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that clean-ass block and you didn't take 5 minutes to spray the alt bracket black?
 
Discussion starter · #62 ·
that clean-ass block and you didn't take 5 minutes to spray the alt bracket black?
Probably should have though of that.

I did think about painting the block, but the overall goal for the project, besides being a learning experience, is (hp / weight) / ($ spent).

I haven't put any money directly into aesthetics yet.
 
Discussion starter · #63 ·
Went to pick and pull to scavenge the missing components from another 96 honda with a d16y7.

Somehow, coolant plug doesn't fit.
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I have no idea where to find this thing. I might try to borrow a die set so I can figure out what size the threads are.


Also took a knock sensor from a 96 EX. Turns out that also doesn't fit :(

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If I am under my hood this weekend, I will see about snapping pictures of what the back of my 97 Y7 block looks like. We shall see if I can get any info with it in the car.


Very strange that 96 stuff didnt work.


Does your block show sings of possibly being modified at all? That big hole looks like it has fresh threads in it
 
Discussion starter · #65 ·
If I am under my hood this weekend, I will see about snapping pictures of what the back of my 97 Y7 block looks like. We shall see if I can get any info with it in the car.


Very strange that 96 stuff didnt work.


Does your block show sings of possibly being modified at all? That big hole looks like it has fresh threads in it


No, it was stock when I got it. Front of the block is stamped d16y7 from the factory, definitely had a y7 head.

The block is very clean (less than 45k miles)

Anything you find would be great
 
Went to pick and pull to scavenge the missing components from another 96 honda with a d16y7.

Somehow, coolant plug doesn't fit.
Image


I have no idea where to find this thing. I might try to borrow a die set so I can figure out what size the threads are.


Also took a knock sensor from a 96 EX. Turns out that also doesn't fit
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That second picture your trying to thread the oil pressure sending unit into the knock sensor threads go down to the left side of the oil filter . And as far as the block coolant plug and pre 95 blocks that same plug is on the front and 96 and up is on the back
 
Discussion starter · #67 ·
That second picture your trying to thread the oil pressure sending unit into the knock sensor threads go down to the left side of the oil filter .
hah, well that explains that.

I've even got a new pressure sender sitting on the shelf. Can't believe I didn't recognize it.

I'll probably find a bolt to thread in the knock sensor. IIRC, the d16y7 does not use a knock sensor.



And as far as the block coolant plug and pre 95 blocks that same plug is on the front and 96 and up is on the back
That is some fantastic info! There are plenty of older civics I can pull this from.
 
Discussion starter · #68 ·
. And as far as the block coolant plug and pre 95 blocks that same plug is on the front and 96 and up is on the back
Right on the damn front of the block. This one in the junk yard even had the exhaust manifold already taken off. 45 second job to get it totally undone.

Cleaned it with carb cleaner overnight. Still a bit grimy, but I might just deal with it.

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Next up are fuel hoses and electrical. Hoping I can get to those this weekend
 
+1 on diesel

Used that trick to clean quite a few motors. Especially if you can afford a few days downtime and your engine is super sludgy[inside]. drain oil, pour diesel in oil cap hole til nearly overflowing, let sit 24-48 hours, yank drain plug, let drain a good half hour or so, fill with cheapass oil to oil cap, turn engine over by hand slowly a few times to prime oil system, drain, perform cheap oil change and filter, idle engine til fully warm, perform another cheap oil service, and bam, sparkly clean engine ready to be back on regular intervals.
 
Nice build, can I ask how you came to the decision of 75.5 pistons? I have the option to order 75 or 75.5, I know 75.5 requires getting a machinist to bore the block, and 75mm doesn't, Wouldn't be a problem besides they're's not really anywhere in Ireland that will bore a block for a reasonable price. All advice appreciated.
 
Nice build, can I ask how you came to the decision of 75.5 pistons? I have the option to order 75 or 75.5, I know 75.5 requires getting a machinist to bore the block, and 75mm doesn't, Wouldn't be a problem besides they're's not really anywhere in Ireland that will bore a block for a reasonable price. All advice appreciated.
The reason why you want 75.5 is so you can set the proper piston to wall clearance. With 75mm pistons your clearance is likely to be too large which will cause piston slap and excessive blow by.
 
The reason why you want 75.5 is so you can set the proper piston to wall clearance. With 75mm pistons your clearance is likely to be too large which will cause piston slap and excessive blow by.
depends on seller/supplier of vitara pistons.

people grabbing the suzuki set of "75mm" is actually 74.9mm.

Sellers who supply honda style vitaras are actually matching to honda 75mm bore.


Either way, if poistons are coming out and being replaced, you need to freshen up the bore.


Unless people like blowby? shitty ring seal? ovalled bores?
 
Discussion starter · #74 ·
Nice build, can I ask how you came to the decision of 75.5 pistons? I have the option to order 75 or 75.5, I know 75.5 requires getting a machinist to bore the block, and 75mm doesn't, Wouldn't be a problem besides they're's not really anywhere in Ireland that will bore a block for a reasonable price. All advice appreciated.
DJ pretty much nailed it:

The reason why you want 75.5 is so you can set the proper piston to wall clearance. With 75mm pistons your clearance is likely to be too large which will cause piston slap and excessive blow by.
In order to ensure the right size for the p2w clearance, I gave a machine shop the block, crank, pistons, and rods.

The bigger reason I went with a shop was for them to inspect and micrometer the crank for bearing fit before I bought them, but I'd also heard it was smart to have them bore over anyway, as mattliston pointed out.

I also had the deck resurfaced (turns out it was nearly perfect)

Since I had it completely apart and at the shop, I paid them to bore it over half a mil, set the p2w, and hone it.

It was almost painful to hand them the block, which still had clearly visible cross hatching from the factory hone, to be bored and re-honed
 
Discussion starter · #75 ·
Couple more trips to pick n pull for some various hoses and to reference existing engines. Got the wiring harness and coolant and vacuum lines on.

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Thinking about doing flywheel, clutch, transmission today.

I've got a brand new performance clutch, but not sure if I need to resurface this flywheel; its stock with few miles on it, and the original machining looks good. Stock bearing, too.

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If there was no issues before the tear down and the surface looks good I would run it. Doesnt look like you have any hot spots or anything either, just a little dirty.
 
If you have a few spare bolts the same thread, grind a v shape on the end, like a notch, and just run it through each hole to double check threads are clean.

brake-clean the flywheel, and give it a good eyeball inspection.

It looks good from the pictures though


Any articular reason you are not thinking about a lightweight flywheel? or is this a get it going type of scenario?
 
the cheapo 12 pound flywheels off of ebay work well, just I would recommend having the balance checked at a shop, or at least balanced to 10k+ rpm.

time crunch or not, doing it ONCE is better than having to come back to it if rushing it
 
Discussion starter · #80 ·
the cheapo 12 pound flywheels off of ebay work well, just I would recommend having the balance checked at a shop, or at least balanced to 10k+ rpm.

time crunch or not, doing it ONCE is better than having to come back to it if rushing it
I'll be getting the car moving under its own power and emissions tested. I actually am moving at the end of the month and would prefer not to tow it out. A new flywheel might be a future option
 
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