4202 headgasket leak after installation

[RRemmers]

Hello all, finnlly had to do some engine work on my 450 loader.It had started using about quart and ahalf of oil in less than 6 hours of run time. It was checked over several times for leaks but none was found seemed like it was blowing out the exhaust. Went ahead and tore down the motor and sent head to machineshop and had them order a rebuild kit for me. Reassembaly went well using the manual as a guide and alittle help from my son-in-law. The kit came with new sleeves,pistons,rings and bearings and alot of other parts that were not used due to we did a inframe on the motor. The problem I ran into is that when we started to add the last of the coolant we discovered a leak between the head and block on the exhaust side of the engine where there is two recesses in the head.The headbolts were torqued to spec according to the manual and the specsheet sent with the gasket set. Has anyone ever experinced this on any of there rebuilds.

[rock digger]

Did you use the old headbolts? I have found sometimes the old bolts have stretched and even though to torqe specs they have bottomed out in the head. I simply put a exra whasher under the bolt and torqe down. Has workrd for me and is a easy and inexpensive fix.
Rock Digger

[teaberry]

The Liner height above the head is also critical. Do you see any burn marks from the liner outward or between liner holes. I had one so low that we had to cut an aluminum sheet purchased from a printshop to add thickness to the gasket. Then after careful torquing the engine has been fine for about three years now of intermittent heavy use.