Hi there Wayne. This job is not for the faint hearted hea. But I will give you the best advice I can from My experiance. I did a allnighter not to long ago. Next time I will buy a new donk and fit it it would of been quicker. Haa haa maybee not. The first time is always the hardest. First of all go and get a workshop manual and read read and read just to be sure you know wot you are doing as I may off missed something. Make your wooden chock like the manual shows you all the sises are there make sure at the wedge you drill a hole the sise off a bit of rope and make a loop in the rope and tie it into place. (This will help you remove it later). Then go and get a special tool most people don't own. The manual doesn't show you need this tool so I didn't have one handy and I had the car all apart including no radiator when I pulled the rocker cover off. That was at midnight. Luckilly mates of mine were at there workshop having a few beers so I was able to go and pick one up from them in my other 1600. :O) It is like a short 10mm allen key that is part of a 1/2 inch drive socket as you will need that to undo the head bolts. While you are at the parts store buy a head gasket and a intake and exhaust manifold gasket that is 1 item. Buy some new coolant a new thermostat and I think that is all you need unless you have oil in the cooling system or water in the oil. Then you will need new oil and oil filter. Next to do is to remove the radiator and the fan. I can't remember why I actually did this but I remember the radiator getting in the way. Then remove the all the fuel line plumbing and the fuel pump so that when you remove the intake manifold you don't go ohh shit and have the thing balancing why you remove them. Remove the exhaust mani and let it drop down out of the way. Remove the rocker cover. There is a large bolt at the front of the cam sprocket crack it loose( It will be tight) but don't undooo it all the way. Turn the engine over by hand to top dead centre with the crank bolt. Now tap the wedge down in between the two halves off the timing chain to hold every thing tight down below. The manual shows you there is a link in the chain I couldn't find mine( Ohh Well You get that) All I did was to make two small scratch marks one on the timing pully and one on the timing chain. Then I removed the pully and let the timing chain fall nicely down onto the wedge. This is where you find out wether the wedge is in there securely enough cause if it isn't the chain will not be held into place properly. Now you can remove the head bolts with your new tool they will be tight. Ohh yea there is on the drivers side a small bolt that holds the head to the timing cover remove that too. Now the head should be able to be lifted off carefully. The head really should be taken to an expert to have it resurfaced and checked out for cracks and corrosion I didn't do that I crossed my fingers and hoped all was fine it was I did check it myself though all seemed ok and she is still running a couple of months later. Clean the left over head gasket from the block and head if you didn't have it resurfaced( make sure it is spotless). Place the head gasket on the block and gently lowere the head into place. Tighten the head bolts to the specifications on the package. Hook the timing chain to the cam sprocket in line with your scratch marks and fit it to the cam and tighten. When I tightened the bolt my wooden wedge actually became dislodged remove it completly. Now make sure your tappets are adjusted right. Bolt on the rocker cover and fuel pump. Clean the gaskets off the intake and exhaust manifolds place the new one into place and replace the intake and exaust manifolds back into place. Now replace the fuel lines and turn the motor over by hand with the crank bolt to check if there is any bolts left inside or any thing. Replace the fan and the radiator Put in the new thermostat. Fill radiator with coolant. Engine with oil and filter if required. And things hopefully will be right for you to fire her up. I don't think I missed any thing. Good luck. Rick White. _____________________________________________________________ Get Your free Ozdat Email Account ---> http://www.ozdat.com --membersozdat------------------------------------------------------- OZDAT Mailing List Please Note:- Send (un)subscribe requests to [EMAIL PROTECTED] Send submissions to [EMAIL PROTECTED] No unauthorised redistribution of this email http://www.ozdat.com/ozdatonline/index.htm http://www.ozdat.com/ozdatonline/listindex.html http://www.mail-archive.com/[email protected]/ ---------------------------------------------------------------------
