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Old 04-27-2012, 09:41 PM   #1
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Default D16Z6 Engine Rebuild (pictures)

Hope this helps someone out. I'm rebuilding this engine for my co-worker, and decided to do a general step by step. So here it goes......


Here is the block tore down and I decided to hone it a little to break the shine in the cylinder walls.
Click the image to open in full size.

Before
Click the image to open in full size.

I'm just using a basic honing tool I picked up at harbor freight. I'm using mineral oil while doing the honing. Remember your not trying to bore out the block, just break the glaze and put a nice cross hatch.
Click the image to open in full size.

After
Click the image to open in full size.

When you finish with all the cylinders, clean the block inside and out really good with warm soapy water, rinse and blow or air dry. But make sure you wipe down the cylinder walls with oil or WD40 to keep them from rusting.
Now once dry you can set in your new main bearings as shown. NOTE: On this particular block I chose to run with a standard set of KING engine bearings as the crank and rods have never been damaged. You have the option to rung OEM bearings in your engine, there are codes on the inside edge of the block in the flywheel area and codes on the crank and rods. Here is a honda chart for this.
Click the image to open in full size.
Click the image to open in full size.

Now we can set the crank in place so we can check the main bearing clearances. make sure the bearings are dry and DO NOT rotate the crank while you do this.
Click the image to open in full size.

Cut and set all 5 plasti-gauge strips on each main journal.
Click the image to open in full size.

Install the upper main bearings and install the housing.
Click the image to open in full size.

Install the main bolts, and dip the threads in clean oil.
Click the image to open in full size.

Tightening sequence
Click the image to open in full size.

step#1 32ftlbs Step#2 53ftlbs
Click the image to open in full size.

Remove cradle and check the clearances. All 5 of mine came in perfect at .0014"
Click the image to open in full size.

Now we will check each rod bearing clearance. cut and lay down your plasti-gauge on the rod journal
Click the image to open in full size.
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Last edited by CaliforniaDad; 04-28-2012 at 06:19 AM.
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Old 04-27-2012, 10:05 PM   #2
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Default Re: D16Z6 Engine Rebuild (pictures)

Install the new rod bearings.
Click the image to open in full size.

when you slide the piston on to the bore make sure the arrow is facing the timing belt side of the motor. no ring will be installed on the piston at this time. be careful when your installing not to scratch anything.
Click the image to open in full size.

Tighten the rod bolts to 23ftlbs.
Click the image to open in full size.

Remove the cap and check the clearance. All 4 of my rods cam out right at .0015"
Click the image to open in full size.

Once all 4 are done remove the crank and rotate the engine over so we can check ring end gap now.
Click the image to open in full size.
Click the image to open in full size.

Install your top ring and make sure any markings on the ring are facing up.
Click the image to open in full size.

Use the piston to push the ring down square in the block as I did here.
Click the image to open in full size.

Use a feeler gauge to check the ring end gap. I was shooting for .012"
Click the image to open in full size.
Click the image to open in full size.

Now check the 2nd ring, here is a closeup of the marking on the ring that needs to be facing up.
Click the image to open in full size.

Check the gap with the feeler gauge as well. I was going for .018"
Click the image to open in full size.
Click the image to open in full size.

Now check the oil control rings. mine came in at .025"
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.

Now that we checked all the rings, lets install them on each piston as shown here.
Click the image to open in full size.

Make sure and coat each piston with fresh oil and do the same for each cylinder bore. I used a basic ring compressor here.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.

Now rotate the block over and lets lube up all the bearing surfaces so we can set in the crankshaft.
Click the image to open in full size.
Click the image to open in full size.

Install your thrust bearings with the notches facing out.
Click the image to open in full size.

Install the crankshaft
Click the image to open in full size.

Slide each rod in place and tighten to 23ftlbs
Click the image to open in full size.

Once all rods are tightened down, install the crank cradle
Click the image to open in full size.

Tighten to spec, step#1 18ftlbs step#2 38ftlbs
Click the image to open in full size.

Apply a little sealant to your new oil pump as shown. Install the oil pump and the oil pump pickup. make sure you use a fresh gasket on the pickup. Just hand tighten snug but do not over do it.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
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Last edited by CaliforniaDad; 04-28-2012 at 06:28 AM.
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Old 04-27-2012, 10:09 PM   #3
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Default Re: D16Z6 Engine Rebuild (pictures)

Damn **** load of pics popped.

Thanks for sharing. I'm bookmarking this in case I get mine rebuilt.

Thanks again
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Old 04-27-2012, 10:17 PM   #4
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Default Re: D16Z6 Engine Rebuild (pictures)

Great job.
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Old 04-27-2012, 10:18 PM   #5
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Default Re: D16Z6 Engine Rebuild (pictures)

apply a little sealant to the rear main seal housing as shown here. And install the cover. Snug up all 4 10mm bolts
Click the image to open in full size.
Click the image to open in full size.

