GT-R Model R32 Series Foreword This service manual has been prepared primarily for the purpose of assisting service personnel in providing effec- tive service and maintenance of the GT-R. ‘This manual includes procedures for maintenance, adjust- ments, removal and installation, disassembly and assembly of components, and trouble-shooting. All information, illustrations and specifications contained it this manual are based on the latest product information ‘time of publication. If your car differs from ns contained in this manual, consult your NISSAN dealer for information. The right is reserved to make changes to specifications and methods at any time without incurring any obligation to make or install similar changes on vehicles and/or parts previously purchased.IMPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the mechanic and the efficient functioning of the ice methods in this Service Manual are desc! in such a manner that the service may be performed safely and accurately Service varies with the procedures used, the skills of the mechanic and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specit recommended by NISSAN must first com- pletely satisfy themselves that neither their safety nor the vehicle's safety will be jeopardized by the service method selected.GENERAL INFORMATION | ENGINE CHASSIS BODY HEATER AIR CONDITIONER ELECTRICAL SYSTEM SERVICE DATA (Australian Design Changes — See Rear) als iGENERAL INFORMATION SECTION G l | CONTENTS Al HOW TO USE THIS MANUAL .......-.2-55 : G2 A2 GENERAL PRECAUTIONS . Gl 5 A3 MODEL VARIATION . : G7 Ad VEHICLE AND UNIT IDENTIFICATION PLATE LOCATION . : AS TOW TRUCK TOWING : cents AG 4WD INSPECTION AND REPAIR PRECAUTIONS « AT 4WD VEHICLE TOWING PRECAUTIONS. .A1_HOW TO USE THIS MANUAL 1, Preparation Operation Explanation ‘This manual describes important items for installation, removal, assembly, disassembly, inspection and repair. CAUTION: A general description of a visual inspection and cleaning of disassembled parts has generally been omitted. However, when the parts will be used again, make sure to perform visual inspection and cleaning as necessary. 2.Configuration Components, Operation Contents and Procedures The configuration components and operation contents and procedures are shown after the title of the ‘operation. The preparation standards and important operation points such as parts which cannot be used again, tightening torque and lubrication locations are also indicated. 2-1 CONFIGURATION COMPONENTS AND OPERATION CONTENTS The necessary operations for installation, removal, assembly and disassembly are indicated by the part (part name) This description is used if the only ideal procedure cannot be determined or there are many types of components. [Point] is used to indicate operation procedures which are necessary. Example: Front accelerator assembly and disassembly €9 IES Ione grease seal HEE inner boating cuter race HEF OMe" bearing user race 4 Inner bearing Di scrow (3) 3- 403-04, 22-29) sat (a) 25-39 (25-24, 18-25) Dis rtor Spacer {Poir 1 UIE Outer grease sea! Hub bolt Nem (ger, feb) ‘Should be lubricated with groas Uniess otherwise indicated use recommended mult- IES 0120" bearing purpose grease. + Always replace after every disassembly Wheel hub e fs GI-2A1_HOW TO USE THIS MANUAL 2.Configuration Components, Operation Contents and Procedures (Cont'd) 2-2 STRUCTURAL PARTS DIAGRAM AND OPERATIONAL SEQUENCE The names of the parts required for removal and replacement and assembly and disassembly opera- tions are shown. The operational sequence must be performed in the sequence of the indicated num- bers. Assembly is the reverse of disassembly except when otherwise indicated. Example: Light combination switch ASSY installation and removal @ Sioering wheel ASSY @ screw (1) 1 Light combination switch ASSY 2-3 OPERATION NAME SYMBOLS (1) (Removal) (Installation) (Additional work required ) (Removal): Indicates an operation (preparation, inspection adjustment, etc.) that is only necessary for removal (Installation): Indicates an operation (preparation, inspection adjustment, etc.) that is only necessary for installation. (Removal) (Installation): Indicates an operation (preparation, inspection adjustment, etc.) that is only necessary for both removal and installation. (Additional work required): Indicates a supplementary operation (removal, installation, etc.) to be per- formed before the operation indicated in the section tile. (2) Tightening torque Indicates an 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-lb) is indicated, the standard tightening torque is the mean value. (3) EB : Should be lubricated with grease. Indicates a type of grease. (4) & : Always replace after every disassembly. (8) [El : Should be lubricated with oil (8) GZ: Sealing point (7) %: Select proper parts. @) Indicates when the CONSULT electronic system diagnosis is used. & : Indicates when the CONSULT electronic system diagnosis is not used. GI-3A1_HOW TO USE THIS MANUAL 2.Configuration Components, Operation Contents and Procedures (Cont'd) (9) [Point No.} ({Point 1}, [Point 2], [Point 3} ...) These sections describe the techniques, special tools, and repair reference values required to perform operations properly GI-4A2_ GENERAL PRECAUTIONS 2 GENERAL PRED 1. Safety Precautions @ The RB26DETT engine exhaust valves contain metallic sodium. Be careful when using or discarding the valves. (Refer to section B3, 80, Cylinder Head Removal and Installation.) © 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 inflammable materials. Special care should be taken when handling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc When working in a pit or other enclosed space, be sure to properly ventilate the area before work- ing with hazardous materials. Do not smoke while working on any vehicle. © Before jacking up the vehicle, use wheel chocks or tire blocks on the wheels to prevent the vehicle from moving, After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting and towing before working on the vehicle. These operations should be done on a level surface. © When the automobile is lifted on a rigid rack, it should be supported in fixed locations. © Before starting removal and installation of the electrical system or other repairs which do not require battery power, always turn off the ignition switch, then disconnect the ground cable from the battery to prevent accidental short circuits. 2. Fast, Accurate Operations © Check the vehicle damage carefully, make a careful diagnosis of the damage and perform the cor- rect operation systematically. © Check the correct part assembly condition before removal or disassembly. Make alignment marks when necessary in locations which will not interfere with the part functions, © Replace oll seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. These items are indicated, “Always replace after every disassembly.” and must be replaced with a new part. © Before servicing the vehicle, protect fenders, upholstery and carpeting with appropriate covers Be careful so that keys, buckles or buttons on your person do not scratch the paint. © Refer to the lubrication section and only use the lubricants which are described, ‘© When replacing parts always use genuine Nissan replacement parts. Verity the inspection circuit in a wiring figure before performing any inspection with a circuit tester. An inspection may be difficult with a normal test probe when a connector pin is extremely small, If this occurs, wind a small pin or wire around the test probe, or sharpen the end of the probe to per- form the inspection. Wind wite around probe. Test robe ‘Sharpan the ond 3. Electronic Trouble Diagnosis System © Use measurement equipment such as the CONSULT elec- tronic system diagnosis tester and an oscilloscope to per- form diagnosis operations efficiently. @ The CONSULT unit is a hand-held compact type of tester. It transmits signals to the vehicle loading control units when the diagnosis connector is connected and can perform all types of diagnosis and testing, GISA2_ GENERAL PRECAUTIONS 3. Electronic Trouble Diagnosis System (Cont'd) functions and applications Diagnosis mode System Engine Hicas Function Work support ‘Transmits commands to the ‘electrical control unit for set ting the status suitable for required operation. Selt-diagnosis results Receives the sell-diagnosis results trom the electrical control unit and displays mal- functioning system names and the number of times a ‘malfunction occurs. ° Data monitor Receives input and output signals from the contro! unit, | displays and records data used to easily determine cause of malfunction. ° Active test ‘Sends commands to the eon- trol unit and pertorms the ‘operation inspection and ver- ification of the output system according to output signal changes, E.CU. part number Displays the part number of the electrical control unit, ° Note: Reter to the CONSULT Operation Manual for further details. 4. Environmental Protection © Do not pour waste oil or cleaning fluids into a drain after an oil change. Use a disposal method that conforms to local laws. GI-6A3 MODEL VARIATION Body type Remarks Drive system Engine Grade [7 door sedan 2door coupe Transmission aw0 RB260ETT GTA i = o Manual 5-speed ——A4 VEHICLE AND UNIT IDENTIFICATION PLATE LOCATION 1. Vehicle Identification Plate and Starting Number © E-BNR32 model BNR32-000001 - (equipped with RB26DETT engine) 2. Engine Serial Number Location GI-8AS TOW TRUCK TOWING [Towing hook Tonig hook 1. Towing Front side Alter removing 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. 2-pole Lift © The 2-pole lifting points are the same as for the rigid rack cAUTIO! (1) Make sure vehicle is empty when lifting. (2) When lifting the vehicle, make sure the side sill and lift arm (rear part) do not contact each other. 3. Board-on Lift © The board-on lift attachment (LM4086-0200) set at the front end of the vehicle should be set on the front of the sill under the front door opening ‘© Position attachments at front and rear ends of board-on lift. CAUTION: Make sure vehicle is empty when lifting. GI-9AS TOW TRUCK TOWING 4. Hydraulic Jack Lifting and Jack Stand Support CAUTION: (1) Make sure vehicle is empty when Ii (2) When the front side is jacked up, raise. ‘the front slightly using the jack and then jack the vehicle up. (3) Use the attachment (LM4519-0000) whenever a vehicle is supported by jack stands. (4) When using jack stands, be careful not to allow the jack ‘stand to crush brake tubes or fuel lines. Safety stand points mT Place jack in riddle of oF jack stand! Place jack in middle of suspension momber.. GI-10A6_4WD INSPECTION AND REPAIR PRECAUTIONS ‘Sime tre roller IM24e5 0000 Simple free roller Measurement roller 200.0 Observe the following precautions to measure the speedome- ter reading and to check braking performance in the 4WD mode. 1. Speedometer Measurement ‘The two methods to measure the speedometer are described below. (1) Measurement with front wheels jacked up © Place the rear wheels on the roller. @ Use the attachment to lift up the front wheels and support the car on jack stands as shown in the figure on the left. Place the transmission in 2nd gear and gradually release the clutch, © When the test is completed, do not apply the brakes sud- denly. CAUTION: (1) Place the jacks securely, and perform the measurement atter making sure the vehicle is stable. (2) Use the free rollers described below whenever possible. (2) Measurement with simple free roller © Set the simple free roller the length of the wheel base [2,615 mm (102.95 in)] forward of the middle of the mea- ‘surement roller as shown in the figure on the left. @ Place the front wheels on the simple free rollers and the rear wheels on the measurement rollers. @ Place the transmission in 2nd gear and gradually release the clutch. © When the test is completed, do not apply the brakes sud- denly. G11A6 4WD INSPECTION AND REPAIR PRECAUTIONS 2. 