Assembly
PISTON INSTALLATIONBefore installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
1. If the crankshaft is already installed:
- Set the crankshaft to BDC for each cylinder.
- Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting rod bolts.
- Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.
- Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
- Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the nuts to:
B16A2 engine: 40 Nm (4.1 kgs.cm, 30 ft.lbs.)
D16Y5, D16Y7, D16Y8 engines: 31 Nm (3.2 kgs.cm, 23 ft.lbs.)
2. If the crankshaft is not installed:
- Remove the rod caps and bearings, install the ring compressor, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.
- Position all pistons at top dead center.
NOTE: Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
CRANKSHAFT INSTALLATION
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.
OIL PAN INSTALLATION
B16A2, D16Y7 Engines:
1. Apply liquid gasket on the oil pump and right side cover mating areas as shown below.
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 as an even bead, centered between the edges of 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.
2. Install the oil pan gasket and oil pan.
NOTE:
- Use a new oil pan gasket.
- Install the oil pan no more than five minutes after applying liquid gasket.
3. Tighten the bolts and nuts finger tight at six points as shown below.
4. Tighten all bolts and nuts, starting from nut (1), clock wise in three steps.
NOTE: Excessive tightening can cause distortion of the oil pan gasket and oil leakage.
Torque: 12 Nm 11.2 kgs.cm, 8.7 ft.lbs.)
D16Y5, D16Y8 Engines:
1. Install the oil pan gasket on the oil pan.
2. Apply liquid gasket to the block mating surfaces of the oil pan, then install it. Apply liquid gasket to the shaded areas.
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 as an even bead, centered between the edges of the mating surface.
- To prevent leakage of oil, 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.
3. Tighten nuts finger-tight at six points as shown.
4. Tighten all bolts and nuts, starting from nut (1), clockwise in three steps.
NOTE: Excessive tightening can cause distortion of the oil pan gasket and oil leakage.
Torque: 12 Nm (1.2 kgs.cm, 8.7 ft.lbs.)
OIL SEALS INSTALLATION
NOTE:
- Engine removal is not required.
- The crankshaft oil seal housing should be dry.
Apply a light coat of grease to the crankshaft and to the lips of the seals.
1. Using the special tool, drive in the timing pulley end seal until the driver bottoms against the oil pump.
When the seal is in place, clean any excess grease off the crankshaft and check that the oil seal lip is not distorted.
2. Measure the flywheel-end seal thickness and the oil seal housing depth. Using the special tool, drive the flywheel-end seal into the rear cover to the point where the clearance between the bottom of the oil seal and the right side cover is 0.5 - 0.8 mm (0.02 - 0.03 inch).
NOTE: Align the hole in the driver attachment with the pin on the crankshaft.