Expansion/Freeze Plug: Service and Repair

ENGINE CORE OIL AND CAMSHAFT PLUGS

Location Of Cup Plugs In Oil Galleries:

Engine core plugs have been pressed into the oil galleries behind the camshaft thrust plate. This will reduce internal leakage and help maintain higher oil pressure at idle.

REMOVAL

Core Hole Plug Removal:

1. Using a blunt tool such as a drift or a screwdriver and a hammer, strike the bottom edge of the cup plug.
2. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug.

INSTALLATION
Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer.
Be certain the new plug is cleaned of all oil or grease.
1. Coat edges of plug and core hole with Mopar(R) Gasket Maker, or equivalent.

CAUTION: DO NOT drive cup plug into the casting, as restricted coolant flow can result and cause serious engine problems.

2. Using proper plug drive, drive cup plug into hole. The sharp edge of the plug should be at least 0.50 mm (0.020 inch) inside the lead-in chamfer.
3. It is not necessary to wait for curing of the sealant. The cooling system can be filled and the vehicle placed in service immediately.

OIL LINE PLUG

Oil Line Plug:

The oil line plug is located in the vertical passage at the rear of the block between the oil-to-filter and oil-from-filter passages. Improper installation or plug missing could cause erratic, low, or no oil pressure.
The oil plug must come out the bottom. Use flat dowel, down the oil pressure sending unit hole from the top, to remove oil plug.
1. Remove oil pressure sending unit from back of block.
2. Insert a 3.175 mm (1/8 inch) finish wire, or equivalent, into passage.
3. Plug should be 190.0 to 195.2 mm (7-1/2 to 7-11/16 inch) from machined surface of block. If plug is too high, use a suitable flat dowel to position properly
4. If plug is too low, remove oil pan and No. 4 main bearing cap. Use suitable flat dowel to position properly Coat outside diameter of plug with Mopar(R) Stud and Bearing Mount Adhesive, or equivalent. Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 inch) from bottom of the block.