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Old 11-22-2006   #13 (permalink)
itjstagame
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Join Date: Mar 2006
Location: Troy, NY
Posts: 610
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Wow sure sounds like a hassel. I can't believe you have your Kawi tool bag still, that's cool. I'm not sure what came in it, I didn't have one.

I just used a regular 3/8" socket hooked to a 12" or 18" extension with an appropriate socket on the end. I think a spark plug socket didn't work for me, or at least I didn't have a spark plug socket in the size I need (17mm?).

My spark plugs were pretty loose feeling, the PO or whoever had used antiseize on the threads (thank goodness). But I know what you're going through, my Audi was the same way, plugs into aluminum without antiseize is never fun. I had one on my Audi I really thought was going to rip the threads, all my friend said I had to take the head off and back it out from the inside :/. Penetrant wouldn't get in there (btw I've always found PB Blaster or Deep Creep to work better as a straight penetrant and not just a lube). I think I just got a bigger wrench or pipe to put over my wrench (for more torque) and prayed that I'd be able to 'feel' if I was destroying stuff. Another thing to try that I use on stuck bolts. Try to tighten it just a tad and then back off. Sometimes bolts and threaded things will screw in farther easier than coming out. If you get it to move at all, even in the wrong direction, it usually will loosen up enough to start coming out. If you get to this stage unscrew a couple turns then turn in one, repeat. Defiantely if it starts to get tight while it's coming out, screw in a bit and try again, usually I can work it loose this way. Another thing, before screwing back in, spray some penetrant on the few threads you did get exposed, they'll carry the penetrant back down in when you screw it down.

Basically... I ran with 4 new plugs and 1 old one on my Audi for quite a while, because it was stuck and I didn't want to destroy my head. Don't over do it and stop if it worries you.

As for heat and a torch, you could try riding it or waiting for it to warm up and then pulling the tank and the plugs when you get back. Granted everything will be hot and the head will have expanded too, but the steel plug threads and aluminum head should expand at a different rate... may help loosen something up anyway.

As for the 2 in the middle. I didn't have any radiator lines, my radiator lines are in the front and side of the engine, to the radiator and stuff, where do your coolant lines run? All I had was a giant crankcase breather hooked to some kind of vaccuum bung and lots and lots of wires. The wires were in little harness that 'clipped' over the frame, I just unclipped these and pushed them as much as I could out of the way. I got a slightly longer extension (like 6" longer) and reach down in with the wrench above the frame. It was a little tight, I think the extension was tilted a bit, but like I said I didn't have to apply much force to move mine, my only worry with this setup was going back in, to prevent cross threading I started them by hand (with the exntetion) with the extention shorter and underneathe the frame (directly underneath) so that the plug would be straight. It's not the best setup I know, but the frame is directly over the plugs and there's only like 2-3" clearance.

I hope some of that is a help and I hope you realize I may not do stuff the 'right' way, always stop and get a second opinion if you think you're breaking something. How much would a shop charge to change plugs?
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