2009
11.27

TOOLS NEEDED;
1 HOTglue gun.
2. THREE 9.5inch led flexstrips. (another for AC controls) and 10 LEDS for cup holder glow.
3. a soldering iron and solder.
4. philips screw driver.
5. electrical tape.
6. afew small flat screw drivers.
7. DREMEL (preferably corded 110 cause battery dremel battery dies quickly!) along with small stone grinder or blade.

Well here it is… the coolest cluster work that anyone can do! Forget those ugly “white face gauge overlays”. Change up your own cluster to be a eye catcher when they are light up and sleeper when they are not ON.

BEFORE YOU START… KNOW THAT IF YOU TRY TO PULL THE NEEDLES OFF OR EVEN MOVE THEM TO MUCH “THEY WILL SNAP OFF” AND YOULL BE LEFT WITH A BUSTED CLUSTER!

NOW YOU WILL SEE SOME PICTURES with the needles removed BUT that was a spare cluster i bought to experiment with just incase this project didnt turn out right… but i swaped in my stock electronics.

Now with that out of the way lets start.

First off is to remove the cluster from your car. With a Philips screw driver remove the 2 upper screws on the clusters trim panel, once you remove those 2 screws simply pull out that panel. After that you’ll see the 4 screws holding the cluster into place on each corner. Simply remove those screws to pull the cluster out a few inches. BUT don’t pull the cluster out to hard cause there are quite a few wire harness plugs in the rear that you need to unplug first. They are all different so no worry about mixing them up!

Now with the cluster pulled out you can really get to work with it on a bench.

From the front you want to remove the front black trim panel on front of the cluster. Then remove the clear cluster cover. Both have little tabs along the sides where with your finger or small screw driver will pop them in a little and they will slide right out. Then pull off the black ring that goes around all the gauges. I believe that just pulled off with a few small snaps. NOW REMEMBER DO NOT MOVE THE NEEDLES OR TRY TO REMOVE THEM! IT WONT WORK! Do not even touch the screws on the front of the faces! Those do not need to be removed!



Now get a blanket or towel out to put the face of the gauges on. Just to prevent any pressure on the needles.

Now put the gauges on their face to see the back. (now with a AUTO and MANUAL transmission only a small difference)

Which should just be the white plastic box showed on the left in the picture. With a flat screw driver go between the cap and tab and lightly pry the tab into the cap and pull up slightly and just work your way around. Then with the cap pulled off remove the electrical board that also holds the leds.

Now you have access to the whole backside openly.

Now look again at the picture and you will see the 4 screws in the center section, 3 on the other side, and 6 on the other side…

Now start removing those Phillips screws in those 3 sections. Left side, right side and center.

Those screws are what holds in the gauges in 3 sections which you can tell. Do not try to pull the gauges out they should slide right out if you have all the screws removed

So pull them all out and set them to the side FACES UP and just put them to the side. You wont have to touch them for awhile….


Now you’ll be able to see the raw shell.

NOW bust out your dremel with a little grinding bit is what I used. You could use a few other cut off or grinder tool but I felt that this was the best bit because of its size to be able to get into tight spots.

Now with your cut off tool start hacking away

You want to remove these tabs that used to help displace the bulb light more evenly BUT NOW you don’t need them!


Though I did miss the middle top tab. Go ahead and cut it out as well.

Now with all the tabs and a little of the right side of the gear selector also cut out…. You don’t need those side caps anyways. I don’t know why they are their!

Hardest part in routing the led strips is the EX or SI clusters is the “gas gauge and temp gauge” side. Due to the gauges being so tight together. AND THIS IS THE SCARIEST PART TO DO…. Now pull the metal caps off the back of the gauges, they slide right off! Now with a few of the screws put them in the holes where they belong with the steel caps in place and route the strips. Now the most mind racking part… on the back of the gauges you need to VERY CAREFULLY bend in the gauges resistors. You need to bend them around so the strips and the gauges will fit. don’t just quickly bend them or they could break. Bend them very carefully…..

Now get your HOT GLUE GUN and after routing your led flex strips from Oznium
Route them in their so they fit and test fit every gauge in their before you do the next.. And then glue them in their while holding the strips their till the glue cools and hardens.

Now with the flex strips all in place… now you can move onto wiring them in.

BUT FIRST you must reattach the gauges into your cluster, so put the screws back in and then the black flat trim, the clear trim, and then the outer black trim panel.

You have two choices for wiring.. Either wire into a ignition source (for light up all the time) OR into the parking lights (so only light up when the parking lights are ON) OR like I did solder onto the stock cluster bulb location. (that way they only come on with the parking lights AND you can still adjust them with your stock dimmer control) which I say is the best way to wire it up…. ONLY PROBLEM this way is testing wires. Sorry I forgot to write down which spot on the board is power or ground…. BUT just solder some other wires onto the board and if your flex strips don’t light up then just switch the wires. Easy fix! To test out simply take your cluster back into the car and plug in the left upper wire harness. Plug it in and then simply turn on your parking lights and test out the dimmer control you know have.
And IF it doesn’t light up simply pull the cluster and either unsolder the wires and simply switch OR easier just cut the wires and switch them and crimp on some wire terminals.
EDIT forgot to add… you also need to solder the black wires on the back of the cluster for those 2 upper inside bulbs. you want to keep those original so the white will be just enough to light up the white dials.




and now you can dimm the leds just like stock if you wired them to the cluster like stock bulbs are.

NOW FOR THE AC CONTROLS pretty much same idea but alittle easier.
pull the center audio console and remove the AC controls.
BEST to use white leds on the temp section just because it looks so much better. or if your cheap or dont care this is what it will look like without the white strip.


kinda weak yes….
this way looks so much better!

Well first with the AC controls once you remove them pull the front knobs off. they simply pull off the front.
and the face has some plastic clips holding it to the unit, just pull the face off.

now pull out the clear plastic

again DREMEL TIME

now BEST to power the led strips to position them better on the back of the face, position them around and glue them down.

NOTE this is a picture of the just colored led strip, but they are simply glued inplace with some more hot glue

and solder the wires to the board.

and if you want to take it EVEN FURTHER change out the leds on the lower button controls.
tho you need raw leds and resistors for them… use th esmall 3MM leds. 5MM are to large for the buttons.



unsolder the stock leds NOTING THE led diodes position inside the head and be sure to solder the led in the same way! and also unsolder the resistors and solder in new resistors for the brighter leds…. you can use stock resistors BUT your leds wont be as bright.

stock yellow led compared to blue led from oznium


use any color you want….

i just really hate not being able to see the AC light during the day.. hard to tell if it was ON or off from a angle. not anymore!

source: http://www.hondacivicforum.com/forum/

Popularity: 18% [?]

2009
11.27

Backstory:
My cv joints were bad and I needed to pass inspection. I figure I’ll save a little time and worry and just replace the whole drive axle assemblies. My first car. I’m on a budget, and save $ where I can.

I’m more mechanically inclined than most, but really, this isn’t a hard job if you have the right tools.

Specifically, get air tools. I found a POS air compressor (old sears paint sprayer) in the back of my dad’s warehouse and bought an impact wrench, ratchet (3/8) and sockets for $85, and spent a few more on a new hose/connectors off craigslist. Got my jack and jack stands there too. Similar finds on ebay.

If you plan on wrenching on stuff in the future, it’s worth it. Or you can just sell the stuff right back on CL. Really though, it pays for itself in one or two jobs.

Whatever, once you get an air ratchet in your hands and hear that sweet sound you’ll know what to do.

For educational use only blah blah blah.
_________________________________

Tool & Budget tip
You can get refurbished axles on the cheap. I got mine at NAPA for around $45 each, after I got the core charge back for bringing in the old part.

They have a warranty which makes it an even better deal – this is part of the reason why I replaced the whole axle assembly instead of just fixing the CV boots. Cleaning out those CV joints will take time, effort, and parts that exceed $45 in my mind.

________________________________

Business:
My car is a 1991 Accord lx. Pretty sure these instructions apply to all 90-93’s, let me know if I’m wrong. I did both axles, so the side I’m working on in the pic might switch around. Get in there and get dirty, it’ll make sense once it’s in front of you.

Get that wheel off. You should probably loosen the axle nut first, but i didn’t and had no problems doing it up in the air . If you’re using a breaker bar, you might need the car on the ground.

*Tool & Budget tip
You can borrow an axle sized impact socket set from your local store. I got mine from Advance auto.

Take a moment to check out how things look. I already knew my stabilizer bar bushings were shot, so I picked those up at NAPA too (ripoff at $15?). These were ugly. I needed a 12 mm on these with a adjustable wrench on one end.

Remove the lower control arm bolt, adjustable wrench on one side. Take the cotter pin out of the lower ball joint nut and take that off. 17mm on both. You might want to remove some other bits, do so at your discretion.

______________________________________________
Disconnecting from the LBJ:
Try to just lift the whole disc/hub straight up off the LBJ. Came off? You’re lucky. Otherwise, stick that LCA bolt right back in (tightening not entirely necessary), tighten that castle nut on a few threads for the heck of it, get your jack and a BFH.

How I did it:

Turn the wheel so you can swing from the front toward the back and get at the LBJ. Place jack under hub, somewhere where it looks beefy. Start jacking. This will compress the spring.

(Pic above sans castle nut, I put in on after.) I swung at the LCA, below the LBJ. Don’t hit the LBJ.

HINT: Tapping on it won’t do a damn thing. Here’s where your martial arts zen powers comes in handy.

Aim through the the LCA and give it a hard pound. Not a tap, not a hit, not a plop, not a strike, a pound. Again. Check your aim. Once more.

That one sounded different! Look:

Lower jack and take off/out castle nut/LCA bolt. Keep things supported.

____________________________

Ok, work on getting those axle splines out of the hub. For me, they just slid out, you might need a punch. Lift the hub off the LCA, turn it to the side, don’t overextend/bend brake lines. It shouldn’t be a problem. Keep the axle supported horizontal with wire, a spare hand, or your knee.

Get a prybar and pry the axle off the intermediate shaft (driver side) or trans (passenger). If doing passenger side, expect some oil to spill out. Put down cardboard/catch can.

This shouldn’t be too difficult.

Pull that ugly SOB out and bring it back to NAPA for some cash/store credit.

Look around again. I found this joint was bad. Note the trans in the back…

________________________
Putting it back:
Stick the new axle in to the trans/intermediate shaft. Greasing the end is a good idea. I found intermediate to be easier and can be done with two hands. You might need to tap the passenger axle into the trans. Gentler here. It’ll slide in all of a sudden and be pressed up to the trans. You should hear a the spring clip (new one supplied on new axle) click into place. Try and pull it out – you shouldn’t be able to. Keep axle supported on the loose end.

Grease the other end and get it into the hub.

Check all your connections.

You might want to spray the brake disc with cleaner – check if you got it greasy.

Reverse of the above pretty much.

Use a new cotter pin on the LBJ.

Done.

