Assembly

Before installing the crankshaft, apply a coat of engine oil to the main bearings and rod bearings.

1. Insert the bearing halves into the cylinder block and connecting rods.

2. Hold the crankshaft so the rod journals for cylinders No. 2 and No. 3 are straight down.





3. Lower the crankshaft into the block, seating the rod journals into connecting rods No. 2 and No. 3, and install the rod caps and nuts finger-tight.

4. Rotate the crankshaft clockwise, seat journals into connecting rods No. 1 and No. 4, and install the rod caps and nuts finger-tight.

NOTE: Install caps so the bearing recess is on the same side as the recess in the rod.





5. Check rod bearing clearance with plastigage, then torque the cap nuts. Apply engine oil to the bolt threads.

Torque:
B16A2 engine: 40 Nm (4.1 kgs.cm, 30 ft.lbs.)
D16Y5,D16Y7,D16Y8 engines: 31 Nm (3.2 kgs.cm, 23 ft.lbs.)

NOTE: Reference numbers on connecting rod are for big-end bore tolerance and do not indicate the position of piston in the engine.

6. Install the thrust washers on the No. 4 journal. Oil the thrust washer surfaces.





7. Install the main bearing caps. Check clearance with plastigage, then tighten the bearing cap bolts in 2 steps.

First step: 25 Nm (2.5 kgs.cm, 18 ft.lbs.)
Second step:
B16A2 engine: 76 Nm (7.8 kgs.cm, 56 ft.lbs.)
D16Y5, D16Y7, D16Y8 engines: 51 Nm (5.2 kgs.cm, 38 ft.lbs.)

NOTE: Coat the thrust washer surfaces and bolt threads with oil.

CAUTION: Whenever any crankshaft or connecting rod bearing is replaced, it is necessary after reassembly to run the engine at idling speed until it reaches normal operating temperature, then continue to run it for approximately 15 minutes.

NOTE:
- Use liquid gasket, part No. 08718-0001 or 08718-0003.
- Check that the mating surfaces are clean and dry before applying liquid gasket.
- Apply liquid gasket evenly, being careful to cover all the mating surface.
- To prevent oil leakage, apply liquid gasket to the inner threads of the bolt holes.
- Do not install the parts if five minutes or more have elapsed since applying the liquid gasket.
Instead reapply liquid gasket after removing the old residue.
- After assembly, wait at least 30 minutes before filling the engine with oil.








8. Apply liquid gasket to the block mating surface of the right side cover, then install it on the cylinder block.





9. Apply liquid gasket to the oil pump mating surface of the block, then install the oil pump on the cylinder block.

Apply grease to the lips of the oil seals.
Then, align the inner rotor with the crankshaft and install the oil pump. When the pump is in place, clean any excess grease off the crankshaft. Check that the oil seal lips are not distorted.

NOTE:
- Apply a light coat of oil to the crankshaft and to the lip of seal.
- Use new O-rings and apply oil when installing them.





10. Install the oil screen.