CON4PRESSION PRESSURE / BELTTENSIONINSPECTION R B 2 6 D E TITR B 2 0 E D E D E T/ C A 1 8/i R B 2 s D EE N G T N E Compressiongaugeinstallation . Warmup theengineandremoveall6 sparkplugs. . Attachthe adapterto theAllencompression gaugeand setrtin a sparkplughole. Compressionpressureinspection ' Depresstheacceleration pedalfully.Turnthe ignitionswitchto STARTpositionandcrank the engine.Readcompression pressureand the enginespeedoncethe gaugeneedle stopsmovrng. . Whenenginespeedis out of specifications, checkthe specificgravityof the batteryand performtestagainif the batteryis functioning properly. . lf the compression pressureis stillnotstandard,inspectthe componentsaroundthe combustion chamber(valves,valveseat,hydraulic valvelifters,pistonrings,cylinderbore, cylinderhead,cylinderheadgasketetc.).Correctany malfunctions and repeat compression test. 3. BELTTENSION INSPECTION AND ADJUSTMENT Inspection Theinspection shouldbeperformed whentheenginecoldor morethanthirtyminutes after theengine hasbeenstopped. RB26DETT / RB2ODE, DET/ RB2sDEENGINE an.trs Standard Power steeringbelt With HICAS Poly-V lowmaintenancebelt I - 10 9- 10 tc 8 - 10 10-12 16 Air corditionercompressorbelt Poly-V lowmaintenancebelt 6-8 7-9 12 Fan belt Poly-V lowmaintenancebelt 3-5 4-6 7.5 EN-43 & ADJUSTMENT BELTTENSIONINSPECTION / D E / D E T/ C A 1 8 /i R B 2 s D EE N G I N E R B 2 6 D E T/TR B 2 O E RB2OEENGINE Tension limit . llew Powersteeringbelt Poly-V lowmaintenancebelt 8- 10 belt comPressor Air conditioner Poly-Vlowbelt maintenance Fan bett Poly-V lowmaintenancebelt 9- 11 15 6-8 7-9 12 3-5 4-6 7 5 C A 1 8 iE N G I N E Belt def€ction (run) lokg of force lE appfcd at tha ' V Po3ltionl Adluslrnsnl Tenrlon llnit Power steeringpump bett Poly-V lowmaintenancebelt I - 11 Air conditionercomPressorbelt Poly-V lowmaintenancebelt 6-8 7-9 12 Fan belt Poly-V lowmaintenancebelt 4-5 4.5 - 5.5 6 10-12 Caution: .1. Whenthe beltis replacedwitha newbeltincreasethetensionslightlymorethanfor the usedbeltto allowfor wear-inof the newbelt. "Adjustment" value. 2. Whenthe beltdeflectionexceedsthe limit,adjustto the installed. belt is 3. Makesurethe pulleygrooveis alignedcorrectlywhenthe Adjustment lTEM PART .... , , Power steering belt Adjustment bolt in power steering pump Air conditioner compressor belt Adjustment bolt in idler Pulley Fan belt Adiustment bolt in alternator EN.44 VALVECLEARANCEINSPECTION & ADJUSTI\,4ENT R B 2 6 D E i i R B 2 ' E D E D E Ti C A I B i/ R B 2 5 D EE N G I N E 4 . V A L V EC L E A R A N C EI N S P E C T I O N AND ADJUSTMENT Additionalwork required(removethe followingparts): . Air duct . Rockercover Inspection . Inspectthevalveclearancewhenthe engineis cold. . Removethe airduct,ornamentsandthe rockercover. . Rotatethe crankshaft and aligncrankshaft pulleymarkwiththe beltcoverindicator. . No. 1 cylinderis at the compression stroketop deadcentrewhenboththe intakeand exhaustsidecamsdo notmovethe valvelifters. i INTAKESIDE C y l i n d eN r o . 1, 2 , 4 E X H A U S TS I D E Cylinder No. 1 , 3, 5 F i r i n go r d e r : 1 - 5 - 3 - 6 - 2 - 4 V"lu"" to be adjusted lntake side Exhaustside . Rotatethecrankshaft one revolution (360.)andalignthemarkon thecrankshaft pulleywith the beltcoverindicator. (No. 'l cylinderpistonexhaustT.D.C), I N T A K ES I D E C y l i n d e rN o . 3 , 5 , 6 E X H A U S TS I D E CyiinderNo. 2, 4, 6 Valve clearancestandard value (20+t-5C) PART INTAKE Valve clearance (cold) mm (Reference value: warm) mm 0 4 5 + 'I r r 0.38r.1' o:, 0 . 5 1 ', " ' : 0 . 4 4 , ' 00 3 Caution: Alwayscheckthe valveswhentheyarecold. E N. 4 5 & ADJUSTMENT VALVECLEARANCEINSPECTION / D E / D E T/ C A IB i/ R B 2 5 D EE N G I N E R B 2 6 D E T/TR B 2 O E Valve clearancemeasurement . Inserta 0.15 - 0.20mm gauge(A)fromsparkplugside. - side.Selecta gauge Insertgauge(B)fromopposite to 0 m. thatwillreducetheclearance thickness Note: Do not use morethantwo gauges(B). UseJIS 150A25feelergauge. Vatveclearance= Gauge(A) + Gauge(B) usinggauge(A)and(B): Reasonsfor measurement '1.The valveclearancesettingis largercomparedto previousengines. 2. Largegaugescannotbe placedparallelto the surface. measurement . Thickfeelergaugehavehighrigidityand cannotbe bent willbe incorrect. easily,so the measurement . The errorfactorincreasesif a numberof thingaugesare willbe incorrect. layeredandthe measurement Valve clearanceadjustment . The valveclearanceadjustment is performedby selectinga shimof suitablethickness. . Whenthe measurement valveclearance(t)is outof the measure shimthickness(T)and soecification, replaceit witha shimthatwill producethe standard dearance. Shim thicknesscalculationmethod 1. Example: Whenthe intakevalveclearance(t) is 0.50mm: value)= 0.05mm 0.50(t)- 0.45(specified . The valveclearanceis 0.05mm greaterthanthe specifiedvalue. . Usea shim0.05mm thickerthanthe currentshimto reducethe valveclearance. 2. Currentshimthickness(T) the . Measure shimto determine thecentreof removed shim. ofthecurrent thickness Caution: shimsagain Donotreusethemeasured 3. Shim selection (T)is 2.40mm. Currentshimthickness 2.4OF\ mm + 0.05mm = 2.450 Selectnewshimwithstampedmark124'401 --2.440-2.455). I valuerange+f 0.03mm. Selecta shimwithinstandard 4. Shim types and classification Thereare 70 typesof shims. Sizesrangefrom2.275 mmto 3.325mm in 0.05mm increments. EN-46 T = 2.440- 2.455mm LUBRICATION SYSTEMINSPECTION R B 2 6 D E - _ R E 2 : : D E D E T/ C A 1 8 i /R B 2 5 D EE N G I N E 5. LUBRICATION SYSTEM INSPECTION 5-1 LUBRICATION OIL LEVELINSPECTION Inspection . The engineoil levelshouldbe checkedbeforestartingthe engineor if theenginehasbeenstarted, the inspection mustbe carriedout ten minutesafterthe enqinehas been turnedoff. . The oil levelshouldbe betweenthe H and L lineson the levelgauge. . The oil mustnothaveanywhiteturbidityor dirt. BetweenL&Hmark Lubricationoil replacementperiod RB20DET / RB26DETT Every5,000kmor 6 months CA18ii RB2OE RB2ODE / RB25DE S D . S E . S G S F c l a s so i l Everv15.000kmor 12 months SE,SF,SG classoil Everv10.000km or 6 months SD class oil Everv15.000km or 12 months SE,SF,SG classoil Everv10.000kmor 12 months SD classoil Note: UsegenuineNissan[TurboX (7.5W- 30)]for servicefor RB26DETT/ RB20DETvehictes. UsegenuineNissanSG class[ExtrasaveX (7.5- 30)]for servicefor CAI Bi/ RB20E,DE / RB25DEvehicles. Oil quantity ITEM RB25DE/RB2ODE/RB2OE H :.,...L.' 4.0 3.0 Approx.3.8 Approx.4.2 3.5 Apptox.4.2 Approx.4.6 Approx.3.2 Approx.3.6 RB2ODET/RB26DETT/4WD cA18i 1,1 E N. 4 7 SYSTEMINSPECTION LUBRICATION / D E / D E T/ C A I B i/ R B 2 5 D EE N G I N E R B 2 6 D E T/TR B 2 O E 5-2 OIL PRESSUREINSPECTION . Removethe oil pressureswitchand connectthe oil pressuregauge to the enginespeed. . Afterwarmingthe engine,makesurethe oil pressureis appropriate (Oi1temperature80"C) GA18' Approx. 1 A p p r o x .1 Approx.3 Approx.3 Approx. 1 .5 Approx.3 Approx. 4 4000 Approx. 4.6 Approx.4 RB26DETT/ RB25DE/ RB2ODE RB2OE cA18i ylinderbiocknghtsrde, : 7,' {.: pressure" fessureswrlcn m 5.3 OIL FILTERREPLACEMENT Removal . Useoil filterwrench(specialservicetool)to removethe filter. Caution: Catchany drippingoilwithragetc.whenremovingthe filter. lnstallation . Beforeinstallingthe newoil filter,cleanthe oilfilterbracketmountingsurfaceon the cylinderblockand coatthe oilfilterseallipslightlywithnewengineoil. . Screwin the oil filteruntila slightresistanceis feltandthemtighten2l3turn' Caution: Makesurethe oil will notleakafterstartingthe engine. or 12 months / RB26DETT Everv10.000km RB2ODET SD.SE.SG SF classoil or 12months SE,SF,SG classoil Every15,000km CA18i/ RB2OE or 12months SD classoil Every10,000km Everv15.000kmor 12 months / RB25DE RB2ODE or 12 months Everv10.000km EN.48 SE,SF,SG classoil SD classoil EXHAUSTSYSTEI\,4 INSPECTION R B 2 6 D E T TR B 2 C E D E ' D E T / C A I B i/ R B 2 5 D EE N G I N E RB2OE RB2ODE/DET/RB2sDE cA18i 6.EXHAUSTSYSTEMINSPECTION (RB26DETT/RB2OE/ DE / DET) 6-1 AIR CLEANERELEMENTINSPECTION lnspection . Removethe bandsshownin the diagramand removethe aircleanerelement. . Thereshouldbe no excessivedirtor damaoeon the air cleanerelement. Periodic replacementinterval RB26DETT Every60,000km RB2OE / DE RB2ODET 6-2 TURBOCHARGER (RB26DETT/ RB2oDET) tNSPECT|ON Functioninspection . Removethe intakemanifoldcanisterhose,and placea cap on the hose. Connecttest hoseto intakemanifoldandattachpressuregauge(compoundgauge). . Performthe engineoperationtestandcheckthatpressuredoesnot riseabove approximately 0.B- 0.9kg/ cm,. a. Whenthe pressuredoesnot reachspecifiedlevel. Checkfor vacuumleakin intakeor exhaustsystemor exhaustgas leak. b. Whenthe pressureexceedsthe maximumpressurelevel(approx.0.8 - 0.9 kg / cm,). Checkif swingvalvecontrollerrubberhoseis disconnected or cut. Checkif swingvalvecontrollermotionmalfunctions (staysclosed). RB26DETT RB2ODET E G 1 5 0 80 0 0 1 G 1 5 0 80 0 0 9 EN--19 EXHAUSTSYSTEMINSPECTION TN G I N E R B 2 6 D E T/TR B 2 O D EE Swing valve controller inspection . Removethe swingvalvecontrollerrubberhosefromthe vacuumtubeside. . The controllerrod muststartoperatingwhencompressedair approx.0.7 - 0 8 kg / cm2 is forcedintothehoseby usingan approx.0.8- 0.9kg/ cm' (RB2ODET) (RB26DETT), air gun. Stopblowingcompressedair as soonas controlrod operationis verified Caution: airpressureis applied.Usethe LPG may be damagedif excessive Thediaphragm pressuregauge(specialservicetook for 1 kg / cm' ) to verifythat the air gun pressurels approx.0.7 - 0.8 kg / cm' (RB26DETT)or 0.8 - 0.9 kg / cm' (RB20DET)beforetestingthe arrnose. RB2ODET 6-3 RECIRCULATIONVALVEINSPECTION Functioninspection valvecompressor(placethe cap . Removethe hoseon upperflowsideof the recirculation on end of the hose)and checkif air blowsbackwhenthrottleis closedquickly. RB2ODET RB26DETT Unitinspection -400+/-150+f 30mmHg(RB26DETT) pressure . Usea handpumpto createnegative muststartto liftupandthe valvediaphragm Therecirculation 50mmHg(RB2ODET). willbemaintained. vacuumoressure EN-50 EXHAUST SYSTEMINSPECTION C A1 8 E N G N E 6-1 AUTOMATIC TEMPERATURE ADJUSTMENT AIR CLEANERINSPECTION Systemdiagram Arrcleaner Freshair ducl When cold n alf -----= lntake manifold Freshair duct Temperature sensor When warm ' @ Warma t t SPIbody Intakemanifold Functioninspection . Removethe airductandstartthe enqine.Insoectthevacuummotorooerationwhenthe engineis coldandwarm. When cold Closed Whenwarm Open Temperature sensorpresettemperature:Approx.40oC. COMPONENTPARTSINSPECTION Temperaturesensor inspection . Removethe hoseto the vacuummotorand connectthe vacuumgauge. . Startthe engineand checkthe negativepressurewhen the temperature of the temperature sensorwas cooled/ warmedby the drier. Whenwarmedup No negativepressure Whencooled Negativepressurecreated Vacuummotor inspection . Removethevacuumhosefromthevacuummotor and mnnectvacuumhandpump. . Usea handvacuumpumpto createnegativepressure -150mmHg). (approx. . Makesurethefreshairducton the change-over valve willclosewhenthe negativepressureis appliedand it will openwhenthereis no negativepressureapplied. 6.2 AIR CLEANERELEMENTINSPECTION Inspection . Removethe clipsandthe nutsand removethe aircleaner element. . Thereshouldbe no excessivedirtor damagein the air cleanerelement. EN-51 Temperature sensor(whencold) lntake manifold A,.'nflowfiPillL @''*' \v To'nta[emanifoE! _IO vdcl.rum gauge F ."-,",".'.Applynegative Visual cnecK FUELSYSTEMINSPECTION R B 2 5 D E/ D E / C A 1 8 E i NGINE 7 F U E L S Y S T E MI N S P E C T I O N . (RB25DE) EASYINSPECTION . Turntheignition switchto ONposition. . Select"Fuelpump"inthe"Function test"mode. F U E LP U M P. IS THEREA PULSAT]ON E V E R Y3 S E C O N D SW H E N . Inspectthe pulsationby holdingthefuelhosewithhand INt TUEL UI'tr J NtrLU ' OR CANYOU HEARTHE O P E R A T I O N O I S EO F T H E F U E LP U M PR E L A Y ? \a/ ,@\ . Holdthe fuelfilterand makesurethe hoseis hardand pulsationcan be feltwhenthe fuelpumpis operating. USINGTHE FUEL PRESSUREMETER FUEL PRESSUREINSPECTION Releasingfuel pressure(RB25DE) OACTVETEST.O ' Revtheengine "Activetest"mode @ n ,,Aniivorcsr,, . Select"Fuelpumprelay"in mode. RELAY OFF FUELPUI\,4P 'STOP'to . Press over engine stoptheengine.Crankthe CAS-RPM(POS) 950rpm (lf the enginedoesnot startcrank3 - 4 times. or three two timesafterremovingthefuse). . Restartthe engineand removethefuelpumpfuse. (Q\ . Afterthe enginestops,crankthe engine4 - 5 1;ts5 1e r(EV consumethefuelin the pipe. (lf the enginedoesnotstart crank4 - 5 timesafterremovingthe fuse). Caution: The batterymay becomeweak easily,use boostercableto connectto anotherbatteryif necessary. @ Releasingfuel pressure(CA18i/ RB20E) . Revtheengine. "Operation . Select"Releasefuelpressure" support"mooe. in . Afterstartingthe engine,removethefuelpumpfuse After the enginestops,crankthe engineover2 - 3 timesto consumethefuelin the pipe. (lf the enginedoesnotstart crank3 - 4 timesafterremovingthefuse). Caution: The batterymay becomeweakeasily,use boostercable to connectto anotherbatteryif necessary. E N. 5 2 I ruelenessuRe I W H I L EI D L I N GP R E S S 'START"TO STOPTHE FUELPUMPOPERATION, AFTERENGINESTOPS, C R A N KT H EE N G I N EO V E R TWOOR THREETII\,4ES. FUELSYSTEMINSPECTION R B 2 6 D E - - R B 2 O ED/ E / D E T / C A 1 B i / R B 2 s D EE NGINE 7 . ' I F U E LP R E S S U R E INSPECTION Releasingfuel pressure(RB2ODE / DET/ RB26DETT) . Afterstartingtheengine,removethefuelpumpfuse.After theenginestops,cranktheengineover2 - 3 timesto consumethefuelin theoioe. . lf the enginedoesnotstart,removethe pumpfuseand cranktheengine3 - 4 timesto consumethefuelrnthe oioe. Caution: The batterymay becomeweakeasily,so useboostercables to connectit to anotherbatteryif necessary. Fuelpressuremeterinstallation (RB26DETT / RB20E/ DE / DET/ CA18i/ RB2sDE) . Connectthefuelpressuremeterbetweenthefuelfilterano thefuelline. . Attachthefuelpumpfuse. Fuel pressureinspection . Startthe engineand checkif the fuelpressureis at standardvalue. . lf the enginedoesnotstart,checkfuelpressureafter5 secondswhenthe ignitionswitchhas beenturnedON. Fuelpressuremeasurement Whenignitionswitchis ON (kg/cm,) Approx. 3.0 Approx.2.5 Approx.3.0 Duringidling Approx.2.5 A p p r o x . 2 . 0 A p p r o x . 2 . 5 5 Approx.1.0 Approx. 3.0 Approx.2.5 Approx.3.0 Approx. 1.0 (kg/cm,) ldlingwhenpressureregulator vacuumhoseis removed (kg/cmr) cA18i RB2ODE. DET RB26DETT r e s sur e 7-2 THERMO-WAX tNSPECT|ON (CA18i) . Inspectthewaxstrokewhenin followingtemperature. 25 80 Approx.25 Approx.30 EN-53 GAS CONTROLINSPECTION EVAPORATIVE RB26DETT/ RB2OE/ DE / DET / CA18i/ RB25DEENGINE 8 EVAPORATIVEGAS CONTROLSYSTEMINSPECTION Throttlechamber Purgecontrolvalve Checkvalve gas : Evaporative <F Purqeair Activecarbon Fueltank - Filter fray Freshair 8-,I PURGECONTROLVALVE INSPECTION CANISTER Inspection -400 . Usevacuumhandpumpto applyapproximately pressure mmHg(-100mmHgRB25DEengine)negative pressure is maintained. vacuum andmakesurethe . In thatcondition,checkthatsmallamountof aircan be suckedfromthe manifoldvacuumpath. FUEL TANK VACUUMRELEAFVALVE(RB2sDE) Inspection . Cleanthevalvehousing. . lf thefueltankvacuum youwillhear releafvalveisnormal, whenthe air is soundfromthe valvewithsmallresistance suckedin throughthe cap. . Replacethe cap ASSYif the valveis closedor no resistanceis felt. EN-54 E G 1 5 1 30 0 0 0 BLOWBYGASREDUCTION DEVICEINSPECTION R B 2 6 D E T TR B 2 iE D E D E Ti C A 1 8/i R B 2 s D EE N G I N E BLOWBYGAS REDUCTION D E V I C EI N S P E C T I O N biowbycontrolvalve 9-1 BLOWBY CONTROLVALVEINSPECTION(EXCLCA18i) Inspection . Checkthe blowbycontrolvalveflowpath. A i r is blown Air passes A i r is drawn t n No air passes Inspection(CA18i) . Removethe aircleanerrockercoverhosewhenthe '1000 rpm enginerev is approximately and checkthat freshair is drawnin. E\ ON-VEHICLEPARTS RB26DETE TNGINE OF ON-VEHICLEPARTS 1O REMOVALAND INSTALLATION AIR DUCTASSEEMBLY 1O-1INTERCOOLER Front tufuocharger outlettube ,r--aolt 1.6 IntercoolerIPoint4] Resonato.lube Bol1 t . 6- 2 . 1 p ] I ts-t E Replace after every disassembly o-'--Nut (2)i.6 - 2.19 Additionalwork requ ired: . Undercover . Frontbumper Cleaningair hoses & air duct [Point1] . Useairgun to removeany dustand rubbishbefore removingeachair hosesand air ducts. Remove& installeach air hoses and tubes [Point2] Removal . Placealignmentmarkon eachair hoseand tubesbefore removal. lnstallation . Alignthealignment andmake markswheninstallation sureto tightenthe clampsecurely. EN-56 ON.VEHICLE PARTS i32' DEiT ENGINE [Point3] Removeand installthe intercoolerinlet hose Removal . FirstremovetheresonatorandthetubeB beforeremovinq hoseA. Installation . AttachhoseA, thenattachresonatorandthe tubeB as a singleunitto install. Removeand installintercooler [Point4] Removal 1. Removethebumperfinisher andthebumper reinforcement. 2. Separatethe rntercooler inletandouflethoses. 3. Removethe mountingboltandtwo nuts. Detach intercooler withoutscratching thefins. Caution: 1. An aluminium finsareusedandcanbe damagedeasily. Do not placeobjectson the intercooler or allowtoolsor otherhardobjectsto contactthefins. 2. Themainunit(tank,fintube)cannotbedisassembled. Installation . Installation operationis the reverseof the removal operation.Performthe stepsin orderof 3, 2, 1. Tighteningtorque (kg-m): 0.93- 1.2 ..--*-t t : i , Outlet hose "l Kq_m E l,4ountinq bolt 0 . 9 3- 1 . 2 Nrounting Removeand installrecirculationhose [Point5] . Removeandinstallthe recirculation hoseandtubeas shown in thefigureon right. Installrecirculationhoseclamp [Point6] . Wheninstalling the recirculation hoseclap,makesureit willnotcontactbumperfinisher. Recirculation valveinspection [Point7] Unitinspection . Usehandvacuumpumptoapplynegative vacuumof-150 +/-20mmHgandcheckthatrecirculation valvediaphragm liftsandvacuumpressure is maintained. [Point8] Removeand installturbochargeroutlet tube . Removeand installthe turbocharqer ou et tubeas shown in thefigureon right. Recirculation valve lnlet hose 0 . 9 3- 1 . 2 ON-VEHICLEPARTS RB26DETTENGINE 1O-2 AIR GLEANERELEMENTASSEMBLY To rear turbocharger To front turbocharger f ACI I Air hose I *n-' -s Arr cleanercase OUCI Additionalwork required: . Removeturbocharger outlethose Air hose and air duct cleaning [Point1] . Usean air gunto blowoff any dirtand dustbefore removingthe aircleanerelement. Removeand installair cleanerelement [Point2] Removal outlethose. 1. Removeturbocharger 2. Removefour bandclipsfromthe air cleaner.Liftair cleanercoverand removethe air cleanerelement. lnstallation . lnstallin reverseorderof removal. [Point3] . Makesurethe aircleanerelementis notdirtyor damaged. ),)\ Periodic replacementinterval: Every 60,000km = _ \-:= -Connector [Point 4] . Firstconnectthe airflowmeterconnectorfor frontturbo charoerandtheninstallthe air cleanercover. EN-58 ,.' ll. Arr flow meter ON-VEHICLE PARTS RB26DETE TNGINE 1O-3 CONNECTORASSY (1) CollectorASSYremovaland installation No.3 Throtllecharnber No 2 Throttlechamber Knockpin (6) __-/0 s; ----- --\3nno.t 9,t1\ \, \ur{r2, /'/ N.o 1 o'n,e,thutb"' 1,,,ffi ""gH-= "{ y Poinr (12) ;:t, ersprlnt washer JJ,i:*; ,ll;A, I'i-, .\ t" V7,i";::;*;el qvl Hose .-tt":"to"Tj,:ld' /R Io! , --a *'"-ruW,fl*6pltr== warer ruDe L"","r,^,^,:."j:,-91^,^ :, :dR. i <?'- - i *_ ,,",Kt$,5 Bort0.64- O.r' $ 1 - F:l"i;r6,i"" l Bort' 4) "^,,?" - " ,m eirtio-zrp) ffi1.30-ouo neptaceaftereveryd'sassembty Fi. \-.4 Ks'' Additionalwork required: . Releasefuelpressurein thefuellines[Point1] . Draincoolingwater[Point2] . Acceleration controlwire[Point3] . Air inlethose . EGIharnessconnector, harnessclamp . Allhoses Releasefuel pressure [Point 1] . Starttheengine . Afterstartingthe engineremovethe fuelpumpfuseand waituntiltheenginestops.Crankenginetwoor threetimes to consumefuelremainingin the fuelpipes. . lf thevehicledoesn'tstart,removethefuelpumpfuseand crankthe enginefourto fivetimesto consumefuel remaining in thefuelpipes. Caution: The batterymay becomeweakeasily,use boostercableto connectto anotherbatteryif necessary. E N. 5 9 n"'" ON-VEHICLEPARTS ENGINE R826DETT Drainingthe coolingwater [Point2] . Makesureto draincoolingwatercompletelyfromthe cylinderblockby removingthe drainplug. Caution: Makesurethe coolantdoesnotspillon the fronttube. Acceleratorwire adjustment [Point 3] . Loosenlocknutto provideadequateslackfor the wireand pulloutercasein the directionof the accelerator acceleralor. . Returnthe locknut 1.0to 1.5turnsfromthe positionthe throttledrumstartsmoving(whenthereis no playin cable) andtighten. Tighteningtorque (kg-m): 0'8 - 1.0 Removethrottle chamber links [Point 4] . Removethemountingnutsindicatedby arrowmarksin the diagram.Separatethreethrottlechamberlinksfrom side. collector . Removethe harnessfromthethrottlesensorandthe throttlevalveswitch. Fuel PiPeremoval [Point5] . Removethreeboltsindicatedby the arrowsand separate the fuelpipe. Air hose removal [Point 6] . Seoaratethe air hoseA, B and C fromthe collectorside. Air hose Booster vacuum removal [Point 7] . Removethe clampboltand removethe boostervacuum tube by separatingit fromthe collectorandthe air chamber. Removeand installair chamberbolts [Point8] Removal . Separatethe air chamberby removingthreebolts. lnstallation . lnsertboltB in air chamberbolthole,beforeperforming finalassemblY. Tighteningtorque (kg-m): 1 . 6- 2 . 1 EN-60 ON.VEHICLE PARTS i 3 2 6 D E T TE N G I N E Removeand installcollectornut [Point9] Removal . Removethe nutsin the reverseorderof thefiqureon the right. Installation . Installthe nutsin theordershownin thefigureon right uniformlyin two to threestages. Tighteningtorque (kg-m): 1.6- 2.1 [Point 10] Removeand installair chamber Remove . Separate theairhosesA, B, C, vacuumhosesD, F and MC valveconnectorand removethe airchamber. Installation . Positionthe airchamberin place,connectthe air hosesC, D, A, vacuumhosesF.E. thenconnectAAC valve. [Point11] Removeand installAACvalve Removal . DetachtheAAC valveby firstremovingfourbolts. Caution: (1) MC valvecannotbe disassembled. (2) Replacegasketwitha newone. Installation . InstallgasketandtheMC valve. Tighteningtorque(kg-m) 0.64- 0.85 [Point 12] AAC valve inspection . Measurethe MC valveresistance A p p r o x . 9- 1 0 Resistance(20.C)O (2) CollectorASSYdisassemblyand assembly (4)pl 0.64' O.B5 Bort - 0.85 (2)gl 0.64 Bort ag B - Acceleralion work unit r (w Knockpin (2) / Intaketemperaturesensor \, 20-3.0 Collector[Point1] EN o l PARTS ON-VEHICLE ENGINE R826DETT Additionalwork required: "Throttlevalveswitch . CollectorASSYinstallation referto for thethrottlevalveswitchadjustment systeminspection" proceoures. CollectorinsPection [Point1] . Measurethe collectorinstallation surfacefor distortionin up,down,lefi' right' six directions(opposingdirections, andverticallY). horizontally ( m m ) : 0.15 Limit 10.4 SIX IN-LINETHROTTLECHAMBERREMOVALAND INSTALLATION No. 3 Throttle No. 2 Throtfle chamber \ chamberlPoint1, lPornt1.2l 660-' $ neptaceaftereverydisassembly Additionalwork required: . CollectorASSY removaland installation . Canisterhose Throttlechamberinspection [Point1] . Checkfor any cracksandthatsupplemental air pathsare notobstructed. air Supplemental Installthrottlechamber [Point2] . lnstallNo. 1 to No.3 throttlechambers. Caution: the chamber. Do not makeany mistakewheninstalling l Throttle -t\ - No. 3 Throttlechamber EN-62 ON-VEHICLEPARTS R 3 2 6f , : T T E N G I N E 10.5 SIX IN.LINETHROTTLECHAMBERLINK ADJUSTMENT A c c e i e r a l od r rum ful 1 ,,, df' ] Detarlof parta \' K:X\ .---_.. \i sx{$r-5-i <Y-\\1"- /tr' Throltle chamber f ully \\ closed stopper Fsat r- I ()\- Detailof partb Installacceleratorwork unit [Point1] . Install sixtn-line throttle chamber andtheaccelerator work unitandconnect No.1,2 and3 throttle linkage. =Bolt(4) 0.64- 0.85 6 in-linethrottlechamberlink adjustment [Point2] 1. LoosennutsA and B for eachthrottlelink.Turnthe centreadjustment of eachthrottlelinkanticlockwise to shortenthelinkage. 2. Shorteneachthrottlelinkuntilacceleration drumcontacts fullyclosedstopperon the accelerator workunitside. 3. Shorteneachthrottlelink,so thethrottlechamberlever openswiderthanfullyclosedstopperon the throttle chamberside. Caution: ( 1 ) D o n o tl o c k t h en u t A a n dB . (2) Thethrottlechamberleveropeningangleshoutdbe adeouate. EN-63 ON.VEHICLEPARTS RB26DETE TNGINE the 4. Insert 1 mm thicknessfeelergaugebetvveen drumandfullyclosedstopperon the accelerator drum work unitside. Securethe accelerator accelerator so it does not move. Fully closed ,'-!t) 'trf 5. Withthicknessgaugeinserted,turnthe centre adjustmentIn No.2 throttlelinkclockwiseto lengthenthe throttlelinkuntilthethrottlechamberlevercontactsthe fullyclosedstopperon the throttlechamberside 6. Whenturningthethrottlelinkwithyourfingers.Youwill whenthefullyclosedstoppercontacts feelresistance thethrottlechamberlever.Shortenthethrottlelinkto the pointjust beforethis resistanceis felt 7. Carryout the steps4, 5, and 6 to adjustthe No. 3 and 1 throttlelinks. 8. Tightenthe locknutA and B afterthe adjustingthree throttlelinks.Afterthe nutsaretightened,No 1 - 3 throttlelinksmustturnwiththe samedegreeof smoothness. Caution: Makesurethe centreadjustmentlinkwillnotrotatewhenthe locknutis tightened. 9. Removethethicknessgaugefromfullyclosedstopper workunitside. on the accelerator Caution: Do notadjustfullyclosedstoppernut. L- ca 1 10. Completelyopenandclosethe six in-linethrottle chambersrepeatedlyand makesurethateachthrottle chambermovessmoothly. EN-64 ON-VEHICLEPARTS R B 2 6 D E TE TNGINE 10.6 INTAKEMANIFOLDASSY (1) IntakemanifoldASSYremovaland installation Intakemanrfoldgasket B o l t( 5 ) 1 . 6- 2 . 1 1lp) lPornt p,us Airdra,n z1/ E leornt ,fryfj ii\ \s4!**^^'Yt-:. B o l (t 4 )1 6 - 2 1 1]pJ lPoint Intakemanifold ASSY B o l t( 2 )1 . 6- llgl tPoint aftereverydisassembly E Repiace kg- m Additionalwork required: . CollectorASSYremovaland installation . Throttlechamberremovaland installation . ECCSharnessconnector andall hoses . Wateroutlethose . Blowbyhose [Point1] Remove& installIntakemanifoldASSY bolts and nuts Removal . Removalis the reverseordershownin thefiqureon the rioht. Installation . Installtheboltsandthenutsin theordershownin thefigure on the right.Tightenin gradualstepsto uniformtightness. 30:4 60:5 1 ,4 , 1 0 ,1 2 ,1 4 6 5: 2 7,9 Air drain plug [Point2] . Carryoutthe operationwhenengineis cool. Caution: Do notremovetheairdrainplugwhentheengineis hot. . Whentoppingup thecoolant, alwaysremovetheairdrain plugto allowairwithintheengineto escape(thisprevents overheating). Tighteningtorque (kg-m): 0.7- 0.8 EN-65 '10 6 'I 2 4 2 are nuts 8 ON-VEHICLEPARTS RB26DETE TNGINE (21 Intakemanifolddisassembly& assembly - o.8a gl Bolt(5)0.6a Balancetube lPoint6] B o t t( 2 ) 1 . 6- 2 . 1 6l E o-rinsIPoint Water temperature FF=".;," "g ,-p Ffii;il Screw(2) 0.23- 0.91---' '.\ D a Fi L-l| Eort(2) 0.64 - o. Liquidgasket --r.*^ -'l \^ ,on',u - r., {s lntake ml _Waler bypassconne^to' ro-; r g-----€5 "j,lI F.",, ptec, Air regLrlator outlet 5l O-ring ASSY[Point2] FueltubeIntector p ) e o r t t zr .re- z . r ;:J;id'senffi2o-30 a; +::;;9,s Replace after every disassembly kg-m Intakemanifoldinspection [Point'l] . Measurethe intakemanifoldsurfacefor distortionsin six up,down,right' differentdirections(atoppositedirections: in severallocations. andvertically) left,horizontally 0.15 L i m i t( m m ) : [Point2] FueltubeASSY . ReplaceO-ringwithnewoneswhenpressureregulatoris removedand installed. Caution: Caremustbe takennotto scratchthefueltubeo-ringsurface the pressureregulator. wheninstalling [Point 3] O-ring (for fuel injector pressure regulator) Precautionswhen handling . NeverreuseO-rings. or . CoattheO-ringwithengineoil (10W-30or equivalent) butdo notapply siliconoil(NUCsiliconL45or equivalent), the oilcoating. remove solventas thismay . AvoidusingdirtyO-ringsand do not allowdirt,dustor foreignobjectsto adhereto O-ringsor otherequipment surfaces. E N. 6 6 x>q) q4,4u",F.]" ON-VEHICLEPARTS r 3 2 €D E T TE N GN E Do notdecenteror rotatethe fuelinlectorsandthe pressureregulatorwheninsertingthemintothefueltube. Do notstoreO-ringsin locationsubjectto ozone,high temperature or in thedirectsunlight. [Point4] Installand removewater bypass connector Removaland cleaning . Removeeightwaterbypassconnectorbolts. lnsertdriver in clearancebetweenintakemanifoldandwaterbypass connectorand moveit lightlyto removeconnector. . Usea scraperandremoveliquidgasket. Caution: Also removeliquidgasketin the grooves. . Wipeoff mountingsurfacewithwhitegasolineetc. lnstallation . Cutthenozzleendof liquidgasket(KP51000150)inthe positionshownin the figure. Usea tubepresserto apply gasket.Installbypassconnectorwithin20 minutesof applying liquidgasket. . Applyliquidgasket(KP1000510)to waterbypass connectorsurfacesin fourlocations, theninstallwater bypassconnectorwithin20 minutes. Caution: (1) Applyliquidgasketcoating3.0mm wide. (2) Coaton theinsideof installation holesas shown. Tighteningtorque (kg-m): 1.6-2.1 Water outlet elbow [Point 5] Removaland cleaning . Removetwowateroutletelbowboltand insertscrew driverhandleas shown. Moveit up anddownto remove theelbow. . Removeliquidgasketfrom intakemanifoldandwater outletelbowby usinga scraper. Caution: Alsoremoveliquidgasketin thegrooves. . Wipeoff mountingsurfacewithwhitegasolineetc. Installation . Cutthenozzleendof liquidgasket(KP51000'150) inthe position shownin thefigure.Usea tubepresserto apply thegasket. . Applythe liquidgasket(KP10 00510)to intakemanifold surfacesin fourlocations. theninstallwithin20 minutes Caution: (1) Applythe liquidgasketcoating3.0mm wrde Tighteningtorque (kg-m): 1.6- 2.1 E N. 6 7 Tube presserWS3993 Waleroullet PARTS ON-VEHICLE ENGINE R826DETT [Point 6] Remove and install balancetube O-ring Removal . Checkthe sizeof the O-ringwhenremovingbalancetube. lnstallation . Alwaysreplacethe O-ringwtthnewoneswheninstalling balancetube. . TherearethreedifferentO-ringsizes. Makesureto install the correctsize. 3 1, 2,3, 4, 5, 6 Cylinder 4 Cylinder1, 2, 5. 6 2 Cyinder3, 4 . Be carefulnotto pinchthe O-ringsduringinstallation. ASSY 1O-7TURBOCHARGER removal& installation ASSY (1) Turbocharger REARSIDE FRONTSIDE *"ry:-/-----ll;at -'-j---,.-_--,,tf:"11,% ttose 6 q 1 q 1 z 1 o . M - l € s* - - 1.+n"'1"" s'4q"*;';1+ :*,,J4_i ffis{*e ?i€F.-:',',"^* C5p-perwashe{ r-r / --'- t iils Sffi\ffi;'-" vJP,""*1, '---ff$B"*r"*" nipo'\=-^8 ' -H$$, I#,2$;;?f y's,e #P/i:x,lr,;;:|tk#ffii; c y l i n d eb rl o c k 1 - , '' \g"*9t-*l l^ Y'^,.;}^,tfy. t^... o" p: . \"'n"i"""n Oilpi g:i;r:h / nf""";n",,, ! * , ,",,,110,0-'', ,\F-, s *".n",E F@.-!:1;, ,,?*lT,Y- ".d'Hry>-;;;';;;";--,"'"if:,"*: F! ts-t $ Reptaceafter every disassembly EN-68 ON-VEHICLE PARTS R 3 2 6D E T TE N G I N E Additional work required: . Removeand installundermver . Draincoolingwater . Separateexhaustfronttube . Removeand installexhaustgas sensorconnector . Intercooler air inlettubeand hose . Air inlethose Note: Alsoremovecoolingwaterfromenginedrainplug. (lf wateris onlydrainedfromtheradiatordraincock,thewaterinsidecvlinderblockwillnotbe drainedcompletely). (2) FrontturbochargerASSYremoval& installation Removal sequence (1) LoosentheflarenutsoftubesA and B. (2) RemoveboltsanddetachtubeA. (3) LoosenflarenutsoftubesC and D on the turbosioe. (4\ RemovehoseB and bolts. (5) RemoveboltsanddetachtubeE. (6) Removethreebolts,coverandgroundcable. (7) Removetwo boltsanddetachtubeH. Makesure thatboltmountedon uppersideis shorterthanlower side. (8) Removethreebolts,coverandgroundcable. (9) (10) Removeoil returnhose. Removethreeboltsanddetachbracket. (11) Removefourturbocharger nuts. (12) Lowerturbochargercarefully. (13) Removesix exhaustmanifoldnuts. (14) Pullthe exhaustmanifoldin direction1 andthenrarse it in direction2 to avoidturbocharger stud. (15) Removeexhaustmanifold. (16) Pulloutturbocharger. Installationsequence . Installation is the reverseof the removalsequence. . Placeturbocharger in bottomof the engine compartment beforeinstalling theexhaustmanifold. E N- 6 9 h. - -' -: ON-VEHICLEPARTS R 8 2 6 D E T TE N G I N E (3) Rear turbochargerASSY removal & installation Additionalwork required: . Frontturbocharger ASSYremovaland installation Removalsequence andtheexhaustmanifold (1) Removefrontturbocharger ASSY Removetwo nutsand the clipsecuringbolt,and Q\ seoaratethe tubeA. (3) Removethreeboltsanddetachexhaustmanifoldcover. (4) RemoveeyeboltB, C and E. (5) Removetvvoboltsand separatetube D fromcylinder blockside. (6) Removethreeboltsanddetachbracket. The sequenceafterthisstepis sameas number11to 16 of removaland installation. thefrontturbocharger Installationsequence . Installation is reverseof removalsequence. . Loosenthe watertubeflarenut beforeinstallingeyeboltB. ASSYdisassembly& assembly Turbocharger (4) FRONTSIDE Air inlettube *BeW"/.fiM Y'1"!*q*F:i:i /'t,"1,.," EGasket tr \ Bolt(2)g 1 . 6- 2 . 1 E GasketI _ Bolt(2)1",4 038-05' ?:J'lt'F3*'3'.# gev"oortzo-V 0.64- 0851 WasherE xg-m $ neptaceaftereverydtsassemblY EN-70 ON.VEHICLE PARTS R3 2 6 D E T TE N G I N E Additionalwork required: . Turbocharger ASSYremovaland installation Watertube inspection [Point1] . Aftercleaningthewaterinletandoutlettubeswithradiator cleaner,blowwithcompressedair and checkfor rustor anyclogging. Oil feed tube inspection [Point2] . Aftercleaningtheoil feedtubewithengineconditioner, blowwithcompressedair and checkfor any clogging. Engine Removeandinstalllockplate [Point3] . Spreadthelockplatepawlswitha screwdriver andloosen nuts. . Position lockplatesandturbocharger mounting nuts. Aftertightening thenuts,bendlockplatepawlsontothe nuIS. lq.) L * Eyeboltdetermination [Point 4] . Oilfeed (turbocharger side)eye boltsare stamped'J' (5) Turbocharger unit inspection Crack inspection Crack burn Inspectron CoolrngwaterinlellPorntB] Exhaustgas leak inspectionlocation Actuator[Point7] -.---- SwingvalveIPoint3j Turbinerotor{Point1,2,4l R o t o .s h a l t P on t 6 . 8 l rq:i,:::lOil leak inspecttontocation E N. 7 1 Compressorwheel [Point5] ON.VEHICLEPARTS ENGINE R826DETT Rotor shaft inspection [Point1] . Makesurethe rotorshaftrotatessmoothlywithno heavinessor draggingwhenturnedby finger. shaft :"j'^'::.. Turbinerotor inspection lPoint2] . Oilmustnotadhereto surface. . Thereis nocarbonaccumulation. . Thevanesoftheturbinemustnotbebent. . Thereis nointerference withturbinehousing. or 7\ll No oenoing r V v-. -'-'!t-''- No nterietence wlh the housing Swing valve insPection [Point3] . Removeactuatorrodpin and makesurethe swingvalve or cracks. movessmoothlywithoutdeformation . Makesurethereare no misalignedseatingsurfacein turbinehousing. Rotor shaft play inspection lPoint 4l . Setthedialgaugeand measureplayandthrustclearance . Insertthe dialgaugein oil returnholeand measurerotor shaftplay. Rotorshaftplay(mm) 0 . 0 5 6- 0 . 1 2 7 Thrustclearance(mm) 0 . 0 1 3- 0 . 0 9 6 Compressorwheel inspection [Point5] . Oil mustnotadhereto suctioninlet. . Theremustbe no interference withcompressorhoustng. . Wheelmustnotbe bentor damaged. Rotor shaft inspection [Point 6l . Theremustbe no carbonsludgeaccumulation. EN.72 \@ No oil adhere. No bendingor other d am a g e . t No carbon s luO0e ON-VEHICLE PARTS RB26DETE TNGINE [Point7] Swing valvecontrollerinspection . Connectthe swingvalvecontroller rubberhoseon the actuatorside. . Checkthe swingvalvecontroller whenthe actuatorrodis installedor removed. . Checkto see if the controllerrodwilloperateswhenthe compressed airpressure(approx. 0.7- 0.8 kg / cmr)is applied.Stopblowingair as soonas rod operates. [Point8] Oil & coolingwater inletand outlet cleaning . Useengineconditioner to cleanthe oilfeedand return passages. . Useradiatorcleanerto cleancoolinowaterfeedand returnDassaoes. . Cleanwithairgun. . Cleanthe compressor wheel,turbinewheel,compressor =housrng andturbinehousing withsamemethods. EN-73 ON-VEHICLEPARTS R B 2 6 D E TE TNGINE (6) Turbochargerfailurediagnosis(Oil leaks,smoke(whiteor blue smoke),lack of power, poor acceleration,abnormal noise) Pointsto be checkedbeforediagnosis: 1. Theengineoillevelmustbe betweentheMINandthe MAXmarkson theoillevelgauge. MAXline,theengineoilwillflowintointake (Wheniheengineoillevelis higherthan may be passandtheturbocharger ductthroughthe blowbygas recirculation to be malfunctioning). determined to deiermineif oil is cooledwhenidlingafterdriving' customer 2. Checkwith replacethe in thefollowingchartis detectedin a unitinspection, lf any malfunction ASSY turbocharger sr;{tl ..r .::r,. . Turbinerotor Oil on rotors l \ Carbon has accumulated z__l @ o !9' o C (/ There is resisianceor scraping when rotatedby firEer A A A o o Rotationby fingeris not Possible Corsiderable shakingbetween rotor shafl and turbo ASSY Carbon sludgehas accumulated Look throLEhoil hole (inspectintenorwithPenligm) in waste oil f|ob @ Highlypossible o Turbimevanes are bent or folded Turbinevanes are bent or folded Swing valveoperation (usearr gunor atr PumP) o @ Rotor scrapes agairEt the housirE Turbineand compressor Rotorshat play irEPection l\ Rotor scrapes agair6t the housing Suctioninletis dirtywithoil Compressorwheel @ z\ The valvedoes not mo\r'e smoothlywhen pressureis opens applied gradually.(LlSually at pressuregreaterthan 0.6 - 0.7 kg/cm') O Possible ZI Slightlypossible E N. 7 4 z__.\ l \ ll A @ ON-VEHICLE PARTS i 3 . al : - i ENGTNE 1O-8 EXHAUSTMANIFOLDASSY REMOVAL& INSPECTION FRONTSIDE REARSIDE Exhaustmanifoid Exhaustmanifoldcover B or ( 3 1 9 Bolt(3)p 0 . 3 8- 0 . 5 ' 1 lPoint4l 0 3 8- 0 . 5 1 l P o r n4t l Exhaustmanifoldgasket \ a I N u t( 6 )1 . 8- 2 . 4 lPoint21pJ W v ,u,,,.Iii"-r oQ4,*,3l 2l lPornt PJ lPoint l-/ kq-m $ Replace after every disassembly Additionalworkrequired: . Turbocharger removal andinstallation . Gasleakinspection IPoint1] Gasleakinspection [Point1] . Afierremoving exhaust manifold, makesurethereare notracesof gasleaksfromanyparts. . Aftertheinstallation, cranktheengineandcheckforany oas teaKS. Removeand installexhaustmanifoldnuts [Point2] Removal . Removalis the reverseof installation seouenceshowntn the diagramon the right. Installation . Theinstallation sequenceis shownin thediagramon right. Tighteningtorque (kg-m): 1.8-2.4 Exhaustmanifoldinspection [Point3] . Measurethe exhaustmanifoldsurfacefor distortions in sixseparatedirections (opposite directions, up,down.left, right,horizontally andvertically) in a numberof locations. Limit(mm): 0.3 EN-75 ; REARSIDE 4 1 3 PARTS ON-VEHICLE RB26DETE TNGINE Install exhaust manifold cover [Point 4] . Attachthe exhaustmanifoldcoverboltsin thefollowing sequence.(bothfront& rear) tightenboltsfor positionsindicatedby A. 1 . Temporarily 2 . Tightenboltsin the positionsindicatedB. 3 . Tightenboltsin holesA to specifiedtighteningtorque. Tighteningtorque (kg-m): 0.38- 0.51 FRONTSIDE A : B L \'--<i REARSIDE fi-'-_--------, .\ .r__r1 )t/ : B SPARK PLUGS 10-9 - o. p) eott1a;o.oa bolt(B) Ornament 0 . 2 3- 0 . 3 1 9 ornament \,,.#)r- J transistor O f n a m e nbt o l t( 2 )0 . 2 3- 0 . 3 1 9 Screw(3) 'w: lgntion aor bracket -i '. :eo *d ='v I 5CarF.p Ug l g n r t r o cno t l harness le/ Kg_m Additionalwork required: . RemoveandinstallairinletPiPe . Removeand installblowbYhose Removeand installignitioncoil bracket [Point1] Removal . Holdthecoilbodywhenremovingthe ignitioncoilbracket. Caution: Do notholdthe coilconnectorwhenremovingit lnstallation . Makesureto attachthe ignitioncoilharnesswhen installingthe ignitioncoilbracketto the cylinderhead \Bolt0.23 0.31 Platinum\tip \ Seatingmetal SParkPlug maintenance [Point2] . Gapinspectionand adjustmentis not necessaryas a platinum tipis used. . Replacethe plugevery'100,000 km. . Whenusinga compressedair sparkplugcleaner,clean the plugsat maximumpressureof 6 kg/cm2for no more than20 seconds. EN.76 , fFt JLT ON.VEHICLEPARTS R B 2 6 D E TE TNGINE 10.10 ROCKERCOVERREMOVAL& INSTALLATION Rockercoverscrew (left& right10 each) Fillercap O-r'ng--,@ -a Grommet Rockercover Rocker cover gasket 1|/ lPoint3l .A I ,.' '/a.tt I orlamenl s3;Tl":":.1' Rocker Rocker covergasketIPoint3l Additionalwork required: . Removeandinstallairinletpipe . Removeand installblowbvhose Removeand install rocker cover screw [Point 1] Removal . Removethe screwsin reversesequenceshownin the figureon the right. Installation . Performinstallation in thesequenceshownin thefigureon theright. Rocker cover installationsurface inspection . Checkthatno oil,dirtor foreignmaterialadheresto the cylinderheadinstallation surface. [Point2] lnstall rocker cover gasket [Point 3] . Makesurethe rockercovergasketis positionedsecurely in groovewithouttwisting,pinchingor protrusion. EN-77 ON-VEHICLEPARTS RB26DETE TNGINE TIMINGBELT REMOVAL& INSTALLATION 10-11 ^ T t m r n gb e l l c o v e r L o o e r ' Urommer lpoint4] / (2),,,J,,_ elBo,t --ffi<l;{:gi' :::'^^.,, _=-.:;.-"J =-ffi|"*\-,Fiql ,,1 *ffi'Pffi c r a n k €-\n s r e s e n s\ { \ , - _ * \ l 2] [Point \ I \Al, l;i,""?l' \ fi\f , - x - . . ) _liirQ@,"6;{ryt \h\'10, d"^^ :. _# 5----J C o n i c aw l asher "':]:;:,N+ t?* qf,ffi*;, ;,,,,;['t'l \^&\ \ [::"1:N \3\J \ Y- \,',,i,nno",,p,aterPo,nt.r "rr::Jil';'"":;"''' h $ W\$, [*,"1J;1\::;q \tr , . i , . -- v I r'mrn9o€rtcover(towerr lpornt4] I g o t t , 3 to . : - o s oil It Engine $ neplace after every disassembly Additional work required: . Draincoolingwater . Removeand install . Undercover . Radiator,fan shroud . Coolingfan . Supplemental belts . WaterpumPPulleY . Sparkplugs . CheckNo. '1cylindercompression T.D.Cposition[Point1] . Installringgearstopper[Point3] inspection [Point1] No. 1 cylinderpressureT.D.C(top dead enter) . Aligncrankpulleytimingmarkand beltcovertiming (0oposition).At thistime,No. 1 cylinderis in indicator T.D.Cpositionwhenthecamshaftis located compression as describedin the followingsituations. Timing indicator ,r 7\ -<-!tr EN-78 ON-VEHICLE PARTS R3 : ' - - ) = - - E N G I N E No. 1 cylinderis at compression topdeadcentre(T.D.C) whenbothintakeandtheexhaustsidecamsdo not movethevalvelifters. Removethe lockercoveroil fillercap fromintakeside and checkthatfrontendof the camshaftfacesintake side. Intakeside Installcrank anglesensor [Point2] . Applychassisgreaseto driveunit(spline) during installation. . Thereis a flangeinsidethedriveunitsplineso thespline position.Checkthealignment hasonlyoneinsertion visuallybeforeassembly. . Checkthatthe crankanglesensorcan be easilyinserted in beltcoverholesandsensormoveslightlyto rightand left,thentightenthe bolts. . Whenthesensordoesn'tmovelightly,loosenbeltcover boltsto position whenthecrankanglesensorwasinserted. Movethebeltcoverlightlyhonzontally andvertically to align it so the beltcoverholesand the camshaftcentreare aligned.Thentightenthe boltsso the crankanglesensor moveslightly. [Point3] Removal Remove& installcrankpulleyand the bolt . Removethe startermotorand attachthe rinooear stopper. . Usea pulleypuller(steering wheelpuller)to removecrank pulley(boltsize:MGx '1.0lengthbelowheadapprox. 