Porosity/Sand Hole Repairing

SAND HOLES OR POROUS ENGINE CASTINGS
Porosity or sand hole(s) causing oil seepage or leakage can occur with modern casting processes. A complete inspection of the engine and the transaxle should be made. If a leak is attributed to the porous condition of the cylinder block or sand hole(s), service can be made with epoxy sealer Devcon Aluminum Liquid F2 or an equivalent meeting Ford specification M3D35-A(E).

CAUTION: Do not service cracks with this epoxy. Service with this metallic plastic must be confined to those cast iron engine component surfaces where the inner wall surface is not exposed to the engine cooling system pressure or oil pressure.

DESCRIPTION

NOTE: Openings larger than 6 mm (1/4 inch) should not be serviced using metallic plastic. Openings in excess of 6 mm (1/4 inch) can be drilled, tapped, and plugged using common tools.

The areas of the cylinder block that can be serviced include the unmachined surfaces extending along the length of the block, upward from the oil pan rail to the cylinder water jacket, and the lower rear face of the cylinder block.

PROCEDURES
The following procedure should be used to service porous areas or sand holes in cast iron smaller than 6 mm (1/4 inch).
1. Clean the surface to be serviced by grinding or rotary filing it down to a clean bright surface.
2. Chamfer or undercut the hole or porosity to a greater depth than the rest of the cleaned surface. Solid metal must surround the hole.
3. Clean the area to be serviced thoroughly. Epoxy sealers meeting Ford specification M3D35-A(E) will not stick to a dirty or oily surface.
4. Mix the metallic plastic base and hardener as directed on the container. Stir it thoroughly until it has a uniform consistency.
5. Apply the service mixture with a suitable clean tool (putty knife, wood spoon, etc.) while forcing the epoxy into the hole or porosity.
6. Allow the service mixture to harden. This can be done by heat curing the surface with a 250-watt lamp placed 254 mm (10 inch) from the serviced area or by letting the area air-dry for 10-12 hours at temperatures above 10° C (50° F).
7. Sand or grind the serviced area to blend with the general contour of the surrounding surface.
8. Paint the surface to match the rest of the cylinder block.