Thread: Rust on block left to exposure

Hi all,

A couple of months ago we bought a 95' 110 with a 300 TDI that supposedly had a blown head.

A long story short, the mechanics put a new head on it that only lasted a fortnight before over heating enough to cook bacon on.
They claim it had a Chem welded crack in the block and sent it back to us on a toe truck in pieces.

After a couple of days I popped the bonnet to investigate this crack they could apparently visually see, but to my horror I was greeted with the pictures I'll add to this post.

I need to buy some feeler gauges to know for sure, but just running a finger along the rust that it's very porous.
I assume this'll make another head attempt pointless?
Would a shave salvage the block, would it even be worth having to remove the engine to get it done if there may be a crack in the block as well?

Thanks, any and all advice welcome

Edit: the photo is too large and I can't edit it on my phone, I hope links are allowed.
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Originally Posted by Tas

I've bought some scotch brite today and will start cleaning when I get a day free.

I'm planning on putting on the block regardless as it's been tested and I know it's fine.
So as long as I don't screw up the head job, if it's loosing fluids still then I guess we can assume it is a cracked block.

I haven't got much more info on the supposed block crack for you guys.
My missus, who was the one dealing with this mess in the beginning, was told by the mechanics after they did the head that the block was cracked and had chem weld in it.
I and a few others have found this suspicious and a potential scapegoat as from what I understand the only way to be sure it's cracked is to take it out and sonic test it.

I'm not Dave (black knight ), but my opinion here is if you can 'see' a crack in a cast iron block then it's over. Maybe some folk can weld it, and maybe they can't. Question is, can YOU see it? Can you take it to an engine rebuilder to test it? I've just done the head gasket in my TDi, and I'm here to tell you that I don't want to do it again. It costs too much. So, test it before you rebuild it, if you are suspicious, and you have the resources. It's a ***** to put it all back together and find you've done it all for nothing.
My two bob's worth.