Spark Plug Jumped Out ??????

I have a 2005 Honda Odyssey and the malfunction light came on and then it started to run terrible. I took it to the dealer and they said the number 2 spark plug jumped out. Of course in the process it damage the engine severely and it will cost over $4,000 to fix.

I have never in my life heard of a spark plug "jumping out".

Any mechanics with any insight?

I am complaining to Honda right now...this doesn't seem one bit normal.

Thanks for the help

Obviously that's slang on their part since a properly installed spark plug cannot disengage from the engine block on its own, though perhaps someone else can explain it better.

When was the last time the plugs were changed? That's likely the source of the problem due to this particular plug not having been properly installed.

Northern I am not mechanically savy, but I had a honda accord that did the same thing not to long ago. The problem was the spark plug has a holder ( do not know the official name) that is put into the engine. The "holder" had cracked. I guess over time the heat and what not wore it out. I got a new wiring harness and put a new spark plug in and it has ran fine ever since. If it happened and you did not drive a long way I would think damage would be minimal. I know it sucked driving down the road and the engine sounded like it was falling apart. I wouldn't think that much damage could be done to the engine with a missing spark plug.

I have seen plugs come out...as Bar said probably cross threaded when changed last....Id have to see pics of 4K worth of damage though. Im no expert but id say thats damn near impossible...shouldnt be anything more than putting in a thread kit and a new plug...Unless u drove under water while it was out i dont see how u could get 4K worth of damage..

It's not often that PPP and Barman express shared perceptions, brother.

:drink:

That's like a Divine Sign to get a second repair opinion from a mechanic that you or a trusted friend views with strong integrity

I had that happen with one of my old beater cars.

There are a couple different ways that spark plugs fit in the engine block:

1.) a ring is welded into the block and threads are cut out of that ring. The spark plug gets screwed into the ring.

2.) the engine block has threads screwed into it directly.

In my case there was a ring that popped out with the spark plug still attached. I bought a heli-coil kit at the auto parts store. That's a kit with a ring that you use a thread-cutter to cut threads in and then you glue that into the engine block.



I asked my mechanic how that would do and he said that is never the best way to do things. Inevitably they get worn out with heat and you have to glue them all over again. Sure enough, that happened to me so I junked the car and bought a new one.

The only way I can think that you need that much work done on your car is if the cam shaft was somehow bent due to uneven pressure from the rest of the spark plugs. All the spark plugs are firing except for the one that came out so it gets off.

The correct option is to replace the head, Like said earlier it was the a cause of someone from replacing it before(cross-thread, not using anti-sieze on the spark plug). Using a heli coil is only temporary.

Ok did a lil research on it. That engine is 1 of the most exotic they have made. The cylinder head is also the exhaust manifold and its all under a lot of complicated stuff.
Hence the 4k price to replace the head...which is aluminum and to the best of my knowledge cant be heli coiled. It could be welded and re threaded but i imagine there is a lot of risk of warpage.
I would find a non dealer import only repair shop...and see if they cant get a head from a salvage yard or even an entire motor. may still run u a few grand but there is no good news in this 1.....

Thanks for the replies.

I was told by the Honda dealer that there were still the original spark plugs installed at the factory.

It sounds like when it "jumped out" parts of the spark plug got into other areas of the engine doing pistons and cylinder head. Before they total took it apart the dealer suggested replacing the spark plug and the coil for about $300 but they could visually see damage to the piston. They did a leakage test and found no leakage. They thought that might be do the job.

I thought it was a dumb plan that would only lead to problems down the road. I called Honda and issued a complaint. Then I asked for a regional manager from Honda. The original estiamte was $1500 to replace spark plug, coil and fix the piston. Honda agreed to pay $800. Then when they took the engine apart they said there was pitting in the head and thats when the price went to over $4,000. I think there may be a design flaw...this shouldn't be happening. Honda agreed to keep my participation at $700. This is probably cheaper than doing a recall. Mine just so happened at a low miles but if it happened at say 100,000 miles then they would just say well the car has 100,000 miles on it these things can happen. The dealer alos said if we went the cheap route and something happened in the future Hinda may not be willing to help at all.

At 105,000 miles there is a major maintence where they replace the timing belt and water pump and the spark plugs. Costs about $1,300 at the dealer. Since they have the engine all apart I am having them replace the water pump and timing belt now for $350 and they should be good for another 100k miles.

What a pain...I paid extra for a Honda because it issuppose to be high quality.

What is the world coming too...buy a Honda and you can't go forward because of the engine or buy a Toyota and you can't stop because of the brakes!!!

Brother, it reads to me like Honda is providing some pretty amazing customer service when weighed against the potential outlay you could otherwise face. Pay out your $700 max exposure and enjoy what should be a solid engine performance for several years ahead.