*BREAKING* - Unfinished 1.6 Honda DOHC 160bhp engine build
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Author:  russ220 [ Wed Aug 19, 2009 12:52 am ]
Post subject:  *BREAKING* - Unfinished 1.6 Honda DOHC 160bhp engine build


Since ive never got any money these days and another year has passed where this build hasnt progressed im going to sell it. i'll try on here first before it goes on ebay.

good news for you guys since you've now the chance to buy my project engine and build it yourself, some stuff is imported from the USA too.

First, the engine:
D16A9 non catalyst engine, taken from a running 1990 216GTi DOHC 5dr, had covered 84,000miles and was stripped down purely to rebuild for more power.

the ECU showed no fault lights prior to the engine removal and the car was a good runner, never overheated and i was the 3rd owner of the car.

it is still the stock bore size, 75mm and you can still see the honing marks down all 4 cylinder bores.

the head is still the stock height never been skimmed.

cam belt has never failed on this car so all valves are all straight.

the stock rods have been marked as to their order, these are undamaged as are the stock pistons.

all ancillaries are present, cooling hoses, 2x rocker covers, halfshaft, engine mounts, ECU, loom, injector resistor box, the valvetrain has all be boxed up into order as to where it came from and labelled. every part is present and labelled.

i have both the stock flywheel and a D16Z6 flywheel which allows fitment of a 212mm clutch (stock is 200mm). uprated 212mm clutches are easier to find.

Also have the DOHC gearbox, the input shaft bearing was noisey prior to removal but was still smooth and faultless in operation.

there is also a D16 SOHC gearbox included, now you have the option of two different gear ratios, the DOHC being the closer cut of the two 'boxes

New parts:

the cams were sent to Bisimoto Honda tuning specialists in canada and have been modified to a stage1 profile. i have all the documents stating the cams spec and fitment information etc. view the link below to see the said bisimoto camshaft service: ... cts_id=299

these are for a D16A1 engine, they're much better design of piston as they do not have a big giant dome on top. They have a higher compression height instead creating better quench properties. they're brand new from USA and are in 76mm bore (1mm oversize).
The piston rings are brand new NPR items, these came with the pistons.

as you can see i brought all new main bearings and big end bearings from Honda, these are the exact specific sizes for this engine and are colour coded to their specific tolerance/fitment (good old honda engineering ay?) also got the 2x new thrust washers for the crank

Skunk2 items again from the USA, suitable for B16 and D16 DOHC engines

also brand new from honda:
complete top end gasket and seal set,
Aux belt
PAS belt
timing belt+tensioner,
Oil pressure sensor,
rotor arm,
dizzy cap,
ignitor module,
oil filter,
fuel filter,
another rocker cover gasket,
8.5mm Magnecor HT leads,
misc parts
Thermal intake gasket
kent degreeing wheel


the cams alone are worth £200 without the import duty and shipping costs from USA.

im located south of Birmingham -M42 J4/5 area

Price list, not including postage.

i can arrange postage on items under 10Kg, over 10Kg buyer to arrange collection/courier.

Engine (no cams), new bearings, ECU, belts + tensioner - £150

Top-end gasket and seal set - SOLD

Red Silicone coolant hoses from groupbuy - SOLD

new Stage 1 cams + FOC degree wheel - £200

new skunk2 Cam gears - £150

new 76mm PG6 pistons + rings - £75

starter motor - £20

PAS pump - £20

Alternator - £20

new Magnacore red HT leads - SOLD

new oil pressure sensor - £5

new Coolant temp sensors - £5

new Rotor Arm - £5

new Dizzy cap - £5

new Ignition module - £50

new Coil - £10

new Oil filter - £5

new Fuel filter - £5

new Thermal inlet gasket - SOLD

212mm flywheel - £15

Driveshafts + half shaft - £25

Honda cam cover - PROV. SOLD

Gearboxes - £30 each

Author:  MarkCoupe [ Wed Aug 19, 2009 9:37 am ]
Post subject:  Re: Unfinished 1.6 Honda DOHC engine build

:o :o :o :o :o :o :o :o

But i thought you had a coupe ?

Author:  russ220 [ Wed Aug 19, 2009 7:44 pm ]
Post subject:  Re: Unfinished 1.6 Honda DOHC engine build

i do have a D16 coupe, but it too is starting to show its age and the laquer is peeling on the rear quarter.

i did plan on it either going in a GTi or this coupe, but the daily driver 1994 fiesta diesel has failed its MOT, needed alot of welding for its MOT on rust and all in i was looking at £3/400 . Some pikey bugger cut the chain and stole the trailer from my grandad's so now i've lost my transport for getting the car to the tuners as it'd need breaking-in on the rollers and then live mapping.

by the time i've got another trailer and finally finished the engine sod's law says the coupe'll start rusting on the rear arches/sills.

i have looked at putting the honda engine into the ZS, only trouble is i've now scrapped the 216GTi it came from and didn't cut the engine mounts out of the bay. though a honda ZS would be pretty sweet, especially with its handling....hmmmm... :drive:

Author:  russ220 [ Fri Aug 21, 2009 5:26 pm ]
Post subject:  Re: Unfinished 1.6 Honda DOHC engine build

i may as well build it up and shift it as a completed build, i'll just fit the thinner cometic MLS 0.030" headgasket but leave the head unskimmed. that way it can run on the stock ECU map

Author:  TheRealStig [ Fri Aug 21, 2009 6:52 pm ]
Post subject:  Re: Unfinished 1.6 Honda DOHC engine build

dont give up on it mate, sounds like you dont really want to but your in two minds like weve all been in at some point, but remember why you got it in the first place ;)

surface rust or paint peel isnt the end of the world either bud

Author:  russ220 [ Wed Apr 20, 2011 11:16 am ]
Post subject:  Re: Unfinished 1.6 Honda DOHC 160bhp engine build -

bump, price reduced :(

Author:  russ220 [ Tue Aug 02, 2011 12:06 pm ]
Post subject:  Re: *BREAKING* - Unfinished 1.6 Honda DOHC 160bhp engine bui

now breaking for spares, prices at bottom of listing

Author:  russ220 [ Thu Aug 25, 2011 4:57 pm ]
Post subject:  Re: *BREAKING* - Unfinished 1.6 Honda DOHC 160bhp engine bui

bttt :)

Author:  gbs100 [ Thu Aug 25, 2011 7:13 pm ]
Post subject:  Re: *BREAKING* - Unfinished 1.6 Honda DOHC 160bhp engine bui

HI how much for the honda cam cover inc p+p :thumbup:

Author:  russ220 [ Sun Mar 12, 2017 2:49 pm ]
Post subject:  Re: *BREAKING* - Unfinished 1.6 Honda DOHC 160bhp engine bui

About a year late but finally sold this lot :lol:

Author:  1234dist [ Sun Mar 12, 2017 8:03 pm ]
Post subject:  Re: *BREAKING* - Unfinished 1.6 Honda DOHC 160bhp engine bui

That's pretty good going, looked like you were trying to do proper pics for rimmers... :lol:

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