Block Inspection
CLEANING AND INSPECTIONIf the engine is disassembled, thoroughly clean the cylinder block with solvent. Remove old gasket material from all machined surfaces. Remove all pipe plugs that seal oil passages and clean out all the passages. Blow out all passages, then bolt holes and other openings with compressed air. Make sure threads in the cylinder head bolt holes are clean. Dirt in the threads may cause binding and result in a false torque reading. Use a tap to true-up threads and to remove all deposits. Thoroughly clean the grooves in the crankshaft bearings and bearing retainers.
Check all machined surfaces for burrs, nicks, scratches and scores. Remove minor imperfections with an oil stone.
Replace all plugs that show evidence of leakage. Inspect the cylinder walls for scoring, roughness or other signs of wear.
BLOCK DISTORTION
Check the cylinder block for flatness of the head gasket surface following the procedure and specifications recommended for the cylinder head. The cylinder block can be machined to bring the head gasket surface within the flatness specifications, but not to exceed 0.254 mm (0.010 inch) stock removal from the original head gasket surface.
SAND HOLES OR PROUS ENGINE CASTINGS
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 attributed to the porous condition of the cylinder block or sand holes, service with Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M3D35-A (E). Do not service 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. For example:
- cylinder block surfaces extending along the length of the cylinder block, upward from the oil pan rail to the cylinder water jacket but not including machined areas.
- lower rear face of the cylinder block.
CAUTION: Service is not recommended to the intake manifold exhaust crossover section, since temperatures can exceed the recommended temperature limit of 260°C (500°F).
- intake manifold
- cylinder head along the valve cover gasket surface
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 Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M3D35-A (E). Openings in excess of 6.35 mm (0.25 inch) can be drilled, tapped and plugged using common tools. Clean service area thoroughly. Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M3D35-A (E) will not stick to a dirty or oily surface.
2. Mix Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M3D35-A (E) and hardener as directed on container. Stir thoroughly until uniform.
3. Apply Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M3D35-A (E) 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.