RD28 Welch Plugs

Hi There,
Thanks heaps to everyone who posts such awesome information!!!

I thought I had a leaking water pump, but discovered that welch plug near the crank at the front of the engine is leaking...

Is there a diagram any where of where all the welch plugs are located?

How i the best way to remove and replace the plug?

Is there any particular sort I should get (brass, stainless, etc...)???

What size is this plug?

Are there any more plugs in the front of the engine?

Do I use any particular sealant on the plug?

Much appreciate any advice.

Here is a pic of the offending plug....

Attachment 71938
Click to get picture right way up!!!!

Vehicle is a '99 Patrol. Bought it with a water leak already. Runs smooth and no exhaust or oil in water and no water in oil so no sign of any overheating damage.

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Originally Posted by EddieOlsen

Hi There,
Thanks heaps to everyone who posts such awesome information!!!

I thought I had a leaking water pump, but discovered that welch plug near the crank at the front of the engine is leaking...

Is there a diagram any where of where all the welch plugs are located?

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Not sure about a diagram for RD28, but I've heard RD28 block is almost the same as RB30.
Assuming that is the case, I can't remember seeing a welch plug at the front of the block near the crank pulley gear, but
I reckon there should be a one.
By the looks of it, the plug is 30mm.
Best way is to take it out and take it to the spare part shop and get the right size.
The welch plugs on the side are 30mm.
They start from the front and go towards the back of the block.
On the exhaust side, there is a welch plug that hide behind the A/C pump mount, which can't be seen easily.(in my RB30)
It is a really smart idea to replace all the welch plugs on both sides of the block(30mm ones) 'cos if a one is out like that,
the rest are on it's way. I've done the stupid thing of doing one at a time and ended up doing all of them in just over a year,
which took me around four times. I have an excuse for the one behind the A/C pump mount 'cos I didn't see it. :icon_bonk:

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How i the best way to remove and replace the plug?

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You hit on the side of the plug. It basically tilts and then you can either bend it using a plier and pull it out
or just pull it out.

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Is there any particular sort I should get (brass, stainless, etc...)???

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Brass for sure. I don't think they sell mild steel ones these days anyway.
Brass will keep you out of trouble for the rest of the vehicle's life.

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What size is this plug?

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30mm I think, but you gonna have to pull it out to confirm or somebody who knows might post information here or
you can go through the repair manual to find out.

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Are there any more plugs in the front of the engine?

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Dunno, you gonna have to find out yourself by looking.

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Do I use any particular sealant on the plug?

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I use five minute epoxy, smeared around the plug hole & plug.
It is a very good idea 'cos the edges on the block can get slightly damaged while removing the old one.
The other reason is sometime it's not as easy as it sounds like to insert the new plug evenly and go in "lopsided".
Such mistakes are easier to correct with epoxy, 'cos even it goes in slightly lopsided, the epoxy will keep it and prevent from
any leaks happening or the plug coming loose.

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Much appreciate any advice.

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Much appreciate for asking. :)

I use two separate sockets to hit the new plug in.
One socket perfectly fit on the top of the plug edge, the other smaller socket goes into the middle of the plug.
I start with the smaller socket and finish with the bigger one.
You need to be pretty patient as the it's too easy to hit the new plug in lopsided. Starting with gentle taps while watching to make
sure the new plug goes in straight, is the way to do it.

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Originally Posted by EddieOlsen

Vehicle is a '99 Patrol. Bought it with a water leak already. Runs smooth and no exhaust or oil in water and no water in oil so no sign of any overheating damage.

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Do all the plugs at once. It may sound like a bigger job than doing a single one, but you will find out within months it is the best way to do it, when other plugs start leaking one by one.

Thanks heaps for all yr info ... yes it is a 30mm plug.

Awesome advice. Will do the rest of the plugs. Do I need to remove exhaust manifold to get at welch plugs?

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Originally Posted by EddieOlsen

Awesome advice. Will do the rest of the plugs. Do I need to remove exhaust manifold to get at welch plugs?

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Well.... it's easier with the exhaust manifold out, otherwise it's a tight fit. I did all the exhaust side ones without taking the exhaust out(RB30), but it would've been much easier and less headaches if I did remove the manifold(I had my own specific reasons for not removing the exhaust manifold which won't apply to you in your case). The inlet manifold(in RB30), must come out to have any access to the welch plugs on that side. I'm guessing it should be the same in your case as well.
If you're going ahead and doing all the 30mm plugs, you may find it's cheaper to buy the whole kit covering all the welch plugs on the block(even though you may not do all of them). Ebay sell the kit for $50 or something. Get a similar good deal from a spare part shop, since it appears you can't wait few days to have it delivered.

Use 30mm & 27mm sockets to gently tap the plugs into the plug hole. Sockets help to tap them in straight.

Much thanks for your insight.
Regards.