• Install
Collar [D]
Damper [E]
Washer [F]
○Be sure the air cleaner housing is inserted to the throttle
body assy securely.
○Be sure the hoses are routed correctly and properly installed.
Install the bolt [G].
Tighten:

•
•

Torque - Air Cleaner Housing Clamp Bolts: 2.0 N·m (0.20
kgf·m, 18 in·lb)

the leads and hoses correctly (see Cable, Wire, and
• Run
Hose Routing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).

3-66 FUEL SYSTEM (DFI)
Air Cleaner
Air Cleaner Housing Disassembly

• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal)
Intake Air Temperature Sensor (see Intake Air Temperature Sensor Removal in the Self-Diagnosis System
chapter)
IMU (see IMU Removal in the Self-Diagnosis System
chapter)
Nozzle Assy (see Nozzle Assy Removal)
Screws [A]
Rubber Cover [B]
Bracket [C]
Dampers [D]
Seals [E]
Ducts [F]
Gaskets [G]

Air Cleaner Housing Assembly

adhesive to the mating surface of the ducts [A] and
• Apply
housing [B], and assemble them.

FUEL SYSTEM (DFI) 3-67
Air Cleaner
the funnels [A] so that the higher side faces inward.
• Install
Tighten
screws [B].
• Install thetheremoved
parts (see appropriate chapters).
•

3-68 FUEL SYSTEM (DFI)
Air Line
Air Intake Duct Removal

• Remove:
Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Meter Bracket (see Meter Unit Removal/Installation in
the Electrical System chapter)
Immobilizer Amplifier (Equipped Models) (see Immobilizer System Parts Replacement in the Electrical System
chapter)
Air Intake Duct Mounting Bolts [A] (Both Sides)
Air Intake Duct Assembly [B]

Air Intake Duct Installation

that the pad [A] is in place on the air intake duct.
• Check
a non-permanent locking agent to the threads of
• Apply
the air intake duct mounting bolts, and tighten them.
the lead correctly (see Cable, Wire, and Hose Rout• Run
ing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).

Air Intake Duct Disassembly

• Remove:
Air Intake Duct (see Air Intake Duct Removal)
•

Seal [A] and Screen [B]
Turn the air intake valve actuator [C] counterclockwise
(90°).

• Remove:
Screws [A]
Air Intake Valve Actuator [B] and Air Intake Valve
Seal [C]

Air Intake Duct Assembly

• Install the seals [A] as shown.

FUEL SYSTEM (DFI) 3-69
Air Line
the air intake valve actuator [A] to the air intake
• Hang
valve [B].

• Assemble:
Right and Left Ducts
Air Intake Valve and actuator [A]

○Insert the projection [B] of the air intake valve into the hole

•

[C] of the duct on both sides.
Tighten the screws.

the tab [A] of the air intake valve actuator to the groove
• Fit
[B] of the duct.
the air intake valve actuator clockwise (90°).
• Turn
Check
that the air intake valve moves smoothly.
•

the seal [A] and screen [B] to the air intake duct.
• Install
Tab [C] of Duct

the pad [A] so that the open side [B] faces down• Install
ward.

3-70 FUEL SYSTEM (DFI)
Air Line
Air Intake Solenoid Valve Removal

• Remove:
Upper Fairing Assembly (see Upper Fairing Assembly
•
•

Removal in the Frame chapter)
Disconnect:
Air Intake Solenoid Valve Connector [A]
Hoses [B]
Remove:
Nut [C]
Air Intake Solenoid Valve [D]

Air Intake Solenoid Valve Installation

the lead and hoses correctly (see Cable, Wire, and
• Run
Hose Routing section in the Appendix chapter).
the air intake solenoid valve and tighten the nut.
• Install
Connect
connector.
• Install thetheremoved
parts (see appropriate chapters).
•

Air Intake Solenoid Valve Unit Test

to the Air Intake Solenoid Valve Unit Test in the
• Refer
Electrical System chapter.

Vacuum Chamber Removal

• Remove:
Upper Fairing Assembly (see Upper Fairing Assembly
•

Removal in the Frame chapter)
Bolt [A]
Vacuum Chamber [B]
Disconnect the hoses [C].

Vacuum Chamber Installation

the hoses correctly (see Cable, Wire, and Hose Rout• Run
ing section in the Appendix chapter).
the projection [A] of the vacuum chamber to the hollow
• Fit
[B].
the bolt.
• Tighten
Install
the
removed parts (see appropriate chapters).
•

FUEL SYSTEM (DFI) 3-71
Fuel Tank
Fuel Tank Removal

WARNING
Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential
for serious burns. Make sure the area is well ventilated and free from any source of flame or sparks;
this includes any appliance with a pilot light. Do not
smoke. Turn the ignition switch off. Disconnect the
battery (–) terminal. To avoid fuel spills, draw it from
the tank when the engine is cold. Be prepared for
fuel spillage; any spilled fuel must be completely
wiped up immediately.
the ignition switch off.
• Turn
Wait
until
cools down.
• Disconnectthetheengine
battery
terminal (see Battery Removal
• in the Electrical System(–)chapter).
• Remove:
Fuel Tank Covers (see Fuel Tank Cover Removal in the
Frame chapter)
the fuel tank cap [A] to lower the pressure in the
• Open
tank.

