Mechanical Problems & Technical Chat - out with the auto in with the manual

hi, i have a ej2 in otherwords a 94 coupe.
i've recently got hold of a nicely tuned d16z engine with manual box attached, i have the ecu, loom, shift linkages, shafts etc. i'm currently running a d15y7 with an auto box, but need a little advise on whats needed to set up the hydraulic clutch, i would like to start the conversion in a week or 2, i've had people suggesting that i simply buy a manual to swap the engine into, but i love my coupe and manual ones are hard to find in the uk in good condition.
many thanks.

I agree. It would be so much easier to just buy a new car and swap the engine. On the other hand, a big project like that is fun to do. I'm not experienced in how to do this for a Honda. But shoot. If you're gonna dive into this. Why not get real crazy and turn the car into a rear wheel drive coupe?

The clutch is a simple bolt-on. You need the pedal assembly, master cylinder, hydraulic line, etc. Find the blank plate next to the brake booster with two bolts. That's where the clutch master cylinder goes.

The shifter is the same way. The holes for it are already in the floor of the car.

right! i see, the master cylinder.. the clutch hydraulics use the same fluid as the breaking system, makes perfect sense. i have the new engine and gear box as one with everything attached ready to drop in, i've got to install the new loom + ecu, so once i get hold of the pedals and master cylinder i should be ready to go.
thanks for the heads-up mk, your a legend!
by the way what sort of power gains should i expect from this conversion, d15y to d16z.

well d16y7 has 108hp stock (i think), and the d16z6 has 125hp. you will gain ~17hp at the crank.
at the wheels is another story, because you are changing the transmission. an auto loses more power from the crank to the wheels than a manual does. i'm not sure what you have at the wheels now and what the z6 has at the wheels. at the wheels you should expect probably a 20hp gain over your past setup or maybe more.

nice one for the info, 20hp isn't bad over all, the d16z engine i have has recently been rebuilt with high compression pistons and has had bit of head work. should have a bit more poke than my old engine. plus, i went to a breakers yard today and have the clutch setup, the clocks and rear disc brakes to replace the drums for that extra stop, will start the conversion tomorrow :D

good luck!
i hate the performance of a automatic honda! :( my 99ex automatic sucks compared to my 96dx manual!
i originaly wanted to just swap the 5speed parts onto my 99ex BUT the 96dx manual looked to good to scrap so im repairing it.
the manual 5speed feels so much more powerful and controllable! i love it most the time. just not in heavy traffic jams.LOL

It's definitely worth doing. I think you will be pleased with the higher performance.

i did a tranny swap on my d16z6 in the winter... the parts you need:

transmission
shift linkage
pedal assembly (you can just bolt on a clutch pedal but the brake will be close to the clutch, thats what i did, works fine)
clutch master cylinder
slave cylinder
clutch
flywheel
flywheel bolts
steel lines
flex line at the end
flywheel dust shield (auto and manual are different)
custom transmission mount (you cannot use the mount from your auto, unless you re-weld the bracket to the frame in the correct location)
*i have a custom mount if you need it*

since you are also upgrading your engine you also need the wiring harness, and a p28 manual ecu.

i think thats everything you need.


edit:

you will also need to run some wires... one is for the reverse lights, the other is for the clutch safety switch. the reverse lights runs from the tranny to the plug that the auto shifter was plugged into, and the safety switch is from the clutch pedal switch to the already stated plug from the auto (right where the center console meets the carpet)

since you are also upgrading your engine you also need the wiring harness
he doesn't need the wiring harness but it would make things a lot easier. it'll just cost more. if you don't get the wiring harness you'll need an OBD2 to OBD1 conversion harness for the ECU end of the wiring, some custom wiring at the distributor, and you'll need to run your own VTEC wires.

not criticizing your comment, just adding to it so there's another option for him

yea i will miss the auto in traffic lol, but still be glad to be manual.
a little progress up-date, i have changed the brake pedal to a manual (smaller) one, installed the clutch pedal, master cylinder and lines ready to hook up to the new gearbox. i'm relying on the my car to get me around, so i need to think of everything to make time off road as quick as poss.
i have a vtec loom + ecu, so i will be changing the whole loom, less mess and it should make things easier for sure.
i must say i really appreciate all the good advise, keep it coming :D

oh and i wanted to ask about the fuel pumps and injectors, as far a performance whats recommended?

Stock is fine on those. The stock fuel pump can already pump much more than the engine ever needs. Unless you have an extreme turbo or supercharger setup, "performance" ignition systems are also a waste of money.

he doesn't need the wiring harness but it would make things a lot easier. it'll just cost more. if you don't get the wiring harness you'll need an OBD2 to OBD1 conversion harness for the ECU end of the wiring, some custom wiring at the distributor, and you'll need to run your own VTEC wires.

not criticizing your comment, just adding to it so there's another option for him

i'm curious as to why you say he will need an OBD2 to OBD1 conversion harness... the d16z6 is an OBD1 engine, as is his current car, no conversion needed.... right?

i'm curious as to why you say he will need an OBD2 to OBD1 conversion harness... the d16z6 is an OBD1 engine, as is his current car, no conversion needed.... right?
yea that's true, but he said he's using a d15y7 (he made a typo).
i'm not sure if he meant D16Y7, or D15B7
because if for some reason he has a D16Y7 (idk maybe it was swapped in), he might be using the OBD2 wiring harness.

i'm going to guess that he has a D15B7 though since it would be the right engine if he has never had the engine swapped before. in that case, you would be right.

we need to get the facts straight.

yeah i wasn't criticizing you either haha, but you had me question my own knowledge for a second, def need to get some facts straight.

lol my bad, its a d15b7, sorry for the confusion.

alright, then you don't need the wiring harness. but since you already have the D16Z6 wiring harness go ahead and use it for sake of simplicity.

you will need a starter from a manual, and the front transmission mount as well...

how's it going so far?

i haven't started the conversion yet, but i have changed the brakes on the rear to disks. i'm having a bit of trouble gettin the brakes to work properly, although i've bled the system through all round and the fluid is running through, the brakes still seem to be a little spongy. would like to get this little issue sorted before i carry on with other things.

hi, i have the engine in and just need to put my dash back, a few bits to do, but yea so far so good. once again cheers for the info :)