Block and head plugs

[zombezoo]

I know the block plugs need to be flush to seal the coolant passage but what about the head plugs? I understand you just need to plug the three oil returns (oil feed is plugged by the deck of the block) but can I tap and plug them at the top of the hole (in the oil galley)? I really don’t want to get the head surfaced if I don’t need to.

[FFWD]

Thread the factory drain holes from the bottom with a 3/8 NPT tap. I can't remember if they need to be drilled out at all. Get some cool anodized 3/8 NPT pipe plugs, or brass if you're cheap. Screw them in until they're just below the surface of the head. You may need to tap a little more to get it right.

Take the time to tap the oil feed in the head and the block for 1/4 NPT and plug it properly. Then you won't end up with a weird oil leak that will necessitate removal of the head to fix.

Leon

P.S. why am I the only one answering?

[zombezoo]

Quote:

Originally posted by FFWD P.S. why am I the only one answering?

You may be the only one who knows! LOL
Thanks again. My desire to tap and plug the top of the hole was due to the fact that oil will run down the holes and collect in the factory drain back tubes. I was concerned that the collected oil would eventually cause a leak. Is there any reason not to tap and plug the top? Also, in regards to plugging the old oil feed in the head, how did you go about this? As far as I can tell the oil is fed up around the corner bolt into a hole drilled through the side of the head. I assume that you can simply drill the outer hole out to allow access to the oil feed hidden in the head bolt hole, tap that and install an allen head plug, then either leave the old plug that you had to drill out open or re-tap it to a larger plug and plug it again? If this is in any way unclear let me know!
Thanks!
Ryan Lada

[KClarryb]

Quote:

Originally posted by zombezoo snip>>> Also, in regards to plugging the old oil feed in the head, how did you go about this? As far as I can tell the oil is fed up around the corner bolt into a hole drilled through the side of the head. I assume that you can simply drill the outer hole out to allow access to the oil feed hidden in the head bolt hole, tap that and install an allen head plug, then either leave the old plug that you had to drill out open or re-tap it to a larger plug and plug it again? If this is in any way unclear let me know! Thanks! Ryan Lada [/b]

Ryan,
I started to do mine like you described, then after taking another look I decided to put a 1/8 allen head pipe plug in from the top under the end cam bearing cap. I know it's not necessary but it does remove the only place you have oil pressure acting against the head gasket. Here's a picture.

[zombezoo]

Thanks!
Ryan Lada

[russ jerome]

I am ashamed to admit how long it took two of us to find that oil passage one day in garage...both of us mechanics of many years and our jackets adorned with ASE patch's............

That is an excellent location to plug, good photo.

[FFWD]

I forgot about that bolt hole feed. No leaks though. I thought about tapping the top of the drains as well, but it was easier from the bottom.

What are you doing about the egr port?

Leon

[zombezoo]

Quote:

Originally posted by FFWD I forgot about that bolt hole feed. No leaks though. I thought about tapping the top of the drains as well, but it was easier from the bottom. What are you doing about the egr port? Leon

Ah! The benefits of having a Snap-On tool salesman for a father...
Hopefully they will have some cool tap extension tool or something to make the job easier.. As for the EGR hole I thought of making a block off plate since my friend *just* bought a plasma cutter but I have access to a band saw if that doesn’t work. However I have been thinking of plugging that with a hex head plug as an alternative.
Thoughts?
Thanks!
Ryan Lada

[FFWD]

I bought some round aluminum stock and welded it in. Cleaned up the port with the die grinder.

[SwiftTech]

you could easily get the block off plate from the jy. Not all cars came with egr. I know the caravans didn't always come with them ans even some of the 2000+ neons didn't have egr. Also you could get it new from the dealer.

[flybyuin2.2]

my 98 Caravan 2.4 came with a egr block off plate

[Cliff Ramsdell]

We used a cast iron plug in the block, three 1/2" pipe plugs in the oil returns, and 3/8 pipe plugs in the oil feed and crank case equalization port.

We then drilled down next to one of the returns to align with the existing equalization port in the head.

When we tapped the head for the 3/8 pipe plugs the deck surface was altered some so we used a steel plug and had both the head and deck cut .004 to give them a good clean up, nothing better than a good flat surface and better to do it now than find out later it needs to be done.

You can find pictures of the buildup on both my pages here:
http://www.members.aol.com/mopartek/hybrid.html

and Scott's pages here:
http://www-unix.oit.umass.edu/~sdean...ybrid_page.htm

We drilled and plugged the EGR port with a pipe plug and because of clearance issues we drilled an intersecting hold in the side of the head to get to the oil feed port in the head. Up top where it intersects under the cam cap we drilled and tapped it for a holley carburetor jet so we can adjust the oil flow to the head and make changes as needed.

Since this is a 2.5 motor we are using Cindy Venolia pistons which have a 6cc larger relief in them to compensate for the 6cc smaller chamber of the Neon head.

Cliff Ramsdell
VP New England SDAC www.sdacne.com
'86 K-Car Wagon 2.5 TIII, 568
Mopartek@aol.com
http://www.members.aol.com/mopartek/home.html
Coming soon: http://www.mopartek.com

Quote:

Originally posted by zombezoo I know the block plugs need to be flush to seal the coolant passage but what about the head plugs? I understand you just need to plug the three oil returns (oil feed is plugged by the deck of the block) but can I tap and plug them at the top of the hole (in the oil galley)? I really don’t want to get the head surfaced if I don’t need to.

[gman]

ok so when I plug the block is it possible to just thread the plugs in just below the deck of the block or do they have to be flush and then get the block resurfaced
P.S please forgive my ignorance
---Garth

[gman]

anyone have an answer I just wanna know befor I drill and put this together thanks
---Garth

[Turbo84Voyager]

McMasterCarr has solid aluminium plugs. I bought 4 they cost a little over $12 shipped.