4/10/10 Went to Autobarn & ordered all the parts necessary to replace the head (gaskets, hoses, thermostat & housing, filters, oil, carbie gaskets, plugs, paint, WD40). I was very surprised when they rang that afternoon & had all the parts ready. A very prompt service! Over the weekend, I had been constantly spraying WD40 down the valve guides to try to free the stuck valves but no luck. They are really going to take a lot of effort to move.
6/10/10 Today was very frustrating as I spent the whole day trying to free up the stuck valves & removing the broken stud. Four valves came out very easily but the remainder were really stuck. I continually sprayed WD40 down the valve guides & eventually with a bit of physical persuasion, they became free. That took most of the morning. Then I spent most of the afternoon drilling out the broken intake manifold bolt. I broke about 5 drill bits & two stud removers in the process but after several hours, I had most of it removed. The thread still needs to be cleaned up & I hope it is not too damaged but I guess we can re-thread if the worst comes to the worst. Tomorrow the cleaning of the head & valves will continue.
7/10/10 Continued to clean cylinder head & remove gaskets. Cleaned & wire brushed valves, starter motor, rocker arm, rocker cover, carbie, intake manifold, fuel pump, ignition leads.
8/10/10 Continued to reface valves & prepare to reassemble cylinder head. Re-threaded broken intake manifold bolt.
11/10/10 Refitted valve springs & collected spray can of Monza Red paint (Slacks Creek).
Dissembled & cleaned the carbie. Fitted all new gaskets & needle & re-assembled. Finished cleaning intake manifold. Everything now ready to paint.
14/10/10 Removed radiator & fan & prepared the engine bay & battery tray for touch up painting. Spray painted all the engine parts. Refitted the cylinder head, valve guides, rocker arm & ensured valves are operating. Refitted exhau st manifold, fuel pump, starter motor & intake manifold.
15/10/10 Completed fitting intake manifold & all bolts in starter motor. Adjusted the valve clearances & tried to turn motor over to ensure all parts are operating so far. No response. Tested all circuits & tests indicate current & ignition switch is operative. Possible that starter is fau lty so it was removed & tested. Working fine. Purchased new battery. Plenty of action with new battery & everything turning over OK. In fact, there is a bit too much action & sparks were flying from the connection. I really think that there is an earthing problem but I will trace that further. Ignition does work & there is spark at the distributor. Cleaned out fuel lines & removed a fair bit of rubbish from engine end. Put several litres of fuel in tank to try & clean out lines. No fuel coming through so that is another task. Later on I noticed that the fuel tank was leaking all this watery black like petrol gunk through into the boot. Not good news but not surprising considering how long the car has been in storage. So that means the fuel tank will have to come out & repaired. Fitted oil filter & sump plug & then filled with oil. No obvious leaks so that is good news. Refitted radiator, hoses, thermostat, alternator, fan belt & filled radiator with water as I really wanted to fire the beast up. I seemed to keep adding water to the radiator & was hearing water leaking out & then noticed water pouring out of the rear welch plug so that was it. No fuel, no water – no go!! Very disappointing!!! Also noticed a small leak under intake manifold where bold was stripped so that will also have to come off again. So a little frustrating but I guess that goes with this type of job.
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