96 Sunfire 2.2L Head Woes

[blebs]

I picked up one of these unknowingly with a leaking head gasket. It leaks coolant from around the bottom right corner of the engine near the bottom headbolt by number 1 spark plug. I just had the head resurfaced and reinstalled for $900 and the darn thing is still leaking. Is this a common problem? There are no cracks, the head went to the machine shop for resurfacing etc, but I'm beginning to think the place that did this job did nothing more then tighten the head bolts and retork the valve rockers. Any sure fire way to know the engine was disassembled without actually doing it yourself?

[alfonz]

hmmm not sure about the placement and where its leaking from, but when I had my coolant leak, it was the actual water pump that was gone. It was pissing coolant out of the releaf valve, I think the seal was coroded or something. In any case I had to replace the water pump. Check the pump to make sure its working as it should. If its going then you should also hear it working pretty hard.

[blebs]

I only wish it were the water pump. It's without doubt, coming from between the block and head right at the passenger side lower head bolt on the corner. I'm thinking the problem now is that the place that did this job never installed new head bolts. I think these are stretched beyond their limits after being retorqued and just won't seal.

[muff34]

I Think I `d be looking for warranty on their work.

[blebs]

Originally Posted by muff34

I Think I `d be looking for warranty on their work.

Man you got that right. It's going back to the shop in the morning. Further looking at this thing, the guy charged me for a head gasket set, then reused? my old exhaust manifold gasket and said it was to save me money. Umm scuse me, but that exhaust manifold gasket comes with the head set, so why would you do that? Further fueling my feeling that he never took it apart to start with.

This time, I'm going to bring that head set to his attention, tell him to call me when it's torn down so I can see it myself, install new head bolts and provide me with all gaskets not used out of the set. If he can't do that, I want my money back and I'll go to someone who will.

[muff34]

Did you take the head to machine shop yourself or did they send it? Ya definately sounds like they may have screwed you. I`d be leary of going back to give another shot at my motor , then intentional damage may appear. I`d definately inquire about it tho. and after taliking to them maybe a call to The Better Buisness Bureau or consumer affairs may be in order.

[blebs]

Originally Posted by muff34

Did you take the head to machine shop yourself or did they send it? Ya definately sounds like they may have screwed you. I`d be leary of going back to give another shot at my motor , then intentional damage may appear. I`d definately inquire about it tho. and after taliking to them maybe a call to The Better Buisness Bureau or consumer affairs may be in order.

They sent the head to the machine shop. Yes, I am leary, but I've got $900 into this and expect them to make it right. The same shop did my sons Mustang heads and did an outstanding job. Same guy too, this is why I'm disturbed by the whole thing and I want to see the engine torn down, before they do anything with the head this time, in an attempt to keep intentional damage at bay. I'm certainly going to make it known to him that I was charged for something that was never used. I expect it to be used this time, along with new head bolts.

[muff34]

Just re-read your first post. Call the machine shop to confirm that job was done. Good Luck and let us know how you make out
Muff

[blebs]

Well I don't know that he took it apart the first time, but he did this time. I went and took pictures and showed him exactly where it was leaking. Take a look around the dowel pin up front here. There is enough corrosion there to keep the gasket from sealing. I can't figure out the black mark by it. It's not indented and is flat flush with the block, but that is where the leak was.

[muff34]

that grey do dad beside it doesn`t look original maybe someone used a little too much heat to remove a bolt and warped the block ever so slightly ????

[hotbug1776]

if they used heat to remove the bolt on the water pump, then you got major problems. I would guess a warped head or wrong torque sequence caused the leak. Stone the block (cleans and deburrs the surface) and have the head checked for warpage and deck it if need be. use a thin bead of RTV on the gasket when you replace it. Make sure you follow the torque sequence, or it will leak again for sure.

[blebs]

I'm still holding on to my originial thought that he never took it apart to start with and simply tightened the head bolts and rocker arms. I certainly would not have put an enginie back together with all that corrosion arouind the dowels. The dark spot is flat. I know this for fact, but the brown around the dowel is a good 1/4" thick junk.