2-1 PRE-INSPECTION PREPARATIONS Braking Performance Check The performance check must be performed in the 2WD mode. To set the 2WD mode, either use the front propellor shaft removal method or remove the fusible link from the engine compartment. Use the method most suitable for the test location, GI-A12AG _4WD INSPECTION AND REPAIR PRECAUTIONS Braking Performance Check (Cont'd) 2-2 INSPECTION POINTS (when fusible link in engine compartment is removed) Trop engine and rerove te 4D fusible Ink 30A From the engine compartment relay box ‘Sari the engine, Repeat the engine deceleration opera- tion from ful throttie to no throtie until the 4WO warning amp on instrument panel lights NOTE: The vehicle may not ‘enter 2WD mode when this operation is per- formed. ¥ ‘Wake sure the 4WD warning lamp lights, then turn key switch off once. [pert _______ Start engine again and make sure the 4WD warning lamp lights. | _y Position vehicle on rollers, set shift and range into neutral position. a Press brake pedal. Release pedal when OK zone is. reached or OK lamp lights NOTE: ithe drag force exceeds 10% of the axle weight winen the drag testis performed, the whee! rotation ‘must be checked withthe vehicle jackes up. It there is no abnormality a his time, it can be assumed that the arag is caused by the viscous torque and there is no brake abnormality | ‘Slop the engine and install the fusible link in the normal location ee Restart engine and make sure the 4WD warning lamp ‘90e8 off and AWD mode is set End GI-13A7_4WD VEHICLE TOWING PRECAUTIONS 1. Towing Precautions = Never tow a 4WD model with front or rear wheels raised and opp rear or front wheels on the ground as this may. cause serious and expensive damage to the transaxle, G44ENGINE | SECTION EN CONTENTS B ENGINE 81 ENGINE SPECIFICATIONS os EN 3 1.Main Engine Specifications ee se wv ENE 3 2.Emission Control Equipment Specification ese eo EN. 4 3.System Diagram sce sown ENS 5 4.Vacuum Diagram . EN- 6 82 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE EN- 7 1.ldle Inspection and Adjustment . seven EN- 7 2.Compression Pressure Inspection ....... esse eo EN- 16 3.Belt Tension Inspection and Adjustment .. . EN- 17 4.Nalve Clearance Inspection and Adjustment os se EN- 19 S.Lubrication System Inspection EN- 32 6.Exhaust System Inspection 7.Fuel System Inspection os essen . 8 Evaporative Gas Control System Inspection . . EN- 26 9.Blowby Gas Reduction Equipment Inspection 0... : EN- 26 10.Removal and Installation of On-vehicle Parts ve EN: 27 11.Engine Removal and Installation oe EN- 89 42.011 Pan, Oil Pump and Oil Strainer Removal and Installation so EN- 92 13.Engine Overhaul sen EN- 98 B83 ECCS (Electronically Concentrated Engine Control System) . wo EN-119 1.Trouble Diagnosis evn sen EN-120 2.Diagnostic System ns. se sevens ENC15O 3.Basic Inspection EN-165 4 System Figure and Circuit Diagram EN-169 5.Actuator System Inspection .. EN-174 6.Sensor System Inspection ose EN-203 TECCS Control Unit Input/Output Signals (RB26DETT) EN-234 8 Deceleration Exhaust Gas Emission Control Equipment Inspection sennnnenrees ENE245 9.Air Conditioner Cut System Inspection EN-245B4 ENGINE ELECTRICAL EQUIPMENT 1.Battery Inspection 2.Alternator 3.Starter Motor Removal and Installation 4.Platinum Plug Inspection 5.Ignition Coil Inspection 85 COOLING SYSTEM 1,Radiator Inspection 2.Radiator Cap Inspection - 3.Cooling Water Filling Procedures... 4,Radiator Removal and Installation 5.Thermostat Inspection 6.Sub Electrical Fan Inspection - 7 Sub Electrical Fan Removal and installation B6 FUEL SYSTEM... 1.Fuel Tank Removal and Installation 2.Fuel Gauge ASSY .... 3.Fuel Pump Removal and Installation B7 EXHAUST SYSTEM 1.Exhaust Pipe, Catalytic Converter and Heat Panel Tightening Torques 2.Exhaust Temperature Warning Equipment Inspection BB ENGINE CONTROL “Accelerator Pedal Inspection and Adjustment B9 ENGINE MOUNTING (4WD) “Front Engine Mounting (RB2SDETT). 2.Rear Engine Mounting (RB26DETT) .. EN-2 EN-246 EN-247 EN-247 . EN-248 EN-248 EN-248 EN-249 EN-249 EN-250 EN-250 EN-251 _ EN-252 EN-252 EN-253 .. EN-254 EN-255, . EN-257 EN-258 EN-260B1_ENGINE SPECIFICATIONS 1. Main Engine Specifications Mode! | E-BNRS2 Item Engine RB260ETT Displacement ‘em? (cu in) 2,568 (156.70) Combustion chamber Pentroot ype Valve arrangement DOHC belt drive Bore x stroke mm (in)| [email protected] x 737 (3.386 x 2.902) ‘Compression ratio 35 Compression pressure kPa (kglom?, psilirpm 1,177 (12.0, 171/300 870 % 665 * 675 Dimensions» W = Hi vom wn oe Tatve [tae valve opening agie (700) weno) 7 Intake valve closing angle (BBDC) (degrees) 53 2 | Exaust valve opening angle (2805) (Geren 8 tye [Esteve va cng anle (TC) (earees) Tere Valve | intake (warm) mm (in) 0.51 (0.020) ce [eau warm vm oat ein ii speed om wi 0 Tnton ing BOS wir 80 Prope: Idle CO density (%) 0.1 max. target : trae Ye Ho density wom max Engine | standard a 7919080 rade fr wrt Cot cima version too) i pn capaciy evel Timea ae oie eapecy Cm a Tor 04 6) Total orgne coor capac Cine | Aveon 80 78) Use recommended genuine Nissan SG grade engine oll [Turbo X (7.5W-20)] or equivalent. EN-3Bi ENGINE SPECIFICATIONS 2. Emission Control Equipment Specification ode! | Me E-BNR32 Item Engine B260ETT Engine fuel sysiem EGOS (MPI) Air/tuel ratio control system Alrtuel ratio feedback Tempe: ture control air cleaner ‘Supplemental start equipment Bi-metal type air regulator Intake heat system Hot water heating Ignition system Breakerless type (ECCS electrical dis- tributor) EGR control system NOx reduction equipment [TV valve operation temperature °C (*F) Catalyzer ype Tiveeswaycalayet C0, HC (NOx) reduction equoment [Catalytic converter size apn (i [capacity in liters (Imp at)} fren Declan exhaust ons reduction 155 an auipmont ° equipment Exhaust gas temperature warning equipment (setting temperature °C ("F)) Thermocouple (850 (1,562)) Evaporative gas control system Canister system Blowby gas reduction system Closed system EN-43. System Diagram Bi ENGINE SPECIFICATIONS 3-1, RB26 DOHC — EGI (ECCS) TWIN-TURBOCHARGER ENGINE dua Bu1vIO omyeseduse S08 18nK3 ‘npou osu 606 rene ous owues 500 ee saned Not? emeroduer wena, sore mou sy rome “7 es ea ul > vourn |) —— tee ue “ot =o I g sums, o i AIBA BUIMS on aye Kame 10 {A EN-5 owns omen ‘mag pue Josues ome “Tata valve opering angle sensor TTT Ee ome err x Detonation sensor output signal Pressure conta signal Engine temperature signal TRUBS Jomo9 On! ODN ‘anyon uonenosioey pesraion Pros. we eats // | Poe Promo” clez/ ‘ miyctron GES ore & : 5 TO enna I oO | as. ro sss Rear turbocharger > i 2 4 ASS rt Clamp | [Point 6 | {Point 5) Balt Ineiesnin~_S | tube air hose sit nos f s—b (18-21, 12-15) Qin Kom ey 624: Aways replace ster every disassembly O— nie (2) (One -21 (1.6 -21, 12-15) L Additional work required Remove undercover. Remove front bumper. (Refer to Section D1-1, Body.) [Point 1] Air hose, air duct cleaning © Before removing each air hose and air duct, blow off any dirt or dust with an air gun. EN-27B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE = 118 (0.83 - Mourting rut (ors na 10. Removal and Installation of On-vehicle Parts (Cont'd) [Point 2] Remove and install each air hose and tube. Removal © Draw alignment marks before removing air hoses and tubes. Installation © Position air hoses and tubes so the alignment marks coin- cide. Insert [approximately 30 mm (1.18 in)] hose or tube and tighten clamps securely [Point 3] Remove and install the intercooler inlet hose. Removal Remove the resonator and tube ® before removing hose ® Installation ® Attach hose @, then combine resonator and tube ® as a single unit and install. [Point 4] Remove and install intercooler. Removal ® Remove the bumper finisher and bumper reinforcement. (Refer to Section D Body for details.) @® Separate the intercooler inlet and outlet hoses. ® Remove the mounting bolt and two nuts. Detach intercooler without scratching the fins . CAUTION: (1) The fins are aluminum and can be damaged easily. Never place anything on the intercooler or allow tools or other hard objects to contact the fins. (2) The main unit (tank, fins, tube) cannot be disassembled. Installation © Assembly is the reverse of disassembly. Perform steps in the sequence @, ®@, O. Tightening torque 9.1 = 11.8 N-m (0.93 - 1.2 kg-m, 6.7 - 8.7 ft-lb) [Point 5] Recirculation hose removal and installation @ Remove and install the recirculation hose and tube as shown in the figure on the left. EN-28B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE Recirculation valve Ait cleaner element i nase ‘Air cleaner A SES 10. Removal and Installation of O Parts (Cont'd) [Point 6] Recirculation hose clamp installation ‘© When the recirculation hose clamp is installed, it must not contact the bumper finisher. [Point 7] Recirculation valve inspection Unit inspection Use a hand vacuum pump to apply a vacuum [-20.042.7 kPa (-150-+20 mmHg, -5.91+0.79 inHg)] and check that recirculation valve diaphragm lifts and vacuum pressure is maintained. [Point 8] Turbocharger outlet tube removal and installation ‘© Remove and install turbocharger outlet tube as shown in figure on lett. Bat hs -21 9m (16-21 hem, / | Additional work required: Remove turbocharger outlet hose. [Point 2] EN-29B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10. Removal and Installation of On-vehicle Parts (Cont'd) [Point 1] Air hose and air duct cleaning © Use an air gun to blow off any dirt or dust before removing the air cleaner element. [Point 2] Air cleaner element removal and installation Removal ® Remove turbocharger outlet hose. @® Remove the four band clips from air cleaner. Lift air cleaner cover and remove air cleaner element. Installation © Install in reverse order of removal. [Point 3] Air cleaner element inspection © Air cleaner element must not be dirty or damaged. Periodic replacement interval: Every 60,000 km (36,000 miles) == [Point 4] Air cleaner cover installation =A) I i Connector Air flow metor e First connect air flow meter connector for front turbo- A charger and then install air cleaner cover. EN-30B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10. Removal and Installation of On-vehicle Parts (Cont'd) 10-3 COLLECTOR ASSY (1) Collector ASSY removal and instal No.2 thratte chamber breech a hi se cotager assy | (£9 Yrote chamber gasket . Nc ey oa — ve te eect sin (o) OME Ap iH > = =) ~. Any TT x eee (ee 2 (066 bata \ Swim Bika on see (ae 2 efng woah (1) run a” ay NA EF } ibe et oe Fea. enn | wa | Hose L vin nin PORI—N O85! [Point 5). Non-separable wit i [Poirt 11)_ 53 BOM ale eae “ I ‘12 - 15) [Point 8] ‘howe vs | baw veer | ~ | eacteraeeente\ eS ot 6-21 (18-24, 2-15) (2): Aways replace ater every cisassomby | Bit tem tay Additional work required Drain and refill cooling water. [Point 2] @ Release fuel pressure in the fuel lines. (Point 1] © Acceleration control wire [Point 3} © Air inlet hose . . EGI harness connector, harness clamp All hoses EN-31B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE TA 10m, (08-10 agem, 58-72 1) LN AZUNN UO Aye uect © Cc, SEG ‘ccalrater wire | \ Out case tock ux |) IE I): Always replace after every disassembly, 10. Removal and Installation of On-vehicle Parts (Cont'd) [Point 1] Release fuel pressure @ Start the engine. © After engine starts, remove fuel pump fuse and wait until engine stops. Crank engine two or three times to use up fuel remaining in fuel lines. © If the vehicle will not start, remove the fuel pump fuse. crank the engine 4 to 5 times to use up fuel in fuel lines. CAUTION: Connect the battery with booster cables to a battery in another vehicle or charged battery since the battery may drain easily. [Point 2] Drain the cooling water. @ Remove drain plug from cylinder block to drain all coolant from block, CAUTION: Make sure coolant does not fall on front exhaust pipe. [Point 3] Accelerator wire adjustment ¢ Loosen lock nut to provide adequate slack for the acceler- ator wire and pull outer case in the direction of the accel- erator, Return 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: 8 - 10 Nem (0.8 - 1.0 kg-m, 5.8 - 7.2 ft-lb) [Point 4] Remove throttle chamber linkage. © Remove mounting nuts indicated by arrow marks, Separate the three throttle chamber links from collector side. © Remove harness from throttle sensor and throttle valve switch, EN-32B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10. Removal and Installation of On-vel Parts (Cont'd) [Point 5] Fuel pipe removal @ Remove the three bolts indicated by the arrows and sepa- rate the fuel pipe. [Point 6] Air hose removal © Separate air hoses ®, ® and © from the collector side. [Point 7] Booster vacuum tube removal © Remove the clamp bolts, separate booster vacuum tube from collector and air chamber and remove tube. Bat Beans VY A & SE | ae | [Point 8] Air chamber bolts removal and installation Removal © Remove the three bolts and separate air chamber. Installation © Insert bolt ® in air chamber bolt hole, before performing final assembly. Tightening torque: 16 - 21 Nem (1.6 - 2.1 kg-m, 12 - 15 ft-Ib) [Point 9] Collector nut removal and installation Removal © Remove the nuts in the reverse order of the figure on the left Installation | © Tighten nuts in order shown in figure on left uniformly in two to three stages, Tightening torque: 16 - 21. Nem (1.6 - 2.1 kg-m, 12 - 15 ft-lb) EN-33B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE Bott (4) (O]sa-03 1m (0.64 - 0.85 kgem, 10. Removal and Installation of On-vehicle Parts (Cont'd) [Point 10] Air chamber removal and installation Removal © Soparate air hoses ®, ®, ©, vacuum hoses ®, © and AAC vaive connector and remove air chamber. Installation * Position air chamber in place, connect air hoses ©, ® ®, vacuum hoses ©, ©, then connect AAC valve con: nector. [Point 11] AAC valve removal and installat Removal © Remove the four bolts and detach AAC valve. CAUTION: (1) The AAC valve cannot be disassembled. (2) Replace gasket with a new one. Installation © Install gasket and AAC valve. Tightening torque: 6.3 - 8.3 Nem (0.64 - 0.85 kg-m, 4.6 - 6.1 ft-lb) [Point 12] AAC valve inspection Measure the AAC vaive resistance. Resistance [20°C (68°F): Approx. 