Do not strip the bolts holding the engine shroud!

[harry]

I have been changing my spark plugs since last week of January. All was well until I stripped the middle allen bolt holding the engine shroud onto the engine and then came weeks of hell trying to remove the bolt (see Rennlist link http://forums.rennlist.com/rennforums/showthread.php?t=412399).

If you are going to do the same I recommend that you push the three bottom spark plug leads out of the way first by sqeezing everything into the engine shroud through the oval opening, including the plug ends. Get a 6mm allen key and cut off the angled part with a Dremmel so that you have a long straight hex-key which you can insert into a 6mm socket, make sure you tap it into the hilt of the bolt socket with a hammer so that it is square onto the bolt and not squint (this is important) and use a ratchet and an extension bar to undo the bolt.

Maurice, do I get some spanners?

Harry

 

[jdpef356]

Maurice, do I get some spanners?

Sounds like Maurice should be supplying some plasters not spanners!!![][]

John

P.S. Good advice for others though.

 

[Guest]

Thanks harry. I take it that this is the best way to remove the sparks then? You're not a fan of the top down approach?

Not done mine yet - first time will be 2008/9 winter.

Cheers
Roddy

 

[harry]

Roddy,

You can replace the left side top and botton and the right side bottom spark plugs w/o too much trouble. You can replace 2 spark plugs on the top right from the top by removing the clutch ventilation hose but the one under the power steering pump is impossible to get to w/o removing the engine shroud. If you plan to do this yourself make sure you have all the right tools and take your time - if you lose it then it will take you 3 times as long as I found out.

Harry

 

[vitesse]

You can buy such an allen key in a set with different lengths with sockets for 1/2"& 3/8" drivers.

 

[Guest]

Thanks harry. There's a post on Rennlist by a guy who got round the PAS pump from the top. I think he has small arms & used Vaseline! Can the pump mountings be released easily I wonder?

Looks like your approach is the orthodox way though & I'll probably do it your way. Will follow your advice. Thanks, Roddy

 

[harry]

ORIGINAL: VITESSE

You can buy such an allen key in a set with different lengths with sockets for 1/2"& 3/8" drivers.

Wish I knew that in advance [].

Harry

 

[harry]

ORIGINAL: roddylennox

Thanks harry. There's a post on Rennlist by a guy who got round the PAS pump from the top. I think he has small arms & used Vaseline! Can the pump mountings be released easily I wonder?

Looks like your approach is the orthodox way though & I'll probably do it your way. Will follow your advice. Thanks, Roddy

I would be a bit afraid of misthreading the spark plug using that method. my hands are also quite small and I didn't attempt it - just not enough room to do it comfortably.

Harry

 

[Fred Hindle]

They are also available in ¼" drive. Also included in the sets of interchangeable ends for screwdrivers. Not sure if 6mm or 7mm socket fits, one of them does.

Cheers,

 

[harry]

Tooled-up.com sells the 100mm long, ball end ones which allows you up to 30 degrees off the axis. Damn, I should have been a little more diligent - didn't realise that the standard one I used for the 2 bolts at the side (which I have to say were easy) would round off the socket on the bolt. I think the problem was that it was off-centre and as significant force was applied on a seized bolt it served to round it off. Anyone doing this should buy the tool. It will be £24 well spent if you don't have to go through the agony I had to go through. I can see why the shops charge more or less £1000 to do this with oil and filter change (the primary reason for doing this myself was that there are no suitable place to service my car i.e. can't trust them and I didn't want to drive '00s of miles and back to get it done and I am fairly mechanically minded since I was young).

Harry

 

[harry]

ORIGINAL: Fred Hindle

They are also available in ¼" drive. Also included in the sets of interchangeable ends for screwdrivers. Not sure if 6mm or 7mm socket fits, one of them does.

Cheers,

Fred,

You need one that is long enough to clear the oval opening with the lip protruding down which does not allow short allen keys on a socket to be put in-line with long axis.

