All Engine Manual (OCR)

R32 ENGINE MANUAL.
CA18i, RB20E, RB20DE,

RB20DET, RB25DE & RB26DETT
GENERAL INFORMATION
SECTION GI
GENERAL INFORMATION
CONTENTS
HOW TO USE THIS MANUAL ................................................................................... GI- 2
GENERAL PRECAUTIONS ...................................................................................... GI- 7
VEHICLE & UNIT IDENTIFICATION PLATE LOCATION .......................................... GI - 10
CONSULT ...................................................................................................... GI-11
TIGHTENING TORQUE OF STANDARD BOLTS........... ................ GI-12
TOWING .............................................................................................................. GI- 13
4WD INSPECTION & REPAIR PRECAUTIONS ................................................... GI- 15
GI-1
GENERAL INFORMATION
HOW TO USE THIS MANUAL
MAINTENANCE OPERATION EXPLANATION
This manual describes important items for installation removal, assembly, inspection, repair
and failure diagnosis,
Caution:
A general description of a visual inspection and cleaning of disassembled parts has
generally been omitted, However, when reusing the parts, make sure to perform visual
inspection and cleaning as necessary.
CONFIGURATION COMPONENTS, OPERATION CONTENTS & PROCEDURES
The configuration components, operation contents and procedures are shown after the title
of each operation. Preparation standards and important operation points such as parts
which can not be used again. tightening torque and lubrication locations are also indicated.
Configuration components & Operation contents
The operations for installation. assembly and disassembly are indicated by the part name.
This description is used when the ideal procedure can nol be determined or there are many
types of components.
[Point] is used to indicate the operation procedures which are necessary.
Example: Front Axle disassembly & assembly
-:lEi Inner grease seal
I
_Innerbeanng - Outer bearing outer race
; outer ! (C!) Screw (3) 0.3 - 0.4
o [I (C!) Bolt (4) 2.5 - 3.4
Al\;' :111" ,; Spacer (POint 1)
IJJ), I DIsc rotor
Ell I i-.(. ,l.. '>:lEll Outer grease seal
Inner bearing I "'.'1_. H b b It
B,ffie I.!:(t;' f J 0
Knuckle
kg - m Ell Outer bearing
Should be lubricated with grease.
Use recommended mUltipurpose grease
Can not be reused
Unit definition
Wheel hub
The unit of measure used in this manual for tightening torque is described in "81 measure
(International unit)" and the units within { } is in meter unit.
Example: Tightening torque: 59 78 N-m {B.O - 8.0 kg-m}
I
SI measure
Meter measure
GI-2
GENERAL INFORMATION
STRUCTURAL PARTS DIAGRAM AND OPERATIONAL SEQUENCE
The name of the parts required for the operations are shown, The operation sequence must
be followed in the order shown,
Assembly is the reverse of disassembly except when otherwise indicated,
Example 1: Light combination switch ASSY installation and removal
SYMBOLS

m

!
*
*
i

2, Screw (1)
1, Steering wheel ASSY
light combination switch ASSY
3. Screw (5)
Connector
Shell cover
DESCRIPTION
Operation where the torque should be checked and the
standard torque value that should be used,
When X to Y N.m (kg-m, ft-Ib) is indicated, the standard
tightening torque is the mean value.
Should be lubricated, Indicate a type of grease
Parts that can not be reused
Should be lubricated with oil
Sealing point
Select proper parts
i Adjust parts
I
, Part need to be checked visually
GI-3
i
GENERAL INFORMATION
Example 2: Fault diagnosis flow chart (RB25DE VEHICLES ONLY)
B
;M
i PiOlcrO, Disconnect
,,-, ;!.'

,
,
'--I
. __ ... _---
/3 ,1
A r ... _--,
-. - ... --------. NG . Check the following
I CHECK POWER SUPPLY.-----c items.
; 1) Turn ignition switch "OW. i I 1) Harness continuity
" 2) Check voltage between I between camshaft
terminal B and ground. I ! position sensor and
Battery voltage should : .,. battery.
... ___ 1 2) ECCS relay.
, 2 I .. 3) Fuslole link.
10K ; 4) Power source for
__
:1) Turn ignition switch
h Disconnect camshaft
I pOSition sensor harness
, connector.
P) Check resistance betwee
I terminal D and ground.
Approx. 0 I
i OK
1
. Check the following
items. :
1) Harness continuity 1
between camshaft &
ground.
2) Ground circuit for
ECM.
HOW TO FOLLOW THIS FLOW CHART
1. Work and diagnostic procedure
Start to diagnose a problem using procedures indicated in enclosed blocks. as shown
in the following example.
A
!cHECK POWER SUPPLY. <E-- Check item being performed.
1
1) Turn ignition switch "ON".
2) Check voltage between
terminal B and ground.
. Battery voltage should
exist.
2. Measurement results
Required results are indicated in bold type in the corresponding block. as shown below.
These have the following meanings:
Battery voltage; 11 - 14V or approximately 12V
Voltage; Approximately OV - Less than 1 V
3. Cross reference of work symbols in the text and illustrations
Illustrations are provided as visual aids for work procedures.
4. Symbols used in illustrations
Symbols included in illustrations refer to measurements or procedures. Before diag
nosing a problem. familiarize yourself with each symbol.
GI-4
GENERAL INFORMATION
Symbol Symbol explanation Symbol Symbol explanation
IV
Check after disconnecting the
lrlJ
Current should be measured with
connector to be measured. an ammeter
()
Check after connecting the
@
Procedure with CONSULT.
i
connector to be measured.

Insert key into ignition switch.

Procedure withcut CONS UL T.
(rs"c:5J
Remove key from ignition switch.
E
A I C switch is "ON"
I
00
Tum ignition switch to "OFF"
[@
A I C switch is "OFF".
!
position.
@)
Tum ignition switch to "ON"
_1ft' j .. J
position. C::fF::':'
Fan switch is "ON".
:

Turn ignition switch to "START"
'I ".
Fan switch is "OFF".
!
position.

@<ce
Turn ignition switch from "OFF" to

Apply fused battery positive
"ACC" position. voltage directly to components.

Tum ignition switch from "ACC"
__ TF:\

Drive vehicle.
to "OFF" position.
...

Turn ignition switch from "OFF" to

Disconnect battery negative
"ON" position. cable.

Turn ignition switch from "ON" to

"OFF" position.

Depress brake pedal.
7?J
Do not start engi ne, or check with

Release brake pedal.
engine stopped.

Start engine, or check with
;;a
I Depress accelerator pedal.
engine running.
!

Apply parking brake

Release accelerator pedal.

Release parking brake.
Pin terminal check for ECM and AIT control
: Check after engine is warmed up
unit connectors.

suffi ci ently.
rc-;u

Voltage shculd be measured with

a voltmeter.
LzJ
.
Circuit resistance should be

U4J
measured with an ohmmeter
GI-5
CONNECTOR SYMBOL
A direction mark is shown to clarify the side of connector
(terminal side or harness side).
Connector symbols shown from the terminal side are
enclosed by a single line.
Connector symbols shown from the harness side are
enclosed by a double line.
Male & Female terminals
Connector guides for male terminals are shown in black
and female terminals in white in wiring diagrams.
Control unit element substances
Element such as control unit will be shown as displayed.
GI-6
GENERAL INFORMATION
Connector symbol
~
1 1 2 ~ 4 1 S I
1617 a19i'Qj
t-'" sing;e iine
! Direction mark
I ~
i ..
View from terminal side
iew from harness stde
Canne ctorsymbol
ra
514 :1 211 ,!
Ilioj9 8 7! fiJi
t
Double line i
Direction mark
/ ~
) Direction mark
GENERAL INFORMATION
GENERAL PRECAUTIONS
Follow the below precautions to ensure safe and proper servicing for your vehicle.
SRS (Supplemental Restrain System) air bag
Information necessary to service the system safely and
correctly is included in the BF section of this service
manual. Make sure you read the section on "SRS air bag"
before maintenance operation.
Improper maintenance, including incorrect removal and
installation of the SRS air bag, can lead to personal
injunes caused by unintentional activation of the system.
Do not use electrical test equipment on any circuit related
to the SRS air bag. '-------------'
All SRS electrical wiring harnesses and connectors are
covered with yellow outer insu lation.
General Precautions
Do not operate the engine for an extended period of time
without proper exhaust ventilation.
Keep the work area well ventilated and free of any
flammable materials.
Care must be taken when handling any flammable or
poisonous materials.
Before servicing the vehicle. cover fenders. upholstery and
carpeting with appropriate covers.
Before jacking up the vehicle, apply wheel stoppers and
only jack up the vehicle at jack up point.
After jacking up the vehicle, support the vehicle weight with
safety stands before working on the vehicle.
Seat cover
F enCler cover
When removing heavy objects such as the engine or
transaxle I transmission, take care not to lose your
balance and drop them. Also, do not allow them to strike
parts, especially the brake tube and master cylinder. '--_________ ....J
GI-7
GENERAL INFORMATION
Before start repairs that do not require battery power.
always turn off the engine and disconnect the ground
cable from the battery to prevent accidental short circuit.
Loosen the screw nut completely when removing the
ground cable from the battery.
To prevent serious burns, avoid contact with hot metal part
such as the radiator, exhaust manifold, tail pipe and
muffler. Carry out the operation when the parts has cooled
down.
Do not remove the radiator cap when the coolant is hot.
Wind wire around probe
An inspection may be difficult with a normal test probe
when a connector pin is extremely small. When this is the
case, wind a small pin or wire around the test probe, or
sharpen the end of the probe to perform the inspection.
Use measurement equipment such as the CONSULT
electronic system diagnosis tester and an oscilloscope to
perform diagnosis operation.
Sharpen the end
Test probe
Check the vehicle damage carefully, make a careful diagnosis of the damage and perform
the correct operation.
Check the correct part assembly condition before removal or disassembly. Make
alignment marks when necessary in locations which will not interfere with the part
operation.
When replacing parts always use correct specified parts or tools.
Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self locking
nuts, etc. with new ones. These parts are indicated "Can not be reused" and must be
replaced with new parts.
Always replace taper-roller bearing and the needle bearing for inner and outer race as a
set.
Take care not to mix up the removed parts.
When replacing parts always use genuine Nissan replacement parts.
Use correct lubricants specified.
Dispose waste oil and cleaning oil in a way that is set by the law.
GI-8
Precautions for ECCS engine
Before connecting or disconnecting ECCS control
module hamess connectoL be sure to turn the ignition
switch to the "OFF" position and disconnect the negative
battery terminal.
Release fuel pressure to eliminate danger before
disconnecting pressurized fuel line from fuel pump to
injectors.
Do not apply any shock to the electric parts such as ECCS
control unit or Airflow metre.
Use measurement equipment to perform diagnosis
operation.
Precautions for Catalyst converter
GENERAL INFORMATION
If a large amount of unburned fuel flows into the converter, the
temperature within the converter will become excessively ~
high. To prevent this, follow the procedure below: ~ r r =
Only carry out the ignition spark or measuring engine
compression checks when necessary and carry out the
tests quickly.
Do not run the engine when the fuel tank level is low,
otherwise the engine may misfire causing damage to the
converter.
Only use gasoline specified.
Do not place burnable objects below the vehicle. Keep
flammable material off the exhaust pipe and the catalyst
converter.
Precautions for fuel
Only use unleaded gasoline for gasoline engine vehicle.
Using a fuel other than that specified could damage the
vehicle.
GI-9
GENERAL INFORMATION
VEHICLE & UNIT IDENTIFICATION PLATE LOCATION
Vehicle identification number (Supplement models only)
E-FR32 ...................................................... FR32-000001 -
E-HR32 ...................................................... HR32-000001-
E-HCR32 ................................................... HCR32-000001-
E-ER32 ...................................................... ER32-000101-
E-ECR32 ................................................... ECR32-000101-
E-HNR32 ................................................... HNR32-000001-
E-BNR32 ................................................... BNR32-000001-
Model number plate
NISSAN MOTOR CO,LTD.JAPAN
".. ..... TYPE .&. 1
,.. "" flPO
1. Type
2. Vehicle identification number
3. Model
4. Body colour code
5. Trim colour code
CHASSIS "Ie
&2
1.0 DE Ct'ASS1S
.,"'" &3
""",,0
"., - 00L.0fI 'IlIN
4& &5

6. Engine model
.;- EftGI!!f
6& &7
,;" YOtOA
7. Engine displacement
8. Transmission model
""',,,.:.. TRAilS All:
8& &9
TRAitS EJE
III
PtANT
ptANT"
9. Axle model
Engine serial number
0
cc
RB26DETT engine CA18i engine RB20E I RB250E engine
GI-10
.
GENERAL INFORMATION
CONSULT
Consult is a hand-held compact type tester. It transmits
signals to the vehicle loading control units when the diag-
nosis connector is connected and can perform all types of
diagnosis and tests.
Note:
Refer to the CONSULT operation manual for further details.
FUNCTION
Operation support
Transmits commands to the electrical control unit for
setting the status suitable for required operation.
Function test Diagnose the ECCS standard checks.
Receives the self-diagnosis results from the electrical
Self-diagnosis control unit and displays malfunctioning system names
and the number of times a malfunction occurs.
Receives input and output signals from the control unit,
Data monitor displays and records data used to easily determine
cause of malfunction.
:
Sends commands to the control unit and performs the
i Active test operation inspection and verification of the output
system according to output signal changes.
ECU part unit Displays the part number of the electrical control unit.
APPLICATION
Engine
AfT HICAS E-TS ASS
SRS
(ECCS) Air bag
Operation support
0
: Function test
0
Self diagnosis
0 0
0 0 0 0
Data monitor
0 0 0
0 0
:
Active test
ECU part number
0 0
i
0
GI-11
I
!
!
GENERAL INFORMATION
TIGHTENING TORQUE OF STANDARD BOLTS
Bolt
I
Tightening torque (without lubricant)
Grade Bolt size diameter
Pitch
Hexagon head bolt Hexagon flange bolt
(mm)
(mm)
N-m kg-m Nm kg-m
M6 6.0
!
1.0 5.1 0.52 6.1
i
0.62
I
i
i
i 125 13 1.3 15
!
15
M8 8.0
I 1.0 13 1.3 16 1.6
.
.
1.5 25 2.5 29 3.0
4T M10
i
10.0
i
1.25 25 2.6 30 3.1
!
i
1.75 42 4.3 51
i
5.2
M12
I
12.0
1.25 46 4.7 56 5.7
M14 14.0 1.5 74 7.5 88 9.0
M6 6.0 1.0 8.4 0.86 10 1.0
1.25 21 2.1
i
25 2.5
M8 8.0
i
1.0 22 2.2 26 2.7
1.5 41 4.2 48 4.9
1T M10 10.0
1.25 43 4.4 51 5.2
!
i
,
I
1.75 71 ! 7.2 84 8.6
i
M12
i
12.0
1.25 77 7.9 92 9.4
M14
i
14.0
I
1.5 127 13.0 147 15.0
!
M6 6.0 1.0 12 1.2 15 1.5
1.25 29 3.0 35 3.6
M8 8.0
1.0 31 3.2 37 3.8
1.5 59 6.0 70 7.1
9T M10 10.0
125 62 6.3 74 7.5
!
1.75 98 10.0 118 12.0
M12 12.0 ,
1.25 108 11.0 137 14.0
M14 14.0 1.5 177 18.0 206 21.0
Special parts are excluded.
This standard is applicable to bolts having the following marks embossed on the bolt head.
Grade Mark
4T 4
7T 7
9T 9
GI12
TOWING
Front
After removing the front spoiler, attach a cable to the hook
in the front part of the front side member.
Rear
Attach a cable to the hook mounted in the rear part of the
rear side member.
2-POLE LIFT
The two-pole lifting points are the same as for the right rack.
Qaution:
Make sure the vehicle is empty when lifting up the vehicle.
GENERAL INFORMATION
Towing hook
Make sure the side sill and lift arm (rear part) do not contact each other when lifting up the
vehicle.
Board-on Lift Front of the vehicle
The board-on lift attachment (LM4086-0200) set at the \,
front end of the vehicle should be set on the front of the \ ~ I
=,,!
sill underthe front door opening. 'I ' . . ~ ~ ~ ~ . = ~ . ~ ~ ~ ~ .
Position the adapter on both sides of the board-on lift ~ = = - \
Caution:
Make sure the vehicle is empty when lifting.
AdaDter
Adapter
GI-13
HYDRAULIC JACK LIFTING & JACK STAND SUPPORT
Caution:
Make sure the vehicle is empty when lifting.
GENERAL INFORMATION
When the front side is jacked up, raise the front sill edge slightly using the jack and then
jack the vehicle up.
Use the attachment (LM4519-0000) when a vehicle is supported by jack stand.
Take care not to allow the jack stand to crush brake tubes or fuel lines when using jack
stand.
Place jack at the centre of tlie suspension
member
GI-14
Place jack at the centre aftne dTfferenffai
gear
GENERAL INFORMATION
4WD INSPECTION & REPAIR PRECAUTIONS
Follow the precautions below to measure the speedometer reading and to check breaking
performance in the 4WD mode,
SPEEDOMETER MEASUREMENT
Two methods to measure the speedometer are described below,
1. Measurement with front wheels jacked up
Place the rear wheels on the roller.
Support the car on jack stand with front wheels jacked
up using the attachment.
Place the transmission in 2nd gear for the manual trans-
mission vehicle and release the clutch slowly, For
automatic vehicles place the shift lever in 2nd and
increase the speed gradually,
When the test is completed, do not apply the brakes
suddenly,
Caution;
Place the jack securely, and perform the measurement
after making sure the vehicle is stable,
Use the free rollers whenever possible.
2. Measurement using simple free roller
Set the simple free roller the length of the wheel base
(2615mm) forward ofthe centre of the measurement
roller as shown in the diagram,
Place the front wheel on the simple free rollers and the
rear wheels on the measurement rollers,
Place the gear in 2nd for the manual transmission
vehicles and gradually release the gear, For automatic
vehicles place the shift lever in 2nd and increase the
speed gradually,
When the test is completed, do not apply the brakes
suddenly,
BRAKING PERFORM CHECK
Pre-Inspection preparations
The performance check must be carried out in 2WD mode,
To switch to 2WD mode, either use the front propeller shaft
removal method or remove the fusible ink from the engine
bay,
GI-15
Simple free roller
/IM24850000
~
~ - ' ,. 'vleasure,;,ent
.-- roller !
.. ' " /
W,heelbase ~
2,615mm ~
<:= Front
" ';
"
Simple free roller
i",\ ... :
,
Measurement
roller
GENERAL INFORMATION
INSPECTION POINTS
(When fusible link in the engine bay is removed)
I Removed the 4WD fusible link 30A from t ~ engine
I bay relay box with engine turned off.
Turn on the ignition. Repeat the engine deceleration
operation from full throttle to no throttle until the 4WD
warning light on instrument panel lights.
: Note: The vehicle may not enter 2WD mode when this
I operation is not performed.
'---" I ..
ITum the ignition switch in OFF position once the4WD I
i warning light has turned on. .
Turn on the ignition switch and make sure the 4WD i
warning light is on. i
I
Position the vehicle on rollers, set shift and range
into neutral position.
I
I Press the pedal. Release pedal when OK zone is
'reached or OK lump lights.
If the drag exceeds 10% of the axle weight when the
drag test is performed, the wheel rotation must be
checked with the vehicle jacked up. If there is no abnor-
mality, it can be assumed that the drag is caused by the
viscous torque and there is no brake abnormality.
i Place the ignition to OFF position and place the fu-I
; sible link back to its normal location.
i
I . ___ _
. Place the ignition back to ON position and make sure i
the 4WD warning light turns off and 4WD mode is'
set.
End
GI-16
4WD VEHICLE TOWING PRECAUTIONS
Towing precautions
Never tow a 4WD vehicle for a distance over 30
km and do not exceed speed limit of 30 km I h.
Never tow a 4WD vehicle with front or rear wheels
raised and opposite rear or front wheels on the
ground as this may cause serious damage to the
transaxle.
GI-17
GENERAL INFORMATION
CONTENTS
SECTION EN ENGINE
CONTENTS
EN1 ENGINE SPECIFICATIONS
MAIN ENGINE SPECIFICATIONS ............................ .......... .......... EN - 6
EMISSION CONTROL EQUIPMENT SPECIFICATIONS ............................ " ........... EN - 7
SPECIAL SERVICE TOOLS..........." ... " ........... "............ EN - 8
SYSTEM DIAGRAM ...................... ............................................. .... EN - 13
VACUUM DIAGRAM ....................................... .............................. EN - 19
EN2 RB26DETT I RB20E I DE I DET I RB25DE I CA18i ENGINE
1. IDLE SPEED /IGNITION TIMING /IDLE MIXTURE RATIO INSPECTION ..... EN 23
2. COMPRESSION PRESSURE INSPECTION .............................. ............ EN - 42
3. BELT TENSION INSPECTION &ADJUSTMENT.................. ... EN - 43
4. VALVE CLEARANCE INSPECTION & ADJUSTMENT ................................. EN - 45
5. LUBRICATION SYSTEM ....................... ...................... EN - 47
6. EXHAUST SYSTEM INSPECTION
RB26DETT I R820DE I DET ! R820E I R825DE............ .... EN - 49
CA18i ............................................................... .. ............ EN - 51
7. FUEL PUMP SYSTEM INSPECTION ........................................................... EN - 52
8. EVAPORATIVE GAS CONTROL INSPECTION ............................................ EN - 54
9. BLOWBY GAS REDUCTION DEVICE INSPECTION ......................... EN - 55
10. ON-VEHICLE PARTS REMOVAL & INSTALLATION
RB26DETT ................................................................................ EN - 56
RB20E................................. ................ EN - 105
RB20DE, DET.. .................................................................... EN -115
CA18i ........................................................................................ EN-137
RB25DE ................................................ ....... EN -151
11. ENGINE REMOVAL & INSTALLATION
R826DETT ................................................................................ EN -180
RB20E, DE, DETT. CA18i .............................................. EN -182
RB25DE .................................................................................... EN - 184
12. ENGINE OVERHAUL
RB26DETT ................................................................................ EN - 186
RB25DE .................................................................................... EN-202
RB20E I DE I DET .......................................................... EN - 217
EN -1
CONTENTS
EN3 ECCS (ELECTRONICALLY CONCENTRATED ENGINE CONTROL SYSTEM)
1. TROUBLE DIAGNOSIS ............. " ............................................................... EN - 231
2. DIAGNOSTIC SYSTEM .............. ... ..... ........................ . ......... EN 259
3. BASIC INSPECTION
RB26DETT I RB20E I DE I DET I CA 18i ...... " ......................... EN - 272
RB25DE ..... .. " .................................. " ...................... EN - 276
4. SYSTEM FIGURE & CIRCUIT DIAGRAM
RB26DETT ................................................................................ EN - 280
RB20E ... ... .............................................................................. EN - 284
RB20DE.. ........ ............... . ...................................................... EN - 288
RB20DET .................................................................................. EN - 292
CA18i ......................................................................... EN - 294
RB25DE ......................... ........... ....................... .. ........... EN - 298
5. ACTUATOR SYSTEM INSPECTION (RB26DETT I CA 18i I RB20E I DE I DET)
5 1 FUEL PUMP SYSTEM INSPECTION ................... ....... .. EN - 302
5 - 2 INJECTOR SYSTEM INSPECTION ................................ .. EN - 314
5 - 3 IGNITION SYSTEM INSPECTION ............................................. EN - 328
5 - 4 IDLE SPEED CONTROL SYSTEM INSPECTION ...................... EN - 339
5 - 5 WASTEGATE VALVE CONTROL SYSTEM INSPECTION
(RB26DETT ONLy).................. .......... EN - 350
5-6 PTC HEATER CONTROL SYSTEM INSPECTION
(CA18i ONLy) ......................................................................... EN - 352
5-7 LOCK UP RELEASE CONTROL SYSTEM INSPECTION
(CA18i AIT ONLY) .................................... ....... EN - 353
6. SENSOR SYSTEM INSPECTION (RB26DETT r CA 18i I RB20E r DE r DET)
6 - 1 CRANK ANGLE SENSOR SYSTEM INSPECTION
6-2
6-3
6-4
6-5
6-6
6 7
6-8
6-9
6 - 10
6 - 11
6 - 12
(CODE No. 11 IN SELF-DIAGNOSIS) ...................................... EN - 354
AIR FLOW METER SENSOR SYSTEM INSPECTION
(CODE No. 121N SELF-DIAGNOSIS)
(RB26DETT I RB20E I DE / DET) .............................................. EN 361
THROTTLE VALVE SWITCH SYSTEM INSPECTION
(RB26DETT I RB20E I DE ! DET) .................. .................. EN - 368
THROTTLE SENSOR SYSTEM INSPECTION
(CODE No. 43 IN SELF-DIAGNOSIS)
(RB26DETT! RB20E I DE / DET) ... .... .. ................................ EN - 371
(CA18i) ................................................................................... EN - 375
INTAKE AIR TEMPERATURE SENSOR SYSTEM
(CA 18i I RB26DETT ONLY) ........... ............................ EN - 378
ENGINE TEMPERATURE SENSOR SYSTEM INSPECTION
(CODE No. 131N SELF-DIAGNOSIS) ............................. EN - 380
EXHAUST GAS SENSOR SYSTEM INSPECTION
(CODE No. 151N SELF-DIAGNOSIS) ....................................... EN 386
DETONATION SENSOR SYSTEM INSPECTION
(RB26DETT / RB20E ONLy)............................... EN - 395
VEHICLE SPEED SENSOR SYSTEM INSPECTION ................ EN - 397
IGNITION SWITCH (START SWITCH) SIGNAL INSPECTION ..... EN - 398
AIR CONDITIONER SIGNAL INSPECTION ................ . ....... EN - 399
NEUTRAL SWITCH SIGNAL INSPECTION ............................... EN - 399
EN-2
CONTENTS
6 - 13 POWER STEERING SWITCH SIGNAL INSPECTION ..... " .. ". EN - 400
6 -14 LIGHT SWITCH SIGNAL INSPECTION (CA18i) ................. , ...... , EN - 400
6 - 15 HEATER FAN SIGNAL INSPECTION (CA 18i) """ ..................... EN - 400
7. RB25DE DIAGNOSIS
DIAG 1 POWER SUPPLY & GROUND CIRCUIT.. ...... ,,,,,,,,..... ..... EN 401
DIAG 2 CRANK ANGLE SENSOR
(CODE NO.11 IN SELF-DIAGNOSIS) ..... ............ EN - 404
DIAG 3 AIR FLOW METER
(CODE No. 121N SELF-DIAGNOSIS) ... ,., .................. ,., , ...... EN - 407
DIAG 4 ENGINE TEMPERATURE SENSOR
(CODE No. 131N SELF-DIAGNOSIS) ..................................... EN - 410
DIAG 5 IGNITION SIGNAL
(CODE No, 211N SELF-DIAGNOSiS) .. ,...................... EN -412
DIAG 6 EXHAUST GAS SENSOR
(CODE No. 151N SELF-DIAGNOSIS) ....................................... EN - 415
DIAG 7 DETONATION SENSOR
(CODE No. 341N SELF-DIAGNOSIS) .... """"',, .............. EN - 417
DIAG 8 THROTILE SENSOR
(CODE No.43 IN SELF-DIAGNOSIS) ..................... . .... EN - 419
DIAG 9 A IT CONTROL
(CODE No. 54 IN SELF-DIAGNOSIS) ........ ,.........". EN - 421
DIAG 10 CRANKANGLESENSOR
(NOT IN SELF-DIAGNOSIS) ...""........... EN - 442
DIAG 11 IGNITION SIGNAL 1
(NOT IN SELF-DIAGNOSIS) ,....."............... . EN - 424
IGNITIONSIGNAL2 ............... ,................................ .. EN 427
DIAG 12 INJECTOR SYSTEM INSPECTION................. .. , EN - 428
DIAG 13 VEHICLE SPEED SENSOR.... ,.... ....... , ....... EN - 431
DIAG 14 AIR CONDITIONER RELAY SiGNAL ..... " ........................... ,. EN - 433
DIAG 15 EXHAUST GAS SENSOR HEATER .. , .............................. , .. , ... , EN - 434
DIAG 16 THROTILE VALVE SWITCH ..................................................... EN - 436
DIAG 17 START SIGNAL ............ , ............. ,., .............................. , ............. EN - 439
DIAG 18 FUEL PUMP CONTROL ....... ,"",., ............................................. EN - 440
DIAG 19 AAC VALVE............ ... ,.......... ....... EN - 443
DIAG 20 AIR REGULATOR ............. , ...... , .............................. , ................ EN - 445
DIAG 21 POWER STEERING HYDRAULIC PRESSURE SW .................. EN - 447
DIAG 22 IDLE REV IS TOO HIGH (AFTER WARM UP) .......................... EN - 449
DIAG 23 HUNTING..................... .. ,.".......... ...... EN - 450
DIAG 24 IDLE INSTABILITY....." .. " .. ,................, ..... ," EN - 451
DIAG 25 WHEN COLD. DIFFICULT TO START OR
CAN NOT START THE ENGINE, ............................... EN - 454
DIAG 26 WHEN WARM, DIFFICULT TO START OR
CAN NOT START THE ENGINE .. .................... , EN - 456
DIAG 27 IN NORMAL CONDITION. DIFFICULT TO START OR
CAN NOT START THE ENGINE ... , ................ EN 458
DIAG 28 HESITATION AFTER WARM UP .. . ......................... EN - 460
DIAG 29 HESITATION WHEN COLD ... . ........ EN - 461
DIAG30 HESITATION IN NORMAL CONDITION ....... , .. EN -462
EN-3
CONTENTS
DIAG 31 ENGINE STALL WHILE REWING ............................................ EN - 463
DIAG 32 ENGINE STALL AFTER WARM uP................ ..... EN - 465
DIAG 33 ENGINE STALL WHEN COLD ................................................... EN - 467
DIAG 34 ENGINE STALL WHEN ACCELERATING INSTANTLy ......... EN - 469
DIAG 35 ENGINE STALL WHEN DECELERATING ................................. EN - 471
DIAG 36 ENGINE STALL WHEN ACCELERATING OR
DRIVING AT CONSTANT SPEED .............................. .. EN - 474
DIAG 37 ENGINE STALL WHEN LOADING BATTERy."........ ....... EN - 476
DIAG 38 POWER SHORTAGE AND TUMBLE (INSTANT POWER
OUTPUT SHORTAGE DURING ACCELERATION) ................ EN - 478
DIAG 39 DETONATION.............. ........................ ..................... EN - 479
DIAG40 SURGE ................................ " ..................... " ..................... EN -480
DIAG 41 BACK FIRE (SPITTING) ...... " ...... " ..... " ....................... " ........... EN - 481
DIAG 42 AFTER BURNING ......... " ........................ " ........................... " .... EN - 481
8. RB25DE COMPONENTS INSPECTION .................................................... EN - 482
9. ECCS CONTROL UNIT INPUT I OUTPUT SIGNALS
RB20DETT ................................ " ......... "" .. " .. "." ....... " .. EN - 490
RB20E I DE I DET ......................... .. " .. , ............. EN - 499
CA18i .......... , ............ ,., .............................................................. EN - 513
RB25DE .................................................................................... EN - 520
10. DECELERATION EXHAUST GAS EMISSION
CONTROL EQUIPMENT INSPECTION ...................................................... EN - 527
11. AIR CONDITIONER CUT SYSTEM INSPECTION .. , ............ , ......... , ......... EN - 528
EN4 ENGINE ELECTRICAL EQUIPMENT
SPECIFICATION .................. , ............... , ........... ,., ........................ , ...... EN - 529
1 BATTERY INSPECTION... .... "............."......" ...... " .... EN - 530
2. ALTERNATOR .................................................................... , .................... EN-530
3. STARTER MOTOR REMOVAL & INSTALLATION ............................ , ....... EN - 531
4. SPARK PLUG INSPECTION ..................................................................... EN - 531
5. PLATINUM PLUG INSPECTION ................... , ............................................. EN - 531
6. IGNITION COILINSPECTION ........................................ , ........................... EN - 532
EN5 COOLING SYSTEM
SPECIFICATION ..... , ............................. , .................................................... EN - 533
1. RADIATOR INSPECTION .......................................................... , .............. EN - 534
2. RADIATOR CAP INSPECTION ................................ , .................................. EN - 534
3. COOLING WATER FILLING PROCEDURE ................................................ EN - 534
4. RADIATOR REMOVAL & INSTALLATION .......................... , ........................ EN - 535
5. SUB ELECTRICAL FAN INSPECTION ....................................................... EN - 536
6. THERMOSTAT INSPECTION ....................................................... ' ... , .. " .. EN - 536
EN6 FUEL SYSTEM
SPECIFICATION ......................................... " .......................................... EN - 537
1. FUEL TANK REMOVAL & INSTALLATION ............................................. "". EN - 538
2. FUEL GAUGE , ... , .......... , ....................................................................... EN - 539
3. FUEL PUMP REMOVAL & INSTALLATION .......................... " ................... EN - 541
EN-4
CONTENTS
EN7 EXHAUST SYSTEM
SPECiFiCATION.............................. ...... EN 542
1, EXHAUST PIPE, CATALYTIC CONVERTER
& HEAT PANEL TIGHTENING TORQUES ............ . ................................... EN - 543
2. EXHAUST GAS TEMPERATURE WARNING EQUIPMENT INSPECTION. EN - 545
ENS ENGINE CONTROL
1. ACCELERATOR PEDAL INSPECTION & ADJUSTMENT...... ..... EN - 546
2. ASCD .............. .................................................................... EN - 547
ENg ENGINE MOUNTING
1. FRONT ENGINE MOUNTING....... ................................................... EN - 560
2. REAR ENGINE MOUNTING ............................................................. EN - 560
EN-5
ENGINE SPECIFICATIONS
EN1 ENGINE SPECIFICATIONS
MAIN ENGINE SPECIFICATIONS
i
1
EHCR32
I
I
I
""_mode'
EFR32 E-HR32, E-HCR32
EHNR32
E-ECR32 E-8NR32 ,
Englnotype C/l.181
i
R82DE R82DDE R820DET i R8250E RB26DETT :
, Displacement (ee) 1809 1998 1998 19S8 2498 2568
CombusUon chamber
Semlsphere i
Pent-roof type
type ,
SOHC beit dnve DOHC belt drove
!
; Bore x Slm,," Imm) 83.0 x 83.6
' 780,697 78,0 x 697 78,0,697 860 x 71 ,7 860 x 73,1
Compression ratio 8,8

:
85 10,0 85
i Compression Pn>S""'" (kg I em') I (fl'm) 12,21135 '25;300
:
13.::: t 300 120/300 1281300 120,'300
'"-
/ 1-
: Maxlmtm ouIpu! (noQ (PS 1 fl'm) 91 /5200 125 I 5608
,
i 55/6400 18016000 280 j 68CC
I Mal<lmum torque (nel) (kgm il\>m)
,
14$ f 3200 17.5! 4400 18815200 27.0! 32J0 23015200 36014400
Fuel consumption ratio (9 I GS.h) I (fllm) 210
/
2400 21512400 20513200 215/2400 2CO! 3200
,
20012800
I Dimensions
MIT 630 )( cOO x 685 845" 590 :>: B55! 630> 660 845;,;66u;.;685 ; 845 x 630 x 660 370 x 665 x 675
,. ,.-
(LxWxH) (mm)
I
AIT ;:;'5x6001.685 330..:590>.:855 830 )( 660 x 685 830 y. 63G x 660
,
,--'"
.... _-
i
I
Intake valve
12 14 5 5 8 7
(dogreas)
,
Intake valve
48
i
52 53
!
:VatveOPering
(dog""'s)
/I cyole
Exhaust valve ; I
I
(degrees)
54
i
54 63
i
E.nausi valv&
I
:
i
(degree.)
14 0
,
2 (BTDC) 7 (STOel
Valve
Intake (W31TT1) (mm) 0.30 o (Automatic adjustment typel 051

clearance
i
Exhaust (wann) (mm) 030
i
C (Automatic adjustment type) aM
,,,--'" ,
MIT 700 600 650
i
650 650 , 950
Idle speed (rpm)
AIT 800
l
650 650 650
'" .
..
I'
MIT 131700 201600 I 15/650
!
15! 650 15/650 20:950 i
, 19n1tion (BTDe" I rpm)
i
'"
..... _--- .....
AIT : 13! 800 20 I 650 ;5! 650 2Q 1650 15/650 151560
....
Preparation
Idle CO d .... ll (%) , Below 0,1
..... __ . ... ....
target value
Idle He density (ppm) Below 50
.
Standard
,
'''--T :
,Engine oil 75W30 75W 30 7.5W" 30 7,5W 30
(laclllry)
Cold climate ....-sion
(SG gradel ,SG gcade hsbo) ,SG 9cade) I'SG gmde UxbC)
011 pan capacity (H level) (Ll .
i
3.4
;
4.0 4.0 4.5 i4WC) & 4.0 4.5
Oil ftftllr capaci1y (L) Approx 0.4
,
Aoorox. 9.0 I ' coolant capacity il) Approx 7.0 Approx.8.0 Apprcx.9.0
i
APPfO)( 9
ApprOx. 9.0
!
'"
EN-6
ENGINE SPECIFICATIONS
EMISSION CONTROL EQUIPMENT SPECIFICATION
i
. Vehicle model
EFR32 E-HR32, EHCR32
E-HCR32
EECR32 EBNR32
EHNR32
!
:
Engine type CA18i RB20E : RB20DE RB20DET RB25DE I RB26DETT i
: Engine fuel sy.stem S::>i {ECCS) ECCS
Air I fuel ratio control s}>Stem A:- f fuel ratio feedback
I
Temperature control air cleaner Automatic:- - :
-
-
-
Supplemental start equipment klle-up solenoid type aIr regbator
i Intake heat sy.stem Hot wafer "fMtln;j , -
-
!
- -
:
.
: Ignition system Breakerless type {ECCS} Breakerless type (EC8S electrical distributor)
i
-
-
- -
-
-
1V valw operation
-
I
-
!
-
I
CO,He INCx)
i temperature
reduction eqt.ipment
' Catalyzer type Three-way catalyst (monolithic tyD6i
!
Catalytic COfI\ferter
(09) X3 (17) X4 (1 3) X3 (1.7)
size (capacity In L)
,
! Deceleration exhaust
0
!
I
!
0
!
: gas reduction Fuel cutoff eqUipment -
- -
, eqUIpment
:
i E>haus\ gas temerature warning ThBr'T1ocQuple
Thermocouole (850)
I equipment (Setting temperature 'C) (940)
r Evaporative gas control system Canister system
i Blowby gas reduction system Closed system
EN-?
SPECIAL SERVICE TOOLS
!
Spark plug wrench
EG17401600
NAME
Allen compression gauge
EG15-50000
Adapter
EG15050101
Electronic system
diagnosis tester CONSULT
EG1180 0000
Seal cutter
KV101 11100
Tube presser
WS3993
Pulley puller
ST2718 0001
..
/1
TOOLS
USE
Removal & Installation of
hexagonal spark plug
Engine compression pressure
inspection
Idle test & adjustment
Oil pan removal
Liquid gasket lubrication
Removal & Installation of crank
pulley
Oil seal drift
ST0153 0000
KV401 00900
8T30022000
CD] ) )) Oil seal insertion
Pulley holder
KV101 09300
KV101 09900
ST3512 0000
ST3153 0000
Valve spring compressor
KV101 16200
ST12070000
KV101 08950
KV101 09210

~ Cam pulley bolt removal &
Installation
EN-8
Valve spring installation &
removal
Valve oil seal puller
KV101 07901
KV10107902
Valve oil seal drift
KV101 07501
Drift attachment
KV101 11400
Valve guide drift
KV101 16000
Engine stand ASSY
ST05015000
Engine attachment
KV101 06500
NAME
Engine sub-attachment
KV101 10700
Pilot bearing puller
ST1661 0001
Ring gear topper
1, KV101 104S0
2, KV101 05610
Adapter harness for mold
coil (1 poles)
EG1116 0000
2
0'::::
1 I)
!
1
EN-9
TOOLS
USE
Valve seal removal
Valve oil seal insertion
Valve guide installation &
removal
Engine main unit over haul
Engine main unit overhaul
Pilot bush removal
Flywheel & drive plate
installation
Ignition primary signal removal
TOOLS
NAME USE
Timing light
EG1443 0000
EG1443 0001
Oil filter wrench
KV101 06250
Vacuum gauge
EG1512 0000
Vacuum hand pump
EG1513 0000
Compound gauge
EG15080001
Fuel pressure gauge
8T1959 0000
Valve seat remover
Intake side, exhaust side
Valve seat drift
Intake side, exhaust side
Valve seat cutter set
N
1)
-'i=- -"
;:- . : . ~
Ignition timing check
Removal & installation of oil
filter
Automatic temperature
adjustment air cleaner inspection
: Automatic temperature
adjustment air cleaner inspection
~ ~ .,. i Turbo charger pressure-charging
~ V inspection
Measuring fuel pressure
Valve seat removal
Valve seat insertion
Valve seat form correction
EN-10
TOOLS
NAME USE
Valve guide reamer for guide
insertion hole correction
Exhaust side
8 iiZlAl1
Valve guide insertion hole and
Guide inner diameter
guide intemal diameter
correction
e
WZD
correction
Intake side
KV101 11600 (6.0 mm)
Exhaust side
KV101 07700 (7.0 mm)
....
Engine sub attachment

,'i i '\J i
KV101 14500

Piston pin press stand
Press stand
ASSY

Press stand ST1303 0020
\ C shaft
Spring ST13030030
Drift KV101 09130
' F,C:' ... ,l
Remove & install piston pin ...... Drift
Centre shaft KV10110810
@
IWlilWiil!1
Centre cap KV101 10820
Centre cap Spring
i
EN -11
Multipurpose tools
Valve guide reamer - Installation of the valve guide,
Valve seal cutter -Installation of the valve seal.
Piston ring compressor -Installation ofthe piston ASSY.
Piston ring expander -Installation & removal of the piston ring,
Measurement tools
V block
Dial gauge
Micrometer
Inside micrometer
Thickness gauge
Valve spring tester
Depth gauge
Protractor
Magnet stand
Plastigauge
Con'rod aligner
Bore gauge
Straight edge ruler
EN -12
TOOLS
m
Z

w
AAC valve
Air regu1ator
Spark plug
sensor
lr,lll'.1
"I II
sensor
Swing v(llv19'
converter
MutHer
Exhaust warning lamp
Exhaust temperature power
Switching modulA
mn

n c
(j) ro :::t
Vl

1
Ie
0
..J
n Q
g 3

u
ro
l.

c
'"
rn
"
'"
'0 "
" ill
" ..
ECCS GQnlJOlunit
valvelswitch
l
--'
Fuel control signal
a
p m
0
'"
o.
"'. ro

'" " ill

=r Q
3
g
0-
w

m

S. 0

"
,
ItO' '!'.
n
"
0
"
"

-

fl
"
'"
Air cleaner
Ail flow metel
I I

I Fucl pump
.. -;)

Monitor & chock
light (red light}

;' )(YffJ'<). --
Vehicle speed sensor
AfT control unit
;0(1)
ro-<
""(I)

m
m3:

m
0G')
g;:o
-

G'>
z
m
:xl
OJ
'"
'"
m

m
Z
Gl
Z
m
(f)
-<

m
s:
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m
z

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!1;
Power transistor unit
Canister
Temperature
Ignitio!1 cOil
Crank anQlo sensor
catalytic conver\flr II l:ur==========::---:-:
Exhaust temperature warning lamp
Exhaust tempclatur sensor
IGN power
module
Air flow meter
6

*
ro

r-... '-----
Air cleaner
;U(J)
m-(
N(J)
0-1
gm
03:
0 :1:_
0
mG>
(j):::O
-
mS:
0
0
C/)

m
z

Z
m
Neutral I I
Vehicle Srep.tl 3eOBDr
----- A I T control unit
'"
!XI
'"
<:>
8
:I:
()
m
!!l
m
()
0
!E
m
Z
G')
Z
m
(f)
-<
(f)
-i
m
:;;:
o

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:;;:
m
z

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T0t nperal\;l2
I I,jllk .lilq!t, ,-;pn"l)f
Exhausl temperature sensor
'.1'1 power
SWitching module
Canistor
'"

Throttle
Air flow meter
" o

,LJ!!!.
uel pump
ontrol
lOd;J!ator
I

swT[Cf)4 t:r F- uel pump
M:naor & check
I
, hti
light (red 19 "'
Neutral
; T control unit
Air c!eaflRf
;:O(f)
tIl-(

C-i
mm
-13:
C
00
::x:-
Ol>
,G)
mAl
"l>
.::3:
m
o
o
!E
-I
C
;:0
til
o
o

;:0
"
m
;:0
m
z
"
z
m
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<>

()
m
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m
()
()
$
<::I
:xl

m
:xl

Z
m
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s:
o

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s:
m
z

m
sen sur output signal
Intake sensor m I LTAlItnmatic temp e a 'lISlment device
II _ IIII!\
\" :: l. 'J. il.
Revolution
Fees COlltrol umt
z cf
2: {D
-0
91 in 5 I il __
e .:g 3 Dso!enoid ON f
o
.!
I
PTChoater

- To 50ark plug [
\ Transmission
From fuel tank
_u, ') Dual ignition f
- jJ Cmnk angle sensor
L..
L J Vf!iilclc speed sensor
v,,)lvo (NT only)
plug
serlsor
!II EXhGust rIl8fllfoid COW;1
lyse!"
'--iMUftIP
SWilCrlinQ module
Exhoust temperature wammg lamp
L-----Exhaust tf:mporaturc sensor
O(J)
l>-(

_. -i
-m

'i;;
ZG')
Cl"
z
ms:
g
!!!
m
"
"
$
m
z
Gl
:it
m
(J)
-<
(J)
-I
m

o

m
z

-J
1-
Power IranSrs,tor unit
Ale
FICO solenoid
Canistor
Tplnpepitl1re., <::.. n<:"r '"
jgnition coil
Si'!1:<)f
sensor
}:x(ax cHtalytic converter
i
Exhaust femperatum sensor IGN power
SWItching module
.... <?

Air flow meter Air cleaner

Fuel pump
MOllitor & check
light (red light)
Neutral
switch

&V L-;;]t I
Transmissfon
I
"t}
--A ! T control unit
;;om
Ill-(

0-1
mm
mis:
z
,,0
zl>
mG')

is:
;0
I!l

m
z
G'l
Z
m
OJ
(;l
-;
m

o
j;
Gl

m
z

CO
I
r,::.
Air regulator

<gm
switch
AAC valve control sIgna1
Recirculation vBlve
I

,Power Inmsisto __
=;;:""-t+- -tcmperat r
e
\ r=-
unit ,=-""'''
sensor 115', (i a
11 ntef I
Carhon j III{
canister :::;- :::;) :1 (

I TJl
Throme valve sw,tch r,' .... _/
nock lS 1 .-.
Spark plug ("- 1 ,I [ I
-----\,.1-
=F== .
. .. +
,t-L,j-, II r-l
3-wa. Od r--cc . ' ,. 1 '.1'1:
r- r:::: y catalytic converter!J .. L' l SFmsor
,_ '"'" ,"", '" c, I e:
'
c><il
.. _ .. .. '"'"' ,.,.'j" " ' '" ' ,
_ .. 11 Cf I
Exhaust temperature L_ . u .. e>
sensor . -I" IGN power In "L urbocharg I /' L
,.,,""' -\. , ,,'
0", sensor 1 Air flow meter
. _. '-::=if,'::::
:;O(/)
Ill-(
N(/)
CD-i

:p:
00
0-
J:
0(;)
::0
m
[!s:
m
o
o
(f)
-

z
.!.t
c:
:;0
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o
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J:
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:;0
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m
:;0
m
z
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m
:IJ
III
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8
'"
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,
9
m
(')
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i

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el
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m
li
z
m
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s:
VACUUM DIAGRAM
RB20 EGI (ECCS) ENGINE
.. iew B
1
Pressure regUlator
Evaporation control
hose ASSY
Canister
Number
1
2
:
:
3
4
5
,
6
Length {mmt
Molded
Molded
Molded
Molded
160
Molded
VACUUM DIAGRAM
RB20 EGI (ECCS) ENGINE
3
Air regulator
View X

6 )' 4
I-tose - /,_
X. "'-,,0" Air hose
Three way connector -"",-') 5 _
\ A:rdUCl)'OO
Hose Da'ld v1'
-Ii....
" --3-5mm
section T - T
Part
I
Intake manifold collector - Pressure regulator
Air regulator - Intake manifold collector ,
,
Air regulator - AAC valve
I Three way connector - Intake manifold collector
Three way connector - Fuel damper
:
Air duct - Three way connector
EN -19
VACUUM DIAGRAM
RB20 DOHC EGI I RB20 DOHC EGI TURBOCHARGER ENGINE
RB20 DOHC EGI {ECCS} ENGINE
I Number Length (mm) Part
I
1 110 Intake manifold collector - Pressure regulator
RB20 DOHC . EGI (ECCS) TURBOCHARGER ENGINE
View E
0ress:.J'e regulator
1
Clamp {Evaporation hose Side\
...
\ Recirculation valve
\ White
""-1-_ , Vacuurr gallery
I Clamp
\ Hose band
,--", \ Protector i19Cmm)
; \' Evaporation hose ASSY
Inter-cooler'
Number Length (mm) Part
1 110 Intake manifold collector - Pressure regulator
2 80 Throttle chamber - Vacuum gallery - ASSY
3 170 Intake manifold collector - Vacuum gallery - ASSY
4 170 Intake manifold collector - Vacuum gallery - ASSY
5 Molded Recirculation \!albe - Vacuum gallery - ASSY
------'
EN-20
CA18i! RB25DE ENGINE
GA18i (EGGS) ENGINE
Fue! return hose
\ / Pressure regulator
'\:, r \ (ThrOtlle/ / 3
1 ~
2
, . body)
~ / ~ ~ ~ L ~ B
Hose band Hose clamp
Front
Radiator shroud
/
View A Do not face the ramp claw towards fuel hose side
Number length (mm) Part
1 110 Intake manifold - Canister
2 80 i Throttle body - Canister
3 170 Pressure regulator - Throttle body
RB25DE ENGINE
E
EGGS harness
VACUUM DIAGRAM
View C
Canister
1
Cross section A A. B B Cross section C C
I Purge hose
@
J
Canisler ...
ViewE
VaclJtJm hose
2
Number I..&ngtb (mm} Part
1 110 Intake manifold collector- Pressure regulator
2 140 IIA unit connector - Fuel damper
------
EN-21
VACUUM DIAGRAM
RB26DEIT OOHC- EGI TWIN TURBOCHARGER ENGINE
RB26DETT DOHC - EGI (ECCS) TWIN TURBOCHARGER ENGINE
Clam;
- :2,-
Clamp baed r
Turbocharged pressure control solenoid
Clamp
Pressure regulator
Double vacuum tube
Clarno
Clamp
Double clamp
i
i
Clamp
Canister
: Number
!
1
2
i
3
4
5
6
7
8
9
10
11
12
13
14
!
3
SWing valve
Clamp coniroller
(front)
Vacuum control tube
Swing valve controller (rear)
I.&ngth (mm)
. .
Part
.. ........
. . . .
: ...
580 Turbocharged pressure control solenoid - Vacuum gallery ,
560 , Turbocharged pressure control solenoid - Vacuum gallery
425 Canister - Vacuum gallery
425 Canister - Vacuum gallery
I
80 Throttle chamber - Vacuum gallery
290 Air chamber - Vacuum gallery
Molded Pressure regulator - Balance tube
120 Vacuum gallery - Vacuum gallery
90 : Vacuum gallery - Vacuum gallery
Molded Vacuum gallery - Swing valve controller (rear)
Molded Vacuum gallery - Swing valve controller (front)
90 Vacuum gallery - Vacuum control tube
EN-22
IDLE SPEED; IGNITION TIMING IIDLE MIXTURE RATIO INSPECTION
RB20E {DE I DET I CA1Si I RB26DETT ENGINE
EN2 RB26DETT I RB20E I DE I DET I RB25DE I CA 18i ENGINE
1. IDLE SPEED f IGNITION TIMING I IDLE MIXTURE RATIO
INSPECTION
Idle standard value
ENGINE TRANSMISSION
Idle speed (rpm} Ignition timi ng CO I He density
. (when air condition is ON) (BTDOI rpm) (%)/(PPM)
MIT 600 (Approx. BOO)
!
20 I 600
RB20E
AIT 650 (Approx. 800) 201650
MIT
RB20DE 600 (Approx. 800) 15/650
AIT
MIT 15/650
below 0.1 f
.
below 50
RB200ET 600 (Approx. 800)
AIT 20/650
!
MIT 700 (Approx. 850) 13/700
,
CA18i
AIT 800 (Approx. 850) 13/800
I RB26DETT MIT 950 (Approx. 950) 20 / 950
Caution:
I
The idle speed, ignition timing, CO and HC density are interrelated. If any adjustments are
made to one, additional inspection is required.
Diagnosis connector (inside fuse box)
ECCS control unit (inside left dash side lower finisher)
EN -23
IDLE SPEED I IGNITION TIMING IIDLE MIXTURE RATIO INSPECTION
RB20E I DE I DET I CA 18; I RB26DETT I RB25DE ENGINE
IDLE SPEED I IGNITION TIMING / IDLE MIXTURE RATIO INSPECTION
ERE PA8.ATI ON
1. Make sure the following parts are in good condition.
Battery
Ignition system
Engine oil and coolant level
Fuses
Control unit harness connector
Vacuum hoses
Air intake system (Oil filler cap, oil level gauge, etc.)
Fuel pressure
Engine compression
Throttle valve
2. Vehicle fitted with Air conditioner should have the A I C switch in OFF position,
3, When checking idle speed, ignition timing and mixture ratio of A I T models, place the
shift lever in "N" position,
4. Insert the probe approx. 40 cm (15.7 in) into rail pipe when measuring CO percentage.
5. Turn OFF the headlight, heater blower and rear defogger.
6. Keep the steering wheel straight.
7. Recharge the CONSULT sufficiently when using consult and connect to the vehicle side
diagnosis connector.
INSPECTION SEQUENCE
INSPECTION START I
"It -J...
NG
'I Repair or
Self diagnosis operation
OK"It
Check & adjust idle speed i'
OK
NG
I Check ignition timing Adjust ignition timing I--
OK
NG
Repair or replace the
Check heated oxygen
heated oxygen
sensor function
sensor input signal
Check heated oxygen
sensor harness cables
i-
OK OKl NG
J,OK
ICheck CO & HC ratio
OK
I Replace heated oxygen sensor
NG .J., NG"
l;heCk emission control Check heated oxygen sensor
and repair or replace 0 K
\
I
IINSPECTION END I'
I
EN -24
IDLE SPEED / IGNITI ON TIMING / IDLE MIXTURE RATIO INSPECTION
RB26DETI/CA18i ENGINE
RB26DETT Engine Idle inspection & adjustment
CA18i Engine Idle inspection & adjustment
EN - 25
RB20E I RB20DE ENGINE
RB20E Engine Idle inspection & adjustment

~ .
Mold type ignition coil
~ (Engine speed measurementunit)
RB20DE Engine Idle inspection & adjustment
EN-26
IDLE SPEED / IGNITION TIMING / IDLE MIXTURE RATIO INSPECTION
RB20DET ENGINE
RB20DET Engine Idle inspection & adjustment
EN-27
IDLE SPEED I IGNITION TIMING I IDLE MIXTURE RATIO INSPECTION
RB26DETT I RB20DE I DET ENGINE
Idle inspection & adjustment (RB26DETT I RB20DE, DET)
Engine speed measurement unit
Warm the engine sufficiently,
Connect CONSULT to diagnosis Connector on vehicle
(attached to fuse block area), Place the ignition to ON
position,
Display the "DiagnOSis mode selection",
Connect the measurement unit to speed
detection terminal in the hamess connected to the ignition coil from the power transistor.
When the measurement is complete, always replace the terminal cap in the detection
area,
Inspection
Engine speed detection termmal
(Yellow & red wire)
Warm the engine sufficiently.
Make sure the air conditioning load, power steering
oil pump load and electrical loads are not applied.
Place the select lever in 'N' for automatic vehicles,
Check the "IDLE POS" and "CAS-RPM" in data monitor
mode in CONSULT.
RB26DETT
* MO"OO' *'0 "" Dj
CAS-RPM (POS) 950
IDLE POSITION ON
Carry out the inspection using engine speed r<iB>\ "
measurement. f=' =========;
Note: I RECCRD
The measurement unit is limited as the speed output voltage is low (approx. 6V Vp-p).
Caution:
Before the inspection, make sure the throttle valve switch (idle connection point) is turned ON
when the accelerator pedal is not pressed.
Adjustment
The idle speed adjustment is basically not necessary as the rated MC VALVE ADJ
value (control target value) is returned to the control unit. If
adjustment becomes necessary, carry out the following
procedures, (i:i\
Select "AAC valve adjustment" in "WORK SUPPORT"
mode, Turn the AAC valve assembly idle adjustment
screw with a screwdriver until idle speed is 900 rpm
(RB26DETT) 600 rpm (RB20DE, DET).
o Return "AAe valve adjustment" screen to "DATA monitor"
and check if the idle speed shown meets the specification,
EN-28
SET ENGINE RPM AT
THE SPECIFIED VALUE
UNDER THE FOLLOWING
CONDITION,
ENGINE WARMED UP
NO LOAD
START
IDLE SPEED i IGNITION TIMING J IDLE MIXTURE RATIO INSPECTION
RB26DETI I RB20DE I DET ENGINE
Make sure the ECCS control unit idle control Ad>\
adjustment volume is turned all the way to left,
Caution:
Do not turn the idle control speed adjustment volume with
excessive force, The adjustment screw turning range is 3/4
ofa turn.

Ad,iuslment Wlttlln indicated range.
Do not tum with excessive force.
__ ,
: j ,
i lid seJ r-
i II
I _OWl
Remove the 2-pin harness connector from the AAC valve to stop the idle speed feedback
control. At this time the AAC valve is completely closed and the idle speed should be
below 900 rpm (RB26DETT) 600 (RB20DE. DET) under normal condition.
RB26DETT RB20DE,DET
Turn the AAC valve ASSY idle adjustment screw with a screw
driver to adjust engine speed to 900 rpm (26DETT).
600 rpm (20DE, DET).
Connect the AAC valve harness connector and
make sure the idle speed is maintained at specified value.
The engine speed increases when the adjustment screw is
turned to left (CCW) and decreases when turned to right
(CW),
If you wish to increase idle speed for any reason, tum the
idle adjustment volume in EeeS control unit to adjust the
speed. Idle adjustment speed increases when the knob is
turned clockwise by a maximum of 250 rpm.
Caution:
The adjustment volume must be set 40
0
- 50
c
away from the
self-diagnosis position as if it is turned all the way to the right
,.,au on,
Adjustment withm :ndicated ['ange.
00 not :U!T1 with excessive force.
Roe
--_--_--1-... -
I
ifd!e soeed - I
: r-)..,
i
(self-diagnosis position), the idle speed is lowered (lowest rpm '--________ ----'
+ 50 rpm).
EN-29
IDLE SPEED I IGNITION TIMING IIDLE MIXTURE RATIO
RB26DETI I RB20DEIDET ENGINE
IGNITION TIMING CHECK & ADJUSTMENT (RB26DETI , RB20DE, DET)
1. When using "Super tuner"
Connect super tuner to timing detection terminal,
Caution:
After the operation is completed, always attach terminal cap to timing detection terminal.
RB26DETT RB20DE, DET
2. Using primary current detector timing light
When using EG1443 0001 or EG1444 0000 connect the sensor to No, 1 cylinder primary
line, (No, 1 cylinder primary line is looped as it is longer than other cylinder primary lines),
Caution:
When using EG 1444 0000 (internal battery model), make sure that the sensor direction
(arrow direction) faces spark plug when sensor is clipped to the primary line,
RB26DETT
EG1444 0000 --"
Power transIstor umt side
Spark piug side

IDLE SPEED 'GNITION TIMING IIDLE MIXTURE RATIO INSPECTION
R626DETI I R620DE I DET ENGINE
Inspection
Make sure the idle speed is at standard value.
Make sure the ignition timing at engine idle is at standard
specification.
Make sure ignition advances to correct advance angle when
the engine is raced.
Caution:
The 0timing mark on the crank pulley is orange and other
points are painted white.
Adjustment
Since there is no variation in ignition timing, over an extended
time period, ignition adjustment is not necessary in principle. r
Adjust ignition timing when the crank angle sensor is 901 Ion
connected. .
Set the ignition timing by adjusting the crank angle sensor
installation position. I I
Make sure the idle speed is at standard. ! ~
~ ' ~ - - ~ - ~ ~ ~ - ,
Sealing tape I
Loosen the three crank angle sensor mounting bolts and !' \}
Camshaft rotalliill
rotate crank angle sensor. Turn the sensor to left to ~ ~ - - __ , __ ~ __
advance ignition timing.
After the adjustment. attach the sealing tape to one of the
three bolts that secure the crank angle sensor.
Sealing tape part number: B2235 U7 410
EN - 31
IDLE SPEED I IGNITION TIMING! IDLE MIXTURE RATIO INSPECTION
CA1SiI RB20E ENGINE
Idle inspection & adjustment (CA18i / RB20E)
Engine speed measurement unit (j) II"< " -,1 i /'l i !'ell -h','
"'I \\ d/; . ..J / \,,-:::'
Warm the engine sufficiently. "\ \ d?' i -...;,
Connect CONSULT to diagnosis connector on vehicle . . / Consult
(attached to fuse block area). Place the ignition to ON
position.
Display the "Diagnosis mode selection".
Connect the measurement unit to the speed detection terminal by connecting the adapter
harness for the mold coil between the coil primary terminal and the primary terminal
harness connector.
CA18i
RB20E
Inspection ffi\
Warm the engine sufficiently. \!!J
Make sure the air conditioning load, power steering oil
pump load and electrical loads are not applied. Place the
select lever in 'N' for automatic vehicles.
Check the "IDLE POS" and "CAS-RPM" in data monitor
mode in CONSULT.
Carry out the inspection using engine speed t<S\
measurement. 'aI
Caution:
Before the inspection, make sure the throttle valve switch
(idle connection point) is turned ON when the accelerator
pedal is not pressed.
Adjustment
RB20E Engine
The idle speed adjustment is basically not necessary as the
rated value (control target value) is returned to the control unit.
If adjustment becomes necessary, remove the ECCS control
unit and carry out the following procedures.
Select "AAC valve adjustment" in the "WORK SUPPORT"
mode. Turn the AAC valve assembly idle adjustment screw
with a screwdriver until idle speed is 600 rpm (M IT) 650
rpm (A IT).
Return the "AAC valve adjustment" screen to "DATA
monitor" and check if the idle speed shown meets the
specification.
EN-32
1:1: MONITOR1:I: NO FI>,IL
CAS-RPM (REFi 675'P;11
AIR FLOW METRE 1 04v
WATER "EMP 79C
02 SENSOR 0.1'v
THROTTLE SENSOR OAOV
IDLE SW ON
RECORD
1*' AAC VALVE
I SET ENGINE RPM AT
i THE SPECIFIED VALUE
I UNDER THE FOLLOWING
i CONDITION.
ENGiNE WARMED UP
NO ,-OAD
[ STAFrr
IDLE SPEELl IGNITION TIMING I IDLE MIXTURE RATIO INSPECTION
CA 1 8i I R820E ENGINE
Make sure the ECCS control unit idle control
adjustment volume is turned all the way to the left
Caution:
Do not turn the idle control speed adjustment volume with
excessive force. The adjustment screw turning range is 314
of a turn.
Turn the ISS unit idle adjustment screw with a screwdriver
to adjust the engine speed to 600 rpm (M 1 T), 650 (A IT).
Connect the throttle sensor harness connector. Make sure
idle speed is maintained at the specific value.
If you wish to increase idle speed for any reason, adjust the
volume in ECCS control unit.
Caution:
The adjustment volume must be set 40 - 50away from the
self-diagnosis position as if it is turned all the way to the right
(self-diagnosis position), the idle speed is lowered (lowest rpm
+ 50 rpm).
Adjustment
CA18i Engine
Remove the harness connector from the intake
temperature sensor to stop the feedback system of the
ignition timing and air - fuel ratio.
Adjust the engine revolution to 700 rpm (M / T), 800 (A I T)
by throttle adjustment screw.
Connect the harness connector for the intake air
temperature sensor and make sure the idle speed is
maintained at the specified value.
caution:
The adjustment volume on the control unit side can not be used
for fine adjustment.
EN-33
Cautioli.
Adjustment Within indicated range.
Do not tUT'1 'Nlth excessive force.
R!,"
...
r Idle ((;6)
is "
RB20E/CA1Si ENGINE
IGNITION TIMING CHECK & ADJUSTMENT (RB20E I CA18i)
Timing light attachment
Connect the timing light using the adapter harness for hold coil for the timing light that
collects the signal from the super tuner.
For normal timing light connect the sensor to No, 1 Hightension cable.
CA18i RB20E
Inspection
RB20E
Do not carry out the inspection as this may cause ignition
timing to become unstable.
Make sure the idle speed is at standard value.
Make sure ignition timing at engine idle is at standard
specification.
Make sure ignition advances to correct advance angle
when engine is raced.
Caution:
r
The 0timing mark on the crank pulley is orange and nthi"rl
points are painted white.
EN-34
"GNITION TIMINo+
. WHILE :DLlNG PR"SS 'S-:-ART'
AND STOP THE IGNITION rv.NG
FEEDBACK CONTqOL. ROTAE
THE CRANK ANGLE SENSOl
AND ADJUST BY USING THE
TIMING LIGHT.
L '" '" ",.
r START ___ -..1
'tl MONITOR'tl NO FAIL 0
1
CAS-RPM (REF) 675 'pm'
WATER TEMP 79"C
IGNITION TIMING 158TBC
RECORD
'-----
RB20EI CA18i ENGINE
Inspection
CA18i engine
In the "Ignition timing adjustment" in "Operation
support" mode and check the ignition timing.
Remove the harness connector for the intake temperature
sensor and fix the timing advance to inspect the ignition
timing.
Make sure ignition timing at engine idle is at standard
specification.
Adjustment
RB20E engine
Adjust the ignition timing by adjusting the distributor
placement position.
Make sure idle speed is standard.
Remove the throttle sensor connector.
Loosen the crank angle sensor mounting bolts and rotate
crank angle sensor. Turn the sensor to left to advance
ignition timing.
After the adjustment, attach sealing tape to the bolts that
secure the distributor.
CA18i engine
Adjust the ignition timing by adjusting the distributor
placement position.
Make sure idle speed is standard.
Loosen the crank angle sensor mounting bolts and rotate
crank angle sensor. Tum sensor to left to advance ignition
timing.
After adjustment, attach sealing tape to the bolts that
secure the distributor.
Sealing tape part number: 82235 U7410
EN - 35
.GNITION TIMING+
: WHILE IDLING PRESS "START
AND STOP THE IGNITION TIMING
FEEDBACK CONTROL. ROTATE
THE CRANK ANGLE SENSO
AND ADJUST BY USING THE
TIMING LlGf-lT.
START
Seahng tape
attachment
IDLE SPEED (IGNITION TIMING I IDLE MIXTURE RATIO INSPECTION
CA18i / RB20E/ DE/DET I RB26DEIT ENGINE
IDLE MIXTURE RATIO (CA18i I RB20E I DE I DET I RB26DETT)
INSPECTION
The air-fuel ratio feedback system which has a self-Ieaming function is used and CO and HC
density adjustment is not necessary as the correction range is wide.
Inspection
Warm up the engine sufficiently and make sure the idle speed i:l MONITOR 1;:{ NO FAil C
and the ignition timing are at standard measure. Check CO
and HG density with GO and HG meter. CASRPM (POS)
EXH GAS SE'<
If the values do not conform to standard measure, perform EXH GAS SEN.R
following procedures to inspect the air I fuel feedback Mlq FC ''';;
condition: : MiR FIC MNTR
95:) ro'"
123\/
11 ";\'
In the data monitor mode, select "Exhaust gas sensor ffl\ I
monitor" and "Exhaust gas sensor monitor (R)". 1=1 ====Re=C=ORD====
Set the engine speed above 1000 rpm (2000 rpm for
RB26DETT engine) and make sure "RICH" and "LEAN" are
displayed alternately.
Short-circuit the self-diagnosis connector on the
vehicle side (near fuse box installation), Or
remove the ECGS control unit and operate adjustment
volume on the control unit side.
Place the ignition to "ON" position and use a lead line to
short circuit the GHK pin and IGN pin of the diagnosis
connector for more than two seconds to release the
settings. (Or otherwise tum the ignition switch to "ON"
and turn the adjustment volume on the side of the EGGS
control unit to the right (CW) until it stops in the self
diagnosis mode switching position B for more than two
seconds and then return it to the original position,
Afterwarming up the engine sufficiently, raise the engine
speed until the exhaust gas temperature waming lamp (or;
the red lamp on side of the control unit) flashes (the
--' '.
, ___
=- ,.$<2

, Adjustme'1t within II)Q,cate-::: 'arv;e
i Do not turn with Clicess:ve
: R
'''---'''-1
flashing will start above approx. 2000 rpm). The rear \
exhaust gas sensor output monitor mode will be set //,8'- " \ c="=I'
! ,\,,; J ,
Ct
' "
au Ion; '. / '''-..
The accelerator pedal must be pressed intentionally during i f ,--
idling to perform the inspection as the air fuel ratio feedback 'Exhaust gas temperature warning Ilgh,
control is stopped,
EN-36
IDLE SPEED' IGNITION TIMING IIDLE MIXTURE RATIO INSPECTION
RB26DETTENGINE
IDLE MIXTURE RATIO INSPECTION (CONT'D FOR RB26DETT)
Use a lead to short-circuit the CHK pin and the IGN pin of I Short these pins 'or approx. 2 sees men,
the diagnosis connectorfor more than two seconds one ' opec them, the GlagnosllWIlode will then.
: change. 0 I I I I .. t.<1 (The mode:
more time to release the self-diagnosis mode. (Otherwise will change LL each time i
turn the adjustment volume of the EGGS control unit side to Ihis
the right (CW) until it stops to select the self-diagnosis mode.
8 for more than two seconds and then return it to the
original position).
Exhaust gas sensor monitor mode switching display
Set the ignition switch to "ON", Use a lead line to short
CHK pin and IGN pin of diagnosis connector for more than
two seconds to switch mode, (Otherwise tum ignition switch
to "ON" and turn adjustment volume on side of the ECGS
control unit to the right (GW) until it stops self-diagnosis
mode switching position B for more than two seconds and
then return volume to original position,
Switching the signal for
eXhaliS( gas sensor -
exhaust gas sensor (R)
Fuse
block
T& Ext,"ust gas senson
outputmonitof
J
:
Appro);. 4 sees
.. -- .... -.
Switching the Signa! for
After warming the engine sufficiently, raise the engine speed: exhaust gas sensor (R)
until the exhaust gas temperature warning lamp (or the red: - e.,naust gas senso
n
n i
lamp on the side of the control unit) flashes (the flashing will ,.....J U L. I
start above approx, 2000 rpm). The rear exhaust gas : I i- . ExhausIgas sensor:
, :outpU! monitor
sensor output monitor mode will be set.
Caution:
Approx. 4 sees
The accelerator pedal must be pressed intentionally during .... --------
idling to perform the inspection as the air-fuel ratio feedback
control is stopped.
Make sure the exhaust gas temperature warning lamp or
the red lamp on the side of the control unit flashes in this
condition,
Short-circuit CHK pin and IGN pin ofthe diagnosis
connector for more than two seconds to release the mode,
Make sure that the exhaust gas temperature warning lamp
flashes at about 2000 rpm.
EN -37
IDLE SPEED {IGNITION TIMING! IDLE MIXTURE RATIO INSPECTION
RB25DEENGINE
IDLE SPEED {IGNITION TIMING {IDLE MIXTURE RATION INSPECTION
(RB25DE ENGINE)
INSPECTION & ADJUSTMENT
I START I
J,
Visually check the following:
Air cleaner clogging
Hoses and ducts for leaks
Electrical connectors

Gasket
!
Throttle valve operation
A ,
~ r t the engine and warm it up. I
B
.J,-
Open the engine hood and run the engine at about
2000 rpm for about 2 minutes.
C
"
Perform diagnostic test mode II (Self-diagnostic
result).
OK NG
\V
Repair or replace components
as necessary .
"
.J,-
Does the engine run smoothly? Run the engine at
about 2000 rpm.
OK
NG
.J,-
~ Clean the injector. I
0 ,
Race the engine for approx. 2 - 3 minutes then run
engine at idle speed.
\V
To E
EN-38
A
--
B
\ \ , I
\, ' " I
" ~ .,-
-=-'-= t.-=-
-' ~
-
,.. Q
,,0 ~
1000 r! min
C
/
~
~
Red lamp Exhaust temperature
warning lamp
o
RB250E ENGINE
E
, position sensor harness connector.

Stop the engine and disconnect the throttle
Restart the engine. ,E ___ -,--:--:=.,.,,-.,----:---.

F
Race engine two or three times at about 2000 If----,
- 3000 rpm then run engine at idle speed.
OK
Idle speed check
(b\ Read idle speed in "IGN RPM (REF)" in
"DATA MONITOR" mode. F
t<ff\ Check idle speed.
Idle speed (rpm) 650 +/- 50
OK NG
W
Race engine two or three times at about
2000 - 3000 rpm then run engine at idle I
speed.
G
'v
Idle speed adjustment
Adjust idle speed by turning idle speed
adjusting screw (lAS).
Idle speed (rpm) 650
H ,
/
Ilgnition timing check
Check the ignition timing using timing light
or su er tuner. p
Ignition timing (BTOC) 15 +/- 2
,/
ToJ
Ignition timing adjustment I
Adjust the ignition timing by adjusting crank L'
angle sensor bolt.
Ignition timing (BTOCC) 15
Attach sealing tape to crank angle sensor
bolts. Part No. B2235U7410
EN-39
//
,
/
/1
/

IGN PRM (REG) 850 rpm
I
START
I
IDLE SPEED I IGNITION TIMING IIDLE MIXTURE RATION INSPECTION
RB2SOEENGINE
K
J
@ Touch "BACK"
Stop the engine and connect throttle
position sensor harness connector.
Start the engine.
i Race engine two or three times at about:
: 2000 - 3000 rpm then run engine at idle
I speed.
Idle speed check
Read idle speed in "IGN RPM (REF)"' in
. "DATA MON ITOR" mode.
Check idle speed.
:
Idle speed (rpm) 650 +/- 50
i
OK
lNG
Check MC valve and replace if necessary
1
Check MC valve harness and replace if
c--
necessary
,
Race engine for two minutes at 2000 rpm. 1
L
0, sensor system check
@ See "M / R F / C MNT" in "Data monitor" mode.
Maintain engine at 2000 rpm check the moni-
tor fluctuates between "LEAN" and "RICH" more
than 5 times in 10 seconds.
-
1 cycle "RICH, LEAN, RICH"
2 cycles "RICH, LEAN, RICH, LEAN"
,
OR
Make sure that exhaust temperature warning
lamp flashes more than 5 times in 10 seconds.
NG OK
, y
\ I
FINISH
I
TOM
EN-40
J
K
'JO FAUc TO
lGN PRM (REG! 1337 rpm I
AIR FLOW METRE 1.SBV :
WATER TEMP SENSOR 80C I
o SENSOR
0: SH .. SGR
BATTVO ... TAG:;: 14.0V!
,THROTTLE SENSOR 8.S2V'
START
L
NO FAUL -=1
,IGN PRM (REG) 825 rprr I
i O,SENSOR O.02V
: 0 SENSOR MONIT2R

L

@
Red lamp
I
Exhaust temperature
waminglamp
IDLE SPEED I IGNITION TIMING I IDLE MIXTURE RATION INSPECTION
RB250E ENGINE
M
I Check 0, sensor input signal
: See "M / R F / C MNT" in "DATA monitor"
.(j)mode.
I Maintaining engine at 2000 rpm and
check the monitor fluctuates between:
I
"LEAN" and "RICH" more than 5 times in
!
10 seconds.
N
1
Check 0, sensor harness I
Turn off the engine and disconnect the
battery ground cable.
Disconnect harness connector from
: ECCS C/U.
i Check for continuity between terminal No.
! 29 of harness connector and the term i-
. nal NO.2.
OK
lNG
I Replace or repair harness
-"
I Replace O
2
sensor I
,
I Carry out operation L
OK
NG
w
FINISH]
Start the engine and warm it up I
,It
t
Race engine then run engine at idle speed I
:
w
CO check
Check the CO measurement with CO,
HC tester.
Idle CO below 0.1 %
HC below 50%
,J.,
Fuel pressure regulator check I
J"
Air flow meter check I
'"
Check the injector and if necessary clean:
w
Replace ECCS C/U and check C/U operation I
EN - 41
TOl
/f'
I
/
M
!
M

IGN PRM (REG)
AIR FLOW METRE
WATER TEMP SENSOR
AULTD:
837 rpm:
1.S8V!
aoc
O.02V
RICH
14.0V
0.52V
:02 SENSOR
I 02 SENSOR MONITOR
: BATTERY VOLTAGE
: THROTTLE SENSOR
i
START
I

I EGGS GIU CONNECT ORI

N
I r:iJEZH13
I EGCS C/U CONNECTO
[ill

Check idle speed(K)
f'
COMPRESSION PRESSURE INSPECTION
RB26::lETT i RB20DET i DE I RB20E I CA 18i I RB25DE N G ~ N
2. COMPRESSION PRESSURE INSPECTION
Compression pressure standard value
Standard value Limit value
Engine
(kg I cm2) (rpm) (kg , em')(rpm)
.
.
RB260ETT 12.0/300 9.0/300
i RB200E, OET 120/300 9.0/300
CA181 1221350 10.2 1350
RB20E
.
12.51300 9.51300
I
RB250E 12.8 i 300 9.8/300
Engine speed measurement unit installation
RB26DETT J RB20DE J DET Engine
Variance limit
between cylinders
(kg I em') (rpm)
1.0/300
1.0/300
!
1.0 I 350
I
1.0. 30e
!
1.0/300
Connect the engine speed measurement unit to the speed detection pin on the harness
connected to the ignition coil from the power transistor.
Always attach the terminal cap with rubber seal after measurement is complete.:;
RB26DETT RB20DE/DET
CA 18i I RB20E Engine
Mold type ignition coil is used for these engines. Connect the engine speed
measurement unit by connecting the adapter for mold coil between the INT side coil
primary terminal and the hamess connector primary terminal.
RB20E CA18i
EN-42
COMPRESSION PRESSURE I BELT TENSION INSPECTION
RB26DETT! R82GE DE DET! GAlai I RB25DE ENGINE
Compression gauge installation .
Warm up the engine and remove all 6 spark plugs. I
Attach the adapter to the Allen compression gauge and ! --"""'-"-Jfr
set it in a spark plug hole.
Compression pressure inspection
Depress the acceleration pedal fully. Tum the ignition switch to START position and crank
the engine. Read compression pressure and the engine speed once the gauge needle
stops moving.
When engine speed is out of specifications, check the specific gravity of the battery and
perform test again if the battery is functioning properly.
If the compression pressure is still not standard, inspect the components around the
combustion chamber (valves, valve seat, hydraulic valve lifters, piston rings, cylinder bore,
cylinder head, cylinder head gasket etc.). Correct any malfunctions and repeat
compression test.
3. BELT TENSION INSPECTION AND ADJUSTMENT
Inspection
The inspection should be performed when the engine cold or more than thirty minutes after
the engine has been stopped.
RB26DETT I RB20DE, DET I RB25DE ENGINE

. . ...
!> . Belt deft&ction (mm. ..
'! . ..!
. . . ..
11. . ... . .. (When 10kg of fOrce llIl!PpHed at the
.' ....
Belt speclftcation
..! ..! ..... I ...... .
PART .
. .. .
New I !Adjustment Tension limit
. . . ..
Standard
PolyV low
8 - 10 9 - 10 15
Power steering
maintenance bett !
With HICAS 8 -10 10 -12 16
Air conditioner compressor bell
PolyV low-
6-8 7-9 12
maintenance beft
Fan belt
PolyV low-
3-5 4-6 7.5
maintenance belt
EN-43
BELT TENSION INSPECTION & ADJUSTMENT
RB26DETT i RB20E I DE I OET i CA 18, i RB25DE ENGINE
RB20E ENGINE
Power steering bell
Poly-V Iow-
maintenance belt
Air conditioner compressor belt
Poly-V low-
maintenance bell
~ - - - - - - - - - - - - - - -
Fan bell
CA18i ENGINE
Power steering pump bell
;---
Air conditioner compressor belt
Fan belt
Caution:
POly-V low-
maintenance bell
Poly-V low-
maintenance belt
Poly-V low-
maintenance belt
Poly-V low-
maintenance belt
Belt deflelltkm (!nm) -
(When 10kg of fi)rce is applied at the
",;posItIon)
New Adjustment Tension Umit
8 - 10 9 - 11
6-8 7-9 12
3-5 4-6 7.5
Belt deflection (mm)
(When 10kg of force 1$ applied at the
o " position)
New AdJuatment Tension limit :
9 - 11 10 - 12
15
e 8 7-9 ~ 2.
4-5 4.5 - 5.5 6
1. When the belt is replaced with a new belt increase the tension slightly more than for the
used belt to allow for wear-in of the new belt.
2. When the belt deflection exceeds the limit, adjust to the "Adjustment" value.
3. Make sure the pulley groove is aligned correctly when the belt is installed.
Adjustment
IT_EM
"ADJUSTMENTPosrrioN-
PART
Power steering belt Adjustment bolt in power steering pump
Air conditioner compressor belt Adjustment bolt in idler pulley
Fan belt Adjustment bolt in alternator
Fan belt
Power steering ump belt
-".
i
L..._ .... __ _
EN-44
VALVE CLEARANCE INSPECTION & ADJUSTMENT
RS260E-, '<SL"E :)E DET,' CA 181 I RB25DE ENGINE
4. VALVE CLEARANCE INSPECTION AND ADJUSTMENT
Additional work required (remove the following parts):
Airduct
Rocker cover
Inspection
Inspect the valve clearance when the engine is cold.
Remove the air duct, ornaments and the rocker cover.
Rotate the crankshaft and align crankshaft pulley mark with the belt cover indicator.
No.1 cylinder is at the compression stroke top dead centre when both the intake and
exhaust side cams do not move the valve lifters.
I
PART
.
VALVE CLEARANCE
i ITEM
MEASUREMENT
, .. "
!
INTAKE SIDE Cylinder No. 1.2,4
I EXHAUST SIDE Cylinder No. 1,3,5
Firing order: 1 53624
Rotate the crankshaft one revolution (360) and align the mark on the crankshaft pulley with
the belt cover indicator. (No, 1 cylinder piston exhaust T.O,C),
.
PART
. .
VALVE CLEARANCe:
ITEM
MEASUREMENT
INTAKE SIDE Cylinder NO.3. 5, 6
EXHAUST SIDE Cylinder No.2, 4, 6
Valve clearance standard value
I
PART
.
. INTAKE
ITEM .
, Valve clearance (cold) mm
0.45'< 'J
(Reference value: warm) mm
0.51','
Cau(jQn:
Always check the valves when they are cold.
EN 45
' ,.'
... Varves to be adjusted
..
Intake side

. ... ';; ,.
I .... ;-' '. . .

Exhaust Side
EXHAUST'
. ....
.
O.38'""uo:J
0.44""'3
VALVE CLEARANCE INSPECTION & ADJUSTMENT
RB26DETT I RB20E I DE I DET I GA1811 RB25DE ENGINE
Valve clearance measurement
Insert a 0.15 - 0.20 mm gauge (A) from spark plug side.
Insert gauge (8) from opposite side. Select a gauge
thickness that will reduce the clearance to 0 m.
Note:
Do not use more than two gauges (8).
Use JIS 150A25 feeler gauge.
Valve clearance = Gauge (A) + Gauge (6)
Reasons for measurement using gauge (Aj and (8) :
1. The valve clearance setting is larger compared to
previous engines.
2. Large gauges cannot be placed parallel to the
measurement surface.
Thick feeler gauge have high rigidity and cannot be bent
easily, so the measurement will be incorrect.
The error factor increases if a number of thin gauges are
layered and the measurement will be incorrect.
Valve clearance adjustment
The valve clearance adjustment is performed by
selecting a shim of suitable thickness.
When the measurement valve clearance (t) is out of
specification, measure the shim thickness (T) and
replace it with a shim that will produce the standard
clearance.
1. Shim thickness calculation method
Example:
When the intake valve clearance (t) is 0.50 mm:
0.50 (t) - 0.45 (specified value) = 0.05 mm
f
II Cam : \
I :\

I
. O.05Lc. / .
Imm\', / I
'I Wide I !--Retainer

I
, -...
I Spnng
'''-1
1
, rU- Valve
The valve clearance is 0.05 mm greater than the specified value.
Use a shim 0.05 mm thicker than the current shim to reduce the valve clearance.
2. Current shim thickness (T)
Measure the centre of removed shim to determine the
thickness of the current shim.
Caution:
Do not reuse the measured shims again.
3. Shim selection
Current shim thickness (T) is 2.40 mm.
2.40 (T) mm + 0.05 mm = 2.450
Select new shim with stamped mark [24.40]
(T = 2.440 - 2.455).
Select a shim within standard value range +/- 0.03 mm.
4. Shim types and classification
There are 70 types of shims. Sizes range from 2.275
mm to 3.325 mm in 0.05 mm increments.
EN-46
,
o Shim
not .

T = 2,440 - 2.455 mm
LUBRICATION SYSTEM INSPECTION
RB26DE-- ; < 6 : ~ DE DET I CAIBi I RB25DE ENGINE
5. LUBRICATION SYSTEM INSPECTION
5-1 LUBRICATION OIL LEVEL INSPECTION
Inspection
The engine oil level should be checked before starting the
engine or if the engine has been started, the inspection
must be carried out ten minutes after the engine has been
tumedoff.
The oil level should be between the Hand L lines on the
level gauge.
Between L & H mark
The oil must not have any white turbidity or dirt.
Lubrication oil replacement period
. ENGINE
REPLACEMENT PERIOD ...
....
OIL USED
. .
.
RB20DET I RB260ETT Every 5,OOOkm or 6 months SO. SE, SG, SF class oil
Every 15,OOOkm or 12 months SE, SF, SG class oil
CA181 I RB20E
Every 1 O,OOOkm or 6 months SO class oil
RB20DE I RB250E
Every 10,OOOkm or 12 months SO class oil
Note:
Use genuine Nissan [Turbo X (7.5W - 30)] for service for RB26DETT I RB20DET vehicles,
Use genuine Nissan SG class [Extra save X (7.5 - 3D)] for service for CA 18i I RB20E, DE I
RB25DE vehicles.
Oil quantity
-
- ..
(lilsupplemen,tvoiultMtllllllan ...
ITEM 011. level (L)
. .- ...
....
. . .<replaCed(L). ._./
. ' . -.
!. , OnIY;9B Oil and oilftlter
ENGINE H
II..: .,.
Hie' . t .
,'repleoemerrt
..
.'.

........
,rep c:emen.,
RB25DE I RB200E I RB20E 4,0 3.0 Approx,3.8 Approx. 4.2
RB200ET I RB26DETT 14WO 4.5 3,5 Approx.4.2 Approx.4.6
GA18i 3.4 2.4 Approx.3.2 Approx. 3.6
EN -47
LUBRICATION SYSTEM INSPECTION
RB26DEr! RB20E! DE ! DET I CA 181 I RB25DE ENGINE
5-2 OIL PRESSURE INSPECTION
Remove the oil pressure switch and connect the oil pressure gauge.
After warming the engine, make sure the oil pressure is appropriate to the engine speed.
(011 temperature ao"c)
.
RB20E, DE,'
.
ENGINE RB26DETT CA18i
'.

DET/RB25DE
Engine speed (rpm) outtet pre&&ure (kg I em")
.
600

- Approx.1
' .. 800
Approx. 1.5 -
2000 Approx.3 Approx.3
.. 4000 -
.'
6000
.......
Approx. 4.6 Approx.4
RB20E RB26DETT I RB25DE I RB20DE
..... !"'"
5-3 OIL FILTER REPLACEMENT
Removal
Use oil filter wrench (special service tool) to remove the filter.
Caution:
Catch any dripping oil with rag etc. when removing the filter.
Installation
Approx. 1
-
Approx.3
Approx.4
CA18!
Before installing the new oil filter, clean the oil filter bracket mounting surface on the
cylinder block and coat the oil filter seal lips lightly with new engine oil.
Screw in the oil filter until a slight resistance is felt and them tighten 213 turn.
Caution:
Make sure the oil will not leak after starting the engine.
. . ....
ENGINE .
..
. REPLACEMENTPERfOD .
L '. OILU$ED ................
RB200ET/RB260ETT Every 1 O,OOOkm or 12 months SO, SE, SG. SF class oil
CA 18i / RB20E
RB200E / RB250E
EN-48
EXHAUST SYSTEM INSPECTION
RB26DETT . RB20E D ~ DET I CA 18i I RB25DE ENGINE
RB20E
RB20DE I DET I RB25DE CA18i
6. EXHAUST SYSTEM INSPECTION
61 AIR CLEANER ELEMEN1' INSPECTION (RB26DETT I RB20E I DE I OET)
Inspection
Remove the bands shown in the diagram and remove the air cleaner element
There should be no excessive dirt or damage on the air cleaner element.
Periodic replacement interval
RB260ETT
Every 60,000 km
RB20E / DE
62 TURBOCHARGER INSPECTION (RB260ETT I RB20DET)
Function inspection
RB20DET
Remove the intake manifold canister hose, and place a cap on the hose. Connect test
hose to intake manifold and attach pressure gauge (compound gauge).
Perform the engine operation test and check that pressure does not rise above
approximately 0.8 - 0.9 kg I cm'.
a. When the pressure does not reach specified level.
Check for vacuum leak in intake or exhaust system or exhaust gas leak.
b. When the pressure exceeds the maximum pressure level (approx. 0.8 - 0.9 kg I cm
2
).
Check if swing valve controller rubber hose is disconnected or cut.
Check if swing valve controller motion malfunctions (stays closed).
RB26DETT RB20DET
EN ..\9
RB26DETT I RB2CDET ENGINE
Swing valve controller inspection
Remove the swing valve controller rubber hose from the vacuum tube side.
The controlierrod must start operating when compressed air approx. 0.7 - 0.8 kg / Cm2
(RB26DETT), approx. 0.8 - 0.9 kg / cm
2
(RB20DET) is forced into the hose by using an
air gun. Stop blowing compressed air as soon as control rod operation is verified.
Caution:
The diaphragm may be damaged if excessive air pressure is applied. Use the LPG
pressure gauge (special service took for 1 kg / Cm2) to verify that the air gun pressure is
approx. 0.7 - 0.8 kg / cm
2
(RB26DETT) or 0.8 - 0.9 kg / cm
2
(RB20DET) before testing the
air hose.
RB26DETT
63 RECIRCUl.ATION VAl.VE INSPECTION
Function inspection
Remove the hose on upper flow side of the recirculation valve compressor (place the cap
on end ofthe hose) and check if air blows back when throttle is closed quickly.
RB26DETT RB20DET
Unit inspection
Use a hand pump to create negative pressure 150 +/- 30mmHg (RB26DETT) 400+/
50 mmHg (RB20DET). The recirculation valve diaphragm must start to lift up and the
vacuum pressure will be maintained.
: ~ ~ .. ~ ~ ~ ~ I EG1513 0000
~ ~ ,
, ~ . . ~ j
EN50
CA18, ENGINE
6-1 AUTOMATIC TEMPERATURE ADJUSTMENT AIR CLEANER INSPECTION
System diagram
Fresn air
Vacuum motof:r=======:;:
Air cleaner
When cold
\
I
I!, I
SPI body
Intake manifoid
Air cleaner
Fresh air duct
i--r-e-m-pe-r-a-tu-re-rr-,
___ :: sensor
,",
When warm
Warm air
SPI body Intake manifold
Function inspection
Remove the air duct and start the engine, Inspect the vacuum motor operation when the
engine is cold and warm,
Condition
Change-over valve fresh air
dud side
When cold Closed
When warm Open
Temperature sensor preset temperature: Approx.40C.
COMPONENT PARTS INSPECTION
Temperature sensor inspection
Remove the hose to the vacuum motor and connect the
vacuum gauge,
Start the engine and check the negative pressure when
the temperature of the temperature sensor was cooled I
warmed by the drier.
When warmed up No negative pressure
When cooled Negative pressure created
Vacuum motor inspection
Remove the vacuum hose from the vacuum motor and
connect vacuum hand pump.
Use a hand vacuum pump to create negative pressure
(approx. -150 mmHg).
Make sure the fresh air duct on the change-over valve
will close when the negative pressure is applied and it will
open when there is no negative pressure applied.
6-2 AIR CLEANER ELEMENT INSPECTION
Inspection
Remove the clips and the nuts and remove the air cleaner
element.
There should be no excessive dirt or damage in the air
cleaner element.
EN -51
--'--""C'--
Temperature sensor (when cold)
<0
, htake
l
manifold
when warm)Vacuum gauge
, '-I:L
Air inflow M bel
i To intake rT)8mfold 10 vacuum gauge

EG1513000Q
, Apply negative IT,
pressure \-- .'
RB25DE I DE I CA18i ENGINE
7 FUEL SYSTEM INSPECTION
EASY INSPECTION (RB25DE)
Turn the ignition switch to ON position,
Select "Fuel pump" in the "Function test" mode.
Inspect the pulsation by holding the fuel hose with hand.

Hold the fuel filter and make sure the hose is hard and
pulsation can be felt when the fuel pump is operating.
FUEL SYSTEM INSPECTION
FUEL PUMP.
I
IS THERE A PULSATiON!
EVERY 3 SECONDS WHE'J I
THE FUEL TUBE is HE"D?
: OR CAN YOu HEAR
I OPERATION NOISE OF :
lUEL PUMP REL"Y?
I PASS II NO II YES]
Hose is hard
Pulsation
FUEL PRESSURE INSPECTION USING THE FUEL PRESSURE METER
Releasing fuel pressure (RB25DE)
Rev the engine. fE\
Select "Fuel pump relay" in "Active test" mode. \J!J
Press 'STOP' to stop the engine. Crank the engine over
two or three times. (If the engine does not start crank 3 - 4
times after removing the fuse).
+ACTIVE TEST.
FUEL PUMP RELAY OFF '1'
CASRPM (POS) 950 rpm ,
F===1;=="==""
Restart the engine and remove the fuel pump fuse.
After the engine stops, crank the engine 4 - 5 times to
consume the fuel in the pipe, (If the engine does not start .. --
. ft j Fuel pump (use !
crank 4 - 5 times a erremovlng the fuse). ,J _1,;- '
C t
' . "I !
au lon, ,:' ,
The battery may become weak easily, use booster cable to,:: .: '
connect to another battery if necessary.",=-, ',,);,
Releasing fuel pressure (CA18i I RB20E)
Rev the engine,
Select "Release fuel pressure" in "Operation support" mode.
After starting the engine, remove the fuel pump fuse. After
the engine stops, crank the engine over 2 - 3 times to
consume the fuel in the pipe. (If the engine does not start
crank 3 - 4 times after removing the fuse).
Caution:
The battery may become weak easily, use booster cable
to connect to another battery if necessary.
EN 52
FUEL PRESSURE.
WHILE !DlING PRESS
"START" TO STOP THE
FUEL PUMP OPERATION,
AFTER ENGINE STOPS. I
CRANK THE ENGINE OVER
TWOORTHREETIMES, ,
START
R826DE-- R820E! DE I DET! CA18i! RB25DE ENGINE
7-1 FUEL PRESSURE INSPECTION
Releasing fuel pressure (RB20DE I DET I RB26DETT)
After starting the engine, remove the fuel pump fuse, After
the engine stops, crank the engine over 2 - 3 times to
consume the fuel in the pipe
If the engine does not start, remove the pump fuse and
crank the engine 3 - 4 times to consume the fuel in the
pipe,
Caution:
The battery may become weak easily, so use booster cables
to connect it to another battery if necessary,
Fuel pressure meter installation
(RB26DETT I RB20E I DE I DET I CA18i I RB25DE)
Connect the fuel pressure meter between the fuel filter and
the fuel line,
Attach the fuel pump fuse,
Fuel pressure inspection
Start the engine and check if the fuel pressure is at
standard value,
If the engine does not start, check fuel pressure after 5
seconds when the ignition switch has been turned ON,
Fuel pressure measurement
. ..
RB20DE,DET
ITEM ENGINE
RB20E ".', ,
I ., , RB26DETT ' ,
,
,
: When ignition switch is ON (kg/em') Approx 3,0 Approx 2,5
,
Dunng idling (kglem<) I Approx 2,5 Approx 2,0
klling when pressure regulator
Approx 3,0 Approx, 2,5
vacuum hose is removed (kg/em')
7-2 THERMOWAX INSPECTION (CA18i)
Inspect the wax stroke when in following temperature,
Temperature ( C) 25 80
Wax.troke S (mm). Approx. 25 Approx,30
I
EN-53
, " ." :
, REl25DE
CA'I81. "
. III'. '"
Approx, 3,0 -
Approx. 2,55 Approx. 1,0
Approx. 3,0 Approx, 10

EVAPORATIVE GAS CONTROL INSPECTION
RB26DETT I RB20E I DE I DET I CAi8i / RB25DE E"<GINE
8 EVAPORATIVE GAS CONTROL SYSTEM INSPECTION
Throttle
Purge control valve
Check valve
... Evaporative gas
, <;:::; Purge air
-, ActIVe carbon
--Filter
Tray
Fresh air
81 PURGE CONTROL VALVE INSPECTION
CANISTER
Inspection
Use vacuum hand pump to apply approximately 400
mmHg (-100 mmHg RB25DE engine) negative pressure
and make sure the vacuum pressure is maintained.
In that condition. check that small amount of air can be
sucked from the manifold vacuum path.
FUEL TANK VACUUM RELEAF VALVE (RB25DE)
Inspection
o Clean the valve housing.
If the fuel tank vacuum releafvalve is normal. you will hear
sound from the valve with small resistance when the air is
sucked in through the cap.
o Replace the cap ASSY if the valve is closed or no
resistance is felt.
EN-54
) ~
!; '\1}
Spring valve v\ I
ave
BLOWBY GAS REDUCTION DEVICE INSPECTION
RB26DEF '<'lEE JE JET, CA181 i RB25DE ENGINE
9 BLOWBY GAS REDUCTION DEVICE INSPECTION
blowby control valve
::lEJJ
F',
,<)'\ Flame arrester
\ '--.J
I 'Buffle plate
,WI.
Blowby path
! Fr--,o; ,
" lV' I
J -"':::;;..J""

(= Fresh air
.. Blowby gas
9-1 BLOWSY CONTROL VALVE INSPECTION (EXCL CA18i)
Inspection
Check the blowby control valve flow path.
CONDITION
Air is blown Air passes
Air is drawn in No air passes
Inspection (CA18i)
Remove the air cleaner rocker cover hose when the
engine rev is approximately 1000 rpm and check that
fresh air is drawn in.
ON-VEHICLE PARTS
RB26DETT ENGINE
10 REMOVAL AND INSTALLATION OF ON-VEHICLE PARTS
10-1 INTERCOOLER AIR DUCT ASSEEMBLY
Front turbocharger
Hosf Qutlettube Bolt L6-2.1tqJ Air hose
Hose Air tube ,! A h .f
! " 1.6--1". '""'"
j, /
ReCirculation valve,,1 ''''P' Nut 1m)
(211Point 7J \ /14, '- " _, &('l6 k 'I Gasket.... , ,,""e.
Bolt 12) I \ }D-'" .., """",
Air (2) 16 \' ! )1Ii \ " 'V 3 ",,,:' Front ,,;:""
II Nut(2J1J5-2.1 Air Rearturbocnarger
[Lv I tr;,., I I, Air hos,,", / ' t" '=--, ,,- ASSY ASSY
"'" \ I AIr \ <V" //:0 ,., -
W ,t ----..J' ! .. - AIr hose

---I Arr tube AIr heise " ./ , , _
Clamp [Point 61\ 51 [Pomt 5J 'Air tube AI" tube ",', , )
AA> I Air hose !,// , Boll "i'? I taA ,,(1 / /
, V' c; 'c
Ain,ube/ rp i A' h I ",-", /i - \'
P
I Ir "- ' , , '-'- ,/ A SSY
( Oint 51 / "" 8 1 Air -', / _ lfcleaner A
Clamp (PointS) ! "' !ReprculanOft tube Air tUbe __ It ? t Air duct
Air hose Q; B,olt (2) 16 - 2.1 R-! ".(! ouc,/Bolt mIMI
<o\'l' ,: ' ; $J 0,38 - 0 51
<I' /;' 'c'". ; ',..:,-..
/
Intercooler sub ! J _ V Air r / 'I,
bracket (RH) , " ':::-:-- !ntercooler sub \ Ali ducl 1 ttll
0...bracketILH) \ , Boll 0,38 - 0,51
\. Intercooler inlet hose ! \
I [Point 3J ,Resonator
Resonator tube
d ;- Bolt (2)
Intercooler [POUlt 4] /

Batt 16 - 2.1 ttll
ttll kg-m
12) 1,6 -
., Replace after every disassembly

Additional work required:
Undercover
Front bumper
[Point 1] Cleaning air hoses & air duct
Use air gun to remove any dust and rubbish before
removing each air hoses and air ducts,
[Point 2]
Removal
Remove & install each air hoses and tubes
Place alignment mark on each air hose and tubes before
removal.
Installation
Align the alignment marks when installation and make
sure to tighten the clamp securely.
EN-56
[Point 3J
Removal
ENGINE
Remove and install the intercooler inlet
hose
ON-VEHICLE PARTS
First remove the resonator and the tube B before removing I'
hose A. , .
Installation
Attach hose A, then attach resonator and the tube B as a
single unit to install.
[Point 4]
Removal
Remove and install intercooler
1. Remove the bumper finisher and the bumper
reinforcement.
2. Separate the intercooler inlet and outlet hoses.
3. Remove the mounting bolt and two nuts. Detach
intercooler without scratching the fins.
Caution:
1. An aluminium fins are used and can be damaged easily.
Do not place objects on the intercooler or allow tools or
other hard objects to contact the fins.
2. The main unit (tank, fin tube) cannot be disassembled.
Installation
Installation operation is the reverse of the removal
operation. Perform the steps in order of 3. 2, 1.
Tightening torque (kg-m): 0.93 -1.2
I ,
Inlet
Outlet Mounting bolt hose i
: hose 0.93 -1.2 ,
? ..

