CoilFix.JPG 1086 hits | 63.92 KB | Posted: 11/6/06 This is what I had to do after the #6 plug blew out of the head at 2AM Sunday 1,000 miles into a 1,4...
5553Kit.JPG 524 hits | 52.41 KB | Posted: 11/16/06 I ordered 3 extra inserts so I could fix all 8 holes. Brian at Promar Engine was very patient & hel...
01Rigged.JPG 547 hits | 68.31 KB | Posted: 11/21/06 This is how I made it the last 400 miles home, and another ~100 driving around before I got the Time...
02Rigged.JPG 793 hits | 84.23 KB | Posted: 11/21/06 The coil barely fits wedged between the extension & the fuel rail, which gives it the most strength ...
03Coil.JPG 488 hits | 79.29 KB | Posted: 11/21/06 The coil was damaged by the spark plug hammering it for ~15 miles, but I broke a little more away so...
04Coil.JPG 454 hits | 58.42 KB | Posted: 11/21/06 Since I didn't clean the wall of the head, the epoxy broke free easily, and I had no trouble backing...
05Hole.JPG 518 hits | 54.72 KB | Posted: 11/21/06 I should have known the camera wouldn't focus on the bottom of the hole, but it's relatively free of...
06FaceCutter.JPG 506 hits | 80.08 KB | Posted: 11/21/06 The first tool starts by cleaning out any remaining spark plug threads (red pointer), then uses a sm...
07FaceCutter.JPG 476 hits | 75.78 KB | Posted: 11/21/06 Even the tools specifically sold for working on these heads aren't long enough to do the job with th...
08FaceCut.JPG 536 hits | 69.84 KB | Posted: 11/21/06 Following the instruction, I loaded the cutter with grease to collect the majority of the shavings. ...
09Reamer.JPG 773 hits | 73.82 KB | Posted: 11/21/06 Next, the reamer is used to enlarge the hole for the tap. More grease catches most of the shavings.
10Ream.JPG 500 hits | 67 KB | Posted: 11/21/06 I didn't want to overload the grease, so I stopped halfway & cleaned it out.
11Ream.JPG 694 hits | 72.02 KB | Posted: 11/21/06 The 3rd run of the reamer makes sure the tapered shoulder is cut correctly, so I cleaned the reamer ...
12Ream.JPG 455 hits | 77.11 KB | Posted: 11/21/06 A lot of metal gets removed for the BigSerts, which have a thicker wall than the normal TimeSerts.
13Tap.JPG 503 hits | 69.5 KB | Posted: 11/21/06 The tap also has a pilot tip, and the instructions recommend grease again. I used a manual ratchet ...
14BigSert.JPG 528 hits | 51.45 KB | Posted: 11/21/06 The insert is threaded onto the installation tip, which slips into the driver, retained by its O-rin...
15Release.JPG 538 hits | 65.23 KB | Posted: 11/21/06 Once the insert is torqued properly, the screw must be loosened to release the tip from the insert.
16Inserted.JPG 489 hits | 51.16 KB | Posted: 11/21/06 The final step is to expand the insert with the last tool, which must be oiled. This sets the inser...
17Done.JPG 854 hits | 59.76 KB | Posted: 11/21/06 The old coil probably still works fine, but I decided to replace it anyway. Same for the spark plug...
18Done.JPG 775 hits | 91.03 KB | Posted: 11/21/06 Once I get the other 7 done, I'll replace the alternator connector.
Spark Plug
