ZC into 4th Gen Wagon Information

HaydzHaydz Moderator
in Engine & Drivetrain
The DOHC ZC swap is fairly easy. I know it looks difficult when you first look at it, but its really not. We're here to help so fire away with any questions you may have after reading this.



Engine Mounts:

All EF/EE/EY D-Series engine mounts are the same (dependant on transmission choice), therefore the DOHC ZC bolts right on in without any welding or chassis modification. It is reccommended that you install new engine mount bushings when you do the swap, but its not necissary unless they are damaged.
-50840-SH3-000 :: MOUNTING ASSY., FR. STOPPER (MT)
-50810-SH3-040 :: RUBBER ASSY., RR. ENGINE MOUNTING (MT)
-50821-SH3-040 :: RUBBER, ENGINE SIDE MOUNTING (MT & AT)
-50805-SH9-020 :: RUBBER, TRANSMISSION MOUNTING (MT)
-50840-SH3-981 :: MOUNTING ASSY., FR. STOPPER (AT)
-50810-SH3-985 :: RUBBER ASSY., RR. ENGINE MOUNTING (AT)
-50805-SH3-983 :: RUBBER, TRANSMISSION MOUNTING (AT)


Shift Linkage:

The standard shift linkage for both 4WD and FWD will connect up without modification if you are using the stock transmission. It is reccommended that you acquire new shifter bushings to ensure a smooth and easy shift.
Its a good time to get a short-shift kit if you own a FWD. Short-shift kits are not available for the RT4WD as it uses cable shifters.
-RT4WD
-FWD


Exhust Manifold:

4-1:The exhust manifold off a SOHC D-Series will bolt up to the DOHC ZC but the ports will not be matched correctly. Some people have also needed to grind a corner off the manifold to get it to bolt right up to the head. An aftermarket 4-1 header will work.
4-2-1: The DOHC ZC Exhust manifold (1st and 2nd piece) will work without problems on the FWD however, for the 4WD you will need to use the SOHC Manifold with ports matched OR you could use the standard DOHC ZC 4-2 header (1st half) and the standard SOHC ZC 2-1 collector (2nd half), in order to clear the sump/oil pan and transfer case but still retain the 4-2-1 configuration.


Transmission:

Always use genuine Honda Manual Transmission Fluid or Automatic Transmission Fluid.
-You will need to retain the flywheel and clutch kit that suits your gearbox choice
-For the RT4WD, use the RT4WD flywheel, clutch kit, intermediate shaft and cover plate (for between the gearbox and motor)
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Power Steering:

Use the power steering pump for the DOHC ZC. This will bolt up to your current power steering fittings. Remember to use genuine Honda Power Steering Fluid.
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Electronics & Engine Accessories:

Its a good time to check all your sensors and replace any damaged or faulty ones.
-If your Wagon is DPFI then you will need to do a DPFI -> MPFI conversion.
-You can use either your stock alternator OR the DOHC ZC alternator
-Use the DOHC ZC engine wiring harness
-Use the DOHC ZC MAP Sensor


Hoses:

-19502-PM4-J01 :: Lower Radiator Hose
-19501-PD2-000 :: Upper Radiator Hose (North America)
-XXXXX-XXX-XXX :: Upper Radiator Hose (Outside North America)


