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E46 M3 (2001-2006) Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006.


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Old Mon, Jan-07-2013, 07:19:43 PM   #11
kuksul08
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Default Re: Help with cavity on engine block between cylinders (blown headgasket)

I don't see why a cement wouldn't work. It's under a lot of compression by the cylinder head and will just provide something for the gasket to press against to maintain full strength. Can you measure how deep the cavity is? It doesn't look like much.

Here are some super high temp cements (1800-2200F) http://www.omega.com/Temperature/pdf...ND_AIR_SET.pdf or http://www.cotronics.com/vo/cotr/ea_ultratemp.htm

Alternatively get it machined down to the depth of the cavity and use a taller head gasket. Anyone know if those are available?
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S54 Valve Adjustment DIY, Excel, Print out: http://dl.dropbox.com/u/28231781/S54...ent%20info.zip
S54 VANOS DIY video (cam bolts, oil pump disk, etc.): http://www.youtube.com/watch?v=9SkT2j3jsU0
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Old Tue, Jan-08-2013, 11:25:04 PM   #12
e46s54guy
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Default Re: Help with cavity on engine block between cylinders (blown headgasket)

I don't have the depth of the cavity. Decking or machining the block will be very costly since the entire bottom end has to be rebuilt and clearance may be too minimal especially since the head was already machined.

Do you have any thoughts on these products to fill the cavity?

http://www.permatex.com/products/pro...sealant-detail

http://permatex.carshopinc.com/produ...id/42287/80697
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Old Tue, Jan-08-2013, 11:28:05 PM   #13
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Default Re: Help with cavity on engine block between cylinders (blown headgasket)

The second link looks promising:
Suggested Applications:
Cylinder head gaskets, ...
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S54 Valve Adjustment DIY, Excel, Print out: http://dl.dropbox.com/u/28231781/S54...ent%20info.zip
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Old Tue, Jan-08-2013, 11:46:15 PM   #14
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Default Re: Help with cavity on engine block between cylinders (blown headgasket)

not sure about cement, but welding and fileing to flat sounds better apternative to me. however the perfect solution is to have it machined flat just like the head. this will make a completely perfect seal.
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Old Wed, Jan-09-2013, 12:00:08 AM   #15
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Default Re: Help with cavity on engine block between cylinders (blown headgasket)

What about the heat affected zone after welding?
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Old Wed, Jan-09-2013, 12:01:47 AM   #16
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Default Re: Help with cavity on engine block between cylinders (blown headgasket)

None of the products being posted have a max service temperature anywhere near what it needs to be to last more than a couple weeks/a month at best.

OP, you have 2 choices:
1) Weld and surface the block
2) Deck the block

How much had to be taken off the head to true it up? if more than .005 or so, weld the block. If less than that, you might be able to get away with decking the block depending on how deep the void is. Also see if you can get a thicker head gasket to offset the material removal.

You can't do either with the block in the car. Looks like the most cost-effective route is a used engine.

Note to people: This is what happens when you continue to drive with a head gasket blown between the cylinders. The higher compression the engine is, the faster you flame-cut the head and/or block.
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Old Wed, Jan-09-2013, 01:55:06 PM   #17
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Default Re: Help with cavity on engine block between cylinders (blown headgasket)

Just throwing this out.... not saying it's a good idea. Maybe braze that divot instead of filling with epoxy? Lower temp to apply than welding, but the brass will take the heat/pressure alot better than plastic would. It would also be easier to dress flat than a weld, assuming the goal is to not pull the block out of the car for a machine shop repair.
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Old Wed, Jan-09-2013, 04:35:11 PM   #18
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Default Re: Help with cavity on engine block between cylinders (blown headgasket)

If you really want to take a short cut, you might talk to an engine builder about whether or not you could get away with o-ringing the block. That's about the only thing that I can think of that you could do without pulling the rest of the engine. If the o-rings can withstand the existing block damage (a big question) then you'd actually have a much more powerfully sealed combustion chamber.
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Old Tue, Feb-12-2013, 07:22:33 PM   #19
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Default Re: Help with cavity on engine block between cylinders (blown headgasket)

We put the head back on with some gasket sealant and the car drives perfectly. Passed leakdown tests and pressure tests. No issues at all so far! Thanks for the comments
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Old Tue, Feb-12-2013, 11:44:57 PM   #20
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Default

Be prepared to redo all of this in few heat cycles. Not sure how someone can trust a gasket maker in such a place. But I am glad it works for now. I sincerely wish you it holds up.

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Discussing Help with cavity on engine block between cylinders (blown headgasket) in the E46 M3 (2001-2006) Forum - Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006. at BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X)