well i was pretty close, thanks for the edits there XR-lane, just got a few quick questions for ya.

with the knock sensor i thaught i remember reading the EF sensor was slightly to small for the late AU engine? SV-Valiant's build thread?

It should fit. And if the thread on the sensor is too small for the block, you can buy a reducer bush from a plumbing supplier.

and didnt SV-Valiant get away with out cutting the air con bolt spacers due to using the AU alternator or does this not apply to the VCT engine?
either way it was only 4mm of the botom two spacers from memory wasnt it?

Unless they changed the aircon compressors, or blocks between series 1 2 and 3 AU's I would say you need to do this. If you bolt it up with the top bolt and spacer, you then can line up the bottom spacers and see how much needs to come off. If you leave it and just bolt them on, the compressor will be on the piss and may through the belt off.

and thinking about it, i might stick with the EF thermostat housing and sensor as being an XR ive got the low coolant sensor in the header tank.

thanks.