[Point 5] Remove and install recirculation hose I i
Recirculation
Remove and install the recirculation hose and tube as shown
in the figure on right.
[Point 6] Install recirculation hose clamp
When installing the recirculation hose clap. make sure it
will not contact bumper finisher.
[Point 7] Recirculation valve inspection
Unit inspection
Use hand vacuum pump to apply negative vacuum of -150
+/- 20 mmHg and check that recirculation valve diaphragm
lifts and vacuum pressure is maintained.
[Point 8] Remove and install turbocharger outlet
tube
Remove and install the turbocharger outlet tube as shown
Recirculation valve
ONVEHICLE PARTS
RB26DETT ENGINE
102 AIR CLEANER ELEMENT ASSEMBLY
hose Air C\leaner e'ement

/1
" /,
To rear turbocharger Air cleaner cover/:cL '
To front turbocharger / /" P
t '
/
1 /,/ /:
Air hose

/"
Air duct
,toJ kg-m
Remove turbocharger outlet hose
[Point 1] Air hose and air duct cleaning
Use an air gun to blow off any dirt and dust before
removing the air cleaner element
[Point 2]
Removal
Remove and install air cleaner element
1. Remove turbocharger outlet hose.
2. Remove four band clips from the air cleaner. Lift air
cleaner cover and remove the air cleaner element
Installation
Instail in reverse order of removaL
[Point 3]
\
Air case
Make sure the air cleaner element is not dirty or damaged.
Periodic replacement interval: Every 60,000 km
[Point 41
First connect the air flow meter connector for front turbo
charger and then install the air cleaner cover.
EN-58
qEl26DETT ENGINE
10-3 CONNECTOR ASSY
(1) Collector ASSY removal and installation
Release fuel pressure in the fuel lines [Point 1]
Drain cooling water [Point 2J
Acceleration control wire [Point 3]
Air inlet hose
EGI harness connector, harness clamp
All hoses
[Point 1] Release fuel pressure
Start the engine
After starting the engine remove the fuel pump fuse and
wait until the engine stops. Crank engine two or three times
ON-VEHICLE PARTS
Fuel pump fuse
I i'l
to consume fuel remaining in the fuel pipes.
If the vehicle doesn't start, remove the fuel pump fuse and
crank the engine four to five times to consume fuel'E l
!fr I , ,.'
remaining in the fuel pipes. - Remove
Caution: :"i' t:::f!.
The battery may become weak easily, use booster cable to
connect to another battery if necessary.
EN - 59
RB26DETT ENGINE
[Point 2] Draining the cooling water
Make sure to drain cooling water completely from the
cylinder block by removing the drain plug.
Caution:
Make sure the coolant does not spill on the front tube.
[Point 31 Accelerator wire adjustment
Loosen lock nut to provide adequate slack for the
accelerator wire and pull outer case in the direction ofthe
accelerator.
Return the lock nut 1.0 to 1.5 turns from the position the
throttle drum starts moving (when there is no play in cable)
and tighten.
Tightening torque (kg-m): 0.8 - 1.0
[Point 4] Remove throttle chamber links
Remove the mounting nuts indicated by arrow marks in the
diagram. Separate three throttle chamber links from
collector side.
Remove the harness from the throttle sensor and the
throttle valve switch.
[Point 5] Fuel pipe removal
Remove three bolts indicated by the arrows and separate
the fuel pipe.
[Point 6] Air hose removal
Separate the air hose A, Band C from the collector side.
[Point 7) Booster vacuum removal
Remove the clamp bolt and remove the booster vacuum
tube by separating it from the collector and the air
chamber.
{Point 8] Remove and install air chamber bolts
Removal
Separate the air chamber by removing three bolts.
Installation
Insert bolt B in air chamber bolt hole, before performing
final assembly.
EN-60
ON-VEHICLE PARTS
~ !
[Point 9] Remove and install collector nut
Removal
Remove the nuts in the reverse order of the figure on the
right.
Installation
Install the nuts in the order shown in the figure on right
uniformly in two to three stages.
[Point 10] Remove and install air chamber
Remove
Separate the air hoses A. B, C, vacuum hoses D, F and
AAC valve connector and remove the air chamber.
Installation
Position the air chamber in place, connect the air hoses C,
0, A, vacuum hoses F, then connect AAC valve.
[Point 11] Remove and install MC valve
Removal
Detach the AAC valve by first removing four bolts.
Caution:
(1) AAC valve cannot be disassembled.
(2) Replace gasket with a new one.
Installation
Install gasket and the AAC valve.
Tightening torque (kg-m) 0.64 - 0.85
[Point 12] Me valve inspection
Measure the AAC valve resistance
Resistance (20C) n Approx. 9 - 10
(2) Collector ASSY disassembly and assembly
Boll (4)tql 0.64 - 0.85
Bolt (2) I'!"'!'I 0.64 - 0.85 .. ,
ONNEHICLE PARTS
Gasket
Me valve \.
chamber.
Bolt(4) I
!R:1064-0.85
Throttle valve
.,-" /
-" - Acceleration work unit
Bracket
/t/ 6_-KnOCk pin (2)
.\' Intake temperature sensor
. 'F '. tql20-30

./ J
,/
Collector [POint 1( '.
v&
EN - 61
RB26DETT ENGINE
Collector ASSY installation refer to "Throttle valve switch
system inspection" for the throttle valve switch adjustment
procedures.
[Point 11 Collector inspection
Measure the collector installation surface for distortion in
six directions (opposing directions, up, down, left, right,
horizontally and vertically).
Limit (mm): 0.15
ON-VEHICLE PARTS
10-4 SIX IN-LINE THROTTLE CHAMBER REMOVAL AND INSTALLATION
('; Replace after every disassembly
Collector ASSY removal and installation
Canister hose
[Point 1] Throttle chamber inspection
Check for any cracks and that supplemental air paths are
not obstructed.
[Point 2] Install throttle chamber
Install No.1 to No.3 throttle chambers.
C.aution:
Do not make any mistake when installing the chamber.
EN -62
ON-VEHICLE PARTS
105 SIX INLlNE THROTTLE CHAMBER LINK ADJUSTMENT
Thrortie :::hamber
NutB
~ ~ , -
~ o . 7hrottle chamber
Nut A Detail of part a
[Point 1] Install accelerator work unit
Install six in-line throttle chamber and the accelerator work
unit and connect No.1, 2 and 3 throttle linkage.
[Point 21 6 inline throttle chamber link adjustment
1. Loosen nuts A and B for each throttle link. Turn the
centre adjustment of each throttle link anticlockwise to
shorten the linkage.
2. Shorten each throttle link until acceleration drum contacts
fully closed stopper on the accelerator work unit side.
3. Shorten each throttle link, so the throttle cham ber lever
opens wider than fully closed stopper on the throttle
chamber side.
Caution:
(1) Do not lock the nut A and B.
(2) The throttle chamber lever opening angle should be
adequate.
EN - 63
Detail of part b
RB26DETT ENGINE
4. Insert 1 mm thickness feeler gauge between the
accelerator drum and fully closed stopper on the
accelerator work unit side. Secure the accelerator drum
so it does not move.
5. With thickness gauge inserted, turn the centre
adjustment in No.2 throttle link clockwise to lengthen the
throttle link until the throttle chamber lever contacts the
fully closed stopper on the throttle chamber side.
6. When tuming the throttle link with your fingers. You will
feel resistance when the fully closed stopper contacts
the throttle chamber lever. Shorten the throttle link to the
point just before this resistance is felt.
7. Carry out the steps 4, 5, and 6 to adjust the No.3 and 1
throttle links.
8. Tighten the lock nut A and B after the adjusting three
throttle links. After the nuts are tightened, No.1 - 3
throttle links must turn with the same degree of
smoothness.
Caution:
Make sure the centre adjustment link will not rotate when the
lock nut is tightened.
9. Remove the thickness gauge from fully closed stopper
on the accelerator work unit side.
Caution:
Do not adjust fully closed stopper nut.
10. Completely open and close the six in-line throttle
chambers repeatedly and make sure that each throttle
chamber moves smoothly.
EN-64
ON-VEHICLE PARTS
l
I
ON-VEHICLE PARTS
R826DETT ENGINE
10-6 INTAKE MANIFOLD ASSY
(1) Intake manifold ASSY removal and installation
Bolt (4) U 2.1 Washer
[Pomt 'I A Spnng washer Intake man;fold ASSY
Bolt (2) 1.6 - 21 Nut (3) 1 6 2.1 A
[Point 11 r:qJ [POint 1]
o Replace after every disassembly
Akg-rn
Collector ASSY removal and installation
Throttle chamber removal and installation
ECCS harness connector and all hoses
Water outlet hose
Blowby hose
[Point 1] Remove & install Intake manifold ASSY
bolts and nuts
Removal
Removal is the reverse order shown in the figure on the
right
Installation
Install the bolts and the nuts in the order shown in the figure
on the right Tighten in gradual steps to uniform tightness.
-
. "- "
Length: No. of bolts lnstaHaUon loeaflon
30: 4 3,5.6,8
Boft length
below head 60: 5 1,4,10,12,14
(mm)
65: 2
"
"""
[Point 2] Air drain plug
Carry out the operation when engine is cool.
Caution:
7, 9
Do not remove the air drain plug when the engine is hot
When topping up the coolant, always remove the air drain
plug to allow air within the engine to escape !tr-is prevents
overheating).
Tightening torque (kg-m): 0.7- 0_8
EN
0 _
10 6 24 8 2 14
11 13 2 are nuts"-_____ J , ,
: 'NEVER
: iOPi::"l
.
ON-VEHICLE PARTS
RB26DETT ENGINE
(2) Intake manifold disassembly & assembly
Balance tube [Point 6J - __ i5) 0,64 - 0,84
'>,., " I

n I '.
16 - 2,
1
-" t3 a-ring ;Point 6] oJJ t3 ' 1('1"-,
\", _o-ringl
[POlntp, I
Injector [Point 31 ,Water temperature
/ rdrum plug 0 7 - 0 8/sensor 2 0 - 30
t3 LJ '\/0
Fuel tube injector ASSY [Point 21 O-nng O"'''-)<') - outlet elbo
I I<? ... [OOlnt51
,'0 "" - '
'" - Ur
1
P: \
"'" Pressure Bolt 1 6 - 2 1
'jlZ:l (poont 2] .......... I '& 1!C1
pt""Jt Screw {21 023 "'" 0 3t--- ,,/ l1li.4 -.J ,/
.. BoJt{2) 1.6-2.1 ----i " /' Intake mamfold [POint 1]
.......- Water bypass conl'lectof
Air 'eguJator ;:s: ,[POint 4] Bolt 1.6 - 2.1
Boltj2) 0.64 - Bolt (4) --J!
Liquid gasket 1.6 - 2.1 @ Bort ,6 -
(; Replace after every disassembly
kg-m
[Point 1] Intake manifold inspection
Measure the intake manifold surface for distortions in six
different directions (at opposite directions: up, down, right,
left, horizontally and vertically) in several locations.
Limit (mm): 0.15
[Point 2] Fuel tube ASSY
Replace a-ring with new ones when pressure regulator is
removed and installed.
Ci3ulipn:
Care must be taken not to scratch the fuel tube a-ring surface
when installing the pressure regulator.
[Point 3] Coring (for fuel injector pressure regulator)
Precautions when handling
Never reuse a-rings.
Coatthe a-ring with engine oil (10W -30 or equivalent) or
silicon oil (NUC silicon L45 or equivalent), but do not apply
solvent as this may remove the oil coating.
Avoid using dirty a-rings and do not allow dirt, dust or
foreign objects to adhere to O-rings or other eqUipment
surfaces.
EN -66
Thickness
, gauge

,. Fuel tube injector ASSY I
I '
Pressure regulatoli
1
t3
ENGINE
Do not decenter or rotate the fuel injectors and the
pressure regulator when inserting them into the fuel tube.
Do not store O-rings in location subject to ozone. high
temperature or in the direct sunlight
[Point 4] Install and remove water bypass
connector
Removal and cleaning
Remove eight water bypass connector bolts. Insert driver
in clearance between intake manifold and water bypass
connector and move it lightly to remove connector.
Use a scraper and remove liquid gasket.
Caution:
Also remove liquid gasket in the grooves.
Wipe off mounting surface with white gasoline etc.
Installation
Cutthe nozzle end of liquid gasket (KP510 00150) in the
position shown in the figure. Use a tube presser to apply
gasket. Install bypass connector within 20 minutes of
applying liquid gasket.
Apply liquid gasket (KP10 00510) to water bypass
connector surfaces in four locations. then install water
bypass connector within 20 minutes.
Cflution:
(1) Apply liquid gasket coating 3.0 mm wide.
(2) Coat on the inside of installation holes as shown.
[Point 51 Water outlet elbow
Remove two water outlet elbow bolt and insert screw
driver handle as shown. Move it up and down to remove
the elbow.
Remove liquid gasket from intake manifold and water
outlet elbow by using a scraper.
Caution:
Wipe off mounting surface with white gasoline etc.
Installation
Cutthe nozzle end of liquid gasket (KP51 000150) in the
position shown in the figure. Use a tube presser to apply
the gasket.
Apply the liquid gasket (KP1 000510) to intake manifold
surfaces in four locations, then install within 20 minutes
Caution:
(1) Apply the liquid gasket coating 3.0 mm Wide
EN - 67
ON-VEHICLE PARTS
,------.... ....... -.

" .
r-/
L
ON-VEHICLE PARTS
RB26DETT ENGINE
[Point 61 Remove and install balance tube
Removal
Check the size of the O-ring when removing balance tube.
Installation
Always replace the O-ring with new ones when installing
balance tube.
There are three different O-ring sizes. Make sure to install .
the correct size. .. .... - ..
...... ' .........
c.
Number of unit Installation location
.;< .. '.
(Hjng A (.mall)
. ...
3 Cylinder 1. 2. 3. 4. 5. 6
o.nnlJ B (large)
4 Cylinder 1, 2. 5, 6
().ring C (nMldlum) 2 Cylinder 3. 4
Be careful not to pinch the O-rings during installation.
10-7 TURBOCHARGER ASSY
(1) Turbocharger ASSY removal & installation
FRONT SIDE REAR SIDE
To cylinder block ':. ! Oil
Gaskel-- . 'I 80110.4 - . I Oil hose
20-3f,ll
-\,J V"i 80It1,6--2,'1:
- "-Yoke ttl! .racKe,<
Oil hose--\.$T I IEyebe';;;:: To cylinder
. '. I 9olt1.-2.1ttl! I -""-'7
0,1 pipe I In! ,'-41
ttl! Bolt (2) 1.3 - 191'-'" Washer
;;.'" e-- Coppar washer 0
Oil & water tube
L//
I 0 Replace after every disassembly
EN-68
::qJ, Bolt (2) 1.0 - ..... copper washer
Eyebolt ttl! .,
2.0 - 3.0
Copper washer
~ 5 6 D : : : T T ENGlNE
Remove and install undercover
Drain cooling water
Separate exhaust front tube
Remove and install exhaust gas sensor connector
Intercooler air inlet tube and hose
Air inlet hose
f'iote:
Also remove cooling water from engine drain plug.
ON-VEHICLE PARTS
(If water is only drained from the radiator drain cock, the water inside cylinder block will not be
drained completely).
(2) Front turbocharger ASSY removal & installation
Removal sequence
(1) Loosen the flare nuts oftubes A and B.
(2) Remove bolts and detach tube A.
(3) Loosen flare nuts of tubes C and D on the turbo side.
(4) Remove hose B and bolts.
(5) Remove bolts and detach tube
(6) Remove three bolts, cover and ground cable.
(7) Remove two bolts and detach tube H. Make sure
that bolt mounted on upper side is shorter than lower
side.
(8) Remove three bolts, cover and ground cable.
(9) Remove oil return hose.
(10) Remove three bolts and detach bracket.
(11) Remove four turbocharger nuts.
(12) Lower turbocharger ca refully.
(13) Remove six exhaust manifold nuts.
(14) Pull the exhaust manifold in direction 1 and then raise
it in direction 2 to avoid turbocharger stUd.
(15) Remove exhaust manifold.
(16) Pull out turbocharger.
Installation sequence
Installation is the reverse of the removal sequence.
Place turbocharger in bottom of the engine
compartment before installing the exhaust manifold.
EN - 69
: Exhaust manifold cover
, .
ON-VEHICLE PARTS
RB26DETT ENGiNE
(3) Rear turbocharger ASSY removal & installation
Front turbocharger ASSY removal and installation
Removal sequence
(1) Remove front turbocharger and the exhaust manifold
ASSY
(2)
(3)
(4)
(5)
(6)
Remove two nuts and the clip securing bolt, and
separate the tube A.
Remove three bolts and detach exhaust manifold cover.
Remove eyebolt S, C and E.
Remove two bolts and separate tube 0 from cylinder
block side.
Remove three bolts and detach bracket.
The sequence after this step is same as number 11 to 16 of
the front turbocharger removal and installation.
Installation sequence
Installation is reverse of removal sequence.
Loosen the water tube flare nut before installing eyebolt S.
(4) Turbocharger ASSY disassembly & assembly
FRONT SIDE RfARSIDE
I
(4) 2.3 -3.0: (4) 2.3 - 3.0
Lock plate (2) [Pant Lock plate (2} [PoInt 3]--4:.... Exhaust gas sensor
Exhaust gas yens : 1 8 - 2 4
A/- -- f'\ 1 8 - 2 4 :;t:!l 'I ,
1fi'71
1
/" -C:-h' I ' /I>/ '" \ \
\ I )7';
Turbocharger Inlet _ J:'ot:.. / :;t:!l 2 3 - 3 0 <'-, Nut \5)2.3 - 3.0
gasket 0 <:;J;::::f-" '". I gasket 0 - , \
Exhaust outlet - '-0-"""-' : ! Exhaust outlet
Front turbo charger ASSY j Rear turbo charger'
\ . l' >: \ --, ' l:>
Air inlet tube - I \ C :./'1
--, -<.;.c.c)., I '
,J?J,-' J '. 'I - J
Jr j , J <1J-
' I 'Exhaust ; I i I !3f' Exhaus1-I"
I, I \ \ :':;; / \ , \ 0 Gasket I outlet &1 \
" 0 Gasket ' cover (3)tc!l' \ \ cover' Bolt (3)[qJ
,Bolt (2)ttll Bolt (2)ttll 0.38-0,51' Bolt(2)ttlI Bolt (2) . 0.38-0.51
1.6-2.1 0.64-0851 ttllEyebolt2.0-3.2 : 1.6-2,1 0.64-0851
_ bit i: I
0 EyebOlt
'./ - . I
Copper W3Shero-l:/ "'" . I: Copper waShert) 0
l.../ Watertube[Polntl j I v' Water tube (Point 1]
,
ttll kg-m
,
EN-70
ON-VEHICLE PARTS
'626DETT E"IGINE
Turbocharger ASSY removal and installation
I
[Point 1] Water tube inspection
i tubel ---,nlet tUb1
I
I '"<"':::5"h>_
After cleaning the water inlet and outlet tubes with radiator , / ""
cleaner, blow with compressed air and check for rust or. J,:'" I AIr gun tv "
any clogging. iRacj,at2:e'an",r_l_
[Point 2] Oil feed tube inspection
After cleaning the oil feed tube with engine conditioner,
blow with compressed air and check for any clogging.
[Point 3] Remove and install lock plate
Spread the lock plate pawls with a screwdriver and loosen
nuts.
Position lock plates and turbocharger mounting nuts,
After tightening the nuts, bend lock plate pawls onto the
nuts.
[Point 4] Eyebolt determination
Oil feed (turbocharger side) eye bolts are stamped 'J'.
(5) Turbocharger unit inspection
Crack inspection
Crack burn inspection
[POint 7]
Excessive pressure leak
Sw,ng valve [POint 31
'--'-- Compressor wheel
[POint 5]
Turbine rotor 1.2,4]
Rotor sha1 [POint 6, 8]
Oil leak inspection location
..........
EN -71
RB26DETT ENGINE
[Point 1] Rotor shaft inspection
Make sure the rotor shaft rotates smoothly with no
heaviness or dragging when turned by finger.
[Point 2} Turbine rotor inspection
Oil must not adhere to surface.
There is no carbon accumulation.
The vanes of the turbine must not be bent.
There is no interference with turbine housing.
[Point 3] Swing valve inspection
Remove actuator rod pin and make sure the swing valve
moves smoothly without deformation or cracks.
Make sure there are no misaligned seating surface in
turbine housing.
[Point 4] Rotor shaft play inspection
Set the dial gauge and measure play and thrust clearance.
Insert the dial gauge in oil return hole and measure rotor
shaft play.
Rotor shaft play (mm) 0.056 - 0.127
Thrust clearance (mm) 0.D13 - 0.096
[Point 5] Compressor wheel inspection
Oil must not adhere to suction inlet.
There must be no interference with compressor housing.
Wheel must not be bent or damaged.
There must be no carbon sludge accumulation.
EN-72
ON-VEHICLE PARTS
I
-\-cc. ?,A
, i
tt-i
l
,,-] j-'
, J'!} I L'" 'l;j \1
I I . ..: No carbon
I j' I }II c?ff!i slu<lge
I
"826DEF ENGINE
[Point 7] Swing valve controller inspection
Connect the swing valve controller rubber hose on the
actuator side.
Check the swing valve controller when the actuator rod is
installed or removed.
Check to see if the controller rod will operates when the
compressed air pressure (approx. 0.7 - 0.8 kg I cm2) is
applied. Stop blowing air as soon as rod operates.
[Point 8] Oil & cooling water inlet and outlet
cleaning
Use engine conditioner to clean the oil feed and return
passages.
Use radiator cleaner to clean cooling water feed and
retum passages.
Clean with airgun.
Clean the compressor wheel. turbine wheel, compressor
=housing and turbine housing with same methods.
EN - 73
ON-VEHICLE PARTS
Air ,gun
Actuator
ON-VEHICLE PARTS
RB26DETT ENGINE
(6) Turbocharger failure diagnosis (Oil leaks, smoke (white or blue smoke), lack
of power, poor acceleration, abnormal noise)
Points to be checked before diagnosis:
1. The engine oil level must be between the MIN and the MAX marks on the oil level gauge.
(When the engine oil level is higher than MAX line, the engine oil will flow into intake
duct through the blowby gas recirculation pass and the turbocharger may be
determined to be malfunctioning).
2. Check with customer to determine if oil is cooled when idling after driving.
,
:
If any malfunction in the following chart is detected in a unit inspection, replace the
turbocharger ASSY.
..... '
....
....
.
..
. '.
>'
In&pectlOrlrGsult
.......
I. ..'
..
"'Lackot InI!lpflCl!on lOcatIOn
... '
QllIeIIk' Smoke
.Abnormal
_""{Poor:

.... .
:
. ..
.
.. ' , ..
.' .....
noise
acceflndiOn" I
Oil on rotors
6 6 6
,
Carbon has accumulated
6 0 0
Turbine rotor
,
Rotor scrapes against the housing
6 0

U

,
Turbime vanes are bent or folded
Suction inlet IS dirty with oil
0 0
:
Compressor wheel Rotor scrapes against the housing
6
n
0
I
'V
r----

Turbine vanes are bent or folded
,
i
I
; There is resistance or scraping
6 6 0
. when rotated by finger
i
Turb!ne and compressor
Rotation by finger is not possible

:
Rotor SI18t play inspection
Considerable shaking between
,
6 6 C
6
rotor shaft and tlft'bo ASSY
,
Look through oil hole Carbon sludge has accumulated
6
L::. 6
I
(inspect intenor with pen light) in waste oil hole
The valve does not move i
!
Swing valve operation
smoothly when pressure is
i applied gradually. (usually opens
,

(use air gun or air pump)
at pressure greater than 0.6 - 0.7
1
I
kg/em')
Highly posslole o POSSible 6 Slightly possible
EN -74
ON-VEHICLE PARTS
10-8 EXHAUST MANIFOLD ASSY REMOVAL & INSPECTION
FRONT SIDE REAR SIDE
Exhaust manifold cover
~
Exhaust mantfOld covek
'" __ --. ;:! Bolt 3 ) , ~
aolt 3 ) ~ I
038-0.51 :
fPOlot4] I
. ,
Exhaust manifold
[Point 3]
<g-rn
I 0 Replace after every disassembly
Turbocharger removal and installation
Gas leak inspection [Point 1]
[Point 1] Gas leak inspection
After removing exhaust manifold, make sure there are
no traces of gas leaks from any parts.
After the installation, crank the engine and check for any
gas leaks.
[Point 2]
Removal
Remove and install exhaust manifold nuts
Removal is the reverse of installation sequence shown in
the diagram on the right.
Installation
The installation sequence is shown in the diagram on right.
[Point 3] Exhaust manifold inspection
Measure the exhaust manifold surface for distortions in
six separate directions (opposite directions. up. down. left.
right, horizontally and vertically) in a number of localions.
Limit (mm): 0.3
EN 75
/r Z, 0.38-0.51
, ~ ~ \ [PO",! 4]
-) / "J'r
/
4 1 3
Exhaust manifold
[Point 3]
Straigh{ gauge"--__ : : : : : : : : : : : : : : : : : ~
1\
~
I
~ S : ~ ~ ~ ~
I Z! , ~
~ , ThicKness gauge
. '
ON-VEHICLE PARTS
RB26Dcr eNGINE
[Point 4] Install exhaust manifold cover
Attach the exhaust manifold cover bolts in the following
sequence. (both front & rear)
1. Temporarily tighten bolts for positions indicated by A.
2. Tighten bolts in the positions indicated B
3. Tighten bolts in holes A to specified tightening torque.
FRONT SIDE A REAR SIDE A
8 'B . \-------_

B B
.. --.. -. _ .. __ .. -
10-9 SPARK PLUGS
(4) 0.04 - Pc;wer transistor
li / Ornament bolt (2) 0 23 - 0 31
Ornament bolt (8) ",/ Screw (31
:123 Ornament. '; <;?k
, 'f

/'"
:gmtion coil harness
Remove and install air inlet pipe
Remove and install blowby hose
[Point 1]
Removal
Remove and install ignition coil bracket
Hold the coil body when removing the ignition coil bracket

Do not hold the coil connector when removing it
Installation
Make sure to attach the ignition coil hamess when
installing the ignition coil bracket to the cylinder head.
[Point 2] Spark plug maintenance
Gap inspection and adjustment is not necessary as a
platinum Up is used.
Replace the plug every 100,000 km.
When using a compressed air spark plug cleaner, clean
the plugs at maximum pressure of 6 kg/cm2 for no more
than 20 seconds.
EN-76
0.23 - 0.31
l
'lgmtion
side
I
Holder - "
Spark plug _
Platinum tip
Seating metal \
\
. \
iwrn"ll'l
.. ______
ON-VEHICLE PARTS
RB26JETT ENGINE
10-10 ROCKER COVER REMOVAL & INSTALLATION
FiI!er cap
",
O-ring-, ~
"Ciit
Remove and install air inlet pipe
Remove and install blowby hose
[Point 1]
Removal
Remove and install rocker cover screw
Remove the screws in reverse sequence shown in the
figure on the right.
Installation
Perform installation in the sequence shown in the figure on
the right.
[Point 2] Rocker cover installation surface
inspection
Check that no oil, dirt or foreign material adheres to the
cylinder head installation surface.
[Point 3] Install rocker cover gasket
Make sure the rocker cover gasket is positioned securely
in groove without twisting, pinching or protrusion.
EN 77
Rocker cover screw
(left & fight 10 each)
0.2 - 0.4 [Point 1J A
Y
~ K ~ \
Grommet
.. Front
7 3 1 5
II:
@
:
I
i it
8 4 2 6
9
~ I
10
ON-VEHICLE PARTS
RB26DETT ENGINE
1011 TIMING BELT REMOVAL & INSTALLATION
TIming belt cover (upper)
Grommet [Paint 4) /
\ Il}- - [Point
tt=!lBolt(2) 0 3 05 I OOTec,Sloner spring
I Timing belt M /
W O-ring 1)\ \ rp a 10 2]
Crank angle sensor I I \ I, ' ernt -. . I
[Pornt 2) --If I I . \ /' \,j/'r, \
Bolt (3) 16 - 2 1 Gramme,," ) J \ Boit tt=!l :7 \0, ' ; :
tt=!l \ 4
1
4-59
1
.-:::,
-OJ'" Washer \ I -
tt=!lBolt 13) 0.3 - 05 Conrcal washer ft\\\- - , -' __ "-
[Point 6] \ J
- I; '\1 I:::
'If\ <" _ . /\,;V' ___ -
I'l Crank pulley [Point 1] . I
Bait [Point 3] I I
45.5;- 47.5 tt=!l I Idler pulley [Point 11]
\ Grommetk \d \ "
\ [Point \ Timing belt plate [POint 8)
\
\ Crank timing pulley [POint 8]
I Crank timing pulley plate [Point 8]
. , I Belt tensioner [POint 9.10, l1J
/ Timing cover (lower) [point 4)
tt=!l Bolt (3) 0.3 - 0.5
tt=!l kg-m
; I'l Engine oil
I ., Replace after every_d_is_a_ss_e_m_b_ly ___________________ ---J
Drain cooling water
Remove and install
Undercover
Radiator, fan sh roud
Cooling fan
Supplemental belts
Water pump pulley
Spark plugs
Check No.1 cylinder compression T.D.C position [Paint 1]
Install ring gear stopper [Point 3]
[Point 1] No.1 cylinder pressure T.D.C (top dead enter) inspection
Align crank pulley timing mark and belt cover timing
indicator (0
0
position). At this time, No, 1 cylinder is in
compression T.O. C position when the camshaft is located
as described in the following situations.
EN -78

t
f"\--' " ,. I
{broc )
.. ----)
ON-VEHICLE PARTS
No, 1 cylinder is at compression top dead centre (TD,C) carr"--;,sh,m!
when both intake and the exhaust side cams do not
move the valve lifters,
Remove the locker cover oil filler cap from intake side
and check that front end of the camshaft faces intake
side,
[Point 2] Install crank angle sensor
Apply chassis grease to drive unit (spline) during
installation,
There is a flange inside the drive unit spline so the spline
has only one insertion position. Check the alignment
visually before assembly,
Check that the crank angle sensor can be easily inserted
in belt cover holes and sensor moves lightly to right and
left, then tighten the bolts,
When the sensor doesn't move lightly, loosen belt cover
bolts to position when the crank angle sensor was inserted,
Move the belt cover lightly horizontally and vertically to align
it so the belt cover holes and the camshaft centre are
aligned, Then tighten the bolts so the crank angle sensor
moves lightly,
[Point 3]
Removal
Remove & install crank pulley and the bolt
Remove the starter motor and attach the ring gear
stopper.
Use a pulley puller (steering wheel puller) to remove crank
pulley (bolt size: M6 x 1,0 length below head approx.
50mm),
EN - 79
i
__ hOI"j
RB26DETT ENG lNE
Installation
Position the washer for the crank pulley bolts so the
surface not marked R contacts the crank pulley side and
then assemble.
Apply engine oil to the threads of the crank pulley bolts.
[Point 4]
Removal
Remove & install timing belt cover
The timing belt cover is separated into upper and lower
parts. After crank angle sensor is removed, remove the
timing belt cover in the order of upper and then lower.
Installation
Installation is in reverse sequence of removal procedures.
Caution:
Care must be taken not to scratch or damage the dried liquid
packing when removing and installing the timing belt cover.
[Point 5] Remove & install belt tensioner nuts
Secure the tensioner with hexagonal wrench when
removing and installing the belt tensioner nuts.
Caution:
Do not loosen inserted stud when disassembly.
[Point 6] Install conical washer
Pay attention to installation direction of the conical
washers. The washer should be set with face with
chamfered side facing the tensioner pulley side.
[Point 7] Install tensioner spring
Assemble the tesioner spring to the belt tensioner pulley I
as shown in the figure.
The tensioner spring must be assembled together with the
belt tensioner pulley in the cylinder block.
Hook the tensioner spring on the upper side of the tensioner
spring stud when the tensioner pulley is free.
EN - 80
ON-VEHICLE PARTS
Not marked ,
- - ' ~ - , - ~ - ~
Nut Conical Washer
washer
Tensioner spring specifications
Spring wire
Set angle (a) Free angle (-)
Classification ..
dlalll6ter
paint .
1,8 mm ApproK 20" Approx, 163' Yellow-green
[Point 8] Install crank timing pulley & plate
Care must be taken ofthe rear and front positioning when
installing timing belt plate, the crank timing pulley and the
timing pulley plateo
[Point 9] Timing belt alignment mark verification
and installationo
Paint a mark on the belt that indicates rotation direction if
paint on the upper belt is unclear when disassembly,
Position the alignment marks on the intake and the
exhaust cam pulleys with the respective belt cover
alignment marks, (Noo 1 cylinder is at TDoC)
Position the alignment mark on the crank timing pulley with
the respective oil pump housing alignment markso At this
time the groove must be straight up (noo 1 cylinder is at
TD,q
Move the belt tensioner clockwise 70 - 80 degree angle,
and secure it temporarily with the belt tensioner nut
I nstall the belt by aligning the timing belt and the pulley
ON-VEHICLE PARTS
pulley
, When set
1
00
'"
___ J
_ ' L __ ,
__ ..r--
---....

'a {When free}
oo ___ __
I
pulley (exhaust)!
Alignment
I
bran. timing pulley Alignment mark
markso Align the n umber of ridges of exhaust cam pulley
alignment mark and the crank pulley (inner) alignment mark '--_
as shown in the figure on right
After loosening the nuts and adjusting the belt tension,
secure the tensioner with the hexagonal wrench so it will
not rotate together and tighten the nut
Caution:
(1) Make sure the timing belt engages correctly with the
pulley and does not float when assembling the
timing belt
(2) Replace belts whenever possible when disassembly
is performedo
EN 81
ON-VEHICLE PARTS
RB26DE,T ENGINE
[Point 10] Timing belt tension adjustment
Remove the spark plug and align the timing belt alignment
mark and the pulley marks and install timing belt on to each
pulley,
Loosen the tensioner securing nut so the belt tension is
applied by the tensioner spring,
In this condition, rotate the crank pulley clockwise more
than two turns to check the belt movement and stop slowly
at No.1 cylinder compression TD,C point. ~ , __ .'... .. . - - - - - _ ~ __ ,:""-,,.'c
Insert the hexagonal wrench in hexagonal hole. Hold the
tensioner by hand so the tensioner does not move, and
tighten the tensioner securing nut to specified lightening
torque,
Tightening torque (kg-m); 4.4- 5.9
The initial tension on the belt in this condition should be
approximately 20 kg,
[Point 11] Install idler & tensioner pulley
Do not loosen inserted studs when disassembly, If studs
are loosened, coat inserted stud with locktite solution
(Japan Locktite KK) or equivalent.
[Point 12] Timing belt inspection
Replace timing belt if any problems are indicated at the inspection,
' "
Item Condition
,
Cause "
,
Tooth missing
~
~
Camshaft lock
"(/
i
Cracked tooth
,
Crank sensor lock
~
Tensioner lock
Cracks on rear
Engine overheat
side
Interference with belt cover etc,
Wear and cracks
~ ~
Belt misalignment
on the side
. ~ ~ ,
Belt plate malfunction
!IlJ.
Worn teeth
Sliding motion resistance in
crank sensor and the camshaft
-
-
Oil or water
~
Oil seal malfunction
adhesion Water leaks in water pump
Caution:
:
!
!
Do not twist or bend the timing belt, Make sure there is no oil film or water on the belt.
EN - 82
ON-VEHICLE PARTS
10-12 CYLINDER HEAD ASSY
(1) Install & remove cylinder head ASSY
CY
W1
0er head bolt (M12x1.5) (14) Cylinder heac bolt (M6x1 ,0)
[Pc.
n
' 2] , ,/0,92 - 12 [Pomt 2J
i,11 T:ghten to 3 Kg-m
' . L t I I ,,-"- pr,ng was er
0.92 - 1,2 [Point 2] , ,ooser 001 s comp etey ,
CYI.lnderhead bolt IMSx1 ,.2, 7ighleo '011 kgm S ' h
'\ .-,. (4) Tlgh:en to 3 kg-m Washer
"'-'ft' (5: Angle wrench 90' Cylinder head ASSY
U Torque wref'lch 11 +/- c.s
Spring Washer Cylinder head bolt (M6xl.0)
Washer---= . 0,92 [Point
Cam pulley
kg-m [Point 3J
., Rep!ace after every disassembly
Drain and refill cooling water [Point 1]
Remove and install:
Collector
Throttle chamber
Intake manifold
Turbocharger, exhaust manifold
Timing belt
Rocker cover
Spark plugs
Install No.1 cylinder compression TD.C position [Point 3)
[Point 1]
Removal
Drain & refill cooling water
Remove cooling water completely from the cylinder block
drain plug,
Caution:
Make sure cooling water will not enter exhaust front tube.
Refill
Refer to "Cooling water filling procedures" for details.
EN -83
.. -- Spring washer
0". :::-'CLE PARTS
RB26DETT ENGINE
[Point 2] Remove and install cylinder head bolts
Removal
Remove the bolts in reverse sequence to the figures on
right.
Installation
I nstall the bolts in sequence shown in the figure on right.
The cylinder head bolt (M12xl.S) are torqued by two-step
method. Tighten the bolts in two steps. ._ .... :-1
(1) Tighten to 3 kg-m.
(2) Tightened to 11 kg-m.
(3) Loosen bolts completely 0 kg-m.
(S) Turn bolts 85 - 90 clockwise when angle wrench is
used.
TIghten bolts to 10.5 -11.5 kg-m when torque wrench
is used.
Cau.tion:
When angle wrench is not used, never attempt to
approximate the tightening angle visually.
Take care not to hit or scratch the gasket seat and the bore
grommet when the gasket is installed.
Clean the cylinder head lower surface and the cylinder
block upper surface to remove all water, oil and foreign
objects when gasket is installed. Use compressed air gun
to blowout the bore holes.
[Point 3] No.1 cylinder compression T.D.C
verification
Before installing the cylinder head ASSY to cylinder block,
the crank pulley and the cam pulley must be positioned at
the No.1 cylinder compression TD.C position.
Align the crank pulley timing mark and the timing belt cover
timing indicator (0
0
position).
Align the intake and the exhaust cam pulley alignment mark
to respective belt cover alignment marks.
EN-84
5
Bore grommet
i
Seat
ON-VEHICLE PARTS
(2) Cylinder head ASSY disassembly & assembly
'ja:,;e spnng retalner
Vaive spring 17, 19. 20]
Valve hfter [POint 141----0 " Spring seat
ShIm [POIl1! 6}-- - ___ ... J I // _./ Valve 011 sea! [Point 23]
Valve collet [Pc;nt 18] --/ / Valve guide [Point
Qt ..,./ ___ Valve seat tpoint 251
r.9l Nut 0,92 - 12 [Point 5]
Spring washer

Baffle plate
"'" /
..._.- :::xhaust valve [Poin121 ,22]
Exhaust valve [Pomt 21, 22]
0<::::::::::. ""@
tc!I Bolt 0 92 - 1.2 '&
-
:
_
BOlt (L92 - 12 [Point 5} "'" 0 0
/
,II" Washer
V ,/"-,, Camshaft bracket [Point 5J
...- /' Ei!Rubber plug [Point 8]
t'.!>..-''''.,/ Cyjirnierhead [Point 13,15,21,24,25]
""'" e /
Camshaft (exhaust side)
'" [Point 4, 9,10,11,12]
,,/ <3 'tf-Bolt\-ll
" 0,92-1,
3 [PointS]
,
r
'it 'fS), "11>
Timing cover ,/ fR..
tc!I 801111)
1,6 _ 2.2 back plate 3}/ \
- ='"""'-
092 - '2toJ
tc!I Bolt (3) , , Camshaft front oil seal [Point 7[ QIl
toJ 0,64 - 0.85 ""
all (2) 2,1 - 2.7 Cam pulley (Poinl 2]
'" , Cam pullev washer
. _. "camDUlleYOOlt1.4-1,9[POint2]toJ
Crank angle sonsor bracket [Point 1]
Bolt 2,1 - 2.7tc!1
Liquid gasket
kg-m
Engine oil
Replace after every disassembly
Remove and install cylinder head ASSY
[Point 11 Instal crank angle sensor bracket
The crank angle sensor bracket is positioned onto the
cylinder head by using know pins. Align the positions
correctly when installing the crank angle sensor.
Crank angle sensor bracket bolt tightening torque
(kg-m): 2.1-2.7
[Point 2] Remove & install cam pulley
Removal
Fix pulley with a pulley holder or sprocket wrench and
remove cam pulley bolts,
Pulley holder: KV101 09900 or
KV101 09300.
ST3152 0000,
ST3153 0000
EN - 85
--- ----....
:':1'1' pulley
RB260ETT ENGINE
Installation
Align the cam pulley knock pin hole and the camshaft knock
pin to install cam pulley.
Use pulley holder or sprocket wrench to tighten cam
pulley bolt
Cam pulley bolt tightening torque (kg-m): 1.4 -1.9
To remove and install cam pulley bolts, use the proper
tools to secure the hexagonal part in front of camshaft.
[Point 3]
Removal
Remove & install timing belt cover back
plate
Remove back plate bolt and detach back plate.
Installation
Assemble canister tube with back plate and then install
back plate.
Back plate bolt tightening torque (kg-m): M6 0.64 - 0.85
M81.6-2.1
[Point 4] Camshaft end play inspection
Set the dial gauge in front of camshaft as shown in the
diagram. Read the dial gauge run-out width when the
camshaft moves in front or rear direction.
Standard value (mm): 0.030 - 0.080
[Point 5] Remove & install cam bracket
Removal (Exhaust and intake camshaft)
Place marks to indicate the bracket position and its
direction before removing the cam bracket.
Remove cam bracket bolts by loosening them gradually in
several stages in reverse sequence shown in the figure.
Installation
Align the crank pulley timing indicator and the timing belt
cover timing indicator (0) so No.1 cylinder is at
compression TD.C position. (This operation is not
necessary when cylinder head is removed as single unit).
Turn the camshaft so No.1 cylinder is at compression
TD.C position. (Operation is easier if the camshaft is
turned 60 before or after No.1 cylinder TD.C point when
cylinder head is installed as single unit).
Verify the position of No.1 cylinder is at compression TD.C
by knock pin in front end of camshaft.
EN -86
ON-VEHICLE PARTS
S.;it(2) 1.6'22 I
Retalne( , , '"'
I
\
I
Grommet u...
,
. 1:\' ..
t--\ / i
, \ / D.64 0.851
,,\,\0;,:: . '-_ Canister tube !
\ "Grommet Timing belt cover '
\ Retainer back
Bolt (2) 0.64 - 0.85
1_. ____ ... ___ _
2 6 10 12 8
Knock pin
,
: (intake)
ON-VEHICLE PARTS
RB26DETT ENG,NE
To install camshaft, temporarily tighten No.1 cam bracket
and check that camshaft thrust section is positioned
securely. i ... -... ..
in the order shown in '. . _.' =i4%-.... ..1
Cam bracket tightening torque (kg-m): 0.92 - 1.2 ",._/ ) _ ._
Caution:
(1) Coat the cam journals and end of the cam shaft with
engine oil before installation.
(2) Do not rotate camshaft. (The valve and pistons may
interfere).
[Point 6] Valve clearance adjustment
Ilr:take Exhaust camshaft I
No.1 cylinder compression T.D.C point
Tum the camshafts (intake and exhaust) so No.1 cylinder
is at the compression TD.C position.
Check knock pin position of camshaft front end to verify
No.1 cylinder compression TD.C position.
PART
VALVE CLEARANCE
ITEM
MEASUREMENT
i INTAKE SIDE Cylinder No.1, 2, 4
EXHAUST SIDE Cylinder No.1, 3. 5
FIring order: 1 - 5 - 3 - 6 - 2 4
Rotate the intake and exhaust camshaft 180.
I
Exhaust side
NO.6 cylinder is at compression stroke top dead enter ... Valves which can be adjusted
when both the intake and the exhaust side cams do not move
the valve lifters.
.
, PART
VALVE CLEARANCE
ITEM
MEASUREMENT
.
INTAKE SIDE Cylinder No.3. 5, 6
EXHAUST SIDE Cylinder No, 2. 4. 6
Valve clearance specifications
(20+i-5
C
C)
PART
INTAKE EXHAUST
:
ITeM .
.
Valve clearance (cold)
mm 0.45- " 0.38'
(Reference value; warm) mm
0.51-' 044
Caution:
Always inspect when the engine is cold.
EN - 87
i
RB26DETT ENGINE
Reference: Compensation by room temperature
RClom
0+/- 5
!
10 +/- 5 20 +/- 5
temperature ("C)
Compensation
+0.02
I
+0.01
I
0
value(mm)
I
Valve clearance measurement
Insert a 0.15 - 0.20 mm gauge (A) from spark plug side.
Insert gauge (8) from opposite side. Select a gauge
thickness that will reduce the clearance to 0 m.
Note:
Do not use more than two gauges for (8).
Use JIS 150A25 feeler gauge.
Valve clearance = Gauge (A) + Gauge (8)
Reasons for measurement using gauge (A) and (8) :
1. The valve clearance setting is larger compared to
previous engines.
2. Large gauges cannot be placed parallel to the
measurement surface.
Thick feeler gauge have high rigidity and cannot be bent
easily, so the measurement will be incorrect.
The error factor increases if a number of thin gauges are
layered and the measurement will be incorrect.
Valve clearance adjustment
The valve clearance adjustment is performed by selecting
a shim of suitable thickness.
When the measurement valve clearance (t) is out of
specification, measure the shim thickness (T) and replace
it with a shim that will produce the standard clearance.
1. Shim thickness calculation method
Example:
When the intake valve clearance (I) is 0.50 mm:
0.50 (t) - 0.45 (specified value) = 0.05 mm
The valve clearance is 0.05 mm greater than the specified
value.
Use a shim 0.05 mm thicker than the current shim to
reduce the valve clearance.
2. Current shim thickness (T)
Measure the center of removed shim to determine the
thickness of the current shim.
Caution:
Do not reuse the measured shims again.
EN -88
ON-VEHICLE PARTS
30 +/- 5
-0.01
~ - .... ---.. - - - '
cam
1
\
,-
' - ~ ~ ' - l
l 00 , , ~ , ~ , ~ : ~ ~ , - ,
3. Shim selection
Current shim thickness (T) is 2.40mm.
2.40 (T) mm + 0,05 mm "2.450
Select new shim with stamped mark [24.40]
(T" 2.440 - 2.455).
Select a shim within standard value range +/- 0.03 mm,
4. Shim types and classification
There are 70 types of shims. Sizes range from 2.275 mm
to 3.325 mm in 0.05 mm increments.
[Point 7] Install camshaft front oil seal
Care must be taken not to scratch or make a burr in the oil
seal. Use a socket smaller than the seal (41 mm) and drive
it into same level as front surface of the oil seal retainer.
Apply a coat of engine oil to the entire perimeter of oil seal
lip.
Caution:
Do not scratch the oil seal and lip.
[POint 81 Install camshaft rear rubber plug
Before installing the rubber plug, wipe off any oil, water etc.
on the surface and clean thoroughly.
When assembling the rubber plug, coat it with adhesive
(three bond 1211) or equivalent.
[Point 9] Intake and exhaust camshaft classification
Intake and exhaust camshaft can be identified by
identification point colour and presence of a spine gear
for driving the crank angle sensor.
Camshaft Identification paint Spline gear
Intake camshaft Pink No
Exhaust camshaft White Yes
(Point 10] Camshaft knock pin insertion
The protrUSion distance is 5 mm for camshaft knock pin
insertion.
Knock pin protrusion distance (mm): 5
EN -89
ON-VEHICLE PARTS

T = 2.440 - 2455 mm
r side ...
WPMlI!J
Identification paint

pin Exhaust Side
.. "-'lin
for driving crank angle senso
Front ....
5 mm
KnOCK pin
R826DETT ENGINE
[Point 11] Camshaft inspection
Cam height inspection
Use a micrometer to measure cam height.
Intake side Exhaust side
Cam iteightstl:mdard value 40.58 40.28
Cam 11ft (reference) 8.58 8.28
Cam journal external diameter inspection
Use a micrometer to measure the external diameter of the
camshaft journal.
No.1 - No.7
Standard value (mm) 27.935 - 27.955
[Point 12] Camshaft run-out inspection
Support both camshaft end journals (No.1 and No.7) by
using V-blocks on the fixed surface.
Avoid the oil groove in the centre of the NO.4 journal and
position the dial gauge vertically.
Rotate the carnshaft by hand one rotation and read the
movement width on the dial gauge.
The run-out is equal to one-half of the movement width
indicated on the dial gauge.
Standard value (mm): 0.05
ON-VEHICLE PARTS
Micrometer
Dial gauge
, ,
\ :.
, I \1
igJd
[POint 13] Cylinder head cam bracket interior diameter inspection
Tighten the cam bracket to specified torque.
Cam bracket bolt tightening torque (kg-m): 0.92 - 1.2
Use the bore gauge or inside micrometer to measure
interior diameter.
'.'
',"
No.1 - No.7
,",'
, "
'"
,
.",
EN-gO
[Point 14] Camshaft oil clearance inspection
The oil clearance can be calculated from the camshaft
journal outside diameter and the bracket interior diameter
measured in [Point 11] and [Point 13],
(Oil clearance) = (Cam bracket interior diameter) -
(Camshaft journal exterior diameter)
No.1 - No.7
[Point 15] Valve lifter inspection
Check the contact and sliding surfaces for wear or
scratches. Replace if damaged.
Use the micrometer to check the valve lifter outside
diameter.
[Point 16] Cylinder head lifter bore inspection
Check bore surface for wear or scratches.
Use inside micrometer to measure valve lifter hole
diameter.
[Point 17] Valve lifter-to-lifter hole clearance inspec-
tion
Check the clearance using values for the valve lifter out
side diameter and valve lifter hole diameter measured in
[Point 15] and [POint 16].
(Clearance) = (Valve lifter hole diameter)
(Valve lifter outside diameter)
[Point 18] Remove & install valve spring
When the cylinder head is removed from the vehicle:
ONVEHICLE PARTS
"'-l
Micrometer i
/ '
_._ ....
Use the valve spring compressor to remove and install the
r >;
valves. I -""'" ,< - \ "\
(",1, '"'
When the cylinder head is installed in the vehicle:
Use the valve spring compressor to install valve spring.
EN - 91
\'.'"
-'"\ 'L'
Val'Ve \.
comp'esso' .,;,
KV'Ol 1'300 '\i, . '!lV' /" I
''.-.., \ I
"""'-:\ \@')\ I
"';::..-.'-///
RB26DETT ENGINE
[Point 19] Remove & install valve collet
Removal
Use tweezers to remove collet.
Installation
Apply a small coating of petroleum jelly to the intemal
surface of the collet.
Use a magnet screwdriver.
1. Upper collet installation
Attach collet to the lower side of the magnetic
screwdriver blade and install in the valve stem.
2. Lower collet installation
Attach the collet to upper side of the magnetic
screwdriver blade and install in the valve stem.
[Point 20] Valve spring inspection
Free length and pressure load inspection
Use the valve spring tester to carry out the inspection.
Standard value Limityatue
Free length (mm) 46.54 -
Installation load (kg) 240 225
identification colour White -
Caution:
Installation load is the force required to compress the spring
length to 35 mm.
Perpendicular inspection
Place a try square by the spring so it contacts spring. Turn
the spring and measure the maximum clearance between
upper spring surface and the right angle to determine the
out-of-square distance,
Limit (mm): 1.8
[Point 21] Install valve spring
Install uneven pitch type spring with narrow end towards
cylinder head (identification colour side).
EN -92
ON-VEHICLE PARTS

, paint (white)
Cylinder heae
ON-VEHICLE PARTS
ENGINE
[Point 22] Valve guide clearance inspection
Protrude the valve approximately 15 mm towards the
combustion chamber and measure the valve deflection by'
swinging it in direction parallel to the dial gauge. ii
The clearance is equal to half of the dial gauge reading.
Intake Exhaust
. .
Limit (mm) 0.1 0.1
If clearance exceeds limit, verify the valve stem diameter
and replace the valve or valve guide.
(Point 23] Valve inspection
Outside diameter measurement
" Y==::==:::::!Il,"
,

,
... a
Valve a b e . d e f
9
Intaktt 10098+/-0.1 97.45+/-0.15
345.
0
.2
60 (L020
1.3
2.6
-
. 0
. 0.Q35
ex
45
0
30'
Exhaust 99.98+/-0.1 95.48+/0.15

70 0.080
.
(1.2)
29 +0.3
.
60.
0
.020
. 0.055
45'30'+/-15'
Be especially careful in handling and disposal of valves as the exhaust valves are fitted with
metallic sodium.
[Point 24] Remove & install valve oil seal
Removal
Use valve oil seal puller to remove the valve oil seal.
Installation
Use valve oil seal drift to install the valve oil seal.
Drift KV101 07501
Drift attachment KV101 14800
i Valve all
: sea! puller
. KV10l 0790
I
..
Caution: I,
Coat inside of the valve seal with engine oil before installation. --<'VaNe oil seal drift
.,---J KV101 07501
Valve oil sea! drift attachnlent
KV101 1480 "'Y,r ___
EN - 93
I
RB26DETT ENGINE
Install valve oil seal as shown,
[Point 25) Remove & install valve guide
Removal
Use valve guide drift and tap it from combustion chamber
side to remove,
Installation
Ream the cylinder head guide hole using the valve guide
reamer at normal temperature (when using 0,5 mm over
size service part) .
. '
Intake side 10,46 - 10.478
I. Rectified standard
value (mm)
Exhaust side 11.46-11.478
. ' ..
ON-VEHICLE PARTS
1--' '
I V81V
j
C 011 :81 i . . .. ~
i. i
17
Jn-7 I m, 1171
I L.. rL. --..l
. 1m
I Intake . Exhaust
Heat the cylinder head in an oil bath to approximately 150
to 160C and use a valve guide drift or press-fit tool to press i
valve guide from camshaft side.
The press-fit dimensions are shown in the figure on right.
Ream inside of inserted valve guide with the valve guide
reamer.
Flni,shed inl!imal diameter
Intake side 6,000 - 6.018
standard value (mm)
Exhaust side 7,000 - 7,018
EN - 94
,
,
i
!
Camshaft Side
Valve g ~ l d e ?
,16.8+/-0.1
I .
~
Intake

[Point 261 Valve seat
Inspection
Inspect the condition of contacting surface of the valve seat :
and the valve.
Replace the valve seat or the valve if contacting surface is
too large or improper, or grind both surfaces and lap with
abrasive compound.
Adjustments
o When surfacing valve seat due to poor contact, inspect the
valve guide clearance and valve step hole clearance.
Use the valve seat cutter or the valve seat grinder and
finish to standard value.
Caution:
When using valve seat cutter, press firmly and cut evenly with
both hands to produce uniform cutting surface.
Removal
o Minimize the valve seat thickness by cutting it, then remove.
Installation
(1) Drive the valve seat into cylinder head using the valve
seat drifter as shown.
(2) When not using the valve seat drifter:
Cool the valve seat for approx. 5 minutes using dry-ice.
Heat the cylinder head to approx. 80
c
C.
o Inject the valve seat into the cylinder head.
Caution:
Do not touch cooled valve seat with bare hands.
ON-VEHICLE PARTS
OOK
o ON.G
N.G
,
Exhaust valve seats are available in 0.5 mm oversize. When LI .. n ... ::.::::: .... ::::: .. ::::: .
using oversize valve seats, cut and grind the sealing
recess in cylinder to fix valve seats.
Exhaust
side
Cylinder head
.' ....
.'
I
Item
finishing
. Valve seat
.' .
Valve oyersize
Id 10, 1
0
, 1
0
,
10. 10.
H
. Standard
+0.0
1
6 ",:::.113
30 -0 '5
343 37.5
0
36
0
36
o :}97:
32
6.6 -0.1
Intake
+/0.05
0.5
365+
0
.
016
36"-0113
30--
015
.
32 34.3 - 5.8
. . 0 .., '.1 09
7
i
Staftdard 32
+0.016
32
'":- 25 - 1
5
!
29.6 32.5 6.6
0
.'
-
-0.1
ExIuwat
0
_ ,. ,
0.5
32 5 +0.016 i":':'" i - -: I
i
+l-{lOt
32
. -
29.6 - - 5.8
. 0 v : 5' :
I
EN - 95
RB26DETT
[Point 27] Cylinder head inspection
Clean and remove oil, gasket, sealing compound, carbon
and other foreign matter.
Measure the lower surface of the cylinder head in six
directions to check for any distortion.
Limit (mm): 0.2
When the distortion is just over the limit, resurface the
cylinder head.
If the distortion exceeds excessively over the limit, replace
the cylinder head.
1013 WATER PUMP REMOVAL AND INSTALLATION
Alternator adjust bar
\ Bolt (1) 0.64 -

.
Bolt (2) 3.2 - 4.3
(2) 3.2 - 4.3
ON-VEHICLE PARTS

pump [Point 1. 21 .
1!:3 LiqUid gasket
kg-m
Bolt (6) 1.6 - 2.1
Drain and refill cooling water
Remove and install:
Cooling fan, water pump relay
Alternator adjustment bolt
Timing belt cover, timing belt
[Point 1J Remove & install water pump
1 6 7 8 9
co "'$ D I)
Remove
Care must be taken not to get coolant on the timing belt.
Wipe it off immediately if any water does spill.
@l!PO@oo-O
Q 12 1t
\9. 0
Remove the water pump bolts in the reverse order shown.
II III J
1 M6 (1) IlIM10 (short)
'4;M 10 Me
EN -96
RB26DETT ENGINE
Installation
Install the bolts in the numbered sequence shown .
Installation
.. . '.
Tightening
location
80ltslze . No. of baits
tonwe(kg-m)
1 M6 1 0.64 - 0.85
7,8,9, 10,11,12 M8 6 1,6-2.1
2,3,4.5 M10 4 3.2 - 4.3
Insert stubby screwdrivers in the bolt holes and move it up
and down to remove the water pump.
C(lution:
Take care not to damage the screws in cylinder block side.
Use a scraper to remove all liquid gasketfrom the surface.
Caution:
Also remove the liquid gasket remaining in grooves.
Wipe the installation surface with white gasoline.
Installation
Cut the nozzle end of liquid gasket tube (KP51 000150) as
shown in the figure and use tube presser for application.
ON-VEHICLE PARTS
,
, I
Cut

, '
I .
Apply continuous bead of liquid gasket (KP510 00150) to .... ___ ... _
water pump sealing surface.
Caution:
Be sure liquid gasket is 2.0 to 3.0 mm wide.
liqUid gasket 2.0 - 3.0 n111
wide along the groove
I
Installation must be carried out within 5 minutes after liquid ! .......
gasket application,
[Point 2] Water pump inspection
Rotate the water pump by hand and check for abnormal
sound and smooth operation.
There must be no traces of water leaks.
EN -97
o
RB26DETI ENGI"E
10-14 THERMOSTAT REMOVAL & INSTALLATION
[Point 2]
Thermostat housing [Point 1]

V / _

Bolt(3)16-21tgl /';
)
i , 1/---
r;;J ',Iquld gasket
,tgl kg,m
Disconnect and connect water inlet hose
Caution:
Loosen engine drain plug to remove cooling water from
the cylinder block,
[Point 1} Remove & install thermostat housing
Insert the screwdriver handle into thermostat housing and
move it up and down lightly to remove the housing,
Use a scraper to remove the liquid gasket.
Caution:
Make sure to remove liquid gasket in grooves,
Wipe off the surface with white gasoline,
Installation
Cut nozzle end of liquid gasket (KP51 000150) tube as
shown,
ON-VEHICLE PARTS
I 2,0 -30 mm to of flail
mating surface and inner seating :
Apply a continuous bead of liquid gasket to sealing surface, surfaces of bolt holes, :
using the tube presser, Install the housing within 5 minutes !
after coating liquid gasket.
EN-98
ONVEHICLE PARTS
[Point 2] Install thermostat
Jiggle valve
I
'Top' mark Giggle valve) must face up when thermostat is
inserted in housing,

.

e> i
[Point 3] Thermostat ..... "
the valve opening temperature and maximum valve [ Strin
g
___ ,..,---t
Hang the thermostat by string in valve and submerge in, houbie-wall i .
heating it up, t===d
Thermostat
The opening temperature is the temperature when the valve
opens and thermostat falls from string. ._ _ v--"
Standard, cold climate
.
Valve opening temperature (OC) 76,5
Max, valve lift mmlOC 10190
1015 INSTALL & REMOVE OIL COOLER, OIL FILTER
Water hose
tUDe
Water tube
Water rlose

80111,6 - 2,1
(4)
O-nng 1 6 - 2 1 0-nn90
01
o 0 ?'r-/

.' 0/,
;; /" \
I "-
___ 0/ 1 '.'-,
0" \ $" Gasket 0
.:rac<eV' (0\'/> Oil fille' \' Spring washer
/ \,,' brack1 Nul(1)
Bolt (2) 0 64 - 0 \ Oil temperature
011 fl,te
r
sensor

o Replace after every dsassembly
Disconnect and connect switch harness connectors
Caution:
Loosen engine drain plug to remove cooling water from cylinder block, (If water is only drained
from the radiator drain cock, the cylinder block wrll not drain completely),
EN -99
RB26DEF ENGINE
[Point 1]
Removal
Remove & install oil filter
1. Remove the oil level gauge.
2. Remove turbocharged pressure control vacuum hose
clamp and move the vacuum hose out of the way.
3. Move main harness clamp out ofthe way. (If the oil filter
come loose, remove the oil filter using the filter wrench).
4. Use oil filter wrench to remove oil filter.
Installation
ON-VEHICLE PARTS
f>. " Aaapter
/
(;ijffflcd
Small ratcnet ;;JI
wrench
L.. . ... __ ._ ... __
Wipe off dust etc. from the oil filter mounting bracket .. "
surface before installing new oil filter. Apply a thin coat of 16
engine oil to oil filter O-ring before installation. - ; ,L-6iifiller"
Screw the oil filter on bracket by hand until a slight \'i': \
resistance is felt, then tighten an additional 2/3 turns using !'Ma'nifOIdCO!l;Cior,? Qr:; ')I(
the oil filter wrench. Start the engine and check for oil leaks . .
Removal. .!-oi> jI . '. ,
Face lower part of all filter down and move out In the ... ... ... -.
direction of the arrow in figure right. Remove through
aperture behind manifold collector.
10-16 OIL PAN, OIL PUMP & OIL STRAINER
(1) Remove & install oil pan, oil pump & oil strainer
A kg-m
Engine oil
Engine ASSY
Drain and refill engine oil
EN -100
ON-VEHICLE PARTS
RB26DETT ENGINE
[Point 1]
Removal
Remove & install oil pan bolts & nuts
Remove bolts and nuts in reverse order of installation
sequence shown in the figure on right
Installation
Install the nuts and bolts in the order of sequence shown in
the figure on right.
Caution:
Make sure there are no dirt, dust or other foreign objects on oil
installation surface.
i
Installation position
Bolt (Nut No. of Tightening
size bolts I nuts torque (kg-m)
:

i, 3, l2.6J
M6 (Bolt) 9 0.64 - 0.85
,
Wj, lz.[
4,7,8,10,11,12,14,15,
Ml0 (Bolt) 14 3.2 - 4.3
16,17,18,19,21,22
1,2,3,5,6,9,13 Ml0 (Nut) 7 3.2 - 4.3
[Point 2] Remove & install oil pan
Removal & cleanr
'ng 1--'- (" ,:;
I !r, 0 '!if. ,- --:;C<" \\1' ''''
Use a seal cutter to remove and clean the oil pan. ... :: ,..,\11
1
1\1
Use a scraper to remove liquid gasket from mating (\ \';<
surface. {KV1n1 11100M
Caution: ' " ............ ___ 1
Use a scraper to remove all liquid gasket and seal material on I
the cylinder block and oil pan flange groove. Remove all I
gasket and other foreign objects in the oil pan.
Clean all contact surfaces with white gasoline.
Installation
- 1
Cut off the nozzle tip of liquid gasket (KP510 00510) at
point shown in the figure on right.

. )
'"""'\. Cut
I

I """"-LLL\L_'
r--- TJ.!l:>.e presser WS3993
Apply liquid gasket to inner sealing surfaces on the oil pan
as shown in the figure on right. ,/ ,
Installation must be performed within 5 minutes. I,
.. .... ----.J
EN - 101
RB26DETT ENGINE
Apply liquid gasket (KP510 00150) to areas 7 mm inside
from center of the oil pan bolt holes.
Caution:
(1) Make sure the liquid gasket is applied 4.0 mm wide.
(2) Wait at least 30 minutes before refilling the engine oil ,
and engine coolant after installation.
[Point 3] Install oil strainer
Make sure the O-ring is installed securely in groove when
installing the oil strainer.
Tightening torque (kg-m): 1.6 - 2.1 (MS)
0.64 - 0.85 (M6)
[Point 4] Oil pump bolt
I
I
There are 4 types of bolts. Make sure to use the correct
bolts when they are installed.
.
installation . Length below Tightaning
No. of bolts
position head (mm)
.
torque (kg-ml
1 20 4 0.92 -12
2 35
!
2 0.92 - 1.2
3 45 1 0.92 - 1.2
4 55
,
1 0.92 - 1.2
ON-VEHICLE PARTS
mm
,r

Groove Bolt role
Remove & install front oil seal I
Use a tool such as screwdriver to remove front oil seal from i ',Sj)li (
II' I
(01, iff
Care must be taken not to scratch or damage the oil seal
retainer. Use oil seal drift and insert it at same level as front L- C" ..
surface of the oil pump housing.
Apply engine oil or chassis grease to area around the oil
seal lip.
-
I -Oll seal drift

",'.
[Point 6] Oil leak & oil pressure inspection ..
After installation warm up the engine and check for any oil I .) \ :c 1 f,lf_ l
leaks and the oil pressure. \ \'.. . 1I,:c' '",
Remove oil pressure switch and attach oil pressure gauge \ : /1; y I
when measuring oil pressure. :, b
!i! ' ..: 1('(Y:"-'J

SWItchL
I Englnt' rev (rpm) .. Idling 2000 6000
Exhau.tPn-ure '(kg" tem') Appral<. 1.5 Approx.3 Approx 4.6
EN - 102
ON-VEHICLE PARTS
ENG,NE
(2) Oil pan disassembly & assembly
Baffle plate
tgI kg-m
(3) Oil pump disassembly & assembly
(7) 0 38 - 0 51

C 0( Pump cover
['
Regulator Valvej
[Point 2]
PurPP hOUSing [POint 1 J
RegUlato0
spring "i
, I
i Regulator...-Q L
I washer
Regulator plug 4,0 -
kg-m
\ Inner gear [Point 2]
Outer gear [POint 1 i
[POint 1J Oil pump inspection
Check inner gear. outer gear and housing for any scratches or wear.
Use thickness gauge to measure the following clearances:
"
,
Standard value (nvn) I Measurement position
,1
I
Outer gear and housing clearance 0,114-0.2
2 Outer gear and inner gear clearance Below 0,180
3 Inner gear and housing side clearance 0,05 - 0,07
4 Outer gear and housing side clearance 0,05 - 0,11
!
5 Inner gear and housing flange clearance 0,045 - 0091
Measurement position 5 is obtained by subtracting the housing flange outside diameter
from the inner gear inside diameter.
EN - 103
RB26DETT ENGINE
_ ... _--.. ""=
Position 5
[Point 2] Regulator inspection
Positior. 3 & 4 \
\
Inside micrometer
Check oil pressure regulator valve sliding surface and the
spring for any wear and damage.
Valve and valve hole clearance (mm): 0.04 - 0.097
[Point 31 Install inner gear
Care must be taken to install the inner gear in a specific
direction,
Face the side with the groove to the cover side.
EN -104
ON-VEHICLE PARTS
HOlJsing
sIde
c::::J
ON-VEHICLE PARTS
"32:::
10-1 COLLECTOR ASSY
(1) Collector ASSY removal & installation
Acceleration wire bracket [Point 2]
Collector ASSY
Collector bolt (4)
1 .8 - 22lPoint 3)

Q,.-.,,,,=

II Collector bolt (3) i
rJ,.// 1.8 - 2.2 IPolnt 3] !
OColiector gasket

Release fuel pressure in the fuel lines [Point 1]
Drain & refill cooling water [Point 4]
Acceleration wire [Point 2]
Air duct
Harness connector
All hoses
Start the engine.
After starting the engine remove the fuel pump fuse and wait
until the engine stops. Crank engine two or three times to
consume fuel remaining in the fuel pipes.
crank the engine four to five times to consume fuel
remaining in the fuel pipes,
Caution:
connect to another battery if necessary,
[Point 3] Accelerator wire adjustment
Loosen lock nul to provide adequate slack for the
accelerator wire and pull outer case in the direction of the
accelerator.
Return the lock nut 1.0 to 1.5 turns from the position the
throttle drum starts moving (when there is no play in cable)
and tighten,
EN - 105
I
RB20E ENGINE
[Point 3] Remove & install collector bolts
Removal
Remove the bolts in the reverse order of the figure on
right.
Installation
Install the bolts in the order shown in the figure on right
[Point 4] Air release plug
For more information referto the section on cooling system
later on in the manual.
Carry out the operation when engine is cool.
Caution:
Do not remove the air release plug when the engine is hot.
Remove the air release plug to release the air within the
engine completely when refilling cooling water.
CSljtion:
Care must be taken not to over tighten the air release plug
boll.
Tightening torque (kgm): 0.7 - 0.8
(2) Collector ASSY disassembly & assembly
ON-VEHICLE PARTS
Acceleration wire
wire brackrt c/' bracket Dot (2)
'.., 0.64 - 0.85
Collector
Water hose .;.-
.. Throttle chamber bolt (4)
1 8 - 22 [POint 1] A
A kg-m
(; Replace after every disassemoly
Remove and install collector ASSY
,
"is
..

A MC valve ASSY bolt (4) 0.86 -1,1
EN - 106
[Point 1] Remove & install throttle chamber bolt
Removal
Remove the bolts in the reverse order of the figure on the
right.
Installation
uniformly in two stages.
Tightening torque (kg-m): First stage 0.9 - 1.1
Second stage 1.8 - 2.2
[Point 2] Throttle chamber gasket
Check the installation direction before installing the throttle i
I
chamber gasket. I
102 INTAKE MANIFOLD ASSY
(1) Remove & install intake manifold ASSY
~ - t I
.:;,----'

"'<
'=
Washer
ONVEHICLE PARTS
~ " .",'- "". j'
~ ~ ". Washer :" Intake manifold ASSY
' ~ Intake manifoid nut (5) 1.8 - 2.2 [Point 1] A
A kg-m
intake mamfold body 18) 1.8 - 2.2 [POint 1] A
I t3 Replace after every disassembly
ECCS harness connector and all hoses
EN107
ONNEHICLE PARTS
RB20E ENGI\lE
[Point 1] Remove & install intake manifold ASSY bolts and nuts
Removal
Remove the bolts and nuts in the reverse order of the figure
on right.
Installation
Install the bolts and nuts in the order shown in the figure on
right.
(2) Intake manifold ASSY disassembly & assembly
Gasket 0
11 7 5 9
IPJ
-, Thermal transmitter 1.5 - 2.0

tt=!J\\fater temperature
Fuel tube ASSY
Fuel damper [Point 1J
:
Remove and install intake manifold ASSY
sensor 1.5 - 2.0
gi
Ia '
.4 Water outlet
Ignition coil bracket ASSY
Bolt IPJ
1.8 - 2.2
Bolt (2) 16 - 2.1tc!l
(1 Replace after every disassemble
liquid gasket
IPJ kg-m
Replace the O-ring to new ones when removing and
I ,Pressure regulator I
Fuel tube Injector i
installing the pressure regulator and the fuel damper.
Caution:
Care must be taken not to scratch or damage the fuel tube
O-ring area when installing the pressure regulator and the fuel
damper.
EN - 108
. ASS'( ,
i Fuel damper ;

r;,
ON-VEHICLE PARTS
RB20E ENGINE
[Point 2J a-ring (for fuel injector, pressure regulator and fuel damper)
Coat the a-ring with engine oil (7 .5W -30 or equivalent) or ,---_______ .... _.-.-,
silicon oil (NUC silicon L45 or equivalent), but do not apply
solvent as this may remove oil coating.
Avoid using dirty a-rings and do nol allow dirt, dust or 'r (ii
foreign objects to adhere to a-rings or other equipment i ! O-flng
surfaces. ,. i Insulator (i!
Care must be taken not to scratch, twist or stretch them by
tools or operator's fingernails when installing a-rings. Insulator (i
Do not decenter or rotate the fuel injectors and the ......... _- -_..... . .
pressure regulator when inserting them into the fuel tube,
Do not store a-rings in location subject to ozone, high
temperature or in direct sunlight.
10-3 REMOVE & INSTALL EXHAUST MANIFOLD ASSY
jlo
Yoke [Point 31 " / ;
Washer [Point 41 " .
Nut 2.8 - 3.2 [Point 2J/
Under cover
Assemble and disassemble exhaust front tube
a 2 sensor connector
[Point 1J Gas leak inspection
kg-m
(1 Reolaee after every disassemble
After removing the exhaust manifold, make sure there are
no traces of gas leaks from any parts,
gas leaks.
EN - 109
ON-VEHICLE PARTS
RB20E ENGINE
[Point 2] Remove and install exhaust manifold nuts
Removal I
9 5 3 8
Removal is the of installation sequence shown in r q'i' '"""
the diagram on right. i \;;',2
Installation ,,0 6 2 4 7
The installation sequence is shown in the diagram on 'f\ .
right
[Point 3] Yoke
Make sure not to make mistake between NO.3 and NO.4
yoke as configurations are different.
,
Item D(mm)
'.
No.3 & No.4 port 22
Other than those above 24
[Point 4] Install washer
Make sure the washer is facing the correct way when
installing.
{
Manifold side
10-4 REMOVE & INSTALL LOCKER COVER
... .. _---,
[Point 1] Remove & install locker cover bolts
Removal
Air duct
Air duct bracket
Blowby hose
the diagram on right.
11 6 3
Installation
4

8 10
.,J
I
"
,
The installation sequence is shown in the diagram on
right.
2
5
12 !
EN -110
ON-VEHICLE PARTS
RB20E ENGINE
10-5 TIMING BELT REMOVAL & INSTALLATION
W
' Belt t8:'S10ner
asner
Conical washer i ! Tensloner spring [Point 7]
[Point 6] \: '
Nut 4.4 - 5.9 t,) G .
Timing belt cover (upper)
[POint 4]
0.3 - 0.5
,
Timing belt cover I
Crank pulley [POint 3]
Power steering pump
pulley
Bolt 10-1
'. I
14.5 - 15.5
"[Pomt 1, rl
kg'11
rl Engine oil

0 Replace after every disassembly
Remove and install the followings:
Under cover
Radiator, shroud
Cooling fan
Supplemental belts
Water pump pulley
Spark plugs
---",

"\,
\
(2) 0.3 - 0.5
timing belt olate [Point 8]
Timing belt [POint 9,10,12, 13J
Crank timing pulley plate [Paint 8]
Check No.1 cylinder compression T.D,C position (Paint 1]
Align the crank pulley timing mark and the belt cover timing indicator. At this time, the
distributor rotor should be in the position shown in the diagram below, or No, 1 cylinder is
in the compression T.D,C pOSition.
f;r'ectionl--=I
, j ,I I -,), ,I '
I ' .
EN - 111
RB20E ENGINE
[Point 3] Pulley puller (steering wheel puller)
Remove the crank pulley by using the pulley puller.
(bolt size: M6 x 1.0 length below head 40 mm)
ON-VEHICLE PARTS
I
[Point 4] Install timing belt cover r .. ...
Attach the gasket (sponge rubber) on the timing belt cover " ..
(upper) as shown In the figure. ....::c-:::--
Secure the belt tensionerfirmly with a hexagonal wrench
when removing and installing the belt tensloner nuts.
Pay close attention to the installation direction of the
conical washers. The washer should be set with face the
Assemble the tensioner spring so it engages the belt
tensioner pulley as shown in the figure on right.
. B- f( i
I ... '
Conical Washer
washer
..
I "
The tensioner spring must be assembled together with the II@o) /;=
belt tensioner pulley in the cylinder block. . / /1, . 3)

[
2) . ,', ; 0
, "
_M ______ .'__ \ __
EN - 112
RB20E ENGINE
Fix the belt tensioner and hook the spring on top of the
stud volt by rotating the spring anticlockwise,
Spring wire
'"
Setangle
diameter ",' .
1,8 mm Approx. 20 Approx, 2270
[Point 8) Install crank pulley and plate
Be careful to observe front and rear positioning of timing
belt plate, crank timing pulley and crank timing pulley plate
when installation is performed,
Check the number of ridges between the cam pulley and
the crank timing pulley alignment marks,
Mark on each pulley at the alignment position with white
paint if the timing belt alignment mark (white paint) is not
clear,
Position the timing belt so the back surface arrow is facing
the engine front and align the alignment mark (white paint)
with cam pulley and the crank timing pulley alignment mark
when installing a new timing belt.
Check the ridges after the installation,
EN - 113
ON-VEHICLE PARTS
When free
Crank"i,ming
pulley",
plate
,[crank pulia
side.
I
TI";i"g I
ii
-I
I
I '
I
7- ,
.9rank pulley ._ ?Foove I
ON-VEHICLE PARTS
RB20E ENGINE
[Point 10] Install timing belt
tensioner pulley (follow point 7),
belt tensioner pulley in the cylinder block,
Insert hexagonal wrench into the belt tensioner hexagonal
hole and rotate clockwise to tighten the nut temporarily,
Align the timing belt alignment marks with each pulley marks
and install timing belt on to pulley,
Tighten the tensioner securing nuts to specified tightening
torque, Tightening torque (kg-m): 4,4 - 5.9
[Point 11] Crank timing pulley
r

, Alignment mark Key groove
Make sure to install the crank timing pulley in a correct way,
Some crank timing pulley has two key grooves and
alignment marks.
I ....J!\111i1W1L.
Loosen all rocker shaft tightening bolts.
Rotate the tensioner anticlockwise two to three times
using hexagonal wrench. (it is not necessary to rotate belts).
Fix the tensioner using hexagonal wrench and tighten the
nuts to specified tightening torque. (At this stage specific
tension will be applied to the belts automatically).
Replace timing belt if inspection indicates any problem.
. .. '
Item
.
Condition

Key groove
Cause
Tooth missing .

Camshaft lock
C racked tooth Crank sensor lock
Cracks on rear
Tensioner lock
Engine overheat
. ..
.
side

Interference with bett cover etc.
Wear and cracks

Belt misalignment
on the side

@fIl}
Worn teeth
j!. ill
- -
Oil or water

9.6 REMOVE & INSTALL OIL PAN, OIL STRAINER, OIL FILTER
Refer to RB20DE, DET section later on in the manual for detail.
EN - 114
ONNEHICLE PARTS
R820DE! DET ENGiNE
10-1 COLLECTOR ASSY
(1) Remove & install Collector ASSY
Collector bolt (2) trll
1.8 - 2.2 [POin!2l.i
Accelerator wire bracket [POint 2J
,
Air release plug [Point 4J
Collector bolt (2) ---..
1.8 - 2.2 [Point 3J trll
f.3 Collector gasket
i
." '
,<:r; '>-,) r
': 1",\\
\1 ~
~ '"
/.
!
\
Collector bolt (2)
1 B - 2.2 [Po,nt 3J
trllColiector bOlt(4) trllCOliector bolt (11
1.8 - 2.2 [Point 4) 1.8 - 2.2 [POint ,,]
:trll kg-m
i f.3 Rep!ace after every disassembly
Release fuel pressure in the fuel line [Point 1]
Acceleration control wire [Point 2]
Air duct (RB20DE). Air inlet pipe (RB20DET)
EGI harness connector. harness clamp
All hoses
After starting the engine remove the fuel pump fuse and
wait until the engine stops. Crank engine two or three times
to consume fuel remaining in the fuel pipes.
crank the engine four to five times to consume fuel
remaining in the fuel pipes.
Caution:
accelerator wire and pull outer case in direction of the
accelerator. Return the lock nut 1.0 to 1.5 turns from the
position the throttle drum starts moving (when there is no
play in cable) and tighten.
EN - 115
RB20DE! DET ENGINE
Position . No. required Bolt length beiowhead (min)
7.10 2 105
8 1 65
1.3.4.6. 4 40
2, 5, 9, 11 4 30
[Point 4] Air release plug
For more detail refer to cooling system later in the manual.
Caution:
Do not remove the air release plug when the engine is still
warm.
Make sure to remove air release plug when refilling the
cooling water to release air within the engine completely
(overheat prevention).
(2) Collector ASSY disassembly & assembly
AI Boit (2) 0.64 -
Accelerator wire bracket
ON-VEHICLE PARTS
Bolt (4) 0.9 - 11 AI
Nonseparable unit
valve:
regulator
""
Th,,''''o chamber gasket [POint 21 t3
Th",ttlo chamber
\
Water hose
AI kg-In
+) Hepiace after every disassemble

EN - 116
Tormtle chamber bolt (4)
- 2.2 [Point 1 J
RB20DE I DEi ENGINE
[Point 1] Remove & install throttle chamber bolts
Removal
Remove the bolts in the reverse order of the figure on right.
Installation
uniformly in two stages.
Tightening torque (kgm): First stage 0.9 -1.1
[POint 2] Throttle chamber gasket
Check the installation direction before installing the throttle
chamber gasket.
10-2 INTAKE MANIFOLD ASSY
(1) Remove & install intake manifold ASSY
ON-VEHICLE PARTS
!
0
)
!
o 0
I
Bottom
A Intake manifold bolt 18 - 2.2 [ P ~ A Intake <na/d nut 1.8 - 2.2 [Point 1J
~ i@4"_ Spring washer
;ntake manifold ASSY '. j l ~ Washer
,
"'''\
Akg-m
(1 Replace after every disassemble
Remove & install connector ASSY
ECCS harness connector. all hoses
EN - 117
i
I
I
RB20DE ! DE ENGINE
[Point 1] Remove & install intake manifold ASSY bolts and nuts
Removal
Remove the bolts and nuts in the reverse order of the figure
on right.
10
9
I
ON-VEHICLE PARTS
6 1
4
13 14
!
,
,
!
Installation
I nstall the bolts and nuts in the order shown in the figure on
right.
!
i
..l i
q:g:aj1{5
!
!
f
I
I
!
I
8 7 2 3 5 11 12 I
(2) Intake manifold ASSY disassembly & assembly
;:;1 injector [POlot 2] i---' Bolt (2) 0.64 - 0.58
... ",,) -----I\i' regula!",

80It(6) 1.6-2.1
0 ! Boit (2) 0.4 - i
J::i! lIqulO gasket

Remove & install intake manifold ASSY
Replace the O-ring to new ones when removing and
installing the pressure regulator and the fuel damper.
Caution:
Care must be taken not to scratch or damage the fuel tube
O-ring area when installing the pressure regulator.
[Point 2] O-ring (for fuel injector pressure regulator)
Never reuse O-rings.
Pressure
Coat the O-ring with engine oil (7.5W -30 or equivalent), but
do not apply solvent as this may remove the oil coating. . .
,"'i
Avoid using dirty O-rings and do not allow dirt, dust or ....,.
i O-ring
foreign objects to adhere to O-rings or other equipment. "
Care must be taken not to scratch, twist or stretch them I

tools or operator's fingernails when installing O-rings.

Do not decenter or rotate the fuel injectors and the pressure I_ .. .. ... ____
regulator when inserting them into the fuel tube.
EN - 118
RB200E ' O"T ENGINE
10-3 REMOVE & INSTALL EXHAUST MANIFOLD ASSY
Exhaust manifold gasket
tql <g-m
t:. Replace after every dIsassemble
Under cover
Disassemble exhaust front tube
Exhaust sensor connector
Gas leak inspection [Point 1]
RB20DET only
Inter cooler air inlet tube hose
Turbocharger
[Point 1] Gas leak inspection
After removing the exhaust manifold, make sure there are
no traces of gas leaks from any parts,
gas leaks,
[Point 2] Remove and install exhaust manifold nuts
Removal
the diagram on right.
Installation
The installation sequence is shown in the diagram on right.
EN - 119
ON-VEHICLE PARTS
RB20DE I DE, ENGINE
[Point 3] Yoke
Make sure not to make mistake between NO.3 and NO.4
yoke as configuration is different.
Item O(mm)
.. No.3 & No.4 port
.
22
:
[Point 4] Install washer
Make sure the washer is facing correct way when
installing.
10-4 REMOVE & INSTALL SPARK PLUG
~ kg-m
\
\
\
\
\
L..-
Ornament
Air duct (RB20DE), Air inlet pipe (RB20DET)
Blowby hose
Power transistor
[Point 1] Remove & install ignition coil bracket bolt
Length of the bracket bolt between RB20DE and RB20DET
are different.
RS20DET .
25
EN -120
ON-VEHICLE PARTS
rp107 C D.5
6
Marifold side
Ignition coil harness
. ~
R820DE I DET ENGINE
(Point 2] Install ignition coil bracket
The ignition coil bracket thickness differs between RB20DE
and RB20DET vehicles.
ON-VEHICLE PARTS
..
When installing ignition coil bracket to cylinder head, check .
that ground line is connected securely. QACyhnder side
Ignition cOil .'IfIIP "'0,.. ">:1
[Point 3] Spark plug maintenance
The Gap inspection and adjustment is not necessary as
platinum tip is used.
Change the spark plug every 100,000 km.
When using compressed air spark plug cleaner, clean the
plugs at maximum pressure of 6 kg/cm
2
for no more than
20 seconds.
Do not use wire brush to clean plugs.
105 REMOVE & INSTALL ROCKER COVER
!=itIer caD
O-nng
,//
Locker cover gasket
! IRI Kg-rn
Locker cover gasket
Air duct (RB20DE), Air inlet (RB20DET)
Blowby hose
[Point 1] Remove & install rocker cover screws
Removal
Perform removal in reverse order of sequence shown in the
figure on right.
Installation
Perform installation in sequence shown in the figure on
right.
EN - 121
bracket Holder
, ____ ____.. .. :
Platinum
Seating
7 3 1
:( : :
8 4
2
5
I

6
9
J
10
ON-VEHICLE PARTS
RB20DE i DET ENGINE
10-6 REMOVE & INSTALL TIMING BELT
Timing belt cover (upper) [Point 4]
I Timing belt [Point 9. 4D. 12]
toJ801!(2)16-2\Gr:ret '\ Nut44-S9[Pornt51toJ \
\ COrllcal Belt tensloner [POInt 9 11]
1 washer /
Crank angle sensor \ , \ [Point 6J I spring -, ':; 3
\ I 1.{/[POlnt71 7 )I - \Y
Q ' .

toJ Bot (3) I Bolt (4) .,-. Gromine \\I....) \l)) , Crank tIming Delt plate
0.4 - 0.5 065 - 0 86 I \' \ I [POint 81
'I' '\ Crank t1mlng pulley [Point 81
Washer . 1 ... -. '4 Washer \ Crank timing pulley plate (Point 8J
\ , __ \ Bolt 4 - 5 9 laler pulley [POint 11]
\ ,"'" --- , \
.'c'j, \ \ belt cover (lower) [Point 4J
\ Grommet
\ toJ! I Bolt (4) 065 - 084toJ
Bolt 145 _ 15,5 Crank puliey 1J toJ kgm
oi'

Under cover
Radiator. fan shroud
Cooling fan
Supplemental belts
Water pump pulley
Spark plug
No.1 cylinder compression TD.C position [Point 1]
Install ring gear stopper [Point 2J
Align the crank pulley timing mark and the belt cover
timing indicator (0 position), At this time, the No.1
cylinder is in the compression T.D.C position when the
camshaft is located as described in the following
situations.
No, 1 cylinder is at the compression top dead centre
when both the intake and the exhaust side cams do not
move the valve lifters,
EN - 122

\
L ... __ ... __ .. ___ .. __
RB20DE j DET ENGINE
Remove the locker cover oil filler cap from intake side
and check that the front end of the camshaft faces
intake side.
[Point 21 Install crank angle sensor
Apply chassis grease to the drive unit (spline) during
installation.
There is a flange inside the drive unit spline so the spline
has only one insertion position. Check the alignment
visually before assembly.
Check that the crank angle sensor can be easily inserted
in belt cover holes and sensor moves lightly to right and
left, then tighten the bolts.
When the sensor doesn't move lightly, loosen belt cover
bolts to position when the crank angle sensor was inserted.
Move the belt cover lightly hOrizontally and vertically to align
it so the belt cover holes and the camshaft centre are
aligned. Then tighten the bolts so the crank angle sensor
moves lightly.
[Point 31 Remove & install crank pulley and the bolt
Remove the starter motor and attach the ring gear
stopper.
Use a pulley puller (steering wheel puller) to remove crank
pulley (bolt size: M6 x 1.0 length below head approx.
50mm)
[Point 41 Remove & install timing belt cover
The timing belt cover is separated into upper and lower
parts. After crank angle sensor is removed, remove the
timing belt cover in the order of upper and then lower.
Installation is in reverse sequence of removal procedures.
Caution:
Care must be taken not to scratch or damage the dried
liquid packing when removing and installing the timing belt
cover.
EN - 123
ON-VEHICLE PARTS
'?,'; KV101 05610
RB20DE I DET ENGINE
Secure the tensioner with hexagonal wrench when
removing and installing the belttensioner.

Do not loosen inserted stud when disassembly,
Pay attention to the installation direction of the conical
washers, The washer should be set with face the
Assemble the tesioner spring to the belt tensioner pulley
as shown in the figure,
Hook the tensioner spring on the upper side of the tensioner
spring stud when the tensioner pulley is free.
I
Spring wire
Set angle Fll1Ie angle
I .. CIaIlSifk:ation
[
diameter . .
. .. '
. paint
I
1.8 Approx.20' Approx. 163' , Yellow
[Point 8] Install crank timing pulley & plate
Care must be taken of the rear and front positioning when
installing timing belt plate, the crank timing pulley and the
timing pulley plate,
EN124
ONVEHICLE PARTS
18- !
I 'Ef\-
, Nut Comea, Washer
washer
_ .. _._ .. __ .. __ --...J
Spring-stopper'
i When ", stud I
",set" '\
Q
.L...--
d" ' /
,
'"'
When Irei!-- .
tim in
I pulley p
Timing belt plate i
'Crank pulley
[side'"
"

r
Groove
L Crank timing pulley
.. __ .....J

ON-VEHICLE PARTS
JET ENGINE
[Point 9] Timing belt alignment mark verification and installation
Paint a mark on the belt that indicates rotation direction if
paint on the upper belt is unclear when disassembly.
Cam pulley (intake)
Position the alignment marks on the intake and the
exhaust cam pulleys with the respective belt cover
alignment marks. (No.1 cylinder is at TO.C)
I Cam
Position the alignment mark on the crank timing pulley with
the respective oil pump housing alignment marks. At this'
time the groove must be straight up (no. 1 cylinder is at
TO.C).
Move the belt tensioner clockwise 70 - 80 degree angle,
and secure it temporarily with the belt tensioner nut.
Install the belt by aligning the timing belt and the pulley lJ ..
marks. Align the number of ridges of exhaust cam pulley Crank timing fl/ i
alignment mark and the crank pulley (inner) alignment mark ..
as shown in the figure on right.
secure the tensioner with the hexagonal wrench so it will
not rotate together and tighten the nut.
Caution:
(1) Make sure the timing belt engages correctly with the
pulley and does not flat when assembling the
timing belt.
(2) Replace belts whenever possible when disassembly
is performed.
Remove the spark plug and align the timing belt alignment
mark and the pulley marks and install timing belt on to each
pulley.
Loosen the tensioner securing nut so the belt tension is
applied by the tensioner spring.
In this condition, rotate the crank pulley clockwise more
than two turns to check the belt movement and stop slowly
at No.1 cylinder compression TD.C point.
Insert the hexagonal wrench in hexagonal hole. Hold the
tensioner by hand so the tensioner does not move, and
tighten the tensioner securing nut to specified tightening
torque.
The initial tension on the bell in this condition should be
approximately 20 kg.
EN 125
ON-VEHICLE PARTS
RB20DE I DET ENGINE
[Point 11] Install idler & tensioner pulley
Do not loosen inserted studs when disassembly. If studs are loosened, coat inserted stud
with locktite solution (Japan Locktite KK) or equivalent
Replace timing belt if any problems are indicated at the inspection .
. :
. .
... Cause Item Condition .....
. . .
Tooth missing

Camshaft lock
! : L.;;::
,
Cracked tooth Crank sensor lock
i
Cracks on rear
I
Tensioner lock

Engine overheat
side
!
:.{..,-
Interference with belt cover etc.
I
!

Wear and cracks Belt misalignment
!
on the side
I,
I
8IJ;tI/1}
!
Worn teeth
- -
Oil or water

Calljion:
Do not twist or bend the timing belt. Make sure there is no oil film or water on the belt
106 REMOVE & INSTALL WATER PUMP
'tell kg-m
liquid gasket
Timing belt cover
EN -126
RB20DE I DET ENGINE
(Point 1] Remove & install water pump
Remove
Care must be taken not to get coolant on the timing belt.
Wipe it off immediately if any water does spill.
Remove the water pump bolts in the reverse order shown.
Installation
Install the blots in the numbered sequence shown.
Wipe off oil liquid gasket from the cylinder block and on the I
water pump and wipe the surface with white gasoline.
Apply continuous bead of liquid gasket (KP51 000150) to
water pump sealing surface.
Caution:
Be sure liquid gasket is 2.0 to 3.0 mm wide.
Installation must be carried out within 5 minutes after liquid
gasket application.
(Point 2] Water pump inspection
Rotate the water pump by hand and check for abnormal
sound and smooth operation.
10-7 REMOVE & INSTALL THERMOSTAT
Thermostat [Point 2]
housing [POint

- I

, ,/
Bolt (3) 1.6 - 2.1!Rl
E:I liquid gasket
!Rl kg-m
Disconnect and connect water inlet hose.
Caution:
Loosen engine drain plug to remove cooling water from
cylinder block.
EN -127
5
ON-VEHICLE PARTS
1 6 7 8 9
UqUld gasket 2.0 - 3.0 mm
wide along the groove
I
C;)
o 0
[Point 1]
Removal
RB20DE! DET ENGINE
Remove & install thermostat housing
Insert the screwdriver handle into thermostat housing and
move it up and down lightly to remove the housing.
Installation
Remove old liquid gasket on the thermostat housing and
the cylinder block and wipe off the surface with white
gasoline.
Cut nozzle end of liquid gasket (KP510 00150) tube.
ON-VEHICLE PARTS
2.0 - 3.0 rr:m wide to center of
I mating surface and inner seating
. surfaces of bolt holes.
o
Apply a continuous bead of liquid gasket to sealing surface
uSing the tube presser. Install the housing within 5 minutes
after coating liquid gasket. L .... ... .. ___ _____ ---C
[Point 2] Install thermostat Jiggle valve "I
'Top' mark (jiggle valve) must face up when thermostatis "
inserted in housing.
[Point 3] Thermostat inspection
Check the valve opening temperature and maximum valve
lift.
Hang the thermostat by string in valve and submerge in
heated water in double walled container and stir water while
heating it up.
The opening temperature is the temperature when the valve
opens and thermostat falls from string.
, ' , .
'StaJ1dard,coki climate
.
"
Valve opening tempefature (OC) 76.5
. ... Max., valve lift rnmt OC .
10190
EN - 128
... ..
I
, ,,,,,," i
walled .- . . ';''' 'LI '
: :: I
---"if:'J ,
.""

ONVEHICLE PARTS
R520DE I DET ENGINE
10-8 REMOVE & INSTALL OIL PAN, OIL STRAINER AND OIL FILTER
Front stabilizer
Radiator fan, shroud
Right & left engine gusset
Engine rear plate (lower) (AfT vehicles)
Engine oil
[Point 1]
Removal
Remove & install oil filter
Use oil filter wrench to remove the oil filter.
Installation
Before installing new oil filter. wipe off dust etc. from
cylinder block mounting surface. Apply a thin coat of
engine oil to oil filter a-ring.
Screw oil filter on bracket by hand until a slight resistance
is felt, then tighten an additional2f3 tum with oil filter wrench .....
After tightening, start engine and check for oil leaks.
[Point 2] Remove & install oil pan bolts
Remove
Remove the bolls in reverse sequence of figure on right.
Installation
Install the bolts in sequence shown in figure on right.
EN129
RB20DE I DET ENGINE
[Point 3] Remove & install oil pan
Removal
Use seal cutter to remove the oil pan.
Caution:
(1) After removing the oil pan, remove oil liquid gasket on
the oil pan flange groove and the oil block using the
scraper. Make sure to remove liquid gasket dropped
inside the oil pan.
(2) Care must be taken not to damage the oil pan.
ON-VEHICLE PARTS
Remove the engine mounting nuts (oil pan side) and use
the hoist crane to move the oil pan forward. Take off the oil
strainer bolts using the wrench before removing the oil pan.
Caution: r
Care must be taken not to pull the hoses and harnesses too .. ... ___ .. __ ..;
much when lifting up the engine using the hoist crane.
Installation
The following procedure must be carried out within 5 Tube presser (WS3993)i
minutes: .
Apply a continuous bead of liquid gasket(KP51 0 00150)
to sealing surface uSing a tube presser. . - . "",
Install the oil pan within 5 minutes after coating. i/ ,_-- ' .

