Engine Mechanical: Overhaul Lexus LX J100 рестайлинг

REASSEMBLY

HINT

1. Thoroughly clean all parts to be assembled.
2. Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
3. Replace all gaskets and oil seals with new ones.

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1. INSTALL SPARK PLUG TUBES HINT: When using a new cylinder head, the spark plug tubes must be installed. Apply adhesive to the end of the spark plug tube. Adhesive: Part No, 08833-00070, THREE BOND 1324 or equivalent Using a wooden block and hammer, tap in a new spark tube until the protrusion from the camshaft bearing cap installation surface of the cylinder head becomes 48.4 - 49.6 mm (1.906 - 1.953 in.). NOTE: Avoid tapping a new spark plug tube In too far by measuring the amount of the protrusion as tapping.
2. INSTALL VALVES Using SST, push in a new oil seal. SST 09201-41020 Install the valve (1), the spring seat (2), the valve spring (3), and the spring retainer (4). Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202-70020 Using a plastic-faced hammer and the valve stem tip taped up with vinyl tape, lightly tap the valve stem tip to assure proper fit. NOTE: Be careful not to damage the valve stem tip.
3. INSTALL SHIMS AND VALVE LIFTERS Install the shim and the valve lifter. Check that the valve lifter rotates smoothly by hand.

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1. INSTALL RH EXHAUST MANIFOLD TO CYLINDER HEAD Place a new gasket on the cylinder head with the white painted marks facing the manifold side. NOTE: Be careful of the installation direction. Install the exhaust manifold with 8 new nuts. Evenly tighten the nuts a little at a time for several times. Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) Install the heat insulator with the 4 bolts.
2. INSTALL LH EXHAUST MANIFOLD TO CYLINDER HEAD Place a new gasket on the cylinder head with the white painted marks facing the manifold side. NOTE: Be careful of the installation direction. Install the exhaust manifold with 8 new nuts. Evenly tighten the nuts a little at a time for several times. Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) Install the heat insulator with the 4 bolts.
3. PLACE CYLINDER HEAD ON CYLINDER BLOCK Place 2 new cylinder head gaskets in position on the cylinder block. HINT: On the rear side of the cylinder head gasket, there is a mark to distinguish the LH and RH banks, a "2UR" for the RH bank and a "2UL" for the LH bank. NOTE: Be careful of the installation direction. Place the 2 cylinder heads in position on the cylinder head gaskets.
4. INSTALL CYLINDER HEAD HINT: The cylinder head bolts are tightened in 2 progressive steps (steps ( c ) and ( e )). If any cylinder head bolt is broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. Install the plate washer to the cylinder head bolt. Install and evenly tighten the 10 cylinder head bolts on one side of the cylinder head a little at a time for several times as in the order shown, then do the other side (Scheme 166) Torque: 32 N.m (325 kgf.cm, 24 ft.lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. NOTE: Do not drop the plate washer of the cylinder head bolt into A area in the Illustration. It will fall down to the oil pan through the cylinder head and the cylinder block. Mark the front of the cylinder head bolt head with paint. Retighten the cylinder head bolts by 90° only for the first time. Then retighten them by 90° further for the second time. Check that the painted mark is now at a 180° angle to the front.
5. INSTALL SPARK PLUGS
6. ASSEMBLE EXHAUST CAMSHAFT Install the camshaft gear spring, the camshaft sub-gear and the wave washer. HINT: Attach the pins on the gears to the gear spring ends. Using snap ring pliers, install the snap ring. Mount the hexagon shaped part of the camshaft in a vise. NOTE: Be careful not to damage the camshaft. Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt. SST 09960-10010 (09962-01000, 09963-00500) Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.
7. INSTALL CAMSHAFT HOUSING PLUGS Remove any old packing (FIPG) material. Apply seal packing to the camshaft housing plug grooves. Seal packing: Part No. 08326-00080 or equivalent Install the 2 camshaft housing plugs to the cylinder heads.
8. INSTALL CAMSHAFTS NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. Otherwise, excessive pressure is put on the cylinder head journal thrust, causing a burr on the journal and damage on the camshaft. To avoid this, follow the steps below. Set the crankshaft pulley position. Turn the crankshaft pulley clockwise or counterclockwise, and put the timing mark of the crankshaft pulley in line with the centers of the crankshaft pulley bolt and the idler pulley bolt. NOTE: Having the crankshaft pulley at the wrong angle can cause the piston head and the valve head to come Into contact with each other when removing the camshaft, causing damage on them. So always set the crankshaft pulley at the correct angle. Install the RH camshafts. Apply MP grease to the thrust portion of the intake and exhaust camshafts. Place the intake and exhaust camshafts. Set the timing mark (1 dot mark) of the camshaft main gear at approx. 