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From Nitro Performance Motorsport Projects Honda k20a2 THE BLOCK The standard honda engine block is quite a good unit but far too weak for the power levels I wanted to achieve, to overcome this problem some heavy engineering was required. Lucky for me I have a friend who is the owner of a machine shop..... The honda block has an open deck layout which under high load allows the cylinders to "walk". This was solved by a set of Darton International ductile iron liners to make the block a semi-closed layout. with a tensile strength of 300,000psi, I would be in no danger of breaking these as they are easily capable of taking around 1000BHP!
BOTTOM END With the block sorted it was time to look at the bottom end, I started by having the crank, bottom pulley, clutch and flywheel balanced. with this done I installed a full set of ACL race series bearing, a set of Manley pro series connecting rods and a set of CP 9.0:1 forged low compression pistons, this package should be capable of taking around 850bhp, the limiting factor being the standard crank, forged ones are available but I wanted to use as many honds parts as possible.
THE CYLINDER HEAD Again some extensive work was required here, because I would be using Brian Crower stainless steel valves, I had to replace the factory valve guides and replace them with KMS silicon-bronze guides. The crower valves have a thicker valve stem than standard, so the guides were cut to size and fitted. While the guides were removed the inlet and exhaust ports were ported and polished to improve gas flow. Brian crower twin coil valve springs were installed to reduce the risk of valve float under high RPM and high load. Titanium retainers were also fitted for strength and to reduce the overall weight of the valve train. ARP head studs are used to hold it all down to a cometic 60thou head gasket. Brian Crower forced induction spec cams are also being used to reduce valve overlap and increase the torque output of the engine.
THE TURBO KIT The turbo kit its self is made by a US based company called "Full Race Motorsport". Included in the kit is the turbo manifold, Garrett t3/67 A/R .70 turbo, intercooler, intercooler pipes, oil lines, vacuum pipes, Tial 44mm waste gate, Tial 50mm dump valve and various unions required for fitting. This is far from a "bolt on kit" tho, for a start it is made for a left hand drive acura RSX-S, which is the US version of our DC5 integra. Intercooler mounting brackets and pipes had to be modified and fabricated. Main engine wiring harnesses had to be relocated and extended. Vast amounts of heat shield had to be fitted, ranging from alloy panels to heat reflective material
ENGINE ELECTRICS Fuel is supplied via a swirl pot, Aeromotive A1000 pump, Aeromotive pressure regulator, Aeromotive filters, AEM fuel rail and RC 1200cc injectors. All mapping is controled via a US spec Hondata K-PRO ECU, fully mapable with anti lag. A HKS EVC 6 keeps the boos in line. When running in is complete i will be looking to run excess of 28psi (2 bar) of boost. The battery has been re-lacoated to behind the drivers seat due to the space being required in the engine bay for pipe work.
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