9 - 10 (0) EN-34B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10. Removal and Installation of On-vehicle Parts (Cont'd) (2) Collector ASSY disassembly and assembly lear (2 \ | 45-631) 7 (Ples-s3 f “Byes Bere oe | man tose om, ge rent | Intake temperature 4 Additional work required: 0-20, 4-22] » Collector ASSY installation Refer to Section B3, 6-3, THROTTLE VALVE SWITCH SYSTEM INSPECTION for the ted -tff-3) throttle valve switch adjustment procedures. Satecer Poe 1 « Refer to section B2, 10-5, 6 IN-LINE | THROTTLE CHAMBER LINKAGE \Wesher | ADJUSTMENT for the related adjustment (Date tage fet procedures. [Point 1] Collector installation © Measure the collector installation surface for distortion in six directions (opposing directions, up, down, left, right, horizontally and vertically) (0.15 mm (0.0059 in) EN-35B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10. Removal and Installation of On-vehicle Parts (Cont'd) 10-4 6 IN-LINE THROTTLE CHAMBER REMOVAL AND INSTALLATION No. 3 trate chamber (Poire a No.2 thraate chamber Ipoine 1, 2) a large enna y 1 @? : Aways replace ater every disassembly Additional work required: © Collector ASSY removal and installation © Canister hose [Point 1] Throttle chamber inspection © Check that there are no cracks and that supplemental air paths are not obstructed. [Point 2] Throttle chamber installation Install the No. 1 to No. 3 throttle chambers. CAUTION: Do not make any mistake when installing the chamber. EN-36,B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10. Removal and Installation of On-vehicle Parts (Cont'd) 10-5 6 IN-LINE THROTTLE CHAMBER LINKAGE ADJUSTMENT _/ NS Beech Nat ‘Accelerate dum tly i < hk gged stopper "| 1 < ‘No, 1 throttle chamber /) | Seages 5 et Detail of pat @) No. 3 troxts linkage | NS INE No.2 trate linkage ) | NING AY is wal Se ee [Point 1] Accelerator work unit installation | @ Install the 6 in-line throttle chamber and accelerator work unit and connect the No. 1, 2 and 3 throttle linkages. Nop sheatie linkage | 20 2 OX acceler wartani OS® 4 [ss a3 hm (068-05 kgm 46-6. fib) | [Point 2] 6 in-line throttle chamber linkage adjustment ® Loosen nuts ® and ® for each throttle linkage. Turn the middle adjustment of each throttle linkage counterclock- wise to shorten the linkage.B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE SSN is 2 Ki Fearon fo Om Accel ato cru YES I Sy 6 Fully closed stopper AIS 10. Removal and Installation of On-vehicle Parts (Cont'd) ® Shorten each throttle linkage until acceleration drum con- tacts fully closed stopper on the accelerator work unit side. @® Shorten each throttle linkage, so the throttle chamber lever ‘opens wider than fully closed stopper on the throttle cham- ber side. CAUTION: 1. Do not lock nuts @ and @). 2. The throttle chamber lever opening angle should be ade- quate. @ Insert a 1 mm (0.04 in) feeler gauge between the acceler ator drum and fully closed stopper on the accelerator work unit side, Secure accelerator drum so it does not move. ® With feeler gauge inserted, turn the middie adjustment in No. 2 throttle linkage clockwise to lengthen throttle linkage until the throttle chamber lever contacts the fully closed ‘stopper on the throttle chamber side. @ When the fully closed stopper contacts, the throttle cham- ber lever. you should feel resistance when turning the throttle linkage with your fingers. Shorten the throttle link- age to the point just before this resistance is felt. EN-38B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE Leck ut renaciustabe) Feel gauge | inl 70. Removal and Installation of On-vehicle Parts (Cont'd) ® Perform steps @, © and © to adjust the No. 3 and 1 throttle linkages. ® Alter the adjustment is completed for the three throttle linkages, tighten lock nuts ® and © Alter the nuts are tightened, No. 1 -3 throttle linkages must turn with same degree of smoothness. CAUTION: The middle adjustment linkage must not turn when the lock nut is tightened. ® Remove feeler gauge from fully closed stopper on acceler- ator work unit side. CAUTION: Do not adjust fully closed stopper nut. ® Completely open and close the 6 in-line throttie chambers repeatedly and check that each throttle chamber moves smoothly. EN-39,B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10. Removal and Installation of On-vel Parts (Cont'd) 10-6 INTAKE MANIFOLD ASSY Tools required Name Application ‘Tube presser jwssee3 Too! Liquié gasket lubrication 202-0051 EN-40B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10. Removal and Installation of On-vehicle Parts (Cont'd) (1) Intake Manifold ASSY Removal and Installation [beg Aways replace atter every cisassemby Th: em thot) Intake manifold gasket Air drain plug | the s2- 18 ove Additional work required: Removal and Installation © Collector ASSY Throttle chamber ECCS harness connector and all hoses Water outlet hose Blowby hose [Point 1] Intake manifold ASSY bolt and nut removal and installation Removal © Removal is the reverse of order shown in the figure on lett. Installation ‘® Installation is performed in order shown in figure. Tighten in gradual steps to uniform tightness. ] Length: Number of ] tenor: nueret T paton xan 30.01.18) @) OG.O@ Boltiongi below Hea) 2a) | O.@. 8 @ @ 65 2.56) (6) o.o Tightening torque: 16 - 21 Nem (1.6 - 2.1 kg-m, 12 - 15 ft-lb)B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10. Removal and Installation of On-vehicle Par (Cont'd) [Point 2] Air drain plug Refer to section B6, 3, for details. ¢ Perform when engine is cool WARNING: Never remove the air drain plug when engine is warm, becau hot water may escape and cause injury. * When pouring coolant into engine, always remove air dre plug to allow air within engine to escape. (This prever overheating.) CAUTION: Be careful not to strip screw threads by over-lorquing the 1 n plug. Tightening torque 7-8 Nem (0.7 - 0.8 kg-m, 5.1 - 5.8 ft-lb) EN-42B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 40. Removal and Installation of On-vehicle Parts (Cont'd) (2) Intake manifold ASSY disassembly and assembly i } pot (9) | (Ob22 a Washer | ; | egigugeremonene | ual nto injctor ASSY | oie 2 TD ireake maritold Paire 1) | BE anes ost | eo Bi Fara | | age é Balt 16-21 (16 -24,12- 18) | Bitte PB SB a a | oss me Mereu—G fSte-21 on | Bet eoydtsin © Atel SOB anaean to Dt (kgm te) 42-19) : [Point 1] Intake manifold inspection ‘© Measure the intake manifold surface for distortions in six separate directions (at opposite directions; up, down, right, left, horizontally and vertically) in a number of locations. Limit: 0.15 mm (0.0059 in) [Point 2} Fuel tube ASSY ‘© O-rings must be replaced with new ones when pressure regulator is removed and installed. | caurion: When pressure regulator is installed, be careful not to scratch |_ the surfaces wi ich contact O-rings.B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 2: Always replace after every disassembly. 202.607 wos 710. Removal and Installation of On-vehicle Parts (Cont'd) [Point 3] O-rings (for fuel injector pressure regulator) Installation precautions © Never re-use O-rings, © Coat O-rings with engine oil (10W-30 or equivalent) or sili- con oil (NUC silicon L45 or equivalent) but do not apply solvent to them as this may remove the oil coating ‘© Do not allow dirt, dust or foreign matter to adhere to O-rings or other equipment surfaces. Do not use dirty O-rings. © Be careful when installing O-rings so tools or operator's fingernails do not make scratches, twist or stretch them. In particular, do not insert them in the fuel tube by making them stretch slightly, © When inserting the fuel injectors and pressure regulator in the fuel tubes, be careful not to install them off-center or rotate them © Do not store O-rings in locations subject to ozone, high temperatures or direct sunlight. [Point 4] Water bypass connector removal and installation Removal and cleaning @ Remove the eight water bypass connector bolts. Insert screwdriver in clearance between the intake manifold and water bypass connector and move it lightly to remove con- nector. @ Use a scraper and remove liquid gasket. CAUTION: Liquid gasket in grooves must also be removed. © Wipe off the surface with white gasoline, etc. Installation © Cut nozzle end of liquid gasket (KP510 00150) in position shown in lett figure. Use a tube presser to apply gasket. EM.aaB2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER EN! Ite: Aways replace after ry disasserbi [ 70. Removal and Installation of On-vehicle Parts (Cont'd) Installation Apply the liquid gasket (KP510 00510) to water bypass con- nector surfaces in four locations at one time without Stopping, then install water bypass connector within 20 minutes CAUTION: (1) Apply liquid gasket coating 3.0 mm (0.118 in) wide (target width). (2) Coat on the inside of installation holes as shown. Tightening torque: 16 - 21 Nem (1.6 - 2.1 kg-m, 12 - 15 ft-lb) [Point 5] Water outlet elbow Removal and cleaning @ Remove the two water outlet elbow mounting bolts. Insert screwdriver handle as shown, and move it up and down to remove elbow. '# Use a scraper to remove liquid gasket from intake manifold and water outlet elbow. cauTio Liquid gasket in grooves must also be removed. ‘© Wipe off the installation surface with white gasoline, etc. Installation © Cut nozzle end of liquid gasket (KP510 00150). Use a tube presser to apply gasket. ‘© Apply the liquid gasket (KP510 00510) to intake manifold at ‘one time without stopping as shown in figure on left. © Complete installation within 20 minutes after liquid gasket application CaUTIO Apply liquid gasket coating 3.0 mm (0.118 in) wide, Tightening torqu 46 - 21 Nem (1.6 - 2.4 kg-m, 12 - 15 ft-lb) [Point 6] Balance tube removal and installation Removal © When removing balance tube, check O-ring size, Installation © When installing balance tube, replace O-rings with new ones, There are three different O-ring sizes. Be careful to install the correct size EN-45,B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10. Removal and Installation of On-vehicle Parts (Cont'd) Number of unit Installation location Oxring ® (emai 3 locations Cylinders 23.45.68 O-ring ® (large) “locations Oylinders 1.2, 5.6 O-ring © (medium 2iocations | Oylinders 3. 4 Be careful not to pinch the O-rings during installation, EN-46B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10. Removal and Installation of On-vehicle Parts (Cont'd) 10-7 TURBOCHARGER ASSY Tools required Name ‘Application Gompoune gauge roocharged pressure control inspection Measure: |eersoe coor Turbocharged pi rol inspect ment tool Dial gauge Turbocharger rotor shaft inspection (1) Turbocharger ASSY removal and installation |” Front ice Eyebott La, “et alo V1 _(0.ss - a9, ASSY Water fibe Saas aeean ‘ | a viata eee as tang) POL HS Bip Ee corer water . (fisconper EP oi andwater tubes 6 9 oe stem tke ty Ls BoM au oh / L Aiways replace after every disassembly, 1&8 Copper washer Oil and water tube Addition work required: Drain and refill cooling water Separate exhaust front tube Remove and install: Undercover Exhaust gas sensor connector Intercooler air inlet tube, hose Air inlet hose Note: Also remove cooling water from engine drain plug. (if water is only drained from radiator drain cock, the water inside cylinder block is not drained completely.) EN-A7B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE Ee (Ko) 77, Ground cable 10. Removal and Installation of On-vehicle Parts (Cont'd) (2) Front turbocharger ASSY installation Removal sequence Loosen the flare nuts of tubes @ and ® Remove bolts, and detach tube @ Loosen flare nuts of tubes © and ® on the turbo side. Remove hose ® and bolts. Remove bolts and detach tube © Remove eyebolts © and @ Remove the two bolts and detach tube @. Make sure that bolt mounted on upper side is shorter than lower side. Remove the three bolts, cover and ground cable. @ @ @66e8e Remove oil return hose. Remove the three bolts and detach bracket. Remove the four turbocharger bolts. Lower turbocharger carefully. Remove the six exhaust manifold nuts. Pull the exhaust manifold in direction @ and then raise it in direction @ to avoid turbocharger stud. Remove exhaust manifold. Pull out