PRESSURE
/ BELTTENSIONINSPECTION
R B 2 6 D E TITR B 2 0 E D E D E T/ C A 1 8/i R B 2 s D EE N G T N E
Compressiongaugeinstallation
. Warmup theengineandremoveall6 sparkplugs.
. Attachthe adapterto theAllencompression
gaugeand
setrtin a sparkplughole.
Compressionpressureinspection
' Depresstheacceleration pedalfully.Turnthe ignitionswitchto STARTpositionandcrank
the engine.Readcompression pressureand the enginespeedoncethe gaugeneedle
stopsmovrng.
. Whenenginespeedis out of specifications, checkthe specificgravityof the batteryand
performtestagainif the batteryis functioningproperly.
. lf the compression pressureis stillnotstandard,inspectthe componentsaroundthe
combustion chamber(valves,valveseat,hydraulic valvelifters,pistonrings,cylinderbore,
cylinderhead,cylinderheadgasketetc.).Correctany malfunctions and repeat
compression test.
3. BELTTENSION
INSPECTION
AND ADJUSTMENT
Inspection
shouldbeperformed
Theinspection whentheenginecoldor morethanthirtyminutes
after
theengine
hasbeenstopped.
RB26DETT
/ RB2ODE,
DET/ RB2sDEENGINE
an.trs
Poly-V low-
Fan belt 3-5 4-6 7.5
maintenancebelt
EN-43
& ADJUSTMENT
BELTTENSIONINSPECTION
/ D E / D E T/ C A 1 8 /i R B 2 s D EE N G I N E
R B 2 6 D E T/TR B 2 O E
RB2OEENGINE
Poly-V low-
Powersteeringbelt 8- 10 9- 11 15
maintenancebelt
Poly-Vlow- 7-9 12
belt
comPressor
Air conditioner 6-8
maintenancebelt
Poly-V low- 7 5
Fan bett 3-5 4-6
maintenancebelt
C A 1 8 iE N G I N E
Belt def€ction (run)
lokg of force lE appfcd at tha
- '
V Po3ltionl
Poly-V low-
Power steeringpump bett I - 11 10-12
maintenancebelt
Poly-V low- 6-8 7-9 12
Air conditionercomPressorbelt maintenancebelt
Poly-V low- 4-5 4.5 - 5.5 6
Fan belt
maintenancebelt
Caution:
.1. Whenthe beltis replacedwitha newbeltincreasethetensionslightlymorethanfor the
usedbeltto allowfor wear-inof the newbelt.
"Adjustment" value.
2. Whenthe beltdeflectionexceedsthe limit,adjustto the
3. Makesurethe pulleygrooveis alignedcorrectlywhenthe beltis installed.
Adjustment
lTEM
PART .... , ,
Power steering belt Adjustment bolt in power steering pump
EN.44
VALVECLEARANCEINSPECTION
& ADJUSTI\,4ENT
R B 2 6 D E i i R B 2 ' E D E D E Ti C A I B i/ R B 2 5 D EE N G I N E
4 . V A L V EC L E A R A N C EI N S P E C T I O N
AND ADJUSTMENT
Additionalwork required(removethe followingparts):
. Air duct
. Rockercover
Inspection
. Inspectthevalveclearancewhenthe engineis cold.
. Removethe airduct,ornamentsandthe rockercover.
. Rotatethe crankshaft and aligncrankshaftpulleymarkwiththe beltcoverindicator.
. No. 1 cylinderis at the compression stroketop deadcentrewhenboththe intakeand
exhaustsidecamsdo notmovethe valvelifters.
i V"lu"" to be adjusted
lntake side
INTAKESIDE C y l i n d eN
r o . 1, 2 , 4
E X H A U S TS I D E Cylinder No. 1 , 3, 5
F i r i n go r d e r : 1 - 5 - 3 - 6 - 2 - 4
Exhaustside
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
PART
INTAKE
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.
Insertgauge(B)fromopposite side.Selecta gauge
to 0 m.
thatwillreducetheclearance
thickness
Note:
Do not use morethantwo gauges(B).
UseJIS 150A25feelergauge.
Valve clearanceadjustment
. The valveclearanceadjustment is performedby
selectinga shimof suitablethickness.
. Whenthe measurement valveclearance(t)is outof
soecification,measure shimthickness(T)and
the
replaceit witha shimthatwill producethe standard
dearance.
1. Shim thicknesscalculationmethod
Example:
Whenthe intakevalveclearance(t) is 0.50mm:
value)= 0.05mm
0.50(t)- 0.45(specified
. The valveclearanceis 0.05mm greaterthanthe specifiedvalue.
. Usea shim0.05mm thickerthanthe currentshimto reducethe valveclearance.
2. Currentshimthickness(T)
. Measure thecentreof removed the
shimto determine
ofthecurrent
thickness shim.
Caution:
Donotreusethemeasured shimsagain
3. Shim selection
Currentshimthickness (T)is 2.40mm.
2.4OF\ mm + 0.05mm = 2.450
Selectnewshimwithstampedmark124'401
--2.440-2.455).
I
Selecta shimwithinstandard valuerange+f 0.03mm.
Lubricationoil replacementperiod
RB20DET
/ RB26DETT Every5,000kmor 6 months S D . S E . S G S F c l a s so i l
Everv15.000km
or 12 months SE,SF,SG classoil
RB2ODE
/ RB25DE
Everv10.000kmor 12 months SD classoil
Note:
UsegenuineNissan[TurboX (7.5W- 30)]for servicefor RB26DETT/ RB20DETvehictes.
UsegenuineNissanSG class[ExtrasaveX (7.5- 30)]for servicefor CAI Bi/ RB20E,DE /
RB25DEvehicles.
Oil quantity
ITEM
H :.,...L.'
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
GA18'
Approx. 1 A p p r o x .1
Approx. 1 .5
Approx.3 Approx.3 Approx.3
4000 Approx. 4
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
EN.48
EXHAUSTSYSTEI\,4
INSPECTION
R B 2 6 D E T TR B 2 C E D E ' D E T / C A I B i/ R B 2 5 D EE N G I N E
6.EXHAUSTSYSTEMINSPECTION
EN--19
EXHAUSTSYSTEMINSPECTION
R B 2 6 D E T/TR B 2 O D EE
TN G I N E
6-3 RECIRCULATIONVALVEINSPECTION
Functioninspection
. Removethe hoseon upperflowsideof the recirculationvalvecompressor(placethe cap
on end of the hose)and checkif air blowsbackwhenthrottleis closedquickly.
RB26DETT RB2ODET
Unitinspection
-150+f 30mmHg(RB26DETT)
pressure
. Usea handpumpto createnegative -400+/-
50mmHg(RB2ODET). Therecirculation muststartto liftupandthe
valvediaphragm
willbemaintained.
vacuumoressure
EN-50
EXHAUST
SYSTEMINSPECTION
C A1 8 E N G N E
lntake manifold
Freshair duct
Temperature
When warm sensor
' @
Warma t t
SPIbody Intakemanifold
Functioninspection
. Removethe airductandstartthe enqine.Insoectthevacuummotorooerationwhenthe
engineis coldandwarm.
COMPONENTPARTSINSPECTION sensor(whencold)
Temperature
Temperaturesensor inspection
. Removethe hoseto the vacuummotorand connectthe
vacuumgauge. lntake
manifold
. Startthe engineand checkthe negativepressurewhen
the temperatureof the temperaturesensorwas cooled/
A,.'nflowfiP-
warmedby the drier. illL @''*'
\v
Whenwarmedup No negativepressure To'nta[emanifoE! _IO vdcl.rum
gauge
Whencooled Negativepressurecreated
F ."-,",".'.-
Vacuummotor inspection Applynegative
. Removethevacuumhosefromthevacuummotor and
mnnectvacuumhandpump.
. Usea handvacuumpumpto createnegativepressure
(approx.-150mmHg). Visual
. Makesurethefreshairducton the change-over cnecK
valve
willclosewhenthe negativepressureis appliedand it will
openwhenthereis no negativepressureapplied.
7 F U E L S Y S T E MI N S P E C T I O N
. F U E LP U M P.
EASYINSPECTION (RB25DE)
. Turntheignition
switchto ONposition. IS THEREA PULSAT]ON
. Select"Fuelpump"inthe"Functiontest"mode. E V E R Y3 S E C O N D SW H E N
INt TUEL UI'tr J NtrLU '
. Inspectthe pulsationby holdingthefuelhosewithhand OR CANYOU HEARTHE
O P E R A T I O N O I S EO F T H E
F U E LP U M PR E L A Y ?
I ruelenessuRe
I
Releasingfuel pressure(CA18i/ RB20E)
. Revtheengine.
. Select"Releasefuelpressure"
in
"Operation
support"mooe.
@ W H I L EI D L I N GP R E S S
'START"TO STOPTHE
FUELPUMPOPERATION,
AFTERENGINESTOPS,
C R A N KT H EE N G I N EO V E R
TWOOR THREETII\,4ES.
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
cA18i RB2ODE.
DET RB26DETT
r e s sur e
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
EN-54
BLOWBYGASREDUCTION
DEVICEINSPECTION
R B 2 6 D E T TR B 2 iE D E D E Ti C A 1 8/i R B 2 s D EE N G I N E
BLOWBYGAS REDUCTION
D E V I C EI N S P E C T I O N
biowbycontrolvalve
Inspection(CA18i)
. Removethe aircleanerrockercoverhosewhenthe
'1000 rpm
enginerev is approximately and checkthat
freshair is drawnin.
E\
ON-VEHICLEPARTS
RB26DETE
TNGINE
OF ON-VEHICLEPARTS
1O REMOVALAND INSTALLATION
AIR DUCTASSEEMBLY
1O-1INTERCOOLER
Front tufuocharger
outlettube
,r--aolt 1.6
IntercoolerIPoint4] Resonato.lube
t . 6- 2 . 1 p ]
Bol1
o-'--Nut (2)i.6 - 2.19
I ts-t
E Replace after every disassembly
lnstallation
. Alignthealignment andmake
markswheninstallation
sureto tightenthe clampsecurely.
EN-56
ON.VEHICLE
PARTS
i32' DEiT ENGINE
[Point6] Installrecirculationhoseclamp
. Wheninstalling the recirculation
hoseclap,makesureit
willnotcontactbumperfinisher.
[Point7] Recirculation
valveinspection
Unitinspection
. Usehandvacuumpumptoapplynegative vacuumof-150
+/-20mmHgandcheckthatrecirculation
valvediaphragm
liftsandvacuumpressure
is maintained. Recirculation
valve
To rear turbocharger
To front turbocharger
f
ACI
I *n-'
I
Air hose
-s
OUCI
Arr cleanercase
Additionalwork required:
. Removeturbocharger outlethose
[Point3]
. Makesurethe aircleanerelementis notdirtyor damaged. ),)\
[Point 4]
. Firstconnectthe airflowmeterconnectorfor frontturbo
charoerandtheninstallthe air cleanercover.
EN-58
ON-VEHICLE
PARTS
RB26DETE
TNGINE
1O-3 CONNECTORASSY
(1) CollectorASSYremovaland installation
No.3 Throtllecharnber
No 2 Throttlechamber Knockpin (6)
__-/0
s;
N.o 1
----- /'/
--\3nno.t
o'n,e,thutb"'
9-
1,,,ffi
,t1\
\ur{r2,
,ll;A,
Poinr
\,
ersprlnt
.\
I'i-,
washer ""gH-= "{ y
(12) ;:t,
JJ,i:*;
- V7,i";::;*;el
.-tt":"to"Tj,:ld' /R
qvl
Io! ,
-
t"
Hose
--a
*'"-ruW,fl*6pltr== n"'"
warer
ruDe
L"","r,^,^,:."j:,-91^,^
:, :dR. i <?'- - i *_
-
,,",Kt$,5 1 F:l"i;r6,i""
Bort' 4) l
Bort0.64- O.r' eirtio-zrp)
"^,,?" - " ,m
ffi1.30-ouo
$ neptaceaftereveryd'sassembty
Fi.
\-.4 Ks''
Additionalwork required:
. Releasefuelpressurein thefuellines[Point1]
. Draincoolingwater[Point2]
. Acceleration controlwire[Point3]
. Air inlethose
. EGIharnessconnector, harnessclamp
. Allhoses
E N. 5 9
ON-VEHICLEPARTS
ENGINE
R826DETT
Air hose
- 0.85
(2)gl 0.64
Bort
- Acceleralion
ag B r
work unit
(w
\,
/ Knockpin (2)
Intaketemperaturesensor
20-3.0
Collector[Point1]
EN o l
PARTS
ON-VEHICLE
ENGINE
R826DETT
Additionalwork required:
. CollectorASSYinstallation "Throttlevalveswitch
referto
for thethrottlevalveswitchadjustment
systeminspection"
proceoures.
[Point1] CollectorinsPection
surfacefor distortionin
. Measurethe collectorinstallation
up,down,lefi' right'
six directions(opposingdirections,
horizontally andverticallY).
Limit ( m m ) : 0.15
660-'
$ neptaceaftereverydisassembly
Additionalwork required:
. CollectorASSY removaland installation
. Canisterhose
[Point1] Throttlechamberinspection
air pathsare
. Checkfor any cracksandthatsupplemental
notobstructed.
air
Supplemental
[Point2] Installthrottlechamber
. lnstallNo. 1 to No.3 throttlechambers. l Throttle
Caution:
Do not makeany mistakewheninstalling the chamber.
-t\ -
No. 3 Throttlechamber
EN-62
ON-VEHICLEPARTS
R 3 2 6f , : T T E N G I N E
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
=-
Bolt(4) 0.64- 0.85
2. Shorteneachthrottlelinkuntilacceleration
drumcontacts
fullyclosedstopperon the accelerator
workunitside.
3. Shorteneachthrottlelink,so thethrottlechamberlever
openswiderthanfullyclosedstopperon the throttle
chamberside.
Caution:
( 1 ) D o n o tl o c k t h en u t A a n dB .
(2) Thethrottlechamberleveropeningangleshoutdbe
adeouate.
EN-63
ON.VEHICLEPARTS
RB26DETE
TNGINE
4. Insert 1 mm thicknessfeelergaugebetvveen
the
accelerator drumandfullyclosedstopperon the
accelerator drum
work unitside. Securethe accelerator
so it does not move.
Fully closed
,'-!t)
'trf
5. Withthicknessgaugeinserted,turnthe centre
adjustmentIn No.2 throttlelinkclockwiseto lengthenthe
throttlelinkuntilthethrottlechamberlevercontactsthe
fullyclosedstopperon the throttlechamberside
6. Whenturningthethrottlelinkwithyourfingers.Youwill
feelresistancewhenthefullyclosedstoppercontacts
thethrottlechamberlever.Shortenthethrottlelinkto the
pointjust beforethis resistanceis felt
9. Removethethicknessgaugefromfullyclosedstopper
workunitside.
on the accelerator
Caution:
L-
Do notadjustfullyclosedstoppernut. ca
1
EN-64
ON-VEHICLEPARTS
R B 2 6 D E TE
TNGINE
10.6 INTAKEMANIFOLDASSY
(1) IntakemanifoldASSYremovaland installation
Intakemanrfoldgasket
B o l t( 5 ) 1 . 6- 2 . 1
1lp)
lPornt p,us
Airdra,n z1/ E
leornt ,fryfj
ii\ \s4!**^^'Yt-:.
B o l (t 4 )1 6 - 2 1
1]pJ
lPoint Intakemanifold
ASSY
B o l t( 2 )1 . 6-
llgl
tPoint
E Repiace
aftereverydisassembly
kg- m
Additionalwork required:
. CollectorASSYremovaland installation
. Throttlechamberremovaland installation
. ECCSharnessconnector andall hoses
. Wateroutlethose
. Blowbyhose
30:4
60:5 1 ,4 , 1 0 ,1 2 ,1 4
6 5: 2 7,9
B o t t( 2 ) 1 . 6- 2 . 1 6l
E o-rinsIPoint
Water temperature
;:J;id'senffi2o-30
ASSY[Point2]
FueltubeIntector
a;
O-ring outlet
5l
FF=".;,"
"g ,-p Ffii;il \^ ,on',u - r.,
p ) e o r t t zr .re- z . r
Screw(2) 0.23- 0.91---'
'.\
--r.*^
-'l lntake ml
{s
_Waler bypassconne^to'
Air regLrlator
-
ro-; r
g-----€5 "j,lI F.",, ptec,
D
Fi
L-l| Eort(2) 0.64 - o.
Liquidgasket
+::;;9,s
a Replace after every disassembly
kg-m
[Point'l] Intakemanifoldinspection
. Measurethe intakemanifoldsurfacefor distortionsin six
differentdirections(atoppositedirections: up,down,right'
left,horizontally in severallocations.
andvertically)
L i m i t( m m ) : 0.15
[Point2] FueltubeASSY
. ReplaceO-ringwithnewoneswhenpressureregulatoris
removedand installed.
Caution:
Caremustbe takennotto scratchthefueltubeo-ringsurface
the pressureregulator.
wheninstalling
E N. 6 6
ON-VEHICLEPARTS
r 3 2 €D E T TE N GN E
3 1, 2,3, 4, 5, 6
Cylinder
4 Cylinder1, 2, 5. 6
2 Cyinder3, 4
1O-7TURBOCHARGER ASSY
ASSY
(1) Turbocharger removal& installation
FRONTSIDE REARSIDE
*"ry:-/-----ll;at
tf:"11,% -'-j---,.-
-_--,,-
-
ttose
s'4q"*;';1+
6 q 1 q 1 z 1 o . M - l € s* - -
:*,,J4_i ffis{*e
C5p-perwashe{ r-r
?i€F.-:',',"^*
/ --'-
Sffi\ffi;'-"
1.+n"'1""
iils
t
-H$$,
c y l i n d eb rl o c k 1 - ,
I#,2$;;?f
\g"*9t-*l '
''
y's,e
l^ Y'^,.;}^,tfy.
vJP,""*1,
'---ff$B"*r"*"
nipo'\=-^8
o"
t^... Oilpi
i:x,lr,;;:|tk#ffii;
p: g:i;r:h /
#P/- . \"'n"i"""n
, *
,",,,110,0-'', !nf""";n",,,
s *".n",E ,\F-,
".d'Hry>-;;;';;;";--,"'"if:,"*:
F@.-!:1;, ,,?*lT,Y-
F! ts-t
$ Reptaceafter every disassembly
EN-68
ON-VEHICLE
PARTS
R 3 2 6D E T TE N G I N E
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.
Installationsequence
. Installation
is the reverseof the removalsequence.
. Placeturbocharger in bottomof the engine
compartment beforeinstallingtheexhaustmanifold.
E N- 6 9
ON-VEHICLEPARTS
R 8 2 6 D E T TE N G I N E
Removalsequence
(1) Removefrontturbocharger andtheexhaustmanifold
ASSY
Q\ Removetwo nutsand the clipsecuringbolt,and
seoaratethe tubeA.
(3) Removethreeboltsanddetachexhaustmanifoldcover.
(4) RemoveeyeboltB, C and E.
(5) Removetvvoboltsand separatetube D fromcylinder
blockside.
(6) Removethreeboltsanddetachbracket.
The sequenceafterthisstepis sameas number11to 16 of
thefrontturbochargerremovaland installation.
Installationsequence
. Installation
is reverseof removalsequence.
. Loosenthe watertubeflarenut beforeinstallingeyeboltB.
Air inlettube
tr
\
E GasketI _
EGasket
*BeW"/.fiM
Y'1"!*q*F:i:i
/'t,"1,.,"
Bolt(2)g Bolt(2)1",4 038-05'
1 . 6- 2 . 1 0.64- 0851
?:J'lt'F3*'3'.# gev"oortzo-V
WasherE
xg-m
$ neptaceaftereverydtsassemblY
EN-70
ON.VEHICLE
PARTS
R3 2 6 D E T TE N G I N E
Additionalwork required:
. Turbocharger
ASSYremovaland installation
[Point3] Removeandinstalllockplate
. Spreadthelockplatepawlswitha screwdriver
andloosen
nuts.
. Positionlockplatesandturbocharger
mountingnuts.
Aftertightening
thenuts,bendlockplatepawlsontothe
nuIS.
[Point 4] Eyeboltdetermination
side)eye boltsare stamped'J'
. Oilfeed (turbocharger
lq.)
L *
(5) Turbocharger
unit inspection
Crack inspection
Crack burn Inspectron
CoolrngwaterinlellPorntB]
Exhaustgas leak
inspectionlocation
Actuator[Point7]
-.---- Compressorwheel
SwingvalveIPoint3j
[Point5]
Turbinerotor{Point1,2,4l R o t o .s h a l t P on t 6 . 8 l
E N. 7 1
ON.VEHICLEPARTS
ENGINE
R826DETT
shaft
:"j'^'::..
lPoint2] Turbinerotor inspection
. Oilmustnotadhereto surface.
. Thereis nocarbonaccumulation.
. Thevanesoftheturbinemustnotbebent. or
7\ll No oenoing
. Thereis nointerference
withturbinehousing.
r V v-. No nterietence
wlh the housing
-'-'!t-''-
Rotorshaftplay(mm) 0 . 0 5 6- 0 . 1 2 7
Thrustclearance(mm) 0 . 0 1 3- 0 . 0 9 6
Compressorwheel inspection
[Point5]
. Oil mustnotadhereto suctioninlet.
. Theremustbe no interferencewithcompressorhoustng.
\@ No oil adhere.
No bendingor
other
d am a g e .
. Wheelmustnotbe bentor damaged.
EN.72
ON-VEHICLE
PARTS
RB26DETE
TNGINE
. Cleanwithairgun.
. Cleanthe compressorwheel,turbinewheel,compressor
=housrngandturbinehousingwithsamemethods.
EN-73
ON-VEHICLEPARTS
R B 2 6 D E TE
TNGINE
Pointsto be checkedbeforediagnosis:
1. Theengineoillevelmustbe betweentheMINandthe MAXmarkson theoillevelgauge.
(Wheniheengineoillevelis higherthan MAXline,theengineoilwillflowintointake
ductthroughthe blowbygas recirculation passandtheturbocharger may be
determined to be malfunctioning).
2. Checkwith customer to deiermineif oil is cooledwhenidlingafterdriving'
lf any malfunctionin thefollowingchartis detectedin a unitinspection,replacethe
turbocharger ASSY
sr;{tl
..r .::r,. .
Oil on rotors l \ z\ l\
Turbinerotor
Carbon has accumulated z__l @ o o
Rotor scrapes agair6t the housing @
Turbimevanes are bent or folded @ !9'
Suctioninletis dirtywithoil o o
Compressorwheel Rotor scrapes agairEt the housirE C
Turbinevanes are bent or folded (/
There is resisianceor scraping
when rotatedby firEer
A A o
Turbineand compressor Rotationby fingeris not Possible
Rotorshat play irEPection
Corsiderable shakingbetween
rotor shafl and turbo ASSY z__.\ A o
Look throLEhoil hole Carbon sludgehas accumulated
(inspectintenorwithPenligm) in waste oil f|ob
l \ ll A
The valvedoes not mo\r'e
smoothlywhen pressureis
Swing valveoperation
(usearr gunor atr PumP)
applied gradually.(LlSually
opens @
at pressuregreaterthan 0.6 - 0.7
kg/cm')
E N. 7 4
ON-VEHICLE
PARTS
i 3 . al : - i ENGTNE
Exhaustmanifoldcover Exhaustmanifoid
B or ( 3 1 9 Bolt(3)p
0 3 8- 0 . 5 1 0 . 3 8- 0 . 5 ' 1
l P o r n4t l lPoint4l
Exhaustmanifoldgasket
\ a
I
v
W
N u t( 6 )1 . 8- 2 . 4
lPoint21pJ ,u,,,.Iii"-r
2l
oQ4,*,3l
lPornt PJ lPoint
l-/ kq-m
$ Replace after every disassembly
Additionalworkrequired:
. Turbocharger
removal
andinstallation
. Gasleakinspection
IPoint1]
[Point1] Gasleakinspection
. Afierremovingexhaust manifold,
makesurethereare
notracesof gasleaksfromanyparts.
. Aftertheinstallation,
cranktheengineandcheckforany
oas teaKS.
[Point3] Exhaustmanifoldinspection
. Measurethe exhaustmanifoldsurfacefor distortions in
sixseparatedirections(oppositedirections,
up,down.left,
right,horizontally
andvertically)
in a numberof locations.
Limit(mm): 0.3
EN-75
PARTS
ON-VEHICLE
RB26DETE
TNGINE
- o.
p) eott1a;o.oa transistor
O f n a m e nbt o l t( 2 )0 . 2 3- 0 . 3 1 9
'w:
Ornament bolt(B) Screw(3)
0 . 2 3- 0 . 3 1 9 lgntion aor bracket
ornament -i '.
:eo
J
\,,.#)r- *d
='v
I 5CarF.p Ug
l g n r t r o cno t l harness
le/ Kg_m
Additionalwork required:
. RemoveandinstallairinletPiPe
. Removeand installblowbYhose
Fillercap Rockercoverscrew
(left& right10 each)
O-r'ng--,@
-a
Grommet
Rockercover
Rocker cover gasket 1|/ I
lPoint3l .A ,.' I
'/a.tt orlamenl
s3;Tl":":.1' Rocker
Rocker
covergasketIPoint3l
Additionalwork required:
. Removeandinstallairinletpipe
. Removeand installblowbvhose
EN-77
ON-VEHICLEPARTS
RB26DETE
TNGINE
*ffi'Pffi
ffi|"*\-,Fiql ,,1 =--
c r a n k €-\n s r e s e n s\ { \ , - _ * \ l \ l;i,""?l' \ fi\f , - x - . . )
[Point2] I \Al,
_liirQ@,"6;{ryt
\h\'10,d"-
^^ :.
_# 5----J
C o n i c aw
l asher
t?* "':]:;:,N+qf,ffi*;,
;,,,,;['t'l \^&\
\ [::"1:N \3\J \ Y- \,',,i,nno",,p,aterPo,nt.r
h "rr::Jil';'"":;"'''
$ W\$, [*,"1J;1\::;q
\tr v
I r'mrn9o€rtcover(towerr
lpornt4]
, . i , . -- I g o t t , 3 to . : - o s
oil
It Engine
$ neplace after every disassembly
inspection
[Point1] No. 1 cylinderpressureT.D.C(top dead enter)
. Aligncrankpulleytimingmarkand beltcovertiming
Timing indicator
(0oposition).At thistime,No. 1 cylinderis in
indicator
compression T.D.Cpositionwhenthecamshaftis located
as describedin the followingsituations.
,r 7\
-<-!tr
EN-78
ON-VEHICLE
PARTS
R3 : ' - - ) = - - E N G I N E
Intakeside
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
[Point6] Installconicalwasher
directionof the conical
. Payattentionto installation
washers.The washershouldbe setwithfacewith
chamferedsidefacingthe tensionerpulleyside
[Point7] Installtensionerspring
. Assemble thetesioner pulley
springto thebelttensioner
asshowninthefigure.
. Thetensionerspringmustbeassembled withthe
together
pulleyinthecylinder
belttensioner block.
. Hookthetensionerspring
on theuppersideofthetensioner
springstudwhenthetensionerpulleyis free.
EN-BO
ON.VEHICLE
PARTS
a i . E DE - T E N G I N E
Freeangb (-)
. Positionthealignment ,;i'/5
markon thecranktimingpulleywith
therespective oilpumphousingalignment marks.At this
mrng
timethe groove mustbe straightup (no.1 cylinderis at
T.D.C).
EN-81
PARTS
ON.VEHICLE
ENGINE
RB26DETT
[Point12] TimingbeltinsPection
. Replacetimingbeltif anyproblems at theinspection.
areindicated
Tensionerlock
Cracks on rear E ngine overheat
side lnterferencewith belt cover etc.
Slidingmotionresistancein
Worn teeth crank sensor and the camshaft
Caution:
Do nottwistor bendthe timingbelt . Makesurethereis no oilfilmorwateron thebelt.
EN-82
ON-VEHICLE
PARTS
-=:.]:-T ENGINE
10-12 CYLINDERHEAOASSY
I is-t
Cam pulley
[Point3]
69 Cylinderheadgasket[Point2]
$ Replaceafter everydisassembly
Additionalwork required:
. Drainand refillcoolingwater '1]
[Point
. Removeand install;
. Collector
. Throttlechamber
. Intakemanifold
. Turbocharger, exhaustmanifold
. Timingbelt
. Rockercover
. Sparkplugs
. lnstallNo. 1 cylindercompression
T.D.Cposition[Point3]
EN-83
O\. . :''CLE PARTS
ENGINE
RB26DETT
approximate thetighteninganglevisually.
. Takecarenotto hitor scratchthegasketseatandthe bore
grommetwhenthe gasketis installed.
. Cleanthe cylinderheadlowersurfaceandthe cylinder
blockuppersurfaceto removeallwater,oil and foreign
ob.iectswhengasketis installed.Usecompressed airgun
to blowoutthe boreholes
W
the crank pulleyandthe cam pulleymustbe positionedat
the No. 1 cylindercompressionT.D.Cposition
. Alignthecrankpulleytimingmarkandthetimingbeltcover
timingindicator(0"Position).
. Aligntheintake
andtheexhaust campulleyalignment
mark
marks.
beltcoveralignment
to respective
EN-84
ON-VEHICLE
PARTS
R3 2 6 D E . i TEN G I N E
va ve spflngTetarner
17' 1s'20)
valveriner
lpoint14]--(>-- -)"'d , :9'": :HX':Jit
ShimlPornt6l- -,
'@d^t , vdlveorlseallpoint231
Valvecollet[P; nl 181 '- - valveguide[Pornt2a]
-
-/ valveseat lPoint25]
g Nut0.92- 1.2lpo]nt5r \ ^-
Springwasher-, \ -- Exhaustvalve[Poinl21,22]
)? 3=-r-
w".n", - i 'P g exnausr
valve 21 221
{Po'nt
aarreprare-J$ v=\
& o,o^
"tn@(E--o
p J e o r r o . s- '22 = - € q-_
,.-D B
Bolr . s -2 -.r 22 lPoint
o r0r92 r p o i n5]t 5 r O
washer-
g/-,Y"tJ"tL"n"o oracket
lpoint5]
g -3t*oruJf,lJi!P!*0rpoinr13,
15,21,24,251
!-_ ^ -":1 ";@fl<.'
. - q.r ! -*gp camshaft,exhaust
s.oe)
ro'i-,zr _ q(ar
rp"i"iag €ffi4pF da5;tl
O"*\ €_ P;i';.]
q rei'",,si
*^@-"ffi,x
Ilk
P
"_rJ F<\
*,;:feffi."jffi4R-g*;.
:;::"
fts,"
" - "";"*:i;r;$
."I?IT9Y\W1
**
backpr"rJ1e"'i
u""tplare
atb-....''
el;t l \
3]--.
[Point
t,.o*
' ."ur TrEn
tpoint
- - o '".. ''
";; t - '*
Q\2.1-2.7 -_€,
@.c"..*n
campurrev
uampullev 2l
rl
{Point
lHornl
to 'ao'r,os:-
--'eo'tt
12)2.1 *e ,,F.\ ,"e-, \:
*\--: ._-S-.-
- s- o.gZ- r.z
r,
_(N
-- *:- - &ilJ,Y,':"rt":i1T'-1.erPo,nr2rg
e- crankangtesensor
bracket 1l
JPornt
gasket
Liqurd
iir, z., _z.rp;
kg-m
Engineoil
Replaceafterevery disassembly
Crankanglesensor
[Point1] Instalcrank anglesensorbracket
. The crankanglesensorbracketis positionedontothe
Solt(2) 2.1 - 2.7
cylinderheadby usingknowpins.Alignthe positions \",i
correctlywheninstalling
the crankanglesensor.
Grankangle sensorbracketbolt tighteningtorque
(kg-m): 2.1- 2.7 Bolt(2)2.1- 2.7
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.
I 13 11
[Point 5] Remove& install cam bracket
Removal (Exhaust and intake camshaft)
. Placemarksto indicatethe bracketpositionand its
directionbeforeremovingthe cam bracket
. Removecam bracketboltsby looseningthemgraduallyin 12 8 4
2 610
severalstagesin reversesequenceshownin thefigure. 1l
lnstallation
. Alignthecrankpulleytimingindicator
andthetimingbelt
'1
covertimingindicator(0")so No. cylinderis at
compression T.D.Cposition.(Thisoperationis not
necessarywhencylinderheadis removedas singleunit).
EN-86
ON-VEHICLE
PARTS
RB26DETE
TNGINE
To installcamshaft,temporarily
tightenNo. 1cam bracket
and checkthatcamshaftthrustsectionis positioned
securely.
Tightencamshaftbolt540"(1.5turns)in theordershownin
thefigureon the previouspage.
Cam brackettighteningtorque (kg-m):0.92- 1.2
Caution:
(1) Coatthe camjournalsand end of the cam shaftwith
engineoilbeforeinstallation.
(2) Do notrotatecamshaft.(Thevalveand pistonsmay
interfere).
[Point6] Valveclearanceadjustment
No. 1 cylindercompressionT.D.Cpoint
. Turnthe camshafts(intakeandexhaust)so No. 1 cylinder
is at thecompression
T.D.Cposition.
. Checkknockpin positionof camshaftfrontendto verify
No.1cylinder compressionT.D.Cposition.
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
INTAKESIDE C y 4 i n d eNr o .3 , 5 , 6
E X H A U S TS I D E C y i n d e rN o .2 . 4 , 6
Valveclearancespecifications \2O+l-5C)
INTAKE EXHAUST
o+/-5 10 J 20 q
30 +/- 5
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.
