Damage Control: Removing Problem Plugs on Ford Modular Engines - Page 2 of 3 - Engine Builder Magazine

Damage Control: Removing Problem Plugs on Ford Modular Engines

Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air.

2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 – 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. Do not work the spark plug back and forth at this point.

Caution: Excessive Motorcraft carburetor tune-up cleaner, or repeating the process several times with too much cleaner fluid, could introduce enough liquid volume to hydro-lock the engine.

3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and high effort may be noticed. The expected removal torque is about 33 lb.-ft. (45 Nm). Repeat the back and forth turning as needed until turning effort is reduced, and remove the spark plugs.

Ford says do not use power tools for the plug removal — spark plugs must be only be removed with hand tools.

Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of three modes. Refer to the appropriate removal procedure as required.

• Mode 1: The ground electrode shield is left behind as an empty shell. (See Figure 2.)

• Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.

• Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground shield.

 

Mode 1 Procedure:

Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the cylinder head.

Note: This tool is only designed to work with an empty ground electrode shield. If porcelain remains, proceed to Mode 2 or 3 removal.

1. Modify vacuum cap to a 3/8′′ (10 mm) length for each ground electrode shield that needs to be removed.

2. Use the installation rod provided with service tool 303-1203 update to install the modified vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and protect the combustion chamber from contamination.

3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4 reduced diameter threads on the tip end).

a. Coat the end of the tap with general-purpose grease.

b. Turn the tap about three to four turns into the ground electrode shield. Back the tap up frequently to break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor is provided with service tool 303-1203 update to connect the tap to a 3/8′′ socket drive.

Caution: Do not attempt to remove the ground electrode shield with the tap and wrench. The tap may break if this is attempted.

4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. SeeFigure 3.

a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.

b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to

prevent thread stripping.

c. Install the nylon washer and jack nut until finger tight.

d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool assembly.

 [inpost_gallery post_id=4970 group=”1″]

You May Also Like

Shop Solutions March 2024

I always keep a pair of needle nose pliers and a small, straight screwdriver in my blast cabinet to hold small parts when blasting.

Engine Builder and Engine Pro present Shop Solutions in each issue of Engine Builder Magazine and at enginebuildermag.com to provide machine shop owners and engine technicians the opportunity to share their knowledge to benefit the entire industry and their own shops. Those who submit Shop Solutions that are published are awarded a prepaid $100 Visa gift card. Submit your Shop Solution at [email protected]. You must include your name, shop name, shop address and shop telephone number. Submitted Shop Solutions not published will be kept on file and reevaluated for each month’s new entries.

Degreeing the Camshaft and Checking Valve-to-Piston Clearance

Jeff McCord of LinCo Diesel Performance walks you through degreeing a camshaft and checking valve-to-piston clearance.

Designing a Better LS Engine

After a customer wanted a Steve Morris Engines’ SMX in an LS version, Steve saw the upside and potential in the market, and a challenge to build a better LS.

The Importance of a Good Valve Job

The valve job ensures the mating surfaces of the valves and the seats properly control the air/fuel mixture.

Other Posts

Compound-Turbo 6.0L Powerstroke Engine

Tyler Lambert’s Ford F-250 started as a project with a simple goal – to extract as much power as possible. Equipped with a 6.0L Powerstroke engine, the truck underwent a series of transformations, including a compound-turbo upgrade, that elevated it to the powerhouse it is now.

6.0L Powerstroke engine
CHE Ford Godzilla Trunnion Kit

The kit includes 16 heat-treated steel trunnions, 32 bronze bushings, and 33 retainer clips.

CHE trunnion kit
Holley Announces 2024 Flagship Events

Experiential events reinforce Holley’s commitment to serving customers across traditional and growing aftermarket verticals.

B&B Performance Adjustable Billet Timing Pointers

Available for SBC, BBC and SBF, pointers come with stainless steel pointer, fasteners and a black anodized finish.

timing pointers