Hi guys, this my first post. I have read others in relation to my question, I guess I am just after some advice.

I have a standard 1995 fiesta si 1.6 zetec.

I was late for a wedding and cruising near the limit, I noticed a tiny pinking noise in the engine and slowed down. When I took my foot off the accelerator the car cut out. I started it up again (still rolling at speed), and noticed a fine white smoke/steam. So I pulled over and stopped.

The car wouldn't start again. There was very little water left. I called the AA and he said there was exhuast fumes in the water and so the head gasket must have gone.

Forward to now: The engine is split, (the head is off), and I can see number 3 piston is a bit brown(heat?) the gasket looks only a little gone (never seen one before).

My question or worry is that the piston rings on number 3 have failed, but then I think I would have got blue smoke not thin white. I should have done a compression test. Do I have to replace the top to test the piston? the engine rotates but gets stiffer at different places.

Also the biggy, How do I know the Head and the Bottom are timed correctly? I mean I have TDC on the bottom end and I can set the Cams ok but we are talking 1 degree out and it might not work properly, so what can I do?

I am going to get new head bolts. Anything else I should look out for? (haha a new engine...)

You wanna get some piccies on this brown piston, as for the timing I suspect but no-one has confirmed that youl require a specialist locking tool to keep the pulleys in the same position. I don't think tipex will work on twincam engines

unsure the reason about the piston....
when i did my head. best thing for the timing of head & bottom end is to use haynes manuel...
but for a quick run down basically you have to align the crank pulley to a ridge on the sump. can't explain properly without pictures. then the head needs the cams with the two notchs at the end with a bar in them (can buy a tool for this), BUT the exhaust cam has an extra lobe which faces towards the inlet/car direction. if it is facing towards you/front of car then it needs to be rotated 360 degrees. seriously though, haynes manuel is gold for this, helped me all the way!
andy

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RR - TBC