Cracked Block
 

Well, looks like I got a cracked block in my DII. The cooling system was pressurizing so I pulled the heads and the head gaskets looked OK. One of the pistons is much cleaner than the other so block is probably cracked behind that liner. Should I just put it back together and try the K&W block sealer?

If the crack is in the cylinder, behind the sleeve all you have to do is re-sleeve it. If the crack is on the deck, you are pretty much screwed.

The crack is behind the liner but the liner doesn't look like it moved. It is probably cheaper to just get a new block than re-sleeve this one. I will try a block sealer and see what happens, if it blows I'll just loose on gaskets and bolts. Has anybody tried chemical block sealers for this type of problem? I read somewhere that some blocks had this issue because of porous aluminum castings.

If the crack is behind the liner and the liner is good, then what is the problem? Does coolant flow where the crack is? If coolant is coming up between the liner and the block, its not the crack, its the liner..

Aluminum behind the liner cracks and the water gets pushed up between the liner and the block into the cylinder.

Art, I am close, send me your number and I'll call you.