Opel Club Cape Town

Don't expect anything special during this project, just need to get the car back on the road. Only have this for the moment:



About 3 welsh plugs have been leaking for the past 2 years, due to no anti-freeze due to the leaking heat matrix. One finally failed about 3 weeks ago, making the car undrivable. To replace the welsh plugs I would have to remove the inlet and exhaust manifolds. The engine has been smoking more lately so i decided to do a compression test. Results - rebuild. Since I was already half way there, decided it's pointless just making it run (by just replacing welsh plugs) as I need the car for the next 4 years, till i'm done studing.

Forgot to take pics of the dirty motor, it was covered in oil and sand, but here is a picture after I cleaned it, high pressure cleaner FTW!



I then drove it into the garage, and the stripping began. Head off



The horrible aircon and powersteeing bracket gave me the most hassels as i couldn't find the bold behind the aircon pump. I was hoping to leave the entire bracket there and simply bolt the motor off. However eventually the motor landed on the desk:




The empty engine bay, need to touch up some paintwork and rust by the battery:



Was surprised to see the motor had never been opened before! everything still standerd on 287000km

Then dropped all the parts off at the engineers (Motor Masters) and am now waiting for them to return. Been two weeks already!!!

Work done:
-Pollish crank
-rebore block 20 thou
-press fit pistons
-skim flywheel (would have liked to have it lightened but don't have the cash now)
-Balance entire bottom end including pressure plate, crank pulley and all bolts

While waiting for the engineers I have modified the linkages to make the throw shorter:





Also touched up the engine bay in the mean time. Now the wait for the engineers continues...

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1996 200is 312000km,272 Kent cam,4-1branch, 57mm Powerflow exhaust, fully balanced bottom end, DIY ported
Short Shift mod

Complete with - cracked windscreen, fading boot spoiler + bumpers, melted fusebox, incorrect grill, no headliner,cracked front disks, warped rear, 1X buckled and scraped mag 2X buckled

Gomoto GT125 71000km, 7kw of frame bending power :-) Still the most reliable vehicle I have owned

update - also replaced the selecter shaft seal in the mean time, STILL NOT BACK FROM THE ENGINEERS!! 3 weeks later!

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1996 200is 312000km,272 Kent cam,4-1branch, 57mm Powerflow exhaust, fully balanced bottom end, DIY ported
Short Shift mod

Complete with - cracked windscreen, fading boot spoiler + bumpers, melted fusebox, incorrect grill, no headliner,cracked front disks, warped rear, 1X buckled and scraped mag 2X buckled

Gomoto GT125 71000km, 7kw of frame bending power :-) Still the most reliable vehicle I have owned

goodluck with it get your parts back yet?

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Vdub VR6
Nissan 200sti
Honda vtec (civic)
Toyota RSI
Toyota runx rsi
Toyota bubble gli
Ford fiesta st

How much did the work at the engineers cost? coz i need to do mine now aswell

finally got the stuff back thanks Racing 1

costs: R852 + vat for engineering and R580 + vat for balancing, but the balacing isn't necessary for a normal rebuild

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1996 200is 312000km,272 Kent cam,4-1branch, 57mm Powerflow exhaust, fully balanced bottom end, DIY ported
Short Shift mod

Complete with - cracked windscreen, fading boot spoiler + bumpers, melted fusebox, incorrect grill, no headliner,cracked front disks, warped rear, 1X buckled and scraped mag 2X buckled

Gomoto GT125 71000km, 7kw of frame bending power :-) Still the most reliable vehicle I have owned

so got the parts back from the engineers, finally! Turns out it has been ready for the past week, they forgot to phone me.

Anyway, since I cant afford to send my head in for a port and polish, after some research, decided to do it myself.

Originally: amazed at how bad the casting is! there are lots of charp edges and lines:









After my diy porting, must still sand it with some 80 grit sandpaper

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1996 200is 312000km,272 Kent cam,4-1branch, 57mm Powerflow exhaust, fully balanced bottom end, DIY ported
Short Shift mod

Complete with - cracked windscreen, fading boot spoiler + bumpers, melted fusebox, incorrect grill, no headliner,cracked front disks, warped rear, 1X buckled and scraped mag 2X buckled

Gomoto GT125 71000km, 7kw of frame bending power :-) Still the most reliable vehicle I have owned

Hey Gouraami, nice build you got goin, but I cant see the pics.

Cant you rather upload them using the forums attachment function please man. I am sure alot of other guys cant see the pics as well.

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keep up the good work

After all my hard work found this on the side of the head, not sure what happened to the original. unless it comes out like this?


By gouraami at 2010-11-03

Also discovered all the exhaust valve guides are badly worn , back to the engineers.

