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Ok, here goes! 1) Remove the old core plug, I assume its rusted through which will be due to a lack of coolant/antifreeze at sometime in its life. You will require good access to remove the old plug and fit a new one! Note the depth that the plug is fitted to inside the machined hole so that you fit the replacement to the same depth.
2) Use a punch or old screwdriver on the outer part of the dome center, not on the edge lip as you may damage the machined hole that the plug fits in. Hit the punch or screwdriver with the objective being to try and flip the plug, so one edge goes in a one edge comes out. Lever the plug out once flipped with a screwdriver, or grab it with mole grips and pull it out. You may also puncture the plug and then pry it out, but be careful do not hammer anything to far through the plug as there may be some casting close behind it! If you have a panel dent puller you may wish to carefully drill a small hole in the plug, screw in the dent puller and whack it out with the slide hammer. Do not drill deeper than the plug. or screw in the puller very far!
3) Clean the machined surface of the plug hole and degrease it. Do not use emery paper or remove any material in the hole outer diameter or the plug will not be a snug fit!
4) Obtain new core plug (very cheap), coat the outer edge of the machined hole with a good gasket sealant such as Hylomar or hermitite. Find a socket approx the size of the core plug that just fits inside the outer lip. Place the socket inside the core plug and align the plug with the hole. Now carefult tap the socket until the core plug is flush with the outside edge of the hole, now drive it home to the depth noted in step 1.
5) Fill the cooling system and run the engine up to normal temp and then check for leaks.
Good luck -Karl
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∙ 14y ago
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