D16a6 Rebuild 88-91 CRX - headwork pictures November 15

[Edison]

I began a quest that many others have done, but I feel this site needs some sort of how-to on a d16 rebuild.

Car: 1989 Honda Civic Si
Engine: d16a6 from an EF Civic 88-89
90-91's have a different Flywheel.

This is what I have:
the block, has about 300,000kms on it, seemed like it was rebuilt before but I am really unsure.
http://img.photobucket.com/albums/v444/tideripsurf/Picture353.jpg
Old pistons and rods
http://img.photobucket.com/albums/v444/tideripsurf/Picture352.jpg
They are in bags numbered 1,2, etc....

Finally the new parts :
http://img.photobucket.com/albums/v444/tideripsurf/Picture351.jpg

Oh, and the gasket set
http://img.photobucket.com/albums/v444/tideripsurf/GasketSetD16D16a6.jpg


I was curious, I need to have the "wrist pins?" pushed out so I can install my new pistons on the existing rods. Where could I get this done, and about how much would it cost?

Thanks er alot oer

[mildtowildengines]

Just saw this post after i sent you the pm, if you need the new pistons hung lemme know thru pm. Im intrested in your gears.

Frank@Mild2Wild Engines

[Edison]

Thanks to mild to wild, this is some of the progress


Block, Cleaned and Honed
http://img.photobucket.com/albums/v444/tideripsurf/CrankanBlock.jpg

Cleaned Block
http://img.photobucket.com/albums/v444/tideripsurf/Block.jpg

Newly assembled pistons
http://img.photobucket.com/albums/v444/tideripsurf/Rods.jpg

Thanks for the work, more pictures coming soon!

[Edison]

This is the Flywheel gasket, the old one looked decent, but a new gasket came with the kit I have.
Out with the old
http://img.photobucket.com/albums/v444/tideripsurf/GasketInstallFlywheel.jpg
In with the new
http://img.photobucket.com/albums/v444/tideripsurf/GasketInstallFlywheel1.jpg

I installed all of the rings as well:
http://img.photobucket.com/albums/v444/tideripsurf/Ringinstall2.jpg
Final Ring going on
http://img.photobucket.com/albums/v444/tideripsurf/Ringinstall3.jpg
One down, 3 to go
http://img.photobucket.com/albums/v444/tideripsurf/Ringinstall4.jpg
All 4 Complete;
http://img.photobucket.com/albums/v444/tideripsurf/Ringinstall7.jpg

[BrettR]

Nice job Donner, replacing the rear main seal (flywheel seal) was a good idea.

This going in your hatch? Boost?

[Nader_D]

kitchen, block, school, work

dude you must not have 1 spare minute :shock:

[Edison]

Nice job Donner, replacing the rear main seal (flywheel seal) was a good idea.

This going in your hatch? Boost?


trying, hey I tried to call you last night, but no luck.

I need a modded pm6

[Edison]

kitchen, block, school, work

dude you must not have 1 spare minute :shock:


ha, I find time for RL though

[mx3frik]

did you gap the rings? OR atleast check them to make sure they are within spec?

[Edison]

The top of the cylinders still needed the rest of the old gasket to be taken off.
I have been told that I shouldn't use a wire brush, but I did cause I am lazy, and the exacto knife would not work.
http://img.photobucket.com/albums/v444/tideripsurf/Dirtycylinders.jpg

The wife helped me alcohol clean the cylinders and oil them, cause my big manly hands couldn't fit ;)
http://img.photobucket.com/albums/v444/tideripsurf/alcoholcylinders.jpg

All Clean!
http://img.photobucket.com/albums/v444/tideripsurf/allcleanedandoiledcylinders.jpg

I used a Ring Compressor borrowed from Srswarts
http://img.photobucket.com/albums/v444/tideripsurf/PushinginthePistons.jpg
http://img.photobucket.com/albums/v444/tideripsurf/UsingRingCompressor.jpg

doesn't it look pretty?
http://img.photobucket.com/albums/v444/tideripsurf/Allpistonsin.jpg

Now I flipped the block upside down, and installed the bearings on the rods and block, if you notice the white stuff, thats the white grease.
http://img.photobucket.com/albums/v444/tideripsurf/NewBearingsandWhiteGrease.jpg

I dropped the crank shaft on, I forgot to take a picture of the Thrustwasher install, but thats okay.
http://img.photobucket.com/albums/v444/tideripsurf/CrankShaftDroppedin.jpg

I am finished for tonight. More updates on their way!

