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droopy128 -> DIY - Motor Swap from D16A6 to D16Y7 (2/18/2008 6:15:42 PM)
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DIY - Motor Swap from D16A6 to D16Y7 by Droopy128
Another major project that I tackle with the help from my good buddy Leon, this car has gone through a major overhaul before I decide to do this swap. The history of the car is that I purchase it for $1200 in January 2007, I basically bought it because the interior and exterior is in very good condition, knowing that the transmission grind like hell, needs head gasket, shocks, and exhaust, bought it anyway. Since then, I’ve replace the following: head gasket, shock (on DIY), rebuilt my own tranny (on DIY), change the entire exhaust, with all stock replacement parts.
A year has passed, and this civic burn & leak oil and am tired of it after a year, so decide to replace the whole motor instead of rebuilding it. So, I bought the used motor on Craigslist for $200, not knowing anything about the history of the motor, so am taking a chance on it based on the previous owner said it’s in great running condition.
The entire swap takes 2 days (approx 14 hours total), these pictures I took are only few of the processes, cuz didn’t have time to stop and think about taking pictures.
This will be a crash course of a swap if you are familiar with it and I will not going into detail how to remove basic stuff, I’ll try to explain as much as possible, so here it goes..
Working from top to bottom.
1. Remove hood for clearance so I can use the cherry picker (motor hoist).
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0002.jpg[/image]
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0004.jpg[/image]
2. Remove the battery, bracket, plate, everything you can take out.
3. Air filter box and tubing, etc..
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0006.jpg[/image]
4. Remove radiator with fan attached, disconnect all the wiring harness from both side of the radiator, bracket etc.. lift the whole thing out. (NO PIX)
5. My A/C was out of freeon and don’t work so I just leave it in tack and just remove the hose from the pump. Remove the power steering pump and move it to the side (don’t disconnect the hose), remove the pump from the bracket and move to the side. (NO PIX)
6. Disconnect the main wiring harness assembly, trace it from the intake and just disconnect it, it’s on the left and other on the right of the car. Whatever hoses that attached to intake or the motor must be disconnect and don’t forget the fuel line too. (NO PIX)
7. Now jack up the car and work on the bottom, basically remove the wheel, drain oil (motor and tranny), tranny linkage, axles, exhaust. (NO PIX)
8. Using the cherry picker, attached a chain and hook it up the motor, (you’ll need to find a secure place where it has enough strength to hold the chain to lift the motor with.. don’t chain up the intake… so just hook it up for now and hold the motor firmly with the cherry picker, can’t lift motor yet cuz all mount still attached. (NO PIX)
9. Remove the pulley and save the pin, put it in a save place. (you need to remove the pulley so the motor and tranny can come out as a whole). If don’t remove pulley then you have to remove the tranny and motor out separately. (NO PIX)
10. Remove the motor mount, tranny mount etc... so on all four sides, and ready for the motor to be lifted out. (NO PIX)
With both motor side by side on the ground, we remove intake, exhaust, motor mount, A/C & bracket, alternator & bracket, tranny, basically everything and install in the new motor.
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0010.jpg[/image]
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0013.jpg[/image]
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0015.jpg[/image]
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0016.jpg[/image]
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0018.jpg[/image]
It was a mess and with all those nuts and bolts everywhere and where does it goes? We know exactly where it goes, although we didn’t separate it, and tossed it all in one bucket. But if you work on car long enough, you’ll know where it all goes.
Fews of things we need to modified are:
The coolant bypass tube behind the motor, using the tube from old motor, but swap the front unit, because it has the fan switch sensor built in where the thermostat sit. The old fan switch was attached to side of the motor next to the oil filter, the new motor don’t have that option.
Old motor where the switch is attached.. took it off but can't install on the Y7 motor, cuz it don't have that fitting on the side of motor like in the pix below.
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0028.jpg[/image]
Plug for the fan switch, with no where to plug in, so extended the wire to plug in the fan switch which on the thermostat housing on the Y7 motor (below).
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0032.jpg[/image]
Timing cover where I use my original motor mount don’t exactly fit it, so the cover must be cut a little, but then it leave a gap. This may not sound important to some but to avoid debris e.g. possibly tiny rock can get in there and cause damages. So plastic was cut out to fill in the gap.
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0040.jpg[/image]
After..
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0042.jpg[/image]
Bottom the cover need to be cut, because I need to use my old pulley, where the belt for my power steering don’t have grove as you can see in the picture, this is the whole reason where it needs to be modified.
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0035.jpg[/image]
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0045.jpg[/image]
All these take one day to do.. we start it about 12 noon and finish with all the assembly by 7pm.
Next day we finish modifying the timing cover and install valve cover and ready to be lifted into the car.
With the car remain on jack stand, we hoist the motor slowly into the car, avoiding possible breakage to any sensor, tubing, hoses, wires, etc as we drop it in.
After align it to the mount area, we install the driver side mount side first, then the passenger side, back mount then front tranny mount. After all in place, we can remove the hoist and reinstall the pulley, and all the drive belts, and power steering pump. Run all the wire harness. Re-install the radiator, battery area, all the hoses, tranny cables, etc.. then the air filter unit.
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0048.jpg[/image]
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0050.jpg[/image]
On the bottom, install the shift linkage, exhaust, axles, put oil in the tranny, reinstall the wheels, then put oil in the motor.
Whoa La.. Finished….!!
Comparison from BEFORE and AFTER
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0002.jpg[/image]
[image]http://i128.photobucket.com/albums/p188/droopy128/civic%20project/DSCF0052.jpg[/image]
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