10° angle. Remove any old packing (FIPG) material from the front bearing cap. Apply seal packing to the front bearing cap (Scheme 177) Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that is cut to a 1.5 mm (0.06 in.) opening. Parts must be assembled within 5 minutes the seal packing application. Otherwise the material must be removed and the packing have to be reapplied. Immediately remove nozzle from the tube and reinstall cap. NOTE: Do not apply seal packing to the front bearing cap grooves. Install the front bearing cap. HINT: Installing the front bearing cap will determine the thrust portion of the camshaft. Install the other bearing cap in the sequence (Scheme 178)with the arrow mark facing forward. HINT: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap. Push in the camshaft oil seal. Apply a light coat of engine oil on the threads and under the heads (D and E) of the bearing cap bolts. HINT: Do not apply engine oil under the heads of the bearing cap bolts (A), (B) and (C). Install the oil feed pipe and the 22 bearing cap bolts (Scheme 180) HINT: Bolt length: 94 mm (3.70 in.) for A 72 mm (2.83 in.) for B 25 mm (0.98 in.) for C 52 mm (2.05 in.) for D 38 mm (1.50 in.) for E Evenly tighten the 22 bearing cap bolts a little at a time for several times as in the sequence (Scheme 181) Torque: Bolt C: 7.5 N.m (80 kgf.cm, 69 in.lbf) Others 16 N.m (160 kgf.cm, 12 ft.lbf) Move a service bolt of the sub-gear upward by turning the hexagon shaped port of the exhaust camshaft with a wrench. Remove the service bolt. Install the LH camshafts. Apply MP grease to the thrust portion of the intake and exhaust camshafts. Place the intake and exhaust camshafts. Engage the intake to the exhaust gear by putting the timing marks (2 dot marks) on each gear. Remove any old packing (FIPG) material. Apply seal packing to the front bearing cap. Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that is cut to a 1.5 mm (0.06 in.) opening. Parts must be assembled within 5 minutes the seal packing application. Otherwise the material must be removed and the packing have to be reapplied. Immediately remove nozzle from the tube and reinstall cap. NOTE: Do not apply seal packing to the front bearing cap grooves. Install the front bearing cap. HINT: Installing the front bearing cap will determine the thrust portion of the camshaft. Install the other bearing cap in the sequence (Scheme 185)with the arrow mark facing forward. HINT: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap. Push in the camshaft oil seal. Apply a light coat of engine oil on the threads and under the heads (D and E) of the bearing cap bolts. HINT: Do not apply engine oil under the heads of the bearing cap bolt (A), (B) and (C). Install the oil feed pipe and the 22 bearing cap bolts (Scheme 187) HINT: Bolt length: 94 mm (3.70 in.) for A 72 mm (2.83 in.) for B 25 mm (0.98 in.) for C 52 mm (2.05 in.) for D 38 mm (1.50 in.) for E Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence (Scheme 188) Torque: Bolt C: 7.5 N.m (80 kgf.cm, 69 in.lbf) Others 16 N.m (160 kgf.cm, 12 ft.lbf) Move a service bolt of the sub-gear upward by turning the hexagon shaped port of the exhaust camshaft with a wrench. Remove the service bolt.
9. CHECK AND ADJUST VALVE CLEARANCE (See «VALVE CLEARANCE»(ref-209781-S12332874272005121100000) ) Turn the camshaft and the position the cam lobe upward, and check and adjust the valve clearance.
10. INSTALL SEMI-CIRCULAR PLUGS Remove any old packing (FIPG) material. Apply seal packing to the semi-circular plug grooves. Seal packing: Part No. 08826-00080 or equivalent Install the 4 semi-circular plugs to the cylinder heads.
11. INSTALL CYLINDER HEAD COVER Remove any old packing (FIPG) material. Apply seal packing to the cylinder heads (Scheme 192) Seal packing: Part No. 08826-00080 or equivalent Install the gasket to the cylinder head cover. Install the seal washer to the bolt. Install the cylinder head cover with the 18 bolts. Evenly tighten the bolts a little at a time for several times. Install the 2 cylinder head covers. Torque: 6.0 N.m (60 kgf.cm, 53 in.lbf)
12. INSTALL ENGINE HANGERS Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
13. INSTALL OIL DIPSTICK AND GUIDE FOR ENGINE
14. INSTALL REAR WATER BYPASS JOINT Install 2 new gaskets to the cylinder head. Install the 4 nuts holding the water bypass joint to the cylinder heads. Alternately tighten the nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
15. INSTALL FRONT WATER BYPASS JOINT Install 2 new gaskets and the water bypass joint with the 4 nuts. Alternately tighten the nuts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
16. INSTALL WATER INLET AND INLET HOUSING ASSEMBLY (See «INSTALLATION»(ref-183461-S11966772252005081300000) )
17. ASSEMBLE UPPER AND LOWER INTAKE MANIFOLDS Install the 2 delivery pipes and the 8 injectors (See «INSTALLATION»(ref-209797-S07415023852005121100000) ). Install new 2 gaskets, the fuel pressure regulator and the fuel pulsation damper. Install the fuel return hose to the lower intake manifold with the 3 bolts. Connect the fuel return hose to the fuel pressure regulator.
18. INSTALL INTAKE MANIFOLD ASSEMBLY Place 2 new gaskets on the cylinder heads with white painted mark facing upward. NOTE: Align the port holes of the gasket and cylinder head. Be careful of the Installation direction. Place the intake manifold assembly on the cylinder heads. Install and uniformly tighten the 6 bolts and the 4 nuts in several passes. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) Install the EVAP pipe to the intake manifold with the 2 bolts. Connect the wire protector to the intake manifold with the 2 bolts. Install the engine wire to the engine hanger. Install the engine wire to the LH No. 1 timing belt rear plate. Install the engine wire to the bracket. Connect the wire protector to the rear water bypass joint and RH cylinder head with the 2 bolts. Install the 2 grounds cables to the RH and LH cylinder head. Install the guide for A/T bracket to the LH cylinder head. Connect the 2 wire clamp to the wire clamp bracket on the RH delivery pipe. Connect the fuel pressure regulator vacuum hose to the fuel pressure regulator pipe. Connect the PCV hose to the PCV valve on the LH cylinder head. Connect the EVAP hose (from charcoal canister) to the VSV for EVAP. Connect the EVAP hose (from charcoal canister) to the EVAP pipe on the intake manifold. Connect the EVAP hose (from intake air connector) to EVAP pipe on the intake manifold. Connect the PS air hose to intake manifold. Connect the No. 1 water bypass hose (from water inlet housing) to throttle body. Connect the throttle control connector. Connect the VSV connector for EVAP. Connect the 8 injector connectors. Connect the ECT sensor. Connect the water sender gauge. Connect the 8 ignition coil connectors. Connect the 2 oxygen sensor connectors.
