Note: You must determine which cup plug is leaking before performing
this procedure. If necessary, perform an engine oil leak dye test.

Each cylinder head on a 2.7L engine has 6 external oil gallery cup
plugs. It is not necessary to remove the original cup plug to install a
new cup plug. The cup plug bore is deep enough to allow for two plugs.
If it becomes necessary to service an oil gallery cup plug, perform the
Repair Procedure.

Note: Inspect the cup plug bore in question for the presense of two
cup plugs. If the cup plug flange is just inside (1-2 mm) the chamfered
edge of the bore, two cup plugs are already in place and the cylinder
head cannot be repaired.

Part No.                  Description

AR 1 04792279      1 Plug, Oil Gallery, 3/8 in.

AR 1 0431 8083     1 Mopar Gasket Maker

Repair Procedure:

1) 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.

2) Clean the cup plug bore with brake cleaner and compressed air. It is not

necessary to remove the existing cup plug.

3) Lightly coat the new cup plug with sealer; p/n 04318083.

4) 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 (Figure 1).

5) Allow the sealant to cure for at least 20 minutes.

6) Assemble any components removed in step # 1 as necessary.

Some or all of this information was provided by the Automotive
Parts Remanufacturers Association (APRA). For more information on
technical bulletins available through APRA call 703-968-2772 or visit www.AutoBulletins.com.