Repair Procedure

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.

Remove component(s) necessary to gain access to the oil gallery cup plug requiring service.
NOTE: SOME OF THE OIL GALLERY CUP PLUGS ARE SERVICEABLE WITH THE HEAD INSTALLED ON THE ENGINE AND THE ENGINE IN THE VEHICLE, WHILE OTHERS REQUIRE REMOVING THE AFFECTED CYLINDER HEAD FROM THE ENGINE. IN EITHER CASE ONLY REPLACE THE CUP PLUG REQUIRING SERVICE.
Clean the cup plug bore with brake cleaner and compressed air. It is not necessary to remove the existing cup plug.
Lightly coat the new cup plug with sealer; p/n 04318083.
Using an appropriate installation tool drive the new cup plug into the bore until the flanged edge of the plug is just inside (1-2 mm) the chamfered edge of the bore. See Fig 1.
Allow the sealant to cure for at least 20 minutes.
Assemble any components removed in step # 1 as necessary.

Fig 1: Oil Gallery Cup Plug

Courtesy of DAIMLERCHRYSLER CORP.

1 - CUP PLUG BORE CHAMFER

2 - ORIGINAL CUP PLUG

3 - NEW CUP PLUG

4 - 1-2 mm