Power Head
Section 1
CONTENTS
Precautions .................................................1-1
Precautions............................................................. 1-1
Precautions for Powerhead................................... 1-1
Engine Control......................................... 1A-1
Precautions...........................................................1A-1
Precautions on Engine Control Diagnosis...........1A-1
General Description.............................................1A-2
Engine Control System Description ....................1A-2
Control Module for System Control.....................1A-4
Electronic Shift System Description ..................1A-14
Switch Panel Description ..................................1A-15
Caution System Description..............................1A-18
Self-Diagnostic System Description..................1A-23
Fail-Safe System Description............................1A-27
Oil Change Reminder System Description........1A-28
Water in Fuel Alert System Description ............1A-28
Troll Mode System Description .........................1A-29
Selective Rotation System Description .............1A-29
Keyless Start System Description.....................1A-31
Multi-Stage Induction Description .....................1A-32
VVT (Variable Valve Timing) System
Description ......................................................1A-35
Component Location .........................................1A-37
Engine Control System Components / Engine
Electrical Device Location...............................1A-37
Diagnostic Information and Procedures..........1A-37
ECM Power and Ground Circuit Check.............1A-37
Troubleshooting with Self-Diagnostic Code ......1A-39
Self-Diagnostic Code “3 – 4” MAP Sensor........1A-39
Self-Diagnostic Code “1 – 4” Cylinder Temp.
Sensor.............................................................1A-40
Self-Diagnostic Code “2 – 3” IAT Sensor..........1A-41
Self-Diagnostic Code “1 – 5” Ex. Manifold
Temp. Sensor .................................................1A-42
Self-Diagnostic Code “3 – 7” Trim Sensor ........1A-43
Self-Diagnostic Code “2 – 1” TPS (Throttle
Position Sensor)..............................................1A-44
Self-Diagnostic Code “1 – 2” SPS (Shift
Position Sensor)..............................................1A-45
Self-Diagnostic Code “1 – 1” Rectifier /
Regulator (Over Charging)..............................1A-46
Self-Diagnostic Code “4 – 3” Fuel Injector ........1A-47
Self-Diagnostic Code “4 – 2” CKP Sensor ........1A-48
Self-Diagnostic Code “2 – 4” CMP Sensor #1...1A-49
Self-Diagnostic Code “2 – 6” CMP Sensor #2
(VVT)...............................................................1A-50
Self-Diagnostic Code “2 – 2” Air Intake
System ............................................................1A-51
Self-Diagnostic Code “3 – 2” MAP Sensor 2.....1A-52
Self-Diagnostic Code “3 – 3” Neutral Switch.....1A-54
Self-Diagnostic Code “5 – 1” VVT Advance ......1A-55
Self-Diagnostic Code “5 – 3” Oil Pressure
Switch..............................................................1A-56
Self-Diagnostic Code “6 – 1” OCV (Oil Control
Valve)..............................................................1A-57
Self-Diagnostic Code “5 – 4” Knock Sensor......1A-57
Self-Diagnostic Code “3 – 6” O2 Sensor...........1A-58
Self-Diagnostic Code “6 – 3” O2 Sensor
Heater .............................................................1A-59
Self-Diagnostic Code “7 – 1” ETV (Electronic
Throttle Valve) ECM........................................1A-60
Self-Diagnostic Code “7 – 2” ETV (Electronic
Throttle Valve) Motor.......................................1A-61
Self-Diagnostic Code “7 – 3” ETV (Electronic
Throttle Valve).................................................1A-62
Self-Diagnostic Code “7 – 4” Sub BCM (Boat
Control Module)...............................................1A-63
Self-Diagnostic Code “7 – 5” DBW (Drive By
Wire) System...................................................1A-64
Self-Diagnostic Code “8 – 1” ESA (Electronic
Shift Actuator) ECM ........................................1A-66
Self-Diagnostic Code “8 – 2” ESA (Electronic
Shift Actuator) Motor .......................................1A-66
Self-Diagnostic Code “8 – 3” ESA (Electronic
Shift Actuator) .................................................1A-67
Self-Diagnostic Code “4 – 1” Model
Distinction Switch............................................1A-68
Self-Diagnostic Code “9 – 4” Keyless System
Authentication Error ........................................1A-69
Self-Diagnostic Code “9 – 5” Keyless System
Communication Error ......................................1A-69
Self-Diagnostic Code “9 – 6” Keyless System
Failure .............................................................1A-69
Troubleshooting Without Self-Diagnostic
Code................................................................1A-69
Service Instructions...........................................1A-70
How to Use the 26-pin and 34-pin Test Cord
Set...................................................................1A-70
Inspection of the ECM and Its Circuit................1A-71