-= In Progress =-
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Comments

  • akiraboyakiraboy HondaCivicWagon.com Founder
    Pacifier, do you have any info on vacuum hose or any wiring that may need to change on this swap? thx
  • HaydzHaydz Moderator
    Use the ZC map sensor, wagon flywheel, wagon clutch, wagon gearbox cover (between engine and gearbox) and thats all you need to worry about... Its all bolt-in and go.. :D
  • shenrieshenrie Council Member
    What about the int shaft for the awd application, or is there one on the 86-89 Integras that works? Also, is the D16A6 that comes in the awd a special block, or do all the D16A6's come with holes tapped for the intermediate shaft?
  • SiWagonSiWagon Council Member
    You can tap the hole.Time consuming.B careful not to tap to deep. :?
  • pas_wagovanpas_wagovan Wagonist
    I am going to go and try to pick up a twin cam ZC on saterday. Can i get away with just a long block for now? if not what is the bear min. do i need.
  • HaydzHaydz Moderator
    You will need long block + wiring loom + intake manifold/assembly exhust manifold (depending on choice) + map sensor from EF3/7... use the wagon flywheel and clutch assembly
  • HaydzHaydz Moderator
    As far as the int shaft goes, i have one from a SOHC ZC and one from a DOHC ZC and they are both interchangable, but i am unaware if this is the same between the D16A6 and the DOHC ZC... I think Shenrie mentioned that the D16A6 and DOHC ZC int shaft are not the same - but you will really need someone in North America to confirm that for you.
  • davensdavens familEE
    I can confirm this...the USDM wagon int shaft and dohc zc int shaft are slightly different.

    I've had them side by side. The differences are minor and with some effort, you might be able to make interchangeable. As I recall, the main difference was the length of splines on one end and placement of collar on the other. Bolt pattern was the same, or pretty damn close though.
  • pas_wagovanpas_wagovan Wagonist
    are you talking about the pilot bearing? what do i have to do to make the shaft fit. do i have to grind the input shaft down or can i get away with some kind of bushing to fill in the gap.
  • davensdavens familEE
    We're strictly talking about interchangeabilty between the two.

    Use your stock 4wd int shaft. I'm like 95% sure it will bolt to a zc block and you already know the other end fits your tranny.
  • HaydzHaydz Moderator
    Updated 17/06/2006.
  • cjswagoncjswagon Band Wagon
    So will an aftermarket 4-1 header work with a ZC swap on a RT 4WD?
  • HaydzHaydz Moderator
    I personally don't know to be honest. I think some people have used aftermarket 4-1 headers on their RT4WD but may have needed to get the lower piece bent slightly downwards towards the cat end.

    Can anyone else confirm?
  • HaydzHaydz Moderator
    Also check out davens' thread for a break-down on the ZC engines.
    http://www.hondacivicwagon.com/board/viewtopic.php?t=957
  • wagodizzlewagodizzle Council Member and EDM expert
    can you use the RT4WD wire harness with a ZC engine? doesn't the RT have the Si engine? :?
  • HaydzHaydz Moderator
    I used the harness that came on my DOHC ZC motor when i purchased it. All the plugs are the same if you are already MPFI (which an RT4WD is) so i don't see why not.
  • wagodizzlewagodizzle Council Member and EDM expert
    alrighty, thats wut i thought. that makes things much easier 8)
  • wagodizzlewagodizzle Council Member and EDM expert
    can you use the ecu from the RT or is it better to go with a different ecu... i heard the PM7 is the best. is this also just simple "plug and play"
  • HaydzHaydz Moderator
    Its all plug and play. My DOHC ran like utter crap on the PM6, changed to a PM7 and WOW what a world of difference!
  • wagodizzlewagodizzle Council Member and EDM expert
    cjswagon wrote:
    So will an aftermarket 4-1 header work with a ZC swap on a RT 4WD?

    might find this info helpful, then again this wasn't talking about the RT 4WD...

    There are several options here.
    -If your engine came with a complete exhaust manifold (header and downpipe), you can use it, of course. It’s a pretty good design, but heavier than aftermarket.
    -If your engine came with a stock 4-2 header, you can get a 92-95 Civic EX downpipe. It will mate up, but may hang alittle low.
    -If your swap didn’t include a header, you can use your stock D15/D16 header, but it will need to be ported to match the ZC exhaust ports. Use an 88 Integra exhaust gasket as a template. However, I would recommend upgrading to a proper 4-2-1 style setup, whether it be aftermarket, or pieced together from a stock ZC header and 94-95 Civic EX downpipe.
    -If you want to upgrade, you can use an aftermarket header for an 88 Integra.
  • con-wagoncon-wagon Band Wagon
    will the pm7 give the stock engine any more power?
  • HaydzHaydz Moderator
    con-wagon wrote:
    will the pm7 give the stock engine any more power?

