After rebuilding a 2.1, I torqued the heads on by the book with a new German gasket set. The engine ran good and did not leak. After running the engine only a few miles I put the Vanagon away for a few days planning to button things up when I had time. In two days I happened to notice the passenger side head was starting to leak coolant. I looked at the gasket on the top of  the head on the front corner and the gasket was pushed out funny. I took the head off and the new rubber gasket had a diagonal split about 3/4 inch long that cut the sealing face of the gasket in two. Has this happened to anyone else or did I just get a bad gasket? The heads are the original heads that came off of the engine. Any ideas?  The gaskets had the VW mark on them so I assume they are OEM.  
Thanks,  Todd Francis  

Todd 

this has happened to me also I have seen gaskets split both on the top and the bottom I think that this occurs as the head is installed one reason is that the push rod tubes press against the head and because of this the head is at an angle when the  head nut is tightened to bring the head into place against the gasket this might create a side load on the gasket and start to tare the gasket and the pressure of the cooling system finishes it off in just a short time 

to prevent this problem I deburr the sharp of the case where the rubber gasket sits with a file after I repair the gasket suface with JB weld. I also use the a little silicone as a lube in both the channel of the gasket and the head sealing surface. the only other thing I do that could help is to wiggle the head as I bring the head down into place and my hope is that this unloads any side pressure on the rubber gasket 

Bob Donalds 

http://www.bostonengine.com

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