Note: We are only using the highest quality fluids in the rebuild.

Oh, and some CRC in the spray pack on the right.

 

You have to send me some of the good Australian beer, none of that Fosters crap

Did you find out the cause of the overboosting?

 

It's actually VB. I wouldn't do that to you.

Still no idea on the overboosting. I checked the wastegate and it is fine as far as I can tell. I have a spare GM boost solenoid so I can test that.

StevHarr is concerned about how the boost control was set up but then he set it up and it ran fine for ages so who knows.

 

We finished the rebuild off on Saturday. We reassembled the head with the new retainers and cotters and bolted it on with new OEM bolts and the 3mm head gasket.

Here is a small movie of the tool we tried to use to do the cotters:

http://S2000.byteserve.com.au/images...d/MVI_0253.avi

It looks pretty simple there but it wasn't exactly the right size for the valve stems and cotters so we had more failure than success and ended up using the conventional method with a C-clamp (see an earlier photo).






A comparison of the stock and Inline 3mm gaskets.








The 3mm gasket looks strange sitting between the head and the block.


Another shot.




This the idler gear in for the cam shafts. It is two part and held together by 3 bolts. There is also a locator pin. If you remove the pin you have a small degree of play and turn the front cog a few degrees clock wise. This makes up for the increased height of the head and more advanced timing due to the pull on the chain.






This is the beast that has held up my engine rebuild so long. Guess I can't really blame him!


The F20C is now the standard engine for PRB Clubmans. So keep crashing them boys.


I've had the Hondata gasket for years. I finally get around to installing it.


Rebuilt Exedy Hyper Single is on and we're ready to install.


StevHarr is my muscle for the day. Thanks Steve.


Hmmm, tight fit.


Success at last! After some rugged finagling we got the block to mate with the gear box.

Enough for today.

 

Oh, one thing we noticed with the 3mm gasket is that the chain is tight. It pushes the tensioner guide all the way until the top of it is pressing against the wall. So I expect when I first run it there will be some serious wear on the guide.

Is this an issue? What have others experienced?

 

any more pics Aus?
How's everything going?

 

Your wish is my command!



Steve's little hands are quite useful.



Look at this spaghetti!

Engine is fitted, plumbed, wired and primed. It even turns over and fires but doesn't run. Need to set the timing tonight as we should be go.

 

Engine is running but the tuning is all over the shop. Was hoping to get it out for a thrash run-in but we're going to have to spend some time tuning first.

StevHarr spent some time setting up the idle tonight but there is lots more to do. On Saturday we'll spend some more time getting it tuned up to abut 4500 and then do some load runs to get it run in properly.

Looks seriously mean driving around with no bonnet on.

 

BTW, we discovered that the UEGO wasn't functioning. Turns out the spade connector on the relay that powers it was a bad connection. And guess what else is powered by this relay: the boost controller!

I guess that explains my the problem that led to this entire episode.