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[Jan Suhr]

I was going to change the thermostat and found out that my cam belt was worn, see other thread here. http://www.omegaowners.com/forum/index.php?topic=145621.0

It was a real hassle to get that "Bastard bolt" out and then the transfer pipe. But eventually I got everything apart.

But today it was reversing everything and put it back together.

I skipped the engine lift mount to make it easier to put it back, I made a 4mm spacer to fill the gap of the lift mount. I thought that would make it easier, but hell no. The oil stick wouldn't cooperate and was off no matter what I did. And it also seemed that the hole in the transfer pipe was off too. Maybe something with the new thermostat that made it align wrong. So I had to enlarge the hole and cut the oilstick bracket for more room for the bolt. That made it hook up in the right place and the "Bastard bolt" could finally go back in its hole and tighten up properly. Damn it took almost two hours!!

[Doctor Gollum]

That suggests the transfer pipe wasn't quite square.

Easiest to get all the bolts loosely located before sequentially tightening everything a bit at a time

Quite easy to crack the aluminium parts if you try and force them...

[Jan Suhr]

Yeah, I did tighten up the thermostat housing. Never thought about loosening it, would probably made things easier... But that dipstick pipe bracket was off as well.

[Doctor Gollum]

It's one of those jobs where a bit of wiggle room really makes it easier

[amba]

I found the easiest way was to run a 12mm hss drill bit through the lifting bracket hole,that allows much more wiggle room but still retains the correct thickness of parts when tightening it all up.The likelihood of ever using the lifting bracket on a 16 year old 200k car is not going to happen so abit of movement wont hurt.

With the extra hoe clearance it tends to align and go back together much easier 

[Nick W]

Turning the first couple of threads on the bolt down to the minor diameter makes fitting it a lot easier. Takes seconds in the lathe, a bit longer with a file.

[Andy B]

Turning the first couple of threads on the bolt down to the minor diameter makes fitting it a lot easier. Takes seconds in the lathe, a bit longer with a file.

core dia 

A lot of screws on my Cortina years ago were like that.