Well, this minor repair sure has turned to **** in my hands. CEL on my girlfriend's 97 Civic DX (D16Y7), pulled the code and it was the upper O2 sensor. Replaced it, reset the codes, went for a test drive... CEL came back on immediately, a few minutes into the drive it started blinking (bad misfire right?). So, I listen to the injectors, they're all clicking, and I figure, well I'll start with the easy stuff and change the plugs. The GF had taken the car to the dealership a year ago for a tuneup, and plugs were changed than (at least she was charged for um...).

Plug 1 & 2 are a little tough to get out, but after a little working back and forth they're out. Anti-seize on, put them back in. Plug 3 is proving to be just as hard, and I give it too much muscle, the threads snap off in the head leaving me with the hex part and all of the porcelain.

I've soaked the thing for 2 days with PB Blaster, and have attempted to get the threads out with an EZ Out to no avail. I've put what I think is a lot of force (crescent wrench on the end of a 1/4" extender attached to the EZ out, cheater bar on the wrench) and I don't want to break the EZ out off.

What the hell do I do now? I've heard heat it with a propane torch and let it cool a few times, trying to get lube to soak in there and get the threads to release. I've also taken off the valve cover to gain better access, however I don't know how (or if) I can remove the spark plug tube (outlined in red below):



Where am I at now? I can get a rebuilt head on ebay for $200. I've yet to put in a head, however don't see any reason why I couldn't deal with it after reading the helms manual and some DIY's.

Anyone have any ideas, this spark plug has really ruined my week.

 

Biggest thing right now would be knowing if and how I can get those damn spark plug tubes off. Having to work 7"away from the broken plug is a total b**ch.

 

http://www.civicforums.com/forums/18...e-removal.html
^seen you there also

i suggest taken the head off and then you can unscrew it from the bottom, they may have cross threaded it and thats why you cant get it out.

 

Yeah, this is definitely a "OMFG &*($#@ How do I get this thing out... quick spam the internets" moment. I've read some success stories of people using a torch to heat up the plug and head around the plug, heat - lube - cool, rinse and repeat to try to get the threads to open up. I posted this in the other forums as well, but correct me if I'm wrong. Do I have to get the head leveled at a machine shop if I take if off? In that case wouldn't I be better off just buying a rebuilt head for under $200?. And if I'm going to do that, do I have any thing to lose from really going to town on this head to try and get the broken plug out?