lf NG repair faulty harness or connectors.

[]]
B
Input signal circuit inspection
• Place ignition switch in the OFF position.
• Disconnect ECCS C/U harness connec-
tors.
• Check for continuity between crank angle 1_N_G_,,
sensor terminal 2 and ECCS C/U terminal
42, 52 (1° signal), between crank angle
sensor terminal 1 and ECCS C/U terminal
41, 51 (120º signal).
OK
1 Repair faulty harness or connector
TOC
EN-314
CRANK ANGLE SENSOR SYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
e e
Input signal inspection '-:(zMONITORING -¡'.~¡NO FAULT
• Connect crank angle sensor and ECCS CAS.RPM (REF) 662rpm

C/U harness connectors. AIR FLOW MTR 1.02V
• Use "CAS. RPM" in data monitor ENGTEMPSEN 81°
mode to measure engine speed.
@ EXH SEN 0.18V
. Measure the voltage between ECCS

THROTTLE SEN 0.38V
C/U terminal 41 , 42, 52,51 and ® NG

INJ PULSE 3.0msec
ground. START MONITORING
~Jfil l ~St~1•1~•!M i l tf;ffif~j*f-~¡ ~i.ti.ffilftifl&lf~1

lgnition SW ON 0V or approx.5V 0V or approx.5V e
Cranking Approx. 5V Approx. 2 ~ 3V
ldling Approx. 0.3~0.7V Approx. 2 ~ 3V ~ ~tl) oo ID
1 ECCS C/U connector 1
42,52,41, 5i
~
OK
Component parts inspection
• Check crank angle sensor.
lf NG replace crank angle sensor.

EN-315
A!R FLOW METER SYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
3. AIR FLOW METER SYSTEM (SELF-DIAGNOSIS DISPLAY 12)
ECCS relay
2 1
16
3 -5 49
1-----~ FUEL INJ CTRL
Air flow meter

&AIJ 59
rn
()
lntake air qty sig 2 f - - - - - - - - - - l ~ - - - . i 27 ()
(f)
Power ground F 3 ()
Signal ground E 4 1------------.- -___. 26

---
e
1------......, IGN TIMING CTRL
Earth A 5 J-----_ _ _ _ ___,
A A
• Place ignition switch in the OFF position . l:d Eü~
•
Lfi¡
Remove air flow meter harness
connector. NG
• Place ignition switch in the ON position .
• Use tester to measure the voltage be-
tween terminal 3 and body earth.
OK 8
• Check for continuity between air
flow meter terminal 5 and ECCS
relay terminal 3. 6
lf NG repair harness or connectors.
8
Ground circuit inspection
• Place ignition switch to OFF position .
• Remove ECCS C/U harness connectors . NG
•
e
Check for continuity between terminal 4
and ECCS C/U terminal 26.
OK
1 Repair harness or connector. 1ECCS C/U connector 1
e 26
Input signal inspection

Check for continuity between air flow meter NG
terminal 2 and ECCS C/U terminal 27 (intake
air quantity signa!).
OK
1Repair harness or connector.
TOO
EN-316
AIR FLOW METER SYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
D D
Input signal inspection ·{~ MONITORINGf¡ NO FAULT
• Connect air flow meter and ECCS C/U
harness connectors. AIRFLOWMTR 1.02V
• Use "AIR FLOW METER" in data ~ ENG TEMP SEN 81ºC
monitor mode to measure input signal. ~ EXH SEN 0.18V
THROTTLE SEN 0.40V
• Measure the voltage between ECCS fa\ INJ PULSE 3.0msec
C/U terminal 27 and body earth. ~
START MONITORING
NG
D
Cranking Approx. 1V
ldllng Approx. 1 .1 V
1 ECCS C/U connector l
27
OK
!L_yJl
...+- r--,.,.' - ~
..__ _·,rn
• Check air flow meter.
lf NG replace air flow meter.
lnspect ECCS C/U terminal far any damage

EN-317
WATER TEMP SENSOR SYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
4. WATER TEMPERATURE SENSOR SYSTEM (SELF-DIAGNOSIS DISPLAY 13)
Engine temperature sensor FUEL INJ CTRL

1---- - -- ~-28 m
(")
f - - -- - - - - - 30 () IGN TIMING CTRL
(/)
()
e IDLE SPEED CTRL
A A
• Place ignition switch in the OFF position .
• Remove engine temperature sensor har- 2 1
ness connector.
NG
..__
rv1
i
• Use tester to measure power voltage
between terminal 1 and body earth.
Voltage: Approx. 5V
B
OK
1 Repair faulty harness or connector. 1
B 2
Earth circuit inspection [fil
• Place ignition switch in the OFF position. NG
. Check for continuity between terminal 2
and body earth.
OK
1 Repair faulty harness or connector.
e
e ·/:t MONITORING'¡.~NO FAULT
Input signal inspectlon ENG TEMP SEN 78°C
• Use "ENG TEMP SENSOR" in data @
monitor mode to check engine coolant
temperature.
NG
---
• Check the power voltage between
ECCS C/U terminal 28 and earth. ® START MONITORING
lgnition switch in ON position
Eng temp Approx. 20°C: 3V
Approx. 80°C: 1V e
!2ilE OO
OK Component parts inspection 1ECCS C/U connector 1
28
• Check water temperature sensor.

. --•..
EN-318
IGNITlON SYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
RB25DE / RB25DET ENGlNE
5. IGNITION SYSTEM (SELF~DIAGNOSIS DISPLAY 21)
Power transistor
ECCS relay
1~2
5~-
10 11
A A
Circuit function inspection ♦ SELF-DIAG RES ♦ 0
• lnspect using "Power balance" in function
OK FAILURE DETECTED TIME
test mode.
• Check if engine rev will decrease 00 IGN SIGNAL PRIMARY O
momentarily.
B FINISH
ERASE 11 PRINT
Earth circuit inspection
. Remove power transistor unit harness NG
-
A
connector. .OWER BALANC~ □
• Check for harness continuity between INSPECT THE BALANCE
terminal E and earth. OF EACH CYLINDER BY
STOPPING INJECTOR
OK OPERATION FOR EACH
1 Repair faulty harness or connector 1 CYLJNDER.
TOC PASS 11 START
. , 'T·s·T
IECCS C/U connector ~
11
EN-319
IGNITION SYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
e
Output signa! circuit inspection
• Remove ECCS C/U harness connector.
• Check for continuity between following
terminals:
ECCS C/U terminal 1 & 2 NG
ECCS C/U terminal 12 & 2
ECCS C/U terminal 1O & E
ECCS C/U terminal 20 & E
OK
1 Repair faulty harness or connector. l
D
Output signal inspection
• Connect power transistor unit and ECCS
C/U harness connectors.
• Check for power voltage between ECCS NG
C/U terminals 1, 2, 3, 11, 12, 13 and body
earth.
Cranking: Approx. 0.2 ~ 0.3V
ldling: Approx. 0.2 ~ 0.3V
2500rpm: Approx. 1V
OK
1 Repair faulty harness or connector. ¡
.Component parts inspection

Check power transistor unit.
lf NG replace power transistor unit.
OK

EN-320
0 2 SENSOR SYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
6. 0 2 SENSOR SYSTEM (SELF-DIAGNOSIS DISPLAY 15)
1----------29
1----------15 m
o
o
en
o
1----IA/F ratio feedback ctrl 1
A
A
Function inspection - 1
• Warm up the engine . @ OK
♦ BASE /VF RATIO TEST ♦
• lnspect using "Base aír-fuel ratio" in HOLD THE ENGINE SPEED

AT 2000+/-200rpm ANO PRESS
function test mode. 1 START.
B NG FINISH
1
T000 2000 2200
Function inspection - 2
• Start the engine. 00 PASS
~----~
11 START
• Hold the engine at 2000 rpm and carry OK
out inspection using "02 SENSOR" (out- 8
put voltage and "0 2 SENSOR MONITOR" f¡MONITORING*NO FAULT
(lean, rich) in data monitor mode.

• Measure the voltage between ECCS ® CAS.RPM (REF)
02 SENSOR
650rpm
0.02V
C/U terminal 29 and earth.
02 SENSOR MTR RICH
Approx. 0.3V (constant voltage): NG
Approx. over 0.6 ~ 1V (variant voltage):
OK FINISH
START
e NG
B
• Remove 0 2 sensor harness connector 1ECCS C/U connector 1
NG
29
and ECCS C/U harness connector.
• Check for continuity between ECCS C/U
terminal 29 and 0 2 sensor harness
connector terminal 2.
OK
1 Repair faulty harness ar connector 1
e
~ Eü~
1 Replace 0 2 sensor 1
!ECCS C/U connector ! 21
9

EN-321
DETONATION SENSOR SYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
7. DETONATION SENSOR SYSTEM (SELF-DIAGNOSIS DISPLAY 34)
Detonation sensor 1 23 m
(')
(')
(/)
IGN TIMING CTRL
o
24
e
Detonation sensor 2
A
Input signal circuit inspection - 1 A
• Remove ECCS C/U harness connector
NG
and sub harness connector. 1 ECCS C/U connector 1 ,...,_...,,...,.....,.
23.24
• Check for continuity between terminal 1
and ECCS C/U terminal 23, terminal 2
23 & 1
OK 24&2
Repair faulty hamess or connector

B
B
Input signal circuit inspection - 2 !li Eü 00
• Remove harness connectors connected
~
NG
at front & rear of the knock sensor. A B
• Check for continuity between sub harness

terminal A and 23, B and 24.
OK Repair faulty harness or connector

e
• Connect knock sensor and ECCS C/U
harness connectors.
• Measure the voltage between ECCS C/U
terminal 23, 24 and earth. NG
lgnition in ON Approx. 4V
Cranking Approx. 4V
ldling Appox. 4V
OK
Replace knock sensor

EN-322
THROTTLE SENSOR SYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
8. THROTTLE SENSOR SYSTEM (SELF-DIAGNOSIS DISPLAY 43)
. FUEL INJ CTRL

Throttle sensor
48
m
Power 1 ()
(')
(/)
Signa! 2 38 () A/C CUT CTRL
e
Earth 3 3 30
A A
System inspection ♦THROTTLE SENSOR ♦
PRESS START WHILE
• Use "THROTTLE SENSOR" in data moni- DEPRESSING THE
tor mode to inspect the system. OK ACCELERATOR PEDAL
Voltage FULLY.
~
Fully open Approx. 4.0V

Fully closed Approx. 0.6V
PASS ¡ ~ I_ _S_TA_R_T_ __,
Open / Close range over Approx. 3.0
FINISH
NG B
B
{tMONITORING f.:¡ NO FAIL
Power supply inspection @
. Place ignition sw in the ON position .
• Use "THROTTLE SENSOR" in data moni-
tor mode to carry out inspection.
NG
----- CAS.RPM (REF)
THROTTLE SEN
0rpm
3.94V
• Place ignition sw in the OFF position.@

• Remove throttle sensor harness -
connector. Measure the power voltage START
between terminal 1 and earth.
Power voltage: Approx. 5V B
OK
1 Repair faulty harness or connector 1
e [y]
NG
• Check far continuity between ECCS C/U
terminal 38 and 2.
OK
1 Repair faulty harness or connector 1 e
Component parts inspection 1 ECCS C/U connector 1 1 3

• lnspect throttle sensor. 3
lf NG replace throttle sensor unit.
[ru
OK
EN-323
A/T CONTROL SYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
9. A/T CONTROL SYSTEM (SELF-DIAGNOSIS DISPLAY 54)
14 10
m ~
o o
o o
(J) 5 11 ;:?.
o
---
e
ª-
e
:;:¡
;:::.:
15· 12
A A
T
• Place ignition switch in the OFF position . E() 00 [21 !A/T C/U connector 1
• Remove ECCS C/U harness and A/T C/U ::'.'.~~:'.'.::.~-::--:--~-, 10, 11 , 12
. harness connectors.
~
NG 1ECCS~ 5 clu oonnl~ct~; 1
Check the continuity between ECCS C/U []]
terminal 14 and A/T C/U terminal 1O,
ECCS C/U terminal 5 and A/T C/U
terminal 11.
OK
1 Repair faulty harness or connector 1

EN-324
1O. CRANK ANGLE SENSOR SYSTEM (NOT IN SELF-DIAGNOSIS)
IGN
,.....,__ _____::'.-l,.,ltl!r--l,.:;:___ __..,.10
.,___----k"l
2 -
0-,...----49
1
59
l-------l lGN TIMING CTRL ¡
Crank angle sensor
120° signa!
JPib
1-----~- - + - - - - - 4 1
m
o
- --=------l----t (")
1° signa! 2 1-------1----42 w FUEL INJ CTRL
1--_;;_----+--I o
Power
1--------+--I
3 52 e
Earth 4 ---------so
¡ 1OLE SPEED CTRL r
A A
•
•
Remove crank angle sensor harness con-
nector.
Check far continuity between terminal 4
- NG
and body earth.
OK
1 Repair faulty harness or connector. 1

,- - .
OK
1 Replace crank angle sensor. ¡

EN-325
POWER SUPPLY & GROUND CIRCUIT FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
RB26DETT ENGINE

1. POWER SUPPLY AND EARTH CIRCUIT
109
ECCSrelay . 59 107
3 - 5 m 108
49 o
16 o(/) 116
58 o
IGN e 10
45
20
50
60
- -
A A
Power circuit inspection-1
• Check for power voltage between ECCS C/ ~ 00E)~
U connector terminal 58 and body earth. 58
OK
[2J
lnspect the following :
#8 10A fuse
Continuity between ECCS C/U -
and the battery. B
lf NG replace faulty harness or
connector. ~[11
B 45
Power circuit inspection-2 (IGN) [Y]
• Place ignition sw to ON position. - NG
• Check for power voltage between ECCS
C/U connector 45 and body earth. -
OK e
Continuity between ECCS C/U ~~~
and the ignition sw. !ECCS C/U connector!
49, 59
connector.
e
Power circuit inspection-3
• Place ignition sw in the ON position. OK
• Check for power voltage between ECCS - D
C/U connector 49 and body earth.
00eol:i1
!ECCS C/U connector!
NG 10, 20, 50, 60, 107, 108 , 116
To D
To E
EN-326
POWER SUPPLY & GROUND CIRCUIT FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
RB26DETT ENGINE
D E
• Place ignition sw in OFF position.
• Remove ECCS C/U harness
connector.
• Check for continuity between
ECCS C/U harness connector
10, 20, 50, 60, 107, 108, 116 and
body earth.
lf NG faulty harness or connector. E
E
ECCS C/U and ECCS relay harness
inspection
• Place ignition sw in the OFF position .
• Remove ECCS C/U connector. NG
. Remove ECCS relay harness connector.
,___

connector side terminal 49 & 59 ECCS F
relay harness connector terminal 5.
OK 1Faulty harness or connector.
F
ECCS relay power supply inspection
• Check for power voltage between ECCS
relay connector terminal 1 & 3 and body
earth.
--NG
OK
lnspect the following: OOEü~
Check for harness continuity between
16
ECCS relay and the battery.
lf NG replace faulty harness or con- []J
nector.
G
connector terminal 16 and ECCS relay -----
NG
harness connector terminal 2.
OK [ Faulty harness or connector.

. Check ECCS relay.
1 Replace ECCS relay

OK

RB26DETT ENGINE
2. CRANKANGLE SENSOR SYSTEM (SELF-DIAGNOSIS DISPLAY 11)
ECCS relay
3 -
+ 59
49
16
~_Pump control
lgn timing control
Crank angle sensor

m
o A/C cut control
Power 3 51
o
mñID 120º sig
1° sig
1
2
1
..._ 1
41
42
(/)
o
e J Fuel injection control j
Ground 4 52
50
0 2 sen heater control
60
-
ldle rev control
A
System inspection
• Carry out the "real-time diagnosis" 00 OK
Finish
f¡ MONITORJNGj'.'.¡ NO FAULT
CAS.RPM (POS) 97 5rpm
in data monitor mode. AIR FLOWMTR 0.95V
• Carry out self-diagnosis mode 2. AIR FLOW MTR (R) 0.94V
WATER TEMP SEN 80ºC
02 SENSOR 0.58V
NG 02 SENSOR (R) 0.51V
A
ECCS C/U input signal inspection ~ START MONITORING
• Start the engine. ~
• Carry out "CAS.RPM" in data monitor OK A
mode toread rpm.
Engine rev: 950+/-50rpm 00€)~
• Use tester to measure the power ta\
1ECCS C/U connector !
voltage between the following '&
terminals: 41~
41 & 51 terminal (120° signa!) voltage
IGN sw ON: OV or SV
ldling: 1.3V
41 & 51 (1 ° signal) voltage A
IGN sw ON: OV or SV sv Average
ldling: 2.6V 1° signa!
~~ voltage
Values above are pulse wave average volt-
age when measured using the circuit tester -
and is only for a reference. Check the wave
shape using the oscilloscope.
0
•
120 signa~ JUL SV
Average
- - ovvoltage
lnspect ECCS C/U terminal for

any damage and ECCS C/U
TOB
connector connections.
EN-328
RB26DETT ENGINE
B B
{/
Crank angle sensor power supply e sensor
inspection
f
• Remove the crank angle sensor
- NG
'ess
ne
harness connector.
• Place ignition sw in the ON position .
• Check the power voltage between crank
angle sensor connector terminal 3 and B
body earth.
OK
Check for continuity between crank
angle sensor terminal 3 and ECCS
relay terminal 5.
e e
Crank angle sensor ground circuit
inspection
. Place the ignition sw in OFF position .
• Check for harness continuity between
crank angle sensor harness connector
- NG
terminal 4 and body earth.
OK
[ Faulty harness or connector. D
o
ECCS C/U input signal circuit
41,51,&1
inspection 52, 4 & 2
• Remove ECCS C/U connector.

ECCS C/U terminal 41 & 51 and crank
angle sensor terminal 1 (120° signal),
- NG
41,51&1
52, 42 & 2
ECCS C/U terminal 42 & 52 and crank

°
angle sensor terminal 2 (1 signal).
OK
1 Faulty harness or connector.

OK
1 Replace crank angle sensor.

EN-329
RB26DETT ENGINE
3. AIR FLOW METER SYSTEM (SELF-OIAGNOSIS DISPLAY 12)
ECCS relay +
3 -<>+-"-- -- --- -- -+----149
~ ~f-:a---- --+-- - - - - i16
59
Air flow meter

Power 5
1----+-- ---'-,--;-'.------134 Boost control
~ -"'-"==·-+-'-1 ' 1 35 ~
o(/)
o - - - - - - Fuel injection ctrl
e
i----+- - ,----,...,- - -26 - - ---- JGN timing control
t-'-"'-.,.,___~,-+--,-; 27
'--7
t-------<~.--¡50
60
A
f¡MONITORING¡~¡NO FAULTI
System inspection
• Carry out "Real-time diagnosis" in @~Finish CAS.RPM (POS) 975rpm
data monitor mode. AIRFLOWMTR 0.95V
AIR FLOW MTR (R) 0.94V
• Carry out self diagnosis mode 2. WATER TEMP SEN 80ºC
02 SEN 0.58V
0 2 SEN (R) 0.5 1V
NG
A ! START MONITORING
Input signa! inspection
A
• Check power voltage by carrying out "air
flow meter" and "air flow meter (R)" in
data monitor. OK 1 ECCS C/U connector 1
• Check power voltage between ECCS
C/U connector 27 & 35 and body earth. 27,~
IGN sw ON: Approx. 0.1V
ldling: Approx. 0.9V
2500rpm (with no load): Approx. 1.3~1. ?V
B
NG \
ow meter (R)
any damage and ECCS C/U Air
\\
w eter
1
B 1

'
• Place ignition sw in the OFF position.
• Remove air flow meter harness connec- B
tor. NG
• Place ignition sw in the ON position.
-
• Check power voltage between air flow
meter harness connector terminal 5 and
body earth.
1 OK
TOC
EN-330
RB26DETT ENGINE
,...--- lnspect the following: e

Harness continuity between air
flow meter (R) terminal 5 and
1ECCS C/U connector 1
ECCS relay terminal 5.
~ -<s_,lr 111
26
connector. •,.._"_ _ . .
e
• Place ignition sw in the OFF position . o
• Check for continuity between air flow NG
meter harness connector terminal 4 and
27,35
ECCS C/U connector terminal 34, air
flow meter (R) harness connector termi-
nal 4 and ECCS C/U connector 26.
OK
1 Faulty harness or connector. 1
D
Input circuit inspection
air flow meter harness connector termi- NG
nal 2 and ECCS C/U connector terminal
35, air flow meter (R) harness connector
terminal 2 and ECCS C/U connector
terminal 27.
OK

Check air flow meter.
NG
OK 1 Replace air flow meter. ¡
Other system inspection

Check for any air leakage from íntake aír
system.
OK

EN-331
RB26DETT ENGINE
4. WATER TEMPERATURE SENSOR SYSTEM (SELF~DIAGNOSIS DISPLAY 13)
r---- - 1
1 RADJATOR FAN CTRL
Water temp sensor~
i-------',1f-,y,,1~2 ' - - - -- - ------<28 ~
()
(/)
f-----'i FUEL INJECTION CTRL 1
30 C">
e t------ IGNITION TIMING CTRL
IDLE REV CONTROL
A
System inspection
• Carry out "Real-time diagnosis" in 00 OK
-Finish
"t:?MONITORING~O FAULT
WATER TEMP SEN 78°C

data monitor mode.
• Carry out self diagnosis mode 2.
®
NG
A
START MONITORING
• Check water temperature by carrying A
out "water temp sen" data monitor. @
. Place ignition sw to ON position .
. Check power voltage between ECCS
OK
1ECCS C/U connectorl
2t_Pl
=1
C/U terminal 28 and body earth.
IGN swON ®
Water temp at 20°C: Approx. 3.5V
Water temp at 80°C: Approx. 1 .2V
NG A
lnspect ECCS C/U terminal for (V)
any damage and ECCS C/U Q)
O)
connector connections. .8
~ 3.5>-----""""
B ¡
Power inspection ~ 1.21---1--- __;:==--r-
• Place ignition sw in the OFF position. 20 80 (ºC)
Coolant temperature
• Remove engine water sensor harness OK
connector.
• Place ignition sw in the ON position . B
• Check power voltage between water ~~-
temp sensor harness connector terminal /
(0
1 and body earth.
\I
r
tertemp
i sor
NG
TOC
EN-332
RB26DETT ENGINE
e B
Power inspection
• Check for continuity between water sen-
sor harness connector terminal 2 and
ECCS C/U connector 30.
OK
1 Faulty harness or connector. I e
Component parts inspection NG (1€) EO f:ii

• Check water temperature sensor.
~
30
(fil)
OK -
1 Replace water temperature sensor. 1
0
'--------

EN-333
IGNITION SYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
RB26DETT ENGINE
5. IGNITION SYSTEM (SELF-DIAGNOSIS DISPLAY 21)
Crank angle sensor

51 3 Power
411----<' - - -----l1 120º s· naf
2 1º si nál Cill]fil)
4 Ground
48
38
30
GruI)
m
o
o(/) Water temp sen
o
28 1
G'w
1 e Throttle valve sw
54
47
ldle contact point ~
13
23
1 Knock sen ID
11 24
1 Knock. sen ®
(IGN coil síde) (C/U side)
<í~1a1lft131¡j1p {112, ffl 1st-$ ~
A
System inspection @ OK ♦ POWER BALANC~
• Carry out "Real-time diagnosis" and
STOP INJECTOR ORIVE AT
self-diagnosis.
. Carry out self diagnosis mode 2.
EACH CYLINOER TO CHECK
® CYLINDER BALANCE.
NG
To lgnition system
(not in self-diagnosis mode) PASS 11 START
A
8
Circuit function inspection @
• Carry out "power balance" in function
test. OR
• "Power balance" in active test. OK . .
• Check if the engine rev will decrease F1rnsh
momentary.
8 NG
Ground circuit inspection 8
NG
• Remove power transistor unit harness ,..._
connector.
. Check continuity between terminal 17
and body earth.
OK
TOC
EN-334
IGNITlON SYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
RB26DETT ENGINE
e e
Output circuit inspection
• Remove ECCS C/U harness connector. NG IECCS C/U connector 1
~
!
(6 5 \ m
1211 )
J,2,3,,4, 5,6 ,
• Remove power transistor (6) connec-
tors.
• Check for continuity between following t ~...¡.__..,~
1 & 1, 11 & 6, 2 & 5,
terminals: 12 & 2, 3 & 3, 13 & 4
ECCS C/U 1 ~ 1 ECCS C/U 11 ~ 6

ECCS C/U 2 ~ 5 ECCS C/U 12 ~ 2 D
ECCS C/U 3 ~ 3 ECCS C/U 13 ~ 4
OK
~©-=>~
j ECCS C/U connector j
1, 2. 3, 11, 12, 13
o
Output signal inspection
• Connect power transistor unit and ECCS
~ =
C/U harness connector.
• Check power voltage between ECCS C/
U terminal 1, 2, 3, 11, 12 & 13 and body ...._N_G_
earth.
When cranking: Approx. 0.05V
When idting: Approx. 0.05V
At 2500rpm: Approx. 0.1V
OK
lnspect following signal systems:
Crank angle sensor
Water temperature sensor
Throttle sensor
Knock sensor
lgnition sw (start) signal

,___
• Check power transistor unit.
OK
1 Replace power transistor.

EN-335
DETONATION SENSOR SYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
RB26DETT ENGINE
6. DETONATION SENSOR SYSTEM (SELF-DIAGNOSIS DISPLAY 34)
w=;
(11)
~
~ 2
.e..nsor
e____...,
1
L._ 1 6 2;
~
73
4
ECCS sub hamess
5
2 6
7
1-
2
-----124
23
m
g
(')
~
, - ----ilGNITION TIMING CTRL
System inspection @ OK
• Carry out "Real-time diagnosis" and - - Finish A
self-diagnosis.
• Carry out self diagnosis mode 2. ® ~ «)~
~
NG
A
C/U terminal 23 & 24 and body earth.
When using oscilloscope
lgnition sw in the ON: Approx. 2.0V
While cranking: Approx. 2.0V
While idling: Approx. 2.0V OK
When using circuit tester
lgnition sw in ON: Approx. 0.4~2.0V
While cranking: Approx. 0.4~2.0V
While idling: Approx. 0.4~2.0V
The value will differ depending on the circuit
tester measurement range . (0.4V is at low
range and 2.0V is at high range ).
NG
ToB
EN-336
DETONATION SENSOR SYSTEM FAULT DIAGNOSIS BY SELF-OIAGNOSIS SYSTEM
RB26DETT ENGINE
B B
• Remove ECCS C/U and ECCS sub har-
NG
ness connector.
-
connector terminal 23 & 24 and ECCS
sub harness connector terminal 1 & 2.
OK B
1Faulty harness or connector. l
Replace knock sensor. !