5 0m m ) . EN-79 PARTS ON-VEHICLE RS26DETE TNGlNE lnstallation . Positionthe washerfor the crankpulleyboltsso the surfacenot markedR contactsthe crankpulleysideand thenassemble. . Applyengineoil to thethreadsof the crankpulleybolts. Tighteningtorque (kg-m): 45.5- 47.5 Remove& installtiming belt cover [Point4 ] Removal . The timingbeltcoveris separatedintoupperand lower parts.Aftercrankanglesensoris removed,removethe timingbeltcoverin the orderof upperandthenlower. lnstallation . lnstallation is in reversesequenceof removalprocedures. Caution: Caremustbe takennotto scratchor damagethedriedliquid thetimingbeltcover. packingwhenremovingandinstalling Tighteningtorque (kg-m): 0.3- 0.5 Remove& installbell tensionernuts [Point5] . Securethetensionerwithhexagonal wrenchwhen the belttensionernuts. removingand installing Caution: Do not looseninsertedstudwhendisassembly Tighteningtorque (kg'm): 4.4- 5.9 Installconicalwasher [Point6] . Payattentionto installation directionof the conical washers.The washershouldbe setwithfacewith chamferedsidefacingthe tensionerpulleyside Installtensionerspring [Point7] pulley . Assemble springto thebelttensioner thetesioner asshowninthefigure. withthe . Thetensioner together springmustbeassembled pulleyinthecylinder block. belttensioner . Hookthetensionerspring on theuppersideofthetensioner springstudwhenthetensionerpulleyis free. EN-BO ON.VEHICLE PARTS a i . E DE - T E N G I N E Tensionerspring specifications puley ,Whenset Freeangb (-) 1 . 8m m A p p r o x . 2 0 " A p p r o x1. 6 3 " Yellow-green Installcranktiming pulley& ptate [Point8] . Caremustbe takenof the rearandfrontpositioning when installing timingbeltplate,thecranktimingpulleyandthe timingpulleyplate. [Point9] Timingbelt alignmentmarkverification and installation. . Painta markon the beltthatindicatesrotationdirectionif painton the upperbeltis unclearwhendisassembly. . Positionthe alignmentmarkson the intakeandthe exhaustcam pulleyswiththe respective beltcover alignment marks.(No.1 cylinder is at T.D.C) Cam ,;i'/5 . Positionthealignment markon thecranktimingpulleywith therespective oilpumphousingalignment marks.At this mrng groove timethe mustbe straightup (no.1 cylinderis at T.D.C). . Movethe belttensionerclockwise70 - 80 degreeangre, and secureit temporarily withthe belttensionernut. . Installthe beltby aligningthetimingbeltandthe pulley marks.Alignthe numberof ridgesof exhaustcam pulley alignment markandthecrankpulley(inner)alignment mark as shownin the figureon right. . Afterlooseningthe nutsandadjustingthe belttension, securethetensionerwiththe hexagonalwrenchso it will notrotatetogetherandtightenthe nut. Caution. (1) Makesurethetimingbeltengagescorrectlywiththe pulleyanddoesnotfloatwhenassembling the timingbelt. (2) Replacebeltswheneverpossible whendisassembly is performed. EN-81 (, r n. Q r aaKme ) PARTS ON.VEHICLE ENGINE RB26DETT [Point10] Timing belt tensionadjustment . Removethe sparkplugandalignthetimingbeltalignment markandthepulleymarksandinstalltimingbelton to each pulley. . Loosenthe tensionersecuringnutso the belttensionis wrench sPring. appliedby thetensioner . In thiscondition,rotatethe crankpulleyclockwisemore thantwoturnsto checkthe beltmovementandstopslowly T.D.Cpoint. compression at No. 1 cylinder . Insertthehexagonal wrenchin hexagonalhole. Holdthe tensionerby handso the tensionerdoesnot move,and tightenthe tensionersecuringnutto specifiedtightening IOrque. Tighteningtorque (kg-m): 4.4- 5.9 . Theinitialtensionon thebeltin thiscondition shouldbe 20 kg. approximately lPoint 11] Installidler & tensionerpulley . Do not looseninsertedstudswhendisassembly.lf studs are loosened,coatinsertedstudwithlocktitesolution (JapanLocktiteKK)or equivalent. [Point12] TimingbeltinsPection at theinspection. . Replace areindicated timingbeltif anyproblems Toothmissing Crackedtooth Camshaft lock Crank sensorlock Cracks on rear side Tensionerlock E ngine overheat lnterferencewith belt cover etc. Wear and cracks on theside Beltmisalignment Belt platemalfunction Worn teeth Slidingmotionresistancein crank sensor and the camshaft Oil or water adhesion Oil seal malfunction Water leaks in water PumP Caution: Do nottwistor bendthe timingbelt . Makesurethereis no oilfilmorwateron thebelt. EN-82 ON-VEHICLE PARTS -=:.]:-T 10-12 ENGINE CYLINDERHEAOASSY (1) lnstall& removecylinderheadASSY C,rnder headbol lvl12Y1 5l (14) Cylinderheadbolt(M6x'1 .0)@ f,,' II ll \ SpringwasherH H \cr Washer'--? 0 92- i.?lpoinr 2]91 \fr , rl l?ii:"1"..*.". (2)Tlghten to 11kg-m Cylinderheadbolt(M6x1.0) o^- 12 [Point 2]p) v--- (3) Loosenboltscompletely o_-(4)Tighten to 3 kg-nr ( 5 )A n g l ew r e n cB h5 ' - 9 0 ' *,"nch 11+f 05 ,.t:rlr" >pnng wasner headASSY Cylinder headbolt(1,46x'1 .0) 0.92- 1.2lPoint 2]F: " R/' c {r-- Springwasher -----J I $ Cam pulley is-t [Point3] Replaceafter everydisassembly 69 Cylinderheadgasket[Point2] Additionalwork required: '1] . Drainand refillcoolingwater [Point . Removeand install; . Collector . Throttlechamber . Intakemanifold . Turbocharger, exhaustmanifold . Timingbelt . Rockercover . Sparkplugs . lnstallNo. 1 cylindercompression T.D.Cposition[Point3] Drain& refillcoolingwater [Point1] Removal . Removecoolingwatercompletely fromthe cylinderblock drainplug. Caution: . Makesurecoolingwaterwillnotenterexhaustfronttube. Refill . Referto "Coolingwaterfillingprocedures" for details. EN-83 .l o1 . - , ---.-^tn -5-:!9r,"# =:4 ,;\l v I' I rl) i ,J"1 O-i i ^i-l--'' .-i@!Y Plr O\. . :''CLE PARTS ENGINE RB26DETT Removeand installcylinderheadbolts lPoint 2] Removal . Removethe boltsin reversesequenceto thefigureson right. lnstallation . Installthe boltsin sequenceshownin thefigureon right. . The cylinderheadbolt(M12xl .5)aretorquedby two-step 11 7 3 method.Tightenthe boltsin two steps. 1 - 1 4 M 1 2 x 15 (1) Tightento 3 kg-m. (2) Tightened to 11kg-m. (3) Loosenboltscompletely0 kg-m. E ".1 (4) Tightento 3 kg-m. (5) Turnbolts85 - 90oclockwisewhenanglewrenchis :i useo. Tightenboltsto 10.5 11.5 kg-mwhentorquewrench is used. Caution: F Whenanglewrenchis notused,neverattemptto thetighteninganglevisually. approximate . Takecarenotto hitor scratchthegasketseatandthe bore grommetwhenthe gasketis installed. . Cleanthe cylinderheadlowersurfaceandthe cylinder blockuppersurfaceto removeallwater,oil and foreign airgun whengasketis installed.Usecompressed ob.iects to blowoutthe boreholes 1 5 9 14 1 5- 1 7 M 6 x 1 . 0 :t ."f :t No. 1 cylindercompressionT.D'G verification . Beforeinstalling thecylinderheadASSYto cylinderblock, pulley andthe cam pulleymustbe positionedat the crank T.D.Cposition the No. 1 cylindercompression . Alignthecrankpulleytimingmarkandthetimingbeltcover timingindicator(0"Position). [Point3] mark . Aligntheintake campulleyalignment andtheexhaust marks. beltcoveralignment to respective EN-84 T i m i n gi n :^----/-dq W ON-VEHICLE PARTS R3 2 6 D E . i TEN G I N E (2) CylinderheadASSYdisassembly& assembly va ve spflngTetarner valveriner lpoint14]--(>-- -)"'d ShimlPornt6lValvecollet[P; nl 181 '- , - Nut0.92- 1.2lpo]nt5r Springwasher-, \ g , vdlveorlseallpoint231 - valveguide[Pornt2a] -, '@d^t g w".n", - i 'P aarreprare-J$ p J e o r r o . s- '22 = - € ,.-D washer- 17' 1s'20) :9'": :HX':Jit -/ \ valveseat lPoint25] ^- -- Exhaustvalve[Poinl21,22] )? 3=-r- g & q-_ v=\ exnausr valve 21 221 {Po'nt o,o^ "tn@(E--o O B Bolr o r0r92 . s -2 -.r 22 lPoint r p o i n5]t 5 r g/-,Y"tJ"tL"n"o oracket lpoint5] !-_ ^ -":1 . - ro'i-,zr _ q(ar rp"i"iag q.r ! -3t*oruJf,lJi!P!*0rpoinr13, 15,21,24,251 -*gp ";@fl<.' camshaft,exhaust s.oe) €ffi4pF da5;tl O"*\ €_ P;i';.] rei'",,si q Ilk *^@-"ffi,x fts, P *,;:feffi."jffi4R-g*;. " :;::" ."I?IT9Y\W1 " - "";"*:i;r;$ Q\2.1-2.7 -_€, 12)2.1 *e gasket Liqurd kg-m ,,F.\ _(N -- *:- e- ** "_rJ pr"rJ1e"'i u""tplare back el;t l \ 3]--. [Point atb-....'' - - @.c"..*n pullev uam campurrev 2l rl {Point lHornl '".. '' ";; t - '* t,.o* TrEn ' ."ur tpoint to 'ao'r,os:--'eo'tt ._-S-.- sr, o.gZ- r.z ,"e-, \: *\--: - o F<\ &ilJ,Y,':"rt":i1T'-1.erPo,nr2rg crankangtesensor bracket 1l JPornt iir, z., _z.rp; Engineoil Replaceafterevery disassembly Additionalwork requ ired: . Removeand installcylinderheadASSY Instalcrank anglesensorbracket [Point1] . The crankanglesensorbracketis positionedontothe cylinderheadby usingknowpins.Alignthe positions correctlywheninstalling the crankanglesensor. Grankangle sensorbracketbolt tighteningtorque (kg-m): 2.1- 2.7 Remove& installcam pulley [Point2] Removal . Fixpulleywitha pulleyholderor sprocketwrenchand removecam pulleybolts. Pulleyholder: KV10109900or KV10109300, sT31520000, sT31530000 EN-85 Crankanglesensor Solt(2) 2.1 - 2.7 \",i Bolt(2)2.1- 2.7 Boll (4) 1.4- 1 Pu ey holder ...\-=<:.7 PARTS ON-VEHICLE RB26DETE TNGINE lnstallation . Alignthecampulleyknockpinholeandthecamshaftknock pinto installcam pulleY. . Usepulleyholderor sprocketwrenchto tightencam pulleybolt. 'l Cam pulleybolt tighteningtorque (kg-m): 1.4- .9 . To removeand installcam pulleybolts.usethe proper toolsto securethe hexagonalpartin frontof camshaft. [Point3] Remove& installtiming belt cover back Plate Removal . Removebackplateboltand detachbackplate. lnstallation . Assemblecanistertubewithbackplateandthen tnstal backolate. Backplatebolt tighteningtorque(kg-m):MO0.64- 0.85 M 8 1 . 6- 2 . 1 Camshaftend play inspection [Point4] . Setthe dialgaugein frontof camshaftas shownin the diagram.Readthedialgaugerun-outwidthwhenthe camshaftmovesin frontor reardirection. Standardvalue (mm): 0.030- 0.080 Remove& install cam bracket [Point 5] Removal (Exhaust and intake camshaft) . Placemarksto indicatethe bracketpositionand its directionbeforeremovingthe cam bracket . Removecam bracketboltsby looseningthemgraduallyin severalstagesin reversesequenceshownin thefigure. lnstallation . Alignthecrankpulleytimingindicator andthetimingbelt '1 covertimingindicator(0")so No. cylinderis at T.D.Cposition.(Thisoperationis not compression necessarywhencylinderheadis removedas singleunit). . Turnthe camshaftso No. '1cylinderis at compression T.D.Cposition.(Operationis easierif the camshaftis turned60obeforeor afterNo. 1 cylinderT D.Cpointwhen as singleunit). headis installed cylinder . Verifl/the positionof No.1 cylinderis at mmpressionT D.C bv knockpin in frontendof camshaft. EN-86 I 2 610 13 1l 11 12 8 4 ON-VEHICLE PARTS RB26DETE TNGINE To installcamshaft,temporarily tightenNo. 1cam bracket and checkthatcamshaftthrustsectionis positioned securely. Tightencamshaftbolt540"(1.5turns)in theordershownin thefigureon the previouspage. Cam brackettighteningtorque (kg-m):0.92- 1.2 Caution: (1) Coatthe camjournalsand end of the cam shaftwith engineoilbeforeinstallation. (2) Do notrotatecamshaft.(Thevalveand pistonsmay interfere). Valveclearanceadjustment [Point6] No. 1 cylindercompressionT.D.Cpoint . Turnthe camshafts(intakeandexhaust)so No. 1 cylinder is at thecompression T.D.Cposition. . Checkknockpin positionof camshaftfrontendto verify No.1cylinder compression T.D.Cposition. . No. 1 cylinderis at the compressionstroketop dead centrewhenboththe intakeandexhaustsidecamsdo not movethevalvelifters. f Valveswhich can be adJusted lntake side PART ITE[I I N T A K ES I D E CylinderNo. 1, 2, 4 E X H A U S TS I D E CylinderNo. 1, 3, 5 Exhaustside Firingorder: 1 - 5 - 3 - 6 - 2 - 4 Rotatethe intakeand exhaustcamshaft'180". No. 6 cylinderis at compressionstroketop deadenter I whenboththeintakeandtheexhaustsidecamsdo notmove thevalvelifters. INTAKESIDE C y 4 i n d eNr o .3 , 5 , 6 E X H A U S TS I D E C y i n d e rN o .2 . 4 , 6 Valveclearancespecifications \2O+l-5C) INTAKE Valve clearance (cold) mm (Reference value: warm) mm EXHAUST 0.45- l 0 3 8 '- , 0 . 5 1 -l O JJ Caution: Alwaysinspectwhenthe engineis cold. EN.87 Valveswhichcan be adjusted Intakeside PARTS ON-VEHICLE RB26DETE TNGINE Reference: Compensationby room temperature o+/-5 +0.02 10 J q 20 +0.01 o 30 +/- 5 -0.01 Valve clearancemeasurement . Inserta 0.15- 0.20mm gauge(A)fromsparkplugside. Insertgauge(B)from oppositeside. Selecta gauge thicknessthatwillreducethe clearanceto 0 m. Note: Do not use morethantwo gaugesfor (B). UseJIS 150A25feelergauge. Valveclearance= Gauge(A) + Gauge(B) usinggauge(A)and(B): Reasonsfor measurement 1. Thevalveclearancesettingis largercomparedto previousengines. 2. Largegaugescannotbe placedparallelto the surface. measurement . Thickfeelergaugehavehighrigidityand cannotbe bent willbe incorrect. easily,so the measurement . The errorfactorincreasesif a numberof thingaugesare willbe incorrect. layeredandthe measurement Valve clearanceadjustment . Thevalveclearanceadjustment is performedby selecting thickness. a shimof suitable . Whenthe measurement valveclearance(t) is out of measuretheshimthickness(T)and replace specification, it witha shimthatwill producethe standardclearance. 1. Shim thicknesscalculationmethod Example: Whenthe intakevalveclearance(t) is 0.50mm: value)= 0.05mm 0.50(t)- 0.45(specified . Thevalveclearanceis 0.05mm greaterthanthespecified value. . Usea shim0.05mm thickerthanthe currentshimto reducethevalveclearance. 2. Currentshim thickness(T) . Measurethe centerof removedshimto determinethe thicknessof the currentshim. Caution: shimsagain. Do notreusethemeasured Do not reuse after EN-88 ON-VEHICLE PARTS R 3 2 6DE - i E N G I N E 3. Shim selection . Currentshimthickness (T)is 2.40mm. 2.40I\ mm + 0,05mm = 2.450 . Selectnewshimwithstampedmark 124.401 (T =2.440-2.455). Selecta shimwithinstandard valuerange+f 0.03mm. 4. Shim types and classification . Thereare 70 typesof shims.Sizesrangefrom2.275mm to 3.325mm in 0.05mm increments. J = 2.440- 2.455mm Installcamshaftfront oil seal [Point 7] . Caremustbe takennotto scratchor makea burrin the oil seal. Usea socketsmallerthantheseal(41mm)anddnve it intosamelevelas frontsurfaceof the oil sealretainer. . Applya coatof engineoil to the entireperimeterof oil seal lrD. Caution: Do not scratchtheoilsealandlio. Installcamshaftrearrubberplug [Point8] . Beforeinstalling the rubberplug,wipeoffanyoil,wateretc. on thesurfaceandcleanthoroughly. . Whenassembling the rubberplug,coatit withadhesive (threebond1211) or equivalent. Intakeand exhaust camshaftclassification [Point 9] . Intakeand exhaustcamshaftcan be identifiedby pointcolourand presenceof a spinegear identification for drivingthe crankanglesensor. Intakecamshaft Pink No Exhaustcamshafi White Yes [Point10] Camshaftknock pin insertion . Theprotrusion distanceis 5 mm for camshaft knockpin insertion. Knock pin protrusiondistance(mm): 5 EN.89 Splinegea. for dnvingcrankangle ON-VEHICLEPARTS R826DETT ENGINE [Point'11] Camshaftinspection Cam height inspection . Usea micrometer camheight. to measure Exhau$t 3Ue Cam.heig.ht,stt dard.value 40.58 40.28 8.58 8.28 Camjournalexternaldiameterinspection . Usea micrometer to measurethe externaldiameterof the journal. camshaft No. 1 - No. 7 27.935- 27.955 [Point12] Camshaftrun-outinspection . Supportbothcamshaftendjournals(No.1 and No.7) by usingV-blockson thefixedsurface. . Avoidthe oil groovein the centreof the No.4 journaland positionthe dialgaugevertically. . Rotatethe camshaftby handone rotationand readthe movementwidthon thedialgauge. . The run-outis equalto one-halfof the movementwidth on thedialgauge. indicated Standardvalue (mm): 0.05 [Point13] l D i a l g a u g e\ h )al q.- Cylinderheadcambracketinteriordiameterinspection . Tightenthe cam bracketto specifiedtorque - '1.2 Cam bracket bolt tightening torque (kg'm): 0.92 . Usethe boregaugeor insidemicrometerto measure interiordiameter. - 'l ' :--.. > ,-v,, - r: . i r \-t- _l r!)/\| | !,::>--:a N o .1 - N o . 7 28.000- 28.O21 EN-90 mrcrometerI -,,,,-:1 ON-VEHICLE PARTS R 3 2 ' f E * I E N GN E [Point14] Camshaftoil clearanceinspection . The oil clearancecan be calculatedfromthe camshaft journaloutsidediameter andthebracketinterior diameter measured in [Point'l1] and[Point13]. = (Cambracketinterior (Oilclearance) diameter) (Camshafijournalexteriordiameter) N o .1 - N o . 7 0.045- 0.086 [Point 15] Valvelifter inspection . Checkthe contactand slidingsurfacesfor wearor scratches.Replaceif damaged. . Usethe micrometer to checkthevalvelifteroutside diameter. Standardvalue (mm): 30.995- 30.965 [Point16] Cylinderheadlifter bore inspection . Checkboresurfacefor wearor scratches. . Useinsidemicrometer to measurevalvelifterhole diameter. Standardvalue(mm): 31.0- 31.020 [Point17] Valve lifter-to-lifterhole clearanceinspection . Checkthe clearanceusingvaluesfor thevalvelifteroul srdediameterandvalvelifterholediametermeasuredin [Point15] and[Point16]. = (Valvelifterholediameter)(Clearance) (Valvelifteroutsidediameter) Standardvalue (mm): 0.025- 0.065 [Point18] Remove& installvalve spring When the cylinderhead is removedfrom the vehicle: . Usethevalvespringcompressor to removeand installthe valves. When the cylinderheadis installedin the vehicle: . Usethevalvespringcompressor to installvalvespring. EN-91 Vaive ON.VEHICLEPARTS RB26DETE TNGINE [Point19] Remove& installvalve collet Removal . Usetweezersto removecollet. lnstallation jellyto the internal . Applya smallcoatingof petroleum surfaceof the collet. . Usea magnetscrewdriver. 1. Uopercolletinstallation . Attachcolletto the lowersideof the magnetic screwdriverbladeand installin the valvestem. 2. Lowercolletinstallation . Attachthe colletto uppersideof themagnetic screwdriverbladeand installin the valvestem. Magnel [Point20] Valvespring inspection Freelengthand pressureload inspection . Usethevalvespringtesterto carryoutthe inspection. 46.54 24.0 22.5 White Caution: lnstallationloadis the forcerequiredto compressthe spring lengthto 35 mm. PerpendicularinsPection . Placea try squareby the springso it contactsspring Turn the springand measurethe maximumclearancebetween upperspringsurfaceandthe rightangleto determinethe distance. out-of-souare '1.8 Limit(mm): [Point21] InstallvalvesPring . Installunevenpitchtypespringwithnarrowendtowards colourside). cvlinderhead(identification EN-92 ON-VEHICLEPARTS R 3 2 6] E T T E N G I N E [Point22] Valveguide clearanceinspection . Protrudethe valveapproximately 15 mm towardsthe combustion chamberand measurelhe valvedeflectionbv swingingit in direction parallel to thedialgauge. . Theclearance is equalto halfof thedialgaugereading. Intake Exhaust 0.1 0.1 Limit(mm) D i a lg a u g e '-J.O .H.gb . lf clearanceexceedslimit,verifythe valvestemdiameter andreplacethe valveor valveguide. [Point23] Valveinspection Outsidediameter measurement - l 1-e --1r '- l: L lll a --r-;' l b c d 1 0 0 . 9 8 + / - 0 .97.45+t-0.15 1 s + s - l 2o^ u^ -. 0o 0. 032! c 99.98+/-0.195.48+/-0.15 ! | /-,i,: lry- -----cJ b a Vatue E q f -fli-?r-it, e t \ c o € N s e f t.J z.o ^ 7' ^" --0000 8 c (1.2) 95 ?q +03 q 45" 30' ^ ^ 0.02c o u - o - o s s45 30' +t-15' Be especiallycarefulin handlingand disposalof valvesas the exhaustvalvesarefittedwith metallic sodium. [Point241 Remove& installvalveoil seal Removal . Usevalveoil sealpullerto removethe valveoil seal. Installation . Usevalveoil sealdriftto installthe valveoil seal. Drift KV10107501 Drift attachment KV10114800 Caution: Coatinsideof thevalvesealwithenqineoilbeforeinstallation. Valveoii sealdriftattachment _iiaJ, KV1011480 l EN-93 PARTS ON-VEHICLE ENGINE R826DETT . lnstallvalveoilsealas shown. Valveorl seal T- Y, Intake [Point 25] Remove & install valve guide Removal . Usevalveguidedriftandtap it fromcombustionchamber sideto remove. lnstallation . Reamthe cylinderheadguideholeusingthe valveguide (whenusing0.5 mm over reamerat normaltemperature sizeservicePart). lntake side 10.46- 10.478 Exhaustside 1 1. 4 6 - 1 1. 4 7 8 150 headinanoilbathto approximately Heatthecylinder toolto press to 160"Candusea valveguidedriftor press-fit side. valveouidefromcamshaft Camshaftside . The press-fitdimensionsareshownin thefigureon right. 10.8+f0.1 . Reaminsideof insertedvalveguidewiththe valveguide reamer. Valveg0ld6.reamer K V 1 0 11 1 6 0 0( i n t a k e l r<V101 07700-(exhausr) _ E N. 9 4 ON-VEHICLEPARTS I 3 2 6 C E - I . TE N G I N E [Point26] Valveseat Inspection . Inspectthecondition of contacting surfaceof thevalveseat andthevalve. . Replacethevalveseator thevalveif contacting surfaceis too largeor improper,or grindbothsurfacesand lapwith abrasivecomDound. Adjustments . Whensurfacingvalveseatdueto poorcontact,inspectthe valveguideclearanceandvalvestepholeclearance. . Usethevalveseatcutteror thevalveseatqrinderand finishto standardvalue. Caution: Whenusingvalveseatcutter,pressfirmlyandcutevenlywith bothhandsto produceuniformcuttingsurface. o.K _po*" Removal . Minimize thevalveseatthickness by cuttingit,thenremove. Installation (1) Drivethevalveseatintocylinder headusingthevalve seatdrifteras shown, (2) Whennot usingthe valveseatdrifter: . Coolthe valveseatfor approx.5 minutesusingdry-ice . Heatthe cylinderheadto approx.80oC. . Injectthevalveseatintothecylinderhead. Caution: Do nottouchcooledvalveseatwithbarehands. . Exhaustvalveseatsareavailable in 0.5mmoversize.When usingoversizevalveseats,cutand grindthe seating recessin cvlinderto fix valveseats. (Cutter diameter) Exhaust side -- p, ?A JO .^ 0.5 ", fio, ffio. +0 113 + i - 01 s 30 0 097 ^^ - -015 +0.016 36.5 + 0 . 0 1 6 'r? _a -196 0 q +0 016 32\::: - co, co :or do__o (Cutter I diameter) :: EN-95 32 34.3 32 34.3 29.6 32.5 37.s ^ ^ 0 O,O ^r +/-u.{J: 2 96 5.8 ^ ^ 0 o o , o1 +/-u.ut 5.8 PARTS ON.VEHICLE ENGINE RB26DETT [Point27] Cylinderhead inspection . Cleanandremoveoil,gasket,sealingcompound, carbon andotherforeignmatter. Measurethe lowersurfaceof the cylinderheadin six directionsto checkfor any distortion. 0.2 Limit(mm): Straightgauge Whenthe distortionisjust overthe limit,resurfacethe head. cylinder overthe limit,replace lf the distortionexceedsexcessively the cylinderhead. 10-13 WATERPUMPREMOVALAND INSTALLATION Alternatoradjustbar ton1',I o oa- o.esg'1-\ \ d GQi, B o l (t 2 )3 . 2- 4 . 3 I ' t'tl''\> r- -l r,":'. ' \ peort1zy s.z- 4 . 3 M Bolt(6)1.6- 2.1pl D Liquidgasret kg-m Additional work required: . Drainand refillcoolingwater . Removeand install: . Coolingfan,waterPumPrelaY . Alternatoradjustmentbolt . Timingbeltcover,timingbelt Remove& installwater pump [Point1] Remove . Caremustbe takennotto get coolanton the timingbelt. Wipe it off immediatelyif anywaterdoesspill . Removethewaterpumpboltsin the reverseordershown. 1 M 6( 1 ) M10 {lonq) EN-96 EM10 (short) 11 M8 ON-VEHICLEPARTS R826DETT ENGINE Installation . Installthe boltsin the numberedsequenceshown. 7, 8 , 9 , 1 0 ,1 1, 1 2 2,3,4.5 M6 1 tv8 6 r\41 0 A 0.64- 0.85 't.6- 2.1 3.2- 4.3 Removaland cleaning . Insertstubbyscrewdrivers in the boltholesand moveit up anddownto removethewateroumo. Caution: Takecarenotto damagethe screwsin cylinderblockside. . Usea scraperto removeall liquidgasketfromthesurface. Caution: Alsoremovethe liquidgasketremainingin grooves. . Wipethe installation surfacewithwhitegasoline. Installation . Cutthe nozzleendof liquidgaskettube(KP51000150)as shownin the figureand usetubepresserfor application. . Applycontinuous beadof liquidgasket(KP51000150)to waterpumpsealingsurface. Caution: Be sureliquidgasketis 2.0to 3.0mm wide. Installation must be carriedout within5 minutesafterliouid gasketapplication. Water pump inspection [Point 2] . Rotatethewaterpumpby handand checkfor abnormal soundandsmoothoperation. . Theremustbe no tracesof waterleaks. EN-97 Llquidgasket2.0 - 3.0 rnm wrdealongthe groove PARTS ON-VEHICLE RB26DETE TNGINE 10-14 THERMOSTATREMOVAL& INSTALLATION Thermostat[Point2] Thermostathousrng[Pornt1] *r,, 1 )6 - 2 . 1 F j Borti3 EILiquidgasket ht t",aK g - m Additional work required: . Disconnect and connectwaterinlethose . Drainand refillcoolingwater Caution: Loosenenginedrainplugto removecoolingwaterfrom thecylinderblock. 'l] Remove& install thermostat housing [Point Removaland cleaning . lnsertthe screwdriver handleintothermostathousingand move it up anddownlightlyto removethe housing. . Usea scraperto removethe liquidgasket. Caution: Makesureto removeliquidgasketin grooves. . Wipeoffthe surfacewithwhitegasoline. ?aq't lnstallation . Cutnozzleendof liquidgasket(KP51000150)tubeas snown. . Applya continuousbeadof liquidgasketto sealingsurface usingthetubepresser.Installthe housingwithin5 minutes aftercoatingliquidgasket EN-98 2.0 - 3.0 mm wideto centerof flat matingsurfaceand innerseating surfaces of boit holes. ON-VEHICLE PARTS ia2a l:--r. ENGTNE Installthermostat [Point2] . 'Top'markfiigglevalve)mustfaceup whenthermostatis insertedin housino. Thermostatinspection [Point3] . Checkthevalveopeningtemperature and maximumvalve tift. . Hangthe thermostatby stringin valveandsubmergein heatedwaterin doublewalledcontainer andstirwaterwhile heatingit up. . Theopeningtemperature isthetemperature whenthevalve opensandthermostatfallsfromstring. 76.5 10/90 10-15 INSTALL& REMOVEOIL COOLER,OIL FILTER Additionalwork required: . Disconnect and connectswitchharnessconnectors . Drainand refillcoolingwater Caution: Loosenenginedrainplugto removecoolingwaterfromcylinderblock.(lfwateris onlydrained fromtheradiator draincock,thecylinder blockwillnotdraincompletely). EN-99 PARTS ON-VEHICLE RB26DETE I NG]NE Remove& installoil filter [Point1] Removal 1. Removetheoillevelgauge. pressurecontrolvacuumhose 2. Removeturbocharged clampand movethevacuumhoseoutof theway. 3. Movemainharnessclampout of theway. (lf the oilfilter comeloose,removethe oilfilterusingthefilterwrench) 4. Useoilfilterwrenchto removeoilfilter. lnstallation . Wipeoff dustetc.fromthe oilfiltermountingbracket surfacebeforeinstallingnewoilfilter.Applya thincoatof engineoil to oil filterO-ringbeforeinstallation. . Screwthe oilfilteron bracketby handuntila slight resistanceis felt,thentightenan additional2/3turnsusing theoilfilterwrench.Starttheengineandcheckfor oil leaks. Removal . Facelowerpartof oil filterdownand moveout in the directionof the arrowin figureright. Removethrough aDerturebehindmanifoldcollector. () ^ -@/^ Small ratchet -V wrench 1/ noup,". h/ OIL PAN,OIL PUMP& OIL STRAINER 1O-16 (1) Remove& instaltoil pan,oil pump & oil strainer g oil pannut(7) - 4 . 3l P o i n1t ] @-'3.2 -springwasher f E oil pumpgasket Oil strainer[Point3] p u m p , i t( B ) l OilP rt 4l 0 . 9t 2 - 1 . lPoint d 2] Eloil pan[Point at Ele '11oll s Front Oil pump pDrain ptug Copper wa\sher ?7*\ t \t\$r \ ), oit panbolt(a)Fl 0 . 6 4- 0 . 8 5l P o r n1t l \ O i lp a nb o l t( 1 4 )3 . 2- 4 . 3t P o i n1t 1 p j i",l Kg-m f | E n g i n eo i t $ neptaceafter every disassemoly Additionalwork required: . EngineASSY . Drainand refillengineoil E N- 1 0 0 ON-VEHICLE PARTS RB26DETE TNGINE Remove& installoil pan bolts & nuts [Point1] Removal . Removeboltsand nutsin reverseorderof installation sequenceshownin thefigureon right. Installation . Installthe nutsand boltsin the orderof sequenceshownin thefigureon right. Caution: Makesurethereareno dirt,dustor otherforeignobjectson oil installation surface. Bolt t Nut 3ize M,E EEM N/6(Bolt) I 0.64- 0.8s 4 , 7 , 8 ,1 0 ,1 1 .1 2 .1 4 ,1 5 , 1 6 ,1 7 ,1 8 ,1 9 . 2 1 . 2 2 M 1 0( B o l t ) 14 3.2- 4.3 1 , 2 , 3 , 5 ,6 , 9 , 1 3 lV10 (Nut) 7 3.2- 4.3 tv l)Al )o ".i Remove& installoil pan [Point2] Removal& cleaning . Usea sealcutterto removeand cleanthe oil pan. . Usea scraperto removeliquidgasketfrommating surface. Caution: Usea scraperto removeall liquidgasketandsealmaterialon the cylinderblockandoil panflangegroove.Removeall gasketand otherforeignobjectsin the oil pan. . Cleanall contactsurfaceswithwhiteoasoline. Installation . Cutoffthenozzletipof liquidgasket(KPs1000510)at pointshownin thefigureon right. Applyliquidgasketto innersealingsurfaceson the oil pan as shownin the figureon right. Installation mustbe performed within5 minutes. EN- 101 ON-VEHICLEPARTS RB26DETE TNGINE . Applyliquidgasket(KPs1000150)to areas7 mm inside fromcenterof the oil pan boltholes. Caution: (1) Makesurethe liquidgasketis applied4.0 mm wide. Waitat least30 minutesbeforerefillingthe engineoil Q\ andenginecoolantafterinstallation. Installoil strainer [Point 3] . Makesurethe O-ringis installedsecurelyin groovewhen installingtheoil strainer. Tighteningtorque (kg-m): 1.6- 2.1(Mg) 0.64- 0.85(M6) Oil PumPbolt [Point4] . Thereare4 typesof bolts. Makesureto usethe correct boltswhenthevare installed. 20 4 0 . 9 2- 1. 2 2 35 2 0 . 9 2- 1 . 2 3 45 0.92- 1.2 4 55 0 . 9 2- 1 . 2 Remove& install front oil seal [Point 5l Removal . Usea toolsuchas screwdriver to removefrontoil sealfrom the frontcover. lnstallation . Caremustbe takennotto scratchor damagethe oil seal retainer.Useoilsealdriftandinsertit at samelevelasfront surfaceof the oil PumPhousing. . Applyengineoilor chassisgreaseto areaaroundtheoil seallip. Oil leak& oil pressureinspection [Point6l . Afterinstallation warmup the engineand checkfor any oil leaksandtheoilPressure. . Removeoil pressureswitchand attachoil pressuregauge whenmeasuringoil Pressure. ldling 2000 6000 Approx.1.5 Approx.3 A p p r o x . 4 . 6 EN - 102 ON.VEHICLEPARTS R 3 2 6D E i T E N G ] N E (21 Oil pan disassembly& assembly B o l it 2 l 0 6 4 - O . ApS Boto.6a-0.85I t",/ Bolt(4) 74r' ri\ \ie-". Rrffla ^l.la ti, lv/ Kg_m (3) Oil pump disassembly& assembly Purnphousrng[Pornt Innergear [Pornt2] Outergear [Point1] piuga.O- z Opl Regulator 19*n-' Oil pump inspection [Point1] . Checkinnergear,outergearand housingfor any scratchesor wear. . Usethicknessgaugeto measurethefollowingclearances: Outergear and housingclearance 0.114- 0.2 2 Outergear and innergear clearance B e l o w0 . 1 8 0 3 lnnergear and housingside clearance 0.05- 0.07 4 Outergear and housrngsrdeclearance 0.05- 0.11 5 lnnergear and housingflangeclearance 0.045- 0.091 position5 is obtainedby subtracting Measurement the housingflangeoutsidediameter fromthe innergearinsidediameter. EN- 103 PARTS ON-VEHICLE RB26DETTENGINE Regulatorinspection [Point2] . Checkoil pressureregulatorvalveslidingsurfaceand the springforanywearanddamage. Valveand valve hole clearance(mm): 0.04- 0.097 Installinnergear [Point3] . Caremustbe takento installthe innergear in a specific direction. . Facethe sidewiththe grooveto the coverside. E N- 1 0 4 Coverside ON-VEHICLE PARTS I 3 2 :E E N GN E 10-1 (1) COLLECTOR ASSY CollectorASSYremoval& installation Air reieaseplug IPoint Acceleration wife bracket[Point2] Collector ASSY IS--.-,.,^ I Y collector oort(a)$l 1 . 8- 2 . 2l P o i n3t l gasket E Collector g :'j:i,i",ili'lr ?3' ft., Fi. $./.1Ks-m E Replace aftereverydisassembly Additionalwork required: . Releasefuelpressurein thefuel lines [Point1] . Drain& refillcoolingwater[Point4] . Acceleration wire[Point2] . Airduct . Harnessconnector . All hoses Releasefuel pressure [Point1] . Starttheengine. . Afterstartingtheengineremovethefuelpumpfuseandwait untilthe enginestops. Crankenginetwo or threetimesto consumefuelremainingin the fuelpipes. . lf thevehicledoesn'tstart,removethefuelpumpfuseand crankthe enginefourto fivetimesto consumefuel remaining in thefuelpipes. Caution: The batterymay becomeweakeasily,use boostercableto connectto anotherbatteryif necessary. Acceleratorwire adjustment [Point 3] . Loosenlocknutto provideadequateslackfor the accelerator wireand pulloutercasein the directionof the accelerator. . Returnthe locknut 1.0to 1.5turnsfromthe oositionthe throttledrumstartsmoving(whenthereis no playin cable) andtighten. Tighteningtorque (kg-m): 0.8- 1.0 E N- 1 0 5 PARTS ON-VEHICLE R B 2 O EE N G I N E Remove& installcollectorbolts [Point3] Removal . Removethe boltsin the reverseorderof the figureon right. lnstallation . Installthe boltsin theordershownin thefigureon right uniformlyin two to threestages. Air releasePlug [Point4] . Formoreinformation referto the sectionon coolingsystem lateron in themanual. . Carryout the operationwhenengineis cool. Caution: Do not removethe air releaseplugwhenthe engineis hot. . Removetheairreleaseplugto releasetheairwithinthe whenrefillingcoolingwater. enginecompletely Caution: Care must be taken not to over tightenthe air releaseplug bolt. Tighteningtorque (kg'm): 0.7- 0.8 (21 & assembly CollectorASSYdisassembly Throttlechambergasket 2l $ tPoint Throttlechamber[Point1] - Throttlechamberbolt (4) 1lpl 1.8- 2.2tPoint p ) M c v a l v e A S SbYo l (t 4 ) 0 . 8-6 1 . 1 Fi. lv.l Kg-m $ neptaceafler every disassemol, Additional work required: . Removeand installcollectorASSY E N- 1 0 6 ON-VEHICLE PARTS i32]: E\GINE Remove& installthrottlechamberbolt [Point1] Removal . Removethe boltsin the reverseorderof thefiqureon the right. Installation . lnstallthe boltsin theordershownin thefigureon right uniformlyin two stages. Tighteningtorque(kg-m): Firststage 0.9- 1.1 Secondstage 1.8- 2.2 Throttle chamber gasket [Point 2] . Checkthe installation directionbeforeinstallinq thethrottle chambergasket. I =il;10.2 (1) INTAKEMANIFOLD ASSY Remove& installintakemanifoldASSY Intakemanifoldgast<et $ -_.4_ Fi t-.1 a Replace aftereverydisassembly Additional work required: . RemoveandinstallcollectorASSY . ECCSharnessconnectorand allhoses E N- 1 0 7 PARTS ON.VEHICLE R B 2 O EE N G I N E [Point1] Remove& installintakemanifoldASSYbolts and nuts Removal . Removethe boltsandnutsin the reverseorderof thefigure on right. lnstallation . Installthe boltsand nuts in theordershownin thefigureon 1 17 right, (2) 3 1 5 I IntakemanifoldASSYdisassembly& assembly .J \* - Arr regulator {4 p) Air ;egulator bolt0.5- 0.6 FueltubA e SSY I P o i n1t l Fueldamper - n ;*,,i Water outlet 7i reguralor Boltt-,4 1 . 8- 2.2 $ I Bolt(2)1.6- 2.191 Replaceafter every disassemble El Liquidsasket Fueltubebolt1.0- 1.2 I *s-' Additionalwork required: . RemoveandinstallintakemanifoldASSY Fueltube ASSY [Point1] . Replacethe O-ringto newoneswhenremovingand installingthe pressureregulatorandthefueldamper. Caution: Caremustbe takennotto scratchor damagethe fueltube andthefuel thepressureregulator O-ringareawheninstalling damoer. E N- 1 0 8 regulator Pressure Fueltube injector Fuel damper f ON-VEHICLEPARTS R B 2 O EE N G I N E [Point 2] O-ring(for fuel injector,pressureregulatorand fuel damper) Precautionswhen handling . CoattheO-ringwithengineoil (7.5W-30or equivalent) or siliconoil(NUCsiliconL45or equivalent), butdo notapply solventas thismay removeoil coating. . AvoidusingdirtyO-ringsanddo notallowdirt,dustor foreignobjectsto adhereto O-ringsor otherequipment surfaces. . Caremustbe takennotto scratch,twistor stretchthemov toolsor operator'sfingernails wheninstallingO-rings. . Do notdecenteror rotatethefuel injectorsandthe pressureregulatorwheninsertingthemintothefueltube. . Do notstoreO-ringsin locationsubjectto ozone,high temperature or in directsunlight. 10.3 REMOVE& INSTALLEXHAUSTMANIFOLD ASSY Exhaustmanifold plor sensor4.1 - 5.1 ? ' * o i P.P yoke[potnt3) . P WasherfPoint4] , p ruut z.a- s.zieornt zj" ri \-/ Kg-m Replaceafter every disassemble Additionalwork required: . Undercover . Assembleanddisassemble exhaustfronttube . O, sensorconnector Gas leak inspection [Point1] . Afterremovingthe exhaustmanifold,makesurethereare no tracesof gas leaksfrom any parts. . Afterthe installation, crankthe engineand checkfor any oas leaks. E N- 1 0 9 PARTS ON.VEHICLE R B 2 O EE N G I N E Removeand installexhaustmanifoldnuts lPoint 2l Removal . Removalis the reverseof installation sequenceshownin the diagramon right. lnstallation . The installation sequenceis shownin the diagramon rioht. 8 10 6 2 11 4 Yoke [Point 3] . Makesure notto makemistakebetweenNo. 3 and No.4 aredifferent. yokeas configurations 22 24 Installwasher [Point4] . Makesurethewasheris facingthe correctway when installing. 10.4 + l\4anifoldside LOCKERCOVER & INSTALL REMOVE LOCKeTCOVer Fillercap Additionalwork required: . Air duct . Air duct bracket . Blowbyhose [Point1] Remove& installlockercover bolls Removal . Removalis the reverseof installation sequenceshownin the diagi'amon right. lnstallation . The installation sequenceis shownin the diagramon rioht. E N- 1 1 0 11 6 3 4 8 1 ON-VEHICLEPARTS R B 2 O EE N G I N E 10-5 TIMINGBELTREMOVAL& INSTALLATION 8 e t l e " sc . e r ,., vvasner Tensoner spr no fPoint7l i ConicatwasherI " glNur4 4 l"."il,t]",".\ i -}- dso * tl6'8 Timrngbelt cover(upper) IPornl4] Timingbeltcover Crankpulley[Point3] Powersteeringpump pulrey p a o r r. o ;t . z Cranktrrnrng beltplatelPoint CranktimingpulleylPoint11] '121 . 3] T i m i n gb e l tl P o i n 9 t , 10, Cranktimingpulleyplate[Point8] {ri^.. l-/ borr ( 2 )0 . 3- 0.5 I ts-. E E n g i n eo i l after Additionalwork required: . Drainandrefillcooling water . Removeand installthefollowinos: . Undercover . Radiator,shroud . Coolingfan . Supplemental belts . Waterpumppulley . Sparkplugs . CheckNo. 1 cylindercompression T.D.Cposition[Point1] . Installringgearstopper[Point3] [Point1] No. 1 cylinderpressureT.D.C(top deadenter)inspection . Alignthecrankpulleytimingmarkandthebeltcovertimingindicator. At thistime,the distributorrotorshouldbe in the positionshownin the diagrambelow,or No. 1 cylinder in thecompression T.D.Cposition. E N- 1 1 ' l PARTS ON-VEHICLE R B 2 O EE N G I N E [Point2] Installring gear stopper . Removethe startermotorand installthe ringgearstopper' '' -*v-ror wheelpuller) [Point3] Pulleypuller(steering . Remove pulley byusingthepulleypuller. thecrank (boltsize:M6x 1.0 lengthbelowhead40 mm) 2718 [Point4] lnstalltiming belt cover . Attachthe gasket(spongerubber)on the timingbeltcover (upper)as shownin the figure. [Point5] Remove& installbelt tensionernuts . Securethe belttensionerfirmlywitha hexagonalwrench the belttensionernuts. whenremovingand installing [Point6] Installconicalwasher . Paycloseattentionto the installation directionof the conicalwashers.The washershouldbe set withfacethe chamferedsidefacingthe tensionerpulleyside a I r I I I -[__T--r \_J t Nrt IPoint7] Installtensionerspring . Assemble thebelt springso it engages thetensioner pulleyasshowninthefigureonright. tensioner . The tensionerspringmustbe assembledtogetherwiththe belttensionerpulleyin the cylinderblock. EN-112 \\ \ l Conical washer ON-VEHICLE PARTS R B 2 O EE N G I N E Fixthebelttensioner andhookthespringon topofthe studvoltby rotatingthe springanticlockwise. pullfy Spri 1 . 8m m Approx.20' Approx.227' When free Timingbeit pulle' [Point8] Installcrank pulleyand plate . Be carefulto observefrontand rearpositioning of timing plate, belt cranktimingpulleyandcranktimingpulleyplate wheninstallation is oerformed. [Point9] Timingbelt alignmentmarkverification . Checkif the cam pulleyalignmentmarkis alignedwiththe cranktimingpulleyalignment markwhenNo.1 cylinder is at compression T.D.C. . Checkthenumberof ridgesbetweenthecampulleyand thecranktimingpulleyalignment marks. Markon eachpulleyat thealignment position withwhite paintif thetimingbeltalignment mark(whitepaint)is not clear. Positionthe timingbeltso the backsurfacearrowis facing the enginefrontandalignthealignmentmark(whitepaint) withcam pulleyandthe cranktimingpulleyalignmentmark wheninstalling a newtimingbelt. Checkthe ridgesafterthe installation. EN- 113 --------- tar ]--lu il t.t tr - -lf-- o)o"u E- ll PARTS ON-VEHICLE R B 2 O EE N G I N E [Point 10] Installtiming belt . Assemblethe tensionerspringso it engagesthe belt tensionerpulley(followpoint7). . The tenstonerspringmustbe assembledtogetherwiththe belttensionerpulleyin the cylinderblock, . Inserthexagonalwrenchintothe belttensionerhexagonal holeand rotateclockwiseto tightenthe nuttemporarily . Alignthetimingbeltalignment markswitheachpulleymarks andinstalltimingbelton to pulley. . Tightenthe tensionersecuringnutsto specifiedtightening 4.4- 5.9 torque.Tighteningtorque (kg-m): [ P o i n t1 1 ]C r a n kt i m i n gP u l l e Y . Makesureto installthecranktimingpulleyin a correctway Somecranktimingpulleyhastwo key groovesand marks. alignment Keygroove [Point12]Timing belt tensionadjustment . Loosenall rockershafttighteningbolts. . Rotatethe tensioneranticlockwise two to threetimes usinghexagonalwrench. (itis notnecessaryto rotatebelts) . Fixthe tensionerusinghexagonalwrenchand tightenthe nutsto specifiedtighteningtorque. (At thisstagespecific tensionwill be appliedto the beltsautomatically). [Point13]Timingbelt insPection . Replacetimingbeltif inspectionindicatesany problem. Toothmissing Cracked tooth @ Tensionerlock Engineoverheat with belt cover etc. lnterference Cracks on rear stde Wear and cracks on the side Worn teeth Oil or water adhesion Camshaftlock Crank sensor lock .J.D Beltmisalignment Belt plate malfunction /,ilh nn Jary ]!lg S lidingmotionresistancein crank sensor and the camshaft Oil seal malfunction Water leaks in water PumP OIL FILTER 9.6 REMOVE& INSTALLOIL PAN,OIL STRAINER, . Referto RB20DE,DETsectionlateron in the manualfor detail E N- 1 1 4 ON.VEHICLE PARTS R B 2 O D /ED E TE N G I N E 10-1 (1) COLLECTOR ASSY Remove& installCollectorASSY cottector bott/2)lctl 1.8- 2.2IPoint --{{3lrci Accelerator wire bracket[Point2] Co ecrorASSI e l | ,---_,--4 gasket E Collector Air releaseplug [Point4] collectofbolt \2) 1 B - 2.2 lPornt31p) & tli \-,i k g - m Repiaceafter every disassembly a Additionalwork required: . Releasefuelpressure in thefuelline[Point1] . Acceleration controlwire[Point2] . Drainand refillcoolingwater . Air duct(RB2ODE), Air inletpipe(RB20DET) . EGIharnessconnector,harnessclamp . All hoses [Point1] Releasefuel pressure . Afterstartingthe engineremovethe fuelpumpfuseand waituntiltheenginestops.Crankenginetwoor threetimes to consumefuel remainingin the fuel pipes. . lf the vehicledoesn'tstart,removethe fuelpumpfuseand crankthe enginefourto flvetimesto consumefuel remaining in thefuelpipes. Caution: The batterymay becomeweakeasily,use boostercableto connectto anotherbatteryif necessary. [Point 2] Acceleratorwire adjustment . Loosenlocknut to provideadeouateslackfor the accelerator wireand oulloutercasein directionof the accelerator.Returnthe locknut 1.0to 1.5turnsfromthe positionthe throttledrumstartsmoving(whenthereis no playin cable)andtighten. Tighteningtorque (kg-m): 0.8- 1.0 E N -1 1 5 ON.VEHICLEPARTS R B 2 O D /ED E TE N G I N E [Point 3] Remove & install collector bolts Removal . Removethe nutsin the reverseorderof thefigureon right. Installation . Installthe nutsin the ordershownin thefigureon right uniformlyin tvvoto threestages. 2 7.10 9 5 2 4 105 65 8 4Q 1,3,4,6, 2 , 5 , 9 .1 1 4 30 [Point4] Air releasePlug . For moredetailreferto coolingsystemlaterin the manual. Caution: Do not removethe air releaseplugwhenthe engineis still warm. . Makesureto removeair releaseplugwhenrefillingthe coolingwaterto releaseairwithinthe enginecompletely (overheatprevention). 0.7- 0.8 Tighteningtorque (kg-m): (21 CollectorASSYdisassembly& assembly *:;::*;l;;,'"'*>e H41, B o l (t a )0 . 9- 1. 19 gasketlPoint2]E Castetq3 Throttle chamber Throttlechamber a:// --..z2*)",. no"" I ts-t $ Repiaceaftef every disassemble Additionalwork required: . Removeand installcollectorASSY E N- 1 1 6 Throttlechamberbolt (4) 1 . 8- 2 . 2 [ P o i n 1t ] $ I ON-VEHICLEPARTS R B 2 O D /ED E TE N G I N E Remove& installthrottlechamberbolts [Point1] Removal . Removethe boltsin the reverseorderof thefigureon right. Installation . Installthe boltsin the ordershownin the figureon right uniformlyin two stages. Tighteningtorque (kg-m): First stage 0.9- 1.1 Secondstage 1.8- 2.2 [Point2] Throttlechambergasket . Checkthe installation directionbeforeinstallino the throttle gasket. chamber .) oVo 10-2 (1) INTAKEMANIFOLDASSY Remove& install intake manifold ASSY lntakemanifoidASSY Fi \-.4 a Replaceafter everv disassemble Additionalwork required: . Remove& installconnectorASSY . ECCSharnessconnector,all hoses E N- 1 ' 1 7 ON-VEHICLEPARTS R B 2 O D /ED E TE N G I N E [Point1] Remove& installintakemanifoldASSYbolts and nuts Removal 'io I 6 . Removethe boltsand nutsin the reverseorderof thefigure on right. lnstallation . lnstallthe boltsand nuts in the ordershownin thefigureon rioht. B 7 13 14 4 2 3 5 (2) Intake manifold ASSY disassembly& assembly pl eott1r;gnt a t"t t I t.o- injector lPornt,, ?