Crack Head, Looking for some advice....... Options

[John]

I am of the opinion that I have 2 cracked cylinder heads but am looking for advice....

I have a basically stock 2.0L engine (euro pistons & cylinders done 12 years ago or so), and have been noticing what sounds like an exhaust leak but only when the engine is hot (after driving at highway speeds for about an hour). After the car sits for an hour or so and is started back up, there is no more exhaust leak sound.

The exhaust leak seems to be coming from the drivers side so I am assuming that the driver side cylinder head may be cracked.

I have had the heat exchanger off numerous times and tried many times to seal it up better, but the last several times, I have not noticed any black leak marks on the copper gaskets. (So I am past thinking it is a leak between the head and the heat exchanger.)

One strange note: About 10 years ago, I had a similar occurance and I had a spare head so I had new valves and seats installed in it and I put that one on. I don't drive the car very often so I don't put that many miles on it over time.

Is it common for 2.0 cylinder heads (driver side) to develop cracks?
Can they be detected and repaired?
Who does a good job at finding and repairing them?

Do spark plugs sometimes leak when hot? (Come to think of it I haven't checked them in a while....)

Any and all advice/suggestions will be greatly appreciated.

[Brad Roberts]

Check the plugs first.

Yes. 2.0 heads have some serious issues with cracking in the exhaust port. I have not found a person yet who can weld the area where they crack. If we do find someone.. we have over 40 pairs of heads that I need to have repaired. From the sounds of it.. you have cracked heads. I wish I could quickly locate a pic for you showing where they crack. It would be very easy for exhaust to escape to atmosphere near some of the cooling fins on the head near the exhaust port.

Oh.. also.. check to see if they are 76 2.0 heads with the air injection ports plugged.


B