Firstly I would like to thank James for doing this. It's something well beyond my capabilities, either due to lack of knowledge, somewhere to do it at my apartment complex, my physical ability (still recovering from significant back injury from January) and mentally (a lot of my plate, and awaiting ADHD work for meds).

Secondly I am really excited by all of this and hopefully will be able to cruise the mean streets of Canberra in the Jaffa again. And grateful to have a mate like James willing to do the work. Without his support I probably would've just up and sold the car and moved on disappointed.

Thirdly I have first hand experience of James' engine work and I can safely say it is better than most engine rebuild shops. His attention to detail is outstanding and his ability to think outside the box when needed is impressive.

The Jaffa turns 50 this year. Even though it's now too late to get it over the line in time for its approximate build date (mid-June going by stamps on several parts), it would be awesome to see it at a show and shine again sometime before the end of the year or early next year.

4 months later

Bottom end is back from the machine shop, it's had everything done. I've wrapped it up in WD40 for a few days while I wait for the paint (@Major Ledfoot it is Volvo Penta Red OEM aerosol). I won't mess around, I want to get the engine buttoned up without delay. I will run it through with bottle brushes and compressed air, seat the freeze plugs, and paint the block. I've also got the sump, I had that hot dipped same as the block, need to wire wheel off a few bits of rust but I'll paint that at the same time as I do the block.

Once that's done, I'll install the rotating assembly, oil pump, cam and button the sump up.

As usual, stay tuned for more updates!

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There was a place in Hornsby I used to buy my B20 2.1ltr head gaskets from

    Freeze plugs installed with Permatex 80008:

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    We went with OEM red

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    An hour of masking, a bunch of prepwash and tack rags and the block is looking pretty röd!

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    I still need to install the rear cam plug and paint inside the bellhousing area, for that I have to take the motor off the stand, I don't have any time until Sunday afternoon so that will give this paint a few days to setup fully before I start handling the block again.

    ^ Nice job. It's interesting how the Penta Red looks somewhat orange to my Beholding Eye, and rather more orange than the B230 engine in the background of the pics.

    Not a bad thing, really, considering the engine's future home.....

    What's your plan for the initial start-up and the breaking in of the cam and lifters? Doing this properly is critical to the longevity to the valvetrain and cam of a solid lifter engine, and these setups are not common configurations any more. I'm pretty sure I stuffed up this process 35 years ago.

      Major Ledfoot I had the same issue with orange paint for the bodywork of the Jaffa, it took a few days before the colour looked close or right.

        I've now installed the cam plug and painted inside the bellhousing.

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        I also painted this, which I think is the oil separator?

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        I dropped it in a tin of paint thinner for a few days which took care of all the crud inside it and hit it with a wire wheel to remove the last bits of paint and some surface rust.

        looks awesome, and following with interest. Maybe once it's finished and run in @paul0075 you might be able to drive it over to Perth?

          gavinh That's the plan. Because the car's been sitting for 18 months, it's going to need to have the brakes sorted out, and I also need to order the new radiator from Sweden (now there's someone making 1972 onwards radiators again), and I also need a new exhaust and the steering box serviced. Not sure what to do about the diff, I am not intending to change it over once the auto is swapped for manual, but I guess it will need to be serviced in some form.

            Do you have reason to suspect there is an issue with the diff? Otherwise just change the oil and carry on!

              jamesinc No but I don't think it's seen a service for quite some time. I know that I do get a bit of a yawning sound occasionally when the car changes gear, but I also had that on my 75 244.

                paul0075 if you come over here I have a complete car with all the parts on it that's been rearended, bought it for spare for my 145.

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                Crank is in, clearances are good, journals are all about 0.07-0.08mm than installed bearing shells.

                Next up:

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                14 days later

                A few more piecemeal updates. Progress has stopped while I wait for timing gears and a new front timing case (the kind that accepts a neoprene seal rather than felt) to arrive.

                Updated rear main seal and housing:
                Volvo B20 rear main seal upgraded

                New OEM Volvo oil pump:
                Volvo B20 bottom end with new oil pump

                I don't have any photos of the old pump, but the thrust surfaces were not in good shape, there was a lot of scoring. I was able to flatten the gears out with a pair of precision-ground flat stones, but even then I was able to catch a nail in places. A lot of money has gone into this engine so it makes no sense to risk it on a worn out oil pump.

                I spent some time with a wire wheel and some rust converter, and cleaned up the sump. I also knocked out a dent in the bottom of it.

                B20 sump with rust converter applied

                Painted Volvo B20 sump

                6 days later

                Crankcase is buttoned up at last

                Fuel pump and spacer installed:
                Volvo B20 mechanical fuel pump

                Fiber cam gear soaked in engine oil:
                Fiber timing gear soaking in oil Volvo B20

                Timing gears installed:
                Volvo B20 timing gears installed

                I didn't grab a photo, but I also replaced the cam thrust plate and spacer ring, as well as the Woodruff keys.

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                Nice work James
                If only that was an 850 engine 😁