turbocharger. Installation sequence ‘© Installation is the reverse of the removal sequence. © Place turbocharger in bottom of engine compartment before installing exhaust manifold. EN-48B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10. Removal and Installation of On-vehicle Parts (Cont'd) (3) Rear turbocharger ASSY removal and installation Additional work required: remove and install front turbocharger ASsY Removal sequence @ Remove front turbocharger and exhaust manifold ASSY. ® Remove the two nuts and clip securing bolt, and separate tube @® ® Remove the three bolts and detach exhaust manifold cover. @ Remove eyebolts ® and © and detach bolt © ® Remove the two bolts and separate tube ® from cylinder block side. ® Remove the three bolts and detach bracket. The sequence after this step is the same as numbers to ® of front turbocharger removal and installation Installation sequence © Installation is the reverse of the removal sequence. © Before installing eyebolt © , loosen water tube flare nut as shown in figure on the left EN-49B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10. Removal and Installation of On-vehicle Parts (Cont'd) (4) Turbocharger ASSY — Assembly and disassembly Front ide (29 Turbocharger Lock plat (2) —— y wrore Weter aise |): Aways replace ater every | Water tube Gisevery, ipa | Steer irae mento fe) Liste teem fy Additional work required: vee | ve tube ‘ube a 3 Radiator cleaner . =< es a Turbocharger ASSY removal and installation [Point 1] Water tube inspection © After cleaning water inlet and outlet tubes with radiat cleaner, blow with compressed air and check for rust o clogging, [Point 2] Oil feed tube inspection After cleaning oil feed tube with engine conditioner, blow with compressed air and check for clogging EN-50B2_RB26 DOHC EGI (ECCS) Twi 'URBOCHARGER ENGINE 10. Removal and Installation of On-vehicle Parts (Cont'd) [Point 3] Lock plate removal and installation Removal © Spread the lock plate pawis with a screwdriver and loosen the nuts. Installation Position lock plates and turbocharger mounting nuts. After tightening the nuts, bend lock plate pawis onto the nuts. [Point 4] Eye-bolt deter fn © Oil feed (turbocharger side) eye bolts are stamped ‘Swing valve [Point 3} Turbine rotor [Poire 1, 2,4) Excossive pressure leak /-—— compressor whee! [Poirt 5] Retr shaft [Point 6, 8] [Point 1] Rotor shaft inspection © When rotor shaft is turned by finger, there must be no heaviness or dragging and shaft must turn smoothly. EN-51B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE at be achore to surtoces. Ne There must be 19 bending or | |, ether damage, ‘© Thore must be ‘There must be no 10. Removal and Installation of On-vehicle Parts (Cont'd) [Point 2] Turbine rotor inspection Oil must not adhere to surtaces. 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 switch valv moves smoothly, without deformation or cracks. © Make sure there are no misaligned seating surfaces in tu: bine housing [Point 4] Rotor shaft play inspection @ Position a dial gauge and measure play and thrust clea! ance. © Insert dial gauge in oil return hole and measure rotor sha play. Rotor shatt play Thrust clearance 0.056 - 0.127 mm (0.0022 - 0.0050 in) 0.013 - 0.098 men (0.0006 - 0.0038 in) [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. [Point 6] Rotor shaft damage © There must be no carbon sludge accumulation. EN-52B2_RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE Cooling water intet OY 10. Removal and Installation of On-vehicle Parts (Cont'd) [Point 7] Swing valve controller inspection ‘© Connect the swing valve controller rubber hose to actuator side © Check swing valve controller whenever actuator rod is installed or removed. Use air gun to blow compressed air [approx. 69 to 78 kPa (0.7 to 0.8 kg/cm?, 10 to 11 psi] into hose and make sure swing valve controller rod operates. Stop blowing air as soon as rod operates. CAUTION: If air pressure is applied excessively the di damaged. Use the LPG pressure gauge [special tool for approx. 98 kPa (1 kg/cm?, 14 psi)] to verity that the air gun pressure is approx. 78 to 88 kPa (0.8 to 0.9 kg/cm’, 11 to 13 psi) before testing the air hose. [Point 8] Oil and cooling water inlet and outlet cleaning @ Use engine conditioner to clean oil feed and return pas- sages @ Use radiator cleaner to clean cooling water feed and return passages. © Clean with air gun Clean compressor wheel, turbine wheel, compressor housing and turbine housing with same methods. FN.83B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE (6) Turbocharger trouble diagnosis (oil leaks, smoke (white or blue smoke), lack of power, poor acceleration, abnormal noise) Items to be verified before diagnosis @ The engine oil leve! must be between the MIN and MAX marks on the oil level gauge. (When higher than MAX , engine oil flows into the intake duct through the blowby gas recirculation pass and turbocharger may be determined to be malfunctioning.) @® Check with customer to determine if oil is cooled when idling after driving, if even one malfunction in the following chart is detected in a unit inspection, replace the turbo- charger ASSY. HW none of these conditions are found during inspection, assume there are no turbocharger problems and search for a malfunction another location. tem Possible associated phenomenon Lack of ‘refer-\ | Inspection tocation ‘symptom ‘onormat | PME" 8° Reter| Oil teak | Smoke | APONM!) "poor accelera tion Turbine has oil on rotors a . Carbon has accumulated a : o 28 | Turbine rotor * Rotor scrapes against the housing a e : ° The turbine vanes are bent or folded, : : Suction inlet is dirty with oi o ° 58 | Compressor wheel [Rotor scrapes against the housing, a 3 ° o The turbine vanes are bent or folded, : : There is sirong resistance or seraping © Both turbine and | when rotates by finger. 6 6 compressor 1. Rotation by finger is not possible : ® |e Aotor shatt play Hager |S not possibl ingpection There is considerable shaking between a rotor shat and turbo ASSY. {Look through ei . 62 [hota tnopectime- [£200 tte has accumuite in waste | . 4 a rior with penlignt) The vaive does not move smoothiy when ‘Swing valve motion. | pressure is applied gradually. (The vaive | 3.7 |(Use air gun or air | normally opens at pressure greater than . pump) 69 to 69 KPa (0.6 to 0.7 kglem?, 9 10 10, sit. | "Refer to previous section (). le: Highly possible 0: Possible 4 EN-54 Slightly possible}B2 RB26 DOHC EGI 10-8 EXHAUST MANIFOLD ASSY REMOVAL AND INSTALLATION (ECCS) TWIN-TURBOCHARGER ENGINE Front side Exhaust manifold cover £29 : Always replace after every cisassemily Oh: em (ham, 3b) Rear side ‘Exhaust manifold cover 1 (ad.-s0 | | tae (23 : Aways replace after every disassembly. tm hoe ay 7 { | ; Be Lae t oso, —~! grant _, \ Sean 5 \Y) ' ; ccmernmsoes i 1 6 Exhaust manifold gasket | | ' | ' Exheuk ments | Exhaust i ' ' ' L Additional work required: Turbocharger removal and installation (Refer to section 10-7) © 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 part of installation. ‘After installation, crank engine and check for gas leaks. [Point 2] EXHAUST MANIFOLD NUTS REMOVAL AND INSTALLATION Removal Removal is the reverse of installation sequence shown in figure. Installation The installation sequence is shown in the figure. Tightening torque 1B = 24 Nem (1.8- 2.4 kg-m, 13 - 17 feb) [Point 3] Exhaust manifold inspection © Measure the intake manifold surface for distortions in six separate directions (opposite directions; up, down, right, left, horizontally and vertically) in a number of locations. Limit (0.3 mm (0.012 in) ‘@ Check that no oil, dirt or foreign matter adheres to cylinder head, exhaust manifold installation surface and gasket. EN-55B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE Front Fear [Point 4] Exhaust manifold cover installation s a | © Attach the exhaust manifold cover bolts in the following . . Sequence (in both front and rear) 4 \ 4 ® Temporarily tighten bolts for positioning hole indicated by j ® . » @) Tighten bolts in the other two locations @ tT) | | 8 Y , Tighten bolts in holes ® to specified tightening torque. 4 Tightening torque | 37-50 Nem (0.98 - O51 kgm, 27-87 Weld) 10-9 SPARK PLUGS Tools required Name ‘Application Special too! Spark plug wrench ‘Small hexagonal spark plug peel EG1740 1600 removal and installation 3 Powertansisior ‘Qcnamont bolt J23-3.0(023- 021, 1.7 -22) Ornament bolt (3) 47 ‘Screw (3) er oo wre racket a Biss" as 0a om c6-00-08 Additional work required: Remove and install: © Air inlet pipe ‘@ Blowby hose A: Nm (kgm, te) EN-56B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE _Ejes- 3.0 Nm (023-01 kom, (Sf 22m) & tanition ea! Cylinder lgrition | ‘as a Bracket Spark plug” so270 —— Platinum tp Seating petal \ eon | Filler cap Rocker cover locker cover gasket Qenament pot 6) Dem age, 110) Vt (Gje3-30023-03,17-22) {Point 1} Ignition coil bracket removal and installation Removal © When removing ignition coil bracket, hold coll to provide additional support while detaching it CAUTION: Do not hold the coil by the connector when removing it. Installation ‘When installing ignition coil bracket to cylinder head, check that ground line is connected securely. [Point 2] Spark plug maintenance Gap inspection and adjustment is not necessary because a platinum tip is used. ¢ Change spark plugs every 100,000 km (60,000 miles). ‘© When using a compressed air spark plug cleaner, clean the plugs at maximum pressure of 588 kPa (6 kg/cm*, 85 psi) for no more than 20 seconds. @ Do not use a wire brush to clean plugs. 10-10 ROCKER COVER REMOVAL AND INSTALLATION Rocker cover scrow {30 for both let and right sides) | Fhe- 402-04, Additional work required: Remove and install: © Air inlet pipe Blowby hose EN-57B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE. [Point 1] Rocker cover screw removal and installation Removal ‘© Perform removal in reverse of sequence shown in the fig- ure on the left. Installation © Perform installation in sequence shown in the figure on the left CAUTION: Perform removal and installation for intake and exhaust sides by same method. Tightening torque 2-4Nm (02-04 kgm, 14-29 Fld) [Point 2] Rocker cover installation surtace inspe © Check that no oil, dirt or foreign matter adheres to the cyl- inder head installation surtace. [Point 3] Rocker cover gasket installation © Make sure the rocker cover gasket is positioned securely in groove without twisting, pinching or protrusion, EN-58.B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10-11 TIMING BELT REMOVAL AND INSTALLATION Tools required Name _ ‘Application ‘Ring gear stopper | kvt01 10480 @ Adapter (crank pulley bolt removal Kvior 10810 and installation ® Stopper piate Ky107 05610 Special toot | Pulley puller crank pulley removal and 'ST2778 0001 installation Boa 1676 oe Timing belt cover (uoper) (Point 4 on 9 6 1 pai) Bisos-onza0 | ots l epee tM ae" x é eA Stomrenet ee tog aa, Conical washer Oss rons} ‘y irom $ soe (ea-88, | ze Be roms ark paley | Bae. (esas, ramet (Ponta) gat 3 Os-s (02-05,22-26) IL: Engine oit (3 | Awave replace ater every disassembly, FA: Nem (haem fb) Additional work required: @ Drain and refill: Cooling water © Remove and install Under cover Radiator, fan shroud Cooling fan | Beit tensioner {Point 9.10.11) L ‘Timing batt cover (lower) ‘pring [Point 7) taler puiey [Post 1] \__ timing bet nate Point Crank timing puley [Pint 8) Cchank timing oulley plate [Point Supplemental belts Water pump pulley Spark plugs ¢ Check No. 1 cylinder compression T.0.C. posi- tion (Point 7] Install ring gear stopper [Point 3] EN-592 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE (oroe {Point 1] No. 1 cylinder pressure T.D.C. (top dead center) inspection © Align the crank pulley timing mark and belt cover timing indicator (0° position) At this time, the No. 1 cylinder is in the compression T.D.C. Position when the camshatt is located as described below. © No. 1 cylinder is at the compression stroke top dead cen- ter when both the intake and exhaust side cams do not move the valve lifters. © Remove oil filler cap from intake side rocker cover and check that the front end of camshaft faces the intake side. [Point 2] Crank angle sensor installation ‘© Apply chassis grease to drive unit spline during installa- tion. © There is a flange inside drive unit spline so spline only has one insertion position. Check the alignment visually before assembly, ‘© Check that crank angle sensor can be easily inserted in belt cover holes and sensor moves lightly to right and left, then tighten bolts © When sensor does not move lightly, loosen belt cover bolts to position when crank angle sensor was inserted. Move belt cover lightly horizontally and vertically to align it so belt cover holes and camshaft center are aligned and then tighten bolts so crank angle sensor moves lightly EN-60B2 RB26 DOHC EGI (ECCS) Twi 'URBOCHARGER ENGINE [Point 3] Removal and installation of crank pulley and bolt Removal @ Remove starter motor, and attach ring gear stopper. (Refer to BS starter motor removal and installation.) © Use a pulley puller (steering wheel puller) to remove crank pulley. {Bolt size: M6 x 1.0, length below head approx. 