Table of Contents 1-iii
Cam Chain Guide / Cam Chain Tensioner
Removal and Installation.................................1D-37
Cam Chain Guide Inspection ............................1D-37
Cam Chain Tensioner Inspection......................1D-37
Cylinder Head Disassembly and Assembly ......1D-38
Cylinder Head Related Parts Inspection ...........1D-42
Valve Guide Replacement ................................1D-45
Valve Seat Repair .............................................1D-47
Engine Bottom Side Disassembly.....................1D-47
Engine Bottom Side Assembly..........................1D-55
Cylinder Inspection ...........................................1D-70
Piston Ring Removal and Installation ...............1D-70
Piston and Piston Ring Inspection ....................1D-72
Balancer Shaft Disassembly and Assembly......1D-73
Balancer Shaft Inspection.................................1D-74
Balancer Shaft Journal Bearing Removal and
Installation.......................................................1D-74
Balancer Shaft Journal Bearing Inspection
and Selection ..................................................1D-75
Conrod Crank Pin Bearing Removal and
Installation.......................................................1D-77
Conrod and Crankshaft Inspection ...................1D-78
Conrod Crank Pin Bearing Inspection and
Selection .........................................................1D-79
Crankshaft Journal Bearing Inspection and
Selection .........................................................1D-81
Crankshaft Thrust Clearance Inspection and
Selection .........................................................1D-83
Specifications.....................................................1D-85
Service Data .....................................................1D-85
Tightening Torque Specifications......................1D-87
Special Tools and Equipment...........................1D-88
Recommended Service Material.......................1D-88
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 Pan / Oil Strainer / Oil Pressure Regulator
Removal and Installation...................................1E-6
Oil Pressure Regulator / Oil Strainer
Inspection..........................................................1E-7
Oil Cooler / Oil Cooler Hose Inspection ..............1E-8
Oil Cooler Removal and Installation....................1E-8
Oil Pressure Switch Removal and Installation ....1E-9
Oil Pressure Switch Inspection ...........................1E-9
Oil Jet / Oil Gallery Jet Removal and
Installation.........................................................1E-9
Oil Jet / Oil Gallery Jet Inspection.....................1E-11
Oil Pump Removal and Installation...................1E-12
Oil Pump Inspection..........................................1E-13
Oil Pump Drive Gear Removal and
Installation.......................................................1E-13
Specifications.....................................................1E-14
Service Data......................................................1E-14
Tightening Torque Specifications......................1E-15
Special Tools and Equipment...........................1E-15
Recommended Service Material.......................1E-15
Special Tool ......................................................1E-15
Engine Cooling System ...........................1F-1
Precautions...........................................................1F-1
Precautions for Engine Cooling System..............1F-1
Precautions for Engine Coolant ..........................1F-1
General Description.............................................1F-1
Engine Coolant Description.................................1F-1
Schematic and Routing Diagram........................1F-2
Cooling Circuit Diagram ......................................1F-2
Water Hose Routing Diagram .............................1F-3
Diagnostic Information and Procedures............1F-4
Engine Cooling Symptom Diagnosis...................1F-4
Repair Instructions ..............................................1F-4
Cooling Circuit Inspection ...................................1F-4
Radiator Cap Inspection......................................1F-5
Radiator Inspection and Cleaning.......................1F-5
Radiator / Cooling Fan Motor Removal and
Installation.........................................................1F-5
Water Hose Inspection........................................1F-6
Water Hose Removal and Installation.................1F-7
Radiator Reservoir Tank Inspection....................1F-7
Radiator Reservoir Tank Removal and
Installation.........................................................1F-8
Cooling Fan Inspection .......................................1F-8
Cooling Fan Relay Inspection .............................1F-8
ECT Sensor Removal and Installation ................1F-9
ECT Sensor Inspection .......................................1F-9
Thermostat Removal and Installation..................1F-9
Thermostat Inspection.......................................1F-10
Water Pump Components.................................1F-11
Water Pump Construction.................................1F-12
Water Pump Removal and Installation..............1F-12
Water Pump Disassembly and Assembly .........1F-13
Water Pump Related Parts Inspection..............1F-16
Specifications.....................................................1F-18
Service Data......................................................1F-18
Tightening Torque Specifications......................1F-18
Special Tools and Equipment...........................1F-19
Recommended Service Material.......................1F-19
Special Tool ......................................................1F-19
Fuel System .............................................1G-1
Precautions.......................................................... 1G-1
Precautions for Fuel System.............................. 1G-1
General Description............................................ 1G-2
Fuel Injection System Description...................... 1G-2
Schematic and Routing Diagram....................... 1G-3
Fuel Tank Drain Hose and Breather Hose
Routing Diagram .............................................. 1G-3
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