My First Rebuild Y7/Z6

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My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:13 am

Sup Guys and Gals,
I'm pretty pumped up about this build and wanted to document it to the best of my abilities. If it wasn't for the net and all the info left behind by others I wouldn't have been able to do anything like this. So Thankz !

When I got this car (1995 VX) 3 years ago the only toolz I owned were made up of the bare home basics; a Hammer, couple screw drivers, vice grips, pliers, and 4 of those $5-$10 socket sets that everyone gets you for Christmas. I'm not a complete stranger to having to work on a car (poor folk do what that gotta do) but I never thought I'd attempt to rebuild an engine.

The reason for the build is mostly to get the engine(D15Z1) thats in my car now out. I want to rebuild the Z1 later. So why didn't I just do a quick swap with a used motor do ya ask, cause I can't stand the idea of putting someone else's POS motor in my car and just cross my fingers. Another thing is I was fed up and got sick of mechanics saying "Naw, I don't know nuttin bout dem dere Jap motors". So fine, SCREW THAT I say, I'll learn to do it myself!

The Goal is simple:
Build a reliable All Motor D-series with a lil bump in hp. This engine will be for a fun DD only and if it ever sees auto-x then cool. I just want to know I built it and it worked.
I started buying parts for this rebuild July 2010

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EDIT 7/26/2011: ^^^It's a nice story so I'll leave it unchanged (but things do change). A week ago today I bought a 1997 Del Sol S, D16Y7 w/ 138k miles, everything stock with A/C. Needing the extra cash I decided to sell the hatch, it was almost a hard decision. But the engine build goes on and will become apart of the new DD. The build continues.....[/i][/b]


:::WARNING!!!::: User name Zen Chameleon is building his first ever engine, this said engine is not running yet. Asking user name Zen Chameleon for help could cause any or all, but not limited to:
headaches, frustration, blurred vision, dizziness, confusion, loss of sleep, constipation, diarrhea, projectile vomiting, bloody knuckels, unnecessary work and research, catastrophic engine failure, crying in front of your girlfriend, cronic masterbation, spontaneous combustion, suicidal thoughts, in some but rare cases could even lead you to achieving your goal or solving your issue.
If you have asked Zen Chameleon for technical advice and experienced any or all of these symptoms please seek professional help from somebody that has real world engine building knowledge and wisdom
:::WARNING!!!:::

[SIZE="4"] The "Accomplishment" List: [/SIZE]


Head D16Z6:

Work done from Performance Porting:
Mild Port and Polish
3 angle valve job
SuperTech springs, new oem retainers
New oem cam and valve seals
Milled .003 for flatness
Hondata intake gasket
New extended intake studs
Freshly cleaned Z6 injectors

AEM cam gear
NGK plug wires

D16Z6 intake mani
AEM fuel rail
B&M fuel pressure regulator
Marshal fuel pressure gauge
AEM CAI



D16Y7 block:

Vat, Bored (0.020), Prepped, Milled, R&R pistons, Resized rods...
D16Z6 Crankshaft: machined, mains .020/ rods .030
ARP rod bolts
PG6 Pistons, 75.5mm

Y7/Z6, ARP head studs


P28 ECU socketed w/ Neptune RTP

98' EX Tranny


What's left:

Cam
Bearings
Gaskets&Seals
Oil pump
Water pump
Timing Belt
Wideband O2
Header


and most important Tuning



I think that's everything....if I missed something let me know please.


Thankz for all the support




A sneak peek of the '97 Del Sol, New DD/Project:
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Last edited by Zen Chameleon on Sun Sep 25, 2011 6:34 pm; edited 2 times in total
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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:13 am

I snagged this D16Y7 from some random dude I ran into. He had yanked this motor out of a junkyard but it just sat around in his garage. I got the head still on the block and he tossed in some used axles, shift linkage, and some other junk. For the price of a pull it yourself short block I think I did alright.
This is the bottom end after pulling the head, crank pully and timing belt.

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Sorry for the cell phone pix. I wish I would have waited to pull this apart so I could have done a full breakdown writeup but oh well.
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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:15 am

My favorite new tool takes some pretty decent pix I think.
I got the block stripped down and everything "looks" to be in ok shape.
For some reason this camera makes things look cleaner than they really are, with that said I still have to clean up most everything seen here:

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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:16 am

I picked this D16Z6 head up from the local Pick'N'Pull (3hours away) during their summer blow out 1/2 price sale. I couldn't pass it up knowing I plan to rebuild it anyway.

