crx rebuild

[ilikerice]

backstory:

A friend I autocross with has a co-worker that has a 91 crx si, bone stock. only aftermarket part is a K&N drop-in air filter. This guy bought it new back in 92 with only 10 miles on it. Currently has 310,000 miles on it. This car is in great shape too. A couple minor issues but nothing that would deter me from ever buying this car if it was offered. So this car has alot of sentimental value with the owner. He heard I used to have a crx and did numerous builds on it. We swapped emails, he checks out my garage, I show him tools previous builds and what I will be working with. After some understanding of what I expect and what he is willing do work with, he drops the car off saturday morning.

The plan:
Basicly the only issue with this car is it drinks 1 qt of oil every 3k miles, and oil leaking from almost every gasket. Also smokes under hard acceleration. Guy only wants OEM parts, and I love replacing parts with OEM parts. The deal is I will pull the motor and work on it, but he has to take the crx out of my driveway because I have a-hole neighbors that like to call the city and slap a giant orange sticker on the windshield saying I have 30 days to prove that this is an operating vehicle or it becomes city property.. yay.. He agrees to this.

The list thus far:
complete gasket rebuild kit
rings
rod bearings
main bearings (if needed)
new clutch w/ bearing
resurface flywheel
lap valves
valve adjustments
new master brake cylinder
new oil pan with plug (original is striped)
new oil pump
new water pump
all belts replaced

think that is it, possible I missed something but dont have the list in front of me.

So dropped of saturday at around 9ish. Got the motor out by 4pm. For an old car everything went abnormally smooth. unlike my other projects, I will actually finish this one and not sell it.

I will be posting pictures as I do the work. I like to send the owner pictures of the stuff I am doing so he knows he is getting new parts and its being done right!

now for the eye candy, sorry for the blue tint on the first couple, didnt know my camera was set that way

[ilikerice]

brake master cylinder complete. sanded down the bottom and resprayed it with some simi gloss rustolium. looks like new

[eTiMaGo]

Honduh or not, these are cool lil cars :)

[yarisugi]

Wait. So is it your car or you're rebuilding it for the owner?

[ilikerice]

rebuilding for owner.

[detroiter]

Looks like it's begging for a k20 swap ;)

[ilikerice]

he talked about swaps. he said he debated doing a b16 but weighed the pro and cons. We talked about it and he decided that he wanted to keep this car as stock as possible and with nothing but Honda OEM parts. Figures in 15-20 years, this car would be such a rare gem to have in stock, unmolested condition. I can respect his wishes and will take much care in working on this car.

[detroiter]

I absolutely agree with that!

[ilikerice]

update with pictures

ok, got the motor semi pulled apart. been just cleaning. these are picture before the cleaning.. just some before pictures.. Just got the head torn apart and will be putting it in the parts cleaner tomorrow.

Showing some pics of how much carbon build up accumulates in a 300k mile motor. Oil fell into the cylinders when I took the spark plugs out. Tube seals were done. All in all, it looks fairly good. no sludge build up. I am impressed how this motor has been holding up.

more pictures tomorrow.

[detroiter]

Nice update!

[Golddeenoh]

did that come with the D15B2 or the D15B7? I had an 88 civic Hatch, same thing except for the ass end of the body. wish i wouldn't have given it away, so much that I could do or have done with it by now.

[ilikerice]

Actually this is an si with the d16a6. You are thinking of the hf or dx trim.

[Golddeenoh]

oh yea, silly me, i got excited seeing one in sch good shape :D

[ilikerice]

I don't blame you.

[junorico24]

Great stuff, I am trying a DIY fixer upper with my Daihatsu Charade.You are a motivator.

Definitely subscribing to this build and learning all I can. :)

[ilikerice]

oh shit, Thanks.. didn't know someone was taking tips.. I was just posting things as I go along. I'll be more thorough with my pictures and what I am doing. I'll post special tools I use also.

[ilikerice]

did a bit of cleaning of the head today.

first is my parts cleaner with all my brushes and soaking containers.

next is a semi clean head.. gotta remove the rest of that gasket, fun

last is a pic of the block.. before the break down. Ill do that friday

[Golddeenoh]

^ 3rd pic, are those Konig Candys just laying there?!?

[ilikerice]

HAHA, yea they are, refer back to this thread for more details. good eye

http://yarisworld.com/forums/showthread.php?t=43377

[Golddeenoh]

i was actually looking at them(on discount tire) before you made the post, so i immediately noticed them. I want some but haven't the cash flow right now or a wife that thinks they will go with my red yaris.

[ilikerice]

I dont think red will look good on red. But they have white. That would look nice.

