ISM, ISMe, and QSM11 – 017-002   Cup Plug

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

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

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

Use a dent puller to remove the plug.

Discard all used cup plugs. Do not use them again.

Use spray cleaner, Part Number 3823717 or equivalent, to clean the cup plug bores.

Inspect the cup plug bores for damage.

Repair the cup plug bores, if necessary.

Refer to the Alternative Repair Manual, L10 Series Engines, Bulletin 3810310 for repair procedures and cup plug bore dimensions.

CAUTION  Excessive sealant can run back into the engine and cause damage to other components. Allow the sealant to dry for a minimum of two hours before operating the engine.

Apply a 2 mm [1/16 in] bead of cup plug lock ‘n seal, Part Number 3375068 or equivalent, to the outside diameter of the cup plug and the inside diameter of the cup plug installation bore.

A cup plug driver must be used to install the cup plug to the correct depth in the cup plug bore.

Use the following cup plug drivers:

• Part Number 3822372 – 9.7 mm [0.38 in] cup plug.
• Part Number 3376816 – 25.4 mm [1.00 in] cup plug.
• Part Number 3376058 – 60.5 mm [2.38 in] cup plug.

Use cup plug driver handle, Part Number 3376795, with cup plug driver, Part Number 3376816.

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

Do not install the plug too deep. The cross drillings in the cylinder block can be blocked shut. If the plug is not installed straight and flat, it must be replaced with a new cup plug.