Replacing block drain plugs with petcocks

The block drain location on the driver's side of the engine block. There was a drain plug installed originally, and one of the previous owners of the truck replaced the hex-head bolt with an Allen-head bolt. He then apparently epoxied the bolt in, because the bolthead immediately stripped out. Using an extractor and a LOT of elbow grease, I finally got the bolt removed. I needed to remove the front driveshaft and the oil filter to get to a position to remove the plug. Instead of installing another bolt, I got a petcock with a 90° bend. This is known on TheDieselStop as a BajaGringo drain, after the gentleman who came up with the idea. This allows you to hook a hose to the petcock and drain coolant out of the engine block without making a mess, and if clean buckets are used, you can even re-use old coolant if you so wish.

The BajaGringo drain installed on the passenger's side. Note that the starter has been removed. I needed to do this in order to remove the old Allen-head drain plug.

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Main Page

Introduction to the project

Before the project begins

Removing external parts and accessories

Removing cylinder heads

Heads, gaskets, and the block after head removal

Removing timing gear cover and camshaft

Cleaning the piston tops

Cleaning the ins and outs of the engine

Final engine block cleaning with compresed air

Oil cooler disassembled

Parts ready for painting

Final painting preparation

Parts after painting

Installing BajaGringo drains

Installing the camshaft

Re-installing the camshaft

Assembling and testing the oil cooler

First steps of modifications for the turbocharger

Comparing the stock head bolts to ARP studs (lengthy!)

Installing the cylinder heads

Installing the head studs

Installing the valvetrain

Installing the intake manifold and injector pump

Assembling and installing the turbocharger

Last touches on engine assembly

Installing radiator

The Finished Project