[s-cars] Spark plug thread refurbishing

[Michael Bess]

All:

The problem has been resolved (for minor cost).  It appears the monkey lad
at the dealer who changed the plugs 3000 miles ago used an air impact wrench
to remove and install the plugs.  (BTW, the plugs in other cylinders were
torqued well above specification, as the breakaway torque was over 35
ft-lb.)  When he did that, he managed to pull the seated insert out a bit
(it is a shouldered solid insert, not an open helicoil).  Thus when trying
to toque the plug, I was actually screwing in the insert.  When we pulled
the plug, the insert came out with it.  Removing the insert from the plug
made it unusable.  Threads on the insert were good, with no aluminum chips
noted, indicating the threaded hole in the head was undisturbed.  Installed
a new insert (with some Loctite I believe)and reinstalled to plug (to the
proper torque ~25 ft-lbs).  All seems OK.  I am planning a nasty call to the
dealer (Mohegan Lake Motors, Yorktown, NY) to inform them that they have
lost a service customer due to their mechanic's ineptitude and desire to
beat the flat rate manual.

Michael Bess
'95 S6


-----Original Message-----
From: Konstantine Bogach [mailto:kbogach at comcast.net] 
Sent: Sunday, January 25, 2004 11:43 AM
To: mlbess at optonline.net
Cc: 'Paul Souza'; s-car-list at audifans.com
Subject: Re: [s-cars] Spark plug thread refurbishing

Michael,

I think timeset will work in this application as far as seat goes. I 
don't trust helicoil even though successfull case were reported. 
Timesert looks as more "solid" approach to me. I think you can go to 
thicker was insert if the first one failed.
Keep us posted.

Thank you.
Konstantin.
P.S. Oh man, I feel you pain!

Michael Bess wrote:

>I too have experienced the dreaded occurrence.  I required a threaded
>insert, which was able to be performed without removing the head.  The Audi
>specialist who did the job did not use the Timesert because I was told that
>its geometry prevented proper plug seating against the head.  Since the
>insert installation, new plug, new coil, all was fine for at least 3000
>miles (car ran strong all the time, no indications of plug related issues).
>I have the MTM/Hoppen 1+ chip modification.  Then it was time for the
normal
>spark plug change (done at the really convenient dealer since I figured
what
>could he possibly do wrong to foul up that job and the 90,000 mile
service).
>All had gone well until yesterday.  As a precaution I had begun the 3000
>mile spark plug torque check. Checking it for the first time yesterday
guess
>what I find, the toque on the same bad cylinder (#2) plug is only 15 ft-lb.
>I crank it about a 1/4 turn expecting the torque to rise, but no change.
>Tried another 1/4 turn and still no change.  Now I'm in a panic.  Did the
>dealer F*** something up (like back the insert all the way out and then do
a
>Mickey mouse reinstall?).  So I called the Audi dude who did the insert job
>and reported the problem.  I'll be bringing it in for him to check
tomorrow,
>hoping for the least amount of problem (maybe the insert did simply back
out
>and it can be simply reinstalled).  Will keep the list apprised of things.

>
>If the insert itself has stripped in the head, what is the fix?  New head??
>Gaaah, I hate to think of the worst that can be. 
>
>Michael Bess
>Project Manager-Die Casting
>International Zinc Association
>
>
>-----Original Message-----
>From: s-car-list-bounces at audifans.com
>[mailto:s-car-list-bounces at audifans.com] On Behalf Of Paul Souza
>Sent: Sunday, January 25, 2004 1:31 PM
>To: Konstantine Bogach; s-car-list at audifans.com
>Subject: Re: [s-cars] Spark plug thread refurbishing
>
>Konstantin,
>
>I can relate.  I just went through this repair on my UrS6.   Not a cheap
>repair.  The onset of symptoms was pretty rapid, but I didn't help the
issue
>any because after the initial symptom showed itself, it rapidly went
>away....and then I proceeded to drive 500+ miles.   So my threads were
>pretty toasted.  I had the head pulled and threads repaired (#5 cylinder).
>
>Paul
>----- Original Message ----- 
>From: "Konstantine Bogach" <kbogach at comcast.net>
>To: <s-car-list at audifans.com>
>Sent: Sunday, January 25, 2004 9:52 AM
>Subject: [s-cars] Spark plug thread refurbishing
>
>
>  
>
>>I can't express my frustration due to the havoc made by loose spark plug
>>in my UrS4.   Just because I did not know about this species congenital
>>defect!  I don't have time to read all posts but it could save me as
>>there were some discussions on the topic quite recently.  :-(
>>So,  connector lead is shuttered,  spark plug's thread is FUBAR as
>>thread in the head,  coil's plastic body is cracked.  Right now I am
>>looking at TimeSert repair kit for deep hole (upto 6'').  Does anybody
>>went through this procedureJ?  Any better product than TimeSert?
>>I don't have necessary tools to measure all geometry.  Does anyone has
>>dimensions for seat diameter and thread length?
>>
>>Does every one has plugs loosening?   Any remedy?
>>
>>Thank you.
>>
>>Konstantin
>>P.S.  Please,  when new person join the list after recent car purchase,
>>welcome him by raising awareness of loose spark plugs (anything else
>>treacherous like this one?) :-)
>>
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>>    
>>
>
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