Bolts for coil pack broke in half.. Now what?

Ommynous · Post by **Ommynous** » 08 Jul 2016, 03:19

FOR A 2001 VOLVO S80

Long story short, I tried replacing my spark plugs. The previous ones were el-cheapo brand I bought because of an issue where oil is getting in the spark plug wells. Unrelated.

The 10mm bolts that secures the coil packs to the engine - 3 of them broke in half when attempting to remove. I've attempted to drill them out, but it's not going very well. I still can't get a new bolt in there. I was thinking about using gasket seal or something to the effect, and sealing the coil packs to the top of the engine. I'm aware this will cause damage to the rubber boots that go on the coil packs and hold the spring. But shouldn't I be able to order just the boots for my next tune up?

Oil is getting on top of the engine. It's either blowing out the spark plug wells, or it's the cam seals. Or possibly the oil cap O-ring. I've examined the o-ring, and it's still flexible, with no obvious sign of cracking of wear. Tightening the oil filler cap presents a snug and secure fit. Or so it seems.

PCV crankcase box was just replaced 3,000 miles ago. Dealership conducted a crankcase pressure test(free of charge, thankfully.) They said the pressure is ok. I've also checked for smoke, and none comes out of dipstick hole, but a very slight amount comes out of oil filler cap.

MAIN QUESTION: With all the above in mind, if I "glue" the coil packs to the engine, will this cause pressure to build up and possibly blow a valve or a seal somewhere? This car really isn't worth it. The interior is messed up, the Siren module has gone out with the sunroof stuck open, Have codes for Cam Control, Brake Pedal sensor(With ABs and STC light to follow) and a code for a large EVAP leak. Not even the AC works in this POS and 2 speakers are blown, with a drivers window that falls off the track if you try rolling it down. If the engine goes, the car goes to the scrap yard.

Thank you so much for any and all replies. I really don't know where to start with this vehicle. I know the previous owner didn't take proper care of the vehicle, and wasn't changing the oil filter regularly, or at all. When I initially removed the PCV box(crank case) about 2 quarts of BLACK oil spewed out. After I had changed the oil several times.

jbkeene · Post by **jbkeene** » 08 Jul 2016, 05:39

so why do you still have this car?

Cees Klumper · Post by **Cees Klumper** » 08 Jul 2016, 23:58

I can't imagine sealing the coil packs in place as you describe could do anything to the engine, cause pressure or what have you. The spark plugs are supposed to effectively seal off the combustion chamber. Have you tried a bolt extractor? Strange that these small bolts were in so extremely tight that they broke off. Good luck with the various fixes, once you get it sorted it should stay fixed for a long time.

Ommynous · Post by **Ommynous** » 09 Jul 2016, 04:28

@jbkeene, I really don't know. I bought it vs a '98 toyota corolla, and now look where I'm at. It's a love hate thing..

@cees klumper I have not tried a bolt extractor. I will soon, but it seems like a kit would be pricey, and money is an object right now. Vs a little $4 tube of gasket seal

Post by **June** » 10 Jul 2016, 17:50

I wonder if you could rent the bolt extractor? At least with the Volvo you got a way safer car with more safety equipment with a S80 than any 1998 car. I had a similar strange oil leak at the cap on my 1998 V70 GT at around 150,xxx miles and it would pass the suction test at idle and I would drive it away and shortly later oil be on top of the engine again. Finally Volvo did a test under boost an it failed. The box was fine, but some fitting hose had a partial block in it. They replaced the hose assembly and problem solved. It was annoying for a little while until the problem was figured out. That was a 5 cylinder car turbo. I traded it in shortly later (6 months or so) due to a reoccurring transmission problem so I can't say how long it stayed fixed beyond that. June

Ommynous · Post by **Ommynous** » 11 Jul 2016, 14:33

Really, that's all it was? A clogged up hose? That makes a lot more sense now that I think about it. It's also note worthy that the oil I keep finding is dirty oil, even when I just change the oil. The dipstick reads at full level, so I'm just not sure where all this extra oil is coming from, so it would seem. I will replacing the hosing, just for good measure.

Post by **June** » 12 Jul 2016, 14:13

The way it was explained to me that these hoses and fittings have air from inside the engine routed to be reburn in the cylinders. Carbon was building up in the hoses like the clogging of arteries in a person not allowing enough flow of air under boost causing pressure to build at higher rpm making oil push out in several places. That's how my mechanic explained it after he figured it out what was going on. That engine had a lot of black carbon under the oil cap by 150xxx even though I always changed the oil every 3000 miles I was shocked when I saw the old cap which was replaced as one of the fixes for the leak before the hoses which really stopped the leaking oil all together. I really hope you get to the bottom of this and can start enjoying your car.