OOEü ~
1ECCS C/U connector 1 ~
23,24 ~
u
T ~e+----------1
EN-337
INTAKE AIR TEMP SENSOR SYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
RB26DETT ENGINE
7. INTAKE AIR TEMPERATURE SENSOR SYSTEM
(SELF-DIAGNOSIS DISPLAY 41)
lntake air temperatura sensor

,-----"-2f-/Ylí"v-l-'-1_ _ _ _ _ _--J36
m
o
L---------------130 O r---~------1FUEL INJECTION CTRL
(/)
o
e
A
System inspection @ OK ~ONITORIN~O FAULT-
• Carry out "Real-time diagnosis" and - - Finish
self-diagnosis. CAS.RPM (POS) 950rpm
• Carry out self diagnosis mode 2. WATER TEMP SEN 38°C
A NG
START MONITORING
• Check intake air temperature using
"intake air temperature sensor" in data A
monitor mode.
• Place ignition sw in the ON position. OK
• Check power voltage between ECCS 1 ECCS C/U connector 1
C/U terminal 36 and body earth. 36
~
IGN sw in the ON position:
lntake air temp at 20°C: 3.5V
lntake air temp at 80°C: 1.2V
NG A
lnspect ECCS C/U terminal for (V)
any damage and ECCS C/U lJ

o
connector connections. :a:
g¡
B c5 3.5 r----_,,__
fil"
(Q
Power supply inspection (1) 1.2 r----+----=-,r--.

• Place ignition sw in the OFF position . 20 80 (ºC)
ln1ake air temperatura
• Remove intake air temperature sensor
harness connector. NG B
intake air temperature sensor harness
connector terminal 1 and body earth.
1 ~ body earth: 5V
OK
TOC
EN-338
INTAKEAIR TEMP SENSOR SYSTEM FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
RB26DETT ENGINE
e B
NG
• Check far harness connector continuity " - - -
between intake air temperature sensor
harness connector 2 and ECCS C/U
connector terminal 30.
OK e
00 eJ r:.

30 cfil>
. Check power transistor unit. - -
0
OK
-
Replace intake air temperature
sensor.

,,.--.
EN-339
RB26DETT ENGINE
8. THROTTLE SENSOR SYSTEM (SELF-DIAGNOSIS DISPLAY 43)
Throttle sensor
Power 1 48
.---,
E Signal
Ground 3
2
'---
38
30
m
()
()
(/')
. : FUEL INJECTION CTRL I
Q
e : IGNITION TIMING CTRLI
50
60
~
A
System inspection ~ OK
• Carry out "Real-time diagnosis" and ~ Finish +"rHROTTLE SENSO~
self-diagnosis.
• Carry out self diagnosis mode 2. ® PRESS START W HILE FULLY
OPENING
PEDAL.
THE ACCEL
A NG
Input signa! inspection tj'\
• Place ignition sw in the ON position.\J!J PASS 11 START
• Carry out "Throttle sensor'' in function
test mode. OR A
• "Throttle sensor'' in operation support ~
mode. 000urit~~
• Check the power voltage between @ 1ECCS C/U connector 1
38 GJ
ECCS C/U connector 38 and
body earth.
When accel pedal depressed: 0.4V
When accel pedal not pressed: 3.BV
NG
B
B
• Place ignition sw to OFF position.
• Remove throttle sensor harness
connector. NG
• Place ignition sw to ON position. - B
throttle sensor harness connector termi-
nal 1 and body earth.
1 ~ body earth: 5V
OK
Check for continuity between ECCS
C/U and throttle sensor. lf NG faulty
TOC harness or connector.
EN-340
RB26DETT ENGINE
e e
1 ECCS CIU connector 1
• Remove ECCS C/U connector. 30
• Remove throttle sensor harness con- - NG
nector. [[]
• Check for continuity between throttle
sensor harness connector terminal 3
and ECCS C/U connector terminal 30.
D
OK
1 Faulty harness or connector. 1 OO&J~
D 38

• Check for continuity between throttle NG []]
-
sensor harness connector terminal 2
and ECCS C/U connector terminal 38.

• Check throttle sensor
OK
1 Replace throttle sensor. 1

EN-341
RB26DETT ENGINE
9. 0 2 SENSOR SYSTEM (02 SENSOR MONITOR IN SELF-DIAGNOSIS DISPLAY)
O sensor (R) ~ 29
F/L-1 1
1 ~
115
0 2 sensor m
(')
3
o A/F RATIO FEEDBACK CTRL
1~ 55 (f)
<Tilli) Q
e
A A
System inspection fi' ♦ BASE NF RATIO TEST ♦
• Carry out "Base air-fuel ratio test" ~
in function test mode. OR PRESS START WHILE KEEP-
ING ENGINE REV AT 2000rpm
• Select "02 sensor monitor", "02 sensor OK +/- 200rpm.
monitor (R)" in data monitor.
• After engine warm-up, set to approx.
Finish
1800
~
2000 2200
2000rpm.
1 PASS ! .___I_ _ s_TA_R_r_ _
Check if LEAN and RICH display is re-
peated over 5 times in 1O seconds. A
1
RICH - LEAN - RICH - LEAN - RICH -¡::1.10N1TORING ¡~o FAULTI
CAS.RPM(POS) 975rpm
1 1 1 2 1 AIR FLOW MTR 0.95V
ALSO
AIR FLOW MTR (R) 0.94V
• Check "0 2 sensor" and "0 2 sensor (R)" WATER TEMP SEN 80°C
in data monitor mode. 02 SEN 0.58V
• Operate diagnosis connector on @ 02 SEN (R) 0.51VI
vehicle side to set to "02 sensor VEH SPEED SEN 0km/h
monitor". START MONITORING j
Check if engine warning lamp will flash
A
more than 5 times within 10 seconds.
B
NG

~,~-
/p,
/1/
\ 1 /
~
1 \
C/U terminal 29 & 55 and body earth.
Engine warning lamp
Engine raced at 2000rpm:
Changes approx. 0.1~0.3V - 0.6 ~ 1.0V
NG
lnspect ECCS C/U terminal for any
TOC damage and ECCS C/U connector
connections.
RB26DETT ENGINE
e B
• Check far continuity between 0 2 sensor NG 1ECCS C/U connectors 1
29, 55
harness connector terminal 2 and ECCS [y]
C/U connector 29 & 55.
0K
1 Faulty harness or connectors. ¡
e
1 Replace 0 2 sensor. 1

e
OOfD~
29.c®r
~~
EN-343
COMPONENT PARTS INSPECTION FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
RB26DETT ENGINE
1 O. COMPONENT PARTS INSPECTION
1. Crank angle sensor

• Remove the crank angle sensor from engine with har-
ness connector still connected.
• Slowly turn the crank angle sensor shaft by hand and
inspect the power voltage between terminal 1 & 2 and
body earth.
Crank angle sen terminal 2 ~ body earth (1° sig):
Turn by hand
Approx. 0V or 5V
Crank angle sen terminal 1 ~ body earth (120° sig):
Approx. 0V or 5V
• lf NG replace crank angle sensor.
• After inspection erase self-diagnosis result and make
sure code No. 11 is not displayed.
Caution:
Remove the fuse or disconnect the connector to avoid
injector from operating.
Abnormality may be detected by self-diagnosis mode if
the crank angle sensor shaft is not turned smoothly.
2. Air flow meter

• Dírectly apply power voltage between air flow meter Hot wire area
terminal +5 and terminal -3 and blow air to hot wire
area. lnspect the change in output power voltage be-
tween terminal +2 and -3.
Output voltage
When air is not blown (V): Approx. 0.8
Blow air
When air is blown (V): Approx. 2
• lf NG inspect hotwire for any damage.
3. Water temperature sensor

• Remove engine water temperature sensor harness
connector.
2
• Check for resistance between water temperature sen-
sor terminal 1 and 2.
Coolant water temperature at 20°C (ko): Approx. 2.5
Coolant water temperature at 80°C (ko): Approx. 0.3
• lf NG replace engine water temperature sensor with a
new one. (kQ)
• After inspection erase self-diagnosis result and make 20
sure code No. 13 is not displayed. ;u 10
<t>
<n
!é: 2.5 f---_,,__
~ 1
o
<t>
0.3
0 .1 ' - -- - -- ~ '=---~(ºC)
Coolant temperature
EN-344
COMPONENT PARTS INSPECTION FAULT DIAGNOSIS BY SELF-DIAGNOSIS SYSTEM
RB26DETT ENGINE
4. Power transistor (Coil side) • PWR TRAN
• Remove the power transistor harness connector. d (Coil

side)
• Use analogue type circuit tester to inspect resistance
value between each power resistor terminal by chang-
ing the positive and negative tester bars.
• lf NG replace the power transistor.
lnspection terminal and value
Coil side 17, 17, 17, 17, 17, 17 (+) O or not (-) O or not
C/U side 1,2, 3,4,5,6 (-) ooO (+) ooQ
Coil side 17, 17, 17, 17, 17, 17 (+) (-) O or not
ooO
Coil side 11, 12, 13, 14, 15, 16 ( -) (+) ooQ
Coil side 11, 12, 13, 14, 15, 16 (+) O or not (-)
ooQ
=O
C/U side 1, 2, 3,4,5,6 (-) (+)
-
5. lntake air temperature sensor

OOEü~
• Remove intake air temperature sensor harness 12
connector.
• Check for resistance between intake air temperature
sensor terminal 1 and 2.
lntake air temperature at 20°C (ko): Approx. 2.5
lntake air temperature at 80°C (ko): Approx. 0.3
(k )
• lf NG replace intake air temperature sensor.
• After inspection erase self-diagnosis result and make 20
:;o 10
sure code No. 41 is not displayed. (l)
(/1
§: 2.s---
g¡ 1
o(l)
0.3
0.1 ~ --=<,-- -----..-----e)
6. Throttle sensor Coolant temperature
• Remove the throttle sensor connector.
• Check the resistance between throttle sensor terminal
2 and 3.
Accel pedal not depressed (ko): Approx. 1.3
Accel pedal lightly depressed (ko): Approx. 5.0
Accel pedal fully depressed (ko): Approx. 9.5
7. ECCS relay
• Check for continuity between terminal 3 and 5 when
power voltage is applied to terminal 1 and 2.
Directly apply power voltage to terminal 1 ~ 2:
Continuity present
No power voltage applied: No continuity
EN-345
FUEL PUMP SYSTEM SYSTEM FAULT DIAGNOSIS

1. FUEL PUMP SYSTEM CONTROL
CONTROL CIRCUIT DIAGRAM RB25DE / RB25DET ENGINE
F/L-6 ECCS relay

1 - - - - - - - - - "5-t<>_
o -F-
3 - - -- ---t49
1 2 16
59
F/L-3 IGN SW #16 ~

V m
o
o
(/)
50+-------,.
6u+------- -----t
Fuel pump
A A
System inspection ♦ FUEL PUMP ♦
IS THERE A PULSATION
• Select "FUEL PUMP" in function test mode
EVERY 3 SECONOS
to inspect the system. WHEN THE FUEL TUBE
• Carry out operation inspection by "FUEL OK IS HELD? OR CAN YOU
PUMP RELAY" in active test mode. HEAR THE FUEL PUMP
• Fuel pump will operate for 5 seconds after RELAY OPERATION
NOISE?
the ignition switch is turned to ON position.
Check if the fuel pump operation noise are 1 PASS ll NO 11 YES ¡
audible. A
FINISH
B NG ♦ ACTIVE TEST ♦ 0
Power inspection FUEL PUMP RELAY ON
NG MONITOR
• Disconnect fuel pump relay.
• Measure voltage between earth and termi- CAS.RPM (POS) Orpm
nal 2 & 3 using the tester.
OK 1 START 11 ON/OFFII STOP

A
• Fuse
• Harness connection between fue!
pump relay and the fuse.
• Connection between fuel pump re-
lay and the ignition switch.
lf NG repair harness & connector.
TOC
EN-346
e B
• Place ignition switch in the OFF position . 3¡.......·- - . .
NG LJJ 1,i-,- - - J
• Remove fuel pump harness connector.
• Check for continuity between fuel pump
harness terminal 3 and the earth.
OK
[ Faulty harness or connectors.
e
D
• Place ignition switch ín the OFF position .
• Remove ECCS C/U harness connector. NG
& harness terminal 18 and fue! pump relay
harness terminal 1.
OK D
Continuity between ECCS C/U and fuel
pump relay.
ECCS C/U connector
lf NG repair harness and the connector. 1B
E 0D
Control signal inspection
• Measure power voltage between earth and
ECCS C/U terminal 18. E
Within 5 seconds after ignition switch is
turned to ON position: 1V
5 seconds after ignition switch is turned to 1B
ON position: Power voltage
OK
• lnspect fuel pump relay. NG
• lnspect fuel pump .
OK
1 Replace fuel pump / relay.

EN-347
IGNlTION SIGNAL SYSTEM FAULT DIAGNOSIS
2. IGNITION SIGNAL - 1
IGN
Power transistor
c1 m
3)
1 1
45 No. 1
12 N
49
m
(")
16
ECCS relay l/23
~
4
o
c13
5
Full
2
10
11
2
7iirrri
(1J21J'fhsis} (Ei6f5W 31211)
A A
Circuit function inspection (fi\ ♦ POWER BALANCE ♦
• lnspect using "POWER BALANCE" in ~ INSPECT THE BALANCE
OF EACH CYLINDER BY
function test mode. OR power balance in OK
STOPPING INJECTOR
"ACTIVE TEST". r-
OPERATION AT EACH
• Check if engine rev will decrease momen- CYLINDER.
tarily. TURN OFF A/C & LIGHTS
NG FINISH 1 PASS 11 START

8 ~----~
Power supply inspection A
• Remove ignition coil harness connector.
• ACTIVE TEST
POWER BALANCE
MONITOR
♦□
NG GAS. RPM(POS) rpm

AIR FLOW METER V
• Use CONSULT or the tester to measure AACVALVE %
power voltage between each coil terminal 1
and earth. [J][JJ[I]l]] MONITOF
ITJ[}]□□
START
OK
lnspect the following: 8
lgnition relay
lgnition switch
Continuity between each coil Harness
terminal 2 and ignition relay terminal 5.
TOC
EN-348
IGNITION SIGNAL SYSTEM FAULT DIAGNOSIS
e e
• Place ignition switch in the OFF position . NG
.....--
• Check for harness continuity between each
coil terminal 3 and earth.
OK
D
Output signal circuit inspection D
• Remove power transistor unit harness
connector.
(1121 ff5161E)
• Check for continuity between the following 2 1,2, 3.4, 5.6
terminals:
Between each ignition coil terminal 1 and NG
Power transistor unit terminal 1 -
Power transistor unit terminal 2
OK

• lnspect power transistor unit & lgnition coil
1 Replace faulty parts 1
EN-349
IGNITION SIGNAL SYSTEM FAULT DIAGNOSIS
3. IGNITION SIGNAL - 2
1 Continue from lgnition signal 1 1

E 1 E
• Remove ignition coil relay connector. NG
• Use CONSULT or tester to measure the
voltage between coil terminal 2, 3 and body
earth.
OK
Check the following: F
Continuity between fusible link,
ignition coil relay and ignition switch.
Continuation between ignition coil
relay and the battery.
F
• lnspect harness continuation between
each coil terminal 2 and 5 .
G
OK
1 Faulty harness or connectors. l
G 1ECCS C/U connector !
16
.Output signa! circuit inspection

Disconnect ECCS relay. NG
• Check for continuation between ECCS C/U
terminal 16 and ECCS relay terminal 2.
OK
Fusible link.
Continuation between ECCS C/U and
ECCS relay harness.
Continuation between ECCS C/U and
ignition coil relay harness.

Check ignition coil & ECCS relay
NG
OK
1 Faulty harness or connectors.

EN-350
lNJECTOR SYSTEM INSPECTION SYSTEM FAULT DIAGNOSIS
4. INJECTOR SYSTEM INSPECTION

®filNo.4
ST 109
43
49 m
58
114
110
112
3
5
6
4
~~3=
1 4
5
®:filNo.5
®:ffiNo. 6
o
9i:rff1
ª3
16
o(/J
ECCSrelay
Q
101
®filNo.1
e
105 @illNo.2
103
@]]No.3
A A
Circuit function inspection ♦ POWER BALANCE ♦
• Carry out "POWER BALANCE" in function
INSPECT BALANCE OF
test mode. OK EACH CYLJNDER BY STOP-
• Operate "POWER BALANCE" in active test i------. PING THE INJECTOR ORIVE
mode. 1 FOR EACH CYLINDER.
• Make sure the injector operation noise is FINISH
audible. 1 PASS l 1L___S_TA_R_T_ __J
NG
B A
Power supply inspection - 1
• Remove sub harness connector.
• Check the power voltage between terminal
3 and ground using CONSULT or tester.
OK
lnspect the following: B
Harness connector.
Continuity between sub harness
connector and the harness.
lf NG repair faulty harness and connector.
e
Power supply inspection - 2
tj l
NG e
• Disconnect sub harness connector.
and 4, 5, 6.
OK
TOO
TOE
EN-351
INJECTOR SYSTEM INSPECTION SYSTEM FAULT DIAGNOSIS
D D
• Remove injector harness
connector.
• Check for continuity between 1 ECCS C/U connector 1 21
terminal 109 and No. 1, 2, 3, 4, 5 109 No.1
No.2
& 6 cylinders. No.3
No.4
E "---te.;---" No.5
No.6
Out put circuit inspection
• Disconnect ECCS C/U harness
connector. E
• lnspect between the following terminals
for continuity:
between terminal 101 and No. 1 cylinder NG 21
101, 103, 105, 110, 112, 114
No.1
between terminal 105 and No. 2 cylinder No.2
No.4
between terminal 11 O and No. 5 cylinder No.6
between terminal 114 and No. 6 cylinder
OK
1Faulty harness or connectors.I

• Check lnjector
OK
1 Replace injector. ¡

EN-352
VEHICLE SPEED SENSOR SYSTEM FAULT DIAGNOSIS
5. VEHICLE SPEED SENSOR SYSTEM

-
,, \ r /,/
' ---
_:.-.:0 ~
m
(') 1-------l FUEL CUT CTRL 1
1 ~
1 Vehicle spd sen 1-----
1
- - - - - - - - - - - - . 53 ~
i---------: IDLE SPEED CTRL 1
A
Vehicle speed sensor inspection
• Use CONSULT and carry out the inspec- OK
tion using "VEHJCLE SPEED SENSOR" in
function test mode.
NG
FINISH
Vehicle speed sensor function inspection NG

• Check vehicle speed meter function
OK
Vehicle speed sensor and vehicle
speed sensor circuit inspection.
B B
Input signal inspection 't¡MONITORl~O FAULT □
Start the engine. NG
Rotate drive axle slowly. VEH SPD SEN O km/h
Detect vehicle speed using "VEHICLE (i)
SPEED SENSOR" in data monitor mode.
Use tester to measure the voltage between
ECCS C/U terminal 53 and earth.
Voltage: approx. O~ 5V · ® START
OK 8
Check for continuity between ECCS .-1
l2iEW
E_C_C_S-C1-,U-co-n-ne-c-tor--,I
C/U and combination meter harness.
IF NG: Repair or replace harness.
5 ~
lnspect ECCS C/U terminal for any damage :
EN-353
AIR CONDITIONER RELAY SYSTEM FAULT DIAGNOSIS
6. AIR CONDITIONER RELAY SYSTEM

#20
Throttle sensor
IGN relay1 e-- e------,To FICD relay
si nal
ACC relay
m
ACC key SW ~---+--a o
o
(f)
Q
e
Air ca pressor
ENG temp
sen síg
Input signa! inspection

• Place ignition switch in the ON position . f1t~©
. Use tester and measure the battery volt- OK 1 ECCS C/U connector 1
~
age between ECCS C/U terminal 9 and
earth.
blow-fan switch is OFF: PWR voltage
blow-fan switch is ON: Approx. 1V
NG
FINI SH
EN-354
EXH GAS SENSOR HEATER SYSTEM SYSTEM FAULT DIAGNOSIS
7. EXHAUST GAS SENSOR HEATER SYSTEM

lgnition
switch
m
()
o(/)
T Heater i t-----~-29
1 - - -- - -115
Q
e
A A
• Remove exhaust gas sensor harness
connector. NG
,---
• Measure power voltage between terminal
1 and earth.
OK
lnspect the following: B
Harness connector.
Continuity between exhaust gas sensor
and the fuse. J ECCS C/U connector 1 ,.--t'-"+-----
115 3 2 1
lf NG repair harness and connector.
B
NG
• Disconnect ECCS C/U harness connector.
------
OK
1 Faulty harness or connectors.

. Check exhaust gas sensor heater. ------
OK
1 Replace exhaust gas sensor.

EN-355
THROTTLE VALVE SWITCH SYSTEM FAULT DIAGNOSIS
RB250E / RB25DET ENGINE
8. THROTTLE VALVE SWITCH SYSTEM

CONTROL CIRCUIT OIAGRAM RB25DE / RB25OET ENGINE
ToA/T C/U
,______! FUEL INJ CTRL
m 1--- - - - 11GN TIMING CTRLI
o
- - - ----+
' 57 o
(f)
- - - -- 54 Q
e
1---- ----! IDLE SPD CTRL 1
A A
Function inspection - 1 ♦ IDLE JUDGEMENT ♦
• Place ignition switch in the ON position. PRESS START WHILE ACCEL
• lnspect using "IDLE JUDGEMENT" in OK PEDAL IS FULLY OPEN.
function test mode.
-
Fully open: OFF
Fully closed: ON
FINISH
PASS 11
.......__ _ S_T._'A_RT
__
NG
B
Function inspection - 2 B
• Place ignition switch in the ON position . E) 00
• lnspect ignition switch "ON-OFF" diagno- (ldle connection point)
sis or measure power voltage between OK 1ECCS C/U connector j
ECCS C/U terminal 54 and earth using the ,__ 54
tester when ignition switch is in ON. lv l
Accelerator pedal depressed OV
Accelerator pedal not depressed 8 ~ 1OV FINISH
NG
e e
• Remove throttle valve switch harness con- CJ
1 2 3
nector. NG
• Use tester to measure power voltage be-
tween terminal 2 and earth .
Power voltage: Approx. 8 ~ 1OV
OK
Harness continuity between throttle
valve switch and ECCS C/U.
lf NG repair faulty harness and
connector.
TOO
EN-356
D D
• Oisconnect ECCS C/U harness connector.
• Disconnect throttle valve switch harness NG 1 ECCS C/U connector
connector.
- 54
1

terminal 54 and throttle valve switch termi-
nal 1.
OK
rFaulty harness or connectors. l

• Check throttle valve switch .
OK
1 Replace throttle valve switch. !
EN-357
START SIGNAL SYSTEM FAULT DIAGNOSIS
9. START SIGNAL
IGNSW
FUEL INJ CTRL
m
o
o(./)
I
IGN TIMING CTRL
Q
e
A A
Function inspection (l) ♦ STARTER SIGNAL ♦
• Place ignition switch in the ON position. PLACE SHIFT LEVER IN
• Use CONSULT and inspect "START "P" OR "N" AFTER FULLY
OPEN IG THE ACCEL PED-
SIGNAL" in function test mode. OR OK
AL. START THE ENGINE
• lnspect start signal using "DATA MONI- STRAIGHT AFTER SE-
TOR" mode. LECTING START.
lgnition switch is in ON position: OFF
lgnition switch is in START position: PASS START
ON 1 1 [
FINISH
NG A
B
~ONITORIN~ NO FAULT 0
Power supply inspection @
• Place ignition switch in OFF position. CAS.RPM (POS) 1326rpm
STARTER SIGNAL OFF
• Remove throttle valve switch harness con-
nector. NG
• Use tester to measure the voltage between
terminal 2 and earth. RECORD
Battery voltage: Approx. 8 ~ 1OV
B
OK
Fuse 1 ECCS C/U connector 1
Continuity between ignition switch 43
LB-¡
and ECCS C/U harness.

EN-358
AAC VALVE SYSTEM SYSTEM FAULT DIAGNOSIS
1O. AAC VALVE SYSTEM

IGNSW
m
o
o
r.n
AAC valve o
21 ~"-l-'-¡1_ _ _ _ _ _ fBi, r;1' r - ----+-----+ 113
e
2 ---~
A A
♦ MCVALVE ♦
Function inspection
• Warm the engine .
(i) TURN OFF A/CANO LIGHTS
SWITCHES BEFORE
• Check the idle rev 600 ~ 700 rpm. STARTING .
. lf not within standard value adjust idle
- OK
speed.
• lnspect using "AAC VALVE " in function
test mode. 1 PASS ST_A_RT_~
1~I_ _
• Disconnect AAC valve harness . A

• Check if ídle rev will decrease . ® FINISH
NG
B
Power inspection
NG
• Measure voltage between earth and AAC
valve terminal 2.
OK B
e
• Check if the engine rev will change when
"UP" or "DOWN" is pressed in "AAC
VALVE" in active test mode. NG
• Disconnect ECCS C/U harness .
,____(j)
harness terminal 4 and AAC valve
® e
connector terminal 1. ♦ ACTIVE TEST ♦ 0
CN OPENING DEG 10%
OK
MONITOR
IR FLOW MTR 1.16V
NGINE TEMP SEN 80°C
• Check AAC valve .
lf NG replace AAC valve.
~11 UP 11 DWN 1~
EN-359
AIR REGULATOR SYSTEM FAULT DIAGNOSIS
11. AIR REGULATOR

F/L-3
' IGNSW
1 ~ 3
qJp
m
o
o
(/)
o
#8
2 18
--
e
3 5
Fuel pump relay -
A
A
• Disconnect fuel pump relay. NG
• Use tester to measure the voltage between
terminal 2, 3 and earth.
OK
Harness continuity between fuel pump B
relay and fuse.
Continuity between fuel pump relay
and ignition switch.
2 1
[fil
B
.Earth circuit inspection

Place ignition switch in the OFF position .
• Remove air regulator harness connectors . NG
• Check for continuity between air regulator
e
harness connector terminal 2 and earth.
OK 1ECCS C/U connectori 5

1 Faulty harness or connectors. 18 1 2
e
Output signa! circuit inspection
. Place ignition switch to OFF position .
• Disconnect ECCS C/U harness connector. NG
ECCS C/U terminal 18 and fuel pump relay
terminal 1.
OK
Continuity between ECCS C/U and
TOO fuel pump relay.
EN-360
AIR REGULATOR SYSTEM FAULT DIAGNOSIS
D D
• Measure voltage between ECCS C/U ter-
minal 18 and earth. 1ECCS C/U connectorl
NG 18
Within 5 sec after ignition switch is placed
~
to ON position: Approx. 1V
5 sec after ignition switch is placed to ON
position: Power voltage
OK
Repair and inspect ECCS C/U
power supply and ground circuit.

• lnspect air regulator.
OK
1 Replace air regulator.