Source: http://www.honda-acura.net/forums/

Popularity: 3% [?]

2009
11.25

Honda Crx Faqs

This is not a definitive list of answers but it will help the newbie get started by answering the most Frequently Asked Questions about the 1984-1987 CRX.

This is not a definitive list of answers but it will help the newbie get started by answering the most Frequently Asked Questions about the 1984-1987 CRX.

Contents:

Basic Questions
Cheap Modification Questions
Body and Cosmetic Questions
Engine Questions
Brake Questions
Suspension Questions
Junkyard Parts List

Basic Questions
Q: What is the best source of information about my CRX?
A: The FACTORY service manual is invaluable. I suggest that every CRX owner get a FACTORY manual. FACTORY manuals turn up on eBay and are well worth the price.
Q: Most web sites do not list parts for the early CRX, can I use parts from the 1988 and newer models on my car?
A: There are not a lot of interchangeable parts between the 1st Generation CRX (1984-1987) and the Second Generation CRX (1988 and later); the engine, transmission, suspension and body are different. Some brake parts and most fasteners are interchangeable.
Q: How fast can I go?
A: How much money do you have? Anything is possible if you throw enough money into the project.
Q: Can I put 16″ wheels on my 1st Gen CRX?
A: You could, but it is not a good idea. Long story short: Racing CRX’s are shod with wide 13 inch wheels and tires. I have a set of 205/50/15 tires on 15×7 wheels for street use and that is as large and wide as you can go. 195/50/15 is better for street use. For racing I use 205/60/13 tires on 13-inch rims.
Q: Where can I get specs for the First Gen. CRX engine?
A: www.quickhonda.net/specs.htm
Q: I am not certain I know what model (HF, DX, Si) my car is, how can I tell
A: This answer comes from Mr. Kwicko- Check the VIN. It should read something like “JHMEC13xxHS000001″. The first (bold) “x” marks the digit for the model. 1 = HF, 2 = Std (or DX), 4 = Si. Now, if you’re still unsure, check the engine code. On the DX and HF models, there is a plate on the
front radiator support, on the driver’s side of the car (under the hood, behind the headlight, facing straight up at you as you look at the motor). D15A2 is the carb’d 1500cc engine. On the Si, the plate is on the opposite, or passenger, side. It will be a D15A3 motor, which is the 1500cc Fuel Injected engine.
Q: Where else can I find parts online?
A: Used, and sometimes new, parts come up on auction sites like www.ebay.com. Check often. For new OEM parts try www.hondaautomotiveparts.com. Also, check my list of links at the end of this file.
Q: What grade of gas should I use in my CRX?
A: You can run any modern engine on any grade of gasoline. Whatever type of gas you use, reset the ECU to that type of gas. This involves removing electrical power to the ECU to “erase” its memory and then restarting the already warm engine and letting it idle for a few minutes WITHOUT touching the gas pedal. I am of the school of thought that says, put the highest octane gas you can find into your car. I own two D series 1.5 liter Hondas and I can tell you that the difference between high octane and low octane is VERY noticeable. If you are cheap and do not care how much power your engine makes, put the cheapest, lowest octane gas you can find into your car. If you really want to maximize the power potential of your
engine, put the good stuff in. I add a bottle of octane booster to every tank as well.
Q: Are all 1st Gen CRX parts interchangeable?
A: The 1st Gen was first sold as 1984 model in 1983. For the 1986 model year, the CRX got a slightly different interior. Honda also changed the electrical connectors in the 1986 model, so some electrical parts from the 84-85 car will need modification to fit on the 86-87 cars. There are some subtle differences in the front fenders, front and rear bumper covers, body cladding, and header panel between years and models.
Q: Could I put the Honda 4WD system from a 1985-1987 Civic Wagon on my CRX?
A: The Honda 4WD only sends 10% of the engine power to the rear wheels, so the extra weight and hassle is not justified. But, you can bolt an Integra D16 engine directly to the 4WD Civic Wagon transmission so you could build a very strong Civic Wagon if you wanted.

Cheap Modification Questions

Q: Nobody seems to sell a Cold Air Intake (CAI) for my 1st Gen. Can I make my own?
A: A few manufacturers used to make a CAI for the ‘85-’87 fuel injected Si model, but they have been off the market for some time now. Occasionally a used example will show up on eBay. The DX and HF are completely out of luck, nobody ever made a CAI for them. I have made my own CAI from some pieces of plastic piping (the thick black plastic pipe that is used as waste pipe) and a K&N filter with a 3 ? inch opening that attaches with a pipe clamp, K&N part number RX-4140.
Q: I am on a budget, how can I make cheap modifications?
A: The 1984-1987 CRX, the 1984-1987 Civic and the 1986-1988 Integra are basically the same car under the skin. Junkyard parts are cheap. See the Suspension section for more details.
Q: I would like to lighten my car.
A: The obvious things to discard are interior trim, sound deadening and the A/C system. Under the front and rear bumper covers are heavy steel beams that are the actual bumpers. If you do not plan on hitting anything, these heavy steel beams can be hack sawed out. If you are planning on having an accident, a car that weighs less than 2,000 pounds should not be your vehicle of choice. Buy a Volvo.
Q: Strut tower braces will stiffen my car and improve my suspension’s response, can I make my own?
A: Yes, you can. You could buy front and rear strut tower braces from online seller www.cyberauto.com or www.greddy.com. You could make your own with imagination and some basic hand tool skills. Go to the hardware store and look for sections of “Uni-strut.” This is predrilled steel that looks like the stuff the highway department uses to mount roadway signs.
Q: Can I relocate my battery?
A: I relocated my battery to behind the passenger’s seat. Rather than buy an expensive kit, I used one cable from a set of jumper cables to connect the battery to the engine compartment. I bolted the ground cable to the passenger’s seat bolt and I ran the positive cable under the console and through the firewall via a factory cut hole that is just above the passenger’s feet. The firewall hole is plugged with a rubber “stopper” that
I drilled a hole in and passed the positive cable through.
Q: Where can I get a set of wider, lighter wheels that will not break my wallet?
A: The Junkyard. Water-cooled VW wheels are the same bolt spacing and nearly the same backspacing as Hondas. Every good junkyard has a ton of VW alloy wheels that are lighter and wider than your stock wheels.
Q: Racing tires work great but they are expensive, do you have a cheap source?
A: Every racetrack has a tire facility. The rich racers take perfectly good tires off their racecars and put on new tires. I bought a set of good, used race tires for $30 each at my local racetrack.
Q: Where can I get longer wheel studs?
A: Honda wheel studs are all the same,12mmx1.5mm, however the wheel studs from a ‘96-98 Acura 3.2TL are longer than a civic’s studs. Not only is there more strength this way but because there is stud sticking out the end of nut, if you do a boo-boo to the end of the threads this allows you to try and repair it easier. And if you can’t, in a pinch, you could cut a bit off the end of the stud and still have full thread contact.

Body and Cosmetic Questions

Q: Where can I buy a body kit for the early CRX?
A: Mugen made a body kit that is no longer being manufactured. www.housemanautosport.com makes a pretty good copy of the Mugen body kit. www.andysautosport.com/crx_ground.html sells a body kit also.
Q: The front piece between the headlights and my fenders are cracked, where can I get replacements?
A: www.certifit.com or you can get the pieces from Honda. Honda quality is better. Certifit is cheaper
Q: Who sells clear corners, taillights and turn signals for the early CRX?
A: As far as I know, no aftermarket manufacturer is selling clear or altezza-style lights for the early CRX. Honda sold the early CRX with clear corners in Europe, the JDM models have amber lights like the US model. Try contacting Honda dealers in Europe like www.crown-honda.co.uk/parts/index.htm. The only trick to installing Euro-spec clear corners: the US corners have two light bulbs in them, the Euro corners only have one. I have drilled a hole in the back of the Euro-spec corners to allow the second bulb to be mounted. Euro-spec corner lights are technically illegal in the US. The 1984-88 Toyota pickup truck turn signal lights are very, close in size to the Honda turn signal lights. A set of aftermarket clear lens for
the Toyota truck will fit nearly exactly over your Honda turn signals.
Q: What seats will bolt into the early CRX?
A: Generally speaking, seats can be swapped from model to model if you stay within the same year. For example, I used to have 1987 Prelude seats in my 1987 CRX Si. The bolts and tracks are the same width. Honda changed the seat track width on nearly all their cars in 1988, so later seats need to be modified to fit.
Some people have installed the more comfortable later model CRX seats by relocating the seat rails to fit the mounting location of the early CRX. The only draw back is that the new seats are a little taller and headroom is compromised.
Q: I want a deeper air dam for my Si or DX.
A: The HF air dam is 1/2″ deeper and about 1/4″ narrower than the Si/DX air dam. The difference in width is not enough to notice.

Engine Questions

Q: I want to make my car a hybrid and install a bigger, stronger engine.
A: At the top of the family tree for the D Series, DOHC 1600cc, 16-valve engine is the JDM spec ZC engine of 135 hp. Next in line was the Euro-spec D16A8 which makes about 120 hp. In the US, we got the D16A1 Black Valve Cover version in the 1988-89 Integra, with 118 hp. And at the end of the line is the D16A1 Brown Valve Cover version in the 1986-87 Integra with 113hp. Daniel (“i want an Si” from the CRX Resource) points out that there is also the SOHC ZC, which came to this country in the form of the D16A6.
Many people refer to all 1986-89 Integra engines as being a ZC, but this is not technically correct. ZC is Honda’s term for the top rated version of its engine. If you can find all of the JDM parts, you could build a USDM D16 into a ZC. But those parts are rare and probably expensive.
The Brown and Black valve cover version of the DOHC D16 engine are very easy to install. Basically, cheap, used Integra parts bolt straight into a 1st Gen CRX. HAS Sport makes a kit to install the later B Series (VTEC) engines into the 1st Gen, but it is an expensive kit.
The 88-89 Integra engine (black valve cover) is slightly more powerful than the 86-87 models for two reasons: Better intake manifold & it has domed pistons. That’s it, everything else besides the ECU & distributor is the same. The 86-87 Integra rods are a little thicker than the 88-89’s rods. Parts are interchangeable between all versions of the D16.
The BROWN Valve cover is equipped with:
-FLAT-TOP pistons
-Thick rods
-Square styled intake manifold
-Vacuum advance ignition with external coil
The BLACK Valve cover is equipped with:
-Domed pistons
-Slightly lighter rods
-Rounded intake manifold.
-Electronic advance distributor with internal coil.
ACTUAL SWAP INFO:
Engine Mounts (total of 3 mounts on 84-87 Civic/CRX’s):
Use the stock Civic/CRX mounts on the rear cross member & front timing-belt side.
Use an 86-89 Integra tranny mount for the tranny. The Civic/CRX tranny mount will make the motor sit crooked if you use it, so don’t.
Axles:
Use a complete set of 86-89 Integra axles including the intermediate shaft.
Knuckle/hub assembly:
In order to use an 86-89 Teg’ engine + transmission, you have to use the 86-89 Integra
knuckle/spindle assembly so that you can utilize the Integra 3-piece axles. The 86-89 Integra axles DO NOT plug into 84-87 Civic/CRX knuckle/spindle’s.
Shift linkage:
Use a complete 86-89 Integra’s shift linkage.
Wiring harness:
Use the 1st Gen CRX Si’s wiring harness. Plugs right into the 87 Integra sensors, injectors, & distributor.
Distributor & ECU:
Make sure you use an 86-87 Integra ECU & Distributor. That’s the only DOHC ECU (besides a JDM one) designed to work with a Vacuum Advance Ignition (distributor) which only came on the 86-87 Integra’s.
***Do not use an 88-89 Teg’ ECU or Distributor****
Simply because it has an internal coil ignition just like all the 88+ civic/CRX/Integra use, which is completely different than the 86-87 ignition components.
Q: I am thinking about an engine swap, how much does each engine weigh?
A: From the CRX Resource:
D15A3 (from the Si) 219 lbs.
EW1 (from the 1500 Std) 208 lbs.
1300 (from the HF) 195 lbs.
D16A1 (from the Integra) 248 lbs.
B16 (the VTEC) 309 lbs

