Hey guys,
I recently bought a 40hp 1200cc motor from down there in Melburg and over this weekend went about pulling out the 1500 that was in my car and replacing it with the 1200.
The 1200 had no generator pulley and no ignition lead to cylinder #1. we used the generator pulley and lead from the 1500 and the 1200 went in.... Eventually.
A problem has come up with the new motor though.

The engine fires ok and runs itself (doesn't die immediately after firing or anything). But there is a fairly loud knocking/clacking sound coming from the drivers side of the car.
We pulled off the covers and redid the valves on all 4 cylinders and tried running the motor again, but still had the same knocking/clacking.

We went about it by finding TDC (just to the left of the timing marks on the pulley?) and setting cylinder #1 to 0.006 as the book detailed we do. Floowoed the process outlined and redid all 4 according to book specs.

Fired the car and same thing happened again with regards to knocking.
There still seems to be a fair amount of play in the valves.
Have we done anything drastically wrong?

There was quite a lot of oil present in the drivers side valve cover when we removed it the first time, but after replacing it and running the motor after the first valve adjustment there was much less oil present.
What could be causing this? An could it also be source of the knock?

The car is running quite fast on idle so far when we've run the car. But we've been hesitant to adjust it lower just yet. This would be advised? And could we expect any change to the situation?

Is there anything else anyone can think of that may be causing this? As we are currently stumped, spend hours and hours trying to work out exactly what's going on but so far have come up empty handed.

So any help that you guys can provide will be hugely appreciated.
We're very much stumped.

Regards
Sam

While it is running,
remove the ignition leads one at a time.
My guess is #1 may be the problem.

But if it gets quiet/er when any lead is removed it is probably internal, in the conrod area.
If oil pressure is currently good, it may just be a loosed gudgeon pin bush which was common in 1200s.
but my guess is that it is a little more serious than that.

Check the rocker shaft studs if original heads.. If it has the original long studs, chances are that one of them has stripped and is allowing the shaft to move. A common problem with 40 hp and early 1500 engines. If that is the case you need a replacement stud similar to the one below. In the early days, the replacement stud here in Australia had a 9/16" UNF thread. Now we'd use M14 x 1.5 !!

DH

Thanks for the replies, I will try and check it out tonight after work.
Will report back.
Hopefully I'm not completely screwed.