[Point 4] OUleak and oil pressure inspection
Start the engine and check for any oil leak and the oil
pressure. To check the oil pressure release the oil
pressure switch and use the oil pressure gauge.
[Point 5] Install oil strainer
Check to make sure the O-ring is installed properly before
installing the oil strainer.
EN -130
ONVEHICLE PARTS
'i920DE- ENGINE
10-9 REMOVE & INSTALL INTERCOOLER (RB20DET)
"'" To ,ntake :namfold
1I'iI@ '<J1C>
'-, r \
CI
t Au' hose
amp
Clamp .
Air hose ---..u
Air tube " I'I"!!
" Nut (2).-..
1.3 - 1.6
I nter
bracket
fl:::l''--<_.''-' Nut 0.4 - 0.5
(2) 0.38 - 0.51
Bolt 0.4 - Air hose

Left front fender protector
Fender stay
Bonnet [Point 1]
Bolt 2) 13 -1.6
[Point 2J

._.J:P, Bolt (2) 1.3 - 1 ,,[Point

bracket
[Point 1] Remove & install bonnet
Remove left side bonnet bolts only (Lift up left side of the
bonnet to operate).
[Point 2] Remove & install intercooler
Remove the fender protector then remove cooler bolts to
remove inter-cooler. Take care not to damage the fins.
Caution:
The fins are aluminium and can be damaged easily. Never
place anything on the intercooler or allow tools or other hard
objects to contact the fins.
The main unit (tank, fins, tube) cannot be disassembled.
EN - 131
ON-VEHICLE PARTS
RS200ET ENGINE
1010 Remove & Install turbocharger ASSY (Include fault diagnosis)
(1) Removal & installation
Under cover
Assemble & disassemble exhaust front tube
0_ sensor connector
,
Intercooler air inlet tubes, hoses
Air inlet pipe
[Point 1] Remove water outlet tube
Remove the water outlet tube by first removing the clamp
located on the rear side of the cylinder block.
Inspection
After cleaning water inlet and outlet tube with radiator
cleaner, blow with compressed air and check for rust or
clogging.
EN -132
ON-VEHICLE PARTS
R820DET ENGINE
[Point 2) Remove oil feed tube J
Remove the oil feed tube by first removing the cylinder block r', -"-4 '
and turbocharger eyebolts, \ 1)1 /
!), /
\ -' '\ .. 0:1 feed tub
Inspection
After cleaning oil feed tube with engine conditioner, blow
with compressed air and check for clogging,
[Point 3) Remove oil return pipe
Remove the oil return pipe by first removing the oil pan
clamp and the turbocharger bolts.
[Point 4] Remove & install lock plate
Removal
Spread the lock plate pawls with a screwdriver and loosen
the nuts,
Installation
Position the lock plates and turbocharger mounting nuts.
After tightening the nuts, bend lock plate pawls onto the
nuts.
[Point 5] Eyebolt determination
Oil feed (cylinder block side and turbocharger side) eyebolts
are stamped "G".
Installation order
1. Turbocharger main unit
2, Water feed tube
3, Oil feed tube
4, Water outlet tube
5, Oil return pipe
EN .. 133
'"
ON-VEHICLE PARTS
RB20DET E:'-JGINc
(2) Turbocharger unit inspection
,,,,,e'dlV' [Point7J
ExceSSive pressure leak
Exhaust gas leaK Inspection location
Crack
Crack j
inspection
Compressor
[Point 5J
Cooling water Rotor shaft [Paint 6, 8J
(Point 8J
valve [Point 3]
Turbine wheel
.. ---- [POint 1, 2. 4J
Oil leak Inspection location I
[Point 1] Rotor shaft inspection I
There must be no heaviness or dragging and the shaft must i
tum smoothly when rotor shaft is tumed by finger.
[Point 2] Turbine wheel inspection
Oil must not adhere to surfaces.
There must be no carbon accumulation,
The vanes of the turbine rotor must not be bent.
There must be no interference with turbine housing.
[Point 3] Swing valve inspection
Remove actuator rod pin and make sure the swing valve
moves smoothly without deformation or cracks,
Make sure there are no misaligned seating surfaces in
turbine housing.
[Point 4} Rotor shaft play inspection
Position the dial gauge and measure play and thrust
clearance.
Rotor shaft play (mm):
Thrust clearance (mm):
0.084 - 0.107
0.045-0.140
EN -134
RB20DET ENGINE
[Point 5] Compressor wheel inspection
Oil must not adhere to suction inlet.
There must be no interference with compressor housing.
Wheel must not be bent, folded or otherwise damaged.
There must be no carbon sledge accumulation.
[Point 7] Swing valve controller inspection
Remove the swing valve controlier rubber hose on the
compressor housing side.
Check the swing valve controller whenever the actuator rod
is installed or removed.
.....
ON-VEHICLE PARTS
IZt 'J '. i
: ,'/, ( r'1'. \ !, I ,
!lJ' / ,( : \' t" I
fI' I j \ i '
'I ,i mr;\\ There must be

; ,I 1 no carbon
1": ' l '/t' sledge :
in j:\ {f,aCcumUlation'
,I' \' !!
\t'\ \ 1\:
'\\' "-.:Y /' , 7"
\ i\"I./ j ;
! J ,,\ ' ..... !
Operates smoothly
Use the air gun to blow compressed air approx. 0.8 - 0.9 ,
kg/cm
2
into hose and make sure the swing valve controlier ;
rod operates. Stop blowing air as soon as the rod r
operates.
Caution:
Make sure to verify the air gun pressure using the LPG
pressure gauge before testing the air hose. If air pressure is
applied excessively the diaphragm may be damaged.
[Point 8] Oil and cooling water inlet and outlet
cleaning
Use engine conditioner to clean the oil feed and return i _
passages. , / -;; 4?/?:tr'/ <:.'"
Use radiator cleaner to ciean cooling water feed and retum :e.WU.
passages. ! 'y_/ CJ-; .. --::)
I
" 011
1
\ Ciean with enWner
Clean using the air gun.
Clean the compressor wheel, turbine Wheel, compressor
housing and turbine housing with same methods.
EN - 135
L conditioner
ON-VEHICLE PARTS
RB20DET
(3) Turbocharger failure diagnosis (Oil leaks, smoke (white or blue smoke), lack
of power, poor acceleration, abnormal noise)
Points to be checked before diagnosis:
1. The engine oil level must be between the MIN and the MAX marks on the oil level gauge.
(When the engine oil level is higher than MAX line, the engine oil will flow into the intake
duct through the blowby gas recirculation pass and the turbocharger may be
determined to be malfunctioning).
2. Check with customer to determine if oil is cooled when idling after driving.
If any malfunction in the following chart is detected in a unit inspection, replace the
turbocharger ASSY
:-:' .....
. t POIIIIible assoeilltlHlpnenomenon,
Inapectiontocatlon .1 Inspection_it
, OiIlUk
Smoke
Abnormal
t.ack of ....
nollM
powerlPoor
. ,
. .
. ' .. I
ace.'enatlen
! Oil on rotors
f::"
{Q'l
f::" f::"
I
".
i
Carbon has accumulated
f::"
,g;;.
c:
I
Turbine rotor
Rotor the housing
f::" C
i

\J
. Turbime vanes are bent or folded
I

Suction inlet.s dirty with oil
0 0
Compressor wheel : Rotor scrapes against the hosing
f::" I

0
u
Turbine vanes are bent or folded

There is resistance or scraping
f::" f::"
0
I
, when rotated by finger
i
Turbine and compresor
I Rotation by finger is not possible
i
i
Rotor shet play inspection
i
Considerable shaking betvveen
f::" f::" 0
f::"
rotor shaft and turbo ASSY ,
I look through oil hole Carbon sllXige has accumuiated
f::"
I
f::" f::"
i (inspect interior with pen light) in waste oil hole
!
The valve does not move
i
I
valve operaUon
smoothly when pressure is
!
I
(use airgun or air pump)
appl.ed gradually, (usually opens

at pressure greater than 0.6 - 0.7
i kg/em')
I
i
Highly possible o Possible f::" Slightly possible
EN -136
ON-VEHICLE PARTS
CA18i ENGiNE
10,1 INTAKE MANIFOLD ASSY
(1) Remove & instal intake manifold ASSY
Throttle body bolt (4) 1.8 - 2.2 tql
"--?l .. -- Gasket.,

Water hose
RTC heater [Point 4] Breather hose
Throttle body ASSY ,.0;:;,
Intake manifold ASSY 3]
:c!lBolt (2) 0.43 - 053" ..J
Intake manifold nut
:c!l18 - 2,2 [Point 2J.... ii :_

tqllntake manifold bOld 1
18 - 22lPo:nt 2]/c6 !
H osa
tql kgm
Release fuel pressure in the fuel lines
Air cleaner ASSY
Fue[ hose
Water hose
Intake side high-tension cable
Vacuum hoses and ECCS harness connectors
Acceleration wire [Point 1]
Water temperature sensor connector
Thermal transmitter connector
[Point 1] Acceleration wire adjustment
accelerator wire and pull outer case in the direction of the
accelerator, Return the lock nut 1 ,0 - 1,5 turns from the
position the throttle drum starts moving (when there is no
play in cable) and tighten.
Tightening torque (kg-m): 0.8 - 1,0
[Point 2] Remove & install intake manifold
the figure on the right.
The installation sequence is shown in the figure.
Note:
Never reuse the gasket.
EN - 137
Intake manifold gasket"
ON-VEHICLE PARTS
ENGINE
[Point 3] Intake manifold inspection
St""ght gauge
\
Measure the intake manifold surface for distortions in four
separate directions (at opposite directions; horizontally and
vertically) in a number of locations.
Limit value (mm): 0.15
[Point 4] PTe heater inspection
Make sure there is no crack on the PTe heater.
(2) Disassemble & assemble throttle body ASSY
Fue! injector cover screw
(2) 0.20 -
U Fuel injector cover
. /

'-c:>
Fuel injector [Point 2J '---G
e. Oring --c:> if Bracket
Pressure regulater [Paint 4J I 'f_ .. (4) 0.64 -
"", e.O.ring . . .--'
."7 . Upperthrottlebooy
'7" ___ . [POint 1J r
cam
sprmg
P:essure sC;:w - - -!?- ;- /1 ! Cam spnng stopper
(2) 0.39 - 'If // i'I1?ln /I,washer
/ /
B k / / Seat
rae et e.lnsulator ./ Cam ASSY [Point 3J /
Thermo wax [POint 7] . I Screw 0.20 - 0.26
Throttle adjust screw'-. \'l' . /. Screw 020 -
--'u 'lJI' e.
Lower throttle body [Point 9J '-.. I Bracket screw
"p i/), 0-- 0.64 - 0.85
. ---Throttle wire bracket
Valve _ ""'-... Screw
Spring \ '\
. Washer \ \ . ,!, Spnng Spacer
FrCD solenoid \ \ i "1\"#'" ,/ Colour
1.2 - 1.6 [POiQI 8],,Jw?'" A> C\ I I @ / Soring retainer
\ , \ / / / / Return spring
. \ ' Valve \ ' Spacer CO .. r Spnng retainer
, t ' , , I \ Arm ASSY .fff{jJI ,..(
I I Spnng Spnng CiI0,
\ 1 Washer Screw __ " ____ __
I Idle revolution adJustmlnt .... " Return spring
solenoid 1 - 16 8J ,V Spring retainer
/ ;""-...-t.?!f /
Dash pot [POint 61 / I \ S. ..- (Ij
Fuel Injectcr harness Dash pot bracket / \ [POint 5
1
./ ;;1
Dash pot bracket screw \ IVT tid /mV/ \
\ 4 0 con ro ru / ;
(2,0.6 - Dash pot nut [P . t 5J S' / h '.
. 2 4 _ 3 3 n oln pnng was er \
. . .-. Nut 0.7 -
kg,rn
e. Replace after every disassembly
EN -138
Remove & install throttle body ASSY
First remove four throttle body bolts to remove throttle body
ASSY.
After the installation check the lightening torque.
Bolt tightening torque (kg-m): 1.8 - 2.2
Always replace gasket with new ones,
[Point 1] Remove upper throttle body
First remove the fuel injector cover then separate the fuel
injector connector.
Loosen four upper throttle body screws to remove.
[Point 2] Fuel injector
Removal
First remove the injector cover to remove upper O-ring,
then extract fuel injector.
Care must be taken not to scratch or damage the fuel
injector and throttle body seal surface.
Cautions when handling O-ring
Never reuse O-rings.
Coat the O-ring with engine oil (7.5 W - 30 or equivalent)
but do not apply solvent to them as this may remove the oil
coating.
Do not allow dirt, dust or foreign objects to adhere to
O-rings or other equipment surfaces,
Care must be taken not to scratch, twist or stretch O-rings
when installing. Do not insert it in the fuel tube by
making it stretch slightly.
Do not store O-rings in location subjectto ozone, high
temperature or in direct sunlight.
Installation
Replace both upper and lower O-rings to new ones.
Coat the lower O-ring with engine oil and install to throttle
body.
Place the fuel injector inside the throttle body and set the
injector position by placing the injector connector and the
injeclor cover,
Use oil seal drift to insert the fuel injector (resistance must
be felt).
Coat the upper O-ring with engine oil. Use oil seal drift to
insert the O-ring.
EN - 139
ON-VEHICLE PARTS
.... -... . !njecto;
'
Connector.
rubber .,--@ Injector wiring
ccnnector
''":J l=ue
1
1"'jector

I

!
__ ,, __ -"=" ___ ._ ... ..J
ON-VEHICLE PARTS
CA 181 ENGINE
[Point 3] Cam ASSY ,"'ottie DOdy--j
Removal
spring ,
Remove the cam ASSY from the upper throttle body. Cam spring
C t
' scepper
au Ion: , ". ,. Wa'\her
Extra care must be taken as there are tension on the cam I / . ;S:>'f!!i1" . \ !
spring, Ca';"SSv . J' i
Seat
. __ ... -1
Inspection
Look for any deformation or wear on the cam spring.
Cap spring free length (mm): 24.5 - 26.5
Installation
Make sure to install the cam ASSY and the cam spring in
right direction.
Replace the seat with new ones.
[Point 4]
Removal
Pressure regulator
Free iength I
Press...;re regu'ator
,
Remove the pressure regulator from the upper throttle body, :
Carry out the fuel pressure inspection.
[Point 5] Throttle drum & A I T control drum ..
: SSY Color :
Removal ; / /Spnng retainer,
First remove the nuts and remove the A I T control drum. / Fatum
Remove throttle adjust screw and return spring and remove Iy tJ'.. .. ,@ h, j
the throttle drum from the lower throttle body, 1/ "" "", lJ) I1J Cl1I. :
"I;
Spring
Inspection Return spnng / \
Inspect visually if there are any warn, cracks or deformation drum
on spring retainer. retainer, and colour, Also inspect i
rotation contact surface. Spring retainer ,
Check deformation and warn on the throttle adjustment (plastiC)
screw and return spring, W / Celor (Plastlc)'1
Return spring free length (mm): 19.5 - 21.5 L (/
Installation
Care must be taken to Install the parts in correct direction
when installing the arm ASSY, return spring, throttle drum
and AIT control drum.
EN - 140
ON-VEHICLE PARTS
CA 18i ENGINE
[Point 6] Remove dashpot I
First remove the dashpot bracket to remove the dashpot.
Inspection .
Check visually for any deformation or cracks on the rubber
part, !
[Point 7] Remove thermos wax
First remove the throttle wire bracket to remove thermo
wax,
Inspection
Check if the pin will extend when the thermo wax is
warmed,
Caution:
Do not pull out the pin,
; Rubbor
__ ... __ _
r-
Thermo wax
[Point 8] FICO solenoid & Idle revolution ...
solenoid Va've
I Spnng !
Removal
: washen,'
Remove FlOC solenoid and idle up solenoid from lower FICO ',! /
solenoid I I c?' /
tI1rottle body, I ..,.,.c:f'_ Valve
Caution: ; if:;! --- Spring
Watch out for spring and the valve as it may jump out. I r fl Washer
Idle revolution
Inspection I
Check that no warn orforeign matter adheres to valve head,
Check the spring for deformation or warn,
Spring free length (mm): 11 -12
Installation
Check the orientation ofthe valve when installing,
[Point 9] Lower throttle body inspection
Check for any clogging in the air passage by carrying out
air blow inspection,
Check for any cracks on lower throttle body,
EN .. 141
ON-VEHICLE PARTS
CA18i ENGINE
10-2 EXHAUST MANIFOLD ASSY
Exhaust manifold gasKet
O
Washer
". . ---LW.. ! , Exhaust manifold nut (6)
. 1.8 - 2.4 [POint 1J
rfJ;/

::::,"''. //'::,. '.
r \,

".
/ / . 0
0
sensor bracket
\ Washer
I I
0, sensor 4.1 - 5.1 [Point 3] /
Exhaust <'lanifold [Point 21
//'..,..
Heat shield plate
.
i 0 Replace after every disassembly
Under cover
Exhaust front tube nuts
02 sensor connector
Exhaust temperature sensor
Hot air duct
[Point 1]
Removal
Remove & install exhaust manifold
the figure.
Installation
The installation sequence is shown in the figure on right.
Check the standard tightening torque after installation.
[Point 2] Exhaust manifold inspection
Measure the exhaust manifold surface for distortions in four
separate directions (opposite directions: horizontally and
vertically) in a number of locations).
[Point 3] Remove & install O
2
sensor
(Zirconium type single pole connector)
Do not use tools with impact such as impact wrench for
removal and installation of the 0, sensor.
EN -142
..... ,
J
,)
Heat shreld plate boit
(5) 0.3 - 0.5
Straight
I
ON-VEHICLE PARTS
CA
1
81 ENGINE
103 LOCKER COVER
~
011 filter cap
Locker Gover screw
f ~ 8 ) 0.1 - 0.3 [Palnl ~ I
_Grommet
<9
I "----Tray
Locker cover
~ kg-m
\LOCker cover gasket
[Point 21
Additiona[ work required:
High-tension cable
Air cleaner ASSY
[Point 1]
Removal
Remove & install locker cover
Removal is the reverse order of installation sequence shown
Installation
The installation sequence is shown in the figure on right
When removing and installing the locker cover, also remove
the cover gasket and wipe off the oil adhere on the gasket
and in the groove.
[Point 2] Locker cover gasket
Make sure the rocker cover gasket is positioned securely
in groove without twisting.
EN - 143
2 4
CA1B; ENGINE
10-4 TIMING BELT (CRANK PULLEY, BELT COVER)
(1) Remove & install timing belt cover
Under CQver
Fan shroud
Supplement belts
Spark plug
No.1 cylinder compression T.O.C position [Point 1 J
[Point 1] No.1 cylinder compression D.T.C
inspection
Align the crank pulley mark and the belt cover timing
indicator to compression T.O.C.
No, 1 cylinder is at compression stroke top dead center
when both the intake and exhaust side cams do not move
the valve lifters.
EN -144
ON-VEHICLE PARTS
ON-VEHICLE PARTS
CA181 ENGINE
[Point 2] Remove & install crank pulley bolts ,--
Remove starter motor and attach ring gear stopper. I'
i/t
l-\ 1-:'
Caution: ,
Coat the screw part with engine oil when tightening the crank
pulley bolt
;, 1i
. / +;fKV16) 1095
- , 'I ,I
j
,., ! !i, I
\ _ ; I, l! j
I / ! i :
, .I J //! '
f I' '1/ .
Do not apply any oil on the damper area when installing or
removing the crank pulley.
I
I ' : I
"---_ I, I II !
[Point 3] Remove crank pulley
Loosen the crank pulley bolts and use pulley puller
(steering wheel puller ST2718 0001) to remove the crank
pulley.
Caution:
Do not hook the pulley puller on the crank pulley groove.
[Point 4] Remove & install belt cover
Do nol scratch packing when removing and installing the
belt cover.
Always tighten the belt cover bolt using the rubber washer. i
I
[Point 5] Install crank pulley plate
Make sure the crank pulley plate is positioned in correct
way.
(2) Remove & install timing belt
Timing belt alignment mark verification and installation
If paint on upper belt is unclear when disassembly is
performed, paint a mark on belt that indicates rotation
direction.
Position the alignment mark of the cam pulleys with
respective timing belt cover alignment marks.
(No.1 cylinder at TD.C)
Install the timing belt so the number of ridges from the
alignment mark to crank pulley (inner) alignment mark will
be as indicated below.
" No_ofrldges Total No. of

between two marks ridges ,
CA18i 43 95
EN -145

>P8ck,ng I
I' , I
""
(
- I
____. __ _____.... _ .. _______ J
Crank pulley Side
II
ON-VEHICLE PARTS
CA :8, ENGINE
Timing belt tension adjustment
Remove spark plug and tighten tensioner bolt (1 & 2)
temporarily.
Hook the lensioner spring (3) on the lower bolt (2).
Hook the spring on the hook (4) and tighten the bolt (1).
Loosen the tensioner (5) and tighten the bolt (2).
Ca[.Jtion:
Make sure the spring is positioned correctly at this stage.
Check if the tensioner (5) will rotate when pushed by finger.
Align the timing belt alignment mark and the pulley , , \\ I',,' _-I 1-
alignment mark to install the timing belt. ( .,I, (.:;
Loosen the tensioner bolt (2). ' (?\, )l ,tc- I !
Tum the cam pulley more than two tums clockwise to check I ((::'JI' 21L
belt and stop slowly at NO.1 cylinder I :'p"".A '.
C?mpresslon r.o. C pOint. ::.- \ \ @ I'
TI.ghten t.ensloner bolts (1 & 2). , ,\
Tightening torque (kg-m): 1.5 - 2.0 ..
(3) Timing belt inspection
Replace timing belt if inspection indicates any problem.
Item Condition Cause
'.
, "
Tooth miSSing

Camshaft lock
'"" '
,
I
Cracks on rear
:JiJ?
Tensioner lock
side
Engine overheat
I
Interference with belt cover etc,
Wear and cracks

Belt misalignment
on the side
,,11
Worn teeth
!f!J1!!J
- +-
Oil or water

Caution:
{1} Make sure the timing belt is not twisted or bent sharply.
Make sure there is no oil film or water on the belt.
(2) Timing belt need to be replaced every 100.000 km.
EN - 146
ON-VEHICLE PARTS
CA' 5' ENGINE
10-5 WATER PUMP
Water pump [Point 1, 2]
Spring washer \
Bolt (3) 1,6 - 2,0 \ . . . - ~ , , ~
i ~ ~ / ~ ' -
o kg.",
~ Replace after every disassembly
Fan shroud
Fan
Water pump pulley
Supplementary belts
liming belt cover
[Point 1] Remove water pump
Be careful not to get coolant on timing belt. If any water does spill, wipe if off immediately,
Caution:
Remove old gasket on the water pump surface using the scraper,
[Point 2] Water pump inspection
Rotate water pump by hand and check for any abnormal sound and smooth operation.
EN - 147
CA181 ENGINE
10-6 THERMOSTAT
Water outlet hose
[Point 1] Remove & install thermostat housing
Removal
Insert screwdriver handle into thermostat housing, Pry lightly
up and down and remove housing,
Installation
Place the jiggle valve on top when installing the thermostat
housing,
Caution:
Remove old gasket on the water outlet surface using the
scraper,
ONVEHICLE PARTS
[Point 2] Thermostat inspection
Check the valve opening temperature and maximum valve I I

Hang the thermostat by string in valve and submerge in , ". , ' i
heated water in double walled container and stir water while Double-walled .,:.,----= 1 ;
heating it up, container
The opening temperature is the temperature when the valve Thermostat ,; " '
opens and thermostat falls from string, '"
,
,
Standard climate Cold climate
ValW Opefflng
82 88
temperatwe,("C)
,Max. i/IlIliellfl
Over 8 195 Over 7 i 100
, /(mIflJ
6
C) ,' .. .
EN -148
ON-VEHICLE PARTS
10.7 OIL PAN & OIL FILTER
(1) Remove & install oil pan
Oil strainer nut
0.7 - 0,8 r a,l steaner II!:! t') Oil seal gasket
t') ali strainer @1'::, .. //.\.(rear)[Pomt4J
gasket 01 oan [Point 4111!:!
a \
ttll Oil strainer bolt i ", \ " L
(2) 1.2 -16 -_ tl \ \.1 \
Ii'!I I
t')0il seal gasket _-, i !.....- -,)
lI!:!(front)\oint4] . '\ __
_, \ '\ I

I,
/ c I \ Ii " &______.,
Drain plug 3,0 - 5.0 I Oil pan bOlt (10) 0,64 - 0.85 [Point 4]
Drain plug washer [Point4it')
kg-m
II!:! liquid gasket
Under cover
Engineoi[
Right & [eft engine gusset
[Point 1] Drain plug washer ['
The drain plug washer has installation direction, make sure
to install in the correct direction,
A[ways replace drain plug with new ones when removing
and installing.
[Point 2]
Removal
Remove & install oil pan bolt
Remove the bolts in reverse sequence shown in figure
on right.
Installation
[nstall bolts in sequence shown in the figure on right.
Tighten bolts to correct tightening torque,
[Point 3] Remove and install oil pan
Removal
Remove the oil pan using the seal cutter (KV101 11100).
Caution:
Remove old liquid gasket on the block pan flange groove
using a scraper.
EN - 149
Oil pan side
!
10 6
2
9 5
3
CA18i ENGINE
Installation
Apply sealing agent (SS60F or equivalent) on the areas
shown in the figure on right to install oil pan gasket.
Apply a continuous bead of liquid gasket (KP51 000150) I
to sealing surface using the tube presser and install the oil
pan within 5 minutes after coating.
Insert two center bolts to oil pan bolt holes, make sure it is
fitted correctly then tighten.
Caution:
Leave for 30 minutes after the installation.
[Point 41 Oil leak & oil pressure inspection
Warm up the engine and check for any oil leaking and the
oil pressure.
Release the oil pressure switch and install the oil pressure
gauge when carrying out the oil pressure inspection.
Engine. revolution (rpm) When idling 2000 4000
,
Exhaust output (kg I em Approx. 1 Approx.3 Approx. 4
(2) Remove & install oil filter
Removal
Use oil filter wrench to remove the oil filter.
Installation
Before installing the oil filter, wipe off dust, etc. from oil
cylinder block surface. Apply a thin coat of engine oil to
new oil filter O-ring.
Screw oil filter by hand until it hit the cylinder block, then
tighten an additional 2/3 turn with oil filter wrench. After
tightening, start the engine and check for oil leaks.
EN - 150
ON-VEHICLE PARTS
ON-VEHICLE PARTS
R525DE ENGINE
10-1 AIR DUCT & AIR CLEANER
kg-m
r::! liquid gasket
Replace after every disassembly
/ // '> -I
Removal I i
Remove the negative terminal from the battery. : .. -:?0-./20.(
Use an airgun to blow off any dirt or dust before removing __ _lfti
. -,. ""4,' -\ Air gUI' ,
the air hose and air duct. IV ; ,_ '
Remove the following: 't . -
2 vacuum hoses from the resonator (between intake --- :.
manifold and canister).
Blowby hose between locker cover and air duct.
Air hose between air duct and air regulator.
Remove airflow meter connector.
EN-151
RB25DE ENGiNE
Put alignment mark on each air hoses and the duct then
remove.
Remove 4 clips on air cleaner case (1 on upper case 3 on
lowercase).
Remove upper case to extract air cleaner element.
Remove the lower case by first removing 4 bolts.
Remove the resonator by first removing the left fender
protector then loosening the resonator boll.
Remove the air duct by first removing the front combination
lamp and the left head lamp ASSY
Care must be taken not to scratch or damage the airflow
meter sensor when removing the airflow meter.
Installation
Installation of the air duct and the air cleaner is carried out !
in reverse order of removal operation.
Air flow meter circuit case is nonseparable, use ASSY when
replacing the air flow meter.
Make sure to insert the air hose and the air duct securely
by aligning the alignment mark correctly and tighten the
band and the clamp.
EN - 152
ON-VEHICLE PARTS
R8250E ENGINE
10-2 INTAKE MANIFOLD COLLECTOR
(1) Remove & install intake manifold collector
Collector bolt
(2) 1.8 - Collector ASSY
boll (2) 1.8 - 2.2-.11.
kgm
Removal
Release the fuel pressure
Warm up the engine.
Select 'Fuel pump relay' in 'Active test' mode.
Select 'cancel' to release the fuel pressure.
Crank 2 - 3 times to consume the fuel left in the piping.
After starting the engine remove the fuel pump fuse.
After the engine stops. crank the engine over two or three
times to consume the fuel left in the pipe.
If the engine does not start, remove the pump fuse and
crank the engine three to four times to consume the fuel
left in the pipe.
Caution:
ON-VEHICLE PARTS
t;QII'ootl)r gasket 0
i
I !

ACTIVE TEST 0
FUEL PUMP RELAY OFF
CAS.RPM (POS) 950 rpm i
!
Fuel DUmp
The battery may become weak easily, use booster cables to
connect it to charged battery if necessary.
Remove the negative terminal from the battery.
Drain cooling water from the radiator drain plug.
Remove accelerator wire.
Remove the AAC valve connector, FICO connector and the
vehicle body ground cable.
Remove the hose A between the brake booster and the
collector.
Remove the hose B between IAA unit and the fuel damper.
Remove the hose C between canister and the collector.
Remove the hose 0 between canister and the throttle
chamber.
EN - 153
R825DE ENGINE
Remove blowby hose E between locker cover and the
collector.
Remove hose F between pressure regulator and the
collector.
Remove three water hoses G.
Remove the hose between air regulator and the collector.
Lift up the collector ASSY when removing the hose for
easier operation.
Remove fuel feed and retum hose H, then remove the clamp
from the collector.
Loosen the hose clamp to remove collector ASSY.
Loosen the bolts in order shown in the figure on right.
Check to see every hoses required are removed.
Installation
Install the collector gasket.
Make sure there is no dust, oil or other foreign matter is on
the sealing surface.
Install the collector ASSY.
Tighten the bolts in the order shown in the figure on right.
Tighten in gradual steps to uniform tightness.
!Installation location
Length (mm) : Tightaning torqu"
No. of bolts (kg-m)
7.10 105: 2 1.8 - 2.2
8 65: 1 1.8 - 2.2
1,3.4.6 40 : 4 1.8-2.2
2.5.9, 11 30 :4 1.8 - 2.2
ONVEHICLE PARTS
I
!
Connect each wiring and the piping in the reverse order of
the removal operation.
Connect the accelerator wire. 1-' -: :::. ;}%
Provide adequate slack for the accelerator and pull nut u,
outer case In the direction of the accelerator uSing the '. ::,-- "",
adjust nut. Retum lock nut 1.0 to 1.5 turns from the position:', , .""ft
the throttle drum starts moving (when there IS no play) and , "
tighten. Oute; \. c:y
- y -
Tightening torque (kg-m): 0.8 -1.0 -,. __ _
EN -154
ON-VEHICLE PARTS
Make sure the radiator drain plug is closed securely and
refill the cooling water from the feed opening. i OPENVVHEN" l"
Release the air using the air release plug after refilling thelIDT fe:ease
cooling water to prevent overheat. , . ,. . ",.
Caution: '''"' ,\ 1:"
Do not remove the air release plug when the engine is warm.
Do not over tighten the air release plug bolt.
(2) Disassemble & assemble intake manifold collector
(2) 064 - Al
Accelerator wire bracket Bolt (4) 09 -11

.....
0
COliector
"1 : Me valve
/1' 'il ' / 1M unit
,/ / 1 : "'-. Gasket (+ Throttle chamber
, ",,/. gasket
"/ fA Chamber(+
, All regulator Throttle chamber boll
J
hos
e
"
'''"
\

Water hose
(+ Replace after eveIY disassembly
Disassembly
Remove throttle chamber
Remove IAA unit
Assembly
Install throttle chamber gasket
Tighten the throttle chamber bolts in order shown in figure
on right uniformly in two stages,
Tightening torque (kgm): First stage 0.9 - 1.1
InstalilAA unit.
EN - 155
d
o 0
Install In dorrect direction
I
,
ON-VEHICLE PARTS
RB25DE ENGINE
10-3 FUEL INJECTOR

Removal
Remove collector ASS. For detailed removal process
refer to "Collector" section. 7"';. .. . ::."'i
Remove fuel injector connector and the lamp.
Remove the connector pin. . I
The operation can be carried out easily if the vehicle body .
ground wires. water temperature sensor connector and the .('1",* jl
thenmal transmItter connector are removed. Wi ...z.-.J . ... , i
Remove air regulator connector. I "--f1: /
Remove the fuel ASSY by first removing the bolts. ,._"
Replace o-ring with new ones when removing fuel injector,
pressure regulator and fuel bumper from the fuel tube.
Do not pull the connector parts when removing the fuel
injector.
Precautions when handling O-ring
Coat the O-ring with engine oil (7.5W 30 or equivalent) but
do not apply solvent as this may remove the oil coating.
Avoid using dirty O-rings and do not allow dirt, dust or
foreign objects to adhere to O-rings or other equipment
surfaces.
Care must be taken not to scratch, twist or stretch them by
tools or operator's fingernails when installing O-rings.
Inspection
Fuel injector resistance
Resistance value (Q): Approx. 13 - 14
Injector can not be disassembled.
EN - 156
RB25DE ENGINE
Installation
Do not rotate or decenter the parts when installing the fuel
injector, pressure regulator and fuel bumper to the fuel tube.
Tighten the pressure regulator and the fuel bumper screws
Install fuel tube ASSY
Connect the air regulator connector.
Install the fuel injector connector and fix it in place using the
clamp.
Install the collector ASSY
104 INTAKE MANIFOLD
!
ON-VEHICLE PARTS
4\
!
Bolt (6) 16 - 2 1
o o ~ lOJ
Intake manifold
I lOJ kg-m : ! tqJBoit (2) 0 4 - C 5
I C liquid gasket
Removal
Remove collector ASSY. For detailed removal process
refer to "Collector" section.
Remove fuel injector ASSY
Remove water hose.
Remove oil level gauge guide bolt
Remove rear water pipe connector bolt
EN - 157
RB25DE ENGINE
Remove intake manifold ASSY bolts and nuts (1,10,13) in
the orders shown in the figure on right.
Remove the intake manifold gasket.
Remove water pipe ASSY.
Installation
Remove old liquid gasket on the water pipe, in the groove
and on the intake manifold, Clean all contact surfaces with
white gasoline or equivalent.
Apply a continuous bead of liquid gasket (KP51 000150)
2,0 - 3.0 mm wide to sealing surface using the tube
pressor.
Caution
Installation should be performed within 5 minutes after
coating the liquid gasket.
Wait at least 30 minutes before refilling engine coolant.
Install the water pipe ASSY
Tightening torque (kg-m):
Install intake manifold gasket.
(A)O,4-0,5
(8) 1.6-2.1
Install the bolts and nuts (2,10, 13) uniformly in several
stages in the order shown in the figure on the right.
Tightening torque (kg-m): 1.8 - 2,2
Install the front oil level gauge guide bolt.
Install the rear water pipe connector bolt.
Install the water hose.
EN - 158
ONVEHICLE PARTS
I
5 6 9 14 11 2 1 .
I . \ I I I
I ' : I ,
. ", 'I I
) ~ W A A 1 1
1]4 I I I
7 8 1312 10 4 3
10 9 6 1 4 13 14
i I I I I
RB25DE ENGINE
105 EXHAUST MANIFOLD
i trlI kg-m
i 0 Replace after every disassembly
Removal
Remove the following:
Under cover
Exhaust front tube
02 sensor connector
Exhaust manifold cover
Remove the exhaust manifold nuts in the order shown in
Remove the exhaust manifold gasket.
Inspection
Look for any distortion on exhaust manifold.
Gas leak inspection
After removing exhaust manifold, make sure there are no
traces of gas leaks from any part of installation.
Installation
Install exhaust manifold gasket
Install exhaust manifold, washer and the yoke.
Make sure not to make mistake between No, 3 and NO.4
yoke as configurations are different.
Item
.
O(mm)
No.3 & No.4 port 22
i
Make sure the washer is facing the correct way when
installing.
EN - 159
ON-VEHICLE PARTS
. , - '': .'
...
Front
r
Manifold side
RB25DE ENGINE
Tighten exhaust manifold nuts in the order shown in the
figure on right
Install exhaust manifold cover.
After installation, crank engine and check for gas leak.
10-6 TIMING BELT
Timing belt cover (Upper)
ON-VEHICLE PARTS
Timing belt ,_ ': __
Grommet , - i 1
Bolt (2) 1.6 - 21\ ..... """ .
p - '. ( ! Belt tensioner "
GO-ring - -;,m-'(' C ' I ;,.. . / /' (,/:i,/- -- - ..
. Nut 44 - 5.9.-4 , . ,
Crank anllie \.. . .f . .... 'j' ;1 f. Onlca ;. enSloner Ii .' . ,'''<:;;C.'.'
sensor ''0' ".) . washer .,' sPrmg '/ ,,,,.',,(';- )
BOlt (3) 0.65 _ 0.86 Gramme . . ! \0. . Crank timing belt plate
0.4 - 0.5 ;;;;..; \ ' Crank timing pulley
Washer '. ( Washor Crank timing pulley plate
, (J)"'., .s)' \. Bolt 4.4 - 5.9 Idler pulley
.
0)'\ J " Timing belt cover (Lower)
Grommet
I """... i Bolt (4) 0.65 - 0.86 ., kgm
! .-. ",J Crank pullev ... Engine all
Bolt 14.5 - 15.5' U
_______________________________________ __ __
Removal
Remove under cover.
Drain cooling water from the radiator engine drain plug.
Remove supplementary belts.
Remove the radiator, the fan shroud and the cooling fan.
Check No.1 cylinder compression TD.C position.
Align the crank pulley timing mark and belt cover timing
mark indicator (0position). Atthis time the No.1 cylinder
is in the compression T.D.C position when the camshaft is
located as described as follow:
No.1 cylinder is at the compression stroke top dead center r----.-.. I
when both the No.1 intake and exhaust side cams do not . Intak!" camshaft Exhaust
move the valve lifters. ' All j'd.. i
ieTlXl>2
I I ' , 'r'/'
, ,\!" I
r 1i
\.
EN - 160
RB25DE ENGINE
Remove the oil filter cam from intake side rocker cover and
check that the front end of camshaft faces the intake side.
Remove crank angle sensor.
Remove starter motor then install ring gear stopper.
Remove crank pulley bolts.
Use pulley puller to remove the crank pulley (bolt size: M6 x
1.0 length below head approx. 50 mm)
Remove crank angle sensor bracket, then remove timing
belt cover. Timing belt cover is separated into upper and
lower sections, first remove the upper section then remove
lower section.
Caution:
Do not scratch dried liquid packing when removing and
installing the timing belt cover.
Remove belt tensioner.
Secure the tensioner finmly with a hexagonal wrench when
removing and installing bolt tensioner nuts.
Caution:
Do not loosen inserted stud at disassembly.
If paint on timing belt is unclear when disassembly is
performed, paint a mark on the belt that indicates rotation
direction.
Remove the timing belt
EN - 161
ON-VEHICLE PARTS
l
..... : IJ
.I."take side __ ..
KV101 05610
'. I
"T071" 0001
'; ,
, ,
Dned liqUid
packing
ON-VEHICLE PARTS
RB25DE ENGINE
Timing belt inspection
Replace timing belt if any problems are indicated at the inspection.
It is recommended to replace timing belt every 100,000 km .
..
Item Condition Cause
..
I

i
Tooth missing

. Camshaft lock
-J;;p
Tensioner lock
,
!
Cracks on rear
Engine overheat !
I
side
Interference with belt cover etc.
I
Wear and cracks

Belt misalignment
on the side
- ';/
/fIlJ I!l/}
i
Worn teeth
1 ''i //
; Sliding motion resistance in
j:' ,
i
-
l
Oil or water


Do not twist or bend the timing belt. Make sure there is no oil film or water on the belt.
Make sure there is no warn or cracks can be found on idler pulley, tensioner pulley, cam pulley
crank timing pulley and the tensioner spring. Also check if they rotates smoothly.
Installation
tensioner pulley as shown in the figure.
The tensioner spring must be assem bled together with the I
ic"TenSioner stud
When the tensioner pulley is free, hook the tensioner spring 1:- . V
on the upper side of the tensioner spring ( rT 7(" r--
[ . I

EN - 162
R525DE ENGINE
Care must be taken to install the conical washer in correct
direction.
Install the crank timing pulley and the plate.
Be careful to observe front and rear positioning oftiming
belt plate, crank timing pulley and crank timing pulley plate
when installation is performed.
Align the alignment marks of the exhaust and intake cam
pulleys with the respective belt cover alignment marks (No.
1 cylinder is at T.D.C).
Align the crank timing pulley alignment mark with the mark
on oil pump housing. The groove must be straight up (No.
1 cylinder compression T.O.C).
Move the belt tensioner clockwise at 70 - BoaC angle, and
secure it temporarily with belt tensioner nut. (This will
minimize the offset between the tensioner shaft and the
timing belt).
Align the timing belt pulley marks and install belt. Align the
number of ridges of exhaust cam pulley alignment mark
and crank pulley (inner) alignment mark as shown in the
figure on right.
secure tensionerwith hexagonal wrench so it does not
rotate together and tighten the nuts.
Caution:
At timing belt assembly, check that il engages correctly with
pulley and it does not float.
Timing belt tension adjustment
Remove the spark plug and align timing belt alignment
marks with pulley marks and install timing belt on to each
pulley.
Loosen the tensioner nut so belt tension is applied by
tensioner spring.
Turn crank pulley clockwise more than two tums to check
belt movement and stop slowly at No.1 cylinder
compression T.D.C.
Insert hexagonal wrench in hexagonal hole. Hold the
tensioner with your hand and tighten the tensioner
securing nut to specified tightening torque.
Tightening torque (kgm): 4.4 - 5.9
At this condition belt tension should be approximately 20
kg.
EN - 163
ON-VEHICLE PARTS
Nul Conical Washer
washer
Crank timing pulley Timing belt
plate 1 .' '1
I
.. .u. t j ~ ~ t
Crank 11
I pulley Side j :-;- '- ~ r o o v
Crank timIng pulley
Cam pulley
Bell tensioner
pulley
Crank timIng
I pulley
Install crank angle sensor bracket
Tightening torque (kg-m):
RB25DE ENGINE
2.1 - 2.7
Install timing belt cover in order of lower then upper.
Tightening torque (kg-m): (A) 1.6 - 2.1
(8) 0.65 - 0.86
Install crank angle sensor
(1) Apply chassis grease to drive unit spline.
(2) There is a flange inside the drive unit spline so spline
only has one insertion position. Check the alignment
before assembly.
(3) Check that the crank angle sensor can be inserted
easily in belt cover holes and sensor moves lightly to
right and left, then tighten bolts.
(4) If the sensor doesn not move lightly, loosen the belt cover
bolts with crank angle sensor inserted. Move belt cover
to align belt cover hole center and camshaft center.
Tighten bolts making sure the crank angle sensor
moves lightly.
Position the washer for the crank pulley bolts so the flat
surface contacts the crank pulley side and then assemble.
Apply engine oil to the threads of crank pulley bolts.
EN164
ONVEHICLE PARTS
Crank
angle
sensor
bracket
,
,
,j 2.1 - 2.7 (3) Ltll[
0 6 5 0 . 8 6 ~
t
Curved surface
10-7 OIL PAN
tcJkg-m
!OLiquld gasket
t:1 Replace after every disassembly
Removal
Drain engine oiL
Remove radiator fan.
Remove front stabilizer.
Remove engine right & left gusset.
RB25DE ENGINE
Remove oil pan bolts in order of sequence shown in the
figure on right.
Insert seal cutter between cylinder block and oil pan.
Remove oil pan by tapping the seal cutter with hammer.
If removing the oil pan from the vehicle, first remove front
ON-VEHICLE PARTS
Oil strainer bolt (2)
1.6-2.1
lift up the oil pan
From the gap between the cylinder block and the oil pan,
use a tool such as spanner to remove oil strainer bolt belt.
Pull the oil pan out.
Caution:
Care must be taken not to strain the hoses and the harness
too tightly when lifting up the engine using the hoist crane.
EN -165
ON-VEHICLE PARTS
RB25DE ENGINE
Installation
Use a scraper to remove aI/ traces of oil liquid gasket from
cylinder block and oil pan surface,
Caution: I ,
Remove all gasket material and other foreign material that I ""
falls into the oil pan.
Clean all contact surfaces with white gasoline or
equivalent.
'Scraper
Cut off nozzle tip of liquid gasket (KP51 000150) at point
shown in the figure on right and insert into tube presser.
1 ~ ~ 3 9 9 3
I ~ ~
Cut
~
Apply a continuous bead of liquid gasket (KP51 0 00150)
to inner sealing surfaces 4 mm wide.
Installation should be performed within 5 minutes,
Caution:
Be sure liquid gasket application is 4,0 mm wide.
Tube presser (WS3993)
Liquid gasket
(KP510 00150)
I
I
Wait at least 30 minutes before refilling engine oil and engine , ____________ ._.....J
coolant.
10-8 OIL SEAL
Valve oil seal
Remove the following parts:
Engine undercover
Cleaning fan
Timing belt cover, timing belt
Cam pulley
Back plate
Rocker cover
Ornament
Camshaft
Hydraulic valve lifter
Valve spring
Use oil seal puller to remove valve oil seal.
To prevent valve omission have the piston in compression
T.D,C position.
EN - 166
RB25DE ENGiNE
Valve oil seal installation measurement is as shown in the
figure on right.
Camshaft oil seal
Engine undercover
Cooling fan
Crank pulley
Timing belt
Crank angle sensor bracket
Cam pulley
Back plate
Remove No.1 camshaft then remove camshaft oil seal.
Apply engine oil to area around the oil seal lip.
Care must be taken not to scratch or damage oil seal
retainer. Use oil seal drift smaller than oil seal (41 mm)
and insert it at same level as front surface of oil seal
retainer.
Front oil seal
Engine undercover
Cooling fan
Crank pulley
Timing belt
Oil pan
Oil pump
Use a screwdriver to remove front oil seal from front cover.
Use oil seal drift and insert new front oil seal at same level
as front surface.
Face the oil seal mark outside (front side) when inserting.
Caution: ;
Do not touch the oil seal lip by finger as grease is applied to i
area around the oil seal lip.
Rear oil seal
Transmission (or A/T)
Flywheel (or drive plate)
Rearplate
Rear oil seal retainer
EN - 167
ON-VEHICLE PARTS
Valve oil seal
Intake exhaust
__ 1
RB25DE ENGINE
Apply engine oil or chassis grease to area around oil seal :
I
lip.
Care must be taken not to scratch or damage oil seal
retainer. Use oil seal drift (External diameter: (100 mm)
and insert it at same level as front surface of oil seal
retainer.
Cleaning
Use scraper to remove liquid gasket.
Caution: I'
Make sure to remove liquid gasket in the groove. ,
Clean the cylinder block side using same method and clean I'
the surface with while gasoline.
ON-VEHICLE PARTS

Rear oil seal installation .
Installation should be performed within 5 minutes.
Cut
I

I
Cut off nozzle tip of liquid gasket (KP51 000150) at point
shown in the figure on right and insert into tube presser.
Apply a continuous bead of liquid gasket (KP51 000150)
to rear oil seal retainer surfaces 2 - 3 mm wide.
r
- a continuous
bead of liquid gasket.
2-3mm'
Cal,ltion: . " 'l
Wait at least 30 minutes before refilling engine oil and engine 1'=""-=-=-=.=,,
start.
Install rear oil seal retainer by aligning to dowel pin.
Tighten 6 bolts uniformly.
EN - 168
ON-VEHICLE PARTS
RB25DE ENGINE
10-9 ROCKER COVER I IGNITION COIL
Ornament bolt (8) or.n. COii namess

- . Ground cable
, _,,---'If ..
, A Bolt1.3 - .. -
. Washer - ... ' Spark plug 2,0 - 3,0
A
Ign>lion coli bracket
Akg-m
Filler cap
Rocker cover gasket
Ornament !
i
:
Rocker cover gasket' -'-j'.-'
Removal
Remove Rocker cover ornament.
- Remove ignition coil hamess and remove ignition coil.
Loosen and remove the rocker bolts (intake and exhaust) in
the order shown in the figure on right.
Remove the rocker cover,
Installation
Install the rocker cover,
TIghten the rocker cover screw uniformly in the order shown
in the figure on right in several stages,
Install the ignition coil bracket.
Install the omament
EN - 169
Rocker cover bolt
rDA
-Grommet
3 7
9 5
7 3 5 9
[ : : : J
8 4 2 6 10
Bolt 0,3 - 0.39
Ignition coil
. ,: Cylinder
Ignition coil bracketW
Holder }fAIIt
Spark plug
ON-VEHICLE PARTS
RB25DE ENGiNE
1010 CYLINDER HEAD
(1) Cylinder head removal & installation
Cyhnder head bolt Cylinder head bolt
(1) Tighten:03kg-m.It!! 092-12
(2) Tighten to 10 kg-m
:'''''/(4) Tighten to 3 ..... 0.5 kg-m 0-----
Cylinder head bolt
0.92 - 1.2" It!!
','"
Spring washer i
(5\ Angle wrench 85" - 90 Washer

(3) Loosen bolts completely e Spring washer
; , Torque wrench 10 0.5 . Cylinder head ASSY
---..
Washer . Cylinder head bolt
. . 0.92 - 1.2 It!!
--
Washer- :
washer
It!! kg-m
Cam pulley
: t3 Replace after every
Removal
Remove cooling water completely from the radiator,
cylinder block drain plug.
Connector and intake manifold
Exhaust manifold
Timing belt
Rocker cover, ignition coil
Spark plug
Remove the cylinder head bolts in the sequence shown
in the figures on right.
Remove the cylinder head, then cylinder head gasket.
Check for any distortion on the cylinder head.
Check for any distortion on the cylinder block surface.
EN -170
4-17 M1x1.5 1- 3 M6x1.0
RB25DE ENGINE
Installation I ~ '
Before installing the cylinder head ASSY to cylinder block,
the crank pulley and the cam pulley must be positioned at
No.1 cylinder compression T.D.C position.
Align the crank pulley timing mark and the timing belt cover
timing indicator (0
0
position).
Align intake and the exhaust cam pulley alignment mark
to respective belt cover alignment marks.
Make sure it is positioned at No.1 compression TD.C
position.
Install cylinder head gasket
Install the bolts in sequence shown in the figure on right
The cylinder head bolls are torqued by two-step method.
lighten the bolts in two steps.
(2) Tightened to 10 kg-m.
(3) Loosen bolts completely 0 kg-m.
(4) Tighten to 3 - 3.5 kg-m.
(5) Turn bolts 80 - 90
0
clockwise when angle wrench is
used.
lighten bolts to 10 +1-5 kg-m when torque wrench is used.
Caution:
When angle wrench is not used, never attempt to
approximate the tightening angle visually.
Install ignition coil and the spark plug.
Install the timing belt.
Install the exhaust manifold.
Install collector and intake manifold.
Check the air flow of the hydraulic bulb lifter.
Push the hydraulic bulb lifter crest surface with finger and
check the slump.
Slump limit value (mm): 1.0
EN - 171
ON-VEHICLE PARTS
7
11
RB25DE ENGINE
There is a possibility of entrained air within the hydraulic
valve lifter ifthe slump is over 1.0 mm. Air need to be
released from hydraulic valve lifter.
Idle the engine for approximately 10 minutes at 4000 rpm
after installing the rocker cover.
Remove the rocker cover and push the hydraulic valve lifter
surface to check the slump of cam base circle.
Replace the hydraulic valve lifter if the value is over the
limit.
ON-VEHICLE ?';,,-:-S
(2) Cylinder head disassembly, assembly & inspection
Valve sprint rera!ner
/ 'falve spring
Valve /' seat
I / Valve oil sea!
Valve collet .....-- / / Valve guide
'"' 0' <"- / , __ Valve seat
Nut 0.92 -1.2
S
h \. Intake air valve
pnng was t?.1'\.. ____ Exhaust aif' valve
Washer----: ! 0
Buffla plata <SfV >0r1iiW
LCJ BOlt092-1.2----ff t (J';':CU
"i"
Washer I
V I I

Cam shaft
Cam shaft (Intake S-l:
Cam shaft (exhaust Side)
"" 'ii'- 80lt LCJ
0.92-1.2
. i
LCJ Bolt (1
1.6 - 2.2
?
Timing belt cover 1: ; l ""
back plate \ "" I L "'--J
LCJ Bolt (3) 0.64 -
Crank angie sensor
LCJ Bolt (2\'-<'lY
2.1-2.7
tcJ kg-m
Liquid gasket
Il Eng;ne oil
Cam snaft fronl oil sealOIl i ? 0.92 -1.2 LCJ
lit Cam pulley I t-___
e?: "-....: Cam pulley washer Bolt 0.92 - 1.2 LCJ
1 "cam pulley 00111.4 - 1.9LCJ
Bolt 2.1 - 27 LCJ
i G Replace after every disassembly
Disassembly
Use the proper tool to secure the hexagonal part in front of
camshaft to remove cam pulley.
Remove timing belt cover back plate.
Position the cam shaft knock-pin to the position shown in
EN - 172
RB25DE ENGII\IE
Remove cam bracket bolts by loosening them gradually in
several stages. in reverse sequence shown in the figure
on right.
Caution:
Before removing camshaft bracket, paint marks to indicate
bracket position and direction.
Remove the cam bracket.
Intake and exhaust camshaft can be identified by
identification paint color and presence of a spline gear for
driving the crank angle sensor.
Camshaft . Identification paint Spline gear
Intake camshaft Purple No
Exhaust camshaft Orange Yes
Remove hydraulic valve lifter.
(1) Hydraulic valve lifter is nonseparable.
(2) Do not store hydraulic valve lifter up side down or on
its side.
(3) Store hydraulic valve lifter in the engine oil when
storing temporarily.
Use valve spring compressor (KV101 08950) to remove
valve springs.
Cylinder head inspection
Use scraper to remove any traces of oil, water scale,
gasket, sealing agent, carbon etc. from cylinder head
surfaces.
Measure lower surface of cylinder head in six directions to
check for distortion.
Limit (mm): 0.2
When distortion is just over the limit. resurface the cylinder
head.
If distortion exceeds the limit, replace cylinder head.
Camshaft visual inspection
Visually inspect camshaft for any warn or damage.
EN - 173
ON-VEHICLE PARTS
I 1
; ntificatton paInt (purplel
tificatiOfi paint (oran
b
II

\ , I
I
I .
. Spline gear for driving crank angle senso1
OK
NG
, ':'==,,==:'J gauge
r \ ..... <"'.
RB25DE ENGINE
Camshaft run-out
Use V-block on fixed surface and support both camshaft
end journals (No.1 & No.7).
Avoid the oil groove in the center of the No.4 journal and
position the dial gauge vertically.
Rotate the cam shaft by hand to one direction and read
the movement width on dial gauge.
The run-out is equal to half of the movement width
indicated on dial gauge.
Standard value (mm): 0.05
Cam nose diameter inspection
Use micrometer to measure diameter of cam nose.
Intake standard value (mm): 39.705 - 39.895 !
Exhaust standard value (mm): 39.205 - 39.395 I
Replace camshaft if diameter value differs.
Camshaft oil clearance
Tighten the cam bracket to specified torque.
Use inside micrometer to measure inside diameter.
Use micrometer to measure outside diameter of camshaft
joumal.
Inspect that the camshaft oil clearance measurement is
within specified value.
Oil clearance = cam bracket inside diameter-
camshaft journal (outside diameter)
Camshaft end play
Assemble camshaft and tighten cam bracket to standard
value.
Set a dial gauge at front end of the camshaft in thrust
direction. When camshaft moves in front and rear
direction, read the dual gauge run-out width.
EN -174
ON-VEHICLE PARTS
gauge
"
I Ii
Q9
Micrometer
RB25DE ENGINE
Valve guide clearance inspection
Protrude valve approximately 15 mm from valve guide home
into combustion chamber. Measure valve deflection by
swinging into direction parallel to dial gauge.
The clearance is equal to half of the dial gauge reading
(deflection width).
Valve guide clearance (mm) Intake: 0.1
Exhaust: 0.1
Replace valve or valve guide if clearance exceeds limit.
Valve guide replacement
Use valve guide remover and tap it from combustion
chamber side to remove seal.
Rectify cylinder head valve guide hole using valve guide
reamer.
Rectified valve standard value (mm)
Intake & exhaust: 6.000 - 6.018
Heat cylinder heat in an oil bath to approximately 150 -
160"C. Use a valve guide drift and press valve guide from
camshaft side.
The press-fit dimensions are shown in figure on right.
Ream the inside of the inserted valve guide with valve guide
reamer.
Finished internal diameter standard value (mm)
Intake & exhaust: 10.175 -10.196
Valve seat inspection
Check contact surfaces of the valve seat and the valve.
Replace valve or valve seat if contacting surface is too
large or improper.
EN -175
ON-VEHICLE PARTS
r
C"',,shaft g'del
. Valve guide '\}
. ,
i T - - ~ - ---- :
! 16.9+/-0.1 I '
Intake I Exhaust
; ; : = = = = ~
RB25DE ENGINE
Valve seat replacement
o Cut and grind valve seat to remove the valve seat.
o Readjust the mounting hole for over size valve seat.
Standard value (mm):
Intake
Exhaust
36.5 +0.016-0
32.0 +0.016-0
o Readjust the valve guide centre and concentric circle.
Heat up the cylinder head in an oil bath to approximately
110 -130
o
e.
Use valve seat drift to tap it until it strike the bottom.
o When not using valve seat drift:
Use dry ice to cool valve seat for approximately 5 minutes.
Heat up the cylinder head to approximately 80 ce.
Insert cooled valve seat into cylinder head quickly.
Caution:
Do not directly touch cooled valve seat with hands.
Valve seat shape and measurement is as shown in the
figures on right.
ONVEHICLE PARTS
... .. .. -
I
i 'J ! U
. I. .+1 __ .
! I I
. .
i Valve seat
.!..D,
.pD
-. -'-'"
. . '
' ..
Cylinder head
.
.'. . .. .' .... "
1tam .vat.e_t meas....,. ..... !mt
.
" ... , ....

.
..
.' . '.' .........
.v. a_Size 'd ' 0, ' 0, ' 0, ' 0,
Slandan:!
36.0
+0 11:1
32.0
-0
37.0 ..
36.0.;)097 33.8.02
Intake
......... .

+{j'13
32.0 37.0
.'
36.5
N
$7
L .Standard
31.5
+C.COO
29.1:;;'2 31.5 -c,o'8o
. .
Exhausf ..

.
. .
EN -176
R825DE ENGINE
Valve inspection
Outside diameter measurement
Use micrometer to measure each dimension.
Valve a
1
. b
.C d
IIrtake 85.3 - 85.5; 80.78 - 81.08 34.00 - 34.02 5.965 - 5.980
Exhau. 87.3 - 87.5182.78 - 83.08 29.00 - 29.07 5.960 - 5.945
Valve spring squareness inspection
Place a right-angle straight edge (L-square) so it contacts
the spring, Tum the spring and measure the maximum
clearance between upper spring surface and the right
angle surface to determine out-of-square distance,
Limit (mm): 1.8
ON-VEHICLE PARTS
(mm)
e f
1.15-1.45 2.60 - 2.90 30
1.35 - 1.65 I 3.2 - 3.4 15
Replace the valve spring if the out-of-square distance is
over the limit. L __ _____ _
Free length and pressure load inspection
Use a valve spring tester to check the spring pressure.
Free length (mm); 43.1
Installation load (kg): 24.0
Hydraulic valve lifter visual inspection
Visually inspect camshaft rotational area on lifter side and
lifter bore rotational area for any warn or damage.
Replace ifthere are any abnormality,
Caution:
Do not disassemble hydraulic valve lifter, It is nonseparable i
unit.
Hydraulic valve lifter outside diameter
Use a micrometer to check the valve lifter outside
diameter.
EN - 177
\
Micrometer
\
ON-VEHICLE PARTS
RB25DE ENGINE
Hydraulic valve lifter hole internal diameter
Hydraulic valve adjuster clearance
Hydraulic valve clearance =
Hydraulic valve clearance hole internal diameter - hydraulic valve exterior diameter
Installation
Install valve associated parts.
For detailed information on how to install new valve oil seal
refer to section on "Oil seal replacement".
Install valve spring with narrow pitch end towards cylinder
head (identification color side down).
Install spring retainer.
Use valve spring compressor to install valve collet.
Apply a small coating of petroleum jelly to the internal
surface of collet.
Use a magnetic screwdriver.
(1) Upper collet installation
Attach collet to lower side of magnetic screwdriver blade
and instali in the valve stem.
(2) Lower collet installation
Attach collet to upper side of magnetic screwdriver blade
and install in the valve stem.
After valve collet installation lightly tap the stem edge with I
a plastic hammer to confirm installation,
Install hydraulic valve lifter.
Tap in camshaft knock pin.
Knock pin protrusion distance (mm): 5
Camshaft installation
Front ...
Knock pin
Turn camshaft so No.1 cylinder is at compression TD.C 'I' Knock pin
position (or turn camshaft 60" before or after No.1 cylinder _
TO.C). I
15'
Temporarily tighten No.1 cam bracket and make sure the
thrust section is positioned securely,
, '
0 0 camshaftl
I (intake) (Exhaust) I

EN - 178
RB25DE ENGINE
Tighten cam bracket bolts 540"(1.5 turns) gradually in
several stages in the sequence shown in the figure on
right.
Tightening torque (kg-m): 0.92 -1.2
ON-VEHICLE PARTS
Install camshaft front oil seal. For detail information refer to
"Oil seal" section. . i I
-"c--"""'<-""--;/- ... _1 [
I
Install timing belt back plate.
I
Bolt (2) 16 - 221PJ
I Retainer
'Grommet '
I . . ' l./
i .:. I I 'I, _,c' ;
.-
J;. : / Timing belt coverl
. back plate
\ ' Grommet
\ Retamer '
Bolt (2) 0.64 - 0851PJ !
Align cam pulley to camshaft knock pin to install.
EN -179
RB26DETT ENGINE
11 REMOVE & INSTALL ENGINE
REMOVE & INSTALL ENGINE
After starting engine, remove the fuel pump fuse and run ,
engine until it stops. Consume fuel left in fuel lines by I -- pu.mp fU'S1
cranking the engine two to three times. rl:"" T'nrIDrnf[[f
When it is not possible to start the engine, remove the fuel pis 1'Jli-, . _ y,1
pump fuse and consume fuel left in fuel lines by cranking .
engine four to five times. liliiin< f" -, I
Caution: \ - I
The battery may become weak easily, connect booster C---".:-,.
cables to charged battery,
for the
accelerator wire. Pull outer case in the direction of the 'tk,
accelerator pedal until throttle drum starts to move (no play". Y :.i!
i -"'/
in cable). Rotate the lock nut 1 to 1.5 turns to tighten. wire 'f\\
Tightening torque (kg-m): 0.8 - 1.0'' /' .
[Point 3] Engine main harness, ground line
separation
Disconnect the connectors behind the battery for
alternator, starter motor and transmission systems.
[Point 4] Air compressor and power steering oil
' ..
pump movement I
Remove bolts securing each unit to brackets. Leave pipes .
connected and secure to side of the body with string. Care
must be taken not to scratch the body.
i-'{,.:;.,:- -""" Bolt 16 - i
,-'
, ,\2.-/ ___---'\- "
[Point 5] Power steering oil tube bracket separation !ttll-;-''-'!;' _ 4 ";\,
Remove bolts and separate the power steering oil tube : .. olt 1,,::::" .. \ , \ 'r
bracket, and move towards the body side. ! From
elf: ;\ tube bra<*ett
f_' _ ... _ oelow \\ \1
[Point 6] Front engine mounting nuts removal
Make sure the engine slings are securely hooked by
engine hoist chain and remove front engine mounting nuts.
EN - 180
RB26:lETT ENGINE
[Point 7] Right front engine mounting bracket
removal
Power steering oil tube will hit the right front engine
mounting and it is not possible to shift the engine forward.
Therefore remove nuts and remove right engine mounting
bracket
[Point 8] Remove & install engine ASSY
Operate the hoist chain, and change the engine angle
gradually to remove the engine. Care must be taken not to
interfere with vehicle body.
EN - 181
RB20E iDE! DET ! CA 181 ENGINE
After starting engine, remove the fuel pump fuse and run
engine until it stops. Consume fuel left in fuel lines by
cranking the engine two to three times.
When it is not possible to start the engine, remove the fuel
pump fuse and consume fuel left in fuel lines by cranking
engine four to five times.
Caution:
The battery may become weak easily, connect booster
cables to charged battery.
Transmission jack set (CA18i only)
Place the transmission jack under the transmission.
Loosen lock nut and provide adequate slack for the
accelerator wire. Pull outer case in direction of the
accelerator pedal until throttle drum starts to move (no play
in cable). Rotate the lock nut 1 to 1.5 turns to tighten.
(Point 3] Engine main harness, ground line
separation
Disconnect the connectors behind the battery for
alternator, starter motor and transmission systems.
[Point 4] Air compressor and power steering oil
pump movement
Remove bolts securing each unit to brackets. Leave pipes
connected and secure to side of the body with string. Care
must be taken not to scratch the body.
[POint 5] Remove & Install propella shaft
Place a cap on the transmission rear seal so the oil will not
leak when the propella shaft is removed.
EN - 182
R520DE' DET i DETT ENGINE
[Point 6] Remove & install rear engine mounting
Support the transmission with transmission jack and
remove rear member bolts and rear engine mounting bolts
and nuts.
[Point 7] Front engine mounting nuts removal
Make sure the engine slings are securely hooked by
engine hoist chain and remove front engine mounting nuts.
Engine mounting nut tightening torque (kg-m): 4.4 - 5.6
[Point 8] Remove & install engine ASSY
Operate the hoist chain, and change the engine angle
gradually to remove the engine. Care must be taken not to
interfere with vehicle body.
EN - 183
RB25DE ENGINE
Standard points
REMOVE & INSTAll ENGINE
This section describes how to use hoist crane and transmission jack to remove and install
the RB25DE engine.
Drain cooling water completely.
Remove bonnet.
Engine bay left side:
Exhaust gas sensor harness disconnection
Ground line connector separation
Air duct. Air cleaner
Power steering oil pump removal
Air compressor removal
Engine bay right side:
Battery (fl\,
Release fuel pressure by selecting "fuel pump relay" 'J!J
in active test mode, and press STOP.
After staring the engine, remove fuel pump fuse and run
engine until it slops. Consume fuel left in fuel line by fiS\
cranking the engine over two to three times. 'aJ
Caution:
The battery may become weak easily, connect booster
cables to charged battery.
Accelerator wire separation
Heater hose
Vacuum hoses separation
Engine main harness & ground line separation
Engine bay front side:
Radiator shroud, radiator
Cooling fan
Engine bay upper side:
ECCS harness connectors
EN184
ACTIVE TEST
FUEL PUMP RELAY OFF
CAS RPM (PaS) 950 rpm
~ 5 5 J : : : EI\JGIr-.;E
Vehicle body. lower side:
Engine undercover
Propella shaft
Transmission control lever (MfT vehicle),
linkage (AiT vehicle)
Exhaust front tube
Rear engine mounted bracket
Right and left engine mounted bracket.
Remove & install engine ASSY
Operate hoist chain and change engine angle gradually,
Care must be taken not to interfere with vehicle and
remove the engine.
EN - 185
ENGINE OVERHAUL
RB26DETT ENGiNE
12 ENGINE OVERHAUL
This section describes the component disassembly of the engine assembly removed from
the vehicle without transmission, It also explains the inspection, replacement of
malfunctioning, damages or warn parts and carry out any necessary adjustments and
sequential assembly in order to produce a standard engine condition,
OVERHAUL CAUTIONS
(1) Disassembly
o Use correct and suitable tools when possible and make sure to carry out safe
procedures,
o Care must be taken with operations on mating surfaces and Sliding surfaces to
prevent loss of surface accuracy,
o Arrange disassembled pars by making marks to organize for easy faults detection
and precise assembly.
o Loosen nuts and bolts in a diagonal direction from outside, Care must be taken to
follow the numerical order when indicated,
(2) Inspection, repair and replacement
o Replace or repair after completing parts inspection following the inspection
procedures. Perform same inspection for the new parts and replace parts as
necessary.
(3) Assembly
o Always use a torque wrench to tighten nuts and bolts to specific tightening torque,
o Tighten nuts and bolts from centre to outside diagonal direction, gradually in two or
three successive stages. Follow the numeric order when indicated,
o Replace gasket, packing, oil seals and O-rings with new ones in principle.
Clean each part thoroughly and blown off with compressed air. In particular, check
that oil and water passages are not clogged or obstructed,
Care must be taken not to scratch or damage sliding or mating surfaces, Clean off all
dust. debris or foreign objects. Lubricate all sliding surface with an adequate
coating oiL
EN - 186
ENGINE OVERHAUL
RB26DEr :eNGINE
121 DISASSEMBLE & ASSEMBLE CYLINDER BLOCK ASSY
Detonation sensor boll (2) 1.6 - 2.1Lt!l
". Detonation sensor Rear all seal [Point 71
Alternator 8diusltment bar """ !liI'_ ----. 0
Water pump. bolt tlwater pump , . ..oJ>
Oilpumobolt ;" tI ,-
092-12 _ '.0.64-0,85
Lt!l \ gasket - A, Rear ali seal retainer [Point 6]
\ E ' block [Point 30. 31. 32. 33]
,f ,',",!J yebol! .. ---..
)
' :J-1 '::-4.1 [POInt 1 ra Oil jet [Point ,11]
" ""j::2;;'S '; olt i313'\i -5..:1.. "'i::I buSh [Point
23
1
.. .... I rower steenng ;, - !Cl "" I
ILl W, I 011 pump bracke III V C) ..........1
011 sea, )'A' d" I Ii?/ Flywheel bolt (6)
;r con Itlone / . I r. r. [P .
. 'CO<'1"reSSQr Bolt 14) 3.8,5.1' ,14.5 - 10/ Oint 4]
Oil pump e "'/ n....J /
bracket MaIO bearing" .. ___ "
Piston 00
p
o
lnt
22. 21lo,31] r _
[Point 9.16.
1
7. 19.
P' " [Pomt12.21) ;
17, Il,., Crankshaft [POint 27 .
..- "Snap ring [POint 13]0 '"
Can rod &\ T Con rod bolt (2) [Point 20] > \ Flywheel [Point 3. 5J
[Point 8. 9.18.19: -- __ \,
Con'rod Malo beaflng cap [Point 25] . Rear plate Main bearing
[Point 10.18. 28. ......... >-5.3 [POint 24]
C
.. _11\ 1 Baffle plate I Spacer 1,......--, /' Spacer M 1'n'I0li pan nut
on roc cap __ . .'$'-.. e
Con'rod ,nut ,Lt!l __ .1 _ _. ! I plate 3.2 - 4.3
{1)1.S+!-O"1 __ , .... __ J
(
2) 60'+5 [Point 10].---"""'" O/,n
g
_ _ .. L
Oil
Bolt (2) 1.6 - 2.1 i\
Bolt (12) '8 ___
I Oil pan
kg-m
tcJ0li strainer bolt -'.'1' (M10) 3.2-4.3
0.64 - 0.85 tcJ Oil pan bolt (M6)/ 0 MOil pan
tI Liquid gasket
Engine all
0.64 - 0.85 Copper washe,&--nrain plug 3.0
Drain and refill cooling water [Point 1]
Remove and install the following parts:
Engine
Collector Starter motor
Throttle chamber Clutch cover, clutch disc
Intake manifold Oil pan, oil strainer
Turbocharger, exhaust manifold Water pump
Timing belt Oil pump
Cylinder head ASSY Oil cooler, oil strainer
Alternator All harnesses and connectors
EN -187
RB260ETT ENGINE
Reference: Engine selection assembly
Piston
(1) Piston selection
I
. Grade No: ..........
1
. . '.'
.2
I
. .
CylindM blOckbo ....
....
Less than 86.010
i
Less t1lan 86.020 I
diameter (min)
".
Greater than 86.00 Greater than 86.01 0
. . ."
Less than 85.965 Less than 85.975 I
Frsto"
I .
Greater than 85.955 Greater than 85.965
PiSton c!ear$nC. (mml . 0.035 - 0.055
ENGINE OVERHAUL

.
3 .
Less than 86 030
Greater tran 86.020
Less than 85.985
Greater than 85.975
Service setting parts; Piston and piston pin sro 1, sro 2. sro 3, 0.50S. 1.00S
Piston grade
(No. t - No.
Front mark
Piston pin grade (0.1)
Main bearing
(2) Main bearing selection
.
. bearing t:lu$ing .
Inner diameter
Distinction
symbol
Cnlnk '. .Grade . . .
... jQumat. Mk
dlamater$l.amp . . .. ' ..
LIlS$ Ih/m. . gTat;Ie No ..
54.957:.
3
6eaql!lickness
Greater than 0,1__..
54.951' . .' ldanlilicatlortCOlOl'
less than 58.651
Greater than
58.645
0.
STO 0
1.818 -1.821
0.02810.046
Black
STD 1
1.821 - 1 824
0.02810.046
Brown
8m 2 I
1 .824 - 1 .827 .
0.026 I 0.046
None
STD 3
1.827 - 1.830
0028! 0.046
Yellow
i
less \han 58.657
Greater \han
58.651
1
8m 1 !
1821 -1824
0.028 ! 0.046
Brown
sm 2
1.824 - 1827
0.028 I 0.046
None
sm 3
1.827 - 1.830
0.028 J 0.046
Yellow
SID 4
1.830 - 1.833
002810046
Blue
!
1.e5$ than 58.563
Greater \han
85.657
'.
2
.. ".
STO 2
1.824 - 1.827
0.G28 i 0.046
None
sm 3
1.827 - 1.830
0.02810.046
Yellow
STO 4
1.830 - 1.833
0.028 I 0.046
Blue
8m 5
1.833 - 1.836
0.028 I 0.046
Green
I
less than 58.670
Greater than
58.$3
. ..
. ...
3 ..
. ....
i sm 3 i
1.827 - 1.830
0.028/0.047
Yellow
STO 4
1.830 -1.833 i
0.02810.047 I'
Blue
sm 5
1.833 - 1.836
0.028 ! 0.047
Green
8TO 6
1.836 - 183
90.028 i 0.047
Pink
ENGINE OVERHAUL
RB26DETT E\jGINE
Piston pin
(3) Piston pin selection
I
GnldIlNo .
.' .
,
l'
2. . .... '
Piston pin hole diameter (mm) 2, .J06 - 21.COO 21.012 - 21.006
! Piston pin extemaldiameter (mm) 20.995 - 20.989 21.001 - 20.995
I
Piston pin clearance(mml
..
0.005 - 0.0' 7
Service setting parts: Piston and piston pm STD 1. STD 2, STD 3, 0.50S, 1.00S
if
Front mark
ad hole j [ jPlston pin grade
j
' ! (01)
'I Cylinder No
Small end i (1 - 6) 14-7--- \
(0 1 't't
oa
f)1
I
I ,{ ! .l): _.;
I , I h'
/ I
I DIStinction Piston grade I
I Large end grade (0.1) symbol (1-3)
Con'rod bearing
(4) Con' rod bearing selection
Connecting rod large end
inside diameter
Leu than 51Jl07
Greeter than 51.000
Less than 51.013
Greater than 51.007
I Crank pin diameter
. .
, Less than 47.974
: Greater than 47.968
LU!S than 47.968
Greater than 47.961
. . .. .
Grede
No.
stamp
.
II I
1
Service setting parts:
1
.
.
Bearing grade No. i srD a : Bearing grade No
Bearing thickness (mm) I 1.500 - '.503 Bearing thickness (mm)
Oil c1earance (mm) 0.020 i 0.039 Oil clearance (mm)
Identification color None Identification COlor
Bearing grade No. SrD 1
Bearing thickness (mm) i 1.503 - 1.506
Oli clearance (mm) ! 0.020 10040
identification color Brown
US 0.08, US 0.12. US 0.25
EN -189
Bearing grade No.
Bearing thickness (mm)
Oil clearance (mm)
Identification color
I
I
STD 1 !
1.503 - 1506 :
0.020 i 0.039
1
1
Brown
STD 2 :
1.506 -1.509!
0.021 10.040 I
Green
RB26DETT ENGINE
[Point 1] Drain & refill cooling water
Draining
Drain cooling water in the cylinder block completely from
the drain plug.
Refilling
Refer to the section "cooling water"' for detailed instruction.
[Point 2] Remove & install engine stand
Install the engine sub attachment using 6 bolts to engine
mounting bracket on right side of the engine.
.. .. ..
: Nut (4) (M12 x Engine sub.
I Bolt (4) 4 - 5 '- attachment I
i .. i.
: \ I"" I '.
: ,\"r::
I "'1 .
I
I' . .. '
. ,
, : Bolt 16)4 - 5
I Engine attachmeni 0' =
[Point 3] Flywheel run-out
Set dial gauge to flywheel where it contacts clutch,
Tum the flywheel and measure the run-out.
Run-out limit (mm): 0.10
[Point 4] Remove & install flywheel
ENGINE OVERHAUL
Dial
Removal I Ring gear Ie bl;]l:." ..
Use ring gear stopper to fix flywheel and remove, : stopper g
Installation ! . " "
Coat the thread and flange of bolts with engine oil after
installing the bolts. \ \ :
after tightening the flywheel bolts, use ring gear stopper to I, i ! \ /1
I <> I I I '\ \ \ '0/ I
secure flywheel and tighten bolts. _:\ \E'&9-') I 1'1 i
Flywheel bolt tightening torque (kg-m): 14,5 -15.5
[Point 51 Flywheel knock pin installation
insert the flywheel knock pin so the pin protrudes 8 to 8.5
mm.
EN 190
pin
Flywheel
[Point 6]
Removal
RB26DETT ENGINE
Remove & install rear oil seal retainer
Insert a screwdriver in the gap between main bearing cap
and rear oil seal retainer to remove seal.
Cleaning
Use scraper to remove liquid gasket
Clean the cylinder block side in the same way,
Wipe mating surface with white gasoline,
Caution:
Also remove liquid gasket in the grooves,
ENGINE OVERHAUL
Installation i
Apply liquid gasket and install unit within 5 minutes, ....... :S,,:'Y993 I
Cut nozzle end of the liquid gasket (KP510 00150) tube as , ... .
shown In the figure on right Use tube presser for I
application, I
Apply liquid gasket continuously to rear oil seal retainer,
Caution:
Make sure liquid gasket width is 2,0 - 3,0 mm,
Refill engine oil and start the engine 30 minutes after
assembly is completed.
[Point 7]
Removal
Remove & install rear oil seal
Use a tool such as screwdriver to remove the seal.
Installation
perimeter area. Use oil seal drift (Outside diameter: 100
mm) to install new oil seal.
Apply a coat of oil or chassis grease to oil seal lip area,
EN - 191
!
Apply liquid gasket tq
inner surface!
around hole I
area i
RB26DETT ENGINE
[Point 8] Con'rod side clearance inspection
Use thickness gauge to measure the thrust clearance
between the con'rod and the crank arm.
[Point 9] Remove & install piston con'rod ASSY
Use a tool such as hammer handle to press the unit to
cylinder head side.
ENGINE OVERHAUL
'
Installation d' /C"?) -d' "I
J/fU I
Set the crank pin at BD.C (Bottom dead center) position. Piston ring I I'

Coat cylinder bore, crank pin and piston with engine oil. ' compressor", "'I
I (\' /m "
Assemble piston with front mark on piston head facing the I /::.=*'1'
front of engine. i (i;i 'J
Use a piston ring compressor to install the piston and the ; J\;\jIJ ':so LJ': :
assembly in cylinder block. [ __ .. __
Care must be taken not to strike or deform oil jet pipe with
large end of connecting rod when installing.
Con'rod nut tightening
Apply engine oil to con'rod and the nuts before assembly.
TIghten nuts in two or three stages.
1st time Torque wrench (kg-m):
2nd time Angle wrench ( 0 ):
Caution:
1.4-1.6
60-65
Oil hole
',i, ,:,1

"
L".
d
-
"\ \ .
\\
"",
.,.
Front
Front mark
Do not visually measure the tightening torque if angle wrench e,..' =-'-..c.c...c...'=-'-'-"-'--'c .. ____
is not available.
[Point 10] Install con'rod bearing
Apply engine oil to bearing surface when installing con'rod
bearing. Do not apply engine oil to rear surface of
bearing, clean this area.
Align con'rod bearing retainer notches and install (left side).
Make sure the con'rod body oil hole and the bearing oil
hole is aligned.
EN - 192
Notch
\

Notch
()
RB260ETT ENGINE
[Point11] Install oil jet
Set the oil jet position securely and check that it does not
inteifere with piston, If oil jet pipe contacts piston or is bent,
replace it with new part,
Oil jettightening torque (kg-m): 3,1 - 4.1
[Point 12] Remove & install piston ring
Removal
Use piston ring expander to remove rings,
Caution:
Care must be taken not to scratch piston,
Installation
Use piston ring expander to install rings,
The stamped marks on top and second piston ring
openings must face up,
Position the piston rings as shown in the figure on right
to install.
Caution:
Care must be taken not to scratch piston,
[Point 13] Remove & install snap ring
Removal
Use snap ring pliers to remove rings.
Installation
Use snap ring pliers and install rings securely in groove,
Caution:
Always replace snap rings with new ones,
[Point 14] Remove & install piston pin
Use a heat gun to heat piston to 60 - 70
n
G when removing
and installing piston pin,
Place suitable tool against piston pin and press or use
plastic hammer,
Apply plenty of engine oil 10 pin, pin hole and con'rod small
hole,
EN - 193
ENGINE OVERHAUL
. ,
i ''''/Eyebolt
Identification mark
: Oil flng spacer T,?p ,ring opening :
, Ollnng I
, \ _ /Upper rail opening:
i FrontUrk;J"'" ;""S".
. " .
~ ~ {C, :
: . / _ 011 ring lower I
Second nng openmg rail opening
,
- - - - ~ - - - - - - - - - - - - - - - - - - - - - - - ~ .... -
RB26DETI ENGINE
Piston pin press-fit
Place the piston front mark so the con'rod oil hole faces
right side of the engine (left side when viewed from front)
and press-fit.

Press-fit the piston pin from the front of piston to the rear side
of piston.
[Point 15] Piston pin inspection
Use the micrometer to measure outside diameter of piston
pin.
Standard unit (mm): 20.989 - 21.001
[Point 161 Piston inspection
Use micrometer to measure outside piston skirt diameter.
Measuring pOint Distance from bottom (mm): 13
Standard (mm): 85.955 - 85.985
Use inside micrometer to measure inside diameter of
piston pin hole.
Five types of pistons are available for service (STO 1, STO
2, STO 3. 0.50S, 1.00S).
[Point 17] Piston pin clearance inspection
Piston pin clearance is the figure obtained by subracting
the piston pin outside diameter [Point 15) from the piston
pin hole inside diameter [Point 16].
Piston clearance at normal temperature (20C):
0--0.004
[POint 18] Con/rod inspection
Bend and torsion inspection
Measure the bend and torsion with con'rod aligner.
Bend limit(mm): 0.15
Torsion limit (mm): 0.3
Small end inside diameter inspection
EN - 194
ENGINE OVERHAUL
Front marK
Micrometer
Micrometer
/
I
-'-"---1
InSide I
,
- ---.
ThICkness i
," gauge
Con'rod I
I a:.gner I
I ; ,
, .---1./

ENGINE OVERHAUL
Con'rod bearing interior diameter inspection
Install con'rod bearing in con'rod and cap. Tighten con'rod .... .. .... -;
nuts to specified torque and measure can 'rod bearing :! /
interior diameter. ! ( y
I
Con'rod nut
1 st time Torque wrench (kgm) 1.4-1.6
lightening torqu!r
2nd time Angle wrench ( 0) 60 - 65
Standard value 47.989 - 48.007
i
[Point 19] Con'rod small end bushing clearance
The measurement difference of the small end inside --
. .. . . I i grade PIston grad
15]ls the bushing clearance (full f1oattype). 'Small end\ '
Bush clearance standard value (mm); 0.005 - 0.017 Ihole rad I, .'.--1': u)
The con'rod small end and piston pin outside diameter are (0 1) ': I
separated into two grades at the factory. Make sure that '. " I
Big end !.
the grades (0,1) conform for both parts because the rod I hole grade 10, '). Identificalion symbol
and pin are selected and fitted according to bushing
clearance,
[Point 20] Con'rod cap bolt
Can 'rod cap bolts have grooves to prevent it from
disengaging,
For this reason do not tap the ends to remove bolts,
[Point 21] Piston ring end gap and side clearance
Ring end gap inspection
Use a piston to press the piston ring into the middle of the
cylinder and measure the gap,
.... - ._ ...... -.
1 7 r
I Thickness ,
Piston '< !
Item Top nng
I Second ring I Oilnng II
Bore grade 1, 2, 3: I' I I
Standard value
(mm) O 24 0 34
0.42 - 0,57 : 0,20 - 0,60 I:
, -, I
Side clearance inspection
Measure the clearance between the piston ring and the
piston ring groove,
Item Top ring Second ring OIll1ng
Standard value
0,040 - 0.D75 0,030 - 0,065 0.065 - 0,135
(mm)
Three types of piston rings (STD, 0,50S, 1 are
available for service,
EN195
-
, I
i mc. kness gauge 0'/-, I

1:

I ..... . __
ENGINE OVERHAUL
RB26DETT ENGINE
[Point 22] Crankshaft thrust clearance inspection/-
Use a thickness gauge to measure the clearance between: O Thickness gaulle
- 'i
the thrust bearing (No.4 bearing) and the crank arm when
moving the crankshaft towards front and rear of the engine. (/'
Standard value (mm): 0.05 - 0.18 .
Limit (mm): 0.3
;Y'
.... ___ ....
[Point 23] Remove & install pilot bushing
Removal
Use a pilot bearing puller to remove pilot bushing.
Installation
The pilot bushing installation position is as shown in the
figure on right.
[Point 24] Remove & install main bearing bolts
Removal
Remove bearing bolts in reverse order of sequence shown
In stallation
Tighten the bolts to specified torque in two to three stages
in the sequence shown in the figure on the right. Make
sure the crankshaft tums smoothly after tightening the bolts
to specified torque.
Main bearing bolt tightening torque (kgm): 4.7 - 5.3
Caution:
Apply engine oil to the bolt threads and bolt seats when
tightening the bolts.
[Point 25] Remove & install main bearing cap
Removal Iff
Use tools such as screwdriver to pry the bearing caps open.
Caution:
\
Pilot bearing puller
ST1661 0000
Care must be taken not to scratch the oil pan rail surface. ','
Installation .. ..
Check the front and rear pOSition and fit onto cylinder block i .
by lightly tapping it In a number of locations with a copper . j ""
hammer.
EN - 196
RB26DETT ENGINE
[Point 26] Main bearing inspection
The bearing end should protrude when Installed in main
bearing cap or cylinder block.
This protrusion is called the crush height.
[Point 27J Crankshaft inspection
Out-of-round and taper inspection
Use micrometer to measure each journal (No.1 - 7) and
each pin (No.1 - 6) in four locations shown in the figure on
right.
The out-of-round value is the difference of the dimensions
in directions A and B.
The taper value is the difference of the dimensions
measured at points 1 and 2.
Out-ot-round and taper limit (mm): 0.005
Pin and journal inspections
Use micrometer to measure pin and journal diameters.
Pin diameter standard value (mm): 47.961 - 47.974
Journal diameter standard value (mm): 54.951 - 54.975
Curve inspection
Use V-blocks on a fixed surface and support journals on
ENGINE OVERHAUL
" Crush heigrt
", !
- ... .... ~ ~
A
B '
~ ... ~ .. ..... -
Dial gauge
both ends of crankshaft (No.1 and No.7).
Position the dial gauge vertically on middle of No.4 journal 1 ~ ~ ~ ~ P J ~ ~ ~
as shown in the figure on the right. c:
Turn crankshaft by hand and read dial gauge movement.
The Run-out is equal to half of dial gauge movement.
[Point 28] Con'rod bearing oil clearance inspection
(A) Using inside micrometer and micrometer
The oil clearance can be calculated from connecting rod
bearing inside diameter and the crankshaft pin diameter
measured in [Point 18] and [Point 27].
(Oil clearance) =
(Bearing inside diameter) - (crankshaft pin diameter)
L.imit value (mm): 0.090
If the oil clearance exceeds the limit, refer to [Point 29] and
select the appropriate bearing.
EN -197
RB26DETT ENGINE
(B) Using plastigauge
Remove any dust from crankshaft pins and bearing
surfaces.
Cut off a piece of plastigauge slightly shorter than the
bearing width. Place the plastigauge on the crankshaft
in direction of axis. Care must be taken not to place on the
oil hole.
Assemble connecting rod bearing in connecting rod cap
and tighten connecting rod nuts to specified torque.
Con'rod nut
1st time Torque wrench (kg-m) 1.4 - 1.6
tightening torque
2nd time Angle wrench (') 60 -65
Remove con'rod cap and bearing and measure plastigauge
width with a plastigauge scale.
Caution:
Never turn the crankshaft or connecting rod while plastigauge
is being inserted.
If oil clearance exceeds the limit value, refer to [Point 29] and
select the appropriate bearing.
[Point 291 Con'rod bearing selection and engaging
Select the correct sized bearing as the con'rod bearing
prevents fluctuation in the oil clearance. Three bearing
thicknesses are available to fit the inside diameter of the
big end of the con'rod and the crank pin diameter gauge.
ENGINE OVERHAUL
When replacing the can 'rod bearing, check big end inside = = = = = = = = = ~
diameter gauge (indicated on the opposite side of the
con'rod hole) and the pin diameter grade (indicated on
crankshaft No.1 counterweightfront surface).
Con'rod bearing selection chart
Corlrpd large end inside Less than 51.007
<:Iiameter Grealerthan 51.000
Crank pin Grade
0
diameter No. stamp
1.;6$$ than Bearing grade No. STO 0
47.974
0
Bearing thickness (mm) 1.500 - 1.503
Greater than Oil clearance (mm) 0.020 10.039
47.968 kJentificatlOn colour None
Less than Beanng grade No. STD 1
47.968
1
Beanng thckness (mm) 1.503 - 1.506
Greater than Oil clearance (mm) 0.020 I 0.040
47.961 Identification colour Brown
EN - 198
Lower pin grade
No.1 - 6 from
i left side
tess tharr51.0'13
I31ea1er than ~ .007
1
Bearing grade No. STD 1
Bearing thickness (mm) 1.503 - 1.506
Oil clearance (mm) 0.020 I 0.039
Identification colour Brown
Bearing grade No sm 2
Searing thickness (mm) 1.506 - 1.509
Oil clearance (mm) 0.021 10040
Identification colour Green
ENGINE OVERHAUL
RB26DEr ENGINE
When using undersize bearings, measure bearing inside
diameter when bearing is installed. Grind pin so oil
clearance conforms to specific value.
Bearing undersize chart
Size ThickrnHls (mm) Grade No.
USO.OB 1.54111.549 8
USO.12 1.561 11.569 12
USO.25 1.626 11.634 25
Caution:
Care must be taken not to scratch fillet roll when the crank pin
is being grounded to use undersize bearing.
[Point 301 Main bearing oil clearance
Using bore gauge and micrometer (Method A)
L- R2.0 journal
/
L- R1.6 pin

i .
Install main bearing in cylinder block and attach bearing
cap. Tighten bearing cap boits to specified torque and
measure bearing inside diameter. . i I
Bearing cap bolt tightening torque (kg-m): 4.7 - 5.3 1"-., ";&'1_ <'
The oil clearance distance can be calculated from the '..... .
values for outside diameter of the crank journal measured '" _. .r
in [Point 27]. ! .A . },.yJ'
" ....
(Oil clearance) = I ", ", J '.
(Bearing inside diameter) - (Crankshaft outside diameter) Bore
If oil clearance exceeds the limit value refer to [Point 31] to
select suitable bearing.
Using plastic gauge (Method B)
Remove all dust and oil from each crankshaft journal and
bearing surfaces.
Cut a piece of plastigauge slightly shorter than the
bearing gauge width. Place a plastigauge on crankshaft
in direction of axis, care must be taken not to place on oil
hole.
Assemble the main bearing and bearing cap and tighten
cap bolts to the specified torque.
Bearing cap bolt tightening torque (kg-m): 4.7 - 5.3
Remove bearing cap and the bearing. Measure
plastigauge width on plastigauge scale.
Caution:
Do not turn crankshaft while plastigauge is being inserted.
If excessive bearing clearance still exists, use a thicker main
bearing or undersized bearing so that the specified bearing
clearance is obtained when measured by method A as well.
EN - 199
RB26DETT ENGiNE
[Point 31] Main bearing selection and engagement
Select correct sized bearing as the main bearing
prevents fluctuation in the oil clearance. Seven different
bearing thicknesses are available to fit the cylinder block
bearing housing and crank journal diameter grades.
f\lQte:
Selection engagement is performed only for standard size.
Check the bearing grade (indicated on bottom face of the
cylinder block) and joumal diameter grade (indicated on
crankshaft No.1 counterweight front surface) when
replacing the main bearing.
Select main bearing with proper thickness according to the
following table.
Cylinder block
.
Less than 58.651 Less 1I1an 58.657
bearing housing Greater than Greater 1I1an
inner diameter 58,645 58.651
Crank Grade
!
journal No. 0 1
diameter stamp
Less than Bearing grade No, STD 0
,
STD 1
54.975
0
Bearing thickness 1.818 - 1.821
!
1.821 -1.824
Greater than Oil clearance 0.028 f 0046 0.028 I 0.046
,
54.969 Identification <:O!or Black Brown
Less than Bearing glade No. STD 1 STD 2
54.969
1
Bearing thickness 1.821 - 1.824 1.824 - 1.827
Greater than Oil Clearance 0.Q28 i 0046 002810.046
, 54.963 ldentificallon <:O!or Brown None
,Less than Bealing grade No, 8TD 2 S-:-D 3
1
54.963
2
Bearing thicl<nes& 1 .824 - 1.827 1.827 - 1.830
'Greater than Oil Clearance 0.028 10.046 0.028/0.046
54,957
...
ldentification color None Yelklw
Less than Searing grade No, STD 3 STD 4
54.957
3
Bearing thickness 1.827 - 1.830 1.830 - 1.833
Greater than Oil clearance 0.02810.046 0.028 I 0.046
54.951 identification color Yellow Blue
When using undersized bearings, measure bearing inside
diameter when bearing is installed and grind journal so oil
clearance conforms to specified clearance,
. Slze Thicknes$(mm) Grade No
US025 1.950 i 1.958 25
C5Iution:
When crankshaft journal is being ground for use with
undersize bearings, do not scratch the fillet roll.
[Point 32] Cylinder block inspection and correction
Remove all oil and water deposits. gasket, seal material
and carbon from cylinder block.
EN - 200
ENGINE OVERHAUL
! Stamp x m p ~ !' /'
' ","" /'l
I";
Less than 58,663 Less 1I1an 58.670
Greater than Greater 1I1an
85,651 58;663
:I 3
..
Sm2 STD 3
1.824 - 1.827 1.827 - 1.830
0.028 i 0.046 002810047
None Yellow
STD 3
,
S'D 4
1.827 - 1.830 1.830 - 1.833
0028 10.D46 002810C47
Yellow Blue
STD 4 STD 5
1.830 - 1.833 1.833 - 1.836
0.028 I 0.046 0.028 i 0.047
Blue Green
STD 5 STD 6
1.833 - 1.836 1.836 -1.83
0.D28 10046 90.02810.047
Green Pink
i.r-R2.0 lournai
/
i
Upper surface distortion and wear inspection
Clean upper face of the cylinder block and measure the
distortion in six directions.
Limit (mm): 0.1
If the distortion exceeds the specified limit, resurface the
face with surface grinder or replace block if necessary.
Cylinder inside diameter inspection
ENGINE OVERHAUL
Use bore gauge to measure cylinder bore for bear, out-of- c-.. l' .J--''''-
round and taper. Measure in three vertical locations (A, B . / (
& C) and two directions (X & Y) for a total of six locations.