Q: Can I put a fuel-injected engine into a car that currently has a carburetor?
A: Fuel injection requires a pressurized fuel system that the carburetored cars do not have. You will need to change the fuel system and a large portion of the wiring harness to put a fuel injected engine in your car.
Q: Can I put a B series engine in my 1st Gen CRX?
A: www.hasport.com makes the kit to do it. Bring a bag of money.
Q: I want a more aggressive ECU (Computer) or a chip and fuel injectors to increase performance in my Si.
A: As far as I know, no one makes a chip or a high performance ECU for the 1st Gen CRX Si. The 1986-87 Integra ECU and fuel injectors will plug right into your car. The Integra ECU will let you rev higher and the injectors will flow more fuel. I suggest that you also install a fuel pressure regulator, a fuel pressure gauge, an air/fuel ration meter and a honed throttle body for increased airflow to match the increased fuel flow.
Q: How can I make more power in my fuel-injected engine?
A: If you get more air and fuel into the engine, the engine will make more power. To supply the “more fuel” I put in a set of 86-87 Integra injectors that I had cleaned and balanced. To get the “more air” I built a better breathing throttle body out of a stock, twin choke throttle body. I opened the throat of the primary choke from 20mm to 26mm and I also smoothed the path to both chokes. Using a Dremel with a cutting wheel I cut the “lip” of the primary throat so that it was even with the “shelf” that surrounds the primary throat. I then drilled down the primary throat on a drill press and with a 61/64″ drill bit. Finally, I cleaned every thing up with a grinding bit on a 3/8″ drill and a wire brush on the same drill.
Q: I was thinking of installing an undersized crank pulley.
A: Don’t bother. I had one on my car and it did nothing to improve performance, all they do is make your alternator and A/C compressor spin slower. The stock crank pulley is designed to work with your engine and should not be changed.
Q: My idle fluctuates up and own by a couple hundred RPM on my fuel injected engine.
A: Your Throttle Position Sensor (TPS) has gone bad. This is the portion of the throttle body that tells the ECU how far open the choke plate is. Normally, if the TPS goes bad you must replace the whole throttle body because the TPS is attached with slot-less screws. But, you can cut slots into the TPS screws with a file or a Dremel tool and unscrew the TPS. Swap in a junkyard TPS and that should fix your problem.
Q: I have a DX, can I put the better breathing Si head on my DX block (the
Si and the DX share the same EW block).
A: This answer comes from the Mk1CRX discussion group on Yahoo Groups: I would definitely go for the Si head. I have done it and I was amazed. I shaved my Si head .040 to recover lost compression, but it’s not necessary, you’ll just have low compression. If you do shave the head, a cam gear is most beneficial, because shaving the head automatically retards cam timing and the gear will get it back to stock or preferably a bit advanced, good for mid range power. I went the dual sidedraft route, very simple manifold
and no worries. Weber Carbs: they are unmatched in the world of carburetion, but very,, expensive, and a PITA to tune and sync the first time, along with being very sensitive to dramatic weather changes. Weber makes sidedrafts, in several varieties. The most common [and arguably the best carb of any configuration ever made] is the DCOE. They’re a twin carburetor design, meaning that there are two distinct throats that act independently of one another, but share the same body. They can be found with 40, 45 and 52mm throats [I think there are more, but those are the most popular, esp. the DCOE 40]. The easiest way to get more power from an engine is to allow it more air with the proper amount of fuel. For my engine, I chose twin DCOE 40 Webers [that's four (count 'em, 4) air horns], with a DC sports header. Mikuni’s are nice, easily tuned, but Webers blow them out of the water if they’re jetted even close. You can find more models and prices of Weber carbs and carb kits at: www.carbs.net
Q: Can I put a single carburetor on my Si head?
A: Rip and Tear Auto from the CRX Resource answers: The carb is a Weber 32/36 DGAV. This is the carb that is used in the single Weber conversion kit for carborated 1st gens. We had to change every jet in the thing. Right now it’s got:
150 primary main
155 secondary main
75 primary idle
60 secondary idle
55 double shot accelerator pump jet
160 primary and secondary air correctors
It still needs a bigger secondary idle jet (don’t have one yet) and I am still playing with the air correctors.
The injector holes are just taped and plugged with standard brass plugs. I originally used the DX cam in the Si head so I could run my stock fuel pump, but have since switched over to a corroborated Accord pump. The Accord pump is electric, and has a built in regulator. Vacuum lines? I have vacuum lines. Well, one anyway, running from the back of the carb to my vacuum advance on my distributor. No it is not smog legal, but hey you can’t have every thing. As far as the design of the adapter plate, I never drew up anything nice because I didn’t need to since I was making the plate my self.
Q: Where can I get stiffer than stock motor mounts?
A: Mugen used to make a set, but they are currently unavailable. But you can cheaply make your OEM mounts stiffer than stock by filling the hollow spaces in the rubber mounts with polyurethane (3-M polyurethane adhesive works well). Clean all of the surfaces inside the OEM motor mounts carefully,
apply the windshield adhesive, and let it cure for about 48 hours before reinstalling.

Brake Questions

Q: Can I put rear disk brakes on my car?
A: Yes, but you will need to graft the rear axle from an Integra onto your car to make it happen. Another alternative is to replace the iron rear drums with aluminum drums from the HF model. This saves weight and works just as well as the Integra rear disks. You will have to change the rear brake backing plate to a HF plate to make the aluminum drums fit, but that is a relatively easy job.
Q Will the Integra’s larger front caliper, and rotors bolt right on to my CRX?
A: Yes, and the Integra brakes will fit under 13″ wheels.
Q: Should I use slotted or cross-drilled rotors?
A: For street driving, the plain OEM style rotors are just fine. Slotted rotors allow the gas that forms between the pad and the rotors to escape. If you do a lot of hard driving in hot conditions slotted disks may be good for you. Cross-drilled also do that and are lighter. But cheap cross-drilled rotors are subject to cracking. Expensive cross-drilled rotors are cryogenically treated to prevent cracking.
Q: I am not certain my brake booster is OK, how do I check I?
A: From the Mk1CRX group on Yahoo groups: To test the brake booster, try the following procedures: 1. With the engine off, press the brake pedal several times. Then press it hard and hold that pressure for 15 seconds. If the pedal sinks, a brake line, wheel cylinder or master cylinder is faulty. 2. Start the engine with the pedal pressed. If the pedal sinks slightly, the booster is working. if the pedal height doesn’t vary, the booster or check valve is faulty. 3. Press the brake pedal with the engine running. Then stop the engine. If the pedal height does not vary for 30 seconds the booster is OK. If the pedal rises, the booster is faulty. 4. With the engine off press the pedal several times with normal pressure. When the pedal is first pressed, it should be low. On consecutive applications, pedal height should gradually rise. If pedal height does not
vary, check booster check valve. The check valve is the thing in the big vacuum line going to the booster, which is below the master cylinder in the engine compartment.

Transmission Questions

Q: Who makes a short shifter for the 1st Gen CRX?
A: I have had both the Pacesetter (terrible) and the DC sport (great) short shifters in my ‘87 Si. If you install a short shifter, the effort to change gears increases. Something to get used to. The ‘88 and later short shifters
will not fit the ‘87 and earlier cars. I used nylon washers in the connecting bolt of the shifter to smooth shift action.
Q: What is the difference between the cheaper Phantom Grip Limited Slip Differential (LSD) and the more expensive LSD from OPM?
A: Shane Portnoff answers: CRE and OPM make a limited slip, $650. The only difference between theirs
and phantom grip is they put clutch plates in between the differential side gears and the carrier. The spring package is sandwiched in between the two side gears putting pressure at the clutch plates, creating “limited slip”. Of course the clutch material will wear out also, but that is replaceable and probably cheaper than a new differential assembly. The phantom grip is just the spring package, so the friction created is between the side gears and the differential carrier. The friction coefficient must be kind of unpredictable plus the gears and carrier assembly will eventually wear out. Also there will be ground up metal inside the trans.
Q: Any tricks to installing a Mugen Limited slip Differential?
A: Yes, the Mugen LS diff is slightly shorter than the stock unit and it will rub against a “rib” inside the transmission case. The solution is to use a pair of pliers to snap the rib off and file down the rough edges. Use 75w90 transmission oil. Break in the new diff by driving in a series of figure-eight’s in a large parking lot. Drain the transmission oil and replace with new 75w90. King Motorsports recommends Redline MT90.
Q: What are the gear ratios of various 1st Gen CRX models?
A: The ratios for the 1.5 (EW5) are
1st: 2.916:1
2nd: 1.764:1
3rd: 1.192:1
4th: 0.866:1
5th: 0.718:1
Reverse: 2.916:1
Final drive: 4.250:1
EW2(1.3)
1st: 3.272:1
2nd: 1.666:1
3rd: 1.037:1
4th: 0.774:1
5th: 0.647:1
Reverse: 2.916:1
Final drive: 4.250:1
Shuttle 1500 (Civic Wagon in the US)
1st: 3.181:1
2nd: 1.823:1
3rd: 1.192:1
4th: 0.866:1
5th: 0.718:1
Reverse: 2.916:1
Final drive: 4.250:1
1.6 (CG) tranny
1st: 3.18:1
2nd: 1.94:1
3rd: 1.35:1
4th: 1.03:1
5th: 0.88:1
Reverse: 2.916:1
Final drive: 3.866:1

Suspension Questions

Q: I want stiffer front torsion bars.
A: Are you sure? Unless your car is a dedicated racer, or you have put a heavier engine in, the stock torsion bars are stiff enough in the front. People who have put stiffer front torsion bars in their cars report that the
ride becomes very hard and uncomfortable for daily driving. You can buy thicker, stiffer torsion bars from OPM Motorsports, they sell 22mm and 27mm torsion bars. Check the list lower in this section for torsion bar and sway bar choices.
Q: What is a good replacement for the rear springs?
A: You have two choices. The best, and more expensive choice is to buy Ground Control coil overs which come with a variety of Eibach springs. Or, you can buy a set of Integra or Civic Wagon springs from the junkyard. On my car, I have the stock torsion bars and a set of Integra springs with one coil cut off. This combination works well.
Q: From what Honda products can I source sway bars and torsion bars?
A: Ballade, from the CRX Resource, provides this handy list:

Both the Si CRX and DX CRX had the same suspension Specs
Stock 84-87 SI&DX: Front sway bar 16mm
Rear internal sway bar 15mm
Torsion bar 20mm @24.5″ Long

Civic Wagon 2WD: Front sway bar 20mm
Rear internal sway bar 15.5mm (won’t fit into CRX beam axle due to end link)
Torsion bar 21mm @22.5″Long (shorter then CRX bar, need wagon torque tubes)
Thicker rear springs (cut to fit)
Civic Wagon 4WD: Torsion Bars 21mm @ 24.75″ Long (will work with CRX Torque tubes.)

