Q – I removed the header pipes on my 2000 Carrera to clean out the secondary air injection ports. Four of the bolts broke off. I am scared that we will have to pull the engine and replace the heads to get them out. What do you suggest? Keith
A – Even using the best methods, the most experienced technician with the patience of a saint, will sometimes snap off bolts. Techs hate it since getting the remains out of the head is one of the worst jobs ever; and you are working upside down. If you tried it at home in your garage, without a hoist, an acetylene torch and an air chisel, you are lucky you did not break even more of them. We expect each broken bolt to take about an hour to drill out cleanly while saving the threads in the head. Note the operative word: cleanly. If you are sloppy with your drilling, if you do not meticulously maintain the center, or if you drill too far, the game is over and you lose. You can ruin the head and be left with a very expensive mess on your hands. Experience, finesse, proper tools, luck and prayer usually get it done. Next time I would pay a pro to do it.
I would like to know why Porsche decided to use bolts into the head instead of the tried and true studs. Was it cost? Ease of assembly? With all due respect to Stuttgart, when we remove header pipe bolts, we replace them with studs and for my money, stainless steel nuts and washers. This is Michigan after all. With stainless, the next time the header pipes need to come off, you will have a fighting chance of doing so without breaking anything. MC