1-ii Table of Contents
Service Instructions.............................................1D-2
Tappet Clearance Inspection ..............................1D-2
Ring Gear Cover Removal and Installation.........1D-2
Cylinder Head Cover Removal and
Installation.........................................................1D-2
Air Intake Silencer Case Removal and
Installation.........................................................1D-5
Electric Parts Holder Removal and Installation ....1D-5
Intake Manifold and Throttle Body
Components......................................................1D-7
Intake Manifold Removal and Installation ...........1D-7
Throttle Body Removal and Installation ............1D-10
Throttle Body Inspection ...................................1D-11
Power Unit Removal and Installation ................1D-11
Timing Chain, Chain Tensioner and Camshaft
Sprockets Components...................................1D-19
Timing Chain, Chain Tensioner and Camshaft
Sprockets Removal and Installation................1D-20
Timing Chain, Chain Tensioner and Camshaft
Sprockets Inspection.......................................1D-24
Camshaft, Tappet and shim Removal and
Installation.......................................................1D-25
Camshaft, Tappet and Shim Inspection ............1D-27
Cylinder Head Assembly Components .............1D-31
Cylinder Head Removal and Installation ...........1D-32
Cylinder Head Disassembly and Assembly ......1D-33
Cylinder Head Components Inspection and
Servicing .........................................................1D-35
Pistons, Piston Rings, Connecting Rods,
Cylinder and Crankshaft Components ............1D-42
Pistons, Piston Rings, Connecting Rods,
Cylinder and Crankshaft Disassembly and
Assembly ........................................................1D-43
Cylinder, Piston and Piston Ring Inspection
and Servicing ..................................................1D-50
Piston Pin and Conrod Inspection.....................1D-53
Crank Pin and Conrod Bearing Inspection........1D-54
Selection of Conrod Bearing .............................1D-56
Crankshaft Inspection .......................................1D-57
Crankshaft Main Bearing Inspection .................1D-58
Crankshaft Drive Gear Inspection .....................1D-61
Crankshaft Oil Seal Inspection..........................1D-61
Power Unit Lubrication ............................1E-1
General Description ............................................. 1E-1
Engine Lubrication Description ...........................1E-1
Schematic and Routing Diagram........................1E-1
Engine Oil Lubrication Chart ............................... 1E-1
Diagnostic Information and Procedures............ 1E-2
Oil Pressure Check .............................................1E-2
Oil Change Reminder System.............................1E-2
Low Oil Pressure Caution System ......................1E-2
Powerhead Lubrication System Diagnosis..........1E-2
Service Instructions............................................. 1E-3
Oil Pump Removal and Installation ..................... 1E-3
Oil Pump Disassembly and Assembly ................1E-3
Inspection Oil Pump Component Parts ...............1E-4
Oil Pressure Switch Removal and Installation ....1E-5
Oil Pressure Switch Inspection ........................... 1E-6
Oil Strainer Removal and Installation ..................1E-6
Oil Strainer Related Parts Inspection ..................1E-6
Power Unit Cooling System.....................1F-1
General Description ............................................. 1F-1
Water Cooling System Description ..................... 1F-1
Displacement Type Water Pump Description .....1F-1
Water Pressure Valve Description ...................... 1F-1
Schematic and Routing Diagram ........................ 1F-2
Cooling Water Circulation Chart.......................... 1F-2
Diagnostic Information and Procedures............ 1F-3
Powerhead Cooling System Diagnosis ............... 1F-3
Service Instructions............................................. 1F-3
Thermostat Removal and Installation.................. 1F-3
Thermostat Inspection......................................... 1F-4
Water Pressure Valve Removal and
Installation ......................................................... 1F-4
Water Pressure Valve Related Item
Inspection.......................................................... 1F-5
Water Pump Removal and Installation................ 1F-5
Water Pump Related Item Inspection ................. 1F-5
Water Tube Removal and Installation ................. 1F-5
Water Tube Related Item Inspection................... 1F-5
Fuel System ............................................. 1G-1
Precautions.......................................................... 1G-1
Precautions on Fuel System Service ................. 1G-1
General Description ............................................ 1G-2
Electronic Fuel Injection System Description ..... 1G-2
Fuel Delivery System Components
Description ....................................................... 1G-4
High Pressure Fuel Pump Control System
Description ....................................................... 1G-7
Air Intake Components Description.................... 1G-8
Idle Air Control System Description ................... 1G-9
Diagnostic Information and Procedures......... 1G-11
Fuel Pressure Inspection ................................. 1G-11
Fuel System Diagnosis .................................... 1G-13
Fuel Injection System Troubleshooting ............ 1G-14
Service Instructions.......................................... 1G-15
Fuel Pressure Relief Procedure ....................... 1G-15
Fuel Line Removal and Installation .................. 1G-15
Fuel Line Inspection ......................................... 1G-15
Fuel Leakage Check Procedure....................... 1G-16
Inspection of Fuel Hose Connections .............. 1G-16
High Pressure Fuel Pump Operating Sound
Inspection....................................................... 1G-16
Fuel Vapor Separator Removal and
Installation ...................................................... 1G-17
Fuel Vapor Separator Disassembly and
Assembly........................................................ 1G-17
Inspection of Fuel Vapor Separator
Component Parts ........................................... 1G-20
Fuel Injector Inspection with Injector in place .. 1G-21
Individual Fuel Injector Operating Sound
Inspection....................................................... 1G-22
Fuel Injector Operating Signal Inspection ........ 1G-22
Fuel Injector Removal and Installation ............. 1G-23
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