Hey Edison,

Thanks for the pics - you do nice work! I'm sure the wire brush will be fine as long as you don't push too hard with it.

Jim

[Edison]

Its been a while, I have neglected the project somewhat, but I have advanced moderately.

The head before it was washed :

http://img.photobucket.com/albums/v444/tideripsurf/Head21.jpg
http://img.photobucket.com/albums/v444/tideripsurf/Head2.jpg

Now the head taken apart and cleaned:
You may notice that the 9 of the valve stem seals were changed, I have to do 7 more.
http://img.photobucket.com/albums/v444/tideripsurf/Headclean2.jpg
http://img.photobucket.com/albums/v444/tideripsurf/Headclean1.jpg


The block looks ugly, but its complete and ready for final assembly!

http://img.photobucket.com/albums/v444/tideripsurf/BlockNov10.jpg

[JDMCRX]

Nice work man :)

[Edison]

So I lapped the valves today (re-seating? reseat?)

anywho here are the pictures:
http://img.photobucket.com/albums/v444/tideripsurf/lappingthevalves.jpg

And here is the valve compressor being used

http://img.photobucket.com/albums/v444/tideripsurf/VavleCompressor.jpg

all finished and looking somewhat clean:

http://img.photobucket.com/albums/v444/tideripsurf/Finishedvavlestop.jpg

http://img.photobucket.com/albums/v444/tideripsurf/finishedvalvesbottom.jpg

I'll move this to the projects section as that's more suitable.

Looks good but you shouldn't use valve lapping compound on modern 4 valve engines. For old school V8's with 2 giant valves it wasn't that bad but the modern stuff is built to such close tolerances that you should have had the valves and seats ground by a guy like Frank.

-Michael

[Edison]

I'll move this to the projects section as that's more suitable.

Looks good but you shouldn't use valve lapping compound on modern 4 valve engines. For old school V8's with 2 giant valves it wasn't that bad but the modern stuff is built to such close tolerances that you should have had the valves and seats ground by a guy like Frank.

-Michael

Yea, if I was an engine builder for a race team that would be reasonable, but spending 250 on rebuilding a stock a6 head was not worth it in my opinion.

And to say that modern stuff shouldn't used valve lapping compound is hearsay. I read all over that it was okay to do, even Frank himself said it would be a cheap alternative. I matched the valves to the seats, and they turned out really nice, imo it looks good and should work perfectly.

I do agree, if you want to build and engine to complete %100 spec, send it off to a shop.

And Frank at mild to wild does a great job!

Edison, did you use assembly lube when putting things together? You know your stuff, but I thought I'd mention it.

[Edison]

Edison, did you use assembly lube when putting things together? You know your stuff, but I thought I'd mention it.
I am using white grease as an alternative.

Oh ok good stuff just thought I'd check :P

[Edison]

Oh ok good stuff just thought I'd check :P :twisted:

There are a few concerns about hand lapping valves. First it wears the valves and seats down - essentially you're putting miles on the engine because it will never wear them at a perfect 45 degree seat angle. It can fix up some minor concentricity problems but most often you end up taking life out of the head.

The second and more important part is cleaning. It's very difficult to wash away all of the valve grinding compound. Make sure you get this part down, and even run a brush through the valve guides as even a splatter of compound will have a very significant effect if it gets into the cylinder.

For the record I have hand lapped my own heads once or twice but for the trouble and results it's more worthwhile to just have the valves ground properly.

-Michael

[speedwerks]

Ive done this rebuild before, thought it was going to be hard but, it was so easy and fun too, looks like a good job man!

[ITR]

So does this thing run or what???

[Edison]

Unfortunately, the engine blew 3 hours after installing it, I had a mastercraft tourq wrench and didn't know how to use it, so I tourqed the botter rod bolts to 8lbs as oppsed to 18lbs as required and through a rod through the block because the lower bolts came loose.l


never again will I build an engine............ unless I have a snap on digital tourq wrench!

[ReStylin]

pjh snap

[ovlov02]

oh fuck dude.

[ovlov02]

vtec sucks eh

[ReStylin]

I hate canadian tire tourq wrenches hoe

[ReStylin]

so does erwan

[Max Powers]

man, tough luck!

Lots of work put into it.

In the end, lesson learned, and if you ever need to do it again it'll be quicker and easier!