Camshaft Green Seal Leaking - 986 Forum - The Community for Porsche Boxster & Cayman Owners

Rdward · 03-08-2010, 04:03 AM

Recently purchased a 99 Boxster one owner, 5 speed with 106k. Really good price = expected problems. CEL was on when I bought the car and these were the codes: 0300,0304,0305,0306, and 1324. After searching here and a few other forums I came to the conclusion that the issue was in the variocam tensioner. I was hoping that is was the solenoid due to this was the easier of my options, however I expected it was the chain guides. It ended up being the guides on the 4-6 side had worn all the way through and the chain had been riding on the metal of the tensioner, also the chain had jumped one tooth. Tensioner replaced along with guides and chain, went ahead and did the 1-3 side which the chain was about to work it's way through the guides too. Also did some other PM work while I was at it: spark plugs, tubes and seals, water pump, thermostat, blah.. blah.. blah.. Needless to say I replaced allot of things that have nothing to do with this post.

I got the car all back together yesterday and started it for the first time. Everything sounded good until I backed the car out of the garage and saw the puddle of oil. Apparently the oil pressure is forcing one of the green cam plugs out of the cover( all the green caps are new). This is only happening on 1 cap and it's on the 1-3 intake side. The pressure seems to be so strong that I can hardly hold it in by hand. My only thoughts is that some how I got some sealant where it didn't belong while reassembling the cam cover. It is a tight work area with the engine in the car so this is likely. Has anyone seen anything like this before.

I have also posted this on the Renntech forum with no responses a few days ago.
Thanks for any responses in advance.

JFP in PA · 03-08-2010, 05:22 AM

The use of too much, or the wrong type of sealant, will cause these plugs to move and leak.............

Rdward · 03-08-2010, 09:34 AM

I thought the plugs were supposed to be installed dry? The sealant I used for the cover was from Sunset and it's what they suggested I use. I did try sealant on the plug(after about six dry runs with it just blowing the plug out) just to see if it would hold. It lasted about 2 minutes and then the oil pressure forced it back out.
Is there any way that oil can get in, but I clogged up the way it goes out with to much sealant? I also was thinking that the plug could be defective and a little smaller than spec.

JFP in PA · 03-08-2010, 10:21 AM

Quote:

Originally Posted by Rdward

I thought the plugs were supposed to be installed dry? The sealant I used for the cover was from Sunset and it's what they suggested I use. I did try sealant on the plug(after about six dry runs with it just blowing the plug out) just to see if it would hold. It lasted about 2 minutes and then the oil pressure forced it back out.
Is there any way that oil can get in, but I clogged up the way it goes out with to much sealant? I also was thinking that the plug could be defective and a little smaller than spec.

Yes, we've seen this problem before; the issue was too much sealant applied to the cover, especially near the end cam journal that was causing a build up of pressure that was pushing out the cam plugs (installed dry)..............use the sealant sparingly........

Rdward · 03-08-2010, 12:07 PM

That side of the engine was a tighter fit than the other. I almost remember putting more sealant on that side just in case I smeared some against the cam while reinstalling it.

Thanks for your help, I'll try resealing it this weekend.

Jake Raby · 03-08-2010, 05:51 PM

These should not give difficulty with leaks, with sealant or without.
When these persistently leak I question the integrity of the expansion plugs at the ends of the camshafts. The oil volume passes through the cams and if these plugs are dislodged the pressure will force oil out or even dislodge the green plugs completely.

Rdward · 03-08-2010, 07:26 PM

Jake, that is what's happening. It is pushing the plug all the way out, not just leaking around the plug. There was one time where I heard the plug smack against the firewall. I'll try replacing it before I pull the cover again. That will definitely be the easier fix.

Jake Raby · 03-09-2010, 04:49 AM

The cam will have to be removed, drilled and tapped for a thread in style plug. We do this on our engines with great results.

seningen · 03-09-2010, 08:09 AM

I had this on one of my rebuilds.

turned out to be too much sealant on the cam cover,
blocking the proper flow of oil which blew the
green plugs many times.

finally took the head cover off - -cleaned it up and sparingly
used sealant -- no problems since.

also you might want to pull the oil cover and check the
strain for sealant.

mike

clearyje · 08-04-2013, 03:25 PM

I just finished