Freeze plug/ block heater leaking

[86mkII]

Hey guys......I found out that I had a coolant leak at my block heater/frost plug.  So I tried to put a new seal or rubber washer under this bolt that I pulled from the block heater and now it won't thread back in.  Was there a nut on the back side that fell off inside and now I am screwed or is there some other reason why this isn't threading on? and no the new washer is not too big...as I tried to thread it back in without the new washer and it still will not start to thread.  If you guys have had a similar problem or have any ideas.  I would really like to hear them.  Thanks

[Vincent Waldon]

Yup, there used to be a toggle nut in the back that was holding the block heater into the block.  With the bolt unthreaded all the way the toggle nut has probably dropped down (harmlessly) into the bottom of the water jacket.




Given that the o-ring is leaking as well probably the easiest approach is to drain the cooling system and then replace the block heater with a new one... they are not that expensive and I've never seen the o-ring and toggle bolt as separate pieces.

[86mkII]

Thanks for the quick response and reference pics Vincent!!  I was afraid that I would have to replace the whole block heater just to get new seals, because my heater still works pretty good. 

The engine is still in the car, is removing the old heater and putting the new one in gonna be a pain? or should the old one just pop out(with a little persuasion) now that the bolt/nut is no longer holding it on?

I have checked a few websites and I only see the heater kits that have everything, including the power cord.  Is there someplace online where I can just buy the heater plug without the cord for a cheaper price or do I have to buy the kit that includes everything?

[Vincent Waldon]

No worries.

The heater will just pry out... if it's been in there for a while it may take a little persuasion since the big seal will be a little stiff. If you don't replace it you stand the risk of it popping out under pressure at the worst possible time.

I've never seen one for sale without the matching cord... perhaps someone else knows of a supplier that carries just the replacement heater.

[86mkII]

Yeah....I was looking around some more and I am just gonna go ahead and buy a whole new kit.  Might as well have everything brand new considering that my car has 264,000 miles on it and to my knowledge it is the original block heater. 

...Anyways, thanks again for all your help!