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Old 09-30-2007, 06:16 PM   #1
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Default 01 Coil-On-Problem.

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





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Old 09-30-2007, 06:42 PM   #2
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thats what she said
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Old 09-30-2007, 06:48 PM   #3
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****, i'll check mine when I get home.
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Old 09-30-2007, 06:56 PM   #4
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I'll put some calipers in there next time I'm at my dad's. Next weekend probably.
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Old 09-30-2007, 07:02 PM   #5
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It's only off by 20 thou... hit the valve cover bores with a flapper wheel in a drill.... problem solved.
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Old 09-30-2007, 07:33 PM   #6
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Quote:
Originally Posted by Arkmage View Post
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.
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Old 09-30-2007, 10:04 PM   #7
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The Denso part #90080-19015 COPs fit in a 99-00 valve cover perfectly.
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Old 09-30-2007, 10:09 PM   #8
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UHH Y8's why not just sand on the plastic abit, it looks like you are pretty close. Instead of trying to **** with metal i say shave and sand on plastic. Or will that cause a short?
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Old 09-30-2007, 10:13 PM   #9
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i'd rather not sand **** 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.
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Old 09-30-2007, 10:35 PM   #10
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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.
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Old 09-30-2007, 11:03 PM   #11
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thanks ben
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Old 10-01-2007, 07:29 AM   #12
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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
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Old 10-01-2007, 11:12 AM   #13
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Quote:
Originally Posted by fmowry View Post
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?
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Old 10-01-2007, 12:25 PM   #14
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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.
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Old 10-01-2007, 12:51 PM   #15
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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:


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.
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Old 10-02-2007, 11:21 AM   #16
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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.
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Old 10-02-2007, 11:30 AM   #17
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shaweet.
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Old 10-02-2007, 07:05 PM   #18
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What's the easiest way to bore out the holes in the valve cover? Dremel and sanding bits?
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Old 10-02-2007, 08:14 PM   #19
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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.
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Old 10-02-2007, 10:26 PM   #20
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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.
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