Integra: Front sway bar 19mm
Rear sway bar 17mm
Torsion bar 22mm they are longer then CRX bars and won’t fit in lower arms
Thicker rear springs

Integra SE Rear internal sway bar 19mm

Q: What is the correct way to lower my 1st Gen CRX?
A: First the basics- The early CRX has torsion bars, rather than springs in the front. Honda used T-bars to save space and allow a lower front profile. In the rear, there is a beam axle located by trailing arms and a Panhard bar with coil springs. Inside the rear axle is a torsion bar that acts as a rear sway bar. In the front, there is a conventional sway bar. To lower the car, you need shorter springs and reset torsion bars.
***Important Note*** When you lower the rear, the axle moves closer to the driver’s side. To correctly reposition the rear axle to the center of the car, you will need an adjustable panhard bar. They are available from www.opmmotorsports.com. Coilovers are the best way to lower the rear. www.ground-control.com sells a couple different options for coilovers. If you are cheap (like me) you can use the rear springs from the Civic Wagon or the Integra and cut one coil off. Cutting coil springs is generally not a good idea, but the simplicity of the CRX rear suspension allows a measure of crudeness. In the front, the front torsion bars can be adjusted lower about 1/2″ by loosening the adjustment nut underneath the car on each side. To get the front really low, you will need to take the torsion bars out and reposition them 1 notch lower. If your car is a 100% racecar, get the thickest torsion bars you can find (OPM Motorsports has a selection). For street and track use, the T-bars out of the 4wd Civic Wagon are thicker than the CRX and usable on the street. Lowering the car reduces suspension travel. You can increase suspension travel by filing off the brake line bracket on the front struts and positioning the struts 1-inch lower in the front knuckles. Camber plates will also give you some more suspension travel. Adjustable struts are expensive, but they allow you the opportunity to fine-tune your suspension. If you are not racing, maybe you do not need adjustable struts.
Increasing camber and caster will wear out your tires faster, but will help you on the racetrack. An alternative to camber plates is to bolt on the lower arms from an Integra to get about 1 degree of negative camber. Caster can be added by loosening the sub-frame, pulling the entire front end
forward with a winch and then re-tightening the sub-frame. Suspension Techniques sells a bolt on rear sway bar, which is a good idea to add to your car. There are many opinions about the front sway bar on the
CRX. Some people suggest removing it completely, others advocate using the thicker Civic Wagon front sway bar. Changing the front sway bar is a PITA. For street and Autocross use, I kept the stock bar with new bushings.
Q: What is the best way to increase negative camber in the front end.
A: You can buy a camber plate from OPM Motorsports (expensive) or you can bolt on the lower arms from a first gen. Integra which you can buy from a junkyard (cheap). The Integra arms are a little longer than the CRX arms so you get about 1 degree of negative camber that way, but you have no real adjustment. The camber plates give you the option to dial in as much or as little camber as you want.
Q: How can I increase caster?
A: Lightspeed used to make a camber plate that included a caster adjustment; but they are hard to find. One trick you can use is to loosen all of the bolts that hold the sub-frame to the car and then use a winch to pull the sub-frame forward a bit. Re-tighten the bolts and you have just increased the caster.
Q: I want to change the camber and toe of my rear wheels.
A: Moog makes a set of shims to make these adjustments. Between the trailing arm and the rear hub are four bolts holding everything together. A guy on the island of Malta has told me that he made the adjustments to his rear suspension with a couple of washers between the trailing arm and the top two
bolts. And he got some toe out by putting an extra washer into the front two bolts.
Q: Quicker steering?
A: The HF model has a quicker steering ratio rack and pinion so you can put that into your DX or Si.
Q: Could I make my own adjustable Panhard Bar?
A: Yes, the following is from the 1st Gen Integra web sire www.g1teg.org
How To modify 84-87 Civic/CRX and 86-89 Integra Panhard bar. To make this mod simpler, I suggest picking a used panhard bar from a wrecking yard. You will also need about 3′ of 3/4″ diameter pipe, and a
suitable sized bolt to fit inside of the above mentioned pipe snuggly. The bolt should be 3-5″ in length, and you will also need two nuts to fit the bolt. I used a 9/16″ bolt because it fit snug in the pipe I used, this size
will vary depending on the pipe you use. This mod does require welding, if you cant weld it, any shop with a MIG welder should be able to weld this for you for a small charge, 1/2 hour of shop time max. Since you will be welding to the parts of the old panhard bar, you will need to remove the bushings, otherwise they will be burned during the welding. I strongly suggest polyurethane bushings as a replacement. Now it is very important to measure the overall length of the panhard bar and keep note of it. The easiest way to do this is to use a piece of cardboard and trace out the panhard bar. Once the panhard bar has been measured, cut a section from the middle about 1′, leaving some of the channel at both ends. All excess paint needs to be removed for welding, sand down the inside of the channel to expose clean metal. Also during welding the undercoat paint will peel and burn off, to get rid off the undercoat just burn it off with a propane or acetylene torch. Let the pieces cool off. Now the bolt you will use for the adjustment should fit snug in the pipe. Cut only the head off of the bolt with a hacksaw. Spin on one of the nuts 1 or 2 turns. Measure the remaining threads left for the nut to spin onto, keep note of this measurement as well as mark the bolt. Now the smaller bushing end (the frame end) is where I put the adjustment, to make it possible to adjust it without removing the whole panhard bar. So this part of the old channel can be cut a little shorter than the bigger bushing end. Now lay the two pieces of the original panhard bar onto the cardboard you traced it on to. Measure the distance between bushing sleeves, subtract the amount of adjustment left on the bolt and this is the length of the pipe overall. Cut the pipe to length, then cut it into 2 sections one short and one long. Now assemble everything on the cardboard, sliding the pipe into the channel until it bottoms against
the bushing sleeves, setting the bolt partially into the short tube at your earlier mark and resting the nut against the long tube. Make sure you allow for the adjustment to mostly shorten the panhard bar, unless you plan on lifting your Teg Now double check your overall length, and mark all the joints with a indelible marker or chalk, so you know where to line things up when welding. It is crucial to keep the pipe straight/square in the channel while welding. Use a vice to hold the channel, then place the appropriate
pipe in the channel, making sure the pipe lays flat against the top part of the channel, double check the marks you made earlier then use the vice to squeeze the channel so that it clamps the pipe in place. Check your marks and begin welding. Repeat this process for the other end. Now insert the bolt into the short piece of pipe and line it up with its marks, then weld it in place. Last is the nut to be welded on the long piece, this is a little tricky to square up. Set the pipe straight up and down in the vice and place the nut on the end, Tack weld the nut to the pipe on one side only. Using a square check and adjust the nut as required and weld completely. Once it has cooled from the welding spin on the second nut all the way, this is the lock nut. Assemble the rest of the panhard bar, paint it and install your new bushings. You can now install this in your car and adjust as necessary. Don’t forget to tighten that lock nut.
Q: How would I install a set of aftermarket torsion bars?
A: This answer comes from the Mullinator’s web site .http://mybiz.aintnoneofyour.biz/crx/
Set the emergency brake and loosen the front lug nuts. ? Raise the car using the bump under the radiator, in the center of the front of the car. This positioning will allow more clearance for your work area. But remember; most folks do not consider working under a car supported only by a jack as safe. You should use jack stands. I warned you. * Remove the wheel. * Remove the 17mm screw that locates the strut cartridge in the steering knuckle. Jiggle the strut to make sure it’s free of the knuckle. Also remove
the 17mm height-adjusting nut and the dust cap on the front of the torque tube. * Hit the newly revealed front opening of the torque tube w/ PB Blaster. * Remove the 2- 12mm screws that hold the cup at the back of the torque tube to the frame rail. * Remove the cup. It is held on pretty well even after you remove the
screws– here’s the best method for removal I’ve found, so far. Hit it with PB Blaster. Liberally. Then alternately tap the top and bottom lips of the cup (the metal part, not the rubber insert) with the edge of your large flat-blade screwdriver. I found my 3lb hammer worked much faster than my 16oz. Patience will pay large dividends. Trust me, it will come off. * Remove the circlip from the rear end of the t-bar.
* HOLD SOMETHING WOODEN LIKE A BROOM HANDLE OR A DOWEL against the back of
the bar and hammer it forward. Again, a 3lb short-handled hammer works wonders here. You need to move the bar just far enough forward to reveal the wire clip at the front. Do not bash the bar past this point, it will make it more difficult to remove the bar later. * Remove the front clip and tap the bar all the way out, toward the rear of the vehicle. Remember this: if you encounter much resistance when attempting to move the bar, you have done something wrong. Double-check that the strut cartridge is free and that you removed the height-adjusting nut. * Remove the torque tube. Once the bar is out, the tube slides to the rear and off of the car. * If you choose not to machine the torque tube, match your aftermarket bars to the stock ones. I got bars stamped L and R, but they were actually two left bars. This will not affect owners who modify the torque tube. Note that after they learned of my experience, OPM diligently inspected the rest of their stock for mistakes and informed the manufacturer to double-check their shipments. Evidently my set was just a fluke. * Install the circlip on the rear of the bar. The rear has the L or R stamping and is slightly larger in diameter than the front. * Set the torque tube in place. Slide it as far forward as you can. Make sure you position the hole for the height-adjustment mechanism over the bolt onto which the nut will install. Do not install the nut, yet. * Grease the splined ends and insert the bar. You will have to align the key on the front end of the bar with the appropriate keyway on the arm that bolts to the lower control arm. * Now rotate the torque tube until its adjusting arm is about halfway up the adjusting bolt. Carefully engage the rear of the bar with the splines in the torque tube. If you apply very slight forward pressure with your hand, you will feel the splines as you wiggle the torque tube. Once you have engaged the splines, USE THE WOODEN DOWEL and your hammer to slide the bar forward until the circlip hits the tube. If you encounter more than moderate resistance, you are doing something wrong. If you go gorilla on the t-bar, you are going to have to buy a whole new set. Don’t even think about getting a replacement torque tube. BTDT. * Don’t worry about the front clip. I don’t see the need to fuss with it. And if you don’t, removal will be much simpler in the future. Install the front dust cap and the height-adjusting nut. * Apply a light coating of grease to the torque tube cup and the rubber insert and reinstall. * Reinstall the screw that locates the strut cartridge in the steering knuckle. * Reinstall the wheel with the lugnuts finger-tight. * Put the wheel back on, drop the car, and set the height-adjusting nut as best you can. Don’t worry about it too much, the height-adjustment procedure takes a few tries before everything is correct. * Tighten the lugnuts.

