I’ve got a 2000 VW Jetta 1.8T manual. Just before Christmas my mechanic, searching for the source of a radiator leak discovered 3 very bad things: 1) radiator was shot; 2) heater core was too; & 3) engine block was cracked. I wasn’t ready (I’m still not) to call the salvage guys: this is the first car I bought new (likely to be the last); it’s a real pleasure to drive & has taken me all over the country; & the blasted engine, which VW replaced in 2007 when the timing belt blew & the car was still under a powertrain warranty, only has about 30,000 miles on it.

May 16, 2017  JB Weld Fixes Cracked Cylinder Heads. If this were a test of a field repair, it would be a test of an extremely crappy field repair. [Project Farm] made no attempt to ensure the piston didn’t make contact with the blob of JB Weld, and in fact, there was some slight knocking from the piston tapping against a blob of epoxy. Still, this repair worked.

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So after spending a couple of hours in mourning, I went online to find out if a cracked engine block is always a death knell or if, perhaps, they can sometimes be repaired. I got all excited when I found sites citing the effectiveness of a product called JB Weld for repairing external cracks (which one in my car engine is) & then welding. Further reading convinced me that neither JB Weld or welding is a reliable repair, that the only technique that can be relied on is called “Cold Metal Stitching” (which as I read about it sounded somewhat like sewing a rip in a piece of clothing). The trick is to find somebody with the skill or willingness to cold metal stitch a crack in a car engine. I called precision machine shops across the state (Rhode Island), finding only one that repaired cracked engine blocks using cold metal stitching but the shop wanted nothing to with a car engine; it worked on BIG engines, from trucks & boats. I found a shop in New Hampshire that uses the process on car engines but it wouldn’t quote me a price without seeing the engine, & I wasn’t about to remove the engine & drive it several hours North, possibly only to be told shop couldn’t – or wouldn’t – do the job. What I’d like to know from members of this community is: 1) Have any of you or anyone you know had a cracked engine block repaired?

& if so, by what method & did the repair last? 2) Is anyone familiar with cold metal stitching as a reliable means of repairing a cracked engine block & if so do you have an estimate for what it costs; & 3) Is it time for me to wake up & get another car? Yes it is possible to have a cracked engine block reliably repaired by a machinist or engine/metal specialist.

It would require removal, complete disassembly down to the bare engine block, and then transport and wait time for the repair. Not to mention the dollar cost. The cost to repair the block once at the appropriate place is likely to be several hundred dollars.

Or you can remove your engine block and replace it with a rebuilt one, which has been ordered and delivered and is sitting right there. Is cost at all an issue? I’d imagine engine repair or replacement along with a new heater core and radiator and ancillary items to be far north of 6-7 grand. Cold metal stitching is used on cast iron components that aren’t subject to drastic temperature changes.