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After replacing the valve cover gasket on my 95 900 SE 2.0T, I realized that the blank plug where the distributor would go was also leaking.
The plug is held in place solely by the bracket that also holds the hard intake pipe between the throttle body and the intercooler hose. It has a rather nonstandard looking O-ring on the end.
To remove: Get the pipe out of the way by undoing the screw clamps on either end, and remove the 10mm bolt under the pipe that secures it to the bracket. The you can take the pipe out entirely. Once the bracket is exposed, it comes off by removing the 12mm bolt holding it into the head.
Pry the plug gently to remove it...
...here's the "Don't Try This At Home" part of the story...
As I pried mine, it suddenly shot out of the head and WENT DOWN THE INTAKE HOSE. A little metallic clatter was the only indication I needed to tell me it got all the way INTO THE INTERCOOLER.
This is the sort of thing that goes way beyond cursing.
It's the sort of thing you tell yourself, "that didn't just happen...you didn't just see this huge plug fly into the hose without as much as catching an edge on the way in."
(Yes, EdG, this was an ow ow ow for the mind.)
I guess they're not kidding when they tell you to stuff up open holes with rags when you take stuff apart.
Anyway, back to the procedure: keep the plug in hand.
To install: Remove the old o-ring, and fit the new o-ring . My old one was so hard that finger pressure broke it. Insert it firmly into the head, and refit the bracket, and pipe. Voila. Should take 15 minutes if you don't END UP DROPPING ^%@#^%! ENGINE PARTS INTO THE #@*^*#@ INTERCOOLER.
keywords: fsik_smooth_move
posted by 66.108....
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