50 mm (1.97 in).] Installation © Position the washers for the crank pulley bolts so the flat surface contacts the crank pulley side and then assemble. @ Apply a coat of engine oil to the threads of crank pulley boits, ———— Tightening torque | 446 - 466 N-m (45.5 - 47.5 ka-m, $29 - 344 fb) ———=—~—_—~—_—=—_ [Point 4] Timing belt cover removal and installation Removal ‘¢ Timing belt cover is separated into upper and lower sec tions. After crank angle sensor is removed, first remove the upper section and then remove lower section in this sequence. Installation ye ‘Dried liquid packing | ‘¢ Installation is performed in reverse sequence of removal. CAUTION: Do not scratch dried liquid packing when removing and install- ing timing belt cover. Tightening torque 3-5 Nem (0.3 - 0 kg-mm, 22- 9.6 fhib) EN-61B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE poz [Point 5] Belt tensioner nut removal and installation © When removing and installing belt tensioner nuts, secure the tensioner firmly with a hexagonal wrench. CAUTION: Do not loosen inserted stud at disassembly. Tightening torque 43-58 Nim (44-59 kgem, 92 - 43 fb) [Point 6] Conical washer installation © Pay close attention to the installation direction of conical washers. The washer should be set with face the chamfered side facing the tensioner pulley side. [Point 7] Tensioner spring installation © Assemble the tensioner spring so it engages the belt ten- sioner pulley as shown in the figure. The tensioner spring must be assembied together with the belt tensioner pulley in the cylinder block ‘© When tensioner pulley is free, hook the tensioner spring on the upper side of tensioner spring stud. Tensioner spring specifications Spring wire | ] Classification et angle: a angte: diameter Set angi Free angle: 0 paint 4.8 mm (0.071 in) | Approx. 20" | Approx. 163" | Yellow-green kee@wruunc~x_EOIe or EN-62B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE ranking Trg pate pulley ns Ny ae | cro fl mar dem Soe anna ploy 20% Gam puter com pater fame (exh ormert [Point 8] Crank timing pulley and plate installation © Be careful to observe front and rear positioning of timing belt plate, crank timing pulley and crank timing pulley plate when installation is performed, [Point 9} Timing belt alignment mark verification and installation Hf paint on upper belt is unclear when disassembly is Performed, paint a mark on belt that indicates rotation direc- tion. '® Position the alignment marks of the intake and exhaust 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 at this time. (No.1 cylinder compression T.D.C.) © Move the belt tensioner clockwise at a 70 - 80° angle, and secure it temporarily with belt tensioner nut. {This will min- imize the offset between the tensioner shaft and timing belt.) © Align 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 left. * After loosening nuts and adjusting belt tension, secure ten- sioner with hexagonal wrench so it does not rotate together and tighten nut. CAUTION: (1) At timing belt assembly, check that it engages correctly with pulley and does not float. (2) When disassembly is performed, replace belts whenever possible. [Point 10] Timing belt tension adjustment @ Remove spark piugs, and align timing belt alignment marks with pulley marks and install timing belt onto each pulley. Loosen tensioner securing nut so belt tension is applied by tensioner spring ® in this condition, turn crank pulley more than two turns clockwise to check belt movement and stop siowly at No. 1 cylinder compression T.D.C. point. @ Insert the hexagonal wrench in hexagonal hole. While hold- ing it by hand so the tensioner does not move, tighten the tensioner securing nut to specified tightening torque. htening torque 3 -58Nm (4 3 feb) © The initial tension on the belt should be approximately 196 N (20 kg, 44 Ib) in this condition. EN-63B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE [Point 11] Idler and tensioner pulley installation * Do not loosen inserted studs at disassembly, If studs are loosened, coat inserted stud with Locktite solution (Japan Locktite KK) or equivatent. [Point 12] Timing belt inspection ¢ Replace timing belt if inspection indicates any problem tem Condition Cause { | Gamshatt lock | Crank angle sensor lock Missing tooth Cracked tooth Tensioner lock Cracks in rear side z {Engine overheating | Interference with belt cover, ete . Belt misalignment Woar and cracks on side surtace — Ga Belt plate malfunction Worn teeth LED crank angle snwor an crankshal il seal maltunction Water leaks in water pump Oil or water adhesion CAUTION: Make sure timing be belt. is not twisted or bent sharply. Also make sure there is no oil film or water on EN-64B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10-12 CYLINDER HEAD ASSY Be careful when handling exhaust valves because metal Tools required sodium Is sealed inside. Refer to Page EN-67. Name ‘Application Pulley holder Cam pulley bolt removal and Kv10" 03900 inctallation Kvi01 09000, T9182 0000, | T3153 0000 Valve spring compressor Valve spring installation and Kvior 11300 it ; removal ST1207 0000 | Kvt01 08980 Valve oil seal puller Valve oll seal removal ecial Special 2! | xvi01 07900 f Valve oll seal drift and drit attach- Valve oil seal insertion 10 oo» é @ Kvt01 14800 Valve guide drift Valve guide installation anc removal Valve guide reamer for guide Valve guide insertion hole ang insertion hole correction {guide internal diameter correction Exhaust side —ee Guide inner diameter correction ae Intake side KV101 19600 6.0 mm (0.296 in) dia. Exhaust side KVI01 07700 7.0 mm (0.276 in) dia EN-65B2 RB26 DOHC EGI (ECCS) TWI 'URBOCHARGER ENGINE { Name ‘Application Valve seat remover, intake side, Valve seat removal ‘exhaust side v Valve seat ari intake side, Valve seat inservon exhaust side Ss? Special too! Valve seat cutter set Toot |vave auras andor [nse mirometr iter aude ee repecton Micrometer Camera i. mspection Om ue Camera . epecon Measurement gk canst , apesion Vale spring water Valve sing et, speston Savers espe Valve spring. specon [Severe eae Chines Rea. ae, poston EN.ARB2 RB26 DOHC EGI (ECCS) TWIN- TURBOCHARGER ENGINE SPECIAL PRECAUTIONS TO ENSURE SAFE DISPOSAL OF SODIUM-FILLED EXHAUST VALVES The handling and disposal of sodium-filled exhaust valves requires special care and consideration. Under conditions such as breakage with subsequent exposure to water, the sodium metal which lines the inner portion of the exhaust valve will react violently, forming sodium hydroxide and releasing hydrogen gas which may result in an explosion or fire e Damage to eyes may result in loss of vi e Contact with skin will result in burns e Fire may occur. @ Basic precautions Never attempt to break valve and remove sodium metal In principle, dispose of used vaives by returning them to the Nissan service office. If valve(s) is/are damaged, remove valve(s), and perform sodium-filled valve disposal operations (neutralization and waste water disposal) @ Processing method In principle, dispose of used vaives by returning them to the Nissan service office {t local industrial waste treatment companies do not perform the required press processing and it is clearly established that a solvent method can be used instead, this type of disposal method is also acceptable. if valve(s) is/are damaged, remove valve(s), neutralize by water reaction and dispose of them with the ‘same method used for ordinary scrap metal, Processing must be performed as follows. Wear rubber gloves to remove valves from cylinder head. @ Pour more than 10 liters (2-1/4 Imp gal) of water into a bucket in a well-ventilated area © Submerge the damaged vaives in the bucket ‘© The reaction is violent so stand 2 to 3 meters (7 to 10 ft) from bucket, © Hydrogen gas is produced so do not bring any naked flame near bucket, © After the reaction is finished (4 - 5 hrs.), use large tweezers to pick the vaives out. The vaives can be disposed of by the same method used for other waste products at this time. © Dealers should check their respective state and local reg- ulations concerning any chemical treatment or waste water discharge permits which may be required to dispose of the resultant (high alkalinity) waste water. CAUTION: Make sure the resultant (high alkalinity) waste water does not contact your skin. If the waste water does contact the skin, wash the affected area immediately with large quantities of water. EN-67B2 RB26 DOHC EG! (ECCS) TWIN-TURBOCHARGER ENGINE (1) Cylinder head ASSY removal and installation (Cylinder head bot (M12 x 1.5) (14) [Point 2} facie a ss ‘Tighten 10 29 (3, 22. Bae 118 fase 1267-07 er iran coor bam conte song waster (eo. 118 (082-12,07-87 [own e— Tohono 29(3.2, “shar { sre wraet 692 Cini: hood AS Cylindor head bote ME x 1.0)[Point 2] 0-118 (os2-12,67-87) ‘ €3 Cylinder heed gasket [Point 25 cam pulley (Point 3} 3 : Ainays replace ar every disassembly. FD: Nm (hg, tb) Additional work required: “Turbocharger, exhaust manifold © Drain and refill: Cooling water (Point 1] Timing belt Remove and install: Rocker cover Collector Spark plugs Throttie chamber @ Installation: Check No. 1 cylinder compression Intake manifold TDC. position [Point 3] [Point 1] Cooling water drain and refill Removal ¢ Remove water completely trom cylinder block drain plug. ‘CAUTION: Do not allow water to enter exhaust front tube. Refilling water: @ Refer to (86) “Cooling Water Filling Procedures” for details. EN-68B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE [Point 2] Cylinder head bolts removal and installation Removal © Remove bolts in reverse sequence of figure on left, Installation Remove bolts in sequence shown in figure on left The cylinder head bolts (M12 x 7.5) are torqued by a two step method in which bolts are tightened two times. @ Tighten to 29 N'm (3 ka-m, 22 ft-lb). @ Tighten to 108 Nem (11 kg-m, 80 ft-Ib). @ Loosen bolis completely 0 N-m (0 kg-m, 0 ft-lb). @ Tighten to 29 Nm (3 ka-m, 22 ft-lb) ® Turn bolts 85 to 90 degrees clockwise when angle wrench is used, Tighten bolts to 103 to 113 Nim (10.5 to 14.5 ka-m, 76 to 83 ft-lb) when torque wrench is used. CAUTION: When angle wrench is not used, never attempt to approximate the lightening angle visually. © When gasket is installed, be careful not to hit or scratch gasket seat and bore grommet. ‘© When gasket is installed, clean cylinder head lower surface and cylinder block upper surface and remove all water, oll and foreign matter. Use compressed air to blow out the bore holes. [Point 3] No. 1 cylinder compression 7.0.C. verification Before installing cylinder head ASSY on oylinder block, the crank pulley and cam pulley must be positioned at the No. 1 cylinder compression T.D.C. point ¢ The crank pulley timing mark and timing belt cover timing indicator (0°) must be aligned © Intake and exhaust cam pulley alignment marks must be positioned with their respective belt cover alignment marks. EN-69B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE (2) Cylinder head ASSY disassembly and assembly Special Precautions to Ensure Safe Disposal of Sodium-filled Exhaust Valves Refer to page EN-66 for details. Valve spring retanes Valve spring Point 17 9,20) | [Spring wos Valve ol sea Point 23) ‘Shim [Point 61 ay [Boo sea ose -12.67-47 (Pom 81 Goes soving washer Inte valve [Point 21.25 veins toms —=Q,_ ie Poi 24) Mme. or 5 soma es2-12,62-00 om 5 nage Washer 8 Lytinder nese [Poon 9315.21.24, 26) ‘Cam shit eshavel ido) (oma gam 1a) Ccamanat bracket [Pent Ss Comsnan niake ice) (Ponta. 910, Bo (1) Ope? (05 22,12-16) Retainer ® onensnn | 4 ~ sea! Point 7) sr-an ar pula [Point 2 es Benson Com euity was Be. cam putey bot iP fone! tae to(ha or rank angie sensor bracket [Pon 1 Jat 26 emi fe) Additional work required: @ Cylinder head ASSY removal and installation [Point 1] Crank angle sensor bracket install Crank angle ion sencor bracket @ The crank angle sensor bracket is positioned onto the cyl- saa inder head by using knock pins (2 locations). Align the 1-28 positions correctly when installing the crank angle sensor fei-29, Positions correctly when installing the crank angle sensor. 