Note: plugs (also known as soft plugs and freeze plugs» it can be very difficult or even impossible to remove if they are installed in the cooling channels of the unit.
1. Drill a small hole in the center of each of the plugs and pull them out with a male puller.
2. Clean the surface of the block from the remnants of the old gasket with a special tool. When doing this, do not hit or scratch the working surfaces of the unit.
3. Remove the main bearing caps and separate the liners from the caps and from the engine block. Label the liners, noting which cylinder they were removed from, and whether they were in the cap or in the block; then set aside.
4 Remove all screw plugs from the oil passages from the block. They usually sit very tightly - sometimes they need to be drilled and then tapped through the holes. Discard the plugs, and install new ones when rebuilding the engine.
5. If the engine is very dirty, wash all strokes with warm water until it is clean, dry the block well and lubricate the working surfaces with a light machine oil with anti-corrosion effect. If you have compressed air, use it to speed up the drying of the block and blow out all the oil passages and holes.
6. Tap the threaded holes with an appropriately sized tap. If possible, clean the holes of chips with compressed air after this operation. You should also clean the threads on the block head bolts, as well as the bolts of the main bearing caps.
7. Install the main bearing caps and tighten the bolts by hand.
8. Treat the working surfaces of the plugs with RTV sealant. install plugs in the block (see pictures). Make sure they go in straight - not skewed and installed tightly, otherwise they will leak. For this operation, there is a special tool - or a large socket with such an outer diameter that it fits into the plug without gaps; half-inch extension and hammer.
9. Apply non-curing sealant (e.g. permatex #2 or Teflon type) onto the new oil passage plugs and screw them into the holes in the block. Make sure they are securely fastened.
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