XK 4.2 Cylinder Block Cracking Between Bores and Deck Sinking
SeriousEngineThe 4.2-litre XK straight-six engine in the Daimler Sovereign features closely spaced Siamese cylinder bores. On pre-1981 unslotted blocks, prolonged thermal stress and minor cooling system neglect cause hairline stress fractures to develop across the thin deck bridge between cylinders. Once cracked, the unsupported block deck sinks slightly away from the head gasket fire-ring, allowing combustion pressure to breach the cylinder head gasket and contaminate the cooling jacket. Permanent repair demands specialist machining to install stepped 'top-hat' flanged liners that recreate a continuous deck sealing face, or retrofitting a late Series 3 factory slotted block.
Pressurised cooling system forcing coolant out through the expansion tank overflow, Milky oil-water emulsion under the oil filler cap and on the engine oil dipstick, Intermittent cylinder misfire on cold start after sitting overnight due to cylinder weeping, Recurrent head gasket failure within 5,000 miles of a standard gasket replacement
- Check coolant with a chemical block tester (combustion leak detector) for exhaust gas
- Inspect the cylinder head gasket seam between cylinders 2-3 and 4-5 for external weeping
- Verify whether the block is a late factory slotted unit by examining the engine number
- Review service records for professional top-hat liner installation or engine rebuilding