Junkyard Parts List

From the ‘84-’87 HF-
right side mirror delete
clock delete
radio delete
bumper supports
door panels
front air dam
rear hatch
center console
rear brake drums and plates
roller rockers ( HF engines only have 8 valves)
two ring pistons
lighter wheel bearings
steering rack
0.655 5th gear (look for the 19 and 29 tooth 5th gear set.)
radiator
axles

From the ‘84-’87 DX (AKA “1500″)-
A pillar grab handle

From the 1985 Si-
140mph speedo

For the 1500 or DX-
The Si exhaust manifold and downpipe

From any ‘85-’87 Si model if you are upgrading to fuel injection-
fuel tank/fuel pump/fuel lines
Wiring harness
ECU

From the ‘86-’87 Integra-
front rotors, calipers and brackets
rear brakes/rear axle/parking brake cables
rear sway bar
engine/transmission/axles/shift linkage/ECU
ECU (manual transmission only)
injectors
radius arms (creates negative camber on the CRX)
rear springs
Integra engine head/intake manifold/fuel rail/throttlebody (may bolt directly to the EW block)

From the ‘85-’87 Civic Wagon (Transit) 4WD-
front sway bar
torsion bars

Popularity: 28% [?]

2009
11.21

Here is how you run a Compression test. It’s actualy quite simple, but a lot of people skip certain steps and end up getting wacky numbers. This thread is to ensure that no one here has this problem.
Running a compression test should ALWAYS be done before slapping a turbo onto a motor. As a wise man (Marty) once told me, boost projects will take the smallest issue you have, and put it center stage. You don’t want that one problem to be piston rings
Anyway, here we go.

Rent a compression tester from Autozone, should be like 40 bucks but you get it all back when you return it. This is what it looks like..

Assembly is very straight forward..

1- Take out your spark plugs (Remove all of them, and leave the holes open, the only one that should not be open when performing the test, is the one with the tester screwed in)
2- pull the ECU fuse so you dont get any fuel or spark to the motor.
3- Screw the tester into the number one cylinder
4- Put the accelerator all the way to the floor, and crank the motor for a few seconds.
5- Record the PSI reading for that cylinder
6- There should be a button somewhere on the tester to reset it, be sure to do this before moving on to the next cylinder.

Repeat steps 3-6 for each cylinder and compare your numbers. General rule of thumb is that they should all be within 10% of each other. Some will argue that its better to have them within 10psi of each other, but 10% seems pretty standard, at least from what I’ve read.

Good luck and have fun!

Popularity: 2% [?]

2009
11.20

Tools Required:

-3/8 Ratchet
-1/2 Ratchet
-10mm socket
-12mm deep socket
-14mm socket
-19mm socket
-5/8 spark plug socket
-6” Extension
-Breaker Bar
-Socket handle to go into the 12mm socket
-Pliers or valve seal removing tool
-Valve spring compressor
-Hose from a leakdown tester
-Compressor
-Rubber mallet
-Telescopic magnet, if you drop the valve keepers
-Cam gear holder or 5mm punch (2) or 5mm allen key (2)
-Engine oil or assembly lube

We got to organize everything that’s going back into the head and identify what they are:
-valves
-valve spring seats
-valve stem seal
-intake valve spring(s)
-exhaust valve spring(s)
-retainer
-valve keepers

Valves (ignore my burnt exhaust valve in the middle)

Valve springs, retainers, valve seats

Top valve spring is the GSR outer intake, the middle is the GSR inner intake and the bottom is the GSR exhaust. The retainer is the 2 columns to the left with the small diameter hole used to hold the valve keepers. *Note* that in the picture the retainers are upside down. The valve seat is the two farthest columns to the right with the bigger diameter hole that goes over the valve guide in the head.

1) First things first, find a place to work on your car.

2) Then pop your hood and remove your spark plug cover(if applicable), spark plug wires and valve cover using the 10mm socket and ratchet.

B18A/B Valve Cover

B18C1/5 Valve Cover

Valve cover removed

3) Then locate the under hood fuse box and take the cover off. **Optional Step**

4) Then locate the 15amp fuse and remove it. This prevents fuel from being squirted into the engine when manually cranking it over to TDC for each cylinder. **Optional Step**

5) Place all the bolts and valve cover grommets in a safe place. For me it’s in the spark plug cover.

6) Now start to remove each spark plug using the 5/8” spark plug socket extension and ratchet, like so. I started at cylinder 4

7) Now that the spark plugs are removed, grab your 19mm socket and proceed to turn the crank to TDC for cylinder 1

The crank pulley bolt is located here

8) Loosen NOT remove both cam gear bolts with your 14mm and breaker bar. Do Not use an impact on these bolts. To make it easy use the two 5mm punches through the cam plate holder and cam holder into the camshaft. Circled here in yellow.

9) Loosen the timing belt tensioner bolt by removing the plug circled in red to expose the tensioner bolt.

10) Remove the cam gear bolts along with the cam gears and key. Make sure to be careful when removing the cam gear & key to not drop or loose it.

11) Remove both cam holder plates by loosening the 10mm bolts on the outside are first. Then the 12mm bolt starting from the outside bolts and working your way in. *The numbers on the picture below are for tightening*

12) Remove the cam holders, taking care to remember how and where you removed them from

B18A/B

B18C1/5

13) Remove your camshafts and place them on a cloth in a safe place, along with the cam gears, key and cam gear bolt.

14) Grab your leakdown tester hose and screw the threaded end into the spark plug hole for cylinder 1. Plug the other end into your compressor. Make sure that the compressor is plugged in and turned on.

15) Very Important Step plug all the oil passages with paper towels. The oil passages are located here

16) Grab your 12mm deep socket and extension then place it over the retainer

17) Give it a good wack with your rubber mallet to loosen the valve keepers from the retainer. Try not to loose the valve keepers

What the valve keepers installed looked like

Valve keeper removed (how it should look after hitting it with the 12mm socket and rubber mallet)

18) Remove the retainer from the top of the valve spring(s)

19) Remove the valve spring(s) to expose the valve seat and valve stem seal

20) Grab your pliers or valve stem seal removal tool and remove the old valve stem seal. Left side has no valve stem seal, the right side does.

With all valves, valve springs, valve stem seals, retainers and keepers removed. *Note* head is off the car. If your doing this with the head on the car, do it one at a time.

21) Install the valve seat buy just placing it over the valve guide. Those that are doing this while the head is still in the car skip this step.

How it looks with no valve seat

How it looks with the valve seat installed (left side)

22) Now lube the valve stem with oil or assembly lube and place it into the valve guide. Those that are doing this while the head is still in the car skip this step.

Next determine which valve stem seal it is that you’re going to install. A black spring around the valve stem seal means it goes on the exhaust side. A white or silver spring on the valve stem seal means that it goes on the intake side. They are not to be interchanged. The stem diameter on the intake side is bigger than the stem on the exhaust side and if you mix them up, your exhaust side will leak and your intake side will wear faster than normal.

Exhaust Side

Intake Side

23) Grab your new valve stem seal and lube up the rubber part with oil or assembly lube and place it over your valve stem. I’m working on the intake side so I grab a white spring valve stem seal.

24) Placed over the valve stem and gently hand push it on, just to make sure it’s seated straight and not crooked. THIS IS NOT correctly on the valve guide, it needs to be pushed on more. Look to next step.

25) Take your 12mm deep socket with handle and place it over the valve stem seal. Then push it onto the valve guide. You’ll hear it click and feel the little click when it’s in place. There’s no need to hammer it on and is unnecessary

Just to show that 12mm fits the valve stem seal perfectly, without damaging the rubber or spring.

Properly installed on the valve guide

26) Grab your valve spring and place the inner spring inside the outer spring (if applicable) paying attention to which end has the tighter coils, because that is considered the bottom and goes towards the valve seat.

27) Lube up the valve springs in oil or assembly lube

28) Place your valve spring(s) back into the head on the valve seat. The bottom of the spring has the coils closer together than the top

29) Place the retainer back on top of the valve spring(s)

The process to get the valve keepers to hold the valve stem and stay put is different depending on which type of valve spring compressor you use. I’m using this type of valve spring compressor so this is the way to put the valve keepers back in.

The valve spring compressor I’m using looks like

30) Carefully place your valve keeper into the retainer. This process is made easier if the valve keeper is lube up with oil or assembly lube.

31) Place the valve spring compressor over the retainer and valve keeper combo

32) Now for the hardest part, trying your best to keep the valve spring compressor straight; begin to push down with all your might until your hands, shoulders, arms and whole body start to shake. That’s about the amount of pressure you need to put into compressing the spring enough to get the valve keepers to seat properly.

Now if this happens just remove the valve keeper and try again

Repeat steps 16 – 32 for the rest of the valve springs and valve stem seals. After your done give everything a once over to make sure it all looks right. Then grab your 12mm deep socket and rubber mallet and place the 12mm socket over the retainer and give the retainer a very light hit just to make sure that the valve keepers are in place and secure. Once you’re done move onto step 33.

All done

33) Make sure there’s still oil in the camshaft journals, if not add some. Engine assemble lube is fine as well

34) Place your camshafts back into its respective spots, intake cam on the intake side and exhaust cam on the exhaust side. Placing the spot where the key goes at the top.

35) Place the key into its spot on the camshaft and slide on the cam gear. Hand tighten the cam gear bolt for now.

B18A/B

B18C1/5

36) Place a generous amount of oil or assembly lube all over the cams

37) Re-install the cam holders onto the camshafts

B18A/B

B18C1/5

38) Then the cam holder plates back into its respective side and tighten the bolts down starting from the middle 12mm bolts working your way out and then finally the 10mm bolts.

39) Now grab two 5mm punches or allen keys and stick them through the cam plate holder and cam holder into the cam

Located here on a B18C1/5 head

I’m not too sure if it’s in the same place on the B18A/B heads, but you’ll be able to find it if you look around for it.

40) Torque down the cam gear bolts to 41 ft lbs for vtec heads and 27 ft lbs for non-vtec heads

B18A/B

B18C1/5

41) Now double check to make sure that the crankshaft is still at TDC by aligning the crank pulley with the arrow on the lower timing belt cover

42) Once the crankshaft is aligned, double check to make sure that the cam gears are still aligned. Should look like this

43) Once it is, slide the timing belt back on making sure not to spin the crankshaft.

