D16Z6 Engine preparation:

1. Unbolt valve cover and remove it
2. Unbolt upper timing belt cover and remove it
3. Rotate engine to TDC
4. Unbolt harmonic damper and remove it
5. Unbolt lower timing belt cover and remove it
6. Unbolt motor mount from the block and set it aside as you will no longer need it
7. Bolt on the 88-91 motor mount onto the block

  8  Loosen the auto tensioner
  9. Remove timing belt
10. Remove auto tensioner
11. Remove water pump
12. Remove camshaft gear
13. Remove camshaft seal
14. Remove crankshaft gear
15. Remove crankshaft seal
16. Clean the block where the timing covers usually are
17. Install new camshaft seal
18. Install new crankshaft seal
19. Install new water pump
20. Install camshaft gear
21. Install crankshaft gear
22. Install new auto tensioner
23. Install new timing belt
24. You will have to trim the timing covers to fit the new motor mount. Remember measure twice cut once!

25. Install lower timing belt cover
26. Install harmonic damper
27. Make sure the engine is timed properly
28. Install upper timing belt cover
29. Install valve cover
30. Remove old spark plugs
31. Install new spark plugs
32. Remove old water neck at front of head. You won’t need this for the swap.
33. Install D16A6 water neck
34. Unbolt and remove distributor cap
35. Unbolt and remove distributor rotor
36. Bolt on new rotor
37. Bolt on new cap
38. If you had a 88’ then you will need a clutch set and flywheel for a 89-91 Si instead of the 88’ as it has a different amount of teeth on the input shaft and the clutch is smaller (Read: weaker) anyways. You need an 89+ flywheel too! The flywheel and clutch sets for 89+ are all the same except when you get a set for a 92’+ hydraulic transmission you won’t have the correct throw out bearing so to make it easy on yourself get a 89-91 Si set. I have a lifetime warranty 91 Si clutch set from AutoZone and have gone through two free clutches this way all I had to do was the labor to swap it.
39. Remove pressure plate and old clutch disc
40. Remove flywheel
41.Get flywheel resurfaced. You didn’t think of this already? You didn’t read the quick note at the beginning of the article? You never did follow directions very well did you? He He! This is optional but make sure it’s in good condition if you are not going to resurface it. Also make sure there is no oil on it if your not sure clean it well with a degreaser. This goes for all the clutch components because if there is oil on them your clutch won’t work.
42. Remove rear main seal
43. Clean block
44. Install new rear main seal
45. Install new pilot bearing into flywheel
46. Install resurfaced flywheel
47. Install new clutch disc and pressure plate
48. Remove old oxygen sensor
49. Install new oxygen sensor
50. Clean the block more!
51. Bolt the transmission to the D16Z6 engine
52. Bolt the D16A6 starter onto the transmission
53. If you didn’t have the S20 transmission back up switch then you need to splice the two wires on the L3 transmission back up switch to the ones on the D16Z6 engine wiring harness. There are in a two-pin connector and it doesn’t matter which one goes to which, but try to be smart and match the colors if possible.