CoilFix.JPG
3743 hits | 63.92 KB | Posted: 11/6/06
This is what I had to do after the #6 plug blew out of the head at 2AM Sunday 1,000 miles into a 1,4...

5553TimeSert.JPG
2077 hits | 67.35 KB | Posted: 11/16/06
$525 later, this arrived. #5553

5553Kit.JPG
2362 hits | 52.41 KB | Posted: 11/16/06
I ordered 3 extra inserts so I could fix all 8 holes. Brian at Promar Engine was very patient & hel...

5553Stuff.JPG
1796 hits | 86.78 KB | Posted: 11/16/06
This is the instruction page for using this kit:
http://www.timesert.com/html/triton_repair.html
...

01Rigged.JPG
2184 hits | 68.31 KB | Posted: 11/21/06
This is how I made it the last 400 miles home, and another ~100 driving around before I got the Time...

02Rigged.JPG
4530 hits | 84.23 KB | Posted: 11/21/06
The coil barely fits wedged between the extension & the fuel rail, which gives it the most strength ...

03Coil.JPG
2051 hits | 79.29 KB | Posted: 11/21/06
The coil was damaged by the spark plug hammering it for ~15 miles, but I broke a little more away so...

04Coil.JPG
1958 hits | 58.42 KB | Posted: 11/21/06
Since I didn't clean the wall of the head, the epoxy broke free easily, and I had no trouble backing...

05Hole.JPG
2075 hits | 54.72 KB | Posted: 11/21/06
I should have known the camera wouldn't focus on the bottom of the hole, but it's relatively free of...

06FaceCutter.JPG
2020 hits | 80.08 KB | Posted: 11/21/06
The first tool starts by cleaning out any remaining spark plug threads (red pointer), then uses a sm...

07FaceCutter.JPG
1819 hits | 75.78 KB | Posted: 11/21/06
Even the tools specifically sold for working on these heads aren't long enough to do the job with th...

08FaceCut.JPG
2357 hits | 69.84 KB | Posted: 11/21/06
Following the instruction, I loaded the cutter with grease to collect the majority of the shavings. ...

09Reamer.JPG
3119 hits | 73.82 KB | Posted: 11/21/06
Next, the reamer is used to enlarge the hole for the tap. More grease catches most of the shavings.

10Ream.JPG
1975 hits | 67 KB | Posted: 11/21/06
I didn't want to overload the grease, so I stopped halfway & cleaned it out.

11Ream.JPG
2121 hits | 72.02 KB | Posted: 11/21/06
The 3rd run of the reamer makes sure the tapered shoulder is cut correctly, so I cleaned the reamer ...

12Ream.JPG
1812 hits | 77.11 KB | Posted: 11/21/06
A lot of metal gets removed for the BigSerts, which have a thicker wall than the normal TimeSerts.

13Tap.JPG
1781 hits | 69.5 KB | Posted: 11/21/06
The tap also has a pilot tip, and the instructions recommend grease again. I used a manual ratchet ...

14BigSert.JPG
2019 hits | 51.45 KB | Posted: 11/21/06
The insert is threaded onto the installation tip, which slips into the driver, retained by its O-rin...

15Release.JPG
2147 hits | 65.23 KB | Posted: 11/21/06
Once the insert is torqued properly, the screw must be loosened to release the tip from the insert.

16Inserted.JPG
2009 hits | 51.16 KB | Posted: 11/21/06
The final step is to expand the insert with the last tool, which must be oiled. This sets the inser...

17Done.JPG
4388 hits | 59.76 KB | Posted: 11/21/06
The old coil probably still works fine, but I decided to replace it anyway. Same for the spark plug...

18Done.JPG
4028 hits | 91.03 KB | Posted: 11/21/06
Once I get the other 7 done, I'll replace the alternator connector.


UPDATE: Turns out I won't be b...