44) Rotate the crankshaft counter-clockwise ever so slightly to take the slack out of the timing belt. You do this via the crank pulley.

45) Tighten the timing belt tensioner bolt with your 14mm socket and rotate the engine via the crankshaft counter-clockwise a full rotation until your back at TDC for cylinder 1 and double check that nothing has moved and is still at TDC. Both at the cam gears and at the crank pulley. If the crank pulley or cam gears are off, loosen the timing belt tensioner bolt and try again. Once your done put back the plug into the timing belt cover.

46) Install the spark plugs back into the cylinders and if they need replacing, now is a good time to do so.

47) Double check that your valve lash is still within spec. If not adjust it to the specs your cam manufacture recommends. Stock specs can be found in the Helms or with a simple search, then install the valve cover back on.

48) Install the spark plug wires, and spark plug wire cover (if applicable) and the 15amp fuse if you took it out as well as the fuse cover.

49) Now that everything back together, look over your work area ensuring that everything is in the car and that you didn’t miss anything.

50) Start her up and listen for any abnormal sounds. If anything sounds wrong shut the car off immediatly.

Congrats you’re all done, shut her off or go for a drive.

Good Luck

Popularity: 27% [?]

2009
11.20

This is a Detailed H22 Civic Swap from Honda Tuning~

Source = Honda Tuning

Fitting the H22 in our Civic engine bay poses a challenge since it’s larger than the B- or D-series engines. Installing the H is like getting a size-12 foot into a size-10 shoe. It’ll fit, but it’s cramped and you’ll lose some functionality.

The first things you’ll sacrifice to do this swap are your power steering and A/C. The Civic engine bay isn’t wide enough for the necessary accessory belts. You can make it work with a lot of cutting, so if your fab skills are up to scratch, have at it. Our recommendation: If you want power steering and A/C, build up a B series instead.

The passenger-side engine mount needs slight trimming to clear the new mount when attached to the car. Also, a new and larger assembly is attached to the rear of the engine for the rear engine mount, again for clearance reasons. One of the studs on the transmission must be cut to clear the engine mount. There are also several minor mods you need to make, such as re-routing hoses.

That said, installing the engine isn’t terribly difficult if you have the right tools. But there’s more to the install than the engine itself. It shares the same general configuration as the B- or D-series engine, but the transmission is another matter. It requires its own amount of cutting and even welding.

The problem is the linkage. The B-series trannies use a rod linkage, while the H series uses cables. The two systems mount to their respective vehicles in totally different ways. The B-series linkage is directly under the shifter, while the H-series cables snake under the console to a hole in the firewall on the Prelude.

The only way to make it work is to weld the entire shifter mechanism onto the Civic center hump, in place of the old shifter. The firewall hole is enlarged with a Sawzall and four nuts are welded in place where the shifter’s mounting bolts will go.

Finally, you need to cut a hole in the Civic floor to route the two shifter cables. This is a tricky proposition. Route them too far back and the cables will kink, making it difficult or impossible to shift; too far forward and you risk cutting through one of the main conduits of the Civic brain. Luckily, Holeshot Racing’s Aaron Bonk knows where to cut and got it right, although even with his expertise, it was a tight cut.

From this point, it’s a straightforward matter of re-attaching the various accessories, hoses, cables and wires. It’s more time consuming than difficult, although if you didn’t keep track of what goes where, you’re screwed. Take notes! For the most part, the various coolant lines and accessories snap into place. The only belt that needs installation is for the alternator.

In the next installment, we’ll add an intake and exhaust system from HyTech and then hit the dyno for a tuning session with Hondata’s Doug MacMillan. For now, we just slapped on the stock Prelude intake pipe with K&N filter and ‘Lude exhaust manifold. Not too glamorous, but it works and gets us on the road.

1

2

[1-2] With the engine out, we performed a couple of last-minute installs, including this clutch from WHO and high-flow fuel rail from AEM.

3

[3] We ditched the stock throttle body (left) in favor of a larger bore from RC Engineering.

4

[4] The D-series engine first needs to be disconnected from the car in every way.

5

[5] And through the magic of photography, it takes seconds. In reality, this is a time-consuming process. If you’re new to this, make sure you label what goes where since you’ll need a lot of the same hoses and connections later.

6

[6] With the engine disconnected, unbolt it from its mounts and raise the car on a hydro lift. Watch your feet. Don’t have access to a lift? Cherry pickers aren’t too expensive to rent. Watch the paint as you hoist the engine out of the bay. Meanwhile, a D-series engine in good working order is worth a few hundred bucks, and makes a worthwhile replacement for ’80s vintage Civics

7

[7] These are the stock engine mounts for the D engine…

8

[8] …and these are the Holeshot Racing replacements. Note there’s no front mount. We didn’t forget to shoot it. It’s just not used. The remaining mounts are adequate to hold the engine in place.

9

[9] The engine bay needs some prep before the engine goes in. For starters, this heater hose is removed since the H22 uses a different routing.

10

[10] Here the rear mount is installed. Note the new heater hose mounted above it (with the screw-clamp).

11

12

[11-12] The passenger-side engine mount needs some trimming to accommodate the bigger engine. You also need to drill new mount holes.

13

[13] The driver-side mount bolts into place without modification.

14

[14] With the tranny bolted to the block, the engine is almost ready to go in.

15

[15] First, we need to cut this mounting stud to fit the passenger-side mount.

16

[16] We installed all of the engine mounts once the H22 was settled in the bay except for this passenger-side mount. Much easier to tighten the nut (where the stud was cut) with the engine out of the car.

17

18

19

20

[17-20] Getting the H into the engine bay is as easy as removing it. Place the engine under the car, lower down the ride, and, voila, it’s in.

21

[21] Ratchet down the two bolts for the driver-side mount.

22

[22] Here’s why we bolted on the passenger side mount before installation – no clearance.

23

[23] The beefy rear mount eliminates the need for a front mount.

24

[24] With the engine secure in the bay, we reinstall the center shaft in preparation for the drive axles.

25

[25] The Prelude axles are too long, so we’ll need new ones.

26

[26] Drive axles installed, it’s time to reattach the hub.

27

[27] We use a steel-braided line for the clutch. It’s not a weak point or anything, but we do need a custom line, so why not go steel-braided?

28

[28] Next we install the starter motor.

29

[29] The alternator and its bracket are reinstalled on the engine block. We’ll attach the belt later.

30

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[31] The stock fan won’t clear the engine, so we go with a smaller, narrower-profile, pusher-type fan.

[31] The stock fan won’t clear the engine, so we go with a smaller, narrower-profile, pusher-type fan.

32

[32] The new fan mounts in front of the radiator, blowing air across it and saving room. Note the proximity of the transmission housing.

33

[33] The engine is only half of it. Connecting the transmission linkage is no picnic, either. This is the original D-series linkage. Note that it’s a rod-type linkage, and the shifter (far right) pulls or pushes on the rods to change gears.

34

[34] The H series uses a cable shifter. The shifter (top) tugs on two cables that change the gears. It’s a bigger problem than it sounds.

35

[35] This is the stock hump in the Civic. It requires some serious modification before the new shifter will fit.

36

[36] Using a Sawzall, we cut away excess material around the shifter and create a large square hole to accommodate the new mechanism.

37

[37] Aaron welds mounting bolts to the Civic floor, giving the new shifter a secure place to sit.

38

[38] The mods result in a less-than-factory look, but it’s no thing. The center console plastic will cover it all anyhow.

39

[39] Finding the right place to cut the hole for the shift cables requires knowledge about the Civic’s innards. A bit of luck doesn’t hurt, either.

40

[40] Even with his experience, Bonk comes close to cutting through the Civic’s brain stem. Yikes! No harm, no foul though.

41

[41] Cut at just the right angle, the hole allows the cables to pass through to the engine compartment without a sharp bend that would make them bind. At this point, reattaching the cables is a snap.

42

[42] Neither the stock Civic nor Prelude fuel line will fit, so we add a new stainless-steel line.

43

[43] Getting close to the end. The coolant hoses are re-installed. Since these are stock Prelude pieces, they fit perfectly.

44

[44] Installed, assembled and ready to go.

Popularity: 33% [?]

2009
11.19

HOW TO WIRE VTEC

1. Disconnect the 1P connector from the VTEC solenoid
valve.
2. Measure resistance between the terminal and body
ground.
Resistance: approx 14—30 ohms
3.If the resistance is within specifications, remove the
VTEC solenoid valve from the cylinder head, and
check the VTEC solenoid valve filter for clogging.
• If there is clogging, replace the engine oil filter and
the engine oil.
4. If the filter is not clogged, push the VTEC solenoid
valve with your finger and check its movement.
• If VTEC solenoid valve is normal, check the engine
oil pressure.

Popularity: 3% [?]

2009
11.19

B-series Tranny Specs

Transmission Name Engine Counter Part 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Reverse Final Drive
S1/J1 JDM B16A X-Si 3.230 2.105 1.458 1.107 0.848 3.000 4.400
Y1; Y1 w/LSD JDM B16A SiR I 3.166 2.052 1.416 1.103 0.870 3.000 4.266
S4C/Y21 USDM B16A2, B16A3; JDM SiR2, JDM SiR2 w/LSD 3.230 2.105 1.458 1.107 0.848 3.000 4.400
Y80/S80 JDM B16B w/LSD; JDM B18C 96-spec R w/LSD 3.230 2.105 1.458 1.107 0.848 3.000 4.400
YS1 USDM B17A1; JDM B16A X-Si w/LSD 3.307 2.105 1.458 1.107 0.848 3.000 4.400
S1/YS1/A1 USDM B18A 3.166 1.857 1.259 0.935 0.742 3.000 4.400
Y80/S80 B18B 3.230 1.900 1.269 0.966 0.714 3.000 4.266
?? B18B (auto) 2.722 1.468 0.975 0.638 —- 1.954 4.357
S80/Y80; S80 w/LSD, Y80 w/LSD JDM B18C SiR-G 3.230 1.900 1.360 1.034 0.787 3.000 4.400
S80 w/LSD JDM B18C Spec-R 3.230 2.105 1.458 1.034 0.787 3.000 4.785
Y80 USDM B18C1 3.230 1.900 1.360 1.034 0.787 3.000 4.400
S80 w/LSD USDM B18C5 3.230 2.105 1.458 1.107 0.848 3.000 4.400
S80 w/LSD EDM B18C Spec-R 3.230 2.105 1.458 1.034 0.787 3.000 4.785

