Cylinder Block Repair

CAST IRON POROSITY DEFECTS

NOTE: Porosity or sand hole(s), which will cause oil seepage or leakage, can occur with modern casting processes. Make a complete inspection of the engine and transaxle. If the leak is attributed to the porous condition of the cylinder block or sand hole(s), service can be made with Devcon Aluminum Liquid F2, an epoxy sealer or equivalent meeting Ford specification M3D35-A(E). Do not repair cracks with this material. Service with this metallic plastic must be confined to those cast iron engine component surfaces where the inner wall surface is not exposed to engine coolant pressure or oil pressure.

1. Openings larger than 6.35 mm (0.25 inch) should not be serviced using metallic plastic. Openings in excess of 6.35mm (0.25 inch)can be drilled, tapped and plugged using common tools. Clean area thoroughly. Metallic plastic will not stick to a dirty or oily surface. Clean surface to be serviced by grinding or rotary filing to a clean bright metal surface. Chamfer or undercut the hole or porosity to a greater depth than the rest of the cleaned surface. Solid metal must surround the hole.
2. Mix the metallic plastic base and hardener as directed on the container. Stir thoroughly until it is of uniform consistency and color.
3. Apply the mixture with a suitable clean tool (putty knife, wood spoon, etc.) forcing epoxy into the hole or porosity.
4. Allow the mixture to harden. This can be accomplished by one of two methods: heat cure with a 250-watt lamp placed 254 mm (10 inches) from the surface, or air-dry for 10-12 hours at temperatures above 10°C (50°F)
5. Sand or grind the area to blend with the general contour of the surrounding surface.
6. Paint the surface to match the rest of the cylinder block.