Installation

1. INSTALL WATER PUMP

(a) Install a new O-ring to the water bypass pipe end.

(b) Apply soapy water to the O-ring.

(c) Connect the water pump to the water bypass pipe end.

(d) Install the water pump and new gasket with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes.

Torque: Bolt: 21 N·m Stud bolt and nut: 18 N·m

HINT: Use bolts 35 mm (1.38 in.) in length.

2. INSTALL WATER INLET AND INLET HOUSING ASSEMBLY

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water inlet housing and water pump.

• Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the 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) Apply seal packing to the sealing groove of water inlet housing as shown in the illustration.

Seal packing: Part No. 08826-00100 or equivalent

• Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 in.) opening.
• 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 a new O-ring to the water inlet housing.

(d) Apply soapy water on the O-ring.

(e) Attach the water inlet housing end to the front water bypass joint hole.

(f) Install the water inlet and housing assembly with the 2 bolts. Alternately tighten the bolts.

Torque: 18 N·m

HINT: Each bolt length is indicated in the illustration.

Bolt length: 76 mm (3.00 in.) for A 22 mm (0.87 in.) for B

3. INSTALL NO.2 IDLER PULLEY (EM-22 )

4. INSTALL TIMING BELT (EM-22 )

5. FILL WITH ENGINE COOLANT

6. START ENGINE AND CHECK FOR ENGINE COOLANT LEAKS

7. RECHECK ENGINE COOLANT LEVEL