Head gasket failure - John Boy

Reading Animac's topic about buying a VW Beetle prompted this topic. It would appear that some particular engines are prone to head gasket failure. What are the design features which cause this?

Head gasket failure - unthrottled

Essentially, it is due to uneven clamping loads between the cylinder head face and the block deck.

Wet liner engines require each liner to protrude above the deck by a fairly uniform amount, other wise the head will effectively clamp the highest liners, leaving the lower ones unsupported.

Uneven clamping across the head can also cause head gaskets to go. The number of bolts, their placement and loading is dictated by the block design and may be marginal in some applications.

One factor that is often cited but is totally irrelevant is the volume of coolant in the block/head. Cooling capacity is determined by flow rate. The static volume is meaningless!

Head gasket failure - Collos25

"The static volume is meaningless"

I think I would revisit this in regards to combustion engine cooling.

Volume,pump dispersal rate etc.

Just a thought.

Head gasket failure - unthrottled

I think I would revisit this in regards to combustion engine cooling.

Volume,pump dispersal rate etc.

I'll revisit it for you.

If the engine is spinning, then the water pump is flowing coolant. The ability of the coolant to absorb heat, for a given temperature rise, is determined by the flow rate. A flow rate of 20 litres of coolant/minute has the same ability to absorb heat from the engine irrespective of whether the engine water jacket holds 1 litre of 20 litres. The only difference is that each water molecule spends longer in the cooling jacket for each pass. Since the flow of water of continuous, this is not relevant.

Temperature differentials are important because they lead to thermal stress and strain. I would argue that they are much more important than absolute temperatures. Some people agonise about whether to run an 85C or a 95C thermostat. I think it'll make little difference. For a start the head runs way hotter than the coolant flowing through it. Average cylinder head temperatures can easily hit 150C hard acceleration so 5-10C difference in cooant temperature isn't going to change this appreciably.

The stat crack open temperature sets the minimum operating temperature. Above this it is the efficacy of the radiator and cowling that determine the cooling temperature. If your engine is running hot, the radiator isn't working properly. Runing a cooler T'stat won't solve this.

What does make a difference is coolant make-up. Water has a much higher specfic heat capacity, heat of vaporisation, and conductivity and lower viscosity than any alcohol or oil. This is why I run 30:70 EG/water and not 50:50, but run the coolant as hot as I can b y taping the radiator grille. This gives the highest average engine temperature for the lowest possible friction, combined with the most even cooling for the least differential expansion.

Head gasket failure - Collos25

You read to many books come into the real world of head gasget failure ie real car engines and not whot a childs physics book tells you.

Bady designed head gasgets,water pumps,o ring failure,head bolt stretch these cause HG failure.

Head gasket failure - unthrottled

Clearly a water pump failure will cause the engine to overheat. That will happen to any engine, irrespective of design.

"Badly designed" head gaskets will tend to show up a flaw in the basic engine design rather than being faulty in themselves. People blame the gasket rather than look for the underlying cause. The MLS was a band-aid for the k-series engine that wouldn't haved been neccesary if Rover's production tolerences were as tight as they should have been.

Head gasket failure - Bobbin Threadbare

You read to many books come into the real world of head gasget failure ie real car engines and not whot a childs physics book tells you.

Bady designed head gasgets,water pumps,o ring failure,head bolt stretch these cause HG failure.

Don't normally bother with replying to these type of nitpicky posts but Collos, please enlighten us as to where the child's physics book has gone wrong? I'm sure that head gasket failure is often a combination of factors anyhow.

Head gasket failure - csgmart

What does the term "wet liner" actually mean please? Can I assume that some engines are dry liners?

Head gasket failure - countryroads

Plastic water pumps failing, badly designed radiators including plastic parts leaking and causing overheats, inedequate cooling capacity, badly designed or underspecced gaskets of course. Basically most cost or weight saving techniques can speed up the process. Modern engines run very hot generally too so there is little margin for error.

The old BMW M50 straight 6s could go 250k on head gaskets with proper use, the replacement, the later M52 and M54 are nowhere near as good..change the materials a bit, up the running temp and there you go, much shorter life.

The main cause that I have found though is simply going too hard on cold engines, thermal expansion differes between materials of course and can cause leaks, stresses and what have you that over time build to become a problem. Then there is owner neglect, not checking levels, replacing leaky waterpumps or other bits. Or component failures such as thermostats sticking shut or cooling fans not cutting in, stupid owners continuing to drive the car with the temperature right up.

A few cars are just crap and prone to it, Rover K series being one. That was for a few reasons, inadequate rigidity between block and head, low coolant capacity with no low level warning, leaky o rings letting coolant out etc etc. Stretch bolts that were too stretchy is a classic. Head gasket is a 40k mile service item on those POS even with the newer gaskets.

I firmly believe though that 90% of the time, it is down to owners and drivers abuse that kills them..its the weak link if you like between huge compression pressures, high pressure hot water and high pressure hot oil, its a couple of mms thick and expected to perform for many thousands of miles, pays to take care of them!

Head gasket failure - focussed

It's not always a design feature that causes or promotes HG failure. An engine can get through the design and prototype testing regime with flying colours but sometimes the problems start when it's put into production. Mass production techniques for casting, heat treeatment, machining and assembly sometimes struggle to retain the rigour and tolerances that the design engineers desire. In particular with cylinder heads the weak point can be the thickness of the deck ie the flat surface that mates with the gasket. The deck thickness is determined mainly by the casting operation and can sometimes vary. Get it too thin and it's liable to distort and contribute to head gasket failure if the motor is used hard, particularly with aluminium.

Head gasket failure - John Boy

Thanks very much for the replies.

csgmart hasn't had one yet to his question about wet liners, but it seems to be answered here:

en.wikipedia.org/wiki/Cylinder_block

Head gasket failure - csgmart

Thanks very much for the replies.

csgmart hasn't had one yet to his question about wet liners, but it seems to be answered here:

en.wikipedia.org/wiki/Cylinder_block

Thanks John Boy - interesting read. I've taken a few engines apart in my time (as a hobby mechanic) but never really heard the term until fairly late on in my life.