Inspection of the BCM and Its Circuit................1A-75
Inspection of the Keyless Control Unit and Its
Circuit..............................................................1A-82
Keyless Control Unit Circuit Voltage Table .......1A-83
Electronic Throttle Body Assembly Operation
Check..............................................................1A-84
ECM Main Relay Inspection..............................1A-85
ECM Removal and Installation..........................1A-85
Switch Panel Inspection....................................1A-86
Key fob Battery Replacement ...........................1A-88
ECM Power Relay Inspection ...........................1A-89
Registering The First Key-Fob ID Code............1A-90
Unpairing an ECM from the Keyless Start
System ............................................................1A-90
Engine Electrical Devices....................... 1C-1
Precautions...........................................................1C-1
Precaution for Engine Electrical Device..............1C-1
General Description .............................................1C-1
Sensor and Switch Description ...........................1C-1
ECM and BCM Power Source Line.....................1C-8
Component Location ...........................................1C-9
Location of Sensor and Switch............................1C-9
Service Instructions.............................................1C-9
Resistance Check ...............................................1C-9
Cylinder Temp. Sensor Removal and
Installation.......................................................1C-11
Cylinder Temp. Sensor Inspection....................1C-11
Ex. Manifold Temp. Sensor Removal and
Installation.......................................................1C-12
Ex. Manifold Temp. Sensor Inspection .............1C-12
CKP Sensor Removal and Installation..............1C-13
CKP Sensor Inspection.....................................1C-13
IAT Sensor Removal and Installation................1C-14
IAT Sensor Inspection.......................................1C-14
CMP Sensor Removal and Installation .............1C-14
CMP Sensor Inspection ....................................1C-15
MAP Sensor Removal and Installation..............1C-16
MAP Sensor Output Voltage Inspection............1C-16
O2 Sensor Removal and Installation.................1C-17
O2 Sensor Output Voltage Inspection...............1C-18
O2 Sensor Heater Inspection............................1C-19
Knock Sensor Removal and Installation ...........1C-20
Knock Sensor Inspection ..................................1C-20
OCV (Oil Control Valve) Inspection...................1C-21
VSV (Vacuum Switching Valve) Removal and
Installation.......................................................1C-21
VSV (Vacuum Switching Valve) Inspection.......1C-22
ESA (Electronic Shift Actuator) and Shift
Position Sensor Removal and Installation ......1C-22
Shift Position Sensor Power Source and
Output Voltage Inspection...............................1C-24
Shift Position Sensor Mounting Position
Adjustment ......................................................1C-26
ESA Motor / Motor Relay Circuit Inspection......1C-28
ESA Motor Relay Inspection .............................1C-29
ESA Motor Inspection .......................................1C-30
ETV Motor Inspection........................................1C-30
TPS Inspection..................................................1C-31
Lever Position Sensor Inspection......................1C-32
ETV Motor / Motor Relay Circuit Inspection ......1C-33
ETV Motor Relay Inspection .............................1C-34
Trim Sensor Removal and Installation ..............1C-34
Trim Sensor Inspection .....................................1C-36
Emergency Stop Switch Inspection...................1C-36
Power Unit Mechanical ........................... 1D-1
General Description .............................................1D-1
Power Unit Construction Description ..................1D-1
Diagnostic Information and Procedures............1D-1
Cylinder Compression Check..............................1D-1
Oil Pressure Check .............................................1D-1
Service Instructions.............................................1D-2
Tappet Clearance Inspection ..............................1D-2
Ring Gear Cover Removal and Installation.........1D-2
Air Intake Silencer Case Removal and
Installation.........................................................1D-2
Electric Parts Holder Removal and Installation ....1D-3
Intake Manifold and Throttle Body
Components......................................................1D-6
Intake Manifold Removal and Installation ...........1D-7
Intake Manifold Disassembly and Assembly.....1D-10
Intake Manifold Component Inspection.............1D-11
Electronic Throttle Body Removal and
Installation.......................................................1D-13
Electronic Throttle Body Inspection...................1D-14
Cylinder Head Cover Removal and
Installation.......................................................1D-15
OCV (Oil Control Valve) Removal and
Installation.......................................................1D-18