I have always been struggling with the sump leaking. While cleaning it yesterday I think I figured out why. If you look at the picture it has been bent up everywhere from over tightening in the past


knocked it level, lets hope my oil leaking problems are over

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1996 200is 312000km,272 Kent cam,4-1branch, 57mm Powerflow exhaust, fully balanced bottom end, DIY ported
Short Shift mod

Complete with - cracked windscreen, fading boot spoiler + bumpers, melted fusebox, incorrect grill, no headliner,cracked front disks, warped rear, 1X buckled and scraped mag 2X buckled

Gomoto GT125 71000km, 7kw of frame bending power :-) Still the most reliable vehicle I have owned

for bluetooth

can you see todays update pictures of the sump? I used a different hosting site

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1996 200is 312000km,272 Kent cam,4-1branch, 57mm Powerflow exhaust, fully balanced bottom end, DIY ported
Short Shift mod

Complete with - cracked windscreen, fading boot spoiler + bumpers, melted fusebox, incorrect grill, no headliner,cracked front disks, warped rear, 1X buckled and scraped mag 2X buckled

Gomoto GT125 71000km, 7kw of frame bending power :-) Still the most reliable vehicle I have owned

If my knowlege serVes me well .the 20NE motor had lower CRs compared to your 20SEH
Which means if you have a 20SEH bottom end And 20ne HEad you still be the same.

IF you decked you head and your block .then you CRs should be up already all you need ithen is flat top pistons And ARP head bolts

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Gouraami I can indeed see them now yes, thanks.

My sump was also bent due to over tightening the bolts but after you straightened it again, it should work yes.

The 20NE head shouldnt make much of a difference if you have the 20seh cam in coz it is actually the block that differs the most between the SEH and NE.

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sprayed and put in new welsh plugs today.

+ just dropped the head off at the engineers again. Realised all the valves and seats are also . Another R1500

Just added up costs so far - R8000! havn't even started assembling yet! Hopefully I have everything I need. Oh yes plus a new heater matrix, R8350

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1996 200is 312000km,272 Kent cam,4-1branch, 57mm Powerflow exhaust, fully balanced bottom end, DIY ported
Short Shift mod

Complete with - cracked windscreen, fading boot spoiler + bumpers, melted fusebox, incorrect grill, no headliner,cracked front disks, warped rear, 1X buckled and scraped mag 2X buckled

Gomoto GT125 71000km, 7kw of frame bending power :-) Still the most reliable vehicle I have owned

the car has been off the road for a month already!

Finally, some progress. The bottom end back in the car. Hopefully the enginners are done with the head tommorow, I must still do the match porting.

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1996 200is 312000km,272 Kent cam,4-1branch, 57mm Powerflow exhaust, fully balanced bottom end, DIY ported
Short Shift mod

Complete with - cracked windscreen, fading boot spoiler + bumpers, melted fusebox, incorrect grill, no headliner,cracked front disks, warped rear, 1X buckled and scraped mag 2X buckled

Gomoto GT125 71000km, 7kw of frame bending power :-) Still the most reliable vehicle I have owned

Lekka man boet. Daai block lyk mos soet koek met daai nuwe pistons in jong.

So are you gonna fit the standard cam?

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the 284 is going back in!

I must actually take better pictures, the camera i'm using is really crap. It struggles to focus properly.

while I was arguing with that bracket with the aircon and power streering pump wondered, how did you break your bracket during your engine rebuild?

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1996 200is 312000km,272 Kent cam,4-1branch, 57mm Powerflow exhaust, fully balanced bottom end, DIY ported
Short Shift mod

Complete with - cracked windscreen, fading boot spoiler + bumpers, melted fusebox, incorrect grill, no headliner,cracked front disks, warped rear, 1X buckled and scraped mag 2X buckled

Gomoto GT125 71000km, 7kw of frame bending power :-) Still the most reliable vehicle I have owned

Oh okay kewl, should run lekker with your ported head yes.

As for the mounting bracket, I have no idea buddy. When I tried to replace the driver side mounting, I just noticed that the top part has broken off. My car dont have aircon, so I think that your bracket is much stronger than mine.

You dont know of anyone that can weld aluminium?

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As for the mounting bracket, I have no idea buddy. When I tried to replace the driver side mounting, I just noticed that the top part has broken off. My car dont have aircon, so I think that your bracket is much stronger than mine.

You dont know of anyone that can weld aluminium?[/quote]
I do but its in Paarl can get it done for free cuz works for engineering company and does pvts

I do but its in Paarl can get it done for free cuz works for engineering company and does pvts[/quote]

LOL! Thanks bud. Please PM me ur contact number. Its just a small piece that needs to be welded back on. Will then buy you a coke and a pie. He he he... coloured style mos.

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good progress uncle!!!

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Current:
'13 Alfa Romeo MiTO Quadrifoglio Verde Sport 125kw 250nm
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'08 Daihatsu Sirion Sport 1.5 VVTi
'02 Euro Opel Corsa 160is
'85 Opel GSI 2 door Boss