#4 cylinder spark plug threads in head pulled out any fix without pulling head or engine to rethread under firewall no room

First, I would highly recommend that you also purchase a set of igniton cables and replace these also because you are most likely to have damaged spark plug boots when you remove the boots from the plugs. Trust me...it happens about 95% of the time, and you will be way ahead of the frustration if you are prepaired.

Pull the spark plug boots off of the spark plugs.

NOTE:

Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug threads to seize, causing damage to cylinder head threads.

Clean the spark plug recess area before removing the spark plug. (spray brake cleaner and compressed air works well) Failure to do so could result in severe engine damage because of dirt or foreign material entering the cylinder head, or by the contamination of the cylinder head threads. The contaminated threads may prevent the proper seating of the new plug. Use a thread chaser to clean the threads of any contamination.

Screw the spark plugs out of the cylinder head.
Check the air gap at the electrode end of the spark plug.

The specification for the plug gap on your vehicle is 1.524mm (0.060 in)

Place a SMALL amount of nickle-based antiseize compound on the spark plug thread, being very careful not to get any on the porcelain portin of the plug. If you do get antiseize on the porcelain part of the plug, it is imperative that you clean it off thouroughly using brake cleaner and a clean rag, otherwise it could cause cylinder misfires.

Screw the spark plug into the cylinder head and torque to specifications.
The spark plug torque specification for your vehicle is 15 Nm (11 ft. lbs.)

NOTE: Failure to properly torque the plugs can cause severe engine damage. Overtightening the plug can damage the threads in the cylinder head and/or make spark plug removal in the future impossible. This will cause you to have to remove the cylinder head for repair the next time the vehicle needs service on the spark plugs.
Undertightening can cause the plug to leak compression and damage the threads in the cylinder head. This can result in the plug blowing completely out of the head causing severe cylinder head damage.

When replacing the ignition cables, make sure they are routed EXACTLY as they were originally routed from the factory. Make sure that all protective wire loom and fasteners are transfered to the new wires and secured properly. Failure to do so can cause damage to the cables, engine misfires and can cause the spark plug wires to "spike" sensitive sensor circuits that are nearby and cause damage to the sensors or your computer modules. Improperly routed ignition cables have also been known to cause interference in radio and stereo systems.

HINT: The rear plugs on your engine are much easier to get to if you remove the two engine struts that go between the engine and the upper radiator support. You can then use a ratchet strap to pull the engine forward to get more room to work on the rear plugs.

You might have already knocked a foreign object into your cylinder. I know it's a lot of work and I'm sorry to say it, but you really should pull that head off. Even if you succeed in removing the ez out and spark plug remains, you may have fine metal shavings in your cylinder.

You can get a HELICOIL spark plug repair kit and repair this yourself or replace the head cylinder

They are underneath the coils,there will be a coil,and under the coil will be a spark plug boot connecting the coil to the spark plug.

2.2L Engine

1. Observe the following service precautions:
   
   Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs from a hot engine can cause the spark plugs to seize. This can damage the cylinder head threads. Clean the spark plug recess area before removing the spark plug. Failure to do so can result in engine damage due to dirt or foreign material entering the cylinder head, or in contamination of the cylinder head threads. Contaminated threads may prevent proper seating of the new spark plug. Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine.
   
2. Turn the ignition OFF .
3. Disconnect the Electronic Ignition (EI) module harness connector.
4. Remove the spark plugs using a 5 / 8 inch spark plug socket.

To install:

WARNING Do not coat spark plug threads with anti-seize compound. If anti-seize compound is used and spark plugs are over-torqued, damage to the cylinder head threads may result.

1. Inspect the gap on the new spark plugs, re-gap the plugs as required. The spark plug gap specification is 42 inch. (1.0 mm).
2. Install the spark plugs and tighten to 15 ft. lbs. (20 Nm).
3. Apply dielectric compound to the spark plug boots and make sure no corrosion is present.
4. Install the ignition coil housing to cam cover and attachment bolts.
5. Tighten the ignition coil housing bolts to 89 inch. lbs. (10 Nm).
6. Connect the EI module harness connector. Push in until a click is heard and pull back to confirm a positive engagement.

