DSG-423 GENERAL INFORMATION
01-37
Cylinder Block Repair - Cast Iron Porosity
Defects
CAUTION: Do not attempt to repair cracks, areas
where temperature will exceed 260°C (500°F) or ar-
eas exposed to engine coolant or oil. These areas
will not repair and could cause future failure.
Repair porosity defects with an epoxy sealer meeting
Ford specification M3D35-A (E).
1. Clean the surface to be repaired to a bright, oil-free
metal surface.
2. Chamfer or undercut the repair area to a greater
depth than the rest of the cleaned surface. Solid
metal must surround the area to be repaired.
3. Apply the epoxy sealer and heat-cure with a 250-
watt lamp placed 254 mm (10 inches) from the
repaired surface, or air dry for 10-12 hours at a
temperature above 10°C (50°F).
4. Sand or grind the repaired area to blend with the
general contour of the surface.
5. Paint the surface to match the rest of the cylinder
block.
Cylinder Block Core Plug Replacement
1. Use a slide hammer or tools suitable to remove the
cylinder block core plug.
2. Inspect the cylinder block plug bore for any damage
that would interfered with the proper sealing of the
plug. If the cylinder block plug bore is damaged, bore
for the next oversize plug.
NOTE: Oversize plugs are identified by the OS stamped
in the flat located on the cup side of the plug.
3. Coat the cylinder block core plug and bore lightly
with Threadlock® 262 E2FZ-19554-B or equivalent
meeting Ford specification WSK-M2G351-A6 and
install the cylinder block core plug.
Cylinder Head - Distortion
• Use a straight edge and a feeler gauge to inspect the
cylinder head for flatness. Compare with
specifications. If the cylinder head is distorted, install
a new cylinder head.
Special Tool(s)
Impact Slide Hammer
T50T-100-A
Special Service Tools called for
by the procedures can be
obtained by calling:
1-800-ROTUNDA
(1-800-768-8632)
Special Tool(s)
Straightedge
303-D039 (D83L-4201-A) or
equivalent
Special Service Tools called for
by the procedures can be
obtained by calling:
1-800-ROTUNDA
(1-800-768-8632)
Straight Edge
Feeler Gauge
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