Boosted D16 with 150k vs New Engine Arrived [UPDATED]

[Weq]

I'll prolly get a big writeup of my over-infalted camshaft install. But basically i stuffed up and i consiquently pulled the head to fix my mistake. Here are some prorgess pics, of the cylinders of a boosted d16 (20k) with 11psi tuned with the e-manage. Everything looked pretty sweet. crosshatching still on cylinder walls, head gasket was in great condition, and yeah...

cheers to rufes1. he is my partner in crime :)

removal of the head was pretty straightforward.. just went step by sep through the honda manual, accept id idnt remove the powersteering pump, just a bolt. the hardest part was getting those damn coolant hoses off, almost welded on some were.. and i was happy there was enough give in my flex pipe, to allow me to simply pull the exhaust manifold/turbo off the head, without needed to go through the trouble of removing ALL the turbo related parts..

next comes prepping of the gasket surface, new head gasket and arp headstuds.. i purchased another d16y1 (thanks chi!) and i will be using it was a doner for a new head + other random bits.

the ****up was when i was installing my new camshaft - possibly 3fold:
1. possibly had a vtec rocker arm stuck under the assembly. those things are damn hard to put on with 1 person - 2ppl needed!
2. overtorqued bolts (it was my first time using the honda manual and they list torque spec's differently).
3. and i didnt adjust valve lash so valve was hitting the piston as a ...
in the end, i broke 2 cam caps.

stuffups are all part of the DIY game, its to be expected..


http://users.bigpond.net.au/weq/block1.jpg
http://users.bigpond.net.au/weq/cylinder2.jpg
http://users.bigpond.net.au/weq/cylinder3.jpg
http://users.bigpond.net.au/weq/cylinder4.jpg
http://users.bigpond.net.au/weq/cylinder5.jpg

[Weq]

http://users.bigpond.net.au/weq/head1.jpg
http://users.bigpond.net.au/weq/head2.jpg
http://users.bigpond.net.au/weq/head3.jpg
http://users.bigpond.net.au/weq/head4.jpg
http://users.bigpond.net.au/weq/head5.jpg
http://users.bigpond.net.au/weq/headoff.jpg
http://users.bigpond.net.au/weq/train1.jpg
http://users.bigpond.net.au/weq/arp.jpg

[wynode]

Looking good.

Where's that turbo? :D

[mytoycivic]

nice i love it

very clean im impressed!

[wynode]

I wonder if the rods are still straight :)

[wynode]

Looking good.

Where's that turbo? :D
Oops must have missed it hehe

[ECU-MAN]

nice, looks like there is no cylinder ridge either.

[Weq]

updated original posts.

i espically like the first pic :)

i got more pics, only a few of my ****up though -- i'll get them going when the new head comes back... if anyone wants info/pics of random parts, just ask.

[[[d a n n y]]]

pistons not looking that great...

[Weq]

the blesmishes are highlighted by the camera. they are just combustion by-products, discolourations. no cracks, the edges are fine. but its still 150k on the engine, but i think its fairly good all things considering.

[PhatSol]

Excellent pics Weq, thanks for taking the time to post them up :thumbsup:

[Weq]

anyone had experience with break in lube? i used the stuff that cam with my camshaft in my failed attempt, but went to repco today and was recommended this stuff called "bearing blue". Basically its just a paste kinda lube which u are supposed to put on the bearing surfaces (the stuff i got with the camshaft was an oil of sort). I was wondering if i should put it all over the camshaftlobes or just on the bearing surfaces?

http://importtuner.com/tech/0102it_zex06.jpg
http://www.importtuner.com/tech/0102it_zex/index.html
as per the above image, it seems as though they used a break in paste on their camshaft install. advice?

[Weq]

update time:
got my spare engine. Pretty happy when it arrived!
http://members.optusnet.com.au/loxy/car/turbo/head/spare_before.jpg
http://members.optusnet.com.au/loxy/car/turbo/head/spare_beforew.jpg

SPent a couple of hours pulling the head after my exam today - at the same time i cleaned the IACV, throttle body and fixed the always faulty FITV!

After
http://members.optusnet.com.au/loxy/car/turbo/head/spare_after.jpg

The big thing i noticed from the start was there was carbon everywhere around the intake and exhaust, and this pattern continued right to the pistons and valves.. hmmm only 80k on this engine, it must of been running quote rich IMO. Either that or forced induction burns cleaner! lol

http://members.optusnet.com.au/loxy/car/turbo/head/spare_piston1.jpg
http://members.optusnet.com.au/loxy/car/turbo/head/spare_piston2.jpg
http://members.optusnet.com.au/loxy/car/turbo/head/spare_piston3.jpg

The other disapointing this was the conditoon of the inside of the head. Hopefully u can see from the pics, it had a thin film of caked on oil.. i dunno, it really looks like its supposed to be there.. the texture was consistant thickness also.. just a THIN skin of black covering everything. Less learnt boys n girls, change ur oil regulaily and make sure its good stuff! check out the comparison compare to my valvetrain with almost double the K's!

http://members.optusnet.com.au/loxy/car/turbo/head/spare_head1.jpg
SPARE VS MINE
http://users.bigpond.net.au/weq/train1.jpg
http://members.optusnet.com.au/loxy/car/turbo/head/spare_head2.jpg
http://members.optusnet.com.au/loxy/car/turbo/head/spare_head3.jpg

In the above pics u can see the shony metally bits, those are where i gave it a rub to to get the oil film off..

