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If the head wasn't properly reconditioned, the valve could be overheating and breaks from metal fatigue. Valve guides do more than just center the valve in the hole, they also allow the valve to dissipate heat. If the valve is not getting enough contact surface it will run hotter than it should and it can break. It's quite rare for this condition to show up in a water cooled engine, but it was very common among air-cooled VW engines. Another possibility, which is actually far more probable, the engine could be running too lean and/or the EGR valve could be faulty causing the exhaust valves to run too hot... resulting in the same thing; overheating valves that break from metal fatigue.

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โˆ™ 2006-03-08 05:25:50
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Q: Why on a 1991 Talon would a new head have a valve break off inside the block destroying the piston twice now?
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