Cylinder inside diameter
I
standard (mm)
86.000 - 86050
Wear limit (mm) 0.2
. Out-of-round limit (rom) 0015
Taper limit (rom) 0.010
(1) Out-of-round measurement is the difference of
measurements in two directions (X & V).
(2) Taper is the difference of measurement at top and
bottom (A & C).
Perform honing or boring when abnormality is found.
Cylinder honing
There are three types of oversize pistons, STD (Standard
+0.02), OS (0.5) and OS (0.1). When oversize pistons are
used, hone the cylinder so the clearance between the
piston and the cylinder conforms to the specified value
described in [Point 33]. Oversize piston rings must be used
that fit the oversize piston.
[Point 33] Piston and cylinder bore clearance
The clearance can be calculated from the measured
values for the piston skirt outside diameter [Point 16] and
cylinder inside diameter [Point 32] (X direction B location).
(Clearance) = (Cylinder inside diameter)-
(Piston skirt outside diameter)
Standard at normal temperature (mm): 0.035 - 0.055
EN - 201

,-,CU( - ,4"i:
_
( '.,. ____-:::w-
1 l",,- ,
0 __ ____ __ ___ ___ ___ .. __ _
I
I_I
..
v
12 ENGINE OVERHAUL
OVERHAUL CAUTIONS
(1) Disassembly
ENGINE OVERHAUL
RB25DE ENGINE
Use correct and suitable tools when possible and make sure to carry out safe
procedures,
Care must be taken with operations on mating surfaces and sliding surfaces to
prevent loss of surface accuracy,
Arrange disassembled pars by making marks to organize for easy faults detection
and precise assembly,
Loosen nuts and bolts in a diagonal direction from outside, Care must be taken to
follow the numerical order when indicated,
Replace or repair after completing parts inspection following the inspection
procedures, Perform same inspection for the new parts and replace parts as
necessary,
(3) Assembly
Always use a torque wrench to tighten nuts and bolts to specific tightening torque,
Tighten nuts and bolts from centre to outside diagonal direction, gradually in two or
three successive stages, Follow the numeric order when indicated,
Replace gasket, packing, oil seals and O-rings with new ones in principle,
Clean each part thoroughly and blown off with compressed air, In particular, check
that oil and water passages are not clogged or obstructed,
Care must be taken not to scratch or damage sliding or mating surfaces, Clean off all
dust, debris or foreign objects, Lubricate all sliding surface with an adequate
coating oil.
EN - 202
ENGINE OVERHAUL
"B25:JE eNGINE
12-1 CYLINDER BLOCK DISASSEMBLE, ASSEMBLE & INSPECTION
OCopper washer_
tt:u Dran plug 3.0 - 4a-A
Reference: Engine selection assembly
Piston
(1) Piston selection
Grade No. 1
Cylinder block bore Less than 86.010
diameter (mm) Greater than 86.00
Piston diameter (rom)
Less than 85.965
Greater than 85.955
! Piston cl&aranee (mm)
Rear plate (NTi
/V'hl
r
,. Dust Gover (lilT)
Oil pan bolt tt:u
0.64 - 0.85
Oi;
2
Less than 86.020
Greater than 86010
Less than 85 975
Greater than 85.965
0.035 - 0.055
tt:u kg-m
Liquid gasket
1'1 Engine oil
o Replace after every d;sasserobly
3
.
Less than 86.030
Greater than 86.Q20
Less than 85.985
Greater than 85.975
Servtce setting parts: Piston and piston ptn STO 1, STO 2, STO 3, 0.50S, 1.00S
Piston grade
(No.1 - No.
Piston pin grade
ront mark
Distinction
symbol
EN - 203
ENGINE OVERHAUL
RB250E ENGINE
Main bearing
:2) Main bearing selection
I Cylinder block bealing housing Less than 58.654 Less than 58.863
inner diameter Greater than 58.545 Greater than 58.654
Crank journal Grade No.
0 1
diame!er stamp
Beanng grade No. STD 0 sm 1
less than 54.975
0
Bearing thickness 1.825/1.821 1.82911 825
Greater than 54.967 Oil clearance 002010045 0.02110046

identification colour Black Brown
Bearing grade NCL sm 1 Sm2
Less than 54.967
1
Bearing thick""""
.829/1.825 1 83311 829
. Greater !han 54.959 011 clearance 0.020/0.045 0.021/0046

Identification colour Brown None
Bearing grade No. Sm2 STD 3
less than 54959
2
Bearing thickness 183311.829 1.83711833
Greall'lr than 54.951 Oil clearance 0.02010.045 0.02210046
Identification colour None Yellow
NO.1 - No.3 No 5 - NO.7 Upper side (with groove, width 19 mm)
No.1 - NO.3 NO.5 - NO.7 Lower side (without groove, width 19 mm)
NO.4 Upper side (thrust metal, with groove, width 26.9 mm)
No.4 Lower side (thrust metal, without groove. width 26.9 mm)
Crank journal oil clearance (mm): 0.020 - 0.047
Service setting parts: SrD a - 6, US 0.25
Piston pin
(3) Piston pin selection
Grade No. 1 2
Piston pin hole diameter (mm) 20.987 - 20.993 20.993" 20.999
Piston pin extemal diameter (mm) 20.995 - 20.989 21.001 - 20.995
P-lSton pinelearanee (mm) 0 .. -0004
u.ss than 58.672
Greater !han 85.863
2
STD 2
1.83311 829
0.02210.047
None
sm3
1.837/1833
0.02210.047
Yellow
STD4
1.84110.837
I
002210.047
Blue
Service setting parts: Piston and piston pin STD 1. STO 2. STD 3. 0.50S, 1.00S
Front mark I
Ojl hoie wi Ip!ston pin grad. e t
\ ','f
. i i\ Cylinder NC'lf-' '.-'\
Srnall Emd : (1 6\ I
I
. .1 I,.. " "
grade (0, 1 .. ,
'/' :-d , \ \ 0
I
/-------1
Distinction' ;=llston 'grade
(0.1) symbOl (1-3)
EN 204
!
I
i
.
ENGINE OVERHAUL
Con'rod bearing
(4) Con'rod bearing selection
Connecting rod large end Inside less than 51.001 less than 51.013
. diameter than 61.000 than 61.007
Measurements
Crank pin diameter
Grade No.
0 1
i slamp
Bearng grade No STD 0 STD 1
Less than 41.974
0
Bearing thickness (mm) i 1.500 1.503 1.503 - 1.506
Greater than 47.968 Oil clearance (mm) 0.020 I 0.039 0.020 10.039
i Identification colour
i
None
,
Brown
Bealing grade No STD 1 8TD 2
Less than 47.968
1
Beanng thickness (mm) i 1.503 - 1.506 1.506 - 1.509
Greater than 47.961 Oil clearance (mm) 0.020 I 0.040 0.021 ! 0.040
identification colour
i
Brown Green
Service setting parts: us 0.08, US 0.12, US 0.25
Ine sub-altachment
Disassembly Engine
Remove engine from the vehicle body with transmission. ' . ''. , attachment I
Disassemble transmission and engine, ' I
Remove exhaust manifold, For detailed information refer tol " '
section on exhaust manifold, i '<n .'
Install engine sub-attachment using 4 bolts on left side of. r DC< MIG x 1.5 (4) !
I . "'L 30 mm
engine, = __ --,
Engine stand ASSY
Engine attachment
Engine sub-attachment
ST0501 SOOO
KV101 06500
KV101 10700
Drain engine oil and cooling water completely.
EN - 205
RB25DE ENGINE
Remove the following in the order shown:
Intake manifold
Oil filter and oil filter bracket
Timing belt
Cylinder head
Oil pan
Water pump
Remove flywheel (Drive plate) bolt
Insert stick etc, in the gap between cylinder block and
the crankshaft to secure flywheel and remove bolts,
Remove Pilot bush
Use pilot bearing puller to remove pilot bush,
Remove rear oil retainer
Use screwdriver to pry the bearing cap open,
Caution:
Care must be taken not to damage rear oil seal retainer.
Remove piston con'rod ASSY
Position the piston con 'rod to BDC (bottom dead center)
position.
Use a hammer handle or similar tools to press unit to
cylinder head side.
Disassemble piston con'rod ASSY
Use piston ring expander to remove piston ring.
Caution:
Care must be taken not to damage piston.
Do not over expand the piston ring,
Use snap ring pliers to remove snap ring.
EN - 206
ENGINE OVERHAUL
Piston ring expander
RB25DE ENG'NE
Remove piston,
Use a heat gun to heat piston to 60"C - 70C,
Place suitable tool against piston pin and use press or
plastic hammer to tap lightly,
Remove main bearing cap.
Remove bearing cap bolts in the sequence shown in the
figure on right
Use screwdriver to pry the bearing caps open.
Care must be taken not to damage oil pan rail surface.
Remove crankshaft.
Remove main bearing cap and main bearing from cylinder
block.
Inspection
Crankshaft side clearance inspection
Use thickness gauge or dial gauge to measure the
clearance between crank arm and the thrust bearing (No.
4 bearing) when moving the crankshaft toward front and
rear of engine.
Standard (mm): 0.05 - 0.18
Limit(mm): 0.3
If the clearance is over the limit value replace No.4 main
bearing.
EN - 207
ENGINE OVERHAUL
_, _ .. _-=.L.l!I""'-___ _
RB25DE ENGINE
Con'rod side clearance
Check that the crankshaft side clearance is within
standard value.
Use thickness gauge to measure the side clearance
between con 'rod and the crank arm.
Standard (mm): 0.2 - 0.3
Limit (mm): 0.4
If the clearance is overlhe limit value replace con'rod.
Piston and piston pin clearance
Use inside micrometer 10 measure piston pin hole
diameter.
Piston pin inside diameter standard value (mm):
20.987 - 20.999
Use micrometer to measure piston pin exterior diameter.
Piston pin exterior diameter standard value (mm):
20.989 - 21.001
Work out the piston pin clearance.
Piston pin clearance = Piston pin hole diameter-
Piston pin exterior diameter (at 20C)
Standard value (mm): -0.004 - 0
Replace piston and piston pin if the piston clearance
exceeds the standard value,
ENGINE OVERHAUL
Piston ring side clearance
Measure the clearance between piston ring and piston ring ,- (f/;;-7' 'I
/ I r
groove. ,
Side clearance value (mm): , Thickness 'Q c;/,
Top rmg: 0.040 - 0.073 ')::
ring: 0.030 - 0.063 " .
all rmg: 0.20 - 0.76 ,liikCi""W"' ___ _
Replace piston pin and piston pin ring if the piston ring side
clearance exceeds the standard value.
Ring end gap inspection
Using a piston, press the piston ring into the middle of the
cylinder and measure the gap.
Ring end gap standard value (mm):
Top ring: 0.24 - 0.44
Second ring: 0.42 - 0.67
Oil ring: 0.20 - 0.76
If the ring end gap measurement exceeds the standard
value with new piston ring, use oversize piston pin and
piston pin ring.
EN,208
R825DE c'JGINE
Con'rod inspection
Use con'rod aligner to measure the bend and torsion.
Bend limit(mm): 0.1 to every 100 mm
Torsion limit (mm): 0.3 to every 100 mm
Con'rod bush oil clearance (small end)
Use inside micrometer to measure small end inside
diameter
Inside diameter standard value (mm):
Grade 1: 21.006 - 21.000
Grade 0: 21.006 - 21.012
Work out the con'rod bush oil clearance (small end).
Oil clearance = Con'rod small end inside diameter
piston pin exterior diameter
Oil clearance standard value (mm): 0.005 - 0.017
Check that the con'rod small end hole grade No. and the
piston pin grade No. when fitted.
ENGINE OVERHAUL
I
Con'rod
aligner
i

:--1 Front mark .,
\ !
'. \ Piston grade (1-3)'
011 hoi !, SmaUend' :
\ I \' hole grad --\\ I
: " : \ (0.1) ;-;p :
; I" ( _ ,
i '-!'\' - \
l
' ; , ,Large 'P;ston p;o
, end grade/ grade (0.1) ,
o. (1 ,.. 6) _,
.. C
Limit (mm): 0.1 ,_ I ,._>"'; .
If the distortion exceeds the specified limit, resurface the l . ,
face with surface grinder L __ ..:. _ .. _. ,_,_ . ..c' ,_,_:t-", Thc.:,c:;.::kr",.e::::ss",9e=au",9:;:cel
Piston pin and cylinder bore clearance
Check the cylinder bore for any damage and burns.
Use bore gauge and measure cylinder bore for wear, out-
of-round and taper Measure in three vertical locations (A,
B, C) and two directions (X, Y) for a total of six locations.
Cylinder inside diameter'
standard (mm)'
86.000 - 86.030
Wear limit (mm) 0.2
Out-of-round limit (mm) 0.015
Taper limit (mm) 0.010
Out-af-round measurement IS difference af measurement
in two directions (X. Y).
Taper is difference of measurement at top and bottom
(A. C).
EN - 209
RB25DE ENGINE
Perform honing and boring when abnormality if inspected.
Caution:
Make sure to check the bore grade No. and the piston grade
No. when replacing the cylinder block or piston.
Use micrometer to measure outside piston skirt diameter.
To prevent cylinder bore distortion, fix main bearing cap
and tighten to specified tightening torque.
Specified position (mm): 18 from piston lower part
Standard (mm): 85.955 - 85.985
Piston and bore clearance =
Bore diameter (X, Y direction)-
Piston pin exterior diameter
Five types of pistons are available for service.
Gradea Exterior diatmlter
Grade 1 85.975 - 85.985 (mm)
GradeZ 85.985 - 85.995
Grade 3 85.995 - 86.005
OS 0.5 86.745 - 86.775
OS 1.0 86.975 - 87.005
Crankshaft inspection
Check for any wear and cracks on crankshaft journal and
pin.
Use micrometer to check each journal and each pin
exterior diameter.
Journal standard diameter (mm): 47.961 - 47.974
ENGINE OVERHAUL
Micrometer
.
:::::h -/1! 2 AI.
pin (No.1 - 6) in four locations shown in the figure on right. I v 10 i 1\ A B I
The out-of-round value is the difference of the dimensions I' , : It ( .) .
in directions A and B. I
The taper value is the difference of the dimensions
measured at points 1 and 2.
Out-of-round limit value A- B (mm):
Taper limit value 1 2 (mm):
0.005
0.005
EN - 210
___ J
ENGINE OVERHAUL
R325DE ENGINE
Main bearing oil clearance inspection
Using micrometer and bore gauge (Method A)
Fit main bearing to cylinder block and main bearing cap.
Tighten to specified tightening torque.
Use bore gauge to measure each main bearing inside
diameter.
Oil clearance = Main bearing inside diameter-
Journal exterior diameter
Standard (mm):
Limit (mm):
Main bearing selection chart
0.020 - 0.047
0.090
bearing cap
Con'rod large end inside Less than S8.654 Less than Lessthan 58.en I
diameter Greater than 58.545 Greater than 58.654 Greater than 58.663 .
i
Crank pin Grade
0 1
diameter No. slamp
less than Bearing grade No,
i
STD 0 ST::l 1
54.975
0
Beanng thickness {mm) 1.825 f '.821 1.829! 1.825
Greater than Oil clearance (mrn) 0.02010.045 0.021 ! 0.046
54.967 colour Black
BroW('!
Less than Beanng grade 'lo. STD 1 STD 2
54.967
1
Bearing thickness {mm} 1.829 ! 1.825 1.833 11.829
Grnater than Oil clearance (mm) 0.02010.045 0.021 10.046
54.959 Identification colour Brown None
Less than Bearing grade No. STD 2 STD 3
54.959
2
Bearing thickness {mm} 1.833 - 1.829 1.837 i 1.833
Greater than Oil clearance (mm) 0.02010.045 0.021 10,046
i
54.951 Identification co!our None Yellow
Caution:
No.1 - No.3, No.5 - NO.7 Upper side (with groove, width 19 mm)
No.1 - No.3. NO.5 - NO.7 Lower side (without groove, width 19 mm)
No, 4 Upper side (with thrust metal, with groove, width 269 mm)
No.4 Lower side (with thrust metal. without groove, width 26.9 mm)
2
STD 2
' .833 ! 1.829
0.02010.047
None
sm 3
i i .837 ; 1,833
0.C22 1 0.047
i
Yellow
I
STD 4
1.841 11.837
0.02210.047
i
Blue
Use undersize main bearing ifthe oil clearance can not be
adjusted using the standard main bearing.
Undersize main bearing
Size I Thickness (mm)
I.r:- R2.5 journal
. pm
USO.25 i 1.950 11.958
Grind the crankshaft journal if the oil clearance value is still L
not within the standard value using the undersize bearing.
Caution:
Retain fillet R when grinding the crankshaft journal.
EN - 211
o
.'
i
I
I
I
ENGINE OVERHAUL
RB25DE ENGINE
Cylinder block housing grade is imprinted on the oil pan
aligning side.
When replacing main bearing, check the bearing grade
(indicated on bottom surface of cylinder block) and joumal
diameter grade (indicated on crankshaft No.1 counter
weight front surface). Select main bearing with proper
thickness according to the selection table.
journa-I g-rad-e ..
No, 1 - 7 from ;eft
Pin!ouma:
No_ 1 - 6 from leif"""''!,]?;''
,
Con'rod bearing oil clearance
Install con'rod bearing to con'rod and can 'rod cap.
.Align con'rod oil hole and bearing oil hole and install.
Oil hole
'\
-'fJJQ
\/ 1.1
Align "otch
Use inside micrometer to measure con'rod bearing inside
diameter.
Con'rod oil clearance =
Con'rod bearing inside diameter Pin exterior diameter
Select correct main bearing from below chart if the con'rod
oil clearance is not within the standard value.
COn'rod !alga end inside Less tI1an 51.007 Less tI1an51.013
diameiar Greater tI1an 51.000 Greallir tI1an 51.007
Crank pin' Grade
(}
1
diameiar No. stamp
less tI1an Beanng grade No. ST;) 0 I Beanng grade No.
41.974
0
Beanng thickness (mmj 1.500 - 1.503 : Bearing thickness (mm)
Greater tI1an Oil clearance (mm) 0.020 I 0.039 Oil clearance (mm)
47.968 identification coiour NOf)e Identification colour
lass tI1an Beanng grade No. STD 1 Bearing grade No.
47.968
1
Bearing (mm) '503 -1.506 Bearing thickness (mm)
Graater tI1an Oil clearance (mm) 0.020/0.040 Oil c:earance (mm)
47.001 identification colour Brown kJentlficaton cOIOlY
Use undersize con'rod bearing ifthe oil clearance can not
be adjusted using standard con'rod bearing.
Size Thickness (mm) Grade No.
US 0.08 1.541 j 1.549 8
US 0.12 1.561 I 1.569 12
US 0.25 1.626 / 1.634 25
EN - 212
SrD 1
1.503 - 1,506 :
0.020 10.039 '
Brown
STD 2
1.506 - 1 509 i
0.021 10.040 :
Green
i
R825DE E"lGINE
Grind the crank pin if the oil clearance value is still not within ...
the standard value using the undersize bearing. I
Select correct main bearing using the chart if crankshaft
con'rod is new.
Con'rod large end grade is printed on large end surface.
ENGINE OVERHAUL
lft".5 cournal
\ Crank pin

Main journal grade No.
: 7 from .
Pin Joumal
grade No
from ieft
.
Using plastigauge (Method B)
Remove all dust from crankshaft pin and bearing surfaces.
Cut off a piece of plastigauge slightely shorter than the
gearing width. Place the plastigauge on crankshaft in
direction of axis, care must be taken not to place on oil
hole.
Assemble con'rod bearing in con'rod cap and tighten
connecting rod nuts to specified torque.
Caution:
Remove cap and bearing and measure plastigauge width
with plastigauge scale.
Standard value and bearing selection is same as method
A.
EN - 213
I'
Cylinde, .
No. 11-6; 81g end g
r
ad_e_(O_.1_)
ENGINE OVERHAUL
RB25DE ENGINE
Piston and con'rod installation ....
Use snap ring plier to install snap ring to installation groove
on the piston.
Always replace snap ring with new ones.
Oii hOle
Position piston front mark so the con'rod oil hole faces right .
side of engine (left side when viewed from front).
Use a heat gun to heat piston to 60
0
e - 70
o
e.
Apply plenty of oil to pin, pin hole, con'rod small hole.
Press-fit piston pin into piston pin con'rod from the front of
piston to the rear side of piston.
Install snap ring on piston front side. After the installation
makesure the con'rod move smoothly.
Use piston pin expander to install piston rings in correct
position.
Caution:
Care must be taken not to damage or scratch piston.
openings must face up.
Install crankshaft
Install main bearing to cylinder block and main bearing cap.
Apply plenty of engine oil on the inside surface of the
bearings.
Aligh the bearing notch and the block cap notch to install.
Place crankshaft on cylinder block and tighten main
bearing cap bolts in several stages.
Apply engine oil to threaded part and flange.
After tightening to the specified torque, check that crank
shaft turns smoothly.
EN - 214
I
.' I' .
Piston nng expander
---.J
I IdentifiCjiOn marK

1#
F'oel I
bearing caPi
4 8 12
RB25DE ENGINE
Piston & con'rod installation
o Install con'rod bearing to con'rod and con'rod cap,
o Apply engine oil to con'rod bearing exterior surface, Do
not apply engine oil to interior surface, instead clean
sufficiently,
Make sure the con'rod main body oil hole and the bearing
oil hole is aligned correctly,
When installing con'rod bolt make sure the bolt head with
larger chamfer of thread is on con'rod side,
ENGINE OVERHAUL
Install piston and con'rod ASSY to crankshaft. Top ring
Position the crank pin to BDC (bottom dead centre). 1;;.::<'" all ricgupperraw
l
Coat cylinder bore, piston and crank pin with engine oiL e\,;:der ,
Position the piston ring openings as shown in the figure on i Front '
nght. I \,i';!,
,
,""-
Second ring 011 ring lower rail i
Check the cylinder position and con'rod cylinder No. _, ___ ._ openmo"
Position piston front mark to engine front and use piston I Piston ring
ring compressor to install piston, ! compressor ',";' ,]2;
i 1- - - -,,'"',cc.r'
be taken not to damage crankshaft and cylinder ; ',\';',' ','
Inner wall by supporting con'rod big end, ' :"I)',J",
-, /8, .ilO"
Co_ __.... ____ : : r !
Tighten con'rod nuts in the following procedures.
o Apply engine oil to con'rod bolts and nuts flange.
Tighten the bolts and nuts.
Torque wrench (kg-m): 1.4 - 1.6
Angle wrench (0): 60 - 65
After installing all con'rod ASSY, rotate the crankshaft and
make sure it rotates smoothly.
Check the con'rod side clearance.
Check the crankshaft thrust clearance.
Pilot bushing replacement
Use a pilot bearing puller to remove pilot bushing,
EN - 215
P,lo! beanrg puller
,-'561 0000
--_.,--
"lB25DE ENGINE
The pilot bushing installation position is shown in the figure '
on right.
Fly-wheel installation (M I T vehicle)
Coat bolts thread and flange with engine oil.
After tightening the flywheel installation bolts halfway, use
the ring gear stopper to secure fly-wheel and tighten bolts.
Tighten bolts in several stages.
Fly-wheel knock pin insertion
Insert the fly-wheel knowck pin so the pin protrudes 8 to 8.5 I
mm.
Reinforcement plate installation (A I T vehicle)
Take care with installation direction when installing
reinforcement plate for A I T vehicles.
Fly-wheel runout
Set dial gauge to fly-wheel where it contacts clutch.
Tum the fly-wheel and measure the run out.
Runout limit (mm) 0.10
EN - 216
ENGINE OVERHAUL
I

tb
8 - 8.5 mm
pin
, rotrusion
" Knock oin
Fly-wheel
Reinforce
I
Crankshaft

ENGINE OVERHAUL
RB20E: DE :CST ENGINE
12 ENGINE OVERHAUL
This section describes the component disassembly of the engine assembly removed from
the vehicle without transmission. It also explains the inspection, replacement of
malfunctioning, damages orwarn parts and carry out any necessary adjustments and
sequential assembly in order to produce a standard engine condition.
OVERHAUL CAUTIONS
(1) Disassembly
Use correct and suitable tools when possible and make sure to carry out safe
procedures.
Care must be taken with operations on mating surfaces and sliding surfaces to
prevent loss of surface accuracy.
Arrange disassembled pars by making marks to organize for easy faults detection
and precise assembly.
Loosen nuts and bolts in a diagonal direction from outside. Care must be taken to
follow the numerical order when indicated.
Replace or repair after completing parts inspection following the inspection
procedures. Perform same inspection for the new parts and replace parts as
necessary.
(3) Assembly
Always use a torque wrench to tighten nuts and bolts to specific tightening torque.
Tighten nuts and bolts from centre to outside diagonal direction, gradually in two or
three successive stages. Follow the numeric order when indicated.
Replace gasket, packing, oil seals and O-rings with new ones in principle.
Clean each part thoroughly and blown off with compressed air. In particular, check
that oil and water passages are not clogged or obstructed.
Care must be taken not to scratch or damage sliding or mating surfaces. Clean off all
dust, debns or foreign objects. Lubricate all sliding surface with an adequate
coating oii.
EN217
RB20E! DE i DET ENGINE
121 DISASSEMBLE & ASSEMBLE CYLINDER BLOCK ASSY
~ Detonation s ~ s o r bolt
(2) 2.5 - 3.5 ..
tqj kg-m
lei liquid gasket
, I[l Engine oil
i 0 ReOiace after every disassembly
Remove and install the following parts:
Engine
Exhaust manifold ASSY
Turbocharger (RB20DET)
Collector ESSY (RB20E)
Intake manifold ASSY
Timing belt
Rocker cover, cylinderhead ASSY
Alternator
Walerpump
EN - 218
ENGINE OVERHAUL
Main beanng cap
[Point 23]
(RB20DE i DET)
RB20E; DE; ::lET ENGINE
[Point 1] Remove & install engine stand
Install the engine sub attachment using 4 bolts on left side
of the engine.
---._ .... - _.
[Point 2] Flywheel run-out
Set dial gauge to flywheel where it contacts clutch.
Turn the flywheel and measure the run-out.
Run-out limit (mm): 0.10
[Point 3J Remove & install flywheel (drive plate) bolts
Removal
Insert a stopper between cylinder block and the crank shaft
to stop crankshaft from moving.
Installation
Coat the thread and flange of bolts with engine oil when
installing the bolts.
[Point 4J Reinforcement plate installation (AfT vehicle)
Take care with installation direction wen installing
reinforcement plate for AiT vehicles.
[Point 5] Remove & install rear oil seal
Removal
Use tool such as screwdriverto remove seal.
Installation
perimeter area. Use oil seal drift (outside diameter:
110mm) to install new oil seal.
Apply a coat of engine oil or chassis grease to oil seal lip
area.
EN - 219
ENGINE OVERHAUL
Dial g ~ u g
Reinforce
plate
Crankshaft
RB20E! DE I DET ENGINE
[Point 6] Remove & install rear oil seal retainer
Removal
Insert a screwdriver in the gap between main bearing cap
and rear oil seal retainer to remove seal.
Cleaning
Use scraper to remove liquid gasket.
Clean the cylinder block side in the same way.
Wipe mating surtace with white gasoline,
Caution.:
Installation
Apply liquid gasket and install unit within 5 minutes.
Cut nozzle end of the liquid gasket (KP51 000150) tube as
shown In the figure on right. Use tube presser for
application,
Apply liquid gasket continuously to rear oil seal retainer.
Caution:
Make sure liquid gasket width is 2.0 - 3.0 mm.
Refill engine oil and start the engine 30 minutes after
assembly is completed.
[Point 7] Con'rod side clearance inspection
Use thickness gauge to measure the thrust clearance
between the con'rod and the crank arm,
[Point 8] Con'rod nut tightening
Tighten nuts in two stages.
(RB20E)
1st time Torque wrench (kg-m):
2nd time Torque wrench (kg-m):
(RB20DE I DET)
1sttime Torque wrench (kg-m):
2nd time Torque wrench (kg-m):
1.4 -1.6
1.4 - 1.6
2.3 - 2.9
3.9 - 4.5
EN - 220
ENGINE OVERHAUL

,
I i
'--____ s:raJ
Cut

, I .
" ---.J
Apply liquid gasKet to
surface!
area
Thickness gaugi,c'
R820E I DE I DET ENGINE
[Point 9] Install con'rod bearing
Coat engine oil to beanng surface when installing con'rod
bearing. Do not apply engine oil to rear surface of the
beanng, clean this area.
Align con'rod bearing retainer notches and Install (left side).
Make sure the con'rod body oil hole and the bearing oil
hole is aligned.
[Point 10] Con'rod bearing oil clearance inspection
(A) Measuring basis
Installcon'rod bearing to con'rod and con'rod cap then
tighten the con'rod nuts to specified torque. Measure
con'rod bearing inside diameter.
Oil clearance can be calculated using the crank pin outer
die measured using points in [Point 27].
(Oil clearance) =
(Bearing inside diameter) - (Crank pin outer die)
Limit value(mm): 0.090
Select the bearing using [Point 11] as a reference if the oil
clearance is over the limit value.
(B) Using plastigauge
Remove any dust from crankshaft pin and bearing surfaces.
Cut off a piece of plastigauge slightly shorter than the
bearing width. Place the plastigauge on the crankshaft in
direction of axis. Care must be taken not to place it on the
oil hole.
Assemble connecting rod bearing in connecting rod cap
and tighten connecting rod nuts to specified torque.
Remove con'rod cap and bearing and measure plastigauge
width with a plastigauge scale.
Caution:
Never turn the crankshaft or connecting rod while plastigauge
is being inserted.
[Point 11] Con'rod bearing selection
Select the correct sized bearing as the con'rod bearing
prevents fluctuation in the oil clearance. Three bearing
thicknesses are available depending on inside diameter
of the big end of the con'rod and the crank pin diameter.
When replacing the con'rod bearing. check big end inside
diameter gauge (indicated on the opposite side of the
con'rod hole) and the pin diameter grade (indicated on
crankshaft No.1 counterweight front surface).
EN - 221
ENGINE OVERHAUL
'inside
i micrometer" ,
i (('\
\1
. Cylinder II' "
; No.stamped ,I! I, I Oil hole .
I ". l i,.k Con'rod big i
c: end grade No!
\ \'J / stamped .
W,: .
u;OOr;ourna!
1 - 6 from left side
sine
ENGINE OVERHAUL
RB20E I DE! DE ENGINE
Con'rod bearing selection chart
RB20E
Bearing grade No. 'Bearing grade No.
Bearing thickness (mm) , 1.506/1502 Bearing thickness (rnm) I
Oil clearance (mrn) 0.014 ! 0.035 Oil clearance (mm) I
colour None Identification colour
Bearing grade No.
Oil clearance (mml
STD 1 , Bearing grade No.
1.S10! 1.506 ! 8eanng thickness Imm)
0.012! 0.034 ,Oil clearance Imm)
Brown tdentflcation colour
sm 1 I
1.51011.506 I
'
Brown
sm 2
1.514/1.510 .
0.011 /0.032
Greep
Bearing used (Width 16mm)
RB20DE I DET
Bearing grade No. .
Beanng thickness (mm; ,
Oil cLearance (mrl)
colour
Bearrng grade No.
Bearing thickness (mmi
Oil clearance (mm)
ide-ntificatlon coiour
None
. Beaflng grade No.
Oil clearance (mm) , 1.014/0.035
lde-ntifjcatloP colour Brown
STD 1 Beaflng grade No. STD 2
1.51011.506 I Beaflng thickness Imm); 1.514/1.510
0.012 i 0.034 . Oil clearance (mm) 0.011 ! 0.032
Brown identificatIon colour Green
When using undersize bearingsr measure bearing inside
diameter when bearing is installed. Grind pin so oil
clearance conforms to specific value.
US008 1.548 ! 1.540 8
USO.12 1 .568 / 1 .560 12
USO.25 1.633 i 1.625 25
Ci3utiQn:
Care must be taken not to scratch fillet roll when the crank pin
is being grounded to use undersize bearing.
[Point 12] Piston pin con 'rod ASSY
Removal
Use tools such as end of hammer and push it towards the
cylinderhead side.
EN - 222
, I
I o I' '\
,I \
RB20E 8E DE" ENGINE
Removal
Set the crank pin at B.O.C (bottom dead center) position.
Coat engine oil to cylinder bore, crank pin and piston.
Use piston ring compressor to install piston pin and con'rod
ASSY to the cylinder block.
Make sure to position oil jet correctly when installing it to
RB200ET engines so that the oil Jet and the piston will not
interfere,
ENGINE OVERHAUL

Positioning,
. hole
Oil jet
Caution: Front mark -

Front mark on the piston should face engine front side when
installing, Oil hole and baffle notch of con'rod and con'rod Oil hole
cap should be on right hand side of the engine when
installing.
[Point 12] Remove & install piston ring
Removal
Use piston ring expander to remove rings.
Cgl,ltion:
Care must be taken not to scratch piston.
Installation
openings must face up.
Position the piston rings as shown in the figure on right
to install.
Caution:
Care must be taken not to scratch piston.
EN - 223
... --
Piston f'ng
expander
----..... ....
Identification mark
,-.... .. ... ----.....
: Oil ring spacer Top nng opening I
. )'I"n
g
I
. " ral opemn
li
,

nng Jower
Second ring open!l1g rail opening
RB20E I DE I DET ENGINE
[Point 14] Remove & install piston pin
(Engine number RB20 - 030511 in case of RB20E for C32) ..
Connection process for the piston and the con'rod is called
press fit method. Piston pin press stand ASSY must be
used to remove the piston pin.
(RB20DE f DEn
Connection process is called full float method. Use a heat ,
gun to heat piston to 60 - 70
G
C when removing and
installing piston pin,
Place suitable tool against piston pin and press or use
plastic hammer.
Piston pin press-fit
Place the piston front mark so the con'rod oil hole faces
right side of the engine (left side when viewed from front)
and press-fit.
Caution:
Press-fit the piston pin from the front of piston to the rear side
of piston.
ENGINE OVERHAUL
.. ~
I
Piston pin
I press stand
... _ .J\SSY ... _.J
Front marK
.,
Front
Micrometer
I
_J
[Point 15] Piston pin inspection I
Use the micrometer to measure outside diameter of piston 1.___
pin skirt. '[
Measuring location from skirt bottom : ~
(RB20E) 20mm 'l 0 ;:-)
(RB20DE f DET) 15mm I
Outside diameter standard value (mm) - .. ~ --
(RB20E) 77.915 -77.965
(RB20E f DET) 77.925 - 77.975
Use micrometer to measure piston pin opening diameter.
(RB20E)
(RB20DE I DET)
Press fit type RB20E for C32
[Point 16] Piston pin inspection
18.987 -18.999
20.987 - 20.999
18.995 - 19.000
Use micrometer to measure outside diameter of piston pin.
(RB20E)
(RB20DE f DET)
18.989 - 19.001
20.989 - 21.001
18.995 - 19.000
EN - 224
L measurement: RB20E: 20mm
RB2QDE I DET 15mm
Micrometer
RB20E; DE! DET ENGINE
Piston pin clearance is the figure obtained by subracting
the piston pin outside diameter [Point 15] from the piston
pin hole inside diameter [Paint 16].
Piston clearance at normal temperature (20C):
0- -0.004mm
Piston clearance at normal temperature (20) for press
fit type RB20 for C32 is between 0.008 - 0.010mm
Insert the piston pin as shown in the figure on the right and
check if it move smoothly.
[Point 17] Con'rod inspection
Use con'rod aligner to measure the bend and torsion.
Bend limit (1/1 00 mm): 0.025
Torsion limit (1/100 mm): 0.025
Small end inside diameter inspection
(RB20E)
(RB20DE I DET)
19.000 - 19.012
21.000 - 21.012
18.965 -18.978
[Point 19J Con'rod small end bushing clearance
The difference between the small end inside diameter [Point !
17] and piston pin outside diameter [Point 15] is the
bushing clearance (full float type).
Bush clearance standard value (mm): 0.005 - 0.017
Con'rod
aligner
ENGINE OVERHAUL
The con'rod small end and piston pin outside diameter are
I
. m ....
separated into two grades at the factory. Make sure that "
the grades (0.1) conform for both parts because the rod
and pin are selected and fitted according to bushing
clearance.
[Point 18] Piston ring end gap and side clearance Th!ckness gau'qw/
gap inspection
Use a piston to press the piston ring into the middle of the
cylinder and measure the gap.
0.22 - 0.45 0.19 - 0.45 0.20 - 0.76
0.22 0.39 0.19-0.45 0.20 - 0.76
EN -225
RB20E I DE i DET ENGINE
Side clearance inspection
Measure the clearance between the piston ring and the
piston ring groove.
tlmll'vl!duif "
(mm)
0.1 0.1
I
[Point 19] Remove & install pilot bushing
Removal
Use a pilot bearing puller to remove pilot bushing.
Installation
The pilot bushing installation position is as shown in the
figure on right
[Point 20] Remove & install pilot converter (AfT)
Make sure to install pilot converter in correct direction .
[Point 21] Crankshaft thrust clearance inspection
Use a thickness gauge to measure the clearance between
the thrust bearing (No.4 bearing) and the crank arm when
moving the crankshaft forward or backward.
[Point 22] Remove & install main bearing bolts
Remove bearing bolts in the roder shown in the figure on
right
Tighten bolts to specified torque in two to three stages in
reverse order shown in the figure. Make sure the crank
shaft turns smoothly after tightening the bolts to specified
torque.
EN - 226
ENGINE OVERHAUL
I Crankshaft side
...
- .
Thickness
/
2 6 10 14 12 S 4
-
,
f -:-. - -
l. . - ....
Ii
I .
5 9 13 11 7 3
RBOE! DE ' DET ENG INE
[Point 23] Remove & install main bearing cap
(RB20E)
Use main bearing bolt to remove bearing cap by shifting it
fOlWard and backward.
Main bearing distinction can be checked by marks on each
main bearing.
Make sure to face the arrow mark on the bearing to engine
front when installing No.3, 4 and 5 bearings.
(RB20DE I DET)
Make sure to install the main bearing cap In correct
orientation when installing.
[Point 24] Main bearing inspection
The bearing end should protrude when installing the main
bearing to the cylinder block or main bearing cap.
This protrusion is called the crush height.
[Point 25] Main bearing oil clearance
Using bore gauge and micrometer (Method A)
Install main bearing in cylinder block and attach bearing
cap. Tighten bearing cap bolts to specified torque and
measure bearing inside diameter.
The oil clearance distance can be calculated from the
values for outside diameter of the crank journal measured
in [Point 27].
(Ojl clearance) = .
(Bearing inside diameter) - (Crankshaft outside diameter) l
If oil clearance exceeds the limit value refer to [Point 26] to
select suitable bearing.
EN - 227
ENGINE OVERHAUL
Crush height
Main bearing
RB20E I DE ! DET ENGI'lE
Using plastic gauge (Method B)
Remove all dust and oil from each crankshaft joumal and
bearing surfaces.
Cut a piece of plastigauge slightly shorter than the
bearing gauge width. Place a plastigauge on crankshaft
in direction of axis, care must be taken not to place on oil
hole.
Assemble the main bearing and bearing cap and tighten
cap bolts to the specified torque.
Remove bearing cap and the bearing. Measure
plastigauge width on plastigauge scale.
Caution:
If excessive bearing clearance still exists, use a thicker main
bearing or undersized bearing so that the specified bearing
clearance is obtained when measured by method A as well.
[Point 26] Main bearing selection and engagement
Select correct sized bearing as the main bearing
prevents fluctuation in the oil clearance. Five different
bearing thicknesses are available to fit the cylinder block
bearing housing and crank journal diameter grades.
Note:
Selection engagement is performed only for standard size.
Check the bearing grade (indicated on bottom face of the
cylinder block) and journal diameter grade (indicated on
crankshaft No.1 counterweight front surface) when
replacing the main bearing.
Select main bearing with proper thickness according to the
following table.
Black Brown
STD 1 STD2
1.829! 1.825 1.833 1 1.829
0.028! a.OdS 0.021 10.046
Brown None
sm 2 STD 3
1.833! 1.829 1.837 1 1.833
0.020! 0.045 0.021 ! 0.046
None Yelkow
EN - 228
ENGINE OVERHAUL
None
STD 3
1.837 i 1.833
0.022 i 0.047
Yellow
8TD 4
1.841 11.837
0.022 ! 0.047
Blue
ENGINE OVERHAUL
RB20E! DE / DET ENGINE
When uSing undersized bearings. measure bearing Inside .- ,-lr-R2 0 'ouma, fl' I
diameter when bearing is installed and grind Journal so all r' 1 I '
"I' v- Rl pin
clearance conforms to specIfied clearance. 'J I .I
. I
"\ r i
USa.25 1,960 ! 1.952 25'" .-/ '
USO.50 2.085 12.077 50
CautiQ!1';
When crankshaft journal is being ground for use with
undersize bearings, do not scratch the fillet roll.
[Point 27] Crankshaft inspection ___ _
Out-of-round and taper inspection 1 2 A
Use micrometer to measure each journal (No, 1 - 7) and ()rt"
e,ach pin (No, 1 - 6) in four locations shown in the figure on , 0 I \\
'r B I,'
right II'-: i
The outol-round value is the difference of the dimensions -if '\. .. ,1--,1"
in directions A and B, _ "
The taper value is the difference of the dimenSions __
measured at points 1 and 2,
Out-of-round and taper limit (mm): Below 0.005
Pin and journal inspections
Use micrometer to measure pin and journal diameters,
(RB20E)
Journal diameter standard value (mm): 54.951 - 54.975 .
(RB20DE I DET) ,
Journal diameter standard value (mm): 54.951 - 54.975
Curve inspection
Use V-blocks on a fixed surface and support journals on
both ends of crankshaft (No.1 and No, 7). i
Position the dial gauge vertically on middle of No, 4 journal
as shown in the figure on the right.
Turn crankshaft by hand and read dial gauge movement.
The Run-out is equal to half of dial gauge movement
EN - 229
RB20E ! DE ' DET ENGINE
[Point 28] Cylinder block inspection and correction
Remove all oil and water deposits, gasket, seal material
and carbon from cylinder block.
Upper surface distortion and wear inspection
Clean upper face of the cylinder block and measure the
distortion in six directions.
Limit (mm): 0.1
If the distortion exceeds the specified limit, resurface the
face with surface grinder or replace block il necessary.
Cylinder inside diameter inspection
ENGINE OVERHAUL
Use bore gauge to measure cylinder bore for out-of- "-- / --1
round and taper. Measure in three vertical locations (A, B i
& C) and two directions (X & Y) for a total of six locations. I

, J:aafcl . 77 .950 - 78.000 __ --,'( ""-.:
Wear 0.2
0.015 ,
0.010
----'
(1) Out-ol-round measurement is the difference of
measurements in two directions (X & V).
(2) Taper is the difference of measurement at top and
bottom (A & C).
Perform honing or boring when abnormality is found.
Cylinder honing
There are three types of oversize pistons, STO (Standard
y
+0.02), OS (0.5) and OS (0.1). When oversize pistons are L ... __ .. __ ._ ... __ ". ____ .i
used, hone the cylinder so the clearance between the
piston and the cylinder conforms to the specified value
described in [Point 29]. Oversize piston rings must be used
that fit the oversize piston.
[Point 29] Piston and cylinder bore clearance
The clearance can be calculated from the measured
values for the piston skirt outside diameter [Point 151 and
cylinder inside diameter [Point 28] (X direction B location).
(Clearance) = (Cylinder inside diameter)-
(Piston skirt outside diameter)
Standard at normal temperature (mm):
(RB20E) 0.025 - 0.045
(RB20DE I DET) 0.015 - 0.035
EN230
TROUBLE DIAGNOSIS
RB26DETT I RB20E! DE i DET i CA1S. I RB25DE ENGINE
EN3 ECCS (ELECTRONICALLY CONCENTRATED ENGINE
CONTROL SYSTEM)
1. TROUBLE DIAGNOSIS
1-1 TROUBLE DIAGNOSIS PROCEDURE
I Customer interview
-------
i
Ask customer in detail about
problem occurrence condition.
environment and the problem.
I Problem confirmation
_______ Check the problem and understand.
occurrence condition. i
I Self-diagnosis I }
I Basic inspection !
- - - - - - - Narrow down suspected systems.
'-=-------r-------' Spark?
Fuel?
Actuator function
Output signal
Harness
I Inspection for individual systems
Input signal
Sensor
I Confirmation test I
Caution:
Engine problems are roughly divided into two types: problems relating to engine main
body and those related to control system. This section explains the trouble diagnostic
method for the control system under the assumption that the engine main body is normal.
Consequently, attention should also be paid to the condition of the engine main body and
gasoline quality.
EN - 231
TROUBLE DIAGNOSIS
RB26DETT i RB20E IDE IDET leAISi I RB25DE ENGINE
FOR ACCURATE & QUICK DIAGNOSIS
Cautions when carrying out diagnosis
Remove the battery terminals and place key switch in
OFF position when removing or connecting ECCS C/U
harness connector from ECCS C/U.
Position the connector and tighten installation screw until
orange projection is level with surface when connecting
ECCS C/U harness connector.
Check the connector pin terminals for any bent or
deformation when removing or connecting ECCS C/U
harness connector.
Make sure to carry out components function check and
ECCS G/U input signal check before replacing EGGS
C/U.
After "Diagnosis procedures" carry out the test drive and
self-diagnosis.
Short circuit will occur if proves from same position
comes in contact when measuring battery voltage of
ECCS G/U components using circuit tester. Make sure
to connect one side of tester prove to different place.
EN - 232

_-:::... ,,<;J
Y

InstallatIOn Red proiection .
screw
Bent
//1.1
1
=--.J
#' :0
Broken
Check input i output !
signal before
replacing ECCS CiU
TROUBLE DIAGNOSIS
RB26DFT! RB20E ! DE 'DET ! CA 18i! RB25DE ENGINE
Cautions when handling ECCS C/U
ECCS C/U installation
Only install EGGS C/U specified for your vehicle.
Do not apply unnecessary power to installation bracket.
Connector installation
Keep the following points in mind when removing & installing the connector:
Bemoval
Make sure the EGCS relay is "OFF" after turning off the key switch.
Hold the connector body to remove connector. Never pull the hamesses to remove.
Installation
Install connector when key switch is in "OFF" position.
Check the ECCS C/U side connector pin for any bent or deformation before installation.
Tighten the bolts securely until red projection is level with surface.
ECCS voltage
Never connect the battery in reverse.
The battery voltage should be between 10V - 16V.
Idle revolution adjustment volume
Do not turn the knob over the lock position.
Do not operate the adjustment volume when below 0
0
,
Moisture & oil content
Care must be taken to keep all rain drops and water droplets away from ECCS C/U.
Take note of water droplets from rapid temperature change. Make sure ECCS G/U has
dried completely before installing to the vehicle.
Do not let oil content adhered to the connector device.
Avoid cleaning EGGS G/U using benzine or white spirit.
Dropping & strong impact
Do not drop, tap or apply strong impact to EGCS G/U device.
Do not use EGCS C/U unit with bent top or bottom cover.
ECCS C/U screw & cover
Do not remove ECGS G/U cover.
Do not rotate screws on EGGS G/U body.
EN - 233
TROUBLE DIAGNOSIS
RB26DETI ! RB20E I DE / DET ; CA 18i I RB25DE ENGiNE
DIAGNOSIS PROCEDURE
(1) Diagnostic worksheet
Feelings for a problem depends on each
customer. It is important to fully understand
the symptoms and conditions of a vehicle
when a customer complains.
Key points
What ........... Vehicle & engine model
Check with your customer in what condition
problem occurs and use as a reference when
carrying out test drive.
When .......... Date, frequencies
. Where ......... Road conditions
: How ............ Operation conditions,
Weather conditions,
Symptoms
Make a good use of a diagnostic worksheet
such as the one shown below in order to
utilize all complaints for troubleshooting.
MR I MRS I Miss I MS
Manuf. !
I Oate I
Startability
Idling
~ : ~ < ; : . "
! Registration Initial registry i
No. date :
I
I Vehicle type :
: Chassis No.1
Engine TIM MIT,AIT I Mileage
NO combustion Partial combusuon
Hard to start (Cold climate. warm climate.
Other (
No first idhng high idle Low idle
Idling unstable
constanHy)
I
(km)
Other [ I
i. Symptoms 1-----.,-----''----------------'----------1
Stumble KnocKing Spilti ng LacK of power
!
Driveability
Engine stall
Incident occurance
Frequency
Weather
condition
Weather
Temperature
Engine conditions
Road conditions
Driving conditions
Other condition
Lack of acceleration
Other [ I
At the time of start
Just after stopping
Other [
While Idling While driving
While loading
Since new Recently
All the time Under certain conditions Sometimes
Not affected
Fine Cloudy Raining SnoWing Others [
Hot V\larm Cool Cold Humid Approx. 'C
Cold After warm-up During warm-up V\later temperature
In town In suburbs Highway Off road (up i down)
Not affected
At starting While Idhng At racing While accelerating
While CruiSing While decelerating While tuming (right! left)
Vehicle speed. km/h, Engine rell: rpm. M! T gear
EN - 234
I
TROUBLE DIAGNOSIS
RB26DETT I RB20E I DE! DET I CA 18i i RB25DE ENGINE
(2) Problem confirmation
Customer's explanation is often insufficient In clarifying
the status of the problem. Reproduction of the problem
on the actual car and its confirmation and analysis are
therefore essential. If unable to reproduce the problem,
ask the customer in detail about its occurrence
conditions and try to reproduce it under the indicated
conditions. If unable to reproduce, manually shake the
concerned harness to check for poor contacts or other
problems.
It is also recommended to collect and analyse the data
using CONSULT while driving.
When checking the actual vehicle, record data on normal
portions to assist in diagnosing a problem.
J
f ~ ~ ~
I 1 see.
this is Ihe
out adive test and !metion test
CONSULT. OR remove vacuum
and apply pressure USlf1g vacuum
crank angle sensor clockwise.
out active test and function test
CONSULT OR rotate crank angle
anti-closkwise
adive test and function test
CONSULT. OR remove O. sensor i
" I
connectoL I
out active test and !metion tes!
CONSULT OR carry out sen
mode 2 In 2000
out active test and function test
CONSULT. OR rotate idle
out act.!ve test an(1 function test
CONSULT OR rotate Idle
screw clockwise.
the engine qUickly and check
contact C8l1Sed by engine torque
RB26DETI! RB20E I DE! DET" CA18i I RB25DE ENGINE
(3) Self-diagnosis
If problems are attributable to the ECCS signal system,
problem diagnosis should be narrowed down using the
self-diagnostic function.
Self-diagnosis
TROUBLE DIAGNOSIS
I What happened up to present?
, How is the signal system at present? Real-time diagnosis or switch ON/OFF
diagnosis using the CONSULT "Data
monitor" function.
(4) Basic inspection
Check to see if three elements of combustion are
functioning normally. Find out which system is faulty: Fuel
system, ignition system or idling control system.
Fuel?
Ignition?
Idling control?
Air-fuel ratio?
Are injector fuel pump operating?
Are spark present?
Is AAC valve operating?
Is air-fuel ratio feedback function normal? ''--________ ---1
EN - 236
TROUBLE DIAGNOSIS
- RB250E ENGINE
(5) Individual system inspection
An effective method to carry Ou: S J agnosis is to check the control unit output
signal first. According to the resv:s 're output signal, continue diagnosis by checking
input signals, individual parts SccC, as acccator and sensors.
[Procedures]

The input data must be monitored 'i;st when using CONSULT.
(Only checking the output data does not provide accurate results).
( Start )
Output signal to
actuator is provided
NO
YES Actuator is
, operating
NO
I
YES Input signal
r
is provided
NO Output harness is
r- broken or shorted
I YES
,-----'-------,
YES I Actuator internal
I resistance IS normal
I
' Actuator is seized
or clogged
NO
:'---
Input sensor !
output is provided.
NO !
YES
Check other I
system!
Actuator
is faulty
Harness I
is faulty ,
! Control unit
is faulty
Sensor
is faulty
! Harness
is faulty
L
[Analysis]
No sensor
output Indicates
a faulty sensor.
Sensor output is
present even With
no input signal.
It indicates
harness is
! broken.
Control unit
Input signal IS
provided With no
output signaL
! IndIcates faiJlt !
with control unit
EN - 237
controi linlt IS
norrar t:ut no
oute",' s S
T""' I
i ::
Actuator
Output signal is
present but
actuator does
nct operate,
Fault With
: actuator.
TROUBLE DIAGNOSIS
RB26DETT I RB20E I DE I DET i CA18, I RB25DE ENGINE
(6) Trouble diagnosis using measuring instruments
(Operations in square frames I I to be periormed with CONSULT.
1, Reproducible problems
Diagnosis
! "SELFDIAG TEST'
When using' __ -1 "DATA MONITOR"
CONSULT ' _ SWitch ON/OFF
- Real time diagnosis
(Data collection)
'-----,
i "DATA MONITOR
I-Input signal monitonng
1-.-, -Monltonng of calculation resutts '-
i sent to output system
i "ACTIVE TEST'
i (Check operation of input &
; output signal system),
OSCilloscope
(Wave observation for Inlector,
ignition system, AAC valve and
other output signals),
When not uSing
CCNSULT ---
Self-diagnosis ___ Oscilloscope
(on-board) (or circuit tester)
(110 signal waveform observaflon)
"DATA MONITOR"
f--
"ACTIVE TEST'
I
'-
(Wavelonm observation using
2,
Non-reproducible r-:="
problems ---j "FIELD TEST'
oscilloscope)
OR
-Wave form observation usin g
oscilloscope,
EN -238
f-- Analysis
I
Understanding
the cause
I--
Analysis
Understanding
the cause
TROUBLE DIAGNOSIS
RB26DETT! RB20E! DE! DET I CA 181! RB25DE ENGINE
12 MAJOR ECCS INPUT SIGNALS AND CONTROL ITEMS
It is important to understand the re,a:onsn,p between the Input signal and control items
(output) of ECCS to efficiently determine the cause of problems.
angle sensor 1 G
Water temperature
sensor
Throttle sensor
gas sensor
ID,'toIMtion sensor
Battery vonage
if conditioner switch
IN,utr,al sWitch
Power steering switch
IlarliticlOtlming start
nt.
I crru"", speed input signal. 11""ili,," timing count.
air volume measuremenl
control of injector injection Ignition timing control.
width.
Engine rpm input signal
speed input
temperature enrichment ignition timing speed change
Icone,cticln. lalteraticm due to water laclcordil1g to water
I cut due to ON signal.
F time enrichment
I injection interruption.
I correction dunng
I cut judgement during
Ispl=ed change.
alf volume measurement.
I cut at Okmih vehicle
sift i
width control by air-fuel
width correction.
1I""iti"n timing change
Ilorlitieln timing change.
angle
IlQrlltlCm timing change
EN - 239
conlrol start at when
IvhF'i"l" speed is below 8
rpm change.
rpm change after
warms UP
Ion.
of engine
Isp"ed reduction when
IS turned.
TROUBLE DIAGNOSIS
RB26DETT i RB20E! DE i DET! CA18i I RB25DE ENGINE
1-3 DIAGNOSIS CHART ITEM BY PHENOMENON
(1) Unable to start ............ No initial combustion.
(2) Unable to start ............ Initial combustion occurs but it is not complete.
(3) Difficult to start ........... Hard to start when engine is cold.
(4) Difficult to start ........... Hard to start after engine warm up.
(5) Difficult to start ........... Hard to start when engine is hot or cold.
(6) Poor idling ................ Fast idling inoperative.
(7) Poor idling ................. Low idle rpm (after warm up).
(8) Poor idling ................. High idle rpm (after warm up).
(9) Unstable idling ........... Engine is cold.
(10) Unstable idling ........... After engine warm up.
(11) Poor driveability ......... Engine breathing.
(12) Poor driveability ......... Knocking.
(13) Poor driveability ......... Lack of output. poor acceleration, poor response.
(14) Engine stalls when start driving.
(15) Engine stalls while idling.
(16) Engine stall while driving.
(17) Engine stall when decelerating or immediately after stopping.
(18) Engine stall when electrical load or power steering load is applied.
EN - 240
TROUBLE DIAGNOSIS
RB26DETI I RB20E I DE / DET i CA18i / RB25DE ENGINE
Diagnosis chart by phenomenon
(1) Unable to start .......... No initial combustion
[Analysis]
, Ignition spark is not generated or no fuel is injected.
, Check if the fuel pump is rotating.
If there is no ignition spark is generated and no injector operating noise is heard, check
the control unit input (crank angle sensor signal) or control unit power supply.
, If the injector is operating but no spark is generated, control unit and crank angle sensor
can be judged as normal. Check the ignition output system (power transistor, ignition,
coil etc.)
, If ignition out spark is generated but injector is not operating, check the ignition output
system (injector power supply, harness etc.)
[Chart]
FUEL PUMP?
Operating? LCheck fuel hose for tension in CONSULT active test mode.
OR
Check if pump operating noise can be heard for five seconds after
turning ON the ignition. (If not check fuel pump system)
INJECTOR?
Operating? --r Injector noise can be heard when cranking
LOR
Check using CONSULT data monitor mode if injector pulse is output
when cranking engine.
If not correct
[
, Check control unit terminal voltage when cranking engine.]
Check injector power supply circuit
, Check crank angle sensor input signal.
IGNITION SPARK?
Is there a
spark?
--r Check if tachometer needle moves during cranking.
L Check using real-time diagnostic mode (CONSULT data monitor).
Check using timing light.
, Remove the plug and check for actual spark.
If not correct
[
' Check control unit output signal (ignition signal) ]
, Check control unit input signal (crank angle sensor)
, Check power transistor and ignition coil resistance value.
EN - 241
TROUBLE DIAGNOSIS
RB26DETT I RB20E I DE I DET I CA 181 I RB25DE ENGINE
[,2: Unable to start .......... Initial combustion occurs but iUs not complete.
(Analysis]
Occurrence of initial combustion means that sparks are created. The three cases
are possible.
1. Initial combustion only.
Is fuel system working? (fuel pump, injector etc.)
2. Engine fires incompletely.
Check if fuel injection quantity is too small or large.
Check the fuel pressure.
Check if water temperature enrichment is provided.
Check if start time enrichment is provided.
Check if ignition liming is normal.
3. Engine fires completely if accelerator pedal is pressed and depressed.
Check if AAC valve operation is normal.
(Chart]
FUEL PRESSURE?
Is pump operating? 1 Check fuel hose tension in CONSULT active test mode.
OR
Check if pump operating noise can be heard for five seconds
after tuming ON the ignition.
INJECTION QUANTITY?
Is fuel pump operating during cranking?
(If not check fuel pump system)
Water temperature ::;r Check water temperature of CONSULT data monitor mode.
enrichment provided?L OR
Disconnect water temperature sensor and check for any
change.
Check water temperature resistance value .
Check water temperature sensor output voltage.
Stan lime enrichment-Check "START' signal ON/OFF (CONSULT data monitor
provided? mode).
IDLING CONTROL?
Is idling rpm [CheCk AAC valve operation (CONSULT active test mode).
increased? Check if AAC valve is fully closed.
Check AAC valve circuit for disconnection or loose connectors.
IGNITION SYSTEM?
Ignition timing Try to advance or retard timing angle.
normal?
Is ignition correct? L Check spark plugs for fouling.
Check for ignition misfiring.
(Check using a timing light or CONSULT real-time diagnostic
mode).
EN - 242
TROUBLE DIAGNOSIS
RB26DETT! RB20E' DE DET CA18i! RB25DE ENGINE
(3) Difficult to start "".,," Hard to start when engine is cold.
[Analysis]
Inspect the system relating to water temperature as this problem only occurs when the
engine is cold.
Fuel injection enrichment from engine temperature sensor signal is not functioning when
temperature is low.
Idling speed control is not functioning.
Start-time enrichment is not functioning.
Cranking speed is too low.
[Chart]
ENGINE TEMPERATURE CORRECTION?
Engine temperatureTCheck using CONSULT data monitor mode.
sensor signal? L OR
Disconnect engine temperature sensor connector and check for
any change.
Check engine temperature sensor resistance value.
Check engine temperature sensor output voltage.
Idling control? tCheck if ACC valve for operation (CONSULT active test).
Check If ACC valve is not fully closed.
Check ACC valve circuit for disconnection, loose connector etc.
START-TIME ENRICHMENT?
'--____ Using CONSULT data monitor mode check if START signal is
provided.
CRANKING SPEED?
Is battery normal?
L-____ Inspect starter, starter cables (resistance, poor contact etc.)
EN243
TROUBLE DIAGNOSIS
RB26DETT I RB20E I DE.' DET , CA 1811 RB25DE ENGINE
I (4) Ditlicullto start ......... Hard to start after engine warm up.
[Analysis]
This problem may also be related to the water temperature control.
Check engine temperature correction is inaccurate.
Check if fuel pressure is correct or if air bubbles are generated in the fuel wen the
engine is hard to start, especially when water temperature is high.
Check it engine cranking speed is low.
[Chart]
Engine temperatureT Inspect using CONSULT data monitor.
sensor signal? L OR
FUEL PRESSURE?
any change .
Check engine sensor resistance value .
Increase fuel --Remove vacuum hose for pressure regulator or clamp return hose.
pressure to check
CRANKING SPEED?
1---- Is battery normal?
"----- Inspect starting system.
EN - 244
TROUBLE DIAGNOSIS
~ ="8 R325DEENGINE
! (5) Difficult to start ......... Hard to start regardless of engine temperature.
[Analysis]
Spark arc is created but air-fuel ratio could be Incorrect
Check fuel pressure.
Check fuel injection quantity. (Is engine temperature correction accurate?)
Check if idling speed is controlled.
Check if cranking speed is too low.
[Chart]
FUEL PRESSURE?
Fuel pump? ~ Use CONSULT active test mode to check fuel hose tension.
LOR
Check if you can hear pump operation noise for five seconds after
tuming ignition switch ON.
Check if you can hear pump operation noise when cranking.
Check if fuel pressure is approx. 2,5 - 3 kg/cm'- (the value differs
depending on CA18L RB20S0HC and DOHC).
Increase fuel --Disconnect vacuum hose for pressure regulator and check for any
pressure to check change. (or clamp retum hose)
Fuel system for Inspect fuel filter.
clogging
Engine Inspect with CONSULT data monitor.
temperature senso{ OR
signal? Disconnect engine temperature sensor connector and check for
any change.
Check engine temperature sensor output Voltage.
Idling control? t Check if AAC valve operation is normal (CONSULT active test).
Check if AAC valve is not fully closed.
Check AAC valve connector circuit is disconnected, loose
connector etc.
IGNITION SYSTEM?
Ignition miSfiring
l
CheCk in real-time diagnostic mode (CONSULT data monitor).
Check crank angle sensor output for missing pulses (CONSULT
data monitor mode or with oscilloscope).
Is spark plug gap normal?
Check for any leak from high-tension cable.
Is ignition timing - Check by advancing or retarding the angle.
normal?
CRANKING SPEED?
1'-____ Is battery normal?
r----- Check charged state.
'----- Check starting system.
EN - 245
TROUBLE DIAGNOSIS
RB26DETT I RB20E ! DE! DET ! CA 18i! RB25DE ENGINE
i (6) Poor idling ............... Fast idling inoperative.
~
[Analysis]
This problem may have been caused by abnormal control of ACC valve and air regulator
as idling speed is controlled by these device.
The air-fuel ratio and ignition timing also relate to this problem.
[Chart]
IDLE CONTROL SYSTEM?
Ai r regulator --'L-IS air regulator resistance normal?
operation Is air regulator seized?
AAC valve IsAAC valve operation signal shown?
IsAAC valve operation normal (CONSULT active test mode).
Is idle judgement ON? (CONSULT data monitor mode).
Check for ACC valve circuit for breaks or loose connectors.
Engine ----.-Check using CONSULT data monitor.
temperature L OR
signal? Disconnect engine temperature sensor connector and check for
any change .
Check water temperature sensor output voltage.
AIR-FUEL RATIO?
Enrich mixture ---Increase fuel pressure (Disconnect pressure regulator vacuum hose
to check or CONSULT active test).
Lean mixture Reduce the fuel pressure (CONSULT active test or apply negative
to check pressure greater than -500 mmHg).
EN -246
TROUBLE DIAGNOSIS
RB26DETT I RB20E ! DE, DET i CA 181! RB25DE ENGINE
(7) Poor idling ............... Low :dle 'pm ,after warm up).
[Analysis]
Idling speed is controlled by AAC valve. A low rpm means insufficient auxiliary air volume
throughAAC valve.
[Chart]
IDLE CONTROL SYSTEM?
AAC valve EIS ACC valve control signal issued?
operation? IsAAC valve operation normal? (CONSULT active test mode).
Measure resistance value of ACC valve and check seizure.
CheckAAC valve circuit for disconnection or looseness.
Input signal? Is idle judgement ON?
L Is air conditioner switch and neutral switch turned ON? (CONSULT
data monitor mode).
IS IGNITION TIMING NORMAL?
EN - 247
TROUBLE DIAGNOSIS
RB26DETT I RB20E' DE I DET I CA18i i RB25DE ENGNE
(8) Poor idling ............ High idle rpm (after warm up)
[Analysis]
High idling can be caused by following points below:
Low engine temperature signal.
Throttle valve switch (Idle judgement) is OFF.
AAC valve is seized.
Air regulator is not energized.
Air regulator is seized.
Control unit adjustment volume is set to HIGH.
Throttle valve is open.
Air is sucked in.
[Chart]
IDLE CONTROL SYSTEM
signal? OR
Engine temperature [CheCk with CONSULT data monitor mode
any change .
Check for engine temperature sensor resistance value.
Check for engine temperature sensor output voltage.
Throttle sensor --Check idle judgement signal with CONSULT data monitor mode or
by using tester.
AAC valve ----;--Is AAC valve control signal present?
control Is AAC valve operation normal? (CONSULT active test mode).
Check AAC valve for seizure.
Disconnect AAC valve connector and close the valve to see if
engine rpm lowers.
Turn off air conditioner and power steering switch OFF and see if
ON signal is disconnected.
Check if neutral switch is OFF or vehicle speed signal input is OK.
Air regulator--Lr-Check air regulator circuit for breaks or loose connectors.
Check air regulator for seizure.
Control unit ---Is adjustment knob set at HIGH position?
adjustment knob
OTHERS
Throttle valve ---Is valve open? (Check for wire binding).
Air suction Block blow-by hose passage and check for any change.
EN - 248
TROUBLE DIAGNOSIS
RB26DETT i RB20E! DE i DET i CA 18!1 RB25DE ENGINE
I (9) Unstable idling ......... Cold engine only.
[Analysis]
Since idling is unstable only when the engine is cold. cause of this problem can be
narrowed down to the relationship between the engine temperature and idle control
system. II also relates to the air-fuel ratio. ignition timing, misfiring etc.
[Chart]
IDLE CONTROL SYSTEM
Engine temperature-Inspect using CONSULT dala monitor mode.
sensor Signal Check engine temperature resistance value.
Check engine temperature output voltage.
AAC valve ---esee if the valve is closed completely. See if idle adjustment is
within specification.
IsAAC valve operation normal? (CONSULT active test).
AIR-FUEL RATIO?
Make the mixture
rich or lean
IGNITION SYSTEM
Use CONSULT active test mode to make the mixture rich or lean or
disconnect pressure regulator vacuum hose or apply additional
vacuum.
Ignition timing-......,...-Advance or retard ignition timing and check for any change.
normal?
Ignition misfiring Check crank angle sensor by real time diagnostic method
(CONSULT data monitor).
Check spark plug condition.
Check ignition system condition by real time diagnostic method
(CONSULT data monitor).
EN 249
TROUBLE DIAGNOSIS
RB26DETT! RB20E I DE! DET ! CA 181! RB25DE ENGINE
[EO) Unstable idling ......... Aft_e_r_w_a_rm_u_p_. __________ ~ ___
[Analysis]
Relates to various factors including air-fuel ratio. ignition system and compression. It is
necessary to determine factors beginning with items that are easy to check.
o Idle rpm control system .... How is MC valve operation?
Air-fuel ration ................... Fuel pressure?
o Injection quantity? (Enriched?)
o Air suction?
o Ignition system................. Ignition timing
Ignition misfiring (Missing signal pulse)
Engine main unit .............. Poor compression
[Chart]
IDLE CONTROL SYSTEM
Disable control--DisconnectAAC valve connector and check for any change.
function
Control circuit---.- Check if control signal is present and check signal condition.
AIRFUEL RATIO
IsAAC valve operation normal? (CONSULT active test).
Disconnect AAC valve connector and check by adjusting with lAS.
Check AAC valve for seizure.
Check if idle judgment is ON (CONSULT data monitor).
Check circuit for breaks and connectors for looseness.
Enrich the mixture -CONSULT active test or remove pressure regulator vacuum hose.
OR clamp return hose.
Lean the mixture --Reduce the mixture ratio by using "FUEL INJECTION" in
CONSULT active test mode, or applying vacuum greater than
-500mmHg.
Stop feedback ~ e r f o r m CONSULT active test
LOR
any change .
Check engine temperature sensor resistance value .
Air suction -- Check vacuum line and blow-by hose.
IGNITION SYSTEM
Ignition timing Advance or retard ignition timing angle and check for any change.
normal?
Ignition misfiring 1 Check ignition system by real-time diagnosis (CONSULT data
monitor mode).
Check condition of the crank angle sensor by rea-time diagnosis.
Check condition of the spark plug.
ENGINE MAIN BODY
Compression---Measure compression pressure (Check valve timing, valve seats,
pressure piston rings etc.)
EN -250
TROUBLE DIAGNOSIS
RB26DETT! RB20E. DE DET CA 181 I RB25DE ENGINE
(11) Poordrivability ......... Engine breathing.
[Analysis]
It is necessary to first verify if the problem occurs during acceleration or during cruising.
1. During acceleration
Engine breathing while accelerator pedal is depressed may be caused by
momentary misfiring or momentary occurrence of lean mixture (ie. no interrupt
injection) .
Inclination of engine during acceleration etc. can increase tension of harness or
air duct that can cause poor contact.
Clogging in fuel system is cause for engine breathing. Sufficient fuel pressure
cannot be maintained during acceleration.
2. During cruising
Lean mixture and engine breathing caused by poor feedback of air-fuel ratio data.
Misfiring of ignition system caused by leaks.
Poor contact or malfunction of signal system, use of low quality gasoline.
[Chart]
1. During acceleration
AIR-FUEL RATIO
Stop feedback T Perform CONSULT active test
LOR
Disconnect exhaust gas sensor.
Enrich mixture --Perform CONSULT active test or disconnect engine temperature
sensor and apply 600 0 resistance after warming up the engine.
Throttle valve --- Check idle judgement ON/OFF operation in CONSULT data
switch monitor mode.
Throttle SenSOf-f --Check if output voltage varies with throttle opening.
Fuel pressure --Check if fuel pressure is maintained even while racing the engine.
Air leak Check air duct looseness.
Air flow meter --- Check output voltage.
output
IGNITION SYSTEM
Ignition misfiring Check signal system (Ignition signal, crank angle sensor signal, air
flow meter signal) for instantaneous break by CONSULT data
monitor.
Check spark plug gap.
Check for any leak from high tension cable.
- Check if ignition coil power supply voltage is lowered.
Ignition timing Check if fail-safe mode is not set due to a detonation sensor error.
EN - 251
TROUBLE DIAGNOSIS
RB26DETT! RB20E I DE I DET , CA 18: RB25DE ENGINE
2. When cruising
AIR-FUEL RATIO
function OR
Disconnect exhaust sensor connector.
Feedback D Perform CONSULT active test
Perform exhaust gas sensor monitor diagnosis to see if exhaust
L
: gas warning lamp (or control unit red lamp) is flashing or check by
CONSULT data monitor.
Check if exhaust gas temperature waming lamp (or control unit red
lamp) is flashing more than five times in ten seconds when engine
is running at 2,000 rpm, or check by CONSULT data monitor.
Throttle valve --- Check idling contact point revolution.
switch
IGNITION SYSTEM
Ignition misfiring - Check for instantaneous break signal system using real-time
diagnosis (ignition signal, crank angle sensor signal, airflow meter
signal) (Use CONSULT data monitor or oscilloscope).
I (12) Poor drivability ......... Knocking.
[Analysis]
This problem may be caused by lean air-fuel mixture, incorrect ignition timing or
malfunctioning or engine main unit or cooling system.
Lean mixture ratio may be caused by fuel enrichment correction not working during
acceleration, incorrect air flow meter output. incorrect air-fuel ratio feedback correction.
Errors in initial ignition timing or knock control system relate to the detonation caused by
incorrect ignition timing.
Other causes can be excessively high cooling engine temperature, increased
compression ratio due to carbon deposits in combustion chamber etc.
[Chart]
AIR-FUEL RATIO?
Fuel pressure? -- Check if fuel pressure remains normal when racing.
Enrich mixture ~ n r i c h air-fuel ratio (CONSULT active test or disconnect pressure
L regulator vacuum hose).
Disconnect engine temperature sensor and check for any change.
Stop feedback L Perform by CONSULT active test mode
OR
Disconnect exhaust gas sensor connector and check for change.
If any change is noted, check the fuel system (fuel pump, sensor
system or clogging in the system).
Injector clogging --Clean with engine conditioner.
Idle judgement Is throttle sensor OFF when accelerating?
IGNITION TIMING?
I Is ignition timing normal?
Knock control----rL-check if detonation sensor error is indicated by self-diagnosis.
Check harness for disconnection or shorts-circuit
EN - 252
TROUBLE DIAGNOSIS
RB26DETT, RB2:JE, JE :;ET CA18, , RB25DE ENGINE
I (13) Poor drivability H"H ... Lack of oLt::JuL poor acceleration, poor response.
[Analysis]
Lack of power, poor acceleration and poor responses are generally caused by insufficient
mixture quantity (lack of fuel, lack of air) or incorrect air-fuel mixture ratio.
In the injection system, these problems are caused by lack of ignition energy or incorrect
ignition timing.
Lack of compression pressure and excessive friction due to seizure in engine main body
are also causes of these conditions.
[Chart]
MIXTURE AIR QUANTITY, AIR-FUEL RATIO
Fuel pressure Check if fuel pressure drops during racing (check for clogging
with fuel pump and fuel system).
Enrich mixture --Enrich by CONSULT active test or disconnect pressure regulator
vacuum hose.
Stop feedback --Check for change by CONSULT active test or disconnect exhaust
sensor connector,
Injector clogging - Clean with engine conditioner (CONSULT active test or pour
conditioner into fuel filter, start engine then race engine).
Air flow meter ---Check output voltage.
output
IGNITION SYSTEM
Spark plug? Is plug gap normal?
Ignition timing ---r-Is ignition timing normal?
r Check by advancing or retarding ignition timing angle,
'-Check detonation sensor for abnomnality (self-diagnosis for
harness disconnection and shorts).
Ignition energy? ,-Check ignition coil power voltage.
L Check for any leak from high-tension cable.
ENGINE MAIN BODY
Compression ---Measure compression pressure (Also check valve liming, valve
pressure? seat contact, piston and rings).
EN - 253
TROUBLE DIAGNOSIS
RB26DETI i RB20E, DE ' DET ! CA 1 ail RB25DE ENGINE
I (14) Engine stall when start driving,
[Analysis]
Engine stall is caused by misfiring when accelerator pedal is pressed or insufficient torque
when starting off .
Misfiring
Too lean or too rich air-fuel mixture ratio.
Large error in ignition timing.
Weak spark.
Insufficient torque
Lean or rich mixture.
Insufficient intake air quantity.
Insufficient compression pressure.
[Chart]
SELF-DIAGNOSIS
I Check if occurrence of error is stored by self-diagnosis function.
AIRFUEL RATIO
Enrich mixture CONSULT active test or disconnect pressure regulator vacuum
hose.
Lean mixture CONSULT active test or apply vacuum greater than -500mmHg
with vacuum hand pump to pressure regulator.
Stop feedback --r-Pe rform CONSU L T active test
LOR
Disconnect exhaust sensor connector (race engine and return to
idle).
Check canister --Check by blocking purge line.
Throttle valve Check if idle judgement is OFF when accelerator is ON (check by
switch CONSULT data monitor),
----Check engine temperature sensor.
Throttle sensor Check if accelerator opening signal is output
IGNITION
Spark Check spark plug condition (fouling, gap, electrodes).
Ignition timing--- Check if ignition timing is correct.
Ignition error Check by real-time diagnosis (Perform CONSULT data monitor)
High-tension Check resistance value and any leak.
cable
INTAKE AIR QUANTITY
f-I--- Check ifthrottle valve opens normally.
1---- Check lor any leak from turbocharger system. Duct inspection.
COMPRESSION PRESSURE
Measure ----Check valve timing, valves for incorrect timing, piston, ring for
compression damage.
EN - 254
TROUBLE DIAGNOSIS
RB26DETT'RB20E DE JET CA,g i RB25DE ENGINE
I (15) Engine stall while idling.
[Analysis]
Engine stall during idling may be caused by one of the following conditions. (check idling
speed. and then check for misfiring).
Improper Idling speed.
Improper AAC valve control (Check for delayed response).
Excessively lean or rich mixture ratio.
Ignition error.
Poor connector contacts etc.
Relation to electrical load ONOFF.
[Chart]
SELFDIAGNOSIS
IDLING CONTROL
Proper control--,-Is idling speed normal or adjusted?

IsAAC valve fully closed? (Check for loose connector).
Close AAC valve fully and check for any change.
AIR-FUEL RATIO
Is AAC valve control signal issued?
. (Race engine and check Voltage).
L
t
Is AAC valve operation normal? (CONSULT active test).
DisconnectAAC valve connector and check by adjusting lAS.
See if idle judgement is ON.
Air-fuel ratio ---Check if exhaust gas temperature warning lamp (control unit red
normal? lamp) will flash more than five times in ten seconds when engine is
running at 2,000 rpm, or check by CONSULT data monitor.
Enrich mixture ---Perform CONSULT active test or disconnect pressure regulator
vacuum hose.
Lean mixture ---Perform CONSULT active test or apply vacuum greater than
-500mmHg with hand pump to pressure regulator.
Stop feedback LPerform CONSULT active test
OR
Disconnect exhaust gas sensor (Set circuit from racing mode one
time and return to idling mode).
Fuel pump ----Check for pump stop.
Fuel system Race engine and check fuel pressure for drop.
clogging
OTHER
Poor contact ---Using real-time diagnosis mOd, check ignition signal, crank angle
sensor signal and air flow meter signal for instantaneous break and
missing pulses. (Use CONSULT data mode or oscilloscope).
Spark plug ----Check for fouling and plug gap.
EN - 255
TROUBLE DIAGNOSIS
RB26DETT! RB20E I DE i DET I CA18i I RB25DE ENGINE
,-I (_1_6_) _E_n_g_in_e_s_ta_ll_w_h_il_e_d_riv_in_g_, ________________ ~
[Analysis]
Engine stall during cruising may be caused by misfiring. If engine stalls during accelera-
tion, it may be caused by misfiring or insufficient torque.
o Too rich or lean air-fuel mixture.
o Ignition error,
o Incorrect ignition timing.
o Insufficient intake air quantity .
Insufficient compression pressure .
Misfinng, fuel pump stop, etc. caused by poor electrical contact.
[Chart]
SELFDIAGNOSIS
(1) When cruising
AIRFUEL RATIO
Throttle valve Check if idle judgement goes OFF at correct time.
switch
Feedback Check if exhaust gas temperature lamp (control unit red lamp) will
flash more than five times in ten seconds when engine is running at
2,000 rpm, or check by CONSULT data monitor.
Stop feedback -r-Perform CONSULT active test. OR
LOisconnect exhaust gas sensor connector.
Intake air quantity-Check for poor contact by CONSULT data monitor (real-time
signal diagnosis),
IGNITION
Ignition timing Is ignition timing correct?
Ignition misfiring-- Check ignition signal, crank angle sensor signal for missing pulses
in CONSULT data monitor.
(2) During acceleration
AIRFUEL RATIO
Throttle valve switch - Check if idle judgement goes ON-OFF when acceleration pedal is
pressed and released (CONSULT data monitor),
Throttle sensor --Check if voltage output varies with throttle opening.
Feedback Check if exhaust gas temperature lamp (control unit red lamp) will
flash more than five times In ten seconds when engine is running at
2,000 rpm, or check by CONSULT data monitor.
Stop feedback -r-Perform CONSULT active test. OR
L Disconnect exhaust gas sensor connector.
Intake air Check for poor contact by CONSULT data monitor.
quantity Check for air flow or leak after turbocharger operation.
MISFIRING
Ignition timing Is ignition normal?
Ignition misfiring --Check ignition Signal and crank angle sensor signal for missing
pulses in CONSULT data monitor.
EN - 256
TROUBLE DIAGNOSIS
RB26DETT! RB20E. DE. DET CA181! RB25DE ENGINE
(17) Engine stall when decelerating or immediately after stopping.
[Analysis]
Reduced engine rpm when releasing accelerator pedal can lead to engine stall, Another
cause is misfiring.
Incorrect adjustment of idling control,
Incorrect air-fuel ratio.
Ignition error.
[Chart]
IDLE CONTROL
Idling speed ---Is idling speed normal? Is idle adjustment correct?
Control Check if AAC valve control signal is output
AIR-FUEL RATIO
Check if AAC valve operation is normal (CONSULT active test).
Check if AAC valve is OK.
Check if idle judgement is ON.
Check by disconnecting AAC valve connector (AAC fully closed).
Stop feedbaCkLPerform CONSULT active test.
OR
Disconnect exhaust gas sensor connector.
Feedback ----Check if exhaust gas temperature lamp (control unit red lamp) will
flash more than five times in ten seconds when engine is running at
2.000 rpm, or check by CONSULT data monitor.
Enrich mixture ---CONSULT active test or disconnect regulator vacuum hose.
Lean mixture CONSULT active test or apply vacuum greaterthan -500mmHg
with hand vacuum pump to pressure regulator.
IGNITION
Ignition misfiring --Check ignition signal, crank angle sensor signal for missing pulses
in CONSULT data monitor.
ENGINE. AfT FUSION CONTROL
Control----- Carry out self-diagnosis.
EN - 257
TROUBLE DIAGNOSIS
RB26DETT! R820E! DE! DET i CA 18i! R825DE ENGINE
~ .. ~
I (18) Engine stall when electrical load or power steering load is a_p_pl_ie_d_. _____ -'
[Analysis]
Check if idling is increased when load switch is turned ON (AAC valve correction quantity
increases when load is applied) .
Check If ON signal is input from each switch .
Check if AAC valve is operating.
[Chart]
IDLE CONTROL
Idling speed ---'L-IS idling speed normal? Is idle adjustment correct?
Check if AAC valve is fully closed.
Control----,--Check if AAC valve control signal is output
Check if AAC valve operation is normal (CONSULT active test).
Check if AAC valve is OK.
Check if idle judgement is ON.
Check by disconnecting AAC valve connector (AAC fully closed).
Input signals ---Check if air conditioner switch and power steering switch signals
are provided (CONSULT data monitor).
EN -258
DIAGNOSTIC SYSTEM
RB26DE1T, RB2GE C:;E uc, CA' 8 , RB25DE ENGINE
2. DIAGNOSTIC SYSTEM
2-1 GENERAL
The diagnostic system periormance has improved greatly concerning warning indication to
drivers, operation of the self-diagnostic system and application of the newly developed
electrical system diagnostic tester CONSULT,
(1) Enhanced fault warning items
In case when a fault occurs in the ECCS system while driving, the exhaust temperature
warning lamp will flash in the instrument panel to warn driver. At the same time, the back up
function will activate to ensure the safety of the occupants and the vehicle. The warning
items has been increased in recent years.
(2) Simplified troubleshooting strategy
The following features have been incorporated for simplifying inspection and problem
diagnosis of ECCS system,
1. Improvement of self-diagnostic function
The diagnostic modes have been rearranged and the mode shift and display
systems have been simplified.
New system
2
Fault warning (Same back up as
past display mode)
Exhaust gas sensor monitor
(Same as past air-fuel ratio
feedback display)
By diagnostic connector
Installed near fuse block
(Also adjustable by the
Self,diagnosis
control unit adjustment knob)
Indicated by exhaust gas
temperature warning lamp
(Also linked with control
unit red lamp)
(The former ON/OFF switch diagnosis
and real-time diagnosis are included in
the operations performed by CONSULT
as explained In item 2 on the next page,
In the past
Back up display
2 Alr,fuel ratio feedback display
3 Normal self diagnoSIS
4 Switch ON/OFF diagnOSIs
5 ReaJ-time diagnosis
Adjustment by control
unit adjustment knob
St'lort-circult these termi'la!s tor appro/(.
2 sec 1he(l open the lerr'f'uoals to change
d,agnosl,c @j I I I I EI-I mode

Indicated by red or
green lamps on
control unit
. OOO"ll.Gll I (Fuse
, b'OCk)

- -- L __ Exflaus! gas temperature
warning lamp
EN" 259
DIAGNOSTIC SYSTEM
RB26DETI j RB20E I DE i DET i CA 18i / RB25DE ENGINE
2. Introduction of electronic system diagnostic tester for fault diagnosis
To enable use of the newly developed electronic system diagnostic tester
CONSULT the diagnostic function have been modified. It will simplify complex
diagnosis procedures.
CONSULT is a hand held type compact and lightweight type tester device
especially designed for automotive service operations. It can be used by
connecting it to the diagnostic connector installed on the vehicle, This tester can
permits data display. recording and printing.
Diagnostic
mode
Supplement
Self-
, diagnostle i
I '
Self-diagnostie
Same no of items are
posslble as previously
described 1
Data
monitor
Used to ldentify malor causes of fault
lae,;orejinQ to results of self-diagnosis
IMonltor and print input I output data of control
Dala recording In case of eng one fault or
teneliir 1e stall.
iF ormer diagncstic modes listed below are
'included in this monitor Item.
i Exhaust gas sensor
momtor
SWitch ON/OFF
Real-time dlagnosls
Displays exhaust gas
sensor output voltage
and lean or rich
mixture
Same as previous
function
Same as previous
function
Used to examine major causes of faults
I"r.(:nrrllng to self-diagnosIs results and data
Active test momtor ~
I Used to check actuator operatIon by giVing
driving Signal to the actuator :
Work Used to reduce additional operation when
support checking Idling etc .
EN -260
Modes can be
selected by
touch-senSitive
keys on
CONSULT
Displayed
data can be
read on the
CONSULT
screen
DIAGNOSTIC SYSTEM
RB26DETT! RB20E! DE, DET ! CA 1811 RB25DE ENGINE
::::::::: "MOC 0 g 0
I,: . .' . ' ..... speed sensor 0
::_.1.. '. voltage 0
[' Throttle sensor 0 0 0
;
I,id ;;,1 Idle position 0 0 I

Intake temperature sensor 0 0 i
1,,';1,'1,;': Detonation sensor 0
,"< switch (Start signal)
Air conditioner, neutral. power steering
.", 011 pressure SWitch, electnc Icao switch
I. "', M iT Signal
'.?II"I,I'
FICO solenoid (CA18i)
PTC heatsr (CA 181)
EN - 261
DIAGNOSTIC SYSTEM
RB26DETT ! RB20E! DE I DET ! GAlS,! RB25DE ENGINE
2-2 SELF-DIAGNOSIS
Self-diagnosis can be performed by indications from warning lamp (exhaust gas
temperature warning lamp) in instrument panel display and ECCS control unit red lamp
display, or by displaying data on the CONSULT screen.
(1) EXHAUST GAS TEMPERATURE WARNING LAMP DISPLAY
There are two diagnostic modes. In each mode, diagnosis is pertormed by operating the
diagnostic connector terminal installed on the vehicle. (Diagnosis can also be pertormed
using the adjustment knob on the control unit). The diagnosis results are displayed by the
exhaust gas temperature warning lamp in the combination meter and the red waming lamp
on the control unit.
Basic operation and indications
warning
Self-dlagnosis
Exhaust gas sensor I
monitor

ignition switch ON

Engine rotation
Ignition SWitch ON
j
DiagnoSIS mode shift
. j
Engine stop
(with igninon switch ON)
status
descnbed above
j
Engine rotabon
Alarm Faulty system indicated by
i warning lamp flashing
. NormaL warning lamp remains OFF
i Fault. Faulty system IS indicated by
, flashing code
Normal: Flashing code "55"
displayed
Lamp ON means "lean" mixture
Lamp OFF means "rich" mixture
(1) Fault warning mode (Mode 1)
the
will be executed. In
this case, the self-diagnosis
mut be selected (see
(2)]
Indicated by exhaust gas temerature warning lamp In instrument
panel and red lamp in control Unit (these lamps are linked together).
Warning
Engine
rotation
Display Condition
Stop ON (lamp check)
ON ON 1 sec CPU backup (Lamp .
OFF Of'FJLrLrL flashes when engine is
1 sec. . OFF)
ON r Crank angle sensor
Rotating OFF OFF,J L---.J backup
" 3 sec.
1 sec, Throttle sensor
backup (lamp flashes
1 sec. when engine is OFF)
OFF ON (lamp check)
Nennal
Rotating OFF .. _ I
EN - 262
DIAGNOSTIC SYSTEM
RB26DETT i RB20E 'DE DE" CA 18, i RB25DE ENGINE
(2) Self-diagnostic mode (Mode 2)
Turn ignition switch ON.
Normally fault warning mooe IS set wner. Ignition
sWitch IS turned ON It is necessary to select
diagnostic mode.
Iinclic81ted by exhaust gas temerature wamlng
lamp in instrument panel and red lamp in
Icemtrol unit (these lamps are linked together).
Short circuit CHK and IGN terminals connected on
the diagnosis connector located on the vehicle
(near the fuse box) for approx. 2 seconds then
separate the terminals.
Example: IndIcation of code number "43".
(Diagnosis connector)
RX TX HI-:
;- 0.4 sec. x 4 ;- 0.2 sec. x 3
Ie
") LH
:;FU
0.4 sec. x 3 0.2 2
(The fault warmng mode and sell-diagnosis mode
alternate each time the operation is performed)
Stop the engine. (igmtion SWitch in ON position).
the engine IS operated In thIS condition the exhaust
Approx. 12 sec.----i
sensor monitor win the next mode is activated.
diagnostic connector terminals
CHK: Diagnosis start (Check) RX: Control unit data reception
IGN: Ignition power supply TX: Control unit data transmission
ClK: Transmission synchronization signal (clock)
GND
I c:!J' .1 : .. "I
.. :". Crank angle sensor 1'signla or 120' is not input for a certain period of time
i;'::' :. after starting the engine. 0 0
, )" system Incorrect signal waveform.
I't. Hot wire disconnection.
I Disconnection or short-circuit in air flow meier power
I ;; hi_ . supply line. ground line or signaal system.
.. tf,eIO'TIw meter signal Signal output is below 0.5 V for a certain penod of time
1./ I i during engine operatiOn.
I
; I Signal output is over 2 V with engine stalled. or when
H : ignition switch is in ON from OFF.
.;, temperature ! Brake or stlort-circuit in engine temperature sensor
.;: . signal system, signal system.
:J ill Air-fuel ratio learning I Air-TIJe
l
ratio is lean towards enrich side for a long
;i control of time.
Ignition signal
system
>i;... Detonation sensor
signal system
. Intake temperature
sensor signal system
Throttle sensor
signal system
'.f!: IC' A i T transmiSSIon
f: "e",

[<;:'1ll,,1"" error
>;!' ,,,,v,, signlal is not generated even though crank angle:
v, signal is entered. I
Disconnection or short-circuit in detonation sensor
signal system .
Disconnection or short-circuit in Intake temperature
senSOr Signal system.
DisconnectIon or short-circuit in throttle sensor signal
system.
DisconnectIon or short-circuit in AfT transmiSSion
system.
No abnonmality found in any of the above SIgnal
EN - 263
i
o
o
o
o
o
o
o
o
o
o
o
o
DIAGNOSTIC SYSTEM
RB26DETI! RB20E / DE! DET! CA18, F.B25DE ENGINE
How to erase memory
(a) Stop the engine in mode 2 and short-circuit terminal "CHK" and'IGN" of the
diagnostic connector for over 2 seconds. Then disconnect to erase the memories.
(the memory is also erased when the self-diagnosis mode is switched to fault
alarm mode).
(b) When method (a) is not used: If the ignition switch "START' operation is performed
successfully 50 times, the memory will be erased automatically.
(The memory will be erased automatically every 50 "START' operation of the ignition
switch).
(3) Exhaust gas sensor monitor mode 2)
ignition switch to "ON" position.
1[l';ICt,8Ckthat self-diagnoSIS mode is set
2
mode can not be changed when engine is
loDelati.no. After warming UP the engine.
limore"se the engine speed until exhaust gas
:It.emperature warning lamp (or corrtrol unit lamp)
Ils,tarts flashing (approx. 2000rpm) and exhaust
gas sensor output (R) mode IS set.
ai r-ruel ratio feedback control is clamped
idling. check by pressing the accelerator
pedal slightly.
In this condition check that exhaust gas
temperature waming lamp flashes.
Connect terminals "CHK" and "IGN" of the
dic,on,osl:ic c,onnector for over 2 seconds then
isc()nr>ect..The exhaust gas sensor ,output
is SWitched after exhaust gas
temperature warning lamp (or red lamp in
I unit) flashes 2 times.
Indication IS made by tOe warolng la'11p (exhaust gas
temperature warning lamp) on the instrument panel and
the red lamp on the control unit
1. Durirg air-fuel ratio seedback control:
OFF: when 8"""usl sensor output is "RICH"
ON: when exhaust sensor output is "LEAN"
I (Referencel The lamp ON and OFF indication ,s the
as that of lhe all-fuel ratio feedback correction
Icoefficent ",dicated by lhe red lamp in the former
I unit.
Wher. ratio feedback control is clamped:
The status immediately befo'e c!aMplng IS
maIntained,
When air-fuel ratio feedback control is faulty: OFF
i I example:
ON {Lean) n n il
OFF L...J
-- . {Lean: AiA+B x 100
1 cycle dt;ty raM Rich: 8!A+8 x 100
The status of the air-fuel ratio IS indicated by the duty
ratiO In one cycle.
Sgna! thaI SWItches
Exfl.."luSi gas sensor and
Exnaust gas sensor {R;
ON (Lean) I n
l
OFF (Alctlj; L---
, I L,,-, ,
,
0.2
4
-;?l
Exhaust gas
sensor output mondor
nIL
Sigrai trat switches
Ext'aust gas sensor (vfd Exhaust gas ,

I I f Ct2
4 sec.
..-
EN - 264
DIAGNOSTIC SYSTEM
RB26DETT I RB20E i DE! DET i CA 181 I RB25DE ENGINE
(2) CONSULT DISPLAY SCREEN
Connect CONSULT to the diagnostic connector on the vehicle (near fuse block). Data is
displayed on the CONSULT screen as touch-sensitive key. The exhaust gas sensor
monitor. switch ON/OFF operation and real-time diagnosis are performed using data
monitor mode.
connector /1
, =TIl
, I
, " : !i
q
(1) "Self-diagnostic" mode
The diagnostic items are same as (1) (2). Faulty system name is indicated,
~ s ,
1
2
3
4
Connect CONSULT to diagnostic connector
of vehicle,
Place Ignition switch to ON.
Inspect wlth "Self-diagnosis' mode.
r"---SELF-DIAG .,1
, RESULTS Numos, of times
i FAiLURE DETECTED TIME the vehicle has
i ENGINETH,,1P SENSOR 0 " d
r oeen riven Since
, detec!!rg the :as!
, problem. if same
proolem is still
Touch "PRINT" key to print, Touch "ERASE" i
to erase data. L ERASE .. ~ . ~
oresent "0 is
displayed.
EN - 265
DIAGNOSTIC SYSTEM
RB26DETT! RB20E! DE! DET i GA18i I RB25DE ENGINE
2-3 FAIL-SAFE FUNCTION AND BACKUP FUNCTION
The fail-safe function ensures the safety of the driver and the vehicle by using the control
U'lit control signals in case of an error in an important system device.
Tr,e back up function ensures normal vehicle operation when an error occurs in an
Important sensor. The control unit will ignore the signal sent from a failed sensor and
outputs prearranged control signals.
The fault alarm mode is set when the backup function is operating and exhaust gas
temperature warning lamp will flashes in the instrument panel to warn the driver.
o
0
0 0
o o
, 0 CPU backup
!
. RB20E Crank angle
! ::mly sensor backup
0
0
!
o
Air flow meter
Engine
temperature
Detonation sensor
Throttle sensor
backup
I t:xnaUSl gas
\Nhen detecti ng error 10
internal circuit of control
unit
Fix Ignition timing at warning
specIfied value lamp ftashes in 1-sec !
Fix fuel injecfion at start- interval
: time. idling and drilling i Reduce speed when
i : CPU IS performed
When crank angle
sensor Signal (1' or
Fix ignition timing at
120') is not displayed . specified value
: for more than 3 seconds
! when engme is started !
i
VVhen intake aIr quantity: Fix ignItion
i Signal IS dIsconnected i pulse v.dth at specified
value
engine operanon Fuel cut at 2400rpm
snon-CirCUltO or I normal engine
\'Vhen Sl1Ort-Clfcuitea Of
VVhen short-clfCUlted
l(arJprcbx .. O.2V max) or
i (approx.
5V min) dUring engine
operation
EN - 266
maXlmb!1m 5f! engine IS
in knock control
I cut at 3200rpm
Controlled by engine rev
and the vehicle speed
C!<I'.U>lgas
/ternperatUire warning
lamp flashes 10
3-sec 1f1terval ("11" IS
i i ndleated In self-
: dlagnoS! s mode)
i ("12" IS Indicated In
. seW-diagnosls mode)
("13" is indicated in
mode)
("34" is Indicated in i
mode)
Exhaust gas
temperature warning
lamp flashes in
1-sec interval
("43" is indicated in '
i self-diagnosis mode) I
DIAGNOSTIC SYSTEM
RB26DETT! RB20E . DE DE CA 181 i RB25DE ENGINE
24 DATA MONITOR
The data monitor can be utilized when performing troubleshooting or trouble diagnosis
according to self-diagnosis result. GONSULTwili monitor and print the EGGS control unit
input and output signal data.
(1) Monitoring items and description
o o
CAS RPM (POS)
i
El"gme rpm calculated 7rom POS (10) or - !
RE F <; 1800) signal sent fiorr era nK f-I A-C-CU-",-c-.Y-S-lig-m-.I-Y-Io-we-.-re-o-a-I--' rpm
o
RB20E CAS RPM (REF)
only
angle sensor :less than Idle speed i
o o
AR FLOW V Air flow meter outp:Jt voltage
Voltage IS set at approx. OV
when engllle IS stopped
10
1
o
ENG TEMP SEN C
Engine temperature value converted
from engine temperature serlsor vottage
I If dlsconne-ctH)'" or i
occurs in sensor CI(cui:, fall-safe
is activated and engine temp is
fixed at a cerium IelRt
o o
o o
o 0
o 0
1
0 o
o
o
o
"XH GAS SEN
EXH GAS SEN (R)
f'lfR ;::!C MNT
MJR FtC :-JNT (R)
o CAR SPEED SEN
o BATIERYVOLT
o THROmE SEN
cHRomE SEN (2)
v Exhaust gas ser.$Of outPut vortage
Alr-fLe! ra;IQ of exhaust gas sensor
i 51gr:a1 d\XIng air-fuel ralJo feedback
Sensor outpJl is fixed at OV
.. vhe'l engine is
-RCH { If cran:p OCCl.TeS the status iJSt
; (LEA\I) RICH Detects rich mixture and :Onlrol before clamp OCCiJrance is
,IS :::perated 10 reduce m1xtLtre ratio 1r)(lICa(eC
LEAN' Detects lean mixture and control:
is operated to Iflcrease mixture ratio
km J h Value calculated from vehicle speed
sensor signal
v ECGS control unit paVler supply voltage i
Th;ottle sensor output voltage
V CA 18i { Throttle sensor Signal 1
: Throttle sensor (2) . S,qnal 2
The value converted from lf1ake Fai; safe IS activated If
1
I
I
o
IN"': i A TEMP SEN 'C temperature sensor output voltage to
inake temperature
disconnection or snort-circUIt I'
occurs and set to this value_
o
o iSTARTSG
o 0 o
IDLE POSmON 1
,
i 0 0 I' iON! ON I OFF se''''g IS detem1lned fcc",
, v AIR CON;:) SIG
'--=--1---=,-1--=--1-------..., OF F) each signal output
10 0 0
NEUTRAL SG
,0 0 0
PW/Si
o
ELECT FAULT SIG
o o
o lNJ PULSE msec Va:ue cOMputed by control uri!
.
0
1
0
IGN TIMING
BlOC
((.) : Value is computed by wntrol umt
is iooicated mcspectlve i
of starter signal after staftng
A vaiue is indica lee '.\li1h engine
stoppeo
Me VALVE
Value computed by control unil : A fixed value is indicated with
"%" proportional soleno:d system engine stopped

, 0 'A I F A;..FHA :rv1ear value of air-fuel rata feedback
! 0 A! F ALPHA, (R: i correction factor tor each cycle
o
o C' 0 AIR CO NO REi_AY i (ON i Icol'ltrol corx:htlon comptJI:ed by control
OFF) lu""
, . ! ON Corn:;ct;on"
ON! : Control condition : open
O
I
' FC:JS/V ( ,'corrtroliedbycontroliOFF,C,--,ITectlon
i i OFF) llnjt :passage ___:
I
PTe HEATER
o
,'N I G CONTS IV
toN - 267
DIAGNOSTIC SYSTEM
RB26DETT I RB20E I DE! DET I CAtBi I RB2SDE ENGINE
(2) Operation and display
'$TEIl'
'
,'" ;"

}:;"-; '"
- "," ; - ""-,--- ," -
1 Connect CONSULT to diagnostic connector
I "i'rMONITOR'{;; NO FAIL cr
on vehicle.
; CAS. RPM (POS) 687rpm
IAIRFLOWMTR t.08V
ENG TEMP SEN 70C
EXHGASSEN 030V
2 Run the engme or drive the vehicle.
EXH GAS SEN MON LEAN!
CAR SPEED SEN
Okmlhi
I
RECORD
I
3 Select desired item on "DATA MONrTOR".
I*"ONITOR4 \;0 FAIL
l:J
I
;CAS. RPM (POS) 685
r
pm
iAIR FLOW MTR 1.06V
4 Press RECORD" key.
i ENG TSMP SEN 80"e
'EXH GAS SE"
O.35V !
EXC; GAS SEN MON LEAN I
,CARSPEEDSEN Okrn/h '
I
'BATTERY VOLT 13_8V !
RECORD i
(1) Exhaust gas sensor monitor
Exhaust gas sensor output voltage and RICH I LEAN status are displayed.

1
2
3
Connect CONSULT to diagnostic connector,
on vehicle.
Run the engine.
: Select EXH GAS SEN, EXH GAS SEN-R,
f1'MONITOR'{;;NO FAIL l:J
: EXH GAS SEN O.t8V
I EXH GAS SEN MON RICH
MIR FIC MNT and MIR FIC MNT-R items L'
on "DATA MONITOR". I'
_____________ ll' __ __ J
(2) Switch ON ! OFF.
The ON I OFF status of each switch is indicated.
1
2
3
4
on vehicle.
Run the engineor drive the vehicle.
EN - 268
DIAGNOSTIC SYSTEM
RB26DETT / RB20E' DE DET CA1S,! RB25DE ENGINE
Diagnosis item
(1) Ignition switch START signal system
(2) Throttle valve switch (idling connection) signal system
(3) Neutral switch signal system
(4) Power steering switch signal system
(5) Electric load signal system (CA 18i)
(3) Real-time diagnosis
Although the diagnosis items are same as those listed in 2-2 (1) (2) self-diagnosis,
and switch ON/OFF in section 2-2, this diagnostic mode provides higher detection
capability than the self-diagnosis mode (2). But it doesn't diagnose intake
temperature sensor signal system for CA 181.
STEP
' . .. OPERAllON
.......... :)
.'
.. ,:
I. REAL-TIME DIAG. nl
on the vehicle.
ENGINE TEMP SENSOR .
2 Run the engine or drive the vehicle.
_ .... ___ .... _J
3 ! Select deslred items on "ACTIVE TEST
!
menu. --------1111
.. DATA (MEMORY1)
4 Press "START' key and input set value.

