I have the engine out of car(D16y7) I’m doing a swap because the existing engine was knocking. Bought a used engine on FB from a guy and did a leak down test on it. Everything was fine until I replaced the head gasket, water pump and timing belt. I follow all the steps I have it all set to TDC On the crank and the camshaft. Belt is on tensioner pulley is on but not tightened. I rotate the engine counterclockwise 3 teeth on the cam gear with my hand on the top of the cam gear and belt. Tension is good so I tighten the tensioner in place and rotate the engine counter clockwise until it’s back at TDC(crank and cam). I do a leak down test and cylinder 1 is less that 10% leakage but the rear of the cylinders are 20% leakage or more at the top of their compression stroke.

Could I have damaged something while cleaning the cylinder head off from gunk? I was extra careful and worked on a layer of cardboard. I’m noticing the leak from the exhaust side of the engine so it’s the exhaust valves. I assumed timing was off but I checked timing countless times and tension.

Any ideas??

 

Is it OEM gasket or aftermarket?

 

it’s an aftermarket gasket. Cleaned all surfaces well and carefully from previous gasket.

 

I just remembered that I had some trouble installing the headgasket. I wasnt sure which way the gasket needed to face. There were no up or down indicators. I flipped a few times and realized that it only lined up with the wholes one way. So I installed it that way.

 

Check the valve lash

 

Could moving and cleaning the head off of the block, mess with the valve lash? Also why is cylinder 1 perfect? Either way ill check valve lash and get back to you!

 

How did you clean the surface? Chemical? Scotchbrite wheel?

 

I checked the valve lash on exhaust and intake valve's. (Intake .20 Exhaust .25) mostly all good cylinder 1 was a little tight and cylinder 3 on the intake side needed loosening. Everything else looked good. ran a leak down test again while I was at it. Cylinder's 2, 3, & 4 still leaking more than 20 percent. Cylinder 4 is really bad. Cylinders 2 and 4 leak on the exhaust side and 3 leaks on the intake side. Could a poorly installed Head Gasket cause these leaks through the intake/exhaust ports?

Punk0mi, I used a razor blade scraper than some fine steel wool to clean on the surfaces. The head was incredibly smooth and I was somewhat impressed as to how smooth it felt to the touch. I spent a lot of time cleaning it carefully. I installed the new head gasket on and new head bolts. I did see a small gouge on the block but nothing that concerned me. It looked as if a dowel pin struck the block at some point in the past.. I also replaced the Cam Shaft Seal and Crank Seal. All torqued properly and in the correct pattern, checking the 2 center head bolts one last time after everything else was torqued in the right pattern. Mind you the manual transmission is mated to the engine now. I highly doubt its a timing issue. I've quadruple checked it by now and even redone it completely. tension feels great.

Sorry for overloading with info. Just trying to give a step by step as to what I've done. Please let me know if you have any ideas. Considering taking the head off again and installing a new head gasket after checking the valves. IDK WHAT TO ELSE TO DO!

 

Just sell it and order a low JDM replacement they are not that much! price has gone up since the last 3 years, i paid $650 for thes swap a couple years ago and another one for about $850 around 2 years ago. Now its about $1000 but this place has healthy swaps and are well known. Fallow their IG for new products and goodies they get in.

This swap all you need is your original harness and just swap the entire intake manifold and distributor from the original engine and then perform the CFK bypass which is super easy and it will run perfect!

.:FFS TechNet : CKF Bypass Trick :. (ff-squad.com)


96-99 ZC / D16A SOHC Long Block (Non VTEC) [ITEM NUMBER 30023] – HMotorsOnline

 

Update! The head was bad. Replaced the head with the head off the old block. Did a good cleaning and installed on the block. Timing set and all the cylinders are within 5% or less on their top compression stroke. Not sure what the problem was i really have no clue but noticed a chipped piece of metal fell out when i took the head off. I could have damaged it somehow when i initially took it off. I do know it was just fine before i replaced the head gasket. Oh well. All good now!

Thank you all for your help!