_ p) aonrZtO.6a' O.SA Air regutator ,-- 1, Fuel tube InjectorASSY p prpenSSY Water-outlet lntake manifold a Liquidgasket Fi \",i K g - m Additionalwork required: . Remove& installintakemanifoldASSY [Point1] Fueltube ASSY . Replacethe O-ringto new oneswhen removingand installingthe pressureregulatorandthe fueldamper. Caution: Caremustbe takennotto scratchor damagethe fueltube the pressureregulator' O-ringareawheninstalling [Point 2] O-ring (for fuel injector pressure regulator) Precautionswhen handling . NeverreuseO-rings. but . Coatthe O-ringwithengineoil (7.5W-30or equivalent), do notapplysolventas this may removethe oil coating. . AvoidusingdirtyO-ringsanddo notallowdirt,dustor foreignobjectsto adhereto O-ringsor otherequipment. . Caremustbe takennotto scratch,twistor stretchthemby toolsor operator'sfingernailswheninstallingO-rings . Do notdecenteror rotatethefuelinjectorsandthe pressure regulatorwheninsertingthemintothefueltube EN-118 Bolt(6) 1 Bolt(2) 0.4 - 1 11 2 ON.VEHICLE PARTS R 8 2 ,D 1 ]E D E TE N G I N E 1O-3 REMOVE& INSTALLEXHAUSTMANIFOLDASSY Exhaustmanifoldgasket Exhaustmanifold Bolt(3)0.a- 0.5I p YokeIPoint3] ')@ washer potnt ti | ) Nut2.8 3.2IPoint2, 3l B o r t (07. i4 - o 5 I Fi \",1xg-m $ Reptaceafter every drsassemble Additional work required: . Undercover . Disassemble exhaustfronttube . Exhaustsensorconnector . Gasleakinspection [Point1] RB20DETonly . Intercoolerairinlettubehose . Turbocharger [Point1] Gas leakinspection . Afterremovingthe exhaustmanifold,makesurethereare no tracesof gas leaksfrom any parts. . Afterthe installation, crankthe engineand checkfor any gas leaks. [Point2] Removeand installexhaustmanifoldnuts Removal . Removalis the reverseof installation seouenceshownin thediagramon right. Installation . The installation sequenceis shownin the diagramon right. E N- 1 1 9 PARTS ON.VEHICLE R B 2 O D /ED E TE N G I N E [Point 3] Yoke . Makesure notto makemistakebetweenNo. 3 and No.4 is different. yoke as configuration c 0.5 P (mm) 22 24 [Point4] Installwasher . Makesurethe washeris facingcorrectway when installing. Manifoldside 1O-4 REMOVE& INSTALLSPARK PLUG Ornamentbolt(B)0.30- 0.39 F i \ l'/ narness Ornament \,- Groundcable Bolt 1.0 - '1.2 lPo]nt1l - 3.0 Sparkplus 2 . o fPoint3l ri \".4 .-'--'/ Washer \ L- ,/ c o i lb r a c k e t lgnition ,,-'1 lPoint2] \ ./'/-/. l9l *n-' Additional work required: . Air duct(RB20DE), Air inletpipe(RB20DET) . Blowbyhose . Powertransistor [Point1] Remove& installignitioncoil bracketbolt . Lengthof the bracketboltbetweenRB2ODE and RB2ODET are different. 22 25 E N- 1 2 0 ON.VEHICLEPARTS R B 2 O D /ED E TE N G I N E Installignitioncoil bracket [Point2] B o l t' 1 . 0. The ignitioncoilbracketthicknessdiffersbetweenRB2ODE and RB20DETvehicles. . Wheninstalling ignitioncoilbracketto cylinderhead,check ground that lineis connectedsecurely. '1.2 [Point3] Sparkplugmaintenance . TheGapinspection andadjustment is notnecessary as plat,num tipis used. . Change thesparkplugevery100,000 km. . Whenusingcompressed airsparkplugcleaner, cleanthe plugsat maximum pressure of 6 kg/cm2for nomorethan 20seconds. . Donotusewirebrushto cleanplugs. 10-5 REMOVE & INSTALL ROCKER COVER 9Ornamentbolt(B)0.30 0.39 F i l l e rc a p Lockercoverbolt0.2 - 0.4 [Point'1] € e - -- ^ Grommet Lockercovergasket Orname'nt I Lockercovergasket Fi l".i xs-m Additionalwork required: . Air duct(RB20DE), Air inlet(RB20DET) . Blowbyhose [Point 1] Remove& install rocker cover screws Removal . Performremovalin reverseorderof seouenceshownin the figureon right. Installation . Performinstallation in sequenceshownin thefigureon rloht. EN- 121 .-4, PARTS ON-VEHICLE R B 2 O D /ED E TE N G I N E 10-6 REMOVE& INSTALLTIMINGBELT Timingbelt cover(upper)[Pornt4] Trmrng b e l t[ P o i n 9t , 1 0 , 1 2 ] "-",ffi..' r,,'"' i,r j"t# -- WW'il. W ^, *?tgO,S'Po;**,)H P" r\ n,r,'*i.lvS::"fu g* @aS1 pl pol(31 o.o.t. ] ?ol'_,0,-9 washer """"";'.fffi\, ,.."/b'\])D conicar Betttensroner 9. '10.111 [Pornt 609\ I - -^6)-... llil'3E w{ - \- wasner\' t"*t'iilln'flil3#:?lF:ill3] SJ"P,; Bolt44-59 ldlerpullevlPoint'111 "iE"-t, 4] bertcover(rower) t, [Point o\",.]#in q"fl,:-';,,..""1,","iixilJ,',os-oaap) 91,n., Jl Ensn" oi $ aftereverydisassemblY Reptace Additional work required: . Undercpver . Drainand refillcoolingwater . Radiator, fan shroud . Coolingfan . Supplemental belts . WaterpumpPulleY . Sparkplug . No. 1 cylindercompression T.D.Cposition[Point1] . Installringgearstopper[Point2] No. 1 cylinderpressureT.D.C(top deadenter)inspection [Point1] . Alignthe crankpulleytimingmarkandthe beltcover At thistime,the No. 1 (0"position). timingindicator T.D.Cpositionwhenthe cylinderis in the compression camshaftis locatedas describedin the following situations. top deadcentre No. 1 cylinderis at the compression whenboththe intakeandthe exhaustsidecamsdo not movethevalvelifters. EN - 122 ON-VEHICLEPARTS R B 2 O D iED E TE N G I N E . Removethe lockercoveroilfillercap fromintakeside and checkthatthefrontendof the camshaftfaces intakeside. Installcrank anglesensor [Point2] . Applychassisgreaseto the driveunit(spline)during installation. . Thereis a flangeinsidethedriveunitsplineso thespline hasonlyone insertionposition.Checkthe alignment visuallybeforeassembly. . Checkthatthe crankanglesensorcan be easilyinserted rnbeltcoverholesand sensormoveslightlyto rightand left,thentightenthe bolts. . Whenthe sensordoesn'tmovelightly,loosenbeltcover boltsto position whenthecrankanglesensorwasinserted. Movethe beltcoverlightlyhorizontally andverticallyto align it so the beltcoverholesand the camshaftcentreare aligned.Thentightenthe boltsso the crankanglesensor moveslightly. l l rn 4 1 n [Point3] Remove& installcrankpulleyandthe bolt . Remove thestartermotorandattachtheringgear stopper. K V ' 1 0015 6 1 0 . Usea pulleypuller(steering wheelpuller) toremovecrank pulley(boltsize: M6x 1.0lengthbelowheadapprox. 50mm) Remove& install timing belt cover lPoint 4] . The timingbeltcoveris separatedintoupperand lower parts.Aftercrankanglesensoris removed,removethe timingbeltcoverin the orderof upperandthen lower. . Installation is in reversesequenceof removalprocedures. Caution: Caremustbe takennot to scratchor damagethe dried liquidpackingwhenremovingandinstalling thetimingbelt cover. EN- 123 PARTS ON-VEHICLE R B 2 O D /ED E TE N G I N E Remove& installbelt tensionernuts [Point5] . Securethetensionerwithhexagonal wrenchwhen the belttensioner. removingand installing Caution: Do not looseninsertedstudwhendisassembly. n-<'( /'.) Hexagonal wrencn Installconicalwasher [Point6] . Payattentionto the installation directionof the conical be setwithfacethe should washer washers.The chamferedsidefacingthetensionerpulleyside. Installtensionerspring [Point7] . Assemblethetesionerspringto the belttensionerpulley as shownin thefigure. . Thetensionerspringmustbe assembled togetherwiththe belttensionerpulleyin thecylinderblock. ; iqipipnr,,.o |, . Hookthetensioner springontheuppersideof thetensioner springstudwhenthetensionerpulleyis free. \,. "r \ /4 a Tensioner spflng Tensionerspring sPecifications 1.8 Approx.20" Approx.163" Yellow [Point8] lnstallcranktiming pulley& plate when . Caremustbe takenof the rearandfrontpositioning installingtimingbeltplate,the cranktimingpulleyand the timingpulleyplate. EN - 124 ON-VEHICLEPARTS i:. ]: fEi ENGINE Timing bettalignmentmarkverificationand installation [Point9] . Painta markon thebeltthatindicates rotation direction if painton theupperbeltis unclearwhendisassembly. Position thealignment markson theintakeandthe exhaustcam pulleyswiththe respective beltcover alignment marks.(No.'l cylinder is at T.D.C) Positionthealignment markon thecranktimingpulleywith the respective oil pumphousingalignmentmarks.At this timethe groovemustbe straightup (no. 1 cylinderis at rD.c). Movethe belttensionerclockwise70 - 80 degreeangle, andsecureit temporarily withthe belttensionernut. I . lnstallthe beltby aligningthetimingbeltandthe pulley marks.Alignthe numberof ridgesof exhaustcam pulley alignment markandthecrankpulley(inner)alignment mark as shownin thefigureon right. . Afterlooseningthe nutsandadjustingthe belttension, securethetensionerwiththe hexagonal wrenchso it will notrotatetogetherandtightenthe nut. Caution: (1) Makesurethetimingbeltengagescorrecflywiththe pulleyanddoesnotflatwhenassembling the timingbelt. (2) Replacebeltswheneverpossiblewhendisassembly is performed. [Point10] Timing belt tensionadjustment . Removethesparkplugandalignthetimingbeltalignment markandthepulleymarksandinstalltimingbelton to each pulley. . Loosenthe tensionersecuringnutso the belttensionis appliedby thetensioner spring. . In thiscondition,rotatethe crankpulleyclockwisemore thantwoturnsto checkthe beltmovementandstopslowly at No. 1 cylindercompression T.D.Cpoint. . Insertthehexagonal wrenchin hexagonal hole. Holdthe tensionerby handso the tensionerdoesnot move,and tightenthetensionersecuringnutto specifiedtightening toroue. Tighteningtorque (kg-m): 4.4- 5.9 . The initialtensionon the beltin thisconditionshouldbe approximately 20 kg. EN- 125 Cranklrmrng ON-VEHICLEPARTS R B 2 O D /ED E TE N G l N E [Point11] Installidler & tensionerpulley . Do notlooseninsertedstudswhendisassembly.lf studsareloosened,coatinsertedstud withlocktitesolution(JapanLocktiteKK)or equivalent. [Point12] Timing belt insPection . Replacetimingbeltif any problemsare indicatedat the inspection Cause Toothmissing Cracked tooth Camshaft lock Crank sensorlock <? Tensionerlock E ngine overheat lnterferencewith belt cover etc. Cracks on rear side Belt misalignment Belt plate malfunction Wear and cracks on the side Worn teeth Slidingmotionresistancein crank sensor and the camshaft Oil or water adheston Oil seal malfunction Water leaks in water PumP Caution: Donottwistor bendthetimingbelt. Makesurethereis nooilfilmor wateronthebelt 10.6 REMOVE& INSTALLWATERPUMP plaott1ryo.64-085 ,t \')/ lt t\ Botr(2)3.2- 4 19 ns-' ti E {s' v Additionalwork requ ired: . Drainand refillcoolingwater . Timingbeltcover WaterpumplPoint1, 2] ffih,u-,, E N- 1 2 6 ON-VEHICLE PARTS R B 2 O D /ED E TE N G I N E Remove& installwater pump [Point1] Remove . Caremustbe takennotto get coolanton the timingbelt. Wipeit off immediately if anywaterdoesspill. . Removethewaterpumpboltsin the reverseordershown. Installation . Installthe blotsin the numberedseouenceshown. . Wipeoffoil liquidgasketfromthe cylinderblockandon the waterpumpandwipethe surfacewithwhitegasoline. . Applycontinuous beadof liquidgasket(KP5'10 00'l50)to waterpumpsealingsurface. Caution: Be sureliquidgasketis 2.0to 3.0 mm wide. Installation mustbe carriedout within5 minutesafterliquid gasketapplication. Waterpump inspection [Point2] . Rotatethewaterpumpby handand checkfor abnormal soundandsmoothoperation. . Theremustbe no tracesof waterleaks. 10-7 REMOVE& INSTALLTHERMOSTAT Thermostat[Point2j ThermostathousinglPoint 1 a \ ff'\,, @ t o-z lPl p r-rquio nr"*"?o'ttt' Fi !',1 ks-m Additionalwork required: . Disconnect andconnectwaterinlethose. . Drainand refillcoolingwater Caution: Loosenenginedrainplugto removecoolingwaterfrom cylinderblock. EN- 127 Liquidgasket2.0 - 3.0 mm wide alongthe groove ON-VEHICLEPARTS R B 2 O D /ED E T E N G I N E Remove& installthermostathousing [Point1] Removal . lnsertthe screwdriver handleintothermostathousingand move it up anddownlightlyto removethe housing. fzo - 3.0 mm wldeto centerof flat lnstallation . Removeold liquidgasketon the thermostathousingand I matingsurfaceand innerseating the cylinderblockandwipeoffthe surfacewithwhite gasoline. . Cutnozzleendof liquidgasket(KP51000150)tube. . Applya continuousbeadof liquidgasketto sealingsurface usingthe tubepresser.Installthe housingwithin5 minutes aftercoatingliquidgasket. Installthermostat [Point2] . 'Top'mark(igglevalve)mustfaceup whenthermostatis insertedin housing. Thermostat insPection [Point 3] . Checkthevalveopeningtemperature and maximumvalve tift. . Hangthe thermostatby stringin valveand submergein andstirwaterwhile heatedwaterin doublewalledcontainer heatingit up. whenthevalve . Theopeningtemperature is thetemperature opensandthermostatfallsfromstring 76.5 '10l90 E N- 1 2 8 ON.VEHICLE PARTS R B 2 O D iED E TE N G I N E 1O-8REMOVE& INSTALLOIL PAN,OIL STRAINERAND OIL FILTER O-ring 6 Oil pan bolt (30) 0 . 5- 0 . 7 Oil strainerbolt ( 2 )1 . 6- 2 . 1 lvll Kg_m I Engineoil E Liquidgasket aflereverydrsassembry E Reolace Additionalworkrequired : . Frontstabilizer . Radiator fan,shroud . Right& leftenginegusset . Enginerearplate(lower)(A/Tvehicles) . Enoine oil Remove& installoilfilter [Point1] Removal . Useoil filterwrenchto removethe oilfilter. Installation . Beforeinstallingnewoilfilter,wipeoffdustetc.from cylinderblockmountingsurface.Applya thincoatof engineoilto oilfilterO-ring. . Screwoil filteron bracketby handuntila slightresistance isfelt,thentightenan additional 2/3turnwithoilfllterwrench. Aftertightening, startengineand checkfor oil leaks. [Point2] Remove Remove& installoil panbolts . Removethe boltsin reversesequenceof figureon right. Installation . Installthe boltsin sequenceshownin figureon right. E N- 1 2 9 1 9 1 5 1 71 3 1 5 9131721 ON-VEHICLEPARTS R B 2 O D /ED E TE N G I N E Remove & install oil Pan [Point 3] Removal . Usesealcutterto removethe oil pan. Caution: (1) Afterremovingthe oil pan,removeoil liquidgasketon theoilpanflangegrooveandtheoilblockusingthe scraper.Makesureto removeliquidgasketdropped insidetheoil Pan. Caremustbe takennotto damagethe oil pan Q\ . Removethe enginemountingnuts(oilpanside)and use the hoistcraneto movetheoil panforward.Takeoffthe oil strainerboltsusingthewrenchbeforeremovingtheoilpan. Caution: Caremustbe takennot to pullthe hosesand harnessestoo muchwhenliftingup the engineusingthe hoistcrane. lnstallation . Thefollowingproceduremustbe carriedoutwithin5 minutes: . Applyacontinuous 00150) beadof liquidgasket(KPS10 to sealingsurfaceusinga tube presser' . Installthe oil panwithin5 minutesaftercoating. Oil leakand oil pressureinspection [Point4] . Startthe engineandcheckforanyoilleakandtheoil Dressure.To checkthe oil pressurereleasethe oil oressureswitchand usethe oil pressuregauge. Installoil strainer [Point 5] . Checkto makesurethe O-ringis installedproperlybefore the oil strainer. installing Tighteningtorque (kg-m): 1.6- 2.1 E N- 1 3 0 . ' , , , , i ' Tubepresser(WS3993) Liquidgasket ON.VEHICLE PARTS R S 2 O D EE T N GN E 10-9REMOVE& TNSTALL TNTERCOOLER (RB2oDET) "'i5=;"*3h"Sj"=@jluri""" Turbocharger *;;"_O M_@4p :::="" .*- . il"*';b,mffi3Tff;:: -'ry4e"';ol ll-, .o""' u" "^^,66; *XgF/H Arrrose \=/ g. cramp-g i";:'iF Airn^<a Inter-cooler bracket Inter-coolef ri. \",1Kg-m Additionalwork required: . Leftfrontfenderprotector . Fenderstay . BonnetlPoint1l Remove& installbonnet [Point1] . Removeleftsidebonnetboltsonly(Liftup leftsideof the bonnetto operate). Remove& installintercooler [Point2] . Removethefenderprotectorthenremovecoolerboltsto removeinter-cooler. Takecarenot to damagethefins. Caution: The finsare aluminium and can be damagedeasily.Never placeanythingon the intercooleror allowtoolsor otherharo objectsto contactthefins. Themainunit(tank,fins,tube)cannotbedisassembled. EN - 131 ff"ct ^ in'"'-"nn'"' s;il'-l 7 ON-VEHICLEPARTS R B 2 O D EE TNGINE Remove& InstallturbochargerASSY (lncludefault diagnosis) 10-10 (1) Removal& installation )) P5 ;::"\T'a'"^'''"'ffi"fl. # {,*"gEK#"O: .<=t4\ l$ -;; leo";'o ,**"I,T::[Q'*-'' 1--#r\ B"!t!TUq \\.,1,,* 1",/ Kg-m $ Reptaceafter every disassemblY Additionalwork required: . Undercover . Assemble fronttube exhaust & disassemble . O^sensorconnector . lniercooler airinlettubes,hoses . Airinletoipe Removewateroutlettube [Point1] theclamp . Remove thewateroutlettubebyfirstremoving block. the cylinder locatedontherearsideof Inspection . Aftercleaningwaterinletandoutlettubewith radiator cleaner.blowwithcompressedair and checkfor rustor clogging. EN - 132 Water outlet tube ON-VEHICLEPARTS R B 2 O D EE TNGINE Removeoil feed tube [Point 2] . Removetheoilfeedtubebyfirstremoving thecylinderblock andturbocharger eyebolts. Inspection . Aftercleaning oilfeedtubewithengineconditioner, blow withcompressed airandcheckforclogging. ....' :- Removeoil returnpipe [Point3] . Removethe oil returnpipeby firstremovingthe oil pan clampandthe turbocharger bolts. Remove& install lock plate [Point 4] Removal . Spreadthe lockplatepawlswitha screwdriver and loosen thenuts. Installation . Positionthe lockplatesandturbocharger mountingnuts. Aftertighteningthe nuts,bendlockplatepawlsontothe nuts. Eyeboltdetermination [Point 5] . Oilfeed(cylinder blocksideandturbocharger side)eyebolts arestamped"G", Installationorder 1. Turbocharger mainunit 2. Waterfeedtube 3. Oil feedtube 4. Wateroutlettube 5. Oil returnpipe EN- 133 €Fl PARTS ON-VEHICLE R B 2 O D EE TNGINE (2\ Turbochargerunit insPection Actuator[Point7] Excessivepressureleak Exhaustgas leak tnspectionlocation valve[Point3] CrackinspectionTurbinewheel lPoin1 t ,2 , 4 l Crack lnspection Compressorwheel [Point5] Coolingwater Rotorshaft[Pornt6, B] [PointB] i- Rotor shaft insPection [Point1] . Theremustbe no heaviness or draggingandtheshaftmust turnsmoothlywhenrotorshaftis turnedby finger. Turbinewheelinspection [Point2] . Oilmustnotadhereto surfaces. . Theremustbenocarbonaccumulation. . Thevanesoftheturbinerotormustnotbebent. . Theremustbenointerference withturbinehousing. Swing valve insPection [Point3] . Removeactuatorrod pinand makesurethe swingvalve or cracks movessmoothlywithoutdeformation . Makesurethereare no misalignedseatingsurfacesin turbinehousing. Rotor shaft play inspection [Point4] . Position thedialgaugeandmeasureplayandthrust clearance. 0 . 0 8 4- 0 . 1 0 7 Rotorshaftplay(mm): (mm): 0.045- 0.140 Thrustclearance E N- 1 3 4 ) Oil leak inspectionlocation ON-VEHICLEPARTS R B 2 O D EE TNGINE Compressorwheel inspection [Point5] . Oil mustnotadhereto suctioninlet. . Theremustbe no interference withcompressor housing. . Wheelmustnotbe bent,foldedor otherwisedamaqed. 'qf;:l,Tiltrl '- d^"1,"9"a. Rotorshaftinspection [Point6] . Theremustbenocarbonsledoeaccumulation. Swing valve controller inspection [Point 7] . Removethe swingvalvecontrollerrubberhoseon the compressorhousingside . Checktheswingvalvecontroller whenevertheactuatorrod is installedor removed. . Usetheairgunto blowcompressed airapprox.0.8- 0.9 kg/cm2intohoseand makesurethe swingvalvecontroller rodoperates.Stopblowingair as soonas the rod operates. Caution: Makesureto verifythe airgun pressureusingthe LPG pressuregaugebeforetestingthe air hose. lf air pressureis appliedexcessively the diaphragmmay be damaged. [Point8] Oilandcoolingwaterinletandoutlet cleaning . Useengineconditioner to cleantheoilfeedandreturn passages. . Useradiator cleaner to cleancoolinq waterfeedandreturn passages. . Cleanusingtheairgun. . Cleanthe compressor wheel,turbinewheel,compressor housingandturbinehousingwithsamemethods. EN- 135 Operatessmoothly PARTS ON-VEHICLE R B 2 O D EE TNGINE (3) Turbochargerfailurediagnosis(Oil leaks,smoke(whiteor blue smoke),lack abnormalnoise) of power,poor acceleration, Pointsto be checkedbeforediagnosis: levelmustbe betweentheMINandtheMAXmarkson theolllevelgauge. 1. Theengineoil (whentheengineoillevelis higherthanMAXline,theengineoilwillflowintotheintake may be passandtheturbocharger ductthroughthe blowbygas recirculation to be malfunctioning). determined 2. Checkwithcustomerto determineif oil is cooledwhen idlingafierdriving' replacethe in thefollowingchartis detectedin a unitinspection, lf any malfunction ASSY turbocharoer 1,. , , Smoke A A A Or Suctioninlet is dirty with oil o C Rotor scrapes agairEt the hosing l\ Oil on rotors Carbonhas accumulated Turbinerotor Rotor scrapesagainstthe housarE rAbnofmal noas€ A a C Turbrmevanesare bent or folded Compressorwheel C @ Turbinevanes are bent or folded There is resistanceor scraping when rotatedby finger Turbineand compresor Rotor shat play arsPection Carbonsludgehas accumulated Look throwh oil lrole (inspectinteriorwith Pen light) in waste oil hole O Highlypossible C C o A Rotationby finger is not Possible Cor6iderable shaking between rotor shaft and turbo ASSY Swing valveoperation (usearr 9unor alr pump) .A Ti€ valvedoes rnt mo\€ smoothlywhen pressureis applied gradually.(t6uallyoPens at pressuregreaterthan 0.6 - 0.7 kg/cm') Possible l\ Slightlypossible E N- 1 3 6 z__.\ ll A ^1_\ ll @ ON.VEHICLE PARTS C A l B ]E N G I N E 10,1 INTAKEMANIFOLDASSY (1) Remove& instalintakemanifoldASSY T, - tn,ou,"Oody bort(4)t.e- z.zp) G a s k e$t RTC heater lPoint4l Breather hose IntakemanifoldASSYIPoint -( '|l # gasketE \-,1 kg-m $ Reptace after every disassembly Additionalwork required: . Releasefuelpressurein thefuellines . Drainand refillcoolingwater . Air cleanerASSY . Fuelhose . Waterhose . Intakesidehigh{ensioncable . Vacuumhosesand ECCSharnessconnectors . Acceleration wireIPoint1] . Watertemperature sensorconnector . Thermaltransmitter connector Accelerationwire adjustment [Point 1] . Loosenlocknutto provideadequateslackfor the accelerator wireand pulloutercasein the directionof the accelerator.Returnthe locknut 1.0- 1.5turnsfromthe positionthe throttledrumstartsmoving(whenthereis no playin cable)andtighten. Tighteningtorque (kg-m): 0.8- 1.0 Remove& installintakemanifold [Point2] . Removalis the reverseof installation sequenceshownin thefigureon the right. . The installation sequenceis shownin thefigure. Note: Neverreusethe gasket. E N- 1 3 7 PARTS ON-VEHICLE CA18E i NGINE Intakemanifoldinspection [Point3] . Measurethe intakemanifoldsurfacefor distortions in four and horizontally (atoppositedirections; separatedirections in a numberof locations. vertically) 0.15 Limit value(mm): Straight PTCheaterinsPection [Point4] . Makesurethereis nocrackonthePTCheater. & assemblethrottlebodyASSY (2) Disassemble coverscrew Fueliniector {2)0 20 .- 0 26I \g 'ut'rntector cover , $o-ring =----dG -€t cl,el lnjector,0j,", ,, _ € e $o-nng-.....-" 'egulator Pressure lPo,nt4l ^' ,.- -V,a \|g-- uT .*?" ':"t, [l i fl I Btackel - Sc'ew{4]OO+- OSSp) rh,ort," ouuy^-_ -__ uppe. / s"u' ^, eoin, J1 ^,V&d*o. ^7*ir9"" o,o- o,u 7] Thermowax lPornt I hrottleadtustscrew=\E yrpo inter_.,. ointgt \ --@ thro.ebod Lower ffi,u S/ Screw0 20 - 0 26p .or-n g (2)p screw Bracket E1^.<-1 =,"ref\rilff}:!,,3"il: -,, -6f"\ olo Fuel injectorharness ri k g - m \-/ a ReplaceaftereverydisassernblY E N- 1 3 8 ON-VEHICLEPARTS .A'3 ENGNE Remove& install throttle body ASSY . Firstremovefour throttlebody boltsto removethrot e body ASSY . Afterthe installation checkthe tighteningtorque. 't.8- 2.2 Bolt tighteningtorque (kg-m): . Alwaysreplacegasketwith newones. [Point1] Removeupperthrottle body . Firstremovethe fuelinjectorcoverthenseparatethefuei injectorconnector. . Loosenfour upperthrottlebodyscrewsto remove. [Point2] Fuelinjector Removal . Firstremovethe injectorcoverto removeupperO-ring, thenextractfuel injector. . Caremustbe takennotto scratchor damagethe fuel injectorand throttlebodysealsurface. Cautionswhen handlingO-ring . NeverreuseO-rings. . CoattheO-ringwithengineoil (7.5W - 30 or equivalent) butdo notapplysolventto themas thismay removethe oil coatrng. . Do not allowdirt,dustor foreignobjectsto adhereto O-ringsor otherequipmentsurfaces. . Caremustbe takennotto scratch,twistor stretchO-rings wheninstalling. Do notinsertit in thefueltubeby makingit stretchslightly. . Do notstoreO-ringsin locationsubjectto ozone,high temperature or in directsunlight. Installation Replacebothupperand lowerO-ringsto newones. Coatthe lowerO-ringwithengineoil and installto throttle body. Placethefuel injectorinsidethe throttlebodyand set the injectorpositionby placingthe injectorconnectorand the injectorcover. Useoil sealdriftto insertthe fuel iniector(resistance must be felt). Coatthe upperO-ringwithengineoil. Useoilsealdriftto inserttheO-ring. E N- 1 3 9 /--\. l: '..-r'\ Conneclor:rJ rubber \9 -lniectorcover \^ Injector wrflng connector F u e lI n i e c t o r PARTS ON-VEHICLE C A ' 1 8Ei N G I N E Cam ASSY [Point3] Removal . RemovethecamASSYfromthe upperthrottlebody. Caution: Extracare must be taken as there are tensionon the cam spring. Inspection . Lookfor anydeformationor wearon the cam spring. 24.5- 26.5 Cap spring free length(mm): lnstallation . Makesureto installthe cam ASSYand the cam springin rightdirection. . Reolacetheseatwithnewones. Free length I Pressurereguator Pressureregulator [Point4] Removal . Removethepressure fromtheupperthrottlebody' regulator . Carryoutthefuelpressure inspection. IPoint5] Removal Throttledrum& A / T controldrum . Firstremovethe nutsandremovethe A / T controldrum. . Removethrottleadjustscrewand returnspringand remove thethrottledrumfromthe lowerthrottlebody. Inspection . Inspectvisually if thereareanywarn,cracksordeformation on springretainer,retainer,and colour.Also inspect rotationcontactsurface. . Checkdeformation andwarnon thethrottleadjustment return spring. screwand 19.5- 21.5 Returnspring free length(mm): lnstallation . Caremustbe takento installthe partsin correctdirection the armASSY returnspring,throttledrum wheninstalling andA,/Tcontroldrum. E N- 1 4 0 Springretarner (plastrc) f< (plastic) /,Retainer Color(plastic \0.J \ ON-VEHICLEPARTS C A l 8 iE N G I N E Remove dashpot [Point 6] . Firstremovethe dashpotbracketto removethe dashpot. Inspection . Checkvisuallyfor anydeformation or crackson the rubber oan. Removethermoswax [Point7] . Firstremovethethrottle wirebracket to removethermo wax. Inspection . Checkifthepinwillextendwhenthethermowaxis warmeo. Caution: Donotpulloutthepin. [Point8] FIGDsolenoid& ldle revolutionadjustment solenoid Removal . RemoveFIDCsolenoidand idleuo solenoidfromlower throttlebody. Caution: Watchoutfor springandthe valveas it mayjumpout. Inspection . Checkthatno warnorforeignmatteradheresto valvehead. . Checkthe springfor deformation or warn. '11- 12 Spring free length (mm): lnstallation . Checktheorientation of thevalvewheninstallino. Lower throttle body inspection [Point 9] . Checkfor any cloggingin the air passageby carryingout air blowinspection. . Checkfor any crackson lowerthrottlebody. EN- 141 Thermowax PARTS ON-VEHICLE C A l 8 iE N G I N E 10-2 EXHAUSTMANIFOLDASSY Exhaustmanifoldqasket - ,f4f;^ -rw--4; ddl V/,^-,T Washer t: l,aa "* if::'liHllli 'u' fru R. o, gl f o,r" "-(.,:-'r.,lpoint ExhaustmanifoldlPoint2] Heat shieldPlate ri. l-/ Kq-m $ Replaceafter everydisassembly Additionalwork required: . Undercover . Exhaust fronttubenuts . O,sensorconnector . Exhaust sensor temperature . Hotairduct Remove& installexhaustmanifold [Point1] Removal . Removalis the reverseof installation sequenceshownin thefigure. lnstallation . The installation sequenceis shownin the figureon right. . Checkthe standardtighteningtorqueafterinstallation. Exhaustmanifoldinspection [Point2] in four . Measuretheexhaustmanifoldsurfacefor distortions and separatedirections(oppositedirections:horizontally in a numberof locations). vertically) Remove& install O, sensor [Point 3] (Zirconium typesinglepoleconnector) . Do not usetoolswithimpactsuchas impactwrenchfor of the O, sensor. removaland installation E N- 1 4 2 Straightgauge ON-VEHICLEPARTS CA18E ] NGINE 10-3 LOCKERCOVER rlOSC LOCKeT COVerSCreW 0.1- 0.3lPoinr1] 3---'(8) Grommet 6 -_ Oil Rttercap \ \.4* fl.-r."y \=2 Fi l".l ks-m Additionalwork required: . High{ension cable . AircleanerASSY Remove& installlockercover [Point1] Removal . Removalisthe reverseorderof installation seouenceshown in thefigureon right. Installation . The installation sequenceis shownin thefigureon right. . Whenremovingandinstalling the lockercover,alsoremove the covergasketand wipeoff the oil adhereon the gasket and in the oroove. Locker cover gasket [Point 2] . Makesurethe rockercovergasketis positionedsecurely in groovewithouttwisting. EN - 143 ON-VEHICLEPARTS C A 1 8E i NGINE 10-4 TIMINGBELT(CRANKPULLEYBELTCOVER) ( 1 ) Remove& installtiming belt cover uppercover ac!.+---:=-=+--.- \r2,_l-_= Lower cove(- B o l t( 4 ) 1 . 2- 1 . 6 I ts-t I Engineoil E Crankpulleybolt12.5 13.slPoint2]Pl Additionalwork required: . Undercover . Fanshroud . Supplement belts . SparkPlug . No. 1 cylinder T.D.Cposition compression [Point1] . Installringgearstopper[Point2] D.T.C No.1 cylindercompression inspection . Alignthecrankpulleymarkandthebeltcovertiming T.D.C. to compression indicator [Point1] . No. 1 cylinderis at compressionstroketop deadcenter whenboththe intakeandexhaustsidecamsdo not move thevalvelifters. E N- 1 4 4 ON-VEHICLEPARTS C A IB i E N G I N E Remove& installcrank pulleybolts [Point2] . Removestartermotorand attachringgearstopper. Caution: Coatthe screwpartwithengineoilwhentighteningthe crank pulleybolt. Do not applyany oil on the damperareawhen installing or removingthecrankpulley. Removecrankpulley [Point3] . Loosen thecrankpulleyboltsandusepulleypuller (steering wheelpullerST27180001) to removethecrank pulley. Caution: Donothookthepulleypulleronthecrankpulleygroove. Remove& instatl belt cover [Point 4] . Do notscratchpackingwhenremovingand installing the beltcover. . Alwaystightenthe beltcoverboltusingthe rubberwasher Installcrank pulleyplate [Point5] . Makesurethe crankpulleyplateis positionedin correct wav. (21 Remove& installtiming belt Timingbelt alignmentmarkverificationand installation . lf painton upperbeltis unclearwhendisassembly is performed,painta markon beltthat indicatesrotation direction. . Positionthe alignmentmarkof the cam pulleyswith respective timingbeltcoveralignmentmarks. (No.1 cylinder at T.D.C) . Installthe timingbeltso the numberof ridgesfromthe alignmentmarkto crankpulley(inner)alignmentmarkwill be as indicatedbelow. cA18i 43 95 EN - 145 Crankpulleyside ON-VEHICLEPARTS CA18E r NGINE Timing belt tensionadjustment . Removesparkplugandtightentensionerbolt(1 & 2) temporarily. . Hookthe tensionerspring(3) on the lowerbolt(2). . Hookthe springon the hook(4) andtightenthe bolt(1). . Loosenthetensioner(5)andtightenthe bolt(2). Caution: Makesurethe springis positionedcorrectlyat this stage . Checkif thetensioner(5)willrotatewhenpushedby finger. . Alignthetimingbeltalignment markandthepulley alignmentmarkto installthetimingbelt. . Loosenthetensionerbolt(2). . Turnthe campulleymorethantvvoturnsclockwiseto check beltmovementand stopslowlyat No. 1 cylinder T.D.CPoint. compression . Tighten bolts(1& 2). tensioner torque(kg-m): Tightening 1 . 5- 2 . O (3) Timingbelt insPection Replacetimingbeltif inspectionindicatesany problem. Toothmissing Cracked tooth @ Camshaft lock Crank sensor lock Tensionerlock Engine overheat Interferencewith belt cover etc. Cracks on rear sloe Wear and cracks on the side .J\> Beltmisalignment Beltplatemalfunction /.Mhx Worn teeth t*tlt'x / A'/.4i // ///// //l '=w!l jJlfuu/ Slidingmotionresistancein crank sensor and the camshaft Oil seal malfunction Waterleaksin waterpump Oilor water adhesion Caution: (1) Makesurethetimingbeltis nottwistedor bentsharply. Makesurethereis no oil film or wateron the belt. (2) Timingbeltneedto be replacedevery100,000km E N- 1 4 6 ON-VEHICLE PARTS C A ' 3 E N GN E 10.5 WATERPUMP Waterpump[Point| 2] ,",(3),u_$\ ffiP Springwasher \ gf.o<-spr.ins =\ '/:,j$t *asne, \ -Bolt(2) 16-20 E is-r p Repiace aftereverydisassembly Additionalworkrequired: . Drainandrefillcoolingwater . Fanshroud . Fan . Waterpumppulley . Supplementary belts . limingbeltcover Removewaterpump [Point1] . Becarefulnotto getcoolant ontimingbelt.lf anywaterdoes spill,wipeifoffimmediately. Caution: Remove oldgasketonthewaterpumpsurfaceusingthescraper. Waterpumpinspection [Point2] . Rotatewaterpumpbyhandandcheckforanyabnormal soundandsmoothoperation. . Theremustbenotracesofwaterleaks. E N- 1 4 7 PARTS ON-VEHICLE C A IB i E N G I N E 10-6 THERMOSTAT ThermostatlPoint2l Gasket houstr Thermostat 1 l lPoint t ds\ -\-"\'t \ ----rll./ ---Ll 7r, \",4 Kg-m dl- B o l t( 3 )1 . 6 ' 2 . 1 $ Replaceaftereverydisassembly Additionalwork required: . Drainand refillcoolingwater . Wateroutlethose Remove& installthermostathousing [Point1l Removal . lnsertscrewdriverhandleintothermostathousing Prylightly up and downand removehouslng. lnstallation . Placethejigglevalveon topwheninstalling thethermostat housing. Caution: Removeold gasket on the water outlet surfaceusing the scraDer. Thermostat inspection [Point 2] . Checkthe valveopeningtemperature and maximumvalve tift. . Hangthethermostatby stringin valveand submergein andstirwaterwhile heatedwaterin doublewalledcontainer heatingit up. . The openingtemperatureis thetemperaturewhenthe valve opensandthermostatfallsfromstring. 82 88 OverI / 95 Over7 / 100 E N. 1 4 8 String Double-wall container Thermostat ON-VEHICLE PARTS ]A'! E\G NE 10.7 otL PAN& OtLFILTER (1) Remove& installoil p a n Oilstrarner nut oz-oaPl=---...-. . $ oil strainel-q, gasket 9i,1;1'Ii'6b\e Eoil sealgasket El(front)\int4l \u" p$oit E +4eet'rt '\.)-erz-?) :1 seaoastet ,rt')Qffi \ " t r , l".l Kg-m p Liquidgasket Q Drainplug washer[Point4]$ pj H, ,''0,o u, - 0 85lPoint 4] Replaceafter every disassembly Additionalworkrequired: . Undercover . Engine oil . Right& leftenginegusset Drain plug washer [Point1] . Thedrainplugwasherhasinstallation direction, makesure to installin the correctdirection. . Alwaysreplacedrainplugwithnewoneswhenremoving andinstallino. Remove& installoil pan bolt [Point2] Removal . Removethe boltsin reverseseouenceshownin floure on right. Installation . Installboltsin sequenceshownin the figureon right. . Tightenboltsto correcttighteningtorque. Removeand installoil pan [Point3] Removal . R e m o v e t h e opi la nu s i n g t h e s e a l c u t t e r ( K V 1 1 01 0 0 ) Caution: Removeold liquidgasketon the blockpanflangegroove usrnga scraper. E N- 1 4 9 Oil pan side lr ON-VEHICLEPARTS CA18E i NGINE lnstallation . Applysealingagent(SS60For equivalent) on theareas pan gasket. shownin thefigureon rightto installoil :.-- . Applya continuous beadof liquidgasket(KP51000150) to sealingsurfaceusingthe tubepresserand installthe oil panwithin5 minutesaftercoating. . Inserttwo centerboltsto oil pan boltholes,makesureit is fittedcorrectlythentighten Caution: Leavefor 30 minutesafterthe installation. Oil leak& oil pressureinspection [Point4] . Warmuptheengineandcheckforanyoilleakingandthe oilpressure. . Release switchandinstalltheoilpressure theoilpressure inspection. outtheoilpressure gaugewhencarrying Whenidling 2000 4000 Approx.1 Approx.3 Approx.4 (21 Remove& installoilfilter Removal . Useoil filterwrenchto removethe oilfilter. lnstallation . Beforeinstallingthe oil filter,wipeoffdust,etc.fromoil cylinderblocksurface.Applya thincoatof engineoil to newoil filterO-ring. . Screwoil filterby handuntilit hitthe cylinderblock,then tightenan additional2 / 3 turnwithoil filterwrench.After tightening,startthe engineand checkfor oil leaks 't.5- 2.1 Tighteningtorque (kg-m): E N- 1 5 0 ON-VEHICLE PARTS R B 2 5 D EE N G I N E 10-1 AIR DUCT& AIR CLEANER I o.ts '," - o.ro.1zy "_ Airhose Airhose p rilo'"" UDe L,"\..t_ ,/ ^ ,/ Rubber \ I chambef\(@ p r . : - r . o 1 z- 1 ; 0 5 2 - 0 6 6 ( 4p)j '"f"' O - r i n gE ,,Y Air cleanefcase . . ' - Ho s e - Air cleanerelement Insutator ^ - ^ ^ ^ ^ F i r u^cz - uoo lv,/ r J r l " , l0 5 2 - 0 6 6 ( 4 ) 0 . 5 2- 0 . 6 6( 2 ) ! - -e/g v, - l Removal . Removethe negativeterminalfromthe battery. . Usean air gunto blowoff any dirtor dustbeforeremoving theairhoseandairduct. Removethe following: . 2 vacuumhosesfromthe resonator(betweenintake manifoldandcanister). Blowbyhosebetweenlockercoverand air duct. Air hosebetweenair ductandair requlator. . Removeairflowmeterconnector. E N- 1 5 1 Resonator bracket E '^'^^,)h n c,l - necfC|l { as2-o66pJ PARTS ON-VEHICLE R B 2 s D EE N G I N E Putalignmentmarkon eachair hosesandthe ductthen remove. Remove4 clipson air cleanercase(1 on uppercase3 on lowercase). Removeuppercaseto extractaircleanerelement. Removethe lowercaseby firstremoving4 bolts. Removethe resonatorby firstremovingthe leftfender protectorthenlooseningthe resonatorbolt. Removetheairductbyfirstremovingthefrontcombination lamoandthe leftheadlampASSY Caremustbe takennotto scratchor damagethe airflow metersensorwhenremovingthe airflowmeter' lnstallation out . lnstallation carried oftheairductandtheaircleaneris operation. in reverseorderof removal . Airflowmetercircuit useASSYwhen caseisnonseparable, meter. theairflow replacing . Makesureto inserttheairhoseandtheairductsecurely andtightenthe markcorrectly byaligningthealignment bandandtheclamP. E N- 1 5 2 ON-VEHICLE PARTS R B 2 5 D EE N G I N E 1O.2 INTAKEMANIFOLDGOLLECTOR (1) Remove& installintakemanifoldcollector coirector ASSY |2i'ftt:'rti:g -Y-V \ -,-aa CollectorgasketE -[] /l \ .'. pcoltectorboit(2)1.8- 2z.-*& l-,i r<9-m E Replaceafter every disassembly \ g ,/) Removal Releasethe fuel pressure . Warmuptheengine. . Select'Fuelpumprelay'in 'Activetest'mode. . Selectcancel'to releasethefuel pressure. . Crank2- 3 timesto consumethefuelleftin the piping. :movethefuelpurp frr". @ Aftertheengine stops, cranktheengine overtwoorthree timesto consumethefuelleftin the pipe. . lf the enginedoesnotstart,removethe pumpfuseand crank the enginethreeto fourtimesto consumethefuel leftin the pipe. Caution: The batterymay becomeweakeasily,use boostercablesto connectit to chargedbatteryif necessary. . . . . Removethe negativeterminalfromthe battery. Draincoolingwaterfromthe radiatordrainplug. Removeaccelerator wire. RemovetheMC valveconnector, FICDconnector andthe vehiclebodygroundcable Removethe hoseA betweenthe brakeboosterandthe collector. Removethe hoseB betweenIAAunitandthefueldamoer. Removethe hoseC betweencanisterandthe collector. Removethe hoseD betweencanisterandthe throttle chamber. EN- 153 ,, irlt , u- 22 \2)P) . B- 2 . 2 FUELPU[,4PRELAY OFF (POS) 950 rpm CAS.RPI\,| PARTS ON-VEHICLE R B 2 5 D EE N G I N E lockercoverandthe RemoveblowbyhoseE befuveen collector. RemovehoseF betweenpressureregulatorandthe collector. RemovethreewaterhosesG. Removethe hosebetweenair regulatorandthe collector. Liftup the collectorASSYwhenremovingthe hosefor easieroperation. RemovefuelfeedandretumhoseH,thenremovetheclamp fromthe collector. Loosenthe hoseclampto removecollectorASSY 11 J Loosenthe boltsin ordershownin thefigureon right. Checkto see everyhosesrequiredare removed. . Remove gasket. collector . Usea toolsuchasa scraper anyleftovergasket to remove onthesurface. r: lnstallation . Installthe collectorgasket. . Makesurethereis no dust,oil or otherforeignmatteris on the sealingsurface. . lnstallthe collector ASSY . Tightenthe boltsin the ordershownin thefigureon right Tightenin gradualstepsto uniformtightness. -1 "9- - 5 . Lengfi {mm}: No. of bolls "7 =3. - "1 - Y; -. -s. , . 105.2 't.8 - 2.2 65:1 1 . 8- 2 . 2 1,3,4,6 40.4 1.8-2.2 2 , 5 , 9 ,1 1 30:4 1.8-2.2 7,10 I ,2 - ' l. Connecteachwiringandthe pipingin the reverseorderof the removaloperation. wire, Connectthe accelerator wireand pull for the accelerator slack adequate Provide usingthe outercasein the directionof the accelerator from the position 1 .5 turns nut 1 .0 to lock Return adjustnut. thethrottledrumstartsmoving(whenthereis no play)and tiohten. 0 . 8- 1 . 0 Tighteningtorque (kg-m): E N- 1 5 4 l- ON-VEHICLE PARTS i 3 r 5 f : E N GN E . Makesuretheradiator drainplugis closedsecurely and NEVER refillthe coolingwaterfromthe feedopening. OPENWHEN . Releasetheairusingtheairreleaseplugafterrefilling the I F]OT ; a coolingwaterto preventoverheat. ... /2 ./ ) (\) Caution: Do notremovetheairreleaseplugwhentheengineis warm. Do notovertightenthe air releaseplugbolt. (21 Disassemble& assembleintakemanifoldcollector pjBort(2)0.64- o Accelerator wire bracket Bolt(4)0.e- 1.1\ l Collector AAC valve lAA unit 9ts't Water hose E Replaceafterevery drsassembly Disassembly . Removethrottlechamber . RemoveIAAunit Assembly . Installthrottlechambergasket lnstallin iorrectdirection . Tighten thethrottle chamber boltsrnordershowninfigure onrightuniformly intwostages. Tightening torque(kg-m): Firststage 0.9- 1.1 Secondstage1.8- 2.2 . Install lMunit. 4 ' + , 0 . '0. -r p E N- 1 5 5 ON-VEHICLEPARTS R B 2 s D EE N G N E FUEL INJECTOR 10-3 ne0-I Fi rol-z.rtz)H l".l k9-m Removal . RemovecollectorASSY Fordetailedremovalprocess referto Collector"section. . Removefuelinjectorconnectorandthe lamp. . Removethe connectorPin . The operationcan be carriedout easilyif the vehiclebody sensorconnectorandthe groundwires,watertemperature connectorare removed. thermaltransmitter . Removeair regulatorconnector. . RemovethefuelASSYby firstremovingthe bolts. . Replaceo-ringwithnewoneswhenremovingfuelinjector, pressureregulatorandfuelbumperfromthefueltube. . Do notpullthe connectorpartswhenremovingthefuel injector. Precautionswhen handlingO'ring . Coatthe O-ringwithengineoil (7.5W-30or equivalent) but do notapplysolventas this may removethe oil coating. . AvoidusingdirtyO-ringsand do not allowdirt,dustor foreignobjectsto adhereto O-ringsor otherequipment surfaces. . Caremustbe takennotto scratch,twistor stretchthemby wheninstallingO-rings. toolsor operator'sfingernails Inspection . Fuelinjectorresistance value(f,|): Approx.13 - 14 Resistance . Iniectorcan not be disassembled. E N- 1 5 6 ON-VEHICLEPARTS R B 2 5 D EE N G I N E Installation . Do not rotateor decenterthe partswheninstalling the fuel pressureregulator in1ector, andfuelbumperto thefueltube. . Tightenthe pressureregulatorandthefuelbumperscrews uniformlyin twoto threestages. Tighteningtorque(kg-m): 0.30- 0.39 . InstallfueltubeASSY Tighteningtorque (kg-m): 1 . 6- 2 . 1 . Connect theairregulator connector. . Install thefuelinjector connector andfixit inplaceusingthe . ctamD. Installthe collectorASSY 10-4 INTAKEMANIFOLD p_@=--- - o.asP aort 1z)o.o+ Airreguraror I El WateroulletpipeASSY B o l t( 6 ) 1 . 6- 2 1 Intakemanifold tt t',i p l e o it z o) n - o s i-,i kq-m A Liquidgasket Removal . RemovecollectorASSY FordetailedremovalDrocess referto "Collector" section . RemovefuelinjectorASSY . Removewaterhose. . Removeoillevelgaugeguidebolt. Oil levelgauge . Removerearwaterpipeconnectorbolt. EN - 157 ON.VEHICLEPARTS R B 2 5 D EE N G I N E RemoveintakemanifoldASSYboltsandnuts(1, the ordersshownin thefigureon right. Removethe intakemanifoldgasket. '10'13)in I 14 11 . RemovewaterPiPeASS\. 1312 10 4 lnstallation . Removeold liquidgasketon the waterpipe,in the groove andon the intakemanifold.Cleanallcontactsurfaceswith whitegasolineor equivalent. 00150) . Applya continuous beadof liquidgasket(KPs'10 2.0- 3.0mmwideto sealingsurfaceusingthetube pressor. Caution shouldbe performedwithin5 minutesafter Installation coatingthe liquidgasket. Waitat least30 minutesbeforerefillingenginecoolant. ?,, ; -. '3. .jt"v, / Installthe waterPiPeASSY Tighteningtorque (kg-m): :"'" - .,..''..'.-;'.| . .ra) '] ,i-. f- ( A ) 0 . 4- 0 . 5 ( B )1 . 6- 2 . 1 (B) bolt(6) 1A-111o , 1 4 1 3 gaskeL. Installintakemanifold inseveral theboltsandnuts(2.10.13)uniformly Install stagesintheordershowninthefigureontheright. 1 . 8- 2 . 2 Tighteningtorque (kg-m): z 3 5 levelgauge g u i d e0 . 4 - 0 . 