    Unless you are getting a tune with an aftermarket device i would say stick with the ECU that matches your engine i.e. a PM6 for a SOHC ZC/D16A6 and a PM7 for a DOHC ZC.
  • HaydzHaydz Moderator
    Also check out Kahuna's thread about which ZC engine is right for you http://www.hondacivicwagon.com/board/viewtopic.php?t=1390.
  • nex_episode_wagon_alaskanex_episode_wagon_alaska New Wagonist
    pacifier so if i did a v-tec zc head or a z6 y8 head i can use the p28 ecu? will the four wheel drive still work? for some reason i thought that the ecu was the part that activated the four wheel drive. if you or anyone has any info on this mini me please let me know. thanks
  • HaydzHaydz Moderator
    The RT4WD isn't integrated with the ECU, therefore you can rest easy and swap it out. As far as mini-me stuff goes... i have no idea! :lol:

    Theres a mini-me thread on here somewhere, have a search around you should be able to find it.
  • Solscud007Solscud007 New Wagonist
    Ok im a noob to engine swaps. I have been sitting on my 91 wagovan for months after the tranny went. Im not sure what the problem is, as I cannot shift. I just want to chuck the whole thing away and start fresh. i saw some people said to jsut keep the stock tranny. But cant i jsut get a ZC motor with tranny and use that?

    Im gonna keep my eye out for a full ZC swap. I guess motor and tranny and what else do I need? ECU and wiring harness according to this thread. is that it? jsut plug and play?

    As my stock exhaust pipe is utter garbage I was gonna get someone to fab up a straight pipe and weld any old muffler to the back. so im not worried about the exhaust mating up.
  • wagodizzlewagodizzle Council Member and EDM expert
    Solscud007 wrote:
    But cant i jsut get a ZC motor with tranny and use that?

    yes, you can. most engine swaps usually include the tranny with the longblock.
    I guess motor and tranny and what else do I need? ECU and wiring harness according to this thread. is that it? jsut plug and play?

    you will need a PM7 ecu, wiring harness from the ZC or an Si, and you will have to perform a DPFI -> MPFI swap. http://fourthgenhatch.net/mpfi.html as for the actual engine itself you can use the stock motor mounts and shift linkage. if you need more help or info check this link as well: http://fourthgenhatch.net/zc.html .

    good to see you back here Solscud007!! :D
  • Solscud007Solscud007 New Wagonist
    Skater Dude wrote:
    Solscud007 wrote:
    But cant i jsut get a ZC motor with tranny and use that?

    yes, you can. most engine swaps usually include the tranny with the longblock.
    I guess motor and tranny and what else do I need? ECU and wiring harness according to this thread. is that it? jsut plug and play?

    you will need a PM7 ecu, wiring harness from the ZC or an Si, and you will have to perform a DPFI -> MPFI swap. http://fourthgenhatch.net/mpfi.html as for the actual engine itself you can use the stock motor mounts and shift linkage. if you need more help or info check this link as well: http://fourthgenhatch.net/zc.html .

    good to see you back here Solscud007!! :D


    Thanks. That helps a lot. I look forward to working on this, this summer.
  • henrystylehenrystyle Band Wagon
    I would like to know where I can pick up a dohc zc 4-2 header for the first half and a standard sohc zc 2-1 collector for the second half. Picking up my engine in the morning.

    give me a buzz: Ant..718-715-9226
    henrystyle1@verizon.net
  • nominousnominous familEE
    I've got a stainless manifold in my shuttle which has a D16A9 AKA ZC engine in there.
    It's been altered to route around the sump/gearbox and mate up with the zorst in the stock location.
    Shipping to USA likely to be pricy but it's for sale.
    It's one from ebay I believe, with heat wrap.
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