OCV (Oil Control Valve) Inspection...................1D-18
Power Unit Removal and Installation ................1D-19
Timing Chain, Camshaft Sprocket, Balancer
Chain Components .........................................1D-27
Timing Chain, Camshaft Sprocket, Balancer
Chain Removal and Installation ......................1D-28
Timing Chain, Camshaft Sprocket, Balancer
Chain Related Parts Inspection.......................1D-35
Camshaft, Tappet and Shim Removal and
Installation.......................................................1D-37
Camshaft, Tappet and Shim Inspection ............1D-39
Cylinder Head Removal and Installation ...........1D-42
Cylinder Head Disassembly and Assembly ......1D-43
Cylinder Head Components Inspection and
Servicing .........................................................1D-45
Counter-Balancer Mechanism Removal and
Installation.......................................................1D-51
Counter-Balancer Mechanism Disassembly
and Assembly..................................................1D-52
Counter-Balancer Mechanism Component
Inspection........................................................1D-54
Pistons, Piston Rings, Connecting Rods,
Cylinder and Crankshaft Components ............1D-55
Pistons, Piston Rings, Connecting Rods,
Cylinder and Crankshaft Disassembly and
Assembly.........................................................1D-55
Cylinder, Piston and Piston Ring Inspection
and Servicing ..................................................1D-65
Piston Pin and Conrod Inspection.....................1D-67
Crank Pin and Conrod Bearing Inspection........1D-68
Crankshaft Inspection .......................................1D-70
Crankshaft Main Bearing Inspection .................1D-71
Crankshaft Drive Gear Inspection.....................1D-74
Crankshaft Oil Seal Inspection..........................1D-74
Oil Filter Stand Seal Ring Inspection ................1D-74
Power Unit Lubrication ........................... 1E-1
General Description.............................................1E-1
Engine Lubrication Description ...........................1E-1
Schematic and Routing Diagram........................1E-2
Engine Oil Lubrication Chart ...............................1E-2
Diagnostic Information and Procedures............1E-3
Oil Pressure Check .............................................1E-3
Oil Change Reminder System.............................1E-3
Low Oil Pressure Caution System ......................1E-3
Powerhead Lubrication System Diagnosis..........1E-3
Service Instructions.............................................1E-4
Oil Pump Removal and Installation.....................1E-4
Oil Pump Disassembly and Assembly ................1E-5
Oil Pump Component Parts Inspection...............1E-6
Oil Pressure Switch Removal and Installation ....1E-7
Oil Pressure Switch Inspection ...........................1E-8
Oil Strainer Removal and Installation..................1E-8
Oil Strainer Related Parts Inspection..................1E-8
Piston Cooling Jet Removal and Installation.......1E-9
Piston Cooling Jet Inspection..............................1E-9
Power Unit Cooling System.....................1F-1
General Description............................................. 1F-1
Water Cooling System Description ..................... 1F-1
Displacement Type Water Pump Description ..... 1F-1
Water Pressure Valve Description ...................... 1F-1
Schematic and Routing Diagram........................ 1F-2
Cooling Water Circulation Chart.......................... 1F-2
Diagnostic Information and Procedures............ 1F-3
Powerhead Cooling System Diagnosis............... 1F-3
Service Instructions............................................. 1F-3
Thermostat Removal and Installation.................. 1F-3
Thermostat Inspection ........................................ 1F-4
Water Pressure Valve Removal and
Installation......................................................... 1F-5
Water Pressure Valve Related Item
Inspection.......................................................... 1F-6
Water Pump Removal and Installation................ 1F-6
Water Pump Related Item Inspection ................. 1F-6
Water Tube Removal and Installation................. 1F-6
Water Tube Related Item Inspection .................. 1F-6
Fuel System .............................................1G-1
Precautions...........................................................1G-1
Precautions on Fuel System Service ..................1G-1
General Description.............................................1G-1
Electronic Fuel Injection System Description......1G-1
Fuel Delivery System Component Description ....1G-4
High Pressure Fuel Pump Control System
Description ........................................................1G-7
Air Intake Components Description.....................1G-8
Electronic Throttle System Description ...............1G-9
Diagnostic Information and Procedures......... 1G-12
Fuel Pressure Inspection ................................. 1G-12
Fuel System Diagnosis .................................... 1G-14