19. CONNECT FUEL INLET HOSE (See «INSPECTION»(ref-209797-S40200985112005121100000) )
20. INSTALL TIMING BELT REAR PLATES Install the RH timing belt rear plates. Install the No. 1 timing belt rear plate to the cylinder he with the 3 bolts and the stud bolt. Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) Install the LH timing belt rear plates. Connect the wire clamp to the No. 1 timing belt rear plate. Install the No. 1 timing belt rear plate to the cylinder head with the 3 bolts. Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf)
21. INSTALL V-BANK COVER Install the 3 V-bank covers. Torque: 7.5 N.m (80 kgf.cm, 69 In.lbf)
22. INSTALL IGNITION COILS (See «REMOVAL»(ref-209808-S07571866222005121100000) )
23. INSTALL OIL DIPSTICK AND GUIDE FOR A/T
24. INSTALL FRONT EXHAUST PIPE (See «COMPONENTS»(ref-209793-S07511980382005121100000) )
25. INSTALL PS PUMP (See «INSTALLATION»(ref-209781-S06041378142005121100000) )
26. INSTALL CAMSHAFT POSITION SENSOR (See «INSTALLATION»(ref-209808-S15929347372005121100000) )
27. INSTALL CAMSHAFT TIMING PULLEYS (See «INSTALLATION»(ref-209781-S20467061782005121100000) )
28. CONNECT TIMING BELT TO CAMSHAFT TIMING PULLEYS (See «INSTALLATION»(ref-209781-S20467061782005121100000) )
29. CHECK ENGINE OIL LEVEL

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1. REMOVE HOOD
2. REMOVE ENGINE UNDER COVERS
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. REMOVE V-BANK COVER
6. REMOVE BATTERY
7. REMOVE AIR CLEANER CAP AND INTAKE AIR CONNECTOR PIPE ASSEMBLY
8. REMOVE RADIATOR RESERVOIR Disconnect the clamp on the wire from the reservoir. Disconnect the reservoir hose from the radiator. Remove the 2 bolts, the reservoir and the grommet.
9. REMOVE RADIATOR AND FAN SHROUD Disconnect the upper radiator hose from the front water bypass joint. Remove the 2 nuts, and disconnect the 2 clamps on the A/C discharge tube from the bracket. Remove the 2 bolts, and disconnect the 2 brackets on the wire from the radiator. Remove the 3 bolts, and disconnect the fan shroud from the radiator. Remove the lower radiator hose. Disconnect the 2 A/T oil cooler hoses from the radiator. Remove the 2 bolts, the 2 nuts, the 2 support collars and the radiator. Remove the fan shroud.
10. REMOVE GENERATOR DRIVE BELT, FAN, FLUID COUPLING AND FAN PULLEY Loosen the 4 nuts holding the fluid coupling to the fan bracket. Remove the generator drive belt. (See «GENERATOR»(ref-167874-S07830458402004102500000) ) Remove the 4 nuts, the fan, the fluid coupling assembly and the fan pulley.
11. DISCONNECT ENGINE WIRE FROM CABIN Remove the glove compartment door. Remove the lower No. 2 panel. Disconnect the 3 connectors from the ECM. Remove the 3 screws, and disconnect ECM from the body bracket. Disconnect the 3 wire harness connectors.
12. DISCONNECT HOSES, WIRES, CONNECTORS, CLAMPS, GROMMET AND CABLES Disconnect the 2 PS air hoses from the hose clamp on the No. 3 RH timing belt cover. Disconnect the generator wire. Disconnect the generator connector. Disconnect the hose clamp for PS air hose. Disconnect the PS air hose from upper intake manifold. Disconnect the 2 heater hoses. Disconnect the engine wire clamp from the bracket on the cowl panel. Disconnect the engine wire grommet from cowl panel. Disconnect the ground strap connector. Disconnect the fuel main hose and the clamps. Disconnect the fuel return hose and the clamp. Disconnect the air inlet hose from the charcoal canister. Disconnect the EVAP hose from the charcoal canister. Disconnect the engine wire from the clamp on the right fender apron. Disconnect the clamp on battery negative (-) cable from the relay box. Disconnect the battery negative (-) cable from the right fender apron. Disconnect the battery positive (+) terminal cable.
13. REMOVE SHIFT LEVER ASSEMBLY AND TRANSFER SHIFT LEVER ASSEMBLY Remove the transfer shift lever knob. Remove the upper console panel. Remove the shift lever assembly. Disconnect the connector. Remove the 6 bolts. Remove the nut and disconnect the transmission control rod from the shift lever assembly. Remove the shift lever assembly. Remove the 4 bolts and the transfer shift lever boot. Remove the transfer shift lever assembly. Remove the clip, the plate washer and the wave washer, and disconnect the transfer rod from the shift lever. Remove the bushing. Remove the 4 bolts, the shift lever and the gasket.
14. REMOVE FRONT EXHAUST
15. REMOVE PROPELLER SHAFT (See «REMOVAL»(ref-183465-S36533044272005082500000) )
16. REMOVE STABILIZER BAR (See «STABILIZER BAR»(ref-165186-S38594966202004082300000) )
17. DISCONNECT A/C COMPRESSOR FROM ENGINE Disconnect the A/C compressor connector. Remove the 3 bolts, and disconnect the A/C compressor from the engine. HINT: Suspend the A/C compressor securely.