EN - 269
DIAGNOSTIC SYSTEM
RB26DETT I RB20E, DE I DET I CA1S, i RB25DE ENGINE
2-5 ACTIVE TEST
The active test mode is utilized to examine the problem diagnosis according to self-
results and data monitor results, CONSULT will give driving signals to the
acwators while isolating the on-board ECCS control unit, to check if the actuator is
functioning normally,
(1) Test items and description
Some test items may not apply to all vehicle modes.
Fuel-injection Changes air-fuel ratio
o
AAC valve opening Sets control value (opemng)
Engine teperature Sets engine temperature
o
Ignition timing Sets delay angle correction value
o
Idle correction S I V
o
FICO S IV Turns ON IOFF o
Fuel pump relay
o
Self learning cant
Clears learned data on air-fuel ratio
feedback correction factor
o
I. ACTIVE TEST
on the vehicle,
FNGINETEMP
2 Run the engine or drive the vehicle,
bAs, RPM (POS)
3 Select desired items on 'ACTIVE TEST'
menu,
,INJ PULSE

Press "START" key and inPut set value,
EN - 270
o
o
o
o o
o
o
o c
.C;
-2'C
I
Sating value
112rprrJ
7,3 ms Data mO'litor
25BTDCi
Setting value
increase and
decrease '<eys,
DIAGNOSTIC SYSTEM
RB260ETI ~ B 2 E :E CA 181 RB25DE ENGiNE
26 OPERATION SUPPORT
CONSULT can be used as an aid for idlng checks and other engine tune-up operations, It
issues instructions to the ECCS control unit to perform control and displays the input and
output signal data being used, Actual tune-up operations must be performed manually by
the mechanic (for example, turning adjustment screw etc),
(1) Support items and description
Idle rev ad)
MC valve adj
Idle SWad)
I Ignition timing ad)
Throttle sensor ad)
Fully closing idle rev correction solenoid and
displays idle rpm speed
Fully close MC valve and displays idle rpm
Displays engme rpm when Idle contact point
changes ITom OFF to ON by fully closing MC valve
Fix Ignition timing feedback control and displays
ignition timing
Fully closes thronle valve and displays throttle
sensor output vonage
Oi
o
o
o
o
Stops fuel pump operation and stall the engine
Fuel pressure release (crank the pedal 10 release fuel pressure Within the
fuel PIPing)
o RB20E
1
2
on vehicle,
Run the engine
3 Select deSired ilem on "WORK
SUPPORT' menu
4 Press "START' key and execute operation.
EN - 271
+GN TiMING ADJ.
PRESS "START' WHEN iDLING
AND STOP IGNrTlON TIMING
FEEDBACK CONTROL
ROTATE CRANKANGLE
I
SENSOAAND LSE TIMING
LlGHTTOADJUST
+GN TiMING ADJ.
fGNITION TiMING FEEDBACK
FIXED
CAS, RPM (REF)
GNl1MING
IDLE POsrriON
S7Srpm
12BTDC I
ON
o
o
I
BASIC INSPECTION
RB26DETT I RB20E I DE / DET / CA18, ENGINE
3 BASIC INSPECTION
Inspect three elements of combustion (1. Is fuel injected? 2. Does the spark ark? 3.
Does the AAC valve work correctly?) and determine if the faulty system is the fuel
system, ignition system or idle control system.
3-1 Injector operation inspection
Check for injector operation noise (click, click, click)
while cranking the engine by placing stethoscope or s
crewdriver on the injector.
IF NG: Inspect injector control circuit.
3-2 Fuel pump inspection
Connect CONSULT to the diagnosis terminal on the (if)
vehicle side (near the fuse block). I.J!!V
Turn the ignition switch "ON" and select the "ACTIVE
TEST" mode. Press "Fuel pump relay" and check for
pump operation noise.
3-3 Fuel pressure inspection
(1) Simple inspection
Pinch the hose between fuel filter and fuel gallery when
the fuel pump is operating. There must be tension and
pulsations in the hose.
EN - 272
ACTIVE TEST 0
FUEL PUMP RELAY ON
CAS. RPM (POS) 9S0rpm
I ON "ON/OFFII OFF I
RB26DETT I RB20E; DE! DEI! CA 181 ENGINE
Run the engine,
Select "FUEL PUMP RELAY" in the "ACTIVE TEST' l'
mode, \!!J
Press OFF switch to release fuel pressure.
(2) Inspection using fuel pressure gauge
Fuel pressure release tth
Remove the fuel pump fuse after starting the engine.
Crank the engine 2 - 3 times to consume all fuel in the
fuel lines.
When engine will not start, remove pump fuse and crank
engine 4 - 5 time to consume all fuel in the fuel lines.
Caution:
Use booster cables to connect it to another vehicle or
charged battery if the battery become weak.
Fuel pressure gauge installation
Connect the fuel pressure gauge between the fuel
strainer and the fuel gallery.
Install fuel pump fuse.
Start the engine and check if the fuel pressure reaches
standard value.
BASIC INSPECTION
ACTIVE rEsT q
FUEL PUMP RELAY OFF I
CAS. RPM (POS) 950rpm
Approx. 3.0 Approl<. 3.0 Approx. 1.0
For the vehicle with starting problems, turn ignition switch
ON and check fuel pressure for 5 seconds when fuel
pump is rotating.
Approx.3.0
IFNG;
Fuel pressure is abnormally high:
Fuel pressure is abnormally low:
Approx 2.5 i Approx. 1.0
I
Pressure regulator is faulty.
Return system is clogged or hose is bent.
Pressure regulator is faulty.
Fuel pump output is faulty.
Fuel supply system is clogged.
Fuel pressure should also be checked when the engine speed is increased.
EN - 273
RB260ETT I RB20E ' DE I OET i CA 18. ENGINE
3-4 Spark inspection
(1) In case of SOHC
Disconnect one of the high tension cables connected to
the spark plug and connect it to spark plug unit. Bring
spark plug closer to engine main body (disconnect
ground cable) and crank the engine to see if the spark
arcs (check with every cylinder).
If it doesn't spark with any of the cylinders, install spark
plug to the centre cable and carry out the spark
inspection. If the spark arcs there is a possibility of fault
with the distributor system.
(2) In case of DOHC
Measure the voltage with a test prove at power transistor
coil side terminal for spark signal of the primary system,
Terminal 1 - 6 when cranking engine Approx. 9.SV
Primary system check can also be performed by timing
light or tachometer needle deflection,
To check if sparks actually arc or not, remove ignition coil
(No, 1 cylinder is easiest), Connect spark plug and
place it against collector or other part for ground, Check
if spark arcs when engine is cranked.
If NG: Inspect ignition control system,
3-5 AAC valve operation inspection
Start the engine.
Set any angle in the "AAC valve opening" items in
"ACTIVE TEST' mode.
Check if idle speed at this time varies from set value,
After warming up the engine check if idle speed lowers
from specified value when AAC valve connectors are
removed.
RB26DETI RB20 (SOHC)
EN - 274
BASIC INSPECTION
!. ACTIVE TEST 0
IIMC I V OPENING 16%
MONITOR
'CAS,RPM (POS) 950rpm
AIR FLOWMETER Q,93V
AIR FLOW METER(R)O,88V
ENG TEMP SEN 87
e
C
lou II UP :1 OWN !Iad I
RB20 (DOHC)
BASIC INSPECTION
RB26DETI I RB20E! DE, DET I CA18! ENGINE
36 Air regulator operation inspection
Start the engine when cold and check if the idle speed lowers when air regulator hose is
closed or partially pressed.
Start the engine when cold and check if specified idle speed will increase after AAC
valve connector is removed and engine warms up.
Connect AAC valve connector and warm up the engine sufficiently.
After warming up the engine remove AAC valve connector again and check if idling
RB26DETT RB20 (SOHel
37 Intake manifold vacuum
Inspect the vacuum when idling after warming up the
engine.
RB26DETT, RB20DET Approx. -480mmHg
i RB20E. DE Approx. 1510 mmHg
CA18i 500 - . 550 mmHg
The vacuum value will be abnormal if there are air leaks
or other problems with combustion or main engine body.
Locate and correct the cause of problem.
EN -275
RB20 (DOHC)
BASIC INSPECTION
RB250E ENGINE
3 BASIC INSPECTION
1 ,:.1 __ ______ ,
Before engine start
Look for fault indication and check recent
se rvice record,
::: the following in the engine bay
IS harness connector connected
:::r:ectly?
,5 any cracks or torsion on
vacuum hose? connected correctly?
disconnection,
Is harness connected correctly with no /'
'----
2
'I Connect CONSULT
, Cornect diagnosis connector to CONSULT
"
and olace Ignition switch to ON position,
. Select "ENGINE" from the item menu,
.. ! ._-----'

I Does the engine start? To 6
4
OK
Idle adjustment screw primary stage
set up revolution inspection
Select "AAC valve adjustment"
mode in "OPERATION SUPPORT",
. Check that engine rpm will drop to NG
600 - 700 rpm when "START" is
pressed (N range),
Check that engine rpm will drop to ftt'\!
600 - 700 rpm when ECCS C I U
adjustment volume is turned right until
it stops,
OK
To5
For engine rpm adjustment use
idle adjustment screw,
EN - 276
2
3
4
Connect
....
'\

'" h connector
z)?( (behind fuse boxl
, "
i CONSULT
-- //'
FAUtlIJl
CAS,RPM (POS) 787rpm
i
CAR SPD SEN Okm,h
L .. ===
START
- .. ..
RB25DE ENGiNE
5
1 Ignition timing inspection
: Afterwarming up the engine, idle the engine
and inspect the ignition timing using timing
light For more information refer to "Idle rev, I NG
ignition timing, air-fuel ratio inspection" section. '
earlier in the manual. i
Ignition timing (BTDCo): 13 - 170
OK Rotate crank angle sensor
to adjust ignition timing.
:
i
6
Throttle sensor idle position inspection
Select "THROTTLE SENSOR AOJ" ffJ\:
from operation support mode.
Check that throttle sensor output voltage is
approx. 0.4 - O.SV (fully closed) and Idle
position IS ON.
Use voltmeter to measure throttle AEt\
7
sensor output Voltage. Make sure it
is between approx. 0.4 - O.SV (fully closed).
Switches input Signal inspection
Select 'ollowing SWitches in "DATA MONrrOR" mode.
a) Start signal
b) idling
c) A/C signal
d) Neutral SW
e) PWRIST Signal
I
Disconnect ECCS C/U and use vottmeter to mspect SWitch
@:
ON/OFF operations.
..... .. ljs .
L::-f{}fi
I"
,
x;'.,'' -;
:
Ig nilion SWan
:
Start signal 0 Power supply voltage
Ignition SW start
i
Idling
Idling after warm up
Power supply volgate 0
accelerator depressed
AIC signal
,A/C off
!
7,0 10.0 0.5 - 07 :
: A/C
-
on
I Neutral
N. P renge
!
SW a 8.0 - 10.0
N. other than P
i
!
PWRIST off
I
PWRISTslg
i
PWRISTon
1
8 0
i
OK8
EN - 277
BASIC INSPECTION
6
6 ____
1+ THROTILEADJ +Ci
,ADJ MONITOR
i THROTILE SENS
iMONITOR
I CAS. RPM (REF)
IDLE
I
Orpm'
ON

I
7
!w10NITOR-.:NO FAUcr -,
'STARTER SiG OFF
'IDLE ON
.Ale S!G OFF
INEUTRAL SIG or,
7

l;{;

RB250E ENGINE
8
Self-diagnosis result confirmation .
Operate "SELF-DIAGNOSIS RESULT" mode. ' NG
Confirm self-diagnosis results.
Is there any problem?
Set to "SELF-DIAGNOSIS MODE 2".
Check the code number by exhaust gas
temperature warning lamp or ECCS C/U red
lamp.
;. Is there any problem?
OK
ICarry out applicable i
iprocedure '
9
I
Injector operation I
. Place a stethoscope or screwdriver on the injector i NG
I '
, and check for injector operation noise (click, click,
! click) while cranking engine.
OK
I Check injector control
circuit
10
I
Fuel pump operation Inspection (B\ I
" Inspect by "FUEL PUMP" in "FUNCTION
TEST' mode or "FUEL PUMP RELAY" in i
"ACTIVE TEST' mode. Check if you can hear
fuel pump operation noise when "OPERATE"
is pressed.
After turning ignition switch "ON", check
for fuel pump operation noise for 5
seconds.
,
NG
a
9
BASIC INSPECTION
8
F::O,AG'NOS,S) U
I SYSTEM
: ENG -EMP SENSOR 0 "
PRINT
10
'. ACTIVE TEST .'
I
i FUEL PUMP RELAY ON!
MONITOR
CAS.PRM (REF) Orpm
---C-h-e-ck fuel pump control i
circuit ' I (Operation L--:.:-...=.....--.....,
10
____ __ _____________ -'1,
When the fuel pump is operating, press the hose i NG
between furl filter and fuel gallery with a finger.
There must be tension and pulsations in the hose.
OK;
(noIse A) /;Y0-,,, ""
\\
, __ "\"u\
; ? --Jl- \ I ',,If/fJ,,,'
\"0 f
\\'\. ,/'7 J
i.-'
--.,--/
11
I Check fuel supply system I
twist orbend. filter I
U I
Finish
L-__ __ I
has pulsation
EN - 278
SYSTEM FIGURE & CIRCUIT DIAGRAM
RB26DETT.' RB20E I DE i DE"- . CA 181 i RB25DE ENGINE
4 SYSTEM FIGURE & CIRCUIT DIAGRAM
Wireless equipment
When installing CB ham radio or a mobile
phone, make sure to observe the fOllowing
pOints as it may affect electronic control
system depending on its installation position.
1. Keep the antenna as far as possible away
from control unit.
2. Keep the antenna feeder line more than 20
em away from the control unit harness.
Control unit
Do not disassemble control unit.
3. Adjust the antenna and feeder line, so that
the standing wave radio can be kept small.
Do not turn diagnosis mode selector
switch forcibly.
4. Make sure to ground the radio to vehicle
body.
If a battery terminal is disconnected,
the memory will return to the initial
setting value.
Battery
Only use 12V battery as power source.
Do not disconnect battery cables while engine
is running.
Do not disconnect injector harness connector
while engine is running.
ECCS parts handling
Air flow meter must be handled with
care to avoid damages.
Do not clean air flow meter with any
type of detergent.
Slight leak in the air intake system
can cause serious problem.
Do not apply shock to crank angle
sensor.
When starting
Do not depress acceleration pedal
when starting.
Do not rev up engine unnecessarily
immediately after starting engine.
Do not rev up engine just prior to
shutdown.
Fuel pump
Do not operate fuel pump when there is no
fuel in lines.
Make sure to tighten fuel hose clamps to the
specified torque,
Control unit harness handling
Securely connect ECM harness connectors.
Poor connections can cause an extremely
high (surge) VOltage to develop in coil and
condenser.
Keep ECM harness at least 1 Ocm away from
adjacent harnesses to prevent ECM system
malfunction due to receiving external noise,
degraded operation of ICs, etc.
Make sure to place ignition switch in "OFF"
position and then disconnect battery ground
cable,
EN - 279
rn
z
!\)
Q:l
o
I Air regulator - -
\ _ - con.rol signal
Reelle I . switch
u all011 valve From b"U
M eery voitage
Ixture control ' ' $1 na! _1
()
Intake air I" ___ --- :.0' - ---
'" pe ' - ='
g A ro oJ o
tlal
2llDai
nt"iCool !'l *: . _ ..
Ic
POWP.f lTdll"'''''V'j
I
Unt.
() -

() .-
____ - rnA -- - - --
r _ '''w' " , i "'''-'
"".,,,, ' -- ' ,! ' .
eha b "",-,-,--_ ' ('!) ,0 U <: F I
" " ' ' ,,' . . .".p
""',' ' .. ,._.. ",,, '
switch I r- - i & chock light 11- ,.-" -[I"
)'nnn j Neutral
ctnk :nglO
Lc[)
plug
h
- --- __ -'1'--__

3-way catalytic converter S ' I
;- wmg va 'Ie
Muffler ..
--r
Exhaust temperature
sensor
Switching module

Swing
(1'1""
0;-, sensor
"-
'ltl
___ .,'. r;-:J
1 '- ; I:. \ _____ peed sensor
SJ4

) I
/ Air clealler
Air flow meIer
,J::.
,
.....
(f)
<
(f)
-f
m
5
"lI
C')
c:
:0
m
-:0
m
N
en
o
m
:t
m
z
!2
z
m

:IJ
Rl
co
CJ
9
m
z
GJ
Z
m (fJ
-<
(fJ
rr1
5:
"T1
G)
C
:n
m
"" o
:n
o
c
=i
o

G)
:n

5:
m
z
I\)
CD

e
"i""!

Diagnosis connector
11: f u -t-:c
Automatic - - _+._
--- -s.u ...
: ';J 'r.iiiJ2' !njt::dor __
{: ,",
".
...!..:
flow
rmtter
0'" ront)
C!11lir.ID
..J.
r--
"1-- ...
.. 1- ----.! (Rea'i - .

lrtlow
i
-- I meter 1
.. ,) L __ ,.
' ... "" f I ... '" l ::
--- s. ,----" -.---1-- --,.----',--
Spark plug DroPfl'. n
9
it
IUl!JI -_+-.. +-_ !---l- '. an9. Ie W1ll.lD
::: 31 tf" -- ------r-:::- -t ,---+-,,-'" : t sensul
.- a- eeon 1101"1 u - 4
""". t W .. ____ ..l
- r>olnt 1. ... .-..-..-._. . ____ _
e 0 J ; n: : O. sensor (ncar)
war trallsist(;r Check pj : - .. i
: !!: ,, __
I (") : : t:ItV -
1 0 I '._
It -- -0-'" st;-s4H-
o
-
r
--

I) t-- --- ; .-: 1 .-. __ .-
1 ;:;: 1 sensor 2 t'O __
, - -_. __ .) I ........... ,
IIG <ifjl!l'l'l!lill} ".. _
<IMD I
, .. ; dlb Chec connec,m : ___ .__ ---i ---e='-8.
i."_.,,,, i ,,'00' ",,'" I !::::'J I ll1ll1 k
____ ___ __
"'"
I
r.,)
(")
:0
(")
c:
::::j
0
;;
G)
::0
l>
==

::0
m
r.,)
."
0
9
:rJ
Rl
m
en
0
Z m
G)
=I
Z
en
z
m
G)
-
Z
en (fJ
-<
(fJ
--t
m
s:
-n
Gl
C
:0
m
QO
Q
:0
0
C
::::j
Cl
:>
Gl
:0

s:
RB260ETT ENGINE
ECCS CONTROL UNIT PIN LAYOUT FIGURE (RB26DETT ENGINE)
a
1c'1.'0) , I ,

j} I G 1 , 6 ; 9110 :nlnl2Jl24ja 121>1271 26{ l'.iIJon 4tI4zjHI.u[{d 46j HI j!1.w1
111t HI 17jlS 191 20 331'34 l5136 40 11,1 lill:t'! ,,1,,1,,1,,1,,1,,1001
i renpirla'
...'
...... ;'1:
Tetmi!J81 1
m
. . ...... " . . .. "
,-['l,I;.'.';'!;r.'
: ... NO'.' '
. ;J!iO;!;>
.' .
1 Iqnltion timinq (Power transistor) Cyl. No.1 11 Ilgnition timing (Power transistor) Cyl. No.6
2 ignition timing (Power transistor) Cyl No 5 12 ilgnltlon timing (Power transistor) Cyl No.2
3 Ignition timing (Power transistor) Cyl No.3 13 Ignition timing (Power transistor) Cyl No.4
! 4 Me valve 14 -
i 5 - 15 -
6 Sub electrical fan relay (engine temp SW) 16 ECCS relay
7 Tachometer speed signal 17 -
, 8 - 18 iFuel pump relay
9 Air conditioner relay (A I C cut signal) 19 Power steering oil pressure sWitch
10 Ground (ignition signal system) 20 Ground (ignition signal system)
21 (RX) Recieve (control Unit data reception) 31 (eLK) Clock (synchronization signal)
I 22 (TX) Transmit (data sent from control unit) 32 Monitor and check lamp (red)
i
23 Detonation senSor 1 (cyl1 - 3) 33
-
24 Detonation sensor 1 (cyl 4 - 6) 34 flow meter ground
,
25 Wastegate valve control solenoid vaive 35 flow meter intake air signal (front)
26 Air flow meter ground 36 Intake alf temperature sensor
i
27 Air flow meter Intake air sianal (rear) 37 -
28 Engine temperature sensor 38 Throttle openlnq output
i
29 Exhaust gas sensor
,
39 -
i 30 Sensor ground (throttle sen. EGN temp) 40
-
i
41 :Crank angle sensor (120' signal) 51 Crank angle sensor (120' signal)
42 Crank angle sensor (1' signal) 52 Crank angle sensor (1' signal)
43 ignition switch START signal 53 Vehicle speed sensor
44 Neutral SWitch 54 Throttle valve sWitch (Idle connection PT)
45 (IGN) Ignition switch (lGN) 55 Exhaust gas sensor (rear)
46 conditioner sWitch 56 Throttle sensor outout signal
47 (CHK) Check (Diagnosis activation) 57 :Throttle valve switch power supply
48 Throttle sensor power supply 58 Battery power supply
49 Control unit power supply 59 Control unn power supply
50 Ground (Control unit) 60 ( - ) ,Ground (control unit)
101 Injecta r No 1 109 Injector power supply
,
102 110 Injector No.5 -
:
! 103 Injector No.3 111 i
-
104
Fuel pump ternimal volt control output
112 Injector No.6
FPCM) 1
105 Injector No.2 113 -
106
Fuel pump ternimall/Olt control output
:
114 Injector NoA
FPCM) 2
107 Injector ground ! 115 -
108 IlnJector ground 116 Injector ground
EN - 282
RB26DETT ENGINE
ECCS COMPONENT PARTS (RB26DETT ENGINE)
I (camshaft drive)
ITtlPnTl;,;tnr type
EN - 283
Rocker cover ornament
front
Front left
Intake manifold collector
work unit
m
z
I\)
Ol

AAC valve
Air reguI810r
r:J
!b
Ii
Spark plug
sensor
Power 1ranSISfOIpt\
unit
sensol
Swing valve
converter

Exhaust temperature power
Air llow meter
Switching module
I
i
.il

'" J

'"
" -

8

" '
'"
" 3
'"
Q
!!1
c
iil

'" ,-
ai i5
z

!/J
if>
US

'"
ECCS control unit
'!:;'WHl.-ll _J 'J
lIlli' ,

pump

Monitor & check
light (red lig!!!)
3 I;;
:;: s,
. 0
" '5
"
<-
-1

Nel,tral
_ sWitch
-

1/-- ./
v
..
- A j T control unit
Air cieane(
./>0

C/l
-<
C/l
-l
m
s:
."
Cl
C
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m

::0
m
II,)
0
m
m
z
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Z
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0

m
m
z

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z
m
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if)
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m
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m
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9
JJ
()
c
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JJ

s::
m
z
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0)
U'I
I
Exhaust gas temperature warning lamp
-----1m
, , r=cJ- rurll
1
1{S}-
IJ
21
40
31
'0'
110
101
"2
'05
'"
"
'09
2 r-:=1 j
"'
38
Power 51 .
1Il .. f1l I -eenn
g
sw
IIDr rela{
&
-

rrtm]
to.
Air regulator 12S
Fi
or
r- - _._ ..... Jl

ReSistor I
"achometor .-.-j,----1 .,
m
(")
(")
rt>
(")
0
z
il
0
r
c:
z
=<
12
,
"
46
" 2,
24-----
9
19---
,.
Lowl fy' :ure SW-Air condition
1----111- ! --
.
....,:. Masnct clutch -
- ------- -,,'" t jeater control amphtier
I
--..--t L
I . -11' -N r relay (AlT)
" H1 Crank I L To HICAS controlLJOit
-, mangle \.!..i..llil.!)
,0
I JrlflOW
-e er
..
45
"
I!
Il
r I j lH I To AiT conlrol unn
, ! Thwtlle sensor
,6
I
2W (,m;
,
51--- -- I 1
I I I 2. m;line telPperature
lrtl
u
I I 321 ToAlT control UJ1lt
sensor
, 23
=:71..; ---.- 32 "
ThOO" SW
-+-- 2
Staller I

.. rr:-i - ---- "J 6 ;
Exhaust gal5 S8ns t( _______ L_
I
: : A! T control unit
llli U
j 36 108 : ;
. .1 l_____ lit> :-U- --1=--*_
f"
l\)
n
::a
o
c:
::::j
c
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s::

::a
CD
l\)
o
m
m
z
e
z
m

JJ
ill
ru
o
m
n1
z
Gl
Z
r'1
(j)
-<

m
s:
:!!
(;)
C
:0
m
QO
Q
:0
o
c
=l
o

:0

RB20E ENGINE
ECCS CONTROL UNIT PIN LAYOUT FIGURE (RB20E ENGINE)

,iii . , ......... """ .0eSc:ripti00 .. "

;t8(!l1lnal
. .......
......
.,.; .,.
I No"
.'., No;
"'.'.>;.
; ,
I 1 (RX) Recieve (control unit data reception) 11 (ClK) Clock (synchronization signal)
L 2 (TX) Transmit (data sent from control unit) 12 (CHK) Check (diagnosis activation)
I
3 Air flow meter intake air signal 13 Monitor and check lamp (red)
4 Sensor qround (Air flow meIer) 14 -
I
5 Engine temeerature sensor 15 'Intake air quantity signal (10 Aff CIU)
..
i
6 Exhaustgas sensor 16 Detonation sensor
7 Throttle sensor (input signal) 17 Throttle openingoutput signal (to Aff C/U)
8
Sensor ground (thattle sensor. Engine
sensor
18
I
9 Crank angle sensor (120' signal) 19 Crank angle sensor (120" signal)
i
10 Crank angle sensor (1
0
signal) 20 Crank angle sensor (1" signal)
,
,
21 Vehicle speed sensor 29 Air conditioner switch
I
22 Throttle valve switch (idle connecllo pornt) 30

i
I
23 Ignition switch (START signal) 31
I
24 Neutral switch 32 Throttle valve switch (power supply)
.25 (lGN) Iqnltion switch (IGN) 33
!
26 Throttle sensor power supply 34 Battery power supply
27 Control unit power supply' 35 Control unitpower supply
I
28 Conlrol unit ground 36 ( . ) Control unit ground
37 Iqnilion signal (power transistor) 43 Tachometer speed Signal
38 Power steering switch 44 Engine AlT control input Signal
39 Ignition si(!nal 45 Engine Aff control input s'gnal
40 ECCS relay 46 lAir conditioner relay UVC cut signal)

41
- 47 Engine Arr control output signal
I
42 Ground (ignition signal system) 48 Ground (iqnitlon signal system)
I
101 k1J8ctor No.1 109 Injector power supply
102
- 110 k1jector No ,2
103 Injector No.3 111
104 Fuel pump relay 112 Injector No.4
,
105 k1
i
ector No ,5 113 /AAC valve
106
.
114 Injector NO.6
107 Injector ground 115
108 Injector ground 116 Injector ground
EN - 286
RB20E ENGINE
ECCS COMPONENT PARTS (RB20E ENGINE)
resistor
heater)
type
EN - 287
m
z
f\)
(
CJ)
-------
"
Power transislor unit
Fuel contro! signal
(tfl
Temperature
Knock
Crank angle sensor
cataly11c converter
ExhalJst temperature warning lamp
jGN power
SWitching module
Air flow meter
Air cleaner
Fuel pump
Momtor & check
light (fed light)
,----- A! T control uni1
....

.....

(f)
-I
m
s:
."
Gi
c:
jJ
m
-jJ
D3
11.:1
0
0
m
m
z
G)
Z
m

:IJ
OJ
'" 0
0
m
rn
z
GO
Z
m
(J)
-<
(J)
-1
m
;;:
-n
Gi
c
JJ
m
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JJ
()
c
=i
0
);
G)
:0
l>
;;:
m
z
I\)
CO
(0
r

sIde)
(ildil!h:ID (C i U sode)
Exhaust gas temperature
warning lamn ,-----------------------,
c
r--'- .
=.
u Jt' as sens

, .... pt;. __ Diagnosis connector
.,--'--::--,,,---"0' z:! .
::: H' ...
41 t
-----: I!? J1r'
;110 :;r
+-
Ale Low I I !"'t't : 1111 n - Au l
-r.'.:J+-+--r ... J f L!..l..!J ?G flow
", ' .:= '- -f :11.lO/ 1- i meier
IbN coli r a Magnet clutch .",. Q!Y - -------

. a:l" . ----1 . Heater control amPhf'El
f
. .. j Crank 1
ITl...JJ] +-4_ --- '" m (.-...,
..' ?-:;.\ -hnr !-_J 4- -1 < ReSistor Check coonee r ("') angle
r I -6d--- 0 i ,_ ___ ._. p_' ' sens.or
__ 2 NJ"I I 1 P<1
wer
I (') I -E'-l b
g I '-j r - I c. Powpr steering SW -:;;..-_. --'l To A / T control
T
I
.L
- );1 ,.' T - ,
g- g. 0 ?'ID" I ,,,' 2.' --- : I umt
&; 3 . _ ' ',* :: c: : r Throttle sensa' .
.. J I : 3 -J',' '- .. : (<lIT]) .
fl K:i "Q ,:=1 _, j iJ valve . To A'..... t I
iI lil ; j' i I ! i con-ro
2. -; .,QQIi 1 L " i
_ v f:,.--_. b '"
I
g . .;; ; 6 - .. iii f sp;ed sensor
Fuel pump relay .. .-- I' 53 n--l (=:) I
. 18 NeutraISW(M!T)
- tFuelpumpcont'ol 44
i [1 t9- :0-1 ._'r:: ) -- adulator DE. N.P reIaV.
Y
(A 7 T) t l To HICAS control unit
Jill! 'l3. ........ Rl," -,
_ 0 l !) --.- ,.----- I, To A! T control
M j' .
o _ ,. ____.. j unit
("-),1.1 ______ _
reSIst " "ll ,.---
.j>,

'"
(")
:Ii
(")
c
=i
0
5>
G)
::.0

s:

::.0
m
'"
0
0
m :0
Cl)
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0 0
0
m
m
-I
m
t:}
In
Z
-;
G)
en
Z
Z
G)
m
Z (fJ
m -<
(Jl
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m
s:
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C
JJ
m
Qo
0
JJ
0
C
-i
0

JJ

s:
I
I
I
RB20DE / DET ENGINE
ECCS CONTROL UNIT PIN LAYOUT FIGURE (RB20DE, DET ENGINE)
10 HI , 10 11) III HI 1
11;> 11 !1 '1 11 \ 1 115
iT...mmaf
.'i ii '/;N,;"!;M/ri,
t_lnai
. "i;,
I,;,.:;;;
;'/'/.1 i.'{'b''./ ,,/ .. ,,1.,..'.,' . ".
I'
'1'.1/;11 .. 1'1 .. , .... ,.'
1 ,lqnition timil1!l (Power transistor) Cvi. No,l : 11 IIQnitlon timing (Power transistor) CyL NO.6
,
2 Ignition timing (Power transistor) CyL No.5 12 Ilgnition timing (Power transistor) CyJ. NO.2
3 ,Ignition timing (Power tranSistor) Cyi. No.3' 13 Ilgnitlon timing (Power transistor) Cyl. No.4
4 AAC valve 14 Engine. ArT control input Sigal (BT2)
L
5 El1!line. AfT control input sigal (BTl) 15 Enqlne. ArT control input siqal (BT3)
6
.
16 ECCS relay
i

7 Tachometer speed signal 17
-
8
.
18 Fuel pum[)relay
9 Air comMoner relay (A I C cut signal) 19 Power steering switch
i 10 Ground (ignition signal system) 20 Ground (ignition Signal system)
.
21 (RX)
.
Recleve (control unit data reception) 31 (elK) Clock (synchromzatlon signal)
i 22 (IX) Transmit (data sent from control unrt) i 32 Monitor and check lamp (red)
23 Detonation sensor 1 (cyll - 3) 33 -
24 Detonation sensor 1 (cyl4 - 6) 34 -
L
25 - 35 -
i
26 Air flow meter ground 36
I
27 Air flow meter Intake air Signal (rear)
L
37 -
i 28 Engine temperature sensor
I
38 Throttle opening output
I
29 Exhaust gas sensor 39 -
I 30 Sensor grounc (throttle sen. EGNtemp) 40

I
41 Crank angle sensor (120' signal) 51 Crank angle sensor (120' signal)
I
42 Crank angle sensor (1' signal) 52 Crank angle sensor IF signal)
43 ignition switch START sl.gnal 53 Vehicle s!!eed sensor
44 Neutral switch 54 Throttle valve SWitch (Idle connection Pl1
45 (IGN) IQnitlon switch (IGN) 55

46 Air conditioner switch 56 Throttle sensor output signal
47 (CHK) ,Check (Diagnosis activation) 57 .Throttle valve switch power supply
48 Throttle sensor power supely 58 Battery power supply
49 'Control unit power sUP[Jly 59 Control unit spower supply
50 Grounc (Control unitt 60 (- ) Grounc (control unit)
101 Injector No.1 109 Injector power supply
102 - 110 Injector No.5
i
,
103 Injector NO.3 111

I
IFuel pump temimal volt control output
104
FPCM) RB20DET
112 Injector No4
105 Injector No.2 113 -
106
- 114 Injector NO.6
107 Injector ground 115 Exhaust gas sensor heater grounc
108 njector flrounc 116 Injector ground
EN - 290
RB20DE ENGINE
ECCS COMPONENT PARTS (RB20DE ENGINE)
outlet
Zirconium manifold
side
EN - 291
m
z

I\)
Crank angle sensor

Air flow met-er
Switching module
1
[

ontrol
-'r odulator

Vehicle spee:d sensor
-':-""
- A r -r conI rol unit
An cloaner
"'"
,
...
en
-<
en
....
m
s::
"11
15
c:
::JJ
m

::JJ
III
I\)
0
a
m
....
m :Jl
z
OJ
!i2
tv
0
0
Z m
m
.-j
m
Z
Cl
z
m (f)
-<
(f)
--l
m
;:
"
Gi
c
:n
m
>?'
Q
:n
0
c
=i
0

G)
:n

;:
RB20DET ENGINE
ECCS COMPONENT PARTS (RB20DET ENGINE)
type (Auto camshaft )
type
type
EN - 293
m
z
f\.)
'"
.t>
RevolutIOn
0,,, sensor output signal
I
J
' Intake temperature sensor AIr cleaner
f: f: device
Temperature I II[illll!I)1 II
_" illl
-,
ECCS control unit

g

3'
s
'" n

" ,\6
-
rev ON-OFF
I
___ I Dash pot
lqmtiurl cuil
PTChealer
=cc(
Noutral
sWitch
.-:: To spark plug
Transmission
distributor
angle sensor

Vohlcle speed sensor
Froni tue1 lank
,.
valve (Ai: only)
------ 0 sensor
!!d---------Exhaust mallifold cover
\
module
Exhaust !ernperature warning lamp
---t::xhaust temperature sensor
't"
.....
(J)
-<

m
s::
!!
G)
c::
::D
m
-n

.....
2!
m
z
G)
Z
m

()
:::
p
m
'" (;?
z
m
(f)
-<
(f)
-i
m
$:
-n
Gi
C
JJ
m
Qo
Q
JJ
o
C
::j
C1
:;;
GJ
Jl
);>
$:
m
z
I\)
<0
{J1
T
IGfIl
<>
Stmlef
____ J
[i1JZ]
l]TIJ"
ECCS
relay
Dropping
resistor
BmpcratUf
Iwaming lar
(ION)
-. . seoJ
I R ,I
13 rariP "
n relay 2 1 j PTe heater relay
'lllPi II i( 3 i 01 dr0
!J.:: l - 0 I " I !i
g < r, ...,
o I 0
,
lJ_
;7:' - .. '''':j ')Oi :!:.
.niior}
ISO'
IGN COIl
, ffi
. .

CililV
IN&EXj
neater
I
PTe
ill
TIT["f11
1l. "0
'
I"" " '.'
__ ._,._ _ 3. '!...
9>. -l ;:: I 1
>11< =4 :g,
'< { Diag'J1osis connector
- '" .. -4 11111111
ill
""
Q
:II
o
c:
::::j
c
);;
G')
:II

is:
-o

....

m
z

z
m

o
l':
92
m
z
9?
z
m
w

.-j
m
s:
'"11
Gi
c
JJ
m
9<>
Q
JJ
()
c
=i
!2
:l>
Gl
JJ
:l>
s:
CA18' ENGiNE
ECCS CONTROL UNIT PIN LAYOUT FIGURE (CA18i ENGINE)

: ", ", 'c_"" "":,'?5

,>,!j'Il',j: j', "'" c_ ,','" ,',' ,?l""
<. ,." ,,'" <,', """;.,,,' ,.e;', ,,' . 'ie i, '. ,..... , ' ,,,
!
1(RX) Recieve (control unit dara reception) 11(CLK) Clock (synchronization signal)
2(TX) Transmit (data sent from control unit)
12(CHK) Check (diagnosis activation)
I 3 Throttle sensor signal 1 13 Monitor & check lamp (red)
4
,
14 -
.
5 Engine temperature sensor 15 -
I
6 Exhaust gas sensor 16 Tachometer speed signal
I
7 Throttle sensor signal 2 17 Throttle opening output (AfT)
i
8 Ground (sensor) 18 Ground (sensor)
9 180' signal 19 180' signal I
10 l' signal 20 1'signal
I
,
21 Vehicle speed sensor 29 :Air conditioner switch
i
22 30 Intake air temperature sensor
I
! 23 lignitlOnswitch "START" siqnal 31 Power steering switch
i
i
24 Neutral SWitch, inhibitor switch 32
-
25(IGN) Ignition switch 'ON" 33 -
I
26 Throttle sensor power suoply 34 'Control unit back up power sueply
I
27 Control unit power supply 35 Control unit power supply
28( - ) Ground (circuit) 36( - ) Ground (circUit)
37 :ignition signal (Intake Side) 43 Light switch
38 ignition signal (Exhaust side) 44 -
39 Ignition primary Signal 45 Heater fan SWitch
40 ECCS relay 46 Rear defogger switch
41 'lj monitor (iniection pulse monitor) 47
-
!
42 Ground (Ignition) 48 Ground (Ignition)
101 Injector 109 -
102 Air conditioner relay 110 Injector
103 FICD solenoid 111 Idle revolution correction solenoid
104 Fuel pump relay 112 -
105 - 113 -
106 PTC heater relay 114 -
107 Injector ground 115 Lock up release solenoid (AfT only)
108 ilnjllctor ground 116 Injector ground
EN - 296
CA 18i ENGINE
ECCS COMPONENT PARTS (CA1Bi ENGINE)
- intake manifold
sensor Intake manllo,IO
Exhaust manifold
EN - 297
m
z
N
cD
CO
000
iTT
..
Crank angle sensor

Exhaust lemperature sensor

A! C signal
FICO solenoid
Canister
Ignition coil
Exhaust temperature warning {amp
10N power

'"

" !![
Q
SWItching module
Air flow
----,-l
u i I
0" _
.3
OJ
(,Q q; - "'--
n
fl? ,3"

ECCS contro!unit
(
rn

"'
5
ro

-'1

6

"In
g

w
is

----------,
,?
Fuel pump
Monitor & check
light (red light) ,
Neutral Ii
i
'- switch .
I
I

---A! T control unit
Ail' cleaner
f'
-
(f)
-<

m
s:
"TI
C>
c:
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m
-::a
III
I\.)
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m
m
z
:JJ
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())
'"
'"
Z
0
m m

111
Z
Gl
z
m Cfl
-<
Cfl
-i
m
:J::
"T1
is
c
:n
m
!lO
0
:n
0
c
=i
0

Gl
:n

:J::
m
z
!\)
<0
<0
r
(1"
!
jc __
ITl .. m
[ill.

Air lil!H!
;t
(1
:Ii
(1
c

c
:;
C>
:rJ
>
s:

:rJ
to
I\)
U'I
C
m
m
Z
C>
Z
m
-
JJ
Rl
'"
o
m
m
Z
(,")
Z
m
(J)
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m
;;;:
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Q
c
::IJ
m
11<'
()
::IJ
()
c
=i
g
f;
::IJ

;;;:
RB25DE ENGINE
ECCS CONTROL UNIT PIN LAYOUT FIGURE (RB25DE ENGINE)
I Termt!ta.:
, No.:::.
...... :.,: ... '. i ' .... <i(
r1<.; . ..... . .. c .. ........:
lermlllPI . ... . ...................... <.> "'(y(;.
. .... No,
I ................. ........ (
,
1 Ignition timing (Power transistor) Cyl No.1 11 ilgn<tion tlmmg (Power transistor) CyL No.6
I
2 Ignition timing (Power transistor) Cyl. No.5 12 lignltion timing (Power transistor) Cyl No.2'
I
3 ignition timing (Power transistor) Cyl No.3 13 Ignition timing (Power transistor) Cvl No.4

4 MC valve 14 Arr control mput slQal (BT2)
!

5 Engine AiT control mput sillal (BT1) 15 Engine. Arr control Input Sigal (8T3)
i
6 16 ECCS relay
I

7 Tachometer speed Signal 17 (f)
.

I
! 8 - 18 Fuel pump relax

9 Air conditioner relay (A I C cut Signal) 19 Power steering switch
i
10 Ground Signal 20 Ground (ignition signal system)
21 (RX) Receive (control unit data reception) 31 (elK) Clock (synchromzation Si9nal)
,
22 (TX) Transmit (data sent from control unit)
.
32 Momtor and check lamp (red)
,
23 Detonation sensor 1 (cyl 1 - 3) 33
24 .Detonation sensor 1 (CXI4 ,:.6)
I
34 -
i 25 - 35 -
i
26 flow meter ground 36 FICD solenoid mputslgnal
27 lAir flow meter intak.e air sional
.
37 ,
-
,
28 Engine temperature sensor 38 Throttle op_enlng output
I
29 Exhaust gas sensor 39 -
I
30 Ground (Sensor) 40 Intake alf output Signal (To Arr ClUJ
41 Crank angle sensor (120signal) 51 .CranK angle sensor (120' signal)
42 Crank angle sensor (1' Signal) 52 Crank angle sensor (F Signal)
43 Ilgnition switch START signal 53 Vehicle speed sensor
44 Neutral switch 54 Throttle valve. SWitch (Idle connection PD
45 (IGN) ilgmtlon switch (IGN) 55 -
46 lAir condlboner switch 56 Throttle sensor output Signal (To Arr C/U)
i 47 (CHK) Check (Diagnosis activation) 57 Throttle valve SWitch power supply
48 Throttle sensor power supPly 58 Battery power supply
49 ( b ) Control unit power supply 59 Control unit spower supply
50 Ground (Control unit) 60 ( ) Ground (control unit) i
I
101 Injector No.1 109 Injector power supply
I
102

110 Injector No.5 i
i
104

112 Injector No.4
,
-
106 - 114 Injector No.6
I
101 Injector ground 115 Exhaust gas sensor heater ground
:
108 Injector ground 116 Injector ground
I
EN - 300
ECCS COMPONENT PARTS (RB25DE ENGINE)
FICD solenoid
valve
P')WE;r unit
Throttle sensor &
throttle
-
---
I
,;,--"'"/"-'-- gas sensor
,
____________ ________ ____ ________________
".c,,",'< Fuel pump
Elevation resistor type Fuel tube
Electronic, turbine type Fuel tank
AAC valVe
ls:miplWl FIG D solenoid
0'.> Ignilion cOil
'X"li
l
Crank angle sensor
Air flow meter
Throttle valve SWitch
Throttle sensor
iii)).;, Engine temperature sensor
,i' Exhaust gas sensor
,dl',y, Delonation censor
Solenoid type
Solenoid type
Small mold type
6-channellow voltage
electronic distribution
Photocell type
Hot wire type
ON I OFF switch
Variable resistor type
ThellTlistor type
Zirconium type (no heater)
,Pressure-electncal type
EN301
Intake manifold collector ,
Intake coliector manifold
Cylinder head (above each plug)
I
Rocker cover ornament
Cylinder head left flint side
Front left
Throttle chamber
Throttle chamber
,lNater outlet
Exhaust manifold
iCylinder block
ACTUATOR SYSTEM INSPECTION
RB26DETT ! CA 181 i RB20E DE DET , RB25DE ENGINE
5. ACTUATOR SYSTEM INSPECTION
Use measurement tools such as a circuit tester, CONSULT electrical system diagnosis
tester and oscilloscope to perform inspections. Refer to EN3, 1, 1-1, (6) in TROUBLE
DIAGNOSIS section for the measurement equipment operation procedures.
The following preparation must be performed when using this equipment.
(1) Using circuit tester and oscilloscope
RB20E
Insert the testing rod from ECCS harness connector side.
ECCS control unit and ECCS harness connector must be
connected when measurements are carried out.
RB20DE I DET I RB25DE I RB26DETT
Always use check adapter to perform the measurement.
(2) USing CONSULT
Connect CONSULT to the diagnostic connector on the
vehicle (near fuse block).
Nola...:
See EN3, 2, 2-2, (2) in TROUBLE DIAGNOSIS section for
details.
EN - 302
RB26DETT
51 FUEL PUMP SYSTEM INSPECTION
CONTROL CIRCUIT DIAGRAM RB26DETT ENGINE
Feel pump relay I:i.lo.I1l
2 r;:;;::; , W1l-

ECCS relay

IGN

1
Fuel M 2
I
,
!
i
1 i

I
, ,
fPCM pin layout
' '
I
.......
Pm 110,
,"
I
I
Eces uni:
1
Fiow velUMI:' control i
:PC 1) ,
,
4 7
5 !
Flow VOlurne C:Dfl!ro' slgnal I
,::ue! pump !
2
(FPC 2) conlrol
:1
3 i
i
modulator
[
4 ruel pumP! - ;
I
(I:PCMi
5 Power S;J::Joiy
6 Shield hne grou(l(j
Case
I
1 Fuel pum:::> i + )
l a
,

, 2
EN - 303
RB26DETT ENGINE
Fuel pump system trouble diagnosis flowchart RB26DETT ENGINE
Purrp sounds for 5
seconds when ignition
switch IS ON
I Fue: pump operation noise Inspectior, ;
c-_____ _____ IL_ _______ ',,"::m:t:'p::d:::o:::e:::,sn1 sound Other

Fuel pump relay operation noise I
When ignition is ON.
fuel pump ;$
Other
Relay opera1ron noise when
ignition IS ON
No sound
ao;)rox. ____
. ther I
Ins ect!on
, "DATAMONITOR'l
! "ACTIVETESr:
: ue pump va age- Inspection'
I'lnspect .voltage between ! "f"JO;;;Fm'-'-accl ____ --; Ab'lormal
.pump pinS 1 - 2 ;
8attery vOltage When ignition switCri IS
ON 5 sees and "ACTIVE TEST ,< is ON
I Fuel pump jnspect,on :Harness contlruity inspection
! 1. Measure reSistance between !Measure resistance Detween '
. pump terminals 1 and 2 , :relay termina1 5 and pump
12. Apo:y battery voltage directly terminal 2
between terminals 1(-) and 2(+)
tIti Other
L Approx, 05
;;, PumQ operation ,
O:her
SOund is produced '
,----'-------,
Connector
Check for faulty connection
and inspect c:rcuit syslem
Replace
fuel pump
Repair
harness

Norma!
! uel pump relay voltage
;inspectlon. Measure voltage
between re;ay lenY]inal 2, 3
and ground
Battery voltage with
ignJtion switch ON
arness continuity '
Measure resistance betweer
relay terminal 1 ard C/U
,terr1inai 18
Replace fuse
or relay
Repair power
supply circuit
system
C Q --'-_____ C.::'.::.th"'e.::.r_,
I
:FLei pump control moduiator !
;control signal inspection i
check voltage between FPCM :
1, 2 and ground
!Eces CIU power inspection
1 "DATA MONITOR"
Repair
harness
Approx, 4 V when ignition switch is ON
for 5 sec and engine cranks. Approx
OV at englr
1
e speed after warmlrg up.
Other
Harness contlnu!ty inspection!
Measure resistance for
term;nal 1 to C/U terminal 10
and FPCM terminal 2 and C/U!
terminal 106
OQ
L
Other
L
RaJair
:eccs CIU power inspection
:11, "DATA MONITOR"
harnes
'i' Measure voltage oetween C!U leml:nal
49 and ground
Battery vo!1age when I
ignition SWItch is ON Other
s
I:nspect InPut, I
system
C/U
Y
powersuppl
Fllel pump control modulato :nspection
circuit syste m
Check voltage between FPCM termirals
7 and 4
7 - B V: When voltage from FPCM
term!nai 1 to ground IS less than 1 V
Battery voltage when;
VOl1age from FPCM 1 to ground IS IN
Voltage from FPCM 2 to ground is 4V Other
.:g_ Measure voltage between C/U leminal
49 and gr:)und .
Battery voltage wnen
ig;1!tion switch is ON Other
,------'------,
ar.d input signal system
Repair ECCS C/u
power supply
circuit system
IEces contcol unit arrangementj
, I, ;1'
"

Check for breaks and circuit sys:em I Replace FPCM
EN 304
RB20E: DE! DET ENGINE
51 FUEL PUMP SYSTEM INSPECTION
CONTROL CIRCUIT DIAGRAM RB20E I DE / DET ENGINE
EGGS tclay
?=>-- ,IGN
l--:;;O-+c---r--t----T-----,------l, EGGS
i : RB2C0E So DET
CCS control unit pin
Iilll
lE"'ITl
ffi
,
, '
" ' '
Ililm
EN - 305
: control un;t
(1M)
I k104 ter RB2:JOET
: ')rot-
L
I i I
I! I = !"II
RB20E I DE ' DET ENGINE
Fuel pump system trouble diagnosis flowchart RB20E I DE I DET ENGINE
Pump sounds for 5
seco'lds when ignition
sWItch is ON
pump opet8tlon nOise inspection
_______ ,-l ______ sound' \Y.her
r.F""':e"l-:p-:r=es::s"uc:,::le-:i'::n"sp::-e"c"t",o-:n""s
Fuel pump relay operation nOise inspection
Vvnen ignition switch IS ON. fuel ,
pump pressure IS appro)c 3,CKg! '
cm
1
(R820DE, DET}2.5kg!cw Other
Ae;ay ODeratmn noise when
Ignition :5 ON No sound
(RB20E)
:FL:el Dump voltage inspection; 2ij
iJrspect voltage between : 1 ". 3 ; Ncrrnal

, "ACTIVE TEST' '
Abnormal
===='-' ;pumo pins 1 - 3
Battery voltage igni1ion SWitch is ON for 5 sees;
and "ACTIVE TEST IS ON. Also after engine warm !
up approx. 5V RB20DET ; Other
Fuel pump Inspection
1, Measure resistance between
pump termi_"'Ials 1 to 3
2. Apply battery voltage directly
between terminals 1 H ta 3(-)
Harness continuity inspectIon
Measure resistance between
relay termlcal 5 and pump
terminal 1
Approx. 0.5 g Other
0flrlF
2
NOll11al
5 3 ,
,Fuel pump relay voltage
!i!1spection. Measure voltage
Ibe-tween relay terminal 2 and
3 and g-ew:.:ue.-n",d ___ r_,-,
Replace fuse
or relay
Battery vOltage with
Ignition swlicr ON
Other
2 Pump operatlor, i RB20E. DE
sound IS proo'r=uc:ce"dc.' _-,O_th..;,e:..,r
l
!Connector ;Repair ; ar:1ess continuity Inspection Repair power
t iChecK for faulty harness Measure resistance between supply circuit
Connector'
Check tor faulty
: cot')nect!on and
I Replace :connection apd Inspect relay ter'lilnal 1 and C!U termlfial: system
fuel pump 'eireu,t system 18 (RB20DE. DE,) 104 (RB20E) i
! inspect ci rcwt system
r.::IRB200ET ' - - - i il
o ___
r
[9j
signal inspection I I
I . 3
1
. 24 check voitage betweer FPCM I CIU power inspection
i :i:L "DATA MONITOR"
I 2 and ground I ,,'-"'.--,:::.:..:.:.:.:..:.:.=-="-'-----=-:-:-----'"
I
Approx. 0 V when ignition switch is ON I IE Measure CIU terminal.
49 and ground (RB20DE.DED 27 and I
I for 5 sec and el"gm cranks Battery I ground (RB20E) :
charge after waming uo. O:her
I GU"b.l' I Battery voltage when
I Dropping res'stor Harness continuity I sWItch is ON
Other
I Inspection. Measure inspectron Measure. I
Repair
harness
I resistance between resistance for FPCM : I
I
terminal 1 - 2, term'nal 2 and CiU I I
'terminal 106
I Og I Other I
Check connec;or for breaks
and Input signal system
Repair ECCS elU
power supply
circuit system
I I I
I leccs CIU pow.r Inspoction Repair I
I "C)ATA MONITOR" harness I (RB20E)
I : 'J!' Measure voltage between ClU temwlal ' I 11 :i. '",' ;)! , i' I )
I L 49 ana ground I ::2 [.;""'5",;1.'1 ;-j ..
Battery voltage when
I Igmtion sWltcn is ON Othe" I (RB20DE. DET)
I Repair E CS CIU power I
I supply circuit system I
log Other I
IECCS control "nit wminal arrangement I
I Fue' pump control modulator Inspection Replace I
I Check VOltage belween FPCM terminals dropping I
I ,7 and 4 resistor I
I 7V when ba1tery I
I VOltage OV I
I
Voltage from FPCM 2
to ground is OV Othe" I
I I I
I Check far connector i Replace FPCM I
L __ - - - - - gcj6
GA181 ENGINE
5-1 FUEL PUMP SYSTEM INSPECTION
CONTROL CIRCUIT DIAGRAM CA18i ENGINE
EGGS
: control ur:it i

, 2 1
1._-' L.
Fuel pump system trouble diagnosis flowchart CA18i ENGINE
[Fue; pump operation noise Hlspectlon!
PlJmp sounds for 5
r Pump doesn't sound! 01'1er
seconds when 19rifion
I
sWItch is ON
IFuel pressure inspectlO:'1sl
IFuel pump relay operation nOise inspection I
When ignition sWitch 15 ON.
01hsr
Re!ay operation nc:se
I
No sourd
fuel pump ;:;ressure IS :gnitlon is ON
approx. i .Okg,'crn;
1....-
r
!

lotrer system I I Fuel system I
uel pump \/0 tage 'nspectlon
"ACTIVE -EOST'
Inspect!on
InspectIon ;Inspect voltage between
Normal
Ab'"Iorm
1 3
,pump pins 1 3
IFese.

I
Battery voltage when igOillon swl1ct> ,$
513
Normal

ON tor 5 sees and "ACTIVE TEST" is ON_
Other I
I
IFuel pump telay vo :age
Replace fu
Measure va
or r.lay
I Fuel oump inspection !Harness continuity It"Ispect,on betwee-: re'ay te,rn'nal 2 ape
11. Measure resist811ce between ;Measure res:stance between 3 aod ground
,
I
pump terminals 1 3
!relay terminal 5 and pump
:2. Apply battery voltage directly :term:ral 1
Battery voltage wltr
,
,
Other
It:;f1!.!ot. SWitch ON Other
.-----'L-L-L--,
between termlna!s 1- 3
1, Approx. 0,7 - 1.5U
se
2. Pump
sOLnd is producoo Otner
Connector i
Check for faulty cO:1rect:on
and inspect circuit system
Replace
fuel pump
Repair
harness
arness continuity lospectJon:
relay terminal 1 and CIU
Repair power
supply circuit
system
Connector
Check for faulty connection
and inspect circuit system
IEces cO:itrol unit terminal arrangement!

Othe'
ECCS C/U power Inspection
i "DATA MONrrDR"
, 1;:' Measure voltage between C!U terminal
: 27 ana ground I
Repair
harness
ignition switch is ON Other
.---L ____ -----,
: Check connector for creaks Repair feeS C1U
i and input signal system power supply

::!;n II U 1$ Ii !111-\" <'II
.;c:,=H''f"=+=tI, circuit system
EN - 307
RB26DETT CRB20E, DE ClET CAIS, ENGINE
(1) Fuel pump relay operation inspection
Place the 19'1IlIOn sWitch ON and select "FUEL PUMP
RELAY' in 'ACTIVE TEST' mode, Press the ON button
and cneck for pump operation noise
ACTIVE TEST
I' FUEL PUMP RELAY ON
, MONITOR
ICAS RPM ,POS)
I
l Boct :inisher intedor

3",
When the igr,ltion sWitch IS in ON position, the relay ,.,'
operation nOise be audibie, There must be a relay Ciic
cut off nOise 5 seconds later
After engine has stopped (stall), turn the Ignition switch to
OFF position 1.5 seconds later.
2) Fuel pump relay power inspection
Disconnect the fuel pump relay and measure the voltage
between following termnals and grourd when the ignition
sWitch is placed in ON position
Engine RB26DETT I RB20E, DE. DET I CA181
Between terminal 2 I: Between terminal 3
I I or fuel pLmp relay I on 'ue
l
pLmp relay
i r:-r.nd:tu harr-ess s:de and I harness s:de and
__ g_ro_u_n_d __ .JI ___ ,_gr_O_L;n_d __ -I
I I Battery votage
RB26DETT CA18i
(3) Fuel pump control signal inspection

\ )

950m'"'11
OFF
Select 'FUEL PUMP RELAY' in "DATA MONITOR" Mode
and check the following.
Kem
I
Foel pump relay:
0'
; When ignition switch is ON
(engine Is not running)
When cranking engine
When idUng
OFFI
j F;;el pwnp relay m;
ON
";::CORD
EN - 308
RB26DETT! RB20E I DE! DET I CA 18i ENGINE
Measure the voltage between the following terminals and
ground when the EGGS control unit connectors are
connected.
18 (
104
1 EC.CS I
I control I
l L@-q) ,M ~ Unit ..
'I.Fuel pump control
modulato!
RB26DE'TT . CA18i RB20E RB20DE. DET
Belween Belween Belween Belween
lermmal18 tenninal 104 terminal 104 termmal18
and ground and ground and ground and ground
Approx. lV Approx. OV Approx. lV I Approx 1V
Batlery Battery Battery
Battery voltage I
voltage voltage vonage
Approx. 1V I Approx OV
Approx. 1V Approx.OV
(4) Fuel pump control modulator control signal
inspection (RB26DETT & RB20DET only)
Measure voltage between the following terminals and
the ground when the EGGS control unit connectors are
connected.
RB26DETT
Belween tennmal
104 and ground
(FPCMl )
Belween terminal
106 and ground
(FPCM2)
4V, OV after 5 sec 4V. OV after 5 sec I
Approx.4V Approx 4V
Approx OV Approx OV
Approx 4 Approx OV
RB20DET
Belween terminal 104 and ground
OV
OV
When cold: OV
After wann-up: Power supply voltage
EN - 309
i
Approx OV Approx OV
Approx 1V ; Approx lV
RB26DETT! RB20E! DE i DET i CA181 ENGINE
(5) ECCS control unit power supply inspection ftl\,
Select "BATTERY VOLTAGE" in "DATA MONITOR" \.1!J
mode and carry out the following inspection.
!;?<L!'!; ' . ' . '. ,.
No!@.;
The same setting as ON state is maintained for a few
seconds right after the ignition switch is turned ON to OFF
and then ON again.
'RBZ6DETI RB0::DE DET
Measure the voltage between the following terminals
and the ground when the ECCS control unit connectors
are connected.
Between EGGS Between EGGS
G/U terminal 40 GIU terminal 27 i GIU terminal 16
and ground and ground and ground
OV Battery voltage
OV Battery voltage OV
OV Battery voHage OV
OV Battery voltage OV
(6) Harness continuity inspection
Disconnect ECCS control unit, fuel pump relay and fuel
pump harness connectors and measure resistance
between the following terminals.
oQ oQ
OQ oQ
Between EGCS
G/U terminal 49
and ground
OV
Battery voltage i
Battery voltage
Battery voltage
oQ
oQ oQ
oQ i
CA18i I RB20E I DE' DET RB26DETT
-
(18) g i
(J)j
8.
L_!J
( ) RB2QDE. DET,
EN 310
RB26DETT ! RB20E DE' DET ! CA 181 ENGINE
[RB20DET & RB26DETI only]
Disconnect each connector and measure the resistance
'.li
,.,. .
.... "'RB'tDoii;
,"
''''""
' .. I . ,'I, '.'
Between EGCS CIU terminal 104 and
FPCM harness termmal 2
Between dropping resistor harr""ss
terminal 1 and FPGM harness 3
Between fuel pump relay harness conector
5 and FPGM harness connector 4
Between fuel pump harness terminal 1
and FPCM harness connector 4

.
Between EGGS CIU terminal 1 04 and
FPCM harness terminal 1
I Between ECCS CIU terminal 106 and
FPGM harness terminal 1
I Between fuel pump relay harness conector
5 and FPCM harness connector 5
I
l
Between fuel pump relay harness conector
is and FPCM harness connector 7
I Between fuel pump harness terminal 1
and FPCM harness connector 4
(7) Fuel pump voltage inspection
0
g
,
I
l
.
,
i
a
g
I
(RB20DET onl
'Fuelpump :
control i ( . ...-1: control unit

3: 'r \ Fuel
" -ilJ\ pump

: ;0 ; c uel ,3 J relay
: 2 pump ... .: harness Side
! Dropping ha
m
eSSr5J! pum"
I, 2:1
: reStstor Side 4, control modu/alo ;
iharness s!de harness Side I
Fue! pump 1 1(}1 ECCS :
control ">2, \ l contrOl:
modul.'or 7 - '''' unrt .
n pump
, ' 'olay
harness Side
HfI Fuel Dumo
: Fuel pump. :4 I 1 control modulator
: harness Side harness side
Disconnect the fuel pump connector and measure the
voltage between the following terminals and ground.

Between fuel pump harness Between fuel pump harness
terminal 2 and ground terminal land grcund
Battery voltage Battery voltage
RB26DETI
RB20E I DE I DET
CA18i
Fuel pump
32
..

"C>' ..
\ ,:
pump harness:
____ .... i
EN - 311
RB26DETT! RB20E! DE! OET I CA 18i ENGINE
(8) Fuel pump inspection
Disconnect the fuel pump connector and measure the
resistance between the following fuel pump terminals.
Check the fuel pump operation by disconnecting the fuel
pump connectors and apply the battery voltage directly to
the following fuel pump terminals.
Pump terminal 1 (2) to battery positive terminal (+).
Pump terminal 3 (1) to battery negative terminal (-).
( ) RB26DETI only.
RB26DETT RB20E I DE I DET
(9) Dropping resistor inspection (RB20DET only)
Disconnect dropping resistor harness connector and
measure the resistance between the following terminals.
Between dropping resistor terminal 1 and 2 0.5
EN - 312
CA18i
CA18i
RB26DETI ENGINE
(10) Fuel pump control modulator inspection
(RB26DETT only)
When the fuel pump control modulator connector is
connected, measure the voltage between the following
terminals.
8.8 - 9.2 V Approx. 4
Battery voltage Approx. 4
EN313
0-1V
Approx.4
RB26DETT E'lGINE
52 INJECTOR SYSTEM INSPECTION
Air flow
'neter
/v
:11eter
i rear'
Englce
teMp
ser$or
Throttle
sensor
i
! i
I L-
I
11 __________
i Neut.ial sw_ltch I
LftJ 3J
EN - 314
ENGINE
[CONTROL DESCRIPTION]
Input signal
Crank angle sensor
120' signal'
1'slgnal .
Tennlnal
No." .
41, 51, Detennm9s injector timing
42, 52 i Reads engine speed
Detects 'ntake air and detennmes
. .
,:'
')
,Air flow meter Intake air,
quantity signai I 27. 35
'.basle Injection quanuty (injection pulse ,Failsafe function activated
when disconnected.
'width) based on engine load.
START signal
I
Engine temperature
!Slgnal
i Exhaust gas sensor
'signal
Throttle valve SW
(Idle conneclion pomt)
! Throttle sensor
i
i Battery vollage
IntaKe ai r temperature
,sensor
,
i
Increase fuel quantity when starting.
43 Determines injection quantity when starter
!SWisON
e onns Injection Increase accor 109 to P rI d
28
engine temperature.
Fuel range changes according to
'engine temperature.
29, 55
Injeeoon pulse width control according to
alf.fuel ratio feedback
54
.
,Fuel cut during deceleration.
. Flow correction dunng acceleration or
38 deceleration.
Interrupt inlection
Idle judgement
53
Fuel cut interrupts speed and fuel cut al 0
kmlh vehicle speed.
49 'Injection pulse width correction
36
Detects intaKe air quantity temperature
,and corrects injection pulse widtih
EN - 315
F ail-safe activated when
short-circuit or
disconnection occurs.
According to control block
condition
Activated when throttle
sensor damage occurs.
I
I
!
.
.
,
!
i
I
RB26DEH ENGINE
Injector system trouble diagnosis flowchart RB26DETT ENGINE
operation nOise lnspectror
Operatic" sounO "au=-d=-ib"l"e _________ '-____ --'-N:.;o-'o:.::.;perat1on sound
; Injector control $ nal inspection
Measure voltage between Ir,jector connector
termlna! 2 (each cylinder) and groUflQ.
Note: Battery voltage whC'i engme is O:'lt1r
lnjector control signal fUnj;I'lg ....
must be verified by
oscilloscope. Verify waveform on osc,[!oscooe
AbnonT',al
! !r.jcto sUPO:Y inspection
i Measure vOltage oetween
: connector 1 (each cylinder) and ground" '
ana dIsconnectIon
! ECCS control Unit terrnll,a! arrangemen: I
Battery voltage
'#hen ignltic'l !S 0,,"
Injector Inspec:ion
'Measure resistance between
! lermma:s 1 - 2.
2 -30 Other
I
Other than voltage
measurement wt;en
Ignition sWitch is ON
I
Repair injector
power supply
circuit system
[DrOPPing inspection
Replace inJectors
I 4 Resistance
Resistor 3 - 5 measurement
6 between
7 terminals
8
Other

till!iliJ
Ha
r
'1ess continuity inspection
'(resistance measurement)
Replace dropping resistor
Injector C!U
harness harr.ess
00
(

103 (#3)
114 (#4)
1101#5)
1121#6)
ECGS. C/U power SLl Iv illsoectlon
(8:: DATAMONITOR" ,
,(b'. Voltage measurement between i
I) terminal 49 and ground :
Battery vOl1age when I
ignition switch is ON. Other
I I
Inspect Input
51 na! s stem
Repair ECCS CIU power
supply circuit system
Other
Repair
harness
EN - 316
RB20E' DE. DET ENGINE
5-2 INJECTOR SYSTEM INSPECTION
CONTROL CIRCUIT DIAGRAM RB20E I DE I DET ENGINE
Air 'egulator (-) 1
,..-__ -, cp Air regulator (+) 2
ST
+)----"'<Yo_---____ -; 23(43)
11(9)
(112)
f110}
(114)

41
ir=ffi(illill No.4

27(49)
4.O(IGl
rt::ffiJill NO.6 g
nOl' .... ' --------+-1
,
{IDill NO.1 j
ECCS relay
,' 53
- ,
- 3,W AT

1 ''t1
T
T
"-"
hrottie vaive SW

(1'
2 ' 2
\Y
c rank angle sensor
120' sional" liB.
,J., 2
Power
,round 4 J J::
A ir flow meter
- 11 FR
hlake aIr Sid 2: I 2 '
Pu.ver ground
311111 "
S!gnalgrour:c
4T4
Power supply
str
Ergine temp senso'
"t
,
i
I
II
I
!
I
!
1
I I
32{S7)
22(54)
1
105
)t-----------WjJ00ill No,2
l1
1l3
)t--
e
-
f
-, -------+--r2h6.Qill No.3.
m
26(48) (") 11
,(38) g t------i 1 No.2
101 1
"
g 10 t-____ So
[
19(41) C J
j!, 1 No.4
28(50) 105
"'t------;- :::
t----------<0 O--'lA
J
h.,----------(3 sensor
t=----;==:::::lJ.
I 1 t 'J..r----" .
__ t """" iS3)2 ehlde spd se
) RB20DE i DET
ECCS control unit pin
[RB20Ej
-
103 '1 ;, , '1
[RB20DE ! DET]

t=ttttj
.....!"'Rx I fX'J CHKIIGNI
[Diagnosis connector) 12Jc:'"fT"CIT'J<jTil---'-.....;:---I'["-".:.r. """-'I.
EN - 317
-
22 : 25 26 27128
RB20E i DE' DET E'JGINE
[CONTROL DESCRIPTION]
C ranK angle sensor
120' signal
1'5ignal
jAir flow meter intake air'
I quantity signal I
I START signal
I .
i Engine temperature
!
i sensor Signal
I
\-
,Exhaust gas sensor !
'Signal
i
!
Throttle valve SW
I
(Idle connection point)
.
!
I Throttle sensor
; Vehicle speed sensor
Battery voltage
( ) RB20DE I DET
9, 19 (41, 51) Determines injector lJming
20. 10 (42. 52) ,Reads engine speed.
3 (27)
23 (43)
5 (28)
6 (29)
32 (57)
7 (38)
21 (53)
27 (49)
I
Detects intake ai r quantity and
determines baslc injection quantity
(injection pulse width) based on
engine load.
Increase fuel quantity when starting
Determines injection quantity when
~ s t r t e r SW is ON.
I ;ertorms Injection increase
. according to engine temperature
I Fuel cut range changes accordi ng to
'engine temperature.
Injection pulse width control
according to air-fuel ratio feedback.
Deceleration fuel cut according to
ON signal.
Acceleration increase when ON
. goes to OFF.
Fiow correction dUring acceleration
or deceleration.
Interrupt Injection.
; Fuel cut Interrupts speed and fuel cut
at 0 kmlh vehicle speed
Injection pulse Width correcllOn.
EN - 318
Fall-safe function
activated when
, disconnected.
I
-
i
Fail-safe activated when
short-circuit or
Accordmg to control
block condition.
.
.
I
-
-
I
-
RB20E: DE DET ENG,NE
Injector system trouble diagnosis flowchart RB20E I DE I DET ENGINE
injector operation nOIse inspectlO:1 :
Operation sOund "au:::d:::'b:::ia=--_______ -' _____ N"'C::.'::.o"'peration sound
Note:
Injector control signal inspection
;Measure voltage between Injector connector
I 1e''Y11n al 2 leach cylinder) and ground.
Ot1&r
Iniector control signal
must be verified by
oscilloscope.
Battery voitage when engine is
rurmng
r"V"eCC""'fy:-C:w:::a"ve"f'-oc.:rm'=-o:Cn:-:o"sc=';;-llo=s::c:::o:::p7C
e
, ,-------,\11' ,J,
InieclOr power supply Inspection
Normal Abnorma!
Measure voltage between injector connector
I 1 (each cylinder) and ground (RB20E).
I
Inspect connecto' lor breaks I Connector 3 and ground (RB20DE I DET).
and dlsconnectlo'1J
Battery vOltage Other thar: battery
IEces control termInal arrangement I
when ,grlltlon ,5 ON voilage when ignition
switch is ON
(RB20E)
I
Injector inspection
terminals 1 - 2 (RB20E)
(RB20DEIDET)
Repai; Injector
power supply
circuit system
(RB20DE. DET)
{
5 (#4)
Ec:-:, .......... -' . \.:; .. :,::
3- 4(#6)
6(#5)
t3 14 g
I
I
Harness continuity Inspection
(resistance meaSlJremer:t)
Inlcctor ClU
t1arness harness
103 (#3)
I

1 - 114 (#4)
110 (#5)
112 (#6)
(RB200E i OET)
(
101 (#1)
1 -
112 (#41
110 (#5)
114 (#6)
00 I O1her
I
ECCS C:U power supply inspection I
DATAMONITOR I
1.' Vol1age C1easurement between .
. J: terminal 27 and ground (RB20E) :
!ermmal 49 and ground (RB20DE ! DE,) i
Battery vOltaB when I
Ign:tlOn $wrtch is ON Other
I
Inspect !nput I Repair CIU power
s,anal svsterr supply circuit system

harness
EN - 319
I
Other
Rep'ael i njeelors
If va:ue is 'lot norma! at mld
connector there is a possibll:!y
of faUlt With the harress, Test
the resistance measurement
with injector unit
f'B26DETI / RB20E! DE,I DET ENGINE
Use "POWER BALANCE" in the CONSULT active
test mode to check the idle speed variation and
check the injector operation.
Caution:
Do not perform test while driving.
ACTIVE TEST :::JI
POWER BALANCE .
MONITOR 1
CAS. RPM (PaS) 950rpmi
AIR FLOW METER 1.1 U
AACVALVE 25%1
-..
I II
RB26DETT
signal and power inspection
Disconnect the injector connectors and measure the
voltage between the following terminals and the ground. i&
!S;,.. \ '.. ,
.t "" ? '."
!('4I' 21 ,
ground
H"""rv voHage
terminal 1 and
ground
Batterv voltage
.

.. .. ::: ..
ground ground
Approx 10V Approx 10V Anrlrnx. 10V Approx. 10V
The voltage decreases as the engine
speed increases (apprax. O.2V decreases
for each 2,OOOrpm of engine speed
increase)
Inspection can be carried out at mid point connector for No.4, 5 & 6 cylinder and power
supply for RB20DE & DET engines.
BelWeen harness
4, 5. 6 and ground
Battery voltage
Approx. 10V
BelWeen harness
terminal 3 and ground
Battery voltage
Approx 10V
The voltage decreases as the engine speed
increases (approx O.2V decreases for each
2.000rpm of engine speed increase)
EN - 320
RB26DETI! RB20E I DE I DET ENGINE
[ECCS control unit connectors)
Control CIrCUIt
Between EGCS G/U
terminals 101.103.105,
"";',", '110,112, 114 and ground
Battery
Approx. 10V
Power supply circuit;
EGCS CIU terminal i
109 and ground :
Battery
Apprax.10V
The voltage decreases as the engine speed
increases (approl( O.2V decreases for each
2.000rpm of engine speed increase)
(2) ECCS control unit power supply inspection
Refer to fuel pump system [EN3, 5, 5 - 1)
Disconnect the control unit and injector connectors and --=-1
ECCS C/U harness Injector R820E ..
harness terminal 2 DET I R826DETT ,
"" fi: '" "0/ ,;-..;._ :2
Terminal 101 (101) [1011 TO No.1 cylinder '<:y'
Termmal110 (105) [105] TO No2 cylinder ---. _-
Terminal 103 (103) [103J TO NO.3 cylinder 00
Terminal 112 (112) [114J TO NoA cylinder
Terminal 105 (110) [110J TO NO.5 cylinder
TermlOal114 (114) [112] TO NO.6 cylinder
( ) RB20DE I DET [ J RB26DETT
[RB26DETT]
Disconnect the harness connector from the injector and
dropping resistor and measure the resistance between
the following terminals.
Terminal 1 TO No.1 cylinder
Terminal 4 TO No 5 cylinder
Terminal 5 TO NO.3 cylinder o Q
Terminal 6 TO NO.6 cylinder
Terminal 7 TO No 2 cylinder
TerminalS TO NO.4 cylinder
EN - 321

RB26DETT I RB20E I DE f DET ENGINE
Inspection can be carned out at mid pOint connector for
No.4, 5 & 6 cylinder for RB20DE & DET engines.
ECCS CIU harness Mid point
connector harness
OQ
I Term.lnal112 TO
Termlnal110 TO
Terrnmal104 TO
Termmal S (No 4 cylinder)
Terminal 6 (No.5 cyiinder) ;
Terminal 4 (No 6 C'-yl_ind_er_l..LI ______ -'
(4) Injector inspection
Disconnect the injector connector and measure the
resistance between the terminals for each injector.
Between injector terminals 1
and 2 (for all cylinder)
(RB20DE I DET)
2 - 3 g 13 - 14 U
Disconnect the injector harness mid connector and
measure the resistance between the following terminals
for resistance.
No.5 cylinder Between Injector terminals 3 and 6
No.6 cylinder Between injector terminals 3 and 4
(5) Dropping resistor
13 - 14
g
Disconnect the dropping resistor connector and measure
the resistance between the following terminals.
Dropping
resistor 3 -
Terminal 4
Terminal 5
TerminalS
Terminal?
Termmal8
Sg
EN - 322
Dropping
GA181 ENGINE
5-2 INJECTOR SYSTEM INSPECTION
CONTROL CIRCUIT DIAGRAM CA 18i ENGINE
!
r
ST iii Z3
E8
3 5- , r
EGGS relay I
dJI;\
,-,
T "vo:tle sensor
'"
,

i--- Signal 1 2 -- 3
1:::-:,;:,:1 i: I I' \'
Crank angie S'1S0r
II. 180"slgnai I ,'
, 2 Power 3t 1
3. Ground . 4; 2
4. r signal
=-+---r--"' __ -;9
'---;.,
Engine :emp ser')sor

1 f---------.,
2/----
=
fiiii
101 10 \: 10 1C 10
1DrlO
37
3S!
3 4
4;
4
l' I 2 I 3 i
-
4
109
"
11 11 11 1'4 "'5: 115 43
441
4
5 46
"I 4 I " I
12: '4
EN - 323
Injection pu se (Ti) monitor
, Jr'/
41f
Injector

[iiiiil
=
S 6
:
7
B I
9: 1C
"
22! 23 2.:.125
""I"
2B
15 16 I 1, 19: 20 29 30: 32
1
3
-3
34
1
35 36
[CONTROL DESCRIPTION}

I Crank aregle sensor
, 120' signal.
l'signal
Air flow meter intake air
i quantity signal
I
START slgr.a1
I
!
Engine temperature
sensor sIgnal
Exhaust gas sensor
s'goal
Throttle sensor
,
,
Battery vonage
!
9.19.
20. 10
3
23
5
6
3. 7
21
27
CAlSi ENGINE
I Reads engine speed.
,Detects intake air quantity and
!determlnes baSIC injection quantity
I (injection pulse width) based on ereglne
load
,Increase fuel quantity when startireg
Determines Injection quantity when
starter SW is ON.
Performs injection increase according to
ienglne temperature.
Fuel cut range chareges according to
engine temperature.
Injection pulse width control according to
air-fuel ratio feedback.
Deceleration fuel cut according to throttle
valve idle position signal.
Acceleration Increase when ON goes to
OFF
Fuel cut at prohibited vehicle speed.
. Injection pulse width correction
EN - 324
I
i
!
I
i
F ali-safe function
acllvated when
disconnected.
-
Fall-safe activated when
short-circuit or
Accordmg to control
block condition.
2 system type
-
.
,
!
I
I
CA181 ENGINE
Injector system trouble diagnosis ffowchart CA 18i ENGINE
I
injector mject:on TSCBC::C:1 I
Remove air c!earJe' cove- '0 ::;rlBCk
Inject;;)g I No fnjectlon
I
10lher system 1
j,nspection. 1
I
IlnJector control s:gnal Inspection
i Measure voltage Injector
!connector terminal 3 a'1d ground.
Battery voltage when engine is running. j
lower 05V when engine rev :S Increased
lO00rpm. 1
Other

\illtY
I Verify wavefor01 on oscIlloscope I
: Injector power supply inspection
Norma: I A' I ",norma
I
I Measure voltage between injector connector
:6 and ground.
j
lnSpect conrector for breaks 1
ar:d disconnection. I
Battery voltage
when IgM on IS ON
I
Other than battery voltage
when jnMlon sWitch IS Of"
"

I I
i !n;ec!or Inspection ! Dropping resistor power
Note:
Injector control signal
must be vertfled by
oscilloscope.
: Measure iesistance between
0IJ ;lnspectlon
i terminalS 3 - 6
13 Q:
i
I
fHarness con ,tinJ:ty hSDsction!
I
, ("esistance
, Injector
'harness
measurerre'1t)
C!U
! harness
3 - 101
oQ ether
1
on Repair
harness
en
Repair ECCS C/U power
supply circuil syslem
IEces control ten"'\')lnal arrangement I
,
4' ,,. ,. 11.., '" "" '"
EN - 325
1 2 I,Measure voftage betwee:i
connector 2 and ground.
Other
Battery voltage I
I
Other
Replace
1
injectors IDropping res'stor
: inspection
:Measlire resistance
iI, 2 I between connector 1
and 2.
I.SQ
I
I
Harness contmulty Inspection:
Dropping Injector
resistor connector
6
R . I
epalr powe
supply circui
system
Other

dropping
resistor
Repair
harness
r
I
CA 181 ENGINE
(1) Injector control signal and power inspection
Disconnect the injector connectors and measure the
voltage between the following terminals and the ground.
Between injector Between injector
harness termmal 3 harness lermi nal 6 and
andground ground
OV Battery voltage
Connect injector connector.
Note:

Between EGGS G/U harness terminal
101 l'Intinrnl
Battery voHage
Battery voltage
(decreases O.SV for engine speed
increase of 1000rpm)
For accurate data use oscilloscope.
(2) ECCS control unit power supply inspection.
Refer to fuel pump system [EN3, 5, 5 - 1]
and ground with ECCS control unit connector
connected.
ov Battery voltage
Battery voltage ov
Disconnect ECCS control unit and injector connector
and measure the resistance between the following
terminals.
Between ECCS C/U injector
harness terminal 101 and 3
00
EN - 326
'cD
; ECGS: I' InJElctcJr
, I i I
;contro I - ; i
I unit
i
'i"

(4) Injector inspection
Disconnect injector connector and measure the
resistance between the following terminals,
Between injector harness
3 and 6
(5) Injection pulse monitor (Ti monitor) signal
inspection
Measure the voltage between the following terminals with
EGGS control unit connected,
Ignition sWitch in ON position
Cranking or engine running
Battery vottage
Battery voltage (approx. 0.5 V
decreases for each 100rpm of
engine speed increase)
(Reference) Inspection using the Oscilloscope
Injection pulse monitor (Ti monitor) is a result of the
injection pulse width within the EGGS control unit and it
may differ slightly with actual injector waveform (about the
same for CA 18i) but the pulse width is same.
If the waveform is abnormal and the Ti monitor is normal,
the ECGS control unit and the input system is normal and
there is a possibility of fault with the injector circuit or the
injector main body.
EN - 327
-_ .... _-
. Injection l :
. pulse width:
: Ti moMor l J --12V
waveform OV
Injector L t2V
waveform ! OV
RB26DETT ENGINE
5-3 IGNITION SYSTEM INSPECTION
CONTROL CIRCUIT DIAGRAM RB26DETI ENGINE
Crank argle sensor
i 120' Signal ( 1
! F signa' i 2 II
lPower ! 3 I
I Ground \. 4
IGN
11--+-__ 07
I
I---i---+ ..
1-_+_--'/'.,
1--+---+.,
m
(')
(')
2
'"
"
0
"
11
::'
2-
c:
j!,
Power transistor

I 2
NO.4
IGN
cOil
relay
Engine temperature sensor

2 2f-'
Detonation

'-----'
[Control description]
'I rank angle sensor Ignition can not be performed!
120' signal 41,51 Ignit.on liming start pomt lhere IS an instantaneous break
:---------,------r-------------"rnthe120"slgnal
IFrll1irlP temperature
Theettle valve sWitch,
, Id Ie connection I
i Throttle sensor
, START' Signal
[D'ltolnatlon sensor
42, 52
28
54
38
43
23,24
nltion timing count IgnitlDn can not be I'H>,form<"rl I
The Ignillon timing IS set according if there is an Instantaneous break
to the map indicated by 120" Signal
es rnjecfion timing according ail-safe is performed when there
engine temperature. .s a short-circuit or disconnecting,
[Gelntnolfor low and high engine 20"G at slarting, gradually
conditions. to 80'G
I cut dunng deceleration
Flow correction during acceleration
deceleration
ine.
detonation and changes
i i
EN - 328
when throttle senso r
IOa,m"Qe occurs.
Idle
11- ail-sate is activated if short-
disconnection occurs
RB26DETT ENGI."E
Ignition system trouble diagnosis flowchart RB26DETT ENGINE
I igr;ition snark inspection I
Strong spark arCS
I
O:'1er
I I
I Inspect other system I Self-diagnosIs
"SELF-DIAGNOSTIC RESULT"
ell SELF-DIAGNOSIS (code No 21)
Norm.::d] Abnormal
ij'DATAMONITOR" I
(Real time dlagnosls)1
NOflllai I Abnormal
I Power transistor control signal Inspection I
I (power tranSIstor unit) :
. . .
,Measure voltage between powef :ransistor I
i 1.2, 3, 4, 5. 6 and ground. '
Other
i Approx. 0.1 - O.3V
! when en :ne is runnino
Ignitio"" primary signa! insoection ! owe' transIstor control signa, !nspectlon :
Measure battery vOllage between : 1"'-' . (ECCS CiU unt)
power transistor term'nals 1, 2, 3, . (E. 6! 5!4j3! 21 1 ) Measure Ihe voltage between CIU
4,5.6 and ground, 'terminals 1 P 3 13 2 11 and grour.d , -,
Appro);. 14V when
engine 1$
: Power tra'1sistor
; :l1spectlon
I
Approx. 0.1 - O.3V \
when engine IS running 01her
I
i ECCS C/U power inspection
I "DATA MONnOR"
rmal
!
Normal Abn:)
:j: Measure voltage t>et\Neen CfU tennlnal
Harness contir:uity
hspectlon. Measure
,resistance between :)Qwer
: transistor mrrmnai 1 ar;d
ower Replace p
transisto
49 am grourd.
Battery vOltage when I
! ignit;on coil terminal 1,
Otrer
Ignition coil power lns00ction:
Repair
harnes
Inspect voltage between COl!
:terminal 2 and ground.
Battery voltage wryon I
Ignllion swrtcr is ON '
I
Ignition coH InspectIon
Measure resIStance between
coli :ermnal 1 and 2.
0.6 0.9 g! Other
Other
ignition
coil power
supply system
circuit
Ignition system secondary I IGN coil
part Inspection I
r
s
Harness cO:itinuity
ignition switch is ON
inspection
I
Repair ECCSICIU
C;U power transistor
1
..
1
Inout signal
12
..
2
system
power supply
: 3
..
3
insoection
circuit system
i
13
..
4
2
..
5
11
..
6
00 I
OUier
I
Rt .
Inspect connectors for i.1 epa"
faulty connect or defects harness
and check Circuit systems.
IEces Unit terminal arrangementj
I"
I '
EN - 329
RB20E i DE; DE ENGINE
53 IGNITION SYSTEM INSPECTION
IGN
,--......., c;!i)
-f--<1".O+-----+ <SOHC+>}-_--:-H;:::au:;:::=t-__ -. 25(45)

40i161
ECCSreiay
:
FUtL
' ... : __ -+
32 (5TI
valve 1 }----,----<22(541
SWitch
m
g
IDLE
Crank
!II
i1)-----i----+119(41)
a
Tachometer
\I
J;;P: +H
<DOHC>

E:1gine temperature sensor
j I

: Detonation se 2

( ) RB20DE,' DET
--------
IGN
coli
reiay
,Crank angle sensor' i The Ignition can not be performed
19 i41) .1 "'nnion timing start point
1120' signal '''' ,If there IS an Instantaneous break
r--------+-- the 120' signal.
ilgnition timing count iThe Ignition can not be performed
ICrank angle sensor
.1'signal 10 (42) 'The Ignition timing is set according ilf there IS an instantaneous break
I i to the map Indicated by 120' signal. :in the l' signal.
! ---r------"-c-h-an-g-e-s-I-nj-e-ct-io-n-tl-m-in-
g
-a-c-c-o-rd-i-ng'-F-a-,I-'s-a-fe-,s""p-e-rl-o-rm-eo-'-w-h-e-n-the-re--i
Engine temperature i to engine temperature. lis a short-circuit or disconnecting,
sensor 5 (28) Control for low and high engine '20'C at starting, gradually
temperature conditions. increaSing to 80'C

Throttle valve switch 32 (57) Controls Ignition bmlng when idling
1-______ +-____ ..,:r=a.._nd=.-igniMn switch is ON
"START' signal 23 (43)
Detonation sensor 16 (23 24)
Controls ignWon timing when
cranking engme.
Detects detonation and cnanges
ignition timing.
EN330
Fail-safe is activated if short-
cirCUit or disconnection occurs.
RB2CE, DE / DET ENGINE
Ignition system trouble diagnosis flowchart RB20E I DE I DET ENGINE
I Ignition spark ,""oecllon I
Slrorg spark arcs
!

Self-diagnosIs
'f"SELF-DIAGNOSTIC RESULT'
4 SELFDIAGNOSIS (code No, 21)
RB20DE,
NO(IT;a: Abnormal
DET RB20E
Ii, "DATA MONITOR"
(Real time
Normal Abno:mal
: Ignition coil irspectlon
: Measure the reSiStanCe
befween IGN coil I1l
Power transistor control signal inspection (power
transistor Jrir)
TIT
Measure voltage betweep power trans:stor terminals
: 2 and ground (RB20E),
Replace Approx_ 0.: 0.3V
IGN coil when en me is runnH"lC
IgPltlon priMary signal Inspection
: Measure batlery voltage betweer power
i trar;slstor terminal 1 and ground (R820E).
! Measure voltage between power
;transistor terminals 2. 3. 4. 5. 6 ar.a
I ground (RB20DE / DET)
6 - 10V when engine:
IS nJnning Other
RB20E
( 1-2)
RB200EIOET

Harness continUity
:nspection, Measure
;esistance between power;
tra;)s'stor terminal 1 and I
: ignition coil terminal 1.
Replace
power
transistor
o Q I 01her
r-----LI ___ ---, I
Ignition COil power inspection Repair
Inspect voltage between COil harness
fermlnal 2 and ground,
Battery voltage when r
ignition sw!tcn IS ON: Other

Ignition COli ,nspectlO'1
Measure reSiStance
o8tween COl! terminal 1
and 2,
IRB2CE)
Ignition system secondary
part inspectiofl
Repair ignition
coil power
supply system
circuit
; Measure voltage betwee:'"\ power transistor terminal
! 1, 2, 3, 4, 5, 6 and ground (RB20DE ! DEn
Other
Power transistor control signal inspect10n
i (ECCS C/U Untt)
: Measure the voltage between C/U terminals
i 37 and ground (RB20E)
Measure the voltage between C;U
lermnals 1,12,3,13,2,11 and ground,
(RB20DE i DET)
Approx, C.l - Q,3V
"irem engine is r.;n:1ing : Other

I
Harness continuity
;Cispectlon
CiU fermlnal 37 and
power transistor terminal
2 (RB20E)
C/U power
(RB20DE! DET)
1 1
12
-
2
3 - 3
13 - 4
2 - 5
11 - 6
,
oQ
Other
,Inspect connectors ror
'faUily connect or defects
and check ClrC:Jlt s stems,
i ECCS CIU power inspection
i
f "DATA MONITOR"
i Measure vOltage between C/U
terminal 27 and ground (RB20E) !
Termmaj 1. 12,3.13,2,11 and I
groul'd IRB20DE i DEn
Battery voltage when I
Ignition switch is ON Other
I J
: Inoul Signal I Repair ECCS C/U
' sysle", power supply
! : circuit system
Repair
harness
!Eces un:t terminal arrangement!
(RB20E)
(RB20DE, DET)
EN331
CA 181 ENGINE
53 IGNITION SYSTEM INSPECTION
ThroHie sensor
I Power , 1 1----+---...,.
i ,
I Ground : 3 i
. Irr-H---+
I Crank angle sensor I I
'j-'- leo j--j--...... --t
/
1 2 PUIir '''' ! ,3 1
13GrClnu ; 42
,; -1. 1 s:ot'"" I
I ... --1
,.
,
m
0
(")
'"
"
7 0
:1.

2-
"

,
'0
i E')Qm8 sensor -;;;:
i c8==---t
L
I:
I The ignition can no! be
I
'ilthere IS an instantaneous break i
1---=-----+---+-- the 180' signal.
:The Ignition can not be r" '1onml'dl
there is an instantaneous break
9 Ignition timing start point.
angle sensor l'
Signal
Engine temperature
isensor
Signal
10
5
3. 7
23
Ignition timing count.
The ignition timing IS set according
to the map indicated by 180' signal.
Injection timing according
the l' i
temperature. I F is performed when there
ICcmtnDlfor low and high engine a short-circuit or disconnecting.
conoilions.
I(:rmtrnl< Ignition timing when idling
ignition timing when
EN - 332
GA1SI ENGINE
Ignition system trouble diagnosis flowchart CA18i ENGINE
Othe"
Self-diagnosIs
. i"SELF-DIAGNOSTIC RESULT'
SELF-DIAGNOSIS (code No. 21)
Norma! Abnormal
(EX)
@
(IN)

(Real tlr:le diagnosis)i
Normai Abl'ormal
!gnltion coil i:1spectlon
Measure the resIstance between
IGN cOil terminal 1 & 3.
7 - 12K g
Replace
IGNcoil
Approx. O.SV when
en ina is runrm
Ignltlo"! pr:mary SIgnal insoection
Measure battery vOltage between power,
transistor termina: 39 and ground,
5 - 10V whe'l '1iine
!s runnm
(IN / EX)

Other
: Power tranSistor
; 'ilspection
I
rma!
e
Power transistor control Signal inspection
(power transistor unit)
! Measure voltage between power transistor termmal
,3 and ground.
, Power transistor control slgnal insoect\on
. (EGCS C/U unit)
! Measure the voltage between C/U
. terreinals 37 and ground (IN).
i the vOltage between C/U
Itermlnal38 and ground (EX).
Approx. O.5V when
engine IS running Olher
I
ECCS CJU power inspoction
jj. "DATA MONffOR"
I
Har'less continuity ,nspection,
Measure res, stance between
power transistor term'nal 5
,and Ignition coil terminal 1"
power
transis tor : : jt voltage bet\veen C/U
: Harness continuity inspection' I temllnal 27 and ground
Ignition cod power inspection
Inspect voltage between coil
terminal 2 and ground,
Other
Repair
harness
G/U tereninal 37 and power
transistor terminal 3 (IN}
:gnrMn swilch is ON Other
C/U terminal 36 and power
I . J
transistor termina: 3 (EX)
Input signal' Repair ECCS CIU
on
Other system , power supply
I
I
inspection] circuit system
I;nspect cornectors for I Repair
faulty connect or defee:s
: harness
i and check C!fcwt systems.:
Ignition co!1 l"iSpection
Measure res,stance between
coil te,rrllrai 1 and 2.
Repair ignition
coil power
supply system
circuit
lEGes contro' unit terminal arrangement I
Ignltion system secondary Replace IGN coil
iii: 'iiil
patt inspection
," Oi_,.;,.,',,,: )aJ9ovIlU :1:_ 1:4 s" l' 11$
EN - 333
RB26DETI! RB20E, DE! DET! CA18i ENGINE
(1) Self-diagnosis
Check faulty system name in "SELF, DIAGNOSTIC rb\
RESULT' mode when the ignition switch is ON and \..!!)
engine IS cranking,
When there is abnormal output, inspect assumed
locations in the following sequence,
Power transistor (short) - ECCS harness (short) -
ECCS control unit
Place ignition switch to ON position, @
Perform diagnosis mode selection procedure with the
diagnosis connector in the vehicle. Check the code
number of the faulty system displayed by the flashing
exhaust gas temperature warning lamp on the instrument
panel (see EN3, 2, 2-2 (2,
(2) Power transistor control signal inspection
Measure the battery voltage between the following
connectors and the ground when the ECCS control unit
connectors are connected,
RB26DETT
2.3,
0
i REs+ LJ
'FAILuRE DETECTED TIME I
! IGN S'GNAL PRIMARY 0 I
I
,.,. . .,. " ... J,
! ERASE i
l
PRINT '
_' ____ ________ __ .J

11,12.13and , iii"313
! ,,1#61.;'
0.2 - 03V ' Q (#2112
,<4113; i

___ ___ J ,.
,,' .. --.. - .. -.-.--..
RB20E I DE I DET
CA18i
Between EGGS G/U
terminal 37 and ground 1, 2, 3. 11. 12, 13 and
0.2 - 0.3V
0.2 - 0.3V 0.2 - 03V
Approx 1.0V Approx. OAV
__ A.',pp,-r_ox_._1_.0_V_---, .. ___ . ____ J
EN - 334
RB26DETI! RB20E I DE I DET! CA1S; ENGINE
(3) Ignition primary voltage signal inspection
CA 18i & RB20E
Measure the battery voltage between the following
terminals when EGGS control unit connector connected.
Between EGGS G/U terminal 39 and ground
6 - 8V 5 - 10V
Approx.l0V
Approx. 8.5V Lower than battery v o ~ g e
RB200E I OET & RB260ETT
Measure the primary voltage of coil side connector of
power transistor.
Between power transistor
IGN call side terminals 1,
2, 3, 4, 5. 6 and ground
side terminal E and
ground
Approx.l0V
14V
l4V
CA18i & RB20E
OV
OV
OV
Disconnect ECCS control unit and power transistor
connector and measure the resistance between the
following terminals.
37 and power transistor terminal 2
Between EGCS CfU harness terminal
Between EGCS GIU harness terminal
EN335
o
RB20E
RB26DETI! RB20E I DE J DET I CA 181 ENGINE
RB20DE I DET & RB26DETT
Disconnect the connectors on input side of the ECCS
C/U and power transistor unit, and measure the
resistance between the terminals.

Power transistor
harness harness side
between terminal 1 and terminal 1
between terminal 11 and termlOal 6
o
Disconnect power transistor unit output side and ignition
coil connector and measure the resistance between the

Ignition cOil
unit harness connector harness
(7 Polanty terminal side) (terminal 1)
between termlflal 3 and terminal 3
o
Disconnect each ignition coil connector and measure the
voltage between the following terminals.
(5) Power transistor inspection
Check the resistance value between all power transistor
terminals with an analog circuit tester probe by changing
the positive (+) and negative (-) poles.
CA18i
analog tester
EN - 336
RB26DETT i RB20E! DE I DET! CA181 ENGINE
RB20E / DE / DET
+1- 0 or not =Q<+I- 00 Q
+1- 0 or not 00 Q =+/- G or not 00 Q
+1- 0 or not 00 Q<+I- 00 Q
RB20DE / DET
'" "1\
:1'
RB26DETT
r--------
Coil side EEEEEE +
(Coil side)
o or not o or not

CIU side 123456
CX)Q
+
CX)Q
2

I " ""
Coil side EEEEEE +
o or not
! q
CX)Q
'" Le-
CX)Q
d _ . ,
COil side 123456 +

SlOtt"
Coii side 123456 +
o or not
f 1121 ?4i
CX)Q
CX)Q
CIU side 123456 +
(6) Ignition coil inspection
Measure primary coil resistance value.
7K - 12K 7K - 12K
RB20E RB20DE / DET I RB26DETT CA18i
EN - 337
RB26DETT i RB20E / DE I DET / CA 181 ENGINE
(7) High tension cable resistance value
Measure the resistance of the high tension cables.
RB20E
I
..
No.1 cylinder 5 - 12K g
I
CA18i
Intake side
Exhaust
side
No.2 eyli nder
I
6 -15K g
I
No.3 cylinder 8 -18K g
No.4 cylinder
i
8 -18K g
No.5 cylinder
I
8 -19K g
No.6 cylinder
I
8 -19K g
Centre cable 4 -10K g
For No.1 cylinder Approx. 11 K g
\-------
For No 2 cylinder Approx. 11 K g
For No.3 cylinder i Approx. 13K 9 i

For NO.4 cylinder Approx. 11 K g I
Centre cable Approx 8K g I
------j
For No.1 cylinder Approx. 5K g :
For No.2 cylinder Approx 7K 9
For NO.3 cylinder Approx 9K g i
For No.4 cylinder Approx 11K g I
Centre cable Approx. 7K 9 I

EN338
RB26DETT ENGINE
5-4 IDLE SPEED CONTROL SYSTEM INSPECTION
IGN
El
@
[-
j.,
+
..
EGGS relay
"
E

2 1
5 I ?::O:+ 3
Throttle valve SWitch

[l--t---+sr
Crank angle sersor
r--t---i"
)-----1.,
Engine temperatve sensor
)----...,'"

m
n
n
'"
"
0
"
q
2.

IJ
AACvalve

2 6' 2 6! AI' regulator
5
B ----\..2., 1
'---'
18

1 ,
5 ...-9--3
2
Q!)

Fuel puma relay
Fuel pump ccn1ro
modulator
Air conditioner switcr

.,
Neutrai switch
..
!
Power steering sWitch
19,
,{InPut.ar
", ," .' ",
fl' ," '. .. "< ',.', .. ' ",; .. "' .. ,,'" .. ,._,,.>.',;, ._, :,
Crank angle sensor
I
42. 52
1'signal
Engine temperature sensor ! 28
'Throttle valve switch
54
(Idle connection pOint)
I
, Throttle sensor 38
I
i Vehicle speed sensor 53
Air conditioner SWitch 46
Neulra I swi tch 44
PO'lrer steering switch 19
I
, Batter; vonage 49
Read engine speed and feedback control is
performed for speed value.
Changes Injection timing according to eng.ne
temperature.
Operates when there is a fault with throttle sensor
(idle Judgement backup)
Fuel cut Clunng deceleration.
I Flow correction dUring acceleration or deceleration
I :nterrupts Injection.
Idle Judgement.
I Starts idle control at vehicle speed below Bkm!h.
I After engine warms up. Increase idle when air
'conditioning is turned ON.
Starts idle control in neutral position.
I Increase idle speed when power steenng oil
pressure is too high
,
'Increase idle speed when battery voltage is low
I (below 12V)
EN - 339
I
I
!
i
RB26DETI ENGINE
Idle speed control system trouble diagnosis flowchart RB26DETI ENGINE
Me valve fLnction 'ns ect!on
: Active test
01her
I
'dIe changes
!lnsoect Input system I
AAC valve controi Signal Inspection I
Battery vOltage inspection between AAC I
valve terrrmal 1 and grourd.
I
Cranking.2 3\/
!dling 6 - 1QV
I
Ot'1er
I
! AAC valve power supply inspection I
I
Measure voltage between .",AC I
terminal 1 and ground.
,.---.J-I __ _
: Air regulator . I
! Inspection (Power,
: maio unlt) .
, Supplemental air supply parts I
inspection !
(Check for any disconnection. i
. clogging etc) .
f',;o disconnec:ion I
or clogging I
Batteri voaage when
Ignition switch is ON
I
01her
Normal I Abnorrlui

IOther system Insoectlon I
Hose disconnected
or clogged

1
va:ve inspectIon
Measure reSistance between
AAC valve terminal 1 and 2
Repair AAc
l
valve
power supply
circuit system
Other
Otrer system:
Harness continUity inspection
InSpection. i
Measure resistance between AAC haflless:
terminal 2 and C/U harness 4.
Replace
AACvaive
o U Other
I
ECCS CtU powor inspection Repair harness
.Il. "DATA MONITOR"
i:g:. Measure voltage between CjU terminal
49 and ground,
ignillOn sWltch is ON

Note: The output data for the
AAC valve system must be
checked With an oscilloscope.
Repair or
replace air
regulator
I Input Signal Inspection I
Repair ECCS
ClUpower
supply circuit
[ECCs control Unit te''71lnal arrangement I
EN .. 340
RB20E 'DE' DEi ENGiNE
Z5{45)
AACvalve
'27 (49}
141
4O\Hi)
Cfrdf
5 3'
valve
J2151}
m
()
switch 22(54)
()
III
"
Crank
0
"
19(41} [
10(42)
c:
"
""
28(00)
Air corditioner switch
Engine temoerature sensor
5 (26)
8(30)
3S{19j
Power steering switch
: 21 (53}
) RB20DE i DET
L
,,c' ..
i .'
. . .' r
. ,,'; ........ '/"'i
.......

