Classic Alfa Forums

This is a bit of a saga, SO:

I have rebuilt a 1500 engine with a replacement block, new seals / gaskets all round. Engine was running OK before rebuild.
Fitted and started and it ran nicely, BUT there is water seeping from the cylinder head. See picture. This is happening on BOTH sides! Its not even at pressure. Just a full cooling system and it leaks.

So I have stripped back. I removed OS head, checked the gasket. Checked the head for problems / distortions. Checked that the head would sit tight to the block with no gasket ie there is nothing stopping it going tight. I then refitted. I did the bolts in sequence to 60ftlbs, and re-filled the cooling system.

No improvement! I then removed the head and re-used the old gasket which had done only a few miles. Refilled the cooling system and this time no leaks!

I then went to the NS head and did the same palaver. Refitted with the new gasket and it still leaks. Stopped there in dispair!

What have I missed? What have I done wrong? The new gaskets are from a reputable supplier.

Has anybody experienced this kind of failure before? If it had been one head I would have assumed I had done something wrong. But BOTH doing the same thing?

Sorry for the long story, but any ideas would be great.

Regards,

Chris.

Did you refit the cylinder head drain bolts?

Chris. That is certainly unusual. I have seen similar problems in the past but it’s rare. Is there a chance it could be coming from the inlet manifold gasket area ? Also the ally washer on your sender unit looks a bit ropey
Lou

Are the new and old gaskets exactly the same Chris - no extra cut outs or bigger cut outs on the new ones?

I presume there are different gaskets for the various bore diameters?
Could your new ones be the wrong size?

Chris,
As the problem is the same both sides...
1. Wrong head gaskets?
2. Torque wrench out of calibration?
3. Setting misread, 6.0 kgm instead of 60 ftlb?
4. Engine mistimed, open valves contacting pistons?

3 unlikely, 4 very unlikely but I cant think what else it could be.

So a report:

In the end I bought 2 new gaskets from a different supplier and fitted them.

I don't have any water leaks and the engine is now running nicely!

This is a very odd one. I would not normally blame new gaskets, but in this case changing them has solved the problem.

Thanks to all who made suggestions.

Chris.

Maybe retorque the head bolts after a time?