Club 80-90 Forums

Help......Sent too long striping down and rebuilding the engine on my T25, finished putting every thing back together this afternoon only to find that the No1 barrel is full of feckin water. Why do I bother with water cooled??

T25 - 1986 - 1.9 - petrol

Can anyone get me a pointer as to how the water got into the barrel?
There is no water in the sump oil.
All the barrel seals have been replaced.
As well as piston rings etc.

The barrels just seem too think to get hair line cracks, and when I cleaned them all up they looked just fine to me.

The head is very pitted paticularly around the holes for the bolts that hold the head on, some of the pitting has eaten away at the edge of the seating of the barrels, but the barrels have a rubber seal around the top of them and a metal seal inside, so surely the water shouldn't be able to make it's way around there?

I do have some pictures, which I can post later as soon as I get them off my phone, which show the head. Is there something obvious that I have missed? or is there anything the I can use to seal around the end of the barrels where they sit in the head?

Any help would be appreciated.

I do get the feeling that I may need a replacement head, any ideas where I can get one if that is the problem.

Here are a couple of pictures, excuse the quality, my phone doesn't take the best pictures in the world.





As you can see the corrosion around the barrel seats could be the problem, I'm guessing that the rubber seal is above the corrosion bit hence the water problem.

I have replaced the metal seals at the top of the barrels as well.

I doubt its porosity of the barrels and if it was you wouldn't see it with the naked eye easily. Looks like that corrosion is compromising the sealing or there's a misfit somewhere. Think I've heard they build them up with JB Weld in the States - but WBX's, me know nutting

JB Weld

would that work and if so for how long?

Someone also told me that they can be welded and skimmed for about £30?

Does anyone know anything about either of these options, both sound a bit dodgey to me!

But there again I no nutting ither

Yes, welding and re-machining, not straight skimming, - dunno about £30 each though, mayeb £30 per chamber

did you use sealant on both ends of the barrels as well as green and black rubber seals,is the head leaking? cj.

No sealant just the seals as directed by the manual.

There are no leaks on the head what so ever other than the No 1 barrel filling with water (above the piston not below) as there is no water in the sump.

The other 3 piston are find!

I'm having someone look at the possiblity of welding the head, but it does look to hopeful at the moment.

Errmm sealant what sort and is it a necessity, as sealant around the block ends of the barrels is going to be a right royal pain?

erm,did it do this before you attacked it ! i always use sealant with the rubber o rings on each end not a lot just enough to help seal,did you tighten head in sequence?cj.

No it didn't do this before I attacked it, however there was that much crap around the barrel head joint that I think it had sealed itself, now it's all nice and clean there is no crap to help keep the seal.

Yep also tighten the head as per the manual and with a dial torque rench.

The general concencuse is that I need a new head!