'"rJii .. *
Crank angle sensor
10. (42)
Read engine speea and feedback control is
1" signal for speed value.
Engine temperature sensor 8. (28)
Changes Injection timing according to engine
temperature.
Throttle valve switch
32. (57) I Starts idle control when ON at idle contact POints
!
(Idle connection pomt)
Vehicle speed sensor 21. (53) Starts idle control at veh.cle speed below 8kmlh
i
Air cond.tioner switch 29. (46)
. After engine wanns up. increase idle when air
i
!
conditionrng IS turned ON.
Neutra I SWitch 24. (44) Starts idle control in neutral position
.
Power steenng SWitch 38 (19)
Increase Idle soeed when power steering oi I
I
,
pressure IS too high.
! Battery voltage 27. (49)
Increase idle speed when battery voltage is low
(below 12V).
EN - 341
R820E; DE! DET ENGINE
Idle speed control system trouble diagnosis flowchart RB20E I DE I DET ENGINE
jAAC vatve control signal inspection i
I I! "ACTrVE TEST' I cf0
:1j)Measure vOltage between ACC .
i valve termmal1 and ground.
OO!t11ng (Duty) display
Cranlcng 2 3V
idlillg 6 - lGV
Other
Supplemental air suppty
parts inspection
, (Check for any disconnection .
Me valve power supply inspection I
Measure voltage between AAC '
: terrli'1al 2 and ground.
clogging etc)
No Clsconnect!on
or clogging

Battery voltage whe'1
ignition swAch is ON
I Me vaJve inspection ,
!Other system Inspectlon
j
Repair: Measure resistance between;
= I AAC valve temlnal 1 and 2 I
9 Q I O.he
c
O:her
Repair AAC valve
power supply
circuit system
I Rep I lace
Harness continuity inspection
Check tf-)e continuity oetween AAC harness Me valve
terminal 1 and C!U ha
r
'1ess termina! 4
(RB20DE. DETi. Between 1 and 27 (RB20E).
oQ I
Other
I
IEGGS CIU power supply Inspection I Repair harness

"DATA MONITOR"
'Measure voltage between C/U
term.nal27 and ground (RB20E).
Tel111inal 49 and ground (RB20DEIDET)
Battery voltage wher I
ignJtion swi'lch IS ON Other
I I
Iloput signal system Inspeclion I Repair ECCS
ClUpower
supply circuit
EN .. 342
Note: The output data for the
AAC valve system must be
checked with an oscilloscope,
I ECCS unit terminal arrangement j
(RB20E)
(RB20DE, DEn
RB26DETT / RB20E ; DE , DET ENGINE
(1) AAC valve control signal inspection
when ECCS control unit connector is connected,
OR
RB26DETT
6-7V
8 - 10V
6-7V
8 - 10V
Measure voltage between AAC valve connector terminal
2 and middle harness connector terminal 3 and ground,
RB20E I DE I DET
Measure voltage between AAC valve connector terminal
1 and ground.
(2) AAC valve system inspection
Use "AAC VALVE OPENING" item in "ACTIVE @
TEST' mode to set an optional angle.
Check that idle speed changes corresponding to setting
value at this time,
EN - 343
--(-{f)
ECCS \
control :
Unit; "':"
) RB20E
RB20E I DE I DET
ACTIVE TEST. 0
AACN OPENING
MONITOR
CAS,RPM (POS)
AIRFLOWMTR
AIR FLOW MER-R
ENG TEMP SEN
27%
950rpm
Q,93V
Q,92V
68C
loull UP II OWN Ilod
!
RB26DETT / RB20E I DE / DET ENGINE
(3) AAC valve power supply inspection
Disconnect AAG valve connector and measure voltage
Between AAG valve Between AAG valve
connector harness connector harness
lerminal1 and ground i terminal 2 and ground
!
RB26DETI
OR:
Measure voltage between the middle harness connector
terminal 7 and the ground.
Disconnect the connector from EGGS control unit and
AAG valve and measure the resistance between the
RB20E I DE I DET
"", Between EGGS control Ul1It harness terminal
4 and AAG valve harness terminal 1
Between EGCS control unit harness termmal
113 and AAG valve hamess terminal 1
RB26DETI
Between EGGS control unit harness terminal
4 and AAe valve harness terminal 2
Between middle connector AAG valve
terminal 3 and AAe valve harness terminal 2
EN - 344
oQ
RB26DE7I. RB20E DE, DET ENGINE
(5) AAC valve inspection
Disconnect the AAC valve connector and measure the
resistance between the following MC valve terminals,
Between AAC valve termmal 1
and 2
RB26DETT
Measurement can also be performed at middle connector
terminals,
Between AAC valve terminal
3and 7
RB260ETT ONLY
(6) Air regulator power supply inspection
Measure the voltage between the following terminals and
ground when the air regulator middle harness is
connected,
Measurement location
Ignibon switch ON
Cranking
kJling
Between middle harness connector
termronal 8 and ground
Battery voltage for 5 sec
Approx 10V
Battery vottage
(7) Air regulator inspection
1, Shutter opening angle inspection (static characteristic)
Visually inspect the shutter angle
Below -20'C
Half open
Above 60'C Fully closed
2, Inspection (dynamic characteristic)
Apply current from the battery to the terminals and check
changes in shutter opening angle, The shutter must
gradually close fully within 7 minutes,
EN - 345
RB20E I DE I DET
TI
~
I"'" "',
~ I -
CA18' ENGINE

Wk;::WSS_T ____
ECGS 'elay
r--
1 .I:TIil.
14 P-j 3 unJ.J

I
I
Thro:tle sensor I
;ij.
2

i Signal 2 4 f-------j----.-----+

\tCt'
Idle re-v correction
solenoid
i FICO solenoid ,
4 I- bU g 1 ;

Power steenng switch
".-. ---+w'3j+-----;
i '-- 1
29' . A'r conditioner switch
43 ... Light sWItch
45 Heater fan swi1Cll
46+'- Rear defogger switch
:-----------
conditioner switch 29
engine warms up. increases idle when air
I I Is turned ON.
31 ower steen ng sWitch ON.
43
r---.. --------.. -----j-------i Turns on Idle rev correction solenoid when switch
45 is turned ON and inceases idle (* D range for
r-----------------+-----------iAI vehicle)
defogger sWItch * 46
solenoid 103
rev correction solenoid 111
ilncreases Idle when air conditiOning IS turned
EN346
power steenng, head lamp,
d"fnn()", swltchs are ON.
CA 18; ENGINE
Idle speed control system trouble diagnosis flowchart CA18i ENGINE
Idle rev correction device tnspection
i ACTIVE TEST
ApPlY battery load and power steering
I load ect. woen Idling afrer engine warm
up,
Idle rev stays constant
I
or I!'crease
:die rev decreases
I I
,Input or system!
Solenoid control signal inspection
inspection Measure voltage between ECCS CIU
,:ermmal 11 and ground OR between
'mid point connector 5 and ground
No power load or power steer:ng load is
a;;::;::!ied wren Icllng: Power voltage
When cower load is apDI cd' OV Otner
I
Solenoid power inspection
Measure voltage between mid
pOint connector harness terminal 2
I and ground.
Battery voltage when :
ignition SWiiCh ,$ ON I
Other
I
Rlpair po

I unit inspection I I
,Measure :esistance betv:een
circuit
: solenoid 2 and o.
20-300 1 Other
J
solenoid
WCCS CIU poiwer supply inspection
i "DATA MONITOR"
between EGGS
CfU terminal 27 and ground.
Battery voltage when I
ign!lion switch IS ON
I
, Harness continuity inspection
! Measure res:stailce between
!
;1 soienold harress terminal 5 and 'I
. C/U hames$ terminal 11. .
o U Other
Other
ECCS C/U power
supply circuit system
Inspect connector for any faults
or bad conneciion.
Repair harness
Wer
IEGGS control unit terminal arrangement I
EN - 347
CA1S; ENGINE
(1) Idle rev correction solenoid control signal
inspection
Use "IDLE CORRECTION S/V" in "ACTIVE TEST"
mode to set the value.
Check that engine speed changes corresponding to
setting value.
Measure voltage between the following terminals
when ECCS control unit connector IS connected.
ov
ov
Battery
i+
,
!
. IDLE CORREC SN
MONITOR
PWRSIG
;
LON :1 ON/OFF 'I OFFl
,_ .. _---- ----
'!:t---------i __ . ____
ov
(2) Idle rev correction solenoid power supply
inspection
Disconnect idle rev correction solenoid connector and
measure voltage between the following terminals.
Disconnect idle rev correction solenoid connector and
measure the resistance between the following terminals.
Between EGGS GIU hamess Side
terminal 111 and idle rev correction 0 Q
solenoid harness side terminal 5
(4) Idle rev correction solenoid unit inspection
Disconnect ECCS control unit and idle rev correction
solenoid connectors and measure the resistance
Between hamess connector termtnal 2 and 5 20 - 30 Q
EN - 348
CA18 ENGINE
(5) FICO solenoid control signal inspection
Use "FICO StY" in "ACTIVE TEST" mode to set
the value.
Check that engine speed changes corresponding to
set value.
Measure voltage between the following terminals
when ECCS control unit connector is connected.
Ale switch OFF Battery
(6) FICO solenoid power supply inspection
Disconnect the connector and measure voltage between
Disconnect FICO solenoid and measure the resistance
I Between ECCS C/U harness side terminal 103
i and FICD solenoid harness side terminal 4
o
(8) FICO solenoid inspection
Disconnect ECCS control unit and FleD solenoid
connector and measure the resistance between following
terminals.
Between harness connector terminal 1 and 4 20 - 30
EN - 349
FICD
solenoid
1 i
1-2'}--t=r--7T 103 I
L@---(.;oi //. ECCS .

RB26DETT ENGINE
55 WASTEGATE VALVE CONTROL SYSTEM INSPECTION
IGN
EGGS relay

EX'1aust Inter
manlfoid coole"
irter-
Air c'eaner
actuator Exhaust
tube charger tube
charger
Airflow
meter
Wastegate
actuator
Wastegate valve control system diagnosis flowchart RB26DETT ENGINE
Wastegate valve controt solenoid contrQI signal
inspection
Measure voltage between SN terminal 2 , C/U
te'mlnal 25 and ground.
Batte'Y voltage when Idling
Without engine ,oad: OV Other
I .
! Inspect air supply:
isystem
'sOlenOid power supply Inspection.
! Measure voltage between SN
.nspection
Repair air
supply system
i terminaJ 1 and ground.
Battery vOltage when
Igri:ion sw\tch is ON
Solenoid inspection
MeaSure the resistance
I
I
Other
I
Repair power supply
circuit system
between SlY terminal 1 and 2.;
30-400
I
Other
I

ECCS CIU power inspection
Solen
ce
old valve
j; "'JA TA MONiTOR"
ig: Measure voltage between C/U terminal
, 49 and groJnd
Batiel)' voltage when
ignition swrtcn is ON .Li _______ O_t_he_r __ -,
I I
Harness continuity inspection Repair EeCS CIU
Measure resistance between SlV i power supply
te'fT1inal 2 and C/U termlna! 25. ' circuit
o U _--'-___ ,
Inspect cirCUli system for connector
break or drsconnec:iort
Repair harness
EN - 350
fees control unit Terminal .arrangement I
RB26DETT ENGINE
(1) Wastegate valve control solenoid control signal
inspection
When wastegate valve control solenoid connectors are
connected, measure voltage between the following
terminals,
OR
When EGGS control unit connectors are connected,
measure the voltage between the following terminals,
termmal 2 and ""'linn
Approx. 0
(2) Wastegate valve control solenoid power supply
inspection
Disconnect waste gate valve control solenoid connector
and measure the voltage between following terminals,
Between solenOld harness
(3) Waste gate valve control solenoid inspection
Disconnect wastegate valve control solenoid connector
and measure the resistance between the following
terminals,
BetNeen solenoid terminals1 and 2 30 - 40 Q
(4) feeS control unit power supply inspection
Refer to the fuel pump system section,
Disconnect the connectors from the wastegate valve
control solenoid and EGGS control unit and measure the
resistance between the following terminals,
EN - 351

n
(')
<f)
". 25

CA1SI ENGINE
5-6 PTC HEATER CONTROL SYSTEM INSPECTION

,
PTC heater
I,
,oot-- I'" Crank angle sensor
,2
3
5 ,
i
1 180" signal ,
2, Power I
3. Ground J
4 1) siena! _
Engine temp
sensor

r&J
PTC g]
heater 10
relay "
(1) PTC heater control signal inspection
When EGCS control unit connectors are connected,
measure the voltage between the following terminals.
Engine temp (below 65'C) when engine i
I
Approx. OV
is runntng (Battery voltage over 13V) ,J.. _________ --'
(2) PTC heater power supply inspection
Disconnect PTG heater connector and measure the
voltage between following terminals.
Low engine temperature when engine
i IS running (Battyer voltage over 13V) ,
Battery voltage
(3) ECCS control unit power
When ECGS control unit connectors are connected.
measure voltage between the following terminals.
When ignition
switch is OFF :
When Ignition
switch is ON
Note:,
OV Battery voltage
Battery voftage OV
Same condition as ON will be retained for 15 seconds after
the ignition switch has been turned from ON to OFF.
EN - 352
, ,
, fECCS! .r--'r1
! I I ' heater
, I <>-t-,
!
L-_: PTC heater
" ,elay
CAIS; ENGINE
Disconnect ECCS control unit; PTC heater connector
and PTC heater relay and measure the resistance
between following terminals.
Between ECCS CIU terminal 106 and i
PTC heater relay harness terminal 1 '
Between PTC relay harness terminal I
5 and PTC heater harness terminal 2 i
i Between PTC heater harness termmal
, 1 and ground
(5) PTC heater inspection
00
Disconnect PTC healer connector and measure
resistance between the following terminals.
Between PTC heater terminia 1 and 2 Aporox. 1 0
5-7 LOCK UP RELEASE CONTROL SYSTEM INSPECTION (AfT VEHICLE)
Lock up release
solenoid
Throttle sen SOt opening ,
(Idle position) -
115r'
ECCS
, control unit
Eng,r.e temperature ----'L,, __ ---'
(1) Lock up release solenoid control signal
inspection
When ECCS control unit connectors are connected.
measure the resistance between following terminals.
Approx. OV
sensor in idle position
Other (apply load) Power voltage
EN - 353
Lock up release

!
I ; ECGS '
I

SENSOR SYSTEM INSPECTION
RB26DETT! RB20E! DE! DET I CA 181 ENGINE
6. SENSOR SYSTEM INSPECTION
Use measurement tools such as circuit tester. CONSULT electrical system diagnosis
tester and oscilloscope to test the sensor system. Refer to section EN 3, 1, 1 - 1, (6) in
TROUBLE DIAGNOSIS section for an explanation of the measurement equipment
operation procedures. Refer to section 5 for the preparation.
6-1 CRANK ANGLE SENSOR
ECCS relay
+
r=:=-,
16
i
I I I
-- 49
,Ignition timing cantrall
m
n
Crank angle sensor 51
n
I Fuel injection control I
I
(J)
120' signal
1
.,
n
0
1'sIgnai 2
42
a
I

Iidle
I
Power supply 3
2-
52
<:
Ground 4
,
::J
l-
50
;:;:
( 11 :[31 4)
i

EN" 354
i
RB26DETT ENGiNE
Crank angle sensor system trouble diagnosis flowchart RB26DETT ENGINE
Self-diagnosis
Ii RESULT-
.:g Self-diagnosis (Code No. 11)
Normal
I
Abnormal
I
,
I 'DATA MONITOR" II
(real-time diagnosis)
Normal Abnorrra!
I
I Inspect other
Crank angle sensor input signal inspection.
sys:ems
,
Nhen engine IS :unnI'1g:
Engu;e rpm display
MONITOR"
i Measure vOltage between ECGS CiU
term nal 41. 42 and ground
<fi: Approx. C.5V between terminal 41 and ground
!
A::::::rox, 2.5V between term',:.:::.,n:::a:::1 :::42=-::a:::nd"-"'Qr:::o:::":::nd=--L ____ O:...':::he:...' _____ --,
: Crank angle sensor power supply
I and ground Inspection
i MeaSure :he voltage between
: te'mlnals 3 and 4 Crank angle sensor output signal inspection
Measure l'1e voaage between
term'nals 1 and 4 and term;nai 2 and 4.
When engine :s q !
Q,5V 1errrul1al-l ard 4 !
2.5V belweer termInal 2 anc .::

I I
InspeCl crank angle
!
sensor and EGGS G;U Measure the resistance
connectOrs for breaks or; between crank angle sensor
disconnection"
i
harness 1 and EGGS G;U
harness 41. crar)k angle
sensor harness 2 and EGGS
GIU harness 42
OQ
I
Other
Battery VOltage when I
ignition sWitch is ON Othef
I
Crank angle sensor inspection
Rotate shaft by hand and
,measure voltage between each
:crank angle sefisor lerrr:inal and
iground.
I
Aepair1har
Inspect EGGS GIU
ness
connector for contact a d
defects.
Voltage betwee n terminal 1 and ground
n Q.5V and OV. repeats betwee
Voltage termmal 2 and ground
Other
repealS between 2.5V anrd...:O:,;v'---__ -'--___ -.
Repair crank
angle Sensor
power supply
or ground
; Inspect crank angle
, sensor connector for i
contact and defects. !
Repair crank angle
sensor
t::!g!e:
For crank angle sensor system inspection, use CONSULT and oscilloscope to check output
waveform.
IEces control Jrit arrangement I
EN - 355
RB20E ! DE! DET ENGINE
6-1 CRANK ANGLE SENSOR

I I .1
40116)
21(49)
r--
m
_, Ignition timin9 control
0
--I Idle speed control
Crank angle sensor
0
I
fJl
120' signal 1
19 t41}
"
I
0
\
1" signal
2
10(42)
"
-
I

Power supply
3
2-
I c:

::l
Ground

1
;:::
.. _-
l' 2 3 4
) RB20DE I DET I
Crank angle sensor system trouble diagnosis flowchart
I Self-diagnosis
"Ii:, "SELF-DIAGNOSTIC RESULT"
leg Self-diagnosis (Code No, 1)
Normal i Abnormal
Abnormal

, Crank angle sensor input signal inspection I
I
I ,:g Measure vOlt,age between EGCS C/U I
When engine:5 ,unnmg: terminal 19 (41).10 (42) and ground. ;
II Engme rorT' dISD'BY I
,a Aoorox O.5V between termwal 41 and ground
Approx. 2.5\1 between terminal 42 and ground Other
I
Crank angle sensor output signal inspectlonl
Measure the voltage between '
termmals 1 and 4 and terminal 2 and 4,
Wher engine is running:
O,5V between terminal ar,d 4
25V belween terminal 2 and 4
OHler
,Measure the
connectors for breaks or, between crank angle sensor
disconnection, I harness 1 and EGGS G/U
harness 19 (41), crank angle
sensor hamess 2 and ECGS
CiU harness 10 142),
[Inspect ECCSC/U connector
Ifor contact and defects.
----'

and ground inspection .
Measure the voitage between I
termlna!s 3 and 4.
Ig'l;!ion SWitChrS,.::O;cN':""-l.. __ O_th_e_r ___ -,
Crank angle sensor in'spection I
,Rotate s"aft by raod and I
'meaSIJre voltage between each
cranK ar:gle sensor termlna; and,
round.
Voltage between term!!1ai ;
and ground repeats between i
O.5V ana OV, :
Voitaoe between terminal 2
and ground repeats between Other
2.SV and OV.
,---
Repair crank
angle sensor
power supply
or ground
I
,nspect crank acgle Repair crank
sensor connector for angle sensor
comact and derects.
EN - 356
CA1Si ENGINE
61 CRANK ANGLE SENSOR
___ ii.ECCS
I J! 0
L._
_3I'SL
111""L!l
Crank ancle sensor
r-us;;'"gnal I
.. -J40
,
tv
I
It--t
9
, I 19
m
(")
(')
<Jl
a
::l
-

2-
I
, Ignition tim:ng control
I 2 Pcwe' i 1
: 3, Ground !

__ pf---t20
c
::l
;:;: speed control
Crank angle sensor system trouble diagnosis flowchart CA 181 Engine
Self-diagnosis
i SELF-DIAGNOSTIC RESULT"
::g Selt-dlagnoSis (Code No. 11)
Normai
'DATAMONITOW
(real-time d!agnosIS)
When engine IS running:
_@_ Engine rpm display
Abnorma,
Abnormal
Crank angle sensor Input signal inspection.
i'DATA MONITOR"
: E Measure voltage between EGGS G;U
I 10. 19.20 and ground.
It: A;:;;::rox, O.SV between :etminai 19,9 ana ground
Aoprox. 2.SV between terminal 10, 20 ana grouna

eID
Crank angle sensor output signal inspection I
Measure the voltage between :
: termina:s 1 and 3 and terminal 4 and 3,
Crank angle sensor power supply.
and ground inspection '
Measure the voltage between
terminals 2 and 3.
8 h
!
attery vo tage w en I
Otr,er
Whetl engine is running: ignition SWitch is eN
O.SV be:ween 'ermlnal 1 and 3
1
2.5V between terminal 4 and 3
Other
I
Crank angle sensor inspection Rep.: r crank
sensor
r supply
und
I
I
Inspect crank angle ! I Harness continuity inspection
sensor and ECCS C!U Measure the
connectors. 'or breaks or I 'betwee0 crank angle sensor
d:sco'1'1ection. harness 1 and ECGS e/U
harness 19. crank angie
sensor harress 4 and ECCS
C/U harness 1O,
09
I
Other
I
Itspeet ECCS GiU connector I
for cor:tact and defects, '
harness
Note:
by hand and angle
measure voltage between each
pow.
crank angle sensor terrpinal and
orgro
around.
Voltage between terminal 1 I
and ground reoeals between :
O.3V and 5V.
Voltage between terminal 4
and ground repeats between
O,3V and 5V_
I
Inspec: crank angle I
sensor connector for i
contact and defects.
Other
era nk
or angle sens
For crank angle sensor system inspection, use CONSULT and oscilloscope to check output
waveform,
EN - 357
RB26DETI! RB20E! DE! DET ! CA 181 ENGINE
(1) Self-diagnosis
If P or 180
0
(1or 120
0
for RB20E I DE! DET) signal is not input within fixed period of
time, "CODE No. 11" or "FAULTY SYSTEM NAME"' will be displayed in normal self-
diagnosis operation when using CONSULT. Examine the following items carefully when
this occurs.
fE\ . When malfunction occurs again, use the real-time diagnosis (CONSULT
\.eJ "DATA MONITOR" mode) or oscilloscope to detect disconnection.
When an abnormality is detected, consider these locations in the follOWing sequence as
there may be other malfunctions besides the crank angle sensor.
ECCS harness (faulty contact) - Crank angle sensor - ECCS control unit
(2) Input signal inspection
Use "CAS.RPM (POS)" item in "DATA MONITOR" to @
determine engine speed.
Measure the voltage between following terminals
with ECCS control unit harness connected.
RB26DETT I RB20E I DE I DET
CA18i
N o t e ~
ECCS C/U terminal EGGS G/U terminal 42
41 (49) and ground
20" i
OV or approx 5V
Approx 0.5V
0.3 - O.7V
OV or approx 5V
2 - 3V
2 -3V
EGGS CIU terminal 19 i EGGS G/U terminal 10 i
and ground (180' signal): ana ground (1' signal) I
Approx. O.3V or 5V ApproK 0.3V or 5V
The voltage in above charts are average voltage values of
the pulse waveform measured by a circuit tester and these
are for reference only, The waveform must be checked by
using an oscilloscope,
EN - 358
1* tAONITOR * NO FAIL" [;J
CAS qpM (POS) 975rpm
}!,,:R FLO'I" MTR O"91V
AIR rLOW MTR (H)
ENG TEMP SEN
EXH GAS SEN
EXH GAS SEN (n)
M/R RiC IVNT
WR FIC MNTR
GA'1 SPEED SEN
Q,92V
78"C
1 22V
O.02V !
RlCH
RICH
Okmth
RECORD __ -1
--.. --... ---
Crank 2!---c-:;/;t1O(42)
angl7
1.\..:./ ontrol uni
n
RB26DETT I RB20E ,DE I DET ! CA18i ENGINE
(3) Sensor output signal inspection
Measure the voltage between following terminals with
crank angle sensor connector connected.
OV or approx 5V Battery voltage
Approx 05V Battery voltage
Battery voltage
Approx 2 - 3V Aporox 2 - 3V Battery vo'tage
Disconnect ECCS control unit and crank angle sensor
connector and measure the resistance between following
terminals.
19
10
9 (or 19)
1
2
10 (or 20) 4
o
EN - 359
RB26DETT I RB20DE I DET
RB26DETT I RB20DE I DET
CA18i
RB26DETT! RB20E ! DE ; DET ; CA 181 ENGINE
(5) Crank angle sensor inspection
Disconnect crank angle sensor from engine, turn the shaft
by hand and measure the voltage using connector.
i"'; ".
i Crank angle sensor 2 and ground W signal) 5V
: Crank angle sensor 1 and ground (120' signal)
Icrank angle sensor 3 ana ground (Battery voltage)
: CranK angle sensor 4 and ground (ground)

Crank angle sensor 4 and ground (1' signal)
OV or approx.
5V
Power voltage
OV
, 03V or approx. i
RB20E
I
5V i

'I O.3Vor approx! _____ ,_. ___ . __ ..
: Crank angle sensor 1 and ground (180'5Ignal) 5V'
I
Qpution:
To prevent injector from operating, remove fuse or connector
before inspection. When an apparent abnormality is
detected by self-diagnosis according to shaft rotation, be
careful as it may not be an actual abnormality in this case. /;;...
EN - 360
RB26DETI ENGINE
6-2 AIR FLOW METER SENSOR SYSTEM INSPECTION
Air flow meter ifont)

I Signal grOllt'O ,
lPower
Air flow meter (rear)
"'f1\
SIC
: Power rou'ld 3
l-l.9na! cround : ., ,
LE.2.
wer
... =s:iJ

t1Jf-: ---"=,...--r-----<I
:' 4

, 2 f-, 27
3 1"-
,
'=' ! I
50
m
o
o
(j)
()
o
:::J

'"
Differs from CONSULT display (R):
Cylinder, air flow meter and CONSULT (data monitor) display items
No 4,5,6 cyi AFM (front) ECCS C/U 35 All flow meter (R)
No, 1,2,3 cyl AFM (rear) ECCS CIU 27 Air flow meter
EN - 361
RB26DETT ENGINE
Air flow meter sensor system trouble diagnosis flowchart RB26DETT ENGINE
r-seTf-diagnosis
iii "SELF-DIAGNOSTIC RESUL r I
(i Selfdiagnosis (GGde Nc 12 '
I
Normal
i Check intake system,
, to make sure there I
Air leaks present
Inspect other;
i sySlerns I
Repair intake
system
Abnormal
, Air flow meter input signal inspection
'i'DATAMONITOR"
Jt Measure voltage between ECCS C/U
terminal 35 and 34 (front), 27 - 26 (reari,
Cranl<.ing: 1V I
Idling: Approx. 1,1V
2 500rpm: 2\/ Other
Air flow meter output signal inspection
Measure the vOltage between
: Air flow meter power supply &
ground inspection
terminais 2 and 4. Measure the voltage between
terrr:inai 5 and 3.
-----,----
CranKing: AoorQ)c ., V
!dl'rg: Aporox. 1.1 V
2.500rpm: Approx 2V Other
Other
Battery voltage
Ign:tion SWItch IS ON

I Air flow meter inspection I
Apply battery voltage d.rreCtiy 10 :
terminal 5 (+1 and 3 (-I and !
: measure the voltage between;
: termmal 2 and 4. While blowing
, air into meter.
Repair air flow
meter power
supply or ground
, faulty connecLon or
Measure the resistance oetween
the follOWing terr1lna!s:
detects. AI' flow meter ECCS C!U

Front 2
4
Rear 2
4
Inspect ECCS C/U connector
for contact and defects.
harness
35
34
27
26
Repair
harness
Approx. 2V wnen blowing air in meter
Approx . V when air is not blowmg

,Inspect air flow meier
:cor,nectots for fau!ty
CO'1nectlons or detects.
EN - 362
Repair intake
system
Other
Replace or clean
air flow meter
RB20E' DE, DE-'- ENGINE
62 AIR FLOW METER SENSOR SYSTEM INSPECTION

!
+ 4()(161
!
I i I
...
27(491
m
(")
(")
(j)
()
0
.
1
:OJ

j intake -;ir quantlty sig
j Power ground
I Signal ground
I Power
C 4! 5)
(Bir(E) (A)
2
i
3
4
5
3 (27)

!
c:

:l
'"

4 (26)
EN - 363
Fuel injection centrol
Ignition timing 8ontrol
( ) RB20DE I DET
RB20E I DE I GET ENGINE
Air flow meter sensor system trouble diagnosis flowchart
Self-diagnosls
J!'SELF-DIAGNOSTIC RESULT"
'4 Se,/-diagnosis (Code No. 12)
rN;;;o;;;nna=i ___ .1 Abnormal
: are roo air leax:s.
No ai, !
Air leaks ::::reSe'11
:eaks j
i Inspect other I
i systems'
I
Repair intake
system
1Aii. ir flow meter input signal inspection
'DATA MONITOR"
i:i Measure vo;::age oo!ween ECCS CiU termInal!
, 3 aod 4 (RB20EI. 27 - 26 (RB20DE I DET). i
c. ranking:. 1 V I
Idling: Appro)(. 1,1 V
2.500rpm. Approx. 2V , Other
Air flow meter output signal inspection
MeasJre lhe voltage between I
2 and 4.
I Air flow meter power supply & I
: ground inspection .
! Measure the voltage between i
i terminal 5 and 3.
8attery vOltage when Other
:gnl!iDn switch is F0;CN'-_..L ______ --,
l
Air flow meter inspection
, Apply baltery voltage directiy 10
i term'ral 5 1+) and 3 (-j and
Cran"ing: Approx. 1 V " measure the vOitage oetween
Approx. 1. i V terminal 2 and 4 whl'e blowing
2.::'lOOrom: 2V Other
[ ;=::=====L _____ ---1
I
Check air flow meter and I Harness continuity inspection
, ECCS C/U connectors for i Measure the resistance between
i faulty connection or tre following terminals:
de"ects. i Air flOW meter ECCS C/U
I ha;;,ess harness
FtB20E 2 3
J. 4
FtB2ODE2 27
DET 4 26
o g I Other
[Inspect ECCS connector.
jtor contact and defects. ! harness
Approx 2V wher blowlflg air in :netsr
Approx. V when air IS not blowing Other
__ ______
Repair air flow
meter power
supply or ground
Replace or clean
air flow meter
Naair leaKS
_C
Inspect aIr meler
connectors for tau:ty .
connect;ofls or
EN - 364
Repair intake
system
RB26DETI ! RB20E DE I DET ENGINE
(1) Self-diagnosis
Normally in a self-diagnosis operation, "CODE No.12" or "FAULTY SYSTEM - AIR
FLOW METER" (when using CONSULT) is displayed if the intake air quantity signal
voltage is abnormally high or low and disconnection or short'circuit in the signal system
should be considered.
(ff\ When malfunction occurs again, use real-time diagnosis (CONSULT "DATA
\.eJ MON ITOR" mode) or oscilloscope to detect instantaneous breaks.
When abnormality is detected, consider these locations in the following sequence as
there may be other malfunctions besides the air flow sensor.
When intake air quantity is low: ECCS harness (faulty contact) - air flow meter-
ECCS control unit - intake system (not airtight)
When intake air quantity is high: ECCS harness (faulty contact) - intake system
(not airtight), faultywastegate valve control-
airflow meter - ECCS control unit
(2) Input signal inspection M
Use "AIR FLOW METER" and "AIR FLOW METER
(R)" in "DATA MONITOR" mode to check the following
items.
ApproK O.3V ApproK O.SV
Approx. 1.1V Approx 1.1V
Approx 1.5 - 2.0V Appro. 15 - 2V
Measure the voltage between following terminals Ii6'\
with ECCS control unit harness connected. \..:fV
Approx O.3V
lV
1 .1
ECCS CIU iermmal4
(26) and ground
(ground I nail
OV
OV
EN - 365
1* MONITOR *NO FAIL 0
: CAS, RPM (POS) 950rom
! AIR FLOW MTR Q,96V
! AIR FLOW MTR (R) 0 SlV
RECORD
lAir flow
: meter 2t-' ----t
RB20DE:DET
RB26DETT I RB20E I DE I DET ENGINE
(3) Air flow meter output signal inspection
Measure the voltage between following terminals when
the air flow meter connectors connected.
.. m"
TT
L".>';
... !.ii.i.U.'.. . ;u.' ..: .. . .. .. ...t.!.' .. i
..... ,.1 ;." .. "' ... '!.'!!.,. quantity 51.9nal) I Signal)
Approx 03V OV
Approx 1 V OV
',>.: .. ; Approx.l.1V OV

'",,; ':-:is!' ;";): "tf';';i,;'r
Air flow meter tenminal ,: Air flow meter tenminal'
B and ground (intake E and ground (ground
elf quantity signal). signal)

Approx O.8V OV
Approx.1V OV
Approx 1.1V OV
(4) Air flow meter power supply inspection
Measure the battery voltage between following terminals
with the air flow meter connector connected.
i
Ignition switch ON, Between air flow meter
. Battery voltage
and engine runnin.::g:..L-: __ le_rm_in_a_1 _5_a_nd-=.g_ro_u_n<l_ . ...J _____ -l
Disconnect ECCS control unit and air flow meter
connector and measure the resistance between
--
AIrflow
harness r.arness harness
"12 & terminal 35(27) 2 & terminal 3 (27)
& termnal 34 (26) 4 & terminal 4 (26)
3 & Body ground 3 & Booy ground
iTo"""'i' '15 & EGGS reay : Terminal 5 & EGGS reay
harness terminal 3 r..arness terminal 3
(6) Air flow meter inspection
Apply the battery voltage di rectly to terminal 5 (+) and 3
(-) and measure the voltage change between
terminals 2 (+) and 4 (-) while blowing airon hot wire.
No air blown Appro .. O.BV
Air blown Approx 2V
EN - 366
- -
6-3 THROTILE VALVE SWITCH SYSTEM INSPECTION
CONTROL CIRCUIT DIAGRAM RB26DETI ENGINE
;
m
(J
(J
(/)
g
a

c
:;J
riC
...
: Ignition liming control
.. I Idle speed
Throttle valve switch system trouble diagnosis flowchart RB26DETI ENGINE
I Ii 'DATA MONITOR" ;
(real-time Cllag;)051s} I
\Jorma!
I
Check Intake system i
to make Suie there
!
are no air leaKS.
ration oedal rot Accele
depres
cepra
sed: [I
ssed: CX)O
: Inspect olher I
I systems
Other
Adiustlor
replace throttle
valve switch
I
AbnorMai
I
i Throttle valve switch output
signal inspection

termInal 2 and 1.
Acceleration not
depressed: 8 - 10V
Acce,eration pedal
depressed: OV
I
' Inspect throttle valve switch
i connectors and EGGS GiU
connectors for faulty connections
or defects_
Other
I
. I Throttle valve switch
inspection
: Measure :he resistance
; tletween terminal 2 and 1.
Acceieration pedal not
depressed' 0 f.!
depressed: c::x) Q
I
Switch and ground Inspection
Measure tre voltage between
:term!nal 57 and 54.
Adjustor
replace throttle
valve switch
Acceleratio;1 Dedal no: depressed: 10V
Acceleratic'l depressed: CV Olher
Measure the resistance between
the foilowlng termlna!s:
Throttle valve EGGS G/U
SWltC'" harness
2
o Q I
I
Inspect ECCS C L: and
throttle va ve sVilich connector for !
contact and
EN367
harness
57
54
Other
I
Repair harness
Inspect EeCS CIU
power supply or
ground or replace
control unit
SENSOR SVSTEMINSPECTION
RB20E ! DE i DET ENGINE
63 THROTTLE VALVE SWITCH SYSTEM INSPECTION
To AfT control unit

. .1
mm rue! inj8ctior control)
,--,
r=o 0- conUle' 3 3 !-
I 2 IMfJr-;
m
o
o
(f)
"
i
1- "gM,ont,mingcortrol
0
'die speed oon1<oI I
.uVl
______ "1ldle contac 1
32157) ;;t
Q.
pOint
j 22 (54)
I
i

I ( ) RB20DE I DET
Throttle valve switch system trouble diagnosis flowchart
Normal
, i'''DATAMONITOR :
: (real-time dIagnosIs)!
Abnormal
Throttle valve switch inspection
Measure the resistance between'
terminal 2 and 1.
Throttle valve switch output
signal inspection
I terminal 2 and 1.
Acceleration pedal rIot
depressed: 0
depressed: ('X) Q:
: Inspect other I
I systems
Acce:eration pedal not
depressed: 8 - 10V
Acceleration Dedal
de:::rssed: OV
---
Other
Adjust or
replace throttle
valve switch r.,----ct:-t""h-Ctt:-, :-h-----.,
nspe ro e va ve SWI C . i Throttle valve switch
connectors and EGGS GiU . inspection
: connectors for faulty connections, Measure the resistance
i o defects. between termInal 2 and L
Acceleration oada! not
00' I Other
dep'essed:oo'"
Switch and ground Inspection i Adjust or
. Measure the voltage between ' replace throttle
terminal 32 (57) and 22 (54). valve switch
Acceleration oedal not depressec: 10V
AcceleratIon pedal depressed: OV
Measure the reSl$tar-ce betwe!r1
the followng terminals:
Throttle valve ECGS GiU
switch harness
2
1
Inspect ECCS G/U connector and
throttle valve switch connector for
contact and defecis,
EN - 368
harness
32 (57)
Repair harness
Inspect ECCS elU
power supply or
ground or replace
control unit
RB26DETT PB2GE DE DET ENGINE
(1) System inspection
Use "DATA MONITOR" to inspect idle contact point
ON-OFF signal to make sure it is operating correctly.
EGGS control unit connector connected.
OR
Measure the voltage between throttle valve switch
connector terminal 2 and ground.
i [, : ~ 1 ~ ~
, jThrottle
valve
:switch >_---.;+22154)
Bet\\'een ECGS CIU !erminal54
and ground (or bet\\'een throttle and ground (or be:ween throttle
valve switch termmal 1 and >J8lve switch term!ool 1 and
8 - 10V 8 - lOV
OV OV
with EGGS control unit connectors connected.
OR
Measure the voltage between throttle valve switch
connector terminal 2 and ground.
Bet\\'een EGCS CIU terminal.
57 and ground (or bet\\'een
throttle valve switch terminal 2
and
8 -10V
terminal 32 and ground (or i
bet\\'een throttle va lve switch'
8 - 10V
(3) Throttle valve switch inspection
(idle contact point)
Disconnect throtlle valve switch connectors and measure
the resistance between throttle valve switch terminals.
Between throttle velve switch
terminals 2 and 1
con
EN - 369
RB26DETT I RB20E i DE I DET ENGINE
Disconnect throttle valve switch and ECCS control unit
connectors and measure the resistance between the
following terminals,
Throttle
valve sWItch
1
2
'11:0''',-,'' CiU Throttle
valve sWitch
1
2
(5) Idle contact point (touch speed) inspection
and adjustment
0'1
0'1
Warm up the engine sufficiently and use "IDLE SW"
in "OPERATION SUPPORT' mode to inspect idle
contact point.
Disconnect AAC valve connector and inspect the
unit when the AAC valve is fully open,
1200 +{- 150
850 +/- 150rpm
900 +/. 150
950 +/- 150
When the tachometer speed does not conform to the
specified value, perform the adjustment as follows:
Loosen throttle valve switch tightening volts (2),
Remove the throllie valve switch connectors, place a test
prove between throttle valve switch terminals 1 and 2 and
measure the resistance,
Depress the accelerator pedal and gradually release the
pedal to lower the engine speed, Rotate the throtlle valve
switch body and secure it in the position where the
tachometer speed conforms to the specified value and
the idle contact point is "ON" (the resistance between
terminal 1 and 2 is 0 '1),
Tighten the throllie valve switch tightening bolts,
Make sure the idle is ON observing by the tachometer
speed as described above,
Connect the throttle valve switch connectors,
EN370
Idle SW adj
Lower CAS,RPM slowly
from 2000rpm to idle and
then check "touch RPM",
Adjustment must be done
after changing SW position, ,
START
RB26DETT
RB20E J DE J DET
6-4 THROTTLE SENSOR SYSTEM INSPECTION
interruot i'1;ec:IOP I
j control
m
- , Fuel Injection contrOl!
0
0
Power
1 1
48
(/)

f-
c;
Ignition timing cortro!1 c
::J
f
Sigpal
2 2 38

f-
I Idle speed centroll c
Ground
3 3
30
:J
'--'
Throttle sensor system trouble diagnosis flowchart RB26DETT ENGINE
Normal
I
Self-diagnosIs I
H."SELF DIAGNOSTIC RESULTS" :
:g: Self-diagnosis (code No. 43;
Abnormal
,
il!'DATAMONITOR" J
(real-time diagnosIs)
Nanna!
I
IThrottie sensor inspection
term;nal 2 and 3.
Change approx.
2kQto 10k {lwhen
accele!'ator pedal is
deoresSed
Other
I
!!l1soect other I
Replace throttle
systems
sensor
Abnormal
Throttle sensor input signal inspection I
I
'I' Measure the voltage between termina: I
: 2 and ground.
Change approx. Q,5V
to 4V when acceleration
pedal is depressed
Other
I I
, Inspect throttle senSor and
i ECCS C!U connectors for faulty
I :hrOtlle sensor
MeasL're the re
j nspection i
sistance
connections or defects,
: oetween terrrlna! 2 and 3.
Other
Change from approx. 2kg
to accelerator
;::-edal IS dep:-essed
,--_---1-_---,
Sensor and ground inspection
terminal 48 and 30,
Replace
throttle
sensor
the following termmals:
Throttle ser..or ECCS CiU
i-)a:ness harness
4B
2 36
3 30
Other
Inspect ECCS control unit
and ground and replace
control unit if necessary
Inspect ECCS G!U connector and throttle Repair harness
sensor cor-rector for contact and defects.
EN" 371
RB20E! DE I DET ENGINE
6-4 THROTILE SENSOR SYSTEM INSPECTION
-] Fuel injection
Thrott!e ser:sor
m

(")
()
1
26(48) (fl
[
-
n
0
2
" 1(38)

r-
3
"
::l
V
81l 0)
'"
I
I (
RB20DE! DET
Throttle sensor system trouble diagnosis flowchart RB20E I DE I DET ENGINE
Normal
Self-diagnosIs
""SELF DIAGNOSTIC RESULTS"
i !J: Self-diagnosIs (code No. 43)
Abr'lorma!
I
Abnormal
-----;
Throttle sensor inspection .
Measure the resistance oetween'
Throttle sensor input signal inspection
""DATAMONITOR"
terminal 2 and 3.
Change from approx.
2kg to 10k Qwhe"'l
accelerator pedal ;3
.. 1(1:23)
i :li:' Measure the voltage between terrl11n - .
2 and ground
depressed Other
Cha'lge from approx. O.5V
10 4 V when accoleratiOn
pedal IS depressed Other
Replace throttle
sensor
I
!Inspect Ihro!tle sensor and I
I ECCS CIU conroctor. for faulty I
: connections or defects. i
I
Throttle sensor inspection I
Measure the resistance I
between term ina! 2 and 3.
Change trom approx, 2kQ I
to lOkQwhen acce'erator
pedal IS depressed
Other
1.-----'----,1
Sensor and ground inspection Replace
Measure the voltage between throttle
terminal 26 (48) and 8 (30). sensor
Approx. 5V
1
Measure the res'stance between
the fo'lowing terrrinals:
11hrottle senso' ECCS C/U !
;- arr:ess har11ess
26 (48)
7 (38)
__ r- _8=(3::;OL) _
Other
I
Inspect ECCS control unit
Inspect ECCS C U 2"'d Repair harness
sensor C0'1nec1cr fe' 2
n
d :Jeiects,
EN - 372
RB26DETI' R820E ' c}E . DET ENGiNE
(1) Self-diagnosis
There is a disconnection or short-circuit in the signal
system when "CODE 43" is displayed in normal self-
diagnosis (mode 2). When this is displayed, check the
throttle sensor resistance or harness continuity, etc.
If the problem occurs again, use real-time diagnosis (j)
mode or an oscilloscope to check for instantaneous
break in the signal.
Use 'THROTILE SENSOR" setting in "DATA MONITOR"
mode to check the following items:
Accelerator pedal not depressed Approx. O.5V
Ignition
: switch ON
NO FAIL 01
:CAS.RPM (REF) O'pm
THROTILE SEN O.50V
RECORD
Accelerator f--_H_al_f-w_a....:Y'---+ __ O_.5_-_4_.0_V_-'.
pedal depressed Fully depressed Approx 40V c-.... --.--.--. -------.--,
and ground with ECCS control unit connectors
connected.
OR
Measure the voltage between terminal 2 and ground with
throttle sensor harness
(3) Throttle sensor power supply inspection
when throttle sensor connectors are connected.

Between throttle sensor terminal 1
and
Approx.5V
(4) Throttle sensor unit inspection
Disconnect the throttle sensor connector and measure
the resistance between the following terminals when the
accelerator pedal is depressed and not depressed.
Between throttle sensor terminal 2 and 3
Approlt 2K g
Approx 2K g - 10K g (Resistance wlil,
Increase as pedal is pressed)
Approx 10Kg
Disconnect ECCS control unit and throttle sensor
connector and measure the resistance between the
following terminals,
ECCS C/U
harness
26 (48)
7 (38)
8 (30)
Throttle
sensor harness
1
2
3
(6) Throttle sensor inspection (RB26DETT)
oQ
Warm the engine adequately and check operation of the
throttle sensor by using "THROTTLE SENSOR
ADJUSTMENT' in "WORK SUPPORT' mode. (The
throttle sensor can not be adjusted).
EN374
.THROTTLc SEN ADJ. I
I
SIGNALANDAOJUSTITTOTHE I
,SPECIFIED VALUE BV ROTATING
,THESENSORBOOYUNDERTHE'
! FOUDWING CONDITION.
'. iGN SW"ON"
ENG NOT RUNNING
ACC PEDAL KEPT OFF
____ ______
.THROTTLE SEN ADJ .0
AD.i MONITOR
THROTTLE SEN O,50V
MOI'.ITOR
CAS.RPM (POS)
IDLE POSITION
9S0rpm
ON
CA181 ENGINE
6-4 THROTTLE SENSOR SYSTEM INSPECTION
Power
Signal 1
I Grou'ld
L:,gnaI2

1
I 2
i
3
14
I
1-----.... ,,' Fuel injecHon control
2S
m
0
0
3
(f)
(")
36
0

::J
7
3
'"
Throttle sensor system trouble diagnosis flowchart CA18i ENGINE
S f d "I - lagnosls
i
I
i SELF DIAGNOSTIC RESULTS I
It I "DATA MONITOR" !
(real-tiMe diagnosIs)!
NOrTlal
Normal
1
Abnormal
I
Throttle sensor inspection
MeaSure the :es!s1ance between
terminal 1 & 3. 2 & 3 and 4 & 3.
Approx. 1.2
2.4k"
between 1 - 3.
vVren acceleraLon
oadal is depressed:
Between 2 3 Aoprcx"
0.3 - 2.4k Q
Between -4 3 A;Jcrox.
0.5 - 2.9k& ..
Other
,-----'--
I
Self-diagnosIs Icode No. 43)
i
! AbnOf'llal
ttlB
3 4
Throttle sensor output
'DATA MONITOR" i
:i Measure the voltage between :erninal !
1 & 3. 2 & 3 and 4 & 3.
3etween 1 - 3 approx. 5V
i When pedal IS depressed'

\I:t:D
2 - 3 apprc;.:, 1 - 5V I'
Between 4 3 approx. 0-;:.6::..:-...:4::..5;:.:'::" _...l __ .:.O:;th:.:;e:;,_--,
I I
Inspect throttle senSor and Throttle sensor Inspection
ECCS C/U connectors for faulty Measure the resistance between
Replace throttle
sensor
conrtections or defects. terminal 1 & 3, 2 & 3 and 4 & 3.
Berween 1 - 3 approx. - 2.4kQ
When acceteration pedal IS de:Jressed'
8etween 2 - 3 approx. 0.3 - 2Akg
I
Between 4 - 3 approx. O'::>-;.,-_-.:.2;;:.9:;k:.:ll=--, __ O:;:::.th::;:e:...r-,
I I
Throttle sensor power supply Replace
and ground inspection throttle
Measure the voltage between sensor
terminal 26 and 36.
Approx. SV I
I
Measure the resistar:ce between
the fo!Jowhg terminals:
Trronle sensor ECCS CiU
harress namess
1 26
2 3
4 7
0" I =ll
Other
I .
Inspect ECCS control unot
I
Inspect EGGS C!U and thrott'e I hamess
sensor corrector lor contact and defects. I
EN - 375
(1) Self-diagnosis
There is a disconnection or short-circuit in the signal
system when "CODE 43" is displayed in normal self-
diagnosis (mode 2). When this is displayed, check the
throttle sensor resistance or harness continuity, etc.
If the problem occurs again, use real-time diagnosis @
mode or an oscilloscope to check for instantaneous
Use "THROTTLE SENSOR" and "THROTTLE SENSOR
2" setting in "DATA MONITOR" mode to check the
following items:
Ignition
switch ON
Accelerator pedal not
depressed
Accelerator
pedal depressed Fully
depressed
Measure the voltage between following terminals and
ground with throttle sensor harness connected.

NO FAIL 0:
:CAS.RPM (REF) Orpm I
[ffi"" ,'",
C RECORD j
EGCS CIU terminal 3 ECCS CIU terminal 7
and ground (OR and ground (OR
throttle sensor termmal throttle sensor termlnal.
2 and 4 and ground) .
Approx.1V
Approx 1 V - 5V
(3) Throttle sensor power supply inspection
when throttle sensor connectors are connected.
Between throttle sensor terrTllnal 1 I
and ground '
Approx.5V
EN - 376
Approx.06V
CA1S, ENGINE
(4) Throttle sensor unit inspection (CA 18i)
Disconnect the throttle sensor connector and measure
Between throttle sensor
Approx. 12 - 2.4 f.l .
terminal 1 and 3
Between throttle sensor. Changes between approx 0.3 - 2.4K f.l
terminal 2 and 3 . when acceleration pedal is depressed "
Between throttle sensor Changes between approx. 05 - 2.9K f.l
terminal 3 and 4 when acceleration pedal IS depressed -,
'1 Normal I! the value IS within 0.3 - 2.4K. The value will not
change even when the accelerator pedal is depressed.
'2.3 The value is not 00 f.l and normal if the value changes when
the accelerator pedal is depressed.
(5) Harness continuity inspection (CA18i)
Disconnect ECCS control unit and throttle sensor
connector and measure the reSistance between the
ECCS C/U
harness
3
7
26
Throttle sensor
harness
2
4
EN - 377
I
I
RB26DETT ENGINE
6-5 INTAKE AIR TEMPERATURE SENSOR SYSTEM INSPECTION
m
0
0
(f) Intake air temp sensor
'"'
(')

36
0
3.
30
9.
'-'
c:
"
""
Intake air temperature sensor system trouble diagnosis flowchart
RB26DETT ENGINE
Self-diagnosIs
!i"SELF DIAGNOSTIC I
I -lit Self-dlagrOSls (code No_ 411 _
Normal I Abnormal
Fue! injection contr;)j
Iintake air temp sensor inspection
; Measure tne resistance betweer
I and 2.
i In_take air te-inp sensor output I
'signal inspection
li-'DATAMONITOR"
-g: Measure the voltage between: \..!..l!)
Aoorox. when cold
Approx. 0.8 to 1.0KQ after
warming up
Othe;
Replace intake
air temperature
sensor
te,enlnal 1 and 2_ !
Intake air telTlp olGolay
ll: 1.SV when cold
O.8V after warming up : 01her
Inspect :ntake air temperature
sensor and ECCS C;U connectors
for faulty connections or defects.
i-Intake air temparature
i sensor inspection
Measure reSistance
between terrnlrial 1 and 2,
Apprex. 2.5KQ when cold
Approx 0.8 - 1.0-l\U after
warm up
I
ECCS CIU power supply and ground
inspection
j"DATAMONITOR"
g Measure tne voltage between
Replace
intake air
temperature
sensor
I termnal 30 - 36_
'@ Intake air temp display I
:g Battery voltage .
I
r.1 H
7
a-r-n-es-s-c-o-n-:t7"in-u-'
it
C-
y
inL.-p-ec---Cti'"o-n-'
! Measure :he resistance be:ween i
;the following ten":1inals:
Intake air te,"p ECCS CIU
sen harr,ess harness
1 36
2 30
Other
I
Inspect ECCS C/U power
supply and ground
Inspect ECCS C!U connector andctake air Repair harness
temp sensor connector for 8,'1d defects,
EN378
6-5 INTAKE AIR TEMPERATURE SENSOR SYSTEM INSPECTION
CONTROL CIRCUIT DIAGRAM CA 18i ENGINE
[1.J1----...... >--1 li'
'--------10' .f2/-
L
-----4 30
'-
.. I Fuel injection co;)jrol
Intake air temperature sensor system trouble diagnosis flowchart CA18i ENGINE
" Self-diagnosIs ,
Ii "SELF DIAGNOSTIC RESULTS" i
i Self-d,agnosis (code No. d1) I
Normal
I
Abr;orrra!
I
Intake air temp sensor inspection
Intake air temp sensor output
Measure the resistance betweer
signal inspection
termmal 1 and 2,

.5kQ when c:;ld
!l: Measure the voltage between
. 810 1,0>( t"J after
terminai 1 and 2 .
Approx. 2
Approx. 0
wafffllng up
I
Olher
w: 'ntake air temp display
I I
'g 1 .5V whe'l cold
speet other I
stems
In
!sy
Replace Intake
air temperature
0_8V after warming up Other
J
I
sensor
; Intake air temperature
Inspect intake a,r temperature-
I
sensor and ECCS C/U connectors:
sensor inspection
for faulty connectlons or defects.
I
Measure the resistance
between termi'1al 1 and 2.
Approx 2.5KQ when C?ld I
Approx.0.8 1 O;{Q at:er :
warm U;J O'her
I
.1
EeeS ClU power supply and ground Repl ace
inspection intak
tem i''DATA MONITOR"
Iit Measure the voltage between
e air
perature
or sens
term:nal 30 - 18"
fntake air terlp display
g Battery VOltage 01t'er
I
Inspect ehes ClU pow
er
Measure lhe resistance between
supply and ground
t;,e fol:owing :ermmals:
!ntaKe air ECGS G/U
sen harr'Jess harness
1 18
2 30
O<l
1
coil
i Ins::tect ECCS C L :C'lnector and intake air [
: tem:) s\?:-:sor or contact and defects,
harness
EN" 379
RB26DETI I CA18i ENGINE
(1) Self-diagnosis
There is a disconnection or short-circuit in the signal system when "CODE 41" is
displayed in normal self-diagnosis or "FAILURE DETECTED IN T/ATEMP SEN" (when
CONSULT is used) is displayed.
If the problem occurs again, use real-time diagnosis mode or an oscilloscope to check
for instantaneous break in the signal.
Use "INT/ATEMP SEN" in "DATA MONITOR" mode
to check the following items:
Temperature display corresponds to i
Idling mtake air temperature. I
Measu re the voltage between the followi ng terminals
and ground with ECCS control unit connectors @
connected.
Ignition switch OFF
Ignition switch
in ON
Idling
Approx20'C
Approx45'C
Approx 20"C
Approx45'C
OV
1.5V
O.BV
1.5V
O.8V
Disconnect ECCS control unit and intake air temperature
sensor connector and measure the resistance between
the following terminals. ( ) CA 18i
I
ECGS GiU hamess terminal 36 (30) I 0 Q
and Intake air temperature sensor 1
I
(4) Intake air temperature sensor inspection
NO FAIL O[
CAS.RPM (REF) Orpm
INT/A TEMP SEN 38"C
RECORD
Disconnect intake air temperature sensor connector, heat ./
or cool it with a hair dryer or industrial dryer and measure
Approx. 20"G Approx 2 5K Q
Approx 50'C Approx. 0.8 - 1.0K Q
EN - 380
RB26DETT ENGINE
66 ENGINE TEMPERATURE SENSOR SYSTEM INSPECTION
E,1g:ne temperature sensor

1
Fuel inject;on control

' ()
28 CO
[,0
r
30
"
Igmtion limi')g control
a
;;>.
Q.
I
c
:diC speed control
@:
,
Engine temperature sensor system trouble diagnosis flowchart
RB26DETT ENGINE
Self -diagnosIs I
"SELF DIAGNOSTIC RESULTS" '
l! Sef-d:agnosis (code No. 13)
Norrr:aI
'DATA MONITOR"
: (Real-tIme dIagnOSIs)
NOrr'lai
Abnorma:
A.bnormal
Engine temp sensor input signal inspection
"DATA MONITOR"
: 'g Measure :he voltage between terminal 1
and ground.
Engine temp dIsplay
'Ii: 3V when cold
1V after warrring up
Inspect intake air temperature
sensor and EGCS C/U connectors,
i for faulty connections or defects.
Olher
: Engine temperature
; sensor inspection
Measure the -res:stance
between lerminal 1 and 2
Engine temp sensor inspection
termlr':al 1 a:1d 2.
Approx: 2.5K1Il when cOld
Approx. O.3K g after warm
up
I
:
I
A;::-prox. 2.SkQwhen cold
Approx. O.3K1Il after
____ --'L"::'L_
Replace engine
temperature
sensor
the voltage between
: terminal 28 and 30.
Engine temp display II
Replace
Engine
temperature
sensor
Battery vco .. lt .. aG::.eL_....L ___ O_th_,e,'
Harness continuitylinSpeCtion Inspect Ebcs e/U power
Measure resistance between supply and ground
the following terml:lals'
Engine temp EGGS C/U
sen harness
1
2
harness
28
30
OQ I = Q
I
Inspect ECCS GIU connector and engine tema: Repair harness
__ __ rn __ __ .. n __ ta=c __ .. d=e __ __ ._--"
EN - 381
RB20E i DE I DET ENGINE
6-6 ENGINE TEMPERATURE SENSOR SYSTEM INSPECTION
Engine tef11perature sensor
m

"....,
(')

5(28)
(')
(j)
BI3U)
()
.........
0
a
9..
! Fue' il1jecLon ;:ontro!
:gnition timing cortml

t=
speed contrG!
I
Engine temperature sensor system trouble diagnosis flowchart
Self-diagnosIs
Q/'SELF DIAGNOSTIC RESULTS"
:g Seif-dlagnosls (code No, 13)
Abnorm;:;1
Abnormal
Engine temp sensor Input signal inspection
8 "DATA MONITOR"
,<It Measure the voltage between terminal 1
and ground,
i' Engine temp display
:g 3\/ when cold
1 V after warming up Other
Engine temperature
sensor inspection
Inspect intake air temperature
sensor and ECCS C/U connectors
'for fau,ty or defects,
: Measure the resistance
i Engine temp sensor inspection'
'Measure the resistance between'
terminal 1 and 2.
Approx. 2.5k 0: when cold
Approx. O.3KQ after
warm:ng up
Other
Replace engine
temperature
sensor
between terminal 1 and 2.
Approx. 2.5-Kg wnen cold
Approx. O.3K a: after warm
up
: te"nlnal 5 (281 and 8 (301,
temp display
Other
Replace
Engine
temperature
sensor
"1. Battery vOllage

I Harness continuity inspection Inspect EeeS e/u power
MeaSUfe tne resistance between supply and ground
i the following terminals:
Engine lemp ECCS C:U
sen harness harness
1 5 (28)
2 8 (30)
Of.!
Inspect ECCS C:U connector and engi"e temp
sensor connector for contact a"1d defects.
EN - 382
GA 181 ENGINE
66 ENGINE TEMPERATURE SENSOR SYSTEM INSPECTION
Engme temperature sensor I

'------------'21 2.1-1 --- -.,,---.,8
m
(")
(")
1 _
r-----..,i Fuel control
,

(fJ
8
a
o
j
'-----.. --------: Ignition l:ming control
I
I L, ----.... .,! Idle speed comro!

Engine temperature sensor system trouble diagnosis flowchart CA16i ENGINE
I
Seif-diagnosis
J!SELF DIAGNOSTIC RESULTS"
:11: Self-diagnosIs (code No. 13)
Normal Abnormal
I I :
diagr.osls) 1 I'
,
Norrr,a: i
[
Engine temp senso, output
signal inspection
:I! "DATA MONITOR"
: -:g, Measure the voltage between
I !ermmal 1 and 2.
EngIne lemp dIsplay
'" ;3V when c::>ld
,g. V after WaflT'lrEg up Other
Ir----"-'---'-----'.;;...:...,I
Inspect in:ake air temperature rE=-n-g-i..lne--te-m-p-e-'-a-tu-'-e----,:
Engine temp sensor inspection (2
Measu;e the resistance between
terminal 1 and 2.
sensor and EGGS CiU connectors sensor inspection (2)
for faulty connections or defects. Measure the resistance
between terminal 1 ard 2.
Approx, 2,5KQ when cold
Aoprox 0 3K Q after
, ..
warm up
I
I
Approx, 2"5kawhen cold i
Approx. after II
warming up
ECCS ClU powe, supply and Repl ace
Other
ground inspection Engi
,...-----'---.,

:g, Measure tne voltage between
tern
ne
peratu,e
sor
Inspect other
systems
sen
Replace engine
temperature
sensor
EGGS CIU terminal 5 and 8.
iL Engine terno display
3V when cold
1 V after w;:)rrr, ,,18 01ner
I
Inspect Ebcs CIU po
Measure :he resistance between
supply and ground
the foHowing terminais:
Engl'1e temp EGGS GiU
i
sen ha
r
1ess harness
1 5
2 8
Inspect ECCS C1U connector ard engire temp Repair harness
sensor for contact and defects.
EN .. 383
wer
R826DETT i R820E / DE i DET I CA 18i ENGINE
(1) Self-diagnosis
There is a disconnection or short-circuit in the signal system when "CODE 13" is
displayed in normal self-diagnosis or "FAILURE DETECTED ENG TEMP SEN" (when
CONSULT is used) is displayed.
If the problem reoccurs, use real-time diagnosis mode or an oscilloscope to check tor
instantaneous break in the signal.
Use "ENG TEMP SEN" in "DATA MONITOR" mode
to check the following items:
ignition switch ON Engine temperature is displayed
Measure the voltage between the following terminals I
0:
ENG TEMP SEN lBoC
RECORD
and ground with ECCS control unit connectors .
connected. 1
'ci' sen W
I ....
Between ECCS Between ECCS
Measurement locatron CIU terminal 28 CIU terminal 5 . I I RB20DE I DET ! CA' 8.
Ignition
sWitch
ON
Approx.
20'C
and ground
Approx.3V
Approx 1V
and ground
Approx. 3V
Approx. 1V
(3) Engine temperature sensor resistance value
inspection
Disconnect engine temperature sensor connector and
measure the resistance between the following terminals,
CA18i
Between engine temperature
sensor connector 1 and 2
RB20E
zn ; \: ]
Engine temperature
RB20DEI DET
RB26DETT
RB26DETT! RB20E I DE IOET ' CA 18, ENGINE
Disconnect ECCS control unit and engine temperature
sensor hamess connector and measure the resistance
between the fOllowing terminals,
EGGS G!U
harness
5 (28)
8 (30)
Engine temp
sen harness
1
2
oQ
EN385
RB20E I RB26DETI
CA18i' RB20DE f DET
III
RB26DETT ENGINE
6-7 EXHAUST GAS SENSOR SYSTEM INSPECTION
IGN
gas
. 2.
Heale' 3
Air fuel ;'atio feedback
cO'ltrol
Cylinder, exhaust gas sensor, CONSULT (data monitor) display
No. 1. 2. 3 cyl
No.4. 5, 6 cyl
'-----
.
O. sensor (front) ! ECCS CIU lennlnal 29 i
0, sensor (reari I ECCS CiU tenninal 551
EN - 386
0, sensa r (R.c)_ ---1
0_ sensor
RB26DETI ENGINE
Exhaust gas sensor system trouble diagnosis flowchart RB26DETI engine
Air-fuei ratio feedback function!
inspection
MONITOR'
:g Ex'1aust gas sensor output
mOnitor,
Normal
'DATA MONITOR"
(Real"tlme diagnosIs)
Inspect other
systems
;
Abnonnal
\iorma!
Exhaust gas senSor input
si9nal inspection
i Measure the voltage between
! 1. (0. sensor {Fn
. 2 O' sensor {R}

[!El
(02 sersor (FJ)

(0" sensor IR1)
DefiectlOn betweep 0 - 1 vJ O:her
1,..----'---;;.......;.-,1

Inspect exhaJst gas sensor andj I ECCS C/U power supply inspection
EGGS GfU concectors for faulty W'DAT.A MONITOR"
contact or detects. : 'J/' D'sco0r;ec; 0 sersor connec1or
,;
and '/G lcce
Er'-'''' U
'..J\-::' y, h<-; 6;-,;:: ;;:,:. ... r,c:. I
Battery -,;ol1a9' '-:;!-:e,
I
ig ..1'tlon sw,tCh IS ON
err"
1 I
Harness continuity inspection Inspect ECCS CI
Measure the resista:lce between U power supply
the follOWing terminals: or replace C/U
0" sersor
EGGS C/U
rarness harness
(3m 1)
tfffi
: 0, seosor (R)2 55
4 3
i 0" sensor {F)1 29
(O"sensor (0 sensor
00
1
Other (R)l iFf)
I
:Oa sensor heater inspection
iMeasure :he resistarce between
Repair harness
follOWing termmals
O<sensor(R) 1- 3
0, sensor IF) 2 - 3
ry vOltage when Batte
:gnitio I n sWItch is ON Other
1
Check ter ta
or replace e
ulty clnnectlons
xhaust gas sensor
sensor heater unit inspection
,Measure FIe resistance between
!followmg terminals:
0, sensor 1 - 3
,0, sensor (Ri! 2 " 3
Og
1 = {l
1
0, sensor heater power supply
Replace 0zsensor
inspection
,following termmals;
!
02 sensor (Ri 1 and ground

sensor (F) 2 and ground
altery VOltage wnen B
9 I
nitlo0 sWitch is ON Other
I
nso( ground ctrcult I :Repair sensor heat!
:power supply CirCUit
EN - 387
RB26DETT ENGINE
(1) Fuel-air ratio feedback function inspection rtl\
Warm up the engine and check the following items \1lV
with "EXH GAS SEN", "EXH GAS SEN-R" (output
voltage), "M/R FIC MNT" and "M/R FIC MNT-R" (lean I
rich) displayed in "DATA MONITOR" mode.
Engine speed at
approx 2,000 rpm
I

';:!(RJ')< "", ,;,
Approx, 0 - 1V IS RICH, LEAN display
displayed, The dlspiay must be synchronized
cycle is 5 times or more with output voltage
in 10 sec in1e_IYa_'_, -.-J1 ___ d_,s.;..p_la,;.,y __ _
Provide setting value in "ACTIVE TEST" (fuel injection
quantity correction) and check exhaust gas sensor
function.
Using diagnosis connector on the vehicle side f<Eh
(near fuse block), set CONSULT to "EXHAUST GAS \<S,J
SENSOR MONITOR" and check the fuel injection
condition by flashing of exhaust gas temperature warning
lamp on instrument panel.
Exhaust gas sensor function
gas temperature warning lamp must flash 5 times

or more in 10 seconds interval when engine is running at
, approx. 2,000 rpm,
Feedback function
Exhaust gas temperature warning lamp must flash
periodically when engine speed is running at approx. 2,000
rpm.
ECCS control unit harness connected.
i Between ECCS C/U
terminal 55 ana ground
Deflection between Deflection between
approx 0 ana 1V approx 0 and 1 V
EN - 388
NO FAII-Oi
I ,
!CASRPM (POS) 1975rpm
iEXHGASSEN 1,14V
EXH GAS SEN-R 1,Q3V
MiR FIC MNT RICH
MlR FIC MNT LEAN
RECORD

ACTIVE TEST
"VEL INJECTION
MONITOR
CAS RPM(REFl
E"'G TEMP SEN
EXH GAS SEN
EXH GAS SEN-R
IN.JPULSE
AAC VALVE
937rom
59'(;
1.33V
1,35V
1,8msec
17'0
RB26DETT ENGINE
Disconnect EGGS control unit and exhaust gas sensor
0, sensor
(Front)
0, sensor
(Rear)
EGGS GIU harness terminal 29
and 0: sensor harness terminal 1
ECGS G/U harness terminal 55
and 0, sensor harness termmal 2 I
EN - 389
00
00
I
CONTROL CIRCUIT DIAGRAM RB20E / DE / DET ENGINE
(RB20DE I DET)
r--
Htji{i) fj}-.
(RB20E)

&-.-----+16
+
EN - 390
m
o
o
(f)
g
2.
Q.

1---- Air fue! ratio teedback
control
RB20E iDE! DET ENGINE
Exhaust gas sensor system trouble diagnosis flowchart
RB20E I DE I DEl engine
Air-fuel ratio feedback function
; inspection
I
Exhaust gas sensor output mOnitor.
Normal Ar.ilionna!
Inspect other i
systems
Abnorwal
Nornai
E h x aus gas sensor ,"pu
; signal inspection
1
(R820E)
1. (RB20E) and ground
2. IRB20DE i DET) and ground
Oeflectlon between 0 - 1 V
Other
iRB20DE ! DET)
I
I
Inspect exhaust gas sensor 3'1d: I ECCS C/U power supply inspection
ECCS GiU connectors lor faulty I ' DATA MONITOR"
,
contact or defects. ; ::i Disconnect 02 sensor con'1ector
I and measure voltago between
EGGS G/U terminal 27 (49) and ground
Batte')' voltage when
I
Ignition SWltch is ON
Other
I
Inspect CI
MeasJ:e :he resistance between U power supply
the follov'Ilng termina:s: or replace C/U
0, sensor EGGS GIU
h'arness harness

: RB20E 1 6
1
, RB20DE ! DET 1 29
(RB20Ej (RB20DEI
0<>
I
Other DEl)
R820DE;DET
I Ri320E
I
I
I Repai r harness
;0:.1; sensor neater inspection
Check for faulty connections
the 'sistance between or replace exhaust g8S sensor
:ermmal 1 and 3.
ry voltage when Batte
igmtio n switch is ON
I
Check lor faulty c
or replace exhau st gas sensor
02 sensor heater unit inspection
Ctf'2h)
(1m 3)
Batt
igM
termmal 1 and 3.
On
I
J
0, sensor heater power supply
inspection
ery voltage when
ion sWitch IS ON Other
I
=n
I
Replace 0;>: sensor
.
IRepalr 0:; sensor ground Chewt I IReoalr 0; sensor heat
: power suoply circu;t
EN - 391
CA18, ENGINE
CONTROL CIRCUIT DIAGRAM CA1Si ENGINE
Exhaust gas sensor
m
o
o
(j)
("}
o
1!------+6
t-------""'![ A:r fuel ratio ;eedback
, control
3-

2-
e:

Exhaust gas sensor system trouble diagnosis flowchart CA lSi Engine
i Self-diagnosis ,
:!J)SElF-DIAGNOSIS RESULTS":
Normal !
Self-d,ag10sis (Code No, 15)
Normal Abnorrr,a!
Norma!
Abnormal
Abnornal
I E, "" haus!ga's sensor irip;:itl
signal inspection . !
i
(!i;: EGGS 6 and ground I
DISPlaY RICH LEAN' I
Display output vortage 0 1 V
.If Display 0 - 1 V OtM'
Inspect exhaust gas sensor and
EGeS C/U connectors for taulty
contact or defects,
EGGS CIU power supply inspection
If DATA MONITOR"
,:I Disconnect 02 sensor connector
and measure voltage beh"Jeer ,
ECGS CfU terminal 27 (49) and ground!
I
ignition S\VlICrh_'S'-O_N!-____ --"O.::thc:":..r-.
I I
I Harness continuity Inspection Inspect ECGS Cf
i Measure the resistance between U power supply
02 sensor harness termiral 1 and' or replace C/U
ECCS C/U harness terminal 6,
OQ
,-
Check for faulty connections or
replace exhaust gas sensor
EN - 392
Repair harness
RB20E I DE IDET I GAlS: ENGINE
(1) Fuel-air ratio feedback function inspection '10 FAIL []
Warm up the engine and check the following items with ,
'AIRFLOWMTR L54V
"EXH GAS SEN" and "M/R FIC MNT' (lean I rich), GAS,RPM (POS! 20l2rpm
displayed in "DATA MONITOR" mode, ' ENG TEMP 80'G
Exhaustgaalien
mortltclr
Approx 0 - 1V is RICH I LEAN dispiay
Engine speed at displayed The display : must be synchronized
, approx 2,OOOrpm i cycle is 5 times or more with output voltage
, 10 10 seconds interval, display
Provide selting value in "ACTIVE TEST' (fuel injection
quantity correction) and check exhaust gas sensor
function.
Note:
"INJ PULSE" display for RB20E is 1/16.
Using diagnosis connector on the vehicle side
(near fuse block), set GONSULTto "EXHAUST GAS
SENSOR MONITOR" and check the fuel injection
condition by flashing of exhaust gas temperature warning
lamp on instrument panel.
Exhaust gas sensor function
Exhaust gas temperature warning lamp must flash 5 times
: or more in 10 seconds interval when engine is running at
i approx, 2,000 rpm.
Feedback function
EXH GAS SEN OJ2V
M!R FIC MNT RICH
RECORD
, ACTIVE TEST
FUEL :NJECTIOI'<
Mon,OR
CAS.RPrv1 iRE:F)
ENG fEMP SE.';
EXHGASSEN
,INJPULSE
: MC VALVE
+11"\.
1037'pm
36"C
0,87V
36%
i
, au OWN II ad i
I Exhaust gas temperature warning lamp must flash I
i periodically when engine speed is running at approx. 2,000
i
EGGS control unit harness connected.
Between ECCS CIU
terminal 1 am ground
Deflection between
approx_ 0 - 1
Between ECCS CJU
terminal 29 and ground :
I
- Deflection between
approx. 0 - 1
EN - 393
---I
I
j
8 m'
.6 (')
-L (t): i (291 01
I O,sen I / Q, (Jl
. ry<. c:'
- . I
RB20E i DE,' DET I CA1B, ENGINE
Disconnect ECCS control Unit and exhaust gas
. il",'!1
o
EN - 394
RB20E
1
RB20DE I DET
RB20DE I DET
RB26DE'f ENGINE
6-8 DETONATION SENSOR SYSTEM INSPECTION
De!onatlon
Sensor 2

24
41 8
2----123
Detonatio'1
sensor 1

-: ..

(1) Self-diagnosis
m
o
o
(f)
o
o
::l
[
c::

Igmtlo(l timing cOntrol i
:
There is a disconnection or short-circuit in the signal system when "CODE 34" in normal
self-diagnosis or "FAILURE DETECTED DETONATION SENSOR" (when CONSULT is
used) is displayed. If the problem occurs again, use real-time diagnosis mode
(CONSULT DATA MONITOR mode) or an oscilloscope to check for instantaneous
Approx. O.3V Approx. O.3V
Cranking Approx O.3V Approx. O.3V
Idling Approx. O.3V Approx.03V
.Caution:
The detonation sensor input signal must be measured by
using oscilloscope as its resistance is greater than the
circuit tester resistance. The signal should also be
checked with self-diagnosis and harness continuity
inspection.
Disconnect ECCS control unit and detonation censor
middle connector and measure the resistance between
Between ECCS CIU terminal 23 and detonation I'
sensor middle harness terminal 2
Between ECCS CIU termmal 24 and detonatIon
sensor mIddle harness terminal 1
EN - 395
1
-'iiI
:::;.Q;
. ill I
==j23 ::5
[QetonatiO'i sensor 24 g i ,
RB20E! DE! DET ENGINE
6-8 DETONATION SENSOR SYSTEM INSPECTION
CONTROL. CIRCUIT DIAGRAM RB20E f DE I DET ENGINE
Detonation sensor
)-__ -;1.
(1) Self-diagnosis
m
o
o
(f)
()
o
"

'"
There is a disconnection or short-circuit in the signal system when "CODE 34" in normal
self-diagnosis or "FAILURE DETECTED DETONATION SENSOR" (when CONSULT is
used) is displayed, If the problem reoccurs, use real-time diagnosis mode (CONSULT
DATA MONITOR mode) or an oscilloscope to check for instantaneous break in the
signal.
iOetonatlOn S:flsor
v
em.
I
(f)
(24) 8

16 g:
Approx 4V Approx.4V
Approx. 4V '. ( ! RB20DE, DE;
__ ____
Caution:
The detonation sensor input signal must be measured by
using oscilloscope as its resistance is greater than the circuit
tester resistance, The signal should also be checked with
self-diagnosis and harness continuity
inspection.
Disconnect ECCS control unit and detonation censor
middle connector and measure the resistance between
RB20E! Belween-E-C-C-S-C-'-'U-'t-e-nn-l-na-I-16 and I
detonation sensor middle harness terminal 2 ,
RB20DE I Belween ECCS CIU terminal 23, 24 and
DET detonation sensor middle harness terminal 1 2
EN - 396
RB20E
RB20DE I DET
-
RB26DETT! RB20E ! DE ! DET ! CA 18' ENGI NE
6-9 VEHICLE SPEED SENSOR SYSTEM INSPECTION
CONTROL CIRCUIT DIAGRAM
RB26DETT ENGINE
r
!
'-:I

I
Fuel cut cO'1trol
I
_______ ._---1

rn
I
(')
()
(fl
,d:e speed
()
I

0
I . ,
"-
I
VehiCle sod sel
2.
c
:0
'"
RB20E I DE I OET ENGINE
m
I------L. Fuel cut C3ntro!
()
()

(fl
(")
1-----i Idle speed control
0
::>

1 :5",
Q.

( ) RB20DE ! DET
CA18i ENGINE
i VehICle speed Z1 1------1-L. FLel cut control
EN - 397
RB20E,DE!DETIGA18iENGINE
{1) Input signal inspection
Select "VEHICLE SPEED SENSOR" in "DATA
MONITOR" mode and check tne following items.
When drive wheels are rotating Vehicle speed is displayed
NO FAIL :J1
I
CAS.RPM (REF} 787rom
CAQ. SPEcD SEN Okm!h
I
I
,

r RECORD
''-________ 1
Measure the VOltage between the following terminals , _______ . _____ ..
with ECCS control unit connectors connected.
Pi .. ;-r-;; .;; ....
I ,'r;K'i >'1i,l:;.;i Ioet RB2Ot: '. . pOhle!. spd sen 1---1 21 153) I
Between ECGS CIU Between EGGS CIU ,..-1/ I EGCS
terminal 45 and ground terminal 21 and ground . .1,'. control
. .. ..... ",I """O,,-It __
Deflection between OV and 5V (also appears .
as deflection around 1V)
6-10 IGNITION SWITCH (START SWITCH) SIGNAL
INSPECTION
CA18i
(1) Input signal inspection @ . 1+' ,,"L.. r---:
In "DATA MONITOR" mode, perform the key operation i i
to check if the ignition switch "START' signal is input' r8' i control I
correctly. . l"n_!I ==='
Measure the voltage between the following terminals Aa>\ i,,1
with ECCS control unit harness connected. \f:!J .. .. .. _. __ -1
! __ ..
ECCS CIU ECCS CIU 23 I
terminal25 i termmal 23 ECCS
and and "munrl 'conlrol
-:- : unIt
OV
Battery vcltage
EN .. 398
RB26DETT / RB20E! DE! DET I CAIS! ENGINE
6-11 AIR CONDITIONER SIGNAL INSPECTION
B26DETI I RB20
Dual press;Jre
Heater fail
c
switch NC switch i ::;)
___________ ---l29 ""
1 - . (46)
i
i (i RB20DE I DET I RB26DETI
f'fl\ CA18i
(1) Input signal inspection 1Jt)-- "" -""---"""--,
In "DATA MONITOR" mode, perform the air conditioner 1-'-1
switch operation to check if the air conditioner switch AlC ECCS
signal is input correctly,
with EGGS control unit harness connected,
control
I Unit
AlC re,ay -'-/1'02
r"
%
CA18i
9 and ground 46 ana ground
ECCS Gil) teml,nal
102.29 ana grcuna
Battery voltage 8-9V
0- 1V Battery voltage
6 -12 NEUTRAL SWITCH SIGNAL INSPECTION
O 0
(Ii)
In "DATA M NIT R" mode, perform shift lever
operation to check if neutral switch signal is
input correctly, te\
Measure the voltage between the following terminals '<a)
and ground with EGGS control unit harness connected.
4 - 5V
Approx.OV
EN"" 399
,--'-
c=.
,.
, rl
i I ECCS
,I control
I ,
C:-, L
um
!

"" ( ) RB26DETI ! RB20DE; ;)",T
RB26DETI i CA18! ENGINE
6-13 POWER STEERING SWITCH SIGNAL
INSPECTION
(1) Input signal inspection .,
In "DATA MONITOR" mode. perform power steering \J!}
operation to check if power steering oil pressure switch
signal is input correctly.
with ECCS control unit harness connected.
ECCS CIU terminal ECCS CIU terminal
31 and ground 19 and ground
Approx.8V Approx.5V
Approx.OV Approx OV
CA18i
6-14 LIGHT SWITCH SIGNAL INSPECTION
(1) input signal inspection
In "DATA MONITOR" mode, perform light switch operation
to check if light switch signal is input correctly.
with ECCS control unit harness connected. \S/
I-_____ -t __ A_p_p_ro_x._o_V_-I
Head lamp ON Power voltage
RB26DETT
-------j
Light switch

l ECCS
; I control
,-0
6-15 HEATER FAN SIGNAL INSPECTION -. -; ",
.. eater an
(1) Input signal inspection sWllcn
In "DATA MONITOR" mode. perform heater fan operation G:)---@--- --I 45 [
to check If heater fan sWitch signal IS Input correctly. 'i: ECCS I
Measure the voltage between the following terminals I / i .
with ECCS control unit harness connected. :0 U It
I
, .
Heater fan ON Power voltage
EN - 400
RB25DE DIAGNOSIS
RB25DE ENG INE
DIAGNOSIS 1 - POWER SUPPLY & GROUND CIRCUIT
ECCS
relay
T
I
107
""
ID----, ,
,
.
i 116
:!J
i
I
("---,}o. -4.-_______ . __ _
-----... -
!
!
Components location

-EC_C_S_control umt .J
EN - 401
B
A
RB25DE ENGINE
I START
Start the engine,
Does the engine start?
NG 1
0K
I Inspect ground circuitD, I
1
0K
I FINISH
Power supply inspection
Place ignition switch to ON position, i
;<is>I, Inspect battery voltage using "BATIERY ; OK
\.Bi VOLTAGE" in "DATA MONITOR" mode, I
I r6\, Use tester to measure the voltage between.
: EGGS C/U terminal 49, 50 and ground, I
NG
o
Ground circuit inspection
Place ignition switch in OFF
position. Disconnect ECGS G/U
harness connector,
Gheck for harness continuity between
EGGS GfU terminal, 10,20,107,108
I and 116 and ground,
Repair harness and connectors
I FINISH I
ECCS C/U terminal and ECCS relay harness
continuity inspection
Place ignition switch in OFF position, .
EGGS G/U and EGGS relay harness NG
Inspect for continuity between EGGS G/U terminal
__ __________
RB25DE DIAGNOSIS
A
1
'* MOr\ITORING
,CAS,RPM (POS) 1 062,p", I'
BATIERYVOL 14,QV
START
A

IIEccs'LClU
v'
:--- '1

B
C
It E:(\ (",.,
.'d'.)
, --- ,.

OK
I Repair harness or connector I_C-------"'------,-,
IVoltage inspection between ECCS C/U
,terminal and ground
Place ignition switch to ON position,
Measure the voltage between ECGS relay
terminal 2, 3 and ground,
! Voltage: Battery voltage
IF NG: Place ignition switch to OFF position,
No. 21 fuse, No,3, NO.6 fusible link.
, Inspect the continuity between EGGS relay and
! the batte .... ry_, ___ ..,-________________ -"
If eli
I
To E
I Repair harness or connector I
EN - 402
RB25DE DIAGNOSIS
RB25DE ENGINE
E
E
I Output signal circuit inspection
: Check the continuation between ECCS C/U NG
I terminal 16 and terminal 1.
!It eo 00
E"'C:C:CS:-CC::::IU""c-on-n-eC-lo-'r I !
. II I
OK
Inspect the following:
Ignition coil harness connectoL
Harness between EGCS C/U and
I UT";)f] .
i'-'!...JI
: _.j ] filll1
: ECCS relay.
I'F NG' Aepair harness or connector .
. Component parts inspection
i (EGCS relay) NG
I
. Aeferto the section on ECGS relay for ,-
inspection. I
I Repair EGGS relay
. Check for any damage on the ECCS C/U I
I terminals and ECCS C/U connector.
Carry out the inspection in the following order after repairs.
Verification inspection
FINISH
I Check for any damage on the.
L I EGCS CfU terminals and
. OK i EGGS CfU connector.
I _Nc.:....:.G_i Check for any damage on the
L i OK EGGS G/U terminals and
I EGCS C/U connectoL
I FINISH 1
EN - 403
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 2 - CRANK ANGLE SENSOR (CODE NO. 11 IN SELF-DIAGNOSIS)
IGN
ECCS relay

.,
F!L6
Crank a'lgle sensor a 51
G s'gnal I I 41
, l' slgr,al .. ""
.
____
Components location
EN -404
m
g
l/l
g
[
c
"
'"
t-----i timing
'njectlon c:::mtrof J
ri Idle saeed oont'ol
B
RB25DE ENGINE
Carry out self-diagnosis I
NG OK
A
Place ignition switch to OFF position, ,
Disconnect crank angle sensor harness
connectors, NG
Place ignition switch to ON position, .
Use tester to measure the voltage between i .
'terminal 3 and ground,
OK Inspect the following:
, Check the continuity between crank
angle sensor terminal 3 and ECCS
relay terminal 3,
Repair harness or connectors,
Input signal circuit inspection
Place ignition switch to OFF position,
Disconnect ECCS CiU harness connectors,
Check the continuity between crank angle sensor NG
terminal 2 and ECCS C/U terminal 42, 52 (1
0
signal),
between crank angle sensor terminal 1 and ECCS
C/U terminal 41 ,51 (120 signal),
C
OK
Repair harness or connector
Input signal inspection
Connect crank angle sensor and ECCS C/U
harness connectors,
' Use "CRANK ANGLE SEN RPM" in "DATA
OK Component parts inspection
(Crank angle sensor)
Refer to the section on crank angle sensor for ,
,inspection, IF NG: Replace crank angle sensor,1
Check for any damage on the ECCS C/U
terminals and ECCS C/U connector,
EN - 405
RB25DE DIAGNOSIS
A
B
.. --------

i Ifecs CIU eonnectoj

LCgJ.fl_-,
4:2, 52 and 2
C
'A1LO!
I :REF) 662rpm I
. AIR FLOW MTR '.02V I
. ENG TEMP SEN 81 .
EXHSEN C.18V
THROTTLE SEN O.38V
NJ PULSE 3.0msec
START
c
lit ' ClB \fB
leees eM
RB25DE DIAGNOSIS
RB25DE ENGINE
Verification Inspection
I Erase memory from self-diagnosis I
I
Test drive
Check for any damage on the I
I Recheck by self-diagnosis ,EGGS G/U terminals and
I
,
1
0K
FINISH
I EGGS G/U connector.
EN - 406
RB25DE DIAGNOSIS
DIAGNOSIS 3 - AIR FLOW METER (CODE NO. 12 IN SELF-DIAGNOSIS)
F/L3 IGN #21 ECCS relay
j ) - ~ ,.
F/L6
Air flow meter
: 1
Intake air qty sig S' 2
Power ground F i 3 ""
Components location
ECCS control unIt
EN - 407
* I !gnitiCn timing control
RB25DE ENGINE
Carry out self-diagnosis
NG i OK
I !FINISH
A ~ I __________
Power supply inspection I
Place ignition switch to OFF position ..
. Disconnect air flow meter harness
connectors. NG
RB25DE DIAGNOSIS
A
B
Place ignition switch to ON position. 11 ec
i Use tester to measure the voltage I I
'b,!woo" """'"," aod gm"d II ~ ~ "l. --- t
Inspectthe following: -, I ~ - : I OK ::1
1
U-n-'
Check the continuity between air flow I J
meter termmal5 and ECCS relay - - ~ ~ - - ~ - - - - - ~ ~
terminal 3.
lfli<i: Repair harness or connectors.
B
Place ignition switch to OFF pOSition.
Disconnect EGGS G/U harness connectors. , NG
Check the continuity between terminal 4 and ECCS 11
LC_/U_te_r_m_in_a_I..,.26_. _______ -______ .-JI !
OK
Repair harness or connector
c
Input signal inspection i
Check the continuity between airflow meter I NG
terminal 2 and ECCS C/U terminal 27 (intake ~
air quantity signal). : I
OK
To 0
I Repair harness or connector
EN - 408
c
- - ~ ~ . 00
RB25DE ENGINE
o
Connect crank air flow meter and ECCS C/U
hamess connectors.
1'6\ Use "AIR FLOW METER" in "DATA
MONITOR" to measure input si nal.
(1'1 Measure the voltage between ECCS C/U
\W terminal 27 and ground. .
... '.
. ' .'
_1181 2'1 (in!IIlW _'" ..
!
Voltaga
. ..... .. ....
'.. ' ..
.' ... ntity fllllnal) .'" ....

fg!lilillnUlltl:h ON Approx. O.3V
;. :.
Cranking .....
Approx. 1V
.' ldlIng .;; Approx. 1.1 V
OK
I Component parts inspection
. (Crank angle sensor)
Refer to the section on crank angle s ensor for
inspection. IF NG: Replace crank angle sensor .
. Check for any damage on the ECCS C/U
, terminals and ECCS C/U connector.
RB25DE DIAGNOSIS
o
FAIL '--..1
I
CAS RPM IREF) 662rpm.
AIR FLOW 1 02V .
ENG TEMP SEN 8"
i EXHSEN a.18V
i THROTTLE SEN OAOV
'iNJ PULSE 3.0msBC
START
o
:1t CIB W
IECCS CIU con"ectaj
Verification inspection I
Erase memory from self-diagnosis
Test drive
for any damage on the
I Recheck by self-diagnosis ECCS C/U terminals and
ECCS C/U connector.
EN - 409
RB25DE ENGINE
DIAGNOSIS 4 - ENGINE TEMPERATURE SENSOR
(CODE NO. 131N SELF-DIAGNOSIS)
Engine terrperature
sensor

Components location
START I
IC8rry out self-diagnosis
NG OK
A
; Disconnect engine temperature sensor i
hamess connector. I Ni
Place ignition switch to ON position, i
Use tester to measure the voltage I '
between terminal 1 and ground, i
Voltage: Approx, 5V '
OK
To 8
EN - 410
RB25DE DIAGNOSIS

I . Fuel injection :::;ontrc! i
I
1 .. t Ignition riming contro:]
I
A
i
I
I
I
I
,-,
,., __ ,---1
R82SJE ENGINE
B
i Ground circuit inspection
'Place ignition switch in OFF position.
ICheck continuity between terminal 2 and ground .
OK I
C
Use "ENG TEMP SENSOR" in "DATA
i MONITOR" to check engine coolant
temperature.
Check the voltage between ECCS C/U
,Voltage: When ignition switch is ON
! Eng temp Approx. 20C 3V
I Approx. 80C 1 V
OK
Component parts inspection
(Engine temperature sensor)
I
Refer to the section on engine temperature
RB25DE DIAGNOSIS
B
C
FAIL LJi
ENG TEMP SEN 78" I
START
: sensor for inspection. lE NQ; Replace crank 'I C
Ii-a_n"'-gl_e_s_e_ns_o_r. ____________ llt E
1
IEees CJU
terminals and ECCS C/U connector.

Test drive
for any damage on the
I Recheck by self-diagnosis ECCS C/U terminals and
OK I ECCS C/U connector.
FINISH
EN - 411
RB25DE ENGINE
DIAGNOSIS 5 -IGNITION SYSTEM INSPECTION
(CODE NO. 21 IN SELF-DIAGNOSIS)
@
IGN '"elay I
i
I I
FiL6
8
1 2- .. +16

ECCS relay ilT3[ i
i
53
I
---- 3 I
Fu'l
Components location
, /
I
riO
>-+ ,
,
I
i ,-' ,\ 0-.

EN - 412
RB25DE DIAGNOSIS
Power transistor
B
A
Carry out self diagnosiS,
NG 10K
. To ignition signal 1 (Item
not In se!f diagnosis)
Circuit function inspection
Inspect using "POWER BALANCE" in til
, "FUNCTION TEST' mode, \,eJ
i Gheck to if engine rev will decrease momentary,
I
IGround circuit inspection
Place ignition switch in OFF position,
'Disconnect power transistor unit harness connector. I NG
Check for harness continuity between terminal E and Ii
ground, I
OK '
i Repair harness or I
B
Output signal circuit inspection
Place ignition switch In OFF position,
Disconnect ECCS C/U harness connector,
Inspect for continuity between the following terminals:
EGGS C/U terminal 1 and terminal 2
ECGS C!U terminal 12 and terminal 2
NG
EGGS G/U terminal 3 and terminal 3
I--
ECCS C/U terminal 13 and terrninal4
,EGCS G/U terminal 2 and terminal 5
ECCS C/U terminal 11 and terminal 6
ECCS CfU terminal 1 0 and terminal E
ECGS C/U terminal 20 and terminal E
OK
, Repair harness or connector.
Output signal inspection
Connect power transistor unit and EGGS
G/U harness connectors,
Inspect battery voltage between EGGS GfU
terminals 1, 2, 3, 11, 12, 13 and ground.
Cranking:
'Idling:
2500rpm:
Approx. 0.2 - 0.3V
Approx. 0.2 - 0.3V
Approx.1V
OK
I
NG
EN - 413
B
RB25DE DIAGNOSIS
A
,"ELF-DIAG REs+"'D
lFAILURE DETECTED TIME \'
IIGNSIGNALPRIMARY 0
, '

ERASE I' PRINTI
A
\
.POWER BALANCE. ;
INSPECT THE BALANCE:
OF EACH CYLINDER BY I
STOPPING INJECTOR
OPERATION FOR EACH
CYLINDER
[FiASsli START
(Power transistor unit)
RB250E ENGINE
. Refer to the section on powe r transistor for
inspection. IF NG: Replace power transistor
. unit.
NG
RB25DE DIAGNOSIS
10K
I Replace power transistor!
I Check for any damage on the ECCS G/U I
terminals and EGGS C/U connector. I
i Verification inspection I
I memory from self-diagnosis I
Test drive
L-----rl- ---'
r---- Check for any damage on the i
CheCk by self-diagnosis I ECCS C/U terminals and '
i EGGS C/U connector.
OK
EN - 414
RB25DE ENGINE
DIAGNOSIS 6 - EXHAUST GAS SENSOR
1
r ,2
7 3
Components location
A
J
, /.//
L-.:.. "
Function inspection 1
, Warm up the engine.
@Inspect using "BASE AIR-FUEL RATIO" in
"FUNCTION TEST" mode. '
NG OK
To B
EN - 415
o sensor
I:
0" sensor r,arr1ess
connectqt
A
RB25DE DIAGNOSIS
Air-fuel ratIo
feedback contro!
AIR-FUEL RATO TES-r+l
I HOLDTHEE'JGINESPEEDAT I
j2000+1-200rpmAND PRESS ;
(START.

1800 2000 2200
START
RB25DE DIAGNOSIS
RB25DE ENGINE
B
Start the engine. .
(j) Hold the engine at 2000 rpm and inspect i OK
using "02 SENSOR" (output voltage and "02
SENSOR MONITOR" (lean, rich) in "DATA .
MONITOR" mode.
M Measure the voltage between ECCS C/U
'4:Y terminal 29 and ground.
c
Approx. 0.3V (constant voltage) NG
Approx. over 0.6 - 1V (variant voltage) OK
I FINISH
B
i FAil J\

B

I
CAS.RPM (REF)
02 SENSOR
02 SENSOR 'viTA
I
START
CIU eonneeto1
'"
j
650rpm i
O.02V I
RICH 1
I
Place ignition switch to OFF position.
Disconnect 0, sensor harness connector and ECCS NG
C/U harness connector.
I ' 1. I'
I -
. Check continuity between ECCS C/U terminal 29
! and 0_ sensor harness connector terminal 2.
.
1
0K
[p",",m"so"'""'ctm
[Jieplace 0, sensor
. I
,. I
I Check for any damage on the ECCS C/U I
and ECCS C/U connector.
__ . __ ._._J
C
: e!' :1e
; i
I 32.'
l !LJI..c.

memory from self-diagnosis I
I
Test drive
Check for any damage on the
I Recheck by self-diagnosis . ECCS C/U terminals and
i ECCS C/U connector.
EN - 416
RB25DE ENGINE
DIAGNOSIS 7 - DETONATION SENSOR
r------.I Zl
[OetonatiO:l sensor I 2,
Components location
EN - 417
RB25DE DIAGNOSIS
Detonation sensor
harrJess connector
I
RB25DE ENGINE
I START I
i
I Carry out diagnosis
A
!NG
[FINISH
Input signal circuit inspection 1
Disconnect ECCS C/U harness connector and
sub hamess connector.
NG
RB25DE DIAGNOSIS
i Check the continuity between terminal 1 and. B
I
ECCS C/U terminal 23, terminal 2 and ECCS CI . ... '.
U terminal 24. I I'c GEl
B . .. 10K I Repair hamess or I i
r------' I
Input signal circuit inspection 2 I i
Disconnect hamess connectors connected front and; NG
rear of the detonation sensor.
Check the continuity between sub hamess terminal A
. and 23. Band 24.
i OK I Repair harness or connector i
'"pot "g",' '",P"'"M
Connect detonation sensor and ECCS C/U
harness connectors.
Measure the voltage between ECCS C/U .
i
terminal 23, 24 and ground.
NG
Measurement location terminal 23, 24 and ground
Ignition switch ON Approx. 4V
, ,
L
Cranking Appro . 4V
I
' I
n
Idling Appro . 4V

i
; OK I Replace detonation sensor I
i terminals and ECCS C/U connector.
[verifiCation inspection
Test drive
NG Check for any damage on the I
ECCS CIU terminals and I
OK ,ECCS C/U
FINISH
EN - 418
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 8 . THROTTLE SENSOR (CODE NO. 43 IN SELF-DIAGNOSIS)
Throt:ie sensor
0
r
Power 1
.,
21 [8

Signal
"
Groune
3 0
.,
,
Components location
START I
rrcc:=-:-=-::::':u.: 1=-=-=-== 0 K
I Carry out self diagnosis
m
(")
(")
III
"
0
"'-
Q.
c

1
A
NG FINISH
System inspection
Place ignition switch to ON position.
Use "THROTTLE SENSOR" in "DATA
MON ITOR" to inspect the system.
Voltage:
Fully open Approx.4.0V
: Fully closed Approx,O.6V
Open I Close range over Approx. 3.0
NG
OK
I---
I
fuel Injection controj
r-
1
AlC cuI control

.-
.. =--,
, "
, /?""/
1
/. /;/
.. '\ -,,' ,,'
, --'
, Throttle s'ensor
harness conneclo:- i
'-----
A
I THROTILE SENSOR.
PRESS START WHILE
PRESSING THE
ACCELERATOR PEDAL
FULLY.
...

I
FINISH
TOB
EN - 419
RB25DE ENGINE
8
(j) Place ignition switch to ON position.
Use "THROTIlE SENSOR" in "DATA
MONITOR" to inc::s=e.;;;.ct:.:.... _=-_____ -<
eii': Place ignition switch to OFF position. ,
is/Disconnect throttle sensor harness connector.!
I
Measure the voltage between terminal 1 and
ground. Battery voltage: Approx. 5V
NG
8
C OK ] Repair harness or connector II
Input signal circuit inspection I'
Disconnect ECCS C/U harness connector. NG
i Check the continuity between ECCS c/u,' i
I terminal 38 and terminal 2. ,
i
I Component parts inspection (Throttle sensor) ,
i Refer to the section on throttle sensor for inspection./
IlENG: Replace throttle sensor unit.
I
OK
. i
Check for any damage on the ECCS C/U ,
terminals and ECCS C/U connector. '
C
RB25DE DIAGNOSIS
8
NO FML OJ
ICAs.RPM IREF) orprr:
i THROTTLE SEN 3,94V'
, !
i
.J
STAR.!.,T __ ---l

U
i2
';

IL'.I:I

.. 1

'Verification inspection
Erase memory from self-diagnosis'
Test drive
NG Check for any damage on the ,
Recheck by r-':"':"':'-jECCS C/U terminals and
OK ECCS C/U connector. ,--__ ...L.. __ --,
EN - 420
RB25DE DIAGNOSIS
R825DE ENGINE
DIAGNOSIS 9 - AIT CONTROL (CODE NO. 54 IN SELF-DIAGNOSIS)
i .I

I
m
(')
(')
'"
"
I 0
a
t" .....
Q.
5,
I:

!
.. - ..
Components location
Carry out self diagnosis
.NG
A
I
Disconnect ECCS C/U harness and AfT C!
U harness connectors,
, Check the continuity between ECCS C/U
terminal 14 and AfT C/U terminal 1 0, ECCS,
C/U terminal 5 and AfT C/U terminal 11 ,
NG
OK
I Repair harness and connectors I
, Check for any damage on the ECCS C/U
EN - 421
10

"
I
0
"
1"
-
2-
I:
::J
::;
"
I
A
, 8:1(J'.\ i21IAlTcluconoectorli
I
I 10, 11, 12"
I"" eN I 1
I

RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 10 - CRANK ANGLE SENSOR (NOT IN SELF-DIAGNOSIS)
F:L 3

ECCS relay
,
t

,
1

"'---"
i8:l
,
.1
"
:0
'"
, Ignition timing contr11
F/L 6
2 1
L-
'"
t%
Pl
CranK angle se"'lsor
2 1
I "
. 120" sigral
n
1
41 rJ)
r-------:--
" Floel injection
1" signa; 2
0
L
"
a
Power 3
'"
Q.
" Ground 4
!-
'"

r--
, Idle speed control I
( )
1 2 3 4
L ______________ _
Components location
EN - 422
RB25DE DIAGNOSIS
RB25DE ENGINE
A
A
,----_ ... - ... ~ .... ~
lIerOO
Place ignition switch to OFF position. .
Disconnect crank angle sensor harness I NG
connector . I
.
. Check for continuity between terminal 4
I and engine ground harness.
i
OK
,
Repair harnes
connector
(Crank angle sensor) NG
Refer to the section on crank angle sensor IL...-
for inspection.
OK
,
s or
I Replace crank angle se nsor I
I Verification inspection I
I
I Ground circuit inspection
I
I FINISH
I
NG Check for any damage on the
ECCS C/U terminals and
EGGS G/U connector.
EN - 423
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 11 -IGNITION SIGNAL 1 (CODE NOT IN SELF-DIAGNOSIS)
IGN 'elay
ECCS relay CD...[!)

