I broke a spark plug and can't get it out...(non turbo Buick)

[d0n_3d]

97 Cavalier...2.2L

I was pulling the plugs out...3 of them came out very easy, the last one however was seized...I tried to gently put some torque on it to see if it would break loose and sure enough something broke alright...the plug and the part where I put the socket on came with it...so now I have the bottom part of the plug still seized in the head...this is an aluminum head mind you.

I tried drilling it out with a 1/4" bit, then put one of those bolt extractors in the hole and hammered it in...I tried to back it out to no avail...the sucker is seized like a mofo...

I guess where I am getting at is...I need to helicoil this thing somehow because we don't plan on keeping this car and it already has 180k miles on it...I just need to get it running again...does anyone know what size tap I need to use for the hole? can I try tapping the normal size hole first? then if that don't work...go the one size bigger tap and helicoil it?

 

[Robbie-87plz]

Sir, at the risk of sounding like an idiot. I'd venture to say..try an auto salvage yard with a head already removed and try to use the gauge to determine the pitch/thread.

 

[GN ERGY]

Just measure the spark plug that you took out. You could try heating that area up with a torch and then try to remove the broken part with the screw extractor you were using.
Tarey D.

 

[EightSecV6]

I dont know what it is about that engine but it has happened to us 3 times! Knock the center of it out and use an easy out, usually they come out fairly easy. 14mm threads. Get it out and use a chaser.

 

[d0n_3d]

Thanks guys for the tips! I couldn't get it out with an EZ out so I just went and bought a 1/2 drill bit that was made to go through ANYTHING...drilled the hole out, bought the Heli coil kit for spark plug holes (14mm x 1.25) and carefully tapped new threads, added the insert, locked it in place with the tool they give you and a hammer...and walla just like new. I vacuumed all the crap out of the cylinder hole with duct tape over a small piece of hose...then took a magnet and got all the chunks out. I'm not sure I would do this on a newer vehicle but on a vehicle that's worth less than what taking the head off and having fixed would cost...this was a no brainer!

 

[TURBOTWIN2]

PB Blaster

Yeah, those 2.2s are notorious for that. I had one once that seized at about a quarter turn. Wouldn't budge even with my 1/2" breaker bar on it with, I'm sure, at least 200 ft/lbs. of turning torque. I was about to use my 1/2" impact gun on it, but I knew that was a clusterflop waiting to happen. I soaked the plug in PB Blaster and went home. The next morning, I got out my regular 3/8" spark plug ratchet and it turned on out like it had already been loosened. PB Blaster is some amazing stuff, just give it time. HTH.