When Low Compression Follows a Head Gasket Replacement on Bobcat’s Deutz Engine

[MikePhua]

Background: From Smooth Operation to Unsuccessful Restart
A compact Deutz-powered Bobcat 863 skid-steer, with only 900 engine hours and its timing belt replaced at 700 hours, suffered a blown head gasket. While the engine still started easily despite burning oil, the replacement job paradoxically resulted in poor compression—far reduced across all cylinders—even after following the workshop manual and adjusting valves meticulously . Readings after installation ranged approximately from 100 psi to a high of 300 psi—considered low across the board .

Possible Causes of Post-Gasket Compression Loss
1. Warped Cylinder Head or Block Warpage
Uneven surfaces can prevent proper sealing even with correct gasket installation. Checking for flatness using a straightedge and feeler gauge is essential. A knowledgeable mechanic recommended this diagnostic step as a priority .
2. Improper Gasket Material or Fitment
Unexpectedly, the service manual originally specified a fiber gasket, not a multilayer steel type. Though the correct gasket was used following manual guidance, verifying compatibility remains crucial for sealing integrity .
3. Valve Leakage or Mis-seating
If valves do not seat properly or have wear, compression will visibly drop. A straightforward test is to pour a small amount of liquid (e.g., oil) into each cylinder and crank the engine: if compression significantly improves, the issue may lie with ring sealing; if not, valves might be the culprit .
4. Piston Rings or Seal Break-In Issues
During reassembly, cleaning may strip the cylinder walls and rings of lubrication. A quick remedy is to add a capful of oil into each cylinder before cranking—this helps the rings seal properly and can noticeably boost compression initially .
5. Timing or Assembly Errors
Even slight mistiming or improper torque sequencing can impair compression. In other engine repair scenarios, incorrect bolt sequence or over-tightening led to poor compression, underscoring the need for methodical and precise reassembly .

Terminology Notes

• Compression Test: Measures air pressure in a cylinder during cranking to assess sealing performance.
  
• Straightedge & Feeler Gauge: Tools used to verify flatness between surfaces.
  
• Valve Seating: How well a valve closes against its seat; poor sealing causes leaks.
  
• Wet Compression Test: Adding oil to test ring seal effectiveness.
  
• TDC (Top Dead Center): Key position for aligning timing marks when reinstalling the head.
  

Real-World Anecdotes

• An engine rebuilder’s approach in a separate case involved cleaning and reinstalling the head, then experiencing virtually zero compression. The breakthrough came only after oil was placed in the cylinders—restoring compression, confirming ring seating as a factor .
  
• Others have highlighted the dangers of improper head bolt tightening. In one discussion, someone admitted tightening bolts "the hardest I could" with a breaker bar—leading to dramatically low compression. Peers emphasized always using torque specifications and proper sequence, warning that excessive force or uneven tightening can warp components .
  

Recommended Troubleshooting Checklist

• Verify head and block surfaces for straightness using straightedge and feeler gauge.
  
• Confirm gasket type and compatibility per engine specifications.
  
• Perform a wet compression test by adding oil to each cylinder and retesting—note changes.
  
• Inspect valve seating: perform a leak-down test if possible.
  
• Re-examine assembly procedure: torque head bolts in correct pattern and stages; confirm TDC alignment and timing.
  
• If accessible, check for carbon buildup or debris on cylinder walls—clean carefully before reassembling.
  

In Summary
Low compression after a head gasket job can stem from surface warpage, improper gasket selection, poor valve or ring sealing, or assembly missteps. The “wet test” can quickly indicate whether rings are at fault. Thorough inspection and methodical reassembly, paired with careful testing, typically leads to resolution—and the engine returning to its reliable performance.