18. DISCONNECT PS PUMP FROM ENGINE Remove the 3 bolts, and disconnect the PS pump from the engine. HINT: Suspend the PS pump securely.
19. REMOVE ENGINE AND TRANSMISSION ASSEMBLY FROM VEHICLE Attach the engine chain hoist to the engine hangers. Remove the 2 nuts and the 4 bolts holding the engine mounting brackets to the frame brackets. Remove the 3 bolts and the transfer case protector. Remove the 8 bolts, the 2 nuts and the frame crossmember. Lift the engine and take out from the vehicle slowly and carefully. HINT: Make sure the engine is clear of all wiring, hoses and cables. Place the engine and transmission assembly onto a stand.
20. DISCONNECT ENGINE WIRE FROM TRANSMISSION Disconnect the 5 connectors. Disconnect the 2 wire clamps.
21. REMOVE OIL COOLER PIPES FOR TRANSMISSION Remove the 3 bolts and the 3 stays. Loosen the 2 union nuts, and remove the 2 oil cooler pipes.
22. REMOVE TORQUE CONVERTER CLUTCH Remove the bolt and the flywheel housing under cover. Turn the crankshaft pulley bolt to gain access to each bolt. Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts.
23. REMOVE TRANSMISSION Remove the 10 bolts. Remove the transmission together with the torque converter clutch from the engine.
24. REMOVE DRIVE PLATE Hold the crankshaft pulley bolt with a wrench, and remove the 8 bolts, the front spacer, the drive plate and the rear spacer.

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1. INSTALL DRIVE PLATE HINT: The mounting bolts are tightened in 2 steps (steps ( c ) and ( e )). If any one of the mounting bolts is broken or deformed, replace it. Apply adhesive to 2 or 3 threads of the mounting bolt end. Adhesive: Part Ho. 08833-00070, THREE BOND 1324 or equivalent Install the front spacer, the drive plate and the rear spacer on the crankshaft. Hold the crankshaft pulley bolt with a wrench, and install and evenly tighten the 8 mounting bolts, a little at a time for several times as in the sequence (Scheme 222) Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) If any one of the mounting bolts does not meet the torque specification, replace the mounting bolt. Mark the mounting bolt with paint. Retighten the mounting bolts by 90° in the numerical order (Scheme 223) Check that the painted mark is now at a 90° angle to ( e ).
2. INSTALL TRANSMISSION TO ENGINE Check the torque converter clutch installation. (See «INSTALLATION»(ref-213160-S40310270452005122600000) ) Attach the transmission to the engine. Install the ground strap and 10 bolts. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) for 14 mm head 72 N.m (730 kgf.cm, 53 ft.lbf) for 17 mm head
3. INSTALL TORQUE CONVERTER CLUTCH BOLTS Apply adhesive to 2 or 3 threads from the bolt end. Adhesive: Part No. 08833-00070, 1324 or equivalent Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly. Torque: 48 N.m (490 kgf.cm, 35 ft.lbf) HINT: First install the black colored bolt, install the other bolts. Install the flywheel housing under cover with the bolt. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
4. INSTALL OIL COOLER PIPE FOR TRANSMISSION
5. CONNECT ENGINE WIRE TO TRANSMISSION Connect the 5 connectors. Connect the 2 wire clamps.
6. INSTALL ENGINE AND TRANSMISSION IN VEHICLE Attach the engine chain hoist to the engine hangers. Slowly lower the engine and the transmission assembly into the engine compartment. Attach the engine mounting brackets to the frame brackets. Keep the engine level with a jack. Install the frame crossmember with the 8 bolts and the 4 nuts. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) for bolts 74 N.m (750 kgf.cm, 55 ft.lbf) for nuts Install the transfer case protector with the 3 bolts. Install the 2 nuts and the 4 bolts holding the engine mounting brackets to the frame brackets. Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) Remove the engine chain hoist.
7. INSTALL PS PUMP Install the PS pump with the 3 bolts. Torque: 62 N.m (632 kgf.cm, 46 ft.lbf)
8. INSTALL A/C COMPRESSOR Install the A/C compressor with the 3 bolts. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) Connect the A/C compressor connector.
9. INSTALL STABILIZER BAR (See «STABILIZER BAR»(ref-165186-S38594966202004082300000) )
10. INSTALL PROPELLER SHAFT (See «INSTALLATION»(ref-183465-S12095768302005082500000) )
11. INSTALL FRONT EXHAUST PIPES
12. INSTALL SHIFT ASSEMBLY AND SHIFT LEVER ASSEMBLY Install the transfer shift lever. Install a new gasket and the shift lever with the 4 bolts. Connect the transfer shift lever rod to the shift lever with the bushing, the wave washer, the plate washer and the clip. Install the transfer shift lever boot with the 4 bolts. Install the shift lever assembly. Connect the transmission control rod to the shift lever assembly with the nut. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) Install the shift lever assembly with the 6 bolts. Torque: 8.3 N.m (86 kgf.cm, 73 in.lbf) Connect the connector. Install the console upper cover. Install the transfer shift lever knob.
13. CONNECT WIRES, CONNECTORS, CLAMPS, GROMMET AND CABLES Connect the 2 PS air hoses to the hose clamp on the No. RH timing belt cover. Connect the generator wire. Connect the generator connector. Connect the hose clamp for the PS air hose. Connect the PS air hose to upper intake manifold. Connect the 2 heater hoses. Connect the engine wire clamp to the bracket on the cowl panel. Connect the engine wire grommet to the cowl panel. Connect the ground strap connector. Connect the fuel main hose and the clamps. Connect the fuel return hose and the clamp. Connect the air inlet hose to the charcoal canister. Connect the EVAP hose to the charcoal canister. Connect the engine wire to the clamp on the right fender apron. Connect the clamp on battery negative (-) cable to the relay box. Connect the battery negative (-) cable to the right fender apron. Connect the battery positive (+) terminal cable.
