What a shit day! Boring read but....

Started off at 10am went to build the engine. Degreased and cleaned it all, ready for assembly. Went to fit the head and noticed that the cylinder 4 inlet valve wasn't fully sealing when the valve was closed. So had to run the head down to my brother who thankfully was about to go on lunch and re ground it infor me. brilliant.

Took the head home, built it all up with the manifolds etc. Put it on the block and the headbolts wouldn't fit through the bolt holes! They are the same re-usable headbolts I took off this enigne so couldn't understand why they didn't fit. Of course it's a new head to the old one but thought alll the holes were the same?

The two bolts together. CVH and 12mm ZVH bolts. You can see just how "beefier" the ZVH bolts are!





I came on here and read up nothing about having to re drill the head, so went down to my local fastners with the CVH headbolts off my old engine and got a set of 10 but in 150 length. Took them up to the yard they fitted the head perfectly but would screw into the Zetec block and if I wriggled then and pulled they would pull out of the threads? The only thing I could think was the engine builder drilled the CVH out to accept a larger/stronger headbolt. So thats what I did. Drilled the headbolt holes out to 12.2mm and I've fitted the head with the original 12mm ZVH bolts.

That also meant I had to completley strip the head bare and clean all the swarf out the re build it!

Then with these little set backs out the way I went about building the engine. Which becuase of all the set backs and running around only took 11 hours

Focus RS Headgasket



And built





Inlet set up.