Engine Block is Oozing Coolant

That sounds an awful lot like the block porosity issues they had way back in the early 90's on the whiteblock 960, but I thought that was just a very large batch of bad castings, and that they had solved it.

Maybe at least research that issue and see if anyone had a fix for it that didn't include replacing the block. It should be all over google.

I hope it's not that, just saying it sounds like that.

What caused it on the 960's was defective castings. The core was out of position or something, so the walls were too thin right from the foundry.

If it is the same thing, it's a manufacturing defect, and it is definitely not common, nor is it anything you did. Maybe go to a dealer and see if there was any recall action on yours. If you're lucky it'll be one of those 10 year warranty kind of deals.

Re: (LloydDobler)

You can bet that I'm working every conceivable angle that I can right now.

Re: (thesternowl)

Well...no dice on the patch-up job.

The only alternative that was given to me was to replace the motor.

I was quoted anywhere from $3000 to $8000 for a replacement.

In my mind, it's just not worth it.

I guess I'll be driving this sucker around, topping off the coolant level every 4 to 6 weeks until I start to experience problems...

New to the S90 world...I was having a slow coolant leak and today my mechanic and I were looking for it..(we did a head gasket last week and it was still losing coolant)...and saw seepage at the webs on the side of the block. OUCH...He has worked on high preasure piping and has an epoxy they use to seal pipes that we are going to use. Strip the exhaust side of the block, degreaser ..blast with walnut shells and or glass bead media, and coat the entire side with the epoxy...He had poured some on his driveway and hitting it with a shovel didn't damage it we were able to peel some off the cement driveway but pulled up the driveway too, it seemed to have soaked in so it does flow..we also will supply a slight vacuum to the cooling system in hopes of drawing it into the pores...will let you know how this works...

I would probably try a silicate solution, like BlueDevil.

It works, but you must follow the instructions exactly. the system MUST be clean or it will not work properly.
Pull the thermostat so it flows freely.