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awg Profile
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Date Registered: 08-2020
TOTAL POSTS: 11
Reply | QUOTE
spark plug cannot be removed


My sons 2003 2.5 was missing since purchase a few months ago, and getting worse he told me, so with a 100K gap in service records, I thought we will replace spark plugs

sure enough, super tight, and old looking, got 3 replaced with platinum

The one nearest the DS will not come out, and despite working very carefully for about 30mins, easing it a bit forward & back, I am now 99% certain it has galled the thread, as I only got it about 2 turns out, and the movement has now become reduced

So I had to just leave it in there

Vehicle now runs much better, no evident miss

However, eventually that plug, which I estimate has ~120k+ on it will fail completely

Plan A..keep driving until that plug gives up

Plan B ?

Questions...I hate to even ask, (but have done this on another vehicle)..will Helicoil Insertion Tools reach down far enough in the well to insert one with head in place ( havent done it with a coil over plug ignition, and I doubt they will reach)

If not, is there any other alternative but (eventual) head removal ?

how difficult is head R&R on the 2.5 for a guy that has pulled half a dozen heads before ?

I do not think I can get it out without destroying the thread, or even breaking the plug ,friggin thing was asking for 100ftlb+

cursed be those who do not use anti-seize on spark plugs


Last edited by awg, 18/Oct/2020, 2:35 pm
18/Oct/2020, 2:31 pm Link to this post Send Email PM   Send Private Message Blog
 
awg Profile
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Date Registered: 08-2020
TOTAL POSTS: 11
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Re: spark plug cannot be removed


looks like you can buy newer style helicoil kits that accommodate the newer style engines with plug-over-coil

I have done it the way this guy does before on older heads, in situ

https://www.youtube.com/watch?v=cSqyN2UfmtE&feature=emb_rel_pause

the worst case is the plug shears off..I have had that in an alloy head

keep the fingers crossed, and hope I dont have to try anything in the near future
18/Oct/2020, 10:09 pm Link to this post Send Email PM   Send Private Message Blog
 
Revhead Kev Profile
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Date Registered: 10-2006
Location: Mona Vale, Sydney, AUSTRALIA
TOTAL POSTS: 5676
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Re: spark plug cannot be removed


Try this, especially if the plug breaks trying to remove it.
Champion Spark Plugs - How to remove broken plug

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Kev X450(c) T30 Guru
03 Titanium Ti T30 Series 1 **MODIFIED**
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18/Oct/2020, 10:42 pm Link to this post Send Email PM   Send Private Message Blog
 
Jimbr Profile
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Date Registered: 01-2020
TOTAL POSTS: 23
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Re: spark plug cannot be removed


Sorry to butt in but was wondering if the engine was hot when you tried to remove the plug.
Was wondering if it might come out if the engine was hot thinking the alloy might expand more than the metal thread on the plug. Probably a dopey suggestion. Would not like to be face with the same problem.
Regards Jim Braddock
19/Oct/2020, 9:15 am Link to this post Send Email PM   Send Private Message Blog
 
Revhead Kev Profile
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Date Registered: 10-2006
Location: Mona Vale, Sydney, AUSTRALIA
TOTAL POSTS: 5676
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Re: spark plug cannot be removed


Please don't be sorry Jim to offer other suggestions.
Could be worth a try also.

---
Kev X450(c) T30 Guru
03 Titanium Ti T30 Series 1 **MODIFIED**
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19/Oct/2020, 10:19 pm Link to this post Send Email PM   Send Private Message Blog
 
Jimbr Profile
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Date Registered: 01-2020
TOTAL POSTS: 23
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Re: spark plug cannot be removed


Thanks Kev.
Regards Jim Braddock
20/Oct/2020, 8:40 am Link to this post Send Email PM   Send Private Message Blog
 
awg Profile
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Date Registered: 08-2020
TOTAL POSTS: 11
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Re: spark plug cannot be removed


thanks for all replies

it was not dead cold, which would have been preferable, but pretty cool

My son lives in Sydney, me in Newcastle

I didnt want to shear it off in there, and the vehicle goes very well now according to him,
so going to have to let sleeping dogs lie, I just cannot understand why people dont change plugs for over 100k...or at least when it begins missing

looking at Youtube, pretty I can do a head R&R, but it always takes forever 1st time,
so vehicle can be off road for a week or more, while you wait for tools or parts.

  
20/Oct/2020, 3:13 pm Link to this post Send Email PM   Send Private Message Blog
 


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