Installation

1. Set crankshaft.
Turn the crankshaft until the set key on the crankshaft facing downward.
2. Install timing chain and camshaft timing gear.
3. Install oil pump (timing chain cover).
4. Install drive belt idler pulley.
Install the pulley with the bolt.
Torque: 43 Nm (32 ft. lbs.)
5. Install crankshaft pulley.
6. Install oil strainer.
Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 20 Nm (14 ft. lbs.)
7. Install oil pan baffle plate.
Install the baffle plate with the bolt and 7 nuts.
Torque: 9.0 Nm (78 inch lbs.)
8. Install No. 1 oil pan.
(a) Remove any old packing Formed In Place Gasket (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan, oil pump and cylinder block.
^ Using a razor blade and gasket scraper, remove ail the old packing FIPG material from the gasket surfaces and sealing grooves.
^ Thoroughly clean all components to remove all the loose material.
^ Using a non-residue solvent, clean both sealing surfaces.

(b) Apply seal packing to the No. 1 oil pan as shown in the illustration.
Seal packing: Part No. 08826 - 00080 or equivalent.
^ Install a nozzle that has been cut to a 3 - 4 mm (0.12 - 0.16 inch) opening.

NOTE: Avoid applying an excessive amount to the surface.

^ Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
^ Immediately remove nozzle from the tube and reinstall cap.

(d) Pour in approximately 15 cm3 (O.9 cu inch) of engine oil into oil pump hole.
(e) Install the No. 1 oil pan with the 21 bolts and 2 nuts.
Torque:
14 mm head: 44 Nm (32 ft. lbs.)
12 mm head: 20 Nm (14 ft. lbs.)
9. Install No. 2 oil pan.
(a) Remove any old packing FIPG material and be careful not to drop any oil on the contact surface of the No. 1 oil pan.
^ Using a razor blade and gasket scraper, remove all the old packing FIPG material from the gasket surfaces and sealing grooves.
^ Thoroughly clean all components to remove all the loose material.
^ Using a non-residue solvent, clean both sealing surfaces.

(b) Apply seal packing to the No. 2 oil pan as shown in the illustration.

CAUTION: Do not use a solvent which will affect the painted surfaces.

Seal packing: Part No. 08826 - 00080 or equivalent.
^ Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening or 3 - 4 mm (0.012 - 0.016 inch) opening.

NOTE: Avoid applying an excessive amount to the surface.

^ Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
^ Immediately remove nozzle from the tube and reinstall cap.
(c) Install the No. 2 oil pan with the 17 bolts and 2 nuts.
Torque: 8.8 Nm (78 inch lbs.)
10. Install bolts holding No. 1 oil pan to transmission housing.
Install the 6 bolts.
Torque: 72 Nm (53 ft. lbs.)
11. Install oil level sensor.

(a) Install a new gasket to the level sensor.
(b) Install the level sensor with the 4 bolts.
Torque: 5.4 Nm (48 inch lbs.)
12. Connect oil cooler pipe bracket to No. 1 oil pan.
13. Install cylinder head.
14. Install water pump.
Install a new gasket and water pump with the 4 bolts and 2 nuts.
Torque: 21 Nm (15 ft. lbs.)
15. Install radiator pipe.
(a) Connect the No. 2 radiator hose to the water inlet.
(b) Install the 2 nuts holding the radiator pipe to the No. 1 oil pan.
Torque: 21 Nm (15 ft. lbs.)
16. Install A/C compressor and bracket.
(a) Install the A/C compressor bracket with the 5 bolts.
Torque: 37 Nm (27 ft. lbs.)
(b) Install the A/C compressor with the 4 bolts.
Torque: 25 Nm (18 ft. lbs.)
(c) Install and adjust the drive belt.
17. Install radiator. Refer to Cooling System.
18. Install engine under cover.
19. Fill with engine oil.
20. Start engine and check for leaks.