1-ii Table of Contents
PAIR Control Solenoid Valve Removal and
Installation.........................................................1B-6
PAIR System Inspection .....................................1B-6
Crankcase Breather (PCV) Hose Inspection.......1B-8
Crankcase Breather (PCV) Hose / Cover /
Separator Removal and Installation ..................1B-8
Crankcase Breather (PCV) Cover Inspection .....1B-9
Specifications.....................................................1B-10
Service Data...................................................... 1B-10
Tightening Torque Specifications......................1B-10
Special Tools and Equipment ...........................1B-10
Recommended Service Material .......................1B-10
Special Tool ......................................................1B-10
Engine Electrical Devices....................... 1C-1
Precautions...........................................................1C-1
Precautions for Engine Electrical Device ............1C-1
Component Location ...........................................1C-1
Engine Electrical Components Location .............1C-1
Diagnostic Information and Procedures............1C-1
Engine Symptom Diagnosis ................................1C-1
Repair Instructions ..............................................1C-1
ECM Removal and Installation............................1C-1
CKP Sensor Inspection .......................................1C-1
CKP Sensor Removal and Installation ................1C-1
IAP Sensor (No.1) Inspection..............................1C-1
IAP Sensor (No.1) Removal and Installation.......1C-2
IAP / TP / IAT Sensor Inspection ........................1C-2
IAP / TP / IAT Sensor Removal and
Installation.........................................................1C-2
ECT Sensor Removal and Installation ................1C-2
ECT Sensor Inspection .......................................1C-3
TO Sensor Removal and Installation ..................1C-3
TO Sensor Inspection .........................................1C-3
STP Sensor Inspection .......................................1C-3
STP Sensor Adjustment......................................1C-4
STP Sensor Removal and Installation ................1C-4
STV Actuator Inspection .....................................1C-5
STV Actuator Removal and Installation ..............1C-5
ISC Valve Inspection...........................................1C-5
ISC Valve Removal and Installation....................1C-5
ISC Valve Preset and Opening Initialization .......1C-6
HO2 Sensor Inspection .......................................1C-6
HO2 Sensor Removal and Installation ................1C-6
GP Switch Inspection..........................................1C-6
GP Switch Removal and Installation ...................1C-6
Specifications.......................................................1C-7
Service Data........................................................1C-7
Tightening Torque Specifications........................1C-8
Special Tools and Equipment .............................1C-8
Recommended Service Material .........................1C-8
Special Tool ........................................................1C-8
Engine Mechanical .................................. 1D-1
Schematic and Routing Diagram........................1D-1
Camshaft and Sprocket Assembly Diagram .......1D-1
Throttle Cable Routing Diagram..........................1D-2
Diagnostic Information and Procedures............1D-3
Engine Mechanical Symptom Diagnosis.............1D-3
Compression Pressure Check ............................1D-3
Repair Instructions ..............................................1D-4
Engine Components Removable with the
Engine in Place .................................................1D-4
Air Cleaner Element Removal and Installation ....1D-6
Air Cleaner Element Inspection and Cleaning ....1D-6
Air Cleaner Box Removal and Installation...........1D-6
Throttle Cable Removal and Installation .............1D-6
Throttle Cable Inspection ....................................1D-7
Throttle Cable Play Inspection and
Adjustment ........................................................1D-7
Throttle Body Components .................................1D-7
Throttle Body Construction..................................1D-8
Throttle Body Removal and Installation ..............1D-9
Throttle Body Disassembly and Assembly........1D-10
Throttle Body Inspection and Cleaning .............1D-15
Throttle Valve Synchronization .........................1D-15
Engine Assembly Removal ...............................1D-17
Engine Assembly Installation ............................1D-21
Engine Top Side Disassembly ..........................1D-24
Engine Top Side Assembly ...............................1D-28
Valve Clearance Inspection and Adjustment ....1D-36
Camshaft Inspection .........................................1D-36
Camshaft Sprocket Inspection ..........................1D-38
Camshaft Sprocket Removal and Installation ...1D-38
Cam Chain Tension Adjuster Inspection...........1D-39
Cam Chain Guide Removal and Installation .....1D-39
Cam Chain Guide Inspection ............................1D-39
Cam Chain Tensioner Inspection......................1D-40
Cylinder Head Disassembly and Assembly ......1D-40
Cylinder Head Related Parts Inspection ...........1D-44
Valve Guide Replacement ................................1D-47
Valve Seat Repair .............................................1D-48
Cylinder Disassembly and Assembly ................1D-48
Cylinder Inspection............................................1D-50
Piston Ring Removal and Installation ...............1D-51
Piston and Piston Ring Inspection ....................1D-52
Engine Bottom Side Disassembly .....................1D-53
Engine Bottom Side Assembly ..........................1D-61
Crank Balancer Disassembly and Assembly ....1D-72
Crank Balancer Inspection ................................1D-73
Conrod Removal and Installation ......................1D-74
Conrod and Crankshaft Inspection....................1D-75
Conrod Crank Pin Bearing Inspection and
Selection .........................................................1D-76
Crankshaft Journal Bearing Inspection and
Selection .........................................................1D-78
Crankshaft Thrust Clearance Inspection and
Selection .........................................................1D-80
Specifications.....................................................1D-83
Service Data......................................................1D-83
Tightening Torque Specifications......................1D-84
Special Tools and Equipment ...........................1D-85
Recommended Service Material .......................1D-85
Special Tool ......................................................1D-86
Engine Lubrication System .................... 1E-1
Precautions...........................................................1E-1
Precautions for Engine Oil ..................................1E-1
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