5-2) |, Grank angle sensor bracket = 26 Nem (2.1 = 2.7 kgem, 15 = 20 fe | botttgtenng torque 21 = 26 Nim (2.1 = 27 kgem, 15 = 20 feb) Blin tegen fy 21-27, 15-20) EN-70B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE | [Point 2] Cam pulley removal and installation Removal Secure the pulley with a pulley holder or sprocket wrench and remove cam pulley bolts. ‘xv101 09900 IKv101 09300 ‘813182 0000, or $T3153 0000) Pulley holder Installation © Align camshaft knock pin and cam pulley knock pin holes to install camshaft pulley © Use a pulley holder or sprocket wrench to tighten the cam pulley bolt, ‘cam pulley bolt tightening hinee 44219.Nim (14 1.9 kg-m, 10. 14 telb Bon @) (Oe 228-22 \ Retainer bask plate wor (2) (Je 83 068 088, 48-61) item em. te) Bret gy. j NS or "4 a RS i > ; R canate ue (264088 x Sra tnnnsterend back plate. ‘To remove and install cam pulley bolts, use the proper tool to secure the hexagonal part in front of camshatt installation Removal @ Remove back plate bolts and detach back plate. Installation @ Assemble back plate with canister tube and then install ‘Back plate bolt tightening torque [M6 [63-83 (0.64- 0.85, 46 -6.1) Nem (kgm, tt) [MB [16-21 (1.6 - 21, 12 18) [Point 4] Camshaft end play inspection Seta dial gauge at tront end of camshatt in thrust direction. When camshaft moves in front and rear direction, read the dial gauge runout width. ‘Standard value (0,030 - 0.080 mm (0.0012 - 0.0031 in} [Point 5] Camshaft bracket removal and installation Removal (intake and exhaust camshafts) ‘© Before removing camshatt bracket, paint marks to indicate bracket position and direction. @ Remove cam bracket bolts by loosening them gradually in several stages, in reverse sequence shown in left figure. EN-71B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE Installation * Align crank pulley timing mark and timing belt cover tim- ing indicator (0°) so No. 1 cylinder is at compression T.D.C. position. (This operation is not necessary when cylinder head is removed as single unit) ¢ Turn camshaft so No. 1 cylinder is at compression 7.0.6 position. (Operation is easier if the camshatt is turned 60° before or after No. 1 cylinder T.D.C. point when cylinder head is installed as single unit) Verity position of No. 1 cylinder is at compression T.D.C. by knock pin in front end of camshaft © To install camshaft, temporarily tighten No. 1 cam bracket and check that camshaft thrust section is positioned securely. @ Tighten cam shatt bolt 640° (1.5 turns) in the numeric order shown in upper left figure. Cam br Ket tightening rque 9.0. 11.8 Nem (0.92 2 kg. 78.7 fb) stallation, coal the cam journals and end of cam- shaft with engine oil, (2) Do not rotate camshaft. (The valves and pistons may inter- fere.) [Point 6] Valve clearance adjustment No. 1 cylinder compression T.D.C. point © Turn camshatts (intake and exhaust) so No. 1 cylinder is at the compression T.D.C. position. © Check knock pin position of camshaft front end to verity No. 1 cylinder compression T.D.C. position. set8 @ No. 1 cylinder is at compression stroke top dead center > eat: vas wth canbe repos when both tho intake and exhaust side came do not move the valve lifters. Intake side Part Valve clearance measurement Item — Intake sige Cylinder No.4, 2, 4 Exhaust side Gylinder No. 1,3, 8 Firing order 15: Baa EN-72B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE ‘& mark: Valves which can be inspected and adjusted Intake side © Rotate intake and exhaust camshafts 180° ‘© No, 6 cylinder is at compression stroke top dead center when both the intake and exhaust side cams do not move the valve lifters. Part Valve clearance measurement Itake side ‘Gylinder No. 3.5, 6 Exhaust side Gylinder No. 2.4.6 Valve clearance specifications [20.28% (68297) Intake Exhaust Iter L Valve clearance (cold) 0.45008 0.38+0.03 mm (in}| __(0.01840.001) (o918+0.001) (Reterence value: hot) osts003 | (O4at008 mm in} (0.020:40.001) (0.017 +00001), CAUTION: Always inspect when engine is cold. Reference: Compensation by room temperature Room ter perc” | ossceaxe) | 028 e028 [202s ones] sos teos0 “Cc (FY Compares zoe | +001 01 Senvaive |) ccomon | croomn | °° | conten ei Valve clearance measurement method ‘© Insert a 0.15 to 0.20 mm (0.0058 to 0.0079 in) feeler gauge ® trom spark plug side. Insert feeler gauge(s) ® from opposite side. Select a gauge thickness that will reduce the clearance to 0 mm (0 in) Note: © Do not use more than two gauges for ®. ‘© The feeler gauge must conform to JIS (Japanese Industrial Standard) 150A25. © Valve clearance = gauge ® + gauge © Reasons for measurement using gauges @ and ® @ The valve clearance setting is larger compared to previous engines. ® The gauges cannot be placed parallel to the measurement surface due to the structure. @ The blade of thick gauges has a high rigidity and does not bend easily, resulting in a large measurement error. ‘©The error increases if a number of thin gauges are layered and the measurement will be incorrect. EN-73B2 RB26 DOHC EGI (ECCS) Twi URBOCHARGER ENGINE 9: Nomuee cr atm (4: Aways reslaca ater every disessersbiy 7 ‘This indicates @ thickness of T = 2.440 - 2.455 ren (0.0061 - 00067 in, Valve clearance adjustment ‘Select the shim for the vaive clearance. © When measured valve clearance (1) does not conform to specified value, measure shim thickness (T) and replace it with a shim that will produce the standard clearance. @® Shim thickness calculation method Example: When intake valve clearance (t) is 0.50 mm (0.020 in) 0.50 (t) - 0.45 (specified value) = 0.05 mm (0.0020 in). @ The valve clearance is 0.05 mm (0.0020 in) greater than specified value. Use shim 0.05 mm (0.0020 in) thicker than current thickness. to narrow valve clearance. ® Current shim thickness (T) measurement method @ Use micrometer and measure center of shim. CAUTION: Dispose of shims which have been measured and do not use them again. ® Shim selection @ When current shim thickness (T) is 2.40 mm (0.0945 in): 2.40 {T) mm (0.0945 in} + 0.05 mm (0.0020 in) 2.450 + selected shim thickness © Read the identification mark [38] (T: 2.440 to 2.455) to select shim closest to required thickness. CAUTION: The shim t kness tolerance is +0.03 mm (0.0012 in). @ \dentity the shim type @ There are 70 different types of shims. Sizes range from 2.275 mm (0.0896 in) to 3.925 mm (0.1308 in) in 0.015 mm (0.0006 in} increments. After installing camshaft, measure valve clearance again to check that clearance is within specifications. EN-74B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE Identification paire (piri i st oreeaton pai ( veto} € DH paoa | ‘Exhaust side Knock pin ‘Spline gear for diving ‘rank angie sensor Front em Sam 029 in) ] : Knock pin Mecrometer [Point 7] Camshaft front oi! seal installation ® Be careful 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 oll 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 8] Camshaft rear rubber plug installation © Before installing rubber plug, remove oil, water, etc., on surface and clean thoroughly. @ When assembling rubber plug, coat it with adhesive (Three Bond 1211), [Point 9} Intake and exhaust camshaft classification @ Intake and exhaust camshafts can be identified by identifi- cation paint color and presence of a spline gear for driving the crank angle sensor. Camshatt Identification paint Spline gear Intake camshaft Pink No. Exhaust camshatt White Yes. [Point 10] Camshaft knock pin insertion © The protrusion distance is 5 mm (0.20 in) for camshaft knock pin insertion. Knock pin protrusion distance mm (0.20 in) [Point 11] Camshaft insp Cam height inspection @ Use a micrometer to measure cam height, [we sige [sense 1m height standar | Cem eartstasars | asa sere) | ana 58s) cam i ierena) | 8ST tao EN-75B2 RB26 DOHC EG! (ECCS) TWIN-TURBOCHARGER ENGINE ‘Camshaft journal outside diameter inspe @ Use micrometer to measure outside diameter of camshaf journal —— —— No.1 = No.7 Standard valve 27-835 - 27.955 mm (1 0996 - 7.1006 inp [Point 12] Camshaft runout inspection @ Use V-blocks on fixed surface to support both camshaft enc journals (No. 1 and No. 7). © Avoid the oil groove in the center of the No. 4 journal anc position the dial gauge vertically. Turn the camshait by hand one rotation and read the move: ment width on dial gauge. @ The runout is equal to one-half of the movement width indi cated on dial gauge. Standard valve 0.05 mr (0.0020 in) [Point 13] Cylinder head cam bracket inside diameter inspection @ Tighten the cam bracket to specified torque. ‘Cam bracket bolt tight. ening torque 8.0- 11.8 Nem (0.92 - 1.2 kg-m, 67 - 8.7 Melb) ‘@ Use bore gauge or inside micrometer to measure inside diameter. — No. 1-No.7 Standard value (28.000 - 28.021 mmm (1.4024 1.1032 in) [Point 14] Camshatt oil clearance inspection © The oll clearance can be calculated from the camshaft jour- nal outside diameter and bracket inside diameter mea- sured in [Point 11] and [Point 13] (Clearance) = (cam bracket inside diameter) — Camshaft journal (outside diameter) ——— No 1-No.7 Standard value 0.045 - 0.086 mmm (0.0018 - 0.0034 in) EN-76B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE ( t 15] Valve lifter inspection © Check contact and sliding surfaces for wear or scratches. Replace if damaged ‘© Use 2 micrometer to check the vaive lifter outside diame- ter. Micrometer Standard value 30.955 ~ 30.965 mm (1.2187 «1.2191 in) >7| [Point 16] Cylinder head lifter bore inspection © Check bore surface for wear or scratches. © Use inside micrometer to measure valve lifter hole diame- ter. Sy, As w Standard value 31.0 - 91,020 mm (1.2205 - 1.2213 in) RN “oe iE 2 5S [Point 17] Valve lifter-to-lifter hole clearance inspection © Check the clearance using values for the valve lifter outside diameter and valve lifter hole diameter measured in [Point 15] and [Point 16] (Clearance) = (valve lifter hole diameter) - (vaive lifter outside diameter) E value 0.025 - 0.065 mm (0,001 Valve [Point 18] Valve spring removal and installation When cylinder head is removed from vehicle: © Use vaive spring compressor (KV101 08980) to remove and install valves. When cylinder head is installed in vehicle. © Use valve spring compressor (KV 101 11300) to remove and install valve springs. EN-77B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE. svaightodge (square) BZ Mako contact [Point 19] Valve collet removal and installation Removal © Use tweezers for removal and installation of collet. Installation ‘© Apply a small coating of petroleum jelly to the internal sur- face of collet, @ Use a magnetic screwdriver. ®D Upper collet installation Attach collet to lower side of magnetic screwdriver blade and install in the valve stem. ® Lower collet installation Attach collet to upper side of magnetic screwdriver blade and install in the valve stem, [Point 20} Valve spring inspection Free length and pressure load inspection e Use a valve spring tester to check spring pressure. [__ standard value Limit value Free length mm (inj| 46.84 (1.8929) Installation toad 296.4 (240, 529) 2207 (22.5, 49.6) NN (xg, 1b) " Identitication color White ~ ‘Note: installation load is the force required to compress the epring to a G5 ‘mm (1.38 in) length, Ive spring squareness inspection Place a right-angle straightedge (i-square, etc.) so it con- tacts spring, Turn spring and measure the maximum clear- ance between upper spring surface and right angle surface to determine out-of-square distance. 