Valve clearanceadjustment
. Thevalveclearanceadjustment is performedby selecting
a shimof suitablethickness.
. Whenthe measurement valveclearance(t) is out of
measuretheshimthickness(T)and replace
specification,
it witha shimthatwill producethe standardclearance.
1. Shim thicknesscalculationmethod
Example:
Whenthe intakevalveclearance(t) is 0.50mm:
value)= 0.05mm
0.50(t)- 0.45(specified
. Thevalveclearanceis 0.05mm greaterthanthespecified
value.
. Usea shim0.05mm thickerthanthe currentshimto
reducethevalveclearance.
2. Currentshim thickness(T)
. Measurethe centerof removedshimto determinethe
thicknessof the currentshim.
Caution:
Do notreusethemeasured shimsagain.
Do not reuse after
EN-88
ON-VEHICLE
PARTS
R 3 2 6DE - i E N G I N E
3. Shim selection
. Currentshimthickness(T)is 2.40mm.
2.40I\ mm + 0,05mm = 2.450
. Selectnewshimwithstampedmark
124.401
(T =2.440-2.455).
valuerange+f 0.03mm.
Selecta shimwithinstandard
[Point8] Installcamshaftrearrubberplug
. Beforeinstalling
the rubberplug,wipeoffanyoil,wateretc.
on thesurfaceandcleanthoroughly.
. Whenassembling the rubberplug,coatit withadhesive
(threebond1211) or equivalent.
Intakecamshaft Pink No
Splinegea. for dnvingcrankangle
Exhaustcamshafi White Yes
EN.89
ON-VEHICLEPARTS
R826DETT
ENGINE
[Point'11] Camshaftinspection
Cam height inspection
. Usea micrometer camheight.
to measure
Exhau$t 3Ue
8.58 8.28
Camjournalexternaldiameterinspection
. Usea micrometerto measurethe externaldiameterof the
journal.
camshaft
No. 1 - No. 7
27.935- 27.955
[Point12] Camshaftrun-outinspection l
. Supportbothcamshaftendjournals(No.1 and No.7) by D i a l g a u g e\ h
)al q.-
usingV-blockson thefixedsurface.
. Avoidthe oil groovein the centreof the No.4 journaland
positionthe dialgaugevertically.
. Rotatethe camshaftby handone rotationand readthe
movementwidthon thedialgauge.
. The run-outis equalto one-halfof the movementwidth
indicatedon thedialgauge.
Standardvalue (mm): 0.05
[Point13] Cylinderheadcambracketinteriordiameterinspection
. Tightenthe cam bracketto specifiedtorque
- '1.2
Cam bracket bolt tightening torque (kg'm): 0.92 -
> ,-v,, - r:
' :--..
'l
. Usethe boregaugeor insidemicrometerto measure . i
r \-t-
r!)/\-
| |
_l
!,::>--:a
interiordiameter.
N o .1 - N o . 7
28.000- 28.O21
mrcrometerI -,,,,-:1
EN-90
ON-VEHICLE
PARTS
R 3 2 ' f E * I E N GN E
0.045- 0.086
EN-91
ON.VEHICLEPARTS
RB26DETE
TNGINE
46.54
24.0 22.5
White
Caution:
lnstallationloadis the forcerequiredto compressthe spring
lengthto 35 mm.
PerpendicularinsPection
. Placea try squareby the springso it contactsspring Turn
the springand measurethe maximumclearancebetween
upperspringsurfaceandthe rightangleto determinethe
out-of-souaredistance.
'1.8
Limit(mm):
[Point21] InstallvalvesPring
. Installunevenpitchtypespringwithnarrowendtowards
cvlinderhead(identification
colourside).
EN-92
ON-VEHICLEPARTS
R 3 2 6] E T T E N G I N E
Limit(mm)
Intake
0.1
Exhaust
0.1
.H.gb
. lf clearanceexceedslimit,verifythe valvestemdiameter
andreplacethe valveor valveguide.
[Point23] Valveinspection
Outsidediameter
measurement
1-e
- l --1r € o
l: '-
E
f -fli-?r-it, e q
t \ --r-;' !
c lll
| /-,i,:
L lry- -----cJ
l N
b
a
Vatue a b c d e f s q
1 0 0 . 9 8 + / - 0 .97.45+t-0.15
1 s + s - l 2o^ u^ -. 0o 0. 032! c t.J z.o ^ 45" 30'
99.98+/-0.195.48+/-0.15 7' ^" --0000 8 c (1.2) ?q
+03 ^ ^ 0.02c
95 o u - o - o s s45 30' +t-15'
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
lnstallation
. Reamthe cylinderheadguideholeusingthe valveguide
(whenusing0.5 mm over
reamerat normaltemperature
sizeservicePart).
lntake side 10.46- 10.478
Exhaustside 1 1. 4 6 - 1 1. 4 7 8
headinanoilbathto approximately
Heatthecylinder 150
toolto press
to 160"Candusea valveguidedriftor press-fit
valveouidefromcamshaftside.
Camshaftside
Valveg0ld6.reamer
K V 1 0 11 1 6 0 0( i n t a k e l
r<V101 07700-(exhausr) _
E N. 9 4
ON-VEHICLEPARTS
I 3 2 6 C E - I . TE N G I N E
[Point26] Valveseat
Inspection
. Inspectthecondition of contacting
surfaceof thevalveseat o.K
_po*"
andthevalve.
. Replacethevalveseator thevalveif contacting surfaceis
too largeor improper,or grindbothsurfacesand lapwith
abrasivecomDound.
Adjustments
. Whensurfacingvalveseatdueto poorcontact,inspectthe
valveguideclearanceandvalvestepholeclearance.
. Usethevalveseatcutteror thevalveseatqrinderand
finishto standardvalue.
Caution:
Whenusingvalveseatcutter,pressfirmlyandcutevenlywith
bothhandsto produceuniformcuttingsurface.
Removal
. Minimize thevalveseatthickness
by cuttingit,thenremove.
Installation
(1) Drivethevalveseatintocylinderheadusingthevalve
seatdrifteras shown,
co,
Exhaust co :or
side -- - do__o (Cutter I
diameter)
p, fio, ffio.
+0 113 + i - 01 s ^ ^ 0
JO ?A
0 097
30 32 34.3 37.s O,O ^r
EN-95
PARTS
ON.VEHICLE
ENGINE
RB26DETT
GQi,
d
B o l (t 2 )3 . 2- 4 . 3 I
' t'tl''\>
r- -l r,":'.
'
\
peort1zy
s.z- 4 . 3
D Liquidgasret
M Bolt(6)1.6- 2.1pl
kg-m
EN-96
ON-VEHICLEPARTS
R826DETT
ENGINE
Installation
. Installthe boltsin the numberedsequenceshown.
M6 1 0.64- 0.85
7, 8 , 9 , 1 0 ,1 1, 1 2 tv8 6 't.6- 2.1
2,3,4.5 r\41
0 A
3.2- 4.3
Removaland cleaning
. Insertstubbyscrewdrivers in the boltholesand moveit up
anddownto removethewateroumo.
Caution:
Takecarenotto damagethe screwsin cylinderblockside.
. Usea scraperto removeall liquidgasketfromthesurface.
Caution:
Alsoremovethe liquidgasketremainingin grooves.
. Wipethe installation
surfacewithwhitegasoline.
Installation
. Cutthe nozzleendof liquidgaskettube(KP51000150)as
shownin the figureand usetubepresserfor application.
EN-97
PARTS
ON-VEHICLE
RB26DETE
TNGINE
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.
lnstallation
. Cutnozzleendof liquidgasket(KP51000150)tubeas
snown.
2.0 - 3.0 mm wideto centerof flat
matingsurfaceand innerseating
. Applya continuousbeadof liquidgasketto sealingsurface surfaces of boit holes.
usingthetubepresser.Installthe housingwithin5 minutes
aftercoatingliquidgasket
EN-98
ON-VEHICLE
PARTS
ia2a l:--r. ENGTNE
[Point2] Installthermostat
. 'Top'markfiigglevalve)mustfaceup whenthermostatis
insertedin housino.
[Point3] Thermostatinspection
. Checkthevalveopeningtemperature and maximumvalve
tift.
. Hangthe thermostatby stringin valveandsubmergein
heatedwaterin doublewalledcontainer andstirwaterwhile
heatingit up.
. Theopeningtemperature isthetemperature whenthevalve
opensandthermostatfallsfromstring.
76.5
10/90
Additionalwork required:
. Disconnectand connectswitchharnessconnectors
. Drainand refillcoolingwater
Caution:
Loosenenginedrainplugto removecoolingwaterfromcylinderblock.(lfwateris onlydrained
fromtheradiatordraincock,thecylinder
blockwillnotdraincompletely).
EN-99
PARTS
ON-VEHICLE
RB26DETE
I NG]NE
Eloil pan[Point
2]
Eleat
'11oll s
Front
Oil pump
pDrain ptug
Copper wa\sher
?7*\ t
\t\$r \
), oit panbolt(a)Fl
\ 0 . 6 4- 0 . 8 5l P o r n1t l
O i lp a nb o l t( 1 4 )3 . 2- 4 . 3t P o i n1t 1 p j
i",l Kg-m
f | E n g i n eo i t
$ neptaceafter every disassemoly
Additionalwork required:
. EngineASSY
. Drainand refillengineoil
E N- 1 0 0
ON-VEHICLE
PARTS
RB26DETE
TNGINE
Bolt t Nut
3ize
M,E EEM N/6(Bolt) I 0.64- 0.8s
tv l)Al )o ".i
4 , 7 , 8 ,1 0 ,1 1 .1 2 .1 4 ,1 5 ,
1 6 ,1 7 ,1 8 ,1 9 . 2 1 . 2 2
M 1 0( B o l t ) 14 3.2- 4.3
. Cleanall contactsurfaceswithwhiteoasoline.
Installation
. Cutoffthenozzletipof liquidgasket(KPs1000510)at
pointshownin thefigureon right.
EN- 101
ON-VEHICLEPARTS
RB26DETE
TNGINE
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
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
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
Purnphousrng[Pornt
Innergear [Pornt2]
Outergear [Point1]
piuga.O- z Opl
Regulator
19*n-'
[Point1] Oil pump inspection
. Checkinnergear,outergearand housingfor any scratchesor wear.
. Usethicknessgaugeto measurethefollowingclearances:
EN- 103
PARTS
ON-VEHICLE
RB26DETTENGINE
[Point2] Regulatorinspection
. Checkoil pressureregulatorvalveslidingsurfaceand the
springforanywearanddamage.
Valveand valve hole clearance(mm): 0.04- 0.097
[Point3] Installinnergear
. Caremustbe takento installthe innergear in a specific
direction.
. Facethe sidewiththe grooveto the coverside.
Coverside
E N- 1 0 4
ON-VEHICLE
PARTS
I 3 2 :E E N GN E
Collector
ASSY
IS--.-,.,^ I
Y
oort(a)$l
collector
1 . 8- 2 . 2l P o i n3t l
g
:'j:i,i",ili'lr
?3'
Fi.
gasket
E Collector
ft.,
$./.1Ks-m
E Replace
aftereverydisassembly
Additionalwork required:
. Releasefuelpressurein thefuel lines
[Point1]
. Drain& refillcoolingwater[Point4]
. Acceleration wire[Point2]
. Airduct
. Harnessconnector
. All hoses
Throttlechambergasket
2l $
tPoint
Throttlechamber[Point1]
E N- 1 0 6
ON-VEHICLE
PARTS
i32]: E\GINE
I =il;-
10.2 INTAKEMANIFOLD ASSY
(1) Remove& installintakemanifoldASSY
Intakemanifoldgast<et
$
-_.4-
_
Fi
t-.1
a Replace
aftereverydisassembly
E N- 1 0 7
PARTS
ON.VEHICLE
R B 2 O EE N G I N E
.J -
\* Arr regulator
{4
bolt0.5- 0.6
p) Air ;egulator
FueltubA
e SSY
I P o i n1t l
Fueldamper -
n
;*,,i
reguralor
Water outlet
7i
Boltt-,4
1 . 8- 2.2
Bolt(2)1.6- 2.191
E N- 1 0 8
ON-VEHICLEPARTS
R B 2 O EE N G I N E
? ' * o i
P.P
yoke[potnt3) . P
WasherfPoint4] ,
zj"
z.a- s.zieornt
p ruut
ri
\-/ Kg-m
Replaceafter every disassemble
Additionalwork required:
. Undercover
. Assembleanddisassemble exhaustfronttube
. O, sensorconnector
E N- 1 0 9
PARTS
ON.VEHICLE
R B 2 O EE N G I N E
[Point 3] Yoke
. Makesure notto makemistakebetweenNo. 3 and No.4
aredifferent.
yokeas configurations
22
24
[Point4] Installwasher
. Makesurethewasheris facingthe correctway when
installing.
+
l\4anifoldside
Fillercap
Additionalwork required:
. Air duct
. Air duct bracket
. Blowbyhose
E N- 1 1 0
ON-VEHICLEPARTS
R B 2 O EE N G I N E
,., 8 e t l e " sc . e r
vvasner
ConicatwasherI i Tensoner spr no fPoint7l
"
glNur4 4 l"."il,t]",".\ i -}- dso
*
tl6'8
Timrngbelt cover(upper)
IPornl4]
Timingbeltcover
Crankpulley[Point3]
Powersteeringpump
pulrey
p a o r r. o ;t . z Cranktrrnrng beltplatelPoint
CranktimingpulleylPoint11]
T i m i n gb e l tl P o i n 9 '121
. 3]
{- t , 10,
Cranktimingpulleyplate[Point8]
ri^..
l-/ borr ( 2 )0 . 3- 0.5
I ts-.
E E n g i n eo i l
after
Additionalwork required:
. Drainandrefillcooling water
. Removeand installthefollowinos:
. Undercover
. Radiator,shroud
. Coolingfan
. Supplemental belts
. Waterpumppulley
. Sparkplugs
. CheckNo. 1 cylindercompression T.D.Cposition[Point1]
. Installringgearstopper[Point3]
E N- 1 1 ' l
PARTS
ON-VEHICLE
R B 2 O EE N G I N E
'' -*v-ror
[Point3] Pulleypuller(steeringwheelpuller)
. Remove thecrank byusingthepulleypuller.
pulley
(boltsize:M6x 1.0 lengthbelowhead40 mm)
2718
[Point6] Installconicalwasher a I
-[__T--r
r I I I
. Paycloseattentionto the installation
directionof the
conicalwashers.The washershouldbe set withfacethe \\
\_J \
chamferedsidefacingthe tensionerpulleyside t l
Nrt Conical
washer
IPoint7] Installtensionerspring
. Assemble thebelt
springso it engages
thetensioner
pulleyasshowninthefigureonright.
tensioner
EN-112
ON-VEHICLE
PARTS
R B 2 O EE N G I N E
pullfy Spri
1 . 8m m Approx.20' Approx.227'
When free
Timingbeit pulle'
tar
[Point8] Installcrank pulleyand plate ---------
. Be carefulto observefrontand rearpositioning
of timing ]--lu
beltplate,
cranktimingpulleyandcranktimingpulleyplate il
wheninstallationis oerformed. t.t tr
E- ll
- -lf-- o)o"u
. Checkthenumberof ridgesbetweenthecampulleyand
thecranktimingpulleyalignment
marks.
EN- 113
PARTS
ON-VEHICLE
R B 2 O EE N G I N E
[ P o i n t1 1 ]C r a n kt i m i n gP u l l e Y
. Makesureto installthecranktimingpulleyin a correctway
Somecranktimingpulleyhastwo key groovesand
alignment marks.
Keygroove
[Point12]Timing belt tensionadjustment
. Loosenall rockershafttighteningbolts.
. Rotatethe tensioneranticlockwise two to threetimes
usinghexagonalwrench. (itis notnecessaryto rotatebelts)
. Fixthe tensionerusinghexagonalwrenchand tightenthe
nutsto specifiedtighteningtorque. (At thisstagespecific
tensionwill be appliedto the beltsautomatically).
[Point13]Timingbelt insPection
. Replacetimingbeltif inspectionindicatesany problem.
Toothmissing
Cracked tooth @ Camshaftlock
Crank sensor lock
Tensionerlock
Cracks on rear Engineoverheat
stde with belt cover etc.
lnterference
S lidingmotionresistancein
Worn teeth Jary ]!lg crank sensor and the camshaft
cottectorbott/2)lctl
Accelerator
wire bracket[Point2]
1.8- 2.2IPoint
--{{3lrci Co ecrorASSI
l
e | ,---_,--4
gasket
E Collector
tli
\-,i k g - m
a Repiaceafter every disassembly
Additionalwork required:
. Releasefuelpressure in thefuelline[Point1]
. Acceleration
controlwire[Point2]
. Drainand refillcoolingwater
. Air duct(RB2ODE), Air inletpipe(RB20DET)
. EGIharnessconnector,harnessclamp
. All hoses
7.10 2 105
8 65
1,3,4,6, 4Q
2 , 5 , 9 .1 1 4 30
*:;::*;l;;,'"'*>e
H41,
B o l (t a )0 . 9- 1. 19
Throttlechamberbolt (4)
z2- --..- 1 . 8- 2 . 2 [ P o i n 1t ] $ I
Additionalwork required:
. Removeand installcollectorASSY
E N- 1 1 6
ON-VEHICLEPARTS
R B 2 O D /ED E TE N G I N E
[Point2] Throttlechambergasket
. Checkthe installation
directionbeforeinstallino
the throttle
chamber gasket. .)
oVo
10-2 INTAKEMANIFOLDASSY
(1) Remove& install intake manifold ASSY
lntakemanifoidASSY
Fi
\-.4
a Replaceafter everv disassemble
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
a t"t t I t.o-
pl eott1r;gnt lPornt,,
injector p) aonrZtO.6a' O.SA
?_
Air regutator
,-- 1,
Fuel tube InjectorASSY
p prpenSSY
Water-outlet
a
Fi
Liquidgasket
\",i K g - m
Additionalwork required:
. Remove& installintakemanifoldASSY
Exhaustmanifoldgasket
Exhaustmanifold
Bolt(3)0.a- 0.5I
YokeIPoint3]
')@
washer potnt ti
-
| ) Nut2.8 3.2IPoint2, 3l
Fi B o r t (07. i4 - o 5 I
\",1xg-m
$ Reptaceafter every drsassemble
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 c 0.5
is different.
yoke as configuration
P (mm)
22
24
[Point4] Installwasher
. Makesurethe washeris facingcorrectway when
installing.
Manifoldside
Ornament narness
Ornamentbolt(B)0.30- 0.39
F i \
l'/ \,-
Groundcable
L- \
./'/-/.
l9l *n-'
Additional work required:
. Air duct(RB20DE),Air inletpipe(RB20DET)
. Blowbyhose
. Powertransistor
22 25
E N- 1 2 0
ON.VEHICLEPARTS
R B 2 O D /ED E TE N G I N E
[Point3] Sparkplugmaintenance
. TheGapinspection andadjustment is notnecessary
as
plat,numtipis used.
. Change thesparkplugevery100,000 km.
. Whenusingcompressed airsparkplugcleaner, cleanthe
plugsat maximum pressureof 6 kg/cm2for nomorethan
20seconds.
. Donotusewirebrushto cleanplugs.
10-5 REMOVE
& INSTALL
ROCKER
COVER
-
F i l l e rc a p 9Ornamentbolt(B)0.30 0.39
Lockercoverbolt0.2 - 0.4 [Point'1]
€
e - -- ^
Grommet
- .-4,
Lockercovergasket
Orname'nt
I
Lockercovergasket
Fi
l".i xs-m
Additionalwork required:
. Air duct(RB20DE),
Air inlet(RB20DET)
. Blowbyhose
EN- 121
PARTS
ON-VEHICLE
R B 2 O D /ED E TE N G I N E
Timingbelt cover(upper)[Pornt4]
b e l t[ P o i n 9t , 1 0 , 1 2 ]
Trmrng
i,r"-",ffi..'
r,,'"'
g*
j"t#
-- WW'il.
@aS1 conicar Betttensroner 9. '10.111
[Pornt
P" r\
n,r,'*i.lvS::"fu
pl pol(31
W^,
*?tgO,S'Po;**,)H
o.o.t.
] ?ol'_,0,-9
I - -^6)-... llil'3E w{
609\ -
\-
q"fl,:-';,,..""1,","iixilJ,',os-oaap)
91,n.,
Jl Ensn" oi
$ aftereverydisassemblY
Reptace
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
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)
EN- 123
PARTS
ON-VEHICLE
R B 2 O D /ED E TE N G I N E
[Point6] Installconicalwasher
. Payattentionto the installation
directionof the conical
washers.The washer should be setwithfacethe
chamferedsidefacingthetensionerpulleyside.
[Point7] Installtensionerspring
. Assemblethetesionerspringto the belttensionerpulley
as shownin thefigure.
. Thetensionerspringmustbe assembled togetherwiththe
belttensionerpulleyin thecylinderblock.
; iqipipnr,,.o |,
springontheuppersideof thetensioner
. Hookthetensioner
springstudwhenthetensionerpulleyis free.
/4 \,. "r \
a Tensioner spflng
Tensionerspring sPecifications
EN - 124
ON-VEHICLEPARTS
i:. ]: fEi ENGINE
EN- 125
ON-VEHICLEPARTS
R B 2 O D /ED E TE N G l N E
Cause
Camshaft lock
Toothmissing
Cracked tooth <? Crank sensorlock
Tensionerlock
Cracks on rear E ngine overheat
side lnterferencewith belt cover etc.
Slidingmotionresistancein
Worn teeth crank sensor and the camshaft
Caution:
Donottwistor bendthetimingbelt. Makesurethereis nooilfilmor wateronthebelt
plaott1ryo.64-085
,t \')/
lt
t\
E
ti
Botr(2)3.2- 4
{s' WaterpumplPoint1, 2]
v ffih,u-,,
19 ns-'
Liquidgasket2.0 - 3.0 mm
. Wipeoffoil liquidgasketfromthe cylinderblockandon the wide alongthe groove
waterpumpandwipethe surfacewithwhitegasoline.
. Applycontinuous beadof liquidgasket(KP5'10 00'l50)to
waterpumpsealingsurface.
Caution:
Be sureliquidgasketis 2.0to 3.0 mm wide.
Installation
mustbe carriedout within5 minutesafterliquid
gasketapplication.
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
ON-VEHICLEPARTS
R B 2 O D /ED E T E N G I N E
[Point2] Installthermostat
. 'Top'mark(igglevalve)mustfaceup whenthermostatis
insertedin housing.
76.5
'10l90
E N- 1 2 8
ON.VEHICLE
PARTS
R B 2 O D iED E TE N G I N E
O-ring
Additionalworkrequired :
. Frontstabilizer
. Radiatorfan,shroud
. Right& leftenginegusset
. Enginerearplate(lower)(A/Tvehicles)
. Enoineoil
E N- 1 2 9
ON-VEHICLEPARTS
R B 2 O D /ED E TE N G I N E
Caution:
Caremustbe takennot to pullthe hosesand harnessestoo
muchwhenliftingup the engineusingthe hoistcrane.
lnstallation
. Thefollowingproceduremustbe carriedoutwithin5 Tubepresser(WS3993)
minutes: Liquidgasket
. Applyacontinuous beadof liquidgasket(KPS10 00150)
to sealingsurfaceusinga tube presser'
. Installthe oil panwithin5 minutesaftercoating.
E N- 1 3 0
ON.VEHICLE
PARTS
R S 2 O D EE
T N GN E
10-9REMOVE& TNSTALL
TNTERCOOLER
(RB2oDET)
"'i5=;"*3h"Sj"=@jluri""" Turbocharger
:::="" *;;"_O
M_@4p
g. Arrrose \=/
*XgF/H cramp-g Airn^<a
^ in'"'-"nn'"'
ff"ct 7
s;il'-l
.*- . il"*';b,mffi3Tff;::
i";:'iF
"^^,66;-'ry4e"';ol
ll-,
.o""'
u" Inter-cooler
bracket
Inter-coolef
ri.
\",1Kg-m
Additionalwork required:
. Leftfrontfenderprotector
. Fenderstay
. BonnetlPoint1l
EN - 131
ON-VEHICLEPARTS
R B 2 O D EE
TNGINE
P5 ;::"\T'a'"^'''"'ffi"fl.
# {,*"gEK#"O: ))
l$ -;;
.<=t4\ leo";'o ,**"I,T::[- Q'*-''
1--#r\ B"!t!TUq \\.,1,,*
1",/ Kg-m
$ Reptaceafter every disassemblY
Additionalwork required:
. Undercover
. Assemble & disassemble fronttube
exhaust
. O^sensorconnector
. lniercooler
airinlettubes,hoses
. Airinletoipe
[Point1] Removewateroutlettube
. Remove thewateroutlettubebyfirstremoving theclamp
locatedontherearsideof thecylinder block. Water outlet
tube
Inspection
. Aftercleaningwaterinletandoutlettubewith radiator
cleaner.blowwithcompressedair and checkfor rustor
clogging.
EN - 132
ON-VEHICLEPARTS
R B 2 O D EE
TNGINE
Inspection
. Aftercleaning
oilfeedtubewithengineconditioner,
blow
withcompressed airandcheckforclogging.
....'
:-
€Fl
thenuts.
Installation
. Positionthe lockplatesandturbocharger mountingnuts.
Aftertighteningthe nuts,bendlockplatepawlsontothe
nuts.
[Point 5] Eyeboltdetermination
. Oilfeed(cylinder
blocksideandturbocharger
side)eyebolts
arestamped"G",
Installationorder
1. Turbocharger mainunit
2. Waterfeedtube
3. Oil feedtube
4. Wateroutlettube
5. Oil returnpipe
EN- 133
PARTS
ON-VEHICLE
R B 2 O D EE
TNGINE
Actuator[Point7] Excessivepressureleak
Exhaustgas leak tnspectionlocation
valve[Point3]
Crackinspection-
Crack Turbinewheel
lnspection t ,2 , 4 l
lPoin1
Compressorwheel
[Point5] Coolingwater Rotorshaft[Pornt6, B]
[PointB]
[Point2] Turbinewheelinspection
. Oilmustnotadhereto surfaces.
. Theremustbenocarbonaccumulation.
. Thevanesoftheturbinerotormustnotbebent.
. Theremustbenointerferencewithturbinehousing.
E N- 1 3 4
ON-VEHICLEPARTS
R B 2 O D EE
TNGINE
[Point6] Rotorshaftinspection
. Theremustbenocarbonsledoeaccumulation.
[Point8] Oilandcoolingwaterinletandoutlet
cleaning
. Useengineconditionerto cleantheoilfeedandreturn
passages.
. Useradiator
cleaner
to cleancoolinqwaterfeedandreturn
passages.
. Cleanusingtheairgun.
. Cleanthe compressorwheel,turbinewheel,compressor
housingandturbinehousingwithsamemethods.
EN- 135
PARTS
ON-VEHICLE
R B 2 O D EE
TNGINE
Pointsto be checkedbeforediagnosis:
1. Theengineoil levelmustbe betweentheMINandtheMAXmarkson theolllevelgauge.
(whentheengineoillevelis higherthanMAXline,theengineoilwillflowintotheintake
ductthroughthe blowbygas recirculation passandtheturbocharger may be
determined to be malfunctioning).
2. Checkwithcustomerto determineif oil is cooledwhen idlingafierdriving'
lf any malfunction replacethe
in thefollowingchartis detectedin a unitinspection,
turbocharoer ASSY
1,. ,
, rAbnofmal
Smoke noas€
Oil on rotors A Or A
Turbinerotor
Carbonhas accumulated A a C
Rotor scrapesagainstthe housarE A
Turbrmevanesare bent or folded
E N- 1 3 6
ON.VEHICLE
PARTS
C A l B ]E N G I N E
10,1 INTAKEMANIFOLDASSY
(1) Remove& instalintakemanifoldASSY
- bort(4)t.e- z.zp)
tn,ou,"Oody
T,
G a s k e$t
IntakemanifoldASSYIPoint
-(
'|l
gasketE
\-,1 kg-m
$ Reptace after every disassembly
Additionalwork required:
. Releasefuelpressurein thefuellines
. Drainand refillcoolingwater
. Air cleanerASSY
. Fuelhose
. Waterhose
. Intakesidehigh{ensioncable
. Vacuumhosesand ECCSharnessconnectors
. AccelerationwireIPoint1]
. Watertemperature sensorconnector
. Thermaltransmitter connector
[Point4] PTCheaterinsPection
. Makesurethereis nocrackonthePTCheater.
& assemblethrottlebodyASSY
(2) Disassemble
Fueliniector coverscrew
{2)0 20 .- 0 26I \g
'ut'rntector
cover
,
$o-ring =----dG
-€t
cl,el lnjector,0j,", ,,
_
€ e ,.- Btackel
$o-nng-.....-" -V,a
'egulator \|g-- - Sc'ew{4]OO+- OSSp)
Pressure lPo,nt4l uT
.*?" ':"t, [l i fl I
^' rh,ort,"
uppe. ouuy^-_ -__
^,V&d*o.
/ s"u'
^, ^-
eoin,
J1
Thermowax lPornt 7]
7*ir9"" o,o- o,u
Screw0 20 - 0 26p
I hrottleadtustscrew=\E
S/ .or-n g
Lower inter_.,.
yrpo
thro.ebodointgt\ --@ =,"ref\rilff}:!,,3"il:
E1^.<-1 Bracket (2)p
screw
olo
Fuel injectorharness
ri k g - m
\-/
a ReplaceaftereverydisassernblY
E N- 1 3 8
ON-VEHICLEPARTS
.A'3 ENGNE
[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) -lniectorcover
/--\.
'..-r'\
butdo notapplysolventto themas thismay removethe oil l:
\^
coatrng. Conneclor:rJ
rubber \9 Injector
wrflng
. Do not allowdirt,dustor foreignobjectsto adhereto connector
O-ringsor otherequipmentsurfaces. F u e lI n i e c t o r
. Caremustbe takennotto scratch,twistor stretchO-rings
wheninstalling. Do notinsertit in thefueltubeby
makingit stretchslightly.
. Do notstoreO-ringsin locationsubjectto ozone,high
temperature or in directsunlight.
Installation
Replacebothupperand lowerO-ringsto newones.
Coatthe lowerO-ringwithengineoil and installto throttle
body.
Placethefuel injectorinsidethe throttlebodyand set the
injectorpositionby placingthe injectorconnectorand the
injectorcover.
Useoil sealdriftto insertthe fuel iniector(resistance
must
be felt).
Coatthe upperO-ringwithengineoil. Useoilsealdriftto
inserttheO-ring.
E N- 1 3 9
PARTS
ON-VEHICLE
C A ' 1 8Ei N G I N E
Inspection
. Lookfor anydeformationor wearon the cam spring.
Cap spring free length(mm): 24.5- 26.5
lnstallation
. Makesureto installthe cam ASSYand the cam springin Free length
I
rightdirection.
. Reolacetheseatwithnewones.
Pressurereguator
[Point4] Pressureregulator
Removal
. Removethepressure fromtheupperthrottlebody'
regulator
. Carryoutthefuelpressure
inspection.
Inspection
. Inspectvisually
if thereareanywarn,cracksordeformation
on springretainer,retainer,and colour.Also inspect
Springretarner
rotationcontactsurface. (plastrc)
. Checkdeformation andwarnon thethrottleadjustment (plastic)
/,Retainer
screwand return spring. Color(plastic
f<
Returnspring free length(mm): 19.5- 21.5 \0.J
\
lnstallation
. Caremustbe takento installthe partsin correctdirection
the armASSY returnspring,throttledrum
wheninstalling
andA,/Tcontroldrum.
E N- 1 4 0
ON-VEHICLEPARTS
C A l 8 iE N G I N E
[Point7] Removethermoswax
. Firstremovethethrottle
wirebracket
to removethermo
wax.
Inspection
. Checkifthepinwillextendwhenthethermowaxis
warmeo.
Thermowax
Caution:
Donotpulloutthepin.
EN- 141
PARTS
ON-VEHICLE
C A l 8 iE N G I N E
10-2 EXHAUSTMANIFOLDASSY
Exhaustmanifoldqasket
- -
-rw--4; Washer
"*
if::'liHllli 'u'
,f4f;^
ddl
V/,^-,T t: l,aa
fru
R. o,
gl f
o,r" "-(.,:-'r.,lpoint
ExhaustmanifoldlPoint2]
Heat shieldPlate
ri.
l-/ Kq-m
$ Replaceafter everydisassembly
Additionalwork required:
. Undercover
. Exhaustfronttubenuts
. O,sensorconnector
. Exhausttemperaturesensor
. Hotairduct
Straightgauge
[Point2] Exhaustmanifoldinspection
. Measuretheexhaustmanifoldsurfacefor distortionsin four
and
separatedirections(oppositedirections:horizontally
in a numberof locations).
vertically)
E N- 1 4 2
ON-VEHICLEPARTS
CA18E
] NGINE
10-3 LOCKERCOVER
rlOSC LOCKeT
COVerSCreW
0.1- 0.3lPoinr1]
Oil Rttercap \ 3---'(8)
6 -_ Grommet
\.4* fl.-r."y
\=2
Fi
l".l ks-m
Additionalwork required:
. High{ensioncable
. AircleanerASSY
EN - 143
ON-VEHICLEPARTS
C A 1 8E
i NGINE
10-4 TIMINGBELT(CRANKPULLEYBELTCOVER)
( 1 ) Remove& installtiming belt cover
ac!.+---
-:=-=+--.-
uppercover
\r2-
,_l-_=
Lower cove(-
B o l t( 4 ) 1 . 2- 1 . 6
-
ts-t E Crankpulleybolt12.5 13.slPoint2]Pl
I
I Engineoil
Additionalwork required:
. Undercover
. Fanshroud
. Supplement belts
. SparkPlug
. No. 1 cylinder
compression [Point1]
T.D.Cposition
. Installringgearstopper[Point2]
E N- 1 4 4
ON-VEHICLEPARTS
C A IB i E N G I N E
[Point3] Removecrankpulley
. Loosen thecrankpulleyboltsandusepulleypuller
(steering
wheelpullerST27180001) to removethecrank
pulley.
