Table of Contents
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Valve Guide Replacement ................................1D-57
Valve Seat Repair .............................................1D-58
Cylinder Disassembly and Assembly ................1D-59
Cylinder Inspection ...........................................1D-60
Piston Ring Removal and Installation ...............1D-61
Piston and Piston Ring Inspection ....................1D-62
Engine Bottom Side Disassembly .....................1D-64
Engine Bottom Side Assembly..........................1D-72
Crank Balancer Disassembly and Assembly ....1D-89
Crank Balancer Inspection ................................1D-90
Conrod Removal and Installation ......................1D-90
Conrod and Crankshaft Inspection ...................1D-92
Specifications.....................................................1D-99
Service Data .....................................................1D-99
Tightening Torque Specifications....................1D-101
Special Tools and Equipment .........................1D-102
Recommended Service Material .....................1D-102
Special Tool ....................................................1D-103
Engine Lubrication System .................... 1E-1
Precautions........................................................... 1E-1
Precautions for Engine Oil .................................. 1E-1
Schematic and Routing Diagram........................ 1E-1
Engine Lubrication System Chart Diagram ......... 1E-1
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 Pressure Switch Inspection ......................... 1E-11
Oil Jet / Oil Gallery Jet Inspection ..................... 1E-13
Oil Pump Removal and Installation ................... 1E-13
Oil Pump Inspection .......................................... 1E-14
Specifications..................................................... 1E-15
Service Data ..................................................... 1E-15
Tightening Torque Specifications...................... 1E-15
Special Tools and Equipment ........................... 1E-16
Recommended Service Material ....................... 1E-16
Special Tool ...................................................... 1E-16
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
Water Hose Inspection........................................ 1F-7
Water Hose Removal and Installation................. 1F-8
Radiator Reservoir Tank Inspection.................... 1F-9
Cooling Fan Inspection ....................................... 1F-9
Cooling Fan Relay Inspection ........................... 1F-10
ECT Sensor Removal and Installation .............. 1F-10
ECT Sensor Inspection ..................................... 1F-10
Thermostat Inspection....................................... 1F-11
Water pump Components ................................. 1F-12
Water Pump Construction ................................. 1F-13
Water Pump Removal and Installation.............. 1F-13
Water Pump Disassembly and Assembly ......... 1F-14
Water Pump Related Parts Inspection .............. 1F-17
Specifications ..................................................... 1F-18
Service Data...................................................... 1F-18
Tightening Torque Specifications...................... 1F-19
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
Diagnostic Information and Procedures ........... 1G-4
Fuel System Diagnosis ...................................... 1G-4
Repair Instructions ............................................. 1G-5
Fuel Pressure Inspection ................................... 1G-5
Fuel Pump Inspection ........................................ 1G-6
Fuel Discharge Amount Inspection .................... 1G-6
Fuel Pump Relay Inspection .............................. 1G-7
Fuel Hose Inspection ......................................... 1G-7
Fuel Level Gauge Inspection ............................. 1G-7
Table of Contents 1-iii
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