Hey guys, I figured it was time to start a build thread. Like many others, I know this isn't the standard path on this forum, but having an online journal of progress is always a good thing that could help others in the future.
Back story: I purchased this Blue 2004 CVT in December, with it needing a couple things, brake line, front brakes, etc. After a freshening up, it lasted 400 miles before the IMA battery started to have issues, and within another 1000 miles, the CVT decided 2020 wasn't it's year....
So, March 31st is the day I pulled out the stock engine and trans, and started the D swap. I was given a running/driving 1999 Civic LX for free, so that is how it started! Made some terrible engine mounts, but couldn't get the wiring figured out. So, when I found a 1993 Civic that had been hit, for $300, I snatched it up! D16Z6, 175K miles, engine ran really smooth.
So I pulled the motor, trans, and the entire wiring harness, including ignition cylinder, gauges, fuse boxes, all of it. Hooked up power and ground to it with the engine in the Insight, and she fired right up! So, even still, my insight has two ignition cylinders, two gauge clusters, and two interior fuse boxes! Sloppy! I'm working on this, obviously.
So, on to axles. I had followed another Insighter that put a D16 into his Insight, and used CRX HF axles. So I bought them, and had to modify the stock hubs quite a bit to get the outer CV joint to fit. Finally get it out on a test drive, and holy shaking car batman! The axles were just a bit too long, so on the search I went for ones that would work. After searching, I found that 1984 Civic axles were a little bit shorter than the CRX HF axles, so rock auto got me a set for just under $100. Hard to argue with that! When I put those axles in, the passenger side worked perfect, but the driver's side inner CV cup was shorter than the factory D16 one, by over a half inch, so the C-clip on the splines couldn't even engage. I don't know if that is a difference in the 1984 axle, or if the aftermarket company put the wrong inner CV cup on. It was identical to the passenger side inner CV cup, so I think it was an error. I simply pulled the stock civic inner CV cup off the old axle and put in on the new axle, and all is good!
So, I have been driving this car a little bit here and there, and have put about 300 miles on it, and it's doing good for the most part. I have many small things that need to get fixed, and I will work on them as time allows.
Many Videos and pics to follow! She leaves 11's for days!
So on to my current problems: The one I want to fix first, is the power steering. Currently it is not working. The module is plugged in, but it's as if it's not even there. I looked for a ground strap on the rack itself, but couldn't find one. I have heard that is an issue with these cars.
Sorry for the long read, hopefully you can find this process enjoyable! Thanks for looking,
John
Back story: I purchased this Blue 2004 CVT in December, with it needing a couple things, brake line, front brakes, etc. After a freshening up, it lasted 400 miles before the IMA battery started to have issues, and within another 1000 miles, the CVT decided 2020 wasn't it's year....
So, March 31st is the day I pulled out the stock engine and trans, and started the D swap. I was given a running/driving 1999 Civic LX for free, so that is how it started! Made some terrible engine mounts, but couldn't get the wiring figured out. So, when I found a 1993 Civic that had been hit, for $300, I snatched it up! D16Z6, 175K miles, engine ran really smooth.
So I pulled the motor, trans, and the entire wiring harness, including ignition cylinder, gauges, fuse boxes, all of it. Hooked up power and ground to it with the engine in the Insight, and she fired right up! So, even still, my insight has two ignition cylinders, two gauge clusters, and two interior fuse boxes! Sloppy! I'm working on this, obviously.
So, on to axles. I had followed another Insighter that put a D16 into his Insight, and used CRX HF axles. So I bought them, and had to modify the stock hubs quite a bit to get the outer CV joint to fit. Finally get it out on a test drive, and holy shaking car batman! The axles were just a bit too long, so on the search I went for ones that would work. After searching, I found that 1984 Civic axles were a little bit shorter than the CRX HF axles, so rock auto got me a set for just under $100. Hard to argue with that! When I put those axles in, the passenger side worked perfect, but the driver's side inner CV cup was shorter than the factory D16 one, by over a half inch, so the C-clip on the splines couldn't even engage. I don't know if that is a difference in the 1984 axle, or if the aftermarket company put the wrong inner CV cup on. It was identical to the passenger side inner CV cup, so I think it was an error. I simply pulled the stock civic inner CV cup off the old axle and put in on the new axle, and all is good!
So, I have been driving this car a little bit here and there, and have put about 300 miles on it, and it's doing good for the most part. I have many small things that need to get fixed, and I will work on them as time allows.
Many Videos and pics to follow! She leaves 11's for days!
So on to my current problems: The one I want to fix first, is the power steering. Currently it is not working. The module is plugged in, but it's as if it's not even there. I looked for a ground strap on the rack itself, but couldn't find one. I have heard that is an issue with these cars.
Sorry for the long read, hopefully you can find this process enjoyable! Thanks for looking,
John