986 engine rebuild problem

[ryan373]

So, I am in the process of rebuilding my engine and while leak checking my cylinders I found that Cylinder #6 was in the 30-40% range. Pretty bad. Most where 5%-10%. Why was this cylinder over 30%? I have pulled the head for 4-6 and have taken the cylinders out without removing the engine case. If you need to know how I will post a pic of my specialty tools used for removing piston lock rings and Wrist pins through the installation hole (it involves bent coat hangers). Anyways, In pulling Cylinder #6 I found that the piston rings where installed correctly and seem to be in perfect shape as they are new. Before I pulled the head I blocked off the inlet which where the valves that seemed to be leaking the most and found it did noting to help my Leakage rate. So why am I leaking so much? Thee head had a valve job done and has also been faced. The only alternative is the Head Gasket. Has anyone had problems with installing these head gaskets? Three layers of embossed stainless with some sort of coating. It is the only thing I see as being at fault. I had squirt some oil into cylinder #6 to see if it helped seal the piston rings during the test and now I notice oil in the center layer of the head gasket.... Why? I torqued the head properly. 30nm, loosen, 20nm, 60 Degree,60 Degree. Does the dead gasket need to be heated for it to properly seal? Anyone have any Ideas? Maybe there was just some dirt or something in there? Any help would be appreciated. Thanks.

[Cajundaddy]

What you describe sounds like a hairline crack in the head that has not been identified. This is common on the 986 3.2L that experience an overheat condition or blocked cooling passages from failed water pump bits.