Valve Cover Replacement Nightmare
scorn6
05-17-2005, 09:55 AM
Sorry for the long post but I think this is a very important reminder.
First off the 3 Series in question is a 94 325is 2.5L Auto.
Anyone ever changed the valve cover gaskets only to drop one of the washers down inside the spark plug porthole because they didn’t bother to expend the necessary time or energy to plug said port hole? Well I did and the results were nearly disastrous even with the spark plugs still in but I somehow persevered and I would like to share this all important and valuable lesson with the group if I may.
If you’ve ever done this before then you should know that the valve cover gasket washers outside diameter is somewhere around 1/100th of a millimeter smaller than the inside diameter of the spark plug port hole. This means that when the washer straddles the elongated upper portion of the spark plug that the coil attaches too, as mine did, it will come to a rest ever so flush and snug with no way to externally grab hold of it no matter what you try. I bought one of the 2lb magnetized telescoping tools but the distance between the diameter of the inside wall of the port hole and the outside diameter of the spark plug would not allow for the magnet end to get close enough to attract the washer.
So after several failed attempts with every sort of magnetized tools, grabbing tool and any other off the wall idea I could think of, I was at a complete loss and insane with self loathing at the possibility of having to pull a head just to retrieve a 25 cent washer. While completely out of ideas and beside myself I was moping around at the local Home Depot when I saw something that instantly ignited the light bulb and offered a shred of hope.
The solution was in a 1/8” diameter x 9” long drill bit used for both metal and wood. With the utmost care I managed to drill 3 holes into the washer close enough to allow me to insert the fingers of the grabbing tool. After about a half hour of tear inducing frustration I was somehow able to unhinge the washer of the port holes grip and carefully extract it. I then had to use a magnetic screwdriver to retrieve all of the metal shavings that had accumulated.
Needless to say I deserve nothing short of a verbal reprimand for such abject stupidity and disregard for something so easily preventable.
First off the 3 Series in question is a 94 325is 2.5L Auto.
Anyone ever changed the valve cover gaskets only to drop one of the washers down inside the spark plug porthole because they didn’t bother to expend the necessary time or energy to plug said port hole? Well I did and the results were nearly disastrous even with the spark plugs still in but I somehow persevered and I would like to share this all important and valuable lesson with the group if I may.
If you’ve ever done this before then you should know that the valve cover gasket washers outside diameter is somewhere around 1/100th of a millimeter smaller than the inside diameter of the spark plug port hole. This means that when the washer straddles the elongated upper portion of the spark plug that the coil attaches too, as mine did, it will come to a rest ever so flush and snug with no way to externally grab hold of it no matter what you try. I bought one of the 2lb magnetized telescoping tools but the distance between the diameter of the inside wall of the port hole and the outside diameter of the spark plug would not allow for the magnet end to get close enough to attract the washer.
So after several failed attempts with every sort of magnetized tools, grabbing tool and any other off the wall idea I could think of, I was at a complete loss and insane with self loathing at the possibility of having to pull a head just to retrieve a 25 cent washer. While completely out of ideas and beside myself I was moping around at the local Home Depot when I saw something that instantly ignited the light bulb and offered a shred of hope.
The solution was in a 1/8” diameter x 9” long drill bit used for both metal and wood. With the utmost care I managed to drill 3 holes into the washer close enough to allow me to insert the fingers of the grabbing tool. After about a half hour of tear inducing frustration I was somehow able to unhinge the washer of the port holes grip and carefully extract it. I then had to use a magnetic screwdriver to retrieve all of the metal shavings that had accumulated.
Needless to say I deserve nothing short of a verbal reprimand for such abject stupidity and disregard for something so easily preventable.
Skycity_BMW
05-17-2005, 04:32 PM
Well . . you learned a valuable lesson.
Good to know ! ! !
You helped someone down the road ! ! !
Good to know ! ! !
You helped someone down the road ! ! !
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