Exhaust bolt change

[amcamc]

Hi everyone,
I recently changed my spark plugs and coil packs on my Carrera 4S to cure a misfire. ( coils were knackered )
While I was on my back under the car I was looking at the various bolts that hold the exhaust together, and they are all very rusty, some to the point where you can no longer make out the facets of the nuts ?
I was toying with the idea of changing all of the bolts for new stainless ones, to enable easy removal in the future if needed, however the manifold bolts scare the hell out of me.
I am sure looking at the state of them that a large number will just shear off, and I think it will be too hard to rectify while laying on the garage floor ?

What do you guys recommend ?
The exhaust is not blowing or leaking at the moment, do I just leave it until it needs changing or am I better off doing it now before they get worse ? ( if that's possible !! )

 

[Motorhead]

A common enough problem according to posts on here and elsewhere Andrew.

You may be able to locate a local specialist familiar with the task of removing troublesome studs from the cylinder heads in-situ. You could try contacting a local Porsche Independent to see if they can recommend someone in your area.

Other than that you're into lying on your back for hours on end struggling to remove the studs, having soaked them in advance with copious amounts of releasing compound.

Good luck..!

Jeff

 

[amcamc]

A common enough problem according to posts on here and elsewhere Andrew.

You may be able to locate a local specialist familiar with the task of removing troublesome studs from the cylinder heads in-situ. You could try contacting a local Porsche Independent to see if they can recommend someone in your area.

Other than that you're into lying on your back for hours on end struggling to remove the studs, having soaked them in advance with copious amounts of releasing compound.

Good luck..!

Jeff

Thanks for the reply Jeff

I would maybe tackle the Cat to silencer bolts (6) and also the sleeve bolts (4), It's just the manifold bolts that I'm not keen on touching.

Part of me says leave well alone until the exhaust needs changing, but will the bolts just be impossible to do if I leave them even longer?

 

[irb26]

Hi
I'd be inclined to leave the head studs alone unless you need to take off the manifolds.
I have removed a number of these and about 50% of them break off if the car is over 10 years or so old - unless they have been changed before, or you take steps to ease there removal.
They can be drilled retapped etc but it isn't a very nice job with the head still on the car.
Thanks

 

[997Mike]

Give RGC Porsche Brackley a call speak to James , he recently did mine

Mike

 

[amcamc]

Give RGC Porsche Brackley a call speak to James , he recently did mine

Mike

Cheers Mike,
I'll give him a shout, although a bit of a treck from Northumberland to Brackley

Were you changing your manifolds or was it general housekeeping ?
Did many of your bolts shear ? be interested to hear.
Andrew

 

[Hacki]

A friend of mine is a Porsche indie here in Germany, the problem is common, indeed. From what I´ve seen in his workshop I wouldn´t touch anything as long as the system is working. The bolts will probably shear up to 50% or more. It´s all rust and junk now anyway, so leave it until it´ll need changing. That´s what I recommend.

Cheers,

Hacki

 

[chips]

Hi,
This task is not for the faint hearted as I changed these bolts on my 997 C4S back in August. Out of the 12 bolts two of them sheared flush at the head (one on bank 1 and the other on bank 2) which had to be drilled and tapped out. I would recommend have them replaced by Porsche Specialized unless you are prepared to spend several hours under the vehicle. If you are attempting to do it yourself then need the following items:

1. Penetrating Fluid ( I used ATF (automatic transmission fluid ) and acetone 50:50 ratio. You need to apply this several times over a period of days and heating the bolts in between applications (allow to cool before applying penetration fluid)
2. Butane torch (heating up the blots)
3. Template for drilling and tapping ( I used metal flat plate 12 mm thick and transfer hole dimensions from exhaust header) or you can purchase a designated template atwww.porscheshop.co.uk/996-997-boxster-exhaust-bolt-repair-kit-including.html
4. M8 tap
5. M8 tapping drill (i used 5 mm and 6 mm drill before using tapping drill (6.9 mm))
6. Torque wrench (header bolts torque setting 17 ft/lb)
7. New set of exhaust header bolts M8x28 (use Porsche bolts as they made of harden steel and not stainless steel)

Hope the above info helps you, Good Luck

Dick

 

[jmaddox]

I was worried about my manifold bolts but researching all the forums the consensus is to leave them alone. Some independents have said they very rarely have to deal with leaks or failures because of these rusting through.

 

[amcamc]

Hi,
This task is not for the faint hearted as I changed these bolts on my 997 C4S back in August. Out of the 12 bolts two of them sheared flush at the head (one on bank 1 and the other on bank 2) which had to be drilled and tapped out. I would recommend have them replaced by Porsche Specialized unless you are prepared to spend several hours under the vehicle. If you are attempting to do it yourself then need the following items:

1. Penetrating Fluid ( I used ATF (automatic transmission fluid ) and acetone 50:50 ratio. You need to apply this several times over a period of days and heating the bolts in between applications (allow to cool before applying penetration fluid)
2. Butane torch (heating up the blots)
3. Template for drilling and tapping ( I used metal flat plate 12 mm thick and transfer hole dimensions from exhaust header) or you can purchase a designated template atwww.porscheshop.co.uk/996-997-boxster-exhaust-bolt-repair-kit-including.html
4. M8 tap
5. M8 tapping drill (i used 5 mm and 6 mm drill before using tapping drill (6.9 mm))
6. Torque wrench (header bolts torque setting 17 ft/lb)
7. New set of exhaust header bolts M8x28 (use Porsche bolts as they made of harden steel and not stainless steel)

Hope the above info helps you, Good Luck

Dick

Thanks for the detailed reply.
i think I’m going to leave well alone for now, and let a specialist tackle them when the time comes!
I might attempt the others in the spring so if I need to remove my pipes for access I will be able to.

 

[amcamc]

I was worried about my manifold bolts but researching all the forums the consensus is to leave them alone. Some independents have said they very rarely have to deal with leaks or failures because of these rusting through.

That suits me !
i might have ago at the other bolts at some point, just in case I need to gain access for servicing

 

[J.C944TurboMan]

Hi there, I bought my first 997 Carrera 2 last year and thought I would treat myself to new improved Exhaust manifolds !
I hit the same nightmare ! Horrible , have left it sat over winter SORN wait till it get warmer to tackle it again
Bolts from manifold to Cats are nasty as well and I believe they are a ball ache in themselves.
No joy if there's no pain

 

[amcamc]

Hi there, I bought my first 997 Carrera 2 last year and thought I would treat myself to new improved Exhaust manifolds !
I hit the same nightmare ! Horrible , have left it sat over winter SORN wait till it get warmer to tackle it again
Bolts from manifold to Cats are nasty as well and I believe they are a ball ache in themselves.
No joy if there's no pain

Hope you get it sorted soon, let me know how you get on !
Think i'm going to leave mine well alone until i'm forced to remove them.

 

[bentley3]

I had the four bolts (two each side) between manifold and cat replaced by OPC and was charged "bargain"£500.
When I queried if this should be a warranty issue, a £200 reduction on further warranty renewal was offered.
Still seems costly for four stainless bolts.

 

[Lancerlot]

I would always recommend obtaining a quotation before having any work done.
It avoids a nasty shock later! []
Regards,

Clive

 

[Blade_uk]

Hi
I’ve managed to remove all18 manifold bolts and 14 exhaust/turbo nuts, turbo’s are being refurbished back very soon, what have you used for replacement bolts ?

cheers
karl