Full
'"
.,
I.
Power transIstor
'No.1
I
No,2
m
(")
No, 3 (")
'"
3
(')
0
"
-

!2.
"

______________ 2,__ __________________
Components location
Q
. ___ control cnL
EN - 424
RB25DE ENGINE
Whole system inspection,
Start the engine.
I Is all cylinder ignited? I
OK
A
I To ignition signal 2 I
NG
I Circuit function inspection I
: Inspect using "POWER BALANCE" in !
"FUNCTION TEST" mode. OR power :
balance in "ACTIVE TEST". L..Q!S,
Check to if engine rev will decrease momentary. I I
NG
FINISH
B
Place ignition switch in OFF position.
Disconnect ignition coil harness connector.
NG
: Use CONSULTor the tester to measure the
voltage between each coil terminal 1 and ground.
Power voltage: Battery voltage
--=---------'
OK
Ignition relay
Ignition switch
Continuity between each coil
C
i Harness terminal 2 and ignition
! relay terminal 5.
_______ -,-__ -'---c _______ --,
NG
Check for harness continuity between each coil
terminal 3 and ground,
OK
0
Output Signal circuit inspection
Disconnect power transistor unit harness connector,
Inspect for continuity between the following terminals:
Between each ignition coil terminal 1 and
Power transistor unit terminal 1
NG
Power transistor unit terrninal4
i Power transistor unit terminal 6
OK
EN - 425
RB25DE DIAGNOSIS
A
.POWER BALANCE.
INSPECT THE BALANCE
- OF EACH CYLINDER BY
I
STOPPING INJECTOR
OPERATION FOR EACH
i CYLINDER,
TURN OFF AlC & LIGHTS
ipASS]: START]
A
ACTIVE TEST .0
POWER BALANCE
MONITOR
'ICAS_RPM(POS) rpm l-
AIR FLOW METER V
.AAC VALVE % I
==ir==ir==ir=='
L 1
I
B
o
RB250E ENGINE
Components inspection
(Power transition unit & Ignition coil) NG
Refer to power transition unit and ignition coil
,inspection in components inspection section.
[l}iace faulty parts
Carry out the inspection in the following order after repairs:
RB25DE DIAGNOSIS
I Recheck ECCS C/U terminal for
Components inspection 1-" ----j" damage and check ECCS C/U
~
~
, harness connector connection.
EN - 426
5
A825DE ENGINE
DIAGNOSIS 11 -IGNITION SIGNAL 2
E
Continue from ignition signal 1]
Disconnect ignition coil relay connector.
i Place ignition switch to ON position.
'Use CONSULT or tester to measure the
voltage between coil terminal 2, 3 and ground.
Power voltage: Battery voltage
OK
i
i Inspect the following:
NG
Continuation between fusible link,
ignition coil relay and ignition switch.
Continuation bel\'I'een ignition coil
F
i relay and the battery,
, Ground circuit inspection
Place ignition switch to OFF position. NG
Inspect hamess continuation between each coil
terminal 2 and 5. G
RB25DE DIAGNOSIS
e;! .ic2.':Jfl I
" :
'-'- ,
= i
L'LJ
Ji :
G
OK
' I
I Repair harness and / or connector I: !}t If'" @:)
! I EGGS GIU connectod i
I 1io-
i t i
Disconnect ECCS relay.
NG
Inspect the continuation between ECCS C/U
terminal 16 and ECCS relay terminal 2.
OK
Fusible link.
Continuation between ECCS C/U and
ECCS relay harness.
i Continuation between ECCS C/U and
i ignition coil relay hamess.
, IF NG: Repair harness and connector.
IComponents inspection
i
. (Ignition cOil & ECCS relay) NG
Refer to ignition coil and ECCS relay inspection I
in components inspection section. I
OK I Replace faulty components
Inspect ECCS C/U terminal for any damage
and ECCS C/U connectorforconnection.
EN - 427
R825DE ENGINE
DIAGNOSIS 12 - INJECTOR SYSTEM INSPECTION
Components location
><1
......
// ".
I
J
EN - 428
RB25DE DIAGNOSIS
RB25DE ENGINE
A
I START I
I
Circuit function inspection
rB\ Inspect by "POWER BALANCE" in
\eJ "FUNCTION TEST' mode.
Operate "POWER BALANCE" in
CONSULT active test.
fi8\ Make sure the injector operation noise
is audible.
NG 'OK
B
I ,Power supply inspection 1
'Place ignition switch to OFF.
FINISH
I
Disconnect sub harness connector. ,
Check the battery voltage between terminal i
3 and ground using CONSULT or tester.
NG
i Inspect the following:
i Harness connector.
I Continuity between sub harness
connector and the harness.
'IFNGR h d t
i-
..
epalr arnessan connec or.
C
Power supply inspection 2
Disconnect sub harness connector.
Inspect between the following terminals
for continuity:
between terminal 3 and 5
I
OK
0 I NG
Disconnect injector harness connector.
Inspect between the following terminals
for continuity:
I between terminal 1 09 and No.1. 2, 3,
4. 5 & 6 cylinders.
To E
EN - 429
RB25DE DIAGNOSIS
A
"OWER BALANCE.
INSPECT THE BALANCE I
. OF EACH CYLINDER BY j
STOPPING THE i
INJECTOR DRIVE FOR I
i EACH CYLINDER.
I PASS [= .. =S=TA=R=T="=i]
A
B
C
IFQ'j

o
:IEccs c/u i
NO.11
U
No.2.
!lilll No.3!
:. NoAI
- No.sl
NO.6
RB25DE DIAGNOSIS
RB25DE ENGINE
E
Out put circuit inspection
Disconnect EGGS G/U harness connector.
Inspect between the following terminals for
continuity:
between terminal 1 01 and NO.1 cylinder
between terminal 1 05 and No.2 cylinder
. between terminal 1 03 and NO.3 cylinder
between terminal 112 and NO.4 cylinder
between terminal 11 0 and NO.5 cylinder
i between terminal 114 and No.6 cylinder
OK
NG
Repair harness or
. connector.
i (Injector)
I Refer to the section on injector for inspection.
NG
Inspect ECCS C/U terminals for any
I
damage and make sure the connectors
are connected correctly.
-------'
IEGGS C/U connector I
101,103,105,110,112,114
Carry out the inspection in the following order after repairs:
I Verification inspection:
I

I Functional check. I I Recheck for any damage on the ECGS C/U I
i NG IterminalS and ECGS G/U connector.
I FINisH I
EN - 430
2
NO.1
No.2
No.3
No.4
NO.5
No.6
RB25DE ENGINE
DIAGNOSIS 13 - VEHICLE SPEED SENSOR
,
"'
(')
(')
(fl
n
:)
:0
53
a

I
L ..
Components location
:.\ .
L' // ECCS
I START I
Whole system inspection i
Use CONSULT and carry out the inspection!
using "VEHICLE SPEED SENSOR" in !
"FUNCTION TEST' mode. I i
NG
1 FINISH i
I Vehicle speed sensor function inspection NG
I Inspect vehicle speed meter function
OK
I Vehicle speed sensor and !
vehicle speed sensor circuit
TO B inspection,
EN - 431
RB25DE DIAGNOSIS
I
.. , Fuel cut control
_I Idle speed conirol
B
RB25DE ENGINE
Start the engine.
Rotate drive axle slowly.
Detect vehicle speed using "VEHICLE
SPEED SENSOR" in "DATA MONITOR".
Use tester to measure the voltage between
ECCS C/U terminal 53 and ground.
Voltage: apprcx. 0 - 5V
NG
B
RB25DE DIAGNOSIS
B
NO FAIL 1':
I CAS. RPM iPOS) 787rp", II
VEH SDD SEN 0 km;r.
START
i-- .
. .--'-----, . ill : (
I
Inspect the following: I I
I
, I EGGS G/U conneclorl ,
. Check the continuity between ECCS I 53 I
I C/U and combination meter harness. 1
IIF NG: Repair or replace harness. . I ! !ool
@.Sl
Inspect ECCS C/U terminals for any
damage and make sure the connectors I'
are connected correct/y. .

NG Check for any damage on the !
f-----1ECCS C/U terminals and 1
ECCS C/U connector.
EN - ..\32
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 14 - AIR CONDITIONER RELAY SIGNAL
i
'----.-. .. ----l
Components location
I START I
NG
!21 E:' ~
II ECCS C/U connectod
Use tester and measure the battery voltage
between ECGS G/U terminal 9 and ground.
When blow-fan switch is OFF: battery voltage
IWhen blow-fan switch is ON: Approx. 1 V
9
NG
Inspect ECCS G/U terminals for any
damage and make sure the connectors
are connected correctly.
I FINISH I
NG i Check for any damage on the
Ground circuit inspection 1---.... ECCS CfU terminals and
ECGS G/U connector.
EN - 433
I ' .. .. "=J."
~ I
~
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 15 - EXHAUST GAS SENSOR HEATER
Components location
EN - 434
RB25DE ENGINE
I START'
A
Disconnect exhaust gas sensor harness connector NG ..
I Measure power voltage between terminal 1 and
ground.
OK
Harness connector.
Continuity between exhaust gas
sensor and the fuse. IF NG:
Repair harness and connector.
B
Place ignition sWitch to OFF position,
Disconnect ECGS G/U harness connector.
Check for continUity between termtnal3 and
IEGGS GiU terminal 115.
OK

!
NG
Repair harness or connector.
i (Exhaust gas sensor heater)
! Refer to the section on exhaust gas sensor
i heater for inspection.
NG
OK
Replace exhaust gas sensor.
,Inspect ECGS GiU terminals for any
i damage and make sure the connectors
,are con nected correctly.
RB25DE DIAGNOSIS
A
i
I
L_
B
i
iI
I
ECCS CIU connec!orl i
115 3 2 .. 2)
, 'Qi]
ilill
l
~ . ~
Verification inspection'
Inspect power supply, ground circuit I-----i' EGCS C/U terminals and
OK EGGS C/U connector.
'---=F-:::I N:':-' S=-=H:-::----'
EN - 435
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 16 - THROTILE VALVE SWITCH
To AfT
control unit
Components location
I::
I I
.. __ .. .E.CC;L,<ontrQLymt._J
EN - 436
m .. -- Fuel injection control
i . Ilgo'1'.OO 1'.mlng controll
,.. ..-Jldle speed control
I
Th e,nttl" ",live sw
RB25DE ENGINE
A
Inspect using "IDLE JUDGEMENT" in
"FUNCTION TEST" mode.
: Reference:
OK
Fully open: OFF
Fully closed: ON
FINISH
B
NG
Inspect ignition switch "ON-OFF" diagnosis or
OK
measure the voltage between ECCS C/U terminal
: 54 and ground using the tester when ignition switch
jisON.
Voltage: Accelerator pedal pressed OV
I
Accelerator pedal not pressed 8 - 10V
NG
I
FINISH
C
Disconnect throttle valve switch harness connector.
: Use tester to measure the voltage between
Battery voltage: Approx. 8 - 10V
!
NG
,
I
: Harness continuity between throttle
ivalve switch and ECCS C/U. IF NG:
: Repair harness and connector
0
NG
Disconnect ECCS C/U harness connector.
-
Disconnect throttle valve switch harness connector.
Check the continuity between ECCS GiU terminal
'54 and throttle valve switch terminal 1.
OK
I Repair harness or connector.
, (Throttle valve switch) NG
I Refer to the section on throttle valve switch for
j
I inspection. ,
I
OK I
I Replace throttle valve switch. I
'Inspect EGGS C/U terminals for any damage and
make sure the connectors are connected correctly.
EN - 437
B
RB25DE DIAGNOSIS
A
'.-::1 D::C'L-=E-J
,
kTART WHEN AGGELERA
PEDAL IS FULLY OPEN.
:
L-. ...
I PASS I'
'--------'
START

i ... ;00
! (Idle CO'1nection poim)
:I EGGS G!U connecto,!
I
54
C
II EGGS G1U
I r roo .
L __ , .. _:_o __
RB25DE ENGINE
%rification inspection i
. I .
i Function inspection
OK
I
FINISH
1------1
1
ECCS C/U terminals and
ECCS C/U connector.
EN - 438
R825DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 17 - START SIGNAL
A
Function inspection
Use CONSULT and inspect "START SIGNAL" in
"FUNCTION TEST" mode. OK
OR
Inspect start signal using "DATA MONITOR" mode.
When ignition switch is ON position: OFF
When ignition switch is START position: ON
B
iNG
FINISH
Disconnect throttle valve switch harness connector. ; NG
Place ignition switch to ON position. -
Use tester to measure the voltage between
Battery voltage: Approx. 8 - 10V
I
OK
Fuse
-,
. Continuity between ignition switch
I and ECCS C/U harness. IF
'Repair harness and connector.
Inspect ECCS C/U terminals for any damage and
make sure the connectors are connected correctly.
EN - 439
RB25DE DIAGNOSIS

B
A
SIGNAL I
I
PlACE SHIFTLEVERTO ''P''OR ;
"N' Wl1l1ACCELERATOR PEDALj
EULLYCLOSED :
i START1l1E ENGINE STRAIGHT ;
! AFTER SELECllNG START I
I i
, J
--,
START
i PASS IL'
, ,----
A
I WONITORINttl: NO FAIL 01
! l
I
CAS, RPM (POS) 1326rpm I
,STARTER SIGNAL OFF
I ,
L
I
RECORD
I
il ECGS CIU connector I
RB25DE ENGINE
DIAGNOSIS 18 - FUEL PUMP CONTROL
FIL6 ECCS relay
i 3
. I 1'-...
I FIL3 IGNSW #16 l M
w..Lil
L1.l2J
,-4 ..
, t 16
L---j' .,
_1_

! 18
Fue! pump relay _
, ,.
4 5
RB25DE DIAGNOSIS
en
0
0
[J)
'"
"
:>
rf
"
"
'"
crr:Iill
UUU0i
J-
I i to= I
Fuel pump L.. ___ ....;i i
- L-c)
(-
Components location
, .
/ i/
0_'_' ___
EN - 440
RB25DE ENGINE
I START I
A I
System inspection
Select "FUEL PUMP" in "FUNCTION fIT',
TEST' to inspect the system. \!J
Operation check by "FUEL PUMP RELAY" in
,"ACTIVE TEST'.
Fuel pump will operate for 5 seconds after the
ignition switch is turned to ON position. Check if
the fuel pump operation noise are audible.
8
Power inspection ,
'Place ignition switch to "OFF" position.'
,Disconnect fuel pump relay. I NG
; Measure voltage between ground and
I terminal 2 & 3 using the tester. I
OK
Check the following:
Fuse
OK
FINISH
Harness connection between fuel
pump relay and the fuse.
Connection between fuel pump relay
I
, and the ignition switch.
!EliG: Repair I-)arness & connector.
c
Ground circuit inspection I
Remove fuel pump harness connector. NG
Check the connection between fuel
pump harness connector 3 and the
'ground.
o
Repair harness or
the connector.
,Remove ECCS C/U harness connector.
I Check the continuity between ECCS CiLi & harness
terminal 18 and fuel pump relay harness terminal 1.
I Check the following:
[Continuity between ECCS C/U and fuel pump relay.
'Continuity between ECCS C/U and pump relay.
lIE NG: Repair harness and the connector.
EN - 441
A
8
c
RB25DE DIAGNOSIS
A
, ''---+Fc--
UEL
PUMp+
I
ISTHERE A PULSATION
EVERY 3 SECONDS
I WHEN THE FUEL TUBE
IS HELD? OR CAN YOU
HEAR THE OPERATION
I NOISE OF THE FUEL
lI,JMP R.ELAY? =,. ==
I PASS II NO II YES
A
ACTIVE TEST .0
FUEL PUMP RELAY ON I
MONITOR ,II,
CAS.RPM (POS) Orpm
[ ;
I START I
RB250E ENGINE
E
Control signal inspection 4
Measure the voltage between ground and ECCS C/U
terminal 18. ,
5 seconds after ignition switch is turned ON: 1V ;
After 5 seconds after ignition switch is turned ON:
OK,
I
Icomponent parts inspection
(Fuel pump relay)
Battery voltage
Refer to the section on fuel pump relay for
'"'::r
, Replace fuel pump relay.
Component parts inspection I NG
(Fuel pump) n
,Refer to the section on fuel pump for inspection. , ;
OK I I
I Replace fuel pump. I
i terminals and ECGS C/U connector.
o
E
I Verification inspection I
RB25DE DIAGNOSIS
~
r9"l
fOlJl T-
t'----l4U.r---
J
J I
I OK NG Check for any damage on the ECCS C/U
I Functional check. r.:::.:------1
term
inals and EGCS G/U connector.
I ~
r-----'-------,NG
I Fuel pressure inspection.
,
f------1
1
Replace malfunctioning parts1
1
0K
I FINISH I
EN - 442
R62SDE ENGINE
DIAGNOSIS 19 - AAC VALVE
Components location
i
, ___ .. c:ontr.9_' u_nd
A
Function inspection
. Warm the engine.
I
Check the idle speed 600 - 700 rpm. OK
IF NG: Adjust idle speed.
, w. Inspect using "AAC VALVE" in
Disconnect AAC valve harness .
Check if idle rev will decrease. '
B
NG
I
Power inspection
Place Ignition sWitch to "ON" position. ' NG
'Measure voltage between ground and AAC valve
terminal 2.
TOC
Repair harness or the connector.
EN - 443
RB25DE DIAGNOSIS
A
I. AAC VALVE
ITURN OFF AlC AND LIGHTS
'SWITCHES BEFORE
STARTiNG.
I PASS I [ START
RB25DE ENGINE
c
I Output signal circuit inspection I
fb\ Check if the engine rev will change when the ;
\...!IV "UP" or "DOWN" is pressed in "AAC VALVE" in !
"ACTIVE TEST' mode,
Disconnect ECGS GiU harness.
, Check for continuity between ECCS C/U
L
: harness terminal 4 and AAC valve connector
terminal 1.
RB25DE DIAGNOSIS
B
[R8j}air harness or connector. 1 c;..,-______ .
'+ACTIVE TEST cl
Component parts inspection (AAC valve) NG
Refer to the section on AAC valve for inspection, n
JoK I
I I Replace AAC valve, I
,
'''-C-h-e-ck-f-o-r damage on the ECCS C/U I
. terminals and EGGS C;U connector. I
I AACN OPENING DEG 10%1'
MONITOR
CAS. RPM (POS) 900rpm I
AIR FLOW MTR 1.16V;
ENGINE TEMP SEN 80"CI
I !
OWN r!QdI
C
1lI Ie 00
I EGGS G(U connector
, 4
i
[91
I
I
Functional check. r--- ____ @heck for any damage on the ECCS C/U
. I I . terminals and EGCS C/U connector.
i OK
[FINiISH I
EN444
RB25DE DIAGNOSIS
f1B25DE ENGINE
DIAGNOSIS 20 - AIR REGULATOR
F/L3

I -
-L r \
i IIGNSW
,..
#8
CL.....lJU
UJjJ.
>I
i
<W
Et='
I I
Fue! ::lump relay Air reglila10r -:!:- !
!
L-___ -"
Components location

,
,
I >/ ECCS control Unit
A
Place ignition switch to OFF position>
Disconnect fuel pump relay. NG
Place ignition switch to ON position. --'---l
i
use tester to measure the voltage between I
terminal 2, 3 and ground. I
OK
Fuse.
TO B Harness continuity between
fuel pump relay and fus!>
Continuity between fuel
pump relay and ignition
switch.
IF Nft Repair harness and
connector.
EN - 445
A
lilW jc
\.iIID ;
I
RB25DE ENGINE
B
/
. Disconnect air regulator harness connectors.
Check for continuity between air regulator harness
Gonnectorterminal2 and ground.
--

I
OK
I Repair harness or connector.
c
Disconnect ECCS CIU harness connector.
Check for harness continuity between ECCS C/U I'
terminal 18 and fuel pump relay terminal 1.
OK
I Inspect the following:
NG
! ContinUity between ECCS C/
U and fuel pump relay. IF NG:
Repair harness and continuity .
D
Control signal inspection =l
Measure voltage between ECCS CIU terminal
18 and ground. NG
Within 5 sec when ignition switch is placed in ON n'
position: Approx. 1 V
After 5 sec when ignition switch is placed in ON i
position: Battery voltage .
"--___ ---',-_ '-___ __ . I
OK
Repair and inspect ECCS C/
U power supply and ground
circuit.
Icomponent parts inspection
(Air regulator) . .
Refer to the section on AAC Replace air regulatoLI
I valve for inspection. .
RB25DE DIAGNOSIS
C
: I ECCS c/u connector I
I 18 LI:!il .
, I .1Q1 T 1

o
I
I @"'E""CC"'S'"'C'"iU"-cC:-on:-:n:-:ec""o""rl
18

I Check for any damage on the ECCS C/U I
[Functional checkt-I -----1 terminals and ECCS C/U connector. i
10K
I FINISH I
EN - 446
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 21 - POWER STEERING HYDRAULIC PRESSURE SWITCH
PWR 5T hydraulic
pressure SiN
r--' , .... _-_ .. ---4
19
Components location
.. --... .. --..
I START I
A
I
Function inspection
(j)Place igni!ionswitch to ON position.
Inspect using "PWR 8T SIG" in
OR
Stop the engine.
Use "DATA MONITOR" to inspect PWR
ST hydraulic pressure switch signal.
When neutral: OFF
OK

When steered: ON i
Start the engine.
Use CONSULT or tester to measure the
voltage between ECCS C/U terminal 19
and ground.
When steered: Approx. OV
Other: Battery voltage
NG I
TOB
EN - 447
A
POWER 5T SIG
PRESS START WHILE FULLY
STEERING THE STEERiNG
WHEEL.
[
or
... PASS I i .. __
A
I
I' i
i CAS.PM (POS) 862rpm I
IGNITION SIGNAL OFF.
[ RECORD I
__________
RB25DE ENGINE
B
Place ignition switch to OFF position<
Disconnect ECCS C/U harness connector.
Disconnect power steering hydraulic pressure
switch harness connectoL
Check for harness continuity between ECCS C/U
terminal i 9 and power steering hydraulic pressure
switch terrninal i. I
NG
OKI
Repair harness or connector<
c
I G ro"O d ,',," It '0' pe",'oo I
Check for continuity between power steering , NG
hydraulic pressure switch terminal 2 and engine ,
ground. I
OK
I Repair harness or connector< I
Component parts inspection I
I (Power steering hydraulic pressure switch) I NG I
. Refer to the section on power steering I
hydraulic pressure switch for i
I
Replace power steering
hydraulic pressure switch.
Check for any damage on the EGCS G/U I
terminals and EGCS G/U connector. i
RB25DE DIAGNOSIS
A
B
IllI ee\ 00
I
, rei s"'c""c,,""' c"';"'u c-o-nn-ec'""to--',
19 '
I t
I
--------'
ICheck for any darn age on the ECCS C/U i
'--__ .,-__ J------, terrninals and ECGS C/U connector. I
EN - 448
R825DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 22 (Phenomenon) IDLE REV IS TOO HIGH (AFTER WARM UP)
1
Throttle sensor & air regulator inspection I
@ Inspect in function test mode. .
Check i!the throttle sensor (idle judgement) is i G
not turned OFF. N
rU\ Make sure the air regulator unit is not locked
'a' or electricity is conducted to air regulator.
OK
i Circuit and throttle sensor
: inspection. i
I Air regulator and circuit inspection .
2
Intake air leak inspection
1;\ Warm up the engine.
off set value by selecting "OWN" in
"FUEL INJECTION RATIO OFF SET
VALUE" in active test mode.
Caution: Carry out the test in minimum time
required. Do not operate during drive.
Warm up the engine.
rU\ Separate air flow meter harness connector.
if the idle rev will decrease after
racing the engine at approx. below 2000rpm
for 30 seconds.
YES
NO I
1 Repair where air is leaking. 1
3
Throttle linkage inspection
Stop the engine. NG
Check if the throttle linkage will move smoothly.'
Check if the throttle valve will close! open fully.
!
OK.

Repair throttle linkage
or inS ect throttle valve.
EN .. 449
2
i
1
r. SENSOR
PRESS START WHILE FULLY
OPENING THE ACCELERATOR
PEDAL.
2
I. ACTIVETES- DI
I
' FUEL INJECTION OFF SET 0'0
MONITOR
I CAS.RPM(POS) 937rpm I'
, ENG TEMP SEN
j 0, SENSOR 133V
: 0; SENSOR IR) 135V:
i I NJ PULSE : .8'11sec I
17
3
c:
1 Air flow me'l
; rarness
j connector
L. __ ...... .. __ ...:
3
'. \
\' II
\ \, _ ...
RB25DE ENGINE
DIAGNOSIS 23 (Phenomenon) - HUNTING
1
Throttle sensor inspection I
Warm up the engine. : YES
Check for any change with hunting when 02 sensorr-=i
connector is separated. :
NO I. . I
2
sensor inspection I
Power balance test
/6'. Star the engine.
@Use "POWER BALANCE" in function test.
Caution; Carry out the test in minimum time NO
required. Do not operate during drive,
Idle rev will decrease for a moment for each'
cylinder.
2
.'Idle rev will decrease for a moment when
each cylinder injector connector is
L..-",s;;;.:eparated.
OK I
I ,
3
Spark plug inspection I
Stop the engine. NG
Disconnect spark plug and check for dirt, n
,damage, gap etc. "
OK I
4

3
Start the engine. YES
Check if engine rev will increase when blow-by
i house is pinched.
i
NO;
I
FINISH
EN - 450
RB25DE DIAGNOSIS
2
-.. -.. l
i THROTTLE SENSOR
PRESS. FULLY
OPENINGTHEACCELERATOR
PEDAL
I .
I
"i"F'=====.J
II START J'

RB25DE ENGINE
DIAGNOSIS 24 (Phenomenon) - IDLE INSTABILITY
1
Operate power balance test
/fj\Start the engine. NO
lJ!)Operate "POWER BALANCE TEST" in function
i
test. Caution: Operate the test in minimum time I
required. Do not operate during drive.
'dle rev will decrease for a moment when
operating each pipes.
1
YES
i
To No. 6
2
Injector inspection
Stop the engine.
(leave harness connector as it is).
NO
Disconnect power transistor connector.
I--
: Place ignition switch from OFF to ON position.
Can you hear operation noise from each injector
when the crank angle sensor shaft is rotated by hand .
. \/yarning: Depending on how the shaft is rotated, self-
i
idiagnosis will display abnormal, disregard this display.;
I
i
I
YES
I Inspect injector and circuit I
3
Ignition inspection
Remove ignition coil ASSY. NG
Install normal spark plug.
i Face the spark plug rear end towards adequate
! ground such as collector and crank the engine.
'Check the spark.
OK
4
Spark plug inspection
Check for dirt, damage, gap etc. on the
spark plug removed from the engine.
105
EN - 451
1
2
4
RB25DE DIAGNOSIS
1
1+ pOWER BALANCE
INSPECT BALANCE OF EACH
BY STOPPING I\lJECTOR
i OPERA'TIONAT EACH PIPES.
.
iTURNOFFAlLAiCAND LIGHTS!
i .
I PASS II START

.. \; \ /1 Operatio"
;,' /{ II ; noise
" ,iJ
, "-\
,
RB25DE ENGINE
5
Fuel pressure inspection I
ttl' Start the engine.
\!JSelect "STOP" in "ACTIVE TEST' and bring .
fuel pressure to zero. '
After engine stop, crank 2 - 3 times. . NG
Inspect fuel pressure using fuel pressure
gauge.
When idlin : A rox.2.Sk I cm
2
the engine.
fuel pump fuse and bring fuel
pressure to zero.
Attach fuel pressure gauge and inspect the
pressure.
OK
Inspect fuel pump and I
circuits.
6
Exhaust gas sensor inspection
11J'\lnspect using "BASE AIR-FUEL RATIO" in
\.rV'FUNCTION TEST' mode.
Select "02 SENSOR MONITOR" in data
monitor.
Set at 2000rpm with no load after warm up.
Check if the display "LEAN, RICH" will repeat
for more than 5 times within 10 --1
vehicle side (within fuse box)
connector and change to "0,
sensor monitor".
Check if the exhaust temperature warning
lamp will flash for more than 5 times within
10 seconds.
T07
EN - 452
NG
RB25DE DIAGNOSIS
5
i+r--A-c-r-Iv-E T-E-S-T
I FUEL PUMP RELAY
I
MONITOR
. CAS.RPM (POS) 950rpm i
I
I , J

6
NO FAil DI
i CAS.RPM (REF) 650rpm I
i 02 SENSOR O.02V I
'02 SENSOR MTR RICH I
START
6
RB25DE ENGINE
7
Start the engine.
Check if the engine rev will increase when
the blow-by hose is pinched using hands.
YES
NO i
Repair leaks
8
!
i
i
Idle adjust screw fixation inspection
,t'E\Start the engine.
\JV Operate "AAC VALVE ADJUSTMENT' in NO
"OPERATION SUPPORT' mode.
Can idle rev be adjusted to 600 - 700rpm
("N" position for A/T) by rotating the idle
adjustment screw.
Start the engine.
Disconnect AAC valve connector.
Can idle rev be adjusted to 600 - 700rpm
("N" position for AfT) by rotating the idle
adjustment screw.
YES
i
I AAC valve and throttle
9
' valve fixation inspection.
Compression pressure inspection
Standard value: 12.8/300 (kg/cm2)/(rpm)
NG
Minimum value: 9.8/300 (kg/cm2)/(rpm)
i Each cylinder difference
I Tolerance: 1.0/300 (kg/cm2)/(rpm)
OK
Inspect piston, piston ring
i
10
I valve, valve seat, cylinder
I head gasket.
, ECCS C/U connector inspection
'Check for any damage or loose connection on
the C/U bin terminal and harness connector.
OK
11
Try replacing with normal C/U. Replace or repair
EN - 453
9
RB25DE DIAGNOSIS
8
r
--.--AAC VALVEADJ ~
SET THE CAS.PRM TO
,STANDARD VALUE U"JDER
'I THE FOLLOWING CONDITION'
AFTER WARM UP,
TURN OFF L ~ LIGHTS AND
AIRCONDfTlONER
START
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 25 (Phenomenon) - WHEN COLD, DIFFICULT TO START OR CAN NOT
START THE ENGINE
1
Inspect battery and starter motor Replace or repair i
2
OK
Fuel pressure inspection' I
(fl',lnspect using FUEL PUMP" in "FUNCTION
mode.
Minch fuel pump with fingers.
if the fuse hose is tense when fuel
pump us operating.
OK
Fuel pump and circuit i
inspection .
3
Air regulator inspection i
Cneck if the power is conducted to air regulator: NG
when the ignition switch is turned to ON position. n
OK ! I
! Inspect air regulator and circuit.!
sensor i:nspection' : OK
'Press accelerator pedal fully and check if n
the engine will start. ---..J I
5
i sensor and circuit!
I
Injector inspection
Remove crank angle sensor (leave harness
connector connected).
Remove power transistor connector.
Check if each injector operation noise can be
heard when the crank angle sensor shaft is rotated
. by hand. Note: Depending on how the shaft is
rotated, abnormal will show in self-diagnosis, in
i NG
,this case determine as normal. I I
OK I .....L,
T06
!tnJector and circuit Inspection "
EN454
2
5
1
+FUELPUMP +
YOU FEEL PULSATION

EVERY 3 SECONDS WHEN
HE FUEL TUBE IS
PINCHED? OR CAN YOU
IHEAR FUEL PUMP RELAY ,
bPERATION NOISE?
, -.J
jPASs i! NO!! YES i,
Rotate by hand
RB25DE ENGINE
6
Ignition inspection
Remove sub-harness in each pipping. .
Install normal spark plug. Face the spark plug NG
I
rear end towards adequate ground such as
collector and crank the engine .
Check the spark.
OK
: Inspect ignition coil, power
i transistor and circuit
7
i Check for dirt, damage, gap etc, on the spark.
iPlug removed from the engine.
NG
OK
I
Repair or replace I
8
ECCS C/U connector inspection
NG
Check for any damage or loose connection on
'-----,
the C/U bin terminal and hamess connector.
I
OK
I Repair or replace I
9
i ECCS C/U power supply and ground circuit
I inspection.
J:!
OK I
I Repair or replace
10
Try replacing with normal C/U.
EN - 455
RB25DE DIAGNOSIS
6
7
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 26 (Phenomenon) - WHEN WARM, DIFFICULT TO START OR CAN
NOT START THE ENGINE
1
E
.
Fuel pressure inspection .
,rtt1nspect using FUEL PUMP" in "FUNCTION NG
mode.
it'<tl'FinCh fuel pump with fingers.
if the fuse hose is tense when fuel
: pump us operating.
OK
I
Fuel pump and circuit
inspection
2
Ivapour inspection
,Disconnect fuel pressure regulator vacuum hose. OK
; Place a hole cap on the vacuum hose.
: Does the en ine start?
NG
Inspect fuel aspect
3
Injector inspection
R,m,," pow,cI'"";'tm ham'" ",",,,tm I i
,heard when the crank angle sensor shaft is rotated,
: by hand. Note: Depending on how the shaft is i
I
this case determine as normal.
---
OK
Injector and circuit inspection.
4
Ignition inspection
,Place ignition switch to OFF position.
i Remove sub-harness in each pipping.
Install normal spark plug. Face the spark plug i
collector and crank the engine.
,Check the spark.
NG
OK
Inspect ignition coil, power
transistor and circuit.
T05
EN - 456
1
2
3
1
1- +FUELPUMP
CAN YOU FEEL PULSATION
,EVERY 3 SECONDS WHEN
THE FUEL TUBE IS
IpINCHED? OR CAN YOU
iHEAR FUEL PUMP RELAY
bPERATION NOISE?
C- ..
I
i
Rotate by hand
4
RB25DE ENGINE
5
Check for dirt, damage, gap etc, on the spark 1-, _,
plug removed from the engine.
6
OK'
I
Repair or replace
ECCS CIU connector inspection
OK
I Repai r or replace
7
ECCS CfU power supply and ground circuit NG
inspection. -
OK
I Repair or replace
8 ,
I Try replacing with normal C/U, I
i,
I FINISH I
EN - 457
RB25DE DIAGNOSIS
5
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 27 (Phenomenon) - IN NORMAL CONDITION, DIFFICULT TO START
OR CAN NOT START THE ENGINE
1 1
I nspect battery and starter motor'
2
OK
Fuel pressure inspection i
l,rtI'lnspect using FUEL PUMP" in "FUNCTION' NG
iJ!VTEST' mode.
'(ff\Pinch fuel pump with fingers,
\:e,;Check if the fuse hose is tense when fuel
pump us operating.
OK
Fuel pump and circuit
inspection
3
Injector fuel leak inspection
Press accelerator pedal fully an check if the NG
engine will start. when the ignition switch is turneC\---t
to START position. : I
OK
[II1spect injector leak. I
4
I Injector inspection
Remove power transistor connector. NG
Place ignition switch to ON position. n
heard when the crank angle sensor shaft is rotated i
by hand. Depending on how the shaft is i
rotated, abnormal will show in self-diagnosis, in U
OK
I Injector and circuit inspection.:
5
Ignition inspection
Remove sub-harness in each pipping.
, Install normal spark plug. Face the spark plug
i rear end towards adequate ground such as
Check the spark.
NG
I collector and crank the engine.
______
Inspect ignition coil, power I
TO 6 transistor and clfcuit.
EN458
----:----
, +FUELPUMP +
bAN YOU FEEL PULSATION
IEVERY 3 SECONDS WHEN
FUEL TUBE IS
INCHED? OR CAN YOU
EAR FUEL PUMP RELAY 'I'
PERATION NOISE'
, ,
! PASS I YES.l
2

I /
Fuel filter I
r f /1--1"',\/ I
3
4
Fully open W
4JI+OO<
c
1
Rotate by hand
5
RB25DE ENGINE
6
NG
Check lor dirt, damage, gap etc. on the spark
plug removed from the engine.
i
OK
i
I
Repair or replace
I
7
I ECCS C/U connector inspection
NG
I Check for any damage or loose connection on

the C/U bin terminal and harness connector,
,
OK
8
ECCS C/U power supply and ground circuit NG
inspection.
OK
I Repair or replace
9
Try replacing with normal CIU, '
EN - 459
RB25DE DIAGNOSIS
6
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 28 (Phenomenon) - HESITATION AFTER WARM UP
(hesitation as throttle valve starts to open)
1 1
/fi',Select "UP" or "DWN" In "FUEL INJECTION
\ibUANTITY CORRECTION" in "ACTIVE TEST'
mode to change correction value,
Caution: Carry out the test in minimum time '
required, Do not operate dUring drive, I
OK
fuel pressure regulator NG
'4!YPlace hole cap on vacuum hose. n
Operate crUising test. I
Is there still hesitation?
NG .
If lean hesitation inspect pressure I
regu lator and fuel pump,
2 I
!canister purge inspection
! Disconnect canister purge hose. NG
'Place hole cap on the purge hose,
Conduct cruise test. '
,Is there still hesitation? , i
I Fuel aspect inspection
EN - 460
2
1+ AC,IVE "TEST + 0
FUELINJECTION OFF SE"T 0%
MONITO"
CAS.RPM(POSj 937rpm
ENG TEMP SEN 59'C
0, SENSOR 1.33V,
O. SENSOR (R) 135Vi
IN-J PULSE 1.8msec,
i AAC VALVE 17%1
[ au II UP II OWN !Lad!
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 29 (Phenomenon) - HESITATION WHEN COLD
1
ISpark plug inspection :
'Remove spark plug and check for any dirt,
damage, gap etc.
NG
R epair or replace I
2
(fi'oSelect "U P" or "OWN" in ;'FUEL INJECTION
CibUANTITY CORRECTION" in "ACTIVE TEST" OK
mode to change correction value.
Caution: Carry out the test in minimum time
required, Do not operate during drive.
Start the engine.
CiPoes the engine rev increase when the blow-by
: hose is pinched?
NG
I Repair leaks I
3
Replace with normal air flow meter.
NG
4
Intake valve deposit inspection .
Remove when deposit is present.
I I
EN461
1
2
2
I. ACTIVETEST C
I
FUEL:NJECTIONOFFSET 0%1
MONITOR
,CAS,RPM(POS) 937rpm
I
ENG TEMP SEN 59'C
O. SENSOR L33V
0', SENSOR (RI L35V
l1NJ PULSE 1.Bmsec
VALVE '
I GU I[ UP II DWN {ad!
RB25DE DIAGNOSIS
RB2S0E ENGINE
DIAGNOSIS 30 (Phenomenon) HESITATION IN NORMAL CONDITION
1 2
Spark plug inspection .... I
Remove spark plug and check for any dirt,' NG
damage, gap etc.
NG
2
rtJ\ Inspect using "BASE AIR-FUEL RATIO" in
TEST' mode.
Select "0, SENSOR MONITOR" in data i NG
monitor,
for more than 5 times within 10 seconds .
. 4l\ Operate vehicle side (within fuse box)
\:a/ diagnosis connector and change to "0
0
sensor monitor".
Set at 2000rpm with no load after warm up,
Check il the exhaust temperature warning
10 seconds.
OK
3
Canister purge
canister purge hose. :
OK Inspect purge and
. Place hole cap on purge hose,
vacuum system
Conduct cruise test.
Is there still hesitation?
4 NG I
fh' Warm up the engine.
(j)Change off set value by selecting "OWN"
in "FUEL INJECTION RATIO OFF SET
VALUE" in active test mode,
Caution.:. Carry out the test in minimum
2
..
I4BASE AIR FUELRATIOTES.'
I HOLDENGINEREV200(.4j-
I 2(.'Om'Tl AND PRESS START.

(Fuse
brock)
J!lL i

i , Exhaust :emp i
: Red iamp : warning lamp ;
.. --.--..
4
I. ACTIVE TEST 0
FUEL INJECTION OFF SET 0%
, MONITOR
CAS.RPM(POS)
ENGTFMPSEN
0, SENSOR
O. SENSOR :R)
INJ PULSE
937rpm
59'C
L33V,
1.35
1.Bmsec
,AAC VALVE
i Qu II UP II OWN II Qd :
I
' time required, Do not operate during drive.
. Warm up the engine. ,
4
raCing the engine at approx. below ' ", .. K .... -
2000rpm lor 30 seconds. I I .

I Repair any leaks 1/ .;.6>', /':\0'\#
. . /'v/ Blow-by hOSe" i
FINISH / ''elf __ ..J
EN462
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 31 (Phenomenon) - ENGINE STALL WHILE REVVING
1
1
.. - .... _.
Fuel level inspection
: Check the level of fuel in the fuel tank. I NG Resupply fuel. I
OK i
2
Power balance test operation
"fI\ Start the engine.
Inspect using "POWER BALANCE" in
Operate "POWER BALANCE" in "ACTIVE
TEST" mode. Caution: Carry out the test in
minimum time required. Do not operate
during drive.
Check if idle rev will decrease for a moment
when checkinq each cylinders.
!fl>\ Check if Idle rev decrease for a moment
each injector connector cylinders are
! disassembled.
NG
3
OK
To No.5
Injector inspection
Place ignition switch from OFF to ON position.
by hand. Note: Depending on how the shaft is
NG
Injector and circuit inspection.!
4
Ignition inspection
Install normal spark plug. Face the spark plug. NG
rear end towards adequate ground such as 11
,Check the spark.
OK
T05
,Inspect ignition coil, powerl
I transistor and circuit I
EN - 463
2
3
4

2
.POWER BALANCE.
FOR EACH CYUNDER STOP
INJECTOROPERAllONAND
CHECK THE BALANCE OF
EACHCYUNDER
TURNOFFAlCANDLIGHTS
START
RB25DE ENGINE
5
(jJ\Slart the engine.
'J!/Sring fuel pressure to zero by selecting "FUEL
PUMP RELAY" in "ACTIVE TEST'.
NG
Crank 2 to 3 times after engine stop.
Use fuel pressure gauge to inspect:
-
When idling: Approx.2.5kg/cm
2
When pressure regulator vacuum hose is
removed: Approx. 3.0kg/c:.cm,-,-2 __ ___ -I
t1\:hStart the engine.
~ r i n g fuel pressure to zero by removing fuel
pump fuse.
I
Inspect using fuel pressure gauge.
OK
Inspect pressure
regulator diaph ragm
6
I
ECCS C/U connector inspection I NG
I the C/U bin terminal and harness connector.
7
I
'lnspect ECCS C/U power supply and ground I NG i
. circulI. :
8 OK I . .
I
Try replacing with normal C/U .
.
OK
FINISH
EN - 464
5
I
RB25DE DIAGNOSIS
5
I. ACTIVE TEST .Ci
: FUEL PUMP RELAY ON i
MONITOR
I CAS.RPM (POS)
i ON IbN/OFFI,
0rpm
OFF
I '
: 1
I ----- I
L. ___ .. __ .. __ .. _____ .. ~
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 32 (Phenomenon) - ENGINE STALL AFTER WARM UP
1 1
!vapour inspection
.rrfhange correction value by selecting "OWN" in "FUEL
i NJECTION CORRECTION" in "ACTIVE TEST' mode.
I
Caution: Carry out the test in minimum time required.
Do not operate during drive.
I pressure regulator vacuum.
. Place hole cap on vacuum hose.
i
Operate cruise test.
Does the engine still stall?
2
NG
I
1" Start the engine.
iJ) Inspect using "POWER BALANCE" in
"FUNCTION TEST' mode.
NG
TEST' mode. caution: Carry out the test in
durin g drive. ,
in .
: Check if idle rev decrease for a moment
when each injector connector pipping are
I
disassembled.
3
OK
To No.
Injector inspection
Remove crank angle sensor (leave hamess
!
NG
I---
by hand. Note: Depending on how the shaft is
,
ilnjector and circuit inspection.i
4
Ignition inspection
Install normal spark plug. Face the spark plug
I Check the spark.
EN - 465
5
1
2
4

ACTIVE TEST 0
FUEL IN.5ECTION OF:: SET 0%
MONITOR
: CAS.RPMIPOS]
i ENG TEMP SEt<
10., SENSOR
0; IRI
INJ PULSE
MC VALVE
937'1'm
59'C
1.33V
1.35
1.Bmsec

2
r-+POWERBALANCE+I
:FOREACHCYUNDERSTOP
! INJECTOROPERATIONAND
:CHECKTHEBAlANCEOF
i EACH CYUNDER
iTURNOFFiVCANDUGHTS I

RB25DE ENGINE
5
Fuel pressure inspection I
!1ii\Start the engine.
fuel pressure to zero by selecting "FUEL I
PUMP RELAY" in "ACTIVE TEST" mode.
When idling: Approx.2.Skg/cm2
removed: Approx. 3.0kg/cm'
the engine,
fuel pressure to zero by removing fuel
pump fuse.
. Crank 2 to 3 times after engine stop.
using fuel pressure gaug;:..e_, _____ _
OK
NG
5
RB25DE DIAGNOSIS
5
r. ACTIVE TEST .0
i FUEL PUMP RELAY OFF
MONITOR
I CAS. RPM (POSI 950rp
I .
I ON '''IN/OFF:1 OFF I
r Inspect pressure i
regulator diaphragm I 5
6
! ECCS C/U connector inspection
)
CheCk for any damage or loose connection on
NG
OK 1
7 i
[Repair or replace I
[Inspect ECCS C/U power supply and ground NG
i circuit.
OK 1
I Repair or replace [
8
Try replacing with normal CIU.
EN -466

I
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 33 (Phenomenon) - ENGINE STALL WHEN COLD
1
'Air regulator inspection
Ch",k U Ih, " ""'co'" to ." C0g
e
'"" ! NG
1
when ignition switch is in ON position.
OK I' I
nspect air regu ator
and circuit.
2
i Press accelerator pedal fully and check if the NG
IThrottle sensor inspection h
engine can be started when the engine is cold. .
,
i Inspect airregulator i
i and circuit. i
3
/fi Start the engine.
\!; Inspect using "POWER BALANCE" in
TEST" mode. caution: Carry out the test in
during drive.
whe c each c lin
Check if idle rev decrease for a moment
when each injector connector cylinders are
disassembled.
NG
2
I
Fuilyopen
fFr:"11 /
;;a <x
1_ .. _
3
3
r +POWERBALANCE+
FOR EACHCYUNDER STOP
INJECTOROPERAllONANO
CHECl< llHE BALANCE OF
EACH CYLINDER. i
\llURN OFF AiCAND LIGHTS
I ___ ._

L.PASSj START
,,-,,-1
-- -
, ./" -/-""--wo .. n .... _I
To No. 7 ,/ . . '. :
4 I ,'c Inector /. '. ,
r:'1-nl:-'e-c-to-r :-in-s-pe-c-t:-io'-n------------,
Place ignition switch to OFF position. i ' TB' . i '.,
OK
Remove crank angle sensor (leave harness ' .,
by hand. NOJe: Depending on how the shaft is
NG
Injector and circuit inspection.
T05
EN - 467
4
,
RB25DE ENGINE
5
Ignition inspection
Remove sub-harness in each cylinders.
Install normal spark plug. Face the spark plug: NG
rear end towards adequate ground such as n
,
: collector and crank the engine. I:
. Check the spark. , :
5
OK
Inspect ignition coil, power 6
: transistor and circuit.
6
Check for dirt, damage. gap etc, NG
on the spark plug removed from : Repair or replace I
the engine. I
7
OK
Fuel P, ressure
fb\Start the engine. .. _, I
fuel pressure to zero by selecting "FUEL:
PUMP RELAY" in "ACTIVE TEST' mode. I
: NG
Crank 2 to 3 times after engine stop. r
When idling: Approx.2.5kglcm
2
When pressure regulator vacuum hose is !
removed: Approx. 3.0kg/cm
2

tWStart the engine.
'!YBring fuel pressure to zero by removing fuel :
I
pump fuse.
I Crank 2 to 3 times after engine stop. J'
using fuel pressure gauge.
OK Inspect pressure :
regulator diaphragm I
8
NG
the C/U bin terminal and harness connector. !
.. i
OK I Repair or replace I
9
Inspect ECCS C/U power supply and ground
NG
circuit.
I
OK
10
! Try replacing with normal C/U. I
OK
!F'N'SH I
EN - 468
7
RB25DE DIAGNOSIS
Ignition coil
7
'. ACTIVE TEST .01
: FUEL PUMP RELAY OFFj
i
MONITOR I
! CAS. RPM (POS) 950rp1
I .
=oN !PNlOFt][Qf:U
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 34 (Phenomenon) . ENGINE STALL WHEN ACCELERATING
INSTANTLY
1
AAC valve inspection
@warmengine
Inspect using "AAC VALVE" in "FUNCTION
TEST' OR
Select "AAC VALVE ADJ" in "ACTIVE
TEST".
Check if the engine rev will change when
"Ou" or "Od" is selected to change AAC
valve opening.
the engine,
if engine rev will decrease when
AAC valve connector is disconnected.
I
NG
-
1 Inspect MC valve
and circuit.
2

I
ower balance test operation
fil'ptart the engine,
using "POWER BALANCE" in
OR use "POWER BALANCE" in "ACTIVE
minimum time required, Do not operate
during drive .
when checking each cylinders.
NG
3
OK
To No.
Injector inspection

!
Remove power transistor connector. NG
Pia" i9
0itioo
<witch 1m OFF to ON ,,,iii," n
heard when the crank angle sensor shaft is rotated'
.
I
Injector and circuit inspection
T04
EN - 469
1
r-.--A-A-C-V-AL-V-E-. l
'STARTINSPECTIONAFTER
TURNINGOFFAICAND
LIGHTS
L ____ .. _
lPASSJ 1 __ sT_AR_T __ !
1
ACTIVE TEST
AAC i V OPENING
MONITOR
CASf'PM(POS)
AIR FLOWMTR
ENG TEMP SEN
9CGrpM
t .16V
80
c
e
UP II OWN II ad !
.POWERBALANCE.
FOREACHCYLINDERSTOP
INUECTOR OPERA1lONAND
CHECKTHEBAlANCEOF
5 EACH CYLINDER.
4
TURNOFFAICANDLIGHTS
START
2
I. ACTIVE TEST .01
POWER BALANCE
CAS. RPM (POS) rpm
AIR FLOW MTR V
AACVALVE %1
L I
Ld
,
...
/1 .
: Operation noise.
\ I
-_._...

RB25DE ENGINE
4
Ignition inspection
Remove ignition coil.
,Install normal spark plug. Face the spark plug NG
I
: rear end towards adequate ground such as I
collector and crank the engine. -.J
Check the s::. I Inspect ignition coil,
5
!I:J',Start the engine.
\!)Bring fuel pressure to zero by selecting "FUEL
PUMP RELAY" in "ACTIVE TEST" mode.
When idling: Approx. 2.5kg/cm2
removed: Approx.3.0kg/cm2
the engine.
pump fuse NO.8.
Inspect using fuel pressure gauge .
OK
NG
OK
r Repair or replace I
I Inspect EGGS G/U power supply and ground! NG
circuil. . . 'l
OK I ! Repair or replace I
[2"ry replacing with normal C/U.
OK
EN - 470
4
5
RB25DE DIAGNOSIS
5
i+ ACTIVE TEST-. LJ\
I FUEL PUMP RELAY OFF

MONITOR .
CAS. RPM (POS) 950rp".j
I
OFF I
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 35 (Phenomenon) - ENGINE STALL WHEN DECELERATING
1
AAC valve inspection
rb\Warm engine.
I I!'! ,
"""" Inspect using "AAC VALVE" in "FUNCTION
TEST" OR
Selecl "AAC VALVE ADJ" in "ACTIVE
TEST".
Check if the engine rev will change when
"Qu" or "Qd" is selected to change AAC
valve opening.
'r<ff\ tart t e engine.
1 if engine rev will decrease when
AAC valve connector is disconnected.
NG
I
OK
InspectAAC valve
and circuit.
2
Adjust screw fixation inspection
Inspect using "AAC VALVE ADJUSTMENT"
in "OPERATION SUPPORT" mode. NG
c..:.=
Check if it is possible to set idle speed to
650rpm ("N" range for AfT) by turning idle
adjustment screw. ,
/iffDisconnect throttle sensor connector. I
1 Id;!J Check if it is possible to set idle speed to :
650rpm ("N" range for ArT) by turning idle ['
adjustment screw.
OK I
I
lnspectAAC valve and:
throttle valve fixation. I
3
r1!,Start the engine.
')Inspect using "POWER BALANCE" in
OR use "POWER BALANCE" in "ACTIVE
during drive.
When checkin each c linders.
the engine.
'4!)Check if idle rev will decrease for a moment
when each cylinder injector connector is
disconnected.
OK I
EN - 471
NG
To No.6
1

AAC VALVE .-
STAATiNSPEC110NAFTER
TLRNINGOFF A/CAND
UGHTS.
START
1
.ACT1VE TEST
AAC ; V OPENING
\>10NITOR
CAS.RPMIPOS}
AIR FLOW MTR
ENG TEMP SEN
.0'
10%
900rom
116V
80'C
b
' I
au lr=u=p==i1II=D=W=N"""i"I: =Od=!!
2
I Me VALVE A:JJ
: ADJUST CAS RPM TO
, STANDARD VALUE lNDI=R
TIiE FOLLOi;"J:NG CONO:T'ON '
I AFTER WARM lJP
: TJRN OFF AiCAND LIGHTS
3

i. ACTIVE TESi .0'1
: POWER BALANCE
,CAS RPM (POS) rpm
'AIR FLOW MTR I
IAACVALVE
4 Jr_; __ 'To_Rj
RB25DE ENGINE
4
Injector inspection
Remove crank angle sensor (leave hamess
connector connected), i NG
Place ignition switch from OFF to ON position,
n
heard when the crank angle sensor shaft is rotated i
by hand. I
I Injector and circuit inspection,
5
Ignition inspection
Remove ignition coil. ,
Install normal spark plug, Face the spark plug I
rear end towards adequate ground such as I i
collector and crank the engine, '"
,Check the spark, ,
OK
Inspect ignition coil, power
6
,1}\ Start the engine,
\!)Bring fuel pressure to zero by selecting "FUEL;
PUMP RELAY" in "ACTIVE TEST' mode, !
Crank 2 to 3 times afler engine stop.
When idling: Approx, 2,5kg/cm2
removed: Approx, __ __ --l
the engine,
pump fuse No, 8,
Crank 2 to 3 times afler engine stop,
Inspect using fuel pressure gauge,
=--:::------'
NG
T07
Inspect pressure regulator
diaphragm,
EN472
4
5
6
RB25DE DIAGNOSIS
6
I. ACTIVE TEST +LJ
I FUEL PUMP RELAY OFF'
,
MONITOR
CAS, RPM (POS) 950rpni
L "" " I
I()N IpNioFFlI OFU
RB25DE ENGiNE
7
(W\ Inspect using "BASE AIR-FUEL RATIO In
TEST" mode.
Select "02 SENSOR MONITOR" In data NG
monitor.
for more than 5 times within 10 sec",o::...:n""ds""_-l
rfr\ Operate vehicle side (within fuse box)
diagnosis connector and change to "02
sensor monitor".
10 seconds.
2
R825DE DIAGNOSIS
2
I WONITORIN,* NO
I CAS. RPM {REF) 825rpm \'
i 02 SENSOR O.02V
102 SENSOR MTR RICH
START
(Fuse
block) i

OK
I Replace 02 sensor I 2
, Inspect throttle sensor and vehicle i
I speed sensor. .
OK I
. ECCS C/U connector inspection , NG
Check for any damage or loose connection on ' .
the C/U bin terminal and harness connector. I
OK
Inspect ECCS C/U power supply and ground NG
circuit.
OK
I Try replacing with normal C/U. I
OK i
I FINISH I
I
I Repair or replace i
EN - 473

RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 36 (Phenomenon) - ENGINE STALL WHEN ACCELERATING OR
1
DRIVING AT CONSTANT SPEED
the engine.
OR use "POWER BALANCE" in "ACTIVE NG
TEST' mode. Caution: Carry out the test in
1
.POWERBALANCE.
I
I STOPINJECTOROPERATlON i
, FOR EACH CYUNDERTO
iCHECKTHEBALANCEOF
, EACHCYUNDERS.
START
during drive.
Check if idle rev will decrease for a moment _1 -7.'--"-
when checking each c{..;.l.;;.in"'d;.;:e.:..rs:;.;.c.... ____ -l
rti'\Start the engine.
\@Check if idle rev will decrease for a moment
disconnected.
2
OK I To No.4
Injector inspection
by hand.
NG
'Injector and circuit inspection.j
3
Ignition inspection
Remove ignition coil. j
Install normal spark plug. Face the spark plug n' NG
. collector and crank the engine.
Check the spark. :
OK
T04
'Inspect ignition coil, power,
! transistor and circuit.
EN - 474
3
AB25DE ENGiNE
4
Fuel pressure inspection ,
,1:l',Start the engine. i
~ r i n g fuel pressure to zero by selecting 'FUEL.
PUMP RELAY" in "ACTIVE TEST" mode. .
Crank 2 to 3 times after engine stop. ~
When idling: Approx. 2.5kg/cm
2
removed: Approx.3.0kg/cm2
riI:f,Start the engine.
~ r i n g fuel pressure to zero by removing fuel
pump fuse NO.8.
Inspect using fuel pressure gauge.
OK Inspect pressure regulator
diaphragm.
5
: Intake air leak inspection
Start the engine. NG
! Check if engine rev will increase when blow-by
. hose is pinched.
OK .
I Repair any leaks
6
r ECCS C/U connector inspection
NG
. Check for any damage or loose connection on
! the C/U bin terminal and harness connector.
OK
7
Inspect ECCS C/U power supply and ground. NG
circuit. I'
8
OK I
I Try replacing with normal C/U.
OK
I FINISH I
EN - 475
4
5
RB25DE DIAGNOSIS
4
1
+ ACTIVE TEST + rl
: FUEL PUMP RELAY o'FF
. MONITOR I
: CAS.RPM (POS) 950rpml
ON JlNlOFFI OFF i
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 37 (Phenomenon) ENGINE STALL WHEN LOADING BATIERY
1
i Inspect battery and alternator
NG ._--
: Repair or replace I
OK
2
I Power balance test operation
t1J\Start the engine.
OR use '"POWER BALANCE" in "ACTIVE
TEST' mode. Caution: Carry out the test in
during drive. I
Check If Idle rev Will decrease for a moment I
when checkln each c linders.
! NG
n
(W,Start the engine.
if Idle rev Will decrease for a moment
disconnected.
3
i
OK i
Injector inspection
To No.4
I Check if each injector operation noise can be
by hand.
I Injector and circuit inspection.1
4
Ignition inspection
NG
Remove ignition coil.
I Install normal spark plug. Face the spark plug.
I
rear end towards adequate ground such as i
collector and crank the engine. .
Check the spark.
OK
T05
I Inspect ignition coil, power
i transistor and circuit
EN - 476
1
4
1
.POWERBftiANEE.-
I STOPIf'<JECTOROPERATION
I FOR EACH CYLINDER TO
CHECKTHE BALANCE OF
EACHCYUNDERS.
START
RB25DE ENGINE
5
.ifi\Start the engine.
~ r i n g fuel pressure to zero by selecting "FUEL
PUMP RELAY" in "ACTIVE TEST' mode.
Use fuel pressu re gauge to inspect:
. NG
When idling: Approx.2.5kg/cm
2
removed: Approx.3.0kg/cm_' _____ ----1
fif,Start the engine .
. r i n g fuel pressure to zero by removing fuel
. pump fuse No.8.
7
Crank 2 to 3 times after engine slop.
Inspect uSing fuel pressure gauge.
"--::::..------"
OK
OK
Inspect ECCS C/U power supply and ground NG
:circuit
-
8
OK
Try replacing with normal C/U.
EN - 477
RB25DE DIAGNOSIS
5
ACTIVE TEST C:
FUEL PUMP RELAY
MONITOR
CAS.RPM (POS) 950rpM
I !
, .
LONPN/OFFI OFF
5
RB25DE DIAGNOSIS
RB25DE ENGINE
DIAGNOSIS 38 (Phenomenon) POWER SHORTAGE AND STUMBLE
(Instant power output shortage during acceleration)
1
'l',Start the engine.
\!)Bring fuel pressure to zero by selecting "FUEL
PUMP RELAY" in "ACTIVE TEST" mode,
NG
-
When idling: Approx.2,5kg/cm2
removed: Approx.3.0kgicm
2
the engine.
ring fuel pressure to zero by removing fuel
pump fuse NO.8.
Crank 2 to 3 times after engine stop,
I
Inspect using fuel pressure gauge,
I
OK Inspect pressure regula
diaphragm,
2
@Start the engine,
Change correction value by selecting "DWN"
in "FUEL INJECTION CORRECTION
'"
"
,
VALUE In ACTIVE TEST.
Caution: Carry out the test in minimum time i
I required. Do not operate while driving.
! tiG'! Check if engine rev will increase when the
\;f!,!blow-by hose is pinched.
NO
YES
I Repair any leaks I
[Inspect compression pressure, ignition timing
: and detonation sensor.
NG
EN - 478
1
1
TEST ci
FUEL PUMP RELAY OFF:
!
MONITOR
I CAS. RPM (PaS)
! '

I ON IpNlOFF]; OFF;
2
I. ACTIVE TEST .01
I
FUEL'NJECTIONOFFSET 0%1
MONITOR
CAS RPM{pOS: 937'prn I
\ ENG TEMP SEN 59'C :
0, SENSOR 1.33V i
0, SENSOR (Ri 1.35V:
INJ PULSE - 1.8msec \
'AAC VALVE 17";-Q :1
..::u.;1 UP il OWN II Qd i
I
RB25DE ENGINE
DIAGNOSIS 39 (Phenomenon) - DETONATION
1
rj'lstart the engine.
Change correction value by selecting "OWN"
VALUE" in "ACTIVE TEST".
[
' Caution: Carry out the test in minimum time

NO
YES
! Repair any leaks I
2
Combustion chamber oil leak inspection I NG
Disconnect spark plug and inspect oil.
OK
! Inspect piston, piston ring, I
valve, valve seat, valve oil ' 2
RB25DE DIAGNOSIS
1
I + ACTrVE -:-EST + 01
:FUELINJECTIONOFFSET Q%:
i MONITOR
, CAS,RPMIPOS)
1 ENG TEMP SEN
0_ SENSOR
! 0: SE4JSOR lR)
'I' INJ PULSE
,AAC VALVE
l Qu il UP
937rpm
59"C
1.33V
1.35VI
1.8msec'
OWN
il?dl
Inspect detonation sensor system.! . " , , ,
seal, engine oil level etc,
OK! I
i
! FINISH! L
EN -479
RB25DE ENGINE
DIAGNOSIS 40 (Phenomenon) . SURGE
1
rtl', Inspect using "BASE AIR-FUEL RATIO" in
"FUNCTION TEST' mOde.
Select "0
2
SENSOR MONITOR" in data NG
monitor.
for more than 5 times within 10 seconds.
,41\ Operate vehicle side (within fuse box)
diagnosis connector and change to "0
2
sensor monitor".
10 seconds.
OK
2
Replace ECCS C/U
OK
EN480
RB25DE DIAGNOSIS
1
3ASEAIR FUEL RATfQ TES.
, I-'OLD ENGINE REV 2000+;
I 200rpmAND PRESS START. I
. ,

L
1 eoo 2000 2200
.. .. ___ .. ___ J
!pAsS] [ -STARTi
1
,...-.. -----
NO FAIL Dr
I CAS.RPM (REF) 825rpm I
. 02 SENSOR O.02V I
102 SENSOR MTR RICH.
Red lamp
START
Exhaust temp
warning lamp
RB25DE ENGINE
DIAGNOSIS 41 (Phenomenon) - BACK FIRE (SPITTING)
1
Remove spark plug.
Check for any dirt on the spark plug.
NG
OK
\ Repair or replace spark plug. \
2
yStart the engine. .:1 YES
I.!J Change correction value by selecting "DWN" 1---,
VALUE" in "ACTIVE TEST' mode.
CautiQn: Carry out the test in minimum time I
required Do nol operate while driving .
(j:fheck if engine rev will increase when the
\ blow-by hose is pinched.
NO
I Repair any
3
Intake valve deposit inspection
Remove if there are any deposit present .
Ignition timing
I
I Check If Injector IS clogged. :
I
I FINISH I
air leaks
DIAGNOSIS 42 (Phenomenon) - AFTER BURNING
1
Engine temperature sensor inspection
NG
Inspect engine sensor and engine sensor
circuit
OK
I Repair or replace :
. Ignition timing
I Check if injector is clogged.
I FINISH I
EN - 481
RB25DE DIAGNOSIS
1
~ .... -
2
2
\+ ACT'VE TES 0
I FUEL INjEC"'"ION OFF SET 0';'" i
! MONITOR I
I
CAS.RPM(pOS) 937'om
E ~ G TEMP SEN 59'C :
0, SENSOR 1.33V I
0'. SENSOR (RI 1.35V I
INJ PULSE 1.8ms,", :
AAC VALVE
~ I UP
RB25DE COMPONENTS INSPECTION
RB25DE ENGINE
8. COMPONENTS INSPECTION (RB25DE)
CRANK ANGLE SENSOR
Inspection
Remove crank angle sensor from the engine, (leave
crank angle sensor harness connector connected),
Place ignition switch to ON position,
Rotate crank angle sensor shaft slowly with hand and
inspect the voltage between terminal 2, 3 and ground,

"

".:....n .. ' Ie
"'i'l,,'." ang
<,-"-,,
"' '--,,--
"
"
Ignition sWitch in Approx, 0, 1V or Approx. OW or
ON position Approx 5V
i
Approx, 5V
!ENG: Replace crank angle sensor.
Erase self diagnosis result from CONSULT after inspection,
Check code No, 11 is not displayed in the screen,
Cau!i.Qn:
Remove injector fuse or connector to avoid injector from
operating while inspection,
AIR FLOW METER
Inspection
Remove airflow meter from the engine,
Apply battery voltage directly between air flow meter
terminal 5+ and terminal 3- and blow air to hot wire,
Check for any change in output voltage between terminal
2+ and terminal 4-,
Air is not blown Approx, 0,8V
Air is blown Approx,2V
IENG: Replace air flow meter OR check for any damage
with the hot wire,
Erase self diagnosis result from CONSULT after inspection,
Check code No, 12 is not displayed in the screen.
ENGINE TEMPERATURE SENSOR
Inspection
Disconnect engine temperature sensor harness
connector,
Measure the resistance between engine temperature
sensor harness terminal 1 and 2,
Approx 2,5K g
Approx, 80'C Approx O,3K g
IF NG: Replace engine temperature sensor,
Erase self-diagnosis result from CONSULT after inspection,
Check code No, 31 is not displayed in the screen,
EN - 482
i
Blow air
(
KQ
l 20
('l 10
Rotate by hand
i
< 1n 2.5,: --"I,
<in 1l
&:
0,1 i
20 ---;:SO"""""'(""'''C) <
w<lter temperatuf"'---.J
IGNITION COIL
Inspection
RB25DE ENGINE
Disconnect ignition coil harness connector.
Measure the resistance between following terminals.
I Primary coil res,sntance value (1 - 2)
IF NG: Replace ignition coil
POWER TRANSISTOR
Inspection
0.6 - 0.9
Disconnect power transistor harness connector.
Measure the resistance by inserting analog type circuit
tester inspection rod - and + to power transistor
terminals.
1-3 1+1- 001 -/+ ooQ
2-3 1+1- ooQ >-I+Oor11Ot ooQ
1 - 3 I + / - 0 or not 00 Q < - I + 00 Q
IF NG: Replace power transistor.
FUEL PUMP
Inspection
Disconnect fuel pump harness connector.
Measure the resistance between fuel pump terminal 1
and3.
Resistance: Approx. 0.4 - 0.7
Check for operation by applying battery voltage between
the following terminals directly:
Connect terminal 3 to + side, terminal 1 to - side.
Caution: Care must be taken to connect battery to correct
sides.
If NG: Replace fuel pump.
THROTTLE VALVE SWITCH
Inspection
Warm the engine.
Disconnect throttle valve switch connector and measure
the resistance between throttle valve switch terminals.
(Idle contact point)
If NG: Repair throttle valve switch.
EN - 483
~ ..
RB25DE INSPECTION
RB25DE ENGINE
Adjustment
Idle contact point touch rev (rpm): 750 - 1050
Adjust if the touch rev is not within the range above.
Disconnect throttle valve switch connector and loosen the
bolt.
Gradually increase the engine rev so idle contact point is
ON (Resistance between terminal 2 and 1 is 0 Q ) at
above engine speed. Move throttle valve switch uniT to
touch pOint and tighten the bolt. Move throttle valve
switch unit to touch paint and tighten the bolt.
Install throttle valve switch connector.
Race the engine few times and check idle rev is within
the standard value.
THROTTLE SENSOR
Disconnectthrottle sensor connector.
Measure the resistance between throttle sensor terminal 2
and 3.
Not pressed Approx 04
Pressed to half way Approx 04 - 5
Completely pressea
I
Approx.5
IF Replace throttle valve switch.
After inspection erase self diagnosis result from CONSULT.
Check code No. 43 will not display in the screen.
AAC VALVE
Inspect the resistance of AAC valve.
Resistance: Approx. 9 - 10
Plunger and switch inspection.
Spring damage inspection.
!ENG: Replace AAC valve.
FICO SOLENOID
Measure the resistance of FICO solenoid.
Resistance: Approx. 22 - 23
EN - 484
RB25DE ENGiNE
Plunger and switch inspection.
Spring damage inspection.
IF NG; Replace FICD solenoid.
AIR REGULATOR
Static characteristic inspection
Visually check the shutler opening.
"' ,-----." - -
'
Fully onen
20'C Approx. half open
Over60'C Fully closed
Dynamic characteristic inspection
Apply battery voltage to terminals and inspect for any
change with shutter opening.
The shutter will close gradually and completely
closed within 7 minutes. (area temperature
approx. 20C).
Reference: Heater resistance value: 70 - 80 g (20C)
IF NG; Replace air regulator.
INJECTOR
Inspection
Disconnect injector harness connector.
Measure the resistance of each iniector cylinder terminal
1 and 2.
i Resistance between injector tenninal 1 and
2 (each cylinder)
If NG: Replace injector.
13 - 14 g
ECCS RELAY, FUEL PUMP RELAY, RADIATOR FAN
MOTOR RELAY
Inspection
Directly apply battery voltage between terminal 1 and 2.
Inspect continuity between terminal 3 and 5.
Directly apply batterY voltage between
terminal 1 and 2
No battery voltage
IE NG: Replace relay.
Present
Not present
EN - 485
o

Plunger /
Spring
GIV

RB25DE ENGINE
IGNITION RELAY, INHIBITOR RELAY
Inspection
Directly apply battery voltage between terminal 1 and 2.
Check for continuity between terminal 3 and 4.6 and 7,
Directly apply battery voltage,
Not present Present
No battery voltage Present Not present
L-______ ______ ______ ___
,IF Replace relay,
POWER STEERING HYDRAULIC PRESSURE
INSPECTION
Inspection
Remove power steering hydraulic pressure switch
harness connector.
Check for continuity between the terminals.
Steering wheel is steered Present
,L,---------------1C--------,
I
Steering wheelis not steered Note present
IF,NG: Replace power steering hydraulic pressure switch,
SPARK PLUG
Inspection & Adjustment
Measure the gap between electric pole,
Replace or repair if out of standard range.
Standard gap (mm): 1.0 - 1.1
Simple inspection
Turn the ignition switch to ON position, tj\
Select "Fuel pump" in the "Function test" mode, I.J!)
Inspect the pulsation by holding the fuel hose with hand.
Hold the fuel filter and make sure the hose is hard
and pulsation can be felt when the fuel pump is operating.
EN - 486

, 1.1 ,-"" :"'," I r=-, 'C
I
, ,
I I
, \d
o
FUEL PUMP.
"
IS THERE A PULSATION!
EVERY 3 SECONDS WHEN:
I
THE FUEL TUBE IS HELD? II
, OR CAN YOU HEAR THE
I OPERATION NOISE OF THE i
FUEL PUMP RELAY? .......J
I PASS I YES!
Hose is hard!
Pulsation
RB25DE ENGINE
Fuel pressure inspection using the fuel
pressure meter
Releasing fuel pressure
Run the englne. @
Select "Fuel pump relay" in "Active test" mode.
Press 'STOP' to stop the engine. Crank the engine over
two or three times. (If the engine does not start. crank 3 - 4
times after removing the fuse).
Restart the engine and remove the fuel pump fuse.
After the engine stops, crank the engine 4 - 5 times to
consume the fuel in the pipe. (If the engine does not start
crank 4 - 5 times alter removing the fuse).
Caution:
The battery may become weak easily. use booster cable to
Fuel pressure meter installation
Connect the fuel pressure meter between the fuel fi Iter and
the fuel line.
Attach the fuel pump fuse.
Start the engine and check if the fuel pressure is at
standard value.
kJli ng (kg I em"
Pressure regulator vacuum hose is
disconnected (kg I cm')
Approx. 2.55
Approx 3.0
If the engine does not start, check fuel pressure 5
seconds after the ignition switch has been turned ON.
5 seconds after ignition sWItch turned to ON Approx 30
.ACTIVE TEST.
FUEL PUMP RELAY OFF
CAS-RPM {POS) 950 rpm
i
STopml
, __ ___
-
-
Fuel pump 'use
I ';Y_-f
l>el . . .'. . 1 L'RerllrNe:>
'>(1"
1/

-------r-------------, ...
I
i Fuel pressure is extremely I Pressure regulator is not working.
high i Return system IS clgged. hose bent
Fuel pressure is extremely
low
Pressure regulator is not workIng.
Fuel pump discharge defect
: F usl system clogged
EN - 487
RB250E COMPONENTS INSPECTION
RB25DE ENGINE
Fuel cut system inspection
o Select "INJ pulse" in "DATA MONITOR" mode uSing
CONSULT. Increase the engine rev to 2000rpm after
starting the engine. Check that "INJ pulse" will decrease
to 0.6 msec for a moment when the accelerator pedal is
released.
EVAPORATIVE GAS CONTROL SYSTEM INSPECTION
Check valve
CANISTER
Inspection
Fue! tanK
Fresh air
o Connect vacuum hand pump to canister throttle negative
pressure opening and make sure the vacuum pressure is
maintained.
o Apply approx. -100mmHg pressure and make sure the
manifold negative pressure opening is continued by
sucking air from the opening.
FUEL TANK VACUUM RELIEF VALVE
Inspection
o Clean the valve housing.
o If the fuel tank vacuum relief valve is normal, you will hear
sound from the valve with small resistance when the air is
sucked in through the cap.
FAIL 0
i CAS.F'PM IREF) 2000rpm
i INJ PULSE 3.1msec
START RECORDING
..

CAS.RPM (REF) 1950rpm
INJ PULSE O.6msec
L
L START RECORDING
4- Evaoorative gas
<--==::::: Purge air
Active carbon '
Fhter
o Replace the cap ASSY if the valve is closed or when
resistance is felt
i Spring valve
Valve
L-__ ... __ . __ . __
EN - 488
RB25DE ENGINE
SLOWSY GAS REDUCTION DEVICE INSPECTION
blowoy control valve
SLOWSY CONTROL VALVE INSPECTION
Inspection
Idle the engine and remove hose from blowby control valve.
Check if operation noise can be heard from the air
passage when valve is operating normally.
Check the blowby control valve flow path.
, Air is blown
Air is drawn in
BLOWSY HOSE
Inspection
. CONl;;ltTlOf..!
Air passes
No air passes
Look for any leakage from the hose and connection area.
Remove the hose and clean using the air blow. Replace
hose If there are any clogs.
EN - 489
~ Fresh air
.. Blowby gas
Blowby control valve
I
EGGS GiU INPUT/OUTPUT SIGNALS
RB26DETT ENGINE
91 CONSULT INSPECTION VALUES
(1) Data monitor
Note: The output signal is displayed as the calculation data on console unit so the correct
value will displayed even if the output circuit (harness) is inadvertently disconnected.
RB26DETT ENGINE
b..;''';'''';''
''r>:
" :'i .
f>A'J:A.MONn'OI't
.. .
' ... ' .', .;;,.;.....:'

;,,:L ..' ....;: .. ,.,
<.'N.0RMAl.. RP.EREl!ICe
.. .......n.-..icir __
.' ';";:
. '; ;',"; t .--. ',VA!'UE .: , .' .' ';;"; .:: --re- ", i : .
,., ,< ,," .,',
!
CAS RPM {Detected ang1c I
speed according to slgnats)
,
AIR FLOWMTR
i
(output 1I01t<lge)
I
AIR FLOV\j MTR {Ry :
(output voltage)
i
ENG TEMP SEN
(ergmc .temperature)
,
EXT GAS SEN
i
(Qutput voltage)
I
EXT GAS SE\I (H)
(output voltage)
i
EX'" GAS SEN
(RIC H I LEAN)
I
EX T
J LEAN)
CAR SPEED SEN
!-__ speed s.gnal)
BATTERY VOLT
7>-/ROITLE SEN
(output voltage)
I
I
"I"aChOrnelV set
Englf1e rurvl*ng
Alter warming up engine
idling (N range. AIC OFF)
After -warming up er"K;pne
After eannmg 2000rprn INith no
up erglf)' load
V\l'riiie dovlrq or wi1n drtve wheels;
. tUfnlng
ignition S\N1lch ON
Engu'l6 stopped
";here must oe no abnOfma'
Crank: angle sensor system
change In speed
Aoprox Or
-
l.2V C2000rpm:
with no load 1 0 - 1 7v'!
Air flow meIer system
"'"'"
2 air flow meter value
can vary 0 GAV
Above approx lO"C
Errglne temperature sepSQr
I
system
Changes 0 - O,3V
!
;tinct C 6- 1V
; Exhaust gas sensor system
I system llur leaf< or aIr
!
' lintake
; RICH. LEAN repeats 5 times' Injector system
! Of more If') 10 seconds i
I
i
Silou!d genEv1311y conform to
:vel1icle s led senser s rem
spoedmete" display
p
1 - MV
Isat1erv
,ECGS control Ur1It pO\l'Jer sys,em
SWITch
ON Throttle f-Jlly dosed 0,5 TlYonle sensor adjustrnenl
Engw!e --,------"'------,---::--------l, Throttle sensor syslerl
stoooed ThrotHe fully open 4 0
:=----+--=
INTrA 1EMP SEN
('ntakternperulure sensor owtput)
After warrr<ng IIp engine Ir'rt<:!",femperature sensor system
t
I
idling iAu flow meter system I
After wenning (/'i range Ate OFF) r--:--7''''':-:,--jlntake system a r leaks or air
INJ PULSE
INJ PULSE (R) ,up engJr08 ' 2000rpm VVlth no 'eoftf! .nput, l'
(injeclion pulse V0dlrn ,oad .!nput $191101 system (entire)
I
IdlirY,)
,N ranqe fi,iG OFF} I
iGN 'IMING After warrnmg p:.:.:.:::.""..:;.::=..::;:..:..'--t-", "_-_'C-:::-::-::::::::"",-J AIr flow rreler systeM
, up engH1e 2000rpm \filth no Advance gf!ater than 10"
load aflgle compared Idle
position
AAC VALVE
AIF ALPHA
(tHrfuol railo feednacJ(
conecllo(1 coeffiCtent)
I
SJGf\,AL
t=
IDLE sw
I
AIR CONO $iG
I
NEUTRALSW
r---
I
PW!8T SIGNAL
! OLE JUDGEMENT
PUMP RELAY
i
AIR CON RELAY
WiG CONT SN
POWER VOLTAGE
PULSE
,
.
,
! After wa(rt"" ng!
idling
I Approx 15 35':'cI"
!
':N range Ale OFF)
IA.S adjustment
I !
I
I
AAC valve system up
2000rpm 'Mlh no
Approx. 30 - 50%
I
'cad
lAir 'flow meter system
I
Arter walffl,ng LIp erl\;W1e
i
IflJcctor system
2:JOOrpm With no load
!
75 - 125".* ,Canister (plXge) Inspe!(;.iior)
; Intake svstem air leal( or air
!suctwn'
' "START" 0'
--1
19f1ltlOn sWltch-, --.. Starter SW syslem
ON I
"OFF" OFF
I
Engine-
T'ol"Ottle fuily c,osec ON
Throttle sensor system
I
Throttle fulfy open OFF
I
,
Ale S\NO .... ON
I
I
Ale SVV OFF OFF
Air conditioner SW system
I
Nor Prange ON
I i
'''e
I
Neutrai SW system
NotNorP OFF
.-----.J
I
Steenng ON
Power sleerirg SW system
i
I
r"J!?Ulral
VVhen Idle , ON
TIYottle sensor
Other than ',-..her< ,ele OFF
IGN SWON i
Stop OFF
\,.-Vhen rev
I
ON
Fue! pump syste:n
Ale ON
I
ON

,
Ale Of-F OFF Ai, COno::;lltH)ner relay s'j$tem
Acc.e! 10 sec j
- ..
Ale Or-..) OFF
ON
:----O::::Fc::F----j
...L--:--__
D'SCFIY \)U'0."?' vpi'!age prow rYleasurernerrt value
:)"':;)'dY Dulse rneasuresurement value
EN .. 490
EGCS C/U INPUT/OUTPUT SIGNALS
(2) Active test
, ,
" " ",', '" ACTIVE TEST ,

SET ITEM,
CONort!Olf, ACTIVE TEST DESCRIPTION "(
",'"

," ,
" .' ,,:, ' .,: ... ,'" ,".' . :,,'
Perform following Inspections to checK If
problem is solved.
Problem occurence' Set temperature nigh or low
Elirninat"'"
ENGINE Engine temperature sensor system
TEMPERATURE
condition :G..au.tl..:lo. Do not set extreme values
Injector system
as this car) cause snark P:Jg bUrning
Air flow meter exhaust gas sensor system
Not eljminated
Other Item msoectop
Perform bi!oWIf1g ,nsoectlOns t:J check if
problem ,$ solved.
EijOOIoatw
Set the airfuel ratio nch or lean. 'Exh ,t "'.,. .
FUEL INJECTION
occurence GaJJ!mn:
00 rot set extreme values as' _ aus gas .,. .... :1S0T system
condition ' thiS may damage or ca:alytic
Air flow meter. eng:ne tempera:ure
system
ocnverter,
l'ljector S;lstem
No! eltmjnated
Other Item irJspector
Perform fO!lo\W19 !nspecti<ms to check If
Delay ignition timing
IS SOlved
Fhmnate
IGNmON TIMING
Problem OCCurence Do not set extrer'l values as
: 19nition timing adjustment ,
cOndition this may damage engine or catalyt:c
i DetonatIon sersor sys'{em
i
converter
I Not elloo,oater<
Oirle
r
,tem inspection
Increase control du!)' ratio nw engine
If the -conditJor. descnbed on left can ret be i AAC VALVE
Engine rUr'!nir.g
speed shOUld .ncrease
OPENING Decrease control dUty reatio The venfied. ccheck AAe vdlve system
engi!1e speed should decrease
Set the Me vale open to stop t'le
i
speCified inte ..... ior operatIOn and the
POWER mjector speed can be d'splayed at mis EI mioate
BLALANCE
i
Eng I ne rU{lni n9
time Injector system

Do not perform thiS operation
while driVlng
Turr'! igmtio1 SWitch ON. OFF ana ON
so pump operation makes a sound
If the coneitlon descnbed on left can 'lot be
FUEL PUMP
!
ignItion switch ON The fuel pressure will nse,
venfied, check relay system 07 fuel pump
RELAY EngIne stoO'
=
Do no! pertorm this operatIon
and fuel pump system
i
except urlder conditIons described on
lelt
!
SELFLEARNING i
The air-fuel rabo feedback correction coefficu,mt learr;:ng factor is cleared
CONT !
EN - 491
i
EGGS G U INPUT OUTPUT SIGNALS
RB26DETI ENGINE
9-2 OSCILLOSCOPE & CIRCUIT TESTER INSPECTION VALUE (RB26DETI ENGINE)
.--.----'--'----1
Terminal
No.
1
2
3
11
12
13
4
7
9
16
18
i
i
I
Signal name I
Power tranSistor
conlrol signal
AAC V'illve control
Signal
Engine speed
signal for
tachometer
:
!
:
i
Alf conditioner relay:
ECGS relay
Circuit
SparkOh.lg
PWR

.,
fees control I.lf\i!
,."
r fees control umt i
Fool pump relav IgmMn
Fuel pump relay

AI idle
Standard l Memo
0.2 - 0.3 V
. .
6
4 ;-- , j---I-'
I -r- i -.:
Cold: 6 - 7V
Warm: 8 - 10V
Approx. 1 V
Air cordition OFF:
Battery voltage
Air conditioner ON:
ilpprox.1 V
Appro . 1V
(Ignition switch OFF:
Battery voltage)
OV
AI Appro . 2,500 rpm
Standard
Approx, O.4V
Approx. 5V
Approx 2.4V
Air condition OFF
Battery voltage
Air conditioner ON:
Approx. 1V
Appro.,OV
OV
Memo,
+
i - -t-,
'--__ -'1 _______ -11_, ,_c_c_s",_,o_n..'.._ffi_'_ 00_"_ ___ 1 ________ -LI ___ ______ ....L __ .J
- 492
EGGS G!U INPUT/OUTPUT SIGNALS
RS26DETT ENGINE
RB260ETT ENGINE
I
11 21 ,1 , 11 8 9/10/ C
2j 2Z ,4f,,f ,alll,.! 2913011 411 ''l4;l....l''I..,f''I .. r'9I5!ll
19 18 d 19120:
,i "I 341 3' 3. "I ",I 391 ,.11 511 52 50' s4 5' sa "I,,!,. 601
CTxl
. elK
I
I
I
IGNI
Terminal
At Idle At Approx. 2,500 rpm
Signal name Circuit
No.
1
Standard Memo Standard Memo
PWR 5T SW

Power steeling ON: Power steenng ON:
Power steerlng
l_.
OV OV
,
19
switch signal
I J
Power steering OFF Power steenng OFF I
,
5V 5V
,
I
Qiagnows connector
(['iLL
21 Receive (control
..
10V 10V
(RX) ! unit daia reception)
I
I
I
!
,
E'CCS control Utllt
I
,
I
Diagnosis
r
,"
22
Transmit (data

transmission from OV OV
!
(TX)
,
control unit)
I
!
I
!
I
I
ECCS conirQll,mit
I
!

,
23 Detonation sensor
I
24
!
signa!
.Ih
Approx.03V Approx.O.3V
I r ECCS control [Bllt \
r=-1
'Nastegate valve

C{)lItro V
25 control solenoid
v
Battery vottage Approx.OV
!
control Signal
I I
fees ;.:omrQi unit
,

!
Airflowrt'l(li't;t
JI, S C 0 -,F"
Air flow meter (rear)
IA
Approx. 1.5
27 Intake air quantity Approx. 1V
Signal
i
V
,
I
ECCS co",,,, ynil I I
,
i
EN - 493
EGGS GLJ I'<PUT OUTPUT SIGNALS
RB26DETI ENGINE
iRB260ETT ENGINE
1011 1001 1051 t01'1 1 2':L 4, 21 2 2324 2 2a 27 28' 29 301 41: 42
1 11 11V112113111 11, 1 13k 14
I CHKi IGNI
,
-
. elK
I
i
i
I
I
I
: Tenninal
No.
Signal name
i
Circuit
Engine lemp sensor

(AFM ground)
28
Engine temperature
r
sensor signal ,
!
! Eees contrQI
,
i

<+'l Exhaust gas
Exhaust gas sensor

29
signal (front)
l ,. _
I
fees control Illit I
I
Ofagnosi$
COflTn
Clock
l
31
(synchronization

(ClK)
signal)
,
: I

,
!
Exhaust gas
temperature
waminglamp
32
Motor & check

"'N
,
lamp (red lamp)
I
Eees control unl!
! i
35
36
Air flow meter
(Front) (Intake air
quantity signal)
Intake air
temperature sensor i
Signal
c;:,e",."," +
tees control unit
3- 32 3
At idle
Standard
Engine temperature
aoc: Appro" 1V
Engine temperature
20'C: Appro .. 3V
Approx. 0 - 1 V
OV
Lamp not lit:
Power vottage
lamp IS lit: OV
Approx.1V
Cold. Approxt.5V
INarm: Approx O.8V I
EN - 494
Memo
i
!
I
i
At Approx. 2,500 rpm
Standard
Engine temperature
80
e
C. Appro . 1V
Engine temperature
20
c
C: Appro . 3V
Deflects between
approx. 0 - 1V
OV
Lamp not lit:
Power vottage
Lamp is lit: OV
Appro . 1.5V
Cold: Approx. 15V
INanm' Approx. O.8V
Memo
!
i
i
I
EGGS G/U INPUT/OUTPUT SIGNALS
R826DETI ENGINE
;RB26DETT ENGINE
1611021103 j 1 2 3141 5: til a' 9110" 2 2 .2 241 22728 2930 41 4 4 45 414849 SO
: 11 121131 Hi 1dle 1,' iii 1 zd," 1-"-31l-,",'l-",t",'t-','t-',::r
37
'+'",'1-""9
r
.:::,If",'l,,-',.+,'1,-','1-','+,.:':;';,:':,l',"'.l',".+",9
Terminal
No.
38
41
51
42
52
43
44
46
Signal name
Throttle sensor
signal
Crank angle sensor
1() signal
Ignitton switch
(START signal)
Neutral sWitch
signal
Air conditioner
sWltcn Signal
Circuit
Throttle itensO(
ECCS control unit
Eees c<mtrol unlt
Air conditk,lnfl'r SW

0;' '"
At idle
Standard
Approx. O.SV
OV
{!gnltion switch
"START' Battery
vottage)
No' Prange: OV
Other than N or P
range 4 - 5V
Air condltiOr'tE:r OFF
Battery vOltage
Air conditioner ON:
OV
EN - 495
Memo
At Approx. 2.500 rpm
Standard
0.5 - 4
(Voltage Increases If
accelerator pedal is
pressed)
03 - O.7V
2 -:lV
OV
N or Prange: OV
Other than N or P
range: 4 - 5V
Air conditioner OFF:
Battery voltage
Air conditioner ON:
OV
! Memo:
ECCS CiU INPUT/OUTPUT SIGNALS
RB26DETT ENGINE
iRB26DETT ENGINE
a: '.27!28,29 q ! "I .,j471 .. 14S1,,1
21 31 41 E4 7j 81 9! 10
13!14!1!! ,-" 18 19120 . ",,,,,,1,. ""II ,.j 571 ,,1,.,.,,1

RX i TX 1
- : CLKI
I
I
I CHKI
IGNI
1
Terminal I
At idle At Appro . 2,500 rpm
.
No. .
Signal name Circuit
Memo: Standard Memo Standard
I
I
Throtlle
; sensor
I
48
Throttle sensor
l/0+
5V 5V
I
(Power supply) !
i
ECCS tOr'ltrol umt I .
i
!

Control unit power
I
49
supply
.
r.-- -,
I
ECCS control ,,!'Ii! !
i
I
D range (or t st) With D range (or 1st) Wlth

rear wheels jacked rear wheels jacked
VeflH::r:speedS!m!!Ol" "'
up: 0.5 - 1.5V up: 0.5 - 1.5V
Vehicle speed
The value actually The value actually
53
ir
deflects between OV deflects between OV
sensor signal
and 5V. However, It and 5V However. it
; L ECCS control unit
appears to deflect appears to deflect
around tV. according around 1 V. according
.
to vehicle speed . to vahicle Speed
Oil

Throttle valva switch

54

Approx. lOV
.
Approx. 10V
I
i
(idle contact point)
i
I
Eees control unit
i
.
i

I

Exhaust gas sensor
N or Prange OV N or Prange: OV
55 Other \han N or P Other than N or P
i
signal (Rear)
range I 4 - 5V range: 4 - 5V
.
I
Eees unit -1
I
4WAS
r+
Approx. 0.5 - 4V
I
56
i
Throttle sensor .
Approx. 0 5V
(Voltage Increases
output signal
i
' as accelerator pedal.
LEecs "011 I I
is pressed)
!
I
EN - 496
EGGS GIU INPUT/OUTPUT SIGNALS
RB26DETT ENGINE
!RB260ETT ENGINE
10 102 loll 105106 HII' 1 1 2' 3 4' Ijj 8 i 9 11) C I 21 2 ' 23 24 2
11 1 l' 14! 1 1 111 1 19 20: '3 3;d 3: 34 3 3
21 28 29 30 41 42
31 38 39' 40 51 S2I 5
45
S S
4148 4S'50
51585960'
Terminal I
No. ;
57
!
Signal name !
Throttle valve sWltch,
(Power supply) ,
Injector control
signal

At idle :
Circuit
Standard I Memo
Throttle valve SW
Battery vollage
InJ$ctOr
, "_I r..\
I / ~ ~
101
103
105
110
112
114
; ECCS control tlnit i
, L-.. __ -.--J
104
106
Fuel pump terminal
vortage control
I Signal (FPCM 1)
I
Fuel pump termmal
voltage control
sIgnal (FPCM 2)
r ruel pump :
~ COflirol ,
Idling (afier warming.
engine): OV '
h ~ ~
I, '
fees control uml
L .. ECCS 1;0011'01 unit \
I
EN - 497
At Appro . 2,500 rpm
Standard
Battery voltage
During mJOdle load:
4V
Duong middle load:
OV
Memo
ECCS C U INPuT/OUTPUT SIGNALS
RB26DETT ENGINE
9-3 ECCS CONTROL UNIT OPERATION CAUTIONS
(1) Control unit equipment
Never install a control unit that is not specified for your vehicle
Do not apply excessive force to the installation bracket.
(2) Connector removal and installation
When removing and installing connectors, do not bend or apply unnecessary force and
observe following points:
1. Connector removal
Turn ignition switch OFF and ECCS relay OFF before removing connectors,
Hold connector firmly to disconnect without applying force to harness,
Do not use a screwdriver or similar tool to loosen the connector lock,
2. Connector installation
Turn ignition switch OFF.
Make sure pins are not bent or control unit connector and then connect securely.
Tighten bolts securely until injector surface reaches orange colour indicator of
connector and surface is even.
(3) Control unit power
Never make a reverse connection to the battery.
Use battery voltage in 10- 16V range.
(4) Idle speed adjustment knob
Do not turn past lock position.
Do not turn adjustment knob when ambient temperature lower than 0.
(5) Water and oil
Care must be taken not to allow rain drops or water to wet the control unit.
Care must be taken that condensation does not form due to sudden increase in
temperature. If there is any moisture, dry control unit adequately before installing in the
vehicle.
Make sure no oil adheres to connectors.
Do not clean the control unit using volatile solvent cleaners.
(6) Dropping and impact
Do not drop the control unit or subject it to strong impact.
Do not use upper and lower covers for the control unit which are dented.
(7) Control unit screws and cover
Do not remove the upper and lower covers from the control unit.
Do not turn the screws in the control unit main body.
EN - 498
RB20E I DE / DET ENGINE
9. ECCS CONTROL UNIT INPUT J OUTPUT SIGNALS
9-1 CONSULT INSPECTION VALUES
(1) Data monitor
value will displayed even if the output circuit (harness) is inadvertently disconnected,
............... '.':' ......... 1 . 'i' > :. ....EDATAMClHrmR ...... : ...... ': .......
MO .. 1iIIT. ORWG .. " .:IiTE. MS.. ..... .' .. ' ... ON . .. .. !'IOR .... MA.I.REFE. RENCE
.. .... . ",...,: ... L', .. C DlTlON :, , . :'. VALUE.
PROSLEMINSPECTKmI
ITEM
CAS RP1\A (Detected angle
speed accordIng to signa,s)
AIR: FLOW MTR
(output voltagei
ENG TEMP SEN
(engine lemperatwre)
i
Tacho'l1eter set
Engir.e fUnrllng
Alter \I'/8fmlf"lg up englO8
ldhrg (N range. Ale OFFl
There ;rllJS( be no abnorma: I
chat1ge ;n speeC!
Approx. D B - " 5V
Crank. ang sensor
Air Row syslerr;
Above aporox_
I Engine temperable sensor
system
EXT GAS SEN
1-_-,',:::o::ut:':Pe::
L
':,:' VO:::;'''':;:9,"e:c'__ .Ji After \'ifarmmg 2000rprn v,.1!r no
load
C113,'1ges betvveen 0 - 0 3V and: ExhaliSl gas sensor system
06- 1\/ Intake system air leak Or "lit!
Intake
inJecto" system
I
:::X r GAS SEN up englno
(RICd I LE.AI\o) i
RICH, LEAN repeats 5 times or
more In 1 0 seconds
CAR SPEEC SEN
(vehicle speed signal"
8ATIERYVOLT
TH"<OTI\'E SEN
(mIl:plJt voltage)
!l\JJ PULSE
(mJeelio'1 pulse width)
t:iO.IE: 1/16 dlsp'ayfor
R320E
IGN TIMING
AAC VALVE
A/F ALPHA
(air-fuel ratio feedb.ack
correction coeffclent)
START SIG!\lAL
IDLE SIN
VVhllc drivlr"q or WIth dnve whec!S
i t.JmH'lg
Igniton sWItch
Engwe swppea
Throttle f.j!!Y closed
Igntion swllch
ON
Engll'1'
: stopped ThrottlE- fu'iy open i
I
' kl11ng (N range, Me
I After warming /-' __ --.::O::,F:..F:..' __ -i
i liP engltle i 2000:pm With no -:
load
ShCI.,.Id generally conform to
specmeter display
11 14V
0.5
40
I
2 3 msec
Reference r
2 - 3 rnsec
Idling (N range. Ale
After warming __ __ -I ___ __ -4
up eng:ne 2000rpm with no
loao.
Advance greater :han 10" angle
compared to idle position
Idling {N range, Ale I Aporox 20.,. A.O"'/"
O
F:;:;'.
After warming 1--__ .:::::.-.:. __ -1 __________ -..,
up eng'M 2000rpm With no 1-
:oad
Ailel warming liP engi'1e
2000:pm WIth no load
Appro);, 30 - 50%
75 - 125"/',
"START' ON
! SWitch --..::...:..:...::..---1-----..::....::..------;
ON "OFF" OFF
Engme Throttle fully closed ON
stopped
Throttle fully open OFF
Vehicle speed sensor system
Battery
ECCS control unlj power
systeM
Throttle sensor adjustment !
Thro!tle sensor system
Air 110w meter system
IfItake system air leaks or air
SlJctlOn {entlrl':; I'1Pl1!)
I"1Put signal syslem {entire)
Alr flow meter system
lAS ad:lIstrnent
AAC valve system
Air flow meler sysfem !
Injector system ;
Canister {pUfge} Inspection
Intake system a;r leak or air
suctmn
Starter SW system
TI'rottle sensor system
I
Ale SWON
I--____ A_'_R_C_O __ N_D_S_._G ____
ON
Ale S\NOFF OFF
Air co"ldjt!oner S'oN system
NEUTRAL SW
No! N or P
Neutral SW sysierl Idle
N oc P farge ON
OFF
Steenng ON i'
Power steenng SW system
Steerirg ne"lra! OFF
PW;ST SIGNAL
FUEL PUMP RE:..AV I' IGN SW ON '-___ S:.:'.:,o:.p __ -<'-____ O_"F ____ -i
rev ON
Fvel pump system
Ale ON ON
i
AIR CONOITIONER RELAY ____ Air condltlone' relay system
I When aeeel 5
, sec Interval
Ale 01\ OFF
EN - 499
i
ECCS C U INPUT OUTPUT SIGNALS
RB20E! DE! DET ENGINE
(2) Active test
,
", ,1.' ",,;:::<AC1"lIiETJ;!S'l' , ," ' "
.....
::SETrrat"
'., ,
JUDGEMENT
.' ".
,"
:PerfcrrY' fo,lowHig Inspections to check jf
!prObJen1 :s solved_
jEllmlnate
ENGINE
Set engine tempera:ure high or low '
ProbtefY' occu;ence ' E,,:glne :ernoerature sensor syste'1".
TEMPERATURE
ncft Cauti.on:. Do not set extreme va:ues as II
CO_ I lor ; nJector sy'Stem
thiS can cause spark plug bGmmg
!Alf 'low f'1!ler. exhaust gas sensor system
,
elirmnaled-
i
! O:her Item 1I1spect,or:
'Pertorm following Inspections to check if
probiem IS solved,
Set the air-fuel ratio rich or lean,
E!immatg'
ProbleM Caufuln. 00 r:at set extreme values as
Exhaust gas sensor system
FUEL INJECTION
cOl)dition thiS may damage engl'ie or catalytic
Ar flow meter, engine temperature sensor
ocnverter.
,systeM
i
!
i injector syste'Y1
: Not eliOJloa1ed
I I
Other Item .nspection
I
i
Perform fe!lowing inspections to check if
problem IS solved
i
iDelay Ignition timing.
ElimlOate'
IGNrrlON TIMING
Problem occurence:Ca.i!tmt Do not set extreme vall.''s as
gnition nmmg adjustment
I
condition IthlS may damage engine or catalytic
I Detonation ser:so
r
system
!

i
,
IOther inspection
I
i
i:'ncrease contro' duty ratio
The engjne
I
AAe VALVE
Engine 'Llnnmg
,speed shot;;d increase ; If the conditon descnbed or !eft can not be
!
OPENING i Decreas.e control duty reaM. The venfied, ccheck AAe valve syster-;
: engine speed should decrease
ITu;n Igmton ON, OFF and ON
so oump operation "'nakes a sourd
If the condition described on left can nOT be
!
FUEL PUMP ignition SWitch ON , The fuel pressure WIll nse
verified. cneck relay system of fuel pump
RELAY Engine stop
Do not perform this operation
and fuel pump system
except under conditions descnbed on
I
left
I
SELFLEARNING
I
CaNT
The 'abo feedback correction coeffiCient ieammg factor 1$ cleared
EN500
RB20E ENGINE
92 OSCILLOSCOPE & CIRCUIT TESTER INSPECTION VALUE (RB20E ENGINE)
Terminal
No.
3
5
6
7
9
10
r_ _i
'iiii" ,_
:1011 1 o.i1 1 1 1 :3 38:1 4 4 I :2 3 4 5 6 7 a !} 10 21 22 2 24':2 26 211 2
111 1 1 11 ,431, 454 4 1'1 f2 1 1 15 161 17 18 HI ;ilO: : 2 30 31 32:3 J4 35::3
Signal name
,Air flow meter
intake air quantity
signal
Engine temperature:
sensor signal I
Exhaust gas sensor
signal
Throttle sensor
signal (Input)
Crank angle sensor
t20' signal
At idle
Circuit
Standard
.. _ .. _-..
I A!ffiowmelor
LtiEl.'4"l .
I

Approx. 1V
I ECCS
..
Engine temp sen

: .. - +
Engine temperature
(AFM q10ulld

ao'c: Approx tV
1/'
Engine temperature
y--.
20'C Approx.3V
iECCScontrol unit :
L--... ___ ..
Approx 0 - tV
Approx 05V
ECCS control unll
EN - 501
Memo
Standard
AppfOX. 1.5V
Engine temperature
soc. Approx tV
Engine temoerature
20"C. Approx 3V
Deflects between
0- Approx 1V
0.5 - tV
(Battery vonage Will
incerase when
acceleration pedal is
pressed)
(V):"-
"
4
2
o
03 - O.7V
23V
Memo:
,
,
,
I
RB20E ENGINE
jRB20E ENGINE
eBiNT I ... IC"M
Tanninal
At idle
No.
Signal name Circuit
Standard
Exhawrttemp
wamI!'lglaml'
Lamp not lit:
13
Monitor & check Power vottage
i
lamp (red lamp)
: eccs control unit ,
Lamp is lit:

ApproK OV
To AfT control unit
Intake air quantity

15 output signal
i
Approx. IV
I
(To AIT CIU)
i
I
I
I

Detonation sensor
L
!
16
signal

Approx.4V
,
i
; ECcs control unit
l __ ___
010werM
Throttle opening
17
I)-

Approx.O.SV
output signal
i
;' L fees control unit I
D range (or 1st) with

rear wheels jacked
up: 0.5 - 1.5V
Ve tucle speed
The value actually
21
sensor signal
!
,deflects between 0
and 5V. However. it

appears to deflect
i fees control unit
around 1 V accordmg
: to vehicle speed.

