Spark plug wire clips are diabolical

I wanted to replace the plastic spark plug wire clips on the valve covers of my 328 since they were all cracked and brittle. Can't remember the last time I had to fuss so much to replace nickel and dime parts.

On the rear 4-3-2-1 bank, the clips near cylinder 4 were broke off flush with the valve cover, so I ended up picking those stumps out with a deck screw. Since the holes the clips push into are threaded (appears to be M7), if you can get a bite on the plastic stump of the clip somehow, you can spin those out slowly.

The clip near cylinder 2 still had enough left that I could grab that one by hand and spin it out. That one was easy. I did need to remove the flex intake hose for access to replace the clip though, since a small peg needs to be driven into the center of the new clips to lock them in place.

The clip near cylinder 1 was hopeless, and right behind the fuel injection meter/manifold. No way I was going to remove the fuel system, but I was able to carefully angle a 12" long 3/16" drill bit through the fuel plumbing nest and surgically drill out that last clip's stump. To put the new clip in I was able to carefully aim a piece of 1/4" rod through the plumbing to hammer the peg in.

I did discover a trick -- instead of the plastic peg, a 10-24 allen head set screw can be used in the center of the clips to lock them in place (it expands the clip barrel as it goes in, just like a lag shield). I did not need to use that trick on the rear bank, but it would probably be handy on the front bank since there would be no access to hammer the pegs in.

Problem is, I don't see a good way to pick out the old clip stumps on the front bank. I might be able to get a Dremel in there with a right-angle chuck but it looked too tight for that. Has anyone replaced the clips on the front bank with the engine and valve cover still in place, and learned any tricks? If not, those will have to wait I guess, and I'll maybe use some floating clips to organize the front wires.

thanks,
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New clips installed:
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Remnants of the old clips and new clips for the front bank:
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The good thing about using a set screw is that you can turn it deeper into the base of the clip, so that it can't ever come in contact with the wire.

Soldering iron is a good idea to help get the old clip stumps out, wish I thought of that. Could even buy or make a right angle tip for the iron to reach into the holes from the side.

I was surprised Ferrari would use clips like this -- they do not seem to be a good design with those tight pegs. I think a modern variation would use barbed christmas-tree fastener instead, that just pushes into the hole to stay put.

 

That's another great idea!

 

Agree, and I am wondering why it wasn't done when my car got new valve cover gaskets a couple years ago during previous ownership. The mechanic did a nice neat job with spiral wrap but it would have been a great time to put proper clips on. In the grand scheme of things the cost is peanuts if it's done at the right opportunity.

 

Normally the owner spared no expense. I cringed at some of the service records since they seemed to nickel and dime the guy, but during the PPI I learned it was the right way to do things, and they were being thorough/proactive and using original parts. So these broken clips were uncharacteristic of the maintenance history and $$ outlay, but lord knows what else I will find as I go over the car little by little.