5 . Installthefrontoil levelgaugeguidebolt. . Installthe rearwaterpipeconnectorbolt. 0.4- 0.5 Tighteningtorque (kg'm): . lnstallthewaterhose. PrPe.l E N- ' 1 5 8 1 4 ON-VEHICLE PARTS R B 2 5 D EE N G I N E 10-5 EXHAUSTMANIFOLD Exhaustmanrfoldgasket $ O r - s e n s4o.r1- 5 . 1 9 K:, Exhaustmanifold /:--9. r3l Washer Nr,,rrto-2r\Fi Exnaustmanrforo " -" il;' 9ts-t fr, tp o a - - o s { 8 ) go, sensor aftereverydisassembiy $ Reptace Removal . Removethefollowing: . Undercover . Exhaustfronttube . O, sensorconnector . Exhaustmanifoldcover . Removethe exhaustmanifoldnutsin theordershownrn thefigureon right. . Removetheexhaustmanifoldqasket. Inspection . Lookfor anydistortionon exhaustmanifold. Gas leakinspection . Afterremovingexhaustmanifold,makesurethereare no tracesof gas leaksfromany partof installation. lnstallation . Installexhaustmanifoldgasket. . Installexhaustmanifold, washerandtheVoke. Front MakesurenottomakemistakebetweenNo.3 andNo.4 yokeas configurations aredifferent. Item No,3& Xo,i! port 22 O$er than those above 24 Makesurethe washeris facingthe correctwaywhen installino. + Manlfold EN - 159 PARTS ON-VEHICLE RB2sDE NGINE Tightenexhaustmanifoldnutsin theordershownin the figureon right. lnstallexhaustmanifoldcover. crankengineand checkfor gas leak. Afterinstallation, 10-6 TIMINGBELT Timingbeit cover(Upper) Timrngbelt crommet ] p aort r.o- z.r\ 121 t=o' N u t4 . 4- 5 . 9g Belt tensioner Conical ,'Tensioner t@--- For rrl fo]!{a)fJ oromme E kg-t E E n g i n eo i l aftereverydisassembly P Reptace Removal . Removeundercover. . Draincoolingwaterfromthe radiatorenginedrainplug . Removesupplementary belts. . Removethe radiator, thefan shroudandthe coolingfan. T.D.Cposition CheckNo. 1 cylindercompression Alignthe crankpulleytimingmarkand beltcovertiming markindicator(0"position).At thistimethe No. 1 cylinder T.D.Cpositionwhenthe camshaftis is in the compression locatedas describedas follow: stroketopdeadcenter No. 1 cylinderis at thecompression whenboththe No. 1 intakeand exhaustsidecamsdo not movethe valvelifters. EN - 160 i'18\ z ON-VEHICLEPARTS R B 2 5 D EE N G I N E Removetheoilfiltercamfromintakesiderockercoverand checkthatthe frontend of camshaftfacesthe intakeside. Remove crankanglesensor. Remove startermotortheninstallringgearstopper. Remove crankpulleybolts. Usepulleypullerto removethecrankpulley(boltsize:M6x 1.0lengthbelowheadapprox.50 mm) . Removecrankanglesensorbracket,thenremovetiming beltcover.Timingbeltcoveris separatedintoupperand lowersections,firstremovethe uppersectionthenremove lowersection. Caution: Do not scratchdriedliquidpackingwhen removingand installing the timingbeltcover. . Removebelttensioner. . Securethetensionerfirmlywitha hexagonal wrenchwhen removingand installing bolttensionernuts. Caution: Do not looseninsertedstudat disassemblv. lf painton timingbeltis unclearwhendisassembly is performed,painta markon the beltthatindicatesrotation direction. Removethetimingbelt. EN - 161 ON-VEHICLEPARTS RB2sDE NGINE Timing belt insPection . Replacetimingbeltif any problemsare indicatedat the inspection' to replacetimingbeltevery100'000km' It is recommended Item Toothmissing Cracked tooth . '../'\ Camshaftlock Crank sensor lock '<./ lock Tensioner overheat Engine with beltcoveretc. lnterference Crackson rear side Belt misalignment Belt platemalfunction Wear and cracks on the side Worn teeth SlidingmotionresistanceIn crank sensor and the camshaft Oil or water adheston Oil seal malfunction Water leaks in water PumP Caution: Do nott*ist or bendthe timingbelt . Makesurethereis no oil filmor wateron the belt pulley Makesurethereis nowarnor crackscan befoundon idlerpulley,tensionerpulley,cam cranktimingpulleyandthetensionerspring.Alsocheckif theyrotatessmoothly. lnstallation . Assemblethe tensionerspringso it engagesthe belt tensionerpulleyas shownin thefigure. . The tensionerspringmustbe assembledtogetherwiththe belttensionerpulleyin the cylinderblock. . Whenthetensionerpulleyis free,hookthetensionersprlng on the uppersideof the tensionerspringstud / A\Y] t( ' L\g)) ) {;</ -'t\t. -li \=o\Tensionerspring securinostud Tensionerspring sPecifications ' 1 . 8m m Tensionerpulley A p p r o x . 2 0 " A p p r o x1 6 3 " Yellow-green EN - 162 ON-VEHICLE PARTS R B 2 5 D EE N G I N E Caremustbe takento installthe conicalwasherin correct direction. lnstallthecranktimingpulleyandtheplate. a f r l l l ]Fil I l \--J l Nut , . Be carefulto observefrontand rearpositioning of timing beltplate,cranktimingpulleyandcranktimingpulleyplate wheninstallation is performed. . Alignthealignmentmarksof the exhaustand intakecam pulleyswiththerespective beltcoveralignment marks(No. 1 cylinder is atT,D.C). . Alignthecranktimingpulleyalignmentmarkwiththe mark on oil pumphousing.Thegroovemustbe straightup (No. 1cylindercompression T.D.C). . Movethe belttensionerclockwiseat 70 - 80"Cangle,and secureit temporarily withbelttensionernut. (Thiswill minimizetheoffsetbetweenthetensionershaftandthe timingbelt). . Alignthetimingbeltpulleymarksandinstallbelt.Alignthe numberof ridgesof exhaustcam pulleyalignmentmark andcrankpulley(inner)alignmentmarkas shownin the figureon right. . Afterlooseningthe nutsandadjustingthe belttension, securetensionerwithhexagonalwrenchso it doesnot rotatetogetherandtightenthe nuts. Caution: At timingbeltassembly,checkthat it engagescorrectlywith pulleyand it doesnotfloat. Timing belttensionadjustment . Removethe sparkplugand aligntimingbeltalignment markswithpulleymarksand installtimingbelton to each pulley. Loosenthe tensionernut so belttensionis appliedby tensionerspring. Turncrankpulleyclockwisemorethantwo tumsto check beltmovementandstopslowlyat No. 1 cylinder comoression T.D.C. Inserthexagonalwrench in hexagonalhole. Holdthe tensionerwithyourhandandtightenthetensioner securingnutto specifiedtighteningtorque. Tighteningtorque (kg-m): 4.4- 5.9 At thisconditionbelttensionshouldbe approximately 20 ko. EN- 163 9 r Conical *""1"t Crank plate + Crank pulleyside Alignment mark PARTS ON-VEHICLE R B 2 s D EE N G I N E Installcrankanglesensorbracket. Tighteningtorque (kg'm): 2 . 1- 2 . 7 Crank angle , sensor bracket 6 i z.t- z.t 1s1p) . lnstalltimingbeltcoverin orderof lowerthenupper. ( A ) 1 . 6- 2 . 1 Tighteningtorque (kg-m): (B) 0.65- 0.86 Installcrank anglesensor (1) Applychassisgreaseto driveunitspline. (2) Thereis a flangeinsidethedriveunitsplineso spline onlyhasone insertionposition.Checkthe alignment beforeassernblY. (3) Checkthatthe crankanglesensorcan be inserted easilyin beltcoverholesandsensormoveslightlyto rightand left,thentightenbolts. lf thesensordoesnnotmovelightly,loosenthe beltcover A\ boltswithcrankanglesensorinserted.Movebeltcover to alignbeltcoverholecenterand camshaftcenter. Tightenboltsmakingsurethe crankanglesensor moveslightlY. 0 . 4- 0 . 5 Tighteningtorque (kg-m): Positionthe washerfor the crankpulleyboltsso the flat surfacecontactsthe crankpulleysideandthenassemble. Applyengineoil to thethreadsof crankpulleybolts. torque(kg-m): Tightening 1 4 . 5- 1 5 . 5 E N- 1 6 4 ON-VEHICLE PARTS R B 2 5 D EE N G I N E 10-7 OIL PAN O-ring 6 Oilpanbolt(30) 0 . 5- 0 . 7 o i l strainer ti, l-,1kg-m E L i q u i dg a s k e t aftereverydisassembly $ Repiace Removal . Drainengineoil. . Removeradiatorfan. . Removefrontstabilizer. . Removeengineright& lefigusset. 121620 2428302622 . Removeoil pan boltsin orderof sequenceshownin the figureon right. Ti7sE272s2s2117 fi . Insertsealcutterbetweencylinderblockand oil pan. . Removeoil pan by tappingthe sealcutterwithhammer . lf removingtheoil panfromthevehicle,firstremovefront enginemountingnut. . Usethe hoistcraneto liftup the oil panforward. . Fromthe gap betweenthe cylinderblockandthe oil pan, usea toolsuchas spannerto removeoil strainerboltbelt. . Pulltheoilpanout. Caution: Caremustbe takennotto strainthe hosesand the harness tootightlywhenliftingup the engineusingthe hoistcrane. EN - 165 e PARTS ON-VEHICLE RB2sDE NGINE lnstallation . Usea scraperto removealltracesof oil liquidgasketfrom cylinderblockand oil pansurface. Caution: Removeall gasketmaterialandotherforeignmaterialthat fallsintotheoilpan. . Cleanall contactsurfaceswithwhitegasolineor equivalent. . Cutoffnozzletipofliquidgasket(KP51000150)atpoint shownin thefigureon rightand insertintotubepresser . Applya continuous beadof liquidgasket(KP510 00150) 4 mm wide. to innersealingsurfaces . lnstallation within5 minutes. shouldbe performed Caution: is 4.0 mm wide. Be sureliquidgasketapplication Waitat least30 minutesbeforerefillingengineoil andengine coolant. 10-8oll SEAL Valveoil seal . RemovethefollowingParts: . Engineundercover . Cleaningfan . Timingbeltcover,timingbelt . CamPulleY . BackPlate . Rockercover . Ornament . Camshaft . Hydraulicvalvelifter . Valvespring . Useoil sealpullerto removevalveoil seal. . To preventvalveomissionhavethe pistonin compression T.D.Cposition. Valveoil seal drift atlachment --.1' KV10111400 EN - 166 ON-VEHICLE PARTS R B 2 5 D EE N G I N E . Valveoilsealinstallation measurement is as shownin tne figureon right. Camshaftoil seal . Removethefollowingparts: . Engineundercover . Coolingfan . Crankpulley . Timingbelt . Crankanglesensorbracket . Campulley . Backolate . RemoveNo. 1 camshaftthenremovecamshaftoil seal. . Applyengineoilto areaaroundtheoilseallip. . Caremustbe takennotto scratchor damageoil seal retainer.Useoilsealdriftsmallerthanoilseal(41mm) and insertit at samelevelas frontsurfaceof oil seal retatner. Frontoil seal . Removethefollowingparts: . Engineundercover . Coolingfan . Crankpulley . Timingbelt . Oil oan . Oilpump . Use a screwdriverto removefrontoil sealfrom frontcover. . Useoil sealdriftand insertnewfrontoil sealat samelever as frontsurface. . Facethe oil sealmarkoutside(frontside)wheninserting. Caution: Do not touchthe oil seal lip by flngeras greaseis appliedto areaaroundtheoilseallio. Rearoil seal Removethefollowingparts: . Transmission (orA / T) . Flywheel(ordriveplate) . Rearplate . Rearoil sealretainer E N- 1 6 7 Oil seal drift KV40100900 '--_r{'@ r ON-VEHICLEPARTS R B 2 5 D EE N G I N E Applyengineoilor chassisgreaseto areaaroundoil sea lip. Caremustbe takennotto scratchor damageoil seal retainer.Useoil sealdrift(Externaldiameter:(100mm) and insertit at samelevelas frontsurfaceof oil seal retainer. Cleaning . Usescraperto removeliquidgasket. Caution: Makesureto removeliquidgasketin the groove. . Cleanthecylinderblocksideusingsamemethodandclean the surfacewithwhitegasoline. Rearoil seal installation . Installation shouldbe performedwithin5 minutes. . Cutoffnozzletipof liquidgasket(KPS1000150)at point shownin thefigureon rightand insertintotubepresser. . Applya continuous 00150) beadof liquidgasket(KP510 wide 3 mm 2 surfaces to rearoilsealretainer Caution: engineoilandengine Waitat least30minutesbeforerefilling v/ F\.0 64- 0.8 . Installrearoil sealretainerby aligningto dowelpin. . Tighten6 boltsuniformlY. (R+ Rear oil seal retatner E N- 1 6 8 ON.VEHICLE PARTS R B 2 5 D EE N G l N E 10-9 ROCKERCOVER/ IGNITIONCOIL Ornarnent lgnitioncoil Groundcable ?Oln^lrT-ra :aa--' - tli \",/ Kg-m Fillercap Rockercover O ring Grommet Rockercovergasket Ornament RockercovergaSket \-.1i<9-m Removal . RemoveRockercoverornament. . Removeignition coilharnessand removeignitioncoil. . Loosenandremovetherockerbolts(intakeandexhaust)in the ordershownin thefigureon right. . Removethe rockercover. Installation . Installtherockermver. . Tightentherockercoverscrewuniformly in theordershown in thefigureon rightin severalstages. 8 4 2 Bolt0.3- 0.39 lgnition coil . Installthe ignitioncoilbracket. qS Vf ry rgnrtron corltacket . Installtheomament. E N- 1 6 9 cv.rinder \LO Sparkplu0 ON.VEHICLEPARTS R B 2 5 D EE N G I N E CYLINDERHEAD 10.10 (1) Cylinderhead removal& installation CVlinderhead bolt @ \J/ Leuserr ut fl.,-(4) Tightento (5)AnSlewr€ II wl rorque ]| o . o z1- . 2 , g l \ ^ \Y g Springwasher -.-\o g Cylinderhead bolt ,^,-^L^- 0.e2-1294 wasnerr'| s/ j-Spring washer f'-"{t ' 0 v , / /d' '.\)€ \ \ \ , \,] H| rs-t $ Cam pulley Replaceafter every disassemblY Removal . Removecoolingwatercompletely fromthe radiator, blockdrainPlug. cylinder . Removethefollowing; . Connectorand intakemanifold . Exhaustmanifold . Timingbelt . Rockercover,ignitioncoil . SparkPlug Removethe cylinderheadboltsin the sequencesnown in thefigureson right. Removethe cylinderhead,thencylinderheadgasket. Checkfor anydistortionon the cylinderhead. Checkfor any distortionon the cylinderblocksurface. E N- 1 7 0 4 - 1 7 | ' . , 411.x5 I - 3 M6x1.0 ON.VEHICLE PARTS R B 2 5 D EE N G I N E Installation . Beforeinstalling thecylinderheadASSYto cylinderblock, the crankpulleyandthe cam pulleymustbe positionedat No. '1cylindercompression T.D.Cposition. . Alignthecrankpulleytimingmarkandthetimingbeltcover timingindicator (0"position). . Alignintakeandtheexhaust campulleyalignment mark to respective beltcoveralignment marks. Intakecam shaft Exhaustcam shafl Makesureit is positioned at No. 1 compression T.D.C position. Installcylinderheadgasket. Installthe boltsin sequenceshownin thefigureon right. : The cylinderheadboltsaretorquedby two-stepmethod. llghten the boltsin two steps. ( 1 ) Tightento 3 kg-m. (2) Tightenedto 10 kg-m. (3) Loosenboltscompletely0 kg-m. (4) Tightento 3 - 3.5 kg-m. (5) Turnbolts80 - 90oclockwisewhenanglewrenchis USEO. Tightenboltsto 10+15 kg-mwhentorquewrenchis used. Caution: Whenanglewrenchis not used,neverattemptto approximate thetighteninganglevisually. . . . . . . Installignition coilandthesparkplug. Installthetimingbelt. Installtheexhaustmanifold. Installcollectorand intakemanifold. Checktheairflowof the hydraulicbulblifter. Pushthe hydraulicbulbliftercrestsurfacewithfingerand checktheslump. S l u m pl i m i tv a l u e( m m ) : 1.0 EN - 171 fiR'S ON-VEHICLE R B 2 5 D EE N G I N E of entrainedairwithinthe hydraulic Thereis a possibility to be valvelifterif the slumpis over 1'0 mm Air need releasedfromhydraulicvalvelifter' 10 minutesat 4000rpm ldlethe engineior approximately afterinstallingthe rockercover' valvelifter Removethe rocKercoverandpushthe hydraulic surfaceto checkthe slumpof cam basecircle' is overthe Replacethe hydraulicvalvelifterif thevalue limit. (2) Cylinderheaddi"""."-bly, ""t"-bly&inspection Valvelrfler- -./ valvecorer-'--"'" /u"V:f31'?'.,11''""' / 9ping seat / / t'd/^r/ Valve - o| seal / .au^ru. " \<- .0.'"n**ffi" * Washer-=-3 Buffleplate----€ P e o r r o . st .zrj -@-Y==--J:?"[',].",""""r" seat ,{/-i A fp ^^ -crr(@@--" O B o r t o .1 e2 g -l E I washer/ nu'o' , /Valve e/ -washer '"1::::.::"::li** *o@;*lT"ililJf""['S W KffiP* --.9-3:Ji9', # ^.#"*\ )t 6.Nr--_ -$---& ri.,nso"*"o:,-a{-*?J _-\D ":'">-t\ \ g..: *\..! F.:.t' g - _ ' 4 F ^ ' " , 0 n ', r g sea6r[Hj::;";";: i l" \r..-.'5-eo'osz-'ze *tr!1liiry'""ffiy*i;ltj,tp;:;:,. ;:;:;:M,-;l*inan' ron' o cam;hafttrontorlsealE[ ffeonz.r - z.zg L",l hg'm gasket A Liquid oil n Engine E ReplaceaftereverydisassemblY DisassemblY . Us" tne propertooltosecurethehexagonalpartinfrontof camshaftto removecam Pulley' . Removetimingbeltcoverbackplate . Positionthe cim shaftknock-pinto the positionshownIn the figureon right. E N- 1 7 2 ON-VEHICLE PARTS R B 2 5 D EE N G I N E . Removecambracketboltsby loosening themgraduallyrn severalstages,in reversesequenceshownin thefigure on right. Caution: Beforeremovingcamshaftbracket,paintmarksto indicate bracketpositionand direction. . Removethe cam bracket. Intakeandexhaust camshaft canbeidentified by paintcolorandpresence identification of a splinegearfor driving thecrankanglesensor. Camshaft Intake camshaft Purple No Exhaust camshaft Orange Yes Removehydraulic valvelifter. (1) Hydraulic valvelifteris nonseparable. (2) Do notstorehydraulicvalvelifterup sidedownor on itsside. (3) Storehydraulicvalvelifterin theengineoilwhen storingtemporarily. . Usevalvespringcompressor(KV10108950)to remove varvespnngs. Cylinderhead inspection . Usescraperto removeanytracesof oil,waterscale, gasket,sealingagent,carbonetc.fromcylinderhead surfaces. . Measurelowersurfaceof cvlinderheadin sixdirections to checkfordistortion. Limit(mm): 0.2 Whendistortion isjustoverthe limit,resurfacethecylinder head. lf distortionexceedsthe limit,replacecylinderhead. Gamshaftvisual inspection . Visuallyinspectcamshaftfor anywarnor damage. E N- 1 7 3 I Splinegearfordrivingcrankangiesensoj C) V /7^ @ K7\J ON-VEHICLEPARTS R B 2 5 D EE N G I N E Camshaftrun-out . Use V-blockon fixedsurfaceand supportbothcamshaft endjournals(No.1 & No.7). . Avoidthe oil groovein the centerof the No.4 journaland positionthe dialgaugevertically. . Rotatethe cam shaftby handto one directionand read the movementwidthon dialgauge. . The run-outis equalto halfof the movementwidth on dialgauge. indicated 0.05 Standardvalue (mm): CamnosediameterinsPection of camnose. diameter to measure Usemicrometer (mm): 39.705- 39.895 Intakestandardvalue 39.205- 39.395 Exhauststandardvalue(mm): Replacecamshaftif diametervaluediffers. Camshaftoil clearance . Tightenthe cam bracketto specifiedtorque. to measureinsidediameter' Useinsidemicrometer 28.000- 28.021 (mm): value Standard l-) ofcamshaft . Usemicrometer diameter outside to measure JOUmal. Standard value (mm): 27.935- 27.955 ls Inspectthatthe camshaftoil clearancemeasurement withinsoecifiedvalue. Oil clearance= cam bracketinsidediametercamshaftjournal (outsidediameter) Standardvalue (mm): 0.045- 0.086 Camshaft end plaY . Assemblecamshaftandtightencam bracketto standard value. . Seta dialgaugeat frontendof the camshaftin thrust direction.Whencamshaftmovesin frontand rear direction,readthedualgaugerun-outwidth. 0.030- 0.080 Standardvalue (mm): EN - '174 ON-VEHICLEPARTS R B 2 5 D EE N G I N E Valveguide clearanceinspection D i a lg a u g e . Protrudevalveapproximately 15mmfromvalveguidehome : \ intocombustionchamber.Measurevalvedeflectionby swingingintodirection parallel to dialgauge. . Theclearance is equaltohalfofthedialgaugereading (deflection width). Valveguide clearance(mm) Intake: 0.1 Exhaust: 0.1 . Replacevalveor valveguideif clearanceexceedslimit. Valveguide replacement . Usevalveguideremoverandtap it fromcombustion chambersideto removeseal. Rectify cylinder headvalveguideholeusingvalveguide reamer Rectifiedvalvestandardvalue(mm) Intake& exhaust: 6 . 0 0 0- 6 . 0 1 8 Heatcylinder heatin an oilbathto approximately 150160oC.Usea valveguidedriftand pressvalveguidefrom camshaftside. . Thepress-fit dimensions areshowninfigureonright. 1 6 . 8+ / -0 . 1 Intake/ Exhaust Reamtheinside oftheinserted valveouidewithvalveouide reamer. Finishedinternaldiameterstandardvalue(mm) lntake& exhaust: 1 0 . 1 7 -5' t 0 . 1 9 6 g u i d er e a m e r( K V 1 0 11 1 6 0 0 ) Valve seat inspection . Checkcontactsurfacesof thevalveseatandthevalve. . Replacevalveor valveseatif contactingsurfaceis too largeor improper. EN - 175 o* q"o," PARTS ON-VEHICLE R B 2 5 D EE N G I N E Valve seat rePlacement . Cut andgrindvalveseatto removethe valveseat. . Readjustthe mountingholefor oversizevalveseat. Standardvalue (mm): 36.5+0.016-0 lntake 3 2 . 0+ 0 . 0 1 6- 0 Exhaust . Read.just the valveguidecentreandconcentriccircle' . Heatup the cylinderheadin an oil bathto approximately 1 1 0- 1 3 0 " C . . Usevalveseatdriftto tap it untilit strikethe bottom. . Whennotusingvalveseatdrift: 5 minutes' . Usedry rceto coolvalveseatfor approximately "C B0 Heatup the cylinderheadto approximately . Insertcooledvalveseatintocylinderheadquickly. Caution: Do notdirectlytouchcooledvalveseatwithhands. . Read.lust thevalveseatusingvalveseatcutterorvalveseat onnoer. .\,= is as shownin the Valveseatshapeand measurement figureson right. * o D-'- . t ,..',.,' op, rg-' .::-. . Urafe so.of,o'u Qo, so.of,o!,' ^^ . -0016 JO.C o ^^ - +0113 Jb. c n o97 Qa 6o, 0D, 32.O 37.0 32.O 37.0 zs.t'.. , zs t',., E N- 1 7 6 6o, ON-VEHICLE PARTS R B 2 5 D EE N G I N E Valveinspection Outsidediametermeasurement . Usemicrometer to measureeachdimension. Valva lnlake Exhaust a b c d e - 34.02 5 965 - 5.980 1 . 1 5 - 1 . 4 52.60 - 2.90 8 5 . 3- 8 5 . 5 8 0 . 7 8- 8 ' 1 . 0 8 34.OO 8 7 . 3- 8 7 . 5 8 2 . 7 8- 8 3 . 0 8 2 9 0 0 - 2 9 0 7 5.960- 5.945 3 . 2- 3 . 4 Valvespring squarenessinspection . Placea righfanglestraightedge(L-square)so it contacts thespring.Turnthe springand measurethe maximum clearancebetweenupperspringsurfaceandthe right anglesurfaceto determineout-of-square distance. Limit(mm): 1.8 . Replacethevalvespringif the oulof-squaredistanceis overthe limit. Contact Freelengthand pressureload inspection . Usea valvespringtesterto checkthe springpressure. Freelength(mm): Installation load(kg): 43.1 24.0 Hydraulicvalveliftervisualinspection . Visuallyinspectcamshaftrotationalareaon liftersideand lifterborerotationalareafor anywarnor damage. . Replaceif thereareany abnormality. Caution: Do notdisassemblehydraulicvalvelifter.lt is nonseparabte un[. Hydraulicvalve lifter outside diameter . Usea micrometerto checkthe valvelifteroutside diameter. Standardvalue (mm): 30.955- 30.965 EN- 177 t v . t---.---,-'lJ ) 30. '15" ON-VEHICLEPARTS R B 2 5 D EE N G I N E Hydraulicvalvelifterhole internaldiameter 3 1 . 0 0-0 3 1 . 0 2 0 Standardvalue (mm): Hydraulic valve adjuster clearance valveclearance= Hydraulic valveclearanceholeinternaldiameter- hydraulicvalveexteriordiameter HVdraulic lnstallation . InstallvalveassociatedParts. . Fordetailedinformation on howto installnewvalveoilseal "Oilsealreplacement". referto sectionon . Installvalvespringwithnarrowpitchendtowardscylinder colorsidedown). head(identification . Installspringretainer . Usevalvespringcompressor to installvalvecollet. . Applya smallcoatingof petroleumjellyto the internal surfaceof collet. . Usea magneticscrewdriver. (1) Uppercolletinstallation . Attachcolletto lowersideof magneticscrewdriverblade and installtnthe valvestem. (21 Lower colletinstallation Attachcolletto uppersideof magneticscrewdriverblade andinstallin thevalvestem. . Aftervalvecolletinstallationlightlytap the stemedgewith a plastichammerto confirminstallation. . Installhydraulic valvelifter. . Tapin camshaftknockPin Knock pin protrusiondistance(mm): Gamshaftinstallation T.D.C . Turncamshaftso No. 1 cylinderis at compression position(orturncamshaft60obeforeor afterNo. 1 cylinder r.D.c). . Temporarily tightenNo. 1 cam bracketand makesurethe securely. thrustsectionis positioned E N- 1 7 8 KnockPln Knockpin ON-VEHICLE PARTS R B 2 5 D EE N G I N E Tightencam bracketbolts540.(1.5 turns)graduallyin severalstagesin the sequenceshownin thefigureon right. Tightening torque(kg-m): 0 . 9 2 -1 . 2 6 Installcamshaftfrontoilseal. Fordetailinformation referto "Oil seal"section. . Installtimingbeltbackplate. . Aligncampulleyto camshaft knockpinto install. Tighteningtorque (kg-m): 1 . 4 -1 . 9 E N- 1 7 9 10 14 12 Ffonti ENGINE REMOVE& INSTALL R826DETTENGINE 1 1 R E M O V E& I N S T A L LE N G I N E [Point 1] Releasefuel Pressure . Afterstartingengine,removethefuelpumpfuseand run engineuntilit stops. Consumefuelleftin fuellinesby crankingthe enginetwo to threetimes. . Whenit is not possibleto startthe engtne,removethefuel pumpfuseandconsumefuellefiin fuellinesby cranking enginefourto fivetimes. Caution: The batterymay becomeweakeasily,connectbooster cablesto chargedbattery. Acceleratorwire adjustment [Point 2] . Loosenlocknut and provideadequateslackfor the wire. Pulloutercasein the directionof the accelerator pedaluntilthrottledrumstartsto move(noplay accelerator in cable).Rotatethe locknut 1 to 1.5turnsto tighten. 0 . 8- 1 . 0 Tighteningtorque (kg-m): Enginemain harness,ground line separation . Disconnect the connectorsbehindthe batteryfor systems. startermotorandtransmission alternator, [Point3] andpowersteeringoil Air compressor pump movement . Remove Leavepipes eachunitto brackets. boltssecuring andsecuretosideofthebodywithstring Care connected thebody. mustbetakennotto scratch lPoint4] !e .iffifierr " ffY;".. Powersteeringoil tubebracketseparation [Point5] oiltube . Removeboltsandseparate thepowersteering side. the body andmovetowards bracket, ..-- v,r*Jo fiom betow Front enginemountingnuts removal [Point6] . Makesurethe engineslingsaresecurelyhookedby enginehorstchainandremovefrontenginemountingnuts. 'hN4 '6) l,----'- ion-teng,nurouFinlS n u t4 . 4 - 5 . 6 E N- 1 8 0 REMOVE& INSTALL ENGINE RB26DETE TNGINE [Point7] Rightfront enginemountingbracket removal . Powersteering oiltubewillhittherightfrontengine mounting andit is notpossible to shifttheenginefonvard. Therefore removenutsandremoverightenginemounting bracket. Remove& installengineASSY [Point8] . Operate thehoistchain,andchangetheengineangle gradually to remove theengine.Caremustbetakennotto interfere withvehiclebody. E N- ' 1 8 1 REMOVE& INSTALLENGINE / D E / D E T/ C A I B iE N G I N E RB2OE '11 REMOVE& INSTALLENGINE fuelPressure Release [Point1] . Afterstarting thefuelpumpfuseandrun remove engine, engineuntilit stops. Consumefuelleftin fuellinesby crankingthe enginetwo to threetimes. . Whenit is notpossibleto startthe engine,removethe fuel pumpfuseand consumefuelleftin fuellinesby cranking enginefourto fivetimes. Caution: The batterymay becomeweakeasily,connectbooster cablesto chargedbattery. Transmissionjack set (CA18ionly) jack underthe transmission. . Placethe transmission Acceleratorwire adjustment [Point 2] . Loosenlocknut and provideadequateslackfor the wire. Pulloutercasein directionof the accelerator pedaluntilthrottledrumstartsto move(noplay accelerator in cable).Rotatethe locknut 1 to 1.5turnsto tighten. 0 . 8- 1 . 0 Tighteningtorque (kg-m): Enginemain harness,ground line seParation . Disconnect the connectorsbehindthe batteryfor systems. startermotorandtransmission alternator, [Point3] Air compressor and power steering oil pumP movement . Removeboltssecuringeachunitto brackets.Leavepipes connectedandsecureto sideof the bodywithstring.Care mustbe takennotto scratchthe body. [Point 4l Remove& Install propella shaft [Point 5] . Placea capon thetransmisslon rearsealso the oil willnot leakwhenthe propellashaftis removed E N- 1 8 2 REMOVE& INSTALL ENGINE R B 2 0 D ED t I D E T TE N G ' N L Remove& installrearenginemounting [Point6] . Supportthe transmission jack and withtransmission removerearmemberboltsandrearenqinemountinobolts andnuts. l (4) 4.4 - 5.6 Frontenginemountingnuts removal [Point7] . Makesurethe engineslingsare securelyhookedby enginehoistchainandremovefrontenginemountingnuts. Enginemountingnut tighteningtorque(kg-m):4.4- 5.6 Frontenginemounting nut Remove& instaltengineASSY [Point8] . Operatethehoistchain,andchangetheengineangle graduallyto removethe engine.Caremustbe takennotto interferewithvehiclebodv. E N- 1 8 3 ENGINE & LNSTALL REI\,4OVE R B 2 5 D EE N G I N E 1 1 R E M O V E& I N S T A L LE N G I N E StandardPoints jackto removeandinstall howto usehoistcraneandtransmission Thissectiondescribes engine. theRB25DE . Draincoolingwatercompletely. . Removebonnet. Enginebay left side: . Exhaustgas sensorharnessdisconnection . Groundlineconnectorseparatlon . Air duct,Air cleaner . Powersteeringoil PumPremoval . Air compressorremoval Enginebay right side: Battery /G.\ "fuelputp rer"y" (E ) . Release byselecting fuelpressure in activetestmode,and PressSTOP. O ncrtvgrEsr O FUELPUMPRELAY OFF CAS-RPM(POS) 950 rpm fuelpumpfuseandrun . Afterstaringtheengine,remove fuel engineuntilitstops.Consurne leftinfuellinebV ffi \Gy theengineovertwotothreetimes. cranking Caution: The batterymay becomeweakeasily,connectbooster cablesto chargedbattery. . Acceleratorwireseparation . Heaterhose . Vacuumhosesseparatior Enginemain harness& ground line separation Enginebay front side: . Radiatorshroud,radiator . Coolingfan Enginebay upPerside: . ECCSharnessconnectors E N- 1 8 4 START INTERRUPT STOP REMOVE& INSTALL ENGINE R525lE ENGINE Vehiclebody,lower side: . Engineundercover . Propellashaft . Transmission controllever(M/Tvehicle), linkage(A/Tvehicle) . Exhaustfronttube . Rearenginemountedbracket . Rightandleftenginemountedbracket. Remove& installengineASSY . Operatehoistchainandchangeengineanglegradually. Caremustbe takennotto interferewithvehicleand removetheengine. E N- 1 8 5 \qt--l.ER)j ^ \r,_r,_" xear_rnemD:r-Rear enqinemountrn bolt(4)4.4- 5.6 UoitiZ;a.+__ s OVERHAUL ENGINE RB26DETTENGINE 12 ENGINEOVERHAUL from removed of theengineassembly disassembly thecomponent Thissectiondescribes of replacement theinspection, lt alsoexplains thevehiclewithouttransmission. and adjustments orwarnpartsandcarryoutanynecessary damages malfunctioning, enginecondition' a standard inorderto produce assembly sequential CAUTIONS OVERHAUL bly ( 1 ) Disassem andmakesureto carryoutsafe . Usecorrectandsuitable toolswhenpossible procedures. to andslidingsurfaces . iare mustbetakenwithoperations on matingsurfaces preventlossof surfaceaccuracY. foreasyfaultsdetection . Arrangedisassembled parsby makingmarksto organize andpreciseassemblY. fromoutside.care mustbetakento . Loosennutsandboltsin a diagonal direction orderwhenindicated followthenumerical repairandreplacement (21 lnspection, theinspection following partsinspection . ieplaceor repairaftercompleting forthenewpartsandreplacepartsas sameinspection Perform orocedures. necessary. (3) Assembly torque tightening . Alwaysusea torquewrenchto tightennutsandboltsto specific gradually intwoor direction, . Tightennutsandboltsfromcentreto outsidediagonal orderwhenindicated' stages.Followthenumeric threesuccessive withnewonesin principle' . Replace packing, oilsealsandO-rings gasket, check air. Inparticular, . Cleanea-hpartthoroughly andblownoffwithcompressed arenotcloggedor obstructed' thatoilandwaterpassages . caremustbetakennotto scratch ordamageslidingormatingsurfacescleanoffall allslidingsurfacewithanadequate dust,debrisorforeignobjects.Lubricate oil. coating E N- 1 8 6 ENGINE OVERHAUL RB26DETE TNGINE 12.1 DISASSEMBLE & ASSEMBLECYLINDERBLOCKASSY Deronation sensorbolt{211.6- 2.1rct t: G-= ___-_ Defonation sensor Rearorlseatlpornt7] 6<= Alternatoradjustmentbar *PffiffiN -A iJ:1il,8*,.",, ""€S-f;ffi* "t*il;E:{ft;i;;'K)q a\ bolt(2rlPornt 201 ir""'"liln "r rn;-=-fi. l-Pn'oa D$, D$ (.4arr uon roo Con r rod bearrrg bearrno IJt lt4arroeanngcaplPornt 25]6;$p11 tcornt?5]^ -\'Z 9?i,:0":,.99-: \ Flywheel[Point3, 5] Rearplare- Mainbearing ootrp J<4*-BarnJprate 32-43 o'*'*,-ffi F "d;;H - r\ Bort(2)1 6 _ 2jVi (/:,8!*it?-,;::;?, Bort(12) / Fi l',1 Kg-m 9 |[."'lTii u.o4 - u. *n A Liquidgasket oil fl Ensine $ A E-r\-I Oilpanboltg . (t\r10) 3.2- 4.3 pan pt oirpanbo*(M6)/ 0.64- 0.85 Copperwain-e€--Orain ptug:.0-a.0gl a-e Replaceafter every disassembly Additionalwork required: . Drainand refillcoolingwater[Point1] . Removeand installthefollowinooarts: . Engine . Collector . Throttlechamber . Intakemanifold . Turbocharger, exhaustmanifold . Timingbelt . CylinderheadASSY . Alternator . . . . . . . Startermotor Clutchcover,clutchdisc Oilpan,oilstrainer Waterpump Oil pump Oilcooler,oilstrainer All harnessesand connectors E N- 1 8 7 ENGINEOVERHAUL RB26DETE TNGINE Reference:Engineselectionassembly Piston (1) Piston selection . 3 Lessthan86.010 Greatefthan86.00 Lessthan86.020 Greaterthan86.010 Lessthan86.030 Greaterthan86.020 Lessthan85.965 Greaterthan85.955 Lessthan85.975 Greaterthan85.965 Lessthan85.985 Greaterthan85.975 0 . 0 3 5- 0 . 0 5 5 Pistonand pistonPin ServicesettingParts: 1,OOS STD 1. STD2, STD3, O.5OS, Pistongrade (No.1 - No. Distinction symbol Prslonprngrade(0 1) Mainbearing (2) Mainbearingselection , . , , ' 3 l , , ' : ' . . ' . ' ' . ,.:.'.' 0 . . 1 7, :' r ':,:l r. 2 ) ' STD 1 1.821 -1 .824 0.028/ 0.046 Brown STD 2 1.824 - 1.827 0.028/ 0.046 NOne STD 3 1.A27- 1.830 o.028| 0.047 Yellow STD1 1.821- 1.824 0.028/ 0.046 Brown STD2 1.824- 1.827 0.028/ 0.046 None STD3 1 . 8 2 -7 1 . 8 3 0 0.028/ 0.046 Yellow STD4 1 . 8 3 -0 1 . 8 3 3 0.028| a.047 Blue STD 3 STD 2 1 . A 2 4 - 1 . A 2 7 1.827 - 1 -830 0.028/ 0.046 0.028/ 0.046 Yellow NOne STD 4 1 . 8 3 0- 1 . 8 3 3 0.028/ 0.046 Blue STD 5 1 . 8 3 3- 1 . 8 3 6 0.028/ 0.047 Green STD3 1.827- 1.830 0.028/ 0.046 Yellow ..3 Servicesetti STD O 1 . 8 1 8- 1 . 8 2 1 0.028/ 0.046 Black STD4 1 . 8 3 -0 1 . 8 3 3 0.028/ 0.046 B IUE STD6 STD5 - 1.83 1 . 8 3 -3 1 . 8 3 6 1 . 8 3 6 0.028/ 0.046 90.028| 0.047 Pink Green S T D O - 6 us 0.25 EoregradeNo. ff;:113,,".",ifl' ) No. i te! side--,-\'\l Iru -5- *383".\\ r'l-lili: {,rl\ No 5 E N- 1 8 8 ENGINE OVERHAUL R826DETT ENGINE Pistonpin (3) Pistonpinselection (mm) 2 1 0 0 6- 2 1 . 0 0 0 2 1 . 0 1 2- 2 1. 0 0 6 2 0 . 9 9 5- 2 0 . 9 8 9 21.0A1- 20.995 0 . 0 0 5- 0 . 0 1 7 Servicesettingparts: Pistonandpistonpin S T D1 .S T D2 , S T D3 . 0 . 5 0 51. . O O S Ffontmark Prngrade (0.1) CylinderNo. ( 1- 6 ) Distinction ( 1- 3 ) Largeend grade(0.1) symbol Con'rod bearing (4)Con'rodbearingselection Lass tfian 51.013 Greaaer than 51.007 0 0 BearinggradeNo. STDO BearinggradeNo. STD 1 Bearingthickness(mm) 1 . 5 0 -0 1 . 5 0 3Bearinglhickness(mm) 1 . 5 0 3- 1 5 0 6 Oil clearance(mm) 0 . 0 2 0/ 0 . 0 3 9Oil clearance(mm) 0 . 0 2 0/ 0 . 0 3 9 ldentifcation color None ldentification coior Brown BearinggradeNo. SID 1 BearinggradeNo. STD2 - 1.509 Bearingthickness(mm) 1 . 5 0 3- 1. 5 0 6 Bearingthickness(mm) 1 . 5 0 6 (mm) Oil clearance 0.020/ 0.040 Oil clearance(mm) 0.021t 0.040 ldentifcation color Brown ldentificationcolor Green Servicesettingparts: us 0.08. us 0.12. us 0.25 UpperjournaI gradeNo. No.1 - No.6from E N- 1 8 9 OVERHAUL ENGINE RB26DETTENGINE Drain& refillcoolingwater [Point1] Draining . Draincoolingwaterin the cylinderblockcompletelyfrom thedrainplug. Refilling . Referto thesection"coolingwater"for detailedinstruction. Remove& installenginestand [Point2] . Installthe enginesub attachmentusing6 boltsto engine mountingbracketon rightsideof the engine. B o l t ( 64)- 5 0x151=25 FlYwheelrun-out [Point 3] . Setdialgaugeto flywheelwhereit contactsclutch' . Turntheflywheelandmeasuretherun-out. 0.10 Run-outlimit (mm): Remove & install flywheel [Point 4] Removal . Useringgearstopperto fix flywheeland remove. lnstallation . Coatthe threadandflangeof boltswithengineoil after ra.s-)s6--\"\ bolts. the installing . aftertighteningthe flywheelbolts,use ringgearstopperto secureflywheelandtightenbolts. 't4.5-15.5 Flywheelbolt tighteningtorque (kg-m): ((6) Flywheelknock pin installation [Point5] . Insertthe flyrvheelknockpinso the pin protrudesB to 8 5 mm. Knockpin protrusiondistance Knockpin Flywheel E N- 1 9 0 ENGINE OVERHAUL RB26DETE TNGINE [Point6] Removal Remove& installrearoil seal retainer . Inserta screwdriver inthegapbetween mainbearing cap andrearoilseal retainerto remove seal. Cleaning . Usescraperto removeliquidgasket . Cleanthe cylinderblocksidein the sameway. . Wipematingsurfacewithwhitegasoline. Caution: Also removeliquidgasketin the grooves. lnstallation . Applyliquidgasketandinstallunitwithin5 minutes. . Cutnozzleendoftheliquidgasket(KPS10 00150)tubeas shownin the figureon right. Usetubepresserfor aoolication. . Applyliquidgasketcontinuously to rearoil sealretainer. Caution: Makesureliquidgasketwidthis 2.0- 3.0mm. Refillengineoil andstartthe engine30 minutesafter assemblyis completed. . Aligntherearoilsealretainer withdowelpinto install. . Tighten 6 boltsuniformly. Rearoil sealretainerbolttighteningtorque(kg-m): 0.64- 0.85 [Point7] Removal Remove& installrearoil seal . Usea toolsuchas screwdriver to removethe seal. Installation . Caremustbe takennotto scratchor damagethe oil seal perimeterarea. Useoil sealdrift(Outsidediameter:100 mm)to installnewoilseal. . Applya coatof oil or chassisgreaseto oil seal lip area. E N- 1 9 1 ENGINEOVERHAUL RB26DETTENGINE Con'rod side clearanceinspection [Point8] . Usethicknessgaugeto measurethethrustclearance betweenthe con'rodandthe crankarm. 0.2- 0.3 Standardvalue (mm): 0.4 Limit value(mm): Remove& installpiston con'rodASSY [Point9] . Usea toolsuchas hammerhandleto pressthe unitto headside. cylinder lnstallation . Setthe crankpin at B.D.C(Bottomdeadcenter)position. . Coatcylinderbore,crankpinandpistonwithengineoil' . Assemblepistonwithfrontmarkon pistonheadfacingthe frontof engine. . Usea pistonringcompressorto installthe pistonandthe con'rodassemblyin cylinderblock. Caution: Care must be taken not to strikeor deformoil jet pipe with largeend of connectingrodwheninstalling. Gon'rodnut tightening . Applyengineoil to con'rodandthe nutsbeforeassembly. . Tightennutsin two or threestages. '' .6 1st time Torquewrench (kg-m): 1.460 - 65 2nd time Angle wrench ( " ): Caution: Do notvisuallymeasurethetighteningtorqueif anglewrench is not available. [Point10] Installcon'rod bearing con'rod . Applyengineoil to bearingsurfacewheninstalling bearing.Do not applyengineoil to rearsurfaceof cleanthisarea. bearing, . Aligncon'rodbearingretainernotchesandinstall(leftside). . Makesurethecon'rodbodyoil holeandthe bearingoil holeis aligned. E N- 1 9 2 ENGINE OVERHAUL RB26DETE TNGINE [Point11] Installoil jet . Setthe oiljet positionsecurelyand checkthatit doesnot I interfere withpiston.lf oiljetpipecontactspistonoris benr, replace itwithnewpart. Oiljettightening torque(kg-m): 3 . 1- 4 . 1 .< Evebort 3.l'41 _r _31 { !-\ o"* .' r'-<-al -' ,''.1-l= , )*- .-.-: _= [Point12] Remove& installpiston ring Removal . Usepistonringexpanderto removerings. Caution: Caremustbe takennotto scratchoiston. Installation . Usepistonringexpanderto installrings. ldentification mark . The stampedmarkson top and secondpistonring openingsmustfaceup. \ Topnng openrng . Positionthe pistonringsas shownin thefigureon right to install. Caution: Caremustbe takennotto scratchpiston. 'l3] [Point Removal ;",;*);^3i -" {/z--Yrr Y aln ..\ \./ Remove& install snap ring . Usesnapringpliersto removerings. Installation . Usesnapringpliersandinstallringssecurely ingroove. Caution: Alwaysreplace snapringswithnewones. [Point14] Remove& installpistonpin . Usea heatgunto heatpistonto 60- 70"Cwhenremoving piston pin. andinstalling Placesuitabletoolagainstpistonpin and pressor use plastichammer. Applyplentyof engineoilto pin,pin holeand con'rodsmall note. E N- ' 1 9 3 )s<-.- / ^ Decononno ooentn0 - OiI nno lower ra opentnq ENGINEOVERHAUL RB26DETTENGINE Piston pin Press-fit . Placethe pistonfrontmarkso the con'rodoil holefaces rightsideof the engine(lefisidewhenviewedfromfront) and pressJit. Caution: Press-fitthe pistonpinfromthefrontof pistonto the rearside of piston. [Point15] Piston Pin inspection . Usethe micrometer to measureoutsidediameterof piston ptn. 20.989- 21.001 Standardunit (mm): [Point16] PistoninsPection . Usemicrometer outsidepistonskirtdiameter' to measure from bottom(mm): 13 pointDistance Measuring 85.955- 85.985 Standard(mm): Useinsidemicrometerto measureinsidediameterof pistonpinhole. value(mm): Standard 20.987- 20.999 Fivetypesof pistonsareavailablefor service(STD1, STD 1.oos). 2.STD3,o.sos, [Point17] Piston pin clearanceinspection . Pistonpin clearanceis the figureobtainedby subracting the pistonpinoutsidediameterlPoint15]fromthe piston oinholeinsidediameter[Point16] Piston clearanceat normal temperature(20oC): 0 - -0.004 [Point18] Con'rod insPection Bend and torsion inspection . Measurethe bendand torsionwithcon'rodaligner. 0.15 Bend limit (mm): 0.3 (mm): Torsionlimit Smallend insidediameterinspection 21.000- 21.0'12 Standardvalue (mm): E N- 1 9 4 Front Micrometer ENGINE OVERHAUL R826DETT ENG]NE Gon'rodbearinginteriordiameterinspection . Installcon'rodbearingin con'rodandcap. Tightencon'rod nutsto specifiedtorqueand measurecon'rodbearing interiordiameter, Con'rcd nut tigh!eningtorque 1 s tt i m e Torquewrench(kg-m) 1 . 4 - 1 . 6 2nd time Anglewrench( ') 60-65 4 7 . 9 8 9- 4 8 . 0 0 7 Standardvalue [Point19] Con'rodsmall end bushingclearance . The measurement differenceof the smallend inside diameter[Point18] andoutsidediameterof pistonpinIPoint 151is the bushingclearance(fullfloattype). Bush clearancestandardvalue (mm):0.005- 0.017 . Thecon'rodsmallend and pistonpinoutsidediameterare separatedintotwo gradesat thefactory.Makesurethat the grades(0.'1) conformfor bothpartsbecausethe rod and pin are selectedand fittedaccordinoto bushino clearance. [Point20] Gon'rodcap bolt . Con 'rodcap boltshavegroovesto preventit from disengaging. . Forthis reasondo nottap the endsto removebolts. lPoint21] Piston ring end gap and side clearance Ring end gap inspection . Usea pistonto pressthe pistonringintothe middleof the cylinder andmeasure thegap. Item Top dng B o r eg r a d e1 , 2 , 3 : 0 . 2 4- 0 . 3 4 S.cond ing 0.42- 0.57 0.20- 0.60 Side clearanceinspection . Measurethe clearancebetweenthe oistonrinoandthe pistonringgroove. - 0.135 0.040- 0.075 0.030- 0.065 0 . 0 6 5 Threetypesof pistonrings(STD,0.505, 1.00S)are availablefor service. E N- 1 9 5 E ENGINE OVERHAUL RB26DETE TNGINE [Point22] Grankshaftthrust clearanceinspection . Usea thicknessgaugeto measurethe clearancebetween thethrustbearing(No.4 bearing)andthe crankarmwhen towardsfrontandrearof the engine. movingthe crankshaft 0 . 0 5- 0 . 1 8 Standardvalue (mm): 0.3 Limit(mm): [Point23] Remove& installpilot bushing Removal . Usea pilotbearingpullerto removepilotbushing. Pilot bearing sr1661 0000 lnstallation . Thepilotbushinginstallation position is as shownin the figureon right. [Point24] Remove& installmain bearingbolts Removal . Removebearingboltsin reverseorderof sequenceshown in thefigureon right. lnstallation . Tightenthe boltsto specifiedtorquein two to threestages in the sequenceshownin thefigureon the right Make thebolts turnssmoothlyaftertightening surethecrankshaft to specifiedtorque. Main bearingbolt tighteningtorque(kg-m): 4.7 - 5.3 Caution: Applyengineoil to the boltthreadsand boltseatswhen the bolts. tightening IPoint25] Removal Remove& installmain bearingcaP . Usetoolssuchas screwdriver to prythebearingcapsopen. Caution: Caremustbe takennotto scratchthe oil pan railsurface. lnstallation . Checkthefrontandrearposttionandfit ontocylinderblock witha copper by lightlytappingit in a numberof locations hammer E N- 1 9 6 ENGINEOVERHAUL R B 2 6 D E TE TNGINE [Point26] Mainbearinginspection . The bearingendshouldprotrudewhenInstalledin main bearingcapor cylinder block Thisprotrusionis calledthe crushheight. inspection [Point27] Crankshaft Out-of-round andtaperinspection Usemicrometer to measureeachjournal(No 1 - 7) and eachpin (No.1 - 6) in fourlocationsshownin thefigureon right. Theoufof-roundvalueis thedifference of the dimensions in directions A andB. Thetapervalueis the differenceof thedimensions measured at points1 and2. Out-of-roundand taper limit (mm): 0.005 Pin and journal inspections . Usemicrometerto measurepin andjournaldiameters. Pin diameterstandardvalue (mm): 47.961- 47.974 Journaldiameterstandardvalue(mm): 54.951- 54.975 Curve inspection . UseV-blockson a fixedsurfaceandsupportjournalson bothendsof crankshaft(No.1 and No.7). . Positionthedialgaugevertically on middleof No.4 joumal as shownin thefigureon the right. . Turncrankshaft by handandreaddialgaugemovement. . The Run-outis equalto halfof dialgaugemovement. L i m i tv a l u e( m m ) : 0.05 inspection [Point28] Con'rodbearingoil clearance (A) Usinginsidemicrometerand micrometer . Theoilclearance canbecalculated fromconnecting rod bearinginsidediameter pindiameter andthecrankshaft measured in[Point1B]and[Point27]. = (Oilclearance) - (crankshaft (Bearinginsidediameter) pin diameter) Standardvalue(mm): 0.020- 0.040 Limit value(mm): 0.090 . lf the oil clearanceexceedsthe limit,referto [Point29]and selectthe appropriatebearing. E N- 1 9 7 ENGINEOVERHAUL R826DETT ENGINE (B) Using plastigauge . Removeanydustfromcrankshaftpinsand bearing surfaces. . Cutoff a pieceof plastigauge slightlyshorterthanthe bearingwidth.Placetheplastigauge on thecrankshaft in directionof axis. Caremustbe takennotto olaceon the oilhole. . Assembleconnectingrod bearingin connectingrodcap and tightenconnectingrod nutsto specifiedtorque. 