Potentially dead MR2 - options

[Iain]

Loose/knackered spark plug?

Bingo!

Interested to know how long you had the error code on for the misfire?

[Alex Knight]

So I've found the problem all... Not sure how thrilled I am though...

Looks like the spark plug was loose and has bashed against the coil and probably hot combustion gas has aided in melting the coil.

My main concern is where all the material went and is it in the cylinder, mainly because the gap on the spark plug has been closed somehow

Very disheartened but think I'm going to try a new plug to see whether it'll even do up properly and then maybe run the engine for a few seconds with coil 3 in c2 to see whether c3 runs properly

Glad you found the issue.

I would personally do a compression test before running the engine again.

[Ferrousfe]

Morning all,

So the threads look to be completely mashed. It won't even go hand tight.

I've got a cheapo inspection camera arriving (thought it'd be a useful tool to have in the box) so hopefully can get a better look and inspect inside the cylinder to see if there's any scoring.

When the misfire code occured, I swapped the coils from 2/3 (plugs weren't "loose" at the time but didn't check torque) and drove for 8 miles, then 8 miles home when it developed a tapping noise about 300m from my house.

Engine has been run for less than 2 minutes since.

I've ordered a spark plug hole repair kit with a threaded insert.

How much of a pain is changing the head, can it be done with the engine in situ or is that crazy talk?

Many thanks for all of your ongoing support. I'm having a tough time at the moment so it means a lot.

Thanks,
Jordan

[Carolyn]

I've done head in the car, once.  I wouldn't do it again.  Best and quickest to take the engine out.

If you're doing a thread repair/replacement with the head in situ, make sure the piston is nearly at the top of its stroke and figure out a way to vacuum out any swarf that ends up inside the cylinder.  A few small bits of ally will blow past the valves quick enough, but you don't want to push your luck .

I'm in Northants too.  We have quite a workshop with loads off tooling, including some specialist tools for rebuilding 1ZZ engines.  PM me if you need assistance.

[Ferrousfe]

Update:
After much messing around trying to find a tap that was long enough to go down the spark tube...

I can confirm I have a spark plug in the hole torqued to spec.

I covered the tap in grease and withdrew every 1cm or so and cleaned the ally off, regreased and carried on.

I'm not running it yet, will scope it tomorrow in the light and see what's in the hole, then will try and hoover, run without spark/injection to try and throw any more crap out, then will put it all back together and test, fingers crossed all!

[Ferrousfe]

Final update:

https://youtube.com/shorts/VUtJi795k-o?si=RyZ4Ub8Y5jw1Xilv

Afternoon all,
Popped to euro car parts this morning and picked up a new coil and plugs.
Looked in the spark plug hole and there was tons of aluminium in there...
I tried vacuuming but it did sod all...

Then, I got a thin metal tube and a bit of silicone tubing and slid it over the end, covered it in grease and pushed it in and span it round, did this many, many, many times till I couldn't see any more bits in the hole.

All back together and running, sounds healthy! High tick over as battery is now knackered but otherwise brilliant!
No smoke out of the exhaust either even with a bit of revving (I had warmed it up for ages first) so all good!

Thank you so much all for motivating me to carry on and get this lovely car running again. It means a lot, have a great Sunday afternoon all!

[Chilli Girl]

Brilliant outcome and well done for persevering. These cars are definitely worth the effort. 

[Iain]

Well done on getting it sorted, glad its back up and running.

[Carolyn]

Well done indeed!!

[Ardent]

Must feel quite satisfying.