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Torque
Threads may strip during spark plug removal or installation.
Plugs may also blow out during normal operation.
Spark plug torque is critical!
Spec is only 7-15 ft.-lbs.
Make sure to look up the exact spec for your application and use a proper
torque wrench.
If the spark plugs are not properly torqued, they WILL cause problems in the
future.
There are only 4 threads in the aluminum cylinder head, the following
slide is a picture of a head off of the vehicle.
The spark plug may bounce around, and cause damage to fuel
injectors, engine harnesses, the hood, etc., be sure to perform a
thorough inspection of the damage.
The following slides will illustrate what a broken ignition coil looks
like, and the plug that broke it.
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Analysis
The power balance quickly identifies that we have a misfire on
cylinder 2
Next we will test compression using the tool
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Diagnosis
Quickly and efficiently we find out that this vehicle has a mechanical
issue.
By the time the technician actually opened the hood of this vehicle he
knew he has a mechanical misfire on cylinder 2.
After compression and leak down testing he finds a tuliped intake
valve.
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Diagnosis Continued
The intake valve became tuliped because the vehicle ran lean.
The engine ran lean because the thread insert used to repair a blown
out plug became loose, causing the plug to not fire.
The engine ran very lean causing the valve to get hot and tulip.
The following slides show the spark plug and insert removed from the
engine. Notice how melted the electrode of the plug is.
The Fix?
The engine had to be removed, and disassembled so the head could
be sent to the machine shop.
The machine shop installed a new valve. The also installed a thread
insert from the inside.
Removal
Plugs may break into two pieces during removal.
The plug is uniquely designed because a regular spark plug could not
fit into the limited head space because of such large valves.
Ford TSB #08-7-6 addresses spark plug removal. *Note* this is Fords
procedure using their tools. Aftermarket procedures may vary and
tools will vary.
The spark plug hex is 9/16, so a special socket must be used.
Removal Continued
Some technicians in the field report that doing a top-engine cleaning
prior to spark plug removal helps. This is because carbon buildup at
the tip of the plug is what causes them to break, not corrosion.
Some technicians try to break the plugs loose a little bit and soak carb
cleaner or penetrating oil down the spark plug tube.
Some technicians are using cordless impact wrenches to remove the
spark plugs with success.
Extraction
The Lisle extractor is the preferred tool to the aftermarket.
This tool will push the porcelain of the spark plug tip in and allow an
extractor screw to remove the rest of the spark plug.
Installation
Torque is critical! When you look up the spec, you will find that the
torque spec can be double some 2 valve motors.
Apply anti-seize to the ground electrode. Nickel anti-seize is a must. It
may cost a lot of money, but can be billed to the customer.
Permatex and Locktite P/N 77124
Ford Motorcraft P/N XL-2