[ilikerice]

Who likes PICTURES?!?!?!

Head and block completely disassembled. Waiting for owner to let me know if he wants to take to machine shop to give it a hot bath, or for me to do a simple wire brush and brake cleaner wash. Got the bearing colors also, gotta wait for those to come in and the rest of the parts.. YAY, fun stuff.

Cylinder walls are still within spec, no scorching or scratches, crankshaft is in top notch. Bearings were just a little discolored, but nothing to be too worried about. New ones while its out, why not? For 310k miles, doesn't look a mile over 50k

[Shroomster]

Look at those cute little pistons!

[junorico24]

Nice build.

Are you using those original pistons or replacing them with after market? I bought a 1.6 ltr Daihatsu 16 valve motor a few days ago and started pulling it apart. Never done this in my life. But what the heck!! Gonna use the 1.3 ltr piston, distributor and manifold that i have in my 1.3 ltr engine in the car right now.So that the sensors and connectors don't have to change.TAKE out the 1.3 bolt in the 1.6, plug and play!! :wink:1.6 has more torque, if the 1.3 rev happy engine is anything to go by. Damn, this 1.6 HD engine is going to be like a pocket rocket go kart haha.Sorry to high jack your thread.

:evil:

[ilikerice]

HAHA.. yea, I remember going from a 1.5 duel port injection motor CRX DX to a 1.8 integra LS motor. almost a 50hp jump but god you feel every bit of it in a light 1900 lbs. car. gezus. Then I got used to it and wanted more power. Did a B16 (vtec) head swap.. mmm. that was fun, but not enough.. had to go turbo.. 215whp on 10psi.. I miss that car so much.. I hope my yaris can do the same one day..

I don't know much about Daihatsu, but I do remember seeing a thread on a rebuild, I think that might have been you.

To answer your question. yes, I will be using the same pistons. just replacing the rings. Pistons still look good. no scratches and the cylinders are not oblong

[ilikerice]

Oh, and quick update. I dropped off the block and head at a machine shop to get a hot bath and pressure washed. Most of the parts just came in yesterday. Just waiting to get a call back from machine shop. I wont be able to do anything til next week anyways, going to Knoxville, TN this weekend to visit friends.

[junorico24]

That block looks in good shape, any chips on the outer cylinder walls? What parts are you replacing?

[ilikerice]

nope. block is in amazing shape.

replacing:
all gaskets and "O" rings from a honda OEM Upper and Lower Gasket kit
oil sump
oil pump
water pump
timing tensioner
T-belt and Accessory belts
piston rings
new oil pan (original threads for the plug are cross-threaded)
rod and main bearings
new clutch disc and throwout bearing
new radiator and vacuum hoses

I feel I am forgetting something. but I think that is about it though

[ilikerice]

back from the machine shop. pretty

[Golddeenoh]

oooo pretty :D

some serious machine shop to deliver at 4am :P

[ilikerice]

time for lapping valves.
thought I would do a DIY bit here also

pic1: Tried to clean these exhaust valves but they are done. Can't get all the carbon off them without damaging them. Gonna have to order new ones

pic2: before and after cleaning. cleaned up nice and smooth.

pic3: I use a stainless steel brush to clean the valves and also the pistons

pic4: dirty piston

pic5: clean piston

pic6: now to lapping valves. Here we have cordless impact (or drill, I just love my Makita. my fav tool.), T30 bit, and a vacuum hose

pic7: Valve grinding compound

pic8: first you want to coat the valve with a little bit of compound on the edges where it contacts with the head

pic9: Insert valve, try to start with the #1 cylinder and work your way up. Keeps things in order. When doing this each valve is being fitted specificly to each separate opening.

pic10: on the other side, connect the hose on the T30 and the other side to the end of the valve. When spinning the valve on the head go at a slow/med speed. Let the valve spin on the head for a couple seconds then release. Repeat this a couple times. Then remove the hose from the valve and pull the valve out

pic11: Clean the compound off the valve AND the head. You want to see a solid grey ring around the valve. This will allow the valve to seat fully on the head for a good seal when closed. If you see any pin needle dark spots (pitting), repeat from pic 8. When you finish, take a sharpie and write on the bottom of the valve E1 (exhaust #1) or I1 (Intake #1) depending which valve it is. You want to keep these in order when you get ready to install them.

pic12: Finished the Intake side. gotta wait for the exhaust valves to get here to finish those and then I can finish the head.

[ilikerice]

next, honing the pistons

Using a honing tool and cordless drill basically you insert this inside the cylinder and slowly spin it with and up and down motion about 5 times. Just trying to get a crossed etches in the cylinder walls. When finished, grab a paper towel and put some oil on it. any motor oil will be fine. and coat the cylinder walls with oil.

