CYLINDER HEAD OIL GALLERY CUP PLUG SERVICE

Fig. 92: Oil Gallery Cup Plug

1. - CUP PLUG BORE CHAMFER
2. - ORIGINAL CUP PLUG
3. - NEW CUP PLUG
4. - 1-2 mm

NOTE: DETERMINE WHICH CUP PLUG IS LEAKING BEFORE PERFORMING THIS PROCEDURE. IF NECESSARY, PERFORM AN ENGINE OIL LEAK INSPECTION.

Each cylinder head on a 2.7L engine has 6 external oil gallery cup plugs. It is not necessary to remove the original cup plug to install a new cup plug (3). The cup plug bore is deep enough to allow for two plugs. If it becomes necessary to service an oil gallery cup plug, perform the Repair Procedure.

NOTE: INSPECT THE CUP PLUG BORE IN QUESTION FOR THE PRESENCE OF TWO CUP PLUGS. IF THE CUP PLUG FLANGE IS JUST INSIDE (1-2 MM) THE CHAMFERED EDGE OF THE BORE TWO CUP PLUGS ARE ALREADY IN PLACE AND THE CYLINDER HEAD CANNOT BE REPAIRED.

Repair Procedure

1. Remove component(s) necessary to gain access to the oil gallery cup plug requiring service.

NOTE: SOME OF THE OIL GALLERY CUP PLUGS ARE SERVICEABLE WITH THE HEAD INSTALLED ON THE ENGINE AND THE ENGINE IN THE VEHICLE, WHILE OTHERS REQUIRE REMOVING THE AFFECTED CYLINDER HEAD FROM THE ENGINE. IN EITHER CASE ONLY REPLACE THE CUP PLUG REQUIRING SERVICE.

2. Clean the cup plug bore with brake cleaner and compressed air. It is not necessary to remove the existing cup plug.

3. Lightly coat the new cup plug with sealer; p/n 04318083.

4. Using an appropriate installation tool drive the new cup plug into the bore until the flanged edge of the plug is just inside (1-2 mm) the chamfered edge of the bore.

5. Allow the sealant to cure for at least 20 minutes.

6. Assemble any components removed in step # 1 as necessary.