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MORE Cylinder head refurb (continues) 05-12 Feb 2006

The head after it got painted

The front crankshaft pulley with a coat of black paint 



After the rocker cover was lifted off...


This is where the crankshaft pulley fits



The old crankshaft oil seal



All the crud cleaned off 



Masked off



Quick coat of etch primer



Followed by more black



Came up nicely



After it dried.....



New water pump.



This is the pump wet side 



The location for the pump. Spot the three bolt holes for the securing bolts. I cleaned off the excess paint from the sealing o-ring face.



Three bolts with washers and spring washers, and it's on....



I threw on a quick coat of heatproof paint onto the stainless downpipe that I aquired second hand.



Looks pretty good



Especially with the paint on all of it




This is a job that would be a nightmare to do if the head was on. Replacement of the grommet in the firewall where the heater pipes fit through. First of all I lubricated the rubber pipes and grommet, and detached the grommet from the firewall, and pulled it towards me. Eventually it came free....



Out with the old, and in with the new.....



The 2 hoses still in situ.



Now, the lower heater hose is larger at the engine end than at the firewall end. So you can't get the grommet back over the heater hose. So you have to disconect the heater hose from the heater matrix by undoing the jubilee clip holding it on. Access is from behind the pedals with a long screwdriver. Not easy, and quite uncomfortable.......



You can clearly see the clip here. 



This is the lower hose once off....



Give it a good squeezing, and get all the rusty crap out of it......



Next you pre-fit the grommet to the hose. Use a mild soapy solution here as a lubricant.....



Push the hose and grommet into position. Slide the top hose into place through the top hole in the grommet. Before pushing the grommet firmly home, make sure that the bottom hose is in place on the heater matrix, and secure it with the jubilee clip that you previously removed...



Then waggle the grommet into place on the firewall, and conect up the heater hoses to the engine



The new cambelt idler roller



And it's other side



This is a light interferance fit into the recess on the oil pump. When I painted this area, I made sure that I masked off the bore of this hole. The securing bolt for the roller is much skinnier than the size of the bore through the roller. Don't force the roller into place using the bolt..... guide it in nice and square.. and then secure with the bolt....