Block Integrity

[Jim Mac]

This is my first A4 engine. I have purchased a boat and have no idea how the motor operated. I have remove the engine to the cabin and have started to take it apart. One of the areas of concern for me is the block area directly behind the starter. It would seem that dirt or other debris had built-up between the starter and block. After wire brushing the block I have found it to be quite pitted from rusting. Would anyone know just how thick that area of the block is.

Could I use a liquid metal filler to build up that part of the block?

Any ideas?

Regards,
Jim

[Don Moyer]

Jim,

Fortunately the cross section of the block in that area is quite thick (possibly a nominal 1/4" in most locations). From our own experience, you can remove quite a bit of deep scaling without fear of poking through into the crank case. In the unlikely event that you would break through (possibly a chance of one in a hundred), you could cover the area with a fiberglass repair kit from West Marine.

Don