Still waiting for the piston rings now.. so

[junorico24]

WOW

[Shroomster]

Really hating the "unsubscribe" option on control panel......

[ilikerice]

LOL, *side note*

in pic 1 and 3 you notice my index finger is exposed form the glove. This was not on purpose. When using a Dremmel, should always use caution. While polishing the valves, it got away from me and hit my finger. Snatched part of my glove off. didnt hurt, but scared the crap out of me.

Another thing, where safety glasses or a face shield while using the stainless steel. Those little bristles after a while become weak and turn into hair thin daggers. They don't hurt when they hit the skin, but I can only imagine the pain if one gets in your eye. I had 1 or 2 stuck in my finger.

[Golddeenoh]

"no more important rule than to ware these, safety glasses"

[ilikerice]

True.. I wear glasses daily so for those who have perfect vision tend to not where any protection what so ever. I used a face shield because one got me right in my nostril.. very awkward feeling, alot of sneezing involved.

[Golddeenoh]

I have 20/17 vision, I will always put on safety glasses, and if dealing with fluids or batteries, goggles.

[ilikerice]

Safety is cool.

[justjesus]

nice. I love my CRXs. They are like my children (according to my landlady!)

I'll be checking this one from time to time!

Dude, you need to move to California. We can go racing in STF, and you can get another CRX, and we can go to the CRX meets out here!
(oh, and you can rebuild my engine! haha)

[ilikerice]

U pay for shipping and cost of parts. I will rebuild you a 'd' or 'b' series motor no charge in labor. I have been really busy with this wedding. Another reason why this is taking a while. Also he is ordering all his from majestic.com some online honda dealer in new jersey. Half the price than my local dealer.

[Shroomster]

Majestic does have good prices.

[justjesus]

My buddy Jason has one really clean CRX, and he tends to get his OEM goodies from Majestic as well.

Thanks Rice ! !! !
That's a heck of a deal :)
I'll let you know when I'm ready for a rebuild (car stll running fine)

[ilikerice]

I had already used plati-guaged the bearing to check.. Forgot to grab the camera.

Used assembly lube putting the bearings back in and the crank and main caps are on.. Rotates smooth. Also checked crank end play. All within spec.

last pic, got the oil pump, water pump, tensioner and oil pickup on. They guy only order 1 set of piston rings.. lol.. so gotta wait for the rest to come in before I can do Rods. At another road block til that happens.

These bearins are done by color codes, gotta match the number on the block with the numbers on the caps to get the correct bearing. easy once you understand what your doing.

[ilikerice]

update:

5 valves got here. 3 were on back order.. still waiting on piston rings though.. ugh..

[justjesus]

you need to do a video on how to do the bearings using the color codes!
that always throws me off ! !

[ilikerice]

I can do that. I think. If not a video at least bunch of pictures. Lol

[Golddeenoh]

slideshow then :D

[justjesus]

LOL at slideshow.

Actually, that would be good too ! !

[NJ Drive]

I've had 3 CRX Si, two 1987 and 1988.
They will never make a car like that ever again. Really special!

[ilikerice]

You said it NJ.. Parts will be arriving tomorrow. Will be doing alot of work on it this weekend. Hopefully will be finished being assembled. Then will have to plan a weekend for him to bring the car back to finish putting it in.

[Killchain]

First time seeing this thread, I'm always amazed of having the ability,skill and patience for motor rebuilds.:thumbsup:

[ilikerice]

Ok, I did most of this last weekend. I haven't had a chance til now to post these up. Been really busy lately and rarely on the computer. Here is the latest.

THere is a big gap from when I put the head on to putting together the timing belt and stuff. I got carried away and so into the build I forgot to grab the camera to take a picture before the cover went on. Last picture is as it stands now. Gonna do valve adjustment tomorrow and hopefully finish it and have it ready to be dropped in the car.

[ilikerice]

Ok, someone was asking how to figure out bearings using the coded numbers and colors.

Ill just do the rod bearings for now. Time is limited for me so this is going to be kinda quick. Sorry, I don't have time to put a slideshow up or video.

Pic 1 and 2: each rod has a number that is cut in half on the side of the rod bearing. by matching up the number you will get a 1-4. In my case I had 2-2-2-3.

Pic 3: on the crank there are letters stamped on the crank once by each in front of each rod journal. as U can see on the picture with the bearings and notebook, I had B-C-B-A.

Pic 5: using the chart here, basically you match up the number with the letter to get a color. So with my first rod bearing (2), I will go over 2 columns and then go down that column til I get to Row (B) and Yellow will be my color for which bearing I will need.