1 s tt i m e Torquewrench(kg-m) 1 . 4 - 1 . 6 2 n dt i m e Anglewrench(") 60-65 . Removecon'rodcapandbeanngandmeasureplastigauge scale. widthwitha plastigauge Caution: or connecting rodwhileplastigauge Neverturnthe crankshaft is beinginserted. lf oil clearanceexceedsthe limitvalue,referto [Point29] and selectthe appropriatebearing. [Point29] Con'rod bearingselectionand engaging . Selectthe correctsizedbearingas the con'rodbearing preventsfluctuation in the oilclearance.Threebearing thicknessesare availableto fit the insidediameterof the big end of the con'rodand the crankpin diametergauge. . Whenreplacingthe con'rodbearing,checkbig end inside diametergauge(indicatedon the oppositesideof the con'rodhole)and the pin diametergrade(indicatedon frontsurface). crankshaftNo. 1 counterweiqht UpperjoumalgradeNo Con'rod bearingselectionchart Lessthan51.@7 Grsbr tlan 51.000 a o . STD1 STDO BearinggradeNo. BearinggradeNo. " ' 1. 5 0 3Bearingthickness(mm) ' 1 . 5 0-3 1 . 5 0 6 Bearingthickness(mm) 1 . 5 0 0 (mm) 0 . 0 2 0/ 0 . 0 3 9 0 . 0 2 0/ 0 . 0 3 9Oil cleararrce Oil clearance(mm) Browl None ldentifcation colour ldentitication colour LesstfEn 47.968 Greaterttran 47j&l. STD 2 STD1 BearinggradeNo. BearinggradeNo. Bearingthickness(mm) ' 1 . 5 0-3 1 . 5 0 6Bearingthickness(mm) 1 . 5 0 6- 1 . 5 0 9 0.02'1/ 0.040 0.020/ 0 040 Oilclearance(mm) Oil clearance(mm) Green Brown ldentifcation colour ldentification colour E N- 1 9 8 ENGINE OVERHAUL RB26DETE TNGINE . Whenusingundersize bearings, measurebearinginside diameter whenbearingis installed.Grindpinso oil clearanceconformsto specificvalue. R2.0jourr | _ R 1 ). (p r n l I l'' [-J Bearingundersizechart Size o us0.08 1 . 5 4 11 1 . 5 4 9 8 us0.12 1 . 5 6 /11 . 5 6 9 12 us0.25 1 . 6 2 6t 1 . 6 3 4 25 Caution: Caremustbe takennotto scratchfilletrollwhenthe crankpin is beinggroundedto use undersizebearing. [Point30] Mainbearingoil clearance Using bore gaugeand micrometer(MethodA) . Installmainbearingin cylinderblockandattachbearing cap. Tightenbearingcap boltsto specifiedtorqueand measurebearinginsidediameter. Bearingcap bolt tighteningtorque (kg-m): 4.7- 5.3 . Theoil clearancedistancecan be calculated fromthe valuesfor outsidediameterof the crankiournalmeasureo in [Point27]. (Oil clearance)= (Bearinginsidediameter)- (Crankshaftoutsidediameter) Standardvalue (mm): 0.028- 0.047 Limitvalue(mm): 0.090 lf oil clearanceexceedsthe limitvaluereferto [Point31]to selectsuitablebearing. Using plasticgauge(MethodB) . Removealldustandoilfromeachcrankshaft journaland bearingsurfaces. . Cut a pieceof plastigauge slightlyshorterthanthe gauge bearing width. Placea plastigauge on crankshaft in directionof axis,caremustbe takennotto placeon oil note. . Assemblethe mainbearingand bearingcap and tighten cap boltsto the specifiedtorque. Bearingcap bolt tighteningtorque (kg-m): 4.7 - 5.3 . Removebearingcap andthe bearing.Measure plastigauge widthon plastigauge scale. Caution: Do notturncrankshaft whileplastigauge is beinginserted lf excessivebearingclearancestillexists,use a thickermain bearingor undersizedbearingso that the specifiedbearing clearanceis obtainedwhenmeasuredbygethod A as well. \ \ t i / t---4 4, \ \,H-l I il) ,--nX',' t / SENSORSYSTEIV INSPECTION R826DETT ENGINE 6.6 ENGINETEMPERATURE SENSORSYSTEMINSPECTION CONTROLCIBCUITDIAGRAMR826DETTENGINE Engrne iemperature sensor m 2 8 " " O a o gnrtion limingconlro f q E dle speed control Engine temperaturesensor system trouble diagnosis flowchart RB26DETTENGINE = Se f-dLagnosis I .SELFDIAGNOSTIC FESULTS' '!: (codeNo.13) Sel-dagnosis Nonnal Abnorrna I Abnormal Enginetemp sensorinput signalinspection "DATANTONITOR' t I Measurethe vollagebetweenterrninal1 ano qrouno. @ i Enginetempdisplay .8 3V when cold 1V atler warrnnq up Enginetemp sensor inspection lvleasurethe reslslancebetween terrnrnal1 and 2. Olher InspectIntakeair temperature Enginetemperature sensorand ECCS C/U connectors sensor inspeclion for faultyconnectrons or defects. l\,4easufe the resistance betweenlermnal 1 and 2. Approx.2.5 Apr r o x . 2 . 5 k t ) w h ecno l d Olher up Sensorand ground inspection Measurethe voltagebetween terminal28 and 30. warmrngup r lnspectothe r Replace Engine temperature sensor SVSIEMS sensor Harnesscontinuityinspection Inspect ECCSC/U power l [,4easure the resistancebetween supplyand ground the followingterminals: Enginetemp ECCSC/U sen narness narness 0a InspectECCSC/U connectorand engrnetemp sensorconnectorfor conlactand defects. E N- 3 8 1 c o A Repairnarness SENSORSYSTEMINSPECTION RB2OE / D E / D E TE N G I N E SENSORSYSTEMINSPECTION 6-6 ENGINETEMPERATURE CONTROLCIRCUITDIAGRAMRB2OE/ DE / DET ENGINE conlrol Fue injectlon m sensot Engineternperature t-*---fr -----1' c) o a 8 o 5128) 8 (30) ldlespeedconlrol C =. Engine temperaturesensor system trouble diagnosis flowchad RB2OE/ DE / DET ENGINE Self-diagnosis RESULTS" IE-"SELFDIAGNOSTIC lcode No 13) € Self-diagnosis Abnormal Normal i, Abnormal Enrinetempse{tsorinputsignalinspection MONITOB" E-'DATA .€. N.4easure the voltage between termlnal l and qround. @ tempdisplaY E Engrne ,S 3V whencolo uP ]V atterwarminq EiliiE-iffi sensorinsPection EnginetemPerature Inspectintakeatr temPeralure sensorand ECCS C/U connectors sensor inspection the resrstance or defecls N-4easure for faultyconnections betweenterminal1 and 2. f/easurethe resistancebetween /* \ll-Y terminal1 and 2. - APProx 2 aKf) wnen colo Approx 0 3K o after warn Other UP Approx.2.5kOwhencold Approx.0.3Ko after warmrngup other Inspect I svsrems I Other Sensorand ground insPection Measurethe voltagebetween terminal5 (28) and I (30). Beplaceengine Replace Engine temperature sensor Olher HarnesscontinuitYinsPectiot Measurethe resistancebeiw€e n the followtngtermlnals: ECCSC/ Engrneternp harness sen harness 5 (28 1 8 (30 2 0a andenginetemp Fnspect EcCs c/u connector for contactanddelecls. sensorconnector EN - 382 cltr Inspect ECCSC/U power I supplyand ground [: Repairharness SENSORSYSTEMINSPECTION CA18E i NGINF 6.6 ENGINETEMPERATURE SENSORSYSTEMINSPECTION CONTBOLCIRCUITDIAGRAMCA18iENGINE Engrnetemperature sensor r---5f-*----+rt t T l m o o a o gnilionI mingconlrol l q c - Engine temperaturesensor system trouble diagnosis flowchart CA18i ENGTNE . Se f-diagnosis .I."SELFDIAGNOSTIC BFSULTS" 1& Self-dagnosis(codeNo. '13) Nomai t " D A I AM O N I T O R " I (Realtinrediagnosrs) | ffi--J---rono, mal Enginetemp sensoroutput signalinspeclion .f,.DAIAN,4ONITOR' the voltagebetween :8 l\,4easure termrnal1 and 2. E Engrnelempdispiay ;'e3 V w h e nc o i d 1V atterwarrnrngup Enginetemp sensor inspection(2) l\,4easure the resistancebetween termrnal1 and 2. Approx.2.5k',when cold Approx.0.3Kf] after warmrngup Inspeclolrrer Olher InspectIntakeair temperature Enginetemperature sensorand ECCS C/U connectors sensor inspection(2) lor fauty connections or defects. N.4easure the resistance betweenterminal1 and 2. Aporo^. 2.5Kf,) whencord .+A o o , o x . 6 .r3ar1no" | ' | 112l Other warmup ECCSC/U power supply and ground inspection ,F ,DATA N,4oNIToR" .& N.,1easure the voltagebetween ECCSCiU terrninal5 and L Other Replaceengine temperature sensor fr . E ergrne r lempdrsplay € 3 \ t when cold l \ ' after warm up Replace Engine temperalure sensor Olher Harnesscontinuityinspection Inspect CIU power l\,4easure the resislancebetween supplyand ground the followingterminals: Engrneternp ECCSC/U sen hafness harness 0{l lnspectECCSC/U connectorand enginetemp sensorconnectorfor contactand detects. EN - 383 cosl Repairnarness INSPECTION SENSORSYSTEI\,4 R826DETTENGINE 6-7 EXHAUSTGAS SENSORSYSTEMINSPECTION CONTROLCIRCUITDIAGRAMR826DETTENGINE gassensor Exhaust Air luel ratro control r__-.0_ It 2 lll -rH r;-T' 1 +----T-+ r * gassensor(tronl) Exhaust eallr t + t Cylinder,exhaust gas sensor' CONSULT(data monitor) display N o .1 2 , 3 c y l No.4. 5, 6 cyl 29 ECCSC/Uterminal O- sensor(rear) ECCS C/U terminal55 EN - 386 SENSORSYSTEMINSPECTION R826DETT ENGINE Exhaustgas sensorsystemtroublediagnosisflowchartRB26DETT engine Air-fuelratioteedback function inspection 'F,'DATA t40NtTOF' gassensoroutput i$ Exhaust monrtor. Normal Abnorrnal Abnormal .-F. Exhaustgassensorinput signalinspection t1t2l lTI4l lvleasure the voltagebetween 1. (O"sensor(F)) 2 . O . s e n s o(rR ) DeUectron belween0 - 1V ECCSC/U connectorsior faully contactor delects. (o,sensor( F ) ) ( O s e n s o rt R ) ) Other ECCSC/U power supply inspection ' ! DATA[,4ON]TOR E D sconneclO sensorconnecior ano T'teasLrre !o taqe !et,,..'eeECCS a U ieiii,ia ;: ;i.r gj.e.i]. Baltery ,Joliaqervhen gn 1on swrtchrs ON Oti'er Harnesscontinuityinspection InspectECCSC/ Measurethe resistancebetween U p o w e rs u p p l y the followingterminals: or replaceC/U O, sensor ECCSC/U .E;r . narness narness Or sensor(R)2 55 O, sensor(F)1 29 (O-,sensor (O,sensor (F)) Other (R)) @uff the resstancebetween l o w r n gt e r m i n a l s : O sensor(B) 1 - 3 O . s e n s o {r F )2 - 3 Repairharness Battery vo iage when gnrlronswrlch Checkfor laulty conneclions or replaceexhaustgas sensor the resistancebetween termrnals: Orsensorl-3 ( O , s e n s o (r R ) )2 - 3 oo " sensor heater oower inspection Measurethe voltagebetween followrngtermrnals: Or sensor(R) 1 and ground O sensor(F) 2 and Balteryvollagewhen 9nl on swrtchis ON RepairO, sensorgroundcircuit EN - 387 Sl ReplaceO, sensor SENSORSYSTEMINSPECTION R826DETTENGINE (1) Fuel-airratioteedbackf unctioninspection ,€\ items 19/ . Warmuptheengine andcheckthefollowing with'EXHGASSEN",'EXHGASSEN-R"(output "M/RF/CMNT-R'(lean/ voltage).M/B F/CMNT"and "DATA mode. MONITOR" in rich)displayed . Providesettrngvaluein "ACTIVETEST"(fuelinjection andcheckexhaustgassensor quantity correction) f unction. onthevehicle . Usingdiagnosis conne-ctor :199-^ ^ @ 'EXHAUST GAS to CONSULT set block), tuse lneai andcheckthefuelinjection MONITOR' SENSOR warning byflashingof exhaustgastemperature condition lampon instrument Panel. Exhaustgas sensorlunction warninglampmustflash5 times Exhaustgastemperature whenengineis runningat or morein 1Osecondsinterval rpm. approx.2,000 Feedbackf unction warninglampmustflas Exhaustgastemperature whenenginespeedis runningat approx2'000 periodically (2\'lirleasu Input signal insPection . re the voltagebetweenthefollowingterminalswith ECCScontrolunitharnessconnected. BEMEEN EUUD U/U BetweenECCS C/U terminal29 and ground terminal55 and ground Deflectionbetween approx.0 and 1V EN - 388 CAS.RPI,4(POS) EXHGASSEN E X HG A SS E N - R M/BF/CMNT I\4/RF/CN,4NT a AcrrvErEsr a I FUELINJECION MONITOB CAS.BPM(REF) ENGTEMPSEN EXHGASSEN EXHGASSEN'R INJPULSE AAC VALVE Qu 1975rpm 1,14V 1.03V RICH LEAN UP 0",1 937rpm 59'C 1.33V 1'35V 1 8msec 17-. DWN od SENSORSYSTEMINSPECTION RB2OE / D E / D E TE N G I N E 6-7 EXHAUSTGAS SENSORSYSTEMINSPECTION CONTROLCIRCUITDIAGRAMBB2OE/ DE / DET ENGINE n 115 Air luel ratro conlrol m o o a e 9, c EN - 390 SENSORSYSTEMINSPECTION RB2OE / D E/ D E TE N G I N E Exhaustgas sensorsystemtroublediagnosisflowchart RB20E/ DE/ DETengine Air-tuelratioteedbacktunction . inspection !].DATAI\,4ONITOR' € Exhaustgas sensoroutputmonitor. Abnormal Exhaustgas sensor input signalinspection Measurethe voltagebetween 1 . { R B 2 0 Ea) n dg r o u n d 2. (FB2oDEi DET)and ground Defleclron between0 - lV ECCSC/U conneclorsfor faulty contactor detects. 1 (R820E) ( R B 2 o D/ED E T ) Other ECCSCrupowersupplyinspection .E DATA[/ONTTOF" Or sensorconnector t' Disconnect andmeasure voltage between ECCSC/U termrnai27 (49)and Baftery voltage when rgnrlron swrtchs ON Harnesscontinuityinspection Measurethe resistancebelween the followingtermlnals: O, sensor ECCSC/U harness harness RB2OE 1 6 RB2ODE/DET1 29 0a InspectECCSC/ U powersupply or replaceC/U RB20DE/DET Repairharness Checkfor laulty connections or replaceexhaustgas sensor Batlery voltage rgnilron swilch Checkfor laulty connections or replaceexhaust gas sensor Measurethe resistancebetween termrnal1 and 3. " sensor heater oower inspection MeasLrre the voltagebetween termrnal1 and ground. Balteryvollagewhen ignrtron swrlchrs ON RepairO, sensorgroundcircutt EN - 391 ReplaceOrsensor /-rt-\ (!I?I]J (RB2oDE/ DEr) SENSORSYSTEMINSPECTION C A 1 8 iE N G I N E 6-7 EXHAUSTGAS SENSORSYSTEMINSPECTION CONTROLCIRCUITDIAGRAMCA18iENGINE Exhauslgas sensor m o o r---H a '= a J T o c : Engine Exhaustgas sensor systemtrouble diagnosisf lowchartCA18i . Setldiagnosis l, "sELF-DtAGNosls FESULTS" (codeNo.15) € Self-diagnosis Abnormal Abnormal Exhaustgas sensor inPut signalinsPection 'i_ 'DATA MONITOF' ECCS6 and ground. RICHl LEAN -a Display Displayoutpul voltage0 EDrsolav0-1V ECCSCru Power suPPlYinspection r- DATAMONITOR'' ,$ Disconnect 02 sensorconnector and measurevoltageDerween ECCSC/U terminal27 (49)and lnspectexhaustgas sensorand for faultY ECCSC/U connectors contaci or delects. Battery vollage wnen ignitionswitchis ON HarnesscontinuitYinsPection the resistancebetween l\,4easure 02 sensorharnesstermlnal1 and ECCS C/U harnessterminal6 lnspectECcSC/ U powersupply or replaceC/U 0 {il Checktor taulty conneclionsor replaceexhaust gas sensor EN - 392 Repairharness SENSORSYSTEMINSPECTION RB2OE / D E/ D E T / C A 1 8 E N G I N E (1) Fuel-airratiofeedbackf unctioninspection . Warmuptheengine andcheckthefollowinq itemswith "EXH GASSEN"and"M/RF/CMNT',0ean / rich) displayed in "DATAMONITOR" mode. ruornrr fr,,lor':rroRrrufr CAS.RPM(POS) AIRFLOWI\,ITR ENGTEMP EXHGASSEN I\,4/R F/CI\,4NT 2012em 1-54V 8O"C 0.72V RICH RECORD . Providesettingvaluein "ACTIVETEST"(fuelinjection quantity correction) andcheckexhaustgassensor function. Note: "lNJPULSE' displayfor RB20Eis 1/16. . Usingdiagnosis connector on thevehicleside (nearfuseblock),setCONSULTto'EXHAUST GAS SENSORMONlTOR" andcheckthefuelinrection condrtionby flashingof exhaustgas temperature warning tampon rnstrument panel. Exhaust gas sensor function Exhaustgastemperature warninglampmustflash5 times or morein 10secondsinterval whenengineis runningat approx.2,000 rpm. Feedbackf unction gastemperature Exhaust warninglampmustf lash periodically whenenginespeedis runningat approx.2.OOO rpm. (2) Inputsignatinspection . Measurethe voltagebetweenthefollowingterminalswith ECCScontrolunitharnessconnected. E--r-^ RB2OE/CAt8iI {|l'snl kitt:i::,rir: :-ri.i.: ,. {!pq. |!'.']r:':i:1,: nemoelo BetweenECCS C/U BetweenECCS C/U terminai1 and ground termrnal29 and ground Deflectronbetween approx. 0 - 1 Deffection between approx.0 - 1 EN - 39s a ncrrveresr | ! FUELINJECIION tll0NtToF CAS.RPN4iREF) ENGTEI\,4P SEN EXHGASSEN INJPULSE AAC VALVE Ou UP +11o.a 1037rpm 36.C 0.87V 4.omsec 369/. OWN od SENSORSYSTEI\,4 INSPECTION B B 2 6 D E Ti TF B 2 O ED i E/DET/CAl8E ] NGINE 6-9 VEHICLESPEEDSENSORSYSTEMINSPECTION CONTROLCIRCUITDIAGRAM RB26DETTENGINE Fuel cut control m o a dle speedconlrol o :l c l RB2OE/ DE / DET ENGINE m o o a o t1 O i53) c ()RB2ODE/DET C A 1 8 iE N G I N E EN - 397 l ldlespeedcontrol SENSORSYSTEMINSPECTION :.:.:E'-T / D E / D E T/ C A I B iE N G I N E RB2OE oRNGft (1) Inputsignal inspection . Select"VEHICLESPEEDSENSOR"in "DATA rtems. modeandcheckthefollowing MONITOR" (REF) CAS.RPM C A RS P E E DS E N c When drive wheelsare rotating Vehiclespeed is disPlayed terminats@ . Measure thefollowing thevoltagebetween connected. unitconnectors withECCScontrol 6-10 rGNtTloNswlTcH (STARTSWITCH)SIGNAL INSPECTION cAl8i @ (1) Inputsignal insPection n . In "DATAMONITOR'mode,performthekeyoperatio "START" is input signal to checkif the ignitionswitch correctlv. 25 (45) ECCS control unrt terminalsA . Measurethevoltagebetweenthefollowing \@i with ECCScontrolunitharnessconnected. RB26DETT/ RB2O ECCSC/U ECCSC/U ECCSC/U 23 25 terminal 45 and terminal terminal ground Batteryvoltage EN - 398 SENSORSYSTEMINSPECTION R B 2 6 D E T/TR B 2 O E / D E / D E Ti C A 1 8 E i NGINE 6-11 AIR CONDITIONER SIGNALINSPECTION B26DETT/ RB2O Dua presslre s w i t ch 4A {9) _ o o U) o l q (46) ( ) RB2ODE/DETiRB26DETT @ (1) Inputsignalinspection . In "DATAMONITOR'mode,pedormtheairconditione I switchoperation to checkil theairconditioner switch signalis inputcorrectly. cA18i A/C switch . Measurethe voltagebetweenthe followingterminals withECCScontrolunitharnessconnected. 6 - 12 NEUTRALSWITCHSIGNALINSPECTION (1) Inputsignalinspection . In "DATAMONITOR"mode,performshiftlever operation to checkif neutralswitchsignalis @ . ^lSililJtiS'Y;rtase between therorowins terminars @ andgroundwithECCScontrolunitharnessconnected. I EN - 399 RB26DETTiRB2ODEiDET SENSORSYSTEMINSPECTION R B 2 6 D E T/T C A 1 8 ]E N G I N E 6-13 POWERSTEERINGSWITCHSIGNAL po*"r'"t"",,nq INSPECTION swtch(1) Input signal inspection fe .|n.,DATAMoN|ToR"mode,performpoWerSteering\g/ (ls) ECCS control switch i = oilpressure tocheckif powersteering operation correctly. signalisrnPut terminals . Measure thefollowing between thevoltage @1 9 connected. r ,BB26DErr unitharness withECCScontrol unit cA18i 6-14 LIGHTSWlrcH SIGNALINSPECTION @ (1) input signal insPection "DATA . ln MONITOR'mode,performlightswitchoperation lo checkif lightswitchsignalis inputcorrectly' terminals . MeasurethJvoltagebetweenthefollowlng @ withECCScontrolunitharnessconnected. Lrghtswitch lcr_ ---6zd--{qs @ EN - 400 I I /l EccsI / I control I t 6-15 HEATERFAN SIGNALINSPECTION (1) Input signal inspection . ln "DATAMONITOR'mode,performheaterfanoperation to checkif heaterfanswitchsignalis inputcorrectly' . Measurethe voltagebetweenthe followingterminals /A\ \.f,i withECCScontrolunitharnessconnected. /t ,1. I unit - I R825DEDIAGNOSIS R 8 2 5 D EE N G I N E DIAGNOSIS 1 . POWERSUPPLY& GROUNDCIRCUTT #21 2.1-- Components location I EN - 401 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E A START Startt le engrne. Doestneengrne NG CAS BAT ol ground D. circutt Inspect OK STABT FINISH A A PowersuPPIYinsPection to ONposition. switch Placeignition -BATTERY voltageusing OK battery Inspect 1S \@ VOLTAGE"in mode. DATAMoNlToB f, rar Usetesterto measurethe voltagebetween ..1,r'ECCSC/U terminal49. 50 and ground. NU D GroundcircuitinsPection E Placeignitionswitchin OFF ECCSC/U position.Disconnect harnessconnector. Checkfor harnesscontinuitybetween t ! E C C SC / Ut e r m i n a1l ,0 , 2 0 ,1 0 7 '1 0 8 I a n d1 1 6a n dg r o u n d . lF NG: Repairharnessandconnectors FINISH c B ECCS C/U terminal and ECCS relay harness continuityinsPection Placeignitionswitchin OFFposition. DisconnectECCSC/U and ECCSrela't harnesr connector. 'U al lnspectfor continuitybetweenECCSC, termin 49, 59 and ECCSrelaYterminal3. Fle m , |!l3i---\ I M qa-.'- ei--.' i NG I I Rpneirharnesso r connecto.lc OK Voltage inspection between ECCS C/U terminaland ground switchto ON position. Placergnition Measurethe voltagebetweenECCSrelay 2,3 andground. terminal NG Voltage:Batteryvoltage lF NG: Placeignitionswitchto OFF position link. , o .6 f u s i b l e N o . 2 1f u s e ,N o . 3 N relayand ECCS between thecontinuity Inspect thebattery. ToE Eer lF l l -Eccs I :6- I Reoairharnessor connector EN - 402 FI825DE DIAGNOSIS R B 2 5 D EE N G I N E E Outputsignalcircuit inspection Checkthecontinuation betweenECCSC/U N G terminal'16andterminal1. OK Inspectthefollowing: lgnitioncoilharnessconnector. HarnessbetweenECCSC/U and ECCSrelay. lF NG: Repairharnessor connector. Component parts inspection (ECCSrelay) NG Referto the sectionon ECCSrelavfor Inspectron. RepairECCSrelay Checkfor anydamageon the ECCSC/U terminals and ECCSC/Uconnector. Carry out the inspection in the lollowing order after repairs. Verifrcation inspection Restart theengine Doestheenoinestart? Powersupplyinspection Checkforanydamageon the ECCSC/Uterminals and ECCSC/U connector. Groundcircurt inspection Checkforanydamageon the ECCSC/Uterminals and ECCSC/Uconnector. EN - 403 R825DEDIAGNOSIS B B 2 5 D EE N G I N E 2 - CRANKANGLESENSOR(CODENO' 11 IN SELF.DIAGNOSIS) DIAGNOSIS 16 m o a o - c i c i 5) Components location " EN - 404 anglesensor _CJAnk RB25DEDIAGNOSIS R B 2 5 D EE N G I N E START Carryoutself-diagnosis OK NG To diagnosis 14 A Powersupplyinspection Placeignitionswitchto OFFposition. Disconnect crankanglesensorharness connectors. NG Placeignition switchto ON position. Usetesterto measurethevoltaqebetween terminal 3 andqround. OK Inspectthe following: Checkthecontinuity betweencrank anglesensorterminal3 and ECCS relayterminal3. lF NG: Repairharnessor connectors. € @ c/u 42 52 and 2 5 l a n dI B Inputsignalcircuitinspection Placeignitron switchto OFFposition. Disconnect ECCSC/Uharnessconnectors. Checkthecontinuitybetweencrankanglesensor NG terminal2 and ECCSC/Uterminat 42,52 (1"signal), betweencrankanglesensorterminal1 andECCS C/Uterminal41, 5 1 (120"signal). c OK Repairharnessor connector Inputsignal inspection ConnectcrankanglesensorandECCSCiU harnessconnectors. Use"CRANKANGLESEN RPM'in 'DATA ,S \G/ MoNlToR"to measure enqrnesoeed. /fl) Measure thevoltagebetweenECCSC/U v termin4 a2 l . 5 2 . 5 1a n dg r o u n d . OK Xg:Q@ NG Component pans inspection (Crankanglesensor) Referto thesectionon crankanglesensorfor inspection. lF NG: Replacecrankanglesensor. Checkfor anydamageon the ECCSC/U terminalsand ECCSC/U connector. EN - 405 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E Carry out the inspection in the following order after repairs' Verificatroninspection Erasememoryfromself-diagnosis byself-diagnosis Recheck onthe Checkforanydamage and ECCSC/Uterminals connector. ECCSC/U EN - 406 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOS|S 3 - AtR FLOWMETER(CODENO.12 tN SELF-D|AGNOS|S) € A r fiow meter o o q SignalgroundE 26 :. Components location \ i \ . -,,'.1 Arrflow meter harnesscon!,eclor EN - 407 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E Ee@ PowersupPlYinsPection Placeignitionswitchto OFFposition. airflowmeterharness Disconnect connectors. Placeignitionswitchto ON position. Usetesterto measurethe voltage 3 andground. betweenterminal %ei@ lnspect the following: betweenairflow Checkthecontinuity meterterminal5 andECCSrelaY 3. terminal lF NG: Repairharnessor connectors. Groundcircuitinspection switchto OFFposition. Placeignition connectors' ECCSC/Uharness Disconnect 4 andECCS terminal between Checkthecontinuity 26. C/Uterminal Repairharnessor connector Inputsignal insPection Checkthe continuitybetweenairflowmeter terminal2 andECCSC/Uterminal27 (intake signal). airquantity Bepairharnessor connector EN - 408 Ele,@ RB25DEDIAGNOSIS R B 2 5 D EE N G I N E D Inputsignal inspection Connectcrankarrflow meterand ECCSC/U harnessconnectors. rroRrNq\iroFAtL cAs.RPM(REF) AIRFLOWMTR ENGTE[,4P SEN EXHSEN THROTTLE SEN INJPULSE Use 'AlBFLOWMETERin DATA r€\ \g/ MONITORtomeasure inoutsional. ,S Measure^the voltagebelweenECCSC/U :. Iermlnat z/ andoround. NG Approx.0.3V A p p r o x1 V ' OK ' ldlirq ''1'. ctv A p p r o x1.. l V Component parts inspection (Crankanglesensor) Referto the sectlonon crankanglesensorfor rnspection. lF NG: Replacecrankanglesensor. Checkfor anydamageon the ECCSC/U terminals andECCSC/Uconnector. Carryout the inspectionin the followingorderafterrepairs. Verificationinspection Erasememoryf romself-diagnosis Recheckby self-diagnosis Checkforanydamageon the ECCSC/Uterminals and ECCSC/Uconnector. EN - 409 662rpm 1.02V 81, O.1BV O.4OV s.omsec RB25DEDIAGNOSIS B 8 2 5 D EE N G I N E SENSOR DIAGNOSIS4. ENGINETEMPERATURE ( c o D E N O .1 3 l N S E L F - D I A G N O S I S ) EnginetemPerature sensor Fuelinjectionconlrol a ! m o o o timrngcontrol lgnrlion o ; -; Componentslocation 5\- ' . 1 Enginelemp sen trr'l ^^nn6^t^r A Power supply insPection Placeignitionswitchto OFFposition. sensor enginetemperature Disconnect harnessconnector. switchto ON position. Placeignition Usetesterto measurethe voltage betweenterminal1 andground. r harnessor connector E N- 4 1 0 Ke@ \' R825DEDIAGNOSIS F 8 2 ' D EE N G I N E B Groundcircuitinspection Placeignitionswitchin OFFposition. Checkcontinuity between terminal 2 andground. c OK Repair harness orconnector Inputsignal inspection Use"ENGTEMPSENSOR Tn DATA 1S1 : MONITOB" to checkenainecoolant NG Iemperalure. Cnect the voltagebetweenECCSC/U (g) terminal28 andoround. Voltage: Whenigniiionswitchis ON EngtempApprox.20oC 3V Approx.80"C 1V OK Componentparts inspection (Engine temperature sensod Refertothesection onengine temperature sensor forinspection. lF NG:Replace crank anglesensor. Checkfor any damageon the ECCSC/U terminals andECCSC/Uconnector. Carryout the inspectionin the followingorderafterrepairs. VerificationInspection Erasememoryfromself-diagnosis Recheckby self-diagnosis Checkforanydamageon the ECCSC/Uterminals and ECCSC/Uconnector. FINISH E N- 4 1 1 DIAGNOSIS RB25DE R B 2 5 D EE N G I N E 5 -IGNITIONSYSTEMINSPECTION DIAGNOSIS (coDE NO.21 lN SELF-DIAGNOSIS) FIL6 fi o ql 3 ECCSrelay ' ,-,tilf st9-9f 3 -Ful Components location -l i",::'"u E N- 4 1 2 RB25DEDIAGNOSIS B B 2 5 D EE N G I N E lsrrr-onc nesO o u ts e l fd i a g n o s r s , FAILURE DETECTEDTIME I G NS I G N A LP R J M A F YO Toignition srgnal1 (ltem n o tI ns e l fd i a g n o s i s ) Circuitf unctioninspection Inspect using"POWER BALANCE" in 'FUNCTION TESI-'mode. Checkto ifengine revwilldecrease ntary mome @ Groundcircuitinspection Placeignition switchin OFFposition. powertransistorunitharnessconnector. Disconnect Checkfor harnesscontinuitybetweenterminalE and grouno. ()POWER BALANCEl) INSPECTTHE BALANCE OF EACHCYLINDERBY STOPPING INJECTOR OPERATION FOREACH CYLINDEF, FASSI B Repair harness orconnector Outputsignalcircuitinspection Placeignitionswitchin OFFposition. DisconnectECCSC/U harnessconnector. Inspectfor continuity betweenthefollowingterminals: ECCSC/Uterminal1 andterminal2 ECCSC/Uterminal12andterminal2 ECCSC/Uterminal3 andterminal3 ECCSC/Uterminal13andterminal4 ECCSC/Uterminal2 andterminals ECCSC/Uterminal11andterminal6 ECCSC/Uterminal10andterminalE ECCSC/Uterminal20 andtermrnal E Repairharnessor connector Outputsignalinspection Connectpowertransistor unitand ECCS C/U harnessconnectors. InspectbatteryvoltagebetweenECCSC/U t e r m j n a 1l s, 2 , 3 ,1 1 , 1 21, 3a n dg r o u n d . Cranking: Approx.0.2- 0.3V ldling: Approx.0.2- 0.3V 2500rpm: Approx.'lV Inputsignalsysteminspection E N- 4 1 3 E err RB25DEDIAGNOSIS RB25DEENGINE Component parts inspection unit) (Powertransistor Referto the sectionon powertransistorfor lF NG. Replacepowertransistor inspection. unit. Reolaceoowertranslstor Checkfor anydamageon the ECCSC/U andECCSC/Uconnector. terminals Carry out the inspection in the following order after repairs' VerificationinsPection Erasememoryfromself-diagnosis Recheckby self-diagnosis Checkforanydamageon the and ECCSC/Uterminals ECCSC/U connector. E N- 4 1 4 R825DEDIAGNOSIS RB2sDE NGINE DIAGNOSIS 6 - EXHAUSTGAS SENSOR (coDE NO.15 tN SELF-D|AGNOSIS) m 2 1 9 5 ( O U' ' Components location START Oarryoutselfdiagnosis NG A OK FINISH Function inspection 1 Warmuotheenoine. "BASEAIR-FUEL ( l)lnspect using RAT|O"in "FUNCTION : TEST mode. NG OK To B FINISH E N- 4 1 5 AIR,FUEL RAIIo TESTl HOLDTHE ENGINE SPEEDAT 2000+l200rpmAND PBESS START RB25DEDIAGNOSIS R B 2 5 D EE N G I N E Functioninspection2 Starttheengine. Holdthe engineat 2000rpmand inspect "O "O, using SENSOR"(outputvoltageand "DATA rich)in SENSORMONITOR'(lean, MONlTOR"mode. Measurethe voltagebetweenECCSCiU terminal29 and ground. voltage) NG Approx.0.3V(constant (variant voltage)OK Aoorox.over0-6 1V START X e- 11: Fcctc^i"""*".-i I InputsignalcircuitinsPection to OFFposition. switch PIaceignition andECCS connector O,sensorharness Disconnect connector. C/Uharness 29 betweenECCSC/Uterminal Checkcontinuity 2. terminal andO-sensorharnessconnector t-; Elee Repairharnessor conneclor ReplaceO, sensor Checkforanydamageon the ECCSC/U andECCSC/Uconnector. terminals Carry out the inspection in the following order after repairs' VenficationinsPectlon Erasememoryf romself-diagnosis Recheckby self-diagnosis Checkfor anydamageon the and ECCSC/Uterminals ECCSC/Uconnector. E N- 4 1 6 iin j.----.---I RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS 7 - DETONATION SENSOR (coDE NO.15 tN SELF-D|AGNOS|S) tl] a = Components location *-;:-_-.-:-"'-: .,:1 E N- 4 1 7 Detonationsensor mid harness connector RB25DEDIAGNOSIS RB2sDE NGINE c/u lnput signalcircuitinsPection1 Placeignitionswitchto OFFposition. DisconnectECCSC/U harnessconnectorand sub harnessconnector. terminal1 and Checkthe continuitybetvveen ECCSC/Uterminal23, terminal2 and ECCSC/ 24. U terminal O K Repairharnessor connector 2 Inputsignalcircuitinspection frontand NG connected connectors harness Disconnect sensor. rearof thedetonation terminalA subharness between thecontinuity Check and23. B and24. Repairharnessor connector OK lnput signal inspection sensorandECCSC/U Connectdetonation harnessconnectors. Measurethe voltagebetweenECCSC/U 23,24 andground. terminal Measurementlocation temltnal23, 24 and ground lgnition switch ON Approx.4V C ran king Approx.4V ldling Approx.4V Replacedetonatlonsensor Checkfor anydamageon the ECCSC/U andECCSC/Uconnector. terminals Carry out the inspection in the following order after repairs' insPection Verification Erasememoryf romself-diagnosis Recheckby self-diagnosis Checkforanydamageon the and ECCSC/Uterminals ECCSC/Uconnector. RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOS|S 8 - THROTTLESENSOR(CODENO.43 tN SELF-D|AGNOSIS) m o Throtliesensor '1 o o za fuC cutcontrol 38 3 :uel injectionconko = = s Componentslocation 'ECCS c o r t r o .L n , t I START OK Oarryoutselfdiagnosis I rrRorrLeselrsonl NG FINISH A System inspection Placeignitionswitchto ON position. USe"THROTTLE SENSOR'in"DATA MONITOR"to inspectthesystem. OK Voltage: Fullyopen Approx.4.0V Fullyclosed Approx.0.6V Open/ Closerange overApprox.3.0 NG FINISH TOB E N- 4 1 9 PFESSSTAFTWHILE PRESSING THE ACCELERATOB PEDAL FULLY RB25DEDIAGNOSIS R B 2 5 D EE N G I N E B Power supply insPection ignitionswitchto ON position. ffi NG : Ptace -THROTTLE SENSOB"in DATA Use MONITOR'toinspeP!etaceignitionswitchto OFF posilion. 19 vDisconnectthrotllesensorharnessconnector. Measurethevoltagebetweenterminal1 and ro retr *vortrontr* (BEF) CAS.RPN,,I THROTTLESEN orprn 3,94V :APProIjll-voltage ground.Battery U OK Repairharnessor connector InputsignalcircuitinsPection connector.NG ECCSC/Uharness Disconnect ECCSC/U between Checkthecontinuity 2. 38andterminal terminal r-_-._.-- | ,,_. Ee .@, l Repairharnessor connector Cornponentparts inspection (Throttlesensor) sensorfor inspection' Referto thesectionon throttle unit. sensor throttle lF NG: Replace OK Checkfor anydamageon the ECCSC/U andECCSC/Uconnector. terminals Carryout the inspectionin the followingorderafterrepairs' Verificationinspection Erasememoryfrom self-diagnosis Recheckby seltdiagnosis Checkfor any damageon the and ECCSC/Uterminals ECCSC/U connector. EN - 420 ) RB25DEDIAGNOSIS R 8 2 5 D EE N G I N E D|AGNOS|S 9 - A / T CONTROL (CODENO.s4 tNSELF-DIAGNOSIS) c - L---i Componentslocation ..'''.: ,:..] START OK Carryoutselfdiagnosis NG FINISH A Inputsignalcircuitinspection Placeignitionswitchto OFFposition. DisconnectECCSC/U harnessandA,/TC/ U harnessconnectors. NG Checkthe continuitybetweenECCSC/U terminal14 andA/TCiUterminat10, ECCS C/U terminal5 andA"rTC/Uterminal11. OK Repairharnessand connectors Checkforanydamageon the ECCSC/U terminals andECCSC/Uconnector. EN - 421 G )@ i5 j lA/Tcti connecta RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS1O- CRANKANGLESENSOR(NOTlN SELF-DIAGNOSIS) FiL6 Crank angle sensor Componentslocation ECCScontrolunlt EN - 422 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E START A Groundcircuitinspection Placeignition switch to OFFposition. Disconnect crankanglesensor harnessNG connector. Checkforcontinuity between terminal 4 andenginegroundharness. A OK Repairharness or conneclor Component parts inspection (Crankanglesensor) NG Referto thesectionon crankanqlesensor for inspection. OK Replacecrankanglesensor Checkfor anydamageon the ECCSC/U terminals andECCSC/Uconnector. Carryout the inspectionin the followingorderafterrepairs. Verification inspection Groundcircuitinspection Checkforanydamageon the ECCSC/Uterminals and ECCSC/Uconnector. EN - 423 Xea RB25DEDIAGNOSIS B B 2 5 D EE N G I N E D|AGNOS|S11 - IGNIT|ONSIGNAL1 (CODENOTlN SELF-DIAGNOSIS) F/16 ECCSrelay r+/rtnt 2 !!III Fdf4r{-d) tElttll_lttlj Componentslocation Power tranststorunil EN - 424 RB25DEDIAGNOSIS R B 2 5 D EE N G ] N E OPOWERBALANCEO INSPECTTHEBATANCE O F E A C HC Y L I N D E R BY STOPPING INJECTOR OPERATION FOREACH CYLINDER. TURNOFFA/C& LIGHTS Whole system inspection Startthe engtne. ls allcylinder ignited? To ignitionsignal2 Circuitf unctioninspection Inspectusing"POWERBALANCE" in "FUNCTION TEST"mode.OR power balancein "ACTIVE TEST". Checkto if enginerevwilldecreasemomentary. E OK Power supply inspection Placeignition switchin OFFposition. Disconnect ignition coilharnessconnector. Placeignitionswitchto ON posrtion. UseCONSULT or thetesterlo measurethe voltagebetweeneachcoilterminal 1 andground. Power voltage: Battery voltage Inspectthefollowing: lgnitionrelay lgnitionswitch Continuitybetvveen eachcoil Harnessterminal 2 andignition relavterminal5. ACTIVE TEST POWER BALANCE t\40N tToR cAS.RPr\r(POS) AIRFLOWI\,4ETER trtrtr8 rdtrILl B 1%e:-,.$rf) c @ 5,t,5 Ground circuit inspection Placeignitionswitchin OFFposition. Checkfor harnesscontinuitybetweeneachcoil terminal 3 andqround. OK Repair harness orconnector Outputsignalcircuitinspection powerlransislorunit harnessconnector. Disconnect Inspectforcontinuity betweenthefollowingterminals: Betweeneachrgnition coilterminal1 and Powertransistor unitterminal1 Powertransistorunitterminal2 Powertransistor unitterminal 3 Powertransistor unitterminal 4 Powertransislor unitterminal 5 Powertransistorunitterminal6 Repairharnessor connector EN - 425 D iXe,@ RB25DEDIAGNOSIS RB2sDE NGINE Components insPection coil) (Powertransition unit& lgnition coil ignition unit and power transition Referto section. inspection in components inspeclion faultyparts Replace Carry out the inspection in ihe lollowing order after repairs: VerificationinsPection ComponentsinsPection RecheckECCSC/Uterminalfor damageandcheckECCSC/U harnessconnectorconnection. EN - 426 r 5 R825DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS 11- IGNITION SIGNAL2 Continuefrom ignitionsignal1 E Power supply inspection Placeignition switchin OFFposition. Disconnect ignitioncoil relayconnector. Placeignitionswitchto ON position. UseCONSULT or testerto measurethe voltagebetweencoilterminal 2,3 andground. Power voltage: Battery voltage OK Inspectthefollowing: Continuation between fusiblelink, ignition coilrelayandignition switch. Continuation betweenignition coil relayandthe battery. F Groundcircuit inspection PIaceignitionswitchto OFFposition. Inspectharnesscontinuation betweeneachcoil terminal2 and5. OK G NG ECCSC/U NG Inspectthefollowing: Fusiblelink. Continuatron betweenECCSC/Uand ECCSrelayharness. Continuation betweenECCSC/U and ignition coilrelayharness. lF NG: Repairharnessandconnector. Components inspection (lgnition coil& ECCSrelay) NG Referto ignitioncoiland ECCSrelayinspection In componentsinspectjonsection. OK Il ee;@ Repair harness and/ orconnector Outputsignalcircuit inspection DisconnectECCSrelay. Inspectthe continuation betweenECCSC/U terminal16 and ECCSrelavterminal2. OK NG Replacefaultycomponents InspectECCSC/Uterminal for anydamage and ECCSC/U connectorfor connection. EN - 427 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS12 - INJECTORSYSTEMINSPECTION 3 Giil € 4 m o i Ftrl*"., No- i o ECCSrelav L)-IJJ -t-----1 l/!!r.t l.l.l -_l;la :EiutttlS q 1'-o o-+ L @ @ N o .1 No.2 3 location Components ECCScontrolunrt EN - 428 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E START A tFowrR elLANtcEl Circuit f unction inspection Inspectby "POWERBALANCEin /G\ "rurucrroN TEST' mooe. fJ "POWER Operate BALANCE" in CONSULTactive test. operation noise ffi Makesuretheinjector \O/ rsaudible. INSPECTTHE BALANCE OF EACHCYLINDERBY STOPPING THE INJECTOR DRIVE FOR EACHCYLINDER. OK NG FINISH B Power supply inspection 1 Placeignition switchto OFF. Disconnect sub harnessconnector. Checkthe batteryvoltagebetweenterminal 3 andgroundusingCONSULT or tester. ierreE NG Inspectthefollowing: Harnessconnector. Continuity betweensub harness connectorandthe harness. lF NG: Repairharnessandconnector c Power supply inspection 2 Placeignitionswitchto OFFposition. Disconnect sub harnessconnector. Inspectbetweenthefollowingterminals forcontinuity: betweenterminal3 and 5 betweenterminal3 and 6 belweenterminal3 and4 OK D NG Disconnect injectorharnessconnector. Inspectbetweenthefollowingterminals forcontinuity: betweenterminal109andNo. 1,2, 3, 4,5&6cylinders. To EN - 429 H No.1 No.2 No.3 No.4 No.5 No.6 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E E Out put circuit insPection DisconnectECCSC/U harnessconnector. Inspectbetweenthefollowingterminalsfor continuitY: betweenterminal10.1andNo. 1 cylinder betweenterminal105andNo.2 cylinder betweenterminal103andNo.3 cylinder betweenterminal112andNo.4 cylinder betweenterminal110andNo.5 cylinder betweenterminal114andNo.6 cylinder e:@9[ con NG OK Flepairharnessor connector. ComponentPartsinsPection (lnjector) forinspection' oninjector Refertotheseclion NG Replaceinjector. foranY ECCSC/Uterminals Inspect connectors damageandmakesurethe correctlY. areconnected Carryout the inspectionin the followingorderafterrepairs: VerificationinsPection Recheckfor anydamageon the ECCSC/U terminalsand ECCSC/U connector. EN - 430 R825DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS13 - VEHTCLE SPEEDSENSOR m o o a - _ 3 o Componentslocation START Whole system inspection UseCONSULT andcarryoutthejnspectionO K " V E H l C L E using S P E E DS E N S O Ri"n "FUNCTION TEST"mode. NG FINISH Vehiclespeedsensorfunctioninspection N G Inspect vehiclespeedmeterfunction OK TOB Vehiclespeedsensorand vehiclespeedsensorcircuit inspection. EN - 431 RB25DEDIAGNOSIS RB25DEENGINE fS,tortrontufrNornlr B InputsignalinsPection Startthe engine. Rotatedriveaxles]ew]y- NG (POS) CAS.RPI\, /a\ b-eieiltehicbspeedusingVEHICLE i'LQ4IA-NIONIIOBspeeoSENSOR" u ,o' W thevoltagebetween Usetesterto measure 53andground. EccS C/Uterminal 0 5V ----Voltage:aPProx. OK Inspectthe following: betweenECCS Checkthecontinuity meterharness. C/U andcombination lF NG:Repairorf9ple99i9M9!'-forany InspectECCSCiUterminals connectors damageandmakesurethe areconnectedcorrectly. Carryout the inspectionin the followingorderafterrepairs' VerificationinsPection insPection circuit Ground Checkfor anYdamageon tne and ECCSCiUterminals ECCSC/U connector. EN - .132 c/u 787r7m R825DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS 14 -AIR CONDITIONER RELAYSIGNAL To FrCDrela,i Duai pressute IGNreiay1 AC rear sw ACC reiay ACC key SW m o o a o )q Components location controtunrt Inputsignal inspection Placeignition switchto ON position. Usetesterand measurelhe batteryvoltage betweenECCSC/UterminalI andground. Whenblow-fanswitchis OFF: batteryvoltage Whenblow-fan switchis ON: Approx.1V InspectECCSC/Utermrnalsfor any damageand makesurethe connectors areconnecledcorrectlv. Carryout the inspectionin the followingorderafterrepairs. Groundcircuitinspection Checkforanydamageon the ECCSC/Uterminals and ECCSC/Uconnector. EN - 433 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS15 - EXHAUSTGAS SENSORHEATER Trl o o (, o x Components location t \ i' controLlntt ,,-l EN - 434 9 R825DEDIAGNOSIS FIB25DE NGINE START A Powersupplyinspection Disconnect gassensorharness exhaust connector.N G Placeignition switch toONposition. powervoltagebetween Measure terminal 1 and ground. OK B lnspectthe following: Harness connector. Continuity between gas exhaust sensor andthefuse.lF NG: Repairharness andconnector. Groundcircuitinspection Placeignitionswitchto OFFposition. DisconnectECCSC/U harnessconnector. NG Checkforcontinuity between termrnal 3 and E C C SC / Ut e r m i n a1l 1 5 . OK Repairharnessor connector. Component parts inspection (Exhaustgassensorheater) Referto the sectionon exhaustoas sensor heaterfor inspection. OK NG Replaceexhaustgassensor. InspectECCSC/Uterminalsfor any damageandmakesuretheconnectors areconnectedcorrectlV. Carry out the inspection in the following order after repairs. Verification lnspection Checkforanydamageon the ECCSC/Uterminals and ECCSC/Uconnector. Inspectpowersupply,groundcircuit EI\ - I+JJ RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS16. THROTTLEVALVESWITCH rf o o U) - _ o q Comoonentslocation d--4"i6-r' valvesw EN - 436 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E START A Function inspection 1 Placeignition switchto ON positron. "IDLE Inspectusing JUDGEMEN'l-' in O K "FUNCTION TEST'mode. Reference: Fullyopen:OFF Fullyclosed:ON FINISH B NG Functioninspection2 Placeignition switchto ON position. Inspectignition switch"ON-OFF" diagnosis or measurelhe voltagebetweenECCSC/Uterminal O K 54 andgroundusingthetesterwhenignition switch i sO N . Voltage: Accelerator pedalpressed0V pedalnotpressed8 - 10V Accelerator NG FINISH c Power supply inspection Placeignrtion switchto OFFposition. Disconnect throttlevalveswitchharnessconnector. NG Placeignition switchto ON position. Uselesterto measurelhe voltagebetween terminal 2 andground. Battery voltage: Approx.8 - 10V Inspectthe following: Harnesscontinuity betweenthrottle valveswitchandECCSC/U. lF NG: Repairharnessandconnector. D Inputsignalcircuitinspection Placeignition switchto OFFposition. NG DisconnectECCSC/U harnessconnector. Disconnect throttlevalveswitchharnessconnector. Checkthe continuitybetweenECCSC/Uterminal 54 andthrottle valveswitchterminal1. OK Repairharnessor connector. Component parts inspection (Throttle valveswitch) NG Referto the sectionon throttlevalveswitchfor jon. inspect OK Replacethrottlevalveswitch. InspectECCSC/Uterminals foranydamageand makesuretheconnectorsareconnectedcorrectlv. EN - 437 ] . I D L E J U D G E I V F N T' A F TW H E NA C C E L E R A OB PEDALIS FULLYOPEN. START connector RB25DEDIAGNOSIS R 8 2 5 D EE N G I N E Carryout the inspectionin the followingorderafterrepairs' insPection Verification Checkforanydamageon the and ECCSCiUterminals ECCSC/U connector. EN - 438 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS 17 - STARTSIGNAL GN SW A START t) snRrrn srcNnrI Function inspection /tr\ Placeignitionswitchto ON position. tU UseCONSULT andinspect"STARTSlGNAL"in "FUNCTION TEST'mode. OK OR Placeignitionswitchto ON position. Inspectstartsignalusing"DATAMONITOR"mode. Whenignition swrtchis ON position: OFF Whenignition switchis STARTposition: ON NG B STARTTHE ENGINE STFAIGHT AFTERSELECTING STARI, FINISH Power supply inspection ?