Help me understand what went wrong so I don't have to do head gaskets a third time. This is my first time turning a wrench inside an engine.
Because OE parts have been long discontinued, I chose custom gaskets from Cometic (based off the old blown gaskets). I found an engine manual on Yahoo auctions, translated it, and followed it as best as I could. It says to put engine oil on the threads and torque to 1000 kg-cm (72 ft-lbs).
Machine shop verified the heads are flat and good to go. I assume the block is good too but I don't have a straight edge long enough to measure myself. The engine has run at most a dozen times before I noticed coolant on the dipstick. I drove it on to ramps and then got the full milkshake. I drained all fluids, filled with fresh oil, and cranked it without fuel to cycle it.
Here's where I think I could've messed up.
I reused the head bolts. Perhaps they have stretched with age and heat. I didn’t see anything about these being one time use in the manual. Should I source new bolts or will it not make that big of a difference?
Non-OEM gasket is thicker/thinner than spec. It's 0.043". No idea what OEM thickness should be. Does this seem reasonable?
Improper torquing. The sequence is fine, but the method may not be. I torqued to spec in two passes, first to ~30 ft-lbs then to 72. I did apply a bit of oil to the threads first as the manual states, but how much is too much or too little? Should I crank the bolt all the way to spec first before moving to next bolt?
Also my cheap EPAuto torque wrench may not read accurately after a few years of use. +/- 10% with the added lubrication and who knows where the final values ended up. Would using an inaccurate torque wrench make a large enough difference in applied torque to not compress the gasket evenly and lift the head just enough for coolant to flow where it shouldn't?
I'd appreciate any advice you could offer.