I’m working on my 1996 Honda Accord with the 2.2L and 392,000 miles and have some questions regarding the engine deck surface for putting a new head on.

The vehicle experienced a pretty bad overheating issue about two years ago resulting in excessive pressure being built up in the cooling system after long drives and has been sitting ever since. The pressure build up was not consistent however and on short drives (3-5 miles after warming up) there was no noticeable hissing coming from the radiator cap. On long drives however you could then hear the hissing. I recently uncovered it and ran through the following tests with the following results…

Compression Check (#1 thru 4)

185, 185, 190, 190


Block Test Kit (Check for exhaust gases through the radiator)

Pass = Blue Dye did not change color


Leak Down Test @ 90psi

Cyl#1 @ TDC = Fail (Very small aerated bubbles coming through the radiator)

Cyl#2 @ TDC = Pass

Cyl#3 @ TDC = Pass

Cyl#4 @ TDC = Pass


Figured this was where the excessive pressure was coming from. At this point it was safe for me to assume the either the head gasket was shot or the head was warped. So after taking it all down to the engine deck and cleaning the surface really well I attached a picture of my gauge readings. I’m a little surprised I was only getting Cyl#1 to fail on the leak down test and not the others due to my readings between the walls of each of the other cylinders exceeding .003” I’m aware of the specs on Alldata saying .003” is the maximum tolerance for warpage so I’m wondering if there is any hope not having the deck shaved given what I have gauged it at? I was hoping to just toss a new head on it and drive it for a while but if I have to pull the engine to resurface it, given the mileage and year of the vehicle I am probably not going to go that far with it.

Didn’t know if there was some special type gasket I could put down which may be a little more forgiving or not. I kind of know my answer but thought I would get a few opinions from others if I could.

BTW, I am using a Snap-on 24" Machinist Straight Edge (GA438A) that has been verified true before I took my readings, including mic'ing my feeler gauges as well.

Thanks in advance for any help you can give.


Sean