14. CONNECT WIRE TO CABIN Connect the 3 wire harness connectors. Install the ECM with the 3 screws. Connect the 3 connectors to the ECM. Install the glove compartment door. Install the lower No. 2 panel.
15. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND GENERATOR DRIVE BELT Temporarily install the fan pulley, the fan and the fluid coupling assembly with the 4 nuts. Install the generator drive belt. (See «GENERATOR»(ref-167874-S07830458402004102500000) ) Tighten the 4 nuts holding the fluid coupling to the fan bracket.
16. INSTALL AND FAN AND FAN SHROUD Place the fan shroud in the installation position. Install the radiator with the 2 support collars, the 2 nuts and the 2 bolts. Connect the 2 A/T oil cooler hoses to the radiator. Install the lower radiator hose. Attach the lower side of the fan shroud to the brackets of the radiator, and install the fan shroud with the 2 bolts Install the 2 brackets on the wire to the radiator with the 2 bolts. Install the 2 clamps on the A/C discharge tube to the brackets on the wire with the 2 nuts. Connect the upper radiator hose to the front water bypass joint.
17. INSTALL RADIATOR RESERVOIR Install the grommet to the reservoir. Attach the lower side of the reservoir to the fan shroud. Install the reservoir with the 2 bolts. Connect the reservoir hose to the radiator. Install the clamp on the wire to the reservoir.
18. AIR CAP AND INTAKE AIR CONNECTOR PIPE ASSEMBLY
19. INSTALL BATTERY
20. FILL WITH COOLANT (See «REPLACEMENT»(ref-183460-S01176940202005081300000) )
21. FILL WITH ENGINE OIL (See «REPLACEMENT»(ref-209806-S17227929372005121100000) )
22. START ENGINE AND CHECK FOR LEAKS
23. INSTALL V-BANK COVER
24. INSTALL ENGINE UNDER COVERS
25. INSTALL HOOD
26. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, and make sure the shift points is correct and operation is smooth.
27. RECHECK ENGINE COOLANT AND OIL LEVELS

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1. INSTALL ENGINE TO ENGINE STAND
2. REMOVE TIMING BELT AND PULLEYS (See «REMOVAL»(ref-209781-S38297666172005121100000) )
3. REMOVE CYLINDER HEAD (See «REMOVAL»(ref-209781-S19449274192005121100000) )
4. REMOVE WATER BYPASS PIPE Disconnect the wire clamp (for knock sensor 1,2) from the bracket of the water bypass pipe. Remove the bolt. Pull out the water bypass pipe from the water pump. Remove the O-ring from the water bypass pipe.
5. REMOVE STARTER (See «REMOVAL & INSTALLATION»(ref-168684-S21087665252004111500000) )
6. REMOVE KNOCK SENSORS (See «INSPECTION»(ref-209797-S37411572162005121100000) )
7. DISCONNECT ENGINE WIRE FROM LH SIDE OF CYLINDER BLOCK Remove the 2 bolts and the engine wire cover from the LH side of the cylinder block. Remove the bolt, disconnect the bracket on the engine wire from the cylinder block.
8. DISCONNECT ENGINE WIRE FROM RH SIDE OF CYLINDER BLOCK Remove the 2 bolts, and disconnect the 2 brackets on the engine wire from the cylinder block.
9. REMOVE OIL COOLER PIPE BRACKET FOR A/T Remove the bolt and bracket.
10. REMOVE ENGINE MOUNTING BRACKETS Remove the 4 bolts and the mounting bracket. Remove the 2 mounting brackets
11. REMOVE WATER PUMP (See «REMOVAL»(ref-183461-S36156444222005081300000) )
12. REMOVE NO. 2 OIL PAN (See «REMOVAL»(ref-209806-S04014594412005121100000) )
13. REMOVE OIL PAN BAFFLE PLATE
14. REMOVE NO. 1 OIL PAN (See «REMOVAL»(ref-209806-S04014594412005121100000) )
15. REMOVE OIL STRAINER
16. REMOVE OIL PUMP (See «REMOVAL»(ref-209806-S04014594412005121100000) )
17. REMOVE ENGINE COOLANT DRAIN UNIONS Remove the 2 drain unions.
18. REMOVE REAR OIL SEAL RETAINER Remove the 7 bolts. Using a screwdriver, ply off the oil seal retainer and the main bearing cap with a screwdriver. Remove the O-ring.
19. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back an a forth. Standard thrust clearance: 0.160 - 0.290 mm (0.0063 - 0.0138 in.) Maximum thrust clearance: 0.35 mm (0.0138 in.) If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. Connecting rod thickness: 22.880 - 22.920 mm (0.9008 - 0.9024 in.)
20. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE Check the matchmarks on the connecting rod and cap to ensure correct reassembly. Remove the 2 connecting rod cap bolts. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and the lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted with the connecting rod cap. Clean the crank pin and the bearing. Check the crank pin and the bearing for pitting and scratches. If the crank pin or the bearing is damaged, replace the bearings. If necessary, replace the crankshaft. Lay a strip of plastigage across the crank pin. Install the connecting rod cap with the 2 bolts. (See «REASSEMBLY»(ref-209781-S25460393412005121100000) ) NOTE: Do not turn the crankshaft. Remove the 2 bolts, the connecting rod cap and the lower bearing. (See procedure ( b ) and ( c ) above) Measure the plastigage at its widest point. Standard oil clearance: 0.027 - 0.053 mm (0.0011 - 0.0021 in.) Maximum oil clearance: 0.065 mm (0.0026 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. HINT: If using a standard bearing, replace it with the one having the same number. If the number of the bearing cannot be determined, sum up the numbers imprinted on the connecting rod cap and the crankshaft, then select the one with the same number as the total. There are 6 sizes of standard bearings, marked "2", "3", "4", "5", "6" and "7". EXAMPLE: Connecting rod cap "3" + Crankshaft "1" = Total number 4 (Use bearing "4") Reference Connecting rod big end inside diameter. Crankshaft crank pin diameter: Standard sized bearing center wall thickness: Completely remove the plastigage.
21. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: Keep the bearings, the connecting rod and the cap together. Arrange the piston and connecting rod assemblies in correct order.
22. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.020 - 0.220 mm (0.0008 - 0.0087 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Thrust washer thickness: 2.440 - 2.490 mm (0.0961 - 0.0980 in.)
23. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE Evenly loosen and remove the 10 main bearing cap bolts a little at a time for several times, in the sequence (Scheme 254) Using 2 screwdrivers, pry out the main bearing cap, and remove the 5 main bearing caps, the 5 lower bearings and the 2 lower thrust washers (No. 3 main bearing cap only). NOTE: Be careful not to damage the cylinder block. HINT: Keep the lower bearing and main bearing cap together. Arrange the main bearing caps and lower thrust washers in correct order. Lift out the crankshaft. HINT: Keep the upper bearings and the upper thrust washers together with the cylinder block. Clean each main journal and bearing. Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. Place the crankshaft on the cylinder block. Lay a strip of plastigage across each journal. Install the main bearing caps. (See «REASSEMBLY»(ref-209781-S25460393412005121100000) ) NOTE: Do not turn the crankshaft. Remove the main bearing caps. (See procedure ( a ) and ( b ) above) Measure the plastigage at its widest point. Standard clearance: 0.040 - 0.058 mm (0.0016 - 0.0023 in.) Maximum clearance: 0.070 mm (0.0028 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. HINT: If using a standard bearing, replace it with the one having the same number. If the number of the bearing cannot be determined, sum up the numbers imprinted on the cylinder block and the crankshaft, then (Scheme 260)and (Scheme 261) for the appropriate bearing number. There are 5 sizes of the standard bearings. For No. 1 and No. 5 position bearings, use bearings marked "3", "4", "5", "6" and "7". For others position bearings, use bearings marked "1", "2", "3", "4" and "5". No. 1, No. 5: EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "5") Others: EXAMPLE: Cylinder block "08" + Crankshaft "06" = Total number 14 (Use bearing "3") Reference Cylinder block main Journal bore diameter (A): Crankshaft main Journal diameter (B): Standard bearing center wall thickness: No. 1 and No. 5 Others: Completely remove the Plastigage.
24. REMOVE CRANKSHAFT Lift up the crankshaft. Remove the 5 upper main bearings and the 2 upper thrust washers from the cylinder block. HINT: Arrange the main bearing caps, bearings and thrust washers in correct order installation.
25. CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
26. REMOVE PISTON RINGS Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and the oil ring by hand. HINT: Arrange the piston rings in correct order installation.
27. DISCONNECT CONNECTING ROD FROM PISTON Using a small screwdriver, pry out the 2 snap rings. Gradually heat the piston to approx. 60°C (140°F). Using a plastic-faced hammer and a brass bar, lightly tap out the piston pin and the pin and remove the connecting rod. HINT: The piston and the pin are a matched set. Arrange the pistons, the pins, rings, the connecting rods and the bearings in correct order for installation.

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1. CLEAN CYLINDER BLOCK Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block.
2. INSPECT CYLINDER BLOCK Inspect for flatness. Using a precision straight edge and a feeler gauge, measure the surfaces contacting the cylinder head and main bearing cap for a warp. Maximum warpage: 0.07 mm (0.0028 in.) If the warp is greater than the maximum, replace the cylinder block. Visually check the cylinder for vertical scratches. If deep scratches are found, rebore all the 8 cylinders and replace all the 8 pistons (See «REPLACEMENT»(ref-209781-S42194830042005121100000) ). If necessary, replace the cylinder block. Inspect the cylinder bore diameter. HINT: There are 3 sizes of the standard cylinder bore diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the top of the cylinder block. Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: Maximum diameter: 94.23 mm (3.7098 in.) If the diameter is greater than the maximum, rebore all the 8 cylinders and replace all the 8 pistons (See «REPLACEMENT»(ref-209781-S42194830042005121100000) ). If necessary, replace the cylinder block. Remove the cylinder ridge. If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder. Using vernier calipers, measure the thread outside diameter of the main bearing cap bolt. Standard diameter: 10.760 - 10.970 mm (0.4236 - 0.4319 in.) Minimum diameter: 10.40 mm (0.4094 in.) If the diameter is less than the minimum, replace the cap bolt.
3. CLEAN PISTON Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool or broken ring, clean the piston ring grooves. Using solvent and a brush, thoroughly clean the piston. NOTE: Do not use a wire brush.
