B5.9G, B5.9LPG – Troubleshooting and Repair Manual – 017-002   Cup Plug

CAUTION  Do not allow metal shavings to fall in the engine when drilling a hole in the cup plug. Damage to engine components can occur.

Use a center punch to mark the cup plug for drilling.

Drill a 1/8-inch hole into the cup plug.

Use a dent puller to remove the plug.

Spray Cleaner, Part No. 3375433

Thoroughly clean the cup plug hole using Scotch-Brite™, or equivalent.

Use spray cleaner, Part No. 3375433, or equivalent, to clean the bore for the final time.

Inspect the cup plug bores for damage.

CAUTION  Excessive sealant can run back into the engine and cause damage to other components. Allow the sealant to dry for a minimum of 2 hours before operating the engine. The plug can come out of the bore if the sealant is not dry.

Cup Plug Sealant, Part No. 3375068

Apply a 2-mm [1/16-in] bead of cup plug sealant, Part No. 3375068, or equivalent, to the outside circumference of the cup plug and the inside circumference of the cup plug bore.

NOTE: Do not install a used cup plug. Discard all plugs after removal.

Install the cup plug with the appropriate cup plug driver. Refer to the Service Products Catalog, Bulletin No. 3377710.

CAUTION  Do not install the cup plug too deeply. If the cup plug is not installed straight and flat, it must be replaced with a new cup plug.

The cup plug must be installed with the edge of the cup plug 0.5 to 1.0 mm [0.020 to 0.040 in] deeper than the leading chamfer of the bore.