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DaX's D16Z6 turbocharger build - older, but maybe not any wiser

DaX's D16Z6 turbocharger build - older, but maybe not any wiser

 
Old 11-01-2018, 04:58 PM
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Default DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Well, it's been nearly 15 years since I was in the turbo Honda game, but I'm back. In 2004 I built a turbo B18A1 (stock bottom end) and put it in a 92 VX that ran 240 whp / 236 wtq. It was tons of fun, but I blew it up within a year, lost the desire to keep spending money on it, and parted it out. I was a poor college student on a tight budget, and it just didn't work out. Since then I have just been throwing the miles on my daily driver - a work-horse 90 Civic DX sedan with a SOHC ZC (non-VTEC) and Si transmission that has 423,000+ miles on it (223,000 of those miles by me). The engine is getting tired, so I was originally just going to rebuild the ZC back to stock, but I ended up buying my sister's 94 Civic EX coupe (single owner), so project car time. I've decided to build the D16Z6 and turbocharge it. My goal is something between a 3-day-a-week car to a daily driver for my 30 mile round-trip commute to and from work, with occasional trips to see family about 150 miles away. Reliability and creature comforts like a full interior and air conditioning are a must. I'll be happy with somewhere around 300 whp on 93 octane (maybe E85?), and my expectations will be exceeded with 350-400 whp.

This will be a 3-phase build to spread out the costs. Phase 1 will be building the engine and transmission to hold high horsepower (doing all the stuff that requires major disassembly), with a goal of having a driveable car at the completion of the phase - built motor and transmission but stock otherwise. Phase 2 will be adding components that will eventually be needed for turbo while the car is driveable. Phase 3 will finally be turbocharging the engine and tuning.

Current State
  • Bottom End
    • D16 block with CSS
    • Eagle H-beam rods
    • CP pistons, 9.0:1 compression ratio
    • ACL Race bearings
  • Cylinder Head
    • Z6 head
    • Ferrea 6000 valves and valve locks
    • Supertech valve springs, titanium retainers, and valve stem seals
    • Comp 59300 cam
    • ARP head studs
    • OEM head gasket
  • Air / Fuel / Engine Management
    • P28 ECU with Hondata S300v3 and boost by gear
    • Hondata 4 bar MAP sensor
    • Go-Autoworks catch can
  • Transmission / Drivetrain
    • S20 EX transmission
    • Competition Clutch Stage 4 (sprung disc)
    • mFactory helical LSD
    • Synchrotech Pro-series carbon synchros
    • HASport mounts
Phase 2 To-Do
  • Bottom End
    • GEM oil sandwich plate purchased
  • Air / Fuel / Engine Management
    • ID1000 fuel injectors purchased
    • PLX wideband purchased
    • GM flex fuel sensor purchased
    • Walbro 450 fuel pump purchased
    • Grams 20 micron fuel filter purchased
    • Aeromotive A1000 FPR purchased
    • Aeromotive fuel pressure gauge purchased
    • GEM fuel rail purchased
    • -6AN engine bay fuel lines purchased
    • GEM vacuum manifold purchased
  • Exhaust
    • 3 inch Thermal R&D cat-back purchased
    • 3 inch test pipe purchased
    • 3 inch catalytic converter purchased
  • Cooling
    • Go-Autoworks dual core radiator purchased
    • SPAL 12-inch radiator fan purchased
    • Go-Autoworks fan shroud purchased
  • Other
    • GlowShift triple A-pillar gauge pod purchased
    • Auto Meter Spek-Pro oil pressure gauge purchased
    • Auto Meter Spek-Pro boost gauge purchased
    • Innovate MTX-D ethanol content gauge purchased
Phase 3 To-Do
  • 3-port MAC solenoid purchased
  • Go-Autoworks SX500 kit
    • Turbonetics TNX 20/60
    • Go-Autoworks cast manifold
    • 3 inch downpipe
    • Tial 38 mm wastegate
    • Tial BOV
    • Go-Autoworks oil & water lines
    • Go-Autoworks charge pipe / couplers / clamps
  • Dyno tuning session
  • Ignition
    • Spark plugs
  • Transmission / Drivetrain
    • Axles
  • Suspension / Wheels
    • Progress coil overs (350/350?)
    • Nitto Neo Gen 195/55/15 tires
    • Rota Slipstream 15x7 42 offset wheels?
So, there's my introduction post for this build. Appreciate any input / guidance the H-T world may have for me, especially regarding turbo choice and manifold choice. Help me not waste $ buying things I don't need, lol.

