15 captured repliesPartial discussion capture · Source accounts, not a confirmed diagnosis
THIS DISCUSSION / SOURCE-DERIVED OVERVIEW
Discussion summary
YOUR RESEARCHCoil pack bolts sheared off
Leading reported evidence
Clean threads of the location screws
Performed · outcome unconfirmed
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
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 performed work without a confirmed outcome
1
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
After i removed the coil packs to change the plugs I cleaned all the threads of the location screws then wire wheeles the heads and apinted them in high temperature paint.
Leading evidence: 'Clean threads of the location screws' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Clean threads of the location screws' (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.
Source reports, not a diagnosis or a success probability. Counts refer to discussions and can overlap.
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 performed work without a confirmed outcome
1
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
What i have found, having recently replaced an 996 engine and other bits and bobs is that every bolt on a Porsche oxidises and the nuts just rot!
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 performed work without a confirmed outcome
1
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
When reassembling them i used copper slip on the threads.
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 performed work without a confirmed outcome
1
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.
Discussions that contain suggestions
1
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.
Suggestion
This is not the sort of thing you would expect if this was an everyday fairly new car which only needs an oil change/air co re gas/ cabin filter change but as cars get older one has to become adept with the spanners/hammer/gas torch/tap/elastoplast to continue driving.
These are separate views of the same evidence. Frequency alone does not establish a fix, and these counts must not be added together.
Clean threads of the location screws
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Discussions that performed work without a confirmed outcome
1
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
After i removed the coil packs to change the plugs I cleaned all the threads of the location screws then wire wheeles the heads and apinted them in high temperature paint.
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.
Suggestion
This is not the sort of thing you would expect if this was an everyday fairly new car which only needs an oil change/air co re gas/ cabin filter change but as cars get older one has to become adept with the spanners/hammer/gas torch/tap/elastoplast to continue driving.
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.
Suggestion
This is not the sort of thing you would expect if this was an everyday fairly new car which only needs an oil change/air co re gas/ cabin filter change but as cars get older one has to become adept with the spanners/hammer/gas torch/tap/elastoplast to continue driving.
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.
Suggestion
When the time comes to have my 991`s plugs changed I will ask for all fixings removed in the process to be replaced with new, in the hope that in so doing will reduce the chance of them shearing at some future time, call it preventative maintenance if you will, and in that regard I might have expected such a process to be a standard procedure in any worthwhile maintenance schedule...
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.
Suggestion
After i removed the coil packs to change the plugs I cleaned all the threads of the location screws then wire wheeles the heads and apinted them in high temperature paint.
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.
Suggestion
When the time comes to have my 991`s plugs changed I will ask for all fixings removed in the process to be replaced with new, in the hope that in so doing will reduce the chance of them shearing at some future time, call it preventative maintenance if you will, and in that regard I might have expected such a process to be a standard procedure in any worthwhile maintenance schedule...
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.
Suggestion
As you describe spangled, I mig welded nuts on to the remaining threads of the broken set screws but even at that I still had to apply a gas welding torch to the area of the housing and whichever screw I was working with, applying no more than the maximum torque/pressure on the screw that I would to any m6 fixing applying heat till it just began to move then taking the heat off till it seized up again then repeat the process again and again till the fixing was removed completely, not a fun task ...
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.
15 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
911uk: 1 discussions
0 evidence records excluded for query context · 0 excluded by outcome qualification · 0 adjusted by outcome qualification.
1 acknowledgements have no verified action link; they do not establish a repair result.
Outcome without a verified action link
I suspect this may cause water ingress issues, or even result in the remaining bolt shearing, so I need to get this fixed.
So I got my 2003 996 Carrera 4 back from its annual service today including 4-yearly spark plug change, and was told two of the bolts securing coils packs have sheared off. Thankfully each was on a different coil pack, but that means I've got two coil packs only each only secured by one bolt. I've had quick look at them and the remaining bolt isn't securing them properly, it's easy to wiggle them round with little force. I suspect this may cause water ingress issues, or even result in the remaining bolt shearing, so I need to get this fixed.
Has anyone tackled this before? Any advice gratefully received.
Can you risk (I guess you're going to have to at some point..) undoing the other bolts to remove the coil packs and see how much of the broken bolts may be sticking out? You may be lucky and have enough to purchase on and remove them, otherwise it's obviously a drill & re-tap job....
