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Old 07-26-2015, 05:59 PM   #1
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Default KA24E freeze plugs fun

Just finished installing two new freeze / expansion plugs on the left side of the engine, but still working on other things so it will likely be next weekend before I fire her up again.

Some hints for others with the KA24E, 4x4, and AC:

Exhaust manifold has to come out. But the head pipe can stay in place; I needed to disconnect the front of the front drive shaft to get a better angle on one of the manifold-to-collector nuts. Fortunately I had replaced the small smog tube that runs parallel to the exhaust manifold; the old one was a pain to remove (fused by rust into the head pipe; let soak for days in advance with Liquid Wrench; do the EGR pipe too (mine was easy)).

AC compressor best needed to come off its mount and hung to the front, but the mount stayed on the engine. If not, there's a funny angle for the front plug.

Uninstall/install through the left wheelwell. I used a John Wayne screwdriver to get the two old plugs out (do both even if only one is leaking), and a 12 inch extension bar and various sockets to put them in. A special 3/8" drive ball joint socket (for old Mopars) worked great on the front plug for getting around the AC bracket.

The factory plugs looked to have had sealer on them. I use Permagasket #2 anyway.

Getting the new plugs to go in squarely was challenging; the boreholes and plug skirts are relatively shallow. Killed a couple of bronze plugs doing so, and eventually had to use a steel plug on the front due to a slight angle.

Kicking myself for not replacing all six in the block when I pulled the out engine a few years ago! They all looked good back then.
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Old 07-26-2015, 08:00 PM   #2
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Replacing freeze plugs when building an engine is crucial and very cheap. Having the correct tool to install them on vehicle is a plus. I invested in such a tool after having a similar problem years ago. Glad to hear you got it now.
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Old 08-24-2021, 07:37 PM   #3
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Hey man, was wondering if the freeze plug on the left side could be the coolant leak issue Iam having.
Just change the thermostat and water pump and Im certain that the seal is good
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Old 08-27-2021, 06:12 AM   #4
DAZE752
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Quote:
Originally Posted by 1lownismo97 View Post
Hey man, was wondering if the freeze plug on the left side could be the coolant leak issue Iam having.
Just change the thermostat and water pump and Im certain that the seal is good
This is an old thread but have you checked your oil? or looking if there's smoke coming out of your exhaust.
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Old 08-27-2021, 11:07 AM   #5
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I was very surprised that one of my original plugs had failed. I've always keep the antifreeze in good condition, and such includes rust inhibitors.


No problem since with the others.
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1990 Nissan Hardbody, Aztec Red
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Intentionally near-stock
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mud and snow tires, HD trailer hitch (cat 3+),
liquid bed liner, G1W dashcam
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Old 08-27-2021, 04:17 PM   #6
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I believe the freeze plugs are 40mm in size…
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