1997 Toyota Truck Tacoma 4WD 2.7L EFI DOHC 4cyl

Toyota Pick-ups, Land Cruiser, and 4 Runner 1997-00
Spark Plug - Removal & Installation




Fig. On the 5VZ-FE engine, you must remove the coil for access to the spark plug



Fig. Use a 3 / 8 in. ratchet, a locking extension, and a spark plug socket to reach the spark plugs which are deep down in the cylinder head



Fig. Once loosened, carefully withdraw the spark plug from the cylinder head



Fig. View of a twin electrode plug that is found in the 5VZ-FE engine


Remove the spark plugs and wires one at a time to avoid confusion and incorrect wiring during installation.

1. Disconnect the negative battery cable, and if the vehicle has been run recently, allow the engine to thoroughly cool.
2. On engines equipped with spark plugs, carefully twist the spark plug wire boot to loosen it, then pull upward and remove the boot from the plug. Be sure to pull on the boot and not on the wire, otherwise the connector located inside the boot may become separated.
3. On engines with coil-over-plug ignition, remove the ignition coil for access to the spark plug. For additional information, please refer to the following topic(s): Engine Electrical, Ignition Coil.
4. Using compressed air, blow any water or debris from the spark plug well to assure that no harmful contaminants are allowed to enter the combustion chamber when the spark plug is removed. If compressed air is not available, use a rag or a brush to clean the area.

Remove the spark plugs when the engine is cold, if possible, to prevent damage to the threads. If removal of the plugs is difficult, apply a few drops of penetrating oil or silicone spray to the area around the base of the plug, and allow it a few minutes to work.

1. Using a spark plug socket that is equipped with a rubber insert to properly hold the plug, turn the spark plug counterclockwise to loosen and remove the spark plug from the bore.

WARNING It is recommended that you NOT use a flexible extension on the socket. Use of a flexible extension may allow a shear force to be applied to the plug. A shear force could break the plug off in the cylinder head, leading to costly and frustrating repairs.
To install:

1. Inspect the spark plug boot for tears or damage. If a damaged boot is found, the spark plug wire must be replaced.
2. Using a wire feeler gauge, check and adjust the spark plug gap. When using a gauge, the proper size should pass between the electrodes with a slight drag. The next larger size should not be able to pass while the next smaller size should pass freely.
3. Carefully thread the plug into the bore by hand. If resistance is felt before the plug is almost completely threaded, back the plug out and begin threading again. In small to reach areas, an old spark plug wire and boot or a short length of rubber hose, placed on the spark plug, could be used as a threading tool. The boot will hold the plug while you twist the end of the wire and the wire is supple enough to twist before it would allow the plug to cross-thread.

WARNING Do NOT use the spark plug socket to thread the plugs. Always carefully thread the plug by hand or using an old plug wire to prevent the possibility of cross-threading and damaging the cylinder head bore. Remember, your truck has aluminum cylinder heads and the spark plug threads in the head are easily damaged.

1. Carefully tighten the spark plug. If the plug you are installing is equipped with a crush washer, seat the plug, then tighten about 1 / 4 turn to crush the washer. If you are installing a tapered seat plug, tighten the plug to 1115 ft. lbs. (1520 Nm).
2. If equipped with coil-over-plug ignition, install the ignition coil assembly(ies).
3. If equipped with spark plugs, apply a small amount of silicone dielectric compound to the end of the spark plug lead or inside the spark plug boot to prevent sticking, then install the boot to the spark plug and push until it clicks into place. The click may be felt or heard, then gently pull back on the boot to assure proper contact.

I hope help you. Good luck.

The Spark Plug hole can be repaired. The professional way is to remove the cylinder head, and use a repair such as a Helicoil.

The spark plug hole is tapped out to a larger thread size, with a special Helicoil tap. Loctite or some other form of thread locker is applied, and the Helicoil is inserted.

Helicoil's are made of Stainless Steel, and are much better than the original material used in the cylinder head. (Be it cast iron or aluminum)
Drag racers use Helicoil's in their engines.

Tapping out the spark plug hole for a Helicoil, or using a special thread chaser, is NOT a good idea, while the cylinder head is still installed on the engine.
The tap creates chips of metal which fall down into the cylinder.
Using a vacuum to try to alleviate the chips, falls short of a good repair job.

Notice: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage.
Gap the spark plug, using round wire type spark plug gap gage. 


Gap Adjust the spark plug gap to 1.14 mm (0.045 in).

DO NOT coat the spark plugs with anti seize compound. Over torquing could occur and damage to the cylinder head threads may result.

If your going to use Platnum plugs, DO NOT GAP them. Just check the gap and if there not the right gap, ask for new one's with the right gap.

