Problem changing plugs

Post by **S.Richardson** » 13 Nov 2007, 20:40

Putting new plugs into my 1.9 DG boxter engine and the plug has seperated from the outside thread
leaving the thread part of the plug left in the head.

Has anyone any idea how I can remove it as its solid fast in the head without taking the head of and getting it drilled out and an helix coil thingy in?
I have tried tapping in a taperd tang attached to a socket and i was considering using a large ease out but its so tight i am concerned even that will rap off.

Ideas would be welcome
Stuart
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Post by **kevtherev** » 13 Nov 2007, 21:47

this is a new one on me

has it sheared of flush with the head?

Post by **S.Richardson** » 13 Nov 2007, 21:55

No the nut part complete with the porcelain inner has parted company and come out leaving the threaded part inc the three probe outer still in its all hollow to the three pin electrode the plug looks to have corroded away just leaving me the internal part of the plug. it justs looks like a heater plug that i am left with,
I cant see away of getting the rest of it out without taking the head off and taking it to an engineering shop to be removed .

Post by **kevtherev** » 13 Nov 2007, 21:58

By all means seek advice from an engineers ...established car garages even

they may well have come across this before and could offer you some advice or even a solution that doesn't involve head removal

Post by **Dubstar** » 20 Nov 2007, 09:32

I had the same problem a few years ago on a Peugeot 405, where the plug sheered off at the nut, bringing the prcelain out with it and just leaving the end in the head. I used a stud extractor to get the piece out. I was worried it might wreck the head, but as it gripped it started turning and came out easily in the end.

Post by **jamesc76** » 20 Nov 2007, 11:05

this happens loads of fords and ive allways got then out by welding a old bolt to whats left, the bonus is with the heat from the mig welder it often free's the threads up may take a few goes tho!!! Oh and when you put the new ones in put some copper slip (anti size compund) on the threads to stop it happening again!!!!

Post by **S.Richardson** » 20 Nov 2007, 14:01

Tried everything to remove it in the end I bit the bullet and removed the head took it to a machine shop were they eventually drilled it out and inserted a new helicoil, but whilst taking the head of its broken a few rings on one piston closest to the rear of the vehicle now I have a further problem in getting the piston liner back on whilst the engine is in the vehicle , looking at haynes manual there is a special tool to remove the circlip to the gudgeon pin . has anyone managed to do this operation without this tool and if so how and what with?

Kind Regards
Stu

Post by **airhead** » 20 Nov 2007, 14:09

How did you manage to get the head off without removing the engine? Tricky business!

The tool you need is a circlip remover. Theyre easy to come by. A needle nosed pliers may do the trick though.

Post by **S.Richardson** » 20 Nov 2007, 14:26

The Head was on the right bank which seems to have more room than the left bank so i had plenty of space to slide the head of the studs but i had to knock of the cylinder liner as they were stuck like f.... to the head but as stated it damaged a couple of rings on the piston nearest yo the rear of the vehicle i now will have to get the piston off the con rod then assemble the new rings and piston into the barrel in one unit then re connect to the con rod which seems the tricky bit as you have to access it through a hole in the front of the water jacket.

Post by **colinMSC** » 21 Nov 2007, 14:30

take the engine out its almost imposible to refit the barrel/ piston onto the con rod.

Post by **toomanytoys** » 21 Nov 2007, 14:49

Yeah drop the engine.... its a shame you couldnt get the barel to seperate from the head initially, would have saved a lot of hassle... if you have damaged the rings... whats the piston like?

To remove the pin may well be a pain in placs... normally there is a burr that forms where the lock rings sit.. this prevents the pin from coming out....

Post by **S.Richardson** » 23 Nov 2007, 16:29

Made a tool out of threaded bar and a plate easy really to get it out after removing the circlip stick a piece of threaded bar through the centre of the gudgeon pin put a nut on the end with a washer just a bit less than the diam of the outside diam of the pin put a plate on with a hole were the threaded bar goes through a nut on the end of that jam timber wedges in from the cylinder barrel and casing ang wind the nut in and the gudgeon pin draws out from the openning .

Not put it back yet but cant see why it wont tap back with a wooden mallet then al i need to do it fit the circlip and gasket etc and jobs done

Post by **kevtherev** » 23 Nov 2007, 17:49

might be worth posting some pictures of the tool and sutch.. as this could be invaluable for the wiki