Kevin, do all new heads come machined absolutely flat?? I dont know. Probably do but have never questioned it.

Anyway got job done today and out the door.

2 more thoughts have came up about reason for failure,
Its a 2003 D4..T engine, sorry cant remember full code, But they fitted fibre gaskets up to 2002 i believe and multilayer steel from then on.

I was asked if it was fibre or steel when i fitted the first gasket and it had a fibre so we fitted a fibre type.

This time i gave the chassis number to main dealers and was supplied a multilayer.
I have noticed the sump has been off this before the first head was done, could it be it had a fibre gasket fitted before i ever saw it causing premature failure then i got the job to fix it?

Also 2 different way to tighten, torque or torque then angle. I done the torque then angle again today and then went over it at 124nm as the last torque stage is and found some moved up to 100 degrees further,??