Ford Fusion: Engine System - General Information / Cylinder Block Core Plug Replacement. General Procedures

Special Tool(s) / General Equipment

100-001 (T50T-100-A) Slide Hammer

Materials

Repair

All core plugs

1. NOTE: Cylinder block core plug shown, cylinder head core plug similar.

   Using the Slide Hammer and a commercially available body dent puller attachment or commercially available freeze plug puller remove the core plug.
   Use Special Service Tool: 100-001 (T50T-100-A)  Slide Hammer.

1. NOTE: Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug.

   Inspect the core plug bore for any damage that would interfere with the correct sealing of the plug. If the core plug bore is damaged, bore for the next oversize plug.
   

Cup-type

1. NOTE: Use care during this procedure so as not to disturb or distort the cup sealing surface.

   NOTE: When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore.

   Coat the cup-type core plug and bore lightly with sealant and install the core plug using a freeze plug installer. Remove the excess sealant after installation.
   Material: Motorcraft® Threadlock 262 / TA-26 (WSK-M2G351-A6)

Expansion-type

1. NOTE: Do not contact the crown when installing an expansion-type core plug. This could expand the plug before seating and result in leakage.

   Coat the expansion-type core plug and bore lightly with sealant and install the core plug using a freeze plug installer. Remove the excess sealant after installation.
   Material: Motorcraft® Threadlock 262 / TA-26 (WSK-M2G351-A6)