Water return block removal

[trevr]

So I did a bang up job and stripped the threads on the water return block, and now it has me working in reverse.

I thought I could plug it using a 14mm x 1mm oil pan plug, but the pitch wasn't quite right and it was spitting coolant when I filled the radiator. I pulled the plug and saw all threads were stripped. I tried putting the stock banjo plug in and it would not thread correctly at all.

So now it needs to come out, and I'll plug it up directly on the block. Here is a pic of what I'm talking about.



I don't want to go as far as to remove the head to just to unscrew the thing. What I'm hoping to do is file it down enough to get it to clear the head. Also, it will work out in my favor, that stud always pulls out when I remove the bolt.

Anyone have any tricks or tips to pulling this thing. I've read somewhere that I can then plug the hole on the block using a 1/2" plumbing plug.

[float_6969]

Good luck with it. I couldn't get mine out at all. It wouldn't budge.

[r34 gtr]

Adjustable wrench (big) and I used a 6 foot length of PVC tubing. My dad didn't think the PVC had the goods, but i showed him. Came off right easy. Big wrench and a lot of torque, that'll do it every time.

[mbmbmb23]

I would hacksaw/dremel off the nipple and unscrew it with vice grips and a hammer.

[meminto]

Yeah your not going to be able to spin it without removing the head, unfortunately...

You might be able to come underneath with a cutting wheel on an angle grinder, but you will have to be very careful, plug up everything that metal shavings could fall into..

The bung you need will be 1/2" BSP

Hope this helps..

[r34 gtr]

Dude not worth it w/o taking off the head. You're just making it into way bigger a job than necessary. I understand it may be more work than you want to do, but you might have to just man up and do it.

Mine came off really easy when I used the big wrench and the pipe. No guff, no fuss, just came right out. then you can replace or repair it properly instead of tearing up your block with a hacksaw and pliers.

That piece is SOLID too, so its going to be a huge pain to cut through.

[davidricardo86]

Try soaking it with some pb blaster over night. Should help a little. If that doesnt work.

I would put a torch to it and get it glowing red hot. After that get a big pipe wrench and rotate it off. This SHOULD do the trick.

If that does not work i would cut it out with a torch. Wait till it cools off, clean up the threads and throw on a new elbow, etc. Anyways goodluck with it because the two metals have probably fused together by now.

[dash]

I'd apply some sorta permanent sealer to that oil pump bolt, reinstall it and let it set up. Clean the threads good. Maybe that 2 part cold weld putty stuff ?Came accross 2 of those bastards that wouldn't budge. Felt like they were going to break.... and both blocks were out the car. Some heat probably would have done the trick thoOther 2 elbows I tried, loosened rather easily

[trevr]

Set about tackling this today. I had two mind sets, first, try and cut it out. If that fails, second, remove head and remove.

Here is how it went..

First was to to loosen the port, I used a 7/8th box wrench which fit perfectly with little change of stripping. I broke it loose quite easily as I was able climb in the engine bay and used my foot and body weight to get it loose.

To get clearance to rotate out, you have to cut the port to the right of the threads going through the block. The plan was to cut the port into four parts using a dremel with a cutting wheel. Here's a picture with the front two sections removed.



Unfortunately, from here, we could not reach the area with the dremel. So we employeed the work of a 4" cutting wheel to finish off the back side of the port. Once that section was removed, the port came right out using the same 7/8th box wrench.

Here is what's left of the port



The block did suffer a scar right above the freeze plug. Anything farther it would have been bad for the freeze plug and the entire block.



And Finally, after taking the old port, what was left of it, to Lowes, picked up 1/2" NPT and finished up the plugging.



Thanks for all the comments above, highly appreciated... thanks guys!
Modified by trevr at 12:37 AM 4/6/2009