Engine rebuild

[JazzMan]

Due to the car being off the road because of the broken wish bone I decided it would be a good idea to tackle the engine rebuild. This was more planned for next winter but never mind!

The current engine had 111k on it, and with the zone chip started running really well so I was not expecting any major issues. Part of the rebuild will involve dropping an M52B28 crank shaft and M20B20 conrods into the block. This will make it a square engine with an increase in capacity to 2.8ltrs. Further the head will receive a new set of performance valve springs and a dbilas 282°/272° camshaft. All gaskets and seals are also being replaced.
http://www.msportster.co.uk/data/p_engine001.jpg (http://www.msportster.co.uk/detail.asp?cat=22)
Head off!

http://www.msportster.co.uk/data/p_engine005.jpg (http://www.msportster.co.uk/detail.asp?cat=22)
Inspection of the head reveals its in prett y good condition!
http://www.msportster.co.uk/data/p_engine012.jpg (http://www.msportster.co.uk/detail.asp?cat=22)
Nice tip for getting the bolt out the end of the cam shaft. Put the old timing belt around it, then loop the open end of the belt round the work mate. This locks it in place and allows the easy removal of he botl!
http://www.msportster.co.uk/data/p_engine015.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=12)
Rocker number out, shaft on its way out
http://www.msportster.co.uk/data/p_engine022.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=12)
Camshaft and everything else removed from head minus the valves
http://www.msportster.co.uk/data/p_engine024.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=12)
First valve out, couldn't take any more out as the valve spring clamp we bought was not big enough, needs to go back for the more expensive one!

The water pump was shot, all the bearings gone so that's why I had a bit of a funny noise from the engine.

More to follow!

[BigFas]

Wow, will watch follow this with interest. Do you have a background in engine work / building cars? Or did you learn everything as you went along with this project?

[Black Sabbath]

I will be watching this thread as well,previous one was good as well

[JazzMan]

Just learning by doing at the moment :D

[mystic sport]

Awesome skills. I know it will be a bit of a bind but if you could do a decent writeup with pics all the way through it would be great.

[Juber]

Now thats skill! I wouldnt even attempt such a big project like that! Bet its fun though!

[Chaos]

You're not wrong about the head/valves, they're in very tidy nick for that mileage. Sounds like you've got a nice set of matching mods to go in there, should be a good end-product, fingers crossed it all goes smoothly. :)

For those wondering what an untidy head looks like at that mileage, try the attached snap from the workshop last Saturday. ;)

[peppernick]

Good luck with the project :cool:

Supercharge? ........ :D



For those wondering what an untidy head looks like
LOL ..... that I would classed as absolutely fc*ked! at any given mileage ....... :p

[JazzMan]

You're not wrong about the head/valves, they're in very tidy nick for that mileage. Sounds like you've got a nice set of matching mods to go in there, should be a good end-product, fingers crossed it all goes smoothly. :)

For those wondering what an untidy head looks like at that mileage, try the attached snap from the workshop last Saturday. ;)

ouch, bit of piston / valve contat there then!


Good luck with the project :cool:

Supercharge? ........ :D

The thought had crossed my mind, repeatedly! Eaton M90 seems to be popular with the E30 boys :D


Awesome skills. I know it will be a bit of a bind but if you could do a decent writeup with pics all the way through it would be great.

Everything I've done so far is covered in an excellent tech article on E30Zone which is why I've not gone into much detail. I'll be documenting everything on the website as I go :)

[Mud]

Looks like a great project, I would love to take apart my engine to have a look at whats shot, seeing as do crazy mileage these days!

[BMW JAY84]

Excellent dude. I would also like to see a write up. Maybe once its done you could post a link on here for anyone who wants to follow it in more detail ?

[JazzMan]

Excellent dude. I would also like to see a write up. Maybe once its done you could post a link on here for anyone who wants to follow it in more detail ?

Here's the link: http://www.msportster.co.uk/detail.asp?cat=22 :) or click any of the photos to take you direct to the correct page

Rather than buying a new valve spring compressor we decided to make an extension for the curent one.
http://www.msportster.co.uk/data/p_engine025.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=24)
After lathing the tube to the correct size with a suitable amount taken out the inside to fit over the clamp it needed holes in the side so that you can still remove the collets after compressing the springs:
The completed adapter attached:
http://www.msportster.co.uk/data/p_engine031.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=24)
And now in use on the head to remove the valves. Looking at this it would seem that it would have been possible to use it without the extension but it would seems to be easier this way up!
http://www.msportster.co.uk/data/p_engine032.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=24)
The intake valves and valve seats look great, but the exhaust seats and valves need re-grinding. They are just starting to pit. All in all everything seems to be in very good condition.
http://www.msportster.co.uk/data/p_engine035.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=24)
All the valves, springs and collets arranged in order waiting to be cleaned up.
http://www.msportster.co.uk/data/p_engine036.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=24)
The head could do with a dip, it seems to be nice and straight but I think I'll find a machine shop to double check everything for me!

[zarnd]

awesome project, and good luck with it all.

Interested to see how it all turns out for you!

cheers

[JazzMan]

awesome project, and good luck with it all.

Interested to see how it all turns out for you!

cheers

If the engine runs again when I'm done I'll be happy :p :D :)

Here's the bits going in:

http://www.msportster.co.uk/data/p_parts041.jpg

http://www.msportster.co.uk/data/p_parts042.jpg

http://www.msportster.co.uk/data/p_tuning043.jpg

http://www.msportster.co.uk/data/p_tuning044.jpg

http://www.msportster.co.uk/data/p_tuning045.jpg

http://www.msportster.co.uk/data/p_tuning46.jpg

[Mah_c180]

Wow great project mate

Hope you get there in the end

[BigFas]

the fact that you're learning by doing makes it even more impressive. good luck and keep us posted

[JazzMan]

The head is off to the local machine shop for crack testing, we'll know if everything is good on Tuesday. If it is then it'll get a bit of clean up.
http://www.msportster.co.uk/data/p_engine037.jpg (http://www.msportster.co.uk/data/engine037.jpg)
Clean valves! This took a lot of time! The exhaust vales were cakes. Used a technique from another Sportster builder placed the valve in drill and used increasingly finer sand paper to take the layers off and then some metal polish to finish it. The intake valves just need a run over with 1200 grit & some degreaser, then metal polish.
This was a 4 hour process with two people and two drills so about 8 work hours to clean them up! Some of them still have a bit of carbon build up but its very small and they still need to be run through the ultrasonic cleaner and degreaser!
http://www.msportster.co.uk/data/p_engine038.jpg (http://www.msportster.co.uk/data/engine038.jpg)
The tops of the valves where cleaned like the bottom half, the centres took a bit more work with sand paper and the edge of a knif blade. The only area left alone was valve seating area, that will be ground in when the head comes back from the machine shop.
http://www.msportster.co.uk/data/p_engine039.jpg (http://www.msportster.co.uk/data/engine039.jpg)
Rest of the engine is out of the Sportster, looking a bit empty now.
http://www.msportster.co.uk/data/p_engine040.jpg (http://www.msportster.co.uk/data/engine040.jpg)
Engine and gearbox out!
http://www.msportster.co.uk/data/p_engine043.jpg (http://www.msportster.co.uk/data/engine043.jpg)
The clutch coming off
http://www.msportster.co.uk/data/p_engine044.jpg (http://www.msportster.co.uk/data/engine044.jpg)
Sump off!
http://www.msportster.co.uk/data/p_engine045.jpg (http://www.msportster.co.uk/data/engine045.jpg)
6 pistons removed from the block and numbered. They need a good clean and the conrods swapping for the 130mm M20B20 ones. I'm going to check the M52B28 conrods and the M50B25 ones I've got knocking about as well see if there's anything more suitable.
http://www.msportster.co.uk/data/p_engine046.jpg (http://www.msportster.co.uk/data/engine046.jpg)
Bores in the block look great!
http://www.msportster.co.uk/data/p_engine047.jpg (http://www.msportster.co.uk/data/engine047.jpg)
Flywheel off, had to lock the crankshaft in place with a metal bar between piston 3 and 4 then the bolts came out really easy!
http://www.msportster.co.uk/data/p_engine048.jpg (http://www.msportster.co.uk/data/engine048.jpg)
Crank bolt came out really easy - surprisingly!

[JL Marc]

good luck mate, i think i will be leaving engine rebuilds to the pros with mine tho

[FullHouse]

some serious dedication and patience, well done on a good job to date

[mikem]

WOW, I`d love to do something like this.

[JazzMan]

M52B28 crank shaft sitting in the M20 block - this end will need some kind of spacer for the oil seal.

http://www.msportster.co.uk/data/p_engine049.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=48)

Crank sits in the block like it was meant to be there, runs round without any clearance issues - only other thing that needs to be tested is the M20B20 130mm conrod with the M20B25 pistons in place to check clearances.

http://www.msportster.co.uk/data/p_engine050.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=48)

One more picture for good measure!

http://www.msportster.co.uk/data/p_engine051.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=48)

One question, how the h*** to do you the cam belt pulley off the crank? It seems to be wedge solid. The cam chain pulley came right off the M52 crank so I assume its the same with the M20 except I've got 20 years of gunk keeping it on!

http://www.msportster.co.uk/data/p_engine052.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=48)

[JazzMan]

http://www.msportster.co.uk/data/p_engine053.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=48)
Puller-me-jig in place. The metal plate is bolted to the bit that needs to come off. In the middle a long bolt (out of an M52 block!) and a nut. Theory is you do up the bolt in the middle and it pops off.
http://www.msportster.co.uk/data/p_engine054.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=48)
The metal is already bent from the first time it wont done up (it moved about 1/2 mm)
http://www.msportster.co.uk/data/p_engine055.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=48)
Carefully the middle bolt was done up until it started pulling off.
http://www.msportster.co.uk/data/p_engine056.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=48)
and here it is finally!
http://www.msportster.co.uk/data/p_engine057.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=48)
There were tiny amount of rust underneath which is what was causing it to stick.
http://www.msportster.co.uk/data/p_engine058.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=48)
Needs a good clean out and polish before test fitting on the M52 crank.

[JazzMan]

http://www.msportster.co.uk/data/p_engine059.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=48)
M20B25 piston test fitted with M20B20 conrod and M52B28 crank! Moves well.
http://www.msportster.co.uk/data/p_engine060.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=48)
Piston / conrod / crank combo at top dead centre - looks good :)

[JazzMan]

Its going to need a thicker than standard head gasket as piston comes ever so slightly further up that before.

A little bit of progress:

http://www.msportster.co.uk/data/p_engine062.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=60)
Crank spacer taking shape on the lathe
http://www.msportster.co.uk/data/p_engine063.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=60)
One step left is to machine down the spacer to the correct size - about 18mm

[arkenphel]

I have absolutely no idea what you are doing, but it's absolutely fascinating and a compelling read.


Also because of the nice pictures... :D

[JazzMan]

:lol: with any luck by the end of it I will have working 2.8 ltr engine (0.2 ltr bigger than before) so more torque in the mid range, more power and with the more aggressive cam shaft more power at the top end!

I've finished the crank spacer:

http://www.msportster.co.uk/data/p_engine065.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=60)
Spacer machine down to size, about 17.90mm with in 0.1mm of the original.
http://www.msportster.co.uk/data/p_engine066.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=60)
Cam belt pulley test fit, this a very tight fit so it will need the "the tool" to get it back off again.
http://www.msportster.co.uk/data/p_engine067.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=60)
As the M52 crank nose it a bit longer than the M20 the washer in the front doesn't sit flush.
http://www.msportster.co.uk/data/p_engine068.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=60)
Washer in the lathe, need to take about 1.25mm off giving 0.1mm space between it and the crank nose.
http://www.msportster.co.uk/data/p_engine069.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=60)
Finished off and the edge smoothed off
http://www.msportster.co.uk/data/p_engine070.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=60)
Test fit of all parts on the M52 crank.
http://www.msportster.co.uk/data/p_engine072.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=60)
Comparison: M52B28 crank and the front and M20B25 at the back

[JazzMan]

Cleaned up all the pistons today, but managed to snap one of the piston rings in the process - doh!

Andy, the chap who came up with the conversion several years ago has recommended I use the standard head gasket with this conversion!

One more discovery after examining the head, its not quite straight - its warped ever so slightly towards the front where the thermostat sits. Check with a steel ruler, but to be 100% sure I used the lathe bed which confirmed it. Off to the machine shop with the head next week then!


The other odd one, it seems in the past somebody tried to use super glue to seal the thermostat housing to the head - that was a PITA to get off!

http://www.msportster.co.uk/data/p_engine072.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=72)
Silver is so last month, so blue it is this time!
http://www.msportster.co.uk/data/p_engine073.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=72)
We used red hamerite on the exhaust plugs and those didn't discolour until we welded something on it - so it seams heat resistance enough!
http://www.msportster.co.uk/data/p_engine074.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=72)
The hammered blue looks great out in the light.
http://www.msportster.co.uk/data/p_engine075.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=72)
Oil pump disassembled and cleaned. It all looks fine nothing really worn so no need to replace it.
http://www.msportster.co.uk/data/p_engine076.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=72)
The parts slot right into place, covered in assembly oil. This stuff is thicker than normal oil and kinda sticks to everything. Should help keep everything lubricated on the fist run.
http://www.msportster.co.uk/data/p_engine077.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=72)
The filter element has a few hardened clumps inside it but nothing major!

[MARTY]

Impressive stuff Jazzman! Much like arkenphel, this sort of stuff goes way past my mechanical expertise but hats off for giving it a go and thanks for an excellent write up and great pics. Very interesting read!

[BigFas]

Absolutely amazing, thanks for keeping us updates, fascinating stuff

[alexsh1]

Just learning by doing at the moment :D

Fascinating!!! But I bet you have all the tools and some engine knowledge.
Personally, I would not do it as I am sure I have to spent shit loads of money
to buy all the tools and I have no expertise

[JazzMan]

Yeah spent the last 3 years buying tools while building the car. I'm still missing a good set of air tools but a decent compressor is a huge chunk of money! Engine hoist was a worthwhile investment! The engine been in, out, in, out and then out of the Sportster. When we did the 2.8 engine swap on my brothers car I need for that! Finally now I've been able to use the engine stand I bought at the same time :lol:

As for the knowledge just what I picked up of the net and out of the workshop manuals, read a few books as well :) E30zone.co.uk an excellent source of knowledge for M20's.

[JazzMan]

Got the head back from the machine shop on Friday (the place in Southampton were very good and friendly (if a little bit odd), unlike the first place!), they took 4 thou off to remove the warp:
http://www.msportster.co.uk/data/p_engine078.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=72)
Starting a bit of valve lapping
http://www.msportster.co.uk/data/p_engine079.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=72)
2 down only 10 to go!
http://www.msportster.co.uk/data/p_engine080.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=72)
All the valves boxed up and ordered
http://www.msportster.co.uk/data/p_engine081.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=72)
Throttle body attaches here, its been ground a bit larger - more pictres to follow on that at some point
http://www.msportster.co.uk/data/p_engine082.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=72)
Valve springs - the larger one has shrunk 2mm over the inside ones and new springs.
http://www.msportster.co.uk/data/p_engine084.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=84)
All valve lapped in - a simple short sentance that will take you hours and hours, especially if you have pits on the valves like we did!
http://www.msportster.co.uk/data/p_engine085.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=84)
A nice mat grey colour is what your after!
http://www.msportster.co.uk/data/p_engine087.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=84)
The valves all have a nice mat dull finish on them as well.
http://www.msportster.co.uk/data/p_engine088.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=84)
Valve stem oil seals going on - a size 11 socket bit proves to be exactly the right size to push these in place.
http://www.msportster.co.uk/data/p_engine091.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=84)
One at a time the new schik valve springs go in, putting the colletes back on proved to be a very fiddly proceedure!
http://www.msportster.co.uk/data/p_engine093.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=84)
All springs now in place!
http://www.msportster.co.uk/data/p_engine095.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=84)
All cleaned up - the head needed a 4 thou skim to take the warp out of it.

[Chaos]

How much did you take out of the throttle body overall?

Valve lapping takes the patience of a saint, you have my sympathy and respect!

[BMW JAY84]

The project continues. Looking good mate. The question has to be when you bringing this down to a meet for us to ogle :)

[JazzMan]

How much did you take out of the throttle body overall?

Valve lapping takes the patience of a saint, you have my sympathy and respect!

The throttle body was supplied by the e30zone shop:

http://www.msportster.co.uk/data/p_tuning04.jpg

Standard throttle body on the right, enlarged one on the left.

It flows 17% more air at full throttle, what I did was open up the inlet manifold as it had about 1mm some overlap at the bottom. It can now flow without any obstructions.


The project continues. Looking good mate. The question has to be when you bringing this down to a meet for us to ogle :)

As soon as its back on the road and the weather permits :)

[Chaos]

Nice attention to detail. :)

[JazzMan]

thanks :) small things like that can give you the little tiny extra bits of power. What I could also do is grind down the rod that the throttle butterfly sits on as well which would increase air flow a bit, but I'd rather it retain its strength.

[Black Sabbath]

Nice work going on there :cool: .You still after a compressor?I might know where there is one going quite cheap if you are.PM me your number and I'll see whats whats with it for you ;)

[JazzMan]

http://www.msportster.co.uk/data/p_engine096.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=96)
Camshaft inserted
http://www.msportster.co.uk/data/p_engine097.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=96)
New oil seal and o-ring for camshaft
http://www.msportster.co.uk/data/p_engine098.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=96)
Rocker shafts and rockers on their way back into the head - the head needs to be propped up so there is room for the valves to open as the last rocker needs the camshaft rotated to slide in. Also make sure the rocker shafts are at the right angle before rotating the camshaft otherwise its not easy to move the into the correct place.
http://www.msportster.co.uk/data/p_engine099.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=96)
Both rocker shafts in and the clips that hold the rockers in place. The spray bar as also been mounted.
http://www.msportster.co.uk/data/p_engine100.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=96)
A closer view of the assembled head
http://www.msportster.co.uk/data/p_engine101.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=96)
Everything now in place on the head, it just needs the rocker cover put in place to shield the inside from dust.

[Chaos]

Everything now in place on the head, it just needs the rocker cover put in place to shield the inside from dust.That's the only time when it's man-points for a guy to use a tea towel. ;)

[JazzMan]

ha ha, its got a rocker cover on it now :D

I need to wait for parts now before carrying on - although the sump still needs to be cleaned up so I can do that next :)

[Mah_c180]

Wow mate, this project is wicked.

youve given great information mate

[JazzMan]

New parts! Conrod bolts, main bearing shells, big end shells, water pump, cam belt and piston rings.
http://www.msportster.co.uk/data/p_engine102.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=96)
http://www.msportster.co.uk/data/p_engine103.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=96)
2.8 crank installed in the block with new bearings, bolts are torqued up.
http://www.msportster.co.uk/data/p_engine104.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=96)
Crank spacer in place
http://www.msportster.co.uk/data/p_engine105.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=96)
Many hours later all the pistons are installed with new bearings, all moving parts have been given a coat of assembly grease - this is more sticky than normal oil so it should stay put until the normal enigne oil is circulated round the engine before first start.
http://www.msportster.co.uk/data/p_engine106.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=96)
Front cover plate in place with new oil seals installed.
http://www.msportster.co.uk/data/p_engine107.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=96)
Oil seal around the crank spacer.
http://www.msportster.co.uk/data/p_engine108.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=108)
Water pump installed along with the gear for the oil pump.
http://www.msportster.co.uk/data/p_engine109.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=108)
Bottom view of engine with all parts installed. New conrod bolts have been torque, then turned to the approated settings!
http://www.msportster.co.uk/data/p_engine110.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=108)
Blue sump! Just resting on the engine for photos.
http://www.msportster.co.uk/data/p_engine111.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=108)
Its not quite this bright in real life, the flash has given it a much strong blue colour!

[JazzMan]

http://www.msportster.co.uk/data/p_engine112.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=108)
Final clean up and degrease of the head.
http://www.msportster.co.uk/data/p_engine113.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=108)
Mmm shiny! Also double check that the cam pulley is turned to the timing mark on the head.
http://www.msportster.co.uk/data/p_engine114.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=108)
Belt tensioner now also installed
http://www.msportster.co.uk/data/p_engine115.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=108)
Head gasket placed on the block.
http://www.msportster.co.uk/data/p_engine116.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=108)
Head placed on block ready for the head bolts to go in.
http://www.msportster.co.uk/data/p_engine117.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=108)
Bolts placed, these were all tighten up as per the Bentley manual and in the correct order. Its a 3 step process.
http://www.msportster.co.uk/data/p_engine118.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=108)
Everything bolted up, the rear oil seal needs to go and the sump bolted on.
http://www.msportster.co.uk/data/p_engine119.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=108)
Final thing was to install the cam belt - turned the engine over severa times and it all sounds good. No interference between valves and pistons from the sounds of it!

[BigFas]

amazing work. You should be proud of yourself

[JazzMan]

amazing work. You should be proud of yourself

Thanks Fas :)

http://www.msportster.co.uk/data/p_engine120.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=120)
Rear cover plated attached to block, sump bolted on and the flywheel on read to be bolted. The bolts need to be tightened up in a specific order and covered in loctite.
http://www.msportster.co.uk/data/p_engine121.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=120)
Clutch back on the fly wheel
http://www.msportster.co.uk/data/p_engine122.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=120)
Gear box slotted on "like a glove" [ace ventura]
http://www.msportster.co.uk/data/p_engine123.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=120)
After a lot of jiggling the engine is back in mated with the drive shaft and on all 4 mounts.
http://www.msportster.co.uk/data/p_engine124.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=120)
Just needs all the ancillaries bolted back on
http://www.msportster.co.uk/data/p_engine125.jpg (http://www.msportster.co.uk/detail.asp?cat=22&offset=120)
Nice blue block, shame it has to be covered by the intake manifold!

[JazzMan]

It runs :D

Turned it over on the start without ECU and plugs. The pressure came up nicely after a short while. Plugged the ECU in and the plugs, and ran the starter after short time the fuel pressurised and off it went

Water pump seems to be defective as it makes a horrible noise sometimes. Initially the engine would die as I came to a stop at a junction but that's sorted itself out after a short while.

Was out for a drive today and made a short video, either on our site in high res: http://www.msportster.co.uk/

Or on YouTube:

http://www.youtube.com/watch?v=dw0A-uSfEHQ

Here are some photos from today:

http://www.msportster.co.uk/data/p_march08_01.jpg (http://www.msportster.co.uk/detail.asp?cat=21)

http://www.msportster.co.uk/data/p_march08_02.jpg (http://www.msportster.co.uk/detail.asp?cat=21)

http://www.msportster.co.uk/data/p_march08_03.jpg (http://www.msportster.co.uk/detail.asp?cat=21)

http://www.msportster.co.uk/data/p_march08_04.jpg (http://www.msportster.co.uk/detail.asp?cat=21)

http://www.msportster.co.uk/data/p_march08_05.jpg (http://www.msportster.co.uk/detail.asp?cat=21)

http://www.msportster.co.uk/data/p_march08_06.jpg (http://www.msportster.co.uk/detail.asp?cat=21)

http://www.msportster.co.uk/data/p_march08_07.jpg (http://www.msportster.co.uk/detail.asp?cat=21)

http://www.msportster.co.uk/data/p_march08_08.jpg (http://www.msportster.co.uk/detail.asp?cat=21)

http://www.msportster.co.uk/data/p_march08_09.jpg (http://www.msportster.co.uk/detail.asp?cat=21)

http://www.msportster.co.uk/data/p_march08_10.jpg (http://www.msportster.co.uk/detail.asp?cat=21)

[Mah_c180]

Wicked project mate. Great job, well done