GReddy Turbo on a ZC Engine

This is my story detailing my install of a GReddy (http://www.greddy) Turbo in my 1990 CRX Si. The information is provided purely as informational and is not meant to endorse a product or company nor is it meant to provide direct instruction.

After dropping in a ZC engine in my CRX, I decided that even with the great improvement that it made, I needed "just a bit more". So in the process of looking around, I had two options to add some extra power to the existing ZC engine. The first option was a Super Charger that Jackson Racing was going to be releasing in the Spring of 2000 (UPDATE: Jackson now has a ZC supercharger at a price of $2800) (Update - 5/10/200 - Here is a link to "the old one" - they are working on a supercharger - but still not released) - I expected a retail price of somewhere in the $2300-2600 range. What I did like about the Super Charger is that it would be "stock like" and make no noticeable changes to the engine bay and have "all time" power. My second option was to go the route of a turbo. Even though there was not an actual Turbo kit directly for the ZC (d16a8 - in the U.S. that is) several people had been successful in mating the GReddy Turbo kit for the 92-95 Honda Civic SOHC VTEC engine (D16Z6) to the ZC since the exhaust manifolds were the same. The cost of the GReddy Turbo was about $1500 without an intercooler. Since my plan was only to boost less than 6psi and I would be using this as a daily driver and needed an efficient system - I decided on the turbo route.

Feb 17 - I ordered my GReddy "11550021 HONDA CIVIC EX VTEC 1992-95 TD04H" from Perfection Performance at http://www.perfperformance.com. (Prices are listed below). After ordering, the salesman John, says that they will email the tracking number today or tomorrow and the package should go out today or tomorrow.

Feb 18 - Still no tracking number from Perfection Performance in email, so I call them. Upon reaching Perfection Performance I get - "Uh, what's your name? What is your phone number? What was it you ordered?" - this isn't a good sign. He assures me that he will call me back with the tracking number today. But a quick check of my on-line credit card statement show that they somehow managed to bill the credit card even if they aren't the quickest in customer communication.

Feb 21 - Still no tracking number. A few early morning calls don't get answered... I'll check later in the afternoon and maybe they'll have it together. After a few "we're working on it" calls, they finally come up with the tracking number promised on Thursday. I check it and it does show that it was shipped on Feb 18th. It's on track to be here on Feb 24th.

Feb 25 - I call to see if my car's timing belt has been fixed at John Eagle Honda, the place that did my engine swap, and two weeks in it's still waiting to be fixed. But there was some good news on the turbo front - after being delivered to several wrong places I finally arrange to pick up the package at the UPS facility and everything appears to be good.

Feb 29 - I stop by John Eagle Honda and talk with Erik to see where we are after receiving my car for the timing belt repair on Feb 10th - it's not looking like it may not be done by them. I decide that I will go until the end of the week and I'll have my car towed back to my house were I'll just replace the timing belt. I also decided that instead of putting a fuel pressure regulator, check valves, retarded timing and a number of other "fixes", I will just do it right and go with a ZDYNE converted ECU. This modified ECU will allow me to use the stock MAP, timing, etc. SO - be aware that this install from this point forward assumes the installation of the ZDYNE modified ECU.

Mar 2 - I spend a few hours porting out the turbo and the exhaust manifold. Though I've been told that it's not necessary with low boost (under 6 PSI) I decided to do it anyway so that should I decide to boost higher in the future I will be ready.

Mar 3 - I talk with Erik at John Eagle Honda and he assures me /again/ that they will be coming in on Saturday to finally finish the car. He says call back on Saturday and I can work out the details for payment and pickup. We'll see.

Mar 4 - Well, Well, Well... Guess what - yep... Not finished. He assures me that they are coming in on Sunday to finish it. Then Erik says "so you should have it by Monday or Tuesday". I guess it really doesn't matter when I get it back since I must wait for the ZDYNE ECU before I could finish the Turbo install.

Mar 7 - The car is done -finally! I go and pick it up and bring it back to the garage and immediately start the install. I also get a message from the fine folks at ZDYNE saying I should have my new ECU in two days.

Mar 9 - I get the oil pan on, oil supply in and the ECU mounted (it came today - the ZDYNE guys are GREAT! - it's good to see quality service and promises kept). I pulled the A/C fan back out completely since it's (the turbo) not going to work with it in there. I also get the new 450/cc min injectors installed. I even get the down pipe "test fitted" and fire it up and it works great - good idle and no codes - pure heaven!

Mar 10 - I get the rest of the turbo kit mounted and even though I though I was going to have to have custom piping made, I found a way to use the stock piping from the kit along with a radiator hose to make the charge piping (much shorter even!). After everything was on I gave it a test drive with only one problem - I hadn't "burped" the cooling system and so it had air in it. Otherwise it was working great!

