ANSWERS: 4
  • heater core
  • I hate to tell you but it sounds like it's a blown head gasket. However a bad radiator cap will have similar symptoms. When you removed it last did you have the cylinder head checked for warpage? It shouldn't be warped past 0.002 in. or it needs to be milled. The cylinder block will rarely warp but it should be within 0.005 in. (I think) of straightness. Good luck. Overheating issues are a pain in the arse.
  • You didn't mention whether or not you're finding coolant in the oil. That could lend a clue as to where it's been going. If you didn't check the cylinder head/cylinder block mating surface for straightness/flatness, you may have changed the head gasket without fixing the underlying problem. Sometimes, the cylinder head will develop cracks that allow cylinder pressure to leak into the cooling system. That, in turn, will force coolant to overflow. Does the engine misfire, especially when warmed up and idling? Before you take the engine apart again, you should consider doing a "leak-down" check, where compressed air is put into each cylinder (thru the spark plug hole). You will hear the air escaping out the radiator filler neck (cap removed) if there is either a bad gasket or a crack, and you'll know which cylinder has a problem before you even disassemble it.
  • Sounds like you have a hard-to-find leak... Did your new hed gasket help for a while? If so you may have a warped cylinder head (caused by overheating) as suggested elsewhere - skimming the head can fix that. If not, there seem to be two places you've not considered. The heater core and hoses may have a leak, but they'd not cause overheating until enough coolant had leaked out. Another possibility is a cracked head or block. If you do have a leak in the engine (warp or crack), there will be signs in the oil - milky scummy stuff. (a real mechanic can probably describe it better) and the coolant will likely be odd too

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