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Old 03-11-2010, 09:10 PM   #1
SpoolinWRX4
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Default '06 STi Spark Plug Snapped in Head.. What to do?

So I was changing plugs in my '06 STi and on the last one, the plug started turning then locked up on me. I thought it was a nasty carbon buildup being that they're factory plugs so I kept trying to break it loose and shortly after, the plug snapped on me.
Now the part that broke off you see the threads are all chewed up and stripped, I never touched them before so I'm assuming it happened from the factory. The car's not under warranty anymore so everything's gonna have to be on me.

My question is at this point, what should I do? Is this fixable without removing the head? If I need a new head I'm thinking while the engine's out and the head's off, I do drop-in pistons since I was planning on doing that down the road anyways. Should I stick with taking the engine apart or is there another way to fix this? Thanks for the help guys!
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Old 03-11-2010, 09:13 PM   #2
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I think it time to pull the head.
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Old 03-11-2010, 09:35 PM   #3
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i had that happen to me on my CRX. the porcelain came out the threads were stuck in.

I tried putting a screwdriver in there to unscrew it. it worked for a little. ended up getting a lag bolt getting it jammed in there and unscrewed it that way. you could prolly do something similar or get an easy out.

I'd try everything before I pulled the head out to get that out.
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Old 03-12-2010, 11:55 AM   #4
boost junkie
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It sucks that the spark plugs are so difficult to reach on these engines, you might be better off pulling the engine out of the car so you have more room to work. If the threads on the head are damaged, you will have to pull the head off the block but you might not have to replace it. Helicoil makes a spark plug port repair kit that will work well as long as it's installed properly.

http://www.hrpworld.com/index.cfm?tp...action=product
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Old 03-12-2010, 01:26 PM   #5
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You could gain a few inches if you unbolt the motor mounts from the crossmember, the pitchmount, etc... And jack the engine up.

This would raise the heads high enough so that it clears the frame rails that are always in the damn way. Giving you more working room to figure out a cheaper solution.

Last edited by teiva-boy; 03-12-2010 at 04:16 PM.
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Old 03-12-2010, 02:41 PM   #6
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Quote:
Originally Posted by teiva-boy View Post
You could gain a few inches if you unbolt the motor mounts from the crossmember, the pitchmount, etc... And jack the engine up.

This would raise the heads high enough so that it clears the frame rails that are always in the damn way. Giving you more work to figure out a cheaper solution.
This seems like your only option. GL man.
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Old 03-12-2010, 11:11 PM   #7
SpoolinWRX4
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thanks for all the replies everyone..

I'm heading down to my shop tomorrow to get an idea of what I can do.. The threads are definately damaged just by how the threads on the broken plug looked so maybe Helicoil would be a possible solution.. I heard that when you do that though it sometimes fails? Not sure what I'm doing yet but I'll let you guys know.. Thanks again!
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Old 03-13-2010, 04:50 AM   #8
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If you do go with a threaded insert, you may want to look at the time sert brand. They are a solid piece instead of a piece of wound wire like the helicoils are. They cost considerably more, but if it were me in this situation I would go with the solid insert over the wound wire insert.
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Old 03-14-2010, 10:24 PM   #9
SpoolinWRX4
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Just talked to my shop about my options.. Looks like I might be building the engine a little earlier than I expected, since the engine's being dropped and the head's coming off.

The plan is at this point is to buy a new head and swap over the cams, valves, springs, etc. from the damaged head. Also I was going to do pistons, (maybe rods) and I was told that you can't just drop in the pistons without doing some kind of machine work to the cylinders or else I'll get a considerable amount of piston slap. So maybe I'll bore the cylinders over .5mm or just hone them out.. Not sure at this point yet. What do you guys think of this? Anything else I should do while the engine's out? I'm hoping to get around 400-450whp when this is all done.
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Old 03-14-2010, 10:46 PM   #10
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Quote:
Originally Posted by SpoolinWRX4 View Post
Just talked to my shop about my options.. Looks like I might be building the engine a little earlier than I expected, since the engine's being dropped and the head's coming off.

The plan is at this point is to buy a new head and swap over the cams, valves, springs, etc. from the damaged head. Also I was going to do pistons, (maybe rods) and I was told that you can't just drop in the pistons without doing some kind of machine work to the cylinders or else I'll get a considerable amount of piston slap. So maybe I'll bore the cylinders over .5mm or just hone them out.. Not sure at this point yet. What do you guys think of this? Anything else I should do while the engine's out? I'm hoping to get around 400-450whp when this is all done.
If the shortblock is not damaged (cylinder walls), no need to bore .5mm
A light hone shall do the trick.
The ej255/257's walls aren't the best in the world. Leaving as much as you can is a better choice.
I'd drop in some forged pistons and call it a day, unless you want some aftermarket bearings and rods.
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Old 03-14-2010, 11:14 PM   #11
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Ok yea that's what I was thinking would be better anyways, just hone out the cylinder walls and drop in some forged pistons. Rods/bearings I'm still not sure about I guess it depends on the condition on the internals. How durable are the stock STi rods? Are they worth replacing?
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