Now flip the engine over and install your clean oil pan with a fresh gasket. I just hand tighten the bolts here. maybe 9ftlbs
Click the image to open in full size.

Install oil filter.
Click the image to open in full size.

Install your water pump tube, make sure you use new rubber seals. you dont want these to leak after its installed.
Click the image to open in full size.

Install the thermostat housing with thermostat installed.
Click the image to open in full size.

Install your PVC box as shown. apply a little sealant to the rubber gasket and slide into block.
Click the image to open in full size.

Install your fresh new water pump, making sure your gasket is in place.
Click the image to open in full size.

Install your dowl pins in the top of the block.
Click the image to open in full size.

Now set your head gasket in place. I used a light high temp copper spray on mine to help seal any imperfections in the head block surface.
Click the image to open in full size.

Time to install the freshly rebuilt head, This head has been surfaced for flatness, 3 angle valve job and new valve stem seals installed. My block was true and flat. Make sure your block and head are flat!! if not have it decked and or resurfaced.
Click the image to open in full size.
Click the image to open in full size.

Install your headbolts and make sure you coat the threads and washers in fresh oil.
Click the image to open in full size.

tighten the headbolts step#1 32ftlbs step#2 53ftlbs
Click the image to open in full size.
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Last edited by CaliforniaDad; 04-28-2012 at 06:10 AM.
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Old 04-27-2012, 10:40 PM   #6
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Default Re: D16Z6 Engine Rebuild (pictures)

Niceee
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Old 04-27-2012, 10:58 PM   #7
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Default Re: D16Z6 Engine Rebuild (pictures)

good write up
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Old 04-27-2012, 11:16 PM   #8
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Default Re: D16Z6 Engine Rebuild (pictures)

Ok I did this a few times on a A6 first and then on a Z6... There is one critical part you forgot.. You can toss away that plasti gauge bs **** away... Its a waste of time.. On the side of your z6/a6 or any honda block where the flywheel is there is capital letters and on the crank you use of this engine block there are # or its the other way around but what you do is go to honda dealer and get the bearing code list paper they have it and it tells you how to order new bearings for your honda engine if you use the right color bearing and I highly stress that all you guys rebuilding engines should use oem honda bearings the aftermarket **** is not as accurate and is inferrior to oem honda bearings.. John Deere tractors use the same bearings as honda and they are also coated the same way.. I have used a ACL crank and bearing kit on a A6 and it failed horribly.. USE OEM HONDA BEARINGS ONLY.... It will cost you around 200$ for all bearings but its well worth it.. SO use them codes and get your z6 or other honda engine built the right way.. Its all ready measure so all you need is the right color.. Bearing are cheaper for the D16Y engines because they are much newer the Z6/A6 bearings cost the same.. Unless you work at honda and you can do what you want..
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Old 04-27-2012, 11:20 PM   #9
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Default Re: D16Z6 Engine Rebuild (pictures)

Also want to add since its all torn apart you should of got the head decked and the block expecially if you are going to turbo the car or N/A.
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Old 04-28-2012, 03:53 AM   #10
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Default Re: D16Z6 Engine Rebuild (pictures)

NICE WRITEUP, seems like one or two of your pics don't match the description, of course I might be crazy. Pic #8 and #38 don't seem to match the description. #8 shows replacing the water pump and #38 shows replacing the oil breather box.
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Old 04-28-2012, 04:11 AM   #11
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Default Re: D16Z6 Engine Rebuild (pictures)

Somebody put this in the FAQs!!!
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Old 04-28-2012, 04:29 AM   #12
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Default Re: D16Z6 Engine Rebuild (pictures)

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Somebody put this in the FAQs!!!
Just did.

Very helpful California Dad
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Old 04-28-2012, 06:24 AM   #13
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Default Re: D16Z6 Engine Rebuild (pictures)

Quote:
Originally Posted by nihad View Post
Ok I did this a few times on a A6 first and then on a Z6... There is one critical part you forgot.. You can toss away that plasti gauge bs **** away... Its a waste of time.. On the side of your z6/a6 or any honda block where the flywheel is there is capital letters and on the crank you use of this engine block there are # or its the other way around but what you do is go to honda dealer and get the bearing code list paper they have it and it tells you how to order new bearings for your honda engine if you use the right color bearing and I highly stress that all you guys rebuilding engines should use oem honda bearings the aftermarket **** is not as accurate and is inferrior to oem honda bearings.. John Deere tractors use the same bearings as honda and they are also coated the same way.. I have used a ACL crank and bearing kit on a A6 and it failed horribly.. USE OEM HONDA BEARINGS ONLY.... It will cost you around 200$ for all bearings but its well worth it.. SO use them codes and get your z6 or other honda engine built the right way.. Its all ready measure so all you need is the right color.. Bearing are cheaper for the D16Y engines because they are much newer the Z6/A6 bearings cost the same.. Unless you work at honda and you can do what you want..
I understand, but my customer did not want go use OEM honda bearings for 2 reasons.