Fuel Injection System Troubleshooting ............ 1G-15
Service Instructions.......................................... 1G-16
Fuel Pressure Relief Procedure ....................... 1G-16
Fuel Line Removal and Installation .................. 1G-16
Fuel Line Inspection......................................... 1G-17
Fuel Leakage Check Procedure....................... 1G-17
Inspection of Fuel Hose Connections .............. 1G-17
High Pressure Fuel Pump Operating Sound
Inspection....................................................... 1G-18
Fuel Vapor Separator Removal and
Installation...................................................... 1G-18
Fuel Vapor Separator Disassembly and
Assembly........................................................ 1G-19
Inspection of Fuel Vapor Separator
Component Parts ........................................... 1G-23
Fuel Injector Inspection with Injector in Place .. 1G-24
Individual Fuel Injector Operating Sound
Inspection....................................................... 1G-24
Fuel Injector Operating Signal Inspection ........ 1G-25
Fuel Injector Removal and Installation ............. 1G-26
Low Pressure Fuel Pump Removal and
Installation...................................................... 1G-28
Low Pressure Fuel Pump Inspection ............... 1G-29
Low Pressure Fuel Line Components .............. 1G-29
Low Pressure Fuel Filter / Fuel Hose
Inspection....................................................... 1G-30
High Pressure Fuel Filter Removal and
Installation...................................................... 1G-30
Water Detection Switch Inspection .................. 1G-31
Ignition System........................................ 1H-1
General Description .............................................1H-1
Ignition System Description.................................1H-1
Ignition Control Description .................................1H-2
Component Location ...........................................1H-4
Ignition System Components Location................1H-4
Diagnostic Information and Procedures............1H-4
Ignition System Symptom Diagnosis...................1H-4
Ignition System Troubleshooting.........................1H-5
Service Instructions.............................................1H-6
Spark Plug Removal and Installation ..................1H-6
Spark Plug Inspection .........................................1H-6
Ignition Coil Removal and Installation .................1H-6
Ignition Coil Inspection ........................................1H-6
Ignition Coil Operating Signal Inspection ............1H-7
CKP Sensor Inspection .......................................1H-8
CMP Sensor Inspection ......................................1H-8
Main Switch Inspection .......................................1H-8
ECM Main Relay Inspection................................1H-8
Starting System .........................................1I-1
General Description .............................................. 1I-1
Electric Starter System Description...................... 1I-1
Starter Motor Operation Condition
Description ......................................................... 1I-2
Start-In-Gear Protection System Description ....... 1I-3
Component Location ............................................ 1I-5
Starting System Components Location................ 1I-5
Diagnostic Information and Procedures............. 1I-5
Starter System Troubleshooting........................... 1I-5
Service Instructions.............................................. 1I-6
Starter Motor Removal and Installation................ 1I-6
Starter Motor Test ................................................ 1I-7
Starter Motor Components................................... 1I-9
Starter Motor Disassembly and Assembly ........... 1I-9
Starter Motor Components Inspection and
Servicing .......................................................... 1I-11
Main Switch Inspection ...................................... 1I-15
Starter Motor Relay Inspection........................... 1I-16
Neutral Switch Removal and Installation............ 1I-16
Neutral Switch Inspection................................... 1I-18
Charging System..................................... 1K-1
General Description .............................................1K-1
Charging System Description..............................1K-1
Battery Requirement Description ........................1K-3
Component Location ...........................................1K-3
Charging System Components Location.............1K-3
Diagnostic Information and Procedures............1K-3
Charging System Diagnosis................................1K-3
Service Instructions.............................................1K-4
Charging System Construction ...........................1K-4
Flywheel Removal and Installation......................1K-5
Battery Charge Coil Removal and Installation ....1K-7
Battery Charge Coil Inspection ...........................1K-8
Rectifier / Regulator Removal and Installation ....1K-8
Rectifier / Regulator Inspection ...........................1K-9
Main Fuse Inspection ........................................1K-10
