The solid copper gaskets are rather difficult to keep sealed, even when
everything is "just so", since they compress very little on installation.
My approach:
1) Pull the manifolds and make sure where the coolant is coming from.
Assuming it is the joint between head & block, pay particular attention to
that area once the head is off; looking for any gouges, cracks, raised
metal, etc. In fact, if it is near one of the short studs, I would probably
remove the stud and rub a flat machinist's file over the area to pick up any
high spots.
2) Pull the head. Use a good straightedge to check the block surface
(working around the liners) for flatness. Also recheck protrusion on each
side of each liner.
3) Check that the head nuts spin easily all the way down the stud threads.
If they bind partway down, replace the stud.
4) Reassemble using a doctored standard gasket as I outlined before, using
solder instead of superglue.
The superglue was a suggestion from Ken Gillanders, and while it would
_probably_ work fine, I know that solder works. The extra half hour sitting
at the dining room table (with lots of newspapers underneath) is a small
price to pay, IMO.
Wouldn't hurt to try to check the calibration of your torque wrench,
especially if you are using a 'clicker' type. Maybe a friend has a beam
type you could borrow.
You may still need to tear the engine down, but all this could be completed
in a weekend (if you have the gasket & wire on hand). IMO it's worth a try.
-- Randall
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