Last edited by DaX; 03-16-2019 at 05:49 AM.
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Old 11-01-2018, 05:33 PM
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Default Re: D16Z6 build - older, but maybe not any wiser

Originally Posted by DaX View Post
So, there's my introduction post for this build. Appreciate any input / guidance the H-T world may have for me, especially regarding turbo choice and manifold choice. Help me not waste $ buying things I don't need, lol.
welcome back! I just recently made the come back myself, you can see my thread (making my return to the fold) I also have been a site member for many years and I had a very similar setup as you back in the days. Parts are way easier to come by these days!

Last edited by TheShodan; 11-02-2018 at 09:32 AM. Reason: Simplify response
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Old 11-02-2018, 04:03 AM
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Default re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

You're off to a great start. Will this be on 91-93 oct.?
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Old 11-02-2018, 06:45 AM
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Default re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Originally Posted by Autoworks View Post
You're off to a great start. Will this be on 91-93 oct.?
Thanks, and yes, 93 octane is abundant where I live so that's what I plan on running.

A few pointed questions now that I have had some time to think about it since writing the post:
  1. In-tank 320 lph pump should be plenty, correct? Any reason to avoid the AEM or Aeromotive in-tank pumps?
  2. Should I even spend $ on an adjustable fuel pressure regulator? I know I had one on my last turbo build, but can someone explain why the OEM one isn't sufficient?
  3. Will a 2.5 inch exhaust work for my goals, or will it choke the turbo down too much?
Here's my stack of parts so far:


A buddy gave me some parts this week also, a cast turbo manifold and a beat up intercoooler. He said despite the dents, the intercooler doesn't leak. The intercooler is 'JDM Sport' brand, and measures 2.25" thick x 21" long to the tanks, with 2.5" inlet/outlet. He said the manifold should work with AC. Honest opinions - should I ditch either / both of these components for better ones? I've been reading and folks seem to not like the cast manifolds with the WG on the #4 runner, which is what this one is.
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Old 11-02-2018, 06:54 AM
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Default re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Originally Posted by DaX View Post
Thanks, and yes, 93 octane is abundant where I live so that's what I plan on running.

A few pointed questions now that I have had some time to think about it since writing the post:
  1. In-tank 320 lph pump should be plenty, correct? Any reason to avoid the AEM or Aeromotive in-tank pumps?
  2. Should I even spend $ on an adjustable fuel pressure regulator? I know I had one on my last turbo build, but can someone explain why the OEM one isn't sufficient?
  3. Will a 2.5 inch exhaust work for my goals, or will it choke the turbo down too much?
Here's my stack of parts so far:


A buddy gave me some parts this week also, a cast turbo manifold and a beat up intercoooler. He said despite the dents, the intercooler doesn't leak. The intercooler is 'JDM Sport' brand, and measures 2.25" thick x 21" long to the tanks, with 2.5" inlet/outlet. He said the manifold should work with AC. Honest opinions - should I ditch either / both of these components for better ones? I've been reading and folks seem to not like the cast manifolds with the WG on the #4 runner, which is what this one is.
1. Both of those pumps will work fine.
2. I would use a regulator, with the single pump/1000s even the AEM on rail will be sufficient.
3. 2.5" will for for your goal.
4. I would not use that cast manifold; WG position and downpipe clearance on that one both "could be much better". That beat tube and fin FMIC could also be better...
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Old 11-02-2018, 07:00 AM
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Default re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Originally Posted by Autoworks View Post
1. Both of those pumps will work fine.
2. I would use a regulator, with the single pump/1000s even the AEM on rail will be sufficient.
3. 2.5" will for for your goal.
4. I would not use that cast manifold; WG position and downpipe clearance on that one both "could be much better". That beat tube and fin FMIC could also be better...
Thanks for the replies. Sticking with 2.5" exhaust will save a few hundred bucks that can be used elsewhere. Yeah, I'll probably just try to sell the manifold and FMIC and go with something better. I mean, I couldn't turn down free parts, sight unseen.
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Old 11-02-2018, 01:50 PM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Originally Posted by DaX View Post
Thanks, and yes, 93 octane is abundant where I live so that's what I plan on running.