@ Placeignitionswitchto OFFposition. €) Disconnect throttlevalveswitchharnessconnector. N G Placeignition switchto ON position. Usetesterlo measurethe voltagebetween terminal 2 andground. Battery voltage: Approx.8 - 10V OK PLACE SHIFTLEVERTO'P'OR Inspect the following: Fuse Continuitybetweenignitionswitch and ECCSC/Uharness.lF NG: Repairharnessandconnector. InspectECCSC/Uterminals foranydamageand makesuretheconnectorsare connectedcorrectlv. EN - 439 CAS.RPM(POS) 1326rpm STARTEFSIGNAL OFF BECORD B €'@ I ECCSC/U connector I RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS18. FUELPUMPCONTROL ECCSrelay qH,,r F/L3 IGN SW #16 2t- Fuel pumprelay Componentslocation EN - 440 B825DEDIAGNOSIS R B 2 5 D EE N G I N E START .FUEL PUMP' ISTHEREA PULSATION E V E F Y3 S E C O N D S W H E NT H EF U E LT U B E I S H E L D ?O R C A NY O U HEARTHEOPERATION N O I S EO F T H EF U E L A Systeminspeclion "FUELPUMP" Select in-FUNCTtON TEST"toinspect thesystem. \9 Operation checkby"FUELPUMPRELAy" in 'ACTIVETEST'. OK Fuelpumpwilloperate for5 seconds afterthe ignition switchisturned to ONposition. Checkif thefuelpumpoperation norse areaudible. I acrrvclesra I FINISH B Power inspection Placeignition switchto "OFF"position. Disconnect fuelpumprelay. Measurevoltagebetweengroundand terminal 2 & 3 usinqthetester. FUELPUMPRELAYON MONITOF CAS.RPIV(POS) orpm NG START ON/OFF STOP A OK Checkthefollowing: Fuse Harnessconnection betweenfuel pumprelayandthefuse. Connection betweenfuelpumprelay andtheignition switch. lF NG: Repairharness& connector. B c Groundcircuit inspection Placeignition switchto OFFposition. Removefuelpumpharnessconnector. Checkthe connectionbetweenfuel pumpnarnessconnector 3 andthe ground. NG Repairharnessor theconnector. D Outputsignalcircuitinspection Placeignitionswitchto OFFposition. NG RemoveECCSC/U harnessconnector. Checklhe continuitybetweenECCSC/U& harness terminal18andfuelpumprelayharnesslerminal1. Checkthefollowing: Continuity betweenECCSC/Uandfuelpumprelay. ContinuitybetweenECCSC/U and pumprelay. lF NG: Bepairharnessandlhe connector. EN - 441 c Eeo RB25DEDIAGNOSIS R B 2 5 D EE N G I N E E Control signal insPection Measurethe voltagebetweengroundand ECCSC/U terminal18. 5 seconds after ignition switch is turned ON: 1V After 5 seconds after ignition switch is turned ON: Battery voltage D Elee OK Componentparts inspection (FuelpumPrelay) onfuelpumprelayfor Referto thesection rnspection. OK NG E €,Q E9!9 ReplacefuelPumPrelaY. ComponentPartsinsPection NG (Fuelpump) onfuelpumpforinspection. Befertothesection OK tuelpumP. Replace Checkfor anydamageon the ECCSC/U terminalsand ECCSC/Uconnector. Carry out the inspection in the following order after repairs' VerificationinsPection Checkfor anydamageon the ECCSC/U and ECCSC/Uconnector. terminals inspection. Fuelpressure EN - 442 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS 19. AACVALVE Components location - START A Function inspection Warmtheengine. Checkthe idlespeed600 - 700 rpm. OK lF NG: Adjustidlespeed. "AAC " VALVE in /G\ Inspectusinq 's/ "FUNCTION TEST"mode. AACvalveharness. <>, Drsconnect W Cfreckif idlerevwilldecrease. RN OFFA/CAND LIGHTS FINISH NG B Power inspection Placeignitionswitchto "ON"position. MeasurevoltagebetweengroundandAACvalve terminal 2. TO NG Repairharnessor theconnector. EN - 443 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E c B Output signal circuit insPection A Checkif theenginerevwillchangewhenthe \E/ "up" or "DOWN'is pressedin AACVALVE in .ACTIVETESI'' mode. NG ECCSC/U harness. ^ Disconnect betweenECCSC/U H: Cnect forcontinuity 4 andAACvalveconnector h"rn"sstermtnal t e r m i n a1l . Ele:@ OK orconneclor. Repairharness c . N .ACTIVETEST 10'6 DEG OPENING AACAr' NG Component parts inspection (AACvalve) Referto the secttonon AACvalvelor inspection' OK MONITOR CAS.FPM(POS) 900rpm AIR FLOWI\,,ITR 1.'16V ENGINETEI,IP SEN 8O"C BeplaceAACvalve. Qu UP DWN od Checkfor anYdamageon the ECCSC/U andECCSC/Uconnector. terminals Carry out the inspection in the following order after repairs' VenficationinsPection check. Functional Checkfor anydamageon the ECCSC/U andECCSCiU connector. terminals EN - 444 R825DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS 20. AIRREGULATOR m c) o a o l q 5 Fuel pump relay Air regulalor Components location f-f ,'T- controlunit Power supply inspection Placeignitionswttchto OFFposition. Disconnect fuelpumprelay. Placeignition switchto ON position. Usetesterto measurethe voltaqebetween terminal 2. 3 andoround. Inspectthefollowing: Fuse. Harnesscontinuity between fuelpumprelayandfuse. Continuity betweenfuel pumprelayandignition switch. lF NG: Repairharnessand connector. EN - 44s RB25DEDIAGNOSIS R B 2 5 D EE N G I N E B Groundcircuit insPection Placeignitionswitchto OFFposition. air regulatorharnessconnectors. Disconnect harness betweenairregulator Checkforcontinuity 2 andground. terminal connector OK NG ReDairharnessor connector. c OutputsignalcircuitinsPection switchto OFFposition' Placeignition NG connector' FCCSC/Uharness Disconnect betweenECCSC/U continuity Checkforharness 1. 18andfuelpumprelayterminal terminal OK Eielm Inspectthefollowing: ContinuitybetweenECCSC/ U andfuelPumPrelaY.lF NG: RepairharnessandconttnuitY. D ControlsignalinsPection MeasurevollagebetweenECCSC/Uterminal 18andground. NG Within5 secwhenignitionswitchis placedin ON 1V position: APProx. After5 sec when ignitionswitchrsplacedin ON position:Batteryvoltage OK c _ - ' ' _ Xc * t- LEsc+r**! ECCSCi RepairandinsPect and power supply ground U circuit. Component Parts inspection NG (Airregulator) Replaceair regulator AAC on section Referto the valvefor inspection. Carry out the inspection in the following order after repairs' VerificationinsPection check. Functional Checkfor anydamageon the ECCSC/U and ECCSC/Uconnector. terminals EN - 446 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS21 . POWEBSTEERINGHYDRAULICPRESSURESWITCH PWRST hydraulic pressure SW _ . - - - . - _ - _ F '\-----l 1 | I *l_ Componentslocation Function inspection Placeignitionswitchto ON position. fr; : Inspectusing'PWRST SlG"in 'FUNCTION TEST"mode. OR Stopthe engine. Use "DATAMONITOR"to inspectPWR ST hydraulic pressure switchsrgnal. Whenneutral:OFF Whensteered:ON Startthe engine. UseCONSULT or testerto measurethe voltagebetweenECCSC/U terminal19 andground. Whensteered:Approx.0V Other:Batteryvoltage . PoWEB ST SIG . PRESSSTARTWHILEFULLY STEERING THESTEERING WHEEL, A frvorrroRrruqflrornt cAS.Pr\,,t(POS) 862rpm I G N I T I OSNI G N A L O F F HECOBD TOB EN - 447 R825DEDIAGNOSIS R B 2 5 D EE N G I N E B Inputsignalcircuit inspection Placeignitionswitchto OFFposition. DisconnectECCSC/U harnessconnector. NG powersteeringhydraulicpressure Disconnect switchharnessconnector. Checkfor harnesscontinuitybetweenECCSC/U pressure hydraulic terminal19andpowersteering switchterminal1. OK orconnector. harness Repair c Groundcircuit insPection Checkfor continuitybetweenpowersteering N G hydraulicpressureswitchterminal2 andenglne grouno. OK Repairharnessor connector. Component Parts inspection (Powersteeringhydraulicpressureswitch) NG Referto the sectionon powersteering hvdraulicpressureswitchfor inspection. Replacepowersteering hydraulicpressureswltch. Checktor anYdamageon the ECCSC/U andECCSC/Uconnector. terminals Carryout the inspectionin the followingorderafterrepairs' insPection Verification check. Functional Checkfor anydamageon the ECCSC/U and ECCSC/Uconnector. terminals EN - 448 R825DE DIAGNOSIS R B 2 5 D FE N G I N E DIAGNOSIS 22 (Phenomenon)- IDLEREV tS TOO HIGH(AFTERWARMUP) 1 Throttle sensor & air regulator inspection 1 I rsnot.rue sENsonO tunction tesrmode. 5S. !.snec11n '!'/ UnecK judgement) rlthethrottlesensor(idle is NG notturnedOFF. Makesuretheair regulator unttts notrocKed 61 \€v or electricity is conducted to arrrequtator. OK PRESSSTABTWHILE FULLY OPENINGTHEACCELERATOB PEDAL. Circuit andthrottle sensor Inspectron. Airregulator andcircuit inspection. Intakeair leak inspection ..=.Warmuo the enqine. / l r \ flChange offsetvalueby selectingDWN in YES "FUEL INJECTION RATIOOFFSET VALUE"in activetest mode. Caution:Carryoutthetestin minimumtime required.Do notoperateduringdrive. Warmup lhe engine. airflowmeterharnessconneclor. ^ Separate @Cnect if the idlerevwilldecreaseafter racingthe engineat approx.below2000rpm for 30 seconds. NO 2 I acrveresr a tr FUELINJECTION OFFSET oei, [40NlTOR cAS.FPr\,4(POS) 937rpm ENGTEIV1P SEN 5S'C O. SENSOB 1.33V (R) o, sENsoR I N JP U L S E AAC VALVE Qu UP 1.3sV 1.8msec 17". DWN lt Od Reoairwhereairis leakino. 3 Throttle linkage inspection Stoptheengine. Checkif the throttlelinkagewillmovesmoothly. Checkif thethrottlevalvewillclose/ ooenfullv. OK FINISH NG Repairthrottlelinkage or Inspectthrottlevalve f Jt/*i,. \i _r J)"* EN - 449 RB25DEDIAGNOSIS R 8 2 5 D EE N G I N E DIAGNOSIS23 (Phenomenon)'HUNTING Throttle sensor insPection Warmuptheengine. Checkforanychangewithhuntingwhen02 sen connectoris seParated. Power balance test ^ Startheenqine. ($u." PowEB BALANCEin functiontest' Caution:Carryoutthetestin mlnimumtime required.Do notoperateduringdrive ldlerevwilldecreasefor a momentfor each linder. dl-erevwilldecreasefor a momenlwhen is connector eachcylinderinjector SparkpluginsPection Stoptheengtne. sparkplugandcheckfordirt' Disconnect damage.gapetc. r or replace. lntake air leak insPection Startthe engtne. whenblow-by Checkif enginerevwillincrease houseis pinched. EN - 450 I serusoR O rnRorrue FULLY PRESSSTARTWHILE THEACCELERATOR OPENING PEDAL. R825DEDIAGNOSIS R B 2 5 D EE N G I N E OIAGNOSIS 24 (Phenomenon)- IDLEINSTABILITY 1 Operatepower balancetest ,G\ Startthe enoine. I poweRenr.ANlce a NO '-U'operate pdwen BALANCE TESTjnfuncrion test.Caution: Operate thetestinminimum time requirgd. Donotoperate during drive. ]NSPECTBALANCE OF EACH PIPESBYSTOPPING INJECTOR OPERAT]ONAT EACHPIPES. TURNOFFALLlJCANDLIGHTS fora momentwhen 6ldle revwilldecrease (&operating pipes. each YES To No. 6 2 Injector inspection Stoptheengine. Removecrankanglesensor. (leaveharnessconnector as it is). NO powertransistorconnector. Dlsconnect Placeignitionswitchf romOFFto ON posrtion. Can you hearoperationnoisefromeachinjector whenthe crankanglesensorshaftis rotatedby hand. Warning:Dependrng on howthe shaftis rotated,selfdiagnosis willdrsplay abnormal, disregard thisdisplay. YES Inspectiniector andcircuit 3 lgnition inspection Placeignitionswitchto OFFposition. Removergnition coilASSY NG Installnormaisparkplug. Facethe sparkplugrearendtowardsadequate groundsuchas collector andcranktheenaine. Checkthespark. OK Inspectignition coil,power transistor andcircuits. 4 Spark plug inspection Checkfordirt,damage,gapetc.on the sparkplugremoved fromtheengine. TO5 EN - 451 ffi \ , \ Operation noise RB25DEDIAGNOSIS F B 2 5 D EE N G I N E FuelpressureinsPection Starttheengine. TEST"andbring in"ACTIVE Select"STOP" to zero. fuelpressure crank2 - 3 times. stop, Afterengine usingfuelpressure fuelpressure Inspect gauge. x . 2 . 5 k Ioc m " W h e ni d l i n q : Startthe engine. Removefuelpumpfuseandbringfuel pressureto zero. Attachfuel pressuregaugeand inspectthe la'x[\ InspectfuelpumPand circuits. ': Fuel frlier:J \ 6 $rorrrontnqNto rntr CAS.RPI\,4(REF) 650rpm O.O2V 02 SENSOF 0 2 S E N S O RM T R R I C H Exhaustgas sensorinsPection in RATIO" using"BASEAIR-FUEL ,6',lnspect tly''ruNcrtoru TEST"mode. indata MONITOR" Select"O,SENSOR monitor. withno loadafterwarmup' Setat 2o0orpm "LEAN'RlCH"willrepeat Checkifthedisplay for morethan5 timeswithln10 seconds ,o,Operatevehicleside(withinfusebox) andchangeto O, @)diaqnosis connector sensormonll0r'. Set at 200orpmwith no loadafterwarm up warning Checkif theexhausttemperature lampwillf lashfor morethan5 timeswithin ReplaceO, sensor TO7 EN - 452 6 m o d e .s h o n - c i r c ulihl e s e openthe Ior a'pprox2 secsJben (rhernode /4-ff-ffF;la Ilmerhs earh Lff.ffTT-l -:rs Pedormeo) RB25DEDIAGNOSIS R 8 2 5 D EE N G I N E 7 Intakeair leak inspection Startthe engjne. YES Checkif theenginerevwillincrease when theblow-byhoseis pinchedusinghands. NO Repairleaks 8 ldle adjust screwf ixationinspection fO Starttheengrne. "AACVALVE s Operate ADJUSTMENT' in N O 'OPEBATION SUPPORT" mode. Canidlerevbe adjusted to 600- TOOrpm ("N"position forA/T)by rotating theidte adtustment screw. the engine. r€\Start \Gr'Disconnect AAC valveconnector. Can idle rev be adjustedto 600 - TOOrpm ("N"positionforA/T)by rotating the idle adjustmentscrew. YES AACvalveandthrottle valvefixationinspection. 9 Compression pressure inspection Standardvalue:12.8i300(kgicm,)/(rpm) N G Minimum value:9.8/300(kg/cmr)/(rpm) Eachcylinderdifference Tolerance:1.0/300(kg/cmr)/(rpm) OK Inspectpiston,pistonring valve,valveseat,cylinder headgasket. 10 ECCSC/Uconnectorinspection Checkforanydamage or looseconnection on theC/Ubinterminal andharness connector. OK 11 Tryreplacing withnormatC/U.l-----.]Replaceor repair FINISH EN - 453 AAC VALVEADJ ' . SETTHECAS.PRI\ITO STANDARD VALUEUNDEB IHE FOLLOWING CONDITION: AFTEBWARMUP TURNOFFALLLIGHTS AND AIRCONDITIONER, RB25DEDIAGNOSIS R B 2 5 D EE N G I N E D|AGNoS|S25(Phenomenon).WHENcoLD,D|FF|CULTToSTARToRcANNoT STARTTHEENGINE 1 . F U E L P U M P' YOU FEELPULSATION WHEN R Y3 S E C O N D S andstartermotorf-llsglessjljePell tnspectOattery OK 2 E FUEL TUBEIS E D ?O BC A NY O U FUELPUMPRELAY Fuelpressureinspection 'FUNCTIONNG usingFUELPUMP'in ,6,lnspect flltesr" mode. ,o.Pinchf uelPumPwithf ingers. 6)Cnect if thefusehoseis tensewhenf uel pumpus operatlng. OK Fuelpumpandcircuit inspection Fueiiilter Air regulatorinsPection NG to airregulator Checkifthepowerisconducted toONposition' isturned switch whentheignition OK andclrcull. Inspectairregulalor 4 ThrottlesensorinsPection pedalfullyandcheckif Pressaccelerator theenginewillstart. OK Throttlesensorandcircuit inspection. 5 lnjector inspection Placeignitionswitchto OFFpositlon. Removecrankanglesensor(leaveharness connectorconnected). Removepowertransistorconnector. NG Placeignitionswitchto ON position. Checkif eachinjectoroperationnoisecan be heardwhenthe crankanglesensorshaftis rotated on howtheshaftis by hand.Note:Depending in rolated,abnormalwillshowin self-diagnosis, as normal. thiscasedetermine OK TO6 andcircuitinsPection Injector EN - 4s4 4 'J5;- F u l l yo p e n :f lrr't gl+uu\ ,/ .\-i) if.',{:--,! 3 Rolate by hand RB25DEDIAGNOSIS R B 2 5 D EE N G I N E 6 lgnitioninspection Placeignitjon switchto OFFposition. jn eachpipptng. Removesub-harness Installnormalsparkplug.Facethesparkplug NG rearend towardsadequategroundsuchas collector andcranktheengine. Checkthespark. OK Inspectignition coil,power transistorandcircutt. 7 Sparkpluginspection Checkfordirt,damage, gapetc.onthespark NG plugremoved fromtheengine. OK Repair or replace 8 ECCS C/U connector inspection NG Checkfor any damageor looseconnectionon the C/U binterminaland harnessconnector. OK Repairor replace o ECCSC/Upowersupplyandgroundcircuit NG Inspectron. OK Repairor replace 't0 Try replacing withnormaiC/L. FINISH EN- 4ss 6 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS26(Phenomenon)-WHENWARM,DIFFICULTTOSTARTORCAN NOT STARTTHE ENGINE 1 FuelpressureinsPection in"FUNCTIONNG usingFUELPUMP" /G Inspect !UtEST" mode. withfingers. ,o,PinchfuelPumP (SCneckifthefusehoseistensewhenfuel pumpusoperatlng. OK Fuelpumpandcircuit inspection 2 Vapour inspection fuelpressureregulatorvacuumhose O K Disconnect Placea holecapon thevacuumhose. Doestheenginestart? NG Inspectfuelaspect J IniectorinsPection Placeignitionswitchto OFFposition. Removecrankanglesensor(leaveharness connectorconnected). Removepowertransistorharnessconnector. NG switchto ON position. Placeignition noisecan be Checkif eachinjectoroperation heardwhenthe crankanglesensorshaftis rotated on howtheshaftis by hand.Note:Depending in willshowin self-diagnosis. abnormal rotated, as normal. thiscasedetermine OK andcircuitinspection lniector 4 lgnitioninsPection Placeignitionswitchto OFFposition. in eachpipping. Removesub-harness plug. Facethesparkplug N G Installnormalspark rearend towardsadequategroundsucnas andcranktheengine. collector the Check spark. OK coil,Power Inspectignition andcircult. transistor TO EN - 456 IFUEL PUN/P1) YOU FEELPULSATION WHEN 3 SECONDS E FUEL I UIJtr I- RB25DEDIAGNOSIS R B 2 5 D EE N G I N E 5 Sparkplug inspection Checkfordirt,damage, gapetc.onthespark N G plugremoved fromtheengine. OK Repairor replace 6 ECCS C/U connector inspection NG Checkforanydamageor looseconnection on the C/Ubinterminaland harnessconnector. OK Repair or replace 7 ECCSC/Upowersupply andground circuit NG inspectron. OK Repairor replace I Try replacing withnormalC/U. FINISH EN - 457 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E TO STABT DIFFtCULT DIAGNOSIS27 (Phenomenon)'lN NORMALCONDITION, OR CAN NOT STARTTHE ENGINE t 1 ()FUEL PUI\,4P ' YOU FEELPULSATION lnsoectbatteryand startermotor Fuel pressureinsPection "FUNCTION usingFUELPUMP'in 4;.,lnspect \ETEST'mooe. SH E N 3 S E C O N DW E FUELTUBEIS ED? OR CANYOU RELAY EAFIFUELPUI\,4P PinchfuelpumPwithfingers Checkif thefusehoseis tensewhenfuel pumpus oPerating. Fuelpumpandcircuit inspection Iniectorfuel leak insPection pedalfullyan checkif the Pressaccelerator switchisturn enginewillstaftwhentheignition to STARTposition. leak. Inspectinjector lniector insPection Placeignitionswitchto OFFposition. Removecrankanglesensor{leaveharness connectorconnected). Removepowertransistorconnector. switchto ON position. Placeignition Checkif eachinjectoroperationnoisecan be heardwhenthe crankanglesensorshaftis rotated on howtheshaftis by hand.Note:Depending in willshowin self-diagnosis, abnormal rotated, normal. as thiscasedetermine lniectorandcircuitinsPection lgnition inspection Placeignitionswitchto OFF position. in eachpipping Removesub-harness plug. Facethesparkplug Installnormalspark groundsuchas rearendtowardsadequate engine. andcrankthe collector Checkthespark. OK TO6 coil,Power Inspectignition ci and rcuit. transislor dI?-., F u l l yo p e n :\l rF.t TI+(f,l\ ,/ ,V f-l X- Rotateby hand R825DEDIAGNOSIS R B 2 5 D EE N G I N E o Sparkpluginspection Checkfordirt,damage, gapetc.onthespark N G plugremoved fromtheengine. OK Fepar or replace ECCS C/U connector inspection NG Checkforanydamageor looseconnection on the C/U binterminaland harnessconnector, OK Repair or replace I ECCSC/Upowersupplyandgroundcircuit N G Inspection. OK Repairor replace I Tryreplacing withnormat C/L. FINISH EN - 459 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E AFTEB WARM UP DIAGNOSIS28 (Phenomenon)- HESITATION (hesitationas throttle valve starts to open) 1 I rcrrveresr O D FuelpressureinsPection'FUEL 'UP'or"DWN"in INJECTION ,erSelect i value. correction modeto change time Carryoutthetestin minimum Caution: required.Do notolelqle lullnggllve,vacuumhose NG reregulator ;DGcon nectluefpressu (6)Placeholecaponvacuum hose test. cruising Operate lstherestillhesitation? o, sENsoF o . S E N S O( B R) TEST' OK in'ACTIVE GzounurtrvcoRREcrtoN" NG inspectpressure lf leanhesitatlon regulatorandfuelPumP. FuelaspectinsPection Canisterpurge inspection canister Disconnect Purgenose. N G Placeholecapon the Purgehose Conductcruisetest. ls therestillhesitation? Inspectpurgeandvacuum system. FINISH EN - 460 OFFSET 09" FUEL INJECTION MONITOR 937rpm CAS.FPIV(POS) 59'C SEN ENG TEI\,4P iNJ PULSE AAC VALVE Qu UP 1.33V 1.3sV l.BMSEC 17'i. DWN ll Od RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS 29 (Phenomenon)- HESTTATTON WHENCOLD (hesitationas throttle valve starts to open) 1 Sparkpluginspection Remove sparkplugandcheckforanvdirt, NG gapetc. damage, NG Bepairor replace 2 Fuelpressureinspection " U P ' o r- D W Ni'n F U E LI N J E C T I O N rerSelect €euRrurtry coRREcloN' in-ACTIVE TEST' OK modetochange correction value. Caution: Carryoutthetestjn minimum time required. Donotoperate duringdrive. Starttheengine. whentheblow-by 61Does theenginerevincrease \g/ hoseis pinched? ACTIVETEST FUEL]NJECIION OFFSET NG Repairleaks 3 OK Replace withnormalarrf lowmeter. NG Replaceairflowmeter. 4 Intake valve deposit inspection Removewhendeoositis Dresenr. FINISH EN - 461 r.33V RB25DEDIAGNOSIS B B 2 5 D EE N G I N E lN NORMALCONDITION 30 (Phenomenon)'HESITATION DIAGNOSIS (hesitationas throttle valve starts to open) 1 2 TE51, ItsASEAlRFUELRATIO Spark plug insPection Removesparkplugandcheckforanydirt, HOLDENGINEREV2000+f 200rpmANDPRESSSTARI Repairor replace Exhaust gas sensor insPection 'BASEAIR-FUEL RATIO"in Inspectusing "FUNCTION TEST"mode. "O, SENSORMONITOR" NG in data Select monllor. Set at 2000rpmwith no loadafterwarm up "LEAN,RICH"willrepeat Checkif thedisplay formorethan5 timeswithin10seconds Operatevehicleside(withinfusebox) andchangeto Oconnector diagnosis sensormonitor". with no loadafterwarm up. Set at 2OOOrpm warning Checkif theexhausttemperature lampwillf lashfor morethan5 timeswithin Canister purge insPection canister Disconnect Purgenose. PlaceholecaPon Purgehose. Conductcruisetest. ls therestillhesitation? ttlt I 7|-rl ExhausttemP w a r n r n gl a m p I purgeano Inspect system vacuum lntake air leak insPection Warmup the engine. "DWN" Changeoffsetvalueby selecting RATIOOFFSET in "FUELINJECTION mode. in test active VALUE" Caution:Carryoutthetestin minimum timerequired.Do notoperateduringdrive. Warmup the enqine. rateairflowmeterharnessconnector. after @cn-.,"[ ii rn" idlerevwilldecrease racingtheenglneat approx.below for 30 seconds. Repairanyleaks 4 O ncrtvEresr O f OFFSET O% FUELINJECTION MONITOB s37rpm CAS.RPM(POS) 59'C SEN ENG TEI\,4P 1.33V o. SENSOR 1.35! o. sENsoR(R) 1.8msec tNLPULSE 17"h AAC VALVE Ou UP owN Qd RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS 31 (Phenomenon)- ENGTNE STALLWHTLEREVVTNG 1 Fuel level inspection Checkthe levelof fuelin thefueltank. 1 NG Resupply fuel OK 2 , F-rN-=I l- Power balancetest operation ,ar Startthe enoine. l l l \9/ Inspectusing'POWERBALANCEin 'FUNCTION TEST"mode. "POWER Operate BALANCE"in "ACTIVE TEST"mode.Caution:Carryoutthetestin minimumtimerequired.Do notoperate duringdrive. Checkif idlerevwilldecreasefor a moment whencheckingeachcylinders. ' \--l | | _ NG OPOWEHBALANCE' FOREACHCYLINDER STOP INJECIOR OPEMTIONAND CHECKTHEBALANCEOF EACHCYUNDER. TURNOFF,6./CAND LIGHTS Checkif idlerevdecrease fora moment ,q1 r€rwheneachinjector connector cylinders are disassembled. To No. 5 OK 3 Iniector inspection Placeignitionswitchto OFFposition. Removecrankanglesensor(leaveharness connectorconnected). Removepowertransislorconnector. NG Placeignition switchfromOFFto ON position. Checkif eachinjectoroperationnoisecan be heardwhenthecrankanglesensorshaftis rotated by hand.Note:Depending on howtheshaftis rotated, abnormal willshowin self-diagnosis, in thiscasedetermine as normal. /l Operationnolse Injectorandcircuitinspectron 4 lgnition inspection Placeignitionswitchto OFFposttion. Removesub-harness in eachpipping. Installnormal plug. spark Facethesparkplug NG rearendlowardsadequategroundsuchas collector andcranktheengine. Checkthespark. OK TOs Inspectignition coil,power transistorandcircuit. EN - 463 '%j,::""',, '%! RB25DEDIAGNOSIS R B 2 5 D EE N G I N E 5 Fuel pressure insPection /G\ Startthe engine. fU'Bringfuelpressureto zeroby selectingFUEL "ACTIVETEST". PUMPRELAY"in NG Crank2 to 3 timesafterenginestop. Usefuelpressuregaugeto inspect: 2.skg/cm' Whenidling.APProx. vacuumhoseis Whenpressureregulator removed:APPToL ,-o''Starttheengine. \6tlring {uelpressure fuel to zerobyremoving pumpfuse. Crank2 to 3 timesafterenginestop' gauge. usingfuelpressure Inspect OK pressure Inspect diaPhragm regulator o ECCS C/U conneclor inspection NG on Checkforanydamageor looseconnection andharnessconnector. theC/Ubinterminal OK Repairor replace tnrpectgCCSC/Upowersupplyandground N G circuit. OK Repairor rePlace 8 Try replacingwithnormalC/U. OK FINISH EN - 464 ACTIVETEST . L--] . RELAY ON FUELPUI\.4P MONITOB CAS.RPM(POS) 0rPm oN c lpN/oFFll oFF RB25DEDIAGNOSIS R B 2 5 D EE N G I N E - ENGTNE DIAGNOSIS 32 (Phenomenon) STALLAFTERWARMUp 1 1 resr O ncrrve Vapourinspection ..DWN" correction valuebyselecting in"FUEL ,6lChange " "ACT|VE \E4NJECTION CORRECTTON in TEST"mode. Caution: Carryoutthetestin mintmum timerequired. Donotoperate duringdrive. pressure regulator vacur-rrn fG\Disconnect \@Place hole cap on vacuum hose. OL/ Operatecruisetest. Doestheenainestillstall? 2 a I FUELINJECTION OFFSET O'/. t\,10NtToR CAS.RPI\,1(POS) 937rpm ENGTE]\IPSEN 59,C o, SENSOR 1.33V o " S E N S O R( R ) i.35\ INJ PULSE ].8msec AAC VALVE 179L UP DWN od NG Power balancetest operation /G\ Start the enqine. '€i Inspectusirig-eOWeR BALANCEin .FUNCTION TEST"mode. "POWER Operate BALANCE" in "ACT|VE TEST"mode.Caution:Carryoutthetestin minimumtimerequired.Do notoperate duringdrive. Checkif tdlerevwilldecreasefor a moment whencheckinqeachpippinq. Checkif idle revdecreasefor a moment ,q, \€r wheneachinjector pippingare connector disassembled. NG .POWER BALANCEO FOREACHCYUNDERSTOP ITUECTOR OPEMTIONAND CHECKTHE BALANCEOF EACHCYUNDER. TURNOFFT/CANDLIGHTS To No. 5 OK 3 Iniector inspection Placeignition switchto OFFposition. Removecrankanglesensor(leaveharness conneclorconnected). Removepowertransistor connector. NG Placeignition switchf romOFFto ON position. Checkif eachinjectoroperationnoisecan be heardwhenthe crankanglesensorshaftis rotated by hand.Note:Depending on howtheshaftis rotated,abnormalwillshowin self-diagnosis, in thiscasedetermine as normal. @ffr^<) :n. =d$l}P Injectorandcircuitinspection 4 lgnitioninspection Placeignitjon switchto OFFposition. Removesub-harness in eachpipping. Installnormalsparkplug.Facethesparkplug rearend towardsadequategroundsuchas collector andcranklhe engine. Checkthespark. EN - 465 4 R825DEDIAGNOSIS RB2sDE NGINE Fuel pressure insPection rer Startthe engine. "FUEL fUBring fuelpressureto zeroby selecting "ACTIVETEST"mode. PUMPRELAY"in stop. 2 to3 timesafterengine Crank 5 O ncrrverEsrILJ FUELPUMPRELAY OFF MONITOF NG gaugeto inspect: Usefuelpressure 2.5kglcm2 Whenidling:APProx. vacuumhoseis Whenpressureregulator removed:APProx.3.0k9/cm' (POS) 950rPn" CAS.RPI\,'1 ON )N/OFF OFF ^ Qt. rt +ha anoina i"ul".",. fuel l&Bringfuelpressure tozerobyremoving fuse. oumo Crank2to 3 timesafterenginestop. gauge. Inspectusingfuelpressure OK pressure Inspect diaphragm regulator ECCS C/U connector insPection NG on Checkfor anydamageor looseconnection the C/U binterminaland harnessconnector. OK Repairor replace 7 tnspectECCSC/U powersupplyandground N G circuit. OK Repairor replace I Try replacingwithnormalC/U. OK FINISH EN - 466 0oog. sT195S RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS 33 (Phenomenon)- ENGINESTALLWHENCOLD 't Air regulator inspection Checkif thepoweris conducted to air regulatorN G whenignition switchis in ON position. OK Inspeclair regulator andcircuit. 2 Throttlesensorinspection Pressaccelerator pedalfullyandcheckifthe NG engrne canbestarted whentheenqineiscold. Inspectair regulator andcircuit. 3 Fullyopen $ + @< I Powerbalancetestoperation Start theengine. frt : 'POWER Inspectusing BALANCEin "FUNCTION TEST"mode. Operate"POWERBALANCE'in"ACT|VE TEST"mode.Cautton:Carryoutthetestin minjmumtimerequired.Do notoperate duringdrive. Checklf idlerevwilldecreasefor a moment whencheckinqeachcvlinders. Checkif idlerevdecrease{ora moment @ : wheneach injector connector cylinders are disassembled. 4 NG .PoWER BALANcE. FOREACHCYUNDEFSTOP INJECTOROPEMNONAND CHECKTHE BALANCE OF EACHCYLINDER. TURNOFFA./CAND LiGHTS T oN o . 7 oK I Iniector inspection Placeignitionswitchto OFF position. Removecrankanglesensor(leaveharness connectorconnected). Removepowertransistorconnector. NG Placeignition switchf romOFFto ON position. Checkif eachinjectoroperation noisecanbe heardwhenthecrankanglesensorshaftis rotated by hand.Note:Depending on howtheshaftis rotated, abnormal wrllshowin self-diagnosis, in thiscasedetermrne as normal. Injector andcircuitinspection TO5 EN - 467 @ffrX) :Rt,>sv /l RB25DEDIAGNOSIS RB2sDE NGINE lgnition inspection switchto OFFposition. Placeignition in eachcylinders' Removesub-harness plug. Facethesparkplug Installnormalspark rearendtowardsadequategroundsuchas andcranktheenglne. collector Checkthespark. coil,Power 6 ignition Inspect circult. and transistor SparkpluginsPection gapetc. Checkfordirt,damage' from onthesparkPlugremoved Repairor replace 7 FuelpressureinsPection '/G Startthe engine. l.=Brrnqfuelpressure to zeroby selectingFUEL ,.ACTIVE TEST''MOdC. PUMPRELAY,in Crank2 to 3 timesatterenglnestop. gaugelo Inspect: UsefuelPressure 2.Skg/cm' Whenidling:APProx. vacuumhosels when pressureregulator rox.3.Okq/cm' ,6Start the engine. luel lo zeroby removing 6tsrinq f uelpressure p u m pf u s e . Crank2 to 3 timesafterenginestop. gauge. Inspectusingfueipressure lnspectpressure regulatordiaphragm ECCS C/U connector insPection on Checkfor anydamageor looseconnection connector. and harness the C/U binterminal Repairor replace InsoectECCSC/U powersupplyandground withnormalC/L. Try replacing EN - 468 I ncrrverrsr O L,-i FUELPUMPRELAY OFF l\,40NlToF (POS) ssorpn CAS.BP[,4 ON 7 )N/OFF OFF RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS 34 (Phenomenon)- ENGTNE STALLWHENACCELERATTNG INSTANTLY 1 AAC valve inspection (f;)warmengine v Inspectusing'AACVALVE-in FUNCTION ItrJ I l. Fl Select"AACVALVE ADJ"in "ACT|VE TEST". Checkiftheenginerevwillchange when "Qu"or "Qd"is selected tochange AAC varveopentng. NG 1 I qcrrveresr t D AAC/VOPENING MONITOR CAS.RPI\,{(POS) AIR FLOW['TR ENG IEI\,4PSEN theengine. re\Stan \G/Check if enqinerevwilldecrease when AACvalveJonnector ts dlsconnected. InspectAACvalve andcircuit. Ou UP lOO,': 900rpm 1.16V 8O"C DWN od 2 Power balancetest operation {€Start theengine. \elnspectusing POWERBALANCEin "FUNCTION TEST"mode. OR use"POWERBALANCE"in "ACT|VE TEST"mode.Caution:Carryoutthetestin minimumtimerequired.Do notoperate duringdrive. Checkif idlerevwilldecreasefor a momenl whencheckingeachcylinders. NG OK I ToNo.5 3 Injector inspection Placeignitionswitchto OFFposition. Removecrankanglesensor. Removepowertransistorconnector. NG Placeignition switchfromOFFto ON position. Checkif eachinjectoroperation noisecanbe heardwhenthe crankanglesensorshaftis rotated by hand. OPOWERBALANCEO FOREACHCYLINDERSTOP INJECIOR OPEMTIONAND CHECKTHE BALANCEOF EACHCYLINDEF. 2 ACTIVETEST 'f POWERBALANCE (POS) CAS.FlPl\,4 rpm AIF]FLOWMTR V q. AACVALVE . 1 r=l Injectorandcircuitinspection L:] 2 6 3 4 START TO4 Operatronnoise EN - 469 RB25DEDIAGNOSIS B B 2 5 D EE N G I N E lgnition inspection Placeignitionswitchto OFFposition. coil. Bemoveignition Installnormalsparkplug.Facethesparkplug ground suchas adequate rearendlowards andcranktheengine. collector CheckthesPark. coil, Inspectignition andcircuit. transistor Fuel pressure insPection ,ar Startthe engine. (UBrinq fuelpressureto zeroby selectingFUEL ..ACTIVE TEST''MOdE. PUNiPRELAY"in stop. engine Crank2to 3 timesafter gaugeto Inspecl: UsefuelPressure 2.Skglcm' Whenidling:APProx. vacuumhoseis pressure regulator When rox.3.Okq/cm' ,.,o,Start the engine. (6bring f uelpressureto zeroby removing f uel pumpfuseNo.B. Crank2 to 3 timesafterenginestop. gauge. Inspectusingfuelpressure ECCSC/Uconnectorinspection on orlooseconnection Checkforanydamage connector. andharness theC/Ubinterminal ir or replace lnspectECCSCiU powersupplyandground withnormalC/L. Try replacing EN - 470 J rEsr lL O ncrrve RELAY OFF FUELPUN,IP t\,roNtToR (POS) 950rPrr CAS.RPN,4 ON )N/OFF OFF RB25DE DIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS 35 (Phenomenon)- ENGTNE STALLWHEN DECELERATING 1 1 AACvalveinspection /G.rWarm engine. : Inspect using"AACVALVEin 'FUNCTION TEST'OR NG Select"AACVALVE ADJ"in "ACTIVE TEST". Checkiftheenginerevwillchange when "Qu"or "Qd"is selected to changeAAC valveopening. theengine. r€\Slart \@/Check if enginerevwilldecrease wnen AACvalveconnector is disconnected. OK 1 resr a tr O ncrrve A A C/ V O P E N I N G [,40NtTOR CAS.RPM(POS) AIR FLOWMTF ENGTEIV1P SEN Inspect AACvalve andcircuit. UP Qu 109: 900rpm 1 16V 80.C DWN Qd 2 Adiust screw fixation inspection using-AACVALVEADJUSTMENT@,lnspect :in OPERATION SUPPORTmode. NG Checkif it is possibleto set idlespeedto 650rpm("N"rangeforA/T)by turningidte adjustmentscrew. throttlesensorconnector. 6lDisconnect \Gr Checkif it is possibleto set idlespeedto 650rpm("N"rangeforA/T)by turningidle adlustmentscrew. OK InspectAACvalveand throttlevalvefixation. 3 Power balancetest operation ,G\ Startthe enoine. \ t / v Inspectusing"POWERBALANCE'in "FUNCTION rEST" mode. "POWER OR use BALANCE"in "ACT|VE TEST"mode.Caution:Carryoutthetestin minjmumtimerequired.Do notoperate duringdrive. Checkif ldlerevwilldecrease for a moment whencheckingeachcylinders. r,qsta rt the engine. \c/Check if idlerevwilldecreasefor a moment wheneachcylinderinjector connector is disconnected. oK I NG J ACTIVETES1 r f POWERBALAI'rcE cAS.RPM(POS) rpm AIFIFLOW I\,ITF] a./" AAC VALVE . T oN o . 6 EN - 471 AAcVALVE ADJ a a ADJUSTCAS FlPMTO STANDARD VALUEUNDEF J thE FOLLOWNGCONDLT ON , AFTERWARMUP ] TURNOFFA,'CAND L GHTS 1 E--l t:j 2 --t o l 4 STAFT DIAGNOSIS RB25DE R B 2 5 D EE N G I N E 4 Iniector inspection Placeignitionswitchto OFFposition. Removecrankanglesensor(leaveharness NG connectorconnected). Removepowertransistorconnector. Placeignitionswitchf romOFFto ON position. noisecan be Checkif eachiniecloroperation shaftis rotated sensor angle heardwhenthecrank by hand. InjectorandcircuitinsPection 5 lgnitioninspection Placeignitionswitchto OFFposition. coil. Removeignition NG Inslallnormalsparkplug.Facethesparkplug rearend towardsadequategroundsucnas andcranktheengine. collector CheckthesPark. OK 6 O ncrrveresr I i--l FUELPUMPRELAY OFF N,4ONITOB CAS.RPM(POS) 950rpn coil,Power Inspectignition transistorand circuit. ON Fuel pressure insPection /G\ Startthe engine. -FUEL to zeroby selecting lUBring fuelpressure "ACTIVETEST"mode. PUMPRELAY"in NG Crank2 to 3 timesafterenginestop. Usefuelpressuregaugeto insPect: 2.Skg/cm' Whenidling:APProx. vacuumhoseis regulator when pressure removed:ApProx.3.Okg/cm' ^ qtrrt fh6 onarina A { f ^ " . " ' . ! I | v v i i Y l l l v . lStsring f uel pressureto zero by removingfuel pumpfuseNo.8. Crank2 to 3 timesafterenginestop. gauge. Inspectustngfuelpressure ,r2. :// Fuel TO7 Inspectpressureregulalor diaphragm. EN - 472 ]N/OFF OFF F825DEDIAGNOSIS R B 2 5 D EE N G I N E 7 Exhaustgas sensorinspection usinq"BASE AIR-FUEL FATtOrn /G\ Inspect r-U"rurucrtoru TESTmode. "O,SENSOR Seiect MONITOR" indara NG monitor. Setat2000rpm withnoloadafterwarmup. "LEAN, Checkifthedisplay RICH"witlrepeat formorethan5 timeswithin10seconds. Operatevehicleside(withinfusebox) re\ \€r' diagnosis connector andchangeto -O2 NoFA|L A,4oNrToRrNqk (REF) CAS.RPI,4 82srpm 02 SENSOBI\,4TR RICH c h a n q ed r a g n o s t cm o d e s h o d c r c u t t f r e s e sensormonitor". Set at 2000rpmwith no loadafterwarm up. Checkif theexhausttemperature warning lampwillf lashfor morethan5 timeswithin 10 seconds. OK ReplaceO, sensor Inspectthrottlesensorandvehicle speedsensor. Iltl OK ECCSC/Uconnectorinspection NG Checkforanydamage or looseconnection on theC/Ubinterminal andharness connector. OK Repairor replace InspectECCSC/Upowersupplyandground N G circuit. OK Repairor replace TryreplacingwithnormalC/U. OK FINISH EN - 473 Redlarnp ' E x h a u stern t p w ar n r n q a m p RB25DEDIAGNOSIS R 8 2 5 D EE N G I N E D|AGNoS|S36(Phenomenon)-ENGINESTALLWHENAccELERAT|NGoR SPEED AT CONSTANT DRIVING 1 Power balancetest oPeration ,/4,Startthe enqine. UInspect usin-geOwf n BALANCE'in "FUNCTION TEST"mode. "POWERBALANCE'in"ACTIVE OR use TEST"mode.Caution:Carryoutthetestin minimumtimerequired.Do notoperate duringdrive. for a moment Checkif idlerevwilldecrease whenchec@ rqstart the engine. \@Checkif idlerevwilldecrease for a moment is connector wheneachcylinderiniector disconnected. 2 oK I l NG ToNo' IniectorinsPection Placeignitionswitchto OFFposition. Removecrankanglesensor(leaveharness NG connectorconnected). connector. Removepowertransistor switchfromOFFto ON position' Placeignitron noisecan be Checkif eachinjectoroperation heardwhenthe crankangiesensorshaftis rotated by hand. @ffix) rRl' >S"/ /l Operalionnolse i\ .- lgntion InjectorandcircuitinsPection 3 lgnitioninsPection Placeignitionswitchto OFFposition. coil. Removeignition NG plug.Facethesparkplug spark Installnormal rearendtowardsadequategroundsuchas collectorandcrankthe engine CheckthesPark. OK coil,Power Inspectignition transistorandcircult. TO4 EN - 474 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E 4 4 Fuelpressureinspection O ecrrverrsr I {* ua-rStaftthe enqine. 'FUEL \U Aringfuelpr"essure to zeroby setectrng PUMPRELAY'in"ACTIVETEST"mode. NG Crank2 to 3 timesafterenginestop. Usefuelpressure gaugeto inspect: Whenidling:Approx.2.5kglcm2 Whenpressure regulator vacuumhoseis removed:Approx.3.Okgicm, FUELPUI\,4P BELAY OFF l\,lONlTOR CAS.RPM(POS) gsorpn ON 4 theengine. 6lStart \ctBringfuelpressure tozeroby removing fuel pumpfuseNo.B. Crank2 to 3 timesafterenglnestop. Inspect gauge. usingfuelpressure OK pressure Inspect regulator diaphragm. Intakeair leak inspection Startthe engine. NG Checkif enginerevwillincrease whenblow-by hoseis pinched. OK Repairanyleaks 6 ECCSC/Uconnectorinspection NG Checkforanydamage or looseconnection on theC/Ubinterminal andharness connector. Repairor replace OK 7 InspectECCSC/Upowersupplyandground N G circuit. 8 0 K Tryreplacing withnormalCiL. Repairor replace OK FINISH EN - 475 z /z Fuel )N/OFF O F F fr825DEDIAGNOSIS R B 2 5 D EE N G I N E 37 (Phenomenon)'ENGINESTALLWHENLOADINGBATTERY DIAGNOSIS 1 Inspectbatteryandalternator Repairor replace I apoweRgernruce I Power balance test oPeration ,6\ Startthe engine. 9lnspect using-POWERBALANCEin 'FUNCTIONTEST"mode. "POWERBALANCE'in"ACTIVE OR use TEST mode.Caution:Carryoutthetestin minimumtimerequired'Do notoperate duringdrive. Checkif idlerevwilldecreasefor a moment STOPIII]ECTOROPEMTION FOREACHCYLINDERTO BALANCEOF CHECKTHE EACHCYLINDERS. @,Start the engine. @Check if idlerevwilldecreasefor a moment ls connector wheneachcylinderinjector disconnected. To No. 4 lniector insPection Placeignitionswitchto OFFposition. Removecrankanglesensor(leaveharness connectorconnected). Removepowertransistorconnector. switchf romOFFto ON position' Placeignition noisecan be operation Checkif eachinjector heardwhenthe crankanglesensorshaftis rotated tDi rJ- /\ uUKj--l .K / .tN,,:dD/ /l Operationnoise 4 ignitioncoil InjectorandcircuitinsPection lgnition insPection Placeignitionswitchto OFFposition. coil. Removeignition Installnormalsparkplug.Facethesparkplug rearendtowardsadequategroundsuchas andcranktheenglne. collector Checkthespark. coil,Power Inspectignition andcircuit. transistor TO5 EN - 476 RB25DEDIAGNOSIS R B 2 5 D EE N G I N E 3 Fuelpressureinspection ,er Starttheenoine. .U BringfuelprLssure tozerobysetecting.'FUEL PUMPRELAY" in"ACTIVE TEST"mode. NG Crank2 to 3 ttmesafterenginestop. pressure Usefuel gaugeto inspect: Whenidling:Approx. 2.5kglcm2 Whenpressure regulator vacuum hoseis removed: Approx. 3.0k9/cm, theengine. 61Stad tg€ring fuelpressure to zeroby removing fuel pumpfuseNo.8. Crank2to 3 timesafterengjnestop. InspectusingJuelpressure gauge. OK Inspectpressureregulator diaphragm. 6 ECCS C/U connector inspection NG Checkforanydamageor looseconnection on the C/U binterminaland harnessconnector. Repairor replace OK 7 InspectECCSC/Upowersupplyandground NG circuit. 8 OK Repairor replace Tryreplacing withnormalC/L. OK FINISH EN - 477 c I ncrrvrresr O[ FUELPUI\,,IP RELAY OFF MONITOR CAS.RPM(POS) 950rpn ON IDN/OFF OFF RB25DEDIAGNOSIS B B 2 5 D EE N G I N E 38 (Phenomenon)'POWERSHORTAGEAND STUMBLE DIAGNOSIS (lnstant power output shortage during acceleration) 1 Fuel pressure insPection /G Start the engine. to zeroby selectingFUEL fUBring tuelpressure "ACTIVETEST"mode. PUMPRELAY'in NG Crank2to 3 timesafterenginestop. gaugeto insPect: Usefuelpressure 2.Skglcm? Whenidling:APProx. vacuumhosels Whenpressureregulator removed:APProx.3 Olg&m1^ O ecrtvergst O 1 Cr"* th6 annine fuel t&Bringfuelpressure to zeroby removing pumpfuseNo.8. Crank2to 3 timesafterengrnestop. gauge. usingfuelpressure Inspect OK lnspectpressureregulator diaphragm. 2 Intake air leak inspection the engine. YES @Start echanqe correction valueby selectingDWN" CORRECTION iN..TUEIINJECTION "ACTIVE TEST" VALUE"in Caution:Carryoutthetestin minimumtime required.Do notoperatewhiledriving. whenthe Xe treckit enginerevwillincrease hoseis pinched W)blow-bv NO Repairanyleaks pressure, timing NG ignition Inspectcompression anddetonationsensor. NO Repairor replace FINISH EN - 478 2 I ncrveresr t D FUEL NJECTIONOFFSETO% MONITOR g37rpm CAS.RPM(POS) 59'C ENGTEMPSEN 1,33V O, SENSOR 1.35V o, sENsoR(R) l.8msec NJ PULSE 179L AAC VALVE Ou UP DWN Qd RB25DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS 39 (Phenomenon)- DETONATTON 1 Intakeair leakinspection (l)Starttheengrne, : Change .DWN' YES correction valuebyselecting in"FUELINJECTION CORRECTTON VALUE"in "ACTIVE TEST". Caution: Carryoutthetestinminimum time required. Donotoperate whiledriving. NO Repalranyleaks 2 OK NG Inspectpiston.pistonring, valve,valveseat,valveoil seal,engineoil leveletc. Inspect detonation sensorsvstem. OK FINISH EN - 479 Q acr veresr O f rUeLttllecrtolOrrSg dl MONITOR CAS.RPI\.4(POS) 937rpm ENGTEI\,IP SEN 59'C O. SENSOR 1 33V o , S E N S O R( R ) 1.35V INJ PULSE l.Bmsec AAC VALVE 17"i Qu whenthe prCheck if enginerevwillrncrease @rblow-bvhoseis oinched. Combustion chamber oil leak inspection Disconnect sparkplugandlnspectoil. 1 UP DWN od RB25DEDIAGNOSIS B B 2 5 D EE N G I N E 40 (Phenomenon) S U R G E DIAGNOSIS 1 Exhaust gas sensor insPection "BASEAIR-FUEL RATIO'in /A Inspectusing .-EiruructtoNTEST" mooe. "O, NG in data Select SENSORMONITOR" monitor. Set at 2000rpmwith no loadafterwarmup "LEAN,RICH"willrepeat Checkif lhe display for morethan 5 tinqllryjlllllqlegengs.- IFASEAIR FUELRATIOTESI HOL0ENGINEREV2000+1PBESSSTART 2OOrpmAND fusebox) side(within vehicle ,o, Operate 18 diagnosis to "o. andchange connector sensormonitor". withno loadafterwarmup' Setat 2ooorpm warning temperature Checkiftheexhaust within 5 times than lamowillflashformore 10 seconds. OK START ReplaceO, sensor II 2 ReplaceECCSC/U :'----_-*-., OK FINISH ,^^':? Red la'np E N- 4 8 0 Ittl .fi-g EiT:1rlr lamp, warntng R825DEDIAGNOSIS R B 2 5 D EE N G I N E DIAGNOSIS 41 (Phenomenon)- BACK FIRE(SPtTTtNG) 1 Sparkplug inspection NG Remove sparkplug. Checkforanydirtonthesparkplug. OK Repairor replacesparkplug. 2 Intake air leak inspection theengine. @Start : Changecorrection -DWN' YES valueby selecting in "FUELINJECTION CORBECTION VALUE'in"ACTIVETEST"mode, Caution:Carryoutthetestin minimumtime required.Do notoperatewhiledriving. whenthe ^6.Checkif enqinerevwillincrease I ltf L Yq/blow-bv hose ts ornched. 2 I Qu NO Repairanyairleaks 3 Intake valve deposit inspection Removeif thereareanydeposltpresent. lgnitiontiming Checkif injectoris clogged. FINISH DIAGNOSIS 42 (Phenomenon)- AFTERBURNTNG 1 Engine temperaturesensor inspection Inspectenginesensorandenginesensor circuit. OK NG Repairor replace lgnitiontiming Checkif injectoris clogged. FINISH EN - 481 ncrrve resr a n FUELINJECTION OFFSET O% [,4ONJTOB CAS.RPM(POS) 937rpm ENGTEI\,4P SEN 59"C O. SENSOR J.33V o . S E N S O R( B ) 1.3sV INJ PULSE 1.8msec AAC VALVE 17"1" UP DWN Qd INSPECTION RB25DECON,lPONENTS F B 2 5 D EE N G I N E (RB25DE) 8. coMPoNENTSINSPECTION CRANKANGLESENSOR Inspection Removecrankanglesensorfromtheengine.