ran the motor for a little bit and was able to get the plug out, there must have been a bad thread on it when it was installed on the assembly line or the plug has been out before and one of the threads was damaged. The block heater will not catch so that it can be tightened up. THe bad thread nocked the height of the threads in the block down i guess. So its going to be down for a little bit. Ordered another drain plug and maybe thatll catch draw up tight enough, unlikely but you never know. May have to go and get another motor if i cant get the hole tapped and a new size plug installed. May have to go and get a prius.
The bad thread nocked the height of the threads in the block down i guess. [...] May have to go and get another motor if i cant get the hole tapped and a new size plug installed.
Man, that sucks big time. The block is the one big chunk that you can't fix by just bolting on a simple replacement part. That hole is big enough that it will be a pain to find a thread tap, and pretty unlikely that a thread repair kit is available.
If you're willing to give up on the block heater, I would try calling a local welding outfit and see if they'll do aluminum - Just have them weld a thick plate over the hole. It would probably be cheaper than a replacement engine, but unless they do house calls, you would either have to pull the block out or tow the car to their shop.
Failing that, drill the threads down smooth and find an appropriately sized expanding rubber stopper to fill the hole.
Alright, got the micrometer out to check the size of the block heater. The drain plug is 1.1000" and the new block heater is 1.0925". this may explain why its not grabbing. The threads in the block look good about halfway back, the threads in the entry of the hole are pretty much gone. I ordered another drain plug from majestic honda with washer, maybe ill get lucky.
thanks for the link tomo, currently have a new drain plug on the way, went out and checked the threads in the block agian and it looks as if a new drain plug will work, if this doesnt work i will give helicoil a call no doubt.
expansion plug purchased from rockauto.com worked. I bought the 28mm and the next size up just in case. I did have to use the washer from the larger plug, the smaller one didnt look big enough. Hopefully it doesnt pop out while driving.