4.8 em (0.071 in} Limit EN-78B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE Identification paint (wtitey [Point 21] Valve spring installation © Install uneven pitch type spring with narrow pitch end toward cylinder head (identification color side down). [Point 22] Valve guide clearance inspection © Protrude valve approximately 15 mm (0.9 in) trom valve guide hole into combustion chamber, Measure valve deflection by swinging it in direction parallel to dial gauge. The clearance is equal to one-half of the dial gauge read- ing (deflection width) ntake valve Intake | Exhaust [___tntske _|___Eshavst___ Limit mm tin} 0.1 (0.004) 0.4 (0.004) ® If clearance exceeds limit, verify valve stem diameter and replace valve or valve guide. [Point 23] Valve inspection Outside diameter measurement FN.79B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE Unit: om (in) Valve a b Bi a 2 | 1 o [= ‘mae | 10098203 | e7a5z015 | eas? ease [13 ee — | aso (3.83664 0.0059) | ( 1-958", ) | (0.29677) | (0.051) | (0.10279; | | a rr S08 lappy Exraust| (5.9962 + 0.0039) | (2.7680: 0.0058) | (1.181 “28 | (0.2756 29m") | caer) | core “°™2) | cozas game) | #97 #18 Be especially careful in handling and disposal of valves because exhaust valves are filled with metal. lic sodium. Refer to Page EN-87. Vat ol sel gin O22 04h enactment KVIO1 14905 77 UR A Valve oil seal wr nz (ose 460) 1 —t Intake Exhaust Unt mm Gn) [Point 24) Valve oil seal removal and install: Removal © Use valve oil seal puller to remove valve seal. Installation Use vaive oil seal drift to install valve seais. Pa Intake Exhaust Too's ievi01 07604 KVi0" 14800 Drift attachment CAUTION: Coat inside of valve oll seal with engine oil before installation. © Install valve oil seal as shown in figure. [Point 25] Valve guide removal and installation Removal @ Use valve guide drift and tap it from combustion chamber side to remove seal, EN-80B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE Valve gue ceamrer Vo wearer (0.867 +0008 Irake Exhaust Unit: mm to) KV101 07700 (exhaust) Installation @ Ream cylinder head valve guide holes with valve guide reamer at normal temperature to rectify the hole diameter [when using 0.5 mm (0.020 in) oversize service part)] 10.48 - 10.478 (0.4118 - 0.4125) 11.46- 11.478) (0.4812 - 0.4519) ater | © Heat cylinder head in an oil bath to approximately 150 to 160°C (302 to 320°F). Use a valve guide drift or press-fit tool and press valve guide from camshaft side. ‘© The press-fit dimensions are shown in figure at left. ‘© Ream the inside of the inserted valve guide with valve guide reamer. lntake side 2382-0238 Finished intornal diam- i (0.2362 - 0.2388), ter standard value 7.000 -7 018 mm (in) | Exhaust si : Exhaust side (02766 - 02783) OK No, [Point 26] Valve seat Inspection © Check contacting surfaces of valve seat and valve. Replace valve or valve seat if contacting surface is too large or improper, or grind both surfaces and lap with abra-~ sive compound. EN-81(ECCS) TWIN-TURBOCHARGER ENGINE © When surfacing valve seat due to poor contact, inspec valve guide clearance and valve stem hole clearance. © Use valve seat cutter or valve seat grinder and finish te standard value. CAUTION: When using valve seat cutter, press firmly and cut evenly wilt Removal © Minimize valve seat thickness by cutting it, then remove. Installation @ Drive vaive seat into cylinder head using valve seat a: shown in figure. © Exhaust vaive seats are available in 0.5 mm (0.020 in) over size. When using oversize vaive seats, cut and grind seat ing recess in cylinder head to fix valve seats | 0 Intake y91 201 (0.004) ice “ (c ‘Unit ene Cn) I Ps Unit mm Gn (60s 20: (0.008) cael ee cseonn sonst Ste a ce Eon ‘a ter finishing Valve saree | ac w0z0% 2 32 as or (1.417379 2) (1.1811 + 0.0059) (1.26) (1.958) (1.476) (9.280 °5 004 vie eC od a wee (azo) | rasroretee (3619 40.0059) | 0.26) (2.358) = {e.2283-0.0020, Exhaust (1.259823 Seat ) {0.9643 + 0.0059) (1.165) (1.280) {0.280 gone) 7 Semen | me wea (9.020) $F) | (5.27955 565% ) {0.9843 + 0.0059) (1.165) ~ 7 (0.2283 + 0.0020) EN-82B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE [Point 27] Cylinder head inspection © Remove all traces of oil, fur, gasket, sealing compound, carbon, and other foreign matter from cylinder head sur- face. © Measure lower surface of cylinder head in six directions to check for distortion. Limit (0.2 men (0.008 in} © When distortion is within the limit, resurface the cylinder head. © If distortion exceeds the limit, replace cylinder head. 10-13 WATER PUMP REMOVAL AND INSTALLATION Tools required Name Application Too! Tube presser ]wssees Liquid gasket application 802-0051 EN-831. M0 (shor others are Me (6) Additional work required: © Drain and refill cooling water. (Refer to section B6, 3.) @ Remove and install Cooling fan, water pump pulley Alternator adjustment bolt Timing belt cover, timing belt CAUTION Loosen engine drain plug to remove cooling water from cylir der block. (if water is only drained from the radi Inder block will not drain completely.) tor in cock, the cy [Point 1] Water pump removal and installation Removal © When removing water pump assembly, be careful not to ge Coolant on timing chain. If any water does spill, wipe it of immediately. © Remove water pump bolts in the reverse of sequence ir figure on left, Installation Install bolts in the numbered sequence in figure on left Number of insta aot size |Nmber 63-83 " * | (oss-08s, 46-61) COSCO | we | 6 [w-2n6-0,0-1) 0.9.8.8 win [4 [sia @a-4s.28-31 Removal and cleaning © Insert stubby screwdrivers in bolt holes as shown, anc Move them up and down to remove water pump, CAUTION: Be careful not to damage screws in cylinder block side, © Use a scraper to remove all traces of liquid gasket fro mating surface. CAUTION: Also remove any liquid gasket remaining in grooves ® Clean installation surface with white gasoline. EN-84B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE see ‘Apaly a continuous bead ot guid gasket 20 to 3.0 mm (0079 19 6.116 in} wide along the (groove of installation surtece. In sections ‘where thre v8 no groove arround bolt hole, ‘coat middie of rsige seal surace. Installation © Cut nozzle end of liquid gasket tube (KP510 00150} as shown in figure and use tube presser for application. ‘© Apply a continuous bead of liquid gasket (KP510 00150) to water pump sealing surface. CAUTION: (1) Be sure lig wide. {2) Installation should be done within § minutes after liquid gasket application. gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) [Point 2] Water pump inspection @ Rotate water pump by hand and check for abnormal sound and smooth operation. ‘© There must be no traces of water leaks. 10-14 THERMOSTAT REMOVAL AND INSTALLATION Tools required Name ‘pplication Tube presser Liquid gasket application ws9993 Toot 1802-0051 Measurement | Thermometer ‘Water temperature measurement too! Therenestat Farrenmeniet [nai ‘rousing [Point 9) [assis pa ie Additional work required: ‘® Drain and refill cooling water. CAUTION: Loosen engine drain plug to remove cooling water from cylin- der block. (if water is only drained from the radiator drain cock, the cyl- inder block will not drain completely.) © Disconnect and connect water inlet hose. EN-85B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE ‘Apply a continuous coat of liquié gasket 20 t0 30 mm (0078 t0 0.118 i) wide to ceontor of lat mating surtace and inner 19 surfaces of bait holes (it provided). Jogie valve [Point 1] Thermostat housing removal and installation Removal and cleaning @ Insert screwdriver handle into thermostat housing. Pry tightly up and down and remove housing, © Use a scraper to remove the liquid gasket. CAUTION: Be sure to also remove liquid gasket in grooves. @ Clean mating surface with white gasoline or equivalent. Installation © Cut nozzle end of liquid gasket (KP510 00150) tube as shown in figure. ‘© Apply a continuous bead of liquid gasket (KP510 00150) to sealing surface using tube presser, and install the housing within 5 minutes after coating. CAUTION: Be sure li gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) wide. Tightening torque 1 6 Hetb) 1 Nem (1.8 = 2.1 kg- [Point 2] Thermostat inst: © “TOP” mark (jiggle valve) must face up when thermostat is inserted in housing [Point 3] Thermostat inspection © Check valve opening temperature and maximum valve lift © Hang thermostat by string in valve and submerge in heated water in double walled container and stir water while heat- ing it up. © The opening temperature is the temperature when the valve opens and thermostat falls from string. Standard, cooled location 765 (170) 70 (0.38) min./@0 (184) opening temp Max. valve litt mom (ir CF) EN-86B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 10-15 OIL COOLER, OIL FILTER REMOVAL AND INSTALLATION Tools required Name ‘Application Oi iter wrench ‘OW titer removal and installation Kv101 06280 Special too! LS [Ehgenee SE casket 01 pressure swten—~ ~ shows ST Brac ring Y ve ‘Season (4: Always replace after every } rt Geer 2) Bas 0-2, 2-1 in | ae ea oe a! 8) ED: kam ti l Bays 0.95, 46-6.1) Cilfiter sensor J Additional work required © Drain and refill cooling water. CAUTION: Loosen engine drain plug to remove cooling water from cylinder block. (it water is only drained from the radiator drain cock, the cylinder block will not drain completely.) © Disconnect and connect switch harness connectors -— [Point 1] Olt filter removal and installation | | Removal | 1. Remove oil level gauge. 2 Remove turbocharged pressure control vacuum hose clamp and move vacuum hose out of the way. 3, Move main harness clamp out of the way. 4, Remove oil filter using oil filter wrench. Sma ratchet wrench EN-87B2 RB26 DOHC EGi (ECCS) TWIN-TURBOCHARGER ENGINE Installation © Before installing new oil filter, wipe off dust, etc. from oil filter mounting bracket surface. Apply a thin coat of engine oil to oil filter O-ring © Screw oil filter on bracket by hand until a slight resistance is felt, then tighten an additional 2/3 turn with oil filter wrench. After tightening, start engine and check for oil leaks. Removal ‘© Face lower part of oil filter down and move out in direction of arrow in figure on left. Remove through aperture behind manifold collector. EN-88B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 11. Engine Removal and Installation Basic items This section describes how to use an engine hoist and transmission jack to remove and install the RB260ETT engine. Additional work required: Inspection and adjustment after installation Position vehicle on a flat and solid surface, Remove and install: Battery Engine hood Cooling water Radiator Starter motor Front drive shaft Transmission ASSY Engine compartment left side: Exhaust gas sensor harness disconnection Ground line connector separation Power steering oi! pump [Point 4] Air conditioning compressor [Point 4] Air injet pump, air cleaner upper case Engine compartment front side: © Cooling fan Engine compartment upper side: ECCS hamess connectors Engine compartment right side: Fuel feed, return hoses separation (Point 1} Accelerator cable separation [Point 2] Engine main harness and ground line separation [Point 3] Heater hose separation Vacuum hoses separation Vehicle body, lower side: © Engine under cover ‘* Front section of exhaust pipe separation © Right and left engine mount brackets [Point 6, 7] © Power steering oil tube separation [Point 5] weece [Point 1] Release fuel pressure “Fa [nmnmosee T | eater staring engine, remove fel puny fuse and cun sgn aici n't supe Cane engine ove wo o tee 4 times to consume fuel in fuel lines. When unable to start vehicle, remove fuel pump fuse and r crank engine four to five times to consume fuel in fuel lines. DRRRREAS 3 CAUTION: | ewe ElRorore rare JE) | The battery can be run down easily, so connect booster cables ET)’ <| 10 another vehicle or charged battery. EN-89B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 11. Engine Removal and Installation (Cont'd) rr =~] [Point 2} Accelerator wire adjustment |—Eys-t0nm(08-1010m.58-72%6) | Loosen lock nut to provide adequate slack for the acceler ig \ r ator wire, and pull outer case in the direction of the accel AREY erator pedal until throttle drum starts to move (when there is no play in cable). Return lock nut 1.0 to 1.5 turns ther tighten, Tightening torque 8-10 Nm (08- 1.0 kgm, 68- 7.2 tb), [Point 3] Engine main harness, ground line separation © Disconnect connectors behind battery for harnesses o alternator, starter motor and transmission systems. [Point 4] Air compressor, power Steering oil pump movement © Remove bolts securing each unit to brackets. Leave pipes Connected and secure to side of body with string, being careful not to scratch body. 1Q\ A> [Point 5] Power steering fluid tube bracket separation © Remove bolts, and separate power steering fluid tube bracket, and move toward body side. [Point 6] Front engine mounting nut removal ¢ Make sure engine slings are securely hooked by engine hoist chain and remove front engine mounting auts. Tightening torque 49-55. Nim (4.4- $6 kg-m, 32-41 feb) S| ENS 4Ur ere" fos ssttm (eae kgm ba i) EN-90B2 RB26 DOHC EGI (ECCS) TWil Right ffi wel WG fete, lates wey “Ee a2 WS By mle 'URBOCHARGER ENGINE Engine Removal and Installation (Cont'd) SN Se) Point 7] Right front engine mounting bracket removal wa Remove nut and remove right engine mounting bracket to move engine toward front of vehicle. [Point 8] Engine ASSY removal and installation Operate hoist chain, and change engine angle gradually, being careful so it does not interfere with vehicle and remove engine. EN-91B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE il Pump and Oil Strainer Removal 12. Oil Pan, and Installation Tools required Name ‘Application Seal cuter Oi pan removal Kvi01 11100 Gil seal insertion al tools Special 0018 Toi seat drt kv407 o0e00 Liquid gasket application Ffube presser ]ws3003 Too! 1302-0051 (1) OIL PAN, OIL PUMP AND OIL STRAINER REMOVAL AND INSTALLATION — an inven eu [Poi 3) BF aay 43 Oil pump gasket , ®. | spring washer RTC E on A See bee ptaneroma Px J EN J _— Ve Boi pond se § = on pump . leans \ 4 pan bot (4) (Point 1 9G Front i soa Pon 3} an plug [int 1 69 copoee ie 38 om Becta 20 ot pn a4) Pon 1 oan bolt (5) (Point 1) Fst - 42132. 