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The valve cover had at least 3 coats of rattle can paint over top of it, Blue, Orange, and Black.
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After hours of work it's almost clean. You can see the paint left on the "inside" of the plug holes.
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It was obvious the PO had literally lifted the hood and covered everything in black spray paint.

Here is the Z6 intake manifold after lots of airplane stripper, degreaser, and brake cleaner.
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If only you could have seen the before pics lol
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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:21 am

98' EX Tranny

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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:24 am

I picked up a Z6 dizzy and a Z6 crank. I'm saving up to get this block sent off next month...hitting that slow time in the build for awhile.

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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:25 am

So Friday (2-18-11) is the Big day to send the head off to Performance Porting, so I did a little work. I pulled the cam because it's going to be heading to Delta for a regrind.


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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:26 am

I also thought it would be a good idea to get that damn black spray paint off the head and clean it up just a little before it's sent off.

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I found that my sister having 2 kids came in handy Razz

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I had put the rocker assembly back on before wrapping it up.

Now It's All Ready To Go!
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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:27 am

Dustin from Performance Porting was kind enough to send me some teaser pics. Enjoy Very Happy

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New: cam seal, valve seals, and retainers
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EDIT: Added pics and sent my injectors to them today also.
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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:28 am

A few more preview shotz:
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Remember this was a junkyard pulled head, and it had a couple bent valves and 2 of which had made sweet monkey love to the pistons. PPorting replaced those valves, milled .002 for flatness, and 3 angle valve job.

Great service from Dustin too, I couldn't be happier. I can't wait to get this thing back and to the next step Wink
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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:29 am

Look what came in the mail today (3-23-11): AEM fuel rail, FPR, and gauge

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And my injectors all minty fresh from PPorting
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And a quick test fit of both on my Z6 mani
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cam seal for my camless head
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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:31 am

Head back from the shop in far far away CO.

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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:33 am

Got a package (3-29-11):

Y/Z6, ARP head studs, used but never seen a heat cycle.
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Glowshift oil pressure gauge and sending unit.
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And I've done a little painting but it still needs some finish work.
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I also have a Z6 AEM cam gear on it's way.
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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:35 am

Not new or abused, Z6 cam gear:
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This thing is barely used and the filter is like new:
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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:36 am

Hondata intake mani gasket:
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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:37 am

I had somebody ask if I planned to "gasket match" the Hondata gasket, I said no and this is why:
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Roof
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right side
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left side
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Pretty flush where it counts

then I held it on the intake mani
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Looks good enough to me
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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:39 am

Thankz to Cfab my P28 ECU is Neptune RTP ready
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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:41 am

(6-02-11) I know it's a sad update, but stuff happens then I went on a camping/rafting vacation so sue me.
I did free up my bills for the next paycheck and got this for $99 @ HF:

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I picked up this AEM CAI (tube only) for $30 shipped.
I'll repaint it soon and swap back and forth between this and my short ram as needed.

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got these from Allen's Fasteners for $40.46 shipped, super fast shipping, great service too! A++ :yes:

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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:42 am

Yeah That's Right MoFo's I got my pistons in today (6-17-11):

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MUUWWHAAHAHAHAHAHAHHAAAA!!!!!!!!!
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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:44 am

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(7-11-11)

Got 2 little packages today, one with the lanyard, and the other with the ES engine mount inserts.
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Packed up the block parts to go to the shop tomorrow.

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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:45 am

PG6 Pistons on D16Y7 rods with ARP rod bolts:

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D16Z6 Crank ground down to .020 mains and .030 rod journals:

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D16Y7 Griddle:

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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:46 am

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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:48 am

Look at the trash in the cylinder left over from the machine shop that you can't really see with the naked eye:

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I figured I'd paint it up real fast too:

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Re: My First Rebuild Y7/Z6

Post  Zen Chameleon on Mon Sep 05, 2011 11:49 am

D16Y7 Block = 2 coats of block primer, painted, and 2 coats of engine clear:

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Back to it's display stand lol:

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Re: My First Rebuild Y7/Z6

Post  Black94Si on Mon Sep 05, 2011 4:34 pm

Ughhh that Sol looks great man. Good progress on the rebuild.
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Re: My First Rebuild Y7/Z6

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