#1 Price
#2 Just about all the bearings were on a long back order.

The standard king bearing are pretty close to honda green bearings. All my clearances ended up right in the middle of factory spec's. I feel more than confident that this engine will last a long time.


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NICE WRITEUP, seems like one or two of your pics don't match the description, of course I might be crazy. Pic #8 and #38 don't seem to match the description. #8 shows replacing the water pump and #38 shows replacing the oil breather box.
I'm not sure what your talking about I looked at the pictures and they match the text. Let me know again what you see.
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Old 04-28-2012, 08:02 AM   #14
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Default Re: D16Z6 Engine Rebuild (pictures)

More to come here shortly
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Old 04-28-2012, 08:04 AM   #15
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Default Re: D16Z6 Engine Rebuild (pictures)

Excellent resource. Will be using this for my engine build if I ever get around to it. The only issue I have is I'm not clear on where exactly the thrust washers go. But I'm sure when I'm ready I can Google it.
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Old 04-28-2012, 08:22 AM   #16
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Default Re: D16Z6 Engine Rebuild (pictures)

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Excellent resource. Will be using this for my engine build if I ever get around to it. The only issue I have is I'm not clear on where exactly the thrust washers go. But I'm sure when I'm ready I can Google it.
Right here. This is my b18c5 but d series is the exact same, couldnt take a pic of the d17a2 im rebuilding cuz its already assembled

Click the image to open in full size.
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Old 04-28-2012, 08:43 AM   #17
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Default Re: D16Z6 Engine Rebuild (pictures)

That's where I thought. Thanks. Everything else is laid out pretty clear so far. Top notch!
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Old 04-28-2012, 09:22 AM   #18
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Default Re: D16Z6 Engine Rebuild (pictures)

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Originally Posted by CaliforniaDad View Post
I understand, but my customer did not want go use OEM honda bearings for 2 reasons.

#1 Price
#2 Just about all the bearings were on a long back order.

The standard king bearing are pretty close to honda green bearings. All my clearances ended up right in the middle of factory spec's. I feel more than confident that this engine will last a long time.




I'm not sure what your talking about I looked at the pictures and they match the text. Let me know again what you see.
I understand they are price even compared to the D16y oem honda bearings but because the a6/z6 and other obd0/1 engines are older thats why the price is just about doubled.. Would sure be nice if oem honda's would sell them for less.. its a markup.. Also there is no way that the king/acl bearings have the same quality.. The rods on a z6 are usually all green but the mains are brown/black but still you dont know in what order with out doing the code's and I know that you dont have the tools to measure it that acuratly I went to school for machining and I had a hard time measure those clearances/bores on the block.. used telescoping gauge..micrometers.. Hondaa used CMM to measure this acuratly thats why they have the codes so you dont have to measure nothing.. Hope it last a long time either way.. But after 5k take the oil pan off and check it out.... After I rebuilt my Z6 I took it apart later the next year and went threw the hole engine to make sure it all looked good and it did..
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Old 04-28-2012, 11:05 AM   #19
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Default Re: D16Z6 Engine Rebuild (pictures)

nice write up! i learned a lot
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Old 04-28-2012, 07:57 PM   #20
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Default Re: D16Z6 Engine Rebuild (pictures)

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Hope it last a long time either way.. But after 5k take the oil pan off and check it out.... After I rebuilt my Z6 I took it apart later the next year and went threw the hole engine to make sure it all looked good and it did..
Will do. thanks for the tips
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Old 04-28-2012, 11:04 PM   #21
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Default Re: D16Z6 Engine Rebuild (pictures)

Okay the next thing we need to do is install the camshaft. But before you do that remove the camshaft gear and install a new camshaft seal.
Click the image to open in full size.

Now lets coat all the surfaces with assembly lube.
Click the image to open in full size.

Put a thin layer of sealant here for the cam seal.
Click the image to open in full size.

Lay in the camshaft and lube all lobes as shown.
Click the image to open in full size.
Click the image to open in full size.

Don't for get the oil control O-ring here.
Click the image to open in full size.

Install the upper half of the valvetrain
Click the image to open in full size.
Click the image to open in full size.

Here is the tightening sequence
Click the image to open in full size.

The 8mm bolts 18ftlbs and the 6mm bolts snug hand tight, or 8ftlbs
Click the image to open in full size.
Click the image to open in full size.