The metal on the PLatnum plugs, are harder and my break apart in the cylinder .

Good luck and hope this helps

i hope this helps more. its hard to explain these things with out being at the car. but i hope this helps. it pretty easy just pull one wire off, unscrew plug from moter, replace with new one, replace with new wire. and repeat 4 or 6 times depending on what engine you have. but write back with anymore specific questions you have.

When you're removing spark plugs, work on one at a time. Don't start by removing the plug wires all at once, because, unless you number them, they may become mixed up. Take a minute before you begin and number the wires with tape.

1. Disconnect the negative battery cable, and if the vehicle has been run recently, allow the engine to thoroughly cool.

When removing the spark plugs on the V-6 engine only on the firewall side, it may be necessary to remove the windshield wiper/motor module assembly from the vehicle. This will allow more room to work between the engine and the engine compartment firewall. Refer to for removal procedures.
Fig. 3: Hold the spark plug boot firmly, while giving it a slight 1/2 twist in each direction before pulling it off of the spark plug. remenber do this one at a time. replace the whole wire with new one.

1. On V-6 models only, remove the windshield wiper/motor module assembly from the vehicle for access to the spark plugs on the firewall side.
2. Carefully twist the spark plug wire boot to loosen it, then pull upward and remove the boot from the plug. Be sure to pull on the boot and not on the wire, otherwise the connector located inside the boot may become separated.
3. Using compressed air, blow any water or debris from the spark plug well to assure that no harmful contaminants are allowed to enter the combustion chamber when the spark plug is removed. If compressed air is not available, use a rag or a brush to clean the area.

Fig. 4: Once all dirt is removed from around the spark plug, carefully loosen and remove the plug Fig. 5: Pull the used spark plug out of the cylinder head once it is completely loosened Remove the spark plugs when the engine is cold, if possible, to prevent damage to the threads. If removal of the plugs is difficult, apply a few drops of penetrating oil(WD40) or silicone spray to the area around the base of the plug, and allow it a few minutes to work.

1. Using a spark plug socket that is equipped with a rubber insert to properly hold the plug, turn the spark plug counterclockwise to loosen and remove the spark plug from the bore.

WARNING Be sure not to use a flexible extension on the socket. Use of a flexible extension may allow a shear force to be applied to the plug. A shear force could break the plug off in the cylinder head, leading to costly and frustrating repairs.To install:

1. Inspect the spark plug boot for tears or damage. If a damaged boot is found, the spark plug wire must be replaced.
2. Using a wire feeler gauge, check and adjust the spark plug gap. When using a gauge, the proper size should pass between the electrodes with a slight drag. The next larger size should not be able to pass while the next smaller size should pass freely.
3. Carefully thread the plug into the bore by hand. If resistance is felt before the plug is almost completely threaded, back the plug out and begin threading again. In small, hard to reach areas, an old spark plug wire and boot could be used as a threading tool. The boot will hold the plug while you twist the end of the wire and the wire is supple enough to twist before it would allow the plug to crossthread.

WARNING Do not use the spark plug socket to thread the plugs. Always carefully thread the plug by hand or using an old plug wire to prevent the possibility of crossthreading and damaging the cylinder head bore.

1. Carefully tighten the spark plug. If the plug you are installing is equipped with a crush washer, seat the plug, then tighten about 1/4 turn to crush the washer. If you are installing a tapered seat plug, tighten the plug to specifications provided by the vehicle or plug manufacturer.
2. Apply a small amount of silicone dielectric compound to the end of the spark plug lead or inside the spark plug boot to prevent sticking, then install the boot to the spark plug and push until it clicks into place. The click may be felt or heard, then gently pull back on the boot to assure proper contact.

The causes for spark plugs leaving the cylinder head are as follows:
1. The threads in the cylinder head were compromised, as in cross-threading.
2. The spark plug, when replaced, was not tightened down properly (like only 2-3 threads in)
3. A combination of the above.

Whe the plugs are fully seated in the cyl heads, and are at the proper torque, it would be extremely RARE for the plug to be jettisoned by the compression of the pistons. You only have roughly 175-185 PSI compression, this will NOT defeat the retention of the threads. Look at the hole in the head...How may threads are damaged? If it is just the end of the hole, the plugs was not in "all of the way". If ALL of the threads are bad, the plug was inserted improperly, and damaged the threads in the head. Rethreading (a "heli-coil") will correct you condition, if properly done.
Hope this helps.