993 Core plug

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993 Core plug

Post by PFM on Sat Dec 04, 2010 5:01 pm

Having got my 1995 993 Hijet back from the MOT, and then waited till today for the snow to melt, I thought I'd better check the levels. Water is now pi**ing out from somewhere just below the distributor Sad I think I can feel a core plug, but it seems intact. Will get some light on it tomorrow - it's not easy to see. Has anyone replaced this plug before?

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Re: 993 Core plug

Post by leopard_pagan on Sun Dec 05, 2010 11:23 am

no, but if a plug has blown, you also need to check your coolant, do you have anti-freeze in it? the right amount?
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Re: 993 Core plug

Post by PFM on Sun Dec 05, 2010 12:22 pm

I think that question should be DID I have enough antifreeze in, but you're quite right! There was before I took it for the MOT but I've had a small leak from the back of the engine (probably from the same place, actually) for some time and regularly top-up. With the garage running it for the emissions test and moving it around whilst waiting for the parts, I guess the water and/or protection levels had dropped. Hence, when it sat in the snow, something gave. Am going to have a look at it this afternoon, but it's a tricky place to get to!

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Re: 993 Core plug

Post by leopard_pagan on Sun Dec 05, 2010 5:17 pm

while doing the gasket job the other month, my mate was telling me about these plugs.. and that they are designed to pop when the block freezes. its a safety thing.

best thing is to phone daihatsu and ask how much a plug is.. as to fitting.. no idea i expect some kind of press will be used to wedge it in!

and... Put antifreeze in it NOW before another plug blows.
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Re: 993 Core plug

Post by PFM on Sun Dec 05, 2010 5:33 pm

Have just de-frosted fingers after investigating. Core-plug is still present, but has a small hole rusted through. They are steel, and it's probably due to many summers running without inhibitor in the coolant. Am considering plugging the hole with metal epoxy as a temporary measure as it's going to be a swine to get to. BTW, usual method of installing a core plug is using a socket as a drift to hammer it in.

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Re: 993 Core plug

Post by leopard_pagan on Mon Dec 06, 2010 6:40 am

ahhh yes, good ol sockets as drifts.. good for wheel bearings too.. on a bike!
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Re: 993 Core plug

Post by rich the mechanic on Tue Dec 07, 2010 6:54 pm

And don't forget to give it a good tap with the ball pain end so you put a little dent in it so it can have a little expansion before it pops, My mate did fix a core plug a few years ago with chemical metal and it held to the summer but it needs to be dry and clean if the hole is small enough you could put a self tapping screw in with a but of chemical metal to seal.
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Re: 993 Core plug

Post by PFM on Tue Dec 07, 2010 7:56 pm

Thanks, Rich - I might try the temporary route for quickness (and interest!). Should be warmer here Friday, so might do it then.

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Re: 993 Core plug

Post by PFM on Tue Jan 11, 2011 7:28 pm

This job got shelved due to the temperature and Christmas. Got some new core-plugs on Saturday, failed to get the old one out and gave up after 1.5 hours. Sunday, old plug came out in 2 minutes, new one fitted, filled system and ran up to temperature - all ok. Very relieved. 5 minutes down the road and overheating like a good 'un! Grrrr. There are 2 metal water pipes right above the crossmember, one goes to the rad and one to the heater (via hoses), and the heater one on mine has split. Luckily I have a 'spares' van, but it looks a pain to get at... Oh well, who wants a new vehicle anyway???

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