EN-361
PWR STEERING OIL PRESSURE SIGNAL SYSTEM FAULT DIAGNOSIS
12. POWER STEERING OIL PRESSURE SIGNAL

PWR ST oil pressure SW

· · · · · · · · · · · · · 2G=~1- _ _ _ _ _____.,19
rn
l o
o(/)
o
e
A A
♦ POWER ST SIG ♦
Function inspection (j)
• Place ignition switch in the ON position. PRESS START WHILE FULLY
• lnspect using "PWR ST SIG" in function STEERING THE STEERING
test mode. OR WHEEL.
• Stop the engine. OK

• Use "DATA MONITOR" to inspect PWR ST
hydraulic pressure switch signal. 1 PASS l~
I _ _s_TA_R_T_ _,
When neutral: OFF
When steered: ON A
• Start the engine. fía\ *MONITORIN~ NO FAULT 0
• Use CONSULT or tester to measure ~
the voltage between ECCS C/U terminal CAS.PM (POS) 862rpm
FINISH IGNITION SIGNAL OFF
19 and earth.
When steered: Approx. OV
Other: Power voltage
B NG RECORD
Input signal circuit inspection A

• Remove power steering hydraulic pres- NG
~~00©
1 ECCS C/U connectorl
sure switch harness connector. 19
• Check for harness continuity between [y]
ECCS C/U terminal 19 and power steering
hydraulic pressure switch terminal 1.
OK
1Faulty harness or connectors. l B
r------------,
e
• Check for continuity between power steer- NG 1 ECCS C/U connectorl
19
ing hydraulic pressure switch terminal 2
and engine earth. [fil

EN-362
COMPONENT PARTS INSPECTION SYSTEM FAULT DIAGNOSIS
13. COMPONENT PARTS INSPECTION
1. Crank angle sensor

• Remove crank angle sensor from the engine. (leave
crank angle sensor harness connector connected).
• Turn the crank angle sensor shaft slowly by hand and
check the voltage between terminal 2, 3 and earth.
Crank angle sensor terminal 2 ~ earth (1° signal): Rotate by hand
Approx. 0.1V or 5V
Crank angle sen terminal 1 ~ earth (120° signal):
Approx. 0.1V or 5V
• lf NG replace the crank angle sensor.
Caution:
Remove the fuse or disconnect the connector to avoid
injector from operating.
Abnormality may be detected by self-diagnosis mode if
the crank angle sensor shaft is not turned smoothly.
2. Air flow meter

• Remove air flow meter from the engine.
• Apply battery voltage directly between air flow meter Hot wire
terminal +5 and terminal -3 and blow air to hot wire.
Check far any change in output voltage between
terminal +2 and terminal -4.
When air is not blown (V): Approx. 0.8
When air is blown (V): Approx. 2
• lf NG replace air flow meter OR check far any damage Blow air
with the hot wire.
• After inspectíon erase self-diagnosis result and make
3. Water temperature sensor

• Disconnect engine temperature sensor harness
connector.
(Kg
• Measure the resistance between engine temperature 20
sensor harness terminal 1 and 2. ~ 10
¡::
~2 _ _ _____,,,.
Coolant water temperature at 20°C (kO): Approx. 2.5
'iij 1
Coolant water temperature at 80°C (kO): Approx. 0.3 (l)
cr. 0."4-------1--------=---·
• lf NG replace engine temperature sensor. 0.1'-----=1-,----.J,,--~
• After inspection erase self-diagnosis result and make 20 80 (ºC)
Cooling water temperature
EN-363
4. lgnition coil -·--.,

• Disconnect ignition coil harness connector.
• Measure the resistance between following terminals:
Primary coil resistance (1 ~2) (O): Approx. 0.6 ~ 0.9
• lf NG replace ignition coil. 3
c::'0)
- +
214
5. Power transistor
• Disconnect power transistor harness connector. ,,\~
• Measure the resistance by inserting analog type cir- ~/ ~~
cuit tester inspection rod - and + to power transistor :.¡ 1 0-[¿,
·, 1
terminals. \
1-3 +t-ooQ -t+ ooQ

)~tf
3 '
2-3 +/- ooQ > - 1 + O or not ooQ E6 5 4 i2 11
1-3 + / - O or not ooQ <- ! + ooQ
• lf NG replace power transistor.
6. Fuel pump
• Disconnect fuel pump harness connector.
• Measure the resistance between fuel pump terminal 1
and 3.
Resistance (0): Approx. 0.4 ~ 0.7
• Check for operation by directly applying power volt-
age between the following terminals:
Connect terminal 3 to + side, terminal 1 to - side.
Caution:
Care must be taken to connect battery to correct sides.
• lf NG replace fuel pump.
7. Throttle valve switch

• Warm up the engine.
• Disconnect throttle valve switch connector and meas-
ure the resistance between throttle valve switch termi-
nals.
(ldle contact point)
Accelerator pedal is not pressed oQ

Accelerator pedal pressed
• lf NG repair throttle valve switch.
EN-364
Adjustment
ldle contact point touch rev (rpm): 750 ~ 1050
• Adjust if the touch rev is not within the range above.
• Disconnect throttle valve switch connector and loas- _
r :it~w~ 321
en the bolt.
• Gradually increase the engine rev so idle contact 0
.~lvf
point is ON (Resistance between terminal 2 and 1
is 00) at above engine speed. Move throttle valve
switch unit to touch point and tighten the bolt.
• lnstall throttle valve switch connector.
• Race the engine a few times and check that the idle
rev is within standard value range.
8. Throttle sensor
• Disconnect throttle sensor connector.
• Measure the resistance between throttle sensor ter-
minal 2 and 3.
Accel pedal notdepressed: Approx. 0.4
Accel pedal depressed to half way: Approx. 0.4~5
Accel pedal fully depressed: Approx. 5
• lf NG replace throttle valve switch.
1 2)------..
[]]
9. AAC valve
• lnspect the resistance of AAC valve.
Resistance (O): Approx. 9 ~ 1O
• Check the plunger and inspect switch.

• lnspect spring for any damage.
• lf NG replace AAC valve.
Plunger
10.FICD solenoid
• Measure the resistance of FIGO solenoid.
Resistance (O): Approx. 22 ~ 23
1 2)------..
• Plunger and switch inspection.
• lnspect spring for any damage.
• lf NG replace FIGO solenoid.
EN-365
11.Air regulator
Static characteristic inspection Look thro
• Visually inspect the shutter opening degree. to check
Temperature range (ºC)
Below -20°C: Fully open X
20°C: Half open a

Over 60°C: Fully closed x~, o penmg
.
Dynamic characteristic inspection

• Check the change in shutter opening degree when the
terminals are energized with the battery. The shutter
should open gradually within 7 minutes (surrounding
area temperature at approx. 20°C).
(Reference)
Heater resistance value (O): 70 ~ 80 at 20ºC
• lf NG replace the air regulator.
12.lnjector 00
• Remove injector harness connector.
• Measure the resistance between each injector cylin-
der terminal 1 and 2.
Resistance (O): Approx. 1.3
• lf NG replace injector.
13.lgnition relay & lnhibitor relay

• Directly apply power voltage between terminal 1 and
terminal 2.
• Check far continuity between terminal 3 and terminal
4, 6 and 7.
When voltage applied (between 3 & 4 ): Not present
(between 6 & 7): Present
No voltage applied (between 3 & 4 ): Preset
(between 6 & 7): Not present
• lf NG replace relay.
14.Power steering hydraulic pressure inspection

• Remove power steering hydraulic pressure switch
harness connector.
• Check far continuity between the terminals.
Steering wheel steered: Continuity present
Steering wheel not steered: Continuity not present
• lf NG replace power steering hydraulic pressure
switch.
EN-366
RB26DETT ENGINE
,,,,..,----._
1. FUEL PUMP SYSTEM INSPECTION
CONTROL CIRCUIT DIAGRAM RB26DETT ENGINE
#8
F/L-11 IGN
18
5 m ECCS relay
()
o 2
16
#41 Air
(/) 49
(>
>------~regulator o:;:¡ 59
104
~2
106 ~
e
:;:¡
;:::;:
A A
System inspection @ ♦ FUELPUMP ♦
• Select "Fue! pump" in function test. ~ IS THERE A PULSATION
Check for pulsation on the fuel hose. EVERY 3 SECONDS WHEN
• Place ignition switch in the ON position. THE FUEL TUBE IS HELD?
• Check for fuel pump operation noise. OR CAN YOU HEAR THE
OPERATION NOISE OF
The fuel pump will operate for 5 sec
after ignition switch is placed to ON.® THE FUEL PUMP RELAY?
NG Fuel pressure inspection ~ PASS 11 NO j] YES

lf NG replace faulty parts.
B A
1
Relay power inspection
Finish
• Place ignition sw in OFF position.
• Disconnect pump relay connector.
• Place ignition sw to ON position.
-NG
• Measure voltage between earth ter-

minal and the terminal 2 & 3 using
the tester. TI 1 1
1 1 -, 1 J /
OK Check the following:

#17 10A fuse
~ª-------~-~
#41 15A fuse
\
1
TOC Harness continuity between Re
the pump relay and the
fuese.
lf NG replace faulty harness
or the connector.
EN-367
RB26DETT ENGINE
e B
Power circuit inspection
• Disconnect ECCS C/U connector. NG
.___
• Connect pump relay connector.
2
• Place ignition sw in the ON position. 5
• Measure voltage between ECCS C/U con-
nector side terminal 18 and the earth.
D e
OK
Disconnect the pump relay con- 1ECCS C/U connectorl
nector and check for continuity 1
between pump relay terminal 1 [Y]
the connector.
E D ·--...
_

• Connect ECCS C/U connectors. 1ECCS C/U connectod
18
• Check the voltage between ECCS C/U rn
connector 18 and the earth.
5 sec after placing ignition sw in ON position:
Approx. 1V E
Other: Battery voltage
• Check the voltage between ECCS C/U
connector 104 & 106 and the body earth. 1ECCS C/U connectod
'"·T°" ¡~v~¡ 1
NG
5 sec after placing ignition sw in ON position: -
Approx. 2V
Other: Approx. OV
5 sec after engine start: Approx. 4V
Other: Approx. 2V F
OK ECCS C/U power supply "'--...1::::iarness connector

inspection using CONSULT.
F
FPCM input signal inspectiQn
• Check voltage between FPCN connector . ~ -
terminal 1 & 2 and the earth. '- ¡---;
5 sec after placing ignition sw in ON position: > -NG
--- F
Approx. 2V
Other: Approx. OV
5 sec after engine start: Approx. 4V
Other: Approx. 2V
OK
TOG
TOH
EN-368
RB26DETT ENGINE
G
G 1

Check harness continuity between
ECCS C/U connector terminal 104 & 106
and FPCM connector terminal 1 & 2.
lf NG replace faulty harness or the
connector.
104&1,106&2
H
Harness continuity inspection - 1 H
u] .
Fuel pu~phamess connector
• Disconnect connectors for fuel pump, )
1
pump relay and FPCM connector.

• Check the harness continuity between the C)
l.
fuel pump harness connecter terminal 2
and the pump relay harness connector
side terminal 5. ~
H
OK
1
Harness continuity inspection - 2 3
• Check the harness continuity between the NG 2
fuel pump harness connecter terminal 1 -
and the FPCM harness terminal 4.
OK
1 Faulty harness or connector
J
.Harness continuity inspection - 3

Check the harness continuity between
-
NG
FPCM connector 5 & 7 and pump relay
l ¡
OK
K
J
NG
• Check the harness continuity between ,___
FPCM connector 6 and theearth.
OK
1 Fauly harness or connector

• Check fuel pump and the fue! pump relay. K
OK
lnspect ECCS C/U terminal for any damage or

ECCS C/U connectors.
EN-369
INJECTOR SYSTEM SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE
2. INJECTOR SYSTEM INSPECTION

F/L-11 IGN
-
~
Dropping resistor
ECCSrelay+
~·-~
#8 59
3-=5 5 l B
+ 10A l ¡~~1
1-=2
49
16
3 5
7
'1
Air flow meter -
Power 5 No.1
Sig earth 4 34 2~ 1
~ 101 --¡::_;:!_J
(1 l 2l3I4I5) lntake air sig 2 35 No.2
Pwrearth 3~ 105
2~, ,.,
No.3
Air flow meter (R) 103 2 ,.... 1
Power 5 No.4
2 :';- 1
Sig earth 4 26 114
No.5
(112rn,415) 1ntake ai r sig 2
27 m 2 =se 1
Pwr earth 3 o 110
'"'
o(/)
2 ~1 ¡
Crank angle sensor o 112
Power
120º signal
3
1
1
51
41
--e lnjector (fil)
(11 ~314) 0 2 sensor (R)
1° signal
Earth
2
4 L
42
52
29
115
}~ ~ , E® lio IGN SW
~
1
o_ sensor
Throttfe sensor 31 ~ 1
~
48
55 zl . ~
..1
GTID) IEi 1
38
30
r
Vehic~pd s ens
53 ~
Ispeed o meter! 1
Water temp sen ~
1 , - -
? f~l1 ·· 28
101 10110! 1 2 3 4 5 6 7 B 9 1 21 22 23 24252627282930 41424344454647 4849 50

10 11111! 11 12 13 14 15 16 17 18 19 2 31 32 33 34 35 36 37 38 39 40 51 52 53 54 55 56 57 58 59 60
A A
System inspection OK @ ♦PWR BALANCE♦
• Start the engine. ___ STOP INJECTOR ORIVE
• Carry out the "Power balance" inspec- TO INSPECT EACH CYL-
INDER FOR BALANCE.
tion in function test mode. OR
TURN OFF AIR CONDI-
"Power balance" in active test. TION ER AND LIGHTS.
• Check the voltage between each injec-
tor harness connector terminal 2 and PASS JIL__S_T._A_RT_ __,
earth. @
IGN sw in ON: Battery voltage
A
When cranking: Approx. 1OV
~
While engine is running: onnector
The battery voltage will decrease as the
engine rev increase. (voltage will decrease
approx. 0.2V to 2000rpm rev incrase).
NG Finish ; 1 g ·9der)
TOS
EN-370
RB26DETT ENGINE
B A
Power supply inspection /
_¿i(
Dropping resistor
• Disconnect the dropping resistor har- NG
ness connector. i
• Measure voltage between dropping the
resistor harness side connector terminal
3 and the earth.
/
A
OK
Check the following:
Check for harness continuity
between the fuse and the drop-
ping resistor terminal 3.
connector.
e
Control signal inspection B
• Connect dropping resistor connectors.
• Place ignition sw in the ON position. -NG
connector 101, 103, 105, 110, 112, 114
and the earth.
connector 101, 103, 105, 110, 112, 114
and the body earth. e
IGN sw in ON position: Battery voltage
While cranking: Approx. 1OV OOID~~
The battery voltage will decrease as the 101,103, 105, 110, 112 14
engine rev increase. (voltage will decrease
approx. 0.2V to 2000rpm rev incrase).
[y]
OK
Check the following:
Crank angle sensor system
Air flow meter system
Water temperature sensor system
0 2 sensor signar system
Throttle sensor system
ECCS C/U power
Vehicle speed sensor system
lgnition sw (start) signal
lf NG replace the faulty parts.
TOD
EN-371
RB26DETT ENGINE
D D
.Harness continuity inspection - 1

Place ignition sw in the OFF position .
• Disconnect dropping resistor and injector
hamess connectors.
• Check the harness continuity between fol-
lowing termínals:
Dropping resistor lnjector - NG
1 1 (No.1) E
7 1 (No.2)
5 1 (No.3)
8 1 (No.4)
4 1 (No.5) 101, 103, 106, 11 0, 112,114
6 1 (No.6)
OK 1 Faulty harness ar connector 1
E
Harness continuity inspection - 2
• Disconnect ECCS C/U harness connector.
• Check the harness contínuity between NG
following terminals:
ECCS C/U lnjector
101 2 (No.1)
105 2 (No.2)
103 2 (No.3)
114 2 (No.4)
110 2 (No.5)
112 2 (No.6)
OK
1 Fauly harness or connector 1

t---
• Check injector and dropping resistor.
OK
1 Replace faulty parts 1

EN-372
IGNITION SYSTEM SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE
3. IGNITION SYSTEM INSPECTION

CONTROL CIRCUIT DlAGRAM RB26DETT ENGINE
#8 59 Crank angle sensor

49 51 3 Power
'---:~~--------,16 41
42
52
1 120° si nal
2 1° si nal
4 Earth
c11 rn 14)
Throttle sensor
IGN
48 1
38
30
@lli)
m
o
o Water temp se
en
Q 28
1 cffl)
e
Throttle valve sw
12 5 4 ~_ _!1~9+-=-2- - ~
3 57 ~l=dl-=-e-=-co::..:.n=ta=-=c:.:...t=º=¡n.;..;.t_
13 1
2 3 f - - - - - - ----.Knock sen (1LJ
2
11
1
24>-----------< Knock sen ~
(IGN coil side) (C/U side}
C1fl16j15~13~2~1) C1I 2j3'i!rs jeJ -=-
4 5 6 7 8 9 445 46 47 48 49 so
t41516171al9 54 55 56 5 7 58 59 60
A A
Overall system inspection ♦ POWER BALANC~
NO STOP INJECTOR DRIVE
• Place ignition sw in the START position. TOE TO INSPECT EACH CYLIN-
• Make sure all cylinders are firing .
DER FOR BALANCE.
TURN OFF AIR CONDI-
YES
TIONER ANO LIGHTS.
• Carry out "Power balance" in
function test mode. OR 00 OK
• Carry out "Power balance" in active Finish PASS 11....____s_TA_R_T_ ~
test.
• Check to make sure the engine rev will B
not decrease momentary. _,,,/1/
o
NG
B
~o .
Circuit function inspection d" º ~~-
• Ptace ignition sw in the OFF position .
. Disconnect ignition coil harness connec- /
tor.
NG
TOF \ Harnes/nnector
• Check the battery voltage between

loK
TOC
EN-373
IGNITION SYSTEM SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE
e e
• Place ignition sw in the OFF position. NG
• Check continuity between terminal 3
and earth. [[]
OK
1Replace faulty terminal or connector.
D D
• Place ignition sw in the OFF position. NG
• Disconnect power transmuission unit
harness connector.
• lnspect between following terminals for
continuity:
Between each ignition coil terminal 1
and power transistor terminal 11, 12, 13, D
14, 15 and 16.
OK 61h2hA st16l1'¡}
1 Replace faulty terminal or connector. 1 11, 12, 13, 14, 15, 16
3 21
E
Function inspection
• Remove ignition coil harness connec- NG E
tor. 1---TO C
and body earth.
OK
F
Power inspection F
• Remove ignition coil relay connector. NG
& 3 and body earth.

Fusible link. F
lgnition sw.
Harness continuity between ignition
coil relay and ignition sw.
Harness continuity between ignition
coil relay and the battery.
connector.
EN-374
IGNITlON SYSTEM SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE
G G
• Place ignition sw in the OFF position . NG
• Check continuity between each coil ter-
minal 2 and ignition coil relay harness
terminal 5.
OK
1 Replace faulty terminal or connector. ¡
H H

• Check for harness continuity between 1ECCS C/U connectorl
16
ECCS C/U terminal 16 and ignition coil
relay harness terminal 2.
[]]
OK lnspect the following:

ECCS relay
Harness continuity between ECCS
relay and ignition coil relay.
connector.

'---
• Check ignition coil relay and ignition coil.
OK
1 Replace faulty parts

EN-375
RB26DETT ENGINE
4. AAC VALVE SYSTEM

IGN
59
AAC valve
¡.-........,,3-+00ll---- -- - ......i.-~49
~ 1 '~º~f-'é2- -+-- - - ~ 16
+
Crank angle sensor
Power 3 51
19
PWR ST oil pressure
2 -1
Neutral sw
SW
(1D)
120° si 1 ,___ __ __._ 41 44 f3J])

m 2
o -:::
1° si 2 - - -- - - 42 o
Earth 4 52 (J)
o 46 Thermo amp
e
Throttle valve sensor
48 Vehicle spd sen
crrnD 38 53 Speedometer
30
····-.
Water temp sen~

.___ _ 1
-'-W,,c.µ,
2_ _ _ _ ~ . 28
System inspection - 1 A
NG
• Warm-up the engine. ♦ MCVALVE ♦
• Check idle rev (rpm): 950+/-50 PRESS START AFTER
TURNING OFF AIR
OK Base rev inspection CONDITIONER ANO
• Check if ECCS C/U idle rev adjust- LIGHTS.
ment volume knob is turned fully left.
• Check if engine rev id at 900rpm when
the AAC valve harness connector is
PASS JJ START
removed.
A
A (Below intake manifold collector)
System inspection - 2 fi' Hamess connector AACvalve
• Carry out "AAC valve" in function ~

test mode. OR
• Carry out "AAC valve opening" in active
test mode.
• Check if engine rev will change when
"Qu" or "Qd" is pressed to change the
valve opening.
• There must be more than 150rpm
change when control duty ratio is
between 80~20%.
1
Contrnue to next page
EN-376
RB26DETT ENGINE
. Make sure the engine rev is at B

900rpm when AAC valve harness
connector is removed. OK
• lf the value is not at correct rev, adjust
engine rev to 900rpm using the idle
adjust screw.
NG lnspect the following input signal

systems: e
Crank angle sensor
Water temperature sensor
Throttle sensor
Vehicle speed sensor system 4
Neutral signal
Power steering oil pressure signal
Air conditioner sw signal
8
1
Power inspection Finish
• Remove MC valve harness connector. NG
• Check far battery voltage between AAC
valve harness connector terminal 1 and
earth.
OK lnspect the following:

• #17 10A fuse
• Harness continuity between
AAC valve and fuse.
lf NG replace the faulty harness.
e
• Remove ECCS C/U harness connector. NG
• Check for continuity between ECCS C/
U connector terminal 4 and AAC valve
OK 1 Faulty harness or connector.

• Check MC valve component parts .
OK
1 Replace AAC valve

EN-377
INJECTION PULSE SIGNAL (Ti MONITOR) SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE
5. INJECTION PULSE
m
()
()
lnjection pulse signa! (Ti monitor) - ------117 (J)
()
e
A A
lnjection pulse monitor (Ti monitor)
signal inspection 00@Pi)~
• Check the power voltage between lECCS C/U connector !
~
ECCS C/U terminal 17 and the body
earth with ECCS C/U connector NG
connected.
When ignition sw in ON: Power voltage
While cranking or engine running:
The power voltage will decrease as the A
engine rev increase. lnjection pulse width
lnspection using oscilloscope Ti monitor ~ - 1zv
• lnjector pulse monitor (Ti monitor) is an waveform !.___ _, OV
actual injector waveform from ECCS

C/U result.
lnjector
waveform
l
-i---J\...__ 12V
OV
OK
lnjector input signa! system

Finish inspection
lnspect injector system.
lf NG replace or repair faulty parts.
EN-378
BOOST CONTROL SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE
6. BOOST CONTROL
CONTROL CIRCUIT D1AGRAM RB26DETT ENGINE
IGN #17
25e-------=--l2Jfl?í-"-f-'---1- - - - - '
Boost control solenoid
m
~hl Knock sen
1
- ---------<23
l-'-- g
(/)
~ Knock sen
"t2.LJ
1
24 °e
IQ\101108 1 2 3 4 S 6 7 8 9 1 2l 22232425262728293 41424344454647484950

ll l 11\ 116 11 12 13 14 15 16 17 18 192 31 32 33 34 35 36 37 38 39 40 51 52 53 54 55 56 57$85960
A A
System inspection
• Start the vehicle to warm up the engine. OK
• Check if the boost control solenoid op-
eration noise can be heard when the
engine rev is increased to over approx.
2200rpm.
NG
Component parts inspection B
lnspect boost control actuator. \ ~ \ íC...'--A1 -.;¡_ ¡
, Boost control solenoid
lf NG replace faulty actuator. - -u
1 OK fe]
B
Finish ~ ss connector
• Place ignition sw in the OFF position. /~

• Remove boost control solenoid harness 8
connector. NG
• Check power voltage between boost
control solenoid terminal 1 and body
earth.
OK
#17 10A fuse
Harness continuity between
control solenoid and the fuse.
TOC
EN-379
BOOST CONTROL SYSTEM FAULT DIAGNOSIS
R826DETT ENGINE
c c
Control signal circuit inspection
OK
• Check harness continuity between ECCS
- 1ECCS C/U connector 1
25
C/U connector terminal 25 and boost

control solenoid connector terminal 2.
NG
Check for faulty harness
D
or connector.
AMONITORINGi:(1\10 FAULT
D
Control signal inspection BOOST CONT SN
• Start the engine . 00 ON
• Check ON-OFF operation using "Boost OK ~
CONT SN" in data monitor mode.

ldling: OFF START MONITORING
When accel pedal is depressed suddenly: ON
C/U terminal 25 and body earth. ® D

When accel pedal is depressed suddenly: 1.0V
@©u~
!ECCS C/U connector 1
25
NG
Check for any disconnected hose
or damaged hoses.

• Check MC valve component parts .
OK
Replace boost control
solenoid or actuator.