4. INSPECT PISTON AND CONNECTING ROD Inspect the piston oil clearance. HINT: There are 3 sizes of the standard piston diameter, marked "1", "2" and "3" accordingly. The mark is stamped on the piston top. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.75 mm (1.2106 in.) from the piston head. Piston diameter: Measure the cylinder bore diameter in the thrust directions. (See step 2 above) Subtract the piston diameter from the cylinder bore diameter. Standard oil clearance: 0.090 - 0.111 mm (0.0035 - 0.0044 in.) Maximum oil clearance: 0.13 mm (0.0051 in.) If the oil clearance is greater than the maximum, replace all the 8 pistons and rebore all the 8 cylinders. (See «REPLACEMENT»(ref-209781-S42194830042005121100000) ) If necessary, replace the cylinder block. HINT Use new cylinder block: Use a piston with the same number mark as the cylinder diameter marked on the cylinder block. The shape of the piston varies for the LH and the RH banks. The LH piston is marked as "LH" and "2L", and the RH piston as "RH" and "2R". Inspect the piston ring groove clearance. Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove. Ring groove clearance: If the clearance is not as specified, replace the piston. Inspect the piston ring end gap. Insert the piston ring into the cylinder bore. Using a piston, push the piston ring to a little beyond the bottom of the ring travel, 105 mm (4.13 in.) from the top of the cylinder block. Using a feeler gauge, measure the end gap. Standard end gap: Maximum end gap: If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum, even with a new piston ring, rebore all the 8 cylinders (See «REPLACEMENT»(ref-209781-S42194830042005121100000) ) or replace the cylinder block. Inspect the piston pin fit. At 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb. Using a rod aligner and the feeler gauge, check the connecting rod alignment. Check for bend. Maximum bend: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If bend is greater than maximum, replace the connecting rod assembly. Check for twist Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If twist is greater than the maximum, replace the connecting rod assembly. Inspect the piston pin oil clearance. Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005 - 22.014 mm (0.8663 - 0.8667 in.) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 - 22.006 mm (0.8660 - 0.8664 in.) Subtract the piston pin diameter from the bushing inside diameter. Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the piston and the piston pin as a set. Using vernier calipers, measure the tension portion of the connecting rod bolt. Standard diameter: 7.200 - 7.300 mm (0.2835 - 0.2874 in.) Minimum diameter: 7.00 mm (0.2756 in.) If the diameter is less than the minimum, replace the bolt.
5. INSPECT CRANKSHAFT Inspect for circle runout. Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.08 mm (0.0031 in.) If the circle runout is greater than the maximum, replace the crankshaft. Inspect the main journals and the crank pins. Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: 66.988 - 67.000 mm (2.6373 - 2.6378 in.) Crank pin diameter: 51.982 - 52.000 mm (2.0465 - 2.0472 in.) If the diameter is not as specified, check the oil clearance (See «DISASSEMBLY»(ref-209781-S12315221652005121100000) ). If necessary, replace the crankshaft. Check each main journal and crank pin for taper and out-of-round (Scheme 300) Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of-round is greater than the maximum, place the crankshaft.

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1. REPLACE OVERSIZED (O/S) PISTONS FOR CYLINDER BORING HINT: Bore all the 8 cylinders to the oversized piston outside diameter. Replace all the piston rings with the ones to match the oversized pistons. Keep 8 new O/S pistons. O/S 0.50 piston diameter: 94.402 - 94.430 mm (3.7166 - 3.7177 in.) HINT: The shape of the piston varies for the LH and RH banks. The LH piston is marked with "LH" and "2L", the RH piston with "RH" and "2R". Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.75 mm (1.2106 in.) from the piston head. Calculate the amount for each cylinder to be rebored as follows: Size to be rebored = P + C - H P = Piston diameter C = Piston clearance: 0.090 - 0.111 mm (0.0035 - 0.0044 in.) H = Allowance for honing: 0.02 mm (0.0008 in.) or less Bore and hone the cylinders to calculated dimensions. Maximum honing: 0.02 mm (0.0008 in.) NOTE: Excess honing will destroy the finished roundness.
2. REPLACE CONNECTING ROD BUSHINGS Using SST and a press, press out the bushing. SST 09222-30010 Align the oil holes of a new bushing and the connecting rod. Using SST and a press, press in the bushing. SST 09222-30010 Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (See «INSPECTION»(ref-209781-S40767452692005121100000) ) between the bushing and piston pin. Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
3. REPLACE CRANKSHAFT FRONT OIL SEAL HINT: There are 2 methods ( a and b ) to replace the oil seal. If the oil pump is removed from the cylinder block: Using a screwdriver, pry out the oil seal. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge. SST 09316-60011 (09316-00011) Apply MP grease to the oil seal lip. If the oil pump is installed to the cylinder block: Using a knife, cut off the oil seal lip. Using a screwdriver, pry out the oil seal. NOTE: Be careful not to damage the crankshaft. Tape up the screwdriver tip. Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge. SST 09316-60011 (09316-00011)
4. REPLACE CRANKSHAFT REAR OIL SEAL HINT: There are 2 methods (a) and (b) to replace the oil seal. If the rear oil seal retainer is removed from the cylinder block: Using a screwdriver and hammer, tap out the oil seal. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010 Apply MP grease to the oil seal lip. If the rear oil seal retainer is installed to the cylinder block: Using a knife, cut off the oil seal lip. Using a screwdriver, pry out the oil seal. NOTE: Be careful not to damage the crankshaft. Tape up the screwdriver tip. Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010

HINT

1. Thoroughly clean all parts to be assembled.
2. Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
3. Replace all gaskets, O-rings and oil seals with new parts.

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1. ASSEMBLE PISTON AND CONNECTING ROD Using a small screwdriver, install a new snap ring on one side of the piston pin hole. Gradually heat the piston to about 60°C (140°F). Coat the piston pin with engine oil. Position the piston front mark to the outside mark on the connecting rod (Scheme 316) NOTE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with "LH" and "2L", the RH piston with "RH" and "2R". Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.
2. INSTALL PISTON RINGS Install the oil ring expander and the 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Code mark: Position the piston rings so that the ring ends are (Scheme 320) NOTE: Do not align the ring ends.