Harry

 

[Fred Hindle]

Harry,
Sorry, I didn't know exactly where on the engine you were using your improvised tool.
Perhaps it maybe worth mentioning it as a technical article in this section. Detail the length of the shaft you had to cut it to and what else you had to do. Would the job have been any easier if heat could have been applied or spraying with WD40 and allowing it to seep in? (If there is no bodywork in danger another good penetrator is brake fluid).
You can get 3/8" drive fittings with long Allen key shafts. I would imagine that motor factors would sell them as separate items.
As you say it is too late for you now, but you'll know the next time[].

Cheers,

 

[IndischRot]

ORIGINAL: harry

Tooled-up.com sells the 100mm long, ball end ones which allows you up to 30 degrees off the axis.

Just be careful; the ball end versions can't endure the torque that the normal version can and the ball end can snap off. The internal hex of the bolt will probably distort ever so slightly because the grip surface of the ball end is actually quite small and when it snaps off the ball end won't come out and then you're hosed even further. Ask me how I know! []

 

[Andy B Aces High]

Not too sure what this engine shourd is, I changed the HT leads this weekend (what a pig of a job) but did not notice this shroud. Is it the metal tray around the engine that has the rubber cover strip tucked into and the lower HT's pass through ?

If not then think they may have been left off my car in the past !

 

[harry]

ORIGINAL: Andy B Aces High

Not too sure what this engine shourd is, I changed the HT leads this weekend (what a pig of a job) but did not notice this shroud. Is it the metal tray around the engine that has the rubber cover strip tucked into and the lower HT's pass through ?

If not then think they may have been left off my car in the past !

I think we're talking the same thing - it is the black tin with the oval opening through which the spark plug leads come through.

 

[harry]

ORIGINAL: phelix

ORIGINAL: harry

Tooled-up.com sells the 100mm long, ball end ones which allows you up to 30 degrees off the axis.

Just be careful; the ball end versions can't endure the torque that the normal version can and the ball end can snap off. The internal hex of the bolt will probably distort ever so slightly because the grip surface of the ball end is actually quite small and when it snaps off the ball end won't come out and then you're hosed even further. Ask me how I know! []

Knowing how stiff mine was it may very well have broke - perhaps just as well I didn't use it. I think if you can get a straight end allen key on a socket that is long enough then that must be the best bet. I actually ground down a section of the lip to get a straight access to the bolt. I'll post some pictures and write up the process when I find some time over the weekend.

Harry

 

[harry]

Looks like this is needed
http://www.tooled-up.com/Product.asp?PID=126360 this is 10cm long so should have plenty of clearance and probably do not need to grind the lip as I mentioned.

Harry

 

[Andy B Aces High]

Thanks Harry, these are the same bits so my car still has them fitted. Is is not possible to change the plugs without taking these off, looked possible when I was changing the leads apart from RH lower bank that may hit the heat exchanger ?

 

[angry]

I did this job on the plug under the pas pump very easy[8|]
But for you show and polish guys stop reading now.
I managed to get the lead off ok and then i bent down the rear corner of the metal cowling with pliers,from the outside in the wheel arch.
I was then able to get a spark plug socket on a wobbly extension bar straight in from the outside.
If you poke a lamp down in the engine bay the light shines through and at that corner it goes straight into the plug tunnel[]
Naughty i know,but it didnt arf make the job easy.
Dan

 

[harry]

ORIGINAL: Andy B Aces High

Thanks Harry, these are the same bits so my car still has them fitted. Is is not possible to change the plugs without taking these off, looked possible when I was changing the leads apart from RH lower bank that may hit the heat exchanger ?

If you want to change the spark plug under the power steering pump, you need to remove the engine shroud to access it. Alternatively angry has suggested a more aggressive approach which I will not personally contemplate. You also need proper tools for the job. I will writ this up in the technical section in due course. I just finished swapping the top 3 sprak plugs on the right bank today....... I started the job in January [&o][:-][][:'(][][]

Harry