A few pointed questions now that I have had some time to think about it since writing the post:
  1. In-tank 320 lph pump should be plenty, correct? Any reason to avoid the AEM or Aeromotive in-tank pumps?
  2. Should I even spend $ on an adjustable fuel pressure regulator? I know I had one on my last turbo build, but can someone explain why the OEM one isn't sufficient?
  3. Will a 2.5 inch exhaust work for my goals, or will it choke the turbo down too much?
1. That would be more than sufficient; at that flow rate or those brands. If you already have one.. If not, a high pressure Walbro 255 (GSS-342) will also be very good. Cost effective too

2. No need for an adjustable regulator, especially if you'll be running 1000cc injectors. My setup was close to 350 on 750cc and I'm on the stock rail and regulator (40% duty cycle WOT 17 PSI 4th gear @6k RPM).

3. 2.5" exhaust should do fine as well. Mine is 2.75 and didn't **seem** to be a choke point. If 300 is all you're looking for, 2.5 would be sufficient.
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Old 11-07-2018, 02:33 PM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Started pulling the motor today. I'm looking for opinions on running a stock head vs. spending the money now and putting in Ferrea 6000 valves and Supertech springs. Will the stock valves / springs limit me in any significant way below 400 whp?
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Old 11-07-2018, 03:21 PM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Originally Posted by DaX View Post
Started pulling the motor today. I'm looking for opinions on running a stock head vs. spending the money now and putting in Ferrea 6000 valves and Supertech springs. Will the stock valves / springs limit me in any significant way below 400 whp?
Not particularly, no. The Z6 springs are pretty stout actually. If you're running the stock cam and rev limit, they'll be fine.
I am IMPRESSED with the strength of the stock valves. I had recently installed a comp cam and my timing belt slipped a couple teeth. Valves contacted pistons (i later discovered) I cracked 2 of the pistons; in fact the only 2 that contacted valves, and the valves came out unscathed. There is also tons of folks that have ran a comp 59300 cam on stock Z6 springs with no troubles. Lots more that have revved to 7500 and beyond. I'd vote upgraded springs if you intend on running over stock revs with a cam though, just for good measure. The Ferrea 6000 are a good choice to upgrade if you choose to do so. Either OEM or Ferrea 6k are good for your goal.

On another note, I have an extra comp 59300, brand new in box, if you're interested!
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Old 11-07-2018, 04:14 PM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

​​​​​​
Originally Posted by Txdragon View Post
Not particularly, no. The Z6 springs are pretty stout actually. If you're running the stock cam and rev limit, they'll be fine.
I am IMPRESSED with the strength of the stock valves. I had recently installed a comp cam and my timing belt slipped a couple teeth. Valves contacted pistons (i later discovered) I cracked 2 of the pistons; in fact the only 2 that contacted valves, and the valves came out unscathed. There is also tons of folks that have ran a comp 59300 cam on stock Z6 springs with no troubles. Lots more that have revved to 7500 and beyond. I'd vote upgraded springs if you intend on running over stock revs with a cam though, just for good measure. The Ferrea 6000 are a good choice to upgrade if you choose to do so. Either OEM or Ferrea 6k are good for your goal.

On another note, I have an extra comp 59300, brand new in box, if you're interested!
Thanks for the input. I'd rather spend the $ elsewhere, but don't want to regret not doing it while the head is off the car. For now I'll just roll with the stock setup. I came home this evening to my ECU being back from Hondata - I sent it in to be recapped. I should have the engine out tomorrow night - all that's left are axles, shift linkage, and exhaust.

Thanks for the offer on the cam - PM me some details. Honestly though, unless it's a killer deal, I don't think I'll jump on it right now. I've got $ flying all over the place and want to get a running engine back in the car before I start buying "nice to haves", if you know what I mean.


