PIPER AIRCRAFT, INC.
PA-28-161, WARRIOR III
MAINTENANCE MANUAL
PAGE 7
Nov 30/06
5D9
74-20-00
(4) Removal of seized spark plugs in
cylinder is done by application of liquid
carbon dioxide (CO
2
) by a conical metal
funnel adapter with a hole at the apex
just large enough to accommodate the
funnel of a 20 lb bottle. (Refer to Figure
14.) When a seized spark plug cannot
be removed by normal means, funnel
adapter is placed over and around spark
plug. Place funnel of CO
2
bottle inside
funnel adapter and release carbon
dioxide to chill and contract spark plug.
Break spark plug loose with a wrench. A
warm cylinder head at the time carbon
dioxide is applied will aid in removal of
excessively seized plug.
B. Inspection and Cleaning
(1) Visually inspect each spark plug for the
following non-repairable defects.
(a) Severely damaged shell or shield;
threads nicked up, stripped, or
crossthreaded.
(b) Badly battered or rounded shell
hexagons.
(c) Out-of-round or damaged shielding barrel.
(d) Chipped, cracked, or broken ceramic insulator portions.
(e) Badly eroded electrodes worn to approximately 50 percent of original size.
(2) Clean spark plug as required; remove carbon and foreign deposits.
(3) Test spark plug both electrically and for resistance.
(4) Set electrode gap at 0.016 to 0.022 inch.
C. Installation
CAUTION: DO NOT INSTALL ANY SPARK PLUG THAT HAS BEEN DROPPED.
(1) Before installing spark plugs, make sure that threads within cylinder are clean and not
damaged.
CA
UTION: MAKE CERTAIN DEEP SOCKET IS PROPERLY SEATED ON SPARK PLUG
HEXAGON AS DAMAGE TO PLUG WILL RESULT IF WRENCH IS COCKED TO
ONE SIDE WHEN PRESSURE IS APPLIED.
(2) Apply anti-seize compound sparingly on threads; install gasket and spark plugs. Tighten to a
torque of 420 inch-pounds.
(3) Carefully insert terminal insulator in spark plug and tighten coupling nut per Chart 1.
Removing Frozen Spark Plug
Figure 14
Spark Plug Coupling Threads Torque (In.-lb.)
5/8-24 90 - 95
CHART 1
SPARK PLUG COUPLING TORQUE
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