Went to change the plugs in my Saturn Ion (2.2 Ecotec) last night. Started at the right (passenger) side of the engine and got the first three with little problem. At the last one (driver's side), though, I ran into trouble. The plug didn't want to turn at all. I finally got it to break loose, but it wouldn't turn very far before hanging up again. Not wanting to strip the plug hole, I threaded the plug back in as tight as I dared.
This is the first plug change I have done on this car, as I have only recently taken possession of it. I always use anti-seize on spark plugs, especially in aluminum heads, but whoever put these plugs in did it dry.
I know there are spark plug thread repair kits available, and I don't have a problem using one, although I'd rather not. Does anyone have any advice for removing the seized plug WITHOUT removing the head or stripping the threads? And/or if the threads do become damaged, has anyone installed a thread repair kit with the head on the engine and done it sucessfully (no further damage)? I really don't want to remove and/or replace the head! Thanks in advance - Chris
