86' 5k CS Turbo - Cylinder Head Plug

Tripod · 02-11-2009, 03:49 PM

I have a freeze/expansion plug on the rear of the cylinder head (~24mm) that is leaking. Is the procedure for removing this from a cylinder head the same as removing a freeze plug from an engine block? "Place punch at side edge of the freeze plug and apply hammer. Yank the old plug out with a set of pliers."

I've thought about tapping a screw into the center of the plug then using the screw head as leverage to pop it out. I'm afraid that advanced rusting of the plug may prove this method futile.

My main concern is working with a somewhat soft 'cylinder head' material.

Tripod · 03-09-2009, 12:36 AM

FYI....I completed the repair on the Cylinder Head Plug (freeze plug) this weekend. The plug had just about completely rusted through. I was able to poke a hole in the plug, get behind it with a blunt screw driver and lever/pop it out. The replacement plug from Audi cost 78 cents. After cleaning the opening in the cylinder head, I coated the the rim of the plug and opening with Permatex Aviation Form-A-Gasket #3 sealant. Then I tapped it into place using a socket that fit into the recess of the plug. It went in easily and fairly straight. No leaks are showing after warming the engine and then cooling. The whole job took about 4 hours.

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