My 1996 Ek1 Engine Rebuild documentation.

[D16EK1]

Hey guys, just posting up some of the documentation of my D16Y4 rebuild.

The whole process took about 2 and a half weeks to get the motor running again as it took about 10 days to get the boss pipe which connects the water pump to the thermostat up. The job was mostly an DIY job (note im only 19 this year ;P) The job of taking the motor out was done at Racing Project (mitcham, victoria)

Reason of rebuild: Engine was drinking engine oil but there were no traces leakage as well as engine wasn't running as smooth as it should of been along with the need of a new clutch kit.

work done: Port and Polish done to the head, Block was sent out for a light hone as there were hairline scratches down the bore, New Rings and conrod bearings, thrust bearing, all crank bearings and big end bearings were fine.

Pictures are shown below on chronological order, enjoy.

First comes first, pics of the car ;D





White Ek1 sedan, Buddy Club wheels, Xforce twin loop, Phillips 6k Hid's.



Air Con compressor is taken off the engine so it stays with the car, proves to be a little bit more work but saves the effort for regas and other contaminants entering the system, hard to see in this picture but wiring loom to ecu has been pulled out and follows the motor alone.



Broken most of the linkage of the motor being held onto the chassis



sorry for the big jump in process, i didnt manage to take a photo of the motor on the engine crane with the tranny still attached but still works out, D16Y4, such an tiney motor~



Motors all completely stripped apart, all cams, cranks, pistons all out.. oh boy look at that mess!



Found the cause of the dissapearing oil, it was from the valve stem seals exhaust side leaking at a slow rate. all that black stuff took about 15mins each piston to remove. good old wire brush and part washer fluids.


Port and polish.



Cnc Mill'd the intake butterfly inlet an extra mm, hoping prevent restriction from the intake.



Engine internals all laid out and ready to be assembled ;D



4 pistons are in, (D series drivers, note how thin the conrods are) weighed the pistons and conrod's without the bearings in are about 669g each. all within an 1g tolerance.



Crank is back in, checking sure the surface is clean then the head is going back on




Sorry for the big jump guys, Dad put most of the motor back together whilst i had uni



forklift'in the motor back into the car as dad said its an easier job.

Thank you for your time, hope you enjoyed reading about this process almost as much as i was working on the car.