[roger1]

Thanks Greg!

I had reported in my last update when I did a test crank of the engine that the starter sounded funny. When starting to dig into that issue, I first noticed that the plastic inspection cover that I got with the 200-4R transmission had broken at the retaining screws. It didn't clear the flexplate obviously. After taking it off and cranking the engine from underneath I could see the flexplate had a bit of runout to it. It also appeared that the runout was causing the pinion gear to wobble. I took a video of it and sent it RobbMc (where I bought the starter) to get his advice. Here is that video:

https://youtu.be/BfkajrEV0FI

Robb (the owner) told me that I needed to add shims under the starter bolts to move the gear away from the flexplate and suggested adding shims 1/32" at a time until I could tell there was no gear contact at the root diameter of the pinion gear. He also said that I could keep adding as long as the backlash didn't go over .031 at any point of an entire rotation of the flexplate but don't add any more than necessary.
So I added 1/32" but it wasn't quite enough. I then added 1/32" more and that did it. Sounded normal and the wobble was totally gone. It's still not that close to the .031 maximum either.

After solving the starter issue I started to do some research on getting an inspection cover that would fit. I hated that plastic one but that's all that's available. They do make a metal one but it has the cutaway for the starter on the wrong side for a Pontiac engine.

So, I dug out the original inspection cover for the Turbo 400 to see if I could modify it to fit the 200-R4. Turns out I could and it wasn't that hard. Just some trimming and modifying the screw holes a little. After blasting and painting I think it looks a lot better than the plastic one too.





So working towards being able to start the engine, I needed to run the power wire to the electric fuel pump and decided to get the tail light wiring done at the same time.

That was fairly time consuming. I didn't like the way American Auto Wire wanted me to run these wires so I did quite a bit of modifying to make the wires close to the way they were done with the original harness. I also had to add a ground wire to each tail light since I'm using the plastic tail light lens housings. Even if I were using the metal housings I think I would have done that anyway.



After putting in some gas and other fluids, I got the engine running. Here's a video:

https://youtu.be/61DNpj5kz2M

After starting, the first thing I noticed was a ticking noise. It also had a bit of engine shaking at idle. I left it running a while and got it warmed up well while I filled the transmission. The ticking didn't go away and when revving I could feel the shake up over 1500 rpm before it would start smoothing out.

I checked and changed some of the parameters on the Edelbrock EFI. The machine shop didn't get some of the adjustments done that were in the instructions. That made the engine start easier but didn't change the shake.

I was afraid that I might have a lifter problem as I had been warned as well as read that these Lunati lifters can have problems sometimes.
Anyway, I decided the first thing to do was pull the spark plugs and do a compression check. 7 of the cylinders where very close being just a couple of psi either side of 150. But one cylinder (#5) measured 180 psi so about 30 higher than the others. #5 was also the side the ticking noise was coming from. Pulled the valve cover on that side and turned the engine to see what was going on and quickly could see the the #5 exhaust valve rocker was loose. Really loose. I measured the lash at 1/8". That explains the higher compression reading. The nut had backed out some and I could turn it with my fingers. Must have been a bad nut. The nuts were a new set that came with the Magnum roller-tip rocker set. Anyway I was kind of hoping the ticking noise and the engine shake issues were related and it appears that is the case.

I did some research what poly lock type nuts would work and ended up ordering a set of Comp Cams 4606 which are 1" long. I think they will be the right length for the studs and clear the stock valve covers too. They will be delivered tomorrow.

I thought about getting the paint stripped off the grilles and repainting them but decided to do a trial fit of The Parts Place chrome trim first. That didn't go so well. I broke one of them. More info on that here:
https://forums.maxperformanceinc.com/forums/showthread.php?p=6329250#post6329250

So I guess I'll order another one and try again. I wish they fit better and didn't require the bending.