22
Throttle valve switch r Thmt1; sw I
Approx. tOV
(Idle contact POint)
. v
"
i
EN - 502
Memo
,
,
i
i
,2122:1 24;( 2627:2
2 30; 31 32: 3 34 35 3
Standard
,
Memo
Lamp not ht:
Power vottage
Lamp is lit:
Approx. OV
Approx 1.5V
Approx 4V
,
i
05 -IV
(Battery vottage will
incerase when
acceleration pedal is
pressed) ,
i
D range (or 1st) with
rear wheels jacked
up 0.5 - 1.5V
The value actually
deftects between 0
and 5V However, it
,
appears to deflect
i
:around 1V according
! to vehicle speed.
: OV when accelerator
i is pressed
I
RB20E ENGINE
Terminal
No.
23
24
25
26
27
29
Signal name
Ignition sWltch
(START signal)
Neutral switch
sIgna!
IgnrtJon sWItch
(ON signall
Throttle sensor
signal
(Power supply)
Control unit pov.;er
supply
Air conditioner
sWltch signal
EGGS GIU INPUT/OUTPUT SIGNALS
RB20E
riiii1 _
37383944412345678912.122224226272
tl 454 1151 i1181920, 3U31:32334353
Circuil
STAAT sw

?
+
Eees controlunil
,,= __ Neulra! sw
(MiT)
lAin
v
ECCS control unit
ECCSr",ay

i i

ECCS control umt ,
- ..
AI idle
Standard
OV
(ignition switch at
START Power
vonage)
N or Prange: OV
Other than N or P
range: Approx. 6V
Power vottage
5V
Power voltage
Power voltage
Air condItioner ON:
Approx.OV I
I
EN - 503
, Memo'
I
AI Approx. 2,500 rpm
Standard
OV
N or Prange OV
Other than N or P
range Approx. 6V
P ower voltage
5V
Power voltage
Power voltage
Air conditioner ON:
Approx.OV
Memo
I
I
i
i
i
ECCS C/U INPUT/OUTPUT SIGNALS
RB20E ENGINE
RB20E ENGINE
- -
641 I 1 3 4"
11 1112,1311141511e
12345:6'7$91
1112 1 15 191
Terminal
No.
32
37
38
39
40
43
i
!
i
,
Signal name
(Power supply)
Power transistor
control sIgnal
Power steering
switch signal
Tachometer signal
(Ignition cOil pnmary
sIgnal detection :
!
ECCS relay
! Tachometer engine
- rev sjgnal '
Circuit
Throtffe valve SW

[

__ /-7\.......
/J .. /" '.
ECCS ;onlrol unJ
__ ---l
!GNCQiI
.... ..
..
Distributor - - -. -

I
.. --,
ECCS control unit
.-.. --.
flower steenng sw

: - +
ECCS conlr'(ll unit i
At idle
1----
Standard
,
i
,
r Powe vortage
0.2 - O.3V
,VI

4
2
0
,
I
,
Power steenng ON:
OV
Powr steenng OFF:
Approx. 5V
Power vortage

- - i I
.c..I...:
Approx.1V
(ignition switch OFF
Power voltage)
EN504
Memo Standard Memo
Power voltage
Approx.1V
(Vi
, ... ..:..'
:ririJj
o Ol DG.
.. .- .
.
. . . ""'.
!
..
- -----... ---
Power steenng ON
OV
Powr steering OFF:
!
Approx. 5V
Approx 10V
OV
Approx 3V
o
I ,i
RB20E ENGINE
RB20E ENGINE
10 1 1031041 1 101;
10911 1 12 WIt 11511,
II
I
i Terminal I
No.
,
44
45
46
47
101
103
105
110
112
114
104
Signal name
Engine AlT total
control input signal
(OT1)
Engine AIT total
control inPut s<gnal
(DT2)
Engine AlT total
control output
signal (DT3)
Injector control
signal
Fuel pump relay
Circuit
Tachome!er

I I I
,---AITcon!rm
ur'lit
: I ECCS control l.Iflit I
Injector

I ECCS ... .onfr(liunit I
-
r-,--rl-=I-r...,-,
1 .( 3 <1 5 6: 7 8 9 1 21 22 23 Z4 25:26 27 2'8
11 12 1 1415 1 17 18 19 2()1 29 32 33'34 35 36
At idle
Standard
Approx. 10V
Air conditioner OFF
Power voltage
Air conoitioner ON
OV
OV
ov
, Memo
I
Standard
Approx 10V
jVj------
: ... ....... .

;:;;:_. ... !
! i
Air condlnoner OFF
Power
Air Condlt,oner
OV
OV
ov
I
Memo
EN - 505
ECCS CU it, PUT:OUTPUT SIGNALS
RB20E ENGINE
IRB20E ENGINE
------.----------------------
Terminal
No.
113
Signal name
AAC valve control
signal
Circuit
At idle At Appro . 2,500 rpm
Standard Standard Memo
EN - 506
ECCS C!U INPUT/OUTPUT SIGNALS
RB20DE! DET ENGINE
92 OSCilLOSCOPE & CIRCUIT TESTER INSPECTION VALUE (RB20DE I DET ENGINE)
Il
\1O"ooI,o:i'O<lol,O<j101 HJjJ 1\" ,: 4i 5i .' 71.: ,1, 241 25; 26; :ni 28129 301141' 43\ 441451 46[47148! 49j501
11[ 12113i 111' 17i ,,12 3, 3a 34j 35i 56! 37j 381 :;9; 151 j 521 53, 54) 55! 56
1
57 i 58! 591 OOJ

R:! ;:KI
I i
I
CHj IGN!
i
,
Terminal:
I
At idle AI Approx, 2.500 rpm
No,
Signal name Circuit
Standard Memo I
Standard Memo
Fool pump relay
19nitionSW

18 Fuel pump relay OV OV
!
I
I './"" ..... '*
1/ ",;;]
!

:
[
POwel' steering SW
Power steering ON:
Power steefing ON:
OV
19
Power steenng

OV
Power steerlng OF F,
SWItch sIgna I Power steering OFF
5V
I
,
i 5V
!
:
""-
!
_ ECCS c(!ntro:i umt i
:
r---..
,
:

Approx 4V
,
Approx.4V
24 signal
v =i }"::'T'l
m--"JL.m_'_
i i
sees control unit
I
i
!
-,--,-
Air floW metcr
.:TIillT
mm
,
, 5 .. ) ;':':.-.J
Air flow meter :
27 (Intake air quantity ,
i...------!
,
Approx, 1V , Approx. 15V
,
signal)
'-' ,
m "
!
,

, ECCS control 1
__ .---.J ,

I (AFM groU:dl
Engrne temperature Engine temperature
28
Engine temperature
!

80'C Approx.1V aoc: Approx. 1 V
sensor signal Engine temperature Engme temperature

20'C Approx,3V 20'Ci Approx, 3V
,
Eees control unil '
.. --.. .:
i
+
(!J IGN O,sensor
29
Exhaust gas sensor

Approx,lV
deflect betv'leen
signal o - approx, lV
I
0001'.' "M I I
I
[
I i
EN507
i
RB200E I OET ENGINE
RB20DE I DET ENGINE
Tennina"
No.
t
32
i
34
35
36
38
40
r
CHkllGNi
i I
.--'---'------'.
Signal name Circuit
,
Exhaust temperarure
waminglamp
Monitor & check

lamp (red lamp)
__ AiT control
, unll
Engine (ArT) total

control input signal
(OT1)
i ECCS "otrol
,
_WTconlrol
unit
Engine (ArT) total
I
control output signal
(OT3) ,
L;cs 00","' un:]
i
AIT oon"o'
<,Ifllt
Engine (ArT) total
cantrot output signal
i
i
!

(DT2)
" 'i
i
: ECCS conlrclunil _J
Throttle sensor
signal

tees control unit
To AJT {)ormOI umt
2. 22 2 ;1 j 2S ;l6i 21 28 3 41'; 44.45146 47,48 49 50
:$ 3 35! 36j 37 JS 4 $1 53 5,u 55: 56 57' 5&! 59 Ii
At idle
Standard Memo
Lamp not lit:
Power volatge
Lamp lit
OV
Approx. 10V
:
i
Approx.OV
i
Approx 10V
!
Approx. O.5V
Standard
Lamp not lit:
Power volatge
Lamp lit:
OV
Approx.l0V
Approx.OV
Approx. 10V
0.5 - 4V (Voltage
increases if
pressed)
Approx. 1.5V
: Memo
:
i
,i
,
,
EN - 508
!
!
RB20DE ! DET ENGINE
RB20DE I DET ENGINE

L'='.:c' :L'c:'.c"c:':L' 'C:'''-'c:''''''.::..c.'2' 1.
1
;.:',-1 ;.:",-1 :.:t3',LI.;":>...:,O:!..!.,"",.;""n.;,1O,,,,;,'S:;'.!':L" __ ,..L;3e.L3::<L':;L''''-':::'''': "'",,-":::',-' :::"LC'l.::",,:'C.'LI 5::153! 56,57
1
55,59,6
Terminal,
No.
41
42
43
44
46
48
Signal name
Crank angle sensor
120() signa!
Crank angle sensor
1" Signal
Ignition sv.ntch
(START signal)
Neutral s"""tch
signal
Air conditioner
switcn signal
Throttle sensor
(Power supply)
Circuit
ECCS control unit'

fees centro! unil 1
___ .. --l
SlAR1 SW

I
(MIT) sw

L .. __ I
ECCS control unit

At idle
Standard
0.3 - 0.7
2-3V
1 JUl JUiJlJuu1J1J
OV
(Ignition sWitch in
'STAHT" Power
voaage)
Nor Prange: OV
Ot/1er than N or P
range: 4 - 5V
Power voltage
Air conditioner ON:
OV
5V
EN509
Memo
Standard Memo:
0.3 - 0.7

4
,
o
IV)

4
,
o
2 - 3V
ov
(ignition switch in
"START' Powel
voltage)
Nor Prange. OV
Other than N or P
range: 4 - 5V
Air condihoner OFF:
Power voltage
Air conditioner ON:
OV
5V
i
I
I
RB20DE I DET ENGIN E
RB20DE f DET ENGINE
9 ,
" 2 '.
212 2: :1 25 ?6,27 26; 3 411 4 4 44;45 48147 46,49 50
M U '

RX I TX'
ClKI
I I
I IGN!
Terminall
No. I
49
53
54
56
i
Signal name
Control unit power ;
supply
Vehicle speed
sensor signal
Throttle opening
output signal
i
57
: Throttle valve switch
101
103
105
110
112
116
,
I
i
(Power supply)
I
I
Injector control
i
signal
Circuit
, GJ 1
I Vehicle speed sensor co
,

lr
Ie Aff control umt
,C
ECCS e-onlrol IIni!
Throttle valWl SW
I [ r"""': A'T
.! C/U

L ___ .---l

--..
I
--8"l
,
"-

I
At idle
Standard
Power vottage
D range (or 1 st) WIth
rear wheels jacked
up 0.5-1.5V
The value actually
deflects between OV
and 5V. However, it
appears to deftect .
'around IV, according I
I to vehicle speed '
Approx, 10V
Approx. O. 5V
I
Power voltage
!
Aifilost power voltage
(V,'-

-
.,j--
..
x.r ""'

i ,.
""
-,

,
EN 510
At Appro",
Memo! Standard i Memo
i
i
i
Power vottage
D range (or 1 s1) with
rear wheels
UP' 0.5 - I.SV
The value actually
deftects between OV
:and 5V. However, It
appears to defieci
around 1 V, according.
to vehicle speed.
OV when accelerator
pedal is pressed
Approx. 0,5 - 4V
(Voltage II increase
when accelerator
pedal is pressed)
Power vollage
Almost power voltage

u . -., , ;
---'---'--I-t

i
,
,
i
RB20DE i DET ENGINE
RB20DE I DET ENGINE

D
1--
-'011Q:i1O:1H).\1tljlO.bo1101i 1 i 2, ,: ., " 6_ 71 ., ,''O 211 2"'0121; 281 '" 41 ,,> 4311 451 46<47j 4111 49! ,oj
; 111 12! 13i 13 11 171 18, 19120
,..j ,,' "" 37' "" SCi 4lj I" 531 541 "IMi 571 ,.! 591 .01
RX I CT:KI
i
I
I IGN I
!
i
1
Terminal:
I
At idle
i
No.
i
Signal name Circuit
Memo! Standard Memo Standard
r

Fuel pump
1-
CQntro!
I
Fuel pump terminal i
,

Cold: OV Cold: OV
'04 voltage control
i D-:..
'Warm: Power VVarm Power
c-l.:/----=
,
signal (FPCM)
-,
!
voltage voltage
I
OO1ltrot urut eccs
EN - 511
ECCS C L; I!'\UTOUTPUT SIGNALS
AB20E! DE ! DET ENGINE
9-3 ECCS CONTROL UNIT OPERATION CAUTIONS
(1) Control unit equipment
Never install a control unit that is not specified for your vehicle.
Do not apply excessive force to the installation bracket
(2) Connector removal and installation
When removing and installing connectors, do not bend or apply unnecessary force and
observe following points:
1. Connector removal
Turn ignition switch OFF and ECCS relay OFF before removing connectors.
Hold connector firmly to disconnect without applying force to harness.
Do not use a screwdriver or similar tool to loosen the connector lock.
2. Connector installation
Turn ignition switch OFF.
Make sure pins are not bent or control unit connector and then connect securely.
Tighten bolts securely until injector surface reaches orange colour indicator of
connector and surface is even.
(3) Control unit power
Never make a reverse connection to the battery.
Use battery voltage in 10- 16V range.
(4) Idle speed adjustment knob
Do not turn past lock position.
Do not turn adjustment knob when ambient temperature lower than OC,
(5) Water and oil
Care must be taken not to allow rain drops or water to wet the control unit
Care must be taken that condensation does not form due to sudden increase in
temperature, If there is any moisture, dry control unit adequately before installing in the
vehicle,
Make sure no oil adheres to connectors.
Do not clean the control unit using volatile solvent cleaners.
(6) Dropping and impact
Do not drop the control unit or subject it to strong impact.
Do not use upper and lower covers for the control unit which are dented.
(7) Control unit screws and cover
Do not remove the upper and lower covers from the control unit.
Do not turn the screws in the control unit main body.
EN - 512
i
I

:
CA 181 ENGINE
(1) Data monitor
value will displayed even if the output circuit (harness) is inadvertently disconnected.
CA1Si ENGINE
.. .' ........ ......... r i
'J'" . ...ffI!M.. .. .
. ....... . ... '.' ..... .. ";":"(.'"0'" ''''''!'.'. .. ': ... .. : .: .... : ... .. .
CAS.RPM angle TachOmeter set There must be no ab:1Ormal
Crank angle sensor sys:eM
soeec according :0 signals) Engine n.Jl'1rnng Change In speed
I
ENG TEMP SEN
After warming up engu'le Above approx 70
Q
C
Erlglfie temperature sensor
{engine temperature)
.
system
EXT GAS SEN Charv;.;les betvJeen 0 - 0 3V ard: ExhaLst gas sensor systel'1
{output voltage!
After warmirg
OB -1V
:In!ake syste1i al' leak Of ai'
EXT GAS
up ergH'Ie
2000rpfT 'Nlth '10 load
"<:ICH ..... EAN repeats 5 Hnes or: intake
(RICH Il...EAN) more In 10 seconds
i Injector system
i
CAR SPEED SEN While dnvmg or WIth drive ""heels Should generally confonn to
Vehicle speed sensor system
!
(vehicle speed Signal) tumlng speed meter display
!
0"'1
Battery
BATTERYVOL7 1" - 14V =CCS cont'oi Ur.lt PO't.'E)f
Engme stooped
systerr
THROITLE SEN
TNert!! fully closed 1 0
(output vor,age)
Igmtion SWItch
Throttle fully open 5.0
ON Throttle sensor adlustment
Englfle
I
f\..!1ly dosed 0.6
Tl-<ROTTLE SEN (2)
stappen
;ot.1pUl voltage)
Throttle fully oper 45
INTIA TE'JlP SEN
Intake air temprature IS :nIaktemperatum sensor
{iNsktemperafure sensor A_fter wartrllrig up englrle
displayed system
output)
Idling Ale
1 2 msec
Air flow meter system
INJ PULSE After warrrnng
Reference
Intake sysle'i'l B'r lea.ks or i1lr
tJnject!on pulse WIdth) up englf'E Sllctlon {er,lre nput)
2000rpm WIth no load 1 2 tl'sec
Irput sigr.al systeM {ef'tll"e;
ldll'lg iN range. Ale
Afr20
v
I
lGN TllVI!NG
Afterwarmmg

Air flow meter syStem
up engme
2000rpm WIth no load
Advance greater lhan 10" angle
compared to idle pOSitIOn
:Alr F.ow meter system
AlF ALPHA
After \Varm;ng L'P engine
IrljeCIOr syste!T'
(alr-fue! catlo feedback 75 - 125% :Canster inspectIOn
correctIOn COeffiCHl:!rrt)
200Crpm With no loaa
! If"take systefCl air leak or air
,
suction
"START" ON
START SIGI\IAL
SWitch
Starter SW systeM
ON
"OFF" OFF
Engine
Throttle fully closed
0"
IDLE SW

Th:-ottle sensor system
7hrottle funyopen OFF
AfCSWON ON
AIR COND SlG
!
All conditioner SW system
Ale SWOFF OFF
Not Prange 0,"
NE UT::(AL SVV
Neutral SW system
NotNorP OFF
I
klle Steenng ON I
!
PW/ST SIGNAL POVY'Etr steering SW system
,
Steering r'teutral OFF
Head :amo, heater
fan, rear cefOgger ON
WfGCONTSN
SWON
Above SW OFF OFF
I
ignition switCh
AIC ON ON
I
FICD SN FCD input system
ON
Ale OFF OFF
Eng temp cold GN
FTC HEATEq Rewllg PTe healer mp..rt system
Eng temp HoI OFF
,
Stop OFF
i
FUE!.. PUMP RELAY ION Sill/Itch ON Fuel pump system
I
,ov ON
I
Ale ON OFF :
AIR RELAY Idle Air conditioner system
Ale OFF OFF
EN - 513
ECCS CU iNPUT/OUTPUT SIGNALS
CA1S, ENGINE
(2) Active test
I ',i>':<'p,', . ,.,. I., h,li;",:.'IACTIVli:TeST.iiii' ".' .. .\I."ifl' .,
... , "". ,'::'"",';',. .;.\ON .... .;. ... ,... .. ,.""".,' . .::.=, ';':AC'::", ::TIV=-,' :.:e::':;TES:;:".;T.;. ... ,be ... , -'$c"",
I I E:un.wa.!e..
ENGINE
TEMPERATURE
FUEL INJECTION
;Set engine te'i1perature high or !ow I
Proolerr; occurence E '191 ne TemoeratGre Se'lSOf system
.G.au:tkul. Do net set extreme values
condItion : In)ct:Jf system
as this can cause spark plug Durning !AI; flow meter, exhaust gas sensor system
Problem occurenc.e
conOltion
; Nol ellm oated
Otl'1er Item Inspection
Pertonn fo;lowwtg inspections to CheCK if
problem is SONed
E.lirruna.te.
Set the air-fuel ratio rich 0"
00 not set extreme values as ,Exnaust gas sensor system
:Air flow meter. engme temperature sersor
thiS may damage or catalytiC system
ocnverter.
Detay 19nit:on tlmmg
Iriector system
Nor elimir.ated
Other Item inspeCTIon
! Perform following Inspections to check if
:problem is solved.
Elimmate'
Problem occurence
IGNITION TIMING i condltwn
.G.a.uti.oL:. 00 not set extreme values as
this may damage engme or catalytic
Ignition trming adjustment
Detonation system
Not eliminated
IDLE
CORRECTION SN
FICO SN
I
FUEL PUMP
RELAY
SELFLEARNING l
CONT .
, converter
! Other item inspection
lTum ig1ition switch ON and OFF The
After engine warm up :'idle rev will If the conOltiOn described on left can no: ce
idling tN range, Ale !.G..a.uti.c..n: 00 not perform thiS operation II(Hified, check Idle correcuon solenOid
OFF) 'Jnder condition aescrioed on :system
: Tum ignlt:o:\ swtch ON ana OFF The
After engi'1e warm up i1dle rev WIll ;ncrease at approx 200rpm
idling (N range Ale G.ai..ili.o.Ir Do not pertorIT' this operatlon
OFF) except under condition described on
left,
ignition SWitch ON
step
i Turn igmtlon switch ON, OFF and ON
:50 pl.;mp operation makes a sound.
i 1l1e fue; pressure Will rise
.G..a.uti.oo.. 00 not oerform thiS operation
except under conditIOns descnbed on
left
If condItion described on left: can not be
verified, check FICD soleroid system
If the condition descnbed on !eft can not be
venfied, Cf',eCk relay system of fuel pump
and tuel pump system
The air-fuel feedbaClo( correction coefficient leammg factor is cleared.
EN - 514
EGCS G/U INPUT/OUTPUT SIGNALS
CA 181 ENGINE
92 OSCILLOSCOPE & CIRCUIT TESTER INSPECTION VALUE (CA1Si ENGINE)
I
Tenninai
NO.
3
5
6
7
9
19
10
20
- -- -'
3383 <\ 414 '21 J 4 S!fi 769101 21221224251262712
43 45 4 : 1111211::;t1 1511 :711fJ!19!2oJ 2: 30313233134353
Signal name
fhrot1le sensor
signal 1
I
Engme temperature
sensor signal
EXhaust gas sensor
signal
Throttle sensor
5ignal2
Crank angle sensor
! 180
11
signal
Circuit
Throttle
sensor r

I ECCS control umt I
i
, , i
: ECC$ eootrot I.mit I
At idle
Standard
Approx.1V
Engine temperature
ao'c: 1V
Engine temperature '
20'C 3V i
Denee! between
approx. 0 - 1 V
Approx O.6v
Approx. 0.3 - O. 7V

o
L
, .. .LJ
Approx. 2 - 3V
I
I

: (Vdlm'" .. --;;
Crank angle sensor r<V).-, 4. ' "
2. ' J
1<) slQnal :, \.... I / v.L "I '
- I" ": 0 ,--'--+.": ", .... ,
I II 'CC'=mum' i i ! I ' II
EN515
Memo:
i
!
At Approx. 2,500 fpm
Standard
Approx. 1V - 5V
(Voltage will increase
when accelerator
pedal is pressed}
Engine temperature
8G'C' lV
Engine temperature
20'C. 3V i
i
Approx. 06V - 4.5V
(Voltage Increase
when accelerator
pedal is pressed)
:
Approx. 0.3 - O.7V
.
,

,
,
0
,
,
Memo
ECCS CIU IN PUT/OUTPUT SIGNALS
CA18i ENGINE
-
1 H)' 1
l..!. .. ' 11.1,*,' 1 11,11
CA 18i ENGINE
i
-
1 2 :1 4: 5 6 7 8- 9' 1
11 12' 1 15 1 17 18 19i 2
21 22 :.I '24 2: 26 27 2
3.1 32 33;34 35 3
At idle At Approx. 2,500 rpm
Terminal I
No. ,
Signal name Circuit
Standard Memo Standard Memo:
J-.IGN
Monitor & check
v Exhausttemp Lamp not ht Lamp nol lit:
13
"
wamtnglamp
i
Power voltage P ower
lamp (red lamp)
i ,ontrol "m' .J;
lamp lit: Approx, OV ,Lamp lit: Approx.OV
i
--'--"---" ! ,
I
,
I
i
i v.L:;l sen + IV, -T-'--,
G ,', ; I
Approx. 1 - 5V

4'
21
i
Vehicle speed , , ",
(Cycle will get shorter I
sensor signal
0'
when vehicle speed
23
24
27
Ignition switch
"START' signal
Neutral switch
Signal
ECCS control unit
power supply
!
I
I
I

Eees control IJl1lt
I
srARTSW

r::-:::::-_Neulraf Switch
(MIT)
(AI'"
... N.P switct\
, I
,
!
,
OV
sWItch in
START: Power
voltage)
N or Prange: OV
Other than N or P
range: 6 -7V
Powervokage
is increased)
OV
switch in
START: Power
voltage)
N or Prange: OV
Other than N or P
range: 6 -7V
Power votiage
Air conditioner OFF: ' Air cond.tioner OFF:
!
r-

, 29 : Air conditioner Power voltage Power voltage
I 2B : s .. tC_h_S_lg_na __ ' __ ______________ __ r_O __ ___ __ ____ _
LL ECCS'"""'"oit OV
EN516
,
i
!
CA18: ENGINE
CA18i ENGINE
, Terminal
No.
30
31
37
:
38
i
39
40
!
-
:lQ11 1 1 lOch 1
111 12 1 1.f;11 11
Signal name
Intake air
temperature senSor
signal
Power steenng
signal
Power transistor
control signal (IN)
Power transistor
control signal (EX)
Ignition primary
signal
ECCS relay
:
.
i
.
Circuit
l ECCS control unit
... -.
i fees confml Unit i
tGNcoil
------<B
OlstrlnUl:1 -- -

>-"-0-. I
i E:CCS ;:;Qfl!rQ! unit l
!
Distnbutor

t Re6!$tor
translsh)t
...:y}\ ;
\

unit:

c/u

l.::'cs I
11 2 3 ,$ 51 \; 71 B 9: 101

At idle At Approx. 2.500 rpm
Standard
Cold: Approx 1.5V
Warm: Approx.08V
Power steenng ON
OV
Power steering OFF
Approx.8V
Approx.05V

..
__
. -
App,ox 05V
,v
it

.
4
2
I
IF
0
:.L
i
,
ApprOK 11V-12V

'V
4<)
: - I
'"
. .
'" 10
1...
..
0
OV
(ignition SWItch OFF:
Power vottage)
Memo
.
I
i
:
:
!
I
Standard
COld. Approx. 1 .5V
Wann: Approx. O.8V
Power steering ON'
OV
Power steenng OFF
Approx.8V
Approx.1V
' ... "1 .
11' _II '. 1,1. ,.
---- --'--

..
.. I
:.:::;: "':X

.'", J;,'T
, .. '
2
01 I . r
... ...L.... . ;
,
L. ___
Approx. IOV - llV

40; "-- i : i--
30; ,'--' t- .
{-:- :- - :
Ti
' " . '1'+":1
.
OV
Memoi
I
I I
: I
I
:
EN,517
ECCS C/U It\PUT/QUTPUT SIGNALS
CAla, ENGINE
i
;CA18i ENGINE
1:': :> 2122 242262
11 12 1 1 15 Hi 17 18 19 20' 30 31 12 3 34 35
,
,
! ! At idle At Approx. 2,500 rpm
, Tenninal
!
No.
Signal name Circuit
Standard Memo Standard Memo
r0-'\"
I Power vottage Lower than power
vottage

<V)
F uei injector pulse
: 1 '
60
....
41 monitor signal
",'
1-"'-
2<l
(li monitor)
ECCS control
o , . "",....E ;
.
. ....
I
,
i
. '1

,
.,.+,
. (i--
I
I
I
F- i!!lS
'1'1
!
Lrght SW
r--
SWitch ON: Switch ON:
43 , Light switch signal
:
ie
V0
1
Power vottage Power vottage
Svvtch OFF: OV Sw<tch OFF: OV
I
,
,
I
!

:

f<,- +
I

Switch ON: SWllch ON'
45
Heater fan switch
Power voltage Power voltage
Signal
Swllch OFF: OV Sw<tch OFF OV
i ECCS centrol umt J ,
i
I
RUf detogg.l!r SW

Switch ON: Switch ON:
,
46
Rear defogger
I
I, v=-:
Power voltage
I
Power voftage
switch s<gnal
!
SWItch OFF: OV
:
SWitch OFF OV
;' fees control UJut J
,
i
I
Power voHage Lower than power

voltage
I
<V)-1" '
I

,
6lJ
i::::::'
101 Injector control
'"
I
110
20

Signal
'
i ECCS control 1JfiJ
i' .: :
i":""';'=:-I
::r
,

I
,
I
Air co:xhtrcner ON: Air conditioner ON:
102
'Air conditioner relay: Power vottage Power voltage
signal
I I
! I
Air conCitioner OFF
I
!
ECCS GOfitrof unit OV OV
I L
i
i
EN518
I
eAtS, ENGINE
CAt8i ENGINE
Terminal
No.
103
104
t06
111
115
-
39 4 " 4
21 22 2. '2 2. 26 21 2.
'1 H 11 1211 1 11sal1 45 4 4
t 2 3 4 5 is 1 8 9 101
!1 12 13 1 15 1 17 16 19 201 30 :)1 32! 3 J4 J5
Signal name
FiC D solenoid
Fuel pump relay
!
I
PTe heater relay
Idle rev correction :
solenoid !
Lock up release
solenoid (ArT)
Circuit
At idle At Approx. 2,500 rpm
ACO I ..
oI
'd 9
n1tlOn

I ECCS Cotllro! unit I
Fuel pump
mII.fy Igl1ihOA

. ....---rr
: .;..-.-
...-.... -_ ....
r;.CCS coolt(ll unit'
Standard
Air condilioner ON.
OV
Air conditioner OFF: I
Power voltage
,"'pprox.OV
(Power vottage for 5
sec after ignition
sWitch IS placed to
ON position)
PTe heater ON:
Approx.OV
PTe heater OFF
Power voltage
Memo Standard
Air conditioner ON:
CV
Air conditioner OFF'
P I
!
I,
ower vo tage
Approx.OV
PTe healer ON:
Approx.OV
PTe healer OFF
Power vonage
I
ldfe rlW correction 1 .
IgnitiQtiSWlkh 2,

VVhen ign sw in on
Engine rewing: Approx. OV
fees control unit i
First 15 sec after engine start: Approx. OV
After 15 sec after engine start: Power vohege
Any of the followings are ON (Power steering.
lights. rear defogger. heater fan s>Mlchl Approx
OV (D range lor AfT]
Lock up released:
Approx.OV
lock
I Lock up released
Approx. OV
lock up applied:
Memo
up applied:
Power voltage
Power
:
i IL_C_C_S_'O_"_"_"_"_OO_' --,I :
EN - 519
I
ECCS C'U INPUT OUTPUT SIGNALS
RB25DE ENG INE
(1) Data monitor
value will displayed even ilthe output circuit (harness) is iradvertently disconnected.
RB25DE ENGINE

ii.i hiiiii.i i i DATA_ITO!!

"ii.:iiii' .. .. i.iii .. i
tTl "c_o.i i ii i i NORMAL REFERENCE
..
i I1!l!.Mi "'i.i
i... /i. i'i i.i ii.' VALUE
ii "i:
I
Cfl.S RPM (Detected arg:e Tacrometer St I The:' mus: De ro aO'>QfIT'81
era:;:'; ang'c sensor system
speed aCCordlrlg:o 519;')0,'8) Engir>::! !'tJ1I1:ng
I
,- s:::;eec
M(warmlrJg 'Jp :
"'i")
AiR FLOil'; MTR engine
,
{outout voltage) (1!irg I,N range, i :
AJ:;:Jrox i C - 1 5V Air flow fl'IE!ter $ystem
AJe GFF) 2000rJ:--:1 vlltmut load
ENG TEMP SEN
t.:p engine Abo\' approx :'C>'C
Engloo tempefillue sensor
s.ys:em
I
EXT GAS SEN
!
,
Changes tlet>A'cn C - 0 3V arc
Ex'iaiJst gas sensor system
I
'-00!PUl voltage)
i
Ater waimi") up 12CiiOIP I j
Dj) - 1V
,ntake system air :eak or 8!f
EXT GAS SEN
eng!f\e ,U rprT' w, 'Yl oa"
RICr, LE.AJ,j receats:;, times or
!:-take
(RICH f LEAN)
!
more In 10 seco'1ds
s't'Stem
CAR SEN
VVrllle dl1\i1ng at With jnvc Wlieels
ShOuld gereraiiy :;omlYm Ie
: Vehicle speed sersor system
(vehicle speec signa!) speedrr-:ete; distllay
I
II;;fHtlCl switch ON

BATTERY VOLT - 14V ECCS control L:nlt oower
Engine stopDeo
i
:sys!em
iN railge. Ale
ACt)rox.. 2 C 28msec
Air fiew meter sys:em
PlJ ....SE Afterwarrr.rg GP OFF; lmake system a,r leaKS:Y air
('r]eCLOr' pLfse engine suctor (entire lrout)
2eDOrpr) With "lJ lead Appro); 2 0 - 2,8rnsec
Inp:.Jl: signal system (ertirel
idling {t'\ /l,!C
15)
IGNTIMING
After v'iarrr,wg up
OFF)
Ar "!low '"TIter syste:T!
enguie
200Crpm With ro load
Advar:ce greater !har angle'
i
i
compared to Idle position
I
AAC VALVE
After :;,';';fJ up
Idli 11 iN range. AF:;
Approx. 12 - 30::)
I
tA S adjusTr1e:1t
OFc, AAC ...'B11Ie system
!Alr flow mete, system
Air ALPHJ1. : !r1jec:or
(al'-fuei ratio feedback CC'TectJor:;
Mter warmlllG up engine
75 - '25% !Carns:er (purge) 'rspe::;t,on
coeffiClent)
20aOrpf'"'l Nltr, no load
; Irta.<.e s,.'s:em. air lea'" or air
i

STARr ON
, START SIGNAL ,S1arter SI/V system
Ignition SWitch ON ,
'OF;:: OFF
i
EngIne stoppe<:! I Plroffie fully closed
I
ON
IDLE SJUOGE\1ENT
flJly open I
Tlort'e sensor sltsterr
OFF
--..
I
Ale SWON eN
i
SIG , Air cor;ci:borer SW system
NC SWOFF OFF
!
Nor P 'ange ON
Nel..t'ai SVV system
.. t\CtN orP
OFF
L
i
Idle
S:eenng ON
P'vV/S"'o SIG"lAL
I
power stee"!ng SW system
Steeri'ig neJtrai OFF
I
Ale ON 0,
AR CON RE ... Av OFF OFF
i
Air con;;toner relay system
A.cee! Me ON OFF
!
Stop OFF
PLMP 'oLAY
IGN SWQN F Lei pump syste'n
\llfrlen re,. ON
CHROTTLE SE\ 5witcn 01\: ".JIly closed
Approx 4 G
{output voltage] Engme slopped
Throttle h,jllyopen 0.5
PCV'JER VOLTAGE oower voltage prove rneasureffiClit value
PULSE PUlse prove measuresl..rement
EN520
i
I
I
I
!
,
RB25DE ENGINE
(2) Active test
:
ENGINE
TEMPERATURE
FUEL INJECTON
iG N rno N TIMING
Me VALVE
OPENING
FUEL PUMP
RELAY
SELF-LEARNING
CONT
POINER
BALANCE
:
Problem occurence
condition
Set er.gll1e temperature high or low
Dc not set extreme values as
i this :::an cause spark plug burning
!
Set t'le alrfuel ratio rien or lean_
Prob,e'TI occurence Do not set extreme values as
condition thIS malt damage or catalytiC
ocnverter.
:
Delay ,gnijlon t:mmg
ProbleM occurence Do not set extreme values as
conditon tbs may damage eng we or cataly:jc
ccrverter.
Inc'ease controi dUty ratio, The engine
Engl1e running
speed s"'Iould Increase.
Decrease contrOl dLly ratio
The engine speed ShOJId decrease.
Tum ignition switch ON OFF and ON so
J0mor, switch ON
pump rr.akes a The fuel
pressure Will nse
Engine stop
.cauti.orL Do rot perform thiS operation
exceot under conditions descnbed on left.
Perfcrm foIIOV't'lrig Inspections to check if
proc!em :s solved.
EljmlM1W
Engine lemperature sensor system
jrlJector system
Air flew meter. eXhaust gas sensor sysle'11
Not elimloaled'
Other item
Perforr'P foliowmg inspections to check ,f
problem IS so:ved
FljmlOare
Exhaust gas sensor syster:1
Air flow meter engine temperature senso:'
t sysem
In,*Klor syster."l
Not eliminated
Oir;e( IteM !nspectior
Perform following inspections to check if
problem 15 solved
Eliminate
ilg:nilion timitlg adjus1rnem
IDetonatlOn sensor system
Not eliminated'
:Other itel!' inspection
If the condition descnbed on left can not
bevenfied. check AAe valve syste:-n
If the conditIOn descnbed on :et can not be
venDed, CheCK relay system of foo, Dump
ar:d rue: pump system
The ratio feedback correction coeffiCIent !earning factor IS cleared.
rev can be d:splayed when AAC
Prob!em occurence
valve openiflg is fixed and set injector
:Elimmate
condition
operation:5 stopped.
Injector system
.G.a..ul.k:n. Do net perform thiS
while drlvmg
EN - 52i
!
:
ECCS CU INPUTOUTPUT SIGNALS
RB25DE ENGINE
92 OSCILLOSCOPE & CIRCUIT TESTER INSPECTION VALUE (RB25DE ENGINE)
: AXl ;:K!
I
I
I Terminal I
: No. .
Signal name
1
2
3
11
12
13
4
5
i Power transistor
control signal
AAC valve control
signal
Engine AIT total i
control input signal:
Circuit
ECCS contr<ri VI'II!
(DT1) : j ..
Il"<'--' J
-.... Taehometo
i
.
:
Tachometer engine i
7
speed signal '
I
ECCS control unit
Lowpressum
AlCrefay sw
:
i
At idle
Standard
0.2 - 0.3 V
.... c e_'" )
6 "
. <-r-
! 1." -;----r:----
COld: 6 -7V
VVarm: 8 - 10V

s--- , ,-;-
(I t --

Approx. 10V
Approx. IV
_

'1 -
- I
... .
...
L
!

Air conditioner OFF: '
:
Power vonage
9 Air conditioner relay
!
,
Air conditioner ON'
:
--... Approx.1V
ECCS control umt
i
L-.. .J
I
A/Tcomroi
l
I,jl'l:ll
!
i
Engine alT total
14 control ,nout signal Approx 10V
(DT2)
ECCS cootro! lIflil 1
i
EN522
Memo Standard Memo
Approx. DAV
Approx.5V
Approx 10V
Approx. 2.4V
IVI
..
.- .
"- "- J
'ffutil1

.
.< ..
-
i
Power voltage
Air COndiTIOner ON
Approx. 1 V
:
i
.
I
Approx.10V
I
i
i
i
EGGS GiU INPUT/OUTPUT SIGNALS
RB25DE ENGINE
RB25DE ENGINE
D 241251261 27! ui 2f3t'IT41: 42143!44!4S!46!47!481.i9I501 i'ol'o:l ",iiOiioo"lO lOJ,,>ii 1 2, 314' ': &[71 8 '.10
11 12: 13 .. 1]1 1S! 191 2Q : 311 32133 341 351361 37 391 1 51\ 521S3! s7i 581 591601
!

i ! I

Tenninal!
At idle At Approx. 2.500 rpm
Signal name Circuit
No.
Standard Memo i
Standard Memo
!
I
AfT comrol Unit
i
Engine Arr total
!
control output signal Approx.OV
,
Approx.OV
(DT3)
ECCS cOrltrol urn1

,
ECC$rclay
i
!

L--....: :

Approx.1V
16 EGGS relay
ClU
sw!!ch OFF. Approx.OV
Power voltage) !
I
Fuel pump rniay

, " ' 't :

18 Fuel pump relay
j Fuel pump
OV
,

I

,. - I
, EeeS control Unit: i
!
I
I
I
POwttr SW
,
!

Power stee:vig ON ;: :we' stef"ng :1'.
I 19
Pmver steenng

ov OV
sWltch signal Power steering OFF
5:-'0---':
---
.
I
--
!
5V 5V
ECCS eomrm umt

!
J i
!
.

I
Approx. O. 3V Approx. 0 3V
24 signal
I
1
.. _--..
.
ECCS c-ontt-ol unit
,
...

i
, AJtffowmeler 1
I

i
Air flow meter
27 (Intake alf quantity

.. _.J
Approx.1V
!
Approx. 1.5V
signal)
"'"',- i
I
!
!
-, ...
'" i ECCS control
i !mil
i
EN .. 523
ECCS C/U INPUT,OUTPUT SIGNALS
RB25DE ENGINE
RB25DE ENGINE
I
; Tenninal
No,
28
29
32
36
38
Signal name
Engine temperature,
sensor signal
Circuil
Engine temperature sen&or

,'I'M
ground,

IGNSW
:
__ . .'
Exhaust gas senSor
signal
ECCS Clltrof unit
Exhl!lusttemp
Morutor & check lamp
tamp !GN
(red lamp, exhaust
i
!
FICO solenoid
Throttle sensor
signal
To A/Tconlrol unit

ECCS control unit i :
To IVT control urnt
At idle
Standard
Engine temperature
ao'c, Approx. 1 V
Engine temperature
20
c
e: Approx. 3V
Approx. 0 - 1 V
Lamp not lit:
Power vottage
Lamp lit: OV
AIC ON :OV '
AIC OFF: Power i
vottage
Approx. O.5V
Memo
Standard
, Eng Ine tempe rature
!
!
80'C. Approx. lV
Eng",e temperature
20"C: Appmx. 3V
Deflect between a - :
I
approx. lV
Lamp not lit:
Power vottage
Lamp lit: OV
Ale ON :ov
Ale OFF Power
voltage
0.5 - 4V (Vottage
Increase when
pressed)
i
:
i
Memo
40 Intake alf quantity Approx. lV Approx. 1.5V
L-____ __ ___ ________________ ____ ________________ ____
EN .. 524
RB25DE ENGINE
: Tenninal
No.
41
42
43
44
46
48
Signal name
Crank angle sensor'
120' signal
Crank angle sensor
l'signal
Ignition switch
(START signal)
Neutral swilch
signal
Air conditioner
switch signal
Intake air quantity
output signal
ECCSC/U INPUT/OUTPUTSIGNALS
RB25DE ENGINE
Circuit
control unil
IGN
.. fces ca(molumt i
l __ 1
----..
I ECCS et.lnlrol unit '
... ---'
AlCSW

1
fan SW
. --_._--
i teeS eontrOI unrl
.--_ ... ---'
At idle
Standard
03 - 07V
OV
(ignition switch
START Power
voltage)
Nor Prange. OV
Other then N or P
range 4 - 5V
Power
Air conditioner ON:
OV
5V
EN - 525
Memo:
Standard
0.3 -O.7V
2 -3V
OV
Nor Prange' OV
Other than N or P
range: 4 - 5V
Power
Air conditioner ON:
OV
5V
Memo!
,
,
:
i
,
!
ECCS C/U INPUT OUTPUT SIGNALS
RB25DE ENGINE
RB25DE ENGINE
Terminal
I
,
At idle
No.
Signal name Circuit
i
Standard
ECCSn:!lev
c-

49
EGGS
i
Power voltage
GIU power supply
:
I
!
i cOntlol unit !
'
D range (or 151) with
1 +
rear wheeis jacked
up' 0.5 - t.5V
I
""",m
The value actually
53
Vehicle speed
deflects between OV
sensor signal
and 5V However, it
, 1 ECCS conttOil.lnit !
: appears to deflect
i
!around1Vaccording
to vehicle speed
wrCIIJ

. - .
,
54
,
(Idle contact pOint) : !
Approx tOY
!
56
57
101
103
105
110
112
114
,
!
i
Throttle opening
output SIgnal
(power supply)
Injector contrOl
signal
I
I [

I
To A/T control Oinil
Approx. O.5V
:
,
I
t ECCS coou," uflit
I
i
Throttle $W
I
Power voltage
i
!
-_ ...
ECCS oomrollJnit
Almost power vollage
EN - 526
i
At Approx. 2,500 rpm I
Memo Standard Memo!
Power voltage
i

i
D range (or 151) with
rear wheels jacked
up 05 -1.5V
The value actually
deftects between OV
and 5V However. it
appears to deflect
around1V according
to vehicle speed.
OV when accelerator
:
pedal is pressed
!
Approx. 05 - 4V
(Voltage will increase
when accelerator
,
pedal IS pressed)
,i
i
,
Power vottage
!
Almost power vottage
EXH GAS EMISSION CONTROL EQUIP INSP
""c:= CA181 ENGINE
10. DECELERATION EXHAUST GAS EMISSION CONTROL
EQUIPMENT INSPECTION
10-1 THROTILE VALVE SWITCH SHORT-CIRCUIT
(RB26DETI I RB20E I DE I DET ENGINE)
Remove the throttle valve switch harness connector and
use a lead line to connect harness connector terminals
(2) and (3).
The throttle valve sequence power and idle connection
points are set ON.
10-2 FUEL CUT INSPECTION
(RB26DETI I RB20E I DE I DET ENGINE)
After warming the engine, place the transmission in to
neutral and run engine at 2000rpm.
Lower the speed to approx. 1000 rpm and then raise the
speed to 2000rpm again and check for fuel cut.
If the accelerator opening angle is fixed, the procedures
described above will be repeated,
(CA18i ENGINE)
After warming the engine, lift up the rear wheels and
remove air cleaner case cover.
Place wheel stopper, hand brake and apply foot brake.
Start the engine and place the gear into D range (Arr
vehicles) or 4 or 5th gear (MfT vehicles). Run engine at
over 2000rprn,
Check if the injector fuel injection will stop operating
when the accelerator pedal is released, and start again
when the engine speed decrease to below approx,
1600rpm,
10-3 DASH POT INSPECTION AND ADJUSTMENT
System inspection (CA18i ENGINE)
o Warm the engine and set the engine rev counter,
o Increase the engine speed to extend dash pot stern,
o Close the throttle valve slowly and check the engine
speed when tip of the dash pot stem and the Ihrottle lever
contacts,
<:(' "\ ; ;" ,,<> '
M ! T Approx. 3000
;:;, 1 A iT I Appro .. 2200
Check if the dash pot will move and resistance can be fell
when the dash pot stem is pushed, Also check if it will
relurn to normai pOSition when hand is removed.
Adjustment
o Adjust using adjustment knob on the throttle lever side
when contact speed is not at standard value.
EN - 527
AIR CONDITIONER CUT SYSTEM INSPECTION
RB26DETT ! RB20E / DE / DET / CA 18, ENGINE
10-4 AB VALVE INSPECTION (A I T VEHICLE)
Remove hose connected to A and place your finger to A.
Increase engine speed to 3000rpm and close the throttle
valve suddenly. At this time check if your finger will feel
any suction for 1 to 2 seconds.
11. AIR CONDITIONER CUT SYSTEM INSPECTION
11-1 AIR CONDITIONER CUT SYSTEM FUNCTION INSPECTION
Turn the air conditioner switch to ON position when the
engine is idling. Check that the air conditioner
compressor will turn ON and then OFF.
EN - 528
ENGINE ELECTRICAL EQUIPMENT
RB26DEIT! RB20E I DE I DET I CA18i I RB25DE ENGINE
EN4 ENGINE ELECTRICAL EQUIPMENT
PREPARATION TOOLS
Hydrometer Batter! specific graVIty Inspection
CircUit tester Resistance, voltage inspections
SPECIFICATION
S114-445 S114-445 S114-505
(LO) (1,0) (1
Mff:M3T27686D,
M1T-70685 I (0,8) I M3T-41185 M3T-41185 M3T-41185
AfTM3T27686H, (1.01 (1.0) (10) 114)
(1,0)
S114,505 S114,505
(14) (1 4)
MiT-70685 M1T-70685
IN sfde:
SMC-102
SMC-200 MPC,302 MPC,302 MPC,302
EX side,
SMC-152
06188-01 D6188,01
D4P82-08 (crank angle (crank angle
sensor)
T2T49171 T2T49171 TOT49171
TOT61271A TOT42071 (crank angle (crank angle (crank angle
BCPR5ES,11 PFR5A,11 PFR5A-11 PFR6A-11
BCPR4ES-11 BCPR4ES-11
PFR4A-11 PFR4A-l1
PFR5A-l1
PFR6A-l1 PFR6A-11
BCPR6ES-11 BCPR6ES,11
PFR7A,11 PFR7A-l1
PFR7A-l1
1,1 1,1 1 1 1,1 1,1
Note: The battery capacity value is the 5-hour rate that conforms to the new JIS standard
and the value is 80% of the former 20-hour rate,
[New model name] (example) 34 B 19 A

position
B dimensions (rounded off)
atte Idth x box height classification
Perf ance rank (starting function added to 5hr capacity)
EN - 529
RB26DETT! RB20E i DE i DET i CA1S; I RB25DE
1. BATTERY INSPECTION
Voltage inspection
Normal (V)
I
124 - 128
L,mlt (charge required) (V)
I(Start limit) (V)
... l
' ___ 12_A_,or I_es_s __ -..;
. 12 (20C)
Specific gravity inspection (20C)
I
:Normal 1.29-1.22
1.22 or less :limlt (charge required) (V)
i
I
There is a vanation width of more
Iservice life than 0.04 between each cell
Additional water does not need to be added to the battery
during service life of normal driving. When driving for
extended periods of time in high temperatures, the fluid level
may decrease according to the vehicle driving conditions.
Check the fluid level with the level indicator (upper flower)
and top up to the upper level as necessary,
Caution: Distilled water must be used to be added to refill
the battery. If ordinary water is used, fluid loss will increase
and may cause discharge,
2. ALTERNATOR
(1) Alternator removal and installation
CA18i ENGINE
,---- ....
I Bolt 1.4 - 1.7 .'.' Nutt'll' I
I, 0.4 - 0.5
jf" , ,,, '
,i!,J !
, .
I
Washer
'Bolt 5,0 - 6,Ot'll
(2) Alternator inspection
Output voltage inspection
RB ENGINE
1.0-:-.2 Bolt
.
: J 'c1' t'll
I "M ,,\washer nuti
i . , 0.4 o.S
I I
I 8011 5.0 6.0'
, Stopper nut;
! ,::': Seacer 0.4 0,5 I
"'8'''' Washer ___ _
Place ignition switch to ON position and check that
charge warning lamp will light.
Standard (V 1 rpm) 13.9 - 14.9 12000 (accessories OFF)
EN530
RB26DETT i RB20E i DE! DET I CA181! RB25DE ENGINE
3. STARTER MOTOR REMOVAL & INSTALLATION
CA18i ENGINE RS ENGINE
-_ .... -_ ......... __ ...
4. SPARK PLUG INSPECTION
Inspection
Check for any looseness with terminals.
Check for any damage or cracks on the insulator
Use thickness gauge to check the spark plug gap.
Spark plug gap (mm): 1.0 -1.1
5. PLATINUM PLUG INSPECTION
(RB20DE, RB20DET, RB26DETT)
Installation precautions
Periodic replacement interval: 100,000km
Gas inspection and adjustment and plug cleaning using
wire brush. should not be performed as this may scrape
off the platinum partucluate from the platinum tip surface.
If plugs are cleaned with an air gun, the cleaning should
be performed in less than 20 seconds at an air pressure
less than 6. Okg I cm
2

Only use parts specified by Nissan, when replacing the
spark plugs.
EN .. 531
Bol: 3.1 - 4.1
-"st,,,ter motor
-----Platinum i p ~
Seating m<'(tal \.
~ . ,
'!:it I
~
R626DETI ! RB20E j DE i DET I CA 18i ENGINE
6. IGNITION COIL INSPECTION
RB20E ENGINE RB20DE I DET I RB26DETT
. ~ ~ ~ Seeo ry Side
Q
~ ~ ... ~ ~ .. -
! Primary ~ ..
, sIde j __ -
i '.---
t=
! ~
Check the primary and secondary coil resistance value.
Primary resistance 0.7-1.2 0.8 - 12 06 - 0.9
Secondary resistance 7 - 12 7 - 12
EN - 532
COOLING SYSTEM
RB26DETT! RB20E I DE I DET I CA 18i I RB25DE ENGINE
ENS COOLING SYSTEM
PREPARATION TOOLS

Radiator cap tester
EG1765 0000
Radiator and cap pressure test I
Radiator cap hose adapter
EG1765 0301
SPECIFICATIONS
1.9
0.9
650
'Nith (AlT)
Plastic
Alumium
410 x 7
2 levels
82 - 88
30 - 50
Appro" 0.7
Approx. 7
Small cap adapter
1.9 1.5 1 5
0.9 0.9 09
650 815 1080
With (AfT) With (AiT) With (AfT)
Plastic PlastiC PlastiC
AJumium All.llium ,A IUiTllurr
One piece unit (lower shroUd)
420 x 8 420:i 5 42-::' 'i ::
31e\f1$ 3 :evels 3 !e'v'-,s
x 5
80
90
76.5 76.5 76.5
30 -50 30 - 50 30 - 50
Approx.O.7 Appc"'( 0.7 Approx 0.7
Approx.8 Approx 9 Appro" 9
EN - 533
L5
0.9
1380
:?Iasti:
:.,
.!: ,- ;;
3 levels
320 'X 4
160
90
76.5
30
App'C" 0.7
Approx.8.7
RB260ETT i RB20E ! DE ! DET ! CA 181 I RB25DE ENGI i'lE
1. RADIATOR INSPECTION
Cooling water teak inspection
Use radiator cap tester and apply pressure (limit 1.0kg!
cm2) and check for leakage.
Caution:
When using the radiator cap tester, always make sure to
connect the hose adapter and filler cap is not deformed.
2. RADIATOR CAP INSPECTION
Inspection
Clean cap rubber packing seal surface and vacuum with
dry brush.
Attach radiator cap tester to cap. Apply pressure and
check that valve operates correctly.
RaCllator cap relief pressure (kg/erne) I 06 - 1.0
Pull vacuum valve with finger and check operation.
3. COOLING WATER FILLING PROCEDURES
1 Make sure the radiator hose and heater hose clamps are
lightened securely.
2 Set the heatercontrolleverto HOT position. (For
vehicles equipped with automatic air conditioners, first
place ignition switch to ON pOSition and remove the
extemal sensor connector).
3 Release the radiator cap and air drain plug. (RB20E:
Intake manifold collector area. RB20DE / DET: Intake
manifold collector area and in front of glove box).
4 Fill the radiator gradually (filling speed: slower than 2L I
min) to the top of the spout with coolant Fill the radiator
until the water in the reserve tank reaches the MAX level
line indicated.
5 After closing the radiator cap and air drain plug (RB
system), start the engine and allow it to idle.
6 The engine will continue to idle until the thermostat
opens. (Touch the radiator flow hose and make sure hot
water is flowing). If a large volume of air remains. the
water temperature gauge needle will move past the
middle as the engine temperature rises abnormally. If
this occurs, stop the engine wait until it cools and add
water to the radiator repeatedly as described above.
Atter the thermostat opens, race the engine for 10
seconds at 2500rpm two or three times. Check that
the water temperature does not rise excessively.
EN - 534
\
'\ \
, ,
COOLING SYSTEM
RB26DETT! RB20E! DE! DET! CA18i! RB25DE ENGINE
7 Stop the engine and allow it to cool, Release the radiator
cap and check the fluid level. If the fluid level lowers,
return to step 4 and repeat the process,
OR vehicle equipped with automatic air conditioning,
connect the fresh air sensor connector,
4. RADIATOR REMOVAL AND INSTALLATION
CA18i ENGINE
IRl kg-m
RB ENGINES (RB20E I DE I OET I RB250E I RB26DETT)
N
(2) 0 33 043 Radiator mounting Re-
et . -, bracket (uppen Bolt 0,33 - 0,43
A --a /" '. . \ server
Radiator cap Radla,or hose \ /1 tank/
COOLING SYSTEM
AB20E
R.adlator I I
mounting --1' D
(upper) " Radiator fit ." - rPJ HoseclamD
, ! Thermo ,,- / 0.26 Radiator
'fIountmg, --SWJtch ,/ Nut 0,33 - OA3. hose
(upper) clamp . (upper)
'I . -0.2. hose
.
.... ..... (lower) Radiator hose I'lower)
/ I .= '''" V/ rPJ
I /rli"":,,, t Hose clamp /
f Y I )'..."'-'\ r,
Radiator ., i '..... AIT 011 cooler' .
ASSY I \' IJ (AlT)
Radiator ! Hose I Hose ci /
d
k \, ,
IRl kgm
COC \ clamp ;; /
Radiator
mounting
rubber (lower)
Radiator shroL.d (upper)
EN535
COOLING SYSTEM
RB260ETT! RB20E I DE I DET 1 CA18i! RB250E ENGINE
Drain and fill cooling water
Remove AfT oil cooler hose (AfT vehicle)
Remove supplementary electrical fan connector
[Point 1] Radiator shroud (lower) removal
While pushing hooks (left and right 2 locations) to
release, remove pawls and detach shroud.
5. SUB ELECTRICAL FAN INSPECTION
(RB20DET I RB26DETT I RB25DE)
Operation
Thermoswltch ON
I
Radiator fan ON condition '1
1
______________
Function inspection
Place ignition switch to OFF position and remove switch
harness connectors and shortcircuit harness connector.
Check that fan motor operates correctly when ignition
switch is placed to ON position.
Thermoswitch inspection
Heat thermoswitch with re water or oil
(heat with heat gun, for example) and check if it conforms
to values in chart below:
Valve rised
90 +/- 3 max
Valve lowered:
83 +/- 3 max.
Non-continuity
6. THERMOSTAT INSPECTION
Inspection
Valve rised:
90 +1- 3 min.
Valve lowered:
83 +/- 3 min.
Continuity
0.3 - 0.5
Check that valve opening temperature and maximum
valve lift conform to specified val ue.
Place a string in thermostat valve and inset it in container
of water. While holding thermostat heat the water.
The valve opening temperature is the temperature when
the thermostat falls off the
EN - 536
r-;:;::' --'-.. I
, Radlato.' S.hro. 11::1 ' -. . .
. IUP;?1P
B
n "" / I
Hook Pusn,
.. ' "",12 I
rr
.
.....;.;... . awls. II
j 1/
- .'--': C .--<
shroud
{lower) ,
/' Pusfi "-
FUSClf18
Radlatcr
tan relay SW .".
FUEL SYSTEM
RB26DETT I RB20E I DE I DET I CA 18i I RB25DE ENGINE
EN6 FUEL SYSTEM
PREPARATION TOOLS
Name
l r c ~ l t tester Fuel gauge inspection
SPECIFICATIONS
..... RB26DETT
None
EN - 537
FUEL SYSTEM
RB26DETT I RB20E I DE i DET i CA 18i i RB25DE
1. FUEL TANK REMOVAL & INSTALLATION
Filler tube [Point 4 J
y/
Bolt (4) 0.33 - 0.43
Fuel tank protector
(Point 3J
Drain fuel
Fuel pressure relief valve [Point 1]
Fuel tank internal pressure relief
Filler tube protector
Inspection hole cover [Point 2]
Fuel gauge unit. fuel pump harness connector [Point3]
Fuel tank protector
Hoses
[Point 1) Fuel pressure relief
After starting the engine. remove fuel pump fuse and wait
until engine stops. Crank engine 410 5 times to consume
fuel in lines.
For vehicle which can not be started, remove fuel pump
fuse, crank engine 4 to 5 times to consume fuel in lines.
CaUjiQJ1
The battery may become weak easily, use booster cables to
connect it to another vehicle or battery if necessary.
[Point 2] Inspection hole cover, harness cover, fuel
gauge unit harness connector removal &
installation
Removal
Remove rear finisher and detach the fuel gauge unit
harness connector.
EN - 538
FUEL SYSTEM
RB26DETT! RB20E! DE! DET / GAl 8; i RB25DE ENGINE
Installation
Check that fuel gauge unit and fuel pump harness
connectors are connected securely.
Check that fuel hose connections are secure.
Bolt tightening torque 0.33 - 045
[Point 3] Fuel tank removal & installation
Removal
Remove feeler tube protector and detach bolt shown in
Remove feeler tube grommet from the body.
Remove fuel tank protector, fuel tank band mount bolts
and detach fuel tank.
Installation
Attach tank and secure by tightening mount bolt on front
side of right member to specified torque.
Band mount bolt tightening torque 28 - 36 kg-m
Protector nut tightening torque 0.33 - 043 kg-m
[POINT 4] Feeler tube installation
Use specified feeler tube bolt to install feeler tube.
2. FUEL GAUGE
(1) Fuel gauge ASSY removal & installation
rover
Fuel gauge
ASSY
EN 539

Tube, Fuel tank
Feel;j'\ 't!J )
tube
I "
033-043 I, '
JOint plate O-nng
FUEL SYSTEM
RB26DETI I RB20E! DE! DET ! CA18i! RB25DE ENGINE
Fuel pressure relief
Internal pressure relief
Inspection hole cover
Fuel gauge limit
Fuel pump harness connector
Fuel hose (return, feed)
[Point 1]
Fuel gauge ASSV bolts installation
Set O-ring to fuel tank side and insert gauge ASSY inside
the tank. Tighten the bolts shown in the figure on the
right.

Extra caution must be taken not to damage float and the
arm when installing gauge ASSY.
Only use specified bolts when installing fuel gauge ASSY.
(2) Fuel pump removal & installation
Removal
Loosen hose clamp on unit side on the pump side.
Lift up the purnp slightly. Remove pump with the insulator
from gauge unit side bracket (PIC A).
Remove pump side harness.
Detach hose.
Installation
Carry out installation operation in reverse order.
(3) Inspection
1. Float inspection
Place the floal al the F (lever upper side) and E (lever
down side and check the resistance.
4-5 Approx.6 Approx.80
2. Pump inspection
Apply battery voltage to harness connecter terminal 1 and
3 and check its operation.
3. Low fuel warning lamp sensor inspection
Connect 12V to 3AW lest lamp or equivalent.

Wash sensor with gasoline or white gasoline and check
that lamp does not light after approx. 3 minutes have
elapsed.
Remove sensor from gasoline or white gasoline and
check that lamp lights within 3 minutes.
EN - 540
Hand start bolls
Test lamp .1
r--@--, 01
. .. C2LJ
RB26DETI I RB20E I DE I DET! CA18i I RB25DE ENGINE
3. FUEL PUMP REMOVAL & INSTALLATION
(1) Fuel pump disassembly

I Y (,

I
I
/ !
__ J
fuel pressure relief
Internal pressure relief
Fuel gauge
CatJtion:
Care must be taken when handling fuel pump.
Do not reuse pump if it is dropped.
Do not allow dirt or debris to adhere to the filter.
Do nottwist orturn harness.
[Point 1] Fuel hose removal & installation
Removal
Raise fuel gauge ASSY, remove 2 hoses in tank (marked
section is outlet side), fuel pump harness connector and
detach fuel gauge ASSY.
Installation
Check fuel hose marking, connect fuel gauge ASSY.
Position pump harness and clamp band 160mm in from
gauge ASSY connecting part and tighten securely.
Care must be taken that fuel hose and fuel harness turn
inside tank from the right to front side of vehicle and do not
cause any interierence with float arm.
EN - 541
FUEL SYSTEM
EXHAUST SYSTEM
RB26DETT! RB20E I DE WET! CA 1811 RB25DE E',G!I';E
EN7 EXHAUST SYSTEM
SPECIFICATIONS
RB20DE
45 50.8 50.8 63.5 70
modium rhodium modium
Appro, 850 Approx. 850 Approx. 85C Approx. 850
Exhaust system part inspection, warning precautions
The heat resistance and corrosion resistance in exhaust system parts and component
shape have been carefully considered in the design process, so only use genuine
Nissan parts for replacement
Clean each connection part and connect securely, making sure there are no gas leaks.
Always use new gaskets in the front and rear of catalytic converter.
Always use new parts for exhaust manifold connection gasket and nuts.
After assembling each part, when warm engine, raise speed to 2,000 to 3,000 rpm and
make sure there are no gas leaks, sealing compound leaks or sealing gaps.
Replace parts rather than repairing extreme deformation in heat insulation panels. If
extreme amount of dirt have accumulated, clean these areas.
When attaching heat insulation panels, make sure there is adequate clearance and no
interference between exhaust pipes.
EN - 542
EXHAUST SYSTEM
RB26DETT i RB20E I DE i DET I CA1Si i RB2SDE ENGINE
1 EXHAUST PIPE, CATALYTIC CONVERTER & HEAT PANEL TIGHTENING
TORQUES
(1) CA18i ENGINE
Nul (3) 4.6 - 6.1 MIT l- A
t'.:lJ1
, Nut (6)
'l

_ ./ i.:lJ\ \
Nut (2) 15 - 1.9 \.
Bolt
0.5 - 0.7
Bo't' (4) Bolt 121 i.:lJ 1 3 - 1 6
o 5 - 0 7 t 4.4 - 5 6 r:;.
8011(2) /
1 3 - 1 6i.:lJGjOlt \ i
AIT 1 '1l
Boll (2) i.:lJ V' A
...... 44-56 lew
1 3 - 1.6\ - B i
i.:lJ Nut 13 - 1 6' Q ' N 1 6"" I
ut 1 3 ,
__________ -1
(2) RB20E ENGINE
MIT, _ A Nut (21
4
.4 - S.6i.:lJ
(3) 4.6 - 6.1 i.:lJ . !

! '. Bolt
Boll'(6) l 4.4- 5.6
0.5 - 0.7 Bolt (6) "
'f' Bolt (2) 1.3 _ 1.6
.44-56
.J)l\/ View A
Nut 1.3 - 1"

\,13-16 Q I
i.:lJ \
Nut(2! 1 5 _ 1 9\ \ View B I
\' \0
' Nut "I .
i.:lJBolt 12) 1 3 _ 1'6 _ B !
1.3 - 1 6, ,
Bolt t'.:lJ
1.3 1.6
(3) RB20DE
MIT, A
Nul (3) 4.6 - 6.1 toJ ... -
, I A Bolt 0.5 - Q.
Nut (2) 4.4 -
\
,
MIT Bolt i .
, ,.." Nut (6) _. A 1.3 - I '
Bo!t (6) l 'BO.II (2).-. 1.3 - /,7 ' \ J ii,
0.5 - 07 .... 4.4 - 0.6 . '- Bolt (2) - (5011 I'
A IsLBe,t (2) 1.3 - 1.6 1.3 - 1.6' .. ' .
4.4 - 5.6 ,/ , , l B I'
j "\\ I ..:.J \. .
l
"=' View A ViewB Nu,1.3 1.6i.:lJ
, ----- '.--.. -----,---,----,,'-,--,----,,---,-----
(4) RB20DET
, ... "-- -- .::::::,,-;:--..AiT-- ------1
I' Nut(3)46-6l ""'Ie' A K
I ABo'1 0.5,07 L_ Nut (2) 1 5 - 1 9 A
I! " "-JI
i .t-=Jl='
Bolt \'
I " '\ Go't (2) Nut (6) 1 3 _ 1 6 '
/ '44 - 5 6 1 3 - 1 6 \,
i Bolt 12) A IT 'b. Bo,t (2) 'A' 'Boll I '
0.5 - 0 7 r Bolt (2) toJ 1 3 _ 1 6 1.3 1 E7\ _ B
! 4.4-5,6 :..c; ANull 3- ;.6 0 '-Nut
l.____. _____ ____ "_ Vlew_!?_",,_ '_'"'_ _
EN - 543
EXHAUST SYSTEM
RB26DETT I RB20E i DE! DET I CA18;! RB25DE ENGINE
(4) RB26DETT ENGINE
(5) RB25DE ENGINE
MIT
Mounting rubber
AIT
EN - 544
RB26DETT j RB20E! DE j DET I GA1SI j HB25DE ENGINE
2. EXHAUST GAS TEMPERATURE WARNING
EQUIPMENT INSPECTION
Basic inspection
Place ignition switch to ON position and check that
exhaust gas temperature warning lamp does not turn on.
Exhaust gas temperature warning lamp must light when
ignition switch is placed at START position and must go
off when engine is started.
Exhaust gas temperature warning lamp replacement
and inspection
Remove vehicle harness from switching module.
Use lead line to ground vehicle side harness connect
exhaust gas temperature warning lamp terminal.
Inspect condition of exhaust gas temperature warning
lamp with ignition switch turned ON.
I..ampJlQnt. .. Faufty circuit between ignition switching module.
... . ... . Faulty key sensing module or sensor.
. .... .... Exhaust gas temperature warning lamp is burned

lIght .. Exhaust gas temperature warning lamp power
.... " ... . '. CirCUit is faulty.
EN - 545
EXHAUST SYSTEM
ENGINE CONTROL
RB26DETT I RB20E / DE I OET I CA 181 i RB25DE ENGINE
EN8 ENGINE CONTROL (INCLUDE ASCD DEVICE)
1. ACCELERATOR PEDAL INSPECTION AND
ADJUSTMENT
Accelerator pedal inspection
The engine must be full throttle when accelerator pedal is
pressed fully (pedal lever contacts the stopper
completely).
Accelerator pedal adjustment
loosen lock nuts so accelerator cable has adequate
slack. Pull outer case in direction of accelerator pedal
from position where throttle drum starts operating (there
must be no play at this point), return lock nuts 1.0 to 1.5
turns and tighten securely.
Tightening torque (kg-m)
RB20DE I DET / RB25DE
. - 1.0 I
l Torottle drum
i ASCtWI're I
. / ---'-
0.8-1.0
CA18i

. ,
$ Locknut
. 0.8 1.0
", . ,: 1'1'
i
Wlrt:.
RB20E
I
Kickdown switch adjustment (RB engine A I T vehicles) .
I Ii Lock nUl 0.8 - 121
Press accelerator pedal to fully open throttle drum. Adjust i
lock nut so the gap is between 0.3 to 1.0mm. I
, , fItl
rI ,
I ! ' . ..,:d... . Kickdown
0.3 - 1.0 switch I

o m'n
\ I
EN - 546
RB26DETT! RB20E! DE! DEI! CAlSI ; RB25DE ENGINE
2. AseD
Specification
Speed setting range
Constant speed control range
IMemory type
Control type. actuator dnver source
IActuator stroke
ISet system
Resume system
Acceleration system
Over drive cancel system
System
AITVEHICLE
Ignition switch
t':::,
\..;.<"
IHICAS'
vehiCleil
Approx. 50 - 1 OOkm I h
Level road +0 I 2 km i h
'Digital memory
Negative pressure control. negative pressure pump
Approx 33mm
Onetouch system (with tap down system)
.
Installed
,Installed (with tap up system)
Installed

Horn relay (coil)

'
. Vacuum: : 'I ( .;t=:- -'I 'Cruise
Small
Ughl
SWitch
M/TVEHICLE
Igmtior,
EB
FUS{J
Ll
Small
: . : ,'123(:::}* "Iamp
: Air valve :Set: 1 Cancel
, lena I cceler : ',';! Horn
-,,,.--.r- ! - -"" SIN! C ' "9,,., ...
Switch J SWltc"
! I a i,i -+1 Ii! II
_____ ---+ A ! T control unit I
ASCD control unit
EN - 547
ASCD
m
z
<.n

()O
21 AseD INSPECTION AND ADJUSTMENT
(1) FAULT DIAGNOSIS
Does not operate
Setting
unstable
Hunting
Cancel
Large gap between
set vehicle speed
Vehicle speed
decrease when
setting
Does not cancel
set / coast
Faulty I SW faulty
Resume i
accelerator SW
faulty
FauKy adjustment
parts
Main unit I Inside circuit I Mafn unit
faulty iaulty
Inside drcult I Main unit
faulty
Faulty val"",
faulty diaphragm
Faulty response
Inside CirCUit I Ma", Unit I Diaphgramn leak I
faulty
h1Side CHcuit Mam umt Catch or leaK"'g
faulty faulty dlaphgramn
inSide circuit Main Unit
faully fautty
Inside CirCUit I Main unit
faulty
ASCD system Wiring. harness
disconnection, piPing
disconnection
Piping breakage, actuator
meter reSistance faulty speed
meter cable
faulty speed meter cable
Actuator wire catch
.,' --
Faulty actuator Wire
adjustment faulty pipings
clogging
Actuator wife locking
:IJ
Rl
'"
o
m
:::j
:IJ
OJ
'"
o
m
o
m
o

()
:::
'"
:0
Ri
en
o
m
m
.'
Cl
L
m
}>
(fJ
o
o
ASCD
RB26DETT I RB20E! DE I DET I CA 18 ! RB25DE ENGINE
INSPECTION & MAINTENANCE PROCEDURE WHEN IT CAN NOT BE SET
Does not
Does main SW lamp turn ON when. turn ON
'----1 main SW IS restored after it is i-' -----I Replace faulty main SW, ASCD
!tumed OFF once. relay, power supply circuit
Turns ON
CheCK piping connection for any Faulty
faults,
I Repair piping I
NOl111al
No
Check controller ground for any continuity
faults (between terminal 3 and body, Faulty harness, inspection
ground),
i
c ontinUity present
Other than
Replace faulty stop lamp SW,
Check for power votage (approx,
approx,12V
clutch SW (MiT). clutch relay
12V) to controller [4 - 3, 5 - 3
(HICAS MIT), inhibitor SW, relay,
; (other than P,N for AlT) ,(AlT) ;
I Approx 12V
Other than
Power voltage is present when Set : approx, 12V
I coast SW is ON (Approx, 12V) I
I Replace faulty set! coast SW, I
(between 7 ,3)
I Approx, 12V
1 Power voltage is present at vehicle Other than
! speed sensor (between 7 - 3) 5V and OV
Inspect vehicle speed sensor
; (Approx, 5V and OV alternatively)
system,
i when wheels are rotated slowl 1
2km i h)
Approx, 5V & OV
Do not
Disconnect ASCD pump operate ; Remove actuator hose and operate i
connector and apply battery voltagel----.....,' the pump, Check if negative
,between terminal 1+ - 3', Check if pressure develop.
: ASCD wire will operate when L-----r----'----,----'
i terminal 4 and 2 is grounded,
Operate
,
Control power voltage (approx, 12V)
Olherthan
is developed between tel111inal8
12V
and 3, when vehicle speed ''s over
Replace faulty controller, I
48kmih and seVcoast SW is ON,
I Approx,12V
Remove controller connector and
check il pump operates when 12V
Donat
and OV IS applied 10 vehicle side
operate
I Repalrfaulty harness to the pump I
harness which corresponds to lor short oircuit
,controller termInal 8+ and body
; ground, terminal 8+ and 9,10-,
I Operate
Other than
Check if set power voltage is
OV
approx, OV between terminal 2 and Replace faulty seVcoast SWI
3 when seVcoast SW is released,
I
Approx.OV
EN - 549
AseD
f1826DETT i R820E i DE f on I CAtSI f RB25DE ENGINE
INSPECTION & MAINTENANCE PROCEDURE WHEN SETIING IS UNSTABLE
(HUNTING)
I I
.... '-:-1
Hunting
Check for bent or any damage
Setting OK 1--"--;
with vacuum piping. '-___ --'
No damage
Not
smooth
Check if ASCD wire movement is smooth Repair or replace
Smooth
Check for any leak or negative pressure in f---i
ASCD pump air valve and release valve. t.:.
p
_
u
_
m
.:..
p
___ . __ -,
No leakage
r-----...L-------,Cracked
Check for any leak or negative
in air valve and release valve I
Not cracked
I DlsconnectASCDpu;;'p connector-an-a--! Do not
i apply battery voltage between terminal 1 + _ ; operate
; 3-. Check if ASCD wire will operate when
terminal 4 and 2 is grounded.
Operate
; Remove actuator hose
and operate the pump.
Check if negative
pressure develop .
Replace controller
INSPECTION & MAINTENANCE PROCEDURE WHEN SETIING IS UNSTABLE
(CANCEL)
I
There is approx. 12V i
. ; present between terminalS f
Voltage between resume I
I
thanOV
Replace faulty ASCD I
Other
! and 3 when set SW is
; placed from ON to OFF
position. The system
automatically cancel itself.
: accelerator switch termrnal1
and 3 is OV.
I OV
I switch.
Abnof111al
Inspect & repiace
/IS there any abnormality with
speed meter needle movement?
vehicle speed sensor
I
and meter cable.
No abnormality
Power voltage (approx. 5V and OV) is Other than
applied alternatively between vehicle 5V & OV I
speed sensor terminal? and 3. when system. I
wheels are rotated at 1 _ 2kmfh. .. ______ ........J
1 Aoprox. 5V & OV
1r;:'Cc-h-ec-:k-:f-or-:le-a-:-k-a-n-:d pressure Leaking Iinspect & replace faultyl
lin air valve and release valve. lASeD pump I
I
[R,uity cont'o:er I Replace I
EN - 550
ASCD
RB26DETT I RB20E / DE I DET I CA18t I RB25DE ENGINE
INSPECTION & MAINTENANCE PROCEDURE WHEN SETTING IS UNSTABLE
(DIFFERENT TO SET VALUE)
I SETTING I
UNSTABLE
I
Catching
I Large difference I Any abnormal catch to actuator I
present
Replace I
to setted value or ASCD wire.
I
I
No catching
Check for any bent. damage to I Damaged
I Replace damaged vacuum
. vacuum piping,
I
I piping,
I Nodamage
" Leaking
Check ASCD pump, alf valve and release Replace faulty ASCD pumpl
valve for negative pressure and leak, I'
I No leakage
Check for any leak or negative pressurel Leaking
Replace faulty ASCD pumpl
in air valve and release valve,
I
I Not cracked
Operate
Disconnect ASCD pump connector and abnormally I Re lace faulty ASCD I
ground terminal 1 + - 3-4,2, Check If p
ASCD wire wiil operate normally, I pump,
I Operate normally
I Faulty controller, Replace cantrolier.1
INSPECTION & MAINTENANCE PROCEDURE WHEN SETTING IS UNSTABLE
(Plunge in vehicle speed)
SETTING
UNSTABLE
Plunge in vehicle
speed when selling
I r Plunge in vehicle
y speed after selling
Not correct
Check if ASCD wire play is I or smooth
normal and move smoothly, I
i Correct play and smooth
I Replace or adjust ASCD I
I wire play, !
Check vacuum pipes for bent orl Damaged Repair. I
damage,
I Nodamage
=--,----':=--,-",-'-,.",---, Other
There is over 1 OV control voltage than 12V
for controller output between
terminal 8 and 3 Just after setting, I
I Approx, 12V
Disconnect ASCD pump connector
and ground terminal 1 .. - 3-4.2, Check
if ASCD wire will operate normally, .
I OK
I Faulty ASCD pump
EN - 551
NG Replace faulty ASCD I
pump,
Replace, I
ASCD
RB26DETT I RB20E I DE I DET! CA1811 RB25DE ENGINE
INSPECTION & MAINTENANCE PROCEDURE WHEN ACCELERATOR DEVICE
DOES NOT OPERATE
Acceleration device
do not operate
l
I' I Does not
IlnSpeCtfollowmg the steps of
I
Check 'f constant speed t
I will operate using f opera e
seticoast Sw.
"Can not set',
-
I Operate
When stopping place
Check if power voltage approx. 12V is 1 V
ignition SW in ON
present when resume I accelerator SW in hher than 2
position with main SW in
ON position (OV between terminal! and 3). I
ON pOSition. Do nol
l-
I Approx. 12V
I
press brake and clutch
Other than
. (OFF position). IF AfT
I Check if voltage is OV between 1 - 31
OV
vehicle, place in D range
I Repairfaulty SW I
when resume i accelerator SW Is OFF.
and apply park brake.
.
OV
Check If speed will Increase when
Do not
Turn off the main switch for
Ehlle crUising ASCD resume I accelerator SW Is placed
increase
few seconds and turn it on
in ON position. again.
l
I
r

i r Check If speed will increase
Donat
Replace faulty
. when resume J accelerator
increase
controller and
i SW is turned to ON pOSition.
t vehicle speed
; sensor,
Do not Check If vehlcie i
Check if the vehicle will crUise at speed will increase: Increase
normal vehicle speed when resume r'
; Replace faulty I
controller and
vehicle speed
sensor.
; to high-cut vehicle
:i accelerator SW is turned OFF. speed (100km I hJ.
! Cruise
I I
Do not increase
Replace faUlty controller
EN - 552
AseD
AB26DETT i AB20E I DE! DET i CA18i / AB25DE ENGINE
INSPECTION & MAINTENANCE PROCEDURE WHEN RESUME DEVICE DO NOT
OPERATE
! Resume device do
not operate
I
Does not
Check If constant speed
operate
I Inspect follOWing the steps of
device will operate USing
I "Can no! set".
set/coast sw.
r-
I Operate
When stoPPing piace
Check if power voltage approx. l2Vis
Otherthan l2V
ignition SW in ON
present when resume / accelerator SW in
I-
position with main SW In
ON position (OV between terminal 1 and 3).
ON position. Do not
-
T Approx. l2V
press brake and clutch
Other than
(OFF position). IF AfT
I
Check if power voltage is OV between 1 - 3\.
OV
vehicle. place In D range
I Repair faulty SW
i when resume / accelerator SW is OFF. .
! and apply park brake.
'-
I
OV
: While cruising
r Set vehicle speed to 80km i hi
I using set i coast Sw.
T
I Break (Make sure the vehicle speed I
will not get below 48km i h).
I
I Check if the vehicle speed will decrease when,
Do not
decrease
Replace faulty controlier. resume SW IS turned ON Make sure the '
. (
: vehicle speed will not get below 48km / h)
Decrease
Other than
Replace faulty
speed (60km j h) when controller.
resume SW IS turned OFF.: resume SW is turned ON.'
80km ! h __________ ---" Below 48km! h
Normal
EN - 553
RB26DETI I R820E! DE i DET ! CA181 i RB25DE ENGINE
INSPECTION & MAINTENANCE PROCEDURE WHEN IT CAN NOT BE
CANCELLED
SETTING CAN NOT
BE CANCELLED
,
i
Is voltage between terminal 5 and 3 '
OV when brake is operated (in N
NG
I Reolace faulty orake SW I
range)?
lor N,P SW
I
I
OK
ASCD
Check if voltage IS present between ~ ~ N ~ ~ _ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
terminal!! and 3 when brake is Inspect and replace stop lamp SW I
operated,
I OK
'-=:--:-::c---
'Check If controller output IS cut
between (8 and 3) when brake
pedal is pressed,
OK
Is there an actuator fault.
OK
lis there harness short circuit.1
(2) FUNCTION INSPECTION
i NG
Replace faulty contrOller
NG
Inspect and replace actuator i
NG
I Inspect and replace harness, I
ASCD function inspection is carried out by driving the vehicle and checking if each
function will operate normally, In this function inspection ASCD control circuit system
function is inspected using free roller,
Qautio!];
Constant drive can not be achieved by ASCD as it is non-load drive on the free roller, Use
(1) fault diagnosis as a reference depending on each problem when carrying out fault
diagnosis,
Turn ON the main switch when ignition switch is placed in ON position and check that
operation lamp will turn on,
Caution:
There is a fault with main switch or ASCD relay if the lamp does not turn on,
Check that the cruise lamp will turn on when driving at a constant speed (60 km/h) and
set I coast switch is placed to ON position. Check if the vehicle speed will increase for
a moment. crUise lamp will turn off and constant drive can not be achieved when
accelerator pedal is released and set I coast switch is placed to OFF position at the
same time,
Caution:
If ASeD circuit is normal, hunting will occur andASCD will be cancelled as it is non-load
drive.
Check that the cruise lamp will not turn on when set switch is pressed when the brake
pedal is pressed slightly (brake switch: OFF, stop lamp switch: ON), driving at a
constant speed (60 km! h), Make sure the vehicle speed will not increase when the
accelerator pedal is released and set switch is placed to OFF position at the same
time (release function inspection),
EN" 554
RB26DETT I RB20E I DE! DET ! CA 181! RB25DE ENGINE
(3) COMPONENT PARTS INSPECTION
Controller inspection
Extract the controller by removing controller bolts. Inspect
ASCD control system using controller connector parts. If
diagnosis result is faulty replace the controller unit.
Controller (ground circuit) inspection
Check the continuity between terminal 3 and body ground
with connector connected.
Between terminal 3 and body ground ContinUity present
Controller (power circuit) inspection
Inspect power voltage between following terminals with
connectors connected.
OV Approx.12V OV
Controller (cancel power supply input) inspection
Measure the voltage between terminal 11 and 3 when
connectors are connected.
Controller (set I coast switch input) inspection
Place ignition switch to ON position. Measure the
voltage between terminal 1 and 3 with connectors
connected.
EN - 555
ASCD
finisher interior
. ,
AseD
RB26DETT ! RB20E! DE I DET! GA18;! RB25DE ENGiNE
Controller (resume I accelerator switch input)
inspection
Place ignition switch to ON position and measure the
power voltage between terminal 1 and 3 with connectors
connected,
MaId_ftcti
l
;!
Controller (vehicle speed sensor output) inspection
Slowly rotate the rear wheels and measure the voltage
between terminal 7 and 3 with connectors connected,
. i-I Approx. 5V and OV altermallvely
Controller (cruise lamp output) inspection
Measure the voltage between terminal 13 and 3 with
connectors connected,
Controller (AfT control unit control output) inspection
[A/Tvehicle]
Drive (ASeD set possible range) and measure the
connected,
Note:
With AfT shift control, ASeD controller is prioritized when
set at ASeD drive,
EN - 556
-- ...
Jasr: sloe :Qwer finisher interim 1
------ .---c-......,
RighI dash side finlsh(f interior
Right dash side lower .fim$her intenor
. >"'p"o '
- .. -..
RB26DETT R320E / DE:; DET ! CA18i! RB25DE ENGINE
Controller (valve output) inspection
Drive (ASCD set possible range) and measure the
connected.
a(+j - 3(-) Approx 12V OV
Main switch inspection
Remove harness connectors and check the continuity
between following terminals on main switch side
connectors.
Continuity
No continUity
present
Continuity
No continuity
present
Continuity
No continuity
present
ContinUity
No continuity No continuity
present
Continuity ContinUity
No COn!inUlty ;
present present
ContinUity Continuity Continuity
present present present
Continuity ContinUity ContinUity
present present present
Set I coast, resume I accelerator & cancel switch
inspection
Remove horn pad and harness connector. Operate each
switch and check continuity between following terminals.
ContinUity
Contmuity
present
Continuity
No contrnUity
EN557
,R!cht d s ~ side
I ~
,
I
ASCD
ii'1istler :n1enQr
, :
RB26DETT! RB20E I DE! DET! CA 1811 RB25DE ENGiNE
Brake, clutch & stop lamp switch inspection
Disconnect harness connector and operate each
switches to inspect continuity between following
terminals.
ASCD relay inspection
Remove ASCD relay and directly apply battery voltage
between terminal 1 and 2. Check the continuity between
terminal 3 and 5.
Clutch relay inspection (HICAS MfT vehicles)
Check the continuity between following terminals when
battery voltage is directly applied between terminal 1 and
2.
3-5 Contmulty present
3-4 Continuity present No continuity
Inhibitor (N.P) relay inspection (AfT)
Check the continuity between following terminals when
battery voltage is directly applied between terminal 1 and
2.
6-7 No continuity Continuity present ,
Continuity present No continUity
EN - 558
ASCD
RB260ETT I RB20E i DE! DET /CA18i i RB25DE ENGINE
AseD pump inspection
Remove connector terminals. Check the motor operation
by directly applying battery voltage between terminal 1
and4.
Apply battery voltage betweebn
termlnai 1 and 4
Resistance inspection
Motor will operate
.... TeFlllirlais . .... .... .; . >!. t ~ I 8 t a ~ ~ ~ ,a
Alf valve 1 - 4 Approx. 70
Release valve 1 - 2 Approx. 70
Vacuum pump ~ - 3 Approx. 8
Operation inspection
Apply battery voltage between terminal 1 (+) and 3(-) and
check if ASCD wire will operate when terminal 4 and 2 is
grounded.
AseD wire adjustment
Loosen lock nuts so ASCD wire has adequate
slack. Pull outer case in direction of actuator from
position where throttle drum starts operating. return lock
nuts approximately 1 turns and tighten securely.
Lock nut tightening torque (kgm) 0.8 -1.0
EN - 559
RB20E
RB20DE I DET
,--- Tcck-nut
Front
ASCD
i Throttle
ENGINE MOUNTING
RB260EIT I RB20E 1 DE 1 DET I CA 1811 RB2SDE ENGINE
ENGINE MOUNTING
FRONT ENGINE MOUNnNG
(1) CA181 ENGINES
fi Bolt (3) ".4 - 5.8
I ,Nut (2) 4.4 -
2.2 -
2.9
REAR ENGINE MOUNnNG
(1) CA181 ENGINES
Ir Nul (2) 4.4 - 5.8
801(2) I }

(ot)
4.4 - 5.8
Nut (2) 2.2 - 2.9
(2) AS ENGINES
(2) RS ENGINES
)-,
(
0 \1 (1)
Bolt (2) Bolt (4) 4.4 - 5.8
4.4 _ 5.8 4.4 - &..8 . ,
Nut (4) 2.2 - 2.9
EN .. 560-
Index
Symbols
2-pole lift ..................................... .
4WD inspection ....................... ..
4WD repair precautions ..................... .
A
. .. G! -13
". GI 15
. GI - 15
A / T control (RB25DE) ............................ EN - 421
MCvalve ................................ EN 274. 443. 484
Active test ................................................ EN - 270
Actuator system inspection ...................... EN - 302
Air cleaner element ..................... EN - 49, 58. 151
Air conditioner relay ................................. EN - 433
Air conditioner signal ................................ EN - 399
Air duct & air cleaner ............................... EN - 151
Airflow meter ................................... EN - 407, 482
Air flow meter sensor (RB20) ............ EN - 361. 363
Air regulator ............................ EN - 275, 445. 485
Alternator ................................................. EN - 530
ASCD ...................................................... EN - 547
Automatic temperature adjustment ............. EN - 51
B
Balance tube .............................................. EN - 68
Basic inspection .............................. EN - 236. 272
Battery inspection .................................... EN - 530
Belt tension................................................ EN - 43
Blowby control valve ........................... EN - 55. 489
Blowby gas reduction device ...................... EN - 55
Blowby hose ............................................ EN - 489
Board-on Lift ......................... '" ..................... GI - 13
Braking periorm check ................................. G I - 15
C
Catalytic converter ................................... EN - 543
Circuit diagram ......................................... EN 279
Collector ASSV ................ EN - 59. 105. 106, 115
Components inspection (RB25DE) ........... EN - 482
Compression pressure inspection .......... ' ... EN - 42
Conical washer ........................................... EN - 80
Connector installation............................... EN - 233
Connector symbol .......................................... GI - 6
CONSULT .................................................... GI - 11
CONSULT display screen......................... EN 265
Crank angle sensor ........ EN - 355, 356, 404, 442
Cylinder head .............................. EN - 83. 85, 170
o
E
ECCS ..................................................... EN 231
ECCS C/U installation ............................. EN - 233
ECCS relay (RB25DE) ............................ EN - 485
ECCS voltage .......................................... EN - 233
Emission control equipment ........................ EN - 7
Engine control ......................................... EN - 546
Engine electrical equipment .................... EN - 529
Engine mounting ..................................... EN - 560
Engine overhaul....................................... EN - 186
Engine specifications .................................. EN - 7
Engine stall ............................................. EN - 254
Engine temperature sensor .... EN - 367, 396. 482
Evaporative gas control ..................... EN 54, 488
Exhaust gas sensor ....... EN - 386, 390, 392, 415
Exhaust gas sensor heater ..................... EN - 434
Exhaust gas temp warning equipment ..... EN - 545
Exhaust manifold .................................... EN - 159
Exhaust manifold ASSY ... EN - 75, 109, 119, 142
Exhaust pipe ........................................... EN - 543
Exhaust system ............................... EN - 49, 542
F
Frontturbocharger ASSY .......................... EN 69
Fuel gauge .............................................. EN - 539
Fuel injector ............................................ EN - 156
Fuel pressure inspection ........................... EN - 53
Fuel pump ..................... EN - 303, 307, 440, 483
Fuel system ............................. EN - 52, 486, 537
Fuel tank ................................................ EN - 537
Fuel tank vacuum releaf valve .................... EN - 54
Fuel tube ASSV ........................................ EN 66
G
Gas leak inspection .................................. EN - 75
General precautions ...................................... GI - 7
H
Heater panel ............................................ EN - 543
How to use this manual ................................. GI - 2
Hydraulic Jack lifting ................................... GI - 14
Idle mixture ratio ....................................... EN 23
Idle speed control system ............... EN - 339, 346
Idle speed inspection ................................ EN 23
Ignition coil ...................................... EN 483, 532
Data monitor ........................................... EN - 267 Ignition inspection ................................... EN - 328
Deceleration exh gas emission control ... EN - 527 Ignition relay ............................................ EN - 486
Detonation sensor .................. EN - 381, 382, 417 Ignition signal .......................................... EN - 424
Diagnosis chart by phenomenon ............ EN - 240 Ignition system ....................... EN - 330. 332, 412
Diagnosis procedure ................................ EN - 234 Ignition timing inspection ........................... EN 23
Diagnostic system .................................. EN - 259 Individual system inspection .................... EN - 237
Diagnostic worksheet .............................. EN - 234 Inhibiforrelay ........................................... EN - 486
OOHC ..................................................... EN - 274 Injector ............................. EN - 314,317.323,484
EN - 562
Input signals and control items............. EN - 239
Inspection pOints ......................................... GI - 16
Intake air temperature sensor........... EN - 378
Intake manifold ....... EN - 65, 107, 117, 137, 157
Intake manifold collector .......................... EN - 153
Intake manifold vacuum.................... .. .. EN - 275
Intercooler ...... . .............................. EN - 57. 131
Intercooler air duct assembly .................... EN - 56
I ntercooler in let hose ................................. EN - 56
J
Jack stand support ...................................... GI - 14
L
Lock up release control system .............. EN ~ 353
Locker cover .................................... EN 110, 143
Lubrication oil level................................. EN - 47
Lubrication system inspection ................... EN - 47
M
Measurement tools ................................... EN - 12
Multipurpose tools ..................................... EN - 12
N
Neutral switch signal ............................... EN - 399
No.1 cylinder pressure T.D.C .................... EN - 78
o
O-ring ........................................................ EN - 66
Oil & cooling water inlet and outlet ............ EN - 73
Oil cooler .................................................. EN - 99
Oil filter .......... .. ............ EN - 48, 99, 129, 149
Oil pan ................................... EN - 129. 149, 165
Oil pressure .............................................. EN - 48
Oil pump bolL. ......................................... EN -102
Oil seal................................................. EN -166
Oil strainer ...................................... EN 100, 129
On-vehicle parts ........................................ EN - 56
Operation support .................................... EN - 271
Operational sequence ................................... GI- 3
p
Platinum plug inspection ......................... EN - 531
Poor drivability ......................................... EN - 251
Poor idling ............................................... EN - 247
Power steering hydraulic pressure ... EN - 447, 486
Power supply & ground circuit ................. EN - 401
Power transistor ...................................... EN - 483
Problem confirmation .............................. EN - 235
PTe heater control system ...................... EN - 352
Purge control valve .................................... EN - 54
R
Radiator cap inspection ............................ EN - 534
Radiator inspection ........... .. ................ EN - 534
Rear turbocharger ASSY ...................... EN - 70
Recirculation hose ..................................... EN - 57
Recirculation valve inspection .............. EN - 50. 57
Remove and install engine ........................ EN - 180
Rocker cover ............................. EN - 76. 120, 169
s
Self-diagnosis .................... , ............. EN - 236. 262
Sensor system inspection ..... .. .............. EN - 354
Six i n ~ l i n throttle chamber ......................... EN - 63
Spark inspection ...................................... EN - 274
Spark plug ................................. EN - 76, 121, 486
Special service tools.................... .. ....... EN - 8
Speedometer measurement.. .................. G I - 15
Start signal ............................................... EN - 436
Starter motor ............................................ EN - 531
Sub electrical fan inspection .................... EN - 536
Swing valve controller ................................. EN - 73
System diagram ......................................... EN -13
System figure ........................................... EN - 279
T
Tensioner spring ......................................... EN - 80
Thermo-wax inspection ............................... EN - 53
Thermostat. ...................... EN - 98. 127, 148. 536
Throttle body ASSY .................................. EN - 139
Throttle sensor ............... EN - 371, 373, 419. 484
Throttle valve switch ................ EN 367, 436. 483
Tightening Torque ......................................... GI - 13
Timing belt ........ EN - 78, 82. 111, 122, 144, 160
Towing............................................ . .......... G I - 13
Trouble diagnosis ..................................... EN - 231
Turbocharger ASSY .................................... EN - 68
Turbocharger failure diagnosis .................... EN - 74
Turbocharger inspection ............................. EN - 49
Turbocharger unit inspection .............. EN - 71. 134
u
Unable to start ................................... EN - 239. 42
Unstable idling ......................................... EN - 234
V
Vacuum diagram ........................................ EN - 19
Valve clearance inspection ......................... EN - 45
Vehicle identification plate location ............... GI - 10
Vehicle speed sensor ....................... EN - 397, 430
W
Wastegate valve control ........................... EN - 350
Water bypass connector ............................ EN - 67
Water outlet elbow ..................................... EN - 67
Waterpump .............................. EN-96, 126,147
EN - 563

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R32 ENGINE MANUAL.

CA18i, RB20E, RB20DE,

W ,t ----..J' ! .. - AIr hose

hose Air C\leaner e'ement

'I ,i mr;\\ There must be

" -ilJ\ pump

gas temperature warning lamp must flash 5 times

YOU FEEL PULSATION

ECCS cOrltrol urn1

0.3 - 1.0 switch I

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