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Originally Posted by alblogg
Well my friend you are in deep s@*! but there is a way out of this. Take one of your spark plugs and go to your auto parts store and tell them what you did. They will sell you a little kit call a heli-core which is new threads and the tool to put them in the hole you have. They have these special for spark plugs and aluminum but be sure to take a spark plug with you to get the right size.
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I think he's saying he twisted the spark plug off and the threads of the spark plug are still in the head. At this point a heli-coil won't do him a lot of good, as he needs to remove the rest of the spark plug.
You're best bet is to pull the head and then remove the remains of the spark plug with an easy-out. I have done it with the head on the vehicle using penetrating oil, an easy-out and applying heat with a torch; but not on an aluminum head, which are easy to damage.
I would soak it for 24 hrs with the best penetrating oil your auto parts store sells, WD-40 won’t do it; you need something stronger. Spray it every couple of hours for 24 hrs and then try to take it out with an easy-out. You may have to drill a small hole through it to get the easy-out started. In either case you will no doubt end up with pieces of metal falling down inside the cylinder, which will have to be removed to prevent damage when the engine is started.
In which case, if you’re successful in getting the rest of the plug out, you can turn the engine over with the starter, with that spark plug removed, for a few seconds to blow out the cylinder. Then start the engine with that spark plug still removed. This may blow all the debris out of the cylinder, but it’s not guaranteed to. Thus, it’s best to remove the head to make this type of repair.
P.S. When replacing spark plugs in aluminum heads always use an anti-siege compound on the threads of the spark plugs when installing them.