4th Gen D-series Cable Tranny Specs

Transmission Name Engine Counter Part 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Reverse Final Drive
L3 88-91 HF 3.250 1.650 1.033 0.823 0.694 2.954 (3.250 Cali) 3.880
L3 88-91 DX 3.250 1.894 1.259 0.937 0.771 3.153 3.880
L3 88-91 Si 3.250 1.894 1.259 0.937 0.771 3.153 4.25
L3 JDM Integra ZXi 3.250 1.894 1.346 1.033 0.771 3.153 4.437
L3 JDM DOHC ZC 3.250 1.944 1.250 0.909 0.878 3.153 3.880
L3 USDM D16A1 Integra
NOTE:
Will not fit 88-91 D-blocks
3.181 1.944 1.347 1.033 0.823 3.153 4.216

5th Gen D-series Hydraulic Tranny Specs

Transmission Name Engine Counter Part 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Reverse Final Drive
P20/A000 92-95 Civic CX/VX D15B8/D15Z1 3.250 1.761 1.066 0.853 0.702 3.153 3.250
P20/A000 92-95 Civic DX/LX D15B7 3.250 1.762 1.172 0.909 0.702 3.153 coupe/sedan: 4.058
Hatch: 3.888
P20/B000 92-95 Civic EX D16Z6 3.250 1.900 1.250 0.909 0.702 3.153 4.250
P20/B000 92-95 Civic Si / 93-95 del Sol Si D16Z6 3.250 1.900 1.250 0.909 0.750 3.153 4.250
?? 92-95 JDM Civic VTi EG4D15B 3.250 1.900 1.250 0.909 0.750 3.153 4.250

6th Gen D-series Hydraulic Tranny Specs

Transmission Name Engine Counter Part 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Reverse Final Drive
?? 96-00 D16Y5 3.250 1.782 1.172 0.909 0.702 3.153 3.722
?? 96-00 D16Y7 Civic DX/LX/CX 3.250 1.762 1.172 0.909 0.702 3.153 coupe/sedan: 4.058
Hatch: 3.722
?? 96-00 Civic EX D16Y8 3.250 1.909 1.250 0.909 0.702 3.153 4.250

Prelude and Accord Tranny Specs

Transmission Name Engine Counter Part 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Reverse Final Drive
P2A5 94-97 Accord DX/LX 3.307 1.809 1.185 0.903 0.685 3.000 4.062
P2U5 94-97 Accord EX 3.307 1.809 1.185 0.933 0.685 3.000 4.062
P2A4 94-97 Accord Lx/EX Wagon 3.307 1.809 1.185 0.903 0.685 3.000 4.062
T2W4 98-01 Accord Euro-R 3.285 2.090 1.481 0.071 0.812 ?? 4.266
U2Q7 98-01 Accord Type-R 3.307 2.090 1.481 1.071 0.870 ?? 4.266
?? 88-91 Prelude 3.166 1.857 1.222 0.906 0.742 ?? 4.062
?? 88-91 Prelude Si 3.166 1.857 1.259 0.935 0.794 ?? 4.062
M2L5 92-96 Prelude S (F22A1) 3.310 1.810 1.232 0.900 0.710 ?? 4.062
M2S4 92-96 Prelude Si (H23A1) 3.307 1.857 1.320 1.034 0.812 ?? 4.266
M2J5 92-96 Prelude Si (JDM F22B) 3.307 1.810 1.269 0.966 0.787 ?? 4.266
M2F4 92-96 Prelude VTEC 3.307 1.950 1.360 1.071 0.870 ?? 4.266
M2A4 92-96 Prelude VTEC (JDM H22A w/o LSD) 3.307 1.950 1.160 1.034 0.787 ?? 4.266
M2B4 92-96 Prelude VTEC (JDM H22A w/ LSD) 3.307 1.950 1.360 1.034 0.787 ?? 4.266
M2Y4 97-01 Prelude BASE 3.285 1.956 1.344 1.034 0.812 ?? 4.266
M2U4 97-01 Prelude SH 3.285 1.956 1.344 1.071 0.870 ?? 4.062

S2000 Tranny Specs

Transmission Name Engine Counter Part 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Gear Reverse Final Drive
?? 99-03 S2000 F20C 3.12 2.05 1.480 1.160 0.970 0.810 ?? 4.100

RSX/EP3 Civic/CRV K-series Tranny Specs

Transmission Name Engine Counter Part 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Gear Reverse Final Drive
?? RSX Base, EP3 Civic Si K20A3 2.684 1.500 0.984 0.733 0.571 —- ?? 4.389
?? RSX Type S K20A2 3.270 2.130 1.520 1.150 0.920 0.720 ?? 4.389
?? 04+ CRV K24 3.533 1.880 1.212 0.921 0.738 —- ?? 4.765

Popularity: 12% [?]

2009
11.18
DPFI MPFI
Pin# Wire Color Function Wire Color Function
A1 Yellow 2 Aux Injector Brown #1 Injector
A2 Black 1 Main Relay/Ground Black 1 Main Relay/Ground
A3 Yellow 1 Aux Injector Red #2 Injector
A4 Black 2 Main Relay/Ground Black 2 Main Relay/Ground
A5 Red 2 Main Injector Light Blue #3 Injector
A6 Green Purge Cut Off Solenoid Valve (Coil) Green Purge Cut Off Solenoid Valve (Coil)
A7 Red 1 Main Injector Yellow 1 #4 Injector
A8 Yellow 3 Sedan LX A/T
A10 Red EGR Solenoid Control Valve (Coil) (A/T only)
A11 Blue/Yellow EACV (Coil) Blue/Yellow EACV (Coil)
A12 Green/Black 2 Main Relay Green/Black 2 Main Relay
A13 Yellow/Black 2 Main Relay Yellow/Black 2 Main Relay/Injector Resistor Box
A14 Green/Black 1 Main Relay Green/Black 1 Main Relay
A15 Yellow/Black 1 Main Relay Yellow/Black 1 Main Relay/Injector Resistor Box
A16 Brown/Black Ground Brown/Black Ground
A17
A18 Black/Red Ground Black/Red Ground
Pin# Wire Color Function Wire Color Function
B1 White/Green Hazard Fuse White/Green Hazard Fuse
B2 Orange Tandem Control Solenoid Valve Blue 1 Fast Idle Control Solenoid Valve
B3 Yellow A/C Clutch Relay Yellow A/C Clutch Relay
B4 Yellow/Green Radiator Fan Relay Yellow/Green Radiator Fan Relay
B5 White/Yellow Alternator White/Yellow Alternator
B6 Green/Orange Check Engine Warning Light Green/Orange Check Engine Warning Light
B7 Green/Orange A/T Shift Position Console Switch (Park, Neutral)
B8 Blue/Red A/C Switch Blue/Red A/C Switch
B9
B10 Orange Crank Angle Sensor
B11 Green/Black A/T Shift Position Console Switch (Drive)
B12 White Crank Angle Sensor
B13 Blue White Main Relay Blue White Main Relay
B14 Blue 2 To Yellow, To Alternator Blue 2 Alternator
B15 White 1 Ignitor Unit White 1 Ignitor Unit
B16 Yellow/Red Speed Sensor Yellow/Red Speed Sensor
B17 White 2 Ignitor Unit White 2 Ignitor Unit
B18
B19 Green/Red Electric Load Detector Green/Red Electric Load Detector
B20 Brown Ignition Timing Adjusting Connector Brown Ignition Timing Adjusting Connector
Pin# Wire Color Function Wire Color Function
C1 Orange Crank Angle Sensor Blue/Green Cylinder Position Sensor
C2 White 4 Crank Angle Sensor Blue/Yellow Cylinder Position Sensor
C3 Orange/Blue TDC Sensor Orange/Blue TDC Sensor
C4 White/Blue TDC Sensor White/Blue TDC Sensor
C5 Red/Yellow TA Sensor Red/Yellow TA Sensor
C6 Red/White 1 TW Sensor Red/White 1 TW Sensor
C7 Red/Blue Throttle (Position) Angle Sensor (TPS) Red/Blue Throttle (Position) Angle Sensor (TPS)
C8 Yellow EGR Lift Valve Sensor
C9 Red/White 2 PA Sensor Red/White 2 PA Sensor
C10 Green/White 3 Brake Switch Green/White 3 Brake Switch
C11 White 1 MAP Sensor White 1 MAP Sensor
C12 Green/White 2 EGR Lift Valve Sensor/Pa Sensor/Ignition Timing Adjusting Connector/TA Sensor/TPS Sensor/TW Sensor Green White 2 Pa Sensor/Ignition Timing Adjusting Connector/TA Sensor/TPS Sensor/TW Sensor
C13 Yellow/White EGR Lift Valve Sensor/Pa Sensor/TPS Sensor Yellow/White Pa Sensor/TPS Sensor
C14 Green/White 1 MAP Sensor Green/White 1 MAP Sensor
C15 Yellow/Red MAP Sensor Yellow/Red MAP Sensor
C16 White 3 O2 Sensor White 3 O2 Sensor

Popularity: 7% [?]

2009
11.15

I was tooling around the garage a couple of weekends ago and came to the conclusion I needed to take something apart… Why would we do that? More power of course!

* Our hapless victim awaits… :evil:

Tools needed:

10MM socket and wrench

12MM socket and wrench

Various socket extensions

#2 Philips head screw driver

Flathead screw driver

Various pliers and channel locks

Intake plenum gasket (depending on the condition of your old one)

IACV O ring (probably a good idea since it won’t be young, and it might not seal properly)

Shop manual of your choice (I made a goof on the coolant lines, that only Helm’s could solve)

This swap is actually very straightforward if you have an F22A6 manifold already on your car. Obviously, it won’t work with the F22A1 or F22A4 manifolds. The process could be substituted if you have an F22A6 manifold that you are going to install, and can hunt down an H22/H23 plenum. All of my research indicateds that they are identical.

Coolant line (depending on the condition of your old ones)

1) Unhook your battery

2) Remove your intake. If you have the stock airbox on the car, it is only necessary to remove the rubber tube.

3) Unplug the IACV, TPS, FPR and all other vacuum lines from the plenum. Make sure you keep track of which is which. Unhook the throttle cable. If you have an auto, you will also need to disconnect the kickdown cable that runs to the tranny.

4) Remove the coolant lines. If you are very careful, you should be able to get the coolant lines off of the IACV and FIV without spilling much at all. I lost about a Nyquil cup full. I then stuck them under something in the upright position. You will have to remove both of the coolant lines running to the throttle body. One line runs into the body just under the throttle plate and one runs out toward the wheel well. Again, if you keep the lines upright, you should lose very little coolant. I went ahead and drained them into a cup, because I already knew that I was going to have to fabricate at least one new hose. Remove only the TB end of the return hose in order to make it easier on reinstallation.

*The coolant pipe circled in yellow is the coolant inlet for the TB. It is connected to the steel tube that also contains the breather tube for the intake, and then a separate hose runs down to the very top of the thermostat housing. The red line is the coolant outlet, which runs to the back of the intake manifold.

5)Once everything is disconnected from the plenum, simply unbolt the 5 screws/nuts holding it down and remove vertically. Be as gentle as possible here, because this is where the plenum gasket is most likely to break. You may not be able to save it, but you can at least try. If it breaks, simply go get a new one. It is also a good idea, as it will lessen the chance of debris falling into the runners if it does break.

