Sand Holes or Porous Engine Castings - Service

Porosity or sand holes, which will cause oil seepage or leakage, can occur with modern casting processes. Make a complete inspection of engine and transmission. If the leak is caused by a porous cylinder block or sand holes, service with an epoxy sealer, Devcon Aluminum Liquid F2(R), meeting Ford specification M3D35-A(E) or equivalent. Do not service cracks with this material. Service with this metallic plastic must be confined to cast iron engine component surfaces where the inner wall surface is not exposed to engine coolant pressure or oil pressure. For example:
a. Surfaces of cylinder block extending along the length of the cylinder block, upward from the oil pan rail to the cylinder water jacket but not including machined areas.
b. Lower rear face of the cylinder block.

The following procedure should be used to service porous areas or sand holes in cast iron:





1. Clean surface to be serviced by grinding or rotary-filing to a clean, bright metal surface. Chamfer or undercut hole or porosity to a greater depth than rest of cleaned surface. Solid metal must surround hole. Openings larger than 6.35 mm (0.25 inch) should not be serviced using an epoxy sealer. Openings in excess of 6.35 mm (0.25 inch) can be drilled, tapped and plugged using common tools. Clean service area thoroughly. An epoxy sealer, Devcon Aluminum Liquid F2, meeting Ford specification M3D35-A(E) or equivalent will not stick to a dirty or oily surface.
2. Mix an epoxy sealer, Devcon Aluminum Liquid F2, meeting Ford specification M3D35-A(E) base and hardener or equivalent as directed on container. Stir thoroughly until uniform.
3. Apply an epoxy sealer, Devcon Aluminum Liquid F2, meeting Ford specification M3D35-A(E) or equivalent with a suitable clean tool (such as putty knife or wood spoon), forcing epoxy into hole or porosity.
4. Allow service mixture to harden. Two methods can be used. Heat-cure with a 250-watt lamp (as per direction on container) placed 254 mm (10 inches) from serviced surface, or air-dry for 10-12 hours at temperatures above 10° C (50° F).
5. Sand or grind serviced area to blend with general contour of surrounding surface.
6. Paint the surface to match the rest of the cylinder block.