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Can't get spark plugs out! 900 1995

My sister has a sweet '95 940 sedan. The sedan was in my possession for a few months probably around 7 years ago.

I finally convinced her to bring me the car to look it over and do some maintenance. I changed water pump, tensioner, timing belt, camshaft seal, accessory belts, trans fluid.

It appears that the same NGK plugs are in the car from when I tuned it up 7 years ago. In my cars I'm usually able to get the plugs out with ease with a 3/8" ratchet. I couldn't budge these plugs, tried a bit of back and forth and they really weren't going anywhere. For now I'm letting sleeping dogs lie, but the car only has 112k on it and with a great body it has lots of life left so I'd like to get those plugs out and changed at some point. The engine runs perfect right now, just wanted to change the plugs, cap and rotor in the spirit of routine maintenance.

My next attempt will be a good soaking with PBlaster but beyond that I'm not sure what to do. I certainly don't want to be stuck holding a spark plug with aluminum head threads in it, but at the same time I realize that the plugs cant stay in there for another 7 years... or can they?

Thanks
Matt

--
'90 245 285k, '93 945 296k








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    Can't get spark plugs out! 900 1995

    Agree with others, not an emergency, but undo them when motor is warm to hot. Use a small amount of anti-seize on threads for new plugs, being careful to not get it on the plug itself. Maybe run a thread cleaner/chaser carefully in there to clean things up. Mike








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      Can'ti get spark plugs out! 900 1995

      Had to do this years ago. Found this sequence worked best.

      Run the engine to operating temp. Try to crack the plugs no more than a half turn. Soak with penetrating oil. Let the engine cool. Then try to remove
      If no success then repeat

      You can go some real damage cranking a plug all the way out of a hot head. .

      Patience Is the key. I








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    Can't get spark plugs out! 900 1995

    I feel your pain. Cant count how many times I have gone to remove a plug and you start having to REALLY apply torque(feels like 60 ft/lbs plus) and you start thinking, "this is aluminum and this plug is certainly starting to cross thread". Sickening feeling. But I agree with the others, soak in PB, start and get hot, soak in PB again, start and get hot, then remove. It will feel terribly similar to something cross threading....but it won't. It will come out. As an aside, I know it is contra conventional wisdom but after removal and cleaning of the spark plug hole threads(rag and paint thinner and my pointer finger), I do use grey anti seize on re-installation. Dont over-torque(I use the "just tight enough" guage). You will never have the issue again.








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    Can't get spark plugs out! 900 1995

    I'm a bit embarrased to admit, but the original spark plugs in our old 740 B230 NA were were still running perfectly fine at 90,000+ miles. You replaced the plugs in that car at ??,??? miles and it only has 112K on it now, so my guess is that she hasn't put that many miles on them. But even so, I kind of like the sleeping dog approach, as long as it's still running good. There are many things that could happen down the road in the next few years (some we don't want to think about too much) that would render a plug change right now to be wasted. For instance, what if it blows a head gasket two years from now? There's a perfect opportunity to fix the spark plug problem at that time.
    I vote to leave the plugs alone and concentrate on some of the other things that an 18 year old car might need. You have replaced the radiator by now, haven't you?








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      Can't get spark plugs out! 900 1995

      That's something I'm going to recommend that she does... its still a Volvo Blackstone model.

      Thanks for the advice all!
      --
      '90 245 285k, '93 945 296k








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    Can't get spark plugs out! 900 1995

    Matt---I can answer your query on two counts---- "but at the same time I realize that the plugs cant stay in there for another 7 years... or can they?"
    I was faced with the same dilemma about a year after I purchased my 1980 245 in 2000. The original owner had a tune-up about 15k miles before selling the car to me (at about 110K). After a year of driving I decided to do a tune-up and T/B change. #'s 1,2 and 3 came out no sweat--#4 would only budge a tiny bit and like you I tried a back and forth procedure--with no luck--and like you, I didn't want to see an aluminum packed spark plug thread. The other plugs looked ok normal for 30k miles and I returned them to keep the 4th company. The car always started normally (except for wet weather--new wires took care of that) and returned 26-28mpg on road trips--20-25 around town. It was around 150k miles later (now over 275k on the car) that the mileage started to drop (last year). I've owned and serviced many aluminum cylinder headed motors and have always tried to do spark plug changes cold. My Volvo trained Danish friend suggested a hot motor attempt--and lo and behold(!!!) the #4 came right out - the set was worn but not the worst I've ever seen.
    So, in short--yes you can probably leave them in another 7 years--and yes there's a good chance they'll come out using a different technique. In your case you know they were installed correctly--I was afraid mine was cross threaded to start with (thankfully, not the case). -- Dave








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      Can't get spark plugs out! 900 1995

      I had to use the hot engine method after repeated attempts and sprays with PB blaster. Had to loosen/tighten many time.

      Bought a nasty plug thread chaser but it was a piece of junk, so I filed three rows of groves in an old spark plug to help clean the threads using gumout and clean terry rags wrapped on a wooden dowel rod.

      Tom








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        Can't get spark plugs out! 900 1995

        Had the same problem on my wife's 945t. Three years after buying the car with I went to change plugs, belts, filters, etc. The plugs would not come out.

        PBlaster, patience and a lot of back and forth finally got all four out but I discovered that one of them wasn't run in all the way anyway, just torqued down against the crud someone else didn't clean out the last time.

        Using a good quality thread chaser coated in grease to clean the carbon out of the plug holes worked wonders and the new ones went in easy. I thought that I'd remove them annually just to keep this from happening again but of course, it's been three years now. :^)

        Might be the last set this car ever sees as I just passed the smog inspection today.

        Erwin
        '94 945T 163,000 mi
        '95 855T 198,000 mi







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