ECCS C/U connectors connection.
EN-380
AIR CONDITIONER CUT CONTROL SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE
7. AIR CONDITIONER CUT CONTROL

To supplemenlal motor fan relay
r------1 Throttle sensor signal
~
(")
(/) _ ___, Water temperatura signa!
Q
e
Engine rev signa!
(Crank angle sensor)
A A
Air conditioner sw input signal
inspection 00 ~ONITORINm NO FAULT
• Place the ignition sw in the ON position . AIR CON SIGNAL ON

. Carry out the "A/C signal" inspection in r -NG
--
data monitor mode.
Air conditioner sw ON: ON
Air conditioner sw OFF: OFF
START MONlTORING
ECCS C/U connector terminal 46 and
body earth.
Air conditioner sw ON: ov ® A
Air conditioner sw OFF: Power voltage ~[íi(@t@f

OK 46
lnspect harness continuity for triple
pressure sw and air conditioner sw.
B
A/C relay control signal inspection
. Start the engine . 00 B
"tMONITORINm NO FAULT
• Check ON-OFF signal of A/C by carry- NG
ing out "A/C relay" in data monitor. AIR CON SlGNAL ON
ECCS C/U connector terminal 9 ®
and body earth.
Air conditioner sw ON: START MONITORING
Approx. 1.0V
Air conditioner sw OFF: Power voltage
B
OK
lnspect harness continuity for air
conditioner relay. I
Que,~~
ECCS C/U connector 1
8
~

EN-381
RB26DETT ENGINE

54 ..___ _....., IGN TIMING CONTROL

ldle contact point
'------'+1..-...1-=-2~-~---,57 ~
o 1-------., FUEL INJ CONTROL
Throttle valve sw 'G]!JD C/J
o
e
1------ IDLE REV CONTROL
A
A
System inspection (ldle contact point)
• Start the vehicle to warm up the @ OK ♦. THR0TTLE SEN ♦
engine. PRESS START WHILE
• Place ignition sw in the ON position. FULLY OPENING THE
• Carry out "Throttle sensor" in function ACCELERATOR PEDAL.
test. OR
• lnspect usíng data monitor mode.
Acceleration pedal not depressed: ON
Finish
Acceleration pedal deoressed: OFF 1 PASS 11 START
• Start the vehicle to warm up the
engine. A
• Check the power voltage between OO©u~~a
ECCS C/U terminal 54 and body earth. 54
Accel pedal not depressed: Approx.11V [y]
Accel pedal depressed: Approx. OV
NG =
B
Power inspection B
• Place ignition sw in the OFF position. Throttle valve sw ' - /J
arness conn f'
• Remove throttle valve sw connector. ---'/. ,
;i
• Place ignition sw in the ON position. NG
• Check the power voltage between throt- ,___
~
tle valve sw harness terminal 2 and body
earth.
OK
B
• Check harness continuíty be-
tween throttle valve sw terminal 2
TOC and ECCS C/U terminal 57.
EN-382
RB26DETT ENGINE
e e
(idle contact point)
• Place ignition sw in the OFF position . 1ECCS C/U connectorl
54
• Remove throttle valve sw harness connec- -
tor.
terminal 54 and throttle valve sw terminal 1 .
OK
ÍFaulty harness or connector.1

• Check throttle valve sw.
OK
[ Replace throttle valve sw. ¡

,,..-- ..
EN-383
0 2 SENSOR HEATER SYSTEM SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE
9. 0 2 SENSOR HEATER SYSTEM

0 2 sensor (R) Ei:)

~ 2 29
115
3
0 2 sensor m
3 ()
> - - - - --AJF ratio feedback control
()
1 ~ 55 en
2 ()
<IwD e
.....,
A A
Power inspection
• Remove 0 2 sensor harness connector. NG
• Place ignítion sw in the ON position .
• Check the power voltage between 0 2
sensor harness terminal 1 and body
earth.
OK
A
B
NG
• Check the harness contínuity between
0 2 sensor harness terminal 3.
OK
1 Faulty harness or connector. 1 B
00 tül:it
Component parts inspection NG !ECCS C/U connector!
11 5
• Check 0 2 sensor heater.
OK
1 Replace 0 2 sensor. 1

EN-384
VEHICLE SPEED SENSOR SYSTEM SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE

m
Vehicle spd sen C) Fuel cut control
()
[/)
Q ldle rev control

e
Vehicle speed sensor function A

inspection NG +.1EH SPD SEN ♦
. Check the speedometer operation. START DRIVING AT 10KM/H
WITHIN 15 SECONDS OF
OK PRESSING 'START'.
Check the vehicle sensor and
vehicle speed sensor circuit.
A
Input signal inspection @ PASS 11 START
• Carry out "vehicle speed sensor" in

A
function test mode. OR
OK
• Read "the vehicle speed sensor" in data
monitor mode.
Finish ©.:>~
The display on the CONSULT is same
~
value as the speedometer display.
• Check the power voltage between ®
the body earth. B
(Behind the combination meter)
When the vehicle is parked: 5Vor 0V
Vehicle speed at 40km/h: 2.5V
NG
B
• Disconnect ECCS C/U and combination
meter connector. NG
• Check far continuity between ECCS C/U
B
connector terminal 53 and combination
meter connector 16.
IECCS C/U connector !
OK 53

,___
• Check vehicle speed sensor
1 Replace vehicle speed sensor.

EN-385
IGNITION SWITCH (START) SIGNAL SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE
11. IGNITION SWITCH (START) SIGNAL
A A
Function inspection ~ ♦ START SIGNA~
• Carry out "starter signal" in function ~ 1. Place the shíft lever in P
or N after fully opening the
test mode. OR OK accelerator pedal.
• Carry out "starter signal" in data monitor 1- - Finish 2. Start the engine directly
after pressing "START".
mode.
IGN sw ON: OFF
IGN sw START: ON
• Place ignition sw in the START. fa\ PASS ''~_ _
ST._A_R_T_ _
• Check the power voltage between ~
A
the body earth.
When the ignition in start: Power voltage 1 ECCS C/U connector 1
4L____a
----;
Other: Approx. OV
NG
B
• Remove ECCS C/U and ignition sw har- B
NG
ness connector.
• Check far harness continuity between
ignition sw harness connector 5.
OK
lnspect the fallowing:
#3 10A fuse
Continuity between ignition sw and
B
ECCS C/U harness.
connector.
43
lnspect ECCS C/U terminal far any damage or
EN-386
POWER STEERING OIL PRESSURE SIGNAL SYSTEM FAULT DIAGNOSIS
RB26DETT ENGlNE
12. POWER STEERING OIL PRESSURE SIGNAL

#8 59
f - - . - - . : : + o =------____.--------<49
-------.-i:::_•·_'-t-,;--2- - - - - - - - - - - - j 1 6
2 1 m
5Power steering
oil pressure sw cffi:)
8
(J)
IDLE REV CONTROL
.------'-'cOr>---J-"~-----------,19 Q
e 1071-------,
108r----
1161--------i
A A
Function inspection @ ♦ P/S SIGNAL ♦
• Carry out "power steering signal" in PRESS START WHILE
function test mode. OR STEERING WHEEL FULLY
OK STEERED.
• Carry out "power steering oíl pressure Finish
sw" in data monitor mode.
Steering wheel not steered: OFF
Steering wheel steered: ON START
. Start the engine.
PASS 11
• Check the power voltage between ® A

the body earth. tn)C)~
Steering wheel not steered: 4.5V 1ECCS C/U connectorl
Steering wheel steered: ov
NG
B
• Disconnect ECCS C/U connector. B
. Remove power steering oil pressure sw NG (Below intake manifold collector) -
Power steering oil
harness connector. ,,__..__~pressure sw
hamess con nector
e
connector terminal 19 and power steer-
ing oil pressure sw harness connector 2.
OK
1 Faulty harness or connector. l
B
JJ
• Check for continuity between power NG OOeol:i
1 ECCS C/U connectorl 2 1
steering oil pressure terminal 1 and body 19
earth.
OK
1 Faulty harness or connector. l
• Check power steering oil pressure sw.
EN-387
NEUTRAL SIGNAL SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE
13. NEUTRAL SIGNAL
Neutral switch m
o
. . - - - - - 2tvOl--'-1--------1 44 o
(J) 1-------,IDLE REV CONTRO
Q
e
A
Function inspection rj"\ A
• Carry out "neutral sw" in function ~ ♦ NEUTRAL SW ♦
test mode. OR NG
PRESS START WHJLE
• Carry out "neutral sw" in data monitor,-----, SHIFT LEVER IS IN ANY
mode. POSITION OTHER THAN
When neutral: ON N ORP.
Other: ON
• Place shift lever in neutral. fa\ 1 PASS 11 START
• Place ignition sw in the ON position.~
ECCS C/U connector terminal 44 and A
the body earth.
When neutral: ov
000 .:)[:4
Other: 4.5V 44
OK
B
• Disconnect ECCS C/U and
~
neutral sw connector and check B
continuity between ECCS C/U
terminal 44 and neutral sw ter- OOEü~
minal 1. 1ECCS C/U connector 1
44
lnspect ECCS C/U terminal for any damage or []]

EN-388
AIR CONDITIONER OPERAT!ON SIGNAL SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE
14. AIR CONDITIONER OPERATION SIGNAL

~-- CONTROL CIRCUIT DIAGRAM RB26DETT ENGINE
To supplemental motor fan relay
_ _____, THROTTLE SEN SIG

m
o
o
(J)
- ~ - - - , WATER TEMP SIG
o
e
ENGINE REV SIGNAL
- - - (CRANK ANGLE SEN)
A A
A/C sw input signal inspection @
• Check air conditioner signal using "air OK AIR CONDITIONER SIG ON
con signal" in data monitor mode. Finish
ECCS C/U connector terminal 46 and START MONITORING
the body earth.
Air conditioner sw ON: ov ® A
Air conditioner sw OFF: Power voltage
NG
E)~(@~
B
~
• Disconnect ECCS C/U and thermo amp NG
connectors.
ECCS C/U connector terminal 46 and B
thermo amp terminal 3.
®Eü [:ti o
OK 1 ECCS C/U connector 1 21
1 Faulty harness or connector. 1 46
lnspect each connector terminal for damage

and check connector contacts.
EN-389
AIR REGULATOR SYSTEM SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE
15. AIR REGULATOR SYSTEM
59 ECCS relay
49,f---.-.-+--><+o o+"-..---
18 16'L__--1..,~_J
To fuel pump - - ~ m
o
Air 1
re ulator 2
~:tt: ECCS sub harness
t
o
(/)
A A
Function inspection
• Carry out "fuel pump" in function 00 NG ♦FUELPUMP ♦
IS THERE FUEL PULSA-
TION EVERY 3 SECONDS
test mode.
WHEN THE FUEL TUBE
• Place ignition sw in the ON position.® IS HELD? OR CAN YOU
• Check fuel pump operation noise. HEARTHEFUELPUMPR&
The fuel pump will operate far approx. 5 LAY OPERATION NOISE?
seconds after ignition sw is placed in the

ON position. J PASS 11 NO JI YES
OK Check fue! pump operation.

1 A
8
Power inspection
. Place ignition sw to OFF position .
. Remove ECCS sub harness connector. NG
sub harness connector terminal 8 and
body earth.
OK Check the following:

Continuity between ECCS sub
8
/,~---~---------~
/A)';-.,::---
~>-(i!.i~~-----
~v ,,. -
~
---._-:_:::s:,
harness and fuel pump relay.
lf NG check harness or connector.
)
e "--
.. ~_
• Place ignition sw to OFF position . "
NG 8
• Check continuity between ECCS sub
harness connector terminal 4 and body
earth.
OK
EN-390
AIR REGULATOR SYSTEM SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE
Component parts inspection NG B

Check air regulator operation.
OK
1 Replace aír regulator. 1

and ECCS C/U connectors connection.
8
EN-391
SUPPLEMENTAL MOTOR FAN CONTROL SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE
16. SUPPLEMENTAL MOTOR FAN CONTROL

F/L-4 Supplemental motor fan relay Supplemental motor fan motor

~ - - - - - - - - - ~3+oo+5'--_ _ _ _ _._ M P-----,
To triple pressure sw
A A
Function inspection Water temp sw ~
OK hamess connector '---
• Remove water temperature sw harness
connector.
l
• Short circuit water temperature sw har-
ness connector terminal 1 ~ 2.
Make sure the radiator fan will operate. A
OK 1 Check water temperature sw.

B 1 OK
Power inspection Finish
• Remove fan relay. NG
• Place ignítion sw in the ON position .
B
• Check power voltage between fan relay //////( '-
Supplementa
box side terminal 1 & 3 and body earth . motorfan
~
OK
Check the followíng:
#13 10A fuse ~ : ! ) ~ " ' - - -- /
25A fusible link
Harness and connector
lf NG replace or repair parts. B
e
• Remove supplemental motor fan motor NG
harness connector.
• Check for continuity between fan motor
terminal 2 & water temperature sw
1 OK
Faulty harness or connector.
To D
EN-392
SUPPLEMENTAL MOTOR FAN CONTROL SYSTEM FAULT DIAGNOSIS
RB26DETT ENGINE
o e
Control signal circuit inspection o O"-___/
• Check for continuity between fan relay ~~~~:::!~-, = fL~
terminal 5 and fan motor terminal 1. NG

• Check for continuity between fan relay
terminal 2 and water temperature sw
terminal 1.
OK
1 Faulty harness or connector. 1 e
Component parts inspection Fan motor Water temp sw

lnspect supplemental motor fan relay, NG
supplemental motor fan motor and water
temperature sw.
OK
1 Replace faulty parts. l
D

and ECCS C/U connectors connection.
EN-393
RB26DETT ENGINE
17. COMPONENT PARTS INSPECTION
1. lgnition coil
• Remove ignition coil harness connector.
• Check the resistance between following terminals:
Primary coil resistance (1~2) (O): Approx. O
Secondary coil resistan ce (3~4) (O): oo
• lf NG replace ignition coil.
2. lgnition coil relay

• Directly apply battery voltage between terminal 1 ~ 2.
Check for continuity between terminal 3 ~ 5.
When battery voltage is applied: Continuity present
When no battery voltage: No continuity
• lf NG replace ignition coil relay.
3. Throttle valve switch

• Warm up the engine.
• Remove throttle valve switch connector.
• Check for resistance between throttle valve switch
terminal 2 ~ 1.
When accelerator pedal is not depressed
(idle contact point ON) (O): O
When accelerator pedal is depressed
(idle contact point OFF) (O): oo
• lf NG replace and adjust the throttle valve switch.
Throttle valve switch adjustment:

ldle contact point touch speed (rpm): 1200+/-150
• lf touch speed is not at above value, use the following
steps to carry out adjustment:
• Remove AAC valve harness connector after engine
warm up.
• Remove throttle valve switch connector and warm up
the installation bolt.
• Lower engine speed by turning the throttle valve
switch from "open" position until touch speed is at
above value (no resistance 00 between terminal
2~1 ). Tighten installation bolt.
• lnstall the throttle valve switch connector.
• Race the engine several times and make sure the idle
rev is at correct value.
EN-394
RB26DETT ENGINE
4. lnjector
• Remove injector harness connector.
• Check the resistance between terminal 1 ~ 2 for each
cylinder.
• lf NG replace injector.
5. Dropping resistor
• Remove dropping resistor connector.
• Check for resistance between dropping resistor termi-
nal 3 ~ 1, 4, 5, 6, 7 & 8.
• lf NG replace dropping resistor.
6. Fuel pump
• Remove fuel pump harness connector.
• Check for resistance between fuel pump terminal 1 ~
2.
Resistance (O): Approx. 0.4 - 0.7
• Place terminal 1 to negative and terminal 2 to positive
terminal to directly apply battery voltage and check for
operation. Make sure the pump will operate.
7. Fuel pump control modulator

• Remove the rear side inner panel inside the boot.
• Check the power voltage between terminal 4 and 7
with FPCM connector still connected.
Power voltage value:
First 5 seconds after placing to ON position (V): 6.4
5 seconds after placing to ON position (V): O
ldling (V): 6.4
8. 0 2 sensor heater
• Remove 0 2 sensor harness connector.
• Check the resistan ce between 02 sensor terminal 1 -
3.
• lf NG replace 0 2 sensor.
EN-395
RB26DETT ENGINE
9. Air regulator
Static characteristic ínspection
• Visually inspect the shutter opening degree.
?
Temperatura range (°C)
Below -20°C: Fully open 1f'""s.
20°C: Half open r§¡~ Opening degree

Over 60°C: Fully closed
Dynamic characterístics ínspection

• Check the change in shutter opening degree when
the termínals are energizad with battery. The shut-
ter should open slowly wíthin 7 minutes (surrounding
area temperature at approx. 20°C).
(Reference)
Heater resistance value (O): Approx. 80 (at 20°C)
• lf NG replace the air regulator.
10.AAC valve
• Remove AAC valve harness connector.
• Check the resistan ce between AAC valve terminal 1 ~
2.
Resistance (O): Approx. 7
• lf NG replace AAC valve.
• Check the plunger and inspect switch.

• lnspect spríngs for any damage.
11. Boost control solenoid

• Remove boost control solenoid connector.
• Check the resístance between solenoid terminal 1
and 2.
Resistance (O): Approx. 32
• lf NG replace boost control solenoid.
12.Supplementary power fan motor

• Remove supplementary power fan motor connector.
• Check if the fan motor will turn when the battery pow-
er is applied directly to terminal 1 ~ 2.
• lf NG replace the supplementary power fan motor.
EN-396
RB26DETT ENGINE
13. Power steering oil pressure switch
• Remove power steering oil pressure switch connec-
tor.
• Check for continuity between power steering oil pres-
sure switch terminal 1 - 2.
When neutral: No continuity
When steered: Continuity present
• lf NG replace power steering oil pressure switch.
14.Supplementary motor fan relay & fuel pump relay

• Check for continuity between terminal 3 ~ 5 when
battery voltage is directly applied to terminal 1 ~ 2.
Battery voltage is applied to terminal 1 ~ 2:
Continuity present
No battery voltage is applied:
No continuity
• lf NG replace relay.
15.Water temperature switch

• Heat up the water temperature switch in hot water
while stirring.
• Check for continuity between terminal 1 - 2.
Water temperature below 90°C: No continuity ~rom~Thermometer
\1
Water temperature above 90°C: Continuity present
t'.I
EN-397
FUEL PUMP SYSTEM SYSTEM DIAGNOSIS INSPECTION
RB20E ENGINE
EN9 SYSTEM DIAGNOSIS INSPECTION (RB20E)

1. FUEL PUMP SYSTEM
ECCS relay
1 ; m
1 o
1
1
o
(f)
uel pump relay
o
1 2 3
1
1
e
l
4 5 6 1 ¡ '------' I
L ___________
ÉE j
,-~-------· j
=_ _
9
j ~t~i ;:o~~Fator
l _____
~ cñ______________________j
RB20DET only
Fuel pump system trouble diagnosis flowchart RB20E ENGINE

1 Fuel pump operation noise inspectionl
Pump sounds for 5 Pump doesn't sound / Other
1
seconds when ignition
switch is turned to ON
1
1 Fuel pressure inspections 1 Fue! pump relay operation noise inspection 1
When ignition switch is ON, Relay operatíon noise can be heard
fuel pump pressure is approx. Other when ignition is placed to ON No sound
r
2.5kg/cm2 L,-
1
Other system
í'
Fuel pump voltage inspection
"DATA MONITOR"
in active test mode
I ®I
1 1 _Fuel
sy~tem
~
1
inspection InspectIon lnspect voltage between Normal
: Abnormal
pump pins 1 - 3
Power voltage when ignition switch is IFuse, relay 1
placed to ON position far 5 secs and
"ACTIVE TEST " is ON.
Other
3 ~
Normal 1 Abnormal
1
Fuel pump relay voltage Replace fuse
Fuel pump inspection 1
inspection. Measure voltage ar relay
1. Measure resistance between Harness continuity inspection
between relay terminal 2, 3
pump terminals 1 to 3 Measure resistance between
and earth
2. Apply battery voltage directly relay terminal 5 and pump
erminal 1 Battery voltage with
between terminals 1(+) to 3(-) ignition switch ON Other
1. Approx. 0.5 Q og 1 Other
2. Pump operation Other
sound is produced 1 1 1
Check for faulty con- Repair Harness continuity inspection Repair power
1 1 harness
Check for faulty con- Replace nection and inspect Measure resistance between relay supply circuit
lcircuit system lterminal 1 and C/U terminal 104 system
nection and inspect fuef pump
circuit system
oo Other
1 1
ECCS C/U power inspection Repair
"DATA MONITOR" ® harness
Measure voltage between C/U ter-
minal 27 and earth. ®
Battery voltage present
when ignition switch is ON Other
1
1
1
¡check connector for breaks Repair ECCS C/
and input signa! system 1 U power supply
c1rcu1t system
EN-398
RB20E ENGINE
1 Fuel pump relay operation inspection ♦ ACTIVE TEST ♦ 0

• Place the ignition switch in the ON position and @
select "FUEL PUMP RELAY" in active test mode. FUEL PUMP RELAY ON
MONITOR
Press the ON button and check for pump operation
noise.
l ON 11 ON/OFFII OFF
• When the ignition switch is in the ON position, ®

the relay operation noise must be audible. There must
be a relay cut off noise 5 seconds later.
• After engine stall, turn the ignition switch to OFF posi-
tion 1.5 seconds later.
2 Fuel pump relay power inspection

• Disconnect the fuel pump relay and measure voltage
between the following terminals and earth when the
ignition switch is placed in the ON position.
Terminal 2 and body earth: Power voltage
Terminal 3 and body earth: Power voltage
3 Fuel pump control signal inspection 1),0NITORIN*NO FAULT□

• Select "FUEL PUMP RELAY" in data monitor mode Fuel pump relay ON
and check the condition of the fue! pump relay (6\
lgnition sw in ON: OFF \..eJ
Cranking: ON
ldling: ON
RECORD
• Measure the voltage between terminal 104 and earth

when the ECCS control unit connectors are connect-
ed.
Within 5 seconds after ignition sw is placed to in the
ON position: Approx. 1V
5 seconds after ignition sw is turned to in the ON
position: Power voltage
Cranking: Approx. OV
ldling: Approx. 1V
EN-399
RB20E ENGINE
4 ECCS control unit power supply inspection

• Select "BATTERY VOLTAGE" in data monitor V
mode and carry out the inspection. m
o
lgnition sw in the ON position: 11 ~ 14V ECCS relay o
>-------ik.W.rt--~,40 en
Note: ...o+--➔27 Q
e
The same setting as ON position is maintained for a few
V
seconds after the ignition switch is turned from ON to
OFF and then ON position again.
• Measure the voltage between ECCS C/U @

terminal 27 and the earth when the ECCS control unit
connectors are connected.
lgnition sw in OFF position: ov
lgnition sw in ON position : Power voltage
Cranking: Power voltage
5 Harness continuity inspection

• Disconnect ECCS control unit, fuel pump relay and m
fuel pump harness connectors and measure resist- o
o
ance between the following terminals. en
o
ECCS C/U harness terminal 104 and fuel pump relay e
harness terminal 1: 00
ECCS C/U harness terminal 1 and fuel pump relay
harness terminal 5: 00
~---
Boot interior right -
~~
6 Fuel pump voltage inspection
• Disconnect the fuel pump connector and measure the
voltage between the fuel pump harness terminal 2 and ~ ~ -·-
earth.
5 sec after ignition sw is turned to ON position:
Power voltage /
Fuel pump hamess connector
,
2
Boot interii r ---..____
right - "--..-;:::
7 Fuel pump inspection ,--
• Remove the fuel pump connector and check the
~
resistance between fuel pump terminal 1 and 3. 0 .. ,_y? o\
Resistance (O): Approx. 0.4 ~ O.
/
Fuel pump hamess connector
Boot interior right ,.

• Check the fuel pump operation by disconnecting the
fuel pump connectors and apply power voltage directly ~~
to the following fuel pump terminals .
Pump terminal 1 to battery positive terminal(+).
Pump terminal 3 to battery negative terminal(·).
~ - ~ o
<
Fuel pump hamess connector ··---._
EN-400
INJECTOR SYSTEM SYSTEM DIAGNOSIS INSPECTION
RB20E ENGINE
2. INJECTOR SYSTEM
Air regulator (·) 1
Air regulator (+) 2 2
OOill No.4
23
27
~~
·f: 2
OOJTI
oou
No.S
No.6
D
40 o
~e;
ECCS relay [iJ..J}]
lTIIT
OOUNo.1
OOUNo.2
H
e
3m ~ No.3
AT
32
22
seasf:©
Throttle valve SW
Thcottle
26 (')
7
m
(')
101
109
110
€:Q:filNo.1
@}])No.2
C/J
Crank angle sensor
(')
----
e
103 2
ttQill_ No.3 s
1 19 112 o
10 @illNo.4 H
28 105 2 e
~No.S
Air flow meter
114 2
1 ®!!]No.6
3
4
6 1
e~
w (Ifísensor
./'-i.
Engine temp sensor
~ -----◄
5
;
8
..__ __.........
21 VEH SPD SEN
EN-401
RB20E ENGINE
lnjector system trouble diagnosis flowchart RB20E ENGINE
l lnjector operation noise inspectionJ

operation sound audible 1
No operation sound
1 1
1?ther system 1 lnjector control signa! ínspection

inspect,on Measure voltage between injector connector
tenminal 2 (each cylínder) and earth. tlD
Note: Battery voltage when engine is
lnjector control signal running Other
1
must be verified by
~
oseilloscope. 1
[ Verify waveform on oscilloscope \V
Normal 1 Abnormal lnjector power supply inspection
1
Measure voltage between injector connector
1
1 (each cylinder) and earth.
¡1nspect connector for breaksl
and disconnection Power voltage when Other than batte ry
ignition is in ON position voltage when ignition
switch is in ON position
1
lnjector inspection Repair injector
Measure resistance between power supply
terminals 1 - 2. circuit system
~
13 -14 Q 1
Other
1 6
Replace injectors
(resistance measurement)
lf the value is not normal at mid
lnjector C/U
connector there is a possibility
harness harness of fault with the harness. Test
101 (#1) the resistance measurement
105 (#2) with injector unit.
103 (#3)
1- 114 (#4)
110 (#5)
112 (#6)
OQ Other
1
ECCS C/U power supply inspection Repair
@ "DATA MONITOR" harness
@ Voltage measurement between
terminal 27 and earth
Power voltage when ignition
switch is in ON posilion Other
1 1
¡1nspect inpu\l Repair ECCS C/U power
signa! system supply circuit system
EN-402
RB20E ENGINE
• Use "POWER BALANCE" in the CONSULT active fffi ♦ ACTIVE TEST

♦□
test mode to check the idle speed variation and ~ POWER BALANCE
the injector operation. MONITOR
Caution: AIR FLOW METER 1.1 U
Do not perform test while driving. AAC VALVE 25%
[I][J][JJ8] TEST
[~][!]□□ START
1 lnjector control signal and power inspection fe\

[lnjector connector] \:al
• Disconnect the injector connectors and measure
power voltage between harness termianl 2 and earth.
lgnition sw in ON position: Power voltage
Cranking: Approx. 10V
[ECCS Control unit connectors]

• Control circuit: Measure power voltage between
ECCSC/Uterminals101, 103,105,110,112, 114and
earth.
,------,r
109,a--------{
101
Cranking: Approx. 10V ECCS 103
C/U 105
• Power supply circuit: Measure power voltage be- 110
112
tween ECCS C/U terminal 109 and earth. 114

• Disconnect control unit and injector connectors and
measure the resistance between following terminals:
ECCS C/U harness lnjector harness terminal 2
101 No. 1 cylinder
110 No. 2 cylinder
103 No. 3 cylinder
112 No. 4 cylinder
105 No. 5 cylinder
114 No. 6 cylinder
Resistance between terminals: on
3. lnjector inspection
• Remove injector connector and measure the resist-
ance between the terminals for each ínjector.
Between injector terminal 1 and 2 for each cylinders:
13 -140
EN-403
IGNITION SYSTEM SYSTEM DIAGNOSIS INSPECTION
RB20E ENGINE
3. IGNITION SYSTEM
IGN ~ - - - . . <SOHC> (ffi)