○During tank removal, keep the tank cap open to release
pressure in the tank. This makes fuel spillage less.

the fuel out from the fuel tank with a commercially
• Draw
available pump [A].

○Use a soft plastic hose [B] as a pump intake hose in order
to insert the hose smoothly.
○Put the hose through the fill opening [C] into the tank and
draw the fuel out.

WARNING
Spilled fuel is flammable and can be explosive under certain conditions. The fuel can not be removed
completely from the fuel tank. Be careful for remained fuel spillage.

3-72 FUEL SYSTEM (DFI)
Fuel Tank

• Remove:
Fuel Tank Bolt [A] (Both Sides)
•

Fuel Tank Bracket Bolts [B]
Disconnect:
Fuel Pump Lead Connector [C]

up the front portion of the fuel tank.
• Lift
Slide
• the clamps, and disconnect the hoses [A].

sure to place a piece of cloth around the fuel hose joint.
• Be
Wipe
the dirt of the surface [A] around the connection
• using offa cloth
or a soft brush.

When removing with flat tip screwdriver
Insert the flat tip screwdriver [A] into slit on the joint lock
[B].
Turn the driver to disconnect the joint lock.
When removing with fingers
Open and push up [C] the joint lock with your fingers.

•
•
•

NOTICE
Prying or excessively widening the joint lock ends
for fuel hose removal will permanently deform the
joint lock, resulting in a loose or incomplete lock
that may allow fuel to leak and create the potential
for a fire explosion. To prevent fire or explosion
from a damaged joint lock, do not pry or excessively
widen the joint lock ends when removing the fuel
hose. The joint lock has a retaining edge that locks
around the housing.

FUEL SYSTEM (DFI) 3-73
Fuel Tank

• Pull [A] the fuel hose joint [B] out of the outlet pipe.
WARNING
Fuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the
pipe because of residual pressure. Cover the hose
connection with a piece of clean cloth to prevent
fuel spillage.
the fuel tank cap.
• Close
Remove
the fuel tank, and place it on a flat surface.
•○Do not apply
the load to the fuel pipe of the fuel pump.
Clean
the
pipe
• Cover the pipe [A].
and the hose joint [B] with the vinyl bags
• [C] to keep it clean.

Fuel Tank Installation

• Note the above WARNING (see Fuel Tank Removal).

3-74 FUEL SYSTEM (DFI)
Fuel Tank
that the pads, hook fasteners and trim are in place.
• Check
If the dampers and trim are damaged or deteriorated, replace them.

○Install the fuel tank pad [A] to the middle of the left and
right.
○Install the pad [B] to the middle of the left and right.
○Install the hook fastener [C] so as to be parallel to the line
[D].
○Install the hook fastener so that its corner [E] touches to
the bracket.
○After installing the right rear trim [F], press the rear end of
the trim against the fuel tank.
○After installing the right front trim [G], slide it forward until
its end touches to the corner [H].
Left Trim [I]
Viewed from Right [J]
Viewed from Top [K]
Viewed from Left [L]

FUEL SYSTEM (DFI) 3-75
Fuel Tank
the hoses correctly (see Cable, Wire, and Hose Rout• Run
ing section in the Appendix chapter).
inspect the dampers [A] for any damage.
• Visually
If the dampers are damaged or deteriorated, replace
them.
If the fuel tank bracket is removed, install the bracket [B]
so that allow mark [C] faces forward.

the vinyl bag on the pipe and fuel hose joint.
• Remove
Check
the
joint lock for deformation and wear.
• If the joint lock
is deformed, replace the fuel hose with a

•
•

new one.
Check that there are no flaws, burrs, and adhesion of
foreign materials on the pipe [A].
Apply engine oil to the pipe.

the fuel hose joint [A] straight onto the fuel outlet
• Insert
pipe until the hose joint clicks.
• Push [B] the joint lock [C] until the hose joint clicks.

and pull [A] the hose joint [B] back and forth more
• Push
than two times, and make sure it is locked and does not
come off.

WARNING
Leaking fuel can cause a fire or explosion resulting
in serious burns. Make sure the hose joint is installed correctly on the delivery pipe.
If it comes off, reinstall the hose joint.
the breather hose [A] and the drain hose [B].
• Connect
the knob of the clamp [C] forward.
• Face
Face
of the clamp [D] outward.
• Aboutthe5 knob
mm (0.2 in.) [E]
the fuel pump lead connector and the battery (–)
• Connect
terminal (see Battery Installation in the Electrical System

•

chapter).
Install the removed parts (see appropriate chapters).

