cracked block - what to do?
15-06-2004, 02:28 PM
#1
Testing the future
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cracked block - what to do?
https://passionford.com/forum/viewtopic.php?t=57571
have taken my cyl. head off to cure a problem where the combustion pressure on boost was leaking into the water jacket on cylinders 2 & 3. the head gasket was damaged in those areas, and i'm not yet sure if the head is warped (will have it checked and skimmed as lightly as possible).
was prepping the block face this afternoon ready for the refit sometime later and found a crack in the block
the crack is on the exhaust side, coming out from the bolt hole between cyl. 1 & 2 and going to the water jacket forwards and backwards.
i assume that this kind of crack can only be caused by tightening the head bolts when there is oil or water in the hole - or is there any other way?
anyway, it's done now. what to do about it? ideally of course, get a new block (and take the opportunity to replace the 205 with a 200). but is it necessary? what will/could happen if i rebuild the engine as is?
have taken my cyl. head off to cure a problem where the combustion pressure on boost was leaking into the water jacket on cylinders 2 & 3. the head gasket was damaged in those areas, and i'm not yet sure if the head is warped (will have it checked and skimmed as lightly as possible).
was prepping the block face this afternoon ready for the refit sometime later and found a crack in the block
the crack is on the exhaust side, coming out from the bolt hole between cyl. 1 & 2 and going to the water jacket forwards and backwards.
i assume that this kind of crack can only be caused by tightening the head bolts when there is oil or water in the hole - or is there any other way?
anyway, it's done now. what to do about it? ideally of course, get a new block (and take the opportunity to replace the 205 with a 200). but is it necessary? what will/could happen if i rebuild the engine as is?
18-06-2004, 10:44 PM
#4
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Originally Posted by STUCOS
think it's time for a new block mate 
Fraid to say I agree mate, with that being the bolt point is pretty much fooked!
10-09-2004, 01:49 AM
#6
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Quite honestly you are best off getting a replacement block. Get a secondhand unit, chemically strip it, hone it and rebuild what you have. That way you'll be dealing with something sound.
Many companies will claim that they can repair the block. It is possible to use a process called stitching, but I doubt it would hold. Either way you would need to use a helicoil / timesert to hold the stud. Cast iron is difficult to weld because of the material structure - you can get a bead on it but it is not going to be any good.
A replacement block will be the cheapest way of fixing the problem you have. Sorry.
Many companies will claim that they can repair the block. It is possible to use a process called stitching, but I doubt it would hold. Either way you would need to use a helicoil / timesert to hold the stud. Cast iron is difficult to weld because of the material structure - you can get a bead on it but it is not going to be any good.
A replacement block will be the cheapest way of fixing the problem you have. Sorry.
11-09-2004, 02:14 PM
#7
Wahay!! I've lost my Virginity!!
This is a very common problem on 205 blocks ,it's not oil or water when tightening that caused the crack but probably you are running high boost.You have to replace the block with either another 205 and using APR stud and nut kit or the best a 200 with lond stud kit.
Roger
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12-09-2004, 01:09 AM
#9
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it is possible to weld cast iron so, that it would be good as new. but definately better and cheaper choise is to buy a replacement block.
you really have to be spesialist on that field, when repairing cast iron. and many of those repair companies dont seem to have knowledge on those types of repairs.
you really have to be spesialist on that field, when repairing cast iron. and many of those repair companies dont seem to have knowledge on those types of repairs.
13-09-2004, 08:04 AM
#10
Testing the future
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cheers for the replies mates.
am getting a replacement 205 block sorted next month (thanks stu
). in the meantime, i've ported the head and had it skimmed and rebuilt it with a new std gasket and bolts and am running 1.5 bar boost on greens with no problems so far. fingers crossed it will last until the end of next month and will make the drive to england to fit the new block.
am getting a replacement 205 block sorted next month (thanks stu
). in the meantime, i've ported the head and had it skimmed and rebuilt it with a new std gasket and bolts and am running 1.5 bar boost on greens with no problems so far. fingers crossed it will last until the end of next month and will make the drive to england to fit the new block.
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