01 Coil-On-Problem.
 

too big for the hole. Can someone with an earlier car measure the ID of the plug hole? kthanks.

http://farm2.static.flickr.com/1148/...46e238.jpg?v=0
http://farm2.static.flickr.com/1380/...839f6d.jpg?v=0
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thats what she said

Shit, i'll check mine when I get home.

I'll put some calipers in there next time I'm at my dad's. Next weekend probably.

It's only off by 20 thou... hit the valve cover bores with a flapper wheel in a drill.... problem solved.

i'll have to check to see if the bores in the head are the same size or larger. that could be a bigger problem.

The Denso part #90080-19015 COPs fit in a 99-00 valve cover perfectly.

UHH Y8's why not just sand on the plastic abit, it looks like you are pretty close. Instead of trying to fuck with metal i say shave and sand on plastic. Or will that cause a short?

i'd rather not sand shit if I dont have to. especially when i dont want to sand through insulation of indeterminate thickness.

but yah if you guys can get some measurements on those bad boys and your valve covers, that'd be greaaaaaaaaaaaaat.

like I said, I will put calipers on both next time I go to my dad's. hopefully by the end of the week or the weekend.

thanks ben

Haven't checked mine yet. Probably have the same problem with my '01. Looks like it's not just a valve cover either. That sucks.

Frank

wanna split the cost of a 20 lb sledge?

I had the same issue on my 1.6. Apparently some coils have those little rings while others don't.

Simple solution- spend a few minutes with a dremel and a carbide cutter to take off the rings.

Joe, I remember your post about that, but my rings are way thinner than yours. I'm not sure I could get the 20 thou plus clearance off that SOB. I can try though. It may be the bottom ring hanging up on the hole in the head.

for ref:
http://img217.imageshack.us/img217/7583/coilhr4.jpg

oh also for you 01+ guys, the flange at the top of the COP unit will run into the 01 coil mounting bosses. one has to go.

GOOD NEWS EVERYONE.

The holes in the head are significantly larger than the holes in the valve cover. like 3/16 in diameter. so that's good. I can probably bore out the VC slightly with no problems.

shaweet.

What's the easiest way to bore out the holes in the valve cover? Dremel and sanding bits?

AlO2 jim hat and a clean copy of Swank. BAM.

I suspect Ark's suggestion is probably reasonable. Or if you have a 1" drill bit you can do it that way--no doubt it's faster. hmm.

Oh come on mount the cover in a mill and use a flycutter. Not that it's what I would do but it would be an incredible waste of time for a smooth surface finish.