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PostPosted: Wed Oct 27, 2004 4:46 pm 
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Pulled it out of the box and started checking things out, and aside from missing 11 manifold studs, it doesn't have a spout for the coolant that comes of of the front of the head, just a smooth front. How much is it gonna cost to get me one put on?

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PostPosted: Wed Oct 27, 2004 5:22 pm 
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what do you mean it doesn't have the spout.... the heater hose fitting isn't on it?.......right at the front of the head?

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PostPosted: Wed Oct 27, 2004 9:20 pm 
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It doesn't have one because the rad hose connects to the intake manifold on the 1.8L, and I would imagine that the same holds true for the G200 as well.

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PostPosted: Thu Oct 28, 2004 7:10 am 
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This is pic of someone else's truck. But the coolant hose that's right above the air pump, that's where it's supposed to attach. There's a hole for it and everything, but nothing for the hose to slide over.
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PostPosted: Thu Oct 28, 2004 8:51 am 
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there is a hole for it? get back to me and see if i can get the one out of my g200 head in good shape....if i can.... i'll just send it to ya. you can have it.... i've been waiting for your "i got it running post" for too long already.

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PostPosted: Thu Oct 28, 2004 9:20 am 
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I'm :? ??? Are you talking about the hose that runs from the top of the rad in the pic? The only other coolant hoses I can see are the heater hoses next to the firewall. If its the upper rad hose, rez is right... it connects to the intake not the head...

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PostPosted: Thu Oct 28, 2004 5:35 pm 
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The little hose, about 2" in diameter that comes right out through the front of the head. IT goes to a valve under the intake manifold, and from there to the heater core, I think, I can't tell cause it's all apart right now. You can see it JUST above the air pump in the picture.

I took a picture of it, but I don't want to have it uploaded on my site, so let me know your address and I'll send it to you.

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PostPosted: Thu Oct 28, 2004 8:27 pm 
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just click my email link

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PostPosted: Fri Oct 29, 2004 9:48 am 
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Sounds like you are talking about the bypass hose. Its the size of a heater hose (probably more like 1 inch diameter)) and should hook to a fitting on the front of the head, dead center and goes under the front of the intake and hooks to a T fitting on the bottom rear of the intake. We're not talking about the radiator hose here, its below that in the picture.

You can see it better in these shots:
http://www.luvtruck.com/Gallery/Project ... 20009.html

http://www.luvtruck.com/Gallery/Project ... gen10.html

http://www.luvtruck.com/Gallery/JohnSch ... /7777.html

http://www.luvtruck.com/Gallery/JohnSch ... 44444.html

If you need a pic of a head with just the port attached let me know. If nothing else it might help a machine shop get the idea of what you need. I would be contacting the seller on that auction and letting them know you have a problem with it. It is probably an honest mistake and they may do something to make it right with you. On the other hand, that could be why it was so cheap. Looks like it is just a matter of whoever cleaned/rebuilt the head pulled the hose connector out (may have been rusted away) and forgot to replace it or wasn't able to.


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PostPosted: Fri Oct 29, 2004 9:53 am 
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Is this the actual item you won?

http://cgi.ebay.com/ebaymotors/ws/eBayI ... 7928185715

If so, the port is visible in the picture. If it comes down to an arguement over "item was shipped exactly as pictured" you'd have them nailed.


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PostPosted: Fri Oct 29, 2004 5:35 pm 
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That's the same one I purchased. I thought that was the port too, til I looked at it from that angle and it's just a little mound that the battery ground attaches to. They want me to pay to ship it back to them, (Utah to Georgia, 40 lbs.) so they can fix it or replace, but I don't have that kinda time or money. I'm gonna take it to a machine shop and see if they can fix it and leave negative feed back.

Since we've established what it is we're talking about, does anyone know how much it'll cost me to get one installed? Are they hammered in, or welded in or what?
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PostPosted: Sat Oct 30, 2004 7:40 am 
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there a compression fit. i took the one out of my extra head to see if it would work for you and it came out ok,but i think you might want to get one made closer to home. it's pressed in and might not be re-usable

i bet if you went to a radiator shop they could hook you up with a new one..... doesn't seem expencive

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PostPosted: Sat Oct 30, 2004 7:49 am 
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Thank you, I thought I had earned a little bit of good news by now. I'll get one on Monday if I can and let ya'll know.