(leave connected). crankanglesensorharnessconnector Placeignitionswitchto ON position. Rotatecrankanglesensorshaftslowlywithhandand 2.3 andground inspectthevoltagebetweenterminal Xs -i a,,fl\ I\ ARr i Xq @-,p Rotateby crankanglesensor. lF NG: Replace EraseselfdiagnosisresultfromCONSULTafterinspection' in thescreen. CheckcodeNo. 11is notdisplayed Caution: Removeinjectorf useor connectorto avoidinjectorf rom whileinspection. operating AIR FLOWMETER lnspection . Removeairflowmeterfromtheengine. . Applybatteryvoltagedirectlybetweenairflowmeter terminal5+ andterminal3- andblowairto hotwlre. Checkfor any changein outputvoltagebetweentermlnal 2+ andterminal4-. Air is not blown Air is blown ivl rO lil f-l . r 1 i 2 r ? 1I4 l l t t /€n at, Approx.0.8V Ee Approx.2V lF NG: ReplaceairflowmeterOR checkfor anydamage withthe hotwire. afterinspection' resultfromCONSULT Eraseselfdiagnosis screen. in the is not displayed CheckcodeNo. 12 SENSOR ENGINETEMPERATURE Inspection . Disconnect sensorharness enginetemperature connector. . Measuretheresistance betweenenginelemperature sensorharnessterminal1 and2. Approx2o"c I npprox2 sKS) Approx8o"c I nPProx0.3x$l sensor. lF NG: Replaceenginetemperature afterinspection. CONSULT from result Eraseself-diagnosis in the screen CheckcodeNo.31 is notdisplayed EN - 482 (KA o c o b (D (r RB25DECOMPONENTS INSPECTION R B 2 5 D EE N G I N E IGNITION COIL Inspection . Disconnect ignition coilharnessconnector. . Measurethe resistance betweenfollowinq terminals. Primary coilresisntance value(i - 2) | 0.6- 0.9 lF NG: Replaceignition coil POWERTRANSISTOB Inspection . Disconnectpowertransistorharnessconnector. . Measurethe resistance by inserting analogtypecircuit testerinspectionrod - and + to powertransistor terminals. +/- coSJ -r* oo f,l 2-3 t - J + / - o o f , J > - / + 0 o r n o@ t 61 + / - 0 o r n o to o Q . - l * co fl lF NG: Replacepowertransistor. F U E LP U M P Inspection . Disconnect fuelpumpharnessconnector. . Measurethe resistance betweenfueloumoterminal1 and 3. Resistance: Approx.0.4 - 0.7 . Checkfor operationby applyingbatteryvoltagebetween thefollowing terminals directly: Connect terminal 3 to + side, terminal 1 to - side. Caution:Caremustbe takento connectbatteryto correct srdes. lF NG: Replace fuelpump. THROTTLEVALVE SWITCH Inspection . Warmthe engine. . Disconnect throttlevalveswltchconnectorand measure the resistance betweenthrottlevalveswitchterminals. (ldle contact point) Acceleratorpedalis not pressed lF NG: Repairthrottle valveswitch. EN - 483 Ele-,e INSPECTION RB25DECOI''lPONENTS R B 2 5 D EE N G I N E Adiustment ldle contact point touch rev (rpm): 750 - 1050 . Adjustif the touchrevis notwithinthe rangeabove . Disconneclthrottlevalveswitchconnectorand loosenthe bolt. theenginerevso idlecontactpolntrs increase Gradually betweenterminal2 and 1 is 0 Q ) at ON (Resistance aboveenginespeed. Movethrottlevalveswitchunitto touchpointandtightenthe bolt. Movethrottlevalve switchunitto touchpointandtightenthebolt. lnstallthrottlevalveswitchconnector. Racetheenginefewlimesandcheckidlerevis within value. thestandard fle Z*) THROTTLESENSOR throttlesensorconnector. Disconnect betweenthroltlesensorterminal2 Measurelhe resistance and3. lrr p€ Not pressed Pressedto halfway A p p r o x0 . 4 Approx0.4- 5 Completely Pressed Approx.5 lF NG: Replacethrottlevalveswitch. AfterinspectioneraseselfdiagnosisresultfromCONSULT CheckcodeNo.43 willnotdisplayin thescreen' AAC VALVE . Inspectthe resistanceof AAC valve. Resistance:APProx.9- 10 *4-==ll u,\,9 . PlungerandswitchinsPection. . Springdamageinspection. I v eLng", I AACvalve. lF NG: Replace FICDSOLENOID . Measurethe resistanceof FICDsolenoid. Besistance: APProx.2 2 - 2 3 EN - 484 Eei, @ R825DECOMPONENTS INSPECTION R B 2 5 D EE N G I N E Plungerandswitchinspection. Springdamageinspectlon. tO4>d Plunger '-(L...-., / \ \ ^ Spring *9 lF NG: ReplaceFICDsolenoid. AIR REGULATOR Static characteristicinspection . Visually checktheshutteropening. Below-20"C Fullyopen 20"c Approx halfopen Over60"C Fuilyclosed Dynamiccharacterlsticinspection . Applybatteryvoltageto terminalsand inspectfor any changewithshutteropening. The shutterwill close graduallyand completely closed within 7 minutes. (areatemperature approx. 20"C). Reference:Heaterresistancevalue: 70 - 80 tJ (20"C) lF NG: Replaceairregulator INJECTOB Inspection . Disconnect injector harnessconnector. . Measure the resistance of eachiniector cvlinder terminal 1 and2. Resistance betweeninjectorterminal1 and 2 (eachcylindeo 13-14Q lF NG: Replaceinjector. ECCS RELAY FUEL PUMP RELAY,RADIATORFAN MOTORRELAY Inspection . Directlyapplybatteryvoltagebetweenterminal 1 and2. . Inspeclcontinuity betweenterminal 3 and5. lF NG: Replacerelay. EN - 485 r -1t2j . l ar- ( __l INSPECTION RB25DECOMPONENTS R 8 2 5 D EE N G I N E RELAY IGNITIONRELAYINHIBITOR Inspection . Directlyapplybatteryvoitagebetweenterminal1 and 2. . Checkfor continuity betweenterminal3 and4, 6 and7 Xe ,@ lF NG:ReplacerelaY. POWERSTEERINGHYDRAULICPRESSURE INSPECTION Inspection pressure switch . Removepowersteeringhydraulic harnessconnector. . cCheck h o n k ffor o r ccontinuity o n l i n u i t v between b e t w e e n the t h e terminals. terminals. We:-p:-''; lF NG: Replacepowersteeringhydraulicpressureswitch SPARK PLUG Inspection & Adiustment . Measurethe gap betweenelectricpole. . Reolaceor repairif outof standardrange. 1 . 0- 1 . 1 Standardgap (mm): FlA .' .. | tr -! e c_ E fl lj F] . FUEL SYSTEMINSPECTION Simpleinspection p?.ti,i?l:.,, . Turnthe ignitionswitchto 9N _,G) \!=/ test mode. . Select"Fuelpump'in the"Function . Inspectthepulsation by holdingthefuelhosewithhand @ . Holdthefuelfilterand makesurethe hoseis hard W can be feltwhenthefuelpumpis operatingandpulsation EN - 486 f= (' FUELPUN,4P IS THEREA PULSATION EVEBY 3 SECONDSWHEN T H E F U E LT U B E I S H E L D ? O B C A NY O UH E A RT H E OPERATIONNOISEOF THE FUEL PUMPRELAY? RB25DECOMPONENTS INSPECTION R B 2 5 D EE N G I N E Fuelpressureinspectionusingthe fuel pressuremeter Releasingf uel pressure . Runtheengine. "Fuelpumprelay" . Select in"Active test"mode. . Press'STOP'to stoptheengine.Cranktheengine over twoorthreetimes.(lftheenginedoesnotstart,crank3 - 4 timesafterremoving thefuse). Restan theengine andremove thetuetpumptuse. @ Aftertheenginestops, cranktheengine4 "-5 timesto consume thefuelinthepipe.(lftheengine doesnotstart crank4 5 timesafterremoving thefuse). Caution: Thebatterymaybecomeweakeasily.useboostercableto connect toanother batteryif necessary. Fuelpressuremeterinstallation . Connect thefuelpressure meterbetween thefuelfilterand thefuelline. . Attach thefuelpumpfuse. Fuelpressureinspection . Starttheengineandcheckifthefuelpressure isat standard value. ldling(kg / cm:, Approx.2 55 Pressureregulatorvacuumhoseis (kg / cm,) disconnected Approx.3.0 lf theenginedoesnotstart,checkfuelpressure 5 secondsaftertheignitionswitchhasbeenturnedON. 5 secondsafterignitionswitchturnedto ON I Approx 3.0 I FN G : Fuelpressure is extremely Pressure regulator is notworking. high Return systemrsctgged. hosebent Fuelpressureis extremely Pressureregulatoris notworking. Fuelpumpdischargedefect low Fr6l <\,ctam ^l^^^a.l EN - 487 IACTIVETEST(' FUELPUI\,4P RELAY OFF CAS-RP|\,4 {POS) 950rpm NSPECTION R 8 2 5 D EC O M P O N E N TI S R 8 2 5 D EE N G I N E Fuelcut systeminspection modeusing . Select"lNJpulse"in "DATAMONITOR" after 2000rpm rev to the engine CONSULT.Increase "lNJ pulse"willdecrease theengine.Checkthat starting pedalis accelerator the to 0.6 msecfor a momentwhen released. ITORINg}l'lo FA L (REF) 1950rpm CAS.BPM 0.6msec I N JP U L S E GAS CONTROLSYSTEMINSPECTION EVAPOBATIVE Throttlechamber Checkvalve f! gas <- Evaporatlve 'F Purqeair Activecarbon Filter Tray Freshair CANISTER lnspection . Connectvacuumhandpumpto canisterthrottlenegative pressureopeningand makesurethevacuumpressurels maintained. pressure and makesurethe . Applyapprox.-100mmHg by pressure openingis continued negative manifold suckingairf romtheoPening. FUELTANK VACUUMBELIEFVALVE Inspection . Cleanthevalvehousing. youwillhear . lf thef ueltankvacuumreliefvalveis normal, whenthealrls soundfromthevalvewithsmallresistance suckedin throughthecaP . ReplacethecapASSYif thevalveis closedor when resistanceis felt. EN - 488 E Gl 5 13 0 0 0 0 o . o Soflno valve . valve R825DECOMPONENTS INSPECTION R B 2 5 D EE N G I N E BLOWBYGAS REDUCTION DEVICEINSPECTTON blowbycontrolvalve Flarnearrester Buffleplate Blowby path Fresh air Blowbygas BLOWBYCONTROLVALVEINSPECTTON Inspection . ldletheengineandremovehosefromblowbycontrolvalve. . Checkif operation noisecan be heardfromtheair passagewhenvalveis operatingnormally. . Checktheblowbycontrolvalveflowpath. Air is blown Air passes Air is drawnin No arrpasses BLOWBYHOSE Inspection . Lookforanyleakage fromthehoseandconnection area. . Remove thehoseandcleanusingtheairblow.Replace hoseifthereareanyclogs. EN - 489 SIGNALS ECCSC/UINPUT/OUTPUT R826DETTENGINE 9. ECCSCONTROLUNITINPUT/ OUTPUTSIGNALS VALUES 9.1 CONSULTINSPECTION (1) Datamonitor dataon consoleunitso thecorrect as thecalculation outputsignalis displayed itlote:The disconnected' is inadvertently eveniitheoutputcircuit(harness) valuewilldisplayed RB26DETTENGINE -olre rorron t, .IX*TTAL RETENEIGE. loNrroREaGl'EG , , .r : - t t , : I l - - - - " - ' Tt€re CAS RPM (Detecled angle speed according to srgnals) AIR FLOW MTR (R) ENG TEMP SEN (engrne temperaure) ' ., . TTVALUE Crank adqle se.sor Approt O7-l2V(2OOOrpm w hrbload 1O- 1 7V) 2 arr now meler val!€ Nole canvaryo-O4V Alter wa.nrog uP engr'€ kjlins (N range. A/C OFF) After wa.mrng ,, : m6l be no abno.mar chanqe rn sPeed A r now meler s'€1em Engrre temperalure Above approx 70'C uP ensrr€ slstem sensor EXT GAS SEN Changesbet@enO_O3V arxi06_]v EXT GAS SEN (R) 2 O O O r p mw l h n o EXT GAS SEN (RICH / LEAN) RICH. LEAN repeats 5 lrmes or more In 10 seconds EXT GAS SEN (R) (R|cts / LEAN) (]AR SPEED SEN €hrcle speed srgna ) ! ,4rire driMng or with dn€ lu. ng wl'Eels Should qererally conform to speedmeter drsPlaY ( INT/A TEMP SEN aklemperaiure sensor olnPu) Vehrcle speed sensor sysiem ECCS BATTER,'VOLT THROTTLE SEN ErhaLrsl gas sensor system ltnake s)€tem arr leak o. arr o 5 Thronb fully closed ON !s 14-2.2 INJ PULSE (iryecnon pulse wdth) (N rarEe A/C OFF) 1 4 - 2 2 INJ PULSE (R) (injecrion pulse wdth) (N ranqe GN TIMING (N rar€e sensor sYsrenr knaktemperature Air flow meter syslem Intake slstem a r leaks or ai. s@non (erlt|re InPd) hpd srgnal syslem (eture) 2o' A/C OFF) 2ooorpm with m system adjushern syslem Throdle seNor ThronE semor knake arr temperatore Aner warm nq uP eng!rE corirol unrt Porer Advance grealer lhan 1O' angle compared to ro|e Air now meter slslem appro\ r5 - t5'6 A/C OFF) Approx 30 - 5O7. AAC vaive sYsiein Air now meter system (arr rEl rano teedback coeffciefi) corecron Aiter wa.mrng up engrre 20oo.pm wth no load 75 - 125'/. ON START SIGNAL ON Engine Throttle lully closed QN A/C SW ON ON IOLE SW AIR COND SIG ON NEUTRAL SW ON PWST SIGNAL QN DLE JUDGEMENT FUEL PUMP RELAY Ot€r t€n wt€n can,sler (purse) rcpecrron lntake syslem arr leak or ar. Starter SW syslem Thronle se6or Alr co.ditiorer Nedral Po@r slstem SW system SW sFlem sleeflrq SW syslem Throttle sensor s!51em rd e FL€lPumP system K]N SW ON ON ON A/(.] QN Arr corditrorEr relay sFrem AC-ON ON WG CONT 5A/ POWER orer VOLTAGE PULS E li o ar pulse @hage p.o\r'e measu.em ProE measuresuremeft PE:6]: - ECCSC/UINPUT/OUTPUT SIGNALS E N GN E (2) Activetest ' ,+rniu,,, Perform followrng inspections to check1 problem is sol\€d. Flminele Setengrne ternperature highor low ENGINE Problem occurence Engineternperature sensofsystem values TEI\,'IPERATURE condrtion aar iron Do notsetextrerne system as lnrscancausespai*p ug burntng Inlector Air flowmeteaexhaust gassensorsystem Not ellminate.l Other rtem Inspectton Perfomrfollowtng tnspections to checkrf problem rs soived. F limrn2ie Set the airfuel ratto|ch or lean gassensorsystem Problem Ca|irnn DO |Ot SelextremevaluesaS Exhausl occurence FUELINJECTION se-so. cono1l|on this may dan'rageengtne of catal),tic Ai. flowmetererq ne temoeratJre slstem ocn!enet njeclorsystem Nol elimin2tr.l Otherrteminspecton PerlonnfollowngInspecttons to check11 problern rs soi\€d DelayignitionUmrng F limrnrlp Problem Cer r.n DO not SetextremevaluesaS occurence GNNON TII\,1ING lgnrtron tirnrng adjustment conotlon thismay damageengtneor catalytc Detonation sensorsystem con\€rtea N.i elimlnaie.l Othef item nspeclion AAC VALVE OPENING Increasecontroldulyratio The engtne speedshouldtncrease lf the conditrondescnbedon leftcan not be Enginerunning Decreasecontroldutyreatio The lenfied ccheck AAC valve system enginespeed shoulddecrease POWER BTALANCE Set the AAC vale open to stop the specrfied injectoroperatronand the rnjectorspeed can be displayedat this F Lm i n z t F Enginerunning time Inlector systefir aa iion Do not performthtsoperatton whrledriMng FUEL PUI'P RELAY TurnignitionswrtchON OFF and ON so pumpoperattonmakesa solnd lf the conditrondescflbedon leftcan not oe lgnitionswitchON The fuel pressurewill nse \enfied. checkrelaysystemoffuel pomp cartion Do not performthisoperatron pump system exceptundercondit/onsdescnbedon and fuel 1eft. SELF-LEARNING CONT The air-fuelratio feedback corection coeffictentleamtnqfactor rs cleared EN - 491 ECCSC U INPUTOUTPUTSIGNALS RB26DETE TNGINE VN A L U E ( R B 2 6 D E TETN G I N E ) INSPECTIO r ESTER s - 2 o s c l L L o s c o P E& C l R C U lT t"',il:"' name I sisnar At idle Circuit Standard Memo rpm At APProx.2,500 Standa rd Approx.0.4V Sparkplug 1 2 3 11 12 13 I ---| t-- -r Powertransistor controlsignal ---.t1 Approx.5V 4 AAC valvecontrol srgnal A p p r o x1. V 7 Enginespeed signalfor tachometer 0 -- 9 18 Approx.2.4V I relay Air conditioner Air conditionOFF: Batteryvoltage ON: Air conditioner Approx.1V A i r c o n d i t i oO nFF: Batteryvoltage ON: Air conditioner Approx.1V ECCS relay Approx.1V (lgnition switchOFF. Batteryvoltage) Approx.0V Fuelpumprelay OV OV EN - .192 Memo ECCSC/UINPUT/OUTPUT SIGNALS R8 2 6 D E T TE N G I N E R B 2 6 O E TETN G I N E Jnx TX cHl( IGN CLK TeIminal No. S i g n a ln a m e 19 Powersteerjng swtch signal PowersteeringONI OV PowersteeringOFF 5V PowersteeringON: OV PowersteerjngOFF 5V 21 (RX) Receive(conlrol unitdatareception) 10v 10v (rx) Transmit(data transmission from controlunjt) OV OV 23 24 Detonation sensor srgnal Approx.0 3V Approx.0.3V 25 \ hstegate valve controlsolenoid controlstgnai Batteryvoltage Approx.0V 27 Air flowmeter(rear) lntakeair quantjty srgnal Approx.1V 22 At idle Circuit Standard At Approx.2,500rpm Memo Standard Approx.1.5 EN - 493 Memo ECCSC'U INPUTOUTPUTSIGNALS R826DETTENGINE RR'ANFTT ENGINE r Terminal No. S i g n a ln a m e Circuit l At idle Standard l\ilemo At Approx.2,500rpm Standard Memo EnginetemPerature 80"C.APProx.1V Enginetemperature 2 0 " C :A p p r o x . 3 V 28 Enginetemperature sensorslgnal Enginetemperature Bo"C:Approx.1V Enginetemperature 2 0 " C :A p p r o x . 3 V 29 Exhaustgas sensor signal(front) Approx.0 - 1V Deffectsbetween approx.0 - 1V Clock (syrchronization signal) OV OV lvlotor& check lamp(redlamp) Lampnot lit: Power voltage Lampis lit: 0V Lampnotlit: Power\onage Lampis lit: 0V Air iow meter (Front)(lntakeair quantity signal) '1V Approx. Approx.1.5V lntakeatr sensor temperature signal C o l d A p p r o x1 . 5 V \ hrm: Approx.0.8V Cold: Approx.1 5V \Abrm:Approx.0.8V 31 (cLK) JC 36 EN-494 ECCSC/UINPUT/OUTPUT SIGNALS R826DETT ENGINE R B 2 6 D E T TE N G I N E TerminaI No. S i g n a ln a m e 38 Throttlesensol srgnaI Circuit At idle Standa rd Approx.0.5V At Approx.2.500rpm Memo Standard 0.5-4 (VoltageIncreasesif pedalis accelerator presseo) 03-0.7v 41 51 Crankanglesensor 1 2 0 "s r g n a l 2-3V (vr - 2-3V 6r, dtd affi 42 52 Crankanglesensor 1 os i g n a l 43 lgnitron switch (STARTsignal) OV (lgnrtion switch "STARI': Battery voltage) 44 NeLJtral switch srgnal N of P range: 0V OtherthanN or P range 4 - 5V N or P range: 0V Otherthan N or P range: 4 - 5V 46 Air conditioner swjtchsignal A i r c o n d rot n e rO F F Batteryvo[age Air condrtioner ON; OV Air conditioner OFF: Batteryvoltage Air conditioner ON: OV EN - 495 OV Memo SIGNALS ECCSC/UINPUT/OUTPUT ENGINE B826DETT RFI?6NFTT ENGINE , Terminal No. S i g n a ln a m e r C ircuit i At idle Standard I Memo : : : l l - ^ ^ lt APProx.2'500rPm Standard Memo 48 Throttlesensor (PowersuPPlY) 49 ControlunitPower suPPlY Batteryvoltage Batteryt0ltage 53 VehiclesPeed sensorslgnal D range(or 1st)with rear wheelsjacked u p : 0 . 5- 1 . 5 V The valueactually deiects between0v and 5V. However,it appearsto deflect around1V,accordlng to vehiclesPeed. D range(or 1st)wlth rearwheeisiacked u p : 0 . 5- 1 . 5 V The valueactually deiects between0V and 5V. However,lt appearsto defect around1V,according to vehiclespeed 54 Throttlevalveswtch (idle contactPoint) 10V Approx. A p p r o x1 0 V 55 E*raustgassensor signal(Rear) N or P range: 0V OtherthanN or P range: 4 - 5V N or P range: 0V Otherthan N or P range:4 - 5V 56 Throttlesensor signal outprJt 5V Approx 0 5V EN - 496 5V Approx.05-4V (Voltageincreases as accelerator Pedal is pressed). ECCSC/UINPUT/OUTPUT SIGNALS R826DETTENGINE R B 2 6 O E T TE N G I N E Terminal No. S i g n a ln a m e 57 Throttlevalveswtch (Powersupply) 101 103 105 110 112 114 Injectorcontrol sjgnal 104 Fuelpumpterminal voitagecontrol s r g n a(lF P C M1 ) 106 Fuelpumpterminal voltagecordrol srgnal(FPCN4 2) C ircuit I At idle Standard At Approx. 2,500rpm Memo Standard Batteryvollage Batteryvoltage Approx.battery voltage Approx.battery vorcge ldling(afferwarming engrne):0V Duringmiddleload. 4V t Duringmiddleload: OV EN - 497 Memo SIGNALS ECCSC,UINPUTiOUTPUT R826DETTENGINE CAUTIONS 9-3 ECCSCONTROLUNITOPERATION (1) Controlunit equiPment foryourvehicle . Neverinstalla controlunitthatis notspecified bracket . Do notapplyexcessiveforceto the installation (2\ Connector removal and installation forceand do notbendor applyunnecessary . Wn"n removing connectors, andinstalling observefollowing Points: 1. Connector removal connectors. . Turnignition switchoFF andECCSrelayOFFbeforeremoving forceto harness' . Holdconnector withoutapplying firmlyto disconnect lock' . Do notusea screworiver or similartoollo loosentheconnector 2. Connectorinstallation . Turnignition switchOFF. thenconnectsecurely' . Makesurepinsarenotbentor controlunitconnectorand . Tightenboltssecurelyuntilinjectorsurfacereachesorangecolourindicatorof andsurfaceis even. connector (3) Control unit Power . Nevermakea reverseconnectionto the battery' . Usebatteryvoltagein 1O- 16Vrange. (4) ldle speed adiustment knob . Do notturnPastlockPosition. lowerthan0"' . Do notturnadlustment knobwhenambienttemperature (5) Water and oil .Caremustbetakennottoa|lowraindropsorwatertoWetthecontro|unit. doesnotformdueto suddenincreasein . care mustbe takenthatcondensation in the beforeinstalling drycontrolunitadequately lf thereis anymoisture, temperature. vehicie. . Makesureno oiladheresto connectors. . Do notcleanthecontrolunitusingvolatilesolventcleaners' (6) Dropping and imPact . Do notdropthecontrolunitor sublectit to stronglmpacl' . Do notuseupperandlowercoversfor thecontrolunitwhicharedented' (7) Control unit screws and cover . Do not removethe upperand lowercoversfromthe controlunit' . Do notturnthescrewsin thecontrolunitmainbody. EN - 498 ECCSC/UINPUT/OUTPUT SIGNALS RB2OE / DE/ DETENGINE 9. ECCSCONTROLUNITINPUT/ OUTPUTSTGNALS 9-1 CONSULTINSPECTION VALUES (1) Datamonitor Note:Theoutputsignalis displayed as thecalcujationdataon consoleunitso thecorrect valuewilldisplayed evenif theoutputcircuit(harness) is inadvertentlv disconnected. RBaOEIDE / DET ENGINE CAS RPM (Detected angte speed accordtr€ to signals) Tachometer set Engine runnrng AIR FLOWMTR vottage) {oLrtput Aiter warmrngup engtne ldling(N range.A/C OFFI E N G T E I \ 4 PS E N ( e r E r n et e m p e r a t u r e ) Affer warmrng up er€ ne EXT GAS SEN ( o u l p u tv o l i a g e ) EXT GAS SEN (RtcH / LEANI CAR SPEED SEN (\€h cle speed srgnal) lnleclor slslem While dnvrg or wlh dnve wheets turnrng Should generally conform to s p e e d m e t e rd t s p l a y V e h r ce s p e e d s e n s o r s y s l e m lgnrtronswrtchON Engrnestopped 11- 14V Battery ECCS conlrolunrlpower swtch ON EngIne stopped Aflerwarmrng up engrne IGNTIMING Anerwarminq up enqrne Aner warming up eng ne 2o00rpmwth no Throltie tully closed o 5 Throltle fully open 4 A b i r n g ( N r a n g e .A / C oFF) l d l i n g( N f a n q e A / C oFF) 200orprnwjth no hling (N .ange A/C oFF) 2000rpm wtlh no A n e r w a r m r n qu p e n q i n e 200orpm wrth no load l g n r l i o ns w l c h ON E ngIne IDLE SW 2 - 3 rnsec 200o|pmwth no "START' START SIGNAL .OFF' Throttle tully ciosed 2-3msec Air iow meter s)slem I n t a k es y s t e m a r r l e a k s o r a t r sucron (en!re Input) n p L ns r g n a l s y s t e m { e n t r r e ) Mn15.. A.fi24. A d v a n c e g r e a t e rt h a n 1 0 . a n g l e comparedlo rdlepositiOn Air flow meter system Apptax 20 - 4AY. Approx30 - 50% 7s - 125% IAS adluslrnent AAC val\€ system Arr flow meter syslem ]njeclor system C a n r s t e r( p u r g e ) r n s p e c t i o n Intake systern a r leak or a r ON StarlerSW system OFF ON A/C SW ON ON A r r c o n d i t r o n e rS W s y s t e m A/C SW OFF NEUTRALSW PWST SIGNAL N or P rarEe ON NotNorP OFF Sieenng ON Sleeflng IGNSW ON neLrlral Slop OFF A/C ON ON A/C OFF OFF A/C ON OFF dling Nedral SW system Polver steenng SW system OFF ON A I R C O N D I I ' I O N E RR E L A Y Throtlle sensor adlustment Throitle sensor sysiem Throttle sensor system A]R COND S G F U E LP U M P R E L A / E n g r n et e m p e f a t u r es e n s o r R I C H .L E A N r e p e a t s5 t r m e s o r more In 10 seconds INJ PULSE ( r n j e c t i o np u i s e w d t h ) N O T F 1 / 1 6 d t s p l a yf o r RB2OE ( a r r - t u erl a l i o f e e d b a c k correclron coeffic|ent) Above appro, 70 C A r flow rneler syslera E*lairsl gas sensor slsterf I n t a k es y s l e m a r f i e a k o r a r r lgfllion AAC VALVE Approx08-15V Crank ange sensor slstell C h a n g e s b e t w e e nO - 0 3 V a n d 0 6 - 1 V Afterwarrning up engrne BATTERY VOLT T H R O T T L ES E N (odpln voflage) There must be no abnormal change rn speed Fr.reipump system Air condrtorEr .elaysystem ECCSC U INPUTOUTPUTSIGNALS F B 2 O E/ D E / D E TE N G I N E (2\ Activetest ACTIVETESr_ qCT|vE TE9T DESCRIPTPI{ to checkif Perfcrn fo lowng lnspections probEri s so \ed FlmLntte nlgnor ow temperatufe SetengLne sensorsystem ternperature Engrne occurence Problem ENGINE Carjtlo[ Do notsel extremevaluesas Lnlector system condrtron thrscancausespark TEIMPERATURE Plugblrnlng gassensorsyslem Air iow meterexhaust Nol elmrnaie.l' Orhe- rtem ,_soector lo checkl' Pe'{orn'o'lowng,nspectlors problem rs sol\ed. Elimrnate ratiorlchor lean Settheair-fuel gassensorsystem Exhaust ProblemoccurenceCautoo. Do notset extremevaluesas ALrflowmeter, sensor englnetemperature FUELINJECTION thrsmaydamageenglneor cataiytc sysrern conorllon ocn\ertet Injeclorsyslem N.t elmrnaied Other rtem Lnspection tlmrng DelayLgnrtion occurcnce Caltion: Do notset extremevaluesas Problem GNITIONTIMING thrsmaydamageengineor catalytic conol!on con\€nel to checklt Performfollowinginspections problems sol\ed. Flimln2lp lgnitiontimrngadlushenl Detonationsensorsyslem Not ehminait.l Other item Inspecton AAC VALVE OPENING Increasecontro duty ratio The englne lf the conditiondescrlbedon leftcan not be speed shouldincrease Enginerunnrng Decrease controlduty reatlo. The venfied ccheck AAC val\€ system enginespeed shoulddecrease FUEL PUT,4P RELAY switchON. OFF and ON Turnignrtron so pump operatlonmakes a sound. lf the conditiondescribed on left can not be lgnrtionswrtchON The fuel pressurew11nse \€rified. check relay system of fLlelpirmp Cado-o- Do not perform this operatron and fuel pump system Enginestop exceptunderconditionsdescnbedon left SELF-LEARNING CONT The arr-fuelratiofeedbackcorrectloncoefficlentleamlngfactorrs cleared EN-500 ECCSC/UINPUT/OUTPUT SIGNALS B B 2 O EE N G I N E 9-2 O S C I L L O S C O P&EC I R C U I T T E S T E IRN S P E C T I OV NA L U E TerminaI No. Signal name 3 Air flowmeter intakearrquantity srgnaI 5 Enginetemperature sensorsrgnal 6 Exhaustgas sensor srgnaI 7 I Throttlesensor srgnal(lnput) Circuit ( R B 2 O EE N G I N E } At idle Standard At Approx. 2,500rpm Memo Standard Appfox.1V Enginelemperature Bo"C: Approx.1V Engrnetemperature 2 0 " C :A p p r o x . 3 V Approx.1.5V Enginetemperature 8 0 " C . A p p r o x1 V Enginetemperature 2 0 " C .A p p r o x . 3 V Approx.0 - 1V Deflectsbetween 0 - Approx '1V Approx 0 5V 0 . 5- 1 V (Batteryvoltagewill rncerasewhen pedaiis acceleration pressed) 0.3- 0.7v 0 . 3- 0 . 7 v Crankanglesensor 1 2 0 "s i g n a l 2-3V 2-3V (v) 6 10 Crankanglesensor 1 "s r g n a l 2 o E N- s 0 1 Memo EUUJ \, \] SIGNALS INPUT/OUTPUT R B 2 O EE N G I N E RB20EENGINE Terminal No. At idle S i g n a ln a m e Circuit Standard I Memo At APProx'2,500rpm Standard '13 & check l\,4onitor lamp(redlamp) Lampnot lit; Power voltage LamPis lit: Approx.0V Lampnot lit: Powervoltage Lampis lit: Approx.0V '15 Intakeair quantlty outputsignal (ToA/T C/U) Approx.lV A p p r o x1 . 5 V sensor Detonation signaI Approx.4V Approx.4V Approx.0.5V 0 . 5- 1 V (Batteryvottagewill incerasewhen acceleration Pedalls presseo) 17 Throttleopening otjtputsignal 21 Vehiclespeed sensorsignal D range(or 1st)with rear wheelsjacked u p : 0 . 5- 1 . 5 V The valueactually deflectsbetween0 and 5V. However,it appearsto deflect around1V according to vehiclespeed. 22 Throttlevalveswitch (idle contactPornt) A p p r o xl o v EN 502 Memo D range(or 1st)wth rearwheelsjacked u p r 0 . 5- 1 . 5 V The valueactually defrectsbetween0 and 5V. However,lt appearsto defect around1V accordlng to vehiclesPeed. 0V when accelerator is pressed ECCSC/UINPUT/OUTPUT SIGNALS R B 2 O EE N G I N E R B 2 O EE N G I N E TerminaI No. S i g n a ln a m e 23 lgnitionswitch (STARTsignal) OV (lgnition switchat START Power vonage) OV 24 Neutralswitch srgnai N or P range: 0V OtherthanN or P range:Approx.6V N or P range: 0V Otherthan N or P range:Approx 6V 25 lgnrtion swtch (ONsignal) Powervoltage Powervoltage 26 Throttlesensor srgnaI (Powersupply) 27 29 At idle C ircuit Standard At Approx.2,500rpm Memo Standard 5V 5V Controlunitpower supply Power voltage Powervoltage Air conditioner sw'tchsignal Air conditioner OFF: Powervoltage Air conditioner ON: Approx.0V Air conditioner OFF: Powervoltage Air conditioner ON: Approx.0V EN - 503 Memo SIGNALS ECCSC/UINPUT/OUTPUT R B 2 O EE N G I N E RB20E ENGINE Terminal No. I 32 Throttlevalveswitch (PowersuPPlY) At idle Circuit S i g n a ln a m e Standard I Memo At aPProx.2'500 rPm Standard i-;l:-*'r ilecru l ' - Powervoitage \ _.-!!r'-, |.-'' Power voltage 0 . 2- 0 . 3 v Powertranststor controlsignal 38 Powersteering switchsignal n -. . 39 slgnal Tachometer (lgnition coil Primary signaldetection 40 E C C Sr e l a y Disq,bul9r ' f -+-6f reroir . !_cru i-=-Po€ .l R6isror tranestor PowersteeringONI OV PowrsteenngOFFI Approx.5V PowersteeringON: OV PowrsteeringOFF: Approx.5V Power voltage A p p r o x1. 0 V Approx.1V (lgnition switchOFF. Powervoltage) OV 1V Approx. 43 Tachometerengine rev srgnal EN - 504 Approx.3V Memo ECCSC/UINPUT/OUTPUT SIGNALS R B 2 O EE N G I N E R B 2 O EE N G I N E Terminal No. S i g n a ln a m e At idle Circuit Standard EngineA/T total controlinpLrt signal Standa rd Approx. 10V (Dr1) - 45 At Approx.2,500rpm Memo A/T control unit A p p r o x1 0 V : , =:t:nsffilsfri EngineA/l total controlinputsignal (D12) 46 A,r conditioner relay Air conditioner OFF Powefvoltage Air conditioner ON OV 47 EngineA/T total contro, or.IpLlt signal(DT3) OV OV Almostpowervoltage Almostpower voltage 101 103 105 110 112 104 lnjectorcontrol srgnal Fuelpumprelay Air conditioner OFF Pov.ier !oftage Arrcondrtroner ON OV 20 0 OV EN - 505 OV Memo SIGNALS ECCSC U INPUTJOUTPUT R 8 2 O EE N G I N E R B 2 O EE N G I N E Approx4 - 5V AAC valvecontrol srgnal EN - 506 ECCSC/UINPUT/OUTPUT SIGNALS R B 2 O D /ED E TE N G I N E 9-2 O S C I L L O S C O P&E C I R C U I TT E S T E RI N S P E C T I OV NA L U E Terminal No. Signal name 18 Fuelpumprelay At idle Circuit rEf-s (RB2ODE / D E TE N G I N E ) Standard At Approx.2.500rpm Memo Standard t g n i i i o nS W @f' Qr,"r p,'p) + ,,---!)\ OV OV PowersteeflngON: OV PowersteeringOFF. Powersteeflng switchstgnal PowersteeringON: OV PowersteeringOFF 5V 23 24 Detonation sensor signaI Approx 4V Approx.4V 27 Air flow meter (lntakeair quantity signal) Approx.1V Approx.1.5V 28 Enginelemperature sensorsrgnal 29 Exhaustgas sensor signaI Enginetemperature 80"C: Approx.1V Enginetemperature 2 0 " C :A p p r o x . 3 V Approx.1V Et\ - 3U/ Enginetemperature 80"C: Approx.1V Enginetemperature 2 0 " C :A p p r o x . 3 V deiect between 0 - approx.1V Memo SIGNALS ECCSCiU INPUT/OUTPUT R B 2 O D /ED E T E N G I N E RB2ODE/ DET ENGINE , t"ffi:"'l 32 34 name sisnar Circuit I Ai idle Standard I Memo l : : : At APProx.2'500rpm Standard & check lvlonitor lamp(redlamP) Lampnot lit: Powervolatge Lamplit: OV Lamp not lit: Powervolatge Lamplit: OV Engine(AfD total signal controlinpLrt '10V Approx. 10V Approx. {Dr1) 35 36 Engine(AfD total controloutpLrtsignal Approx.0V Approx.0V Engine(A,/T)total controloutputslgnal (D12) Approx.10V 10V Approx. (Dr3) 38 Throttlesensor srgnal Approx.0.5V 0.5 - 4V (Voltage increasesif pedalis accelerator presseo) 40 Intakeair q uanttty oulputslgnal A p p r o x1 V Approx.1.5V E N- 5 0 8 Memo ECCSC/UINPUT/OUTPUT SIGNALS R B 2 O D /ED E TE N G I N E R B 2 O D E/ D E T E N G I N E TerminaI No. S i g n a ln a m e At idle Circuit Standard At Approx.2,500rpm Memo Standard 0 . 3- 0 . 7 6 41 Crankanglesensor 1 2 0 "s i g n a l 2,, 0il 2-3V 42 2-3V Crankanglesensor 'l'signai -_ 0.5trr'- lgnation swtch (STARTsignal) OV (lgnition swrtchin "STARI'': Power \ cltage) OV (lgnrtion switchn "STARI-' Power voltage) Neutralswtch signaI N or P range:0V OtherthanN or P range:4 - 5V N or P range: 0V OtherthanN or P range:4 - 5V 46 Arr conditioner switchsignal A r rc o n o [ t o n eUr F F Powervoltage Air conditioner ON: OV Air conditioner OFF: Powervoltage Air condilioner ONi OV 48 Throttlesensor (Powersupply) 5V 43 trI\ - 5U9 Memo SIGNALS ECCSC/U INPUT/OUTPUT R B 2 O D /ED E TE N G I N E R B 2 O D E/ D E T E N G I N E *il:"'l name sisnar | At idle C ircuit Standard I Memo :a: lt lPProx. 2,500rpm Memo Standard ControlunitPower supply Powervollage Power voltage 53 Vehiclespeed sensorsignal D range(or 1st)wth rearwheelsjacked '1.5V u p : 0 . 5The valueactually deflectsbetween0V and 5V. However,lt appearsto deflect around1V,according to vehiclesPeed. D range(or 1st)with fearwheelsJacked up: 0.5 - 1.5V The valueactually deffectsbetween0V and 5V. Howeve(lt appearsto deiect around1v, accordlng to vehiclespeed 54 Throttlevalveswitch (ldle contactPoint) A p p r o x 1. 0 V 0V when accelerator pedalis pressed A p p r o x . 05 V Approx.0.5 ' 4V (Voltagewillincrease when acce|eralor pedalis pressed) 49 56 Throttleopening outputsignal 57 Throttlevalveswitch (PowersuPPlY) 101 103 105 110 112 Powervoltage Power voltage Alrnoslpowervoltage Almost Powervolage Injectorcontrol srgnal E N- 5 1 0 ECCSC/UINPUT/OUTPUT SIGNALS R B 2 O D iED E TE N G I N E R B 2 O D E/ D E T E N G I N E Terminal No. Signal name At idle Circuit Standard At Approx.2,500rpm Memo Standard l] r' ;".r p, p104 Fuelpumpterminal voltagecontrol signal(FPClvl) I -L I conror mod0ralor ,:\ - ECCSconlror unrr I I C o l d :0 V V\hrm: Power voltage i E N- 5 1 1 C o l d :0 V \ hrm; Power voltage Memo SIGNALS ECCSC U INPUT'OUTPUT / D E / D E TE N G I N E RB2OE CAUTIONS 9-3 ECCSCONTROLUNITOPERATION (1) Controlunit equiPment foryourvehrcle' . Neverinstalla controlunitthatis notspecified bracket . Do notapplyexcesstve installation to the force (2) Connector removal and installation forceand . Wh"n removing do notbendor applyunnecessary connectors, andinstalling observefollowing Points: 1. Connector removal connectors. . Turnignition switchoFF andECCSrelayOFFbeforeremoving forceto harness' . Holdconnector withoutapplying f irmlyto disconnect lock' . Do notusea screwdriver or similartoolto loosentheconnector 2. Connectorinstallation . TurnignitionswitchOFF. .Makesurep|nsarenotbentorcontro|unitconnectorandthenconnectSecUre|y. . Tightenboltssecurelyuntilinjectorsurlacereachesorangecolourindicatorof andsurfaceis even. connector (3) Control unit Power . Nevermakea reverseconnectionto the battery. . Usebatteryvoltagein .10- 16Vrange. (4) ldle speed adiustment knob . Do notturnpastlockPosition. lowerthanOoC' . Do notturnadjustment knobwhenambienttemperature (5) Waterand oil . care mustbe takennotto allowraindropsor waterto wetthecontrolunit. doesnotformdueto suddenincreasein . care mustbe takenthatcondensation in the beforeinstalling drycontrolunitadequately lf thereis any moisture, temperature. vehicle. . Makesureno oil adheresto connectors. . Do notcleanthecontrolunitusingvolatilesolventcleaners. (6) Dropping and imPact . Do notdropthecontrolunitor subjectit to strongimpact' . Do notuseupperandlowercoversforthecontrolunitwhicharedented' (7') Control unit screws and cover . Do notremovetheupperandlowercoversf romthecontrolunit' . Do notturnthescrewsin thecontrolunitmainbody. E N- 5 1 2 ECCSC/UINPUT/OUTPUT SIGNALS C A ' 1 8Ei N G I N E 9. ECCS CONTROLUNIT INPUT/ OUTPUTSIGNALS 9.1 CONSULTINSPECTION VALUES (1) Datamonitor Note:The outputsignalis displayed as thecalculation dataon consoleunitso thecorrecr valuewilldisplayed evenif theoutputcircuit(harness) is inadvertentlv disconnected. CAl8i ENGINE ,li: , .'..,liti cotonr ' , j..:t'.:..:i !{t: . -,t Tachometer set Engine runnrng There must be no abnorrnal c n a n g eI n s p e e o ENGTEMP SEN lergrne remperature) Afrer warm,ng up engrne Abo\r'e approx 70"C EXT GAS SEN ( R I C H/ L E A N ) CAR SPEED SEN ( v e h i c l es p e e d s r g n a l ) up engrne T H R O T T L ES E N Should generally corform to s p e e d m e t e rd i s p a y lgnrtronswitch ON E n g r n es l o p p e d 11- 14V IHROTTLE SEN (2) (oLrtputvoitage) ] N T / AT E M P S E N (rnlaktemperalure sensor lgnrlion swtch ON Engrne Throtlle tully closed 1 0 Thron|e tully closed 06 Crank angle sensor slstem Engrne temperature sensor Vehrcle speed sensor s)€1err Battery E C C S c o n t r o lu n r tp o \ , € r 5 0 Throltle sensor adtustmenl Thfonle sensor system 4 5 I n l a k ea r r t e m p e r a l u r er s Aner wannrng up engrne ldling (N range A/C INJ PULSE ( r n j e c i o np u i s e w d t h ) 1 '2 2000rpmwith no load ldlng (N range IGN TIMING ,.:-i C h a n g e s b e M e e n 0 - 0 3 V a n d Exhaust gas sensor system 06 - 1V l r i a k e s y s t e ma r r e a k o r a r r 2000lpm wth no load R I C H .L E A N r e p e a l s 5 t m e s o r m o r e 1 n1 0 s e c o r d s While dnvrng of wth drive whee s tumrng BATTERY VOLI i PRCiSL:ES t t CAS RPM (Detected angle s p e e d a c c o r d r n gt o s r g n a l s ) EXT GAS SEN (outpLl voitage) ' ..1:.1 A/C After warming 2OOOrpm wlh no oad rnsec lntaktemperature sensor Arr now meter system I n l a k es y s l e m a r r l e a k s o r a r r sucton lennre nput) Input signal syslern (ent re) Mtf 1s. Atf20" Advance grealer fhan 10" angle comparedto idle posrlron Air flow meter system Air llow metef system (arr-tuel fato feedback corre.lon coeffcrent) Aner warmrng up engrrE 2 O O 0 r p mw l h n o l o a d STAR']-' START SIGNAL 75 - 125vo ON Starter SW system ON Engrne IDLE SW Throttle tully closed ON Throttle sensor syslem A/C SW ON AIR COND SIG ON A r r c o n d r l i o n e rS W s y s t e m A/C SW OFF ON N E U T R A LS W Neutral SW system Steenng PWST SIGNAL ON Povt€r steenng WG CONT SA/ FICD SA/ ON Head amp heater fan rear defogger SW ON ON A/C ON ON AIC OFF Eng temp cord ON Eng temp Hoi FUEL PUMP RELAY IGN swtch ON Slop ON A I R C O N D I T I O N E RR E L A Y C a f l s t e r ( p u r g e )i n s p e c t r o n r{ake syslemarr leak or air ldle A/C ON A/C OFF OFF SW slstem F I C D i n p L ns y s l e m PTC healer InpLnsystem Fuel pump syslem A i r c o n d i l r o n e rs y s t e m SIGNALS ECCSC'U INPUT/OUTPUT C A 1 8 iE N G I N E (2) Aciive test r:1]U:]:.r,:r' r,:sl, ACTI/ETEST !*'.r. ACTIVETEETDESCRIPTIO{ Perfor.nfo lowrng nspectionsto check lf problemts so \€o. F mLn:JP hlghor low Setenginetemperature sensorsystem Engnelemperatlre Problernoccurence ENGINE Cal]tion.Do notset extremevalues Inlector system condrt 0n TEIVIPERATURE burnlng as thiscancausesparkpLug Arrflowmeler.exhaustgas sensorsysrem Nol clm nated Ot_er tem nsoeclion FUELINJECTION Pedorm follow!nginspectionsto check if pfoblemis sol\€d Flimrn2te ratronchor lean. Setthearr-fuel Exhaustgas sensorsrsrem Problem occurenc€Calllio-rtDo notsetextremevaluesas Aif flowmeter englnetemperature sensol condttlon or catal)'tlc thisrnaydamageengLne system ocn\€rter. lnlectorsystem Not elirninaied Other rtem Inspectlon IGNITIONTII,IING Performfollowlnginspectionsto check if problemrs solt€d. ttmrng Delayrgnrtlon Flimrn2tt Problem occurenceCArdion Do not set extremevaluesas lgnitiontrmingadjustment thrsmay damageenglneor cataYlc condrtron Detonationsensor system convefler Nol elimin2led Other item inspectlon TurnignitionswitchON and OFF The lf the condihondescribedon lell can not be idle revwill change warm uP engrne Affer solenol0 IDLE \€riied. checktdlecorrectlon pedom operatron this hling (N range,A/C Carxio-o.Do not SA/ CORRECTION slstem exceptundefcondltlondescrlbedon oFF) left Turnrgniton swtch ON and OFF The AfterengrnewarrnuP rdlerevwll increaseal approx200rprn lf the condrlroldescrrbedon leftcan not be ldling(N rangeA/C Ca!tjo-c|:Do not performthis operaton \€rified.checkFCD solenoldsystem FCD SA/ exceptunderconditiondescnbedon oFF) lefr. FUELPUMP RELAY SELF,LEARNING CONT lgnitionswitchON switchON OFFandON Turnignrtron makesa sound so plmp operation describedon leftcannotbe f thecondition willrise Thefuelpressure \€nied, checkfelaysystemof fuelpump Do notperformthlsoperatlonandfuelPurnp Ca!!-oxLsystem on descnbed except!nderconditlons left coerfclentlealnlngfactorrs ceared ralo feedbao(correctlo'1 fhe arr-fuel EN- 514 ECCSC/UINPUT/OUTPUT SIGNALS C A l 8 iE N G I N E 9 - 2 O S C T L L O S C O p&EC t R C U t TT E S T E Rt N S P E C T I O V NA L U E( C A l S iE N G T N E ) TerminaI No, S i g n a ln a m e 3 Throttle sensor signal1 5 Enginetemperature sensor srgnal At Approx.2,500rpm At idle Circuit Standa rd Approx. 1V Memo Standa rd Appfox.1V - 5V (Voltagewillincrease whenaccelerator pedalis pressed) Enginetemperature 80"C: 1V Enginetemperature 20"c 3v Enginetemperature 80"C: 1V Enginetemperature 20"C: 3V Deflectbetween approx.0 - lV 6 Exhaustgas sensor srgnal 7 Throttlesensor signal2 Approx.0.3 - 0.7V I '19 Deflectbelween a p p r o x0 - 1 V !"1;l-.-.,:- Approx 0 6V Approx. 0.3- 0.7V Crankanglesensof '180"signal Approx. 2 - 3V (v) Crankanglesensor 1 os r g n a l 6 6 2 2 0 E N- 5 1 s l Approx.06V-4.5V (Voltageincrease whenaccelerator pedalis pressed) Approx.2 - 3V 10 20 Memo SIGNALS ECCSC/U INPUT/OUTPUT C A l 8 iE N G I N E C A 1 8 iE N G I N E ' t"',il:"'l 13 name sisnar l,4onitor& check lamp(redlamp) Circuit Standard Vehrclespeed sensorsrgnal I Memo :::: At APProx.2,500rpm Standard LamPnot lit: Powervoltage Lamplit: APProx.0V Lampnot ht: Powervoltage 0V Lamplit: APProx. (v) '1 Approx. " 5V get shorter (Cyclewill whenvehiclesPeed is increased) 6 21 | At idle 2 0 OV (lgnition switchin STARI Power voltage) OV (lgnition switchin START Power voltage) 24 Neutralswitch signaI N or P range:0V OtherthanN or P range:6 - 7V N or P range: 0V Otherthan N or P range. 6 - 7V 27 ECCS controlunit power suppty Powervoltage Powervoltage OFF: Air conditioner Powervoitage ON: Air conditioner OV OFF: Air conditioner Power voltage ON: Air conditioner OV 23 ta lgnitionswitch "START'signal Air condittoner switchsignal E N- 5 1 6 Memo ECCSC/UINPUT/OUTPUT SIGNALS C A 1 8 iE N G I N E CA'I8iENGINE TerminaI No. S i g n a ln a m e 30 lntakeatf remperaturesensor stgnal Cold: Approx.1.5V l brm: Approx.0.8V C o l d :A p p r o x1. . 5 V Wbrm: Approx.0.8V Powersteenng signaI PowersteeringON: OV PowersteeringOFF Approx.BV PowersteeringON: OV PowersteenngOFF. Approx.BV Approx0.5V A p p r o x1. V At idle C ircuit Standa rd (;)it-Il]l--l-t-,1 37 4f-:.-. -- Powertranststor control signai(lN) - ,fltr-4- A' -- -+- 108 -rrr:F 1 rl IGN_coil -F-:*i:= .o Approx 0 5V Powertranslstor controlsignal(EX) Standa rd Memo l 1 T 't:t:t:'J'ta''J' i r : r c ' * . . .i ,l 1 l l ' | :p?'.\'. lvl-T-ttr I 6l-i 1 l I -. I I oisrribu'o1 38 At Approx. 2,500rpm Itdemo ;iuk+irffifr J-- F - r t L t , I L Jl l+iroF{':i,.1 i-i- -,-- 39 40 A p p r o x 1. 1 V- 1 2 V A p p r o x 1. 0 V- 1 1 V OV (lgnition swtch OFF: Power voltage) OV lgnitionprimary stgnal ECCS relay E N- 5 1 7 SIGNALS ECCSCiU INPUT/OUTPUT C A 1 8 ]E N G I N E C A 1 8 iE N G I N E ' t"',1::"'l sisnar name 41 Circuit I At idle Standard I Memo l : : : at APProx.2'500rpm Standard Powervoltage Lowef than Power volage SwitchON: Powervoltage SwitchOFF: 0V FuelinjectorPUlse monitorsrgnal (ll monitor) 43 Lightswitchsignal SwitchON: Power voltage SwitchOFF: 0V 45 Heaterfan swtch srgnaI SwitchON: Powervonage SwitchOFF: 0V SwitchON: Power voltage SwitchOFF] 0V 46 Reardefogger switchsignal SwitchON: Powervoltage SwitchOFF] 0V SwitchON: Power!oltage SwitchOFF: 0V Powervollage Lowerthan Po\4er vo|tage e rN : A i r c o n d i l r o nO Powervoftage r FF A r rc o n dt r o n eO OV ON: Air conditioner Power voltage OFF: Air conditioner OV '101 110 Injectorcontrol srgnal 102 relay Air conditioner srgnal E N- 5 1 8 Memo ECCSC/UINPUT/OUTPUT SIGNALS C A ' l 8 iE N G I N E C A 1 8 iE N G I N E Terminal No. S i g n a ln a m e Circuit At idle Standard FICDsolenoid Air condilioner ON: OV Air conditioner OFF: Powervoltage 104 Fuelpumprelay Approx.0V (Powervoltagefor 5 sec atterjgnrtion swtch rs placedto ON posrtion) '106 PTC heaterrelay '103 ,-,11t_ PTC heaterON: Approx.0V PTC heaterOFFr Powervoltage At Approx. 2,500rpm Memo Standard Air conditioner ON: OV Air conditioner OFF: Powervoltage Approx.0V PTC heaterON: Approx.0V PTC heaterOFFI Power \/oltage '1. Whenign sw in 111 115 ldle rev correction sotenoro Lock up release solenoid(Aff) on 2. Enginerewing: Approx.0V First15 sec afrerenginestart:Approx.0V Afler15 sec afterenginestarl: Powervoltage Any ofthe followings are ON (Powersteering, laghts, reardefoggetheaterfan switch)iApprox. 0V (D rangefor A/T) Lockup released: Approx.0V Lock u pa p p l e o : Power vottage E N- 5 1 9 Lockup released: Approx.0V Lockup appljed: Powervoltage Memo ECCSCiU INPUTOUTPUTSIGNALS R B 2 5 D EE N G I N E 9. E C C SC O N T R O LU N I T I N P U T/ O U T P U TS I G N A L S VALUES 9.1 CONSULTINSPECTION (1) Datamonitor dataon consoieunitso thecorrect as thecalculation outputsignalis displayed Note:The disconnected. is lnadvertently evenif theoutputcircuit(harness) valuewilldisplayed RB25DEENGINE toR rr,r:,r.,t,trtr',r. AlR FLOWt'/TR lol,tptltvoltage) Ailerwarmng up kl lrg engI€ hlrg (Nrange wthottload 2000rpm A/COFF) ENGTEMPSEN lengrnetemPerature) EXTGASSEN \oltage) roLrlPut EXTGASSEN (RICH/ LEAN) Theremuslce no aonorma Crankangiesensorsyslem chaarge^ speeo set Tacfometer Engne runnng al.q]e CAS RP[,4(Detected to srgnals) speedaccordrng AitefwarmrngLtPenglne l\hile dfl\,1n9or w th drve wheels tLlrnlng BATTERYVOLT €n ttonswrtchON Engrneslopped IN.]PULSE ( nFclronpulsewldtl'r) Aiterwarmng !p engne LGNT [,4ING AJlerwamlrg up engrne AAC VALVE A/FALPHA (a r-fuelratrofeedbackconeclron coeffcient) bnitionswrtchoN Enginestopped NEUTRALSW ldle PWSTSIGNAL AIR CON RELAY ACCeI POWERVOLTAGE sensor Engr€ temperaure syslem ldlrng(N range A/C oFF) 2000rpfirwlthm loao tlhrg (N range A/C oFF) IGNSW ON SYsteTn Vehrce SpeedsensoT Battery ECCScontrolwrt Power system 11 Afterwarmrngup engr€ 2000rpmw tir m load AR CONDS G SEN THROTTLE (ouFutvoltage) Shoudgene€ y conbrrnto spee0meler0 splay A r fow metersystem A p p r o x . 