alright gentlemen, I am new to the forum scene but I here that this is the place to gather some information...

first off I am working on a 2003 Evo 8

I disassembled the motor and sent the head to the machine shop for a port and polish from a local tuner...

They installed Ferrera Valves (stock Size)

New Valve Guides (ferrera)

Valve Stem Seals (ferrera)

Valve Locks (ferrera)

SKUNK2 2.0L 4G63BT DOHC 2003-05 EVO VIII CAMSHAFT SET

SKUNK2 PRO-SERIES 95-05 EVO/ECLIPSE 2.0L 4G63BT (INCL. SPRING BASE AND TI RETAINERS)

the other parts of the build consisted of....

Cometic Head Gasket (3)

Unorthodox Cam Gears

Greddy timing Belt and Balancer Belt

Arp Head Studs

OEM Intake MANI Gasket

Stock Intake Mani

The story starts when we put the "fresh" head back on the car...
we called ARP for the torque specs on the head (80lbs) in a 2 sequence 40 then 80, we broke it down some more and did 23, 53, 80... everything went as expected...

we finished the assembly on the rest of the engine timing belt and spun the motor over with a ratchet... everything seemed fine. now came time to add the fluids to the radiator, here is where the problem begins...

as fast as we poured the water into the radiator, it was pouring out of the exhaust! YES that’s right the exhaust! Every cylinder when the motor was at TDC was filled to the top of the tube seals where the plugs go WITH WATER... as the story continues we rip the head back off the motor thinking 4 sure head gasket (cracked, upside down, something stupid) replace it with a fresh new gasket again from cometic... followed the torque spec and sequence and this time we didn’t put the t-belt back on so there were 2 pistons that were up and 2 down... the cams had 2 valves open on 2 cylinders... this time only the cylinders with the closed valves had water filled in them! Immediately I think Intake manifold water port near cyl no.4... Disassembled 1 more time (3rd time) take off the mani and copper spray the metal gasket from mistu and cross our finders and hope... copper sprayed the head gasket and reinstalled the head once again... same problem!!! cylinder #4 and 1 filling with water (starting on #4 and slowly going to #1)... I don't know what else to do or try... this has never happened... the only other thing which was in the back of my head the whole time is that the porter cut into one of the jackets for the water or some kind of a crack... but again would that fill all the cylinders???!!!?? I really don't know again.... please anyone I will take all I can for input...

We are on out last limb here.... attempting 1 last disassembly and reassembly with the intake mani gasket using RTV grey instead of the copper and another new headgaset (3rd one)

PLEASE IF THERE IS ANYTHING U CAN THINK OF PLEASE ADVISE!!! THANKS!!

 

Pressure test the block and head, this will show any cracks, leaks, etc.

 

well 1 crack doesnt fill all 4 cylinders with water.. are you sure you have the right headgasket?? and is it installed properly not upside down etc.. i have seen someone put a VW vr6 head gasket upside down and water pour right out of it when filled..

 

i thought the same thing originally... thats why we tried 3 diffrent head gaskets... i called cometic and specifically checked the part # 3 diffrent times with 2 diffrent people.. the gasket only fits on one way... i am afraid that they cut into a water jacket when the head was ported.... What also makes it weird is that when the motor was at TDC all the cylinders filled when the motor wasnt at TDC then only the 2 cylinders that were in the up position in the bore filled?!

Thanks for all the input... I will keep everyone posted as to what happens.. heading tonight to work on it the new plan is to regasket the intake mani and excessivly gasket goo the water port near cly 4 and 1 more time with a new head gasket (#4 for a total of almost $400 in head gaskets )... and see what happend

wish me luck!!

 

bump for kvons poor car

 

You will need a new head, and a STOCK Head Gasket.

 

Did the shop who ported the head hit a water jacket?

 

Any reasoning behind your statement?

 

Because the head is probably f'd. and it is best to use oem gaskets.

 

Probably? do you not know the rules behind Evo Advanced section? your not supposed to be posting BS responses if you dont know wtf ur talking about.

 

Sorry man, just trying to help. I have seen the same problem with what the poster mentioned earlier. A local shop to us "ported" a head and went thru every port into a jacket. Sorry, Didn't mean to post what seemed to be BS.

 

Its no problem, just the rules of the forum. Thats what were assuming the issue is, but we arent 100% sure yet. Still waiting on more people to chime in.

 

Pressure test the head. If they went into a water jacket it's not the end of the world. It'll be expensive but not totally fubard. But if this is what happened, never ever ever ever ever send anything to that machine shop. It's one thing to go into a water jacket when porting. It's an entirely different animal to send that head to a customer without checking your work. I wouldn't trust anything that machine shop gives you. They obviously don't care about what comes out of their shop.

That is of course, if that's the issue.

I'm reading over what you wrote again, did you say the two cylinders with CLOSED valves filled up with water? And the two cylinders with OPEN valves stayed dry? The more I think about this the more it doesn't really look like it's a port issue. If the cylinders with closed valves filled with water it wouldn't be a crack in the port, you'd see water build up on the back of the valves.

Next time you take it off put a straight edge on it and check if it's warped. If the head or block are warped no matter what gasket you put on there it's gonna leak through. The leak would have been worse with the cometic than with the stock gasket. Check that, or have the machine shop check it, then if it's not too bad you can just have it decked, which should have been done anyway if you're using a cometic gasket.

The stock gasket is fine for most applications. A cometic gasket needs a very good surface on both head and block to seal. Any motor you actually need a cometic on is gonna have the block out anyway. Since you're not taking out the block, you can't deck it, so a stock gasket will seal better.

Sorry for the rambling post, I think as I type.

 

You should call they guy who did the head and ask him for ideas.
I agreed with your reasoning for changing the HG and intake once, but since you are sure they are one right, there does not seem to be a lot of point in changing them.
You could remove the head and pour water in it yourself. If water is leaking out profusely, it should be easy to see in the ports. Just figure a way to block off the water ports for testing. Maybe leave the intake on?

 

first, pressure check the head.

whats strange is that you have water in all 4 cylinders without turning hte engine over??

make certain you have the head dowels in the right location & or check that they didnt face so much off the head, that the dowel holes are now to shallow & are preventing the head from comletely seating.