Caution:
Donothookthepulleypulleronthecrankpulleygroove.
Crankpulleyside
[Point5] Installcrank pulleyplate
. Makesurethe crankpulleyplateis positionedin correct
wav.
cA18i 43 95
EN - 145
ON-VEHICLEPARTS
CA18E
r NGINE
Toothmissing
Cracked tooth @ Camshaft lock
Crank sensor lock
Tensionerlock
Cracks on rear Engine overheat
sloe Interferencewith belt cover etc.
Slidingmotionresistancein
Worn teeth '=w!l jJlfuu/ crank sensor and the camshaft
Caution:
(1) Makesurethetimingbeltis nottwistedor bentsharply.
Makesurethereis no oil film or wateron the belt.
(2) Timingbeltneedto be replacedevery100,000km
E N- 1 4 6
ON-VEHICLE
PARTS
C A ' 3 E N GN E
10.5 WATERPUMP
Waterpump[Point| 2]
'/:,j$t
,",(3),u_$\
Springwasher
\
ffiP
gf.o<-spr.ins
=\ *asne,
\ -Bolt(2)
16-20
E is-r
p Repiace
aftereverydisassembly
Additionalworkrequired:
. Drainandrefillcoolingwater
. Fanshroud
. Fan
. Waterpumppulley
. Supplementary belts
. limingbeltcover
[Point1] Removewaterpump
. Becarefulnotto getcoolant
ontimingbelt.lf anywaterdoes
spill,wipeifoffimmediately.
Caution:
Remove oldgasketonthewaterpumpsurfaceusingthescraper.
[Point2] Waterpumpinspection
. 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
Thermostat houstr
1
lPoint l t
ds\
-\-"\'t
\ ----rll./
---Ll
dl- B o l t( 3 )1 . 6 ' 2 . 1
7r,
\",4 Kg-m
$ Replaceaftereverydisassembly
Additionalwork required:
. Drainand refillcoolingwater
. Wateroutlethose
82 88
E N. 1 4 8
ON-VEHICLE
PARTS
]A'! E\G NE
Oilstrarner
nut
oz-oaPl=---...-.
$ oil strainel-q,
gasket
9i,1;1'Ii'6b\e
.
E
+4eet'rt
p$oit
:1
\u"seaoastet
H, ,''0,o u, - 0 85lPoint
4]
Drainplug washer[Point4]$ pj
t r ,
l".l Kg-m
p Liquidgasket
Q Replaceafter every disassembly
Additionalworkrequired:
. Undercover
. Engineoil
. Right& leftenginegusset
lnstallation
. Applysealingagent(SS60For equivalent) on theareas
shownin thefigureon rightto installoil pangasket.
:.--
E N- 1 5 0
ON-VEHICLE
PARTS
R B 2 5 D EE N G I N E
I o.ts
Airhose p rilo'"" '," - o.ro.1zy
"_ Airhose
UDe L,"\..t_ ,/ ^
,/ Rubber \ I 0 5 2 - 0 6 6 ( 4p)j
chambef\(@ '"f"'
p r . : - r . o 1 z- 1 ; O - r i n gE
,,Y Air cleanefcase
. . ' - Ho s e
Air cleanerelement
- Insutator
^ - ^ r
u^cz - uoo lv,/
^ ^ ^ F i
r J r l " , l0 5 2 - 0 6 6 ( 4 )
Resonator
0 . 5 2- 0 . 6 6( 2 ) ! - bracket n c,l - necfC|l
-e/g v,
- l
E
'^'^^,)h
{ as2-o66pJ
Removal
. Removethe negativeterminalfromthe battery.
. Usean air gunto blowoff any dirtor dustbeforeremoving
theairhoseandairduct.
Removethe following:
. 2 vacuumhosesfromthe resonator(betweenintake
manifoldandcanister).
Blowbyhosebetweenlockercoverand air duct.
Air hosebetweenair ductandair requlator.
. Removeairflowmeterconnector.
E N- 1 5 1
PARTS
ON-VEHICLE
R B 2 s D EE N G I N E
Removetheairductbyfirstremovingthefrontcombination
lamoandthe leftheadlampASSY
Caremustbe takennotto scratchor damagethe airflow
metersensorwhenremovingthe airflowmeter'
lnstallation
. lnstallation out
carried
oftheairductandtheaircleaneris
in reverseorderof removal
operation.
. Airflowmetercircuit useASSYwhen
caseisnonseparable,
theairflow
replacing meter.
. Makesureto inserttheairhoseandtheairductsecurely
byaligningthealignment andtightenthe
markcorrectly
bandandtheclamP.
E N- 1 5 2
ON-VEHICLE
PARTS
R B 2 5 D EE N G I N E
1O.2 INTAKEMANIFOLDGOLLECTOR
(1) Remove& installintakemanifoldcollector
|2i'ftt:'rti:g
-Y-V coirector
ASSY
\ -,-aa
CollectorgasketE
-[]
/l
\ irl-
\ .'.
t , u- 22 \2)P)
pcoltectorboit(2)1.8- 2z.-*& g
l-,i r<9-m . B- 2 . 2
,/) ,,
E Replaceafter every disassembly
Removal
Releasethe fuel pressure
. Warmuptheengine. FUELPU[,4PRELAY OFF
(POS) 950 rpm
. Select'Fuelpumprelay'in 'Activetest'mode. CAS.RPI\,|
: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.
EN- 153
PARTS
ON-VEHICLE
R B 2 5 D EE N G I N E
11
Loosenthe boltsin ordershownin thefigureon right. J
Checkto see everyhosesrequiredare removed.
. Remove gasket.
collector
. Usea toolsuchasa scraper anyleftovergasket
to remove
onthesurface.
r:
lnstallation
. Installthe collectorgasket.
. Makesurethereis no dust,oil or otherforeignmatteris on
the sealingsurface.
. lnstallthe collector
ASSY
. Tightenthe boltsin the ordershownin thefigureon right
Tightenin gradualstepsto uniformtightness.
-1 "9- - 5 ,2 - ' l.
. Lengfi {mm}: "7 =3. - "1 - Y; -. -s. , .
No. of bolls
105.2
't.8 - 2.2
7,10
I 65:1 1 . 8- 2 . 2 l-
2 , 5 , 9 ,1 1 30:4 1.8-2.2
Collector
AAC valve
lAA unit
Water hose
9ts't
E Replaceafterevery drsassembly
Disassembly
. Removethrottlechamber
. RemoveIAAunit
Assembly
. Installthrottlechambergasket
lnstallin iorrectdirection
. Tightenthethrottle
chamber
boltsrnordershowninfigure
onrightuniformly
intwostages.
Tighteningtorque(kg-m): Firststage 0.9- 1.1
Secondstage1.8- 2.2
. Install
lMunit.
4 ' + , 0 . '0. -r p
E N- 1 5 5
ON-VEHICLEPARTS
R B 2 s D EE N G N E
ne0--
I
Fi
rol-z.rtz)H
l".l k9-m
Removal
. RemovecollectorASSY Fordetailedremovalprocess
referto Collector"section.
. Removefuelinjectorconnectorandthe lamp.
. Removethe connectorPin
. The operationcan be carriedout easilyif the vehiclebody
groundwires,watertemperature sensorconnectorandthe
thermaltransmitter connectorare removed.
. Removeair regulatorconnector.
. RemovethefuelASSYby firstremovingthe bolts.
. Replaceo-ringwithnewoneswhenremovingfuelinjector,
pressureregulatorandfuelbumperfromthefueltube.
. Do notpullthe connectorpartswhenremovingthefuel
injector.
Precautionswhen handlingO'ring
. Coatthe O-ringwithengineoil (7.5W-30or equivalent)but
do notapplysolventas this may removethe oil coating.
. AvoidusingdirtyO-ringsand do not allowdirt,dustor
foreignobjectsto adhereto O-ringsor otherequipment
surfaces.
. Caremustbe takennotto scratch,twistor stretchthemby
wheninstallingO-rings.
toolsor operator'sfingernails
Inspection
. Fuelinjectorresistance
Resistance value(f,|): Approx.13 - 14
. Iniectorcan not be disassembled.
E N- 1 5 6
ON-VEHICLEPARTS
R B 2 5 D EE N G I N E
Installation
. Do not rotateor decenterthe partswheninstalling the fuel
in1ector,pressureregulator
andfuelbumperto thefueltube.
. Tightenthe pressureregulatorandthefuelbumperscrews
uniformlyin twoto threestages.
Tighteningtorque(kg-m): 0.30- 0.39
. InstallfueltubeASSY
Tighteningtorque (kg-m): 1 . 6- 2 . 1
. Connect theairregulator
connector.
. Install
thefuelinjector andfixit inplaceusingthe
connector
ctamD.
. Installthe collectorASSY
10-4 INTAKEMANIFOLD
@=--- Airreguraror
El WateroulletpipeASSY
B o l t( 6 ) 1 . 6- 2 1
Intakemanifold tt
t',i
i-,i kq-m p l e o it z o) n - o s
A Liquidgasket
Removal
. RemovecollectorASSY FordetailedremovalDrocess
referto "Collector"
section
. RemovefuelinjectorASSY
. Removewaterhose.
. Removeoillevelgaugeguidebolt.
Oil levelgauge
. Removerearwaterpipeconnectorbolt.
EN - 157
ON.VEHICLEPARTS
R B 2 5 D EE N G I N E
'10'13)in
RemoveintakemanifoldASSYboltsandnuts(1, I 14 11
the ordersshownin thefigureon right.
Removethe intakemanifoldgasket.
. RemovewaterPiPeASS\.
1312 10 4
lnstallation
. Removeold liquidgasketon the waterpipe,in the groove
andon the intakemanifold.Cleanallcontactsurfaceswith
whitegasolineor equivalent.
. Applya continuous beadof liquidgasket(KPs'10 00150)
2.0- 3.0mmwideto sealingsurfaceusingthetube
pressor.
Caution
shouldbe performedwithin5 minutesafter
Installation
coatingthe liquidgasket. ?,, '3.
; -. .jt"v,
Waitat least30 minutesbeforerefillingenginecoolant. :"'"
- -
/
.,..''..'.-;'.|
,i-.
']
. .ra) f-
Installthe waterPiPeASSY
Tighteningtorque (kg-m): ( A ) 0 . 4- 0 . 5
( B )1 . 6- 2 . 1
(B) bolt(6)
1A-111o ,
gaskeL. 1 4 1 3 1 4
Installintakemanifold
theboltsandnuts(2.10.13)uniformly
Install inseveral
stagesintheordershowninthefigureontheright.
Tighteningtorque (kg-m): 1 . 8- 2 . 2 z 3 5
. Installthe rearwaterpipeconnectorbolt.
Tighteningtorque (kg'm): 0.4- 0.5
. lnstallthewaterhose.
PrPe.l
E N- ' 1 5 8
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.
Washer r3l
Nr,,rrto-2r\Fi
" -"
Exnaustmanrforo tp
o a - - o s { 8 ) go, sensor
fr,
9ts-t
il;'
$ Reptace
aftereverydisassembiy
Removal
. Removethefollowing:
. Undercover
. Exhaustfronttube
. O, sensorconnector
. Exhaustmanifoldcover
. Removethe exhaustmanifoldnutsin theordershownrn
thefigureon right.
. Removetheexhaustmanifoldqasket.
Inspection
. Lookfor anydistortionon exhaustmanifold.
Gas leakinspection
. Afterremovingexhaustmanifold,makesurethereare no
tracesof gas leaksfromany partof installation.
lnstallation
. Installexhaustmanifoldgasket.
. Installexhaustmanifold,
washerandtheVoke.
Front
MakesurenottomakemistakebetweenNo.3 andNo.4
yokeas configurations
aredifferent.
Item
No,3& Xo,i! port 22
O$er than those above 24
+
Manlfold
EN - 159
PARTS
ON-VEHICLE
RB2sDE NGINE
lnstallexhaustmanifoldcover.
crankengineand checkfor gas leak.
Afterinstallation,
10-6 TIMINGBELT
Timingbeit cover(Upper)
Timrngbelt
crommet ]
p aort
121r.o- z.r\
N u t4 . 4- 5 . 9g
t=o' Belt tensioner
Conical ,'Tensioner
t@--- For
rrl
fo]!{a)fJ oromme
E kg-t
E E n g i n eo i l
P Reptace aftereverydisassembly
Removal
. Removeundercover.
. Draincoolingwaterfromthe radiatorenginedrainplug
. Removesupplementary belts.
. Removethe radiator,thefan shroudandthe coolingfan.
T.D.Cposition
CheckNo. 1 cylindercompression
stroketopdeadcenter
z
No. 1 cylinderis at thecompression
whenboththe No. 1 intakeand exhaustsidecamsdo not
movethe valvelifters.
EN - 160
ON-VEHICLEPARTS
R B 2 5 D EE N G I N E
Removetheoilfiltercamfromintakesiderockercoverand
checkthatthe frontend of camshaftfacesthe intakeside.
Remove
crankanglesensor.
Remove
startermotortheninstallringgearstopper.
crankpulleybolts.
Remove
Usepulleypullerto removethecrankpulley(boltsize:M6x
1.0lengthbelowheadapprox.50 mm)
. Removecrankanglesensorbracket,thenremovetiming
beltcover.Timingbeltcoveris separatedintoupperand
lowersections,firstremovethe uppersectionthenremove
lowersection.
Caution:
Do not scratchdriedliquidpackingwhen removingand
installing
the timingbeltcover.
. Removebelttensioner.
. Securethetensionerfirmlywitha hexagonal wrenchwhen
removingand installingbolttensionernuts.
Caution:
Do not looseninsertedstudat disassemblv.
EN - 161
ON-VEHICLEPARTS
RB2sDE NGINE
. '../'\ Camshaftlock
Toothmissing
Cracked tooth
'<./ Crank sensor lock
Tensionerlock
Crackson rear Engine overheat
side with beltcoveretc.
lnterference
SlidingmotionresistanceIn
Worn teeth crank sensor and the camshaft
Caution:
Do nott*ist or bendthe timingbelt . Makesurethereis no oil filmor wateron the belt
pulley
Makesurethereis nowarnor crackscan befoundon idlerpulley,tensionerpulley,cam
cranktimingpulleyandthetensionerspring.Alsocheckif theyrotatessmoothly.
lnstallation
. Assemblethe tensionerspringso it engagesthe belt
tensionerpulleyas shownin thefigure.
. The tensionerspringmustbe assembledtogetherwiththe
belttensionerpulleyin the cylinderblock.
. Whenthetensionerpulleyis free,hookthetensionersprlng
on the uppersideof the tensionerspringstud / A\Y] t(
'
L\g)) )
{;</ -'t\t.
\=o\- -li
Tensionerspring
securinostud
Tensionerspring sPecifications
Tensionerpulley
EN - 162
ON-VEHICLE
PARTS
R B 2 5 D EE N G I N E
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
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
Installcrank anglesensor
(1) Applychassisgreaseto driveunitspline.
(2) Thereis a flangeinsidethedriveunitsplineso spline
onlyhasone insertionposition.Checkthe alignment
beforeassernblY.
(3) Checkthatthe crankanglesensorcan be inserted
easilyin beltcoverholesandsensormoveslightlyto
rightand left,thentightenbolts.
A\ lf thesensordoesnnotmovelightly,loosenthe beltcover
boltswithcrankanglesensorinserted.Movebeltcover
to alignbeltcoverholecenterand camshaftcenter.
Tightenboltsmakingsurethe crankanglesensor
moveslightlY.
Tighteningtorque (kg-m): 0 . 4- 0 . 5
E N- 1 6 4
ON-VEHICLE
PARTS
R B 2 5 D EE N G I N E
O-ring
Oilpanbolt(30)
0 . 5- 0 . 7
o i l strainer
ti,
l-,1kg-m
E L i q u i dg a s k e t
$ Repiace aftereverydisassembly
Removal
. Drainengineoil.
. Removeradiatorfan.
. Removefrontstabilizer.
. Removeengineright& lefigusset.
121620 2428302622
. Removeoil pan boltsin orderof sequenceshownin the
figureon right.
Ti7sE272s2s2117
fi e
. lf removingtheoil panfromthevehicle,firstremovefront
enginemountingnut.
. Usethe hoistcraneto liftup the oil panforward.
. Fromthe gap betweenthe cylinderblockandthe oil pan,
usea toolsuchas spannerto removeoil strainerboltbelt.
. Pulltheoilpanout.
Caution:
Caremustbe takennotto strainthe hosesand the harness
tootightlywhenliftingup the engineusingthe hoistcrane.
EN - 165
PARTS
ON-VEHICLE
RB2sDE NGINE
lnstallation
. Usea scraperto removealltracesof oil liquidgasketfrom
cylinderblockand oil pansurface.
Caution:
Removeall gasketmaterialandotherforeignmaterialthat
fallsintotheoilpan.
. Cleanall contactsurfaceswithwhitegasolineor
equivalent.
. Cutoffnozzletipofliquidgasket(KP51000150)atpoint
shownin thefigureon rightand insertintotubepresser
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.
. Valveoilsealinstallation
measurement
is as shownin tne
figureon right.
Camshaftoil seal
. Removethefollowingparts:
. Engineundercover
. Coolingfan
. Crankpulley
. Timingbelt
. Crankanglesensorbracket
. Campulley
. Backolate
. RemoveNo. 1 camshaftthenremovecamshaftoil seal.
. Applyengineoilto areaaroundtheoilseallip.
. Caremustbe takennotto scratchor damageoil seal Oil seal drift
KV40100900
retainer.Useoilsealdriftsmallerthanoilseal(41mm)
and insertit at samelevelas frontsurfaceof oil seal
retatner.
Frontoil seal
. Removethefollowingparts:
. Engineundercover
. Coolingfan
. Crankpulley
. Timingbelt
. Oil oan
. Oilpump
. Use a screwdriverto removefrontoil sealfrom frontcover.
. Useoil sealdriftand insertnewfrontoil sealat samelever
as frontsurface.
. Facethe oil sealmarkoutside(frontside)wheninserting.
Caution:
Do not touchthe oil seal lip by flngeras greaseis appliedto
areaaroundtheoilseallio. '--_r{'@
r
Rearoil seal
Removethefollowingparts:
. Transmission (orA / T)
. Flywheel(ordriveplate)
. Rearplate
. Rearoil sealretainer
E N- 1 6 7
ON-VEHICLEPARTS
R B 2 5 D EE N G I N E
Cleaning
. Usescraperto removeliquidgasket.
Caution:
Makesureto removeliquidgasketin the groove.
. Cleanthecylinderblocksideusingsamemethodandclean
the surfacewithwhitegasoline.
E N- 1 6 8
ON.VEHICLE
PARTS
R B 2 5 D EE N G l N E
Ornarnent lgnitioncoil
Groundcable
?Oln^lrT-ra
:aa--' -
tli
\",/ Kg-m
Fillercap
Rockercover
O ring
Grommet
Rockercovergasket
Ornament
RockercovergaSket
\-.1i<9-m
Removal
. RemoveRockercoverornament.
. Removeignition
coilharnessand removeignitioncoil.
. Loosenandremovetherockerbolts(intakeandexhaust)in
the ordershownin thefigureon right.
. Removethe rockercover.
Installation
. Installtherockermver.
. Tightentherockercoverscrewuniformly in theordershown
in thefigureon rightin severalstages.
8 4 2
Bolt0.3- 0.39
lgnitioncoil
. Installthe ignitioncoilbracket.
Vf qS cv.rinder
. Installtheomament. rgnrtron ry
corltacket
\LO
Sparkplu0
E N- 1 6 9
ON.VEHICLEPARTS
R B 2 5 D EE N G I N E
10.10 CYLINDERHEAD
(1) Cylinderhead removal& installation
Leuserr ut
CVlinderhead bolt @ \J/
f'-"{t
' 0 v , /
'.\)€ /d'
\ \
\ ,
\,]
Cam pulley
H| rs-t
$ Replaceafter every disassemblY
Removal
. Removecoolingwatercompletely
fromthe radiator,
blockdrainPlug.
cylinder
. Removethefollowing;
. Connectorand intakemanifold
. Exhaustmanifold
. Timingbelt
. Rockercover,ignitioncoil
. SparkPlug
E N- 1 7 0
ON.VEHICLE
PARTS
R B 2 5 D EE N G I N E
Installation
. BeforeinstallingthecylinderheadASSYto cylinderblock,
the crankpulleyandthe cam pulleymustbe positionedat
No. '1cylindercompression T.D.Cposition.
. Alignthecrankpulleytimingmarkandthetimingbeltcover
timingindicator(0"position).
. Alignintakeandtheexhaust campulleyalignment
mark
to respective
beltcoveralignment
marks.
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
/
/u"V:f31'?'.,11''""'
/ 9ping seat
Valvelrfler- -./ / / - o| seal
Valve
t'd/^r/
valvecorer-'--"'" .au^ru.
nu'o'
"
\<- -@-Y==--J:?"[',].",""""r"
, /Valve seat
.0.'"n**ffi" *
Washer-=-3 ,{/-i
A ^^
-crr(@@--"
Buffleplate----€ fp
- B o r t o .1
e2 g
-l O
P e o r r o . st .zrj E
washer/ I e/ -washer
'"1::::.::"::li**
*o@-
;*lT"ililJf""['S
W KffiP* # --.9-3:Ji9',
^.#"*\
)t 6.- F.-
Nr--_ :.t'
g
ri.,nso"*"o:,-a{-*?J
-$---& g..:
":'">-t\ _-\D
_ ' 4 F ^ ' " , 0 n ', r g \
*\..!
-
\-
sea6r[Hj::;";";:
i l" cam;hafttrontorlsealE[
*tr!1liiry'""ffiy*i;ltj,tp;:;:,.
;:;:;:- M,-;l*inan' ron' o r..-.'5-eo'osz-'ze
ffeonz.r - z.zg
L",l hg'm
gasket
A Liquid
oil
n Engine
E ReplaceaftereverydisassemblY
DisassemblY
. Us" tne propertooltosecurethehexagonalpartinfrontof
camshaftto removecam Pulley'
. Removetimingbeltcoverbackplate
. Positionthe cim shaftknock-pinto the positionshownIn
the figureon right.
E N- 1 7 2
ON-VEHICLE
PARTS
R B 2 5 D EE N G I N E
Intakeandexhaust camshaft
canbeidentifiedby
paintcolorandpresence
identification of a splinegearfor
driving
thecrankanglesensor.
Camshaft
Intake
camshaft Purple No
Exhaust
camshaft Orange Yes I Splinegearfordrivingcrankangiesensoj
Removehydraulic
valvelifter.
(1) Hydraulicvalvelifteris nonseparable.
(2) Do notstorehydraulicvalvelifterup sidedownor on C) /7^ @
(3)
itsside.
Storehydraulicvalvelifterin theengineoilwhen
V K7\J
storingtemporarily.
. Usevalvespringcompressor(KV10108950)to remove
varvespnngs.
Cylinderhead inspection
. Usescraperto removeanytracesof oil,waterscale,
gasket,sealingagent,carbonetc.fromcylinderhead
surfaces.
. Measurelowersurfaceof cvlinderheadin sixdirections
to
checkfordistortion.
Limit(mm): 0.2
Gamshaftvisual inspection
. Visuallyinspectcamshaftfor anywarnor damage.
E N- 1 7 3
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
indicated on dialgauge.
Standardvalue (mm): 0.05
CamnosediameterinsPection
to measure
Usemicrometer of camnose.
diameter
Intakestandardvalue(mm): 39.705- 39.895
Exhauststandardvalue(mm): 39.205- 39.395
Replacecamshaftif diametervaluediffers.
Camshaftoil clearance
. Tightenthe cam bracketto specifiedtorque.
Useinsidemicrometer to measureinsidediameter'
Standard value (mm): 28.000- 28.021
l-)
. Usemicrometer ofcamshaft
diameter
outside
to measure
JOUmal.
Standard value (mm): 27.935- 27.955
ls
Inspectthatthe camshaftoil clearancemeasurement
withinsoecifiedvalue.
Oil clearance= cam bracketinsidediameter-
camshaftjournal (outsidediameter)
'174
EN -
ON-VEHICLEPARTS
R B 2 5 D EE N G I N E
Valveguide clearanceinspection
D i a lg a u g e
. Protrudevalveapproximately15mmfromvalveguidehome : \
intocombustionchamber.Measurevalvedeflectionby
swingingintodirectionparallelto dialgauge.
. Theclearance is equaltohalfofthedialgaugereading
(deflection
width).
Valveguide clearance(mm) Intake: 0.1
Exhaust: 0.1
. Replacevalveor valveguideif clearanceexceedslimit.
Valveguide replacement
. Usevalveguideremoverandtap it fromcombustion
chambersideto removeseal.
Rectify
cylinderheadvalveguideholeusingvalveguide
reamer
Rectifiedvalvestandardvalue(mm)
Intake& exhaust: 6 . 0 0 0- 6 . 0 1 8
Heatcylinder 150-
heatin an oilbathto approximately
160oC.Usea valveguidedriftand pressvalveguidefrom
camshaftside.
. Thepress-fit
dimensions
areshowninfigureonright. 1 6 . 8+ / -0 . 1
Intake/ Exhaust
Reamtheinsideoftheinserted
valveouidewithvalveouide
reamer.
Finishedinternaldiameterstandardvalue(mm)
lntake& exhaust: 1 0 . 1 7 -5' t 0 . 1 9 6
g u i d er e a m e r( K V 1 0 11 1 6 0 0 )
. Whennotusingvalveseatdrift:
5 minutes'
. Usedry rceto coolvalveseatfor approximately
B0 "C
Heatup the cylinderheadto approximately
. Insertcooledvalveseatintocylinderheadquickly.
Caution:
Do notdirectlytouchcooledvalveseatwithhands.
thevalveseatusingvalveseatcutterorvalveseat
. Read.lust .\,=
onnoer.
is as shownin the
Valveseatshapeand measurement
figureson right.
* o D-'-
. op,
t rg-'
,..',.,'
Qa Qo, 6o, 6o, 0D,
.::-. . so.of,o'u so.of,o!,' 32.O 37.0
Urafe ^^ . -0016 ^^ - +0113 37.0
JO.C o Jb. c n o97 32.O
zs.t'.. ,
zs t',.,
E N- 1 7 6
ON-VEHICLE
PARTS
R B 2 5 D EE N G I N E
Valveinspection
Outsidediametermeasurement
. Usemicrometer to measureeachdimension.
Valva a b c d e
lnlake 8 5 . 3- 8 5 . 5 8 0 . 7 8- 8 ' 1 . 0 8 34.OO- 34.02 5 965 - 5.980 1 . 1 5 - 1 . 4 52.60 - 2.90 30.
Exhaust 8 7 . 3- 8 7 . 5 8 2 . 7 8- 8 3 . 0 8 2 9 0 0 - 2 9 0 7 5.960- 5.945 3 . 2- 3 . 4 '15"
Valvespring squarenessinspection
. Placea righfanglestraightedge(L-square)so it contacts
thespring.Turnthe springand measurethe maximum
clearancebetweenupperspringsurfaceandthe right
anglesurfaceto determineout-of-squaredistance.
Limit(mm): 1.8
. Replacethevalvespringif the oulof-squaredistanceis
overthe limit. Contact
Hydraulicvalveliftervisualinspection
. Visuallyinspectcamshaftrotationalareaon liftersideand
lifterborerotationalareafor anywarnor damage.
. Replaceif thereareany abnormality. t . )
Caution:
Do notdisassemblehydraulicvalvelifter.lt is nonseparabte
v
t---.---,-'lJ
un[.
EN- 177
ON-VEHICLEPARTS
R B 2 5 D EE N G I N E
Hydraulicvalvelifterhole internaldiameter
Standardvalue (mm): 3 1 . 0 0-0 3 1 . 0 2 0
lnstallation
. InstallvalveassociatedParts.
. Fordetailedinformation on howto installnewvalveoilseal
"Oilsealreplacement".
referto sectionon
. Installvalvespringwithnarrowpitchendtowardscylinder
head(identificationcolorsidedown).
. Installspringretainer
. Usevalvespringcompressor to installvalvecollet.
. Applya smallcoatingof petroleumjellyto the internal
surfaceof collet.
. Usea magneticscrewdriver.
(1) Uppercolletinstallation
. Attachcolletto lowersideof magneticscrewdriverblade
and installtnthe valvestem.
. Installhydraulic
valvelifter.
. Tapin camshaftknockPin
Knock pin protrusiondistance(mm):
Gamshaftinstallation
. Turncamshaftso No. 1 cylinderis at compressionT.D.C KnockPln Knockpin
E N- 1 7 8
ON-VEHICLE
PARTS
R B 2 5 D EE N G I N E
6 10 14 12
Ffonti
Installcamshaftfrontoilseal. Fordetailinformation
referto
"Oil
seal"section.
. Installtimingbeltbackplate.
. Aligncampulleyto camshaft
knockpinto install.
Tighteningtorque (kg-m): 1 . 4 -1 . 9
E N- 1 7 9
ENGINE
REMOVE& INSTALL
R826DETTENGINE
1 1 R E M O V E& I N S T A L LE N G I N E
[Point 1] Releasefuel Pressure
. Afterstartingengine,removethefuelpumpfuseand run
engineuntilit stops. Consumefuelleftin fuellinesby
crankingthe enginetwo to threetimes.
. Whenit is not possibleto startthe engtne,removethefuel
pumpfuseandconsumefuellefiin fuellinesby cranking
enginefourto fivetimes.
Caution:
The batterymay becomeweakeasily,connectbooster
cablesto chargedbattery.
E N- ' 1 8 1
REMOVE& INSTALLENGINE
/ D E / D E T/ C A I B iE N G I N E
RB2OE
E N- 1 8 2
REMOVE& INSTALL
ENGINE
R B 2 0 D ED t I D E T TE N G ' N L
removerearmemberboltsandrearenqinemountinobolts
andnuts.
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
theRB25DE engine.
. Draincoolingwatercompletely.
. Removebonnet.
fuelpumpfuseandrun
. Afterstaringtheengine,remove
engineuntilitstops.Consurne leftinfuellinebV ffi
fuel
theengineovertwotothreetimes. \Gy
cranking
Caution: START INTERRUPT STOP
The batterymay becomeweakeasily,connectbooster
cablesto chargedbattery.
. Acceleratorwireseparation
. Heaterhose
. Vacuumhosesseparatior
Enginebay upPerside:
. ECCSharnessconnectors
E N- 1 8 4
REMOVE& INSTALL
ENGINE
R525lE ENGINE
Vehiclebody,lower side:
. Engineundercover
. Propellashaft
. Transmission controllever(M/Tvehicle),
linkage(A/Tvehicle) \qt--l.ER)j -
. Exhaustfronttube
^ \r,_r,_"
xear_rnemD:r-Rear
enqinemountrn
. Rearenginemountedbracket bolt(4)4.4- 5.6 UoitiZ;a.+__
s
. Rightandleftenginemountedbracket.
Remove& installengineASSY
. Operatehoistchainandchangeengineanglegradually.
Caremustbe takennotto interferewithvehicleand
removetheengine.
E N- 1 8 5
OVERHAUL
ENGINE
RB26DETTENGINE
12 ENGINEOVERHAUL
Thissectiondescribesthecomponent disassemblyof theengineassemblyremovedfrom
thevehiclewithouttransmission. replacement
theinspection,
lt alsoexplains of
damages
malfunctioning, orwarnpartsandcarryoutanynecessary and
adjustments
sequentialassembly inorderto produce enginecondition'
a standard
CAUTIONS
OVERHAUL
bly
( 1 ) Disassem
. Usecorrectandsuitable toolswhenpossibleandmakesureto carryoutsafe
procedures.
. iare mustbetakenwithoperations on matingsurfaces to
andslidingsurfaces
preventlossof surfaceaccuracY.
. Arrangedisassembled foreasyfaultsdetection
parsby makingmarksto organize
andpreciseassemblY.
. Loosennutsandboltsin a diagonal fromoutside.care mustbetakento
direction
followthenumericalorderwhenindicated
repairandreplacement
(21 lnspection,
partsinspection
. ieplaceor repairaftercompleting theinspection
following
orocedures.Perform sameinspectionforthenewpartsandreplacepartsas
necessary.
(3) Assembly
. Alwaysusea torquewrenchto tightennutsandboltsto specific torque
tightening
. Tightennutsandboltsfromcentreto outsidediagonaldirection, intwoor
gradually
threesuccessivestages.Followthenumeric orderwhenindicated'
. Replace gasket, oilsealsandO-rings
packing, withnewonesin principle'
. Cleanea-hpartthoroughly andblownoffwithcompressed air. Inparticular,
check
thatoilandwaterpassages arenotcloggedor obstructed'
. caremustbetakennotto scratch ordamageslidingormatingsurfacescleanoffall
allslidingsurfacewithanadequate
dust,debrisorforeignobjects.Lubricate
coatingoil.