43 20-99) (sas ye6s css, 46-61 BB : Liquid gasket 3: Atways rorlace after every dis sssambly. ELEN gem wb) Additional work required @ Engine ASSY removal and installation @ Engine oi draining and refilling EN-92 T}6.3- 8.3 (0.68 -0.85, 46-6.)B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE. 12. Oil Pan, Oil Pump and Oil Str Removal and Installation (Cont'd) {Point 1] Oil pan bolt, nut removal and installation Removal fe Remove bolts and nuts in reverse order of installation shown in figure on left Installation @ Tighten nuts and bolts in numerical order shown in figure on left CAUTION: Make sure there is no dirt, dust or debris on oil pan installa- tion surface. iniataion positon | Botsize | Naber ot]. Teaheina rave oe-8 we 9 |roes-085.48-80 OOOO SE) uo | ga-aae-a0 2006698 | mom) 7 | are a ioy [Point 2] Oil pan removal and installation Removal and cleaning © Insert seal cutter between cylinder block and oil pan and remove oil pan by tapping seal cutter © Use a scraper to remove ail traces of liquid gasket from mating surface CAUTION: (1) Use a scraper to remove all liquid gasket and seal mate- rial attached to cylinder block and oil pan flange groove. Remove all gasket material and other debris that falls into the oil pan. (2) Be careful not to scratch oil pan. © Clean all contact surfaces with white gasoline or equiva- lent. gasket (KP510 00510) at point ‘shown in figure on left and insert in tube presser. EN-93B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE (020%) | Bot hole ss-33 (084-08, 46-63) BOrINg—D ge Oe-n | gsm (agi, tb) {Bs Aways: & ater every cisassemby. 42. Oil Pan, Oil Pump and Oil Strainer Removal and Installation (Cont'd) Installation Apply liquid gasket to inner sealing surfaces as shown in fig- ure. Installation should be performed within 5 minutes after coating. Apply a continuous bead of liquid gasket (KP510 00150) to mating surfaces of oil pan. © Apply liquid gasket (KP510 00150) to areas 7 mm (0.28 in) inside from center of oil pan bait holes. CAUTION: (1) Be sure liquid gasket application is 4.0 mm (0.157 in) wide. (2) Wait at least 30 minutes before refilling engine oll and engine coolant. [Point 3] Oil strainer installation ‘© When installing oil strainer, make sure O-ring is inserted securely in groove and then install. . Mg] 16-21 (16-21, 12-15) Tightening torque N:m {kg-m, tb) M6] 63-83 (064-085, 45-61) ee eee:es“ee:ul®l® [Point 4] Oi! pump installation bolts © There are 4 types of bolts so be careful not to mistake them when they are installed ite | eee aay at | Number of pote | anenng wrens > 207 * _oserta'sr-an ® 95126 2 |ose!r3er-0n ® sam 1 lesrizer-an ® sen 1 [esortaer-an [Point 5] Front oil seal removal and installation Removal © Use a screwdriver to remove front oil seal from front cover. EN-94B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 12. Oil Pan, Oil Pump and Oil Strainer Installation oil pump housing, lip. and proper oil pressure. switch and attach oil pressure gauge. Removal and Installation (Cont'd) [Point 6] Oil teak and oil pressure check © After installation, warm up engine and check for oil leaks © Be careful not to scratch or damage oil seal retainer. Use oil seal drift and insert it at same level as front surface of © Apply engine oil or chassis grease to area around oil seal © To perform oil pressure inspection, remove oil pressure Engine spees (om tating 2,000 6.000 Jem? pap |*PP**. 147 Approx. 296 Approx, 451 Delivery pressure kPa (ka/em?, ph |AP42" 17 |pmnon 8 Art switch (2) OIL PAN DISASSEMBLY AND ASSEMBLY Gil temperature at 80° (1707) 12) 3.82 (064-085, 46-61) ge ay Bate plate Hie ‘oss oy een) 1: Nem tka, ab) EN-95B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 12, Oil Pan, Oil Pump and Oil Strainer Removal and Installation (Cont'd) (3) OIL PUMP DISASSEMBLY AND ASSEMBLY Bo 13.7 5.00.28 -051,2.7-37) Purp neusing {Point 1} 9 in corr 5 ". ner gear (Point 1.3) ‘Outer gear Point} Regulater pug 9 - 69 (40 - 7.0, 29-51) TA: Nem kgm, a) [Point 1] Oil pump inspection Check inner gear, outer gear and housing for scratches ¢ wear, @ Use a feeler gauge and measure the following clearances Measurement position Standard value tom in © [Octer gear ans housing clearance: 0.114 02 (0.0088 - 0.0078) @ [Outer gear and inner gear top clearance | 0.180 (00071) max @ [Inner gear and housing side clearance _| 0.08 - 0.07 (0.0020 - 0.0028) @ [Outer gear and housing sige clearance | 005 - 0.17 (0.0020 - 0.0043) 0.085 - 0.08% @ nner gear and housing ange clearance | 00S" 0) CAUTION: Measurement position @) is the the housing flange outside diame! diameter. jure obtained by subtractin from the inner gear insid EN-96B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 12. Oil Pan, Oil Pump and Oil Strainer Removal and Installation (Cont'd) Measirement position @, @ Inside micrometer Wossucament positon @) [Point 2] Regulator inspection © Check oil pressure regulator valve sliding surface and spring for wear and damage. Valve and valve hole clearance 0.04 - 0.097 mm (0.0016 - 0.0088 in} osests8 [Point 3] inner gear installation © Be careful because the inner gear has specitic assembly direction, © The side with the groove must face the cover side. side EN-97Be RECO VW EGU EUS) ERIN: TURSULRARGEN ENGINE 13. Engine Overhaul This section describes the complete disassembly of the engine assembly removed from vehicle without transmission. It also explains the inspection, replacement of malfunctioning, damaged or worn parts, necessary adjustments and sequential assembly order to produce a standard engine condition 18-1 OVERHAUL CAUTIONS (1) Disassembly ® Use correct and suitable tools whenever possible, and do not try any unsafe or unreasonable pro- cedures. ® Be careful with operations on mating surfaces and sliding surtaces to prevent loss of surface accu- racy. ® Make marks on disassembled parts for organized, thorough damage detection and precise assem- bly. @® Loosen nuts and bolts in a diagonal direction from the outside, being careful to follow the numeri- cal order when indicated (2) Inspection, repair and replacement @ Repair or replace after completing parts inspection following the inspection procedures. Perform the same inspection for the new parts and replace parts as necessary. (3) Assembly Always use a torque wrench to tighten nuts and bolts to the specified torque. Tighten nuts and bolts from the center to the outside diagonal direction, gradually in two or three successive stages. Follow the numerical order when indicated. Gaskets, packing, oil seals and O-rings should be replaced with new ones in principle Each part should be cleaned thoroughly and blown off with compressed air. In particular, check that oil and water passages are not clogged or obstructed Be careful not to scratch or damage sliding or mating surfaces. Clean off all dust, debris or foreign matter. Lubricate all sliding surfaces with an adequate coating of oil ®@ 62 @ 143-2 CYLINDER BLOCK ASSY ASSEMBLY AND DISASSEMBLY Tools required Name ‘Application Engine stand ASSY Engine main unit overhaul 'sT0s01 $000 Engine attachment kv101 06500 Special tools [Engine sub-attachment Kv101 14500 EN-98B2 RB26 DOHC EGI (ECCS) TWI URBOCHARGER ENGINE 73. Engine Overhaul (Cont'd) oy | Tepeaton ear avie bearing ort [ear oi seal instalation xevaoi 800 [Rear oi seat ert ~ sT3002 2000 SA Pilot bearing puller | Pilot bushing removal sree 0008 | Piston ring compressor Fision ASSY installation Tools Piston ring expander Piston ring removal and installa- ion Dial gauge Grankchat et. inepection Magnetic stand (Granishatt, etc inspection inside micrometer ‘Connecting rod, et. inepection Plastigage (Oi cearance Inapection MeasuremenFicrometer Pision, ete inspection Connecting rod algner [Connecting rod inspection Bore gave Teylinder block, ee. inepecton V-bock ‘Crankshaft, ete inepection Svaightedge Oylinder block, ee. inepection Engine aingor Engine removal and installation QA Service set tinge } Front eae EN-99B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 13. Engine Overhaul (Cont'd) wae Peo RE Ga water oume 2 ear ol sea! (Point 7] Water purge bolt etainer 80m 16) 153-83 (068 - 08s, 45-63) F1ywnee! bolt 6) (Point 4) consort fa = 152 (185 - 185, 105-112), ou pune smpreseer Fa Bas “BS Piston pin fPoin 4,5, 97,33) oe Connecting roe Woint 8. ¢, 10, 9] —) connecting tod bol (2) MT antes Piston rng {Pore 1221) Crankshan L tPoin 22,27, 28) 83 S009 cea oi 1) Flywnee (Point 3. 5) Main bearing cap [Point 25) ‘Rear plate ain bearing Bott Gjwrseeress, BP connecting rad bearing 4 28) [Point 24) {Point 10,18, 28,25) =o connecting rod oN ibpan nit Ee gees atte plate Sering washer (FO) on strainer freets Eet Bevaie oi os ee Cul pet ‘atpen bot oon 3, Brinn epnce ater every csssonay >= SSO oma Se ee aa nm oom ne) 3 ce Be Sonam Additional work required: Water pump @ Drain and rel: cooling water {Point 1) oir pump @ Remove and install: Oil cooler, oil strainer Engine All harnesses and connectors Collector Throttle chamber intake manifold Turbocharger, exhaust manifold Timing belt Cylinder head ASSY Alternator Starter motor Clutch cover, clutch disc it pan, oil strainer EN-100B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 13. Engine Overhaul (Cont'd) Reterence: Engine selection assembly Part (Grade Indication ‘Selection Combination @ Piston selection Fao game Fare mare (NT Sho eR Piston | ‘caiaton| yb Piston sin grade (0.1) ne _[SSSEES | SSen, [sare | Sebo arama [ae aera ‘Main bearing ‘Jone joaal grade Wo, x #7 NovTan Ne. Reo ie Lows sin, * Josie oe “i. om af si Z a EREEEETS a aa SEL / [cod ata |ee seinem Sanere Saican” cama tiene sonae OS) / | coma [amici |eoensoe | corse Fermaik @ Piston pin selection F page 1 e mI, : > a) \ilives. cece fanaa ay) , itn Zee te Ad i Sean ao Liteon Gane ns Sas z 3 2 | | copoonns e | | Giant || ates sacceneann- cam |e o28 moo cone & se EN-101B2 RB26 DOHC EGI (ECCS) TWIN-TURBOCHARGER ENGINE 13. Engine Overhaul (Cont'd) [Point 1] Cooling water, drain and refill Draining © Drain the water in the cylinder block completely from the drain plug. Refilling @ Refer to Cooling Water Filling Method (86) for details {Point 2] Engine stand installation and removal @ The engine sub-attachment is attached by 6 bolts to engine mounting bracket on right side of engine. | Engine attachment | (&V7I01 06500) a: Nm (kgm, fib) Bott (6) IMIO x 1.5 £ = 25) 20-49 (4-5, 29 - 36) i ial gauge [Point 3] Flywheel runout © Set dial gauge to flywheel where it contacts clutch @ Turn the flywheel and measure the runout. Runout (total in F reading) (0.10 mm (0.0059 in} EN-102B2 RB26 DOHC EGI (ECCS) TWIN. -TURBOCHARGER ENGINE 13. Engine Overhaul (Cont'd) [Point 4] Flywheel removal and installation Removal © Use ring gear stopper to secure flywheel and remove. Installation © Before installing bolts, coat the thread and flange of bolt with engine oil. ‘© Alter tightening the flywheel installation bolts halfway, use the ring gear stopper to secure flywheel and tighten bolts, 142 - 162 Nem (145 = 18.5 kgm, 105-112 fib) Flywheel bol tightening torque 2.85 mm [Point 5] Flywheel knock pin insertion (0398-0335 19) in Insert the flywhee! knock pin so pin protrudes 8 to 8.5 mm protrusion distance {0.815 to 0.336 iin). Rreck pin Flywheel [Point 6] Rear oil seal retainer removal and installation Removal ‘© Insert a screwdriver in the gap between main bearing cap and rear olf seal retainer to remove seal. Cleaning © Use a scraper to remove liquid gasket. CAUTION: Also remove gasket in grooves. © Clean the cylinder block side in the same way. @ Clean mating surface with white gasoline or equivalent. EN-103B2 R626 DONE EGI[ECUS) TWIN-TURBUCRARGER EN wove ‘Roply @ continuous bead of liquid gasket to ‘mating surfaces 2.0 10 30 rr (0.079 100.178 Int ‘wide, ‘Apply lau gasket to roner surface rie Je3- 831m 10.64 05 kgm, te 13. Engine Overhaul (Cont'd) Installation © Apply liquid gasket to mating surface and install unit within 5 minutes after coating. Cut nozzle end of liquid gasket (KP510 00150) tube as shown in figure and use tube presser for application. © Apply liquid gasket continuously to rear oil seal retainer as shown in the figure on left CAUTION: (1) Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) {2) Refill engine oil and start engine 30 minutes after assem- bly is completed. Align rear oil seal retainer with dowel pins. Tighten the 6 bolts uniformly. Rear oll seal retainer bolt tightening torque 63-83Nm (0640.85 kgm, 4.6 - 6.1 feb} [Point 7] Rear oil seal removal and installation Removal © Use a screwdriver or suitable tool to remove the seal Installation © Be careful not to scratch or damage the oil seal perimeter area. Use an oil seal dritt [outside diameter: 100 mm (3.94 in)] to install new oil seal. Apply a coat of engine oil or chassis grease to oil seal lip perimeter area, EN-104