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Possible head gasket coolant leak? or ? 200

Looking for additional diagnosis suggestions, etc.
1989 245 DL MT5spd non-turbo 275K+miles

For many years ran with loosened coolant expansion tank cap due to one-time radiator leak fixed with a stop leak additive. Last year during annual state safety inspection, unbeknownst to me at the time, the technician helped out by topping-off the coolant in the expansion tank and fully tightened the cap. (No good deed goes unpunished!) Shortly after that I noticed “white” smoke (steam) coming from the exhaust after warm up, rust on garage floor, and rusting of the brand new exhaust system. Not sure if smoke/steam is due to coolant leaking only once engine warms or if only seeing smoke/steam as warming exhaust system releases trapped water.

1. No coolant in oil.
2. Coolant level has probably gone down but is happening so slowly as to make me question what I'm seeing. No detectable engine oil or brake fluid loss.
3. Spark plugs look normal for miles.
4. Boroscope (limited capability cheapie) doesn't reveal any obvious cylinder problems.
5. Compression test (cold) doesn't reveal anything obvious: #1 195 psig, #2 188 psig, #3 197 psig, & #4 199 psig. (Although cylinder 2 is lowest, it is well within what most consider acceptable range.)

Anybody experience this? Any thoughts for performing a better diagnosis? What else could it be other than head gasket? Leakdown testers aren't cheap – would it help diagnosis?
Thanks for any thoughts / suggestions








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    Possible head gasket coolant leak? or ? 200

    [Sorry, I somehow managed to reply to another post (system has been so slow recently), so I'll copy my reply from yesterday up to here in case it helps:]

    Sure does sound suspicious, but not as suspicious as it could be.

    There are a numnber of ways a head gasket can leak
    https://haynes.com/en-us/tips-tutorials/7-different-ways-head-gasket-can-fail

    Loosing coolant out through the exhaust pretty much means going through a cylinder unless it can somehow get out behind an exhaust valve. One of the plugs usually looks different and soon becomes spotless of carbon deposits after repeated steam cleanings. Your observations don't confirm that, so I think that raises major doubt and your head gasket may be okay.

    Even more to the point, if the low pressure cooling system is leaking into the higher pressure combustion and exhaust system then as soon as the engine gets really hot the coolant will turn to steam at the leak. Some may come out the exhaust, but at the same time the cooling system pressure rises, the level will suddenly start to rise in the reservoir and may vapourize or even leak out under the rad cap. If you can run virtually forever with the rad cap loose then this isn't what's happening, in fact that's one of the diagnoses I was taught for a coolant head gasket leak in our red blocks (with the rad cap off, idle until the thermostat opens and keep going for another 15-20 minutes with the rad cap off, there should be no boil up).

    If the excessive smoke out the tailpipe is basically white then that can be normal under certain conditions. This is the time of year where damp weather allows condensation to form and even accumulate in exhaust systems, especially if you park outdoors overnight, and especially if you do a lot of short trips. 240s (and 140s) with a rear muffler across way at the back are horrible for not getting hot enough to evaporate condensation in the rear muffler. If you do a lot of short trips then condensation can build up to the point it's dripping out the tail pipe onto the drive, especially when parked on a slope, and it will be rusty as the muffler and pipes start to go. Any of that sound likely in your case? I try to make sure my tailpipes hang down at a slight angle to help with draining. I figure better to hang low and risk taking a knock than rot out quicker.

    Barring other symptoms, it will take compression and leakdown tests to do a more formal diagnosis of the head gasket.

    If the coolant level is dropping slowly then there are a number of possibilities where it may not be the head gasket and you may not see evidence on the floor. When was the last time the water pump was changed? Is the rad cap known to be good? Any hint of stains on/under the rad hiding behind something? Any hint of a sweet smell in the cabin?

    After a good trip and the hot engine gets cool enough to touch (but not enough for leaks to fully dry), take a dry paper towel to all the cooling hoses and connections you can reach, at/under the reservoir, from the rad to the block, above/below/beside the water pump (esp. above between the pump and the head) the return line at the back of the pump under the exhaust, the heater hoses on the back and right up to the firewall. Start by carefully inspecting into the water pump bearing weep hole (if there is one, either on top or below) with a good light for signs of green fluid. Even then it may still be leaking and evaporating, so you won't catch a drip, but still worth the effort if you can confirm where the problem is.

    I'm rather guessing there's a good chance it's just the cooling system and not the head gasket based on what you've said so far.
    --
    Dave -still with 940's, prev 740/240/140/120 You'd think I'd have learned by now








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      Possible head gasket coolant leak? or ? 200

      Thanks for the extensive reply & suggestions.

      We've had this car for 20+(?) years so I'm familiar with its nuances. But as it has been a garage queen for about 5 years (doesn't get driven much) it's hard to make a concrete statement about coolant level. The white smoke / steam was a new behavior immediately post-inspection. While running a no-pressure cooling system is not great, I've done that for many (10?) years with little issue.

      I immediately assumed a head gasket leak, but the lack of apparent spark plug or piston top "cleaning" makes me question that. I was hoping that someone had seen this specific behavior before and could provide insight.

      As well as having neither time nor money to throw parts at problems, I like to get fixes right so I'll have to try some more diagnosis and maybe spend $$$ on a leakdown gauge set before proceeding. I want to fix this problem before buying a new muffler for the now rusted-out new muffler to pass the now overdue state inspection. (Sometimes I think I should simplify my life, but what fun would that be?)

      Thanks again for taking the time to provide those extensive suggestions.








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      Possible head gasket coolant leak? or ? 200

      Hi Dave,

      I had to give a thumbs up your writing down so many of the ideas of what I would say in this matter
      With as much information that you put into your posts, it like reading a textbook from several authors in collaboration. Great job!

      When he says he leaves the cap loose that is for sure going to be causing some coolant loss.
      I agree with BRUCE S. posting that sealer is never a good thing and besides, I have never seen written how long it’s supposed to fix a leak?
      Running a cap loose doesn’t show much faith it it working either.

      I have read that gasoline when stored in a boats tank will vent fumes. This is just from barometric pressure changes.
      As much as four to eight ounces can evaporate everyday as its sitting on the water being slightly agitated.
      The movement in turns imparts energy into the fuel, of which is the same as heating it.
      Boats are really sincere about the ventilations of all spaces.

      Looking forward to all your posts.

      Phil








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    Possible head gasket coolant leak? or ? 200

    pull the plugs and pressure test the cooling system. use a vacuum hose to listen to each plug hole for hissing.








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      Possible head gasket coolant leak? or ? 200

      Good suggestion - going to try this as soon as I get time.
      (I've been out of this business so long I'm forgetting the obvious things like this. Is that a good thing?)








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    Possible head gasket coolant leak? or ? 200

    Your compression numbers and plugs looked good. If none of the piston tops were cleaner than the others, you may not have a problem. I would be concerned that the engine may not be reaching its full operating temp.

    I would change out the thermostat and the radiator. Stop Leak is never good.
    --
    Bruce S. near D.C.







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