Mar 11 - It's the weekend and I've been driving it around and about the only real problem I have is that I now I need a BOV (Blow Off Valve) to release the pressure in the charge tubing when I am shifting (and the throttle plate slams closed). I also notice that my constant pounding on the gas has really appeared to have sucked up the gas. I'm one happy guy : )

Mar 14 - I Talk with Marcelo and he mentions the best way to "replace" the removed A/C evaporator fan is to mount it outside the condenser or otherwise I might have over-heating problems come summer with the A/C on. I also decide to go cheap on the BOV and get a Bosh unit from the following address for $25 shipped - cheap insurance against a blown turbo. ABJ Auto Supply and ask for Criag, 1-888-885-3500 / (617) 776-2978

Mar 17 - Since I need to "tap" the charge piping for the BOV, get the exhaust hanger mount removed/re-welded and a custom intake pipe made, I make a trip down to the muffler shop.

Mar 19 - I increased the maximum boost to around 9 psi and added a page detailing the process. In the next week I should have some actual dyno sheets up.

Mar 21 - I have the dyno sheets up and it looks like about 160hp and 138 torque. I'm still working on that BOV that seems to be "lost in the mail". I should also be out to the track for some times soon. I have also run a few tanks of gas through the car and should have some gas mileage figures up soon.

Mar 26 - I received the BOV in the mail and hooked it right up and it works great. I've added the BOV info and pictures on the pages.

Mar 29 - I have gas mileage figures up and to my amazement - the mileage hasn't changed over the mileage that I was getting with the ZC alone without the turbo - and that's with some pretty wild driving!

Apr 24 - Well I guess with all that air being pushed in the engine it has to get out somehow - I gave my car a drive without the catalytic converter and WOW - there must have been 20% more power! I'm not going to suggest that you run your car against federal law - but - it is MUCH faster without a cat!

Apr 30 - Several people have asked if you can use this turbo kit on a d16a6 stock engine in an Si - my assumption is yes and from accounts of others it is possible. The exhaust manifold is the same (the Si manifold will fit a ZC) so I reasonable assume the same for the second generation CRX Si. It should also fit early Del Sols (my guess) with the d16z6 as this was the 92-95 Civic engine.

May 30 - If you are looking for other turbo systems you might check out: http://www.f-max.com/

Aug 10 - Everything is still working great and it's still just as powerful as always. Very happy with the turbo with the exception of the A/C related issues.

Let's get started! Below are each section of the install broken down into different pages.
Click on the links to display the page.

NOTES: Do yourself a favor - purchase two items: An air wrench and a Impact wrench - they speed up the process, allow you to turn bolts in tight areas, and remove bolts that you might otherwise be unable to get out.

Tool	Use
8/10/12/13/14/17mm box/open end wrenches & Sockets	Most of the bolts on the GReddy kit are 12mm as are many on the Honda itself
Philips & Flat-Blade screw drivers	Various
Grinder (table or drill mounted)	You will need a grinder to remove at minimum the "tabs" from the exhaust manifold
Anti-Seize Lubricant	Allow easy future disassembly of the exhaust bolts.
Teflon Tape	Used for oil fittings
Permanent marker - any color other than black.	Marking oil return holes on oil pan.
Razor or knife	Various
Impact Wrench and Air Wrench	Really - you need these
Ratchets and Extensions	Various
Full socket set from 8mm to 24mm You will also need deep well sockets	Various
Pliers, adjustable wrenches, etc	Various
~3ft of 1/2" vacuum hose	Exhaust gas burn off
~2ft of 1" vacuum hose ~2ft of 1/8" vacuum hose	Connection to BOV

GReddy Turbo Kit Part #11550021 from "Perfection Performance" at: http://www.perfperformance.com	$1550
Turbo Shipping Charges	$60
2 Cans of High-Temp Black Paint (optional) from Home Depot (1500 degree)	$6
ZDYNE "Silver" ECU upgrade	$595
ZDYNE 450cc/min Fuel Injectors	$256
Oil Supply Extension	$1
Oil pan gasket	$13
Exhaust manifold Gasket	$25
Oil-Pan Gasket & Sealant	$16
Charge pipe "hose" extension	$19
Misc Hoses and BOV	$40
Anti-Freeze	$6
Oil Filter	$3
4 Quarts of Mobil-1 Synthetic Oil	$13
Total	$2603

Here are my gas mileage results after I've put about 900 miles on the turbo. Basically the mileage is still down from the stock but by only a few MPG - not bad for a jump of ~50 hp and more "aggressive" driving abilities. I'm very happy with these numbers. Don't forget that you MUST use 92+ octane gas after you install your turbo to lessen the possibility of detonation.

Apr 30 - I continue to get good gas mileage with the turbo setup. Generally about 30 and 32 on the highway.

Dyno figures are finally here. It looks like the ZC with the Turbo will put out 160hp and 138 f/p of torque (with the catalytic converter). It looks like with some tuning it should be able to go into the 170hp range - not bad considering that an Integra Type-R is right in the same range (see more here). Here is a link to an 8psi Super Charged d16a6 engine (like the stock engine in the Si) at 147hp/127tq. Here is a link to a ZC/GReddy Turbo'ed site that is pulling 13.0's with slicks. These figures were taken at a boost of ~8 psi without the aid of an intercooler, full HKS exhaust, new catalytic converter and no tuning. And on with the show: