Project Freeze My engine Off (SAAB B207R Supercharged)

[evocarlos]

update on the astra
well its been off the road since jan when the head lifted and then filled the sump with coolant.....

in the meantime i bought a A/C tig welder and done the workshop up
its nice to get to working on the car again
the sump had a hole for the oil temp


did lol


i have planned to just drop in a z20net engine as the aem dont care what engine it is.
to run the net i had to get a suitable flywheel to bolt to the crank to give me output to the m32 box a standard net fly wheel with the lugs machined down is what ive got for the job


mounting face at the same height as the m32/z22se flywheel


new rear crank seal going in this one was leaking


took me ages to find the 2 extra machined ARP flywheel bolts


theres the expensive part lol the clutch cost more than this engine and the signum put together lol


got the engine in the car last sunday all bolted in


most of the other stuff got bolted on the same day


bought a standard astra g 2.2 lower rad hose as im moving the elec pump the issue is now the oil cooler is in the way and the selector on the m32


hoping to get the rest of the work done later after i did a chain job today

 

[evocarlos]

its alive again but a few issues with not having the 2.2 trigger wheel the fuel pump would not run so had to use one of the 12v outputs one the aem to run it then another output to run the tach but it runs and its smooth will see how it goes with the mapping part once i finish all the little bits

 

[evocarlos]

You can tell shows season is soon ive only gone and washed the bloody thing lets see if we can keep the head on this one for more than 140miles lol

 

[corsaZ22se]

you got nearly 2 months till VBOA mate. plenty of time to get her shinny again

 

[evocarlos]

was not happy with the one loom half so ive rebuilt it made all the wires the same length and added in plugs so the aem is unpluggable
bit of a mess from before


pin location and usage figuring out


saab fuel injector loom sockets and throttle body plugs for the interconnect


nice!



1st layer of tape


2nd layer of cloth tape

 

[evocarlos]

So the car ran but there was a problem with a missfire from the get go heres with 60psi on #2 cylinder and the output on the guess'o'meter (BSFC)

 

[evocarlos]

Putting together the new reinforced 2.2 also had a new set of pistons come
Put some metal filler in the areas where water can meet oil


Glass razors and a wipe down


Then to cut the holes for the water to get thru


Match the holes in the head


Close enuff


Crank in with new shells


Lower support lubed and fittes


New Diamond pistons


Valve recesses as standard


Now to make the decision on grind the rods or grind the pistons so the rods go all the way home

 

[vocky]

did you buy the block already done or did you get it done yourself ?

 

[evocarlos]

did you buy the block already done or did you get it done yourself ?

im working closely with a machine shop to supply them
this is rev 1.0 im currently waiting for 1.1 that will include closer tolerance on the insert to block and move the machining close to the oil feed

 

[evocarlos]

People saying the b207 can handle 400 bolllocks i tell ya bolllocks

Heres a p**stake of bore wash


Now you see it


Now you dont

 

[figo126]

take it that's a spare engine you've picked up on your travels ,,,,,,,,

 

[evocarlos]

take it that's a spare engine you've picked up on your travels ,,,,,,,,

Yes need an engine in to get to the vboa show

After fitting a replacement piston and building it up with a new gasket and skimmed head its back where its ment to be

 

[chill]

My B207 has been great up to 380 hp, i do have a maps which go over 400 hp but have not felt the need to use them for any long term time. and this thread makes me think i wont use them

any idea on whats actually failing

 

[evocarlos]

chill this engine was given to me so i could get the car back on the road for vboa but it turns out ever since fitting there was an issue the knock sensors was going ballistic and i had pinking at low rpm i believe the engine came from an accident damaged car that had a front end smash so i guess the piston damage was from when it stopped moving quickly lol it was my own fault for not doing a compression test at the start its all fixed now the map just needs adjusting to the stage 3 cams and I'll see what fails 1st then the new wedged 2.2 can go in and make some real power

 

[evocarlos]

I also had an issue with it getting to hot after pulling the thermostat i found the "wax xxxx" thermostat installed even though its marked 82c its a 94c stat ive now fitted a mk4 astra one and its now back to staying at 85c and the fans cool it fine
When at vboa i found one plug with a cracked ceramic and one with a large gap so while at the show i fitted a fresh set of astra vxr plugs and got the engine to pass 3000rpm without missfire or spark blow out ive not really done much on it since down to work load but also i foubd my timing lamp broken so now i have a replacement i have confirmed the timing offset in the ecu is correct and i can move forward

 

[evocarlos]

New fuel pump and a fuel pressure sensor for the aem will be good to have reading and safety function for fuel

 

[evocarlos]

Bit of an update been afk for a while.

New dremel to mod the diamond pistons the forged rods dont quite fit the gap


10mins later

Now they fit


Stocked up on crank seals


Finally got round to fitting the new fuel pump and pressure sensor


Found a nice spot for the sensor out the way still letting the cover fit and access to the oil filter


And i think i found the issue with the aem keep changing the new VE readings one of the o rings on the FPR was split swapped the reg over and its all working


After configuring the stack sensor to the aem the fuel pressure is now monitored 46psi with no vac to the FPR


3bar - 43psi with 8hg applied to the FPR bumps up to 66psi with boost


Had a squeak thought it was the alternator so put new bearings in


Then found the belt split ffs

Hows it go "whoop i did it again" #1 this time same as before cracked piston can tell from the missfire and the oil spewing out the cap.
I think pistons made from digestive biscuits would be stronger

 

[corsaZ22se]

what pistons do you have in to go through them like that?

 

[evocarlos]

what pistons do you have in to go through them like that?

Its a bog standard b207 everyone keeps saying there good for 400hp i can't see how ive not even pushed it yet lol going to swap out #1 this weekend and try again then get the forged 2.2 build finished ready to drop in

 

[corsaZ22se]

oh.
i have 2 sets of those in the shed.
what your saying is they make good paper weights then?