16 captured repliesDiscussion pagination complete · Source accounts, not a confirmed diagnosis
THIS DISCUSSION / SOURCE-DERIVED OVERVIEW
Discussion summary
YOUR RESEARCHSnapped off bolt while replacing AOS
Leading reported evidence
Replace with an aluminum bolt by a p.o
Performed · outcome unconfirmed
No successful repair reported for this finding.
0
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0
Unsuccessful attempts
1
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Performed · outcome unconfirmed
Fwiw I don't think Porsche used aluminum bolts on intake manifolds from stock - it may have been replaced with an aluminum bolt by a p.o.
Leading evidence: 'Replace with an aluminum bolt by a p.o' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Check bottom side of the intake manifold' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
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Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
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0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Performed · outcome unconfirmed
Fwiw I don't think Porsche used aluminum bolts on intake manifolds from stock - it may have been replaced with an aluminum bolt by a p.o.
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
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Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that contain suggestions
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0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
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0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
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Counts describe captured discussions, not unique people or a diagnosis. Author identities are not reliably stored. Exact duplicate evidence is counted once across matching discussions; one discussion counts at most once per action/state. Multiple repairs reported together remain a combination. Suggestions and failed attempts do not establish a fix. Matches cover whole discussions and can include related faults, model variants and incomplete threads.
16 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
Rennlist: 1 discussions
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Generation: 20261026T183130Z · outcome-qualification-6. Deterministic extraction; no AI model inference. How we use sources
Help!
My 996.2 Carrera was exhibiting all the signs if a bad air oil separator (AOS). White smoke, especially on start, whinny engine, etc.
So, my friend and I decide to tackle replacing the AOS. About 6 hours into the project (what a total bear), we are trying to take out the last bolt (furthest in of course) on the driver side air plenum. And... it snaps off. Now (see the picture) I have the air plenum out and the AOS removed, but I'm trying to decide what to do about the broken bolt. It's an aluminum bolt in an aluminum header. Any ideas? Anyone experience this too? It seems strange for an aluminum-to-aluminum part to corrode in place.
Right now the car is clogging up the wife's garage space and the clock is ticking...
Yep... that's within my plan to drill it out. Clearance is an issue, but with a 90-degree drill we should get it. Another day though. I'm pretty frustrated now.
That sucks, but it could always be worse. Take a deep breath, refocus and then come back to it. If that's the intake manifold in the picture, I'd put some tape over it to prevent anything ending up in your engine - especially metal shavings from the drilling.
stuff cheap clean shop rags into clean heavier gauge Ziploc bags
you'll get a complete seal and you can remove any debris with
a vacuum before removing the 'plug'
I did this on my 928 when I had a lot of the air intake stuff for an extended period of time
there was a big opening just waiting for something to drop
into it
Check the bottom side of the intake manifold. I think that may be a flange where the bolt goes through and is exposed on the bottom side. If s you may be able to grip it with some vice grips and either back it out enough to grip it on the top side with vice grips, or screw it through the flange and remove it that way.
Tried that. The broken bolt is nearly flush with the top and does not extend below the bottom of the intake manifold. Nothing to grab onto (though we tried from the top anyway.)
I'm planning to stop by the Porsche dealership today in hopes they will have a new aluminum bolt (assuming we can drill out the old one). But I may end up fabricating something to fit instead...
my wag is that sucker is froze in there and just keep drilling with a larger and larger bit until it is VERY thin .plan on getting a tap for the threads DO NOT BREAK OFF AN EASY OUT .....i would not even try one . getting the drill centered helps much and take your time
Fwiw I don't think Porsche used aluminum bolts on intake manifolds from stock - it may have been replaced with an aluminum bolt by a p.o. though. I believe the stock bolts are M6 x 1 x 25 easy enough to look up though...good luck with it!
Looks like they are M6 x 35. See this diagram:
http://www.autoatlanta.com/porsche-p...section=107-10
I ordered two from the local Porsche dealership. $1.39 each...
Good news. After well over 100 miles, still no smoke. No smoke on start. No smoke in the first few minutes. No smoke period. It seems the air oil separator is truly a problem part and replacing it remedies a fair number of smoke problems. I like a great running 911!
This is a source reference. Confirm exact model applicability in the original material.