2 0 - 2 8 m s e c Inlakesystema r eaKs0r alr sLcton{entirernpul) A p p r o x2 0 - 2 8 m s e c npLrt signalsystem(entlre) 15. Advancegrealerthan10"ange 2000em wrthno load comparedto tde Poston Alterwarmng up ld r€ (N range.A/C Approx12 - 30% OFF) eng rle DLE SJUDGEMENT FUELPUMP RELAY AboveapproxiO'C - 03v and Detween0 Changes gas sensorsyslem ExhaLrst 06- lv ntakesystemalr eak or alT AnerwarmrngLlp 2000rpmw th rx)load intake enqrie 5 t mesor RlCfl.LEANrepeats nedor sysrcrn mofe n 10 seconos C A RS P E E DS E N (\ehcle speedsignal' STARTSIGNAL A r frowmetersystem Approxl0-15V 75 - 125% STARI ON OFF OFF ThrotUefLilyclosed ON Throttetullyopen OFF A/C SW ON ON A/C SW OFF OFF N or P range ON NotNorP OFF Steenng ON Steenng rcu'tral OFF ArC ON ON OFF OFF A/CON OFF Stop OFF Arriow metersystem lAS adjuslnent AAC vaivesvstem Air iow metersyslem nlectorsyslem Canrster(purge)nspeqlon ntakesyslemalr eak or alr slcton StarterSW system ThTott e sensorslslem Arrcondtoner SW system NeLtalSW system PowersteenngSW syslem Arrcondtoret reay syslem FLE pumpsystem ON switchON Throttlefullvc osed lgnrtron EngrnestoPPed Throttetu y open Approx4 0 Appror0 5 sensorsyslem Throttle value Drsoav oo\r€rvoltagepro\e measurement !€lue ls c a! oulsepro\e Tneasuresulemenl N-5 ECCSC/UINPUT/OUTPUT SIGNALS R B 2 5 D EE N G I N E (2\ Active test ACTIVETEST JT'DGE ENTA DN! 'ECTF |TEH ' Acrnrpirus'.oescnPipR,',. Setengrrctemperature hlghor low ENGINE Problemoccurence Cardion Do not Set extreme ValUeS aS IEMPERATURE cono|l|on thrscancausesparkplugburntng Set the air-fuelralio rich or lean ProblemoccurenceC2r,lron DO not SetexlremevaluesaS FUELINJECTON condrlion thrsmaydamageengrneor catal!,tic ocnlener GNTNONTII\,IING Delayrgnition umrng Problemoccurence C2LdionDO notset exlremeva t€S aS cono|Ilon thismaydamageeitgrneor catalytic con\€net Pefonn folowng Inspections 1ochecktf problems solved. Fliminrle Engrnelernperature sensorslstem Inlectorsyslem Air ilow meter exhaustgas sensofsyslem Nai elimtneleal Othertem inspection Perfom foilowrngInspectionsto check lf problemrs solved Flimrnaie gas sensofsyslem Exhaust Arrflowrneterengrneternperature sensor systenl Inlectorsystem Nol eliminaied Olheritem inspecton Perfonnfollowing nspectionsto check if probiemrs solved Flimrn2le lgnition limingadjuslme Detonation sensorslstem Nol ehmrnaled Otherrteminspectron Increase conlroldutyratto.Theengtne AAC VALVE OPENING FUELPUMP REtAY SELF-LEARNING CONT POWER BALANCE Enginerunning lgnition switchON Engrnestop Decreasecontroldlty ratto The engrnespeedshollddecaease. f lhe condition descnbedon lefican not beverified.checkAAC valvesystem Turnrgnition swllchON OFFandONso pumpoperalron makesa sound.Thefuel lf lhe condrtiondescnbedon leftcan not be pressure wrllnse venfed. check relaysyslem offuel pump Do nolperformlhisoperalron and fuelpumpsystenl CaUi.o-rL exceptunderconditi0ns descrrbed on 1eff. The air-fuelratiofeedbackcorection coefficrenllearntnqfactorts cleared. Eng ne rev can be drsplayedwhenAAC Problemoccurencevalveopeningis flxed and set rnlector operalrons stopped. condition Car{ron Do notpedormlhis operation whrlednMng EN - 521 Flirnrneie Injector systern SIGNALS ECCSC U INPUT,OUTPUT R B 2 s D EE N G I N E VALUE (RB250EENGINE) osclLLoscoPE & clRcutT TESTERINSPECTION s-2 Terminal No. Standard 0.2- 0.3v 1 2 3 11 12 13 At Approx.2,500rpm At idle C irc uit S i g n a ln a m e (v) - 6 . _ . . l- Approx.0.4V - ' . - . : Powertransistor controlsignal Cold: 6 - 7V Vvarm:8 - 10V 4 AAC valvecontrol srgnaI EngineA/T total controlinputsignal (Dr1) i Approx.5V (v)-r'-:-_-_-_ t|l 10 -,r1 --f|- -Ttl 5 - ir r' .--'--:+zrs ,1,.--- l5 10 5 f+ 5 Afi contol un 10V Approx. 10V Approx. Approx.1V Approx.2.4V lvt 7 Itlemo Standard Memo ., - - -.l -" i ; ; ; . ; ' F Tf-lTl-r-TTtf Tachometerengine speedsignal "IIilLTI]rlL l.ih- l]]- , t .:-_ti- 9 relay Air conditioner OFF: Air conditioner Powervoltage ON: Air conditioner Approx.1V 14 Enginea/T total controlinputsignal (D12) Approx.10V EN - 522 OFF: Air conditioner Powervoltage ON: Air conditioner Approx.1V Approx.10V ECCSC/UINPUT/OUTPUT SIGNALS R B 2 5 D EE N G I N E R B 2 5 D EE N G I N E Termina I No. 15 Signal name C ircuit EngineAff total controloLrtputsrgnal At Approx.2,500rpm At idle Standard Memo Stan dard Approx.0V (Dr3) 16 E C C Sr e l a y Approx.1V (lgnrtion switch OFF. Powervoltage) 18 Fuelpumprelay OV '19 Powersteenng swtch signal t l v i = PowersteenngON OV PowersteeringOFF Memo Approx.0V Approx.0V : l!.,/erstee^ng_N OV D-\!Fr <.;.--,^ ^:: 5V ----5i."",, 23 24 Detonation sensor sigml 27 Air iow meter (lntakeair quantity signal) I rio"i""*t"** i i - - - - Approx.0.3V Approx.1V EN - 523 Approx.0.3V A p p r o x1. . 5 V SIGNALS ECCSCiU INPUT,OUTPUT FIB25DEENGINF R B 2 5 D EE N G I N E . t"il:"'l name sisnar r t At idle Circuit Standard l I Memo At APProx. 2,500 |pm Standard Memo En9ire renperaturc s€nsor Enginetemperature 1V 80"C:Approx. Enginetemperature 20'C: Approx.3V temperature Engine 1V 80"C:Approx. Enginetemperature 20"C:Approx.3V 28 temperature Engine sensors!gnal 29 gassensor Exhaust signal 0 - 1V Approx. 32 [,ilonitor& check lamp (redlamp,exhaust temperature warninglamp) Lampnot lit: Powervoitage Lamplit: 0V Lampnot lit: Powervoltage Lamp lit: 0V t-tuu so€notcl A/C ONrov A/COFF:Power vomge A/C ON :0V AiCOFF: Power vorcge Approx.0.5V 0.5 - 4V (Vottage increasewhen pedalts accelerator presseo) 38 40 Throttlesensor srgnal Intakeair quantity oLrtputsagnal Approx.1V EN - 524 Deflectbetween0 '1V approx. Approx.1.5V ECCSC/UINPUT/OUTPUT SIGNALS R B 2 5 D EE N G I N E R B 2 5 D EE N G I N E TerminaI No. S i g n a ln a m e At idle Circuit Standard 03-0.7v 41 At Approx. 2,500rpm Memo Standard 0 . 3- 0 . 7 v Crankanglesensor 1 2 0 "s i g n a l 2-3V lv) 6 42 Crankanglesensor 1 "s i g n a l -r ' . -T- - , ftfl{f+nnflnI , +fffHfl+HilIiI 0r!!u!Fu!uu . - . . , . - 43 Jgnition switch (STARTsignai) OV (lgnition swilch STARI Power voltage) OV 44 Neutralswitch srgnal N or P range: 0V OtherthanN or P range:4 - 5V N or P ranger0V OtherthanN or P range:4 - 5V 46 Air conditioner switchsignal Air conditioner OFF: Powervoltage Arr conditioner ONI OV Air conditioner OFF: Powervoltage Arr conditioner ONI OV 4A Intakeair quantjty outpLrtsrgnal EN - 525 Memo ECCSC/UINPUTOUTPUTSIGNALS R B 2 5 D EE N G I N E RB25OEENGINE ' t"'.,il:"'l sisnar name Circuit At idle Standard t I Memo : : : l lt lPProx- 2.500rpm Standard ECCS C/U powersupPlY Powervoltage Powervoltage 53 Vehiclespeed sensorslgnal D range(or 1st)with rearwheelsiacked u p : 0 . 5" 1 . 5 V The valueactually deflectsbetween0V and 5V However,lt appearsto de{lect aroundlV according to vehiclespeed. D range(or 1st)with rear wheelsJacked u p ;0 5 - l . 5 V The valueactually deflectsbetween0v and 5V. However,rt appearsto deflect aroundlVaccordlng to vehiclespeed. 54 Throttlevalveswitch (ldlecontactPolnt) 49 Approx.10V 0V when accelerator pedalis pressed Memo 56 Throttleopening oLrtputsrgnal Approx.0.5V Approx.0.5 - 4V (Voltagewill increase when accelerator pedalis pressed) 57 Throttlevalveswtch (powersuPPlY) Powervottage Powervonage Almostpowervoltage Almostpower voltage 101 103 105 '110 control InJector srgnal 112 EN - 526 ENGINEELECTRICAL EQUIPMENT B B 2 6 D E T /TR B 2 O E / D F / D E T/ C A 1 8/i R B 2 5 D EE N G I N E EN4 ENGINEELECTRICAL EQUIPMENT PREPARATION TOOLS Hydrometer Batteryspeoficgravtyinspection Circuittester Resistancevoltageinspections SPECIFICATION Note: The batterycapacityvalueis the 5-hourratethatconformsto the newJIS standard andthevalueis 80%of theformer2o-hourrate. (example) name] [Newmodel + + Terf + rnallpolarity + position | | dimensions(roundedoff) I B+tteryl.l€ngth qatteryl-*idth x box heightclassification Perfdffiancerank(startingfunctionaddedto 5hr capacitv) EN - 529 EQUIPMENT ENGINEELECTRICAL R B 2 6 D E T TR/ B 2 O ED/ E / D E T / C A 1 B iR/ B 2 5 D E N GN E 1. BATTERYINSPECTION Voltage inspection Normal 1 2 . 4- 1 2 . 8 N) 1 2 . 4o r l e s s Limit(chargerequired) (V) (V) (Startlrmrt) 12(zo"C) Specific gravity inspection (20"C) Normal 1 . 2 9- 1 . 2 2 required) (V) Limit(charge 1.22or less Servicelife Thereis a variationwidthof more than0.04 betweeneachcell Additionalwalerdoes not needto be addedto the batter, duringservicelileof normaldriving.Whendrivingfor the fluidlevel extendedperiodsof time in hightemperatures' to thevehicledrivingconditions maydecreaseaccording (upperi lower) levelindicator the level with fluid Checkthe andtop up to the upperlevelas necessary. watermustbe usedto be addedto refi Caution:Distilled the battery.lf ordinarywateris used,fluidlosswillincrease andmaycausedischarge. 2. ALTERNATOR (1) Alternatorremovaland installation RB ENGINE C A 1 8 iE N G I N E -"f;-s-'h;l ."f'q ,",,.-.ffi i1;'5T.1 ,*-*;".fr", (21 AlternatorinsPection Output voltage insPection . Placeignitionswitchto ON positionand check thal chargewarninglamPwilllight. EN-530 ENGINEELECTRICAL EOUIPMENT BB26DETT/ RB20Ei DE / DET/ CAi Sr/ FiB25DEENGTNE 3. STARTERMOTORREMOVAL& INSTALLATION CAIsiENGINE RBENGINE B o l t3 . 1- 4 . 1 Startermotor *-,"rt", ll Washe Nut 4. SPARKPLUG INSPECTION Inspection . Checkfor anylooseness withterminals. . Checkfor anydamageor crackson theinsulator. . Usethickness gaugeto checkthesparkpluggap. S p a r kp l u g g a p ( m m ) : 1 . 0- 1 . 1 5. PLATINUMPLUG INSPECTION (BB2ODE,RB2ODET, RB26DETT) precautions Installation Periodic replacementinterval: 100,000km Gasinspection andadjustment andplugcleaningusing wirebrush,shouldnotbe performed as thismayscrape off the platinumpartucluate fromthe platinumtip surface. lf plugsarecleanedwithan airgun,thecleaning should be performed in lessthan20 secondsat an airpressure lessthan6.0k9/ cmr. Onlyusepartsspecified by Nissan,whenreplacing the plugs. spark EN - 531 EQUIPMENT ENGINEELECTRICAL RB26DETT/ RB2OEi DE / DET/ CA18i ENGINE o. IGNITIONCOILINSPECTION side) CA18i(Exhaust CA18iENGINE(lntakeside) RB2ODE/DET/RB26DETT RB2OEENGINE value. . Checktheprimaryandsecondary coilresistance EN - 532 COOLING SYSTEM RB26DETT / RB2OE/ DE / DET/ CA18i / RB2sDEENGINE ENs COOLINGSYSTEM PREPARATIONTOOLS SPECIFICATIONS Onepieceunit(owershroud) EI\ - CJJ SYSTEM COOLING R B 2 6 D E T/TB B 2 O E/ D E / D E T/ C A 1 8 /i R B 2 5 D EE N G I N E 1. RADIATORINSPECTION Cooling water leak insPection . Useradtator cap testerandapplypressure(limit1 Okgi cm2)andcheckfor leakage. Caution: Whenusingthe radiatorcap tester,alwaysmakesureto connectthe hoseadapterandfillercap is notdeformed. 2. RADIATORCAP INSPECTION Inspection . Cleancap rubberpackingsealsurfaceandvacuumwith drybrush. ano . Attachradiator captestertocap.Applypressure checkthatvalveoperatescorrectly. . Pullvacuumvalvewithfingerandcheckoperation. J. COOLINGWATERFILLINGPROCEDURES hoseandheaterhoseclampsare 1 Makesurethe radiator tightenedsecurelY. Setthe heatercontrolleverto HOTposition.(For first airconditioners, withautomatic vehiclesequipped andremovethe placeignition switchto ON position externalsensorconnector). capandairdrainplug. (RB20E: Releasethe radiator area. RB20DE/ DET:Intake collector lntakemanifold in frontof glovebox). and manifoldcollectorarea gradually (fillingspeed:slowerthan2L / Filltheradiator min)to thetopof thespoutwithcoolant.Fillthe radiator untilthe waterin the reservetankreachesthe MAXlevel lineindicated. capandairdrainplug(RB closingthe radiator After 5 starttheengineandallowit to idle. system), to idleuntilthethermostat 6 Theenginewillcontinue opens.(Touchthe radiatorf low hoseand makesurehot the wateris flowing).lf a largevolumeof airremains, past the gaugeneedlewillmove walertemperature lf abnormally' rises temperature middleas theengine add thisoccurs,stoptheenginewaituntilit coolsand water to the radiatorrepeatedlyas describedabove. Afterthe thermostatopens,racethe enginefor 10 secondsat 2500rpmtwoor threetimes.Checkthat doesnot riseexcessively. watertemperature the EN - 534 COOLING SYSTEM RB26DETT/ RB2OE/ DE / DET/ CA18i/ RB25DEENGINE 7 Stoptheengineandallowit to cool. Releasethe radiator capandcheckthefluidlevel.lf thefluidlevellowers. returnto step4 and repeatthe process. OR vehicleequipped withautomatic airconditioning, connectthefreshairsensorconnector. 4. RADIATOR REMOVAL ANDINSTALLATION C A l 8 iE N G I N E Bolt(2) 0.33- 033 - -- '' Nut0.33- 0143a. Reservertank __xo Fadjator moudlng &racket (uppe.tt , s iff ijgj / .//-n t,! Radialor shroud ttowert I -/ RadiatorASSY / A 1l / / R ,../ 43 kg-m RB ENGfNES(RB20EI DE I DET tRB25DE/ RB26DETT) (2) 0.33 - 0.43 .-|l R a dr a t o r m o unt i n g (upper) pao*o.ss - 0.43 F,?giiii,fiS:l''* Radiatorcap Badiatorhose - Radiator m o un l r ng (upper) v' Reseryer QnrJ ,afr \-,i -!-'- 6- ,rn-- 9 - Nut0.33 0.43 Radiatorhose (lowe4 Hose clarnp Atf otl co( r (A/T nose Fladiator shroud(lower) Radiator mo unt r n g rubber(lower) Fi. lv.l Kg-m Badiatorshroud(upper) \p*Screw ( 4 )P 0.33- 0.43 EN - 53s FUELSYSTEM RB26DETT/ F]B2OE / DE / DET / CA18i/ RB25DEENGINE EN6 FUELSYSTEM PREPARATION TOOLS FLrelgaugeinspection SPECIFICATIONS EN - 537 FUELSYSTEM / D E / D E T/ C A l 8 i / R B 2 5 D EE N G I N E F I B 2 6 D E T/ TR B 2 O E 1. FUEL TANK FEMOVAL& INSTALLATION Fillertube IPornt4] Canister N u t0 . 3 3- 0 . $ Q ) 2 - 7- IPoint3] -Y.'/ A,, F u e itanKASSY \ ) rQ-z d Fueltankprotector IPoint3] Bolt(4) 0. 3 3- 0 . 4 3 Additionalwork required: Drainfuel Removethefollowing: reliefvaive[Point1] Fuelpressure Fueltankinternalpressurerelief Fillertubeprotector holecoverIPoint2] Inspection [Point3] Fuelgaugeunit,fuelpumpharnessconnector FueltankProtector Hoses 'l [Point ] Fuel pressure relief . Afterstartingthe engine,removefuelpumpfuseandwait untilenginestops.Crankengine4 to 5 timesto consume f u e li n l i n e s . . Forvehiclewhichcan notbe started,removefuelpump fuse,crankengine4 to 5 timesto consumefuelin lines. Caution: The batterymay becomeweakeasily,use boostercablesto connectit to anothervehicleor batteryif necessary. [Point 2l Inspection hole cover, harness cover,fuel gauge unit harness connector removal & installation Removal . Removerearfinisheranddetachthefuelgaugeunrt harnessconnector. ?i..'-1l ry'Lcover EN - 538 FUELSYSTEM RB26DETI/ RB2OE/ DE / DET / CA18i/ RB2sOEENGINE Additionalwork required: Removethefollowing: Fuelpressurerelief Internalpressurerelief holecover Inspection gauge limit Fuel Fuelpumpharnessconnector Fuelhose(return,feed) l P o i n t1 I Fuel gauge ASSY bolts installation . SetO-ringto fuellanksideand insertgaugeASSYinside thetank.Tightentheboltsshownin thefigureon the right. Caution: Extracautionmustbe takennotto damagefloatandthe gaugeASSY armwheninstalling f uelgaugeASSY iedboltswheninstalling Onlyusespecif (2) Fuel pump removal& installation Removal . Loosenhoseclampon unitsideon the pumpside. pumpwiththe insulator . Liftup thepumpslightly.Flemove (PlC A) fromgaugeunitsidebracket . Removepumpsideharness. . Detachhose. lnstallation . Carrvout installation operationin reverseorder. (3) Inspection 1. Float inspection . Placethefloatat the F (leverupperside)and E (lever andcheckthe resistance. downside)positions 2. Pumpinspection terminal1 and . Applybatteryvoltageto harness connecter 3 andcheckitsoperation. Low fuel warning lamp sensor inspection Connect12Vto 3.4Wtestlampor equivalent Washsensorwithgasolineor whitegasolineandcheck that lampdoesnotlightafterapprox.3 minuleshave elaDSed. Removesensorfromgasolineor whitegasolineand checkthatlamplightswithin3 minutes. EN 540 Handstartbolts FUELSYSTEM RB26DETT / RB2OEI DE I DEr I CA18iI RB25DEENGINE 3. FUEL PUMP REMOVAL& INSTALLATION (1) Fuel pump disassembly Additional work required: Removethefollowing: fr ral nraqcr rro raliaf Internalpressurerelief Fuelgauge Caulion: . Caremustbe takenwhenhandling fuelpump. . Do notreusepumpif it is dropped. . Do not allowdirtor debristo adhereto the filter. . Do nottwistor turnharness. [Point 1] Fuel hose removal & installation conn*o. ;:1TF,?0"' Removal ourlerhose\t^ ) tttar*tng . RaisefuelgaugeASS! remove2 hosesin tank(marked Floatarm Pump sectionis outletsjde),fuelpumpharnessconnector and detachfuelgaugeASSY Band clamp.' Installation Checkfuelhosemarking, connectfuelgaugeASSy. pump Position harnessandclampband160mmin from gaugeASSYconnecting padandtightensecurely. Caremustbe takenthatfuel hoseandfuel harnessturn insidetankfromthe rightto frontsideof vehicleanddo not causeanyinterference withfloatarm. EN - 541 Approx. 160mm hose SYSTEM EXHAUST RB26DETT/ FB2OE/ DE / DET/ CA18r/ RB25DEENG NE EN7 SYSTEM EXHAUST SPECIFICATIONS Exhaust system part inspection,warning precautions . The heatresistanceandcorrosionresistancein exhaustsystempartsand component so onlyusegenuine in thedesignprocess, considered shapehavebeencarefully Nissanpartsfor rePlacement. makingsurethereareno gasleaks' partandconnectsecurely, . Cleaneachconnectlon . Alwaysuse newgasketsin the frontand rearof catalyticconverter' . Alwaysuse newpartsfor exhaustmanifoldconnectiongasketand nuts' . Afteiassemblingeachpart,whenwarmengine,raisespeedto 2,000to 3,000rpmand makesurethereare no gas leaks,sealingcompoundleaksor sealinggaps' in heatinsulationpanels.lf . Replacepartsratherthan repairingextremedeformatron cleantheseareas' extremeamountof dirthaveaccumulated' andno clearance panels,makesurethereis adequate . Whenattaching heatinsulation erencebelweenexhaustpipes. interf EN - 542 EXHAUSTSYSTEM RB26DETT / RB2OE/ DE / DET/ CAI Bi / R825DEENGINE EXHAUSTPIPE,CATALYTICCONVERTER& HEAT PANELTIGHTENING TORQUES (1) CAl8i ENGTNE N u t( 3 )4 . 6 - 6 . 1 Bort{a)el 0 . 5- 0 . 7 A/T (21 RB20EENGTNE M / Tr Nut(3)4.6- 6.1gl t l u tt Z l+ . a- S . O P Bolt(6) 0.5 - 0.7 -. Bon(2)p i N u t( 2 )1 . 5- 1 . 9 gl (t 6 )t"/ B o l rct trorr 9 9 9 9 9 a 4 4 - 5, 6" ^1"/ - " JiR V Bo't(2)g::i'.':l; |3} ::A /ri& 44 5b gBott (2) i'"t- i; .f4 *)'l/ Eror l!.1 u'h'o (3) RB20DE M/T Nut(3)4.6- 6.1$) N u r( 2 )4 . 4- 5 . 6 9 Bolt(6)0.5- 0.7g| N u t1 6 ) 1. 3 - 1 . 6 \ - / 9l ruutlt g - 't.6 Nut1.3-1.69 View A (4) RB20DET Nu t ( 3 4 ) .6-6.1 M/T A/r ---i=, ^ N u t( 2 )4 . 4 - d'i- glBoro.5-0.7 ,r, 121 r.s- r.sg Bolt(6) 0.5 - 0.7 BoltI / 1 . 3- 1 . 6 Bort(2)I 4 . 4- 5 . 6 0 . 5- 0 . 7 Bolt(2)Pl 4 . 4- 5 . 6 Nut1.3-1.6gl EN - 543 SYSTEM EXHAUST R B 2 6 D E T/TR B 2 O EI D E I D E T I C A l 1 i I R B 2 5 D EE N G I N E (4) R826DETT E N G I N E Nut (2) 4.4 - 5.6 N u r( 4 )4 . 6- 6 . 1I Bolt(4) 0 . 5- 0 . 7 o l t0 . 5 - 0 . 7 9lBott (2)4.4- 5.6 Bot1.3-1.6 Nut(2)pl ry1s-16 Nut1.3-1.6 Srp u'"Jo fil'-(]ue (5) RB25DEENGINE M/T !9lo.s- o.ztzt-0 Insulator Insulalor .,::p 1.3-,r.6(2)ggggg Pta e' z ' ,'::::1", $Foo,u'i) - ' r . s- , ' *; , ::";;*ir.9,"",,!,::it:is\ .-rli,^, ca^op1 .. _-1,3 16 q/i-;4round ine r.oP 1 . 3- 1 6 9 !'1--rs-rog rubber N,4ounting f,:l:r*:;',"o,' -' , ,t'i-' 4.6- 6.1 {3)F) / *' i'-""*'n-'" rrsu'alor I n s u l a l o r 0 . 5 - 0 7 ( 6 ) '[ q' { Clamp -o5:.01gl t , . rrn"r.t ten'o sensor o.s2 0.66p: EN - s44 A/T tnsutalor EXHAUSTSYSTEM R B 2 6 D E T/TR B 2 O E / D E/ D E T/ C A 1 8/i F B 2 s D EE N G I N E 2. EXHAUSTGAS TEMPERATURE WARNING EQUIPMENTINSPECTION Basic inspection . Placeignrtion switchto ON position andcheckthat exhaustgaslemperature warninglampdoesnotturnon. . Exhaustgastemperature warninglampmustlightwhen ignitionswitchis placedat STARTpositionandmustgo offwhenengineis staned Exhaust gas temperaturewarning lamp replacement and inspection . Removevehicleharnessfromswitching module. . Useleadlineto groundvehiclesideharnessconnecl exhaustgastemperature warninglampterminal. . Inspectcondition of exhaustgastemperature warning lampwithignition switchturnedON. Faultycircuitbetlveenignitionswitchingmodule. Faultykey sensingmoduleor sensor. gastemperature Exhaust warning lamp,s burned out. gastemperature Exhaust warning lamppower circuitis faulty. EN - 545 C A 1 8E i NGINE i ] ENGINE coNTRoL E N G T N E / c A l B i i R B 2 5 D / D E/ D E r R B 2 6 D E r/rB B 2 0 E EN8 (INCLUDE ASCDDEVICE) CONTROL ENGINE cAl8i AND PEDALINSPECTION 1. ACCELERATOR ADJUSTMENT Acceleratorpedal i nsPection pedalis . The enginemustbe fullthrottlewhenaccelerator pressedfully(pedallevercontactsthe stopper completely). Acceleratorpedal adiustment . Loosenlocknutsso acceleratorcablehas adequate pedal R B 2 O E of accelerator slack.Pulloutercasein direction trompositionwherethrottledrumstarlsoperating(there . ia--- I ,^ ^^^ mustbe no playat thispoint),returnlocknuts1.0to 1.5 turnsandtightensecurelY. Locl( nul 0 . 8- 1 . 0 'ThrottLe.drum Locknut 0.8 - 1.01 F,ont RB2ODE/DET/RB25DE i l Kickdown switch adiustment (RB engine A / T vehicles) . Pressacceleratorpedalto fullyopenthrottledrum. Adjust locknutso the gap is between0.3to 1.Omm. E N- 5 4 6 0 . 3- 1 . 0 ASCD RB26DETT/ RB2OE/ DE / DET/ CA18i/ FB2sDEENGINE 2. ASCD Specification A p p r o x5. 0 - 1 0 0 k m/ h Levelroad+0 I -2 km I h Speedsettingrange Constanlspeedcontrolrange Memory type Digitalmemory Control type.actuator dnversource Negativeoressurecontrol.negativepressurepump Actuator stroke Approx.33mm Setsystem One-touch system(withtap downsystem) Resumesystem Installed Acceleratjon system Installed (wrthtap up system) Overdrivecancelsystem Installed System A / T VEHICLE swltcn Clulch s wi t c h Brake swrlh c * l |,-J t-i ASCDcontrolunI Eq:T[qilil i t l l7 t t 5 t4 t8 t l horn retay ASCDrelay 3l -. -------&{1*a " *- 5 illrlal iFGl ffi #e ASCD main fA d Stoplamp l 1 4 5 ASCD controlunit Set,' coas swilr 3 t1 AND ADJUSTMENT 2.1 ASCDINSPECTION (1) FAULTDTAGNOSTS *rl """ I r*, I R t Does not operate Setting u nstable m z (n @ l Faulty :::i:-:t::: il&* Resume/ set/ coasl accelefatorSW SW faulty faulty gPFhrrpsW ,,irbidir, $iq!! 8w(!nr[ ] W:a,,:' htdbltortlw (A/D' ierXtOf- t|YY' Faultyadjustmeni orfaultyparts lvlainunit lnsrdecircut faulty faulty Faultyval\€, [,4ainunit faulty faultydiaphra Hunting unit lnsidecircurt [,,lain FaLrlty fespon faulty faulty Cancel lnsidecifcurt M a i nu n r t Diapfgramnle faulty faulty Large gap between set vehiclespeed lnsidecrrcurt M a i nu n i t Catchor leak d iaphgramn faulty faully Vehiclespeed decreasewhen setting Does not cancel Insidecrfcuit [,4ainunrt faully faulty lnsidecircuit Mainunit faulty laulty ASCD RB26DETT / RB2OE/ DE / DET/ CA'l8 / RB25DEENGINE INSPECTION & MAINTENANCE PROCEDURE WHENIT CAN NOT BE SET DoesmainSW lampturnON when mainSW is restoredafterit ts turnedOFFonce. relay,powersupplycircuit TurnsON Faulty Checkcontroller groundforany faults(betweenterminal3 and groun0). Faultyharness,inspection present Continuity Otherthan ReplacefaultystoplampSW, (approx. approx. Checkforpowervoltage 12V SW(lV/T), clutchrelay ' 12V)to controller jnhibitorSW.relay 3, 5 3 (HICASI\4/T), 14 (otherthaneN forA/T)l (A,T) Approx.12V Powervoltageis presentwhenSer / coastSW is ON (Approx.12V) (between7 - 3) Replacefaultyset / coastSW. Approx.12V Powervollageis presentat vehtcle Otherthan speedsensor(between7 - 3) 5V and0V lnspectvehiclespeedsensor (Approx.5V and0V alternatively) system. whenwheelsare rotatedsiowly(1 Approx.5V & 0V Donot DisconnectASCD pump operare connector andappiybatteryvollage betweenterminal1+ - 3-. Checkil ASCDwirewilloperatewhen t e r m i n a4l a n d 2 i s Removeactuatornoseandoperale the pump. Checkif negative pressureoeverop. Operate Controlpowervoltagetapprox.l2\. , ls developed betweenterminalI and3, whenvehiclespeedis over 48km/hand seUcoastSW is ON. Approx. 12V Removecontroller connector and checkif pumpoperateswhen12V and0V is appliedto vehicleside harnesswhichcorresponds to controller terminal8+ and body ground,terminal8+ and 9,10-. Do not operate Operate Otherthan Checkif set powervoltageis OV approx.0V betweenterminal2 and 3 whensercoastSW is released. Approx.0V EN - 549 Repairiaultyharnessto the pump or shortcircuit. ASCD RB26DETT/ BB20E/ DE / DET i CA18r/ BB2sDEENGINE WHEN SETTINGIS UNSTABLE PROCEDURE & MAINTENANCE INSPECTION (HUNTING) SETTING UNSTABLE Damaged No damage Checkif ASCDwiremovementis Not smooth Smooth for any leakor negativepressurein pumpairvalveandreleasevalve. Leaking ReplacefaultyASCD pump No leakage Checkfor any leakor negative in airvalveandreleasevalve. Notcracked Cracked Removeactuatorhose andoperatethe PUmP. Checkif negative pressure develop. pumpconnectorand DisconnectASCD applybatteryvoltagebetweenterminal1+ 3-. Checkif ASCDwirewilloperatewhen terminal4 and2 is grounded. Operate IS UNSTABLE WHENSETTING PROCEDURE & MAINTENANCE INSPECTION (cANCEL) SETTING UNSTABLE Thereis approx.12V presentbetweenterminalI and 3 whenset SW is placedf romON to OFF position.The system Voltagebetweenresume/ switchtermlnal1 accelerator and 3 is 0V. with ls thereany abnormality ReplacefaultyASCD switch. Abnormal vehiclespeedsensor andmetercable. No abnormality Powervoltage(approx.5V and0V) is betweenvehicle appliedalternatively speedsensorterminal7 and3, when wheelsare rotatedat 1 - 2km/h. 5V & 0V Approx. Checkfor leakandnegatlvepressure in airvalveandreleasevalve. Faultycontroer EN - 5s0 Leaking ASCD RB26DETT/ RB2OE/ DE / DET / CAl8i / RB25DEENGINE INSPECTION & MAINTENANCE PBOCEDUREWHEN SETTINGIS UNSTABLE (DIFFERENT TO SET VALUE) SETTING UNSTABLE Largedifference to settedvalue Nocatching Checkfor any bent,damageto vacuumprprng. Replace damagedvacuum piping. No damage ASCDpump,airvalveandrelease va,veforneoative oressure andleak. Noleakage Checkfor any leakor negativepressu ReplacefaultyASCDpu in airvalveandreleasevalve. Notcracked Qperate Disconnect ASCDpumpconnectorand abnormally ReplacefaultyASCD g r o u n dt e r m i n a1l + - 3 - 4 , 2C . h e c ki f pump. Operate normally Faultycontroller. INSPECTION & MAINTENANCE PROCEDURE WHEN SETTINGIS UNSTABLE (Plungein vehiclespeed) SETTING UNSTABLE Plungein vehicie speedwhensetting Checkif ASCDwire playis Notcorrect or smooth Correctplayand smooth Checkvacuumpipesfor bentor damage. Nodamage Other Thereis over10Vcontrolvoltage than'12V forcontroller outputbetween terminal8 and 3 justaftersetti A p p r o x1. 2 V Disconnect ASCDpumpconnector andgroundterminal1+ - 3-4,2.Check if ASCDwirewilloperatenormally. F a u l tA y S C Dp u m p EN - 551 Replaceor adjustASCD ASCD R B 2 6 D E T TB/ B 2 O E/ D E / D E T / C A 1 8 i /B B 2 s D EE N G I N E INsPEcT|oN&MA|NTENANCEPRoCEDUREwHENAccELERAToRDEVICE DOESNOTOPERATE Doesnot Checkif constantspeed devicewilloperateusing set/coastSW. Operate WhenstopptngPlace ignitionSW in ON positionwith mainSW ON position.Do not pressbrakeandclutch (OFFposition).lF A,/T vehicle,placein D range andapplyparkbrake. W h i l ec r u r s i nAqS C D powervoltageaPProx.1 Otherthan 12V SW in presentwhenresume/ accelerator (0Vbetweenterminal1 and3) ON Dosition Checkif powervoltageis 0V between1 SW is OFF when resume/ accelerator Otherthan OV Do not tor Checkif speedwillincreasewhen increase urnoffthe mainswitch it on turn and seconds few SW is Placed resume/ accelerator inONposition. rfspeedwillincrease Do not Replacefaulty and whenresume/ accelerator tncrease controller vehiclespeed SW is turnedto ON Position sensor. Do not Checkif lhe vehiclewillcruiseat cruise normalvehtclesPeedwhenresume SW is turnedOFF / accelerator Checkif vehicle speedwillincrease to high-cutvehicle s p e e d( 1 0 0 k m/ h ) . Do nol increase EN - 552 Replacefaulty and controller vehiclespeed sensor. ASCD R B 2 6 D E T/TR B 2 O E / D E/ D E T/ C A l 8 i/ R B 2 s D EE N G I N E INSPECTION & MAINTENANCE PROCEDURE WHEN RESUMEDEVICEDO NOT OPERATE Besume device do not ooerate r l w h e n s l o p p r npql a c e Doesnot Checkif constant speed device willoperate using sevcoastSW. Operate Inspectfollowingthe stepsof "Can notset". | l OheckrfpOWETVoltageapprox.12Vis Otherthan 12V r rma / a.^alar^l^|" qW in I I ipresent\r lpositiow n i t hm a i nS W r n l | |ON positil rn (0V betweenterminal1 and3) ' I O Np o s i t r o nD. o n o t | | '12V Approx. lpressbrakeandclutch [-l Otherthan SWrnoN lrsnition | positron). lFA/I I I r l(OFF oltageis 0Vbetween 1place inDrange lvehicle. | | |when resli m e / a cceleratorSW is OFF parkbrake. I l! landapply wilffi;s-_-l OV Repair faultySW OV Set vehiclespeedto 80km/ h usingset / coastSW. Break(l\4ake surethe vehiclespeed w i l ln o tg e t b e l o w4 8 k m/ h ) . Checkif the vehiclespeedwilldecreasewhen Do not decrease Replacefaultycontroller. resumeSW is turnedON ([/ake surethe vehiclespeedwillnotget below48km/ h) Decrease Otherthan Checkif thevehicle: Otherthan Speedhasde()reaseo to oerow willreturnto set vehic e 80km/ h 48km / h Replacefaulty speed(80km/ h) wh 'I controller. resumeSWis t u r n e dO N resumeSW is turner O F F Below48km/ h 80km/ h Normal EN - 553 ASCD / D E/ D E T/ C A 1 8 /i R B 2 5 D EE N G ] N E B B 2 6 D E T /TR B 2 O E WHEN IT CAN NOT BE PROCEDURE & MAINTENANCE INSPECTION CANCELLED SETTINGCAN NOT BE CANCELLED ls voltagebetweenterminal5 and3 0V whenbrakeis operated(in N ge is presentbetween 11and3 whenbrakeis Inspectand replacestoplamPSW outputis cut Checkif controller (8and3)whenbrake betlveen pedalis pressed. ls therean actuatorJault. Inspectand replaceactuator ls thereharnessshortcir Inspectandreplaceharness. (2) FUNCTIONINSPECTION . ASCDfunctioninspection is carriedoutby drivingthevehicleandcheckingif each ASCDcontrolcircuitsystem functionwilloperatenormally.In thisf unctioninspection functionis inspectedusingfreeroller. Caution: Constantdrivecan not be achievedby ASCDas it is non-loaddriveon the free roller.Use on eachproblemwhencarryingoutfault depending (1)faultdiagnosis as a reference diagnosis. andcheckthat . TurnoN the mainswitchwhenignition switchis placedin oN position lamPwillturnon operation Caution: Thereis a faultwithmainswitchoTASCDrelayif the lampdoesnotturnon. speed(60kmih) and . checkthatthecruiselampwillturnon whendnvingat a constant for set/ coastswitchis placedto ON position.Checkif thevehiclespeedwillincrease when drivecan notbe achieved a moment,cruiselampwilllurnoffandconstant position at the placed to oFF acceleratorpedalis releasedand set / coastswitchis sametime. Caution: as it is non-load lf ASCDcircuitis normal,huntingwilloccurandASCDwillbe cancelled dnve. . checkthatthecruiselampwillnotturnon whensetswitchis pressedwhenthebrake pedalis pressedslightly(brakeswitch:OFF,stoplampswitch:ON)'drivingat a whenthe constantspeed(60km/ h). Makesurethevehiclespeedwillnotincrease position same placed at the to OFF acceleratorpedalis releasedand set switchis inspection). function time(release EN - 554 ASCD RB26DETT/ RB2OE/ DE / DET/ CA.l8J/ FIB2sDEE N G I N E (3) COMPONENTPARTSINSPECTTON Controller inspection . Extractthecontrollerby removingcontrollerbolts. Inspect ASCDcontrolsystemusingcontrollerconnectorparts.lf diagnosis resultis faultyreplacethecontroller unit. Controller (ground circuit) inspection . Checkthecontinuity betweenterminal3 andbodyground withconnector connected Betweentermrnal3 and booygrouno I present Conttnutty (powercircuit)inspection Controller . Inspect powervoltagebetween followrng terminals with connectors connected. Controller (cancel power supply input) inspection . Measurethevoltagebetweenterminal.11and3 when connectors areconnectec. Controller (set / coast switch input) inspection . Placeignitjonswitchto ON position.Measurethe vollagebetweenterminal1 and 3 withconnectors connected. EN - 555 ASCD / F I B 2 O/ED E / D E T/ C A I B i/ R B 2 5 D EE N G i N E FB26DETT Controller (resume/ acceleratorswitch input) inspection . Placeignitionswitchto ON positionand measurethe Renl oash srdelowerfinls powervoltagebetweenterminal1 and 3 withconnectors connected. / Controller(vehiclespeedsensoroutput)inspection thevoltage . Slowlyrotate andmeasure therearwheels connected. with connectors 7 and3 terminal between I nopro, 5V and0V ahermatrvely Controller(cruiselampoutput)inspection 13and3 with . Measure terminal between thevoltage connected. connectors "" *"n.jllniil_|"'::",,"::,., I / /---2- \e\ \ \ Controller (A/T control unit control output) inspection [A / T vehicle] . Drive(ASCDset possiblerange)and measurethe voltagebetweenterminal12 and 3 withconnectors connected. Note: when WithA/T shiftcontrol,ASCDcontrollerls prroritized setat ASCDdrive. E N- 5 5 6 lr]]] t3F-11 -r- r'E-V{Y. lRr ti J) ASCD / D E/ D E T/ C A 1 8 /i R B 2 5 D EE N G L N E R B 2 6 D E T/TR B 2 O E Brake,clutch & stop lamp switch inspection . Disconnectharnessconnectorand operateeach switchesto inspectcontinuitybetweenfollowing terminals. ASCD relay inspection . RemoveASCDrelayand directlyapplybatteryvoltage between betweenterminal1 and2. Checkthecontinuity terminal3 and5. Clutch relay inspection (HICASM/Tvehicles) . Checkthe continuitybetweenfollowingterminalswhen batteryvoltageis directlyappliedbetweenterminal1 and c + Front Inhibitor (N.P)relay inspection(A/T) . Checkthecontinuity when terminals betweenfollowing batteryvoltageis directlyappliedbetweenterminal1 and 2. +Front EN - 558 ] ASCD RB26DETT/ RB2OE/ DE / DET/ CA18i/ RB25DEENGINE ASCD pump inspection . Removeconnector terminals.Checkthemotoroperation by directlyapplyingbatteryvoltagebetweenterminal1 a n d4 . Applybatteryvoltagebetweebn terminai1 and 4 Motorwilloperate Resistance inspection , ' l ' r ' r temfinak ,, :r:.1.1.. A r rv a l v e1 - 4 Release valve '1 - 2 Approx.70 Approx.70 Vacuumpumpl-3 Approx.8 Operationinspection . Applybatteryvoltagebetweenterminal1(+)and3(-)and checkif ASCDwirewilloperatewhenterminal4 and2 is grounoeo. RB2OE ASCDwire adiustment . Loosenlocknutsso ASCDwirehasadequate slack.Pulloutercasein direction of actuatorfrom positionwherethrottledrumstartsoperating,returnlock nutsapproximately 1 turnsandtightensecurely. L o c kn u rt r g h t e n r nt ogr o u e{ k g - m ) | 0 . 8- 1 . 0 Accele;i;;;;; L o c kn u l0 . 8 - 1 0 1 F r o n r RB20DEID E T ...''. EN - 559 ENGINEMOUT.ITING / R82OE/ DE/ DET/ CAI 8I / BBASDEENGINE RBA6DETT ENGINEiIOUNTING FRONTENGINEMOUNNNG (1) CAl8r El{Gll{Es (2) RB ENGTNES Nrt (2) Nr, (2) 1.1 REARENGINEMOUNNNG (1) CAl8l ENGINES FB ENGINES Nd (2) 22 - 2.9 EN:560 lndex Symbols E Gl-13 2 - p o l lei f t. . . . . . . . . . . . . . Gl - 15 4WD inspection . .l.-. 1 . 5 4 W Dr e p a ipr r e c a u t i o n s . . . . . . . . . . . . . . . . . .G . . . . E N- 2 3 1 E C C S. . . . . . . . . . . . . . . . . . . .- 2 3 3 E C C SC / Ui n s t a l l a t i o n . . . . . . . . . . . . . . . . .E. N E C C Sr e l a y( B B 2 s D E .). . . . . . . . . . .. . . E N 4 8 5 , . EN-233 Eccsvoltage...... E m i s s i ocno n t r oel q u i p m e n.t. . . . . . . . . . E N 7 5 .... EN 46 Enginecontrol e lq u i p m e n. t. . . . . . . . . .E N - 5 2 9 E n g i n ee l e c t r i c a .. . . EN- 560 Engrnm e ounting . . E N- 1 B o E n g i no e v e r h a u. .l . . E n g i n es p e c i f i c a t i o .n.s. . . . .. . . . . . . . . . . E N 7 2 . . . . . .... . . . E N 5 4 E n g i n es t a l l sensor. EN - 367. 396' 482 Enginetemperature E v a p o r a t i v e g a s c o n t r o | . . .. ...... . . . E N 5 4 , 4 8 8 E x h a u s t g a s s e n s o r . . .E . .N . . 3 8 6 , 3 9 0 , 3 9 2 ,4 1 5 Exhaustgas sensorheater'.. . .. . . . . EN 434 -545 EN Exhaustgastempwarningequipment. . - 159 . . . E N . E x h a u sm t anifold 1 1 9 '142 d S S Y. . E N - 7 5 , 1 0 9 , E x h a u sm t a n i f o lA E N 543 . E x h a u spti p e . . . . . . . . 4 9 , 542 EN E x h a u sst y s t e m . . . A B . . . . . . .E. .N - 6 8 B a l a n cteu b e . . . . . . . . EN-236. 272 Basicinspection . .. EN - 530 Batteryinspection . . EN-43 Belttension......... B l o w b y c o n t r o l v a l v e . . . . . . ....... . . . . . .E. N 5 5 ' 4 8 9 device... .. . .... . ... EN - 55 Blowbygas reduction . . . . . . . . . E N- 4 8 9 B l o w b yh o s e ....G| -13 Board-onlift......... . ... . .G|-'15 c h e c k. . . . . . .. . . B r a k i npge d o r m c '. .. EN - 543 converter Catalytic . . . .. . . E N - 2 7 9 C i r c u idt i a g r a m E N - 5 9 . 1 0 5 1 0 6 ,1 1 5 CollectorASSY . .. . EN - 482 inspectlon {RB25DE) Components pressureinspection. .. . .... EN - 42 Compression . . . . . . . .E. N - 8 0 Conicalwasher..... C o n n e c t oi nr s l a | 1 a t i o n . . . . . . . . . ... .......... . E N 2 3 3 .. .. . . . G| - 6 symbol Connector GI- 11 . . . . . . . . .. . CoNSULT C O N S U L T d i s p lsacyr e e n . . . . . . . . . . . . . . .. E N 2 6 5 Crankanglesensor...E ..N ... 355' 356' 404' 442 . EN - 83, 85, 170 Cylinderhead D ... . .. . . EN - 267 Datamonitor exhgas emissioncontrol . EN - 527 Deceleration D e t o n a t i o n s e n s o r . . . . . .. E . .N . . .- .3. 8. 1 ' 3 A 2 4 1 7 D i a g n o sci sh a r tb y p h e n o m e n o n. . . . . . E N - 2 4 0 D i a g n o s i s p r o c e d u r e . . . . . . . . .. . . . . . . E N - 2 3 4 D i a g n o s t i c s y s t e m . . . . . ... . . . . . . . . E N - 2 5 9 D i a g n o s t i c w o r k s h e e t . ... ... ..... . . . . . . . .E N 2 3 4 - 274 . . . E N D O H C. . . . . . . . . . . . . . . . . . F ASSY .. .... .. . . . . EN - 69 Frontturbocharger . . . . . . . . . .E N - 5 3 9 Fuelgauge ' . . . . . . . . . E N- 1 5 6 F u e li n j e c t o r . . . . . . . . .. . . . . . E N - 5 3 F u e lp r e s s u rien s p e c t i o n F u e | p u m p . . . . . . . . . . . .. . E . .N ..- 303, 307, 440' 483 EN - 52, 486, 537 Fuel system . . . E N- 5 3 7 Fueltank.............. F u e tl a n kv a c u u mr e l e avf a l v e . . . . . . . . . E N - 5 4 ........E . .N . - 66 F u e t u b eA S S y G G a sl e a ki n s p e c t i o.n. . . . . . . . . . . . . . . . . . . . . . E N 7 5 G e n e r a l p r e c a u t i o n s . . . . . . . . . . ... ....... ... ...G l - 7 H . .. EN-543 Heaterpane|......... H o w t o u s e t h i s m a n u a | .. .. . .. .. . .. . . . . . . . G l - 2 H y d r a u l iJca c kl i f t i n g. . . . . . . . . . . , . . . . . . .. . G l 1 4 I . . .. .. EN - 23 ldlemixtureratio EN - 339' 346 . .... ... ldlespeedcontrolsystem. EN- 23 . . . . . . . . . . . . l d l es p e e di n s p e c t i o n . . . . E N 4 8 3 ,5 3 2 . . . . . . 1gni1ioncoi|................ E N-328 . . l g n i t i o inn s p e c t i o n .. EN- 486 l g n i t i orne l a y . . . . . . . . . . . . . . .. E N - 4 2 4 l g n i t i osni g n a l EN-330' 332' 412 l g n i t i o sn y s t e m . . . . . l g n i t i o tni m i n gi n s p e c t i o .n. . . . . . . . . . . . . E N 2 3 systeminspection... .. . .. .. . EN 237 Individual . . E N- 4 8 6 l n h i b i t or re l a y . . . . . . . . 1 n j e c t.o. .r. . . . . . . . . . . . . . . . .E. .N. . .3. .1.4. ' 3 1 7 ,3 2 3 '4 8 4 EN - 562 I n p u st i g n a l sa n dc o n t r oilt e m s . . . . . . . . . . . .E. .N. .- 2 3 9 l n s p e c t i op no i n t s . . . . . . . . .G . . l., 1 6 I n t a k ea i r t e m p e r a t usr e n s o r . . . . . . . . . . . . .E. .N. .-.3 7 8 lntakemani{o|d..E ..N . . .- 6 5 , 1 O 7 ,1 1 7 . 1 3 7 , 1 5 7 I n t a k em a n i f o lcdo | | e c t o r . . . . . . . . . . . . . . . . . E . .N . . -. .i.5. .3 I n t a k em a n i f o lvda c u u m. . . . . . . . . . . . . . . . . . . . .E. .N. .-.2. 7 5 Intercooler . . . . . . . . .E . .N- 5 7 . 1 3 1 Intercoola e irrd u c ta s s e m b l y. . . . . . . . . . . ..... E . N- 5 6 l n t e r c o o li e r n l eht o s e. . . . . . . . . . . . . . . . . . . . . . .E. .N. -. .5. 6 .... R a d i a t oc ra pi n s p e c t i o n . . . . . . . . . . . . . . . . E . .N . .-.5. .3. .4. . . Radiatorinspection ..... EN - 534 F e a rt u r b o c h a r gAeSrS Y. . . . . . . . . . . . . . . . . . . .E. N . . -. .7.0. . R e c i r c u l a t ihoons e . . . . . . .E. N - 5 7 R e c r r c u l a t ivoani v ei n s p e c t i o. n . . . . . . . . . .E . .N . - 50. 57 R e m o v ae n di n s t ael ln g i n e . . . . . . . . . . . . . . .E . .N . .-. 1. 8 . .0. Rockercover EN - 76, 120, 169 J s 14 EN - 353 1 1 0 ,1 4 3 EN-47 EN.47 M Measurement tools Multipurpose tools EN-12 EN - 12 N R Self-diagnosis .....EN - 236. 262 S e n s osr y s t e m i n s p e c l i o n . . . . . . . . . . . . . .E. .N. .- .3. .5.4. . S i xi n - l i nteh r o t t lceh a m b e r . . . . . . . . . . . . . . . E . .N . .-. 6 . .3. . . S p a r ki n s p e c t i o n . . . . . . . .E. N - 2 7 4 Sparp klug............ E N - 7 6 . 1 2 1 .4 8 6 S p e c i as le r v i cteo o | s . . . . . . . . . . . . . . . . . . . . . . . .E. .N. .- .I. . . . . S p e e d o m e t e r m e a s u r e m e n t . . . . . . . . . . . . .G. .l.-.'.1.5. . . . . . S t a ns i g n a. l. . . . . . . . . . . . . . . .E. N - 4 3 6 S t a r t em r otor........ ......E . N- 5 3 1 S u be l e c t r i c a l f ai n s p e c t j 0.n. . . . . . . . . . . . . . .E. .N. .- 5 3 6 S w i n vg a l v e c o n t r o l l.e. r. . . . . . . . . . . . . . . . . . . . .E. .N. -. .7. 3 .... System diagram.. . . . . . . . .E. .N - 1 3 S y s t e mf i g u r e . . . . . . . ......E . N- 2 7 9 T Tensionerspring ........... EN- 80 T h e r m o - w ianxs p e c t i o n . . . . . . . . . . . . . . . . . .E. .N. .- .5. .3. . . . . T h e r m o s t a t . . . . . . . . . . . .E . .N . . -. g . .A . .,.1. 2 7 . 1 4 8 ,5 3 6 T h r o t r lbeo d yA S S Y . . . . . . . . . . . . . . . . . . . . . . E ..N . .-. .1.3. 9 .... Throttlesensor EN 371, 373. 419, 484 T h r o t t l e v a l vs e . .N . .- 3 6 7 , 4 3 6 . 4 8 3 w i t c h. . . . . . . . . . . .E T i g h t e n i nTgo r q u e . . . . . . . . .G . . .l - 1 3 T i m i n gb e l t. . . . . . .E N - 7 8 , 8 2 , 1 1 1 ,1 2 2 . 1 4 4 . 1 6 0 Towing.................. . . . . . . . .G . .l.- 1 3 T r o u b ld ei a g n o s i s . . . . . . .E . N-231 T u r b o c h a r g e r A S S Y . . . . . . . . . . . . . . . . . . .E . .N . .-.6. .8. . . . . T u r b o c h a r g e r f a i l u r e d i a g.n. o . .s. .i .s. . . . . . . . .E. .N. .- 7 4 T u r b o c h a r gi e n rs p e c t i o. n. . . . . . . . . . . . . . . . . . . . .E. .N . .-. 4 . .9 T u r b o c h a r guenr i ti n s p e c t i o.n. . . . . . . . . .E. .N. - 7 1 , 1 3 4 U . . . . . . . . . . . . . . . . . .E. .N. -. .5.3. 1 EN - 251 . . . . .E . N- 2 4 7 ..EN-447,486 E N- 4 0 1 E N- 4 8 3 . . . . . . . . . . . . . .E . .N . .-. 2. 3 5 EN- 352 U n a b l et o s t a r t U n s t a b lied l i n g . . . . .E. N - 2 3 9 . 4 2 . . . . . . . . . .E. .N - 2 3 4 V Vacuum diagram . . . . . . . . .E . .N - 1 9 V a l v ec l e a r a n cien s p e c t i o.n. . . . . . . . . . . . . . . . . .E . .N . .-. .4 5 Vehicle i d e n t i t i c a t ipolna t el o c a t i o.n. . . . . . . . . . .G. .l .- 10 V e h i c l sep e e ds e n s o r . . . . . . . . . . . . . . . .E. .N . .-. .3.9 7 . 4 3 0 w W a s t e g a tvea l v ec o n t r o.1. . . . . . . . . .. . . . . . . . . .E. .N - 3 5 0 W a t e rb y p a s sc o n n e c t o.r. . . . . . . . . . . . . . . . . . . .E . .N . . -. .6. 7 W a t e ro u t l eet l b o w . . . . . . .E . N- 6 7 W a t e pr u m p . E N - 9 6 , 1 2 6 ,1 4 7 EN - 563