Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSMERCURY1999SABLE V6-3.0L DOHC VIN SREPAIR AND DIAGNOSISENGINE, COOLING AND EXHAUSTENGINESERVICE AND REPAIRGENERAL PROCEDURESCYLINDER BLOCKSAND HOLES OR POROUS ENGINE CASTINGS - SERVICE
1999 Mercury Sable V6-3.0L DOHC VIN S
Sand Holes or Porous Engine Castings - Service
1999 Mercury Sable V6-3.0L DOHC VIN SSECTION Sand Holes or Porous Engine Castings - Service
Porosity or sand holes which will cause oil seepage or leakage can occur with modern casting processes. Make a complete inspection of engine and transaxle. If the leak is caused by porosity of the cylinder block or sand holes, service with an epoxy sealer meeting Ford specification M3D35-A (E). Do not service cracks with this material. Service with this metallic plastic epoxy resin 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.
- 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 the surface to be serviced by grinding or rotary-filing to a clean, bright metal surface. Chamfer or undercut the hole or porosity to a greater depth than the rest of the cleaned surface. Solid metal must surround the hole. Openings larger than 6.35 mm (1/4 inch) should be serviced using an epoxy sealer meeting Ford specification M3D35-A (E). Openings in excess of 6.35 mm (1/4 inch) can be drilled, tapped and plugged using common tools. Clean the service area thoroughly. An epoxy sealer meeting Ford specification M3D35-A (E) will not stick to a dirty or oily surface.
2. Mix the base of an epoxy sealer meeting Ford specification M3035-A (E) and hardener as directed on the container. Stir thoroughly until uniform.
3. Apply an epoxy sealer meeting Ford specification M3D35-A (E) with a suitable clean tool (such as a putty knife or wood spoon), forcing the epoxy into the hole or porosity.
4. Allow the service mixture to harden. Two methods can be used. Heat-cure with a 250-watt lamp (as per direction on container) placed 254 mm 0 inches) from the serviced surface or air-dry for 10-12 hours at temperatures above 10O°C (500°F).
5. Sand or grind the serviced area to blend with the general contour of the surrounding surface.
6. Paint the surface to match the rest of the cylinder block.
- 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.
- 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 the surface to be serviced by grinding or rotary-filing to a clean, bright metal surface. Chamfer or undercut the hole or porosity to a greater depth than the rest of the cleaned surface. Solid metal must surround the hole. Openings larger than 6.35 mm (1/4 inch) should be serviced using an epoxy sealer meeting Ford specification M3D35-A (E). Openings in excess of 6.35 mm (1/4 inch) can be drilled, tapped and plugged using common tools. Clean the service area thoroughly. An epoxy sealer meeting Ford specification M3D35-A (E) will not stick to a dirty or oily surface.
2. Mix the base of an epoxy sealer meeting Ford specification M3035-A (E) and hardener as directed on the container. Stir thoroughly until uniform.
3. Apply an epoxy sealer meeting Ford specification M3D35-A (E) with a suitable clean tool (such as a putty knife or wood spoon), forcing the epoxy into the hole or porosity.
4. Allow the service mixture to harden. Two methods can be used. Heat-cure with a 250-watt lamp (as per direction on container) placed 254 mm 0 inches) from the serviced surface or air-dry for 10-12 hours at temperatures above 10O°C (500°F).
5. Sand or grind the serviced area to blend with the general contour of the surrounding surface.
6. Paint the surface to match the rest of the cylinder block.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.