6) Replacing the plenum is pretty much the opposite of removal, at least until it is bolted on. Obviously, I took the opportunity to clean everything I could while the plenum was off of the car.

7) I first re-connected the coolant lines because they were the hardest to gain access to and are the most complex part of the install.

Since the H22 throttle body doesn’t have a separate coolant channel to keep the plate warm, simply take some coolant hose and loop it from the thermostat housing to the back of the IM.

*Here you can see in the left bubble where the coolant comes out of the thermostat housing. In the right side of the left bubble you can see the metal tube that is attached to the breather.

*In the right bubble you can see where I ran the coolant line down to the back of the IM where the drain line from the TB used to go. This is where leaving the old drain line attached to the IM comes in handy. To avoid crawling under the car to gain a view, simply trace the hose to its origin, pull it off and place the looped hose in its place. Don’t forget the hose clamp!

Now that the TB is bypassed, the rest of the coolant hoses need to be hooked back up.

The FIV on the H series is located on the bottom of the TB instead of on the front of the plenum like the F22 (the Air Boost Valve is located in the Accord FIV position on USDM H22s. JDM H22s have a block off plate there instead.)

You will want to remove the H series IACV from the plenum and put the F22 IACV in its place. Now is probably a good time to replace the IACV O ring. make sure to lube it with motor oil prior to install. They are interchangeable, but you will have to use both IACV bolts from the Accord as the H series IACV has one long bolt and one short bolt.

The reason you don’t want to use the H series IACV is that the inlet sits so close to the intake runner, it is impossible to not kink the coolant hose.

*You can see how the inlet circled in yellow points straight down into the runner. A hose will not fit inbetween here and the runner unless you are very creative. I just used the F22 IACV.

NOTE: The nipples circled in red were the outlets for the FIV and IACV respectively. The FIV inlet, circled in blue, will simply be rerouted to the H FIV as the hose is long enough. The outlet from the IACV (left red circle) will stay the same. It is the FIV outlet (the right red circle) that we will be making.

Since everything else lines up, simply take about an 18″ length of coolant tube and run it from the new FIV outlet to the IACV inlet (you will want to gauge the necessary length of the hose based on your preferences).

Mine looked about like this when I was done:

*You can see how the side facing entrance nipple made it much easier to get a hose on without kinking it.

That pretty much finishes the coolant hoses. It is a good idea to open the bleeder bolt and top off the cooling system when you are done to avoid any unwanted complications.

8) You will reuse your stock throttle cable. My H22 throttle body was a manual and my car is an auto, so you may need to swap the throttle plates. Just make sure that everything is on tight and note how the return spring came off and make sure it goes back on the same way.

There was one complication with the F22 throttle plate that I didn’t notice at first. The little stop tab on the F22 throttle plate (at least on mine) was located about 1-2mm closer to the stop screw. When I got done and started the car, it was idling at 2500 RPM. Once I backed the stop screw off, everything was fine. You may want to check this before putting the plenum on the car.

You may also need to move the kickdown cable bracket from the F22 TB over the the H. Hook your throttle cable/s back up to the TB.

*Every time I have tried to use an F22 throttle cable and an H series IM bracket, the little nut on the cable wants to occupy the same space as the bracket. Simply take the F22 bracket off and screw it onto the H plenum. This lowers the mounting point just enough for it to fit perfectly.

Readjust the throttle cable to spec.

10) The vacuum lines pretty much go back to the same relative area that they were before. The most important is the MAP sensor which hooks to a metered orifice in the TB. It still goes on the nipple closest to the throttle plate.

11) The two hoses that used to mount right next to the map on the F22 TB simply go right around to the back top of the plenum. The location should be fairly obvious.

*Here you can see the new vacuum hose connection points near the TB.

12) The cruise control and the IAB will each occupy a nipple on the side of the plenum opposite the TB. If your car is a manual, you can also cap off one of the side nipples and run the IAB to the nipple on the back driver side of the plenum (pretty much the same as the F22). If you have an auto, you will need to hook the vacuum line for the engine mount control solenoid to the back nipple.

13) The Fuel Pressure Regulator hose will run to the big vacuum nipple right on the front of the plenum.

14)Reinstall your intake. If you are using the stock tube like me, it WILL fit on the H series TB, you will just have to work it because it is a tight fit.

**Product Review: I was amazed by how much of a difference it made.

I started with a stock F22A4 and after adding intake/full exhaust was rather disappointed.

I first swapped the A6 manifold. It improved low end torque significantly, but
didn’t really contribute to the pull in the top end. It did pull to almost 6K though instead of falling off at 5.2K.

Then I installed the cam, and it was a very significant change. Well more than ALL previous stuff combined!

The H series plenum made almost as much of a difference as the A6 cam and manifold. It sounds meaner, pulls harder at all speeds/RPM’s and pulls right into the rev limit at 6700 RPM.

All in all, highly recommended and well worth the effort.

FOLLOW UP:

There are 3 parts to the intake manifold. I don’t have time to upload the diagram and post it at the moment, so here is a link:

Intake Manifold Diagram

You will notice that there are 3 parts to the Intake manifold.

There is the upper part with the throttle body. This is the part with PGM-FI on the top. It is called a plenum, basically derived from “common chamber” in Latin. This is also the only part I replaced.

Below that is the IAB (Intake Air Bypass) assembly. These are the butterflies that open up at high RPM for better breathing.

Then at the very bottom of the intake manifold are the “runners” that run the air from the plenum and IAB assembly into the individual cylinders.

The IAB assembly is the same as on an H22/H23, so the H22/H23 plenum will bolt right on.

H23 Intake Manifold Diagram

Here is a diagram of the H23 plenum (it is the same as the H22). You can see that part #10 in this diagram is substantially larger than part #10 in the first diagram.

Why do we want to do this? A larger intake plenum allows for more efficient breathing, especially at high RPM when the engine is pulling in a lot of air). The more air we can flow and add fuel to, the more power we make. It basically serves as a reservoir of air. The air in here is available to the cylinders at all times.

It also has a larger throttle body which also flows more air. This mainly causes more power in the top end because of the increased flow, but it also improves throttle response and bottom end torque because it is easier for the engine to pull in air. It also gives a meaner intake tone, because the engine is expending less energy on sucking in air, and can readily receive the air it needs.

The F22A6 intake manifold has shorter runners than the H23 manifold (an H22 manifold will not bolt up, as far as I know) so that again provides a little high RPM increase. You don’t lose torque though, because the runner length is the same as it was.

This modification basically allows you to create a better flowing intake manifold without a lot of effort (for those who have an A6 manifold on their car), and everything is OEM, so there aren’t any reliability issues. It also resulted in a substantial increase in power, throttle response, and possibly gas mileage. The last tank gave me the typical mileage, but I was flogging the snot out of it, so it will probably go up slightly if I back off.

Popularity: 12% [?]

2009
11.15

Here is a boost controller that incorporates quick spool up, minimal spikes, and minimal hassle. You will merely have to clean it once in a while, or else put a tiny filter in front of it so that dirt never reaches it. Then set it, and forget it.

“Grainger valve” is just a nick-name for a simple ball & spring check valve with adjustable spring tension. McMaster-Carr sells them  as part number: 48935K25
The above set up is adjustable and you will get to see if you like the quick spool up. If you do like it then you should add the simple parts below to make a 2-stage controller. Then you go from one boost level to another with the flip of a toggle switch.




You can follow the diagram below to have the quick spool up, *ONLY* when you floor it. Sometimes “lazy” driving is required, and you don’t want quick spool up. A wide-open-throttle switch is even better than a toggle switch; you only go to high boost when you floor it. It makes the “drivability” of the car excellent! Try it; you’ll like it! The Grainger valve controls the high boost setting, while the “low” setting is permanently at minimum boost, which is usually about 7 psi.

Please note that the unused vacuum barb on the solenoid valve is blocked off! I represented the block with a black rectangle. You must cap off this nipple. Again, there is a small (about .020″) vent hole drilled into the output barb of the Grainger valve to act as a vent.


Because of several requests, below you will see a fully manual “high-low” boost setup with adjustable “high”, and adjustable “low” settings. The bleed to adjust “low” acts as the vent. If you’re gonna run around with the low setting closed a lot, then add a vent anyway! The  Grainger valve controls the “high” setting.

Not all solenoids flow the same. Some flow much more than others. Apply 12Vto one at a time, and blow through them with your mouth. Use the ones that are easiest to blow through.
Solenoid valves cannot hold back high pressure that exceeds their spring power; at some point pressure will leak past the closed valve. Get a Mityvac and apply pressure to the center barb while12V is applied to it. Since you have capped off the top barb, it shouldn’t let any air through, and it should hold a pressure equal to your highest boost setting. If you want to run 18 psi boost, but the barb leaks at 12psi (for example), then pressure-test the OTHER bottom barb, and whichever one holds MORE pressure is the one you want to face the yellow restrictor in the diagram.




Here’s how you make and adjust it:
To make the valve, move the check ball to the other side of the spring.

Take it from here, and put it



THERE! Then screw on a brass barb fitting.(McMaster Carr part number) 5346K51



Drill a tiny hole (about .020″) in a brass barb first… (90degree brass barb is part # 44555k142)

Take a bigger stronger bit, like a .035″ or .040″bit, and slip it all the way down your chuck until it barely protrudes. Adjust it so that it’s *almost*
long enough to go all the way through the brass, but not quite. Drill with the larger bit until it bottoms out against the chuck. Now you have
a thin brass wall left that’s easy to drill through with the little .020″ bit.



Then bang the barb into the hole with a hammer. It should be in there really tight!



Then assemble the whole thing, and the finished product looks like this.
The barb with the orifice drilled in it (the 90^ barb) has to face the wastegate actuator,  and the un-drilled barb (the straight one) has to face the source of boost (intake manifold or turbo output nipple)


To adjust the valve, unlock the lock-nut, and screw the unit together, so that it gets shorter. The shorter you make it, the higher the boost goes. You should be able to get it really close to 14 lbs without hitting cut out.  Re-lock the lock ring, and it’ll stay where you set it.

The knurled knob turns to make the valve body shorter or longer. The lock ring stops the movement after adjustments are made.  The vent orifice needs no filter, as it never sucks air in. Making the valve longer LOWERS boost, while making the valve shorter RAISES boost.



If you don’t want to make your own, DarrenDawes is making and selling these controllers.

Here is a schematic from a factory T2 sticker that shows one possibility of tapping into existing lines.


A late model T1 set up, like my 89’s.




It has been noted that spiking seems to be minimal when the lines are kept short, and the vent hole is kept small. Try .020″ – .022″ for a vent  hole.

Popularity: 3% [?]

2009
11.13

Honda Civic 99-01 & Integra 00-01 OBDII ECU pinout schematics

Popularity: 11% [?]

2009
11.13

Del-Sol ESI H22 Axle Setup

Popularity: 1% [?]