1-ii Table of Contents
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-2
IAP Sensor Inspection.........................................1C-2
IAP Sensor Removal and Installation..................1C-2
TP Sensor Inspection..........................................1C-2
TP Sensor Removal and Installation...................1C-2
TP Sensor Adjustment ........................................1C-2
IAT Sensor Removal and Installation..................1C-3
IAT Sensor Inspection.........................................1C-3
ECT Sensor Removal and Installation ................1C-3
ECT Sensor Inspection .......................................1C-4
TO Sensor Removal and Installation ..................1C-5
TO Sensor Inspection .........................................1C-5
STP Sensor Inspection .......................................1C-5
STP Sensor Adjustment......................................1C-5
STP Sensor Removal and Installation ................1C-6
STV Actuator Inspection .....................................1C-7
STV Actuator Removal and Installation ..............1C-7
ISC Valve Inspection...........................................1C-7
ISC Learned Value Reset and Opening
Initialization .......................................................1C-7
HO2 Sensor Inspection .......................................1C-8
HO2 Sensor Removal and Installation ................1C-8
GP Switch Inspection..........................................1C-8
GP Switch Removal and Installation ...................1C-8
Specifications.......................................................1C-8
Service Data........................................................1C-8
Tightening Torque Specifications........................1C-9
Special Tools and Equipment .............................1C-9
Recommended Service Material .........................1C-9
Special Tool ........................................................1C-9
Engine Mechanical .................................. 1D-1
General Description .............................................1D-1
ISC Valve System Description ............................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 Body Components .................................1D-7
Throttle Body Construction..................................1D-8
Throttle Body Removal and Installation ............1D-10
Throttle Body Disassembly and Assembly........1D-11
Throttle Body Inspection and Cleaning .............1D-15
Throttle Valve Synchronization .........................1D-15
ISC Learned Value Reset .................................1D-17
Engine Assembly Removal ...............................1D-18
Engine Assembly Installation ............................1D-22
Engine Top Side Disassembly ..........................1D-25
Engine Top Side Assembly ...............................1D-31
Valve Clearance Inspection and Adjustment ....1D-43
Camshaft Inspection .........................................1D-44
Cam Chain Tension Adjuster Inspection...........1D-45
Cam Chain Guide Inspection ............................1D-46
Cam Chain Tensioner Inspection......................1D-46
Cylinder Head Disassembly and Assembly ......1D-46
Cylinder Head Related Parts Inspection ...........1D-49
Valve Guide Replacement ................................1D-52
Valve Seat Repair .............................................1D-53
Cylinder Inspection............................................1D-54
Piston Ring Removal and Installation ...............1D-55
Piston and Piston Ring Inspection ....................1D-56
Engine Bottom Side Disassembly .....................1D-58
Engine Bottom Side Assembly ..........................1D-65
Conrod Removal and Installation ......................1D-79
Conrod / Crankshaft Inspection.........................1D-80
Conrod Crank Pin Bearing Inspection and
Selection .........................................................1D-81
Crankshaft Journal Bearing Inspection and
Selection .........................................................1D-83
Specifications.....................................................1D-84
Service Data......................................................1D-84
Tightening Torque Specifications......................1D-86
Special Tools and Equipment ...........................1D-87
Recommended Service Material .......................1D-87
Special Tool ......................................................1D-88
Engine Lubrication System .................... 1E-1
Precautions...........................................................1E-1
Precautions for Engine Oil ..................................1E-1
Schematic and Routing Diagram ........................1E-2
Engine Lubrication System Chart Diagram .........1E-2
Engine Lubrication Circuit Diagram.....................1E-3
Diagnostic Information and Procedures............1E-5
Engine Lubrication Symptom Diagnosis .............1E-5
Oil Pressure Check .............................................1E-5
Repair Instructions ..............................................1E-6
Engine Oil and Filter Replacement .....................1E-6
Engine Oil Level Inspection.................................1E-6
Oil Strainer / Oil Pressure Regulator Removal
and Installation ..................................................1E-6
Oil Strainer Inspection and Cleaning...................1E-7
Oil Pressure Regulator Inspection ......................1E-7
Oil Cooler Removal and Installation....................1E-7
Oil Pressure Switch Removal and Installation ....1E-8
Oil Pressure Switch Inspection ...........................1E-9
Oil Jet Removal and Installation..........................1E-9
Oil Jet / Oil Gallery Jet Inspection .....................1E-12
Oil Pump Removal and Installation ...................1E-12
Oil Pump Inspection ..........................................1E-13
Oil Pipe Removal and Installation .....................1E-13
Oil Pipe Inspection ............................................1E-14
Specifications.....................................................1E-14
Service Data......................................................1E-14
Tightening Torque Specifications......................1E-14
Special Tools and Equipment ...........................1E-15
Recommended Service Material .......................1E-15
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