How To Remove a Core Plug
Ball pein hammer
Punch or old flat slotted screwdriver
Power drill and drill bit
Small pry bar
Water pump or vice grip pliers
***In an ideal world the engine or cylinder head would be removed and on the bench ready for rebuild, with good access to the core plugs. If fitting with the engine or cylinder head in situ access might be blocked by any number of different items in the engine bay which could require removing to gain access to the core plug openings.***
The engine block or cylinder head should be drained of any remaining coolant before removing any core plugs
The easiest way to remove the original core plug is to use a punch or flat slotted screwdriver on one side so that the core plug spins in the opening making it easier to get a small pry bar or screwdriver behind it.
Dish type core plugs can sometimes have a solid lip that they butt up against, in which case drilling or piercing a hole in the plug and then using a bar or screwdriver is the easiest way to pry the plug out.
How To Fit a Core Plug
Ball pein hammer
Flat round Punch
Power drill with wire attachments or small wire brush
Old sockets – slightly smaller than cup core plug you are trying to fit
And of course correct size core plug or core plug kit you are installing
***Again because of various items in the engine bay it may not be easy to access the openings for the core plug to be installed***
As with most automotive repairs area, you are working on (in this case the core plug opening) must be thoroughly dry of any coolant and cleaned of any rust, old paint or localised debris before installing. It is also worthwhile using some sort of sealant to provide a guaranteed seal once the new core plug is installed. High-quality sealants like Elring Dirko, Victor Reinz Reinzosil or Hylomar Blue are recommended but use only a small smear around the edge of the core plug.
A cup type core plug can be installed with an automotive socket slightly smaller than the core plug its self. The core plug should be a snug fit, making sure it is square in the opening and not crooked. Once positioned the socket can be gently tapped moving the cup core plug into its final position.
Dish type core plugs should be installed with the concave side facing inwards and the convex (bump) facing outwards. A dished type core plug will need to be positioned correctly in the opening and then given a sharp hit to the centre of the convex (bump) with a ball pein hammer or flat ended punch. The plug will then expands slightly sealing tight to the end of the opening. Sometimes the opening will have a lip which the core plug will sit against which makes it a lot easier to install.
It is also worth noting that some sealants take longer to cure than others, check the curing times before refilling the coolant and be mindful of any leaks before and during running the engine up to temperature.
Unfortunately, there is no off the shelf catalogue available for any engine core plugs sets/kits. All the core plugs sets/kits listed on the web store have been created from scratch using engine data or engines that have come through our workshop for repair.
Should you require a kit that is not listed we would be more than happy to create a bespoke kit for your application.