Engine Case Plugs
 

I have several engine cases to clean and have been looking at pulling out the gallery plugs.

I have found the replacement 'core' plugs which are part numbers 911.101.185.00and are available from Porsche but some of the threads I have read say there are three plugs and i can only find the two shown on the PET.

Do any of the 'solid' plugs need to be removed?

There are several shown in Wayne's book which he advises coating in JB weld.

http://i197.photobucket.com/albums/a...Lane/Plugs.jpg

http://i197.photobucket.com/albums/a...ane/Plugs2.jpg

The early Sand Cast cases are also quite different and are there any plugs in these cases that need to be removed?

Thanks

Hi Chris,

Don't know if it's of any help, but I removed three of plugs from the RH case half a few weeks ago, the ca.23mm high pressure feed bungs (front and rear) plus the ca.13mm bung that's very near the cooling fan hsg dowel.

On the high pressure gallery, used a slide hammer to remove the pulley end, then a length of rod down the gallery to remove the opposite end from behind. I did look at and consider the other plugs, but at the time thought the galleries they were bunging looked accessible without removal.

Also removed the front and rear bungs from each of the cam carriers, to extract the cam spray bars.

Posted some pics on my build thread...page 3 iirc.

HTH,
S

When ever I rebuild an engine...I remove all plugs to give access to oil galleries.
I am a bit paranoid...so I thread each place that the plugs were removed and then screw in hex type plugs.
If you use pipe type threaders...you will seal the galleries without sealant (goop or silicone).
This gives me great peace of mind knowing that the plugs will never "push" out under oil pressure.
Bob

I just did a set of 7 R cases. I too removed all plugs. It was relatively easy using "easy out" tools. The bores they came from where a little marked afterwards. I Intended to make my own plugs but like the idea of tapping the holes and fitting screwed plugs. ( as I did on my cam towers)

What size taps did you use and where?

Andy

I used pipe plugs in my case. I won't do it again. You have to be very careful not to screw the plug in too far around the pressure relief pistons and the large front oil passage. I had to shorten both plugs in order to make it work. They don't leak but I just don't like the install.

I've had good luck with screw in pipe plugs, though I did have to whittle on the one by the front oil passage, though that may have been overkill. Had to purchase a 3/4" pipe tap - a big sucker for a non-plumber.

The first time I did this I made the mistake of using aluminum pipe plugs. They worked fine, but when it came time to remove them I couldn't - the hex tool (which was the proper size) just distorted the aluminum. So much for saving a few grams. Now I use brass. Three plus the spray bar plugs are all I have ever felt were really beneficial.

JB welding externally to deal with oil weeping out past plugs is not the same as locating plugs which need to be removed to clean out gunk which might be in oil passages.

Excellent advice , I will take care to ensure the screwed plugs do not interfere with any part function around the oil relief system. I'll use brass plugs in either NPT or BSP sizes since I have taps for both.

Andy