Cylinder head gasket leakage

CYLINDER HEAD GASKET LEAKAGE

Model

All vehicles with K8 & K16 engines

Affected vehicles

All vehicles with K8 and K16 four cylinder engines up to the following definitive engine numbers and approximate VINs: K series engines are built on two separate engine assembly systems. Affected engines are up to the following numbers (approximate production build date March 2001). Engine number 413284 (system 1) Engine number 667323 (system 2) Approximate VIN introductions: MGF RD 527784 R25 RF 585534 R45 RT 543110 R75 RJ 208514

Date

2001-05-30

Reference

TB0022

Attached: 301508

Attached: 122902

Attached: 261001

Bulletin text

All vehicles with K8 & K16 engines

Title: CYLINDER HEAD GASKET LEAKAGE Affected range: All vehicles with K8 and K16 four cylinder engines up to the following definitive engine numbers and approximate VINs:

K series engines are built on two separate engine assembly systems. Affected engines are up to the following numbers (approximate production build date March 2001). Engine number 413284 (system 1) Engine number 667323 (system 2)

Approximate VIN introductions: MGF RD 527784 R25 RF 585534 Description: Cylinder head gasket failure causing either oil to enter the cooling system, coolant contamination of engine oil or a visible external coolant leak at the head joint face. If undetected, overheating can result. The original cylinder head / gasket to block alignment method used 2 nylon hollow dowels one either end of cylinder head. The 2 nylon dowels have since been replaced with steel dowels to improve alignment. This along with associated head gasket modifications to improve sealing and oil drain back have reduced the possibility of such failures occurring. All engines from the introduction numbers above have the latest head gaskets and dowels fitted.

Action required: On confirmation that cylinder head gasket is leaking, replace gasket and fit the latest steel alignment dowels supplied with the later type head gasket described.

Detail: Diagnosis: If an external coolant leak is visible, confirm that leak is • actually originating from the head gasket and not from the inlet manifold gasket above. If manifold gasket is suspected replace gasket and carry out pressure test to confirm satisfactory, Workshop Manual repair number 30.15.08 refers. If external head joint leak is confirmed or coolant found • to be contaminated with oil or engine oil contaminated with coolant, proceed with head gasket repair as described below.

TB0022 Issue 1 N o : 30.05.01 Section: ENGINE

R45 RT 543110 R75 RJ 208514

Procedure: 1. Referring to Workshop Manual repair number 12.29.02 , replace the cylinder head gasket with new part GUG702613HG. Ensure that the old nylon dowels are removed from block and discarded. Replace with the new steel dowels supplied with the later type head gasket. IMPORTANT: Fit dowels (see illustration) to a height of 10 to 11mm above block face. Follow Workshop Manual repair closely paying particular attention to the following points: Clean mating faces of cylinder head and cylinder block and check for damage. • Ensure that correct cylinder head bolt torque and tightening sequence is used. • 2. If coolant was found to be contaminated, flush system thoroughly and replace any excessively contaminated cooling system components if necessary. To assist coolant flushing use a degreaser such as Unipart GEM327. Flush cooling system as many times as required to ensure that system is clear of contamination before refilling with correct coolant strength, i.e. 50%. 3. Ensure that cooling system is bled correctly, refer to refill section of Workshop Manual repair number 26.10.01. 4. If engine oil was found to be contaminated, flush engine using an approved engine flush product such as Unipart GEM316 before refilling with correct grade oil. 5. In all instances, carry out a final cooling system pressure test to confirm no loss of pressure. If any loss is detected investigate further to establish the cause, i.e. check all hose connections etc.

Additional information: Cylinder head gasket failure often occurs as a result of coolant loss caused by leakage from other gaskets and hoses etc. Always ensure that the cooling system is checked thoroughly to prevent a repeat failure.

Parts information: GUG702613HG Cylinder head gasket (latest gasket including 2 steel dowels) • This gasket is compatible with all 8 valve and 16 valve four cylinder engines.

Cylinder head gasket sets: Part numbers have also changed but will be advised at the time of ordering. • If the original part number is ordered i.e. as seen on EPC, an automatic supersession will apply and the latest part numbers advised.

Obtain cooling system and oil flush from local sources or obtain the following from Unipart: •

GEM327 Cooling system flush - 5 litres

GEM316 Engine flush - 5 litres

Warranty information: Use complaint code: 1S6M Use S.R.O.: 12.29.02 Time allowance: Refer to the RTS CD for time allowance applicable to the vehicle / derivative Submit additional claim for flushing etc dependant on requirements.