E N- 1 8 6
ENGINE
OVERHAUL
RB26DETE
TNGINE
12.1 DISASSEMBLE
& ASSEMBLECYLINDERBLOCKASSY
sensorbolt{211.6- 2.1rct
Deronation
t:
G-= Defonation ___-_
sensor
Alternatoradjustmentbar 6<= Rearorlseatlpornt7]
*PffiffiN -A
"t*il;E:{ft;i;;'K)q
iJ:1il,8*,.",,
""€S-f;ffi*
uon roo a\
ir""'"liln "r rn;-=-fi. l-Pn'oa
bolt(2rlPornt
201
\
Flywheel[Point3, 5]
D$,
D$ (.4arr
lt4arroeanngcaplPornt25]6;$p11 Rearplare- Mainbearing
Con
r rod bearrrg
bearrno
IJt tcornt?5]^ ootrp
o'*'*,-ffi F "d;;H
Bort(2)1 6 _
- r\
2jVi (/:,8!*it?-,;::;?, A
Bort(12) E-r\--
/ I Oilpanboltg
9 |[."'lTii *n . 3.2- 4.3
(t\r10)
Fi
l',1 Kg-m u.o4 - u. pt oirpanbo*(M6)/ a-e pan
0.64- 0.85 Copperwain-e€--Orain ptug:.0-a.0gl
A Liquidgasket
fl Ensineoil
$ Replaceafter every disassembly
Additionalwork required:
. Drainand refillcoolingwater[Point1]
. Removeand installthefollowinooarts:
. Engine
. Collector . Startermotor
. Throttlechamber . Clutchcover,clutchdisc
. Intakemanifold . Oilpan,oilstrainer
. Turbocharger,
exhaustmanifold . Waterpump
. Timingbelt . Oil pump
. CylinderheadASSY . Oilcooler,oilstrainer
. Alternator . All harnessesand connectors
E N- 1 8 7
ENGINEOVERHAUL
RB26DETE
TNGINE
Reference:Engineselectionassembly
Piston
(1) Piston
selection
. 3
Lessthan86.010 Lessthan86.020 Lessthan86.030
Greatefthan86.00 Greaterthan86.010 Greaterthan86.020
0 . 0 3 5- 0 . 0 5 5
Pistonand pistonPin 1,OOS
STD 1. STD2, STD3, O.5OS,
ServicesettingParts:
Pistongrade
(No.1 - No.
Distinction
symbol
Prslonprngrade(0 1)
Mainbearing
(2) Mainbearingselection
'
, . , , 3
l , , ' : ' . . ' . ' ' .
Servicesetti S T D O - 6 us 0.25
) No. i
EoregradeNo. ff;:113,,".",ifl' te! side--,-\'\l
Iru -5-
*383".\\
r'l-lili: No 5
{,rl\
E N- 1 8 8
ENGINE
OVERHAUL
R826DETT
ENGINE
Pistonpin
(3) Pistonpinselection
(mm) 2 1 0 0 6- 2 1 . 0 0 0 2 1 . 0 1 2- 2 1. 0 0 6
2 0 . 9 9 5- 2 0 . 9 8 9 21.0A1- 20.995
0 . 0 0 5- 0 . 0 1 7
Servicesettingparts: Pistonandpistonpin S T D1 .S T D2 , S T D3 . 0 . 5 0 51. . O O S
Ffontmark
Prngrade
(0.1)
CylinderNo.
( 1- 6 )
Distinction
Largeend grade(0.1) symbol ( 1- 3 )
Con'rod bearing
(4)Con'rodbearingselection
Lass tfian 51.013
Greaaer than 51.007
No.1 - No.6from
E N- 1 8 9
OVERHAUL
ENGINE
RB26DETTENGINE
B o l t ( 64)- 5
0x151=25
[Point 3] FlYwheelrun-out
. Setdialgaugeto flywheelwhereit contactsclutch'
. Turntheflywheelandmeasuretherun-out.
Run-outlimit (mm): 0.10
((6)
. Coatthe threadandflangeof boltswithengineoil after ra.s-)s6--\"\
the
installing bolts.
. aftertighteningthe flywheelbolts,use ringgearstopperto
secureflywheelandtightenbolts. 't4.5-15.5
Flywheelbolt tighteningtorque (kg-m):
Flywheel
E N- 1 9 0
ENGINE
OVERHAUL
RB26DETE
TNGINE
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.
. Aligntherearoilsealretainer
withdowelpinto install.
. Tighten6 boltsuniformly.
Rearoil sealretainerbolttighteningtorque(kg-m):
0.64- 0.85
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
lnstallation
. Setthe crankpin at B.D.C(Bottomdeadcenter)position.
. Coatcylinderbore,crankpinandpistonwithengineoil'
. Assemblepistonwithfrontmarkon pistonheadfacingthe
frontof engine.
. Usea pistonringcompressorto installthe pistonandthe
con'rodassemblyin cylinderblock.
Caution:
Care must be taken not to strikeor deformoil jet pipe with
largeend of connectingrodwheninstalling.
Gon'rodnut tightening
. Applyengineoil to con'rodandthe nutsbeforeassembly.
. Tightennutsin two or threestages.
'' .6
1st time Torquewrench (kg-m): 1.4-
2nd time Angle wrench ( " ): 60 - 65
Caution:
Do notvisuallymeasurethetighteningtorqueif anglewrench
is not available.
E N- 1 9 2
ENGINE
OVERHAUL
RB26DETE
TNGINE
Topnng openrng
. Positionthe pistonringsas shownin thefigureon right
to install.
;",;*);^3i
-"
{/z--Yrr
Caution: Y aln
..\ \./
Caremustbe takennotto scratchpiston.
^ /
)s<-.-
Decononno ooentn0
OiI nno lower
- ra opentnq
E N- ' 1 9 3
ENGINEOVERHAUL
RB26DETTENGINE
[Point16] PistoninsPection
. Usemicrometer outsidepistonskirtdiameter'
to measure
Measuring from bottom(mm): 13
pointDistance
Standard(mm): 85.955- 85.985
Useinsidemicrometerto measureinsidediameterof
pistonpinhole.
value(mm):
Standard 20.987- 20.999
Fivetypesof pistonsareavailablefor service(STD1, STD
1.oos).
2.STD3,o.sos,
Smallend insidediameterinspection
Standardvalue (mm): 21.000- 21.0'12
E N- 1 9 4
ENGINE
OVERHAUL
R826DETT
ENG]NE
Gon'rodbearinginteriordiameterinspection
. Installcon'rodbearingin con'rodandcap. Tightencon'rod
nutsto specifiedtorqueand measurecon'rodbearing
interiordiameter,
E
lPoint21] Piston ring end gap and side clearance
Ring end gap inspection
. Usea pistonto pressthe pistonringintothe middleof the
cylinder
andmeasure thegap.
Item Top dng S.cond ing
B o r eg r a d e1 , 2 , 3 :
0 . 2 4- 0 . 3 4
0.42- 0.57 0.20- 0.60
Side clearanceinspection
. Measurethe clearancebetweenthe oistonrinoandthe
pistonringgroove.
E N- 1 9 5
ENGINE
OVERHAUL
RB26DETE
TNGINE
Pilot bearing
sr1661 0000
lnstallation
. Thepilotbushinginstallation
position
is as shownin the
figureon right.
[Point26] Mainbearinginspection
. The bearingendshouldprotrudewhenInstalledin main
bearingcapor cylinder
block
Thisprotrusionis calledthe crushheight.
[Point27] Crankshaftinspection
Out-of-round
andtaperinspection
Usemicrometer to measureeachjournal(No 1 - 7) and
eachpin (No.1 - 6) in fourlocationsshownin thefigureon
right.
Theoufof-roundvalueis thedifference of the dimensions
in directions
A andB.
Thetapervalueis the differenceof thedimensions
measured at points1 and2.
Out-of-roundand taper limit (mm): 0.005
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
E N- 1 9 7
ENGINEOVERHAUL
R826DETT
ENGINE
2 n dt i m e Anglewrench(") 60-65
. Removecon'rodcapandbeanngandmeasureplastigauge
widthwitha plastigaugescale.
Caution:
Neverturnthe crankshaft or connecting rodwhileplastigauge
is beinginserted.
lf oil clearanceexceedsthe limitvalue,referto [Point29] and
selectthe appropriatebearing.
Con'rod bearingselectionchart
Lessthan51.@7
Grsbr tlan 51.000
o a .
E N- 1 9 8
ENGINE
OVERHAUL
RB26DETE
TNGINE
Size o i / il)
4,
\
us0.08 1 . 5 4 11 1 . 5 4 9 8 ,--nX','
us0.12 1 . 5 6 /11 . 5 6 9 12 \ t
\ \,H-l
t /
us0.25 1 . 6 2 6t 1 . 6 3 4 25
Caution:
Caremustbe takennotto scratchfilletrollwhenthe crankpin
is beinggroundedto use undersizebearing.
Using plasticgauge(MethodB)
. Removealldustandoilfromeachcrankshaft journaland
bearingsurfaces.
. Cut a pieceof plastigauge slightlyshorterthanthe
bearing gauge width. Placea plastigauge on crankshaft
in directionof axis,caremustbe takennotto placeon oil
note.
. Assemblethe mainbearingand bearingcap and tighten
cap boltsto the specifiedtorque.
Bearingcap bolt tighteningtorque (kg-m): 4.7 - 5.3
. Removebearingcap andthe bearing.Measure
plastigauge widthon plastigauge scale.
Caution:
Do notturncrankshaft whileplastigauge is beinginserted
lf excessivebearingclearancestillexists,use a thickermain
bearingor undersizedbearingso that the specifiedbearing
clearanceis obtainedwhenmeasuredbygethod A as well.
SENSORSYSTEIV
INSPECTION
R826DETT
ENGINE
6.6 ENGINETEMPERATURESENSORSYSTEMINSPECTION
CONTROLCIBCUITDIAGRAMR826DETTENGINE
Engrne
iemperature
sensor m
2 8 O
a
" " o gnrtion
limingconlro
f
q
E dle speed control
= Se f-dLagnosis
I .SELFDIAGNOSTIC FESULTS'
'!: (codeNo.13)
Sel-dagnosis
Nonnal Abnorrna
Abnormal
i Enginetempdisplay
.8 3V when cold @
1V atler warrnnq up Olher
r
lnspectothe r
Measurethe voltagebetween
terminal28 and 30.
Engine
temperature
sensor
SVSIEMS
sensor
Harnesscontinuityinspection Inspect ECCSC/U power
l
[,4easurethe resistancebetween supplyand ground
the followingterminals:
Enginetemp ECCSC/U
sen narness narness
0a c o A
E N- 3 8 1
SENSORSYSTEMINSPECTION
/ D E / D E TE N G I N E
RB2OE
6-6 ENGINETEMPERATURESENSORSYSTEMINSPECTION
CONTROLCIRCUITDIAGRAMRB2OE/ DE / DET ENGINE
conlrol
Fue injectlon
sensot
Engineternperature m
c)
t-*---fr
-----1'
5128)
8 (30)
o
a
8
-
o
C ldlespeedconlrol
=.
i,
Abnormal
Enrinetempse{tsorinputsignalinspection
E-'DATAMONITOB"
.€. N.4easure
the voltage between termlnal l
and qround.
tempdisplaY
@
E Engrne
,S 3V whencolo
-
uP
]V atterwarminq Other
6.6 ENGINETEMPERATURESENSORSYSTEMINSPECTION
CONTBOLCIRCUITDIAGRAMCA18iENGINE
Engrnetemperature
sensor
r---5f-*----+rt
t - T l
m
o
o
a
o gnilionI mingconlrol
l
q
c
-
. Se f-diagnosis
.I."SELFDIAGNOSTIC BFSULTS"
1& Self-dagnosis(codeNo. '13)
Nomai
" D A I AM O N I T O R "
t I
(Realtinrediagnosrs)
| Enginetemp sensoroutput
ffi--J---rono, mal signalinspeclion
.f,.DAIAN,4ONITOR'
:8 l\,4easure
the voltagebetween
termrnal1 and 2. fr
E Engrnelempdispiay
;'e3 V w h e nc o i d
1V atterwarrnrngup Olher
0{l cosl
EN - 383
INSPECTION
SENSORSYSTEI\,4
R826DETTENGINE
gassensor
Exhaust Air luel ratro
r__-.0_ control
It 2 lll
-rH r;-T'
1
+----T-+ r *
gassensor(tronl)
Exhaust
eallr t
+ t
N o .1 2 , 3 c y l 29
ECCSC/Uterminal
No.4. 5, 6 cyl O- sensor(rear) ECCS C/U terminal55
EN - 386
SENSORSYSTEMINSPECTION
R826DETT
ENGINE
Exhaustgas sensorsystemtroublediagnosisflowchartRB26DETT
engine
Air-fuelratioteedback
function
inspection
'F,'DATA
t40NtTOF'
i$ Exhaust gassensoroutput
monrtor.
Normal Abnorrnal
Abnormal
.-F.
Exhaustgassensorinput t1t2l
signalinspection lTI4l
lvleasure the voltagebetween (o,sensor( F ) )
1. (O"sensor(F))
2 . O . s e n s o(rR )
belween0 - 1V
DeUectron ( O s e n s o rt R ) )
Other
Baltery ,Joliaqervhen
gn 1on swrtchrs ON Oti'er
Harnesscontinuityinspection InspectECCSC/
Measurethe resistancebetween U p o w e rs u p p l y
the followingterminals: or replaceC/U
O, sensor ECCSC/U
narness narness .E;r .
Or sensor(R)2
O, sensor(F)1
55
29 (O-,sensor
@uff
(O,sensor
Other (R)) (F))
Repairharness
the resstancebetween
l o w r n gt e r m i n a l s :
O sensor(B) 1 - 3
O . s e n s o {r F )2 - 3
Battery vo iage when
gnrlronswrlch
RepairO, sensorgroundcircuit
EN - 387
SENSORSYSTEMINSPECTION
R826DETTENGINE
Exhaustgas sensorlunction
Exhaustgastemperature warninglampmustflash5 times
whenengineis runningat
or morein 1Osecondsinterval
approx.2,000 rpm.
Feedbackf unction
warninglampmustflas
Exhaustgastemperature
whenenginespeedis runningat approx2'000
periodically
EN - 388
SENSORSYSTEMINSPECTION
/ D E / D E TE N G I N E
RB2OE
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
ECCSCrupowersupplyinspection
ECCSC/U conneclorsfor faulty .E DATA[/ONTTOF"
contactor detects. t' Disconnect
Or sensorconnector
andmeasurevoltage
between
ECCSC/U termrnai27 (49)and
Baftery voltage when
rgnrlron
swrtchs ON
Harnesscontinuityinspection InspectECCSC/
Measurethe resistancebelween U powersupply
the followingtermlnals: or replaceC/U
O, sensor ECCSC/U
harness harness
RB2OE 1 6 /-rt-\
(!I?I]J
RB2ODE/DET1 29 (RB2oDE/
0a DEr)
RB20DE/DET
Repairharness
Checkfor laulty connections
or replaceexhaustgas sensor
Batlery voltage
rgnilron
swilch
RepairO, sensorgroundcircutt
EN - 391
SENSORSYSTEMINSPECTION
C A 1 8 iE N G I N E
Exhauslgas sensor m
o
r---H
'=
o
a
a
J
T
o
c
:
Engine
Exhaustgas sensor systemtrouble diagnosisf lowchartCA18i
. Setldiagnosis
l, "sELF-DtAGNoslsFESULTS"
€ Self-diagnosis(codeNo.15)
Abnormal
Abnormal
HarnesscontinuitYinsPection lnspectECcSC/
the resistancebetween
l\,4easure U powersupply
02 sensorharnesstermlnal1 and or replaceC/U
ECCS C/U harnessterminal6
0 {il
Repairharness
Checktor taulty conneclionsor
replaceexhaust gas sensor
EN - 392
SENSORSYSTEMINSPECTION
RB2OE
/ D E/ D E T / C A 1 8 E N G I N E
RECORD
Ou UP OWN od
. Usingdiagnosis connector on thevehicleside
(nearfuseblock),setCONSULTto'EXHAUST GAS
SENSORMONlTOR" andcheckthefuelinrection
condrtionby flashingof exhaustgas temperature
warning
tampon rnstrument panel.
(2) Inputsignatinspection
. Measurethe voltagebetweenthefollowingterminalswith
ECCScontrolunitharnessconnected.
E--r-^
RB2OE/CAt8iI nemoelo
{|l'snl
kitt:i::,rir:
BetweenECCS C/U BetweenECCS C/U
terminai1 and ground termrnal29 and ground
:-ri.i.: ,.
EN - 39s
SENSORSYSTEI\,4
INSPECTION
B B 2 6 D E Ti TF B 2 O ED
i E/DET/CAl8E
] NGINE
6-9 VEHICLESPEEDSENSORSYSTEMINSPECTION
CONTROLCIRCUITDIAGRAM
RB26DETTENGINE
c
l
m
o
o
a ldlespeedcontrol
o
-
t1 O
i53) c
l
()RB2ODE/DET
C A 1 8 iE N G I N E
EN - 397
SENSORSYSTEMINSPECTION
:.:.:E'-T / D E / D E T/ C A I B iE N G I N E
RB2OE
c
When drive wheelsare rotating Vehiclespeed is disPlayed
. Measure
thevoltagebetween terminats@
thefollowing
connected.
unitconnectors
withECCScontrol
terminalsA
. Measurethevoltagebetweenthefollowing
with ECCScontrolunitharnessconnected. \@i
RB26DETT/ RB2O
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
(46)
( ) RB2ODE/DETiRB26DETT
cA18i
(1) Inputsignalinspection
. In "DATAMONITOR'mode,pedormtheairconditione I
@
switchoperation to checkil theairconditioner
switch A/C switch
signalis inputcorrectly.
6 - 12 NEUTRALSWITCHSIGNALINSPECTION
(1) Inputsignalinspection
. In "DATAMONITOR"mode,performshiftlever
operation
to checkif neutralswitchsignalis @
. ^lSililJtiS'Y;rtase
between
therorowins
terminars
@
andgroundwithECCScontrolunitharnessconnected.
I RB26DETTiRB2ODEiDET
EN - 399
SENSORSYSTEMINSPECTION
R B 2 6 D E T/T C A 1 8 ]E N G I N E
6-13 POWERSTEERINGSWITCHSIGNAL -
INSPECTION po*"r'"t"",,nq
(1) Input signal inspection swtch-
fe (ls)
.|n.,DATAMoN|ToR"mode,performpoWerSteering\g/ ECCS
operationtocheckif powersteering switch i =
oilpressure control
unit
signalisrnPut
correctly.
. Measure thevoltagebetween terminals
thefollowing @1
withECCScontrol unitharness connected. 9 r ,BB26DErr
cA18i
6-14 LIGHTSWlrcH SIGNALINSPECTION
(1) input signal insPection @
"DATA Lrghtswitch
. ln MONITOR'mode,performlightswitchoperation lcr_ ---6zd--{qs I
lo checkif lightswitchsignalis inputcorrectly' /t I
. MeasurethJvoltagebetweenthefollowlng terminals /l EccsI
@ / I control
I
withECCScontrolunitharnessconnected. ,1. I unit I
t -
EN - 400
R825DEDIAGNOSIS
R 8 2 5 D EE N G I N E
1 . POWERSUPPLY& GROUNDCIRCUTT
DIAGNOSIS
#21
2.1--
Components location
EN - 401
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
START A
NG ol
ground
Inspect D.
circutt
OK
STABT
FINISH
A A
PowersuPPIYinsPection
switch
Placeignition to ONposition. f,
-BATTERY
1S battery
Inspect voltageusing OK
\@ VOLTAGE"in DATAMoNlToB mode.
rar Usetesterto measurethe voltagebetween
..1,r'ECCSC/U terminal49. 50 and ground.
D
NU
GroundcircuitinsPection
Placeignitionswitchin OFF E
position.Disconnect ECCSC/U Fle m
harnessconnector.
Checkfor harnesscontinuitybetween t !
E C C SC / Ut e r m i n a1l ,0 , 2 0 ,1 0 7 '1 0 8
a n d1 1 6a n dg r o u n d . I
lF NG: Repairharnessandconnectors
FINISH c
B
ECCS C/U terminal and ECCS relay harness
, |!l3i---\
Eer
continuityinsPection
Placeignitionswitchin OFFposition. I
NG M
DisconnectECCSC/U and ECCSrela't harnesr qa-.'- ei--.'
connector.
i
'U al
lnspectfor continuitybetweenECCSC, termin I
49, 59 and ECCSrelaYterminal3.
I Rpneirharnesso r connecto.lc
OK
E
Outputsignalcircuit inspection
Checkthecontinuation betweenECCSC/U N G
terminal'16andterminal1.
OK
Inspectthefollowing:
lgnitioncoilharnessconnector.
HarnessbetweenECCSC/U and
ECCSrelay.
lF NG: Repairharnessor connector.
RepairECCSrelay
Verifrcation
inspection
Restart
theengine
Doestheenoinestart?
Groundcircurt
inspection Checkforanydamageon the
ECCSC/Uterminals
and
ECCSC/Uconnector.
EN - 403
R825DEDIAGNOSIS
B B 2 5 D EE N G I N E
2 - CRANKANGLESENSOR(CODENO' 11 IN SELF.DIAGNOSIS)
DIAGNOSIS
16
m
o
a
o
- c i
c i
5)
Components location
" anglesensor
_CJAnk
EN - 404
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
START
Carryoutself-diagnosis
NG OK
To diagnosis
14
A
Powersupplyinspection
Placeignitionswitchto OFFposition.
Disconnectcrankanglesensorharness
connectors. NG
Placeignition
switchto ON position.
Usetesterto measurethevoltaqebetween € @
3 andqround.
terminal c/u
OK Inspectthe following:
Checkthecontinuitybetweencrank
42 52 and 2
anglesensorterminal3 and ECCS 5 l a n dI
relayterminal3.
lF NG: Repairharnessor connectors.
B
Inputsignalcircuitinspection
Placeignitronswitchto OFFposition.
Disconnect ECCSC/Uharnessconnectors.
Checkthecontinuitybetweencrankanglesensor NG
terminal2 and ECCSC/Uterminat 42,52 (1"signal),
betweencrankanglesensorterminal1 andECCS
C/Uterminal41, 5 1 (120"signal).
OK Repairharnessor connector
c
Inputsignal inspection
ConnectcrankanglesensorandECCSCiU Xg:Q@
harnessconnectors.
,S Use"CRANKANGLESEN RPM'in 'DATA
\G/ MoNlToR"to measure
enqrnesoeed.
/fl) Measure
thevoltagebetweenECCSC/U
v termin4 a2l . 5 2 . 5 1a n dg r o u n d .
NG
Verificatroninspection
Erasememoryfromself-diagnosis
Checkforanydamageonthe
byself-diagnosis
Recheck ECCSC/Uterminalsand
ECCSC/U connector.
EN - 406
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
€
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.
Disconnectairflowmeterharness
connectors.
Placeignitionswitchto ON position. %ei@
Usetesterto measurethe voltage
betweenterminal 3 andground.
Ele,@
Groundcircuitinspection
switchto OFFposition.
Placeignition
DisconnectECCSC/Uharness connectors'
Checkthecontinuitybetween 4 andECCS
terminal
C/Uterminal26.
Repairharnessor connector
Inputsignal insPection
Checkthe continuitybetweenairflowmeter
terminal2 andECCSC/Uterminal27 (intake
airquantitysignal).
Bepairharnessor connector
EN - 408
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
D
Inputsignal inspection rroRrNq\iroFAtL
Connectcrankarrflow meterand ECCSC/U
cAs.RPM(REF) 662rpm
harnessconnectors. AIRFLOWMTR 1.02V
r€\ Use 'AlBFLOWMETERin DATA ENGTE[,4P
EXHSEN
SEN 81,
O.1BV
\g/ MONITORtomeasureinoutsional. THROTTLESEN O.4OV
INJPULSE s.omsec
,S Measure^the voltagebelweenECCSC/U
:. Iermlnat
z/ andoround.
NG
Approx.0.3V
A p p r o x1 V
' ' ldlirq ''1'. A p p r o x1.. l V ctv
Verificationinspection
Erasememoryf romself-diagnosis
Checkforanydamageon the
Recheckby self-diagnosis ECCSC/Uterminals
and
ECCSC/Uconnector.
EN - 409
RB25DEDIAGNOSIS
B 8 2 5 D EE N G I N E
EnginetemPerature Fuelinjectionconlrol
sensor m
a o
o
o timrngcontrol
lgnrlion
! o
;
-;
Componentslocation
'
. 1 Enginelemp sen trr'l
5\- ^^nn6^t^r \'
A
Ke@
Power supply insPection
Placeignitionswitchto OFFposition.
Disconnectenginetemperature sensor
harnessconnector.
Placeignitionswitchto ON position.
Usetesterto measurethe voltage
betweenterminal1 andground.
r harnessor connector
E N- 4 1 0
R825DEDIAGNOSIS
F 8 2 ' D EE N G I N E
B
Groundcircuitinspection
Placeignitionswitchin OFFposition.
Checkcontinuitybetween terminal
2 andground.
OK
c Repair
harness
orconnector
Inputsignal inspection
1S1 Use"ENGTEMPSENSOR Tn DATA
: MONITOB"
to checkenainecoolant
NG
Iemperalure.
(g) Cnect the voltagebetweenECCSC/U
-
terminal28 andoround.
Voltage: Whenigniiionswitchis ON
EngtempApprox.20oC 3V
Approx.80"C 1V
OK
Componentparts inspection
(Enginetemperature
sensod
Refertothesection
onenginetemperature
sensorforinspection.
lF NG:Replace
crank
anglesensor.
VerificationInspection
Erasememoryfromself-diagnosis
Checkforanydamageon the
Recheckby self-diagnosis ECCSC/Uterminals
and
ECCSC/Uconnector.
FINISH
E N- 4 1 1
DIAGNOSIS
RB25DE
R B 2 5 D EE N G I N E
DIAGNOSIS5 -IGNITIONSYSTEMINSPECTION
(coDE NO.21 lN SELF-DIAGNOSIS)
FIL6
fi
o
ql 3
ECCSrelay
,-,tilf
st9-9f 3
'
-Ful
Components location
-l
i",::'"u
E N- 4 1 2
RB25DEDIAGNOSIS
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
Circuitf unctioninspection
Inspectusing"POWER BALANCE"
'FUNCTION TESI-'mode.
in
@ ()POWER BALANCEl)
Checkto ifengine revwilldecrease ntary
mome INSPECTTHEBALANCE
OF EACHCYLINDERBY
STOPPINGINJECTOR
OPERATIONFOREACH
CYLINDEF,
Groundcircuitinspection
Placeignition
switchin OFFposition. FASSI
Disconnectpowertransistorunitharnessconnector.
Checkfor harnesscontinuitybetweenterminalE and
B
grouno.
E err
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
RB25DEDIAGNOSIS
RB25DEENGINE
VerificationinsPection
Erasememoryfromself-diagnosis
Checkforanydamageon the
Recheckby self-diagnosis ECCSC/Uterminalsand
ECCSC/U connector.
E N- 4 1 4
R825DEDIAGNOSIS
RB2sDE NGINE
m
2 9 O
U'
1 5 ( '
Components location
START
Oarryoutselfdiagnosis AIR,FUEL
RAIIo TESTl
NG HOLDTHE ENGINE
SPEEDAT
OK 2000+l200rpmAND
PBESS
FINISH START
A
Function inspection 1
Warmuotheenoine.
"BASEAIR-FUEL
( l)lnspect using RAT|O"in
: "FUNCTION
TEST mode.
NG OK
To B FINISH
E N- 4 1 5
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
Functioninspection2
Starttheengine.
Holdthe engineat 2000rpmand inspect
"O, "O
using SENSOR"(outputvoltageand
"DATA
SENSORMONITOR'(lean, rich)in
MONlTOR"mode.
Measurethe voltagebetweenECCSCiU START
terminal29 and ground.
Approx.0.3V(constantvoltage) NG
-
Aoorox.over0-6 1V (variant
voltage)OK
X e- 11:
Fcctc^i"""*".-i
InputsignalcircuitinsPection I iin
switch
PIaceignition to OFFposition. t-; j.----.---
DisconnectO,sensorharnessconnectorandECCS -I
C/Uharness connector.
betweenECCSC/Uterminal
Checkcontinuity 29
2.
terminal
andO-sensorharnessconnector
Elee
Repairharnessor conneclor
ReplaceO, sensor
VenficationinsPectlon
Erasememoryf romself-diagnosis
E N- 4 1 6
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
DIAGNOSIS 7 - DETONATIONSENSOR
(coDE NO.15 tN SELF-D|AGNOS|S)
tl]
Components location
E N- 4 1 7
RB25DEDIAGNOSIS
RB2sDE NGINE
c/u
lnput signalcircuitinsPection1
Placeignitionswitchto OFFposition.
DisconnectECCSC/U harnessconnectorand
sub harnessconnector.
terminal1 and
Checkthe continuitybetvveen
ECCSC/Uterminal23, terminal2 and ECCSC/
U terminal24.
O K Repairharnessor connector
Inputsignalcircuitinspection2
Disconnect connectors
harness frontand NG
connected
sensor.
rearof thedetonation
Check subharness
between
thecontinuity terminalA
and23. B and24.
OK Repairharnessor connector
Replacedetonatlonsensor
Erasememoryf romself-diagnosis
Checkforanydamageon the
Recheckby self-diagnosis and
ECCSC/Uterminals
ECCSC/Uconnector.
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
8 - THROTTLESENSOR(CODENO.43 tN SELF-D|AGNOSIS)
DIAGNOS|S
m :uel injectionconko
Throtliesensor o
'1 o
za o
38 fuC cutcontrol
3 s =
=
Componentslocation
'ECCS
c o r t r o .L n , t I
START
Oarryoutselfdiagnosis
OK
I rrRorrLeselrsonl
NG
A FINISH PFESSSTAFTWHILE
PRESSING
THE
System inspection ACCELERATOB
PEDAL
Placeignitionswitchto ON position. FULLY
USe"THROTTLE SENSOR'in"DATA
MONITOR"to inspectthesystem. OK
Voltage:
Fullyopen Approx.4.0V
Fullyclosed Approx.0.6V
Open/ Closerange overApprox.3.0
NG
FINISH
TOB
E N- 4 1 9
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
B
*vortrontr* ro retr
Power supply insPection
: Ptace
ffi ignitionswitchto ON position. NG
Use -THROTTLE SENSOB"in DATA (BEF)
CAS.RPN,,I orprn
THROTTLESEN 3,94V
MONITOR'toinspeP!-
19 etaceignitionswitchto OFF posilion.
vDisconnectthrotllesensorharnessconnector.
Measurethevoltagebetweenterminal1 and
:APProIjll--
voltage
ground.Battery
r-_-._.--
U
OK Repairharnessor connector
| ,,_. Ee .@,
InputsignalcircuitinsPection
ECCSC/Uharness
Disconnect connector.NG
Checkthecontinuity ECCSC/U
between
38andterminal
terminal 2.
l
Repairharnessor connector
OK
Verificationinspection
Erasememoryfrom self-diagnosis
EN - 420
)
RB25DEDIAGNOSIS
R 8 2 5 D EE N G I N E
9 - A / T CONTROL
D|AGNOS|S (CODENO.s4 tNSELF-DIAGNOSIS)
-
L---i
Componentslocation
..'''.:
,:..]
START
OK
Carryoutselfdiagnosis
NG G )@ i5 j
lA/Tcti connecta
A FINISH
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
EN - 421
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
FiL6
Crank angle sensor
Componentslocation
ECCScontrolunlt
EN - 422
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
START
A A
Groundcircuitinspection
Placeignition
switch
to OFFposition.
Xea
Disconnectcrankanglesensor
harnessNG
connector.
Checkforcontinuity
betweenterminal
4
andenginegroundharness.
OK
Repairharness
or
conneclor
Verification
inspection
Checkforanydamageon the
Groundcircuitinspection ECCSC/Uterminals
and
ECCSC/Uconnector.
EN - 423
RB25DEDIAGNOSIS
B B 2 5 D EE N G I N E
F/16
ECCSrelay
r+/rtnt 2
!!III
Fdf4r{-d) tElttll_lttlj
Componentslocation
Power tranststorunil
EN - 424
RB25DEDIAGNOSIS
R B 2 5 D EE N G ] N E
OPOWERBALANCEO
INSPECTTHEBATANCE
Whole system inspection O F E A C HC Y L I N D E R
BY
Startthe engtne. STOPPING INJECTOR
OPERATION FOREACH
ls allcylinder
ignited? CYLINDER.
TURNOFFA/C& LIGHTS
To ignitionsignal2
Circuitf unctioninspection
Inspectusing"POWERBALANCE" in
"FUNCTION
TEST"mode.OR power
E ACTIVE
TEST
balancein "ACTIVE TEST". OK POWER BALANCE
Checkto if enginerevwilldecreasemomentary. t\40N
tToR
cAS.RPr\r(POS)
AIRFLOWI\,4ETER
Inspectthefollowing:
lgnitionrelay
lgnitionswitch
Continuitybetvveeneachcoil c
Harnessterminal 2 andignition
relavterminal5. @ 5,t,5
Ground circuit inspection
Placeignitionswitchin OFFposition.
