Head Removal VolvoPenta 3.0

[TFastle]

Well, I had a thread going about two spark plugs twisted off on my FourWinns Horizon 170 with a VolvoPenta 3.0 GS (1999 WT series). I got one out but broke and easy out off in the other. Plan B is to pull the head and try to extract that way.

It looks like a fairly easy head to pull and as if I can do it with the engine in the boat and can leave the manifold on for simplicity. Am I being overly optimistic here or is this true? Also, any input with regard to tricks or things to make note of or look for would be greatly appreciated. Have worked on and rebuilt lots of motorcycles and jetskis, less so with boats and cars but tend to fix everything myself.

Another question for a machinist type person. I hope to remove the easy out from the inside by basically pounding it out. Very little of it is sticking out either side and not enough to grab and turn. Any other idea on extracting it or am I screwed with this head?

Yeah, I know I may have done some stupid things so far so don't need that reiterated. I have found this forum to be a GREAT source of information. Any helpful input would be GREATLY APPRECIATED!

Thanks!!!

 

[T-Max]

Re: Head Removal VolvoPenta 3.0

.... or am I screwed with this head?...

I would say you definitely should not be "screwed with this head." Worst case scenario ($$-wise) would be to take it to a competent mechanic or machinist and let them remove the problematic spark plug / broken extractor. Someone who's had lots of experience doing it.

As far as doing it yourself, you might consider this as a last resort approach: First, get the extractor out (shouldn't be too hard to punch it out from the inside with a punch/drift) and then you can likely fit some kind of a small hacksaw blade through what remains of the spark plug. I would think you'd be able to fit a powered jig saw blade thru there. But if possible, I'd perfer to do it using a hand-held hack saw, assuming you can work it out as far as the frame of the saw goes. Maybe a hand-held jig saw frame would be large enough to fit around the head and give you working room. If so, you thread the blade through the plug and then attach the frame.

Then you carefully saw the plug down to just shy of the threads in the head. You have to be careful, which is why I prefer to do it by hand.

You can do this all around the plug's circumference, or at least in a couple of places, and then likely break out a piece of the plug. That will release the rest of it and you can then easily get it out.

If you do mess up the threads in the head a bit, you can always chase them out with a thread chaser and be good to go. Worse case scenario you resort to a helicoil deal.

You might accomplish the same thing with an appropriate file, but I think a hacksaw is the way to go.

They also have those round carbide "blades" that fit into a hacksaw frame. Those things cut ANYTHING and you might make use of it here. I used one years ago to make a special "socket tool" for my Porsche engine overhaul by cutting a large chunk out of a 1 & 13/16" socket so that I could insert an open end wrench thru part of the socket to hold a nut as I turned the large nut with the socket. That was a lot of tool steel to cut but the blade did the job just fine.

But if it were me, my first approach would be to consult with a pro and let him do it. It's gotta be a lot cheaper than a new head.

 

[TFastle]

Re: Head Removal VolvoPenta 3.0

Thanks Bubba. Yes, hate to monopolize the forum like this but, when it rains it pours. I am agreeing that taking the head to a machine shop would be wise. Hopefully they will be able to get it out. Just want to make sure there is not some hidden issue that will make pulling the head a (another) nightmare. But, as my Dad used to say, "fun is 90% work and 10% fun so you better learn to enjoy the work." Have to look at is as an interesting and educational adventure (just wish I had the time for it!). Thanks again.