DISCLAIMER: The procedures, methods and products written up here was for my circumstances only. I make no assertions that your results will be the same nor do I claim that this is the best way to do it. USE AT YOUR OWN RISK!


I will be writing detail info on the progess of 1.0 bar(14.5lb) pulley installation + DIY AEM EMS tuning for your reference.
I WILL KEEP UPDATING THE PROGESS SINCE I AM STILL ON THE PROGRESS OF TUNING.

My car is US-spec MY03 S2000 with Vortech SC. F20C
Other power related mod is Amuse dual Ti.

My 1.0bar project part list were......(some parts are not in pic)

-. AEM EMS 1052
-. AEM UEGO Gauge
-. AEM 2-bar MAP sensor
-. 3.8in aluminium pulley for Vortech V-2 charger
(This is smallest pulley you can get for F20C while retaining 9000rpm redline)
-. Shorter SC belt ( 6PK1245 or 6PK1240 )
-. Cometic 2mm gasket( CR ratio of 9.9:1)
-. New OEM head bolts + OEM liquid gasket
-. Hondata heatsheld gasket
-. 750cc RC Injectors (high Imp.)
-. Honda Type-2 coolant.
-. Engine oil(used Motul 300V 10w-40)
-. OEM oil filter
-. OEM Cam cover gasket.
-. Spark Plugs, Recommand NGK 7405 (heat range of 9)


I will be posting brief info on hardware installations, BUT I will go into detail about DIY AEM EMS tuning later.

I recommand to remove front bumper,fender,hood to give better room to work on.
Also it prevents from damaging body parts.
Since I took off the front fender, I also installed J's fender brace.
After brace installation, dont forget to check door gap before you put the front fenders.
Also make sure door closes without any abnormal movement.

 

Cometic 2mm head gaket Installation.

Please follow the Honda service manual's instruction on how to install 2mm head gasket.
After removing S/C hardware, take off the cam cover.
(Please look at Vortech SC installation manual about removing SC assembly)

This is picture of right after you remove red cam cover.
You will see beautiful VTEC cams



After removing the cam assembly, it's time to loose head bolts that holds the head.
You will also have to disconnect all vacumme + coolant line on the intake manifold.



Pic of top of piston. Took me about 3-4 hours to reach this stage.
F20C showed much cleaner piston head, valve train parts compare to other makers' engines.
I see absolutly no sludge anywhere(car has 30k miles)
Perhaps it is because I always used syn-oil?


Engine head.


Pic after I cleaned the head part.


Installed RC injectors and Hondata heatsheild gasket while I took off intake manifold.



Re-installed head. I have installed new head bolts. Please follow instructions on how to install new head bolts.
Check for any tiny cracks on retainers.



Re-installed cam assembly. This is perfect time to check your valve clearence.
Install new cam cover gasket kit from Honda.


DUE TO 2MM GASKET CAUSING EXTENDING CHAIN TRAVEL, NOW YOUR F20C WILL HAVE 2deg. RETARD ON TIMING.
DO NOT RE-INSTALL SC assebly yet because you have to check timing with timing light to check synconazation with AEM EMS.
It's almost impossible to check once you put SC back on.

Finished (Sorry for dirty engine pic)

 

Vortech FMU removal
REMOVE the Vortech supplied FMU.
Please refer to the instuctions from Vortech SC manual to how to remove Vortech FMU.
BUT do NOT use stock fuel return line. Keep the Vortech supplied return fuel line which is much thicker for increased fuel pressure.


AEM EMS mounting
Disconnect batt.
Disconnect Vortech Black box and reconnect all wirings(refer to Vortech manual)
Stock ECU is located on driver side kick panel.
Take off the stock ECU and be careful not to pull harness too hard.
You will have to fabricate a brace to mount EMS securely, I used 2 bolts that holds stock ECU.
The space is VERY tight and don't forget to connect serial port cable too.
I had to put silicone hose over the serial cable since it was rubbing against the chassis.
If you have AEM EMS 1012(which is tad bigger), you might have to get extended harness to install at different place.



I will be posting one by one when I have time.

 

awesome thread!

 

Looking fwd to the continued story!

 

Great information.

Thanks!!

I have a question.

What is the pulley size for 11lbs of boost?

Thanks,

Everett

 

Wow, i can't believe this thread, This is EXACTLY what i am going to do, this is awsome.
Great Work, keep up the good job!
And lets see a dyno on that bad boy when you get done, good luck
Fred

 

Awesome post, this will benefit several of us including myself. for taking the time to take pics and document it all.

I'm looking forward to your DIY EMS tuning.

 

marking this as well ... good luck with everything

 

Congrats Kim....
I hope you share all the experience and thoughts about the Upgrade and its worth...
I hope you get all the bugs Fixed with AEM EMS and Than I hope you DO a dyno in to see some great results.....
Cheers


marked tread