She lives!

So many parts to put back, rough sequence:

- Cam cover with new gasket

- Exhaust manifold with new gasket

- Thermostat to water rail housing with newly cut gasket

- Water temp gauge sensor

- ECU water temp sensor

- Water rail

- Plugs and HT leads

- Coil connector

- Oil breather

- Cam belt middle cover

- Alternator bracket and alternator

- Water pump pulley
- Aux belt tensioner bracket
- Aux belt

- Inlet/plenum arrangement with new gaskets to the head

- Air temp sensor

- Accelerator cable

- Throttle position sensor

- IACV cable

- Fuel rail and injectors

- Injector and cam sensor loom

- Various cable tie stand offs for all fuel lines.

- Refill coolant

- Coolant cap off to monitor bubbles

- Cam sprocket cover off to monitor cam belt tension after running

....all set...

Ignition - turnover - engine fires and runs.

Oil pressure comes up immediately.

Water temp rising slowly - at around 90ºC indicated (means nothing since the gauge is not calibrated) the fan comes on - and importantly goes off. Pre head gasket change the cooling system couldn't hold the temperature down so this is a good sign.

Coolant hoses staying flexible - no longer over pressurised from combustion gases.

No white smoke from the exhaust.

On turn off just a hiss from the cooling system - no spewing into the overflow bottle.

That will do for a first test! (video)

Some project.

RESULT - She's alive!

No guarantees yet - needs a road test once the CV19 lockdown is relaxed in Wales!


Addendum
All good disassembly/assembly projects should end up with a few extra parts - this one is entirely intentional. I couldn't remove it without cutting the connector off because of the alternator bracket. It isn't generally connected or used on a Zero/Emerald combination - although if it is a thermostat the emerald does support multiple temp inputs?

Not needed and no longer fitted.