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Old 11-07-2018, 04:19 PM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Originally Posted by DaX View Post
​​​​​​

Thanks for the input. I'd rather spend the $ elsewhere, but don't want to regret not doing it while the head is off the car. For now I'll just roll with the stock setup. I came home this evening to my ECU being back from Hondata - I sent it in to be recapped. I should have the engine out tomorrow night - all that's left are axles, shift linkage, and exhaust.

Thanks for the offer on the cam - PM me some details. Honestly though, unless it's a killer deal, I don't think I'll jump on it right now. I've got $ flying all over the place and want to get a running engine back in the car before I start buying "nice to haves", if you know what I mean.
If you can swing it for the valves, I would honestly say do it now. After you build everything, you'll cuss and fuss at EVERY notion of tearing it all down unless it's absolutely necessary. Lol! Ferrea F6067 and F6068 are the ones you'll want and they range from about 240 and up for all of them.
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Old 11-07-2018, 04:30 PM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Do OEM keepers work with Ferrea 6000's, or do you have to upgrade to the Ferrea keepers too?
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Old 11-07-2018, 04:47 PM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

That one I don't quite have the answer to. From my understanding, stock keepers will work fine, just get some new ones if they're seriously aged.
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Old 11-08-2018, 03:50 AM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Originally Posted by DaX View Post
Do OEM keepers work with Ferrea 6000's, or do you have to upgrade to the Ferrea keepers too?
I know for a fact OEM keepers will work with the b-series Ferrea 6000 valves (I know because I'm going to be using the 6000s in my GSR head for my turbo project, and Shodan confirmed they would work). I'm not 100% sure about d-series valves though, but I would assume they would too.

Glad to see even more people getting back into the Honda scene! Looks like we have several good builds going on the forums now!
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Old 11-08-2018, 05:12 AM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

I would personally use the Ferrea Keepers especially since they cost like $70 bucks or something.
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Old 11-08-2018, 08:08 AM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Well, I went ahead and spent the $ on the head now. Ferrea 6000 valves and keepers, Supertech seals, springs, and retainers.
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Old 11-08-2018, 08:19 AM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Originally Posted by DaX View Post
Well, I went ahead and spent the $ on the head now. Ferrea 6000 valves and keepers, Supertech seals, springs, and retainers.
Woohoo! No AC for you either? You'll like the extra room that frees up!
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Old 11-08-2018, 08:26 AM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Originally Posted by Txdragon View Post
Woohoo! No AC for you either? You'll like the extra room that frees up!
AC is a creature comfort I must have! I am doing this build to retain AC.
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Old 11-08-2018, 08:54 PM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Good choices on the head parts. You will be glad you did it.
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Old 11-09-2018, 03:08 AM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Here we go - engine/tranny out and torn down to the long block. My daughter is going to be an integral part of this project.

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Old 11-09-2018, 03:58 AM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Awwwww yeah! Let the fun begin!
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Old 11-09-2018, 08:13 AM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

That head looks like some miles have been on it. Lol Looking forward to see your progress
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Old 11-09-2018, 03:28 PM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Finished tearing the block down this evening. I'll package it up in the morning and ship it off for CSS. Also hoping to get the valve cover and oil pan cleaned and boxed up in the morning to send off for modification.
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Old 11-09-2018, 04:09 PM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Can't wait to see the block after CSS!
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Old 11-10-2018, 09:32 AM
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Default Re: DaX's D16Z6 turbocharger build - older, but maybe not any wiser

Block, oil pan, and valve cover are in the mail. I figured I'd start working on getting the LSD installed in the transmission today and ran into my first snag. I'm running into issues with the OEM bolts being tight when threading into the LSD, like it's the wrong pitch threads. Also, it appears that the heads of the bolt are in contact with the body of the LSD when they start threading in. I have verified that the bolts are still tight in all the holes when trying to thread them in from the back side of the LSD, to ensure it isn't just the heads of the bolts contacting the body of the LSD that's making them tight. Yes...I know they are left hand threaded. Is there something I'm missing here? I've reached out to OBX, and am waiting to hear back from them.
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