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PostPosted: Sat Oct 30, 2004 1:29 pm 
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A machine shop won't charge much for that (Hardly any work is needed). I work at a machine shop. Machinist charge by the hour and it is usually around $25. That shouldnt take more than 35/40 min, atleast for a skilled machinist.

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PostPosted: Sun Oct 31, 2004 11:00 am 
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you know.... you should get the new neck longer with that 90 degree bend already in the spout.....i tried to get the front bypass hose the other day and it cost me $35 and i had to wait for it.....it would've cost $18 if it was a straight hose.

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PostPosted: Tue Nov 02, 2004 9:05 am 
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I wasn't able to get the 90 degree one, but they did hammer one in for me and didn't even charge me, so I'm off to putting everything together.

Which brings me to my next question, I've been told that you need to replace head bolts if you take off an aluminum head, is this true? Or is there another way to tell?

And when I put the new head gasket on, where to I put high temp silicone?

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PostPosted: Tue Nov 02, 2004 11:20 am 
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I think that's referring to the majority of people who don't like messing with the "allen head" bolts and prefer a standard hex head bolt and therefore change over. My allen head bolts have been in out of my head and still work fine.


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PostPosted: Tue Nov 02, 2004 12:47 pm 
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No sealers on a head gasket. You put the high temp silicone aside while doing the head, and maybe use a very thin coating on the carb to intake gasket and perhaps the intake to head gasket when you get to that point. There is mention of using a thread sealer on the middle bolt on the exhaust side in one of the books. That bolt hole goes through to a water jacket. I've done with and without and I think it only makes a real difference when you go to remove that bolt again. Hi temp silicone probably would not even do for that, as that bolt gets right up to full exhaust temps.

The secret to successful head gasket work is cleanliness. You want the head smooth, the block smooth, and both clean enough to eat off of. If you are not going to have the block machined, go over it very carefully with a razor blade to remove any old gasket gunk. When I did my last one, I also gave it a hit with 800 grit sand paper on a sanding block, but you have to be very careful to sand evenly. You don't want a low spot, especially between cylinders where is is thin already. For cleaners I used Goof Off (pure xylene, Goo Gone has other stuff that may leave residues) but acetone would probably work as well. Once both the head and block were clean I wiped them off with a tack cloth right before assembly to get any dust/dirt off that had landed on them. The cleaner and smoother things are, the longer your replacement gasket will last.


Replacement head bolts are available at http://www.headbolts.com for $40 for a set. Isuzu wanted $40 a bolt the last time I heard. The head bolts on these are not torque to yield type bolts that you use only once. They can be reused if they are in good shape still. I have to swap around a few last time I did this as I had a few that were severely rusted. Don't forget to oil the threads and the bolt heads when you put them in. Also doesn't hurt during the cleaning phase to chase the block threads with a tap to clean them out. 12mm tap, 1.5 thread pitch, coicendentally the same as the lug nuts. I cross cut an open ended lug nut with a hack saw to make a thread cleaner for the bolts actually.


One last thing, when you take off the old head, be sure not to lose the locator rings. They fit in a niche around two of the head bolts (front right and back left I think) and help get the gasket on the block straight. Put the gasket down, the locator deals in to line it up, then carefully lower the head down. An extra pair of hands is a big help there. I also back off the valvle adjusters all the way, that way you don't chance denting the gasket with a valve, and you can turn the cam over to line up with the sproket even with pistons all the way up.


Oh yeah, one more tip. The exhaust manifold is easy to put on after the head is installed, but the intake is much harder. I installed the intake along with the EGR pipe, then put the exhaust manifold on after the fact.

If you have any questions I just did a head gasket this summer, so its all fairly fresh in my head. PM me if you need an immediate answer, I'll see the email alert from that before I might get back here. :)


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PostPosted: Tue Nov 02, 2004 8:44 pm 
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Wow, that should just about cover it. Hopefully I'll have it running by Friday.

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PostPosted: Wed Nov 03, 2004 10:26 am 
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Shit!!!!! I get out there workin' my ass off to get it together and everything's going great, no, better than great, perfect. I give the block one last wipe and set down the hea gasket. . .And the fuckin' coolant passages don't line up!!!! Now I have to sit and wait cause I can't afford to buy another head gasket because I wasn't counting on this being a problem when I bought the gasket kit. I swear I'm gonna blow someting up. And I think I may have broken a toe kicking the wall when I found out.

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