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Bought a Defender in late 95 that within a year had a pinhole leak in a welch plug (I always used to call the core plugs - and then you don't get spelling mistakes;)!) clouds of steam but no overheating as I stopped immediately. Replaced only the one and have had no problems since (with core plugs anyway!). From a few comments on this thread the plugs going are exhaust manifold side? Mine was. I wondered if it was radiant heat on the outer surface that made it corrode quicker, perhaps on an existing flaw. Anyway If that is the case here I would also not pull out the engine if the leaky plug was accessible in the engine bay - I don't believe it was anything but a component failure and I have not seen any since in 2 x 300 Tdi 1 x 200 Tdi and so far the Td5 (touch wood he says nervously hoping the landrover gods won't take note...:p)
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I must admit that I wouldn't pull the engine unless the rear welch plugs were known to be leaking.
If they weren't, I'd pull all the accessible welch plugs out and check them for corrosion. You might have only one faulty plug.
At most, to replace the plugs in the side of a V8, you only need to remove the exhaust manifolds (a bugger of a job to refit in a P38A!) and then only if you need more access.
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G`day Nick ,
Some of the plugs can`t be got at with the engine in , there are also some in the heads and the mechanic may consider they all should be done but if he`s only talking about the main block plugs ..............
If the leaks at the bellhousing the engine needs to come out ... IF ...... it is the plugs at the back of the block and this .. if .. needs investigating because coolant likes to show at the bellhousing from up higher even from the inlet manifold .
If it`s any of the six on the sides they can all be done with the engine in .
The exhaust manifolds/extractors downpipes ( whatever it has ) need to come off , the engine mounts and the part that bolts to the block need to come out and the starter as well to get at them .
It`s a mongerel job but it can be done will the right frame of mind by anyone with a bit of nous, the biggest problem is getting enough throw with the mash hammer to refit the plugs .
The plugs are easily removed by spinning and extracting with nothing more than a hammer and punch and a pair of muligrips .
If you`re in a situation where it`s possible ........ as soon as a couple of plugs are removed they will tell the story for the others .
The reason the plugs have failed needs investigating .
Cheers
