Spark Plug Hole Thread Repair

WARNING: This page is about a different car, the 2007 Mazda B3000, 2006 Mazda B3000, 2005 Mazda B3000, 2004 Mazda B3000, and 2003 Mazda B3000. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

The cylinder head must be removed from the engine before installing a tapersert. If this procedure is done with the cylinder head on the engine, the cylinder walls can be damaged by metal chips produced by the thread-cutting process.
Do not use power or air-driven tools for installing taperserts. Cylinder head damage may occur.

NOTE:

This repair is permanent and will have no effect on the cylinder block or spark plug life.

Clean the spark plug seat and threads.

Fig 1: Cleaning Spark Plug Seat & Threads
Courtesy of MAZDA MOTORS CORP.
Start the tap into the spark plug hole, being careful to keep it properly aligned. As the tap begins to cut new threads, apply aluminum cutting oil.

Fig 2: Tapping Spark Plug Hole
Courtesy of MAZDA MOTORS CORP.
Continue cutting the threads and applying oil until the stop ring bottoms against the spark plug seat.
Remove the tap and metal chips.
Coat the threads of the mandrel with cutting oil.

Fig 3: Coating Threads Of Mandrel With Cutting Oil
Courtesy of MAZDA MOTORS CORP.
Thread the tapersert onto the mandrel until one thread of the mandrel extends beyond the tapersert.

NOTE:

A properly installed tapersert will be either flush with or 1.0 mm (0.039 in) below the spark plug gasket seat.

Fig 4: Tightening Tapersert With Torque Specifications

Courtesy of MAZDA MOTORS CORP.

Tighten the tapersert into the spark plug hole.
Turn the mandrel body approximately one-half turn counterclockwise and remove.

Fig 5: Removing Mandrel Body
Courtesy of MAZDA MOTORS CORP.
Use a feeler gauge and straight edge to check for cylinder head flatness. Refer to CYLINDER HEAD INSPECTION .