+ J---"""".2::-H..--..i1UUL--r-------,
+---- ------27
ECCS relay
........................>---
o::::J..J2]
- - + - - -..... 40
Tachometer
39...__--t""N+-----~
1-fmq.2 ~ ·
5 ~ -3
Throttle _ L A/T
valve
switch 1
n - - - - - - - - 32
------22 +it' ¡:¡:¡.
IDLE
;DOHC; - - - - 5 1
e- rrb)
Crank angle sensor m
l ----f-- ----.19 g Power transistor 1 - .
IGN
--------10 (1)
C')
coil
relay
\ 4 ~ - - - - - - . 28 e No. 1 1
No. 2 2
Engine temperature sensor No.3 3
~ ~------! No.4
Every cylinder for RB20E

petonation se11 1 1 1-----··--..'. _ _ _ 16
No.
EN-404
IGNITlON SYSTEM SYSTEM DIAGNOSIS INSPECTION
RB20E ENGINE
lgnition system trouble diagnosis flowchart RB20E ENGINE
l lgnítíon spark inspection 1

Strong spark ares Other
1
1 1
l lnspect other system 1 Self-diagnosis

® "SELF-DIAGNOSTIC RESULT"
® SELF-DIAGNOSIS (code No. 21)
Normal 1
Abnormal
l(Real
"DATA MONITOR"® I
time diagnosis)
c1D3 1
Normal Abnom,al
,.
'-
lgnition coil inspection ,11

Measure the resistance be-
itween IGN coil terminal 1 & 3. nt Power transistor control signal inspection
(power transistor unit)
Measure voltage between power transistor
7-12K g 1 Other (1 ¡2 !ffl! si 6) terminals 2 and earth.
1 Approx. 0.1 - 0.3V when
Replace engine is running Other
IGN coil
1
lgnition primary signal inspection Power transistor control signal inspection
Measure battery voltage between (ECCS C/U unit)
power transistor terminal 1 and (El s¡ ;j4)';¡2 ¡1) Measure the voltage between C/U terminals
earth. 37 and earth.
6 - 1OV when engine
Approx. 0.1 - 0.3V when
is running Other
engine is running 1 Other
1
1 :owar ~ransistor 1
Harness continuity inspection ECCS C/U power inspection
rnspection
C/U terminal 37 and power "DATA MONITOR" ®
Norma! Abnormal transistor terminal 2. Measure power voltage
1
1 1
between C/U terminal 27 ®
and earth.
Harness continuity inspection. Replace power
Measure resistance between transistor Battery voltage when 1
power transistor terminal 1 ignition switch is ON Other

and ignition coil terminal 1.
og 1
Other I
Input signal 1
Repair IECCS C/
system inspection U power supply
1 1 circuit system
lgnition coil power Repair oa Other
inspection lnspect voltage harness
between coil terminal 2 1 1
and earth. lnspect connectors for Repair
faulty connect or defects harness
Battery vollage when 1
Other and check circuit systems.
ignition switch is ON
1 1
lgnition coil inspection Repair ignition
Measure resistance coil power supply
between coil terminal system circuit
1 and 2.
0.8 - 1.20 Other
1
1 1 .
lgnition system secondary 1 Replace IGN COII
part inspection
EN-405
RB20E ENGINE
1 Self-dia'gnosis ♦SELF-DIAG RE~ 0

• Check faulty system in "SELF-DIAGNOSTIC
RESULT'' mode when the ignition switch is placed in FAILURE DETECTED TIME
the ON position and engine cranking. IGN SIGNAL PRIMARY O
• When there is abnormal output, inspect assumed
locations in the following sequence.
Power transistor (short) - ECCS harness (short) -
ECCS control unit
ERASE 11 PRINT
• Perform diagnosis mode selection procedure with the
diagnosis connector in the vehicle. Check the code
number of the faulty system displayed by the flashing
exhaust gas temperature warning lamp on the instru-
ment panel.
2 Power transistor control signal inspection

• Measure the power voltage between ECCS C/U ter-
minal 37 and the earth when the ECCS control unit
connectors are connected .
Cranking: 0.2 ~ 0.3V
ldling: 0.2 ~ 0.3V
At 2,500 rpm: Approx. 1.0V
3 lgnition primary voltage signal inspection
~~
minal 39 and earth with ECCS control unit connector
connected.
ECCS \_
Cranking: 5 ~ 10V
C/U . (v-¡_
At 2,500 rpm: Lower than power voltage

• Disconnect ECCS control unit and power transistor m
(')
(")
connector and measure the resistance between 7 (/)
(")
ECCS C/U harness terminal 37 and the power tran- e
sistor terminal 2.
Resistance (O): O
EN-406
RB20E ENGINE
5 Power transistor inspection

• Check the resistance between all power transistor ter-
minals using an analog circuit tester probe by chang-
ing the positive and negative pales.
1- 3 +/- O or not ooQ < +/- ooQ

2-3 +/- or not ooQ = +/- O or not ooQ
1- 2 +/- O or not =O < +/- =O
6 lgnition coil inspection

• Measure the primary coil resistance value.
Primary coil resistance value (1 ~ 2): 0.8 - 1.2
Secondary coil resistance value (1 - 3): 7 - 12
7 High tension cable resistance value

• Measure the resistance of high tension cables.
No. 1 cylinder: 5 ~ 12Ko
No. 4 cylinder: 8 - 18Ko
Centre cable: 4 ~ 1OKo
EN-407
IDLE SPEED CONTROL SYSTEM SYSTEM DIAGNOSIS INSPECTION
RB20E ENGINE
4. IDLE SPEED CONTROL SYSTEM
IGN
MCvalve
~
+l---...._-----...---lr.'-i:~t::.----------t27
ECCS relay i--------t-------.,40
;ª!
ThrottleFU~
valve 32
switch 22
IDLE
Crank an le sensor
1 19 m
(')
10 (')
(J)
(') 29
28
e
Air conditioner switch
24
5 N,P rela
8 Neutral switch
38
Power steering switch
-
¼~clesd~ni------------➔
21
ldle speed control system trouble diagnosis flowchart RB20E ENGINE

AAC valve control signar inspection
"ACTIVE TEST" ®
Measure voltage between AAC
valve terminal 1 and earth. ® ~
Opening (Duty) display
Cranking 2- 3V Other
ldling 6 ~ 1OV
1 1
¡supplemental air supply parts inspectionl MC valve power supply inspection
(Check for any disconnection, clogging etc) Measure voltage between AAC terminal
No disconnection Hose disconnected or 2 and earth.
or clogging clogged Battery voltage when
1
ignition switch is ON Other
1 1
1Other system inspection Repair 1
1
AAC valve inspection RepairMC valve
Measure resistance between powersupply
MC valve terminal 1 and 2
circuit system
9-10 Q 1 Other
1
1
Harness continuity inspection Replace
Check the continuity between AAC harness MCvalve
terminal 1 and C/U harness terminal 1 and 27.
OQ 1 Other
ECCS C/U power supply inspection Repair harness

"DATA MONITOR" ® Note: The outp ut data for the
Measure voltage between C/U AAC valve system must be
terminal 27 and earth. ®
checked with a n oscilloscope.
Battery voltage when
ígnition switch is ON Other
1.
!Input signal system inspection 1 Repa1rECCS
C/U power
supply circuit
EN-408
IDLE SPEED CONTROL SYSTEM SYSTEM DIAGNOSIS INSPECTION
RB20E ENGINE
1 AAC valve control signal inspection

• Measure the voltage between ECCS C/U terminal
113 and earth when the ECCS control unit connector
is connected.
Cranking: 2~3V
ldling (when cold): 6~7V
ldling (after warm-up): 8 ~ 10 V
• Measure voltage between the AAC valve connector

terminal 1 and earth.
2 AAC valve system inspection @ ♦ ACTIVE TEST ♦ 0

• Use "AAC VALVE OPENING" item in active test AACN OPENING 27%
mode to set an optional angle. MONITOR
• Check that idle speed changes according to setting AIR FLOWMTR 0.93V
value at this time. AIR FLOW MER-R 0.92V
ENGTEMP SEN 68°C
~]I UP l DWN 1 Qd 1
3 AAC valve power supply inspection

• Disconnect AAC valve connector and measure pow-
er voltage between AAC valve connector harness
terminal 2 and earth.
When ignition sw is in ON position: Power voltage

• Disconnect the connector from the ECCS control unit
and AAC valve and measure the resistance between
ECCS C/U harness terminal 113 and AAC valve har-
ness terminal 1.
Resistance (.O): o
5 AAC valve inspection

• Disconnect the AAC valve connector and measure
resistance between AAC valve terminal 1 and 2.
Resistance (.O): 9 ~ 1O
EN-409
CRANK ANGLE SENSOR SYSTEM SYSTEM DIAGNOSIS INSPECTION
RB20E ENGINE
5. CRANK ANGLE SENSOR SYSTEM
ECCS relay
+·>---------t....-iRíl"-+----~-----..io
o-+---------...,7 >--~--11GN TIMING CTRL [
Crank angle sensor m

o FUEL INJ CTRL
1
f---,-----"'--------1---,
i-------+---..-19 o(/)
2 10 Q
e t10LE SPEED CTRL 1
3
4
Crank angle sensor system trouble diagnosis flowchart RB20E ENGINE
Self-diagnosis
"SELF-DIAGNOSTIC RESULT"@
Self-diagnosis (Code No. 11) ®
Normal 1 Abnormal
1
"DATA MONITOR" 1
(real-time diagnosis)
Normal 1 Abnormal
1
lnspect other Crank angle sensor input signa!
systems inspection
When engine is running:

"DATA MONITOR"
Measure voltage between ECCS
C/U terminal 19, 10 and earth.
®
®
(1 iril 14)
. Engine rpm display

® Approx. 0.5V between terminal 41 and earth
® Approx. 2.SV between terminal 42 and earth Other
1
Crank angle sensor output signal inspection Crank angle sensor power supply
Measure the voltage between and ground inspection
erminals 1 and 4 and terminal 2 and 4. Measure the voltage between
When engine is running: ~erminals 3 and 4.
0.5V between terminal 1 and 4
2.5V between terminal 2 and 4
Other Battery voltage when
ignition switch is ON ¡ Other
1 1 1
1
lnspect crank angle Harness continuity inspection Crank angle sensor inspection Repair crank angle
sensor and ECCS Measure the resistance between Rotate shaft by hand and sensor power supply
C/U connectors for crank angle sensor harness measure voltage between each orgrou nd
breaks or discon- 1 and ECCS C/U harness 19, crank angle sensor terminal and
nection. crank angle sensor harness 2 earth.
and ECCS C/U harness 10. Voltage between terminal 1
OQ T Other and ground repeats between
0.5Vand 0V.
1 Other
1 Voltage between terminal 2
lnspect ECCS C/U connector Repair and ground repeats between
for contact and defects. harness 2.5V and 0V.
r 1
lnspect crank angle Repair crank
sensor connector for angle s enser
contact and defects.
EN-410
RB20E ENGINE
1 Self-diagnosis
• lf 1° or 120° signal is not input within fixed period of
time, "CODE No. 11" or "FAULTY SYSTEM NAME"
will be displayed in normal self-diagnosis operation
when using CONSULT. Examine the following items
carefully when this occurs.
• lf a malfunction occurs again, use the @
real-time diagnosis (CONSULT data monitor mode)
or oscilloscope to detect disconnection.
• When an abnormality is detected, consider these
locations in the following sequence as there may be
other malfunctions besides the crank angle sensor.
ECCS harness (faulty contact) - Crank angle sen-
sor - ECCS control unit
* MONITOR
CAS.RPM (POS)
AIRFLOWMTR
*NO FAIL [;)
975rpn
0.91V
2 Input signal inspection (j) AIR FLOW MTR (R) 0.92V
• Use "CAS.RPM (POS)" item in data monitor mode to ENG TEMPSEN 78°C
EXH GAS SEN 1.22\/
determine engine speed. EXH GAS SEN (R) 0.02V
M/R R/C MNT RICH
M/R F/C MNT-R RICH
RECORD
• Measure the voltage between ECCS C/U terminal 41

and earth (120° signa!), between ECCS C/U terminal
42 and earth (1° signal). 1
~ 1 m
o
o(./)
Crank 2 ~2
~
o
angle sen e
Note:
The power voltage value above are average voltage
value of the pulse waveform measured by circuit tester
and these are far reference only. The waveform must be
checked using oscilloscope.
EN-411
RB20E ENGINE
3 Sensor output signal inspection

• Measure the voltage between the following terminals:
Crank angle sensor terminal 2 and earth (1° signal):
lgnition sw in ON position: OV or approx. 5
Cranking: 2~3V
ldling: 2 ~3V
Crank angle sensor terminal 1 and earth (120° sig-
nal):
lgnition sw in ON position : OV or approx. 5
Cranking: 0.5 V
ldling: 0.3 - 0.7 V
Crank angle sensor terminal 3 and ground (power):

• Disconnect the ECCS C/U and the crank angle sen-
sor connector and measure the resistance between
ECCS C/U harness terminal 19 and crank angle sen-
sor 1, ECCS C/U harness terminal 1O and crank angle
sensor 2.
Resistance (O): O
5 Crank angle sensor inspection

• Disconnect the crank angle sensor from the engine,
turn the shaft by hand and measure the power voltage
using connector.
Crank angle sen 2 and earth (1 ° sig): 0V or 5V
Crank angle sen 1 and earth (120° sig): OV or 5V
Crank angle sen 3 and earth (Battery voltage ):
Power voltage
Crank angle sen 4 and earth 0V
Caution:
To prevent injector from operating, remove fuse or con-
nector befare inspection. Abnormality may be detected
by self-diagnosis mode if the shaft is not turned smooth-
ly.
EN-412
AIR FLOW METER SENSOR SYSTEM SYSTEM DIAGNOSIS INSPECTION
RB20E ENGINE
6. AIR FLOW METER SENSOR SYSTEM
ECC~ay
+ 40
~ 27 FUEL INJ CTRL
m IGN TIMING CTRL

(')
(')
- 1 (J)
lntake air quantity sig 3 o

Powerearth
2
3 r:;.
---e
Signal earth 4 4
Power 5
c112 m41 5)
(B) (F) (E) (A)
Air flow meter sensor system trouble diagnosis flowchart RB20E ENGINE
Self,diagnosis
"SELF-DIAGNOSTIC RESULT"®
Self-diagnosis (Code No. 12) ®
Normal 1 Abnormal
1:•□ATA MONITOR" 1
Normal Abnormal
,,
'-
1 Air flow meter input signa! inspection

Check intake system to
make sure there are no
air leaks.
"DATA MONITOR"
Measure voltage between ECCS C/U ®
terminals 3 and 4.
®
(1 12 m41 s)
Noair 1 Air leaks present Cranking: Approx. 1V
leaks 1 idling: Approx. 1.1 V Other
1
¡Inspect otherl Repair intake 2,500rpm: Approx. 2V
systems system
Air flow meter output signal 1Air flow meter power & ground inspection 1
inspection Measure the voltage between terminal 5 and 3.
Measure the voltage between Battery voltage when
Other
terminals 2 and 4. ignition switch is ON
ldling:Approx.1.1V Other
1
Air flow meter inspection
l.
R epa1r air flow
2,S00rpm: Approx. 2V meter p owersupply
Apply battery voltage direct!y to
terminal 5 (+) and 3 (-) and meas- or grou nd
1 1
Check air flow Harness continuity inspection ure the voltage between terminal 2
meter and ECCS Measure the resistance be- and 4 while blowing air into meter.
C/U connectors for tween the following terminals: Approx. 2V when blowing
faulty connection or Air flow meter ECCS C/U air to meter Other
defects. harness harness Approx. 1V when air is
not blown
2 3
4 4 1 1
Og Other lnspect intake system Replace or elean
for air leaks. air flow meter
1 R epair
1.
Air leaks present
¡ Inspect ECCS C/U connectorl harness No air leaks 1
for contact and defects. 1 1
lnspect air flow meter Repair intake
connectors for faulty system
connections or defects.
EN-413
RB20E ENGINE
1 Self-diagnosis
• Normally in a self-diagnosis operation, "CODE No.12"
or"FAULTY SYSTEM-AIR FLOW METER" (when us-
ing CONSULT) is displayed if the intake air quantity
signal voltage is abnormally high or low and discon-
nection or short-circuit in the signal system should be
considered.
• lf a malfunction occurs again, use real-time @
diagnosis (CONSULT data monitor mode) or oscillo-
scope to detect instantaneous breaks.
• When an abnormality is detected, consider these loca-
tions in the following sequence as there may be other
malfunctions besides the air flow sensor.
When intake air quantity is low:
ECCS harness (faulty contact) - air flow meter -
ECCS control unit - intake system (not airtight)
When intake air quantity is high:
ECCS harness (faulty contact) - intake system (not
airtight), faulty wastegate valve control - air flow meter
- ECCS control unit
2 Input signal inspection

• Use "AIR FLOW METER" and "AIR FLOW METER \.e,)
ri3\ * MONITOR~O FAULT □
(R)" in "DATA MONITOR" mode to check the following AIR FLOWMTR 0.96V
items. AIR FLOW MTR (R) 0.87V
lgnition sw is in ON position: Approx. 0.5V
At 2,500 rpm: Approx. 1.5~2V
RECORD
• Measure power voltage between following @

terminals with ECCS control unit harness connected.
ECCS C/U terminal 3 and earth (intake air quantity
signal) Airflow
• 3
lgnition sw is in ON position: Approx. 0.3V meter

4
Cranking: Approx. 1V ~ ECCS
C/U
ECCS C/U terminal 4 and earth (earth signal)
lgnition sw is in ON position: Approx. 0V
ldling: Approx. 0V
EN-414
RB20E ENGINE
__ .-----.
3 Air flow meter output signa! inspection
• Measure the voltage between the following terminals
when the air flow meter connectors are connected.
Air flow mtr terminal B and earth
lgnition sw is in ON position: Approx. 0.8V
ldling: Approx. 1 .1 V
Air flow meter terminal E and eawrth
lgnition sw is in ON position: Approx. OV
Cranking: Approx. OV
ldling: Approx. OV
4 Air flow meter power supply inspection

• Mea su re the power voltage between the air flow meter
terminal 5 and earth with the air flow meter connector
connected.
lgnition sw in ON and engine running: Power voltage

• Disconnect ECCS control unit and air flow meter
connector and measure the resistance between
following terminals.
Air flow meter harness and ECCS C/U harness
2 3
4 4
3 Body ground
5 ECCS relay harness 3
Resistance (O): o
6 Air flow meter inspection

• Apply the battery voltage directly to terminal 5 ( +) and
3 (-) and measure the voltage change between termi-
na Is 2 (+) and 4 (-) while blowing air to hot wire.
Air blown: Approx. 0.8V
No air blown: Approx. 2V
EN-415
THROTTLE VALVE SWITCH SYSTEM SYSTEM DIAGNOSIS INSPECTION
RB20E ENGINE
To A/T control unit

FUEL INJ CTRL
Full contact m
int 3 ("')
o
(/)
IIGN TIMING CTRL !
Power 2 32
ldle contact
oint
1 1 22 --e
("')
IIDLE SPEED CTRL !
Throttle valve switch system trouble diagnosis flowchart RB20E ENGINE
"DATA MONITOR" @ 1
l (real-time diagnosis)
Normal I Abnormal
1
Throttle valve switch inspection Throttle valve switch output
Measure the resistance between signal inspection
terminal 2 and 1. Measure the voltage between
terminals 2 and 1.
Acceleration pedal not
depressed: 00
Accelerator pedal not depressed: 8 - 1OV
depressed: 000 Other Other
1..--_.....___ __,I Accelerator pedal depressed: OV
lnspect other¡ Adjust or

lsystems replace throttle
valve switch
lnspect throttle valve switch
connectors and ECCS C/U
Throttle valve switch
inspection
connectors for faulty con- Measure the resistance ~
nections or defects. between terminal 2 and 1. ~
Acceleration pedal not
depressed: 00
depressed:ooO Other
1 1
Switch and ground inspection Adjust or
Measure the voltage between replace throttle
terminals 32 and 22. valve switch
Acceleration pedal not depressed: 10V 1
Acceleration pedal depressed: OV Other
~----1....--~I
Harness continulty inspectlon lnspect ECCS C/U
Measure the resistance between power supply or
the following terminals: ground or replace
Throttle valve ECCS C/U control unit
switch harness harness
2 32
1 22
QQ Other
1 1
lnspect ECCS C/U connector and Repalr harness
throttle valve switch connector for
EN-416
RB20E ENGINE
1 System inspection
• Use "DATA MONITOR" to inspect the idle
contact point ON-OFF signal to make sure it is oper- 32 m
Throttle o
o
ating correctly. valve (f)
switch 22 O
e
minal 22 and earth (or between throttle valve switch
terminal 1 and earth) with ECCS control unit connec-
tor connected.
lgnition sw in ON position or engine running:
Accelerator pedal not depressed: 8 - 1OV
Accelerator pedal depressed: OV
• Measure power voltage between ECCS C/U @

,.-.......
terminal 32 and earth (or between throttle valve
switch terminal 1 and earth) with ECCS control unit
connectors connected.
lgnition sw in ON position: 8 - 1OV
3 Throttle valve switch inspection

(idle contact point)
• Disconnect throttle valve switch connectors and
measure the resistance between throttle valve switch
terminal 1 and 2.
Accelerator pedal not depressed: 00
Accelerator pedal depressed: OOQ
(4) Harness continuity inspection

• Disconnect throttle valve switch and ECCS control
unit connectors and measure the resistance between
the following terminals.
ECCS C/U harness 22 and throttle valve sw 1: 00
ECCS C/U harness 32 and throttle valve sw 2: 00
_,,.,.-------.,_
EN-417
RB20E ENGINE
5 ldle contact point (touch speed) inspection and ♦ IDLE SWADJ ♦

adjustment . · (j)
• Warm up the engine sufficiently and use "IDLE SW" Lower CAS.RPM slowly
in operation support mode to inspect idle contact from 2000rpm to idle and then
point. check "touch RPM".
Adjustment must be done af-
ter changing SW position.
• Disconnect AAC valve connector and inspect the @ START

unit when the MC valve is fully open.
ldle contact point tachometer speed (rpm):
850+/- 150 rpm
• When the tachometer speed does not conform to the

specified value, perform the adjustment as follows:
• Loasen the throttle valve switch tightening bolts (2).
• Remove the throttle valve switch connectors, place a
test probe between the throttle valve switch terminals
1 and 2 and measure the resistance.
• Depress the accelerator pedal and gradually release
the pedal to lower the engine speed. Rotate the
throttle valve switch body and secure it in the posi-
tion where the tachometer speed conforms to the
specified value and the idle contact point is "ON" (the
resistance between terminal 1 and 2 is 00).
• Tighten the throttle valve switch tightening bolts.
• Make sure the idle is ON observing the tachometer
speed as described above.
• Connect the throttle valve switch connectors.
EN-418
THROTTLE SENSOR SYSTEM SYSTEM DIAGNOSIS INSPECTION
RB20E ENGINE
8. THROTTLE SENSOR SYSTEM
Throttle sensor
1-------1 FUEL INJ CTRL
Power 1 1 ,-.....,.----26 m
o
o(j)
Signal 2
o
Ground 3 3
- - - -.. 8
--
e
Throttle sensor system trouble diagnosis flowchart RB20E ENGINE
Self-diagnosis
"SELF DIAGNOSTIC RESULTS"@
Self-diagnosis (code No. 43) ®
Normal 1
Abnormal
l"DATAMONITOR"®I
Normal Abnormal
1
Throttle sensor inspection
Measure the resistance between
terminal 2 and 3.
c1 m3) Throttle sensor input signal inspection
"DATA MONITOR"
Measure the voltage between terminal®
® c1m3)
Change from approx. 2 and earth.
2k0 to 1Okn when accel Other Change from approx. 0.5V to
pedal is depressed
4V when acceleration pedal Other
is depressed
1 1
¡Inspect otherl Replace throttle 1
systems sensor lnspect throttle sensor and Throttle sensor ínspection
ECCS C/U connectors for faulty Measure the resistance be-
connections or defects. tween terminal 2 and 3.
Change from approx. 2k Q
to 10k uvhen accelerator Other
pedal is depressed
1 1
Sensor and ground inspection Replace
Measure the voltage between throttle
terminal 26 and 8. sensor
Approx. 5V 1 Other
1 1
Harness continuity inspection lnspect ECCS control unit
Measure the resistance between and ground and repla ce
the following terminals: control unit if necessary
Throttle sensor ECCS C/U
harness harness
1 26
2 7
3 8
OQ 00 Q
l lnspect ECCS C/U connector and throttle

sensor connector for contact and defects.
I 1
Repair harness
EN-419
RB20E ENGINE ·
1. Self-cliagnosis
• There is disconnection or short-circuit in the signal
system when "CODE 43" is displayed in normal self-
diagnosis (mode 2). When this is displayed, check
the throttle sensor resistance or harness continuity
etc.
• lf the problem occurs again, use real-time (i)

diagnosis mode or oscilloscope to check for instanta-
neous break in the signal.
2. Input signal inspection @

• Use "THROTTLE SENSOR" setting in data monitor
mode to check the following items: ~ONITORINci:r NO FAULT □
lgnition sw in ON position accelerator pedal not de- CAS.RPM (REF) Orpm
pressed: Approx. 0.5V THROTTLE SEN 0.50V
lgnition sw in ON position accelerator pedal depressed
to half-way: Approx. 0.5 ~ 4.0V
lgnition sw in ON position accelerator pedal depressed
fully: Approx. 4.0V
RECORD
• Measure power voltage between ECCS C/U ®
terminal 7 and earth (or throttle sensor terminal 2 and
earth) with throttle sensor harness connected.
lgnition sw in ON position: Approx. 0.2V m
2 7 o
Cranking: Approx. 0.2V ()
Engine running with accelerator pedal not pressed: Thmttle ~ (J)
Q
sensor v·
e
Approx. 0.5V
Engine running with accelerator pedal depressed
fully: Approx. 0.5 ~ 4.0V
3. Throttle sensor power supply inspection

• Measure power voltage between throttle sensor ter-
minal 1 and ground with throttle sensor connectors
connected.
lgnition sw in ON position with engine running:
Approx. SV
4 Throttle sensor unit inspection

• Disconnect the throttle sensor connector and meas-
ure the resistance between throttle sensor terminal 2
and 3.
Accelerator pedal not depressed: Approx. 2kO
Accelerator pedal partially depressed:2kO ~ 10kO
Accelerator pedal fully depressed: Approx. 10kO
EN-420
RB20E ENGINE
... ············ ··:,
_.-- .. ~, &26
• Disconnect ECCS control unit and throttle sensor con-
nector and measure the resistance between following ~2J-1; 8;
termina Is. (J)
()
ECCS C/U harness 26 and throttle sensor harness 1 : ic
ECCS C/U harness 7 and throttle sensor harness 2:
ECCS C/U harness 8 and throttle sensor harness 3:
Resistance (O): O
EN-421
RB20E ENGINE
9. ENGINE TEMPERATURE SENSOR SYSTEM
Engine temperature sensor FUEL INJ CTRL
t---------- 5 m
()
8 () IGN TIMING CTRL
(/)
Q
e IDLE SPEED CTRL
Engine temperature sensor system trouble diagnosis flowchart RB20E ENGINE
Self-diagnosis
"SELF DIAGNOSTIC RESULTS" ®
Self-diagnosis (code No. 13) ®
Normal 1 Abnormal
1
!"DATA MONITOR"
(Real-time diagnosis)
®I
Normal 1 Abnormal
Engine temp sensor input signal inspection