Anyone got recommendations on if i should attempt to clean this stuff off? or should i just put a nice oil through it? Hints and tips appreciated!

Lastly hear are some pics of the injectors. Everything on this engine just seemed gummy to me, but then again ive only had a little experience with a fwe different engines.

[Weq]

http://members.optusnet.com.au/loxy/car/turbo/head/injector1.jpg
http://members.optusnet.com.au/loxy/car/turbo/head/injector2.jpg

So what do u rekon guys? SHould i just give the head surface a nice clean with some acetone/carby cleaner and try and get everything spik and span, or should i send the head off to the pro's and get it professionaly cleaned up...

Pro's and cons.. will this buildup effect my running? i dont really plan on building her up so i dont know weather to spend the money.

[jono]

Was lots of fun picking up that engine and especially getting it off the trailer.

Carby Cleaner rocks!!!!!!!!

The difference changing you oil every 5,000.

Once you do your oil, you could run some of that stuff nulon makes for freeing lifters
http://www.nulon.com.au/prod_LFTU.htm
Just a suggestion. Anyone care to comment?

[Weq]

ALso guys to add, never beleive anything they say at repco. I went in asking for some break in blue for my cam lobes and bearings and they recommended me this stuff called 'Bearing blue' ANyways it turns out this stuff is just for 'reading' and marking stuff on engine internals. Like u can use it to see how well bearing journels are shaped, and if surfaces and consistant and flush after grinding.... im sure if i used this stuff my cam would of worn in incorrectly, and at worst, seized up!!!

Anyways i got this assembly lube made by Nulon - L70 or something! anyone used it before? The guy at Auto Pro said its good and its application chart says engine assembly and anti seizing...

[ECU-MAN]

yes bearing blue is a bit different , :) and like Jono says, this is why dealers service your car every 5000kms.:)

[HRV-80Y]

so when's my buddy who eats xr6 turbo's for breakfast gona b back on d road...? :D :wave: :thumbsup: :p

[Chi]

Hahah i can see the blue marker messages me and RT! left on ur cover lol

[Weq]

Looky what just arrvied.

http://members.optusnet.com.au/loxy/car/turbo/head/new_headgasket1.jpg
http://members.optusnet.com.au/loxy/car/turbo/head/new_headgasket2.jpg

Woot, now just gotta finalise this head!

[Weq]

Ok just got off the phone with Rufes1. The guy they use for there head checking/reconditioning will hot tank/acid dip the head, clean everything up, replace the valve stem seals and make sure everything is well (valves, surface, cracks etc). FOr this im looking at a little under 300. They have to replace valve seals because of the fact that the chemicals they use will errode all the seals.

Now futher talking - taking into consideration head age, im going to give the head to rufes1 to take into work and a mechanic is going to check over it and clean it up with there parts washing machine. If all looks good that will be the extent of the service and i will be boosted by sunday!!

[Mugen boy]

how much did nippon hit you up for frieght??? cos i look into and it was mor fore freight than gasket!

[Weq]

gasket cost me 68aud shipped.

same price for freight as gasket - but still cheaper then honda :) this actually wasnt the gasket i asked for.. i was bidding on a felpro.. hmm, gotta check the specs, it feels a bit thicker then my stock..

[Rufes1]

250 for head service he said approx, didnt ring and quote, but yeh a clean and use of a straight edge should be enough

[saboteur]

Maybe they can fit cam also, when checking head? :D

[jords]

Weq, looks like you deep in it but your loving it, well done man can't wait to see it back on the road, hope all goes well. Where did you order the gasket from?

Post more pics as the rebuild continues.

[Weq]

gasket was from an ebay seller - big_junk@hotmail.com
damn i miss my car, im gonna be boost hard sunday night, WATCH OUT SYDNEY!

[Lukezen27]

Any updates on the projected

:D

[Weq]

Previous turbo kit has been sold. motor has been rebuilt with forged internals. new setup is here waiting to go on. i gotta put a deposit on a house, so its been pushed back a little bit (money for tuning/exhaust)

[Lukezen27]

What PSI with the D16Y1 take after forged internals?

[MR-VTEC]

yeah whta kinda of power are you expecting?

[ah8118]

hehehe lets see some figures!!!