Not the end of the world if you have to...
I should be able to remove the other bolts as it's only been a couple of days since they were removed to change the spark plugs. I very much doubt it will be possible to remove by using a vice grip on the remains of the bolt (since otherwise my Indy Porsche specialist would have done this), so I suspect it will require a drill-out or screw extractor.
I'd be interested if anyone has done this before and managed to do it without removing the engine to get better access for a drill.
What he said :yeah:
What i have found, having recently replaced an 996 engine and other bits and bobs is that every bolt on a Porsche oxidises and the nuts just rot!
I have sucessfully ground and drilled and tapped most things, not that i like it, but it is because i have a couple of 20 year old cars that I have to do it.
It helped that i have a means of getting the car to a working height and am not afraid to use a drill.
If the worst happens then for a few bob i can insert a helicoil and we are back in business.
This is not the sort of thing you would expect if this was an everyday fairly new car which only needs an oil change/air co re gas/ cabin filter change but as cars get older one has to become adept with the spanners/hammer/gas torch/tap/elastoplast to continue driving.
In other words, welcome to classic car ownership.
I have to admit that I do become a tad frustrated when I read of Porsche nuts bolts and screws shearing, and martin t`s post did nothing to ease my mind..!
I have not worked on any water cooled Porsche other than a friends 928 many years ago on which the water pump housing had sheared set screws, and what fun that was..I salute any who find it a simple task to drill out steel screws broken off in an alloy housing, without the use of a jig of sorts to stop the drill skipping off the the side and into the alloy. I guess in the case of the coil packs fixings perhaps using the coil pack fixing holes as a guide might work..?
When the time comes to have my 991`s plugs changed I will ask for all fixings removed in the process to be replaced with new, in the hope that in so doing will reduce the chance of them shearing at some future time, call it preventative maintenance if you will, and in that regard I might have expected such a process to be a standard procedure in any worthwhile maintenance schedule... :?:
Not the easiest location to get to, but welding a nut to the remains of the bolt and then using a spanner on that can work well. Of you have enough space to get in with the welder, this is a lot less tricky than trying to drill out an M6.
The heat from welding can really help with unseizing the threads and the aluminium will be unaffected.
Replace with stainless fasteners in unstressed situations like this.
The 928 water pump fixings were 6mm too. As you describe spangled, I mig welded nuts on to the remaining threads of the broken set screws but even at that I still had to apply a gas welding torch to the area of the housing and whichever screw I was working with, applying no more than the maximum torque/pressure on the screw that I would to any m6 fixing applying heat till it just began to move then taking the heat off till it seized up again then repeat the process again and again till the fixing was removed completely, not a fun task ... the alloy pump housing that was part of the 928 block..one slip of overheat and the block could have been scrapped.. I guess the worst case in the OP`s scenario is new valve cover... :?:
Just to add to my contribution:
After i removed the coil packs to change the plugs I cleaned all the threads of the location screws then wire wheeles the heads and apinted them in high temperature paint.
When reassembling them i used copper slip on the threads. This means that in years to come the screws will not have rusted, the threads will still be lubed and the heads will not have rusted away.
I could have just bought new screws and copperslipped them but there was nothing wrong with the ones that came out that a bit of prep could not improve.
The old ways still work
Beware Copperslip with Ally, it makes corrosion worse, you really should use Aluminium grease or one of the more expensive inert greases.
Have a look on line to find more on the subject.
Thanks for the heads-up Martin....I am pretty well versed in the old ways, I operated on a make do and mend way of working for many a year. just that these fixings and others seem to be well known for causing issues such as you experienced and given the likely cost of new...
I think were I doing the job myself I would have new fixings to hand from the outset, and if paying to have it done would specify new fixings to hold the kit in place. Also think deMort suggested that some coils have metal inserts in the fixing holes which adds to the chance of the screws seizing in the head of the coil and the heads breaking off the fixings, followed by struggling to pull the coils out of position..?
I am with you on the use of anti-seize compounds though wonder how they might affect torque values and handle the heat.. :?:
I use this instead of copper slip. V high temperature anti seize paste.
https://tygrisindustrial.com/tygris...ygris-nickel-anti-seize-compound-tg8005-500g/
Mark