"DATA MONITOR" ®
Measure the voltage between terminals 1 ®
and earth.
~ ® Engine temp display

® 3V when cold ~
1V after warming up Other
Engine temp sensor inspection
Measure the resistance between 1 1
terminals 1 and 2. lnspect intake a ir temperature Engine temperature sensor
Approx. 2.5k gvhen cold sensor and ECCS C/U connectors inspection
Approx. 0.3KQ3fter warm- for faultv connections or defects. Measure the resistance be-
ing up Other tween terminals 1 and 2 .
Approx. 2.5K'1when cold 1
Approx. 0.3KO after warm Other
1 1
¡
Inspect otherl
systems
Replace engine
temperature
up
1 1
Replace Engine
Sensor and ground ínspection
sensor Measure the voltage between temperature
terminals 5 and 8. sensor
® Engine temp display 1
Other
® Battery voltage
1
Harness continuity inspection lnspect ECCS C/U power
Measure the resistance between supply and ground
the following terminals:
Engine temp ECCS C/ U
sen harness harness
1 5
2 8
1
ºº 1 =O
1
lnspect ECCS C/U connector and Repair harness
engine temp sensor connector for
EN-422
RB20E ENGINE
1 Self-diagnosis
• There is a disconnection or short-circuit in the sig-
nal system when "CODE 13" is displayed in normal
self-diagnosis or "FAILURE DETECTED ENG TEMP
SEN" (when CONSULT is used) is displayed.
• lf the problem reoccurs, use real-time diagnosis mode
or an oscilloscope to check for instantaneous break
in the signal.
*MONITORIN-ct:r NO FAULT[J
ENG TEMP SEN 78ºC

• Use the "ENG TEMP SEN" in data monitor mode ®
to check if the engine temperature is displayed when
ignition sw in the ON position.
RECORD
• Measure the voltage between ECCS C/U terminal 15

Engine tem
sen
A 5 ~
o(/l
and ground with ECCS control unit connectors (B\
~----8 Q
connected. \.eJ e
lgnition sw in ON position with engine temp at 20°C:
Approx. 3V
lgnítion sw in ON position with engine temp at 80°C:
(V)
Approx. 1V
Q)
O)
~
o
> 11-----+----~
20
Engine temperature
3 Engine temperature sensor resistance value

inspection
• Disconnect engine temperature sensor connector and
measure the resistance between engine temperature
sensor connectors 1 and 2.
Engine temperature at 20°C: Approx. 2.5k0
Engine temperature at 80°C: Approx. 0.3k0

• Disconnect ECCS control unit and engine tempera-
ture sensor harness connector and measure the re-
sistance between the following terminals:
ECCS C/U harness 5 & engine temp sen harness 1
ECCS C/U harness 8 & engine temp sen harness 2
Resistance (O): 00
EN-423
02 SENSOR SYSTEM SYSTEM DIAGNOSIS INSPECTION
RB20E ENGINE
1O. 0 2 SENSOR SYSTEM

(RB20DE / DET)
Exhaustgassensor +1------+c...-
+-- - - - NF ratio feedback

ctrl
Heatera - - - - - -- --29
J---- -- -- ---+115
m
(")
(")
(f)
(")
e
(RB20E)
r-o l - - -- - - - -- - 6
0 2 sensor system trouble diagnosis flowchart RB20E ENGINE
Air-fuel ratio feedback function inspection

"DATA MONITOR" @
Exhaust gas sensor output monitor. ®
Normal 1 Abnormal
,J
1
(il "DATA MONITOR"
(Real-time diagnosis)
Normal I Abnormal
¡"ACTIVE TEST"
(Eng temp, fue! inj)
1
1~ Normal I Abnormal
I' 1
lnspect other 1 Exhaust gas sensor input
l
systems signal inspection
Measure the voltage between
1 and earth
Deflection between O- 1V 1 Other

,r------'-------,1
,.,.........-----,------------,
lnspect exhaust gas sensor and
....-------'-----------,
ECCS C/U power supply inspection
ECCS C/U connectors for faulty "DATA MONITOR" @
contact or defects. Disconnect 0 2 sensor connector and ®
measure voltage between ECCS C/U
terminal 27 and earth
Battery voltage when igni-
tion switch is ON Other
1 1
Harness continuity inspection lnspect ECCS C/U
Measure the resistance between power supply or
the following terminals: replace C/U
0 2 sensor ECCS C/U
harness harness
1 6
1 Other
1 1
Check for faulty connections ar 1
Repair harness
!replace exhaust gas sensor
EN-424
02 SENSOR SYSTEM SYSTEM DIAGNOSIS INSPECTlON
RB20E ENGINE
1 Fuel-air ratio feedback function inspection

• Warm up the engine and inspect the following * MONITOR * NO FAULT □
items with "EXH GAS SEN" and "M/R F/C MNT" (lean CAS.RPM (POS) 2012rpm
AIR FLOW MTR 1.54V
/ rich) displayed in data monitor mode.
ENG TEMP 80ºC
Exhaust gas sensor at 2,000 rpm: EXH GAS SEN 0.72V
Output voltage is displayed at approx. O - 1V. The M/R F/C MNT RICH
display cycle is 5 times or more in a 1O second inter-
val.
RECORD
Exhaust gas sensor monitor at 2,000rpm:
RICH / LEAN display must be synchronized with out-
♦ ACTIVE TEST ♦ □
put voltage display.
FUEL INJECTION +11%
• Provide setting value in "ACTIVE TEST' (fuel injection MONITOR
quantity correction) and check exhaust gas sensor ENG TEMP SEN 36°(
function. EXH GAS SEN 0.87V
Note: INJ PULSE 4.0msec
AAC VALVE 36%
"INJ PULSE" display for RB20E is 1/16.
1 Qu 11 UP DWN 11 Qd 1
®
11
• Using diagnosis connector on the vehicle side

(near fuse block), set CONSULT to "EXHAUST GAS
SENSOR MONITOR" and check the fuel injection
condition by checking the flashing exhaust gas tem-
perature warning lamp on the instrument panel.
Exhaust gas sensor function

Exhaust gas temperature warning lamp must flash 5 times
or more in a 1O second interval when engine speed is at
approx. 2,000 rpm.
Feedback function
Exhaust gas temperature warning lamp must flash
periodically when engine speed is at approx. 2,000 rpm.
4 ~~
B
2 Input signa! inspection ~
• Measure the voltage between ECCS C/U terminal
29 and ground with ECCS control unit harness con-
nected.

• Disconnect ECCS control unit and exhaust gas
connectors and measure the resistance between
ECCS C/U harness terminal 6 and 0 2 sensor harness
terminal 1.
EN-425
DETONATION SENSOR SYSTEM SYSTEM DIAGNOSIS INSPECTION
RB20E ENGINE
11. DETONATION SENSOR SYSTEM
Detonation sensor 1 1----~ i-------23 ------1 IGN TIMING CTRL 1
m
()
()
~----24 (/)
()
e
Detonation sensor 3 ----16
1 Self-diagnosis
• There is a disconnection or short-circuit in the signal
system when "CODE 34" in normal self-diagnosis
or "FAILURE DETECTE□ DETONATION SENSOR"
(when CONSULT is used) is displayed. lf the problem
reoccurs, use real-time diagnosis mode (CONSULT
data monitor mode) or an oscilloscope to check for
an instantaneous break in the signal.
1Detonation sensor
m
2 Input signal inspection o
o
(J)
• Measure the voltage between ECCS C/U terminal IDetonation sensor
o
23 and earth with ECCS control unit harness con- e
nected. i""""""" ~,~ 16
lgnition sw in ON position: Approx. 4V
ldling: Approx. 4V
Caution :
The detonation sensor input signa! must be measured by
using oscilloscope as its resistan ce is greater than the cir-
cuit tester resistance. The signal should also be checked
with self-diagnosis and harness continuity inspection.
m
(')
()
(f)
Q
e
• Disconnect ECCS control unit and detonation sensor
mid connector and measure the resistance between
ECCS C/U terminal 16 and detonation sensor mid
harness terminal 2.
Resistance (O): o
EN-426
VEHICLE SPEED SENSOR SYSTEM SYSTEM DIAGNOSIS INSPECTION
RB20E ENGINE
[ FUEL CUT CONTROL

:::,..,\,/,-:
---
,;-a, --.
m
(')
- I IDLE SPEED CONTROL 1
1 oen
[Vehícle spd sen: 21 (')
e
1 Input signa! inspection

• Select "VEH ICLE SPEED SENSOR" in data
* MONITOR * NO FAULiQ

monitor mode and check if the vehicle speed is dis- CAR SPEED SEN Okm/h
played when drive wheels are turning.
RECORD
• Measure the voltage between ECCS C/U terminal @

21 and earth with ECCS control unit connectors con-
nected. IVehícle spd ~ ,-...v/ 21
When drive wheels are turning slowly:
__[4-V ECCS
Voltage will deflect between 0V and 5V. --: C/U
,,.,..,-•..
EN-427
ECCS C/U INPUT/ OUTPUT SIGNALS SYSTEM DIAGNOSIS INSPECTION
RB26DETT ENGINE
EN10 ECCS CONTROL UNIT INPUT/ OUTPUT SIGNALS

1. CONSULT INSPECTION VALUES - RB26DETT ENGINE
(1.1) Data monitor
Note: The output signal is displayed as the calculation data on console unit so the correct value
will be displayed even if the output círcuit (harness) is inadvertently disconnected.
CAS.RPM (Detectad angle

speed accordin to si nals En ine runnin chan e in speed
AIR FLOW MTR Approx. 0.7-1.2V
Ou After warming up the engine (2000rpm without load 1.0 - 1.7V)
AIRFLO ) ldling (N range, NC OFF) Note: 2 air-flow meter value can Air flow meter system
Output volta e vary O - 0.4V
ENGTEMP SEN Engine temperatura sensor
After warming up the engine Above approx. 70°C
s stem
Changes between O - 0.3V

and 0.6- 1V Exhaust gas sensor system
After warning up 2000rpm without 1 - - - - - - - - - - - - - - 1 lntake system air leak ar air
G the angina load intake
RICH/LEAN RICH. LEAN repeats 5 times or lnjector system
EXT GAS SEN (R) more in 10 seconds
RICH/LEAN
CAR SPEED SEN Should generally conform to
(Vehicle speed signal)
While driving orwith drive wheels turning
speedometer display
system
lgnition sw in ON position Battery
BATTERY VOLTAGE 11 - 14V ECCS control unit power
Engine stopped
s stem
THROTTLE SEN lgnition sw in ON /-T__h_ro_tt_le~fu_ll._cl_o_se_d-t------º"'.'"·-::-5------; Throttle sensor adjustment
(Output voltage) Engine stopped Throttle fully open 4.0 Throttle sensor system
INT/A TEMP SEN
(lntake temperatura sensor 1nta ke temperatura sensor
After warming up the engine lntake air temperatura is disp/ayed
out ut system
INJ PULSE ldling
¡ -.....l_n'-'·ec.:c,=cti:"o:-Cn_.p;,,;cu"'lsC-'e'-w;;.;.,-id..;.t~h'----1 Afiar warming up N ran e, A/C OFF 1.4_2 _2 msec Air flow meter system
Reference 1 - - - - - - - - t lntake system air leaks or air
INJ PULSE (R) the engine 2000rpm without suction (entire input)
ln'ection ulse width load 1.4-2.2 msec
Input signal system (entire)
ldling Approx. 15 - 35%
JGN TIMING After wamning up 1-"(-::N-::r-::an~e__, _N_C:-,-O_F"'.'"F"-1--------------, Air flow meter system
the engine 2000rpm without
load Approx. 30 - 50%
ldling 75 - 125%
AACVALVE After wamning up ¡...,~N_r.:..a..cn.,_e:..:.•.;.A/.;;..C;;....O_F_F_.)+-------------, IAS adjustment
the engine 2000rpm without MC valva system
A/FALPHA lnjector system
(Air-fuel ratio feedback After warrning up the engi ne
2000rpm without load 75 - 125% Canister (purge) inspection
correction coefficient) lntake system air leak or air
suction
"START' ON
START SIGNAL
lgnition sw in ON "OFF"
t-----------------.,..----------1
OFF S1arter sw system
1 - - - - - - - - - - - - - 1 Engine stopped l-:T::-h-ro...,tt-.-le--':-'fu':-:ll-c:--lo-se-d-:--1-------'o~N:--------+------------,
IDLE SW Throttle full O en OFF Throttle sensor system
A/CSWON ON
AIRCOND SIG 1--A/..;.;...C_S_W_O-'-F-F----1-------F-F------; Air conditioner sw system
0
NEUTRALSW ldle
PW/ST SIGNAL
IDLE JUDGEMENT
When idlin ON
1------::0-.-th,...e-r""'th_a_n""'i...,dl
...i n - - - - - t - - - - - -=F=F-------1 Throttle sensor system
0
FUEL PUMP RELAY Stop OFF
lgnition sw in ON ¡----,-W"'h,...e_n_r_.e_w...,in--+------::-:-cN:--------; Fuel pump system
0
!die A/C ON ON
AIR CON RELAY
1------➔--"-N;;.,C;...;:O.:..F.:..F_ _+-----ºé--F::-F-------1 Air conditioner relay system
Accel 10 seconds A/C ON OFF
W/GCONT SN ON
OFF
POWER VOLTAGE Displa robe measurement value
PULSE robe measurement value
EN-428
RB26DETT ENGINE
Active test
Perform following inspections to

check if problem is solved.
Set engine temperature Eliminate:
~ghtr low. Engine temperature sensor system
ENGINE Problem occurrence au ,on: lnjector system
TEMPERATURE condition Do not set extreme values .
. k Atr flow meter, exhaust gas sensor
as th 1s can cause spar t
sysem
plugs to burn. Not eliminated:
Other item inspection

Set the air-fuel ratio rich check if problem is solved.
Eliminate:
or lean.
Exhaust gas sensor system
Problem occurrence Caution:
FUEL INJECTION Air flow meter, engine temperature
condition Do not set extreme values
sensor system
as this may damage en-
lnjector system
gine or catalytic converter
Not eliminated:
other ítem inspection
Delay ignition timing. check if problem is solved.
Caution: Eliminate:
IGNITION TIMING Problem occurrence Do not set extreme values lgnition trming adjustment
condition
as this may damage en- Detonation sensor system
gine or catalytic converter Not eliminated:
Other item íns ection
lncrease control duty ratio.
The engine speed should lf the condition described on left
AAC VALVE increase.
Engine running Decrease control dut can not be verified, check AAC
OPENING
. dy valve system
ratio. The engine spee
should decrease.
Set the AAC value open to
stop the specified injector
operation and the injector
POWER speed can be displayed at Eliminate:
Engine running
BALANCE this time. lnjector system
Caution:
Do not perform this opera-
tion while drivin .
Turn ignition sw to ON,
OFF and ON so the pump
operation makes noise. lf the conditíon described on left
FUEL PUMP lgnition SW in ON The fuel pressure wíll rise. can not be verified , check re lay
RELAY Engine stopped Caution: system of fuel pump and fuel pump
Do not perform this opera- system
tion except under condi-
tions described on left.
SELF-LEARNING
The air-fuel ratio feedback correction coefficient learning factor is learned.
CONT
EN-429
RB26DETT ENGINE
2. OSCILLOSCOPE & CIRCUIT TESTER INSPECTION VALVE (RB26DETT ENGINE)
~nnM~uvu~~~aa«~~u~~~
~~UMH~D~~~~~~M~~~~~~
1 (V) ~ --,-,~..,.....,.-,.- .,.--, (V) ,--- , - - - - -

6 1
2 6 >--·
Power tran- 4 11--+-.........---+-+-rl-+---T-I 4 i
3 ._,_...,..._-+-i
2 ........-+-----+--- 2 A
sistor control o ;,._.....+""t-''1--+_ _t"-;-...... o
11 i ' 1
signal .-·i
12
13
- -1--;
¡ :
1
'
¡ ..¡ i.eoms
1 1
.
...L LL 1 1
AAC valve
4
control signal
V)
1 r :1
Engine speed 5
1 1 1' -11 1
7 signa! for 1 1 I < . I' 1
!
tachometer
;
- 5ms ·- r-
1
A/C relay Low pressure SW

_.lno,lr\U~._f',--IJ.+
Air conditioner OFF: Air conditio ner OFF:

Air conditioner Battery voltage Battery voltage
9
relay Air conditioner ON: Air conditioner ON:
Approx. 1V Approx. 1V
Approx. 1V
C/U
16 ECCS relay (lgnition sw OFF: Approx. OV
Battery voltage)
Fuel pump rc lay
Fuel pump
18
relay
ov ov
EN-430
RB26DETT ENGINE
.,,,----.. RB26DETT ENGINE
2 3 4 5 6
11 12 13 14 15 16 17 18 19 20
7 8 9 10
a 21 22 23 24 25 26 27 28 29
31 32 33 34 35 36 37 38 39
41 42 43 44 45 46 47 48 49 50
51 52 53 54 55 56 57 58 59 60
PWRSTSW
Power steering ON: Power steering ON:

19
Power steering ov ov
switch signa! Power steering OFF: Power steering OFF:
SV SV
ECCS C/U
Diagnosis connector
Receive
21 (RX) (Control unit V 10V 10V
data reception) .,,.
ECCS CIU
Diagnosis connector
Transmit
(Data trans-
22 (TX)
m ission from
OV ov
control unit)
ECCS CIU
23 Detonation
Approx. 0.3V Approx. 0.3V
24 sensor signa!
Wastegate Wastegate
contro SN
valve control V
25 solenoid con-
Battery voltage Approx. OV
trol signa!
ECCS C/U
Air flow meter

27 (rear) intake air Approx. 1V Approx. 1.SV
quantity signa!
ECCS C/U
EN-431
RB26DETT ENGINE
RB26DETT ENGINE
~u~~uuu~~n~au"~~~~~~
~UH~H~U~~~~~~M~~D~~~
Engin1 temp sensor
~ Engine temperature Engine temperature

(AFM ground)
Enginetemp 80°C: Approx. 1V BOºC: Approx. 1V
28
sensor signa! Engine temperature Engine temperature
20ºC: Approx. 3V 20°C: Approx. 3V
ECCS C/U
lgnition swi1ch
+·H&--, Exhaust
Exhaust gas IGN
Deflects between
29 sensor signa! Approx. O - 1V
approx. O - 1V
{front)
ECCSC/U
Clock (synchro-
31 {CLK)
nization signal)
ov OV
Exhaustgas
temparature
warning !amp
Motor & check Lamp not lit: Lamp not lit:
32 lamp Power voltage Power voltage
(red lamp) Lamp lit: OV Lamp lit: OV
Air flow meter

(front) intake
35 Approx. 1V Approx. 1.5V
air quantity
signal
ECCS C/U
lntake air temp sen
36
lntake air temp
sensor signal ~ Cold: Approx. 1.5V
Warm: Approx. O.BV
Cold: Approx. 1.SV
Warm: Approx. 0.8V
~
EN-432
RB26DETT ENGINE
RB26DETT ENGINE
31 32 33 34 35 36 37 38 39 51 !52 53 54 55 56 57 58 59 60
Throttle sensor
Engine temperature
Throttle sensor 80°C: Approx. 1V
38 Approx. 0.5V
signat Engine temperature
20°C: Approx. 3V
0.3 - 0.7V 0.3 - 0.7V

rv)¡
41
Crank angle
6'
4 •&
!
.
1
¡
, •
1 1
(
6 >-1---l--+--+--+--+--l-+-+-I
2 2
sensor 120° o 1 11 1 1
o
51
signa! ....¡.
,_,_ ' 1
'' ! !
,..... ~
~tºtl
l 1
LL ~ .... , -~ _LU '
1
2-3V 2-3V
rank angl
sen
Crank angle
42
sensor1°
52
signa!
ov
lgnition switch (lgnition switch
43
(START signal) "START": Battery
ov
voltage)
~--Neutral
(MIT) switch
N or P range: 0V N or P range: 0V
Neutral switch
44 Other than N or P Other than N or P
signal
range: 4 - 5V range: 4 - 5V
ECCSC/U
Air conditioner SW
Air condítioner OFF: Air conditioner OFF:

46 Air conditioner ON:
switch signa! Air conditioner ON:
ov 0V
EN-433
RB26DETT ENGINE
RB26DETT ENGINE
~~~M~~vu~~~~a~•~Q~~w
Mn"~~~D~~~~~~M~~ff~~oo
Throttle sensor
48 5V 5V
(Power supply)
Control unit
49 Battery voltage Battery voltage
power supply
D range (or 1st) with D range (or 1st) with

rear wheels jacked up: rear wheels jacked up:
Vehiclo spoed sensore 0.5 - 1.5V 0.5- 1.5V
The value actually de- The value actually de-
Vehicle speed
53 flects between DV and flects between OV and
sensor signal 5V. However, it appears 5V. However, it appears
to deflect around 1V, to deflect around 1V,
ECCS C/U according to vehicle according to vehicle
speed. speed.
c,u.,.-+--~1
Throttle valve Throttle valve SW
54 switch (idle Approx. 10V Approx. 10V
contact point)
. 0 2 sensor
Exhaustgas N or P range: OV N or P range: 0V
55 sensor signa! Other !han N or P Other than N or P
(Rear) range: 4 - 5V range: 4 ~ 5V
4WAS
Approx. 0.5 ~ 4V
Throttle sensor (Voltage increase as
56 Approx. 0.5V
output signa! accelerator pedal is
depressed
ECCSC/U
EN-434
RB26DETT ENGINE
R826DETT ENGINE
~U~M~UVU~~~Ga~a~Q~~~
~~~~~~~H~~~~~M~~u~~ro
Throttle valve SW
Throttle valve
57 switch Battery voltage Battery voltage
(power supply)
Approx. Battery Approx. Battery

101 voltage voltage
(V) (V)
103 1 '
60 60 ,.1'
105 lnjector control ~ 40 '
1 11
20 1 20
110 signal o o
7[
112 i '
1
114
ECCS C/U
1-1-1-- Oms· - 20msl ' 1
1 1 1 1 1 1 ! '
Fuel pump ter-

minal voltage ldling (after warrning !dling (after warrning
104 engine): OV engine): OV
control signal
(FPCM 1} ECCS C/U
Fuel pump ter-

minal voltage During mid load:
106 OV
control signal
(FPCM 2) ECCS C/U
EN-435
RB20E ENGINE
1. CONSULT INSPECTION VALUES - RB20E ENGINE

(1.1) Datamonitor
Note: The output signal is displayed as the calculation data on console unit so the correct
value will be displayed even if the output circuit (harness) is inadvertently disconnected.
CAS.RPM (Detected angle Tachometer set There must be no abnormal

speed according to signals) Engine running change in speed Crank angle sensor system
AIRFLOWMTR After warming up the engine
(Output voltage) ldling (N range, NC OFF} Approx. 0.8 - 1.5V Air flow meter system
ENGTEMP SEN
After warming up the eng ine Above approx. ?OºC Engine temperature sensor
(Engine temperature) system
EXTGASSEN Changas between O - 0.3V Exhaust gas sensor system
(Output voltage) After warning up 2000 rpm without ,___ _ _a:..;n.;,;d_0....;.6.;;._-....;1....;V_ _ _- l lntake system air leak or air
EXTGAS SEN the engine load RICH. LEAN repeats 5 times or intake
(RICH/LEAN) more in 1Oseconds lnjector system
CAR SPEED SEN Should generally conform to Vehicle speed sensor
(Vehicle speed signal) While driving orwith drive wheels tuming
speedometer display system
lgnition sw in ON position Battery
Engine stopped
system
THROTTLE SEN lgnition sw in ON 1--T_h....;ro....;tt....;le_f_ul...:.ly_c....;lo;.;s_ed--11------....;º_·5;;...__ _ _ _~ Throttle sensor adjustment
(Output voltage) Engine stopped Throttle fully open 4.0 Throttle sensor system
INJ PULSE ldling 2 _ 3 msec Air flow meter system

(lnjection pulse width)
Afie r warming up (N range, NC OFF) ' - - - - - - - - - 1 lntake system air leaks ar air
the engine Reference .-
1/16 display for RB20E 2000rpm without suction (entire input)
load 2 ~ 3 msec Input signal system (entire)
ldling M/T15º, NT20º
IGN TIMING After warming up 1-....:.(N;.;.....;ra:..;n.;ag:.;;;e.:..;,N..;..;;C....;O:..;F....;F...:.)-1-_ _ _ _ _ _ _ _ _ _--1
·ne
the engl Air flow meter system
2000rpm without Advance greater than 10° angle
load comparad to idle position
~~ A~ro~~-~%
AACVALVE After warming up ~(N....;.;,;ra:..;n;.a:g....;e....;,Al..;..;;.C..;O;.;F..:.F.:..)4-_ _ _ _ _ _ _ _ _ _~ IAS adjustment
the engine 2000rpm without AAC valve system
Air now meter system

(Air-fuel ratio feedback After warr:iing up the engi ne
2000rpm without load 75 - 125% Canister (purga) inspection
correction coefficient) lntake system air leak or air
suction
START SIGNAL "START" ON
f-----------1 lgnition sw in ON ~=====·= ·o=F=F=" =====~==========O=F=F=========~+-sta_rt_er_s_w_s_y_s_te_m_ _ _ ~
Engine stopped Throttle ful ly closed ON
IDLESW Throttle sensor system
Throttle fully open OFF
NCSWON ON
AIRCONDSJG 1 - - - - - - - - - + - - - - - --F-F------IAir conditioner sw system
N C SWOFF 0
N or P range ON
NEUTRALSW ldle 1--....;....;_ _..:a:...;.._-1-------F-
F- - - - - - I Neutral sw system
Other than N or P 0
PW/ST SIGNAL
Steering ON
l - - - - " - - - ' ' - - - - 1 - - - - - --F-F-------, Power steering sw system
Steering neutral 0
Stop OFF
FUEL PUMP RELAY lgnitíon sw in ON 1---..;;.;;:.!:..._ _-1-------=:..:.N..:...._______ Fuel pump system
When revving 0
NC ON ON
Id/e
AIR CON RELAY 1--------+--....;....;N..:.C;;.....;;O....;F..:.F_ _+-_____O.;_;_F:..F_ _ _ _--1 Air conditioner relay system
Accel 1O seconds NCON OFF
EN-436
RB20E ENGINE
Active test

check if problem is solved.
Set engine temperature Elirninate:
high or low.
Engine temperature sensor system
ENGINE Problem occurrence Caution:
lnjector system
TEMPERATURE condition Do not set extreme valuesk Air flow meter, exhaust gas sensor
as this can cause spar
system
plugs to burn. Not eliminated:

Eliminate:
or 1ean.
. Exhaust gas sensor system
FUEL INJECTION Problem occurrence eau tion: . t emperat ure
Aºir fl ow meter, engine
condition Do not set extreme va Iues t
as this may damage en- si~nsot r sys tem
. . nJec or sys em
gine or catalyt1c converter Not eliminated:
Caution: Eliminate:
Problem occurrence
IGNITION TIMING Do not set extreme values lgnition timing adjustment
condition
AACVALVE increase. .
Engine running Decrease control duty can not be venfied, check AAC
OPENING
valve system
ratio. The engine speed
should decrease.
operation will make noise. lf the condition described on left
FUEL PUMP lgnition SW in ON The fuel pressure will rise. can not be verified, check relay
RELAY Engine stopped Caution: system of fuel pump and fuel pump
tion except under condi-
SELF-LEARNING
CONT
EN-437
RB20E ENGINE
2. OSCILLOSCOPE & CIRCUIT TESTER INSPECTION VALVE (RB20E ENGINE)
-
37 38 39 40 41 42
43 44 45 46 4748
-
1 2 3 4 5 6 7 8 9 10
11 12 13 1415 16 17 18 19 20
-
21 22 23 24 25 26 27 28
29 30 3132 33 34 35 36
Air flow meter

3 intake air Approx. 1V Approx. 1.5V
V
quantity signal =
ECCS C/U
Engine temp sen
Engine temperature Engine lernperature

engine temper- (AFM ground)
·v 80°: Approx. 1V 80°; Approx. 1V
5 ature sensor
Engine temperature Engine temperatura
signal
20°: Approx. 3V 20°: Approx. 3V
Exhaust gas Deflects between

6 Approx. O - 1V
sensor signal Approx. O - 1V
0.5 ~ 1V
Throttle sensor (Battery voltage will
7 Approx. 0.5V
signal (input) i ncrease when accel
pedal is depressed)
0.3- 0.7V 0.3 ~ 0.7V

M 1 (V) ~ -.--,-...,......,
6 1-+..¡.....;,-++-l-l--+--l--l 6 t-1"---t--,r-,--t-1- + - ~r l
Crank angle 4 1 1 ' • 4
2 1 1. 1 ,1 -....,.....
i..,._ 2'.
9 sensor 120° o, 1 1 tH 1 o
signal H-- -t--+-<'-+-t------..
2 ~ 3V
©
120• SI
Crank angle
10 sensor1°
signa!
ECCS C/U
EN-438
RB20E ENGINE
RB20E ENGINE
- -
37 38 39 40 41 42
43 44 45 46 47 48
1 2 3 4 5 6 7 8 9 1O
11 12 13 1415 16 17 18 19 20
-
21 22 23 24 25 26 27 28
29 30 31 32 33 34 35 36
Lamp not lit Lamp not lit:

Monitor&
Power voltage Power voltage
13 check lamp
Lamp is lit: Lamp is lit:
(red lamp)
ECCSC/U Approx. OV Approx. OV
To A/T control unit
lntake air
quantity output
15 Approx. 1V Approx. 1V
signa!
(ToA/T C/U)
ECCS C/U
Detonation se
V
Detonation
sensor signa)
ECCS C/U
Thrott!e sensor
0.5 - 1V
Throttle (Battery voltage
17 opening output Approx. 0.5V will increase when
signal accelerator pedal is
depressed)
D range (or 1si) with D range (or 1si) wíth

rear wheels jacked up: rear wheels jacked up:
Vehicle speed sensor~ 0.5 _ 1.5V 0.5 -1.5V
The value actually de- The value actually de-
Vehicle speed
21 flects between O and flects between O and
sensor signal 5V. However, it appears 5V. However, it appears
to deflect around 1V to deflect around 1V
speed. speed.
A/T C/U
Throttle valve
OV when accelerator
22 switch (!die Approx. 10V
pedal is depressed
contact point)
ECCS C/U
EN-439
RB20E ENGINE
RB20E ENGINE
-
37 38 39 40 41 42
43 44 45 46 47 48
-
1 2 3 4 5 6 7 8 9 1O
11 12 13 14 15 16 17 18 19 20
-
21 22 23 24 25 26 27 28
29 30 3132 33 34 35 36
o
lgnition switch (lgnition switch at
23 OV
(START signal} START:
Power voltage)
ECCSC/U
_ _ _ Neutral SW
(M/T)
..,__ _ N.P SW
Neutral switch (A/T) N or P range: OV N or P range: OV

24 Other than N or P Other than N or P
signal
range: Approx. 6V range: Approx. 6V
ECCSC/U
lgnition switch
25 Power voltage Power voltage
(ON signal)
ECCSC/U
Throttle sensor
26 signa( (Power 5V 5V
supply)
ECCS retay
Control unit
power supply
A/CSW
Air conditioner OFF: Air conditioner OFF:

Air conditioner Power voltage Power voltage
29
switch signal Air conditioner ON: Air conditioner ON:
Approx. OV Approx. OV
EN-440
RB20E ENGINE
RB20E ENGINE
- -
37 38 39 40 41 42
43 44 45 46 47 4ll
1 2 3 4 5 6 7 8 9 10
11 12 13 1415 16 17 18 19 20
-
21 22 23 24 25 26 27 28
29 30 31 32 33 34 35 36
Throttte valve SW
[~AIT
Throttle valve
L I C/U
32 switch (power Power voltage Power voltage

supply)
ECCS C/U
..----·.
IGNcoil 0.2 ~ 0.3V Approx. 1V

+ (V)
6
4
Power 2 /
1,1
o 1
37 transistor con- V
·-...
trol signal
ECCS C/U 1 1
Power steering sw

Power steering DV DV
38 Power steering OFF:
switch signal Power steering OFF:
Power voltage Approx. 10V

M (v
!
40 4
30
!
3
1
Tachometer 20 2
:i
39 10 1
signal o r 1
!
,-- .... ," ___¡__ '-5ms
1 1,
ECCS relay
Approx. 1V
40 ECCS relay C/U
(ignítion switch OFF: ov
Power voltage)
Tacho meter
M (V)
Tachometer 5
1
-1 5
1 1 :1 1
1 1 1 T T
43 engine rev o
signal
ECCS C/U
~- • • m - •m
1
EN-441
RB20E ENGINE
RB20E ENGINE
-
37 38 39 40 41 42
43 44 45 46 4748
-
1 2 3 4 5 6 7 8 9 1O
11 12 13 1415 16 17 18 19 20
-
21 22 23 24 25 26 27 2B
29 30 3132 33 34 35 36
-~~ Tachometer
EngineA/T
total control
44 Approx. 10v Approx. 10V
input signal
(DT 1)
- - - A/T control unit (V) (VJ--,~-~-~

6
EngineA/T ' 6if--'--t-+-i-t-+-->-+---i-
4
2
total control V o
45
input signar
(DT 2) 4 .... ... ,ms
A/C relay
Low pressure SW
+ Air conditioner OFF: Air conditioner OFF:
Air conditioner Power voltage Power voltage
46
relay Air conditioner ON: Air conditioner ON:
ov OV
- - - A/T control
unit
EngineA/T
total control
47
output signal ov ov
(DT 3)
Almost power voltage Almost power voltage

101 ¡. (V)---,---~---
103 6(,..-f 1 1 60 '
105
4 ' 40" 1
'
lnjector controi 20 11 20 1 1 1
110 signal o o 1H-'-+--+-+--f'-+-i-'+--1--7
112
laCCSC/U 1-~ 20msi
114 ¡
-
' 1
Fue! pump
104
relay ov ov
EN-442
RB20E ENGINE
RB20E ENGINE
- -
37 38 39 40 41 42
43 44 45 46 47 48
1 2 3 4 5 6 7 8 9 10
11 12 13 1415 16 17 18 19 20
-
21 22 23 24 25 26 27 28
29 30 31 32 33 34 35 36
Cold: 6- 7V Approx. 4 - 5V
Warm: 8 ~ 10V M
1 1 1 1
MCvalve
M
15
10 ~~
1
1
1
n
1
15
10
5 11
,,
lí 1; :rl 11
'1
113 ! : 1 1
~
íl l
control signal 5
1 1: o 1
o ! 1
1 1 ¡_.. ·• ms I i ;
.... 1----+--2ms l : i 1 1
1 1 ¡
¡
'
EN-443
ECCS C/U INPUT / OUTPUT SIGNALS SYSTEM DIAGNOSIS INSPECTION
1. CONSULT INSPECTION VALUES - RB25DE / RB25DET ENGINE

(1.1) Datamonitor
Note: The output signal is displayed as the calculation data on console unit so the correct
value will be displayed even if the output circuit (harness) is inadvertently disconnected.
CAS.RPM (Detected angle

Tachometer set There must be no abnormal
speed according to sig- Crank angle sensor system
Engine running change in speed
nals)
After warming up
ldling
AIRFLOWMTR the engine
Approx. 1.0 - 1.5V Air flow meter system
(Output voltage) ldling (N range, 2,000rpm without
NC OFF) load
ENGTEMPSEN Engine temperature sensor
After warming up the engine Above approx. 70°C
(Engine temperatura) system
EXTGASSEN Changes between O - 0.3V Exhaust gas sensor
(Output voltage) and 0.6 - 1V system
Alter warning up
2000rpm without load lntake system air leak or
EXTGASSEN the engine RICH. LEAN repeats 5 times
air intake
(RICH/ LEAN) or more in 1O seconds lnjector system
CAR SPEED SEN Should generally conform to Vehicle speed sensor
While driving or with drive wheels turning
(Vehicle speed signal) speedometer display system
Battery
lgnition sw in ON position
Engine stopped
system
ldling Air flow meter system
Approx. 2.0 - 2.Bmsec
INJ PULSE Afler warming {N range, NC OFF) lntake system air leaks or
(lnjection pulse width) up the engine air suction (entire input)
2,000 rpm without load Approx. 2.0 - 2.8msec Input signa! system {entire)
ldling
15°
Af!er warming {N range, NC OFF)
IGN TIMING Air fiow meter system
up the engine Advance greater !han 10° an-
2000rpm without load
gle comparad to idle position
Afler warming ldling IAS adjustment
AACVALVE Approx. 12 - 30%
up the en ine (N ranga, NC OFF) AAC valve system
Air fiow meter system
Afler warming up the engine
(Air-fuel ratio feedback 75- 125% Canister (purge) inspection
2000rpm without load
correctlon coefflcient) lntake system air leak or
air suction
"START" ON
START SIGNAL lgnition sw in Starter sw system
"OFF" OFF
ON
Throttle fully closed ON
IDLE JUDGEMENT Engine stopped 1hrottle sensor system
Throttle fully open OFF
NCSWON ON
AIRCONDSIG Air conditioner sw system .-··-..
NC SWOFF OFF
N or P range ON
NEUTRALSW Neutral sw system
Other than N or P O FF
ldle
Steering ON
PW/ST SIGNAL Power steering sw system
Steering neutral OFF
NCSWON ON
Air conditioner relay
AIR CON RELAY NCSWOFF OFF
system
ACCEL AJCSWON OFF
lgnition sw in Stop OFF
FUEL PUMP RELAY Fuel pump system
ON When rewing ON
lgnition sw in Throttle fully closed Approx. 4 .0
THROTTLE SEN
ON Throttle sensor system
(output voltage) Throttle ful/y open Approx. 0.5
Engine stopped
POWER VOLTAGE Display power voltage probe measurement value
PULSE Display pulse probe measurement value
EN-444

Set engine temperature check if problem is solved.
Eliminated:
high or low.
Engine temperatura sensor system
ENGINE Problem occurrence Caution:
lnjector system
TEMPERATURE condition Do not set extreme values .
. k Air flow meter, exhaust gas sensor
as th 1s can cause spar system
plugs to bum. Not eliminated:

Eliminated:
or lean.
Exhaust gas sensor system
Problem occurrence Caution:
FUEL lNJECTION condition Do not set extreme values Air flow meter, engine temperature
sensor system
as this may damage en-
lnjector system
gine or catalytic converter
Not eliminated:
Other ítem inspection
Caution: Eliminated:
Problem occurrence
IGNITION TIMING Do not set extreme values lgnition timing adjustment
condition
Other item ins ection
MCVALVE in crease.
Engine running can not be verified, check MC
OPENING Decrease con1ro 1 duty
. . valve system
ratio. The eng1ne speed
should decrease.
Set the MC value open to
stop the specified injector
operation and the injector
POWER speed can be displayed at Eliminated:
Engine running
BALANCE this time. lnjector system
Caution:
Do not perform this opera-
tion while drivin .
operation will makes noise. lf the condítion described on left
FUEL PUMP lgnition SW in ON The fuel pressure will rise. can not be verified, check relay
RELAY Engine stopped Caution: system of fuel pump and fue! pump
tion except under condí-
SELF-LEARNING
CONT
EN-445
ECCS C/U INPUT / OUTPUT SIGNALS SYSTEM DIAGNOSIS INSPECTION
R825DE / RB25DET ENGINE
2. OSCILLOSCOPE & CIRCUIT TESTER INSPECTION VALVE (RB25DE / DET ENGINE)
~nnM~~vu~~~~~~~~a~~~
~~UMU~~~~~~~~~~~~~~~
CHK I IGN
1
1 {VJ,---,-
6 r, . . ,
j I TTTT"f7'
i--~
,. 6
Approx. 0.4V
1 !
2 4 · o 4 1
Power 2R . 1 1
3 2 --
tran sistor o, i
11 º l
control signa! ! '7
12 ¡ _¡
13 ECCS C/U tri.~b±ÉJ t i

