HELP! Cross thread on ignition coil bolt.

[jpatel15]

I have a 2004 Cayenne turbo and the bolt that holds one of my ignition coils in went in crooked when i was replacing it and now the first half of the threads in the hole are damaged and I can get the bolt to go in straight. Can anyone help. PLEASE!

[Mike_A]

don't know what the bolt size and thread is (maybe a 6 or 8mm x 1.5), but the easy way is to take it to your local auto parts store and get a tap and a tap handle of the proper size and thread. A starter tap (as opposed to a bottom tap) will proabably work best depending on the depth of the hole..to be safe get both. Then use your best machinist steady hand to retap the hole. You will know you have done a good job if and when your the tap turns freely after a few turns ( when you have succeeded in matching the remaining good threads). Don't jack it up! Practice on a hole in a piece of aluminum and you will see what I mean. Either that or have somebody who has done this work before stop over for beer.

[Loren]

The bolts are M6 x 16.5.

[wirunner]

I have a 2004 Cayenne turbo and the bolt that holds one of my ignition coils in went in crooked when i was replacing it and now the first half of the threads in the hole are damaged and I can get the bolt to go in straight. Can anyone help. PLEASE!

I actually broke the screw having the same problem on a previous CS 2004. Believe it or not, the coil stayed in fine with no screw at all :P

[jpatel15]

The coil is pretty solid even without the bolt and I have driven it for a test drive without a misfire, but I'm taking it in tomorrow for a specialist to tap the hole just to be on the safe side.

thanks for all the great help guys!

[1schoir]

I have a 2004 Cayenne turbo and the bolt that holds one of my ignition coils in went in crooked when i was replacing it and now the first half of the threads in the hole are damaged and I can get the bolt to go in straight. Can anyone help. PLEASE!

I actually broke the screw having the same problem on a previous CS 2004. Believe it or not, the coil stayed in fine with no screw at all :P

Those screws are made of soft enough metal that you can drill a hole in the middle of them, starting with a very small diameter drill bit, going to the next couple of sizes and then using an "Easy-out" to get the remants of the screw out. Using a "left-handed" drill bit might get it out completely while you are drilling, if you get lucky.

Since those screws are not exposed to the same kind of heat that exhaust manifold bolts are, they probably require a lot less force (torque) to back them out. Here's a little saga with tips on removing snapped bolts: http://www.ppbb.com/phorum/read.php?19,155...140#msg-1552140

Regards, Maurice.