Hi all

Been running a 1.4 mpi 8v 02 plate for 2 months now. Had evidence of oil in coolant (expansion tank was gradually filling up with oily sludge + mayo under oil filler cap, not condensation) so changed head gasket. Also changed head bolts due to corrosion on some. Flushed colling system clean with flushing agent and changed oil. Torqued head bolts using procedure in Haynes (20Nm + 90 deg+ 90deg). Engine was ok for about 3 days but now the oily sludge has returned. The one thing I didnt do (and I am kicking myself about it now) was check the head for trueness. Now I suspect head is warped hence inability to seal totally. Anyone have any other ideas?

Close to scrapping as its becoming a bit of a millstone as also had many common fabia faults (rear door leaks - fixed, heater flap fault - not fixed yet, central locking gremlins - not fixed yet)

Couldnt see any evidence of block or head cracks when it was apart.

Sorry for long post, wanted to give full info. Any advice gratefully received.

Whoops, you wouldn't be the first and you won't be the last, you should ALWAYS have a head licked flat and pressure tested because cracks are rarely if ever visible until they're under pressure.

 

Head gaskets always fail for a reason and that reason is always head casting distortion, whether through boost lift (VRS) or overheating (MPI).

How many of the headbolts were corroded, and in which positions? Did you endeavour to clean up the female threads in the block that these corroded ones (and all the others) go into?

Edited 8 January, 201610 yr by Wino

Wino,

it was the rear ones outside of the rocker cover that had also evidence of corrosion down the stems and threads

I cleaned the muck out of the threads to prevent hydraulic problems on reassembly but I didnt run a tap down the threads before closing

As long as none of the new bolts felt too 'graunchy' on their way into any of the holes that previously had corroded bolts in, that probably wasn't the problem.

Was the head corroded much? Also there are 3 core plugs under the rocker shaft which can corrode and let oil and water mix. Also how did you clean the oil from the coolant circuit? Bit of washing powder works well. You may just be getting old oil that's been stuck in the rad and heater finding it's way out slowly

Head wasn't corroded much at all. Interesting point about the core plugs. When you say they are below the rocker shaft, do you mean they are under the rocker cover and therefore usually covered in oil (so shouldn't corrode?) or that they lie on the outside of the head but below the level of the rocker shaft?

Cleaned oil from system with Wynns coolant flush. Thought about the possibility of old oil coming out but it was the fact that it was increasing after not having much come out.

Have ordered a 2nd hand head off fleabay and will get that skimmed, pressure tested and check the core plugs, too.

Thanks for all the replies so far.........

Core plugs are under the rocker cover and under the rocker shaft in the oily bit lol. But they do corrode thru from the coolant side.head could be warped but 20yrs experience with these motors says they never warp enough to mix oil and water. It's a nice thick gasket and should take up most of the difference.