Sump Plug Stuck

[clift_d]

I think you want to find a really big nut that just fits over the mangled head of the plug, maybe so you need to tap it gently on with a hammer. Clean up the head of the plug, hold the nut in position and fill it up with weld. The body of the nut will protect the thread etc around the plug from spatter, and the heat from the welding pool in the nut will go a long way to un-seizing the plug without overdoing it on the sump. If you can drill a blind hole into the head of the plug without going through to the sump, that you can also fill up with weld, then that will allow the heat of the weld to penetrate further down the thread and when it cools will help pull the plug threads away from the sides.

Once it's all cooled down stick a really big spanner on, give the spanner a tap with a hammer to loosen, a tap to tighten, a couple of taps to loosen, a tap to tighten, etc until it starts to come out.

A little bit like this

[shaky]

I am no expert on this but my 1600 A/C requires me to remove the strainer plate to change the oil, (oh the joys of oily arms). Couldn't you just do this with your engine and not bother with the sump plug. There are plenty of 2.0 A/C owners on here that should be able to advise.

I did read somewhere that the sump plug can easily strip threads in the sump. This may have happened here if the plug is rounded like it is..... It is only supposed to be tightened till the copper washer squashes.

[shepster]

Try hammering on a smaller Torx socket.

[mickeyflyn]

Weld a nut on top of the plug I have found has saved me a few times on my motorbikes .