Pic 4: as you can see each bearing has a color on the side of it for easy verification.

Same thing as the crank, except the Letters for the crank are on the block where the rear main seal goes as shown in pic 6.

the numbers are on the crank and you can use the diagram in pic 5 to show you which numbers go for which journal.

Hope this helps a bit for the D16A6 builders

[Shroomster]

if you don't mind my asking, what spring compressor tool is that you're using in seventh pic? is it honda specific or universal?

[ilikerice]

Universal. I ordered it online. comes with 3 commonly used adapters, but has cutouts for others so if you wanted a larger or smaller one you can put it there. If I remember I will get a pic of it next time im in the garage

[yaris2010RS]

....that colour code thing is odd....

[Golddeenoh]

it has been a week any further progress?

[junorico24]

How's the build?

Here's is a Yaris cousin Daihatsu Charade.

http://i1052.photobucket.com/albums/s457/Ridko29/aec51cc7-9bf4-44cc-849f-efcaec351a7b.jpg

It's not done yet.Below is a 1.6 ltr block with a 1.3 ltr head. Will put a 1.3 ltr piston in the 1.6 block.


http://i1052.photobucket.com/albums/s457/Ridko29/20130411_161217.jpg


It's only a mock up. Gotta send it to the machine shop for cleaning, re-surfacing and port and polish. Yaris is my daily :)

[ilikerice]

Cool project. Yea still sitting in my garage. They owner has the transmission and getting it cleaned up. Also he wants to detail his engine bay also. I told him we should hold off until my wedding is finished and done with. Then I can finish his Crx. Been so busy these last 2 weeks. I'll get video and pic when I start her up

[DebbyM46227]

I've had 3 CRX Si, two 1987 and 1988.
They will never make a car like that ever again. Really special!

:thumbup: I had 3 CRX's, bought them all new - never an Si, mine were all the middle (DX?) model, not the HF either. I had a blue & gray '85, a red '87 and my favorite, the red 1988 I kept for 9 years until I sold it to a co-worker's daughter in 1997. She had the rusted rear wheel-well's fixed and she sold it....I still see it being driven around after all these years.

I still miss my CRX, the Yaris doesn't replace it.

[ilikerice]

Yea, I remember talking to you about our crx's. such great little cars. I had a red 91 si I wrecked, blue 88 hf, and found a blue 89 dx super cheap then sold the 88. 89 dx ended up getting a integra LS swap, turbo charged, then b18 vtec head, then a CRV B20 with vtec head. Had siR headlights and hood and mugen front bumper, buddy club rear bumper and sideskirts w/door caps. Repainted darker blue and ran my red rims with it..

I would do it again.. except, i wouldn't sell it

[justjesus]

is it running now?

[ilikerice]

Not yet. I was just about to revive this thread. I haven't had a chance to work on it. Mainly because the owner keeps wanting to clean things. He wanted to take the brake booster out and refinish it last weekend and now he wants to replace the evaporator and expansion valve under the dash. I am leaving to go to DC this weekend. I was gonna stay here and finish it up but my wife wants me to go too.. Live in the moment.

This morning I got the motor in the car. all mounted up. I will have pictures when I get back. Next weekend its full blown wide open, gonna get it running before sunday (autocross day)

[ilikerice]

Update. I cant find my camera so I have to use my phone camera. Also cant find the damn usb cord to connect to my computer. I will post it up soon enough though.

Cranked up the car today. runs like a champ. Drove it around. now gotta get some miles on it and change the oil again. Pics and video will be posted hopefully later today.

[ilikerice]

Incoming pictures and a video.

Footnote: Wife took the video in low quality so she could text it to the owner. I just uploaded it for you guys to see.

Pics are from Friday morning. I got too anxious and already mounted up the motor then realized.. OH damn, forgot to take a pic before. Well, here you go.

I finished it saturday around lunch time and had autocross today. Been test driving it most of saturday.

And the video:

http://www.youtube.com/watch?v=Tg5yN0Wu-r8

[racerb]

One of my first racecars was an '84 CRX 1.5 then a few years later I bought an '89 Civic Si and an '89 CRX Si, choosing to race the Civic because it actually handled better! Great cars, just feel out of love with Hondas in the early nineties in favor of my first Nissans.

racerb :clap:

[junorico24]

Wow.. Awesome!!

[ilikerice]

Ok, Last post on this. Car is finished and back in the owners hands. Here is a quick video of the last bit of valve adjustment I did and a walk around of the motor while running.
Hope you guys enjoyed this project as much as I did.

http://www.youtube.com/watch?v=T8plh39MsEI