Assembly

1. Install engine coolant drain unions as follows:






(a) Apply seal packing part No. 08826-00100, or equivalent, to two or three threads.
(b) Install the RH and LH drain unions, then tighten to 49 Nm (500 kg.cm 36 ft.lb).






NOTE: After applying the specified torque, rotate the drain union clockwise until its drain port is facing forward.

2. Install water seal plate as follows:
(a) Remove any old Formed In Place Gasket (FIPG) packing material and be careful not to drop any oil on the contact surfaces of the seal plate and cylinder block.
- Using a razor blade and gasket scrape all the old packing (FIPG) material gasket surfaces and sealing groove.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces






(b) Using nozzle that has been cut to a 2-3 mm (0.08-0.12 in) opening, apply seal packing part No. 08826-00080, or equivalent, to the seal plate as shown in the illustration.

NOTE:
- Parts must be assembled within five minutes of application.
- Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.

(c) Install the seal plate with the two nuts, then alternately tighten the nuts in several passes to 14 Nm (145 kg.cm, 10 ft.lb).
3. Install oil pump, refer to Engine Lubrication.
4. Install No.1 oil pan, refer to Engine Lubrication.
5. Install oil strainer, refer to Engine Lubrication.
6. Install oil pan baffle plate.
7. Install No.2 oil pan, refer to Engine Lubrication.
8. Install water pump.
9. Install engine wiring as follows;






(a) Install the engine wire to the LH side of the cylinder block with the four bolts.
(b) Install the engine wire cover with the two bolts.






(c) Install the engine wire to the RH side of the cylinder block with the two bolts.
(d) Connect the crankshaft position connector.
10. Install knock sensors, tighten to 44 Nm (450 kg.cm, 33 ft.lb).
11. Install starter, tighten to 39 Nm (400 kg.cm, 29 ft.lb).
12. Install water bypass pipe as follows:






(a) Install a new O-ring to the water bypass pipe.
(b) Apply soapy water to the O-ring.
(c) Push the water bypass pipe end into the pipe hole of the water pump.
(d) Install the water bypass pipe with the bolt, tighten to 18 Nm (185 kg.cm, 13 ft.lb).
(e) Install the engine wire clamp to the bracket on the water bypass pipe.






13. Install the RH engine mounting bracket with the four bolts, then tighten to 36 Nm (370 kg.cm, 27 ft.lb).

NOTE: The RH mounting bracket is marked with "R".






14. Install the LH engine mounting bracket with the four bolts, tighten to 36 Nm (370 kg.cm, 27 ft.lb).

NOTE: The LH mounting bracket is marked with "L".

15. Install cylinder heads.
16. Install timing belt and pulleys.
17. Disconnect engine from engine stand
.