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Cylinder Block Repair

WARNING: This page is about a different car, the 2007 Mazda B3000, 2006 Mazda B3000, 2005 Mazda B3000, 2004 Mazda B3000, and 2003 Mazda B3000. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
  • Do not attempt to repair cracks.
  • Do not attempt to repair areas where temperature will exceed 260°C (500°F).
  1. Repair porosity defects with an epoxy sealer.
    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 in) 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.
    Fig 1: Identifying Porosity Defect
    G03312352Courtesy of MAZDA MOTORS CORP.
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