Checkfor harnesscontinuitybetweeneachcoil
3 andqround.
terminal
OK Repair
harness
orconnector
D
Outputsignalcircuitinspection
Disconnect powerlransislorunit harnessconnector. iXe,@
Inspectforcontinuity
betweenthefollowingterminals:
Betweeneachrgnition coilterminal1 and
Powertransistorunitterminal1
Powertransistorunitterminal2
Powertransistorunitterminal3
Powertransistorunitterminal4
Powertransislorunitterminal5
Powertransistorunitterminal6
Repairharnessor connector
EN - 425
RB25DEDIAGNOSIS
RB2sDE NGINE
Components insPection
(Powertransition coil)
unit& lgnition
Referto power transitionunitand coil
ignition
inspeclionin components inspection section.
faultyparts
Replace
VerificationinsPection
RecheckECCSC/Uterminalfor
ComponentsinsPection damageandcheckECCSC/U
harnessconnectorconnection.
EN - 426
r 5
R825DEDIAGNOSIS
R B 2 5 D EE N G I N E
11- IGNITION
DIAGNOSIS SIGNAL2
Continuefrom ignitionsignal1
E
Power supply inspection
Placeignitionswitchin OFFposition.
Disconnectignitioncoil relayconnector.
Placeignitionswitchto ON position. NG
UseCONSULT or testerto measurethe
voltagebetweencoilterminal 2,3 andground.
Power voltage: Battery voltage
OK
Inspectthefollowing:
Continuationbetween fusiblelink,
ignition
coilrelayandignition switch.
Il ee;@
Continuationbetweenignition coil
relayandthe battery.
F
Groundcircuit inspection
PIaceignitionswitchto OFFposition. NG
Inspectharnesscontinuation
betweeneachcoil
terminal2 and5.
OK Repair
harness
and/ orconnector
G
ECCSC/U
Outputsignalcircuit inspection
DisconnectECCSrelay. NG
Inspectthe continuation
betweenECCSC/U
terminal16 and ECCSrelavterminal2.
OK Inspectthefollowing:
Fusiblelink.
Continuatron betweenECCSC/Uand
ECCSrelayharness.
Continuation betweenECCSC/U and
ignition
coilrelayharness.
lF NG: Repairharnessandconnector.
Components inspection
(lgnition
coil& ECCSrelay) NG
Referto ignitioncoiland ECCSrelayinspection
In componentsinspectjonsection.
OK Replacefaultycomponents
InspectECCSC/Uterminal for anydamage
and ECCSC/U connectorfor connection.
EN - 427
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
DIAGNOSIS12 - INJECTORSYSTEMINSPECTION
3 Giil
€ m
o :EiutttlS
-_l;la
Ftrl*".,
4 i i No-
o
ECCSrelav
-t-----1
l/!!r.t
1'-o o-+
L)-IJJ
l.l.l q @ N o .1
L
@ No.2
location
Components
ECCScontrolunrt
EN - 428
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
START
A tFowrR elLANtcEl
Circuit f unction inspection
Inspectby "POWERBALANCEin
/G\ "rurucrroN
INSPECTTHEBALANCE
OF EACHCYLINDERBY
fJ TEST'
mooe. STOPPINGTHE
Operate"POWER BALANCE" in INJECTORDRIVE
FOR
CONSULTactive test. EACHCYLINDER.
ffi Makesuretheinjector
operation
noise
\O/ rsaudible.
NG OK
FINISH
B
Power supply inspection 1
Placeignition
switchto OFF. ierreE
Disconnectsub harnessconnector.
Checkthe batteryvoltagebetweenterminal
3 andgroundusingCONSULT or tester.
NG
Inspectthefollowing:
Harnessconnector.
Continuity
betweensub harness
connectorandthe harness.
lF NG: Repairharnessandconnector
c
Power supply inspection 2
Placeignitionswitchto OFFposition.
Disconnectsub harnessconnector.
Inspectbetweenthefollowingterminals
forcontinuity:
betweenterminal3 and 5
betweenterminal3 and 6
H
belweenterminal3 and4 No.1
OK NG
No.2
D No.3
No.4
Disconnectinjectorharnessconnector. No.5
Inspectbetweenthefollowingterminals No.6
forcontinuity:
betweenterminal109andNo. 1,2, 3,
4,5&6cylinders.
To
EN - 429
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
E
Out put circuit insPection
DisconnectECCSC/U harnessconnector. e:@9[
Inspectbetweenthefollowingterminalsfor con
continuitY:
betweenterminal10.1andNo. 1 cylinder
betweenterminal105andNo.2 cylinder
betweenterminal103andNo.3 cylinder
betweenterminal112andNo.4 cylinder
betweenterminal110andNo.5 cylinder
betweenterminal114andNo.6 cylinder
NG
Flepairharnessor
OK connector.
ComponentPartsinsPection
(lnjector)
forinspection'
oninjector
Refertotheseclion
NG
Replaceinjector.
ECCSC/Uterminals
Inspect foranY
damageandmakesurethe connectors
correctlY.
areconnected
VerificationinsPection
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
NG
FINISH
Vehiclespeedsensorfunctioninspection N G
Inspect
vehiclespeedmeterfunction
OK
Vehiclespeedsensorand
vehiclespeedsensorcircuit
TOB inspection.
EN - 431
RB25DEDIAGNOSIS
RB25DEENGINE
B fS,tortrontufrNornlr
InputsignalinsPection NG
(POS)
CAS.RPI\, 787r7m
Startthe engine.
Rotatedriveaxles]ew]y-
/a\ b-eieiltehicbspeedusingVEHICLE
u i'LQ4IA-NIONIIOB-
speeoSENSOR"
,o' thevoltagebetween
Usetesterto measure
W EccS C/Uterminal 53andground.
-
0 5V -----
Voltage:aPProx.
OK
Inspectthe following: c/u
CheckthecontinuitybetweenECCS
C/U andcombination meterharness.
lF NG:Repairorf9ple99i9M9!'--
InspectECCSCiUterminals forany
damageandmakesurethe connectors
areconnectedcorrectly.
VerificationinsPection
Checkfor anYdamageon tne
insPection
circuit
Ground ECCSCiUterminalsand
ECCSC/U connector.
EN - .132
R825DEDIAGNOSIS
R B 2 5 D EE N G I N E
14 -AIR CONDITIONER
DIAGNOSIS RELAYSIGNAL
IGNreiay1 To FrCDrela,i
Duai pressute
AC rear sw
m
ACC reiay o
o
ACC key SW a
o
)-
q
Components location
controtunrt
Inputsignal inspection
Placeignitionswitchto 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.
Checkforanydamageon the
Groundcircuitinspection ECCSC/Uterminals
and
ECCSC/Uconnector.
EN - 433
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
Trl
o
o
(,
o
x 9
Components location
t \
EN - 434
R825DEDIAGNOSIS
FIB25DE NGINE
START
A
Powersupplyinspection
Disconnectexhaustgassensorharness
connector.N G
Placeignition
switch
toONposition.
Measurepowervoltagebetween terminal
1 and
ground.
OK
lnspectthe following:
Harnessconnector.
Continuity
between gas
exhaust
sensor
andthefuse.lF NG:
Repairharness andconnector.
B
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.
OK
Replaceexhaustgassensor.
InspectECCSC/Uterminalsfor any
damageandmakesuretheconnectors
areconnectedcorrectlV.
Verification
lnspection
Checkforanydamageon the
Inspectpowersupply,groundcircuit ECCSC/Uterminals
and
ECCSC/Uconnector.
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
] . I D L E J U D G E I V F N T'
Function inspection 1
Placeignitionswitchto ON positron. A F TW H E NA C C E L E R A -
"IDLE
Inspectusing JUDGEMEN'l-' in O K OB PEDALIS FULLYOPEN.
"FUNCTION
TEST'mode.
Reference: Fullyopen:OFF
Fullyclosed:ON
FINISH START
B NG
Functioninspection2
Placeignition switchto ON position.
Inspectignitionswitch"ON-OFF" diagnosis
or
measurelhe voltagebetweenECCSC/Uterminal O K connector
54 andgroundusingthetesterwhenignition switch
i sO N .
Voltage: Accelerator pedalpressed0V
Acceleratorpedalnotpressed8 - 10V
NG FINISH
c
Power supply inspection
Placeignrtionswitchto OFFposition.
Disconnect throttlevalveswitchharnessconnector.
Placeignitionswitchto ON position. NG
Uselesterto measurelhe voltagebetween
terminal2 andground.
Battery voltage: Approx.8 - 10V
Inspectthe following:
Harnesscontinuity
betweenthrottle
valveswitchandECCSC/U. lF NG:
Repairharnessandconnector.
D
Inputsignalcircuitinspection
Placeignition
switchto OFFposition.
DisconnectECCSC/U harnessconnector. NG
Disconnectthrottlevalveswitchharnessconnector.
Checkthe continuitybetweenECCSC/Uterminal
54 andthrottle
valveswitchterminal1.
OK Repairharnessor connector.
Component parts inspection
(Throttle
valveswitch) NG
Referto the sectionon throttlevalveswitchfor
jon.
inspect
OK Replacethrottlevalveswitch.
InspectECCSC/Uterminalsforanydamageand
makesuretheconnectorsareconnectedcorrectlv.
EN - 437
RB25DEDIAGNOSIS
R 8 2 5 D EE N G I N E
insPection
Verification
Checkforanydamageon the
ECCSCiUterminalsand
ECCSC/U connector.
EN - 438
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
17 - STARTSIGNAL
DIAGNOSIS
GN SW
START
A
t) snRrrn srcNnrI
Function inspection /tr\ PLACE
SHIFTLEVERTO'P'OR
Placeignitionswitchto ON position. tU
UseCONSULT andinspect"STARTSlGNAL"in
"FUNCTION STARTTHEENGINE
STFAIGHT
TEST'mode. OK AFTERSELECTING
STARI,
OR
Placeignitionswitchto ON position.
Inspectstartsignalusing"DATAMONITOR"mode.
Whenignition swrtchis ON position: OFF
Whenignition switchis STARTposition: ON
B NG
FINISH
CAS.RPM(POS) 1326rpm
Power supply inspection STARTEFSIGNAL OFF
?@
Placeignitionswitchto OFFposition. €)
Disconnect throttlevalveswitchharnessconnector. N G
Placeignitionswitchto ON position.
Usetesterlo measurethe voltagebetween BECORD
terminal2 andground.
Battery voltage: Approx.8 - 10V B
OK €'@
Inspect the following:
Fuse I ECCSC/U connector
I
Continuitybetweenignitionswitch
and ECCSC/Uharness.lF NG:
Repairharnessandconnector.
InspectECCSC/Uterminalsforanydamageand
makesuretheconnectorsare connectedcorrectlv.
EN - 439
RB25DEDIAGNOSIS
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'
A ISTHEREA PULSATION
Systeminspeclion E V E F Y3 S E C O N D S
Select"FUELPUMP" in-FUNCTtON W H E NT H EF U E LT U B E
TEST"toinspect thesystem. \9
I S H E L D ?O R C A NY O U
Operationcheckby"FUELPUMPRELAy" in HEARTHEOPERATION
'ACTIVETEST'. OK N O I S EO F T H EF U E L
OK A
Checkthefollowing:
Fuse
Harnessconnection betweenfuel
pumprelayandthefuse.
Connectionbetweenfuelpumprelay
andtheignitionswitch.
lF NG: Repairharness& connector.
B
c
Groundcircuit inspection
Placeignition
switchto OFFposition.
Removefuelpumpharnessconnector. NG
Checkthe connectionbetweenfuel
pumpnarnessconnector 3 andthe
ground.
c
Repairharnessor
D
theconnector. Eeo
Outputsignalcircuitinspection
Placeignitionswitchto OFFposition.
RemoveECCSC/U harnessconnector. NG
Checklhe continuitybetweenECCSC/U& harness
terminal18andfuelpumprelayharnesslerminal1.
Checkthefollowing:
ContinuitybetweenECCSC/Uandfuelpumprelay.
ContinuitybetweenECCSC/U and pumprelay.
lF NG: Bepairharnessandlhe connector.
EN - 441
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
E D
Control signal insPection
Measurethe voltagebetweengroundand ECCSC/U Elee
terminal18.
5 seconds after ignition switch is turned ON: 1V
After 5 seconds after ignition switch is turned ON:
Battery voltage
OK
Componentparts inspection
(FuelpumPrelay) NG E
onfuelpumprelayfor
Referto thesection €,Q
rnspection.
E9!9
OK ReplacefuelPumPrelaY.
ComponentPartsinsPection NG
(Fuelpump)
onfuelpumpforinspection.
Befertothesection
OK
tuelpumP.
Replace
VerificationinsPection
Fuelpressure
inspection.
EN - 442
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
DIAGNOSIS
19. AACVALVE
Components location
START
A RN OFFA/CAND LIGHTS
Function inspection
Warmtheengine.
Checkthe idlespeed600 - 700 rpm.
lF NG: Adjustidlespeed. OK
"AAC " FINISH
/G\ Inspectusinq VALVE in
's/ "FUNCTION TEST"mode.
<>, Drsconnect AACvalveharness.
W Cfreckif idlerevwilldecrease.
B NG
Power inspection
Placeignitionswitchto "ON"position. NG
MeasurevoltagebetweengroundandAACvalve
terminal
2.
Repairharnessor theconnector.
TO
EN - 443
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
c B
Output signal circuit insPection Ele:@
A Checkif theenginerevwillchangewhenthe
\E/ "up" or "DOWN'is pressedin AACVALVE in
.ACTIVETESI'' mode. NG
^ Disconnect ECCSC/U harness.
H: Cnect forcontinuity betweenECCSC/U
h"rn"sstermtnal 4 andAACvalveconnector
t e r m i n a1l .
OK c
orconneclor.
Repairharness
.ACTIVETEST . N
DEG
OPENING
AACAr' 10'6
NG MONITOR
Component parts inspection (AACvalve) CAS.FPM(POS) 900rpm
Referto the secttonon AACvalvelor inspection' AIR FLOWI\,,ITR 1.'16V
ENGINETEI,IP SEN 8O"C
OK
BeplaceAACvalve.
Qu UP DWN od
VenficationinsPection
EN - 444
R825DEDIAGNOSIS
R B 2 5 D EE N G I N E
DIAGNOSIS
20. AIRREGULATOR
m
c)
o
a
o
l
5
Fuel pump relay Air regulalor
Components location
Inspectthefollowing:
Fuse.
Harnesscontinuitybetween
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. NG
Disconnect
Checkforcontinuitybetweenairregulatorharness
connectorterminal2 andground.
OK ReDairharnessor connector.
c
OutputsignalcircuitinsPection c
switchto OFFposition'
Placeignition NG
DisconnectFCCSC/Uharness connector' Eielm
Checkforharness betweenECCSC/U
continuity
18andfuelpumprelayterminal
terminal 1.
OK
Inspectthefollowing:
ContinuitybetweenECCSC/
U andfuelPumPrelaY.lF NG:
RepairharnessandconttnuitY.
D
ControlsignalinsPection
_ - ' ' _
MeasurevollagebetweenECCSC/Uterminal
18andground. NG Xc *
t-
Within5 secwhenignitionswitchis placedin ON LEsc+r**!
position:
APProx. 1V
After5 sec when ignitionswitchrsplacedin ON
position:Batteryvoltage
OK
RepairandinsPectECCSCi
U power supply ground
and
circuit.
VerificationinsPection
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
fr; Placeignitionswitchto ON position. . PoWEB ST SIG .
:
Inspectusing'PWRST SlG"in
'FUNCTION PRESSSTARTWHILEFULLY
TEST"mode. STEERING
THESTEERING
OR WHEEL,
Stopthe engine.
Use "DATAMONITOR"to inspectPWR
ST hydraulicpressure switchsrgnal.
Whenneutral:OFF
Whensteered:ON
A
Startthe engine.
UseCONSULT or testerto measurethe frvorrroRrruqflrornt
voltagebetweenECCSC/U terminal19 cAS.Pr\,,t(POS) 862rpm
andground. I G N I T I OSNI G N A L O F F
Whensteered:Approx.0V
Other:Batteryvoltage
HECOBD
TOB
EN - 447
R825DEDIAGNOSIS
R B 2 5 D EE N G I N E
B
Inputsignalcircuit inspection
Placeignitionswitchto OFFposition.
DisconnectECCSC/U harnessconnector. NG
Disconnectpowersteeringhydraulicpressure
switchharnessconnector.
Checkfor harnesscontinuitybetweenECCSC/U
terminal19andpowersteering pressure
hydraulic
switchterminal1.
OK orconnector.
harness
Repair
c
Groundcircuit insPection
Checkfor continuitybetweenpowersteering N G
hydraulicpressureswitchterminal2 andenglne
grouno.
OK
Repairharnessor connector.
Replacepowersteering
hydraulicpressureswltch.
insPection
Verification
EN - 448
R825DE
DIAGNOSIS
R B 2 5 D FE N G I N E
1 1
Throttle sensor & air regulator inspection I rsnot.rue
sENsonO
5S. tunction
!.snec11n tesrmode. PRESSSTABTWHILEFULLY
'!'/ UnecK judgement)
rlthethrottlesensor(idle is OPENINGTHEACCELERATOB
notturnedOFF. NG PEDAL.
61
Makesuretheair regulator unttts notrocKed
\€v or electricity
is conducted
to arrrequtator.
OK
Circuit
andthrottle
sensor
Inspectron.
Airregulator
andcircuit
inspection.
NO Qu UP DWN lt Od
Reoairwhereairis leakino.
3
Throttle linkage inspection
Stoptheengine. NG
Checkif the throttlelinkagewillmovesmoothly.
Checkif thethrottlevalvewillclose/ ooenfullv.
OK
Repairthrottlelinkage
or Inspectthrottlevalve
FINISH
f Jt/*i,.
\i _r J)"*
EN - 449
RB25DEDIAGNOSIS
R 8 2 5 D EE N G I N E
DIAGNOSIS23 (Phenomenon)'HUNTING
SparkpluginsPection
Stoptheengtne.
sparkplugandcheckfordirt'
Disconnect
damage.gapetc.
r or replace.
EN - 450
R825DEDIAGNOSIS
R B 2 5 D EE N G I N E
24 (Phenomenon)- IDLEINSTABILITY
OIAGNOSIS
1
Operatepower balancetest I poweRenr.ANlce a
,G\ Startthe enoine. ]NSPECTBALANCEOF EACH
'-U'operate
pdwen BALANCE NO PIPESBYSTOPPING
INJECTOR
TESTjnfuncrion OPERAT]ONATEACHPIPES.
test.Caution:
Operate
thetestinminimum
time TURNOFFALLlJCANDLIGHTS
requirgd.
Donotoperate
duringdrive.
6ldle revwilldecrease
fora momentwhen
(&operating pipes.
each
YES
To No. 6
2
Injector inspection
Stoptheengine.
Removecrankanglesensor.
(leaveharnessconnector as it is). NO
Dlsconnect powertransistorconnector.
Placeignitionswitchf romOFFto ON posrtion.
Can you hearoperationnoisefromeachinjector
whenthe crankanglesensorshaftis rotatedby hand.
Warning:Dependrng on howthe shaftis rotated,self-
diagnosis willdrsplay
abnormal, disregard
thisdisplay.
3
YES
lgnition inspection
Inspectiniector
Placeignitionswitchto OFFposition.
andcircuit
ffi
\ , \
Operation
noise
Removergnition coilASSY NG
Installnormaisparkplug.
Facethe sparkplugrearendtowardsadequate
groundsuchas collector andcranktheenaine.
Checkthespark.
OK Inspectignition
coil,power
transistor
andcircuits.
4
Spark plug inspection
Checkfordirt,damage,gapetc.on the
sparkplugremoved fromtheengine.
TO5
EN - 451
RB25DEDIAGNOSIS
F B 2 5 D EE N G I N E
FuelpressureinsPection
Starttheengine.
Select"STOP" in"ACTIVE TEST"andbring
fuelpressure to zero.
Afterengine stop, crank2 - 3 times.
Inspect fuelpressure usingfuelpressure
gauge.
W h e ni d l i n q : x . 2 . 5 k Ioc m "
Startthe engine.
Removefuelpumpfuseandbringfuel
pressureto zero.
Attachfuel pressuregaugeand inspectthe
la'x[\
': Fuel frlier:J
InspectfuelpumPand \
circuits.
6
$rorrrontnqNto rntr
CAS.RPI\,4(REF) 650rpm
02 SENSOF O.O2V
0 2 S E N S O RM T R R I C H
Exhaustgas sensorinsPection
,6',lnspectusing"BASEAIR-FUEL RATIO"in
tly''ruNcrtoru TEST"mode.
Select"O,SENSOR MONITOR" indata
monitor. 6
Setat 2o0orpm withno loadafterwarmup' m o d e .s h o n - c i r c ulihl e s e
openthe
"LEAN'RlCH"willrepeat Ior a'pprox2 secsJben
(rhernode
Checkifthedisplay /4-ff-ffF;la
earh Lff.ffTT-l Ilmerhs
-:-
for morethan5 timeswithln10 seconds rs Pedormeo)
,o,Operatevehicleside(withinfusebox)
@)diaqnosis connector andchangeto O,
sensormonll0r'.
Set at 200orpmwith no loadafterwarm up
Checkif theexhausttemperature warning
lampwillf lashfor morethan5 timeswithin
ReplaceO, sensor
TO7
EN - 452
RB25DEDIAGNOSIS
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 . AAC VALVEADJ '
'OPEBATION SETTHECAS.PRI\ITO
SUPPORT" mode. STANDARD VALUEUNDEB
Canidlerevbe adjusted to 600- TOOrpm IHE FOLLOWING
AFTEBWARMUP
CONDITION:
("N"position forA/T)by rotating
theidte TURNOFFALLLIGHTS AND
adtustment screw. AIRCONDITIONER,
r€\Startthe engine.
\Gr'DisconnectAAC valveconnector.
Can idle rev be adjustedto 600 - TOOrpm
("N"positionforA/T)by rotatingthe idle
adjustmentscrew.
YES
AACvalveandthrottle
valvefixationinspection.
9
Compression pressure inspection
Standardvalue:12.8i300(kgicm,)/(rpm) N G
Minimum value:9.8/300(kg/cmr)/(rpm)
Eachcylinderdifference
Tolerance:1.0/300(kg/cmr)/(rpm)
OK Inspectpiston,pistonring
valve,valveseat,cylinder
headgasket.
10
ECCSC/Uconnectorinspection
Checkforanydamage or looseconnection
on
theC/Ubinterminal
andharness connector.
OK
11
Tryreplacing
withnormatC/U.l-----.]Replaceor repair
FINISH
EN - 453
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
D|AGNoS|S25(Phenomenon).WHENcoLD,D|FF|CULTToSTARToRcANNoT
STARTTHEENGINE
1
andstartermotorf-llsglessjljePell
tnspectOattery . F U E L P U M P'
YOU FEELPULSATION
OK R Y3 S E C O N D SWHEN
2 E FUEL TUBEIS
Fuelpressureinspection E D ?O BC A NY O U
'FUNCTIONNG FUELPUMPRELAY
usingFUELPUMP'in
,6,lnspect
flltesr" mode.
,o.Pinchf uelPumPwithf ingers.
6)Cnect if thefusehoseis tensewhenf uel
pumpus operatlng.
OK
Fuelpumpandcircuit Fueiiilter
inspection
Air regulatorinsPection NG
Checkifthepowerisconducted to airregulator
whentheignition isturned
switch toONposition'
OK
andclrcull.
Inspectairregulalor
4
ThrottlesensorinsPection OK
Pressacceleratorpedalfullyandcheckif
theenginewillstart.
Throttlesensorandcircuit
inspection. 4
5 'J5;-
lnjector inspection F u l l yo p e n .\-i)
Placeignitionswitchto OFFpositlon. :f lrr't ,/
Removecrankanglesensor(leaveharness
gl+uu\
connectorconnected). if.'-
,{:--,!
Removepowertransistorconnector. NG
Placeignitionswitchto ON position.
Checkif eachinjectoroperationnoisecan be
3
heardwhenthe crankanglesensorshaftis rotated
by hand.Note:Depending on howtheshaftis
in
rolated,abnormalwillshowin self-diagnosis,
thiscasedetermine as normal.
OK
andcircuitinsPection
Injector
TO6 Rolate by hand
EN - 4s4
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
6 6
lgnitioninspection
Placeignitjonswitchto OFFposition.
Removesub-harness jn eachpipptng.
Installnormalsparkplug.Facethesparkplug
NG
rearend towardsadequategroundsuchas
collectorandcranktheengine.
Checkthespark.
OK
Inspectignition
coil,power
transistorandcircutt.
7
Sparkpluginspection
gapetc.onthespark NG
Checkfordirt,damage,
plugremovedfromtheengine.
OK
Repair
or replace
8
ECCS C/U connector inspection
NG
Checkfor any damageor looseconnectionon
the C/U binterminaland harnessconnector.
OK Repairor replace
o
ECCSC/Upowersupplyandgroundcircuit NG
Inspectron.
OK
Repairor replace
't0
Try replacing
withnormaiC/L.
FINISH
EN- 4ss
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
DIAGNOSIS26(Phenomenon)-WHENWARM,DIFFICULTTOSTARTORCAN
NOT STARTTHE ENGINE
1
FuelpressureinsPection IFUEL PUN/P1)
/G InspectusingFUELPUMP" in"FUNCTIONNG YOU FEELPULSATION
3 SECONDSWHEN
!UtEST" mode. E FUEL I UIJtr I-
,o,PinchfuelPumP withfingers.
(SCneckifthefusehoseistensewhenfuel
pumpusoperatlng.
OK
Fuelpumpandcircuit
inspection
2
Vapour inspection
Disconnectfuelpressureregulatorvacuumhose O K
Placea holecapon thevacuumhose.
Doestheenginestart?
NG
Inspectfuelaspect
J
IniectorinsPection
Placeignitionswitchto OFFposition.
Removecrankanglesensor(leaveharness
connectorconnected).
Removepowertransistorharnessconnector. NG
Placeignitionswitchto ON position.
Checkif eachinjectoroperationnoisecan be
heardwhenthe crankanglesensorshaftis rotated
by hand.Note:Depending on howtheshaftis
abnormal
rotated, in
willshowin self-diagnosis.
thiscasedetermine as normal.
OK
andcircuitinspection
lniector
4
lgnitioninsPection
Placeignitionswitchto OFFposition.
Removesub-harness in eachpipping.
Installnormalsparkplug. Facethesparkplug N G
rearend towardsadequategroundsucnas
collectorandcranktheengine.
Check spark.
the
OK coil,Power
Inspectignition
andcircult.
transistor
TO
EN - 456
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
5
Sparkplug inspection
gapetc.onthespark N G
Checkfordirt,damage,
plugremovedfromtheengine.
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
'
lnsoectbatteryand startermotor YOU FEELPULSATION
3 S E C O N DW
SH E N
E FUELTUBEIS
Fuel pressureinsPection ED? OR CANYOU
"FUNCTION RELAY
EAFIFUELPUI\,4P
usingFUELPUMP'in
4;.,lnspect
\ETEST'mooe.
PinchfuelpumPwithfingers
Checkif thefusehoseis tensewhenfuel
pumpus oPerating.
Fuelpumpandcircuit
inspection
leak.
Inspectinjector dI?-.,
F u l l yo p e n
,V
:\l rF.t ,/
lniector insPection TI+(f,l\ f-l
Placeignitionswitchto OFFposition. X-
Removecrankanglesensor{leaveharness
connectorconnected).
Removepowertransistorconnector.
Placeignitionswitchto ON position.
Checkif eachinjectoroperationnoisecan be
heardwhenthe crankanglesensorshaftis rotated
by hand.Note:Depending on howtheshaftis
abnormal
rotated, in
willshowin self-diagnosis,
thiscasedetermine as normal.
Rotateby hand
lniectorandcircuitinsPection
lgnition inspection
Placeignitionswitchto OFF position.
Removesub-harness in eachpipping
Installnormalspark plug. Facethesparkplug
rearendtowardsadequate groundsuchas
collectorandcrankthe engine.
Checkthespark.
OK
coil,Power
Inspectignition
TO6 and rcuit.
transislor ci
R825DEDIAGNOSIS
R B 2 5 D EE N G I N E
o
Sparkpluginspection
gapetc.onthespark N G
Checkfordirt,damage,
plugremovedfromtheengine.
OK
Fepar or replace
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
FuelaspectinsPection
Canisterpurge inspection
Disconnect Purgenose. N G
canister
Placeholecapon the Purgehose
Conductcruisetest.
ls therestillhesitation?
Inspectpurgeandvacuum
system.
FINISH
EN - 460
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
29 (Phenomenon)- HESTTATTON
DIAGNOSIS WHENCOLD
(hesitationas throttle valve starts to open)
1
Sparkpluginspection
Removesparkplugandcheckforanvdirt, NG
damage,gapetc.
NG
Bepairor replace
2
Fuelpressureinspection
" U P ' o r- D W Ni'n
rerSelect F U E LI N J E C T I O N
€euRrurtry coRREcloN' in-ACTIVE TEST' OK
modetochange correctionvalue.
Caution: Carryoutthetestjn minimum time
required. Donotoperate duringdrive.
Starttheengine.
61Does theenginerevincrease
whentheblow-by
\g/ hoseis pinched? ACTIVETEST
FUEL]NJECIION
OFFSET
NG
Repairleaks
3 r.33V
Replace
withnormalarrf lowmeter.
OK
NG
Replaceairflowmeter.
4
Intake valve deposit inspection
Removewhendeoositis Dresenr.
FINISH
EN - 461
RB25DEDIAGNOSIS
B B 2 5 D EE N G I N E
30 (Phenomenon)'HESITATION
DIAGNOSIS lN NORMALCONDITION
(hesitationas throttle valve starts to open)
1 2
TE51,
ItsASEAlRFUELRATIO
Spark plug insPection
HOLDENGINEREV2000+f
Removesparkplugandcheckforanydirt, 200rpmANDPRESSSTARI
Repairor replace
Repairanyleaks
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
31 (Phenomenon)- ENGTNE
DIAGNOSIS STALLWHTLEREVVTNG
1 1
Fuel level inspection
Checkthe levelof fuelin thefueltank. Resupply
fuel
, F-rN-=I
NG
OK
2 l- \--l |
|
Power balancetest operation
' _
,ar Startthe enoine.
\9/ Inspectusing'POWERBALANCEin
l l l
'FUNCTION
TEST"mode. NG
"POWER
Operate BALANCE"in "ACTIVE OPOWEHBALANCE'
TEST"mode.Caution:Carryoutthetestin FOREACHCYLINDER STOP
INJECIOR
OPEMTIONAND
minimumtimerequired.Do notoperate CHECKTHEBALANCEOF
duringdrive. EACHCYUNDER.
TURNOFF,6./CAND
LIGHTS
Checkif idlerevwilldecreasefor a moment
whencheckingeachcylinders.
,q1 Checkif idlerevdecrease
fora moment
r€rwheneachinjector connector
cylinders
are
disassembled.
3 OK To No. 5
Iniector inspection
Placeignitionswitchto OFFposition.
Removecrankanglesensor(leaveharness
connectorconnected).
Removepowertransislorconnector.
Placeignition NG
switchfromOFFto ON position.
Checkif eachinjectoroperationnoisecan be
heardwhenthecrankanglesensorshaftis rotated
by hand.Note:Depending on howtheshaftis
rotated,
abnormal willshowin self-diagnosis,
in /l
thiscasedetermine as normal. Operationnolse
Injectorandcircuitinspectron
4
lgnition inspection
'%j,::""',,
Placeignitionswitchto OFFposttion.
Removesub-harness in eachpipping.
Installnormalsparkplug. Facethesparkplug
NG
rearendlowardsadequategroundsuchas
collectorandcranktheengine.
'%!
Checkthespark.
OK
Inspectignition
coil,power
TOs transistorandcircuit.
EN - 463
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
OK pressure
Inspect
diaPhragm
regulator
o
tnrpectgCCSC/Upowersupplyandground N G
circuit.
OK
Repairor rePlace
8
Try replacingwithnormalC/U.
OK
FINISH
EN - 464
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
DIAGNOSIS - ENGTNE
32 (Phenomenon) STALLAFTERWARMUp
1 1
Vapourinspection O ncrrve
resr a I
correction
valuebyselecting..DWN" in"FUEL
FUELINJECTION OFFSET O'/.
,6lChange " "ACT|VE
t\,10NtToR
\E4NJECTION CORRECTTON in TEST"mode. CAS.RPI\,1(POS) 937rpm
ENGTE]\IPSEN 59,C
Caution:
Carryoutthetestin mintmum timerequired. o, SENSOR 1.33V
Donotoperateduringdrive. o " S E N S O R( R ) i.35\
INJ PULSE ].8msec
pressure
fG\Disconnect regulatorvacur-rrn AAC VALVE 179L
\@Place hole cap on vacuum hose. OL/ UP DWN od
Operatecruisetest.
Doestheenainestillstall?
2 NG
Power balancetest operation
/G\ Start the enqine.
'€i
Inspectusirig-eOWeR BALANCEin
.FUNCTION
TEST"mode.
"POWER
Operate BALANCE" in "ACT|VE NG
TEST"mode.Caution:Carryoutthetestin
minimumtimerequired.Do notoperate .POWER BALANCEO
FOREACHCYUNDERSTOP
duringdrive. ITUECTOR
OPEMTIONAND
Checkif tdlerevwilldecreasefor a moment CHECKTHEBALANCEOF
EACHCYUNDER.
whencheckinqeachpippinq. TURNOFFT/CANDLIGHTS
Checkif idle revdecreasefor a moment
,q,
\€r wheneachinjector connector pippingare
disassembled.
3 OK To No. 5
Iniector inspection
Placeignitionswitchto OFFposition.
Removecrankanglesensor(leaveharness
conneclorconnected).
Removepowertransistor connector. NG
Placeignitionswitchf romOFFto ON position.
Checkif eachinjectoroperationnoisecan be
heardwhenthe crankanglesensorshaftis rotated
by hand.Note:Depending on howtheshaftis @ffr^<)
rotated,abnormalwillshowin self-diagnosis,
thiscasedetermine as normal.
in :n. =d$l}P
Injectorandcircuitinspection
4
4
lgnitioninspection
Placeignitjonswitchto OFFposition.
Removesub-harness in eachpipping.
Installnormalsparkplug.Facethesparkplug
rearend towardsadequategroundsuchas
collectorandcranklhe engine.
Checkthespark.
EN - 465
R825DEDIAGNOSIS
RB2sDE NGINE
5
Fuel pressure insPection O ncrrverEsrILJ
FUELPUMPRELAY OFF
rer Startthe engine. "FUEL
fUBring fuelpressureto zeroby selecting MONITOF
"ACTIVETEST"mode.
PUMPRELAY"in
stop. NG (POS) 950rPn"
CAS.RPI\,'1
2 to3 timesafterengine
Crank
gaugeto inspect:
Usefuelpressure
2.5kglcm2
Whenidling:APProx. ON )N/OFF OFF
vacuumhoseis
Whenpressureregulator
removed:APProx.3.0k9/cm'
^ Qt. rt +ha anoina
i"ul".",.
fuel
tozerobyremoving
l&Bringfuelpressure
oumo fuse.
Crank2to 3 timesafterenginestop.
Inspectusingfuelpressuregauge.
OK pressure
Inspect
diaphragm
regulator
EN - 466
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
33 (Phenomenon)- ENGINESTALLWHENCOLD
DIAGNOSIS
't
Air regulator inspection
Checkif thepoweris conducted to air regulatorN G
whenignitionswitchis in ON position.
OK
Inspeclair regulator
andcircuit.
2
Throttlesensorinspection
pedalfullyandcheckifthe NG
Pressaccelerator
engrnecanbestartedwhentheenqineiscold.
Fullyopen
Inspectair regulator
3
andcircuit. $ + @<
I Powerbalancetestoperation
frt Start
theengine.
:Inspectusing 'POWER BALANCEin
"FUNCTION
TEST"mode.
Operate"POWERBALANCE'in"ACT|VE NG .PoWER BALANcE.
FOREACHCYUNDEFSTOP
TEST"mode.Cautton:Carryoutthetestin INJECTOROPEMNONAND
minjmumtimerequired.Do notoperate CHECKTHEBALANCE OF
EACHCYLINDER.
duringdrive. TURNOFFA./CAND
LiGHTS
Checklf idlerevwilldecreasefor a moment
whencheckinqeachcvlinders.
@ Checkif idlerevdecrease{ora moment
: wheneach
injector
connectorcylindersare
disassembled.
4 oK I T oN o . 7
Iniector inspection
Placeignitionswitchto OFF position.
Removecrankanglesensor(leaveharness
connectorconnected).
Removepowertransistorconnector.
NG
Placeignitionswitchf romOFFto ON position.
Checkif eachinjectoroperation noisecanbe
heardwhenthecrankanglesensorshaftis rotated
@ffrX)
by hand.Note:Depending
rotated,
on howtheshaftis :Rt,>sv /l
abnormal wrllshowin self-diagnosis,
in
thiscasedetermrne as normal.
Injector
andcircuitinspection
TO5
EN - 467
RB25DEDIAGNOSIS
RB2sDE NGINE
lgnition inspection
Placeignitionswitchto OFFposition.
Removesub-harness in eachcylinders'
Installnormalspark plug. Facethesparkplug
rearendtowardsadequategroundsuchas
collectorandcranktheenglne.
Checkthespark.
Inspect coil,Power 6
ignition
and
transistor circult.
SparkpluginsPection
gapetc.
Checkfordirt,damage'
onthesparkPlugremovedfrom Repairor replace
FuelpressureinsPection 7
'/G Startthe engine. I ncrrverrsr O L,-i
l.=Brrnqfuelpressure to zeroby selectingFUEL FUELPUMPRELAY OFF
,.ACTIVE TEST''MOdC.
PUMPRELAY,in l\,40NlToF
Crank2 to 3 timesatterenglnestop.
gaugelo Inspect: (POS) ssorpn
CAS.BP[,4
UsefuelPressure
Whenidling:APProx. 2.Skg/cm'
when pressureregulator vacuumhosels ON )N/OFF OFF
rox.3.Okq/cm'
,6Start the engine. 7
6tsrinq f uelpressure lo zeroby removingluel
p u m pf u s e .
Crank2 to 3 timesafterenginestop.
Inspectusingfueipressure gauge.
lnspectpressure
regulatordiaphragm
InsoectECCSC/U powersupplyandground
withnormalC/L.
Try replacing
EN - 468
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
InspectAACvalve
andcircuit. Ou UP DWN od
2
Power balancetest operation
{€Start theengine.
\elnspectusing POWERBALANCEin
"FUNCTION
TEST"mode.
OR use"POWERBALANCE"in "ACT|VE NG
TEST"mode.Caution:Carryoutthetestin
minimumtimerequired.Do notoperate
duringdrive.
Checkif idlerevwilldecreasefor a momenl OPOWERBALANCEO
whencheckingeachcylinders. FOREACHCYLINDERSTOP
INJECIOR
OPEMTIONAND
CHECKTHE BALANCEOF
3 OK I ToNo.5 EACHCYLINDEF.
Injector inspection
Placeignitionswitchto OFFposition.
Removecrankanglesensor.
Removepowertransistorconnector. 2
NG ACTIVETEST 'f
.
PlaceignitionswitchfromOFFto ON position. POWERBALANCE
Checkif eachinjectoroperation
noisecanbe (POS)
CAS.FlPl\,4 rpm
heardwhenthe crankanglesensorshaftis rotated AIF]FLOWMTR V
AACVALVE q.
by hand.
1 2 3 4
r=l START
L:] 6
Injectorandcircuitinspection
TO4
Operatronnoise
EN - 469
RB25DEDIAGNOSIS
B B 2 5 D EE N G I N E
lgnition inspection
Placeignitionswitchto OFFposition.
Bemoveignition coil.
Installnormalsparkplug.Facethesparkplug
ground
adequate
rearendlowards suchas
andcranktheengine.
collector
CheckthesPark.
J
coil,
Inspectignition
andcircuit.
transistor rEsr lL
O ncrrve
RELAY OFF
FUELPUN,IP
t\,roNtToR
Fuel pressure insPection
,ar Startthe engine. (POS) 950rPrr
CAS.RPN,4
(UBrinq fuelpressureto zeroby selectingFUEL
..ACTIVETEST''MOdE.
PUNiPRELAY"in ON )N/OFF OFF
Crank2to 3 timesafter enginestop.
UsefuelPressure gaugeto Inspecl:
Whenidling:APProx. 2.Skglcm'
When pressureregulatorvacuumhoseis
rox.3.Okq/cm'
,.,o,Start the engine.
(6bring f uelpressureto zeroby removing f uel
pumpfuseNo.B.
Crank2 to 3 timesafterenginestop.
gauge.
Inspectusingfuelpressure
ECCSC/Uconnectorinspection
Checkforanydamage on
orlooseconnection
andharness
theC/Ubinterminal connector.
ir or replace
lnspectECCSCiU powersupplyandground
withnormalC/L.
Try replacing
EN - 470
RB25DE
DIAGNOSIS
R B 2 5 D EE N G I N E
35 (Phenomenon)- ENGTNE
DIAGNOSIS STALLWHEN DECELERATING
1 1
AACvalveinspection
/G.rWarm engine.
: Inspect using"AACVALVE- in 'FUNCTION
TEST'OR
Select"AACVALVE ADJ"in "ACTIVE NG
TEST".
Checkiftheenginerevwillchange when
"Qu"or "Qd"is selected 1
to changeAAC
valveopening.
O ncrrve
resr a tr
A A C/ V O P E N I N G 109:
theengine. [,40NtTOR
r€\Slart
\@/Check CAS.RPM(POS) 900rpm
if enginerevwilldecrease wnen AIR FLOWMTF 1 16V
AACvalveconnector is disconnected. ENGTEIV1P SEN 80.C
OK Inspect
AACvalve
andcircuit. Qu UP DWN Qd
2
Adiust screw fixation inspection
@,lnspect using-AACVALVEADJUSTMENT-
:in OPERATION SUPPORTmode. NG
Checkif it is possibleto set idlespeedto
650rpm("N"rangeforA/T)by turningidte
adjustmentscrew.
6lDisconnect throttlesensorconnector.
\Gr Checkif it is possibleto set idlespeedto
650rpm("N"rangeforA/T)by turningidle
a AAcVALVE
ADJ a
adlustmentscrew. ADJUSTCAS FlPMTO
STANDARD VALUEUNDEF J
OK thE FOLLOWNGCONDLT ON ,
InspectAACvalveand AFTERWARMUP
] TURNOFFA,'CAND L GHTS
throttlevalvefixation.
3
Power balancetest operation
,G\ Startthe enoine.
\ t /
v Inspectusing"POWERBALANCE'in
"FUNCTION
rEST" mode.
"POWER
OR use BALANCE"in "ACT|VE NG
TEST"mode.Caution:Carryoutthetestin
minjmumtimerequired.Do notoperate
duringdrive.
Checkif ldlerevwilldecrease for a moment
whencheckingeachcylinders.
r,qsta rt the engine.
J
\c/Check if idlerevwilldecreasefor a moment . ACTIVETES1 r f
POWERBALAI'rcE
wheneachcylinderinjector connector is cAS.RPM(POS) rpm
disconnected. AIFIFLOW I\,ITF]
AAC VALVE a./"
oK I 1 2 4
T oN o . 6 E--l --t STAFT
t:j o l
EN - 471
DIAGNOSIS
RB25DE
R B 2 5 D EE N G I N E
4
Iniector inspection
Placeignitionswitchto OFFposition.
Removecrankanglesensor(leaveharness
connectorconnected). NG
Removepowertransistorconnector.
Placeignitionswitchf romOFFto ON position.
Checkif eachiniecloroperationnoisecan be
heardwhenthecrank angle shaftis rotated
sensor
by hand.
InjectorandcircuitinsPection
5
lgnitioninspection
Placeignitionswitchto OFFposition.
Removeignition coil.
NG
Inslallnormalsparkplug.Facethesparkplug 6
rearend towardsadequategroundsucnas O ncrrveresr I i--l
collectorandcranktheengine. FUELPUMPRELAY OFF
CheckthesPark. N,4ONITOB
OK CAS.RPM(POS) 950rpn
Inspectignitioncoil,Power
transistorand circuit. ON ]N/OFF OFF
Inspectpressureregulalor
TO7 diaphragm.
EN - 472
F825DEDIAGNOSIS
R B 2 5 D EE N G I N E
7
Exhaustgas sensorinspection NoFA|L
A,4oNrToRrNqk
usinq"BASE
/G\ Inspect AIR-FUEL FATtOrn
r-U"rurucrtoru
TESTmode. (REF)
CAS.RPI,4 82srpm
"O,SENSOR
Seiect MONITOR" indara NG 02 SENSOBI\,4TR RICH
monitor.
Setat2000rpm withnoloadafterwarmup.
"LEAN,
Checkifthedisplay RICH"witlrepeat
formorethan5 timeswithin10seconds.
re\ Operatevehicleside(withinfusebox)
\€r' diagnosis
connector andchangeto -O2 c h a n q ed r a g n o s t cm o d e s h o d c r c u t t f r e s e
sensormonitor".
Set at 2000rpmwith no loadafterwarm up.
Checkif theexhausttemperature warning
lampwillf lashfor morethan5 timeswithin
10 seconds.
OK
ReplaceO, sensor
Inspectthrottlesensorandvehicle
Iltl
speedsensor.
OK ' E x h a u stern
t p
Redlarnp w ar n r n q a m p
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
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 NG
OR use
TEST"mode.Caution:Carryoutthetestin
minimumtimerequired.Do notoperate
duringdrive.
for a moment
Checkif idlerevwilldecrease
whenchec@
rqstart the engine.
\@Checkif idlerevwilldecreasefor a moment
wheneachcylinderiniectorconnectoris
disconnected.
oK I ToNo'
2 l
IniectorinsPection
Placeignitionswitchto OFFposition.
Removecrankanglesensor(leaveharness
@ffix)
connectorconnected). NG rRl' >S"/
/l
Removepowertransistor connector. Operalionnolse
switchfromOFFto ON position'
Placeignitron
noisecan be
Checkif eachinjectoroperation
i\
heardwhenthe crankangiesensorshaftis rotated
by hand.
.- lgntion
InjectorandcircuitinsPection
3
lgnitioninsPection
Placeignitionswitchto OFFposition.
Removeignition coil.
NG
spark
Installnormal plug.Facethesparkplug
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. FUELPUI\,4P
BELAY OFF
\U Aringfuelpr"essure 'FUEL
to zeroby setectrng
PUMPRELAY'in"ACTIVETEST"mode.
l\,lONlTOR
OK pressure
Inspect regulator
diaphragm.
8 0 K Repairor replace
Tryreplacing
withnormalCiL.
OK
FINISH
EN - 475
fr825DEDIAGNOSIS
R B 2 5 D EE N G I N E
37 (Phenomenon)'ENGINESTALLWHENLOADINGBATTERY
DIAGNOSIS
1
Inspectbatteryandalternator Repairor replace
To No. 4
lgnition insPection
Placeignitionswitchto OFFposition.
Removeignition coil.
Installnormalsparkplug.Facethesparkplug
rearendtowardsadequategroundsuchas
collectorandcranktheenglne.
Checkthespark.
coil,Power
Inspectignition
andcircuit.
transistor
TO5
EN - 476
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
3 c
Fuelpressureinspection I ncrrvrresr O[
,er Starttheenoine. FUELPUI\,,IP
RELAY OFF
.U BringfuelprLssure tozerobysetecting.'FUEL
in"ACTIVE
MONITOR
PUMPRELAY" TEST"mode.
Crank2 to 3 ttmesafterenginestop. NG CAS.RPM(POS) 950rpn
Usefuel pressure gaugeto inspect:
Whenidling:Approx. 2.5kglcm2 ON IDN/OFF OFF
Whenpressure regulatorvacuum hoseis
removed: Approx. 3.0k9/cm,
61Stad theengine.
tg€ring fuelpressureto zeroby removing
fuel
pumpfuseNo.8.
Crank2to 3 timesafterengjnestop.
InspectusingJuelpressuregauge.
OK Inspectpressureregulator
diaphragm.
6
ECCS C/U connector inspection
Checkforanydamageor looseconnection NG
on
the C/U binterminaland harnessconnector.
OK Repairor replace
7
InspectECCSC/Upowersupplyandground NG
circuit.
OK Repairor replace
8
Tryreplacing
withnormalC/L.
OK
FINISH
EN - 477
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 O ecrtvergst O
/G Start the engine.
fUBring tuelpressure to zeroby selectingFUEL
"ACTIVETEST"mode.
PUMPRELAY'in
Crank2to 3 timesafterenginestop. NG
Usefuelpressure gaugeto insPect:
Whenidling:APProx. 2.Skglcm?
Whenpressureregulator vacuumhosels
removed:APProx.3 Olg&m1- 1
^ Cr"* th6 annine
t&Bringfuelpressure fuel
to zeroby removing
pumpfuseNo.8.
Crank2to 3 timesafterengrnestop.
Inspectusingfuelpressuregauge.
OK lnspectpressureregulator
diaphragm.
2
Intake air leak inspection
@Start the engine. YES
echanqe correction valueby selectingDWN"
iN..TUEIINJECTION CORRECTION
"ACTIVE TEST"
VALUE"in
Caution:Carryoutthetestin minimumtime
required.Do notoperatewhiledriving. 2
whenthe I ncrveresr t D
Xe treckit enginerevwillincrease FUEL NJECTIONOFFSETO%
W)blow-bv hoseis pinched MONITOR
CAS.RPM(POS) g37rpm
ENGTEMPSEN 59'C
NO O, SENSOR 1,33V
Repairanyleaks o, sENsoR(R) 1.35V
NJ PULSE l.8msec
AAC VALVE 179L
pressure,
Inspectcompression timing NG
ignition Ou UP DWN Qd
anddetonationsensor.
NO Repairor replace
FINISH
EN - 478
RB25DEDIAGNOSIS
R B 2 5 D EE N G I N E
39 (Phenomenon)- DETONATTON
DIAGNOSIS
1
1
Intakeair leakinspection
Q acr veresr O f
(l)Starttheengrne, rUeLttllecrtolOrrSg dl
: Change correction .DWN' YES MONITOR
valuebyselecting
in"FUELINJECTION
CAS.RPI\.4(POS) 937rpm
CORRECTTON ENGTEI\,IP SEN 59'C
VALUE"in "ACTIVE TEST". O. SENSOR
o , S E N S O R( R )
1 33V
1.35V
Caution:Carryoutthetestinminimum time INJ PULSE l.Bmsec
AAC VALVE 17"i
required. Donotoperatewhiledriving.
Qu UP DWN od
prCheck if enginerevwillrncrease
whenthe
@rblow-bvhoseis oinched.
NO
Repalranyleaks
2
Combustion chamber oil leak inspection NG
Disconnect
sparkplugandlnspectoil.
OK
Inspectpiston.pistonring,
valve,valveseat,valveoil
seal,engineoil leveletc.
Inspect
detonation
sensorsvstem.
OK
FINISH
EN - 479
RB25DEDIAGNOSIS
B B 2 5 D EE N G I N E
40 (Phenomenon) S U R G E
DIAGNOSIS
1
Exhaust gas sensor insPection IFASEAIR FUELRATIOTESI
"BASEAIR-FUEL RATIO'in
/A Inspectusing HOL0ENGINEREV2000+1-
.-EiruructtoNTEST"
mooe. PBESSSTART
2OOrpmAND
"O, in data NG
Select SENSORMONITOR"
monitor.
Set at 2000rpmwith no loadafterwarmup
"LEAN,RICH"willrepeat
Checkif lhe display
for morethan 5 tinqllryjlllllqlegengs.-
,o, Operatevehicleside(withinfusebox)
18 diagnosis connectorandchange to "o.
sensormonitor".
Setat 2ooorpm withno loadafterwarmup'
Checkiftheexhaust temperature warning
lamowillflashformore than 5 times within
10 seconds.
START
OK
ReplaceO, sensor
2 II
ReplaceECCSC/U :'----_-
- Ittl
.fi-
OK -*-., -g
FINISH
,^^':?
Red la'np
EiT:1rlr
lamp,
warntng
E N- 4 8 0
R825DEDIAGNOSIS
R B 2 5 D EE N G I N E
1
Sparkplug inspection
Remove sparkplug. NG
Checkforanydirtonthesparkplug.
OK Repairor replacesparkplug.
2
Intake air leak inspection
@Start theengine. 2
: Changecorrection valueby selecting-DWN' YES
I ncrrve
resr a n
in "FUELINJECTION CORBECTION FUELINJECTION OFFSET O%
VALUE'in"ACTIVETEST"mode,
[,4ONJTOB
CAS.RPM(POS) 937rpm
Caution:Carryoutthetestin minimumtime ENGTEI\,4P SEN 59"C
O. SENSOR J.33V
required.Do notoperatewhiledriving. o . S E N S O R( B ) 1.3sV
^6.Checkif enqinerevwillincrease
I ltf L
whenthe INJ PULSE 1.8msec
AAC VALVE 17"1"
Yq/blow-bv hose ts ornched.
Qu UP DWN Qd
NO
Repairanyairleaks
3
Intake valve deposit inspection
Removeif thereareanydeposltpresent.
lgnitiontiming
Checkif injectoris clogged.
FINISH
42 (Phenomenon)- AFTERBURNTNG
DIAGNOSIS
1
Engine temperaturesensor inspection
Inspectenginesensorandenginesensor NG
circuit.
OK Repairor replace
lgnitiontiming
Checkif injectoris clogged.
FINISH
EN - 481
INSPECTION
RB25DECON,lPONENTS
F B 2 5 D EE N G I N E
(RB25DE)
8. coMPoNENTSINSPECTION
CRANKANGLESENSOR
Inspection
Removecrankanglesensorfromtheengine.(leave
crankanglesensorharnessconnector connected).
Placeignitionswitchto ON position. Xs -i
Rotatecrankanglesensorshaftslowlywithhandand a,,fl\
inspectthevoltagebetweenterminal 2.3 andground
I\ ARr i Xq
@-,p
Rotateby
lF NG: Replacecrankanglesensor.
EraseselfdiagnosisresultfromCONSULTafterinspection'
CheckcodeNo. 11is notdisplayed in thescreen.
Caution:
Removeinjectorf useor connectorto avoidinjectorf rom
whileinspection.
operating
AIR FLOWMETER
lnspection
. Removeairflowmeterfromtheengine. ivl
rO lil
. Applybatteryvoltagedirectlybetweenairflowmeter f-l .
terminal5+ andterminal3- andblowairto hotwlre. r 1 i 2 r ? 1I4 l l
Checkfor any changein outputvoltagebetweentermlnal t t
2+ andterminal4-.
/€n
at,
Air is not blown Approx.0.8V
Air is blown Approx.2V
Ee
lF NG: ReplaceairflowmeterOR checkfor anydamage
withthe hotwire.
Eraseselfdiagnosis resultfromCONSULT afterinspection'
CheckcodeNo. 12 is not in
displayed the screen.
ENGINETEMPERATURE SENSOR
Inspection
. Disconnect sensorharness
enginetemperature
(KA
connector.
o
. Measuretheresistancebetweenenginelemperature c
o
sensorharnessterminal1 and2. b
Approx2o"c I npprox2 sKS) (D
(r
Approx8o"c I nPProx0.3x$l
sensor.
lF NG: Replaceenginetemperature
from
result
Eraseself-diagnosis CONSULT afterinspection.
in the screen
CheckcodeNo.31 is notdisplayed
EN - 482
RB25DECOMPONENTS
INSPECTION
R B 2 5 D EE N G I N E
IGNITION COIL
Inspection
. Disconnect
ignitioncoilharnessconnector.
. Measurethe resistancebetweenfollowinq
terminals.
Primary value(i - 2) |
coilresisntance 0.6- 0.9
lF NG: Replaceignition
coil
POWERTRANSISTOB
Inspection
. Disconnectpowertransistorharnessconnector.
. Measurethe resistance by inserting
analogtypecircuit
testerinspectionrod - and + to powertransistor
terminals.
+/- coSJ -r* oo f,l
2-3 + / - o o f , J > - / + 0 o r n o@
t 61
t - J + / - 0 o r n o to o Q . - l * co fl
lF NG: Replacepowertransistor.
F U E LP U M P
Inspection Ele-,e
. Disconnect fuelpumpharnessconnector.
. Measurethe resistance
betweenfueloumoterminal1
and 3.
Resistance: Approx.0.4 - 0.7
THROTTLEVALVE SWITCH
Inspection
. Warmthe engine.
. Disconnect throttlevalveswltchconnectorand measure
the resistancebetweenthrottlevalveswitchterminals.
(ldle contact point)
lF NG: Repairthrottle
valveswitch.
EN - 483
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 fle Z*)
bolt.
Gradually increase theenginerevso idlecontactpolntrs
ON (Resistance betweenterminal2 and 1 is 0 Q ) at
aboveenginespeed. Movethrottlevalveswitchunitto
touchpointandtightenthe bolt. Movethrottlevalve
switchunitto touchpointandtightenthebolt.
lnstallthrottlevalveswitchconnector.
Racetheenginefewlimesandcheckidlerevis within
thestandard value.
THROTTLESENSOR
throttlesensorconnector.
Disconnect
betweenthroltlesensorterminal2
Measurelhe resistance
and3.
lrr p€
Not pressed A p p r o x0 . 4
Pressedto halfway Approx0.4- 5
Completely
Pressed Approx.5
lF NG: Replacethrottlevalveswitch.
AfterinspectioneraseselfdiagnosisresultfromCONSULT
CheckcodeNo.43 willnotdisplayin thescreen'
AAC VALVE
. Inspectthe resistanceof AAC valve.
Resistance:APProx.9- 10
. PlungerandswitchinsPection.
. Springdamageinspection.
*4-==ll
u,\,9
I
AACvalve.
lF NG: Replace
v eLng",
I
FICDSOLENOID Eei, @
. Measurethe resistanceof FICDsolenoid.
Besistance: APProx.2 2 - 2 3
EN - 484
R825DECOMPONENTS
INSPECTION
R B 2 5 D EE N G I N E
Plungerandswitchinspection.
Springdamageinspectlon.
tO4-
>d
Plunger '-(L...-.-
lF NG: ReplaceFICDsolenoid. , / \ \ ^
Spring *9
AIR REGULATOR
Static characteristicinspection
. Visuallychecktheshutteropening.
Below-20"C Fullyopen
20"c Approx halfopen
Over60"C Fuilyclosed
Dynamiccharacterlsticinspection
. Applybatteryvoltageto terminalsand inspectfor any
r -1t2j
changewithshutteropening. . l
The shutterwill close graduallyand completely
closed within 7 minutes. (areatemperature ar-
approx. 20"C).
Reference:Heaterresistancevalue: 70 - 80 tJ (20"C)
lF NG: Replaceairregulator
INJECTOB
Inspection
. Disconnectinjectorharnessconnector.
. Measure the resistance
of eachiniector
cvlinder
terminal (
__l
1 and2.
Resistance
betweeninjectorterminal1 and
2 (eachcylindeo 13-14Q
lF NG: Replaceinjector.
lF NG: Replacerelay.
EN - 485
INSPECTION
RB25DECOMPONENTS
R 8 2 5 D EE N G I N E
IGNITIONRELAYINHIBITOR RELAY
Inspection
. Directlyapplybatteryvoitagebetweenterminal1 and 2.
. Checkfor continuitybetweenterminal3 and4, 6 and7 Xe ,@
lF NG:ReplacerelaY.
POWERSTEERINGHYDRAULICPRESSURE
INSPECTION
Inspection
. Removepowersteeringhydraulic pressure switch We:-p:-'';
harnessconnector.
. cCheck
h o n k ffor
o r ccontinuity b e t w e e n the
o n l i n u i t v between t h e terminals.
terminals.
lF NG: Replacepowersteeringhydraulicpressureswitch
.' .. | tr -! e
c_
FlA
f=
SPARK PLUG
Inspection & Adiustment E
. Measurethe gap betweenelectricpole. fl
. Reolaceor repairif outof standardrange. lj
F]
Standardgap (mm): 1 . 0- 1 . 1
. ('
FUELPUN,4P
IS THEREA PULSATION
FUEL SYSTEMINSPECTION EVEBY 3 SECONDSWHEN
Simpleinspection T H E F U E LT U B E I S H E L D ?
. Turnthe ignitionswitchto p?.ti,i?l:.,, O B C A NY O UH E A RT H E
9N _,- G) OPERATIONNOISEOF THE
. Select"Fuelpump'in the"Function test mode. \!=/
FUEL PUMPRELAY?
. Inspectthepulsation by holdingthefuelhosewithhand
@
. Holdthefuelfilterand makesurethe hoseis hard W
andpulsation can be feltwhenthefuelpumpis operating-
EN - 486
RB25DECOMPONENTS
INSPECTION
R B 2 5 D EE N G I N E
Fuelpressureinspectionusingthe fuel
IACTIVETEST('
pressuremeter
Releasingf uel pressure FUELPUI\,4P
RELAY OFF
. Runtheengine.
"Fuelpumprelay" CAS-RP|\,4
{POS) 950rpm
. Select in"Active
test"mode.
. Press'STOP'to stoptheengine.Cranktheengine over
twoorthreetimes.(lftheenginedoesnotstart,crank3 - 4
timesafterremoving thefuse).
Fuelpressuremeterinstallation
. Connect thefuelpressure
meterbetween
thefuelfilterand
thefuelline.
. Attach
thefuelpumpfuse.
Fuelpressureinspection
. Starttheengineandcheckifthefuelpressure
isat
standardvalue.
ldling(kg / cm:, Approx.2 55
Pressureregulatorvacuumhoseis
(kg / cm,) Approx.3.0
disconnected
lf theenginedoesnotstart,checkfuelpressure
5
secondsaftertheignitionswitchhasbeenturnedON.
5 secondsafterignitionswitchturnedto ON I Approx 3.0
I FN G :
Fuelpressure
is extremely Pressure
regulator
is notworking.
high Return
systemrsctgged. hosebent
EN - 487
R 8 2 5 D EC O M P O N E N TI S
NSPECTION
R 8 2 5 D EE N G I N E
Fuelcut systeminspection
. Select"lNJpulse"in "DATAMONITOR" modeusing
CONSULT.Increase the enginerevto 2000rpm after
"lNJpulse"willdecrease
startingtheengine.Checkthat
to 0.6 msecfor a momentwhen the acceleratorpedalis
released.
ITORINg}l'lo FA L
CAS.BPM (REF) 1950rpm
I N JP U L S E 0.6msec
GAS CONTROLSYSTEMINSPECTION
EVAPOBATIVE
Throttlechamber
Checkvalve
f! gas
<- Evaporatlve
'F Purqeair
Activecarbon
Filter
Tray
Freshair
CANISTER
lnspection
. Connectvacuumhandpumpto canisterthrottlenegative
pressureopeningand makesurethevacuumpressurels
maintained.
. Applyapprox.-100mmHg pressureand makesurethe
manifold negative by
openingis continued
pressure E Gl 5 13 0 0 0 0
suckingairf romtheoPening.
FUELTANK VACUUMBELIEFVALVE
Inspection
. Cleanthevalvehousing.
youwillhear
. lf thef ueltankvacuumreliefvalveis normal,
soundfromthevalvewithsmallresistance whenthealrls
suckedin throughthecaP
. ReplacethecapASSYif thevalveis closedor when o . o
Soflno valve . -
resistanceis felt. valve
EN - 488
R825DECOMPONENTS
INSPECTION
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.
BLOWBYHOSE
Inspection
. Lookforanyleakagefromthehoseandconnectionarea.
. Remove thehoseandcleanusingtheairblow.Replace
hoseifthereareanyclogs.
EN - 489
SIGNALS
ECCSC/UINPUT/OUTPUT
R826DETTENGINE
9. ECCSCONTROLUNITINPUT/ OUTPUTSIGNALS
9.1 CONSULTINSPECTION VALUES
(1) Datamonitor
outputsignalis displayed
itlote:The as thecalculation dataon consoleunitso thecorrect
valuewilldisplayedeveniitheoutputcircuit(harness) disconnected'
is inadvertently
RB26DETTENGINE -olre
rorron
t- ,
loNrroREaGl'EG I .IX*TTAL RETENEIGE. , , .r : - t t , : ' ., .
TTVALUE ,,
l - - - - " - ' :
Tt€re m6l be no abno.mar Crank adqle se.sor slstem
CAS RPM (Detecled angle
chanqe rn sPeed
speed according to srgnals)
Approt O7-l2V(2OOOrpm
Alter wa.nrog uP engr'€ w hrbload 1O- 1 7V) A r now meler s'€1em
kjlins (N range. A/C OFF) Nole 2 arr now meler val!€
AIR FLOW MTR (R) canvaryo-O4V
Engrre temperalure sensor
ENG TEMP SEN After wa.mrng uP ensrr€ Above approx 70'C
(engrne temperaure)
EXT GAS SEN
Changesbet@enO_O3V
arxi06_]v ErhaLrsl gas sensor system
EXT GAS SEN (R)
2 O O O r p mw l h n o ltnake s)€tem arr leak o. arr
appro\ r5 - t5'6
(N rar€e A/C OFF)
AAC vaive sYsiein
Approx 30 - 5O7.
ON
Starter SW syslem
START SIGNAL
ON
Engine Throttle lully closed QN
slstem
Thronle se6or
IOLE SW
A/C SW ON ON
Alr co.ditiorer SW system
AIR COND SIG
ON
Nedral SW sFlem
NEUTRAL SW
ON
Po@r sleeflrq SW syslem
PWST SIGNAL
QN
Throttle sensor s!51em
DLE JUDGEMENT t€n wt€n rd e
Ot€r
FL€lPumP system
FUEL PUMP RELAY K]N SW ON ON
A/(.] QN ON
Arr corditrorEr relay sFrem
AC-ON
ON
WG CONT 5A/
(2) Activetest
' ,+rniu,,,
Perform
followrng
inspections
to check1
problem
is sol\€d.
Flminele
ENGINE Problem Setengrne ternperature
highor low
occurence Engineternperature
sensofsystem
TEI\,'IPERATURE condrtion aar iron Do notsetextrerne values
as lnrscancausespai*p ug burntng Inlectorsystem
Air flowmeteaexhaust
gassensorsystem
Not ellminate.l
Other rtem Inspectton
Perfomrfollowtng
tnspections
to checkrf
problemrs soived.
F limrn2ie
Set the airfuel ratto|ch or lean
Problem Ca|irnn DO |Ot SelextremevaluesaS Exhausl
occurence gassensorsystem
FUELINJECTION
cono1l|on this may dan'rageengtne of catal),tic Ai. flowmetererq ne temoeratJre
se-so.
ocn!enet slstem
njeclorsystem
Nol elimin2tr.l
Otherrteminspecton
PerlonnfollowngInspecttons
to check11
problern
rs soi\€d
DelayignitionUmrng
F limrnrlp
Problem Cer r.n DO not SetextremevaluesaS
occurence
GNNON TII\,1ING lgnrtrontirnrngadjustment
conotlon thismay damageengtneor catalytc
con\€rtea
Detonation sensorsystem
N.i elimlnaie.l
Othef item nspeclion
Increasecontroldulyratio The engtne
AAC VALVE speedshouldtncrease lf the conditrondescnbedon leftcan not be
Enginerunning
OPENING Decreasecontroldutyreatio The lenfied ccheck AAC valve system
enginespeed shoulddecrease
Set the AAC vale open to stop the
specrfied injectoroperatronand the
POWER rnjectorspeed can be displayedat this F Lm i n z t F
Enginerunning
BTALANCE time Inlector systefir
aa iion Do not performthtsoperatton
whrledriMng
TurnignitionswrtchON OFF and ON
so pumpoperattonmakesa solnd
FUEL PUI'P lgnitionswitchON The fuel pressurewill nse lf the conditrondescflbedon leftcan not oe
RELAY cartion Do not performthisoperatron\enfied. checkrelaysystemoffuel pomp
pump system
exceptundercondit/onsdescnbedon and fuel
1eft.