-
i
0m
1
1
1
Cold: 6- 7V Approx. 5V
. - - - - - --<+ (V) Warm : 8 - 10V 1
1 n · ~
1
~
'
r· 1
. .
101. .J.. .
AAC valve 5~)
4 o j_J .
control signa! i i
~~~~..,.
--!--;--'!-'--r
~
rr t : j , i ~a=lFi
~ - -AJT control unit
EngineNT
total control
input signa!
(DT 1) ECCS C/U
. . -- - · Tachometer Approx. 1V Approx. 2.4V

(V),,.
5·
Tacho meter
7 engine speed o .u.....;-'--..+-''-i--i--+-l--'
signa!
ECCS C/U
I~±:± ms I jJ
lTJT '.I ~LJ
Low pressure
A/C relaySW
Air conditioner OFF: Air conditioner OFF:

9
relay Air conditioner ON: A ir conditioner ON:
ECCS C/U
. . - - - A/T control
unlt
Engine NT to-
14 tal control input Approx. 10V Approx. 10V
signa! (DT 2)
ECCS C/U
EN-446
~llDMB~U~~~~~~"~~Q~~~
nu~~n~~~~-~~~~~~~~~~
¡ ICHK IGN
A/T control unit

Engine A/T
total control Approx. OV
15 Approx. OV
output signal
(TO 3) ECCS C/U
,------
ECCS relay
Approx. OV
C/U
16 ECCS relay (lgnition switch OFF: Approx. OV
Power voltage)
ECCS C/U
Fuel pump
18
relay
OV ov
Power steering SW

Power steering ov ov
19 Power steering OFF: Power steering OFF:
switch signal
5V 5V
ECCS C/U
---j Detonation ••~

Detonation sen
23 Detonation
Approx. 0.3V Approx. 0.3V
24 sensor signal
ECCS C/U
Air flow meter

27 (intake air Approx. 1V Approx. 1.5V
quantity slgnal)
ECCS C/U
EN-447
21 22 23 24 25 26 27 28,29 30 41 42 43 44 45 46 47 48 49 50
31 32 33 34 35 36 37 38 39 40 51 52 53 54 55 56 57 58 59 60
CHK I IGN
1
Engine temperature sensor
Engine temperatura Engine temperatura

Engine temper- (AFM 80º: Approx. 1V 80°: Approx. 1V
28 ature sensor ground)
Engine temperatura Engine temperatura
signal
20°: Approx. 3V 20°: Approx. 3V
·--.........
Exhaust gas Deflect between O -

29 Approx. O - 1V
sensor signal Approx. 1V
Monitor & Exhaust tomp

warning lamp
Check lamp
,_.µ¡,__IGN Lamp not lit Power Lamp not lit: Power
(red lamp, ex-
32 voltage voltage
haust tempera-
Lamp lit: 0V Lamp lit: 0V
tura warning ECCSC/U
lamp)
IGNSW
FICO solenoid A/CON: 0V A/CON: 0V
36 FICD solenoid " A/C OFF: A/C OFF:
Power voltage Power voltage
ECCS C/U
To A/T control unit
~
0.5 - 4V (Voltage
Throttle sensor increase when ac-
38 Approx. 0.5V
signa! celerator pedal is
ECCS C/U depressed)
To A/T CQntrol unit
40
lntake air
quantity output
~ Approx. 1V Approx. 1.5V
signal
ECCS C/U
EN-448
2 3 4 5 6 7
12 13 14 15 16 17 18 19 20
S 9 10
a ~nnM~~nu~~~aa~••D~~~
~ll~~U~D~~~~~~~~~~~~~
Crank angle
41 sensar120°
signa!
2-3V 2-3V
Crank
~ = - - - - 1 angle (V',._.---~,
sensor 6 ;_·-'-"--'---'--'-.¡_¡_-"-"-'
Crank angle 4 ~·+l-l--l-1-1-1-1+-1-H-<1-H-l+I
2::-1-H+-H+H-H-H+-H+H-,
42 sensar1° 0::-1.u..¡..LJ..Lcµ.j..l.j-u.-4-'-'-'-j
signa!
ECCS C/U
IGN
OV (lgnitian switch
lgnitian switch
43
(START signa!}
START: Power ov
valtage}
ECCS C/U
~ - --.-N.PSW
N or P range: OV N or P range: OV
Neutral switch
44 Other than N ar P Other than N ar P
signa!
range: 4 - SV range: 4 - 5V
ECCS C/U
AJCSW
Air canditianer OFF: Air canditianer OFF:

Air canditianer Power valtage Power voltage
46 Air canditioner ON: Air canditianer ON:
switch signa!
ov ov
Tnrottle
sensor
lntake air
48 quantity output sv 5V
signa!
ECCS C/U
EN-449
~~U~H~VU~~M~ü"~«a~~~
~~u~n~n~~~~~~~~~ff~~60
CHK I IGN
1
ECCS C/U
power supply
ECCS C/U
D range (or 1st) with rear D range (or 1st) with

wheels jacked up: 0.5 - rear wheels jacked up:
1.5V 0.5-1 .SV
se"sor The value actually de- The value actually de-
Vehicle speed
53 flects between O and flects between O and
sensor signal 5V. However, it appears SV. However, it appears
to deflect around 1V to deflect around 1V
speed. speed.
A/TC/U
Throttle valve
0V when accelerator
54 switch (ldle Approx. 10V
pedal is depressed
contact point)
ECCS C/U
To AfT control unlt
Approx. 0.5 ~ 4V
Throttle
(Voltage will in crease
56 opening output Approx. 0.5V
when accelerator
signa!
ECCS C/U pedal is depressed)
Throltle valve SW
Throttle valve
57 switch (power Power voltage Power voltage
supply)
ECCS C/U
Almost power voltage Almost power voltage

lnjector
101
(V)
1 1 M
103 60 60 1 1
40 40
105 lnjector control 20
' 1 1
20
1 1
1.
110 signa! o 1
o 1
112
114
ECCS C/U - 20ms 1
1
- :ums
1
;
EN-450
SERVICE DATA
ENGINE MECHANICAL SERVICE DATA
1. COMPRESSION PRESSURE MPa {kg/cm2 } / (300rpm)
1.23 {12.5} 1.26 {12.8} 1.20 {12.2} 1.18{12.0}

0.93 {9.5} 0.96 {9.8} 0.90 {9.2} 0.88 {9.0}
0.10{1.0} 0.10{1.0} 0.10{1.0} 0.10 {1.0}
2. AUXILIARY BELT DEFLECTION

Fan belt
Tension gauge is used

(RB20E, RB25DE, RB25DET)
490~578 {50~59} 382~4 70 {39~48} 225 {23}
666~ 755 {68~ 77} 558~647 {57~66} 284 {29}

666~ 755 {68~ 77} 558-657 {57~66} 284 {29}
670~ 760 {68~ 77} 550~640 {56~65} 280 {29}
670~ 760 {68~ 77} 550-640 {56~65} 280 {29}

670~ 760 {68~ 77} 550~640 {56~65} 280 {29}
Pushed with 98N {10kg}

(RB20E, 25DE, 25DETT) (mm)
8 ~ 10 9 ~ 11 15
6~8 7~9 12
3~5 4-6 7.5
SD-1
SERVICE DATA
(RB26DETT) (mm)
8 ~ 11 10 ~ 12 16
6~8 7~9 12
3~5 4~6 7.5
lntake & exhaust (mm)
0.15
0.1 0.1
0.3 0.3
Turbo charger
(RB25DET) (mm)
49 ~ 54 {365 ~ 405} (M / T)
33 ~ 39 {250 ~ 290} (A/ T)
0.120 ~ 0.200
(RB26DETT) (mm)
59 ~ 64 {440 ~ 480}
78 ~ 84 {587 - 627}
0.013 ~ 0.097
3. CAM SHAFT (mm)
39.242 ~ 39.432 40.58

39.123 ~ 39.313 39.705 ~ 39.895 40.28
0.014 ~ 0.090 0.045 ~ 0.086
0.045 ~ 0.086
0.065 ~ 0.110 0.016 ~ 0.101
0.030 ~ 0.060 0.060 ~ 0.110 0.030 ~ 0.080
0.043 ~ 0.066 0.035 ~ 0.065 0.035 ~ 0.065
1.0
4. ROCKER SHAFT (RB20E) (mm)

,--.----------------,
0.007 ~0.049
SERVlCE DATA
5. CYLINDER HEAD (mm)

DIAG (A)
e
f
d
a
~---b-----<
- - -- a - - - -
0.2 0.2 0.2 0.2
126.8 85.3 ~ 85.5 85.3 ~ 85.5 100.88 ~ 101.08

80.78 ~ 81.08 80.78 ~ 81.08 97.3 ~ 97.6
38.0 ~ 38.2 34.0 ~ 34.02 34.0 ~ 34.02 34.5 ~ 34.7
6.965 ~ 6.980 5.965 ~ 5.980 5.965 ~ 5.980 5.965 ~ 5.980
1.15 ~ 1.45 1.15 ~ 1.45 1.15 ~ 1.45 1.3
2.4 ~ 2.8 2.6 ~ 2.9 2.6 ~ 2.9 2.6 ~ 2.9
45° 15' ~ 45° 45' 45° 15' ~ 45° 45' 45° 15' ~ 45° 45' 45° 30'
126.0 87.3 ~ 87.5 87.3 ~ 87.5 99.88 ~ 100.08
82.78 ~ 83.08 82.78 ~ 83.08 95.33 ~ 95.63
33.0 ~ 33.2 29.00 ~ 29.07 29.00 ~ 29.07 30.0 ~ 30.2
6.965 ~ 7.970 5.945 ~ 5.960 5.945 ~ 5.960 6.905 ~ 6.920
1.35 ~ 1.65 1.35 ~ 1.65 1.35 ~ 1.65 1.2
3.0 ~ 3.7 3.2 ~ 3.4 3.2 ~ 3.4 2.9 ~ 3.2
45° 15' ~ 45° 45' 45° 15' ~ 45° 45' 45° 15' ~ 45° 45' 45° 15' ~ 45° 45'
0.1 0.1 0.1 0.1
<t:>10.460 ~ 10.478
<t:>10.185 ~ 10.196
<t:>11.460 ~ 11.478
ct>7.000 ~ 7 .018 ct>6.000 ~ 6.018

ct>6.000 - 6.018
--- ct>8.000 ~ 8.011 <t:>7.000 ~ 7.018
DIAG (B) RB26DETT DIAG (B) RB20E / RB25DE / RB25DET

Cam shaft side Cam shaft side
Valve guide 11' Valve guide 'lf
16.8+/-0.1 10.8•/-o., ¡ 16.8+/-0.1
lntake Exhaust lntake

Exhaust
SD-3
SERVICE DATA
16.7 ~ 16.9 Refer to diag B
(1)36.500 ~ 36.516 <1>36.500 ~ 36.516
32.000 ~ 32.016<1> (1)32.500 ~ 32.516
RB20E
+0.016
<l>37 .8:'.'º2 45°

lntake side oversize 0.5 Exhaust side [oversize (0.5))
RB25DE / RB25DET
lntake Exhaust
side <l>D
side
RB26DETT
Exhaust
side
(mm)
36.403 ~ 36.613 36.597 ~ 36.613

32.0 29.85 ~ 30.15
33.6 ~ 33.8 32.0
Refer to 37.0 34.3
diagram 37.5
above 31.920 ~ 32.096 32.580 ~ 32.596
28.9 ~ 29.1 24.85 ~ 25.15
29.6
32.5
SD-4
SERVICE DATA
RB20E RB25DE / RB25DET

Valve oil seal
lntake exhaust
(mm)
Refer to above diagram
1.9
1.8
2.2
44.1 45.58 (EX) 45.58 (EX)
51.2 39.4 (IN) 39.4 (IN)
Below 0.5
Below 0.5
Below 0.2
Below 0.2
270 ~287 270 ~ 287
108 {11.0} {27.5 ~ 29.2} (EX) {27.5 ~ 29.2} (EX)
250 {25.5} 223 ~ 252 223 ~ 252
{22.7 ~ 25.7} (IN) {22.7 ~ 25.7} (IN)
35.0 35.0 (EX) 35.0 (EX)
40.0 30.8 (IN) 30.8 (IN)
RB26DETT
Valve oil seal
11.7
Exhaust
(mm)
Refer to above diagram

1.8
46.54
240 {24.0}
35.0
SD-5
SERVICE DATA
6. CYLINOER BLOCK
y 2
A
ij¡::::==~~TTX (Bv B
X
Degree of taper: 1 - 2 Elliptic degree: A-B
(mm)
<t:>86.000 ~ 86.030 <t:>86.000 ~ 86.030

0.2
0.015
0.010
0.025 ~ 0.045 0.015 ~ 0.035 0.035 ~ 0.055
<t:>58.645 ~ 58.672 <t:>58.645 ~ 58.670
-0.004 (retract) ~ O
0.040 ~ 0.073
0.030 ~ 0.063
0.065 ~ 0.135
0.1
0.1
0.22 ~ 0.45 0.21 - 0.38 0.24 ~ 0.34
0.19 ~ 0.45 0.18 ~ 0.44 0.42 ~ 0.57
0.20 ~ 0.76 0.20 ~ 0.76 0.20 ~ 0.60
0.1 0. 1
0.2 - 0.3
0.4
0.1 0. 15
0.3 0.3
<t:>45.000 ~ 45.013 <t:>51.000 - 51.013
0.005 ~ 0.017
0.05 - 0.18
0.3
<t:>54.951 ~ 54.975
<t:>47.961 ~ 47.974
0.005
0.005
0.05
0.020 ~ 0.047 0.028 ~ 0.047
0.090 0.090
0.011 ~ 0.035 0.020 ~ 0.040
0.090 0.090
SD-6
SERVICE DATA
7. PISTON SELECTION
Front mark
r1)"º'"'
Bore grade No.
. !~~ma~
P1stonp1n ~
grade
RB20E (mm)
77.970
77.960
77.952 77.935 77.945 77.955 77.965
77.915 77.925 77.935 77.945 77.955
o 1 o o 1 o 1 o
0.025 ~ 0.045
Service setting: STO 1, 2, 3, 4, 5 OS (0.5), (1.0)
RB25DE / RB25DET
86.030
86.020
85.985 85.995 86.005
85.975 85.985 85.995
O 1 O 1 o
0.015 ~ 0.035
Service setting: STO 1, 2, 3, 4, 5 os (0.5), (1.0)
RB26DETT
85.965 85.975 85.985

85.955 85.965 85.975
o o o
0.035 ~ 0.055
Service setting: STD1, 2, 3, OS (0.5), (1.0)
SD-7
SERVICE DATA
8. PISTON PIN SELECTION

Pistan pin grade (1 - 3)
Front mark Pistan grade (0.1)
Big hol Cylinder No. ID rnark

grade (0.1) (1 - 6)
RB20E (mm)
19.006 19.012
19.000 19.006
18.993 18.999
18.987 18.993
0.005 ~ 0.017 0.005 ~ 0.017
-0.004 ~ O -0.004 ~ O
RB25DE / RB25DET / RB26DETT (mm)
21.006 21.012
21.000 21.006
20.993 20.999
20.987 20.993
0.005 ~ 0.017 0.005 ~ 0.017
-0.004 ~ O -0.004 ~ O
SD-8
SERVICE DATA
9. CONROD BEARING SELECTION

Upper journal grade
from left No.1 -
(Jo
✓l oo8g
~I ¡3~13~12.,. , ,111
2 ¡~31~2
1n111 ol oIol
RB20E (mm)
Bearing grade No. STO0 STO 1

Bearing thickness (mm) 1 .502 ~ 1.506 1.506 ~ 1.510
Oil clearance (mm) 0.014 / 0.035 0.013 / 0.033
Grade colour None Brown
Bearing grade No. STO 1 STD2
Bearing thickness (mm) 1.506 ~ 1.51 O 1.510 ~ 1.514
Oil clearance (mm) 0.012 / 0.034 0.011 / 0.032
Grade colour Brown Green
Service setting: STO O, 1, 2 us 0.08, 0.12, 0.25
RB25DE / RB25DET / RB26DETT (mm)
Bearing grade No. STO0 STO 1

Bearing thickness (mm) 1.500 ~ 1.503 1.503 ~ 1.506
,,,--,
Oil clearance (mm) 0.020 I 0.039 0.021 / 0.039
Grade colour None Brown
Bearing grade No. STO 1 STO 2
Bearing thickness (mm) 1.503 ~ 1.506 1.506 ~ 1.509
Oil clearance (mm) 0.020 / 0.040 0.021 / 0.040
Grade colour Brown Green
Service setting: STO O, 1, 2 us 0.08, 0.12, 0.25
S0-9
SERVICE DATA
10. MAIN BEARING SELECTION
Lower journ
grade No. fr
left No.1 -
No.2 o. N .4 N .5 N .6 No.7
No. bearing housing
rade No.
RB20E / RB25DE / RB25DET (mm)
Bearing grade No. STOO STO 1 ST02

Bearing thickness 1.825 / 1.821 1.829 / 1.825 1.833 / 1.829 ·---
Oil clearance 0.020 / 0.045 0.021 / 0.046 0.022 / 0.047
Grade colour Black Brown None
Bearing grade No. STO 1 STO 2 ST03
Bearing thickness 1.829 / 1.825 1.833 / 1.829 1.837 / 1.833
Oil clearance 0.020 / 0.045 0.021 / 0.046 0.022 / 0.047
Grade colour Brown None Yellow
Bearing grade No. STD2 STO 3 STD4
Bearing thickness 1.833 / 1.829 1.837 / 1.833 1.841 / 1.837
Oil ctearance 0.020 ! 0.045 0.021 / 0.046 0.022 / 0.047
None Yellow Bfue
RB26DETT (mm)
,•···----..
Bearing grade No. STDO STO 1 STD2 STD3

Bearing thickness 1.818 / 1.821 1.821 / 1.824 1.833 / 1.829 1.827 / 1.830
Oil clearance 0.028 / 0.046 0.028 / 0.046 0.022 / 0.047 0.028 / 0.047
Grade colour Black Brown None Yelfow
Bearing grade No. STO 1 STD2 STD3 STD4
Bearing thickness 1.821 / 1.824 1.82411.827 1.837 / 1.833 1.830 / 1.833
Oif clearance 0.028 / 0.046 0.028 / 0.046 0.022 / 0.047 0.028 / 0.047
Grade colour Brown None Yellow Blue
Bearing grade No. STD2 STO 3 STD4 STD5
Bearing thickness 1.833 / 1.829 1.827 / 1.830 1.841 / 1.837 1 .833 ~ 1.839
Oil clearance 0.020 / 0.045 0.028 / 0.046 0.022 / 0.047 0.028 / 0.047
Grade cofour None Yellow Blue Green
Bearing grade No. STD3 STD4 STD5 STD6
Bearing thickness 1.827 / 1.830 1.830 / 1.833 1.833 / 1.836 1.836 / 1.839
Oil clearance 0.028 / 0.046 0.028 / 0.046 0.028 / 0.046 0.028 / 0.047
Grade colour Yellow Bfue Green Pink
-·-
SD-10
SERVICE DATA
__,,---
ENGINE LUBRICATION & COOLING
1. ENGINE OIL CAPACITY (L)
3.0
Approx. 3.8 Approx. 3.9 Approx. 4.2
Approx. 4.0 Approx. 4.1
Approx. 4.2 Approx. 4.3 Approx. 4.6
Approx. 4.4 Approx. 4.5
2. COOLANT {L)
3. LLC CONCENTRATION (%)
4. RADIATOR CAP (MPa {kg/cm2})
5. ENGINE OIL PRESSURE
Approx. 0.37 {3.8} Approx. 0.47 {4.8}

Approx. 0.1 {1.0} Approx. 0.32 {3.3} Approx. 0.52 {5.3}
SPECIFICATIONS
VEHICLE SPECIFICATIONS - ..,
E-HR33
010 032 048 056 060 064
SSEFECUA SSEAECUA SSEAELCUA SKEFECA SKEFECMA SKEFECUA

SEDAN COUPE
GTS, GTS urban runner
GTS GTS type G
GTS type G GTS ruban runner S
4720 4640
1720
1360 1340
2720
1480
1470
1895 1820
1425 1415 ·- ·.......
11 15 1085 1090
RB20
1998
Gasoline
720 740 750 710 710 720
580 580 590 550 560 560
1300 1320 1340 1260 1270 1280
5
820 840 850 81 0 810 820
755 755 765 725 735 735
1575 1595 1615 1535 1545 1555
55
55
185/70R14 88S, 205/60R15 91H
185/70R1 4 88S, 205/60R15 91H
135
180
18.0 17.7 18.0
11.4 10.2 11 .8 11 .4
15.5
5.2
8 .6 (Pedal pressure of 22kg) 7.2 (20 kg) 8.6 (22 kg)
846 24) /
846 (24) / 0.5 841 (25) / 0.5
0.5
345 (26) / 0.2
SP-1
SPECIFICATIONS
VEHICLE SPECIFICATIONS
E-HR33
010 032 048 056 060 064
SSEFECUA SSEAECUA SSEAELCUA SKEFECA SKEFECMA SKEFECUA
SEDAN COUPE
GTS, GTS urban runner
GTS GTStype G
GTS type G GTS ruban runner S
4720 4640
1720
1360 1340
1470
1895 1820
1425 1415
1115 1085 1090
RB20
1998
Gasolina
720 740 750 710 710 720
580 580 590 550 560 560
1300 1320 1340 1260 1270 1280
5
820 840 850 810 810 820
755 755 765 725 735 735
1575 1595 1615 1535 1545 1555
55
55
185/70R14 88S, 205/60R15 91 H
185/70R14 88S, 205/60R 15 91 H
135
180
18.0 17.7 18.0
11.4 10.2 11.8 11.4
15.5
5.2
8.6 (Pedal pressure of 22kg) 7.2 (20 kg) 8.6 {22 kg)
846 24) /
846 (24) / 0.5 841 (25) / 0.5
0.5
345 (26) / 0.2
SP-2
SPECIFICATIONS
E-HR33
092 096 100 104 108 112
SKEAECMA SKEAECUA SKEAECUMA SKEAELCA SKEAELCMA SKEAELCUA
COUPE
GTS urban runner
GTS urban runner S
GTS urban runner S
4640
1720
1340
2720
1480
1470
1820
1415
1090 1060
RB20
1998
Gasoline
730 740 740 740 740 750
560 560 560 560 570 570
1290 1300 1300 1300 1310 1320
5
830 840 840 840 840 850
735 735 735 735 745 745
1565 1575 1575 1575 1585 1595
55
55
185/70R14 88S, 205/60R15 91H
185/70R14 88S, 205/60R15 91H
135
180
17.7
10.2
15.5
5.2
7.2 (20 kg) 8.6 (22 kg) 7.2 (20 kg) 8.6 (22 kg)
841 (25) / 846 (24) /
0.5 899 (26) / 0.5 841 (25) / 0.5
0.5
345 (26) / 0.2
SP-3
SPECIFICATIONS
E-HR33 E-ER33 E-BCNR33

116 134 138 142 145 003
SKEAELCUMA SSGACCOA SSGACC- SSGACLOA SSGACLOUA SKQFCCUMA
OUA
COUPE SEDAN COUPE
GTS urban
GTS25t TYPE G GT-R
runner S
4640 4720 4675
1720 1780
1340 1360
2720
1480
1470 1470 / 1460 1490
1820 1895 1820
1415 1425 1415
1060 1115 1085 1090
_,.,-- RB20 RB25 RB26
1998 2498 2568
Gasoline
750 800 810 810 820 880
570 600 600 610 610 650
1320 1400 1410 1420 1430 1530
5 6 4
850 900 910 910 920 965
745 775 775 785 785 785
1595 1675 1685 1695 1705 1750
55
55
185/70R14 205 / 55R16 89V 225 /
86S, 205/ 45ZR17, 225
60R15 91 H 205 / 55R16 89V, 225 / 50R16 92V / 50R17 94V
~
135 145
180
17.7 16.2 14.4
10.2 8.9 8.1
15.5 50*
5.2 5.7
8.6 (22 kg) 7.7 (30 kg)
846 (24) / 1,200 (25) /

899 (26) / 0.5
0.5 0.65
354 (25) /
345 (26) / 0.2
0.2
,,-··,
SP-4
SPECIFICATIONS
E-BCNR33
004 008 009 011
SKQFCCUMAZ SKWFCCUMA SKWFCCUMAZ SKBFCUMAN
COUPE
GT-R V spec GT-R V spec
GT-R GT-R V spec
N1 N1
4675
1780
13602720
1480
1490
1820
141 5
1090
RB26 .•··--...._
2568
GASOLINE
880 880 880 880
660 660 670 660
1540 1540 1550 1640
4
965 965 965 965
795 795 805 795
1760 1760 1770 1760
55
55
225/45ZR17, 225/50R1794V
145 135 145 135
180
14.4
8.1
50
5.7
7.7 (30 kg)
1,200 (25) / 0.65
354 (25) / 0.2
SP-5
SPECIFICATIONS
ENGINE SPECIFICATION
mmi1t'-§~11rui
~~llt~~1
2,568
SOHC belt
DOHC belt drive
drive
78.0 X 69.7 86.0 X 71.7 86.0 X 73.7
9.5 10.0 9.0 8.5
1.23{12.5}/ 1.18{12.0}/
1.26{12.8}/300 1.20{12.2}/300
300 300
140{ 190}/6400 M/T 184{250}/6400 206{280}/
96{130}/5600
147 {200}/6400 NT 180{245}/6400 6800
172{17.5}/ M/T 294{30.0}/4800 368{37.5}/
230{23.5}/4800
4400 NT 275{28.0}/4800 4400
292{215}/ 272{200}/
,---. 258{190}/3200 292{215}/2000
2400 2800
2WD 845x595x680
845x590x655 845x630x680 870x656x675
4WD 845x595x690
2WD 830x696x680
830x590x655 830x630x680 830x630x680
4WD 830x696x690
Early operation 20 Early operation 20
14 7
lnactive operation O lnactive operation O
Early operation 40 Early operation 40
50 53
lnactive operation 60 lnactive operation 60
58 57 57 63 58
10 3 3 7 2
O (Automatic adjustment) 0.51
O (Autornatic adjustment) 0.44
600 650 650 950

650(N 650 (N
650 (N range) 650 (N range)
range) range)
20/600 15/650 15/650 20/950
20/650 15/650 15/650 15/650
Below 0.1
Below 50
2WD4.8
4.8 5.0 5.1 6.4
4WD 5.3
1.0 1.0 0.8 1.0
0.4 0.4 0.4 0.4

8 .5 8.5 8.5 9.0
SP-6
INDEX
INDEX
Symbols Basic inspection
RB20E / RB26DETT ............ . EN-307
2-pole lift ............................................Gl-13
RB25DE / DET ...................... EN-309
4WD lnspection .............................. ... Gl-17
Boost control
RB26DETT .............. EN-379, EN-396
Brake fluid ....... ... ... ................. .. ....... EN-25
A Brake hose ............. ........... ............. . EN-23
A/T control system
RB25DE / DET ...................... EN-324
AAC valve system e
RB25DE / DET ........ EN-359, EN-365
Cam shaft
RB26DETT .............. EN-376, EN-396
RB20E ..... ......................... .. .. ... EN-83
Abbreviation ...... ................................Gl-15
RB25DE / DET ...................... EN-122
Accelerator control system
RB26DETT ............................ EN-193
RB25DE / DET ...................... EN-142
Circuit diagram
RB26DETT ............................ EN-239
RB20E .. ..... ............................ EN-263
Active test ......... ............................. EN-306
RB25DE / DET .... .. ...... ...... .... EN-265
Air-cooled oil cooler
RB26DETT .... .......... ...... ........ EN-267
RB26DETT ................ ............ EN-231
Collector ASSY
Air cleaner & air duct
RB20E ..................................... EN-92
RB20E ...... ............................... EN-67
RB25DE / DET ........... .. ......... EN-103
RB25DE / DET ...................... EN-363
RB26DETT ............................ EN-158
RB26DETT .............. EN-344, EN-394
Air conditioner cut control
Compression pressure ...................... SD-1
RB26DETT ......... ......... .......... EN-381
Compression pressure inspection ... EN-20
Air conditioner operation signal
Connector symbol ............................... Gl-6
RB26DETT ............................ EN-389
Conrod bearing selection ................ .. SD-9
Air conditioner relay system
Consult ................................ EN-301, Gl-11
RB25DE / DET ...................... EN-354
Consult inspection values
RB20E .............. ..................... EN-436
RB20E ................................... EN-413
RB25DE / DET ..... .... ....... ..... . EN-444
RB25DE / DET ........ EN-316, EN-363
RB26DETT ................... ..... .... EN-428
RB26DETT ......... .. ... EN-330 EN-344
Coolant ................................ EN-65, SD-11
Air regulator '
Cooling fan
RB25DE / DET .... .... EN-360, EN-366
RB20E .. .............. ......... ............ EN-97
RB26DETT .............. EN-390, EN-396
RB25DE / DET .................. ... . EN-1 36
Auxiliary belt deflection .......... ............ SD-1
RB26DETT ... ............ ......... .... EN-235
Auxiliary belt tension ........ ............... EN-21
Crank angle sensor system
Auxiliary motor fan
RB20E ........ ........................... EN-41 O
RB25DE / DET ...... ......... ..... .. EN-137 ·
RB25DE / DET .. ..... EN-314, EN-325,
RB26DETT ........................... . EN-236
RB26DETT .............. EN-328, EN-344
Cylinder block ......... ... .... ... ... .............. SD-6
RB26DETT ............... ............. EN-209
B Cylinder head
RB26DETT ......................... ... EN-203
Back-up function ....................... .. ... EN-299
IN-1
INDEX
Cylinder head gasket Exhaust manifold

RB20E ..................................... EN-87 RB20E ..................................... EN-76
RB25DE / DET ...................... EN-128 RB25DE / DET ....................... EN-115
RB26DETT ............................ EN-200 RB26DETT ............................ EN-178
Exhaust system
RB25DE / DET ...................... EN-144
RB26DETT ............................ EN-248
D
Data monitor .................................. EN-303
Detonation sensor system
F
RB20E ................................... EN-426
RB25DE / RB25DET ............. EN-322 Fail-safe function .......................... EN-299
RB26DETT ............................ EN-336 Fault diagnosis by self diagnosis
Diagnosis items by phenomenon .. EN-275 system .......................................... EN-312
Diagnostic system ......................... EN-294 FICD solenoid
Diagnostic worksheet .................... EN-271 RB25DE / DET ...................... EN-365
Dropping resistor Front disc brake
RB26DETT ............................ EN-395 RB25DE / DET ........................ EN-28
Dual mode muffler Fuel injector
RB25DE / DET ...................... EN-146 RB20E ..................................... EN-71
RB25DE / DET ...................... EN-108
RB26DETT ............................ EN-164
Fuel pump
E
RB26DETT ............................ EN-395
ECCS C/U input & output signals .. EN-428 Fuel pump & fue! gauge
ECCS C/U pin layout RB26DETT ............................ EN-245
RB20E ................................... EN-264 Fuel pump control modulator
RB25DE / DET ...................... EN-266 RB26DETT ............................ EN-395
RB26DETT ............................ EN-268 Fuel pump system control
ECCS relay RB20E ................................... EN-398
RB26DETT ............................ EN-345 RB25DE / DET ...................... EN-346
Electronically concentrated engine control RB26DETT ............................ EN-367
system ........................................... EN-269 Fuel tank
r Engine removal
RB20E ................................... EN-250
RB26DETT ............................ EN-240
Function test.. ................................ EN-301
RB25DE / DET ...................... EN-254
RB26DETT ............................ EN-259
Engine lubrication & cooling ............. SD-11
G
Engine mechanical .......................... EN-67
Engine mechanical cervice data ........ SD-1 Garage jack .......................................Gl-14
Engine oil. ........................................ EN-63 General precautions ............................Gl-7
Engine oil capacity ........................... SD-11
Engine oil pressure ........................... SD-11
Engine specification ........................... SP-6
H
Engine temperature sensor system
RB20E ....... ............................ EN-422 How to use this manual ....................... Gl-2
Exhaust gas sensor heater system
RB25DE / DET ...................... EN-355
IN-2
INDEX
N
ldle inspection ................................. EN-15 Neutral signa!
ldle mixture ratio .............................. EN-19 RB26DETT .... ........................ EN-388
ldle speed control system
RB20E ................................... EN-408
lgnitíon coil
RB25DE / DET ...................... EN-364
o
RB26DETT ... ... ............ .......... EN-394 02 sensor monitor ......................... EN-304
lgnition coil relay 02 sensor system
RB260ETT .... ... ..................... EN-394 RB25DE / DET .... .................. EN-321
lgnition relay & lnhibitor relay RB26DETT .............. EN-384, EN-395
RB25DE / DET ...................... EN-366 Oil filter ............................................ EN-64
lgnition signal Oil filter bracket & oil cooler
RB25DE / DET ........ EN-348, EN-350 RB25DET .................. ............ EN-156
lgnition system Oil filter bracket & water-cooled oil cooler
RB20E ................................... EN-404 RB26DETT ............................ EN-228
RB25DE / DET .... ... .. ......... .... EN-319 Oil pan & oil filter
RB26DETT .............. EN-334, EN-373 RB20E ................ .. ................... EN-90
lgnition timing inspection ................. EN-17 RB25DE / DET ...................... EN-120
lnjection pulse RB26DETT ............................ EN-190
RB26DETT ............................ EN-378 Oil pump
lnjector RB20E ..... ................. ............... EN-94
RB26DETT ............... .. ........... EN-395 RB25DE / DET ...................... EN-131
lnjector system inspection RB26DETT ............................ EN-226
RB20E ........ .... ........... ............ EN-401 Operation support .......................... EN-306
RB25DE / DET ........ EN-351 , EN-366 Oscilloscope & circuit tester inspection
RB26DETT ............................ EN-370 RB20E ..... .............................. EN-438
lntake air temperature sensor system RB25DE / DET ...................... EN-446
RB26DETT .............. EN-338, EN-345 R826DETT ............................ EN-430
lntake manifold
RB20E ..................................... EN-73
RB25DE / DET ....................... EN-111 p
RB26DETT ... ......................... EN-174
lntake manifold collector Phenomenon confirmation ............ EN-272
RB20E .. ... ......... .. ............ ......... EN-68 Pistan pin selection ....................... .. .. SD-8
RB25DE / DET ...................... EN-105 Pistan selection ............................... .. SD-7
RB26DETT ............... ............. EN-166 Power steering hydraulic pressure
lnter-cooler inspection
RB25DET .............................. EN-148 RB25DE / DET ...................... EN-366
RB26DETT ............................ EN-160 Power steering oil pressure signal l
RB25DE / DET ...................... EN-362
1
RB26DETT ........... ... EN-387, EN-397
Power supply and earth circuit
M
RB25DE / DET .......... ............ EN-312
T
Maintenance .................................... EN-15 RB26DETT ............................ EN-326
Male & Female terminals ...... ...............Gl-6 Power transistor
Master cylinder cap RB25DE / DET ... ................... EN-364
RB20E, RB25DE / DET ... ....... EN-26 RB26DETT ............................ EN-345
RB26DETT .............................. EN-41
IN-3
INDEX
R Throttle valve switch system

RB20E ................................... EN-416
L \'-- Radiator
RB25DE / DET ........ EN-356, EN-364
RB25DE / DET ...................... EN-134
RB26DETT .............. EN-382, EN-394
RB26DETT ............................ EN-233
Tightening torque ............................... Gl-12
Radiator cap ..................................... SD-11
Timing belt
Real-time diagnosis ....................... EN-305
) Rear disc brake
RB20E ..................................... EN-47
RB25DE / DET ........................ EN-53
RB26DETT .............................. EN-42
RB26DETT .............................. EN-58
Rigid rack support position ................ Gl-14
Towing ...............................................Gl-13
Rocker cover
Turbo-ch arger
RB20E ..................................... EN-78
RB25DET ............................... EN-150
RB25DE / DET ....................... EN-118
RB26DETT ............................ EN-178
RB26DETT ............................ EN-188
Rocker shaft u
RB20E ..................................... EN-79
Units conversion ................................Gl-16
V
~ s Valve clearance
RB26DETT ............................ EN-198
Self-diagnosis ................................ EN-296
Vehicle & unit identification plate ....... Gl-10
Self-diagnosis mode ...................... EN-302
Vehicle specification ........................... SP-1
Service tooIs ...................................... EN-8
Vehicle speed sensor system
Spark plug
RB20E ................................... EN-427
RB25DE / DET ........................ EN-43
RB25DE / DET ...................... EN-353
RB26DETT .............................. EN-45
RB26DETT ............................ EN-385
START signal
RB25DE / DET ...................... EN-358 w
RB26DETT ............................ EN-386
Water outlet
Supplemental motor fan control
RB20E ................................... EN-102
RB26DETT .............. EN-392, EN-396
Water pump
System diagram
RB20E ..................................... EN-98
RB20E .. .................................... EN-11
RB25DE / DET ...................... EN-138
RB25DE .................................. EN-12
RB26DETT ............................ EN-237
RB25DET ................................ EN-14
t
Water temperature sensor system
RB26DETT .............................. EN-13
RB25DE / DET ........ EN-318, EN-363
System outline ............................... EN-263
RB26DETT .............. EN-332, EN-397
~.
T
Thermostat & water inlet
RB20E ................................... EN-100
RB25DE / DET ...................... EN-140
Throttle sensor system
RB20E ................................... EN-419
RB25DE / DET ........ EN-323, EN-365
RB26DETT .............. EN-340, EN-345
)
\ IN-4

R33 - Engine Manual Ocr

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~ NISSAN

R33 ENGINE MANUAL. RB20E, RB25DE, RB25DET &

HOW TO USE THIS MANUAL

CONFIGURATION COMPONENTS, OPERATION CONTENTS & PROCEDURES

Configuration components & Operation contents

Example: Front Axle disassembly & assembly

m Outer bearing outer race

t.9J Bolt (4) 2.5 - 3.4

El ; Should be lubricated with grease.

J.:'P';,. : Use recommended multipurpose grease Wheel hub

STRUCTURAL PARTS DIAGRAM AND OPERATIONAL SEQUENCE

Example 1: Light combination switch ASSY installation and removal

1. Steering wheel ASSY

Operation where the torque should be checked and standard torque

m Should be lubricated. lndicates a type of grease used.

Parts that can not be reused.

Should be lubricated with oil.

* Select genuine parts.

Parts need to be checked visually.

Example 2: Fault diagnosis flow chart

HOW TO FOLLOW THIS FLOW CHART

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

4. Symbols used in illustrations

Eü Check after disconnecting the

() Check after connecting the

@-~ lnsert key i nto ignition switch.

~•E::() Remove key from ignition switch.

00 Tum ignition switch to "START'

0 Do not start engine, ar check with

~ Apply parking brake.

~ Release parking brake.

~ Voltage should be measured with

LaJ measured with an ohmmeter.

CONNECTOR SYMBOL Connector symbols

A direction mark is shown to clarify the side of connector

View from terminal side

iew from harness side

• Connector symbo!s shown from the harness side are

Control unit element substances

• Befare servicing the vehicle, cover fenders, upholstery

• Before jacking up the vehicle, apply wheel stoppers

• Befare start repairs that do not require battery power,

• To prevent serious burns, avoid contact with hot metal

Precautions for ECCS engine

Precautions for Catalyst converter

Precautions for fuel

VEHICLE & UNIT IDENTIFICATION PLATE LOCATION

B ift. ~ ltJ • ~ ~ ~ +± MAOE IN JAPAN

Engine serial number

RB Vehicles: Lower rear left cylinder block

TIGHTENING TORQUE OF STANDARD BOLTS

1.25 13 1.3 15 1.5

1.75 42 4.3 51 5.2

1.5 41 4.2 48 4.9

1.25 29 3.0 35 3.6

1.75 98 10.0 118 12.0

Front of the vehicle y

GARAGE JACK & RIGID RACK SUPPORT POSITION

Riaid rack bearina

Garage jack bearing

A/C Air conditioner

MAIN UNITS CONVERSION

Acceleration m/s2 G 9.80665