Water pump disaster...

While do other things I'm putting parts into the cleaner - today the water pump which was fine until I dropped it on to the garage brick floor and cracked the impeller!

£180 new unit or £110 exchange unit - not pleased with myself.

Engine breakdown... pt15

Rear engine plate and crankshaft housing and oil seal – I remove the bolts from the plate and seal housing the lifted them off. Popped out the old oil seal and cleaned off the old gaskets.

1hr

Engine breakdown... pt14

Clutch and Flywheel - repositioning the engine on the flat surface of the trolley I removed the six bolts holding the clutch cover and pulled out the plate, I think its about half worn so I will replace it anyway.

Then the eight bolts holding the flywheel to the crankshaft, using a large screw driver in the starter ring to stop it turning I lifted it away.

1hr

Timing chain assemble...

Dropped the timing chain assemble in to the cleaner for 10 minutes, oiled the chain and bagged for refit later.

30 mins

Head assembly...

With the valves reground it was time to refit them and paint the cylinder head. Using a block of wood to protect the valve head they went in without any issues.

Then using masking tape I covered up the out/inlets and the top camshaft area, I then gave the head a couple of coats of high temperature aluminium paint.

3hrs

New parts...

Received a box of goodies - shells, thrush washers, top and bottom gaskets - VAT free offer from Rimmers.

Engine breakdown... pt13

Timing chain assembly and cover – I started by removing the crankshaft pulley, wedging the crank with a block of wood and undoing the large bolt.

By removing the remaining bolts I lifted off the cover and started undoing all the bolts holding the gear assembly, chain guides and timing chain tensioner. Using a allen key to remove the jackshaft keep plate I then slipped out the jackshaft.

I dropped some the bits into the ultrasonic clean which does a good job given enough time.

1.5 hrs (I had very cold fingers!)

Engine breakdown... pt12

Removing the pistons next, I started by removing the remaining big end caps and shells, the condition of these shells are similar to the others already removed.

Cleaning the bores with a clean rag to minimise any damage to the piston rings I pushed the first piston up and out and placing into a numbered box containers I had set-up earlier.

Containing with the other three being careful not to let the rings catch on anything, the rings all look fine with plenty of spring in them and the bores look fine too. I will need to borrow some of my fathers measuring tools to check them properly.

One thing we did last time when we rebuilt the engine, we number the con rods and caps, also R for right hand side.

2hrs

Reseat the valves...

Using a valve grinding stick, I start with some coarse paste to remove the build-up of carbon and muck around each valve seats. Some values would have been in an open position for more than 20 years.

Using the fine paste next to achieve a matt grey finish on the head and the valve face will ensure a tight seal.

1.5hrs