Hey all...
I actually don't own a Mini atm, but I keep contemplating it when my BMW dies. I DO however work on them fairly often as I'm a BMW/Mini Tech at a local independent shop.
Anyway, my question is this...Are spark plugs getting shot out common? I've repaired 6 mini's having had a plug shot out in the last 6 months. I have only had 1 BMW and purely numbers wise I work on MANY more BMW's. Usually the plugs are non-factory so I chalk it up to improper installation by the owner. But a few times they were factory, likely original plugs.
Is this something that just happens or is it usually just a negligent installation?

By the way, it's not usually the end of the world if a plug gets shot out. For the most part it's an easy repair I think we only charge a few hundred dollars for. Don't let the dealership tell you, you need a new head...because ya don't!

 

Do you mean physically completely unscrewed from the threads in the head? Or that the threads in the head somehow were damaged and the plug was thus physically ejected from the plug hole? Or, somehow the electrode on the plug is gone entirely? Just haven't heard the term before; guessing it is one of the first two.

 

He means that the plug is ejected from the head like a rocket. Usually #2.

I check torque on the plugs every 5000 miles at my regular oil changes. And only cold as in overnight cold. 20 ft/pounds.

Rich

 

It's fairly "Common" because there are a lot of negligent mechanics and owners out there. MINIs have soft aluminum heads, that will expand faster than the hard steel threads on the spark plugs. If the plugs are torqued to 27NM (20lbft) you will be fine, but if not the high compresion ratio with the S/C or turbo running will blow those things out like no tomorrow.

That being said, most of US never have a problem, because we have enough sense to take 5 minutes to go into the garage with a torque wrench and check the numbers every few months.

 

I think it's usually due to people not applying enough torque with the aftermarket plugs. Then heat/cool/heat cycle and they loosen and walk out, then blammo. I had 60k on OEM plugs and didn't have any issue. Not bound up either when I switched to Brisks.

Always check torque every 5k when changing the oil and rotating tires.

 

Ya I meant totally ejected from the head taking all or most of the threads with it.
Good to hear it's not really a mini problem but more of a installer issue.

 

Man, I am really glad that I joined this forum. I never would have known to check the torque on the spark plugs. One question tho, is this common on the justas as well or more of an issue with the S?

 

Of the 6 I have done 5 were S's. I would imagine that is because S owners are more apt to change their plugs for something "better" than a non-S owner. That's my theory anyway...

 

What generation? 1st Gens had a problem with the no 2 being blown out but after some research we found that it was mainly Denso plugs that were going. It was also likely that the person installing them were not completly compressing the compression spring thus getting a false sense that they were tight. Basically it was installer error. That being said, I have had my NGKs in for a few years now with no need to re-check the torque and I have not had a problem.

Has the 2nd gen also had this issue? I haven't read much on that.

 

I have yet to see a 2nd gen have this problem, but I've only had a few of them come in. Newest one was a 06 JCW but they were not original nor even correct plugs so that was installer error I'm sure.

 

How is it that every Mini s that blows a plug, blows cylinder 2? Mine included! I think it is something in the manufacturing process that leads to this cylinder blowing out and taking the threads with it. There is no way that every inept installer torqued the other three correctly and missed number 2. People are blaming aftermarket plugs. From what I have read this cylinder will blow any brand plug out

 

My 2002 R53 blew out number 2 this morning. It was running great (as usual) and then *pop*. On the bright side it was a perfect day for a walk back home. Came back, reinstalled and then torqued all four plugs. I didn't know this was a thing.

I'm using NGK Iridium plugs and had never re-torqued them after install them a year ago. Two of the other plugs weren't tight. I looked up the problem here on NAM before I walked home. Lesson learned.

 

You got lucky, most people who blow plugs out of the head end up needing to install a Time-sert to fix the problem quick and cheap.

 

Only so lucky... it just did it again. Is the Time-sert pretty easy to do?

 

'easy' is in the eyes of the mechanic! It involves drilling the head of your motor ..... perhaps better left to someone with the right tools and experience but hey ... Do you feel lucky?

videos
http://www.timesert.com/html/install.html

helicoil is another product that works the same way ... may be easier to find. My ACE hardware has these

 

A Helicoil is NOT the same as a Timesert. I have use a BackTap to fix a head once but if that didn't work TimeSert was the next choice and the way to go. It takes special tools but is MUCH better than a Helicoil. If you read all the posts you'll find that even though the Helicoil seems to work, most times it comes out the next time you remove the plug.

Do it right the first time and you won't be sorry.

///Rich

 

I'm in Gaithersburg, Maryland and can't find any shops that work with Time-serts. They're all talking about Helicoils which I don't want. I'd be willing to pay someone experienced to come by and install it but haven't had any luck.

 

Things are looking up. I just found a thread repair kit at Advance Auto Parts that utilizes a Time-sert style insert. Tool with 4 inserts, $4.99. The red Loctite cost more . Doesn't come up in any general searches of their site, I found it at a store. Autocraft AC1046. Unfortunately the hex head of the cutting tool is too large for the spark plug tube. Just found one with a smaller hex head on ebay. I'll give that a shot.

Found a T-Handle to use with it at Harbor Freight.

 

This should work...

http://www.ebay.com/itm/201290589637

 

This tool would not cut into the aluminum. I contacted the seller and they told me to return it for a refund. I asked why it wouldn't cut and they said turn it in for a refund.

So I sprang for the Time-Sert 4412E-111 kit for $224 from Amazon and it was money well spent. The install went off with one hitch... the insert tool went completely through the insert. It had resistance on it right up to the point that it was totally free.

I talked to Time-Sert customer support, they said that had never happened before and I'd need to remove the head or have someone hand crank the motor to push the tool back up which sounded sketchy to me. I bought a magnetic retrieving tool from Napa and was able to pull the insert tool up and get the thread started after about several tries. The rest was easy. The tip to use grease to catching the shavings was right on time. I used red Loctite and am letting it sit overnight.

Considering how much this could've cost at a shop, with the temptation to charge for a new head, I'm happy with the price.

 

And you can also sleep easy as you know the job was done right.



///Rich

 

Exactly.

 

Four years later, still money well spent.