Engine Block Plugs

REMOVAL AND INSTALLATION
To remove a large core plug, drill a 12.70 mm (0.50 inch) hole in the center of the plug and remove with an Impact Slide Hammer 307-005 or 100-001. On a small core plug, drill a 6.35 mm (0.25 inch) hole in the center of the plug and pry it out with a small pin punch. Clean and inspect the plug bore.

Prior to installing a core plug, the plug bore should be inspected for any damage that would interfere with the proper sealing of the plug. If the bore is damaged, true the surface by boring for the next specified oversize plug.

Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug.

Coat the plug and / or bore lightly with an oil-resistant (oil galley) Stud and Bearing Mount EOAZ- 19554-BA or equivalent meeting Ford specification WSK-M2G349-A 1 or Threadlock(R) 262 E2FZ- 19554-B or equivalent meeting Ford specification WSK-M2G351 -A6 and install plug following the procedure for cup-type or expansion-type below.

CUP-TYPE





Cup-type core plugs are installed with the flanged edge outward. The maximum diameter is located at the outer edge of the flange. The flange on cup-type plugs flares outward with the largest diameter of the outer (sealing) edge.

CAUTION: It is important to push or drive the plug into the machined bore by using a properly designed tool. Do not drive the plug into the bore using a tool that contacts the flange. This will damage the sealing edge and result in leakage and/or plug blowout.

NOTE: If the core plug replacing tool has a depth seating surface, do not seat the tool against a non-machined (casting) surface.

When installed, the flanged trailing, edge must be below the chamfered edge of the bore to effectively seal the plugged bore.

EXPANSION-TYPE





Expansion-type core plugs are installed with the flange edge inward. The maximum diameter of this plug is located at the base of the flange with the flange flaring inward.

CAUTION: It is imperative to push or drive the plug into the machined bore using a properly designed tool. Do not drive the plug using a tool that contacts the crowned portion of the plug. This will expand the plug prior to installation and may damage the plug and/or plug bore.

NOTE: If the core plug replacing tool has a depth seating surface, do not seat the tool against a non-machined (casting) surface.

When installed, the trailing (maximum) diameter must be below the chamfered edge of the bore to effectively seal the plugged bore.