3. INSTALL BEARINGS Align the bearing claw with the groove of the connecting rod or the connecting cap. Install the bearings in the connecting rod and the connecting rod cap.
4. INSTALL MAIN BEARINGS HINT: Main bearings come in widths of 19.5 mm (0.768 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing cap. Install the 19.5 mm (0.768 in.) bearings in the other positions. Upper bearings have an oil groove and an oil holes; lower bearings do not. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings. HINT: A number is marked on each main bearing cap to indicate the installation position.
5. INSTALL UPPER THRUST WASHERS Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK
7. PLACE MAIN BEARING CAPS AND LOWER THRUST WASHERS ON CYLINDER BLOCK Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward. Install the 5 main bearing caps in their proper locations.
8. INSTALL MAIN BEARING CAP BOLTS HINT: The main bearing cap bolts are tightened in 2 steps (steps ( b ) and ( d )). If any one of the main bearing cap bolts is broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the main bearing cap bolts. Install and evenly tighten the 10 main bearing cap bolts a little at a time for several times as in the sequence (Scheme 328) Torque: 27 N.m (275 kgf.cm, 20 ft.lbf) If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt. Mark the front of the main bearing cap bolt with paint. Retighten the main bearing cap bolts by 90° in the numerical order (Scheme 329) Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly.
9. CHECK CRANKSHAFT THRUST CLEARANCE (See «DISASSEMBLY»(ref-209781-S12315221652005121100000) )
10. INSTALL PISTON AND CONNECTING ROD ASSEMBLES Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. NOTE: The shape of the piston varies for the LH and RH banks. The LH piston is marked with "LH" and "2R", the RH piston with "RH" and "2R".
11. PLACE CONNECTING ROD CAP ON CONNECTING ROD Match the numbered connecting rod cap with the connecting rod. Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap. Check that the outside mark of the connecting rod cap is facing in correct direction.
12. INSTALL CONNECTING ROD CAP BOLTS HINT: The connecting rod cap bolts are tightened in 2 steps (steps ( b ) and ( d )). If any one of the connecting rod cap bolts is broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. Install and alternately tighten the 2 connecting rod cap bolts a little at a time for several times. Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts. Mark the front of the connecting cap bolt with paint. Retighten the cap bolts 90° see scheme 330 Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly.
13. CHECK CONNECTING ROD THRUST (See «DISASSEMBLY»(ref-209781-S12315221652005121100000) )
14. INSTALL REAR OIL SEAL RETAINER Remove any old packing (FIPG) material, and be careful not to drop any oil on the contact surfaces of the oil seal retainer and the cylinder block. Using a razor blade and a gasket scraper, remove old FIPG from the seal surface. Clean all the components to remove the redundant FIPG completely. Clean sealing surfaces with solvent so that any residue does not remain on the seal. Apply seal packing to the oil seal retainer see scheme 331 Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that is cut to a 2-3 mm (0.08-0.12 in.) opening. Parts must be assembled within 5 minutes after the seal packing application. Otherwise the material must be removed and the seal packing have to be reapplied. Immediately remove the nozzle from the tube and reinstall the cap. Install a new O-ring to the cylinder block. Install the oil seal retainer with the 7 bolts. Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf)
15. INSTALL ENGINE COOLANT DRAIN UNIONS Apply seal packing to 2 or 3 threads from the end of the drain unions. Seal packing: Part No. 08826-00100 or equivalent Install the 2 drain unions. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) HINT: After applying the specified torque, rotate the drain union clockwise until the drain port is facing forward.
16. INSTALL OIL PUMP (See «INSTALLATION»(ref-209806-S30089202822005121100000) )
17. INSTALL OIL STRAINER (See «INSTALLATION»(ref-209806-S30089202822005121100000) )
18. INSTALL NO. 1 OIL PAN (See «INSTALLATION»(ref-209806-S30089202822005121100000) )
19. INSTALL OIL PAN BAFFLE PLATE (See «INSTALLATION»(ref-209806-S30089202822005121100000) )
20. INSTALL NO. 2 OIL PAN (See «INSTALLATION»(ref-209806-S30089202822005121100000) )
21. INSTALL WATER PUMP (See «INSTALLATION»(ref-183461-S11966772252005081300000) )
22. INSTALL ENGINE MOUNTING BRACKETS Install the mounting bracket with the 4 bolts. Install the 2 mounting brackets. Torque: 36 N.m (370 kgf.cm, 27 ft.lbf)
23. INSTALL ENGINE WIRE TO LH SIDE OF BLOCK Install the bracket on the engine wire with the bolt. Install the engine wire cover with the 2 bolts.
24. INSTALL WIRE TO RH SIDE OF BLOCK Install the 2 brackets on the engine wire with the 2 bolts.
25. INSTALL OIL COOLER PIPE BRACKET FOR A/T Install the bracket with the bolt.
26. INSTALL KNOCK SENSORS (See «INSPECTION»(ref-209797-S37411572162005121100000) )
27. INSTALL STARTER (See «REMOVAL & INSTALLATION»(ref-168684-S21087665252004111500000) )
28. INSTALL WATER PIPE Install a new O-ring to the water bypass pipe. Apply soapy water to the O-ring. Push the water bypass pipe end into the pipe hole of the water pump. Install the water bypass pipe with the bolt. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) Install the wire clamp to the bracket of the water bypass pipe.
29. INSTALL CYLINDER HEADS (See «INSTALLATION»(ref-209781-S41437323792005121100000) )
30. INSTALL TIMING BELT AND PULLEYS (See «INSTALLATION»(ref-209781-S20467061782005121100000) )
31. DISCONNECT ENGINE FROM ENGINE STAND