3-76 FUEL SYSTEM (DFI)
Fuel Tank
Fuel Tank and Cap Inspection

the tank cap.
• Open
inspect the gasket [A] on the tank cap for any
• Visually
damage.

•

Replace the tank cap if the gasket is damaged.
Check to see if the water drain pipe [B] and fuel breather
pipe [C] in the tank are not clogged. Check the tank cap
breather also.
If they are clogged, remove the tank and drain it, and then
blow the breather free with compressed air.

NOTICE
Do not apply compressed air to the air vent holes
[D] in the tank cap. This could cause damage and
clogging of the labyrinth in the cap.

Fuel Tank Cleaning

WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the tank in a well-ventilated area, and
take care that there are no sparks or flame anywhere near the working area. Do not use gasoline
or low flash-point solvents to clean the tank.

• Remove:
Fuel Tank (see Fuel Tank Removal)
•
•
•
•

Fuel Pump (see Fuel Pump Removal)
Pour some high flash-point solvent into the fuel tank and
shake the tank to remove dirt and fuel deposits.
Draw the solvent out of the fuel tank.
Dry the tank with compressed air.
Install:
Fuel Pump (see Fuel Pump Installation)
Fuel Tank (see Fuel Tank Installation)

FUEL SYSTEM (DFI) 3-77
Evaporative Emission Control System (Other than US and CA Models)
The Evaporative Emission Control System routes fuel vapors from the fuel system into the running engine or stores
the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.

Parts Removal/Installation

WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition
switch off. Do not smoke. Make sure the area is
well ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.

NOTICE
If gasoline, solvent, water or any other liquid enters
the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become
contaminated, replace it with a new one.
the hoses according to the diagram of the sys• Connect
tem (see Cable, Wire, and Hose Routing section in the
Appendix chapter). Make sure they do not get pinched or
kinked.

Hose Inspection

to the Evaporative Emission Control System In• Refer
spection (Other than US and CA Models) in the Periodic
Maintenance chapter.

Purge Valve Inspection

to the Purge Valve Inspection in the Self-Diagnosis
• Refer
System chapter.

Canister Inspection

to the Evaporative Emission Control System In• Refer
spection (Other than US and CA Models) in the Periodic
Maintenance chapter.

COOLING SYSTEM 4-1

Cooling System
Table of Contents
Exploded View........................................................................................................................
Coolant Flow Chart.................................................................................................................
Specifications .........................................................................................................................
Special Tools and Sealant ......................................................................................................
Coolant ...................................................................................................................................
Coolant Deterioration Inspection.......................................................................................
Coolant Level Inspection...................................................................................................
Coolant Draining ...............................................................................................................
Coolant Filling ...................................................................................................................
Pressure Testing ...............................................................................................................
Cooling System Flushing ..................................................................................................
Coolant Reserve Tank Removal .......................................................................................
Coolant Reserve Tank Installation ....................................................................................
Water Pump............................................................................................................................
Water Pump Removal .......................................................................................................
Water Pump Installation ....................................................................................................
Water Pump Inspection.....................................................................................................
Water Pump Impeller Disassembly/Assembly ..................................................................
Water Pump Impeller Inspection .......................................................................................
Water Pump Housing Disassembly ..................................................................................
Water Pump Housing Assembly .......................................................................................
Mechanical Seal Inspection ..............................................................................................
Radiator ..................................................................................................................................
Radiator and Radiator Fan Removal ................................................................................
Radiator and Radiator Fan Installation .............................................................................
Radiator Inspection ...........................................................................................................
Radiator Cap Inspection ...................................................................................................
Radiator Filler Neck Inspection .........................................................................................
Thermostat .............................................................................................................................
Thermostat Removal.........................................................................................................
Thermostat Installation......................................................................................................
Thermostat Inspection ......................................................................................................
Hoses and Pipes ....................................................................................................................
Hose Installation ...............................................................................................................
Hose Inspection ................................................................................................................
Water Temperature Sensor ....................................................................................................
Water Temperature Sensor Removal/Installation .............................................................
Water Temperature Sensor Inspection .............................................................................

4-2
4-5
4-7
4-8
4-9
4-9
4-9
4-9
4-9
4-9
4-10
4-10
4-10
4-11
4-11
4-11
4-11
4-11
4-11
4-12
4-12
4-12
4-13
4-13
4-15
4-16
4-16
4-17
4-18
4-18
4-19
4-19
4-20
4-20
4-20
4-21
4-21
4-21

4

4-2 COOLING SYSTEM
Exploded View

COOLING SYSTEM 4-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11

Fastener
Coolant By-pass Fitting Bolt
Thermostat Housing Mounting Bolts
Water Temperature Sensor
Thermostat Cap Bolts
Water Hose Clamp Screws
Water Hose Fitting Bolts
Water Pipe Mounting Bolt
Oil Cooler Mounting Bolts
Water Pump Cover Bolts
Coolant Drain Bolt (Water Pump)
Impeller Bolt

12. Thermostat