With the problems with the original engine taking time to resolve with the prospect of the engine being scrap, I decided to fit an engine purchased from long term storage. It turned over by hand freely & was listed as a reconditioned block. The engine number confirmed this was a recon at some point. It was a late 600cc block, which features slight differences such as a shorter distributor shaft, differing oil galleries and oil filter. I had figured it would be a simple task of fitting items to it and getting it started. Sadly, this was not the case.
Rigged up for test runs it was found the timing was set up way out due to the mis orientation of the tang on the distributor spindle. Getting this sorted and firing was a huge task. Note how the distributor is twisted 45 degrees plus in order to set the points.
The fuel pump on the block started to give problems. When removed the arm fell off having been fractured for some time. This is compared to the arm on the other type of pump. Luckily I can swap parts around to remedy the fault.
After running it was time to re torque the head, but one of the studs pulled clean out of the block. It was suggested that some chemical metal would be sufficient for the repair. I also noticed the core plug was weeping but luckily had a spare of the correct size.
This meant having to get inventive with a method to clear out the hole ! Needless to say, the repair was insufficient. The only option was to remove the head and get the hole re tapped with a different size, or fitting a helicoil threaded insert. Either way this meant a partial strip down and another trip to the engineers. Whilst this is all being done I decide to resurrect the original block, correcting the timing error and reverting to standard coolant with a sealant additive.
Firstly the coolant needs to be drained, but this proved problematic. The plug was solid with debris and when freed liquid sand plopped out. It was clear the whole water channel needs flushing. The amount of sediment removed suggests that coolant flow was severely inhibited.
Chunks of dirt removed from within the block and cylinder head. With everything cleaned down and the block back from the engineer, re assembly has stopped whilst the original block is re fitted and test run.