SELF-LEARNING
The air-fuelratio feedback corection coeffictentleamtnqfactor rs cleared
CONT
EN - 491
ECCSC U INPUTOUTPUTSIGNALS
RB26DETE
TNGINE
s - 2 o s c l L L o s c o P E& C l R C U lT VN
INSPECTIO
r ESTER A L U E ( R B 2 6 D E TETN G I N E )
At idle I rpm
At APProx.2,500
t"',il:"' name
I sisnar
Circuit Memo
Standard Memo Standa rd
Approx.0.4V
Sparkplug
---| t-- -r
1
2
3 Powertransistor
11 controlsignal ---.t1
12
13
Approx.5V
AAC valvecontrol
4
srgnal
A p p r o x1. V Approx.2.4V
Enginespeed
7 signalfor
tachometer 0
-- I
Air conditionOFF: A i r c o n d i t i oO
nFF:
Batteryvoltage Batteryvoltage
9 relay
Air conditioner ON:
Air conditioner Air conditioner ON:
Approx.1V Approx.1V
Approx.1V
ECCS relay switchOFF.
(lgnition Approx.0V
Batteryvoltage)
Fuelpumprelay OV OV
18
EN - .192
ECCSC/UINPUT/OUTPUT
SIGNALS
R8 2 6 D E T TE N G I N E
R B 2 6 O E TETN G I N E
PowersteeringONI PowersteeringON:
Powersteerjng OV OV
19
swtch signal PowersteeringOFF PowersteerjngOFF
5V 5V
21 Receive(conlrol
(RX) unitdatareception) 10v 10v
Transmit(data
22
(rx) transmissionfrom OV OV
controlunjt)
23 Detonation
sensor
24 srgnal Approx.0 3V Approx.0.3V
\ hstegate valve
25 controlsolenoid Batteryvoltage Approx.0V
controlstgnai
EN - 493
ECCSC'U INPUTOUTPUTSIGNALS
R826DETTENGINE
RR'ANFTT ENGINE
r l
At idle At Approx.2,500rpm
Terminal Circuit
S i g n a ln a m e Standard l\ilemo Standard Memo
No.
Enginetemperature EnginetemPerature
Bo"C:Approx.1V 80"C.APProx.1V
Enginetemperature
28 Enginetemperature Enginetemperature
sensorslgnal
2 0 " C :A p p r o x . 3 V 2 0 " C :A p p r o x . 3 V
Deffectsbetween
Exhaustgas sensor Approx.0 - 1V
29 approx.0 - 1V
signal(front)
Clock
31 OV OV
(syrchronization
(cLK) signal)
EN-494
ECCSC/UINPUT/OUTPUT
SIGNALS
R826DETT
ENGINE
R B 2 6 D E T TE N G I N E
0.5-4
Throttlesensol (VoltageIncreasesif
38 Approx.0.5V
srgnaI acceleratorpedalis
presseo)
03-0.7v
41 Crankanglesensor
51 1 2 0 "s r g n a l
2-3V 2-3V
(vr -
6r-
, dtd
42
52
Crankanglesensor
1 os i g n a l affi
OV
lgnitron
switch (lgnrtion
switch
43 "STARI': Battery OV
(STARTsignal)
voltage)
NeLJtral
switch N of P range: 0V N or P range: 0V
44 OtherthanN or P Otherthan N or P
srgnal
range 4 - 5V range: 4 - 5V
EN - 495
SIGNALS
ECCSC/UINPUT/OUTPUT
ENGINE
B826DETT
RFI?6NFTT ENGINE
, r i : : : l l - ^ ^ -
At idle I lt APProx.2'500rPm
Terminal S i g n a ln a m e C ircuit
Standard Memo Standard Memo
No.
Throttlesensor 5V 5V
48 (PowersuPPlY)
Throttlevalveswtch 10V
Approx. A p p r o x1 0 V
54 (idle contactPoint)
N or P range: 0V N or P range: 0V
E*raustgassensor OtherthanN or P Otherthan N or P
55
signal(Rear) range: 4 - 5V range:4 - 5V
Approx.05-4V
(Voltageincreases
Throttlesensor Approx 0 5V
56 signal as accelerator
Pedal
outprJt
is pressed).
EN - 496
ECCSC/UINPUT/OUTPUT
SIGNALS
R826DETTENGINE
R B 2 6 O E T TE N G I N E
Throttlevalveswtch
57 Batteryvollage Batteryvoltage
(Powersupply)
Approx.battery Approx.battery
101 voltage vorcge
103
105 Injectorcontrol
110 sjgnal
112
114
Fuelpumpterminal
104 voitagecontrol ldling(afferwarming Duringmiddleload.
s r g n a(lF P C M1 ) engrne):0V 4V
106
Fuelpumpterminal
voltagecordrol
t Duringmiddleload:
srgnal(FPCN4 2)
I OV
EN - 497
SIGNALS
ECCSC,UINPUTiOUTPUT
R826DETTENGINE
CAUTIONS
9-3 ECCSCONTROLUNITOPERATION
EN - 498
ECCSC/UINPUT/OUTPUT
SIGNALS
RB2OE
/ DE/ DETENGINE
9. ECCSCONTROLUNITINPUT/ OUTPUTSTGNALS
9-1 CONSULTINSPECTION VALUES
(1) Datamonitor
Note:Theoutputsignalis displayedas thecalcujationdataon consoleunitso thecorrect
valuewilldisplayed
evenif theoutputcircuit(harness)is inadvertentlv
disconnected.
RBaOEIDE / DET ENGINE
E N G T E I \ 4 PS E N E n g r n et e m p e f a t u r es e n s o r
( e r E r n et e m p e r a t u r e ) Affer warmrng up er€ ne Above appro, 70 C
lgnrtronswrtchON Battery
BATTERY VOLT 11- 14V ECCS conlrolunrlpower
Engrnestopped
lgfllion swtch
Throltie tully closed o 5
T H R O T T L ES E N ON Throtlle sensor adlustment
(odpln voflage) EngIne Throitle sensor sysiem
stopped Throltle fully open 4 A
INJ PULSE b i r n g ( N r a n g e .A / C
( r n j e c t i o np u i s e w d t h ) oFF)
2 - 3 rnsec Air iow meter s)slem
Aflerwarmrng I n t a k es y s t e m a r r l e a k s o r a t r
N O T F 1 / 1 6 d t s p l a yf o r up engrne sucron (en!re Input)
200o|pmwth no
RB2OE 2-3msec n p L ns r g n a l s y s t e m { e n t r r e )
l d l i n g( N f a n q e A / C
Mn15.. A.fi24.
IGNTIMING
Anerwarminq oFF)
up enqrne Air flow meter system
200orprnwjth no A d v a n c e g r e a t e rt h a n 1 0 . a n g l e
comparedlo rdlepositiOn
hling (N .ange A/C
Apptax 20 - 4AY.
AAC VALVE Aner warming oFF) IAS adluslrnent
up eng ne 2000rpm wtlh no AAC val\€ system
Approx30 - 50%
"START'
ON
START SIGNAL l g n r l i o ns w l c h StarlerSW system
.OFF'
ON OFF
E ngIne Throttle tully ciosed ON
IDLE SW
Throttle sensor system
A/C SW ON ON
A]R COND S G A r r c o n d i t r o n e rS W s y s t e m
A/C SW OFF
N or P rarEe ON
NEUTRALSW Nedral SW system
NotNorP OFF
Sieenng ON
PWST SIGNAL Polver steenng SW system
Sleeflng neLrlral OFF
Slop OFF
F U E LP U M P R E L A / IGNSW ON Fr.reipump system
ON
A/C ON ON
dling
A I R C O N D I I ' I O N E RR E L A Y A/C OFF OFF
Air condrtorEr .elaysystem
A/C ON OFF
ECCSC U INPUTOUTPUTSIGNALS
F B 2 O E/ D E / D E TE N G I N E
(2\ Activetest
ACTIVETESr_
qCT|vE TE9T DESCRIPTPI{
to checkif
Perfcrn fo lowng lnspections
probEri s so \ed
FlmLntte
SetengLne temperatufe nlgnor ow Engrne sensorsystem
ternperature
ENGINE occurence
Problem
Carjtlo[ Do notsel extremevaluesas Lnlector
system
TEIMPERATURE condrtron thrscancausespark
Plugblrnlng gassensorsyslem
Air iow meterexhaust
Nol elmrnaie.l'
Orhe- rtem ,_soector
Pe'{orn'o'lowng,nspectlorslo checkl'
problem rs sol\ed.
Elimrnate
ratiorlchor lean
Settheair-fuel Exhaust gassensorsystem
ProblemoccurenceCautoo. Do notset extremevaluesas ALrflowmeter, sensor
englnetemperature
FUELINJECTION conorllon thrsmaydamageenglneor cataiytc sysrern
ocn\ertet Injeclorsyslem
N.t elmrnaied
Other rtem Lnspection
to checklt
Performfollowinginspections
problems sol\ed.
tlmrng
DelayLgnrtion Flimln2lp
Problem Caltion: Do notset extremevaluesas
occurcnce lgnitiontimrngadlushenl
GNITIONTIMING conol!on thrsmaydamageengineor catalytic Detonationsensorsyslem
con\€nel Not ehminait.l
Other item Inspecton
Increasecontro duty ratio The englne
speed shouldincrease lf the conditiondescrlbedon leftcan not be
AAC VALVE Enginerunnrng Decrease controlduty reatlo. The venfied ccheck AAC val\€ system
OPENING
enginespeed shoulddecrease
TurnignrtronswitchON. OFF and ON
so pump operatlonmakes a sound. lf the conditiondescribed on left can not be
FUEL PUT,4P lgnrtionswrtchON The fuel pressurew11nse \€rified. check relay system of fLlelpirmp
RELAY Enginestop Cado-o- Do not perform this operatron and fuel pump system
exceptunderconditionsdescnbedon
left
EN-500
ECCSC/UINPUT/OUTPUT
SIGNALS
B B 2 O EE N G I N E
Air flowmeter
3 intakearrquantity Appfox.1V Approx.1.5V
srgnaI
Enginelemperature Enginetemperature
Enginetemperature Bo"C: Approx.1V 8 0 " C . A p p r o x1 V
5
sensorsrgnal Engrnetemperature Enginetemperature
2 0 " C :A p p r o x . 3 V 2 0 " C .A p p r o x . 3 V
0 . 5- 1 V
Throttlesensor (Batteryvoltagewill
7 Approx 0 5V rncerasewhen
srgnal(lnput)
acceleration pedaiis
pressed)
0.3- 0.7v 0 . 3- 0 . 7 v
Crankanglesensor
I
1 2 0 "s i g n a l
2-3V 2-3V
(v)
6
Crankanglesensor 2
10 o
1 "s r g n a l
E N- s 0 1
EUUJ \, \] SIGNALS
INPUT/OUTPUT
R B 2 O EE N G I N E
RB20EENGINE
At idle I At APProx'2,500rpm
Terminal Circuit
S i g n a ln a m e Memo Standard Memo
No. Standard
Intakeair quantlty
'15 Approx.lV A p p r o x1 . 5 V
outputsignal
(ToA/T C/U)
sensor
Detonation Approx.4V Approx.4V
signaI
0 . 5- 1 V
(Batteryvottagewill
Throttleopening Approx.0.5V incerasewhen
17
otjtputsignal acceleration Pedalls
presseo)
EN 502
ECCSC/UINPUT/OUTPUT
SIGNALS
R B 2 O EE N G I N E
R B 2 O EE N G I N E
OV
lgnitionswitch (lgnition
switchat
23 OV
(STARTsignal) START Power
vonage)
lgnrtion
swtch
25 Powervoltage Powervoltage
(ONsignal)
Throttlesensor
26 srgnaI 5V 5V
(Powersupply)
Controlunitpower
27 Power voltage Powervoltage
supply
Air conditioner
OFF: Air conditioner
OFF:
Air conditioner Powervoltage Powervoltage
29
sw'tchsignal Air conditioner
ON: Air conditioner
ON:
Approx.0V Approx.0V
EN - 503
SIGNALS
ECCSC/UINPUT/OUTPUT
R B 2 O EE N G I N E
RB20E ENGINE
i-;l:-*'r
I il- ecru
l ' -
Throttlevalveswitch \ _.-!!r'-, Powervoitage Power voltage
32 (PowersuPPlY) |.-''
0 . 2- 0 . 3 v
Powertranststor
controlsignal
PowersteeringONI PowersteeringON:
OV OV
Powersteering
38 PowrsteenngOFFI PowrsteeringOFF:
switchsignal
Approx.5V Approx.5V
Approx.1V
switchOFF.
(lgnition OV
40 E C C Sr e l a y
Powervoltage)
1V
Approx. Approx.3V
Tachometerengine
43 rev srgnal
EN - 504
ECCSC/UINPUT/OUTPUT
SIGNALS
R B 2 O EE N G I N E
R B 2 O EE N G I N E
EngineA/T total
controlinpLrt
signal Approx.
10V A p p r o x1 0 V
(Dr1)
Air conditioner
OFF Air conditioner
OFF
46 A,r conditioner
relay Powefvoltage Pov.ier
!oftage
Air conditioner
ON ArrcondrtronerON
OV OV
EngineA/T total
47 contro, or.IpLlt OV OV
signal(DT3)
104 Fuelpumprelay OV OV
EN - 505
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 (RB2ODE
/ D E TE N G I N E )
t g n i i i o nS W
rEf-s @f'
18 Fuelpumprelay Qr,"r p,'p- OV OV
) + ,,---!)- \
PowersteeflngON:
PowersteeringON:
Powersteeflng OV
OV
switchstgnal PowersteeringOFF.
PowersteeringOFF
5V
23 Detonation
sensor
24 signaI Approx 4V Approx.4V
Enginetemperature Enginetemperature
Enginelemperature 80"C: Approx.1V 80"C: Approx.1V
28
sensorsrgnal Enginetemperature Enginetemperature
2 0 " C :A p p r o x . 3 V 2 0 " C :A p p r o x . 3 V
Et\ - 3U/
SIGNALS
ECCSCiU INPUT/OUTPUT
R B 2 O D /ED E T E N G I N E
, I l : : :
Ai idle I At APProx.2'500rpm
t"ffi:"'l name
sisnar Circuit Memo
Standard Memo Standard
Engine(AfD total
Approx.0V Approx.0V
35 controloutpLrtsignal
(Dr3)
Engine(A,/T)total
Approx.10V 10V
Approx.
36 controloutputslgnal
(D12)
0.5 - 4V (Voltage
Throttlesensor increasesif
38 Approx.0.5V acceleratorpedalis
srgnal
presseo)
E N- 5 0 8
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
6
Crankanglesensor
41 2,,
1 2 0 "s i g n a l 0il
2-3V 2-3V
Crankanglesensor
42 'l'signai
-_ 0.5trr'-
OV OV
lgnation
swtch (lgnitionswrtchin (lgnrtion
switchn
43 "STARI'':
(STARTsignal) Power "STARI-' Power
\ cltage) voltage)
48 Throttlesensor
(Powersupply) 5V
trI\ - 5U9
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
| :a:
At idle I lt lPProx. 2,500rpm
*il:"'l name
sisnar C ircuit Memo
Standard Memo Standard
0V when accelerator
Throttlevalveswitch A p p r o x 1. 0 V
54 pedalis pressed
(ldle contactPoint)
Approx.0.5 ' 4V
Throttleopening (Voltagewillincrease
56 A p p r o x . 05 V when acce|eralor
outputsignal
pedalis pressed)
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
E N- 5 1 1
SIGNALS
ECCSC U INPUT'OUTPUT
/ D E / D E TE N G I N E
RB2OE
CAUTIONS
9-3 ECCSCONTROLUNITOPERATION
E N- 5 1 2
ECCSC/UINPUT/OUTPUT
SIGNALS
C A ' 1 8Ei N G I N E
lgnrtronswitch ON Battery
BATTERY VOLI 11- 14V E C C S c o n t r o lu n r tp o \ , € r
E n g r n es l o p p e d
STAR']-' ON
START SIGNAL Starter SW system
ON
Engrne Throttle tully closed ON
IDLE SW
Throttle sensor syslem
A/C SW ON ON
AIR COND SIG A r r c o n d r l i o n e rS W s y s t e m
A/C SW OFF
ON
N E U T R A LS W Neutral SW system
Steenng ON
PWST SIGNAL Povt€r steenng SW slstem
A/C ON ON
FICD SA/ F I C D i n p L ns y s l e m
ON AIC OFF
Eng temp cord ON
PTC healer InpLnsystem
Eng temp Hoi
Slop
FUEL PUMP RELAY IGN swtch ON Fuel pump syslem
ON
A/C ON
A I R C O N D I T I O N E RR E L A Y ldle A i r c o n d i l r o n e rs y s t e m
A/C OFF OFF
SIGNALS
ECCSC'U INPUT/OUTPUT
C A 1 8 iE N G I N E
!*'.r.
ACTI/ETEST
ACTIVETEETDESCRIPTIO{
r,:sl,
Perfor.nfo lowrng nspectionsto check lf
problemts so \€o.
F mLn:JP
Setenginetemperature hlghor low Engnelemperatlre sensorsystem
ENGINE Problernoccurence
Cal]tion.Do notset extremevalues Inlector
system
TEIVIPERATURE condrt0n
as thiscancausesparkpLug burnlng
Arrflowmeler.exhaustgas sensorsysrem
Nol clm nated
Ot_er tem nsoeclion
Pedorm follow!nginspectionsto check if
pfoblemis sol\€d
Flimrn2te
Setthearr-fuelratronchor lean. Exhaustgas sensorsrsrem
occurenc€Calllio-rtDo notsetextremevaluesas Aif flowmeter englnetemperature
Problem sensol
FUELINJECTION condttlon or catal)'tlc
thisrnaydamageengLne system
ocn\€rter. lnlectorsystem
Not elirninaied
Other rtem Inspectlon
Performfollowlnginspectionsto check if
problemrs solt€d.
ttmrng
Delayrgnrtlon Flimrn2tt
occurenceCArdion Do not set extremevaluesas lgnitiontrmingadjustment
Problem
IGNITIONTII,IING condrtron thrsmay damageenglneor cataYlc Detonationsensor system
convefler Nol elimin2led
Other item inspectlon
TurnignitionswitchON and OFF The
Affer engrnewarm uP idle revwill change lf the condihondescribedon lell can not be
IDLE hling (N range,A/C Carxio-o.Do not pedom this operatron \€riied. checktdlecorrectlonsolenol0
CORRECTIONSA/ oFF) exceptundefcondltlondescrlbedon slstem
left
Turnrgniton swtch ON and OFF The
AfterengrnewarrnuP rdlerevwll increaseal approx200rprn lf the condrlroldescrrbedon leftcan not be
FCD SA/ ldling(N rangeA/C Ca!tjo-c|:Do not performthis operaton \€rified.checkFCD solenoldsystem
oFF) exceptunderconditiondescnbedon
lefr.
switchON OFFandON
Turnignrtron
makesa sound
so plmp operation describedon leftcannotbe
f thecondition
FUELPUMP lgnitionswitchON Thefuelpressurewillrise \€nied, checkfelaysystemof fuelpump
RELAY Do notperformthlsoperatlonandfuelPurnp
Ca!!-oxL- system
except!nderconditlonsdescnbedon
left
SELF,LEARNING coerfclentlealnlngfactorrs ceared
ralo feedbao(correctlo'1
fhe arr-fuel
CONT
EN- 514
ECCSC/UINPUT/OUTPUT
SIGNALS
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 )
Appfox.1V - 5V
Throttle
sensor (Voltagewillincrease
3 Approx.
1V
signal1 whenaccelerator
pedalis pressed)
Enginetemperature Enginetemperature
Enginetemperature 80"C: 1V 80"C: 1V
5
sensorsrgnal Enginetemperature Enginetemperature
20"c 3v 20"C: 3V
Deflectbetween Deflectbelween
approx.0 - lV a p p r o x0 - 1 V
Approx.06V-4.5V
Throttlesensor (Voltageincrease
7 Approx 0 6V
signal2 whenaccelerator
pedalis pressed)
I Crankanglesensof
'19 '180"signal
Approx.2 - 3V 2 - 3V
Approx.
(v)
6 6
10 Crankanglesensor 2
2
20 1 os r g n a l 0
E N- 5 1 s
SIGNALS
ECCSC/U INPUT/OUTPUT
C A l 8 iE N G I N E
C A 1 8 iE N G I N E
' | ::::
At idle I At APProx.2,500rpm
t"',il:"'l name
sisnar Circuit
Standard Memo Standard Memo
(v) '1
6 Approx. " 5V
(Cyclewill get shorter
Vehrclespeed 2
21 sensorsrgnal
0 whenvehiclesPeed
is increased)
OV OV
lgnitionswitch (lgnition
switchin switchin
(lgnition
23 "START'signal STARI Power START Power
voltage) voltage)
N or P range:0V N or P range: 0V
Neutralswitch OtherthanN or P Otherthan N or P
24
signaI range:6 - 7V range. 6 - 7V
OFF:
Air conditioner OFF:
Air conditioner
Air condittoner Powervoitage Power voltage
ta ON: ON:
Air conditioner
switchsignal Air conditioner
OV OV
E N- 5 1 6
ECCSC/UINPUT/OUTPUT
SIGNALS
C A 1 8 iE N G I N E
CA'I8iENGINE
lntakeatf
30 remperaturesensor Cold: Approx.1.5V C o l d :A p p r o x1. . 5 V
stgnal l brm: Approx.0.8V Wbrm: Approx.0.8V
PowersteeringON: PowersteeringON:
Powersteenng OV OV
signaI PowersteeringOFF PowersteenngOFF.
Approx.BV Approx.BV
Approx0.5V A p p r o x1. V l
(;)it-Il]l--l-t-,1 1 T
4f-:.-. -- -
Powertranststor
37
signai(lN)
control
,fltr-4- A' a''J'
't:t:t:'J't-
-- -+- 108
i r : r c ' * . . .i ,l 1
' |
-rrr:F 1 rl l l
lgnitionprimary
39
stgnal
OV
40 ECCS relay (lgnition
swtch OFF: OV
Power voltage)
E N- 5 1 7
SIGNALS
ECCSCiU INPUT/OUTPUT
C A 1 8 ]E N G I N E
C A 1 8 iE N G I N E
' I l : : :
At idle I at APProx.2'500rpm
t"',1::"'l sisnar
name Circuit
Standard Memo Standard Memo
Powervoltage Lowef than Power
volage
FuelinjectorPUlse
41 monitorsrgnal
(ll monitor)
SwitchON: SwitchON:
Power voltage Powervoltage
43 Lightswitchsignal
SwitchOFF: 0V SwitchOFF: 0V
SwitchON: SwitchON:
Heaterfan swtch Powervonage Power voltage
45
srgnaI SwitchOFF: 0V SwitchOFF] 0V
SwitchON: SwitchON:
Reardefogger Powervoltage Power!oltage
46
switchsignal SwitchOFF] 0V SwitchOFF: 0V
'101 Injectorcontrol
110 srgnal
A i r c o n d i l r o nOe rN : ON:
Air conditioner
relay
Air conditioner Powervoftage Power voltage
102 srgnal A r rc o n dt r o n eO r FF OFF:
Air conditioner
OV OV
E N- 5 1 8
ECCSC/UINPUT/OUTPUT
SIGNALS
C A ' l 8 iE N G I N E
C A 1 8 iE N G I N E
Air condilioner
ON: Air conditioner
ON:
'103 FICDsolenoid
OV OV
Air conditioner
OFF: Air conditioner
OFF:
Powervoltage Powervoltage
Approx.0V
(Powervoltagefor 5
104 Fuelpumprelay ,-,11t_ sec atterjgnrtion Approx.0V
swtch rs placedto
ON posrtion)
'1. Whenign sw in
on
2. Enginerewing: Approx.0V
ldle rev correction First15 sec afrerenginestart:Approx.0V
111 Afler15 sec afterenginestarl: Powervoltage
sotenoro
Any ofthe followingsare ON (Powersteering,
laghts,
reardefoggetheaterfan switch)iApprox.
0V (D rangefor A/T)
Lockup released:
Approx.0V Lockup released:
Lock up release Lock Approx.0V
115
solenoid(Aff) Lockup appljed:
u pa p p l e o : Powervoltage
Power vottage
E N- 5 1 9
ECCSCiU INPUTOUTPUTSIGNALS
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
9.1 CONSULTINSPECTION VALUES
(1) Datamonitor
Note:Theoutputsignalis displayed dataon consoieunitso thecorrect
as thecalculation
valuewilldisplayedevenif theoutputcircuit(harness) disconnected.
is lnadvertently
RB25DEENGINE
rr,r:,r.,t,trtr',r. toR
A/C SW ON ON
Arrcondtoner SW system
AR CONDS G OFF
A/C SW OFF
N or P range ON
NeLtalSW system
NEUTRALSW OFF
NotNorP
ldle
Steenng ON
PWSTSIGNAL PowersteenngSW syslem
Steenng rcu'tral OFF
ArC ON ON
OFF OFF Arrcondtoret reay syslem
AIR CON RELAY
ACCeI A/CON OFF
Stop OFF
IGNSW ON FLE pumpsystem
FUELPUMP RELAY ON
EN - 521
SIGNALS
ECCSC U INPUT,OUTPUT
R B 2 s D EE N G I N E
At idle At Approx.2,500rpm
Terminal C irc uit
S i g n a ln a m e Standard Itlemo
No. Standard Memo
0.2- 0.3v Approx.0.4V
1 (v) -
l- - ' . - . :
2 6 . _ . .
3 Powertransistor
11 controlsignal
12
13
Cold: 6 - 7V Approx.5V
Vvarm:8 - 10V
(v)-r'-:-_-_-_
l5
AAC valvecontrol 10
t|l
10 -,r1 --f|- -Ttl
4
srgnaI 5 5 - ir r'
.--'---
:+zrs ,1,.---
Afi contol un
f+
EngineA/T total i
5 controlinputsignal 10V
Approx. 10V
Approx.
(Dr1)
Approx.1V Approx.2.4V
lvt ., - - -.l
-" i ; ; ; . ; '
Tachometerengine F Tf-lTl-r-TTtf
7
speedsignal "IIilLTI]rlL
l.ih- l]]-
, t .:-_ti-
OFF:
Air conditioner OFF:
Air conditioner
Powervoltage Powervoltage
9 relay
Air conditioner ON:
Air conditioner ON:
Air conditioner
Approx.1V Approx.1V
Enginea/T total
14 controlinputsignal Approx.10V Approx.10V
(D12)
EN - 522
ECCSC/UINPUT/OUTPUT
SIGNALS
R B 2 5 D EE N G I N E
R B 2 5 D EE N G I N E
Termina
I At idle At Approx.2,500rpm
Signal name C ircuit
No. Standard Memo Stan dard Memo
EngineAff total
15 controloLrtputsrgnal Approx.0V Approx.0V
(Dr3)
Approx.1V
16 E C C Sr e l a y (lgnrtion
switch
OFF. Approx.0V
Powervoltage)
18 Fuelpumprelay OV
t v i : l!.,/erstee^ng_N
l = PowersteenngON
'19 Powersteenng OV OV
^::
swtch signal PowersteeringOFF D-\!Fr <.;.--,^
5V
----5i."",,
I rio"i""*t"**
23 Detonation
sensor i i - - - -
24 sigml
Approx.0.3V Approx.0.3V
EN - 523
SIGNALS
ECCSCiU INPUT,OUTPUT
FIB25DEENGINF
R B 2 5 D EE N G I N E
. r t l
At idle I At APProx. 2,500 |pm
t"il:"'l name
sisnar Circuit
Standard Memo Standard Memo
Enginetemperature Enginetemperature
temperature 80"C:Approx.1V 80"C:Approx.1V
Engine
28 Enginetemperature Enginetemperature
sensors!gnal
20'C: Approx.3V 20"C:Approx.3V
gassensor
Exhaust Deflectbetween0 -
29 0 - 1V
Approx. approx.
'1V
signal
[,ilonitor& check
lamp Lampnot lit: Lampnot lit:
(redlamp,exhaust Powervoitage Powervoltage
32
temperature Lamplit: 0V Lamp lit: 0V
warninglamp)
0.5 - 4V (Vottage
Throttlesensor increasewhen
38 Approx.0.5V acceleratorpedalts
srgnal
presseo)
EN - 524
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
Crankanglesensor
41
1 2 0 "s i g n a l
2-3V
lv)
6 -r ' . -T- -
Crankanglesensor
, ftfl{f+nnflnI
42 , +fffHfl+HilIiI
1 "s i g n a l 0r!!u!Fu!uu
. - . . , . -
OV
Jgnition
switch (lgnition
swilch
43 OV
(STARTsignai) STARI Power
voltage)
Air conditioner
OFF: Air conditioner
OFF:
Air conditioner Powervoltage Powervoltage
46
switchsignal Arr conditioner
ONI Arr conditioner
ONI
OV OV
Intakeair quantjty
4A
outpLrtsrgnal
EN - 525
ECCSC/UINPUTOUTPUTSIGNALS
R B 2 5 D EE N G I N E
RB25OEENGINE
' t : : : l
At idle I lt lPProx- 2.500rpm
t"'.,il:"'l sisnar
name Circuit
Standard Memo Standard Memo
Approx.0.5 - 4V
Throttleopening (Voltagewill increase
56 Approx.0.5V when accelerator
oLrtputsrgnal
pedalis pressed)
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
1. BATTERYINSPECTION
Voltage inspection
Normal N) 1 2 . 4- 1 2 . 8
Limit(chargerequired) (V) 1 2 . 4o r l e s s
(Startlrmrt) (V) 12(zo"C)
2. ALTERNATOR
(1) Alternatorremovaland installation
C A 1 8 iE N G I N E RB ENGINE
-"f;-s-'h;l
."f'q
,",,.-.ffi
i1;'5T.1
,*-*;".fr",
(21 AlternatorinsPection
Output voltage insPection
. Placeignitionswitchto ON positionand check thal
chargewarninglamPwilllight.
EN-530
ENGINEELECTRICAL
EOUIPMENT
BB26DETT/ RB20Ei DE / DET/ CAi Sr/ FiB25DEENGTNE
3. STARTERMOTORREMOVAL& INSTALLATION
CAIsiENGINE RBENGINE
Startermotor B o l t3 . 1- 4 . 1
*-,"rt",
ll
Washe
Nut
4. SPARKPLUG INSPECTION
Inspection
. Checkfor anylooseness withterminals.
. Checkfor anydamageor crackson theinsulator.
. Usethickness gaugeto checkthesparkpluggap.
S p a r kp l u g g a p ( m m ) : 1 . 0- 1 . 1
5. PLATINUMPLUG INSPECTION
(BB2ODE,RB2ODET, RB26DETT)
Installation precautions
Periodic replacementinterval: 100,000km
Gasinspection andadjustment andplugcleaningusing
wirebrush,shouldnotbe performed as thismayscrape
off the platinumpartucluatefromthe platinumtip surface.
lf plugsarecleanedwithan airgun,thecleaning should
be performed in lessthan20 secondsat an airpressure
lessthan6.0k9/ cmr.
Onlyusepartsspecified by Nissan,whenreplacing the
spark plugs.
EN - 531
EQUIPMENT
ENGINEELECTRICAL
RB26DETT/ RB2OEi DE / DET/ CA18i ENGINE
o. IGNITIONCOILINSPECTION
CA18iENGINE(lntakeside) CA18i(Exhaust
side)
RB2OEENGINE RB2ODE/DET/RB26DETT
. Checktheprimaryandsecondary value.
coilresistance
EN - 532
COOLING
SYSTEM
RB26DETT
/ RB2OE/ DE / DET/ CA18i / RB2sDEENGINE
ENs COOLINGSYSTEM
PREPARATIONTOOLS
SPECIFICATIONS
Onepieceunit(owershroud)
EI\ - CJJ
SYSTEM
COOLING
R B 2 6 D E T/TB B 2 O E/ D E / D E T/ C A 1 8 /i R B 2 5 D EE N G I N E
1. RADIATORINSPECTION
Cooling water leak insPection
. Useradtatorcap testerandapplypressure(limit1 Okgi
cm2)andcheckfor leakage.
Caution:
Whenusingthe radiatorcap tester,alwaysmakesureto
connectthe hoseadapterandfillercap is notdeformed.
2. RADIATORCAP INSPECTION
Inspection
. Cleancap rubberpackingsealsurfaceandvacuumwith
drybrush.
. Attachradiator
captestertocap.Applypressure
ano
checkthatvalveoperatescorrectly.
. Pullvacuumvalvewithfingerandcheckoperation.
J. COOLINGWATERFILLINGPROCEDURES
hoseandheaterhoseclampsare
1 Makesurethe radiator
tightenedsecurelY.
Setthe heatercontrolleverto HOTposition.(For
vehiclesequipped withautomatic airconditioners,first
placeignition switchto ON position andremovethe
externalsensorconnector).
