For the sake of this article, the term “light-duty” will apply to smaller diesel engines used in pickup trucks, AG equipment, and autos with engines made by GM, International, Cummins, Kubota, Yanmar, Volvo, Mercedes and many others (up to engines with bores starting at four inches in diameter). These small bore engines were often not designed to be rebuilt and often have cast-in cylinder sleeves and valve seats.
The biggest challenge these small engines present is they often have thin walls and have a higher rate of failures during normal operating conditions. In my article in January of 2010 I covered the issues of categorizing repairs into those that crack due to accidents and those that crack under normal operating conditions. If you missed that one I strongly recommend you go to AERA’s website and read it. It outlines many types of cracks and why they happen. This information is critical to produce permanent repairs.