Interesting suggestion on what is occuring but what do you know that supports this theory? Are the folks with head gasket problems finding there heads are warped and need redecking before reinstall?
My experience (with subaru engines) is that when everyone starting switching to alum blocks with alum heads they didn't think about mismatching thermal growth that utimatly wears out the gasket under the thermal fight at the block and head interface. Subaru switched from a closed deck motor to an open deck in the late 90s as a means to reducing casting costs and casting time. What followed is the block now heats up faster than the head in certain spots and physically wears the gasket out and the seal fails over time. Ironiclly Subarus leak an oily coolant brown mix on to the exhaust as the first sign of gasket failure. Nearlly all the failures happen on the thinest head to block gasket area far away from the cylinder. The first fix was a coolant sealent and then they updated the gaskets with more robust sealing material. When I did a few HG replacements I used a flexible gasket sealer with the new gasket to futher decrease the likely hood of failure.
I'm not sure if the head gaskets problems that have occured on the v6 are due to the warping that you descibe or something similar to what occured on the Subaru motors.
LeF-T_4X4 if I had to speculate he is saying our motors being Naturally asporated are low compression and his experience (judging by his signature) is with higher compression engines (turbo charged) where the failure tend to occur from the cylinder into the coolant not coolant into cylinder. Force induction engine tend to have better gaskets and higher clamping forces applied to the gasket due to the large internal cylinder pressures.
Low cylinder pressure - as in an NA, fairly low revving, not really high volumetric efficiency engine. The 1GR is 10:1, which is high for regular pump gas (i.e. 87 octane), but it's pretty sedate compared to higher performance engines.
As for supporting evidence, the symptoms match it. If it was a substandard gasket on sealing combustion pressure, you'd pressurize the cooling system and blow coolant everywhere under the hood (BMWs are famous for this with hard usage - but the I6 heads typically warp more with high temp relative to the iron block, so it's under hard usage, not on cool down). Losing coolant tends to point towards something happening while the engine isn't operating.
I also believe a few people who had a HG job done had the heads resurfaced, and they were out of tolerance for flatness. So something is causing the heads to warp.
What you describe on Subarus is exactly what I'm describing. Differential thermal expansion causing gasket failure. The leaking area is going to be the spot that falls below the minimum clamping pressure to form a seal with that gasket.
A head having a permanent warp means nothing other than the strain in some part of it exceeded approximately 0.2% so that it plastically deformed. You can have the same phenomenon happen and not have a permanent warp. But usually a gasket problem has moved things around quite a bit, so there is usually some out of flatness condition.
It's just a working theory, and it's worth exactly what you paid for it. :humble: