Broken Spark Plug & Tube Seals
Working on a 2.5 with a broken spark plug, broke off just under the hex part of the plug. Removing valve cover & spark plug tube, I knock out some of the ceramic & was able to use a large EZ-Out 1/2 drive, the plug broke further down flush with the spark plug threads. Continued breaking ceramic till was able to use EZ-Out once again. Thread section would not move, only expand larger in the cyl head. With a harden punch I slowly grown up the ceramic out to the point it could be blown out with cyl compression. Then took a 1/2" drill bit, with the bit flutes packed with grease to help with the steel shavings. I drilled thru the thread part of the spark plug being careful not to hit the piston. After the 1/2" bit i used a 9/16 bit. then cleaned the top of the piston with a magnet.
Using the thread repair kit I tap out the head stopping just 1/16 before entering into the compression chamber so the thread insert would not fall in to the piston compression chamber during engine operation. It took 1 long insert & had to grind a short one the get a good fit.
Now the spark plug tube seals. the valve cover is plastic & has a oil baffle over the seals edges. Cant remove them with out breaking away at the baffle. Is there any way to remove the baffle to get to the seals?