Releasethe radiator capandairdrainplug. (RB20E:
lntakemanifold area. RB20DE/ DET:Intake
collector
manifoldcollectorarea and in frontof glovebox).
Filltheradiator gradually (fillingspeed:slowerthan2L /
min)to thetopof thespoutwithcoolant.Fillthe radiator
untilthe waterin the reservetankreachesthe MAXlevel
lineindicated.
5 After closingthe radiator capandairdrainplug(RB
system), starttheengineandallowit to idle.
6 Theenginewillcontinue to idleuntilthethermostat
opens.(Touchthe radiatorf low hoseand makesurehot
wateris flowing).lf a largevolumeof airremains, the
walertemperature gaugeneedlewillmove past
the
middleas theengine temperature rises abnormally' lf
thisoccurs,stoptheenginewaituntilit coolsand add
water to the radiatorrepeatedlyas describedabove.
Afterthe thermostatopens,racethe enginefor 10
secondsat 2500rpmtwoor threetimes.Checkthat
the watertemperature doesnot riseexcessively.
EN - 534
COOLING
SYSTEM
RB26DETT/ RB2OE/ DE / DET/ CA18i/ RB25DEENGINE
4. RADIATOR
REMOVAL
ANDINSTALLATION
C A l 8 iE N G I N E
Bolt(2)
- -- '' 0.33- 033 Reservertank
Nut0.33- 0143- a.
__xo
Fadjator moudlng
&racket (uppe.tt ,
s iff ijgj
(upper)
- Radiator
6- ,rn-- 9
m o un l r ng -
Nut0.33 0.43
(upper)
Radiatorhose (lowe4
Hose clarnp
Atf otl co(
r (A/T
nose
Radiator Fladiator
mo unt r n g shroud(lower)
rubber(lower)
Badiatorshroud(upper) \p*Screw ( 4 )P
Fi.
lv.l Kg-m 0.33- 0.43
EN - 53s
FUELSYSTEM
RB26DETT/ F]B2OE
/ DE / DET / CA18i/ RB25DEENGINE
EN6 FUELSYSTEM
PREPARATION
TOOLS
FLrelgaugeinspection
SPECIFICATIONS
EN - 537
FUELSYSTEM
/ D E / D E T/ C A l 8 i / R B 2 5 D EE N G I N E
F I B 2 6 D E T/ TR B 2 O E
Fillertube IPornt4]
Canister
d
Fueltankprotector
Bolt(4) 0. 3 3- 0 . 4 3 IPoint3]
Additionalwork required:
Drainfuel
Removethefollowing:
Fuelpressure reliefvaive[Point1]
Fueltankinternalpressurerelief
Fillertubeprotector
InspectionholecoverIPoint2]
Fuelgaugeunit,fuelpumpharnessconnector
[Point3]
FueltankProtector
Hoses
'l
[Point ] Fuel pressure relief
. Afterstartingthe engine,removefuelpumpfuseandwait
untilenginestops.Crankengine4 to 5 timesto consume
f u e li n l i n e s .
. Forvehiclewhichcan notbe started,removefuelpump
fuse,crankengine4 to 5 timesto consumefuelin lines.
Caution:
The batterymay becomeweakeasily,use boostercablesto
connectit to anothervehicleor batteryif necessary.
EN - 538
FUELSYSTEM
RB26DETI/ RB2OE/ DE / DET / CA18i/ RB2sOEENGINE
Additionalwork required:
Removethefollowing:
Fuelpressurerelief
Internalpressurerelief
Inspectionholecover
Fuel gauge limit
Fuelpumpharnessconnector
Fuelhose(return,feed)
l P o i n t1 I
Fuel gauge ASSY bolts installation
. SetO-ringto fuellanksideand insertgaugeASSYinside
thetank.Tightentheboltsshownin thefigureon the
right.
Caution:
Extracautionmustbe takennotto damagefloatandthe
armwheninstalling gaugeASSY
f uelgaugeASSY Handstartbolts
Onlyusespecif iedboltswheninstalling
(3) Inspection
1. Float inspection
. Placethefloatat the F (leverupperside)and E (lever
downside)positions andcheckthe resistance.
2. Pumpinspection
. Applybatteryvoltageto harness terminal1 and
connecter
3 andcheckitsoperation.
Caulion:
. Caremustbe takenwhenhandling fuelpump.
. Do notreusepumpif it is dropped.
. Do not allowdirtor debristo adhereto the filter.
. Do nottwistor turnharness.
EN - 541
SYSTEM
EXHAUST
RB26DETT/ FB2OE/ DE / DET/ CA18r/ RB25DEENG NE
EN7 SYSTEM
EXHAUST
SPECIFICATIONS
EN - 542
EXHAUSTSYSTEM
RB26DETT
/ RB2OE/ DE / DET/ CAI Bi / R825DEENGINE
Bort{a)el
0 . 5- 0 . 7
A/T
(21 RB20EENGTNE
M / Tr t l u tt Z l+ . a- S . O P
Nut(3)4.6- 6.1gl
(3) RB20DE
M/T N u r( 2 )4 . 4- 5 . 6 9
Nut(3)4.6- 6.1$)
Bolt(6)0.5- 0.7g|
N u t1 6 )
1. 3 - 1 . 6 \ - /
9l ruutlt g - 't.6
View A Nut1.3-1.69
(4) RB20DET
^ N u t( 2 )4 . 4 - ---i=, A/r
) .6-6.1 M/T
Nu t ( 3 4
glBoro.5-0.7 d'i- r.s- r.sg
,r, 121
EN - 543
SYSTEM
EXHAUST
R B 2 6 D E T/TR B 2 O EI D E I D E T I C A l 1 i I R B 2 5 D EE N G I N E
(4) R826DETT E N G I N E
Nut (2) 4.4 - 5.6
N u r( 4 )4 . 6- 6 . 1I
Bolt(4)
o l t0 . 5 - 0 . 7
0 . 5- 0 . 7
Bot1.3-1.6
9lBott (2)4.4- 5.6 Nut(2)pl
Nut1.3-1.6
u'"Jo
fil'-(]ue
ry1s-16
Srp
(5) RB25DEENGINE
M/T
.,::p
1.3-,r.6(2)ggggg
Pta e' z '
,'::::1", $Foo,u'i) , - ' r . s-
r.oP
' *;
, ::";;*ir.9,"",,!,::it:is\ -
_-1,3 16
q/i-;-
4round ine
1 . 3- 1 6 9
f,:l:r*:;',"o,'
-'
-o5:.01gl
Clamp
, ,t'i-'
i'-""*'n-'" A/T
4.6- 6.1 {3)F)
/ *' rrsu'alor
{ rrn"r.t ten'o sensor
t , . tnsutalor
I n s u l a l o r 0 . 5 - 0 7 ( 6 ) '[ q'
o.s2 0.66p:
EN - s44
EXHAUSTSYSTEM
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 positionandcheckthat
C A 1 8E
i NGINE
exhaustgaslemperature warninglampdoesnotturnon.
. Exhaustgastemperature warninglampmustlightwhen
ignitionswitchis placedat STARTpositionandmustgo
offwhenengineis staned
Exhaust gas temperaturewarning lamp replacement i ]
and inspection
. Removevehicleharnessfromswitching module.
. Useleadlineto groundvehiclesideharnessconnecl
exhaustgastemperature warninglampterminal.
. Inspectcondition of exhaustgastemperaturewarning
lampwithignition switchturnedON.
Faultycircuitbetlveenignitionswitchingmodule.
Faultykey sensingmoduleor sensor.
Exhaust gastemperature
warning
lamp,s burned
out.
Exhaust gastemperature lamppower
warning
circuitis faulty.
EN - 545
ENGINE coNTRoL
/ D E/ D E r
R B 2 6 D E r/rB B 2 0 E / c A l B i i R B 2 5 D E N G T N E
EN8 CONTROL
ENGINE ASCDDEVICE)
(INCLUDE
cAl8i
1. ACCELERATOR PEDALINSPECTION AND
ADJUSTMENT Locl( nul
0 . 8- 1 . 0
Acceleratorpedal i nsPection
. The enginemustbe fullthrottlewhenacceleratorpedalis
pressedfully(pedallevercontactsthe stopper
completely).
Acceleratorpedal adiustment
. Loosenlocknutsso acceleratorcablehas adequate
slack.Pulloutercasein direction pedal R B 2 O E
of accelerator
trompositionwherethrottledrumstarlsoperating(there
'ThrottLe.drum
mustbe no playat thispoint),returnlocknuts1.0to 1.5 . ia--- I ,^ ^^^
turnsandtightensecurelY.
RB2ODE/DET/RB25DE
i l
E N- 5 4 6
ASCD
RB26DETT/ RB2OE/ DE / DET/ CA18i/ FB2sDEENGINE
2. ASCD
Specification
Speedsettingrange A p p r o x5. 0 - 1 0 0 k m/ h
Constanlspeedcontrolrange Levelroad+0 I -2 km I h
Memory type Digitalmemory
Control
type.actuator
dnversource Negativeoressurecontrol.negativepressurepump
Actuator
stroke Approx.33mm
Setsystem One-touchsystem(withtap downsystem)
Resumesystem Installed
Acceleratjon
system Installed
(wrthtap up system)
Overdrivecancelsystem Installed
System
A / T VEHICLE
swltcn
Clulch Brake
s wi t c h swrlh
c
* l
|,-J
t-i
ASCDcontrolunI
Eq:T[qilil
i t l l7 t t 5 t4 t8 t l
horn retay
-------&{1*a -
ASCDrelay " *- fA
3l -. 5 illrlal
#e
ASCD main d
1 4 5 3 t1
ASCD controlunit
Set,'
coas
swilr
AND ADJUSTMENT
2.1 ASCDINSPECTION
(1) FAULTDTAGNOSTS
t l
:::i:-:t:::
unit
lnsidecircurt [,,lain
Hunting FaLrlty
fespon
faulty faulty
lnsidecifcurt M a i nu n r t
Cancel Diapfgramnle
faulty faulty
Setting
u nstable lnsidecrrcurt M a i nu n i t Catchor leak
Large gap between
m set vehiclespeed faully faulty d iaphgramn
z
(n Vehiclespeed Insidecrfcuit [,4ainunrt
@ decreasewhen faully faulty
setting
lnsidecircuit Mainunit
Does not cancel laulty faulty
ASCD
RB26DETT
/ RB2OE/ DE / DET/ CA'l8 / RB25DEENGINE
INSPECTION
& MAINTENANCE
PROCEDURE
WHENIT CAN NOT BE SET
Checkcontrollergroundforany
faults(betweenterminal3 and Faultyharness,inspection
groun0).
present
Continuity
Otherthan ReplacefaultystoplampSW,
Checkforpowervoltage (approx. approx.12V SW(lV/T),
clutchrelay
12V)to controller
14 ' 3, 5 - 3 jnhibitorSW.relay
(HICASI\4/T),
(otherthaneN forA/T)l (A,T)
Approx.12V
Powervoltageis presentwhenSer
/ coastSW is ON (Approx.12V) Replacefaultyset / coastSW.
(between7 - 3)
Approx.12V
Powervollageis presentat vehtcle Otherthan
speedsensor(between7 - 3) 5V and0V lnspectvehiclespeedsensor
(Approx.5V and0V alternatively)
system.
whenwheelsare rotatedsiowly(1
Approx.5V & 0V
Donot
DisconnectASCD pump operare Removeactuatornoseandoperale
connector andappiybatteryvollage the pump. Checkif negative
betweenterminal1+ - 3-. Checkil pressureoeverop.
ASCDwirewilloperatewhen
t e r m i n a4l a n d 2 i s
Operate
Controlpowervoltagetapprox.l2\. ,
ls developed
betweenterminalI
and3, whenvehiclespeedis over
48km/hand seUcoastSW is ON.
Approx.
12V
Removecontroller connector and
checkif pumpoperateswhen12V Do not
and0V is appliedto vehicleside operate Repairiaultyharnessto the pump
harnesswhichcorresponds to or shortcircuit.
controller
terminal8+ and body
ground,terminal8+ and 9,10-.
Operate
Otherthan
Checkif set powervoltageis
OV
approx.0V betweenterminal2 and
3 whensercoastSW is released.
Approx.0V
EN - 549
ASCD
RB26DETT/ BB20E/ DE / DET i CA18r/ BB2sDEENGINE
Damaged
No damage Not
smooth
Checkif ASCDwiremovementis
Smooth
Leaking ReplacefaultyASCD
for any leakor negativepressurein
pumpairvalveandreleasevalve. pump
No leakage
Cracked
Checkfor any leakor negative
in airvalveandreleasevalve.
Notcracked Removeactuatorhose
DisconnectASCD pumpconnectorand andoperatethe PUmP.
applybatteryvoltagebetweenterminal1+ - Checkif negative
3-. Checkif ASCDwirewilloperatewhen pressuredevelop.
terminal4 and2 is grounded.
Operate
PROCEDURE
& MAINTENANCE
INSPECTION IS UNSTABLE
WHENSETTING
(cANCEL)
SETTING
UNSTABLE
Thereis approx.12V
presentbetweenterminalI Voltagebetweenresume/ ReplacefaultyASCD
and 3 whenset SW is acceleratorswitchtermlnal1 switch.
placedf romON to OFF and 3 is 0V.
position.The system
with Abnormal
ls thereany abnormality vehiclespeedsensor
andmetercable.
No abnormality
Powervoltage(approx.5V and0V) is
betweenvehicle
appliedalternatively
speedsensorterminal7 and3, when
wheelsare rotatedat 1 - 2km/h.
5V & 0V
Approx.
Leaking
Checkfor leakandnegatlvepressure
in airvalveandreleasevalve.
Faultycontroer
EN - 5s0
ASCD
RB26DETT/ RB2OE/ DE / DET / CAl8i / RB25DEENGINE
INSPECTION
& MAINTENANCE PBOCEDUREWHEN SETTINGIS UNSTABLE
(DIFFERENT
TO SET VALUE)
SETTING
UNSTABLE
Largedifference
to settedvalue
Nocatching
Checkfor any bent,damageto Replace damagedvacuum
vacuumprprng. piping.
No damage
ASCDpump,airvalveandrelease
va,veforneoative
oressure
andleak.
Noleakage
Checkfor any leakor negativepressu ReplacefaultyASCDpu
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.
SETTING
UNSTABLE
Plungein vehicie
speedwhensetting
Notcorrect
Checkif ASCDwire playis or smooth Replaceor adjustASCD
Correctplayand smooth
Checkvacuumpipesfor bentor
damage.
Nodamage
Other
Thereis over10Vcontrolvoltage
than'12V
forcontroller
outputbetween
terminal8 and 3 justaftersetti
A p p r o x1. 2 V
DisconnectASCDpumpconnector
andgroundterminal1+ - 3-4,2.Check
if ASCDwirewilloperatenormally.
y S C Dp u m p
F a u l tA
EN - 551
ASCD
R B 2 6 D E T TB/ B 2 O E/ D E / D E T / C A 1 8 i /B B 2 s D EE N G I N E
INsPEcT|oN&MA|NTENANCEPRoCEDUREwHENAccELERAToRDEVICE
DOESNOTOPERATE
Doesnot
Checkif constantspeed
devicewilloperateusing
set/coastSW.
Operate
WhenstopptngPlace powervoltageaPProx.1
Otherthan 12V
ignitionSW in ON SW in
presentwhenresume/ accelerator
positionwith mainSW (0Vbetweenterminal1 and3)
ON Dosition
ON position.Do not
pressbrakeandclutch Otherthan
(OFFposition).lF A,/T OV
Checkif powervoltageis 0V between1
vehicle,placein D range SW is OFF
when resume/ accelerator
andapplyparkbrake.
Do not tor
Checkif speedwillincreasewhen increase urnoffthe mainswitch
resume/ acceleratorSW is Placed few secondsand turn it on
W h i l ec r u r s i nAqS C D
inONposition.
Do nol increase
EN - 552
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
Doesnot
Checkif constant
speed
Inspectfollowingthe stepsof
device
willoperate
using "Can
notset".
sevcoastSW.
- r - Operate
l w h e n s l o p p r npql a c e |
| l OheckrfpOWETVoltageapprox.12Vis
SWrnoN Otherthan 12V
lrsnition I I ipresent\r r rma / a.^alar^l^|" qW in
lpositiow n i t hm a i nS W r n l | |ON positil
rn (0V betweenterminal1 and3)
'
I O Np o s i t r o nD. o n o t | |
'12V
lpressbrakeandclutch [-l Approx.
Otherthan
l(OFFpositron).
lFA/I I I r
placeinDrange oltageis 0Vbetween1- OV
lvehicle. | | |when resli m e / a Repair faultySW
parkbrake. I l! cceleratorSW is OFF
landapply
OV
Set vehiclespeedto 80km/ h
wilffi;s-_-l usingset / coastSW.
Normal
EN - 553
ASCD
/ D E/ D E T/ C A 1 8 /i R B 2 5 D EE N G ] N E
B B 2 6 D E T /TR B 2 O E
& MAINTENANCE
INSPECTION WHEN IT CAN NOT BE
PROCEDURE
CANCELLED
SETTINGCAN NOT
BE CANCELLED
ls voltagebetweenterminal5 and3
0V whenbrakeis operated(in N
ge is presentbetween
11and3 whenbrakeis Inspectand replacestoplamPSW
outputis cut
Checkif controller
betlveen(8and3)whenbrake
pedalis pressed.
ls thereharnessshortcir Inspectandreplaceharness.
(2) FUNCTIONINSPECTION
. ASCDfunctioninspection is carriedoutby drivingthevehicleandcheckingif each
functionwilloperatenormally.In thisf unctioninspectionASCDcontrolcircuitsystem
functionis inspectedusingfreeroller.
Caution:
Constantdrivecan not be achievedby ASCDas it is non-loaddriveon the free roller.Use
(1)faultdiagnosis as a referencedepending on eachproblemwhencarryingoutfault
diagnosis.
. TurnoN the mainswitchwhenignition switchis placedin oN positionandcheckthat
operation lamPwillturnon
Caution:
Thereis a faultwithmainswitchoTASCDrelayif the lampdoesnotturnon.
. checkthatthecruiselampwillturnon whendnvingat a constant speed(60kmih) and
set/ coastswitchis placedto ON position.Checkif thevehiclespeedwillincrease for
a moment,cruiselampwilllurnoffandconstant drivecan notbe achieved when
acceleratorpedalis releasedand set / coastswitchis placedto oFF position at the
sametime.
Caution:
lf ASCDcircuitis normal,huntingwilloccurandASCDwillbe cancelled as it is non-load
dnve.
. checkthatthecruiselampwillnotturnon whensetswitchis pressedwhenthebrake
pedalis pressedslightly(brakeswitch:OFF,stoplampswitch:ON)'drivingat a
constantspeed(60km/ h). Makesurethevehiclespeedwillnotincrease whenthe
acceleratorpedalis releasedand set switchis placed to OFF positionat the same
time(release function inspection).
EN - 554
ASCD
RB26DETT/ RB2OE/ DE / DET/ CA.l8J/ FIB2sDEE N G I N E
(3) COMPONENTPARTSINSPECTTON
Controller inspection
. Extractthecontrollerby removingcontrollerbolts. Inspect
ASCDcontrolsystemusingcontrollerconnectorparts.lf
diagnosis resultis faultyreplacethecontroller
unit.
Controller(powercircuit)inspection
. Inspect
powervoltagebetween followrng
terminals
with
connectorsconnected.
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(vehiclespeedsensoroutput)inspection
. Slowlyrotate
therearwheels andmeasurethevoltage
between 7 and3
terminal with connected.
connectors
I nopro, 5V and0V ahermatrvely
Note:
WithA/T shiftcontrol,ASCDcontrollerls prroritized
when
setat ASCDdrive.
E N- 5 5 6
ASCD
/ D E/ D E T/ C A 1 8 /i R B 2 5 D EE N G L N E
R B 2 6 D E T/TR B 2 O E
+ Front ]
+Front
EN - 558
ASCD
RB26DETT/ RB2OE/ DE / DET/ CA18i/ RB25DEENGINE
Resistance
inspection
, ' l ' r '
r temfinak ,, :r:.1.1..
A r rv a l v e1 - 4 Approx.70
Release valve '1 - 2 Approx.70
Vacuumpumpl-3 Approx.8
Operationinspection
. Applybatteryvoltagebetweenterminal1(+)and3(-)and
checkif ASCDwirewilloperatewhenterminal4 and2 is
grounoeo. RB2OE
ASCDwire adiustment
. Loosenlocknutsso ASCDwirehasadequate
slack.Pulloutercasein directionof actuatorfrom
positionwherethrottledrumstartsoperating,returnlock
nutsapproximately1 turnsandtightensecurely.
Accele;i;;;;;
L o c kn u rt r g h t e n r nt ogr o u e{ k g - m ) | 0 . 8- 1 . 0 L o c kn u l0 . 8 - 1 0 1 F r o n r
RB20DEID E T
...''.
EN - 559
ENGINEMOUT.ITING
/ R82OE/ DE/ DET/ CAI 8I / BBASDEENGINE
RBA6DETT
ENGINEiIOUNTING
FRONTENGINEMOUNNNG
Nr, (2)
1.1
REARENGINEMOUNNNG
Nd (2) 22 - 2.9
EN:560
lndex
Symbols E
2 - p o l lei f t. . . . . . . . . . . . . . Gl-13 E C C S. . . . . . . . . . . . . . . . . . . . . . E N- 2 3 1
4WD inspection Gl - 15 E C C SC / Ui n s t a l l a t i o n . . . . . . . . . . . . . . . . .E. N . .- 2 3 3
-
. .l.-. 1
4 W Dr e p a ipr r e c a u t i o n s . . . . . . . . . . . . . . . . . .G . 5 E C C Sr e l a y( B B 2 s D E .). . . . . . . . . . .. . . E N 4 8 5
Eccsvoltage...... , . EN-233
A -
E m i s s i ocno n t r oel q u i p m e n.t. . . . . . . . . . E N 7
Enginecontrol .... EN 46 - 5
e lq u i p m e n. t. . . . . . . . . .E N - 5 2 9
E n g i n ee l e c t r i c a
Engrnm e ounting .. . . EN- 560
E n g i noe v e r h a u. .l . . . . E N- 1 B o
-
E n g i n es p e c i f i c a t i o .n.s. . . . .. . . . . . . . . . . E N 7
. . . . . .... . . . E N 5 4 - 2
E n g i n es t a l l
Enginetemperature sensor. EN - 367. 396' 482
-
E v a p o r a t i v e g a s c o n t r o | . . .. ...... . . . E N 5 4 , 4 8 8
E x h a u s t g a s s e n s o r . . .E . .N -
. . 3 8 6 , 3 9 0 , 3 9 2 ,4 1 5
-
Exhaustgas sensorheater'.. . .. . . . . EN 434
EN -545
Exhaustgastempwarningequipment. .
. . . . E N - 159
E x h a u sm t anifold
E x h a u sm t a n i f o lA d S S Y. . E N - 7 5 , 1 0 9 , 1 1 9 '142
. E N - 543
E x h a u spti p e . . . . . . . .
EN - 4 9 , 542
E x h a u sst y s t e m . . .
B
F
B a l a n cteu b e . . . . . . . . . . . . . . .E. .N - 6 8
EN-236. 272 Frontturbocharger ASSY .. .... .. . . . . EN - 69
Basicinspection
. .. EN - 530 Fuelgauge . . . . . . . . . .E N - 5 3 9
Batteryinspection
. . EN-43 F u e li n j e c t o r ' . . . . . . . . . E N- 1 5 6
Belttension.........
- F u e lp r e s s u rien s p e c t i o n . . . . . . . . .. . . . . . E N - 5 3
B l o w b y c o n t r o l v a l v e . . . . . . ....... . . . . . .E. N 5 5 ' 4 8 9
Blowbygas reduction device... .. . .... . ... EN - 55 F u e | p u m p . . . . . . . . . . . .. . E ..- 303, 307, 440' 483
. .N
. . . . . . . . . E N- 4 8 9 Fuel system EN - 52, 486, 537
B l o w b yh o s e
....G| -13 Fueltank.............. . . . E N- 5 3 7
Board-onlift.........
B r a k i npge d o r m c h e c k. . . . . . .. . . . ... . .G|-'15 F u e tl a n kv a c u u mr e l e avf a l v e . . . . . . . . . E N - 5 4
F u e t u b eA S S y ........E . - 66
. .N
c G
Catalytic converter '. .. EN - 543 -
C i r c u idt i a g r a m . . . .. . . E N - 2 7 9 G a sl e a ki n s p e c t i o.n. . . . . . . . . . . . . . . . . . . . . . E N 7 5
CollectorASSY E N - 5 9 . 1 0 5 1 0 6 ,1 1 5 G e n e r a l p r e c a u t i o n s . . . . . . . . . . ... ....... ... ...G l - 7
Components inspectlon {RB25DE) . .. . EN - 482 H
Compression pressureinspection. .. . .... EN - 42
. . . . . . . .E. N - 8 0 Heaterpane|......... . .. EN-543
Conicalwasher.....
C o n n e c t oi nr s l a | 1 a t i o n . . . . . . . . . ... .......... . E N 2 3 3
- H o w t o u s e t h i s m a n u a | .. .. . .. .. . .. . . . . . . . G l - 2
-
Connector symbol .. .. . . . G| - 6 H y d r a u l iJca c kl i f t i n g. . . . . . . . . . . , . . . . . . .. . G l 1 4
CoNSULT . . . . . . . . .. . GI- 11
- I
C O N S U L T d i s p lsacyr e e n . . . . . . . . . . . . . . .. E N 2 6 5
Crankanglesensor...E ..N -
... 355' 356' 404' 442 ldlemixtureratio . . .. .. EN - 23
Cylinderhead . EN - 83, 85, 170 ldlespeedcontrolsystem. . .... ... EN - 339' 346
l d l es p e e di n s p e c t i o n . . . . . . . . . . . . . . EN- 23
D 1gni1ioncoi|................ . . . . . . . . E N - 4 8 3 ,5 3 2
... . .. . . EN - 267 l g n i t i o inn s p e c t i o n . . E N-328
Datamonitor
exhgas emissioncontrol . EN - 527 l g n i t i orne l a y . . . . . . . . . .. EN- 486
Deceleration
D e t o n a t i o n s e n s o r . . . . . .. E . .N. . .- .3. 8. 1 ' 3 A 2 4 1 7 l g n i t i osni g n a l . . . . . .. E N - 4 2 4
D i a g n o sci sh a r tb y p h e n o m e n o n. . . . . . E N - 2 4 0 l g n i t i o sn y s t e m . . . . . EN-330' 332' 412
-
D i a g n o s i s p r o c e d u r e . . . . . . . . .. . . . . . . E N - 2 3 4 l g n i t i o tni m i n gi n s p e c t i o .n. . . . . . . . . . . . . E N 2 3
systeminspection... .. . .. .. . EN 237 -
D i a g n o s t i c s y s t e m . . . . . ... . . . . . . . . E N - 2 5 9 Individual
- l n h i b i t or re l a y . . . . . . . . . . E N- 4 8 6
D i a g n o s t i c w o r k s h e e t . ... ... ..... . . . . . . . .E N 2 3 4 -
D O H C. . . . . . . . . . . . . . . . . . . . . E N - 274 1 n j e c t.o. .r. . . . . . . . . . . . . . . . .E. .N. . .3. .1.4. ' 3 1 7 ,3 2 3 '4 8 4
EN - 562
I n p u st i g n a l sa n dc o n t r oilt e m s . . . . . . . . . . . .E. .N. .- 2 3 9 R
l n s p e c t i op no i n t s . . . . . . . . .G. . l., 1 6
I n t a k ea i r t e m p e r a t usr e n s o r . . . . . . . . . . . . .E. .N. .-.3 7 8 R a d i a t oc ra pi n s p e c t i o n . . . . . . . . . . . . . . . . E . .N. .-.5. .3. .4. . .
lntakemani{o|d..E ..N
. . .- 6 5 , 1 O 7 ,1 1 7 . 1 3 7 , 1 5 7 Radiatorinspection ..... EN - 534
I n t a k em a n i f o lcdo | | e c t o r . . . . . . . . . . . . . . . . . E
. .N. . -. .i.5. .3 F e a rt u r b o c h a r gAeSrS Y. . . . . . . . . . . . . . . . . . . .E. N . . -. .7.0. .
I n t a k em a n i f o lvda c u u m. . . . . . . . . . . . . . . . . . . . .E. .N. .-.2. 7 5 R e c i r c u l a t ihoons e . . . . . . .E. N - 5 7
Intercooler . .N- 5 7 . 1 3 1
. . . . . . . . .E R e c r r c u l a t ivoani v ei n s p e c t i o. n
. . . . . . . . . .E
. .N. - 50. 57
Intercoola e irrd u c ta s s e m b l y. . . . . . . . . . . ..... E . N- 5 6 R e m o v ae n di n s t ael ln g i n e . . . . . . . . . . . . . . .E . .N. .-. 1. 8. .0.
l n t e r c o o li en l eht o s e. . . . . . . . . . . . . . . . . . . . . . .E. .N. -. .5. 6
r .... Rockercover EN - 76, 120, 169
J s
14 Self-diagnosis .....EN - 236. 262
S e n s osr y s t e m i n s p e c l i o n . . . . . . . . . . . . . .E. .N. .- .3. .5.4. .
S i xi n - l i nteh r o t t lceh a m b e r . . . . . . . . . . . . . . . E . .-. 6
. .N . .3. . .
S p a r ki n s p e c t i o n . . . . . . . .E. N - 2 7 4
EN - 353
1 1 0 ,1 4 3
Sparp klug............ E N - 7 6 . 1 2 1 .4 8 6
S p e c i as le r v i cteo o | s . . . . . . . . . . . . . . . . . . . . . . . .E. .N. .- .I. . . . .
EN-47
S p e e d o m e t e r m e a s u r e m e n t . . . . . . . . . . . . .G. .l.-.'.1.5. . . . . .
EN.47
S t a ns i g n a. l. . . . . . . . . . . . . . . .E. N - 4 3 6
M S t a r t emr otor........ ......E . N- 5 3 1
S u be l e c t r i c a l f ai n s p e c t j 0.n. . . . . . . . . . . . . . .E. .N. .- 5 3 6
Measurement
tools EN-12 S w i n vg a l v ec o n t r o l l.e. r. . . . . . . . . . . . . . . . . . . . .E. .N. -. .7. 3
....
Multipurpose
tools EN - 12 System diagram.. . . . . . . . .E. .N - 1 3
N S y s t e mf i g u r e . . . . . . . ......E . N- 2 7 9
T
Tensionerspring EN- 80
...........
T h e r m o - w ianxs p e c t i o n . . . . . . . . . . . . . . . . . .E. .N. .- .5. .3. . . . .
T h e r m o s t a t . . . . . . . . . . . .E . .N. . -. g
. .A. .,.1. 2 7 . 1 4 8 ,5 3 6
T h r o t r lbeo d yA S S Y . . . . . . . . . . . . . . . . . . . . . . E ..N . .-. .1.3. 9
....
Throttlesensor -
EN 371, 373. 419, 484
T h r o t t l e v a l vs ew i t c h. . . . . . . . . . . .E. .N. .- 3 6 7 , 4 3 6 . 4 8 3
T i g h t e n i nTgo r q u e . . . . . . . . .G . . .l - 1 3
T i m i n gb e l t. . . . . . .E N - 7 8 , 8 2 , 1 1 1 ,1 2 2 . 1 4 4 . 1 6 0
Towing.................. . . . . . . . .G . .l.- 1 3
T r o u b ld ei a g n o s i s . . . . . . .E. N-231
T u r b o c h a r g e r A S S Y . . . . . . . . . . . . . . . . . . .E . .N. .-.6. .8. . . . .
T u r b o c h a r g e r f a i l u r e d i a g.n. o . .s. .i .s. . . . . . . . .E. .N. .- 7 4
T u r b o c h a r gi e n rs p e c t i o. n. . . . . . . . . . . . . . . . . . . . .E. .N . .-. 4
. .9
T u r b o c h a r guenr i ti n s p e c t i o.n. . . . . . . . . .E. .N. - 7 1 , 1 3 4
U
U n a b l et o s t a r t . . . . .E. N - 2 3 9 . 4 2
. . . . . . . . . . . . . . . . . .E. .N. -. .5.3. 1 U n s t a b lied l i n g . . . . . . . . . .E. .N - 2 3 4
EN - 251
. . . . .E. N- 2 4 7 V
..EN-447,486
Vacuum diagram . .N - 1 9
. . . . . . . . .E
E N- 4 0 1 V a l v ec l e a r a n cien s p e c t i o.n. . . . . . . . . . . . . . . . . .E. .N. .-. .4 5
E N- 4 8 3 Vehicle i d e n t i t i c a t ipolna t el o c a t i o.n. . . . . . . . . . .G. .l .- 10
. . . . . . . . . . . . . .E . .N. .-. 2. 3 5
V e h i c l sep e e ds e n s o r . . . . . . . . . . . . . . . .E. .N. .-. .3.9 7 . 4 3 0
EN- 352
w
W a s t e g a tvea l v ec o n t r o.1. . . . . . . . . .. . . . . . . . . .E. .N - 3 5 0
W a t e rb y p a s sc o n n e c t o.r. . . . . . . . . . . . . . . . . . . .E . . -. .6. 7
. .N
W a t e ro u t l eet l b o w . . . . . . .E. N- 6 7
W a t e pr u m p . E N - 9 6 , 1 2 6 ,1 4 7
EN - 563