Just finished putting our 91 240 back together after bumfuddling a couple head gaskets - yes there is at least one guy out there dumb enough to invert one end-to-end (me!) - bouncing the head off the exhaust manifold adding some lovely scratchwork that yielded my first trip to a machine shop on the second try, losing a water pump bolt (still not sure where it is but it is not in the lower timing cover), figuring out the harmonic balancer was failing, and breaking a sensor connector on the block (two spade connectors, extra wire, and epoxy to seal and strengthen work wonders)......

I turned the key after the third attempt and.......... IT'S ALIVE! Everything works. No idiot lights or bells going off. And best of all, no bright green coolant running down the block this time!

Thanks to everyone who helped me through this one. I had never pulled a head before, and learned a lot. And saved at least $600 above and beyond my roughly $200 in parts (3 head gasket sets, a harmonic balancer, and new head bolts). And I am pretty sure the dang thing runs even better now! Pretty cool tooling down the street covered in grease with an idiotic smile on my face watching the moms hide their children.....

But seriously, thanks. This forum is a lifesaver. And now my daughter can continue practicing on her learner's permit in the car we bought when she was born.

Dave
'91 240 Original Owner