Jan 8 - Finally! It's time to put it all back in the car.
This is the last phase and it took most of the day to complete. Nothing major to report other than the down pipe was unexpected part that needed to be replaced. After it was all done it was rolled over a few times and it started right up. The only problems were a leaking injector seal and the A-Pipe was loose since we had used an 98 Civic pipe until I could re-work my Stock Si header. After a spin around the block everything looked good and ran well and was surely more powerful.
| This is the connector end of an 89
Integra ECU (Manual Transmission only) PG7 (an 88 Integra Manual will also
work just fine). I should
mention that you will have to take the circuit board out of the casing
from the Integra ECU and put it into the Si housing. I am told the
JDM "ZC" ECU is a direct fit. It is highly recommended
that you replace your stock ECU. I should note that I found this ECU
using http://www.valuparts.com/
"Junk Yard" search engine - be sure to call around to a few
locations that it comes back with and don't pay more than 100$ - some
places will ship to you.
You can also send your ECU to http://www.zdyne.com to have it reprogrammed for ZC performance - expect about $230-250. |
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| The upper radiator hose is from a 84 Honda Accord and though it fits good - it is a little long. I just has to be trimmed down a bit. Note the new radiator. |  |
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| (Photo taken from the bottom of
the engine bay)
What's wrong with this picture? Well let's start with the fact that the stock ZC exhaust header has two down pipe holes as opposed to the stock Si's one. You either have to purchase a an after market (DC Sports or Kamikaze) or you can "fix" your stock Si header to work on the ZC by "filing" down the Si header as the ports in the ZC block are a little larger than the Si header - as shown below. |
^^ Rear Of Engine ^^ |
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| Here is the stock ZC header (left) and the stock Si header (right) head to head. As you can see - the ZC is a 4-2 and the Si is a 4-1 and it is for this reason that you can NOT use your Si down pipe with the ZC header. Shown without the heat shields. |  |
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| In this photo you see the ZC exhaust gasket imposed on the Si header. At the top you can see the "extra" header portion of the header that must be ground away. |  |
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| This is the header after it's been ground out and painted with hi-temp paint. Also be sure to paint your heat shield with a hi-temp semi-gloss black paint and it will look like original stock. |  |
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| On the left is the Integra connector (be sure to have the end that is cut from the original wiring harness - if not a DX or Integra connector will work) and on the right is the stock Si connector. If you are patient you can just pop the pins from the Si connector and plug them into an Integra connector. |  |
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| Here is the connector after it has been re-pinned to the Integra connector. And of course the two remaining wires are for the cam angle sensor that is built into the Si distributor but is on the second cam of the ZC engine. |  |
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| This is the cam angle sensor wire. I was lucky to have the mating connector that was just cut off at the wires. Marcelo removed the pins, re-attached new, longer, wires and put butt splices that will hook up to the remaining two wires from the Si harness as shown in the photo above. |  |
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| Wondering exactly what goes where?
Colors in picture are only for cross-reference and do not indicate wire color |
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| Wire Letter | Wire Color | |
| A | Blue | |
| B | Blue/Yellow | |
| C | White | |
| D | White/Red | |
| E | Peach | |
| F | White/Blue | |
| G | Peach/Blue | |
| Since the wiring in these older cars
can be hard to distinguish here actual pin outs for the plugs. NOTE
- mark the wires or do one at a time so you can keep track of which is
which.
If you can't get enough here - also check my ECU wiring color-code list (in excel format) |
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| Marcelo is expertly performing a valve train adjustment on the head before everything is started up. |  |
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| Now what's the deal with the hood? The first time you attempt to shut your hood you'll notice that the top of the cam cover hits the hood. The JDM CRX's have a "bulge" in the top as shown in the photo. You can get hoods from RedShift Racing at http://www.redshift.ca/ . I am told by Brett Diller [88crxboy@home.com] that the ZC hoods will fit the standard USDM front end and it is the SiR that is the longer hood. |  |
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!!!WARNING!!! After running with the "hood down" on the cam cover it caused the cover to rub on the timing belt and it slipped back a few teeth on the exhaust side (where it rubs). YOU MUST trim out the hood ribbing (and the hood insulation) or run without the cover.
Shown here is the cam cover and towards the bottom you can see where it rubs on the hood insulation. |
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| You've done the install and you
wonder - what in the hell does this loose vacuum hose (hose with screw in
it on the upper right of the photo) go to? Nothing. plug it up
and everything will be ok. The Si Manifold has a location to connect
this to the ZC doesn't.
This hose goes to the purge cut on the charcoal canister if you are wondering. |
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| In doing another swap on a ZC we ran
across two additional ports on the ZC manifold as shown in this
photo. I don't know what they go to. We just capped them off.
It is suspected that only the automatic ZC's (the preferred engine) have the extra ports. This ZC was a 1991 engine. |
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This last phase took about eight hours to complete - though I should mention that as many as three people were working on the car at once. Items that slowed things down were the "missing" A-Pipe from the header to the cat, finding all the right bolts (I might suggest putting the bolts back in the locations where they were removed were possible) and a few other items.