Engine head and gasket of my Tata Harrier replaced at 20,000 km

Since then, I have driven the SUV for around 400 km and haven't found any difference in the engine performance or sound, so I am happy.

BHPian subuiyer recently shared this with other enthusiasts.

Harrier KZA+

I went for the 4th service (minor) at ~20K km / 18 months and was told that the coolant was leaking. Only then I noticed that in the 3rd service, a liter of coolant was topped up – very rare because this is a closed-loop system and big losses mean leakage. I had driven 5K km since then and never felt anything unusual. I had a Mum-Ahm trip planned in a few days, so asked them to resolve it.

They kept it overnight and said couldn’t find any leakage. Didn’t think they did any pressure tests. They were short-staffed and had just left the vehicle running for some time instead. There was no change in the texture of engine oil (e.g., milky) and no change in exhaust gases, so I ruled out coolant entering combustion chambers. I was worried about the physical warping of the metal due to the excessive buildup of heat.

Nevertheless, travelled to Ahm armed with the option of topping up with water (a la carburettor days) – the SC workshop head also recommended this. But the temperature never exceeded usual levels and the vehicle ran amazingly as ever – 530 Kms each way covered in under 9 hrs even with 3x 30-min stops.

The very next day after my return to Mumbai, took to SC after topping up with another liter of water. This time they did more serious testing and confirmed bubbling from the engine joint – pointing to the engine gasket as the most likely source of leak. It also meant opening the engine head and that worried me.

After another day the advisor confirmed that the culprit was the gasket and would have to be replaced – under warranty. Several parts involved and I knew it would be at least 2 weeks.

After about 10 days all the parts had come, and they opened the block and replaced the gasket with necessary machining (apparently needed to align). Strangely, I was told they needed more time because the tool required to refit the timing belt was not available with the SC and had to come from elsewhere.

I received my vehicle exactly on the 21st day.

The first thing I asked was to see the old gasket. To my surprise, the advisor told me for the first time that the engine head was also replaced along with the gasket. Wanted to dig more but could not.

I could not make out any tell-tale signs of coolant leak on the head or the gasket, e.g., no cracks, no holes, no oxidation, or other similar marks. 400 KMS since and I cannot make out any difference in the engine performance or sound, so I am happy. The coolant leakage is gone. Total I had to pay – zero (not counting 21 days without a vehicle). They also had topped up DEF about 7L.

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