Failed hardness test on cylinder head.... Engine write off?

PhilB

Member
Jun 2, 2020
5
0
New Zealand
Hi Everyone,
We recently purchased a 1996 Disco 1, V8 3.9L Auto which has done 110kms (69k miles) in pretty good nick - passed all the checks.
Very soon into ownership we noticed minor coolant leaks appearing, trouble starting when cold and pretty poor open road performance. Whilst annoying, I wasn't that concerned as the Disco was destined for easy retirement - being our back up 4WD as we live 1km up a 4WD forest track.
After 4 weeks without starting, she turned over twice and blew apart the starter motor. New starter motor in and compression test showed Cylinder #1 was down. Upon starting she ran rough when cold with white smoke with the glycerin burning smell. She ran pretty good though when warmed up. Seemed like the coolant leak filling up #1 had caused a hydraulic type effect to have blown the starter apart.
In the hope of a head gasket issue, I took the heads off and had them checked by a local Rover mechanic. He ran a hardness test on the heads, producing a failed test due to a reading being below '60 Rockwell.' He said this is a sign of how hot the engine had been in the past and it is likely the block and the liners will have an issue in them as well / citing not economic to repair. The Disco is 100kms away from the mechanics shop, up a 4WD track and we live off grid so I'm fairly limited on testing equipment for the block.

My notes from taking the heads off also included:
-The front and rear manifold bolts (RS when opening bonnet) had risen up 10mm and had obvious signs of coolant leaking - one of those bolts above low compression cyl
-The exhaust manifold bolts were finger tight - I thought it was a miracle and had a few beers to celebrate!
-The head bolt (on the LS when opening bonnet) between the two rear cylinders was loose and the bolt was rusty. Obvious signs of leakage around the gasket.
-Approaching the previous owner (who had now moved countries) they then remembered it had overheated twice. It looks like the gaskets were replaced recently so I'm contemplating if it was just a bad gasket replacement without any bother to fix the cooling issue.

My question to the forum is
a) Whether you would recommend just putting new gaskets on - on the assumption that the 3.9's are fairly resilient to overheating and chancing that was the issue??
b) I have found a second hand engine with a mechanics warranty but It would be the same price as purchasing the vehicle.

Many Thanks All
 

bendts

Well-known member
Jan 27, 2015
277
18
Farmland
I had a severe overheating issue about 12 years ago in my D2. Had a very small leak from the head gasket into the #1 cylinder - It would suck out the coolant in about 3 to 5 minutes and spike the temp gage.

Had new head gaskets installed and it ran fine.

5 years later i smelled the leaking coolant and decided on a full rebuild. Pulled it, tore it down, rebuilt it and still going strong.

Never heard of or did a hardness test. I think he's looking for some $$$.

When I did the rebuild I also found some fairly loose bolts and nuts. May just be the result of an expanding and contracting all aluminum block-intake-heads. Just a theory.
 
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Swedjen2

Well-known member
Sep 12, 2018
594
127
California
oh great, another bloody test.
Phil, most of the members are N.A. so used to miles, not Klicks. unless ex-mil.
Do you live near Hobbiton in the Shire? ;)
 
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PhilB

Member
Jun 2, 2020
5
0
New Zealand
oh great, another bloody test.
Phil, most of the members are N.A. so used to miles, not Klicks. unless ex-mil.
Do you live near Hobbiton in the Shire? ;)
Haha hello there Frodo, Yes even down here in middle earth we use klicks.
We are a fair few ... 'miles' away from Hobbiton but very close to the studios where it was all put together.
If I get the Disco working again we'll take you on a tour!
 

p m

Administrator
Staff member
Apr 19, 2004
15,631
864
58
La Jolla, CA
www.3rj.org
Still, take it with a grain of salt. Yes, heads can get softer if the engine was overheated badly - but the heads had to be over 200C in order for the alloy to get annealed.
By that time many other things will be so badly wrong that heads are of no consequence.
 
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