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How to change engine core plugs on my 2006 trail

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You may have to disconnect the carb
Plugs facing the bulkhead may be unreachable without lifting out the engine, so you may have to have the job done at a garage.
Do not cut a hole in the bulkhead. It is load-bearing and, unless you weld a battery and drain the engine block, saving the coolant if you want to reuse it (See how to flush engine radiator).
Catch the coolant in a clean container,
Removing core plugs
With either type of plug, the usual way of removing it is to carefully drive a small screwdriver blade through the middle of the plug and prise it out.
Take care to pull out a cup-type plug straight, or it may jam.
The edges of a cup plug may project far enough for you to pull it out with two pairs of pliers. Grip the edges firmly and pull with an even amount of force on both pairs of pliers. Do not lever against the block - you may damage the plug seating.
Scrape the remains of the old sealant from the hole with a piece of wood.
Replacing a core plug Smear the mating surfaces of both plug and hole with gasket sealant.
Insert a disc-type plug with the domed side outwards. Make sure it rests squarely on the shoulder inside the hole. Tap it in the middle with a flat-headed punch to expand it. It must be a firm fit
For a cup-type plug, find a socket which fits snugly inside the cup. Hold the cup absolutely square and flat against the hole, and drive it home by tapping the socket with a soft-faced hammer.
Do not let the plug get crooked, and leave a little of the rim protruding in case you have to remove the plug later.
There may not be room to swing a hammer. For example, the Leyland 'B'-type enginr has a disc plug just in front of the bulkhead and masked by the engine backplate. But there is a hole in the backplate facing the plug.
Insert the new plug, put a 2 in. (50 mm) bolt through the hole in the backplate, and fit a washer and nut to it on the other side. Screw up the bolt to press the plug firmly home.
You may be able to adapt this method for replacing other awkward plugs.

Posted on Dec 20, 2016


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