I like to use a little Gask-a-sinch on new seals, helps them stick in place. Now install the vtec solenoid.
Click the image to open in full size.
Click the image to open in full size.

Install the remaining sensors into the head.
Click the image to open in full size.
Click the image to open in full size.

Water neck and gasket installed next. I used gascasinch here as well.
Click the image to open in full size.
Click the image to open in full size.

Install your intake manifold gasket, I used gascasinch here on both sides.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.

here is the product im using.
Click the image to open in full size.

Install your intake manifold.
Click the image to open in full size.
Click the image to open in full size.

Hook up your PVC and water lines.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.

I forgot to install the timing cover before I dropped in the camshaft, So I just removed the cam-gear and re-installed the cover as shown.
Click the image to open in full size.

Install your timing belt tensioner pulley.
Click the image to open in full size.

Install your inner timing belt washer and timing gear.
Click the image to open in full size.
Click the image to open in full size.

Now line up the cam gear on TDC as shown, as well as line up the crank gear at TDC.
Click the image to open in full size.
Click the image to open in full size.

Install your timing belt like this, #1 crank #2 tensioner #3 water pump #4 cam gear. then rotate the cam 3 theeth to set tension on the belt, now tighten up the tensioner pulley bolt.
Click the image to open in full size.
Click the image to open in full size.

Now we can adjust the valves. rotate the engine over to TDC #1. The adjustment will go like this. #1 then #3 them #4 then #2
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.

I'm using this valve adjustment tool that works great on honda heads.
Click the image to open in full size.

Starting with number 1 cyl, im setting the lash at .008" and the exhaust at a .010"
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.

Once you have both intake and exhaust adjusted on cyl #1 rotate the crank as shown so you can do cyl #3
Click the image to open in full size.
Click the image to open in full size.

Same for Cyl #4
Click the image to open in full size.

Then Cyl #2
Click the image to open in full size.
Click the image to open in full size.

Now install your valve cover gaskets and grommets. I also used a little gaskasinch on the gasket and the head.
Click the image to open in full size.
Click the image to open in full size.

Don't forget a lil dab of sealant on the corners of the gasket at each curved point
Click the image to open in full size.


Now install the upper timing cover just under the valve cover as shown.
Click the image to open in full size.


Tighten the bolts on the timing cover and the valve cover. I just did then hand tight "snug"
Click the image to open in full size.
Click the image to open in full size.

Install the crank pulley key and timing belt gear washer. Then install the lower part of the motor mount. 2 14mm bolts to 38ftlbs
Click the image to open in full size.
Click the image to open in full size.

Install the lower timing cover and all the bolts hand tight.
Click the image to open in full size.


Install the crank pulley and crank pulley bolt. 134ft lbs
Click the image to open in full size.
Click the image to open in full size.

You can install the alternator and all the alternator brackets.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.

Install your exhaust manifold gasket. I prayed mine in a ultra high temp copper spray.
Click the image to open in full size.

Install your exhaust manifold and cover as shown. (hand tight)
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Click the image to open in full size.
Click the image to open in full size.

Install the power steering mounting bracket.
Click the image to open in full size.


Lets get it off the engine stand so we can get the flywheel and clutch installed before we attached the trans.
Click the image to open in full size.


Install the flywheel and apply a little blue lock tight on the bolt threads, tighten to 87ft lbs
Click the image to open in full size.

Install the clutch using a honda alignement tool. tighten the bolt to 22ft lbs
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.

Install your transmission and tighten all the bolts to factory spec.
Click the image to open in full size.


Now is a good time to install the engine wiring harness.
Click the image to open in full size.

Lets get the bad boy stuffed back in the car.
Click the image to open in full size.

All the next pictures are just hooking up all the remaining item to the engine.
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Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.

The rest is just hoses and vacuum lines ect ect.

Well here it is!!! Sounds and runs so smooth. Not a leak in sight and smooth as a baby butt.
http://www.youtube.com/watch?v=Cr347...ature=youtu.be
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Last edited by CaliforniaDad; 05-17-2012 at 05:39 PM.
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Old 04-29-2012, 12:03 AM   #22
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Default Re: D16Z6 Engine Rebuild (pictures)

great write up
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Old 04-29-2012, 04:23 PM   #23
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Default Re: D16Z6 Engine Rebuild (pictures)

gonna be cracken VTEC like a CHAMP. (well ...Sohc vtec )
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Old 04-29-2012, 04:49 PM   #24
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Default Re: D16Z6 Engine Rebuild (pictures)

Very nice write up. Came out great.
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Old 04-29-2012, 05:02 PM   #25
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Default Re: D16Z6 Engine Rebuild (pictures)

Thanks! the Vtec on this engine doesn't seem to "hit" very hard. you can hardly feel it.
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