Cracked Zetec Head....Some Advice Please

Doesn't even look like a crack although it's hard to tell from a photo. Looks like a normal corrosion mark along the edge of the gasket. It's nowhere near anything critical though so it should be possible to grind it out and weld it back up if it is a crack.

-- Dave Baker - Puma Race Engines

Seems a strange place to crack, if it really is cracked on that line. Was it crack tested properly, or is it an opinion based on a visual inspection? Mike.

That's a very funny place for a crack. If indeed that is the problem and I have my doubts I'd chunk it all out with a Dremel style tool, weld it back up then grind the surface (unless the head is shot in other places like valve guides whena recon may make sense for those reasons)

I have my doubts that's where you are losing coolant though. Let us know the final outcome.

Mike

It was just inspected visually. It hasn't been tested in any way. It's a real shame as the car has never let me down. My only thougt was trying to persue the line of manufacturing defect, but the car is too old.

Kev

Certainly looks like a normal corrosion mark. I'd be more inclined to say it's the head gasket that's been leaking, but can't really be 100% sure going by a photo. I'd get the cylinder head pressure tested first, which will confirm the condition off the head, and then you can decide on what action to take.

There's an even easier way to tell. Just rub the mark with a piece of coarse wet and dry paper and see if it disappears. Anyway, I've just dug out an identical Zetec head which is waiting to be ported and where the 'crack' is it's solid metal all the way down to the far side of the head. The waterway doesn't start until the edge of the steam hole 10mm further up in the posted pics. The 'crack' would have to run north/south rather than east/west to get to a waterway. I'm now 99.9% sure it's just the mark of the edge of the gasket.

There's a core plug on the side of the head that could be leaking but in the pics it appears in good condition and there is no sign of corrosion in the waterways which would indicate lack of antifreeze. I doubt very much if there is anything wrong with that head but only an independent expert opinion would tell. If it has been removed needlessly then the garage ought to rebuild it all free of charge.

-- Dave Baker - Puma Race Engines

Hi Chris and eveybody who offered useful advice.

I went back to the garage to look at the head with the mechanic. He'd cleaned it up around the 'failure' and indeed it was a hairline crack. I've had a recon head fitted and it's been running fine now for a couple of days...touch wood.

If I offset the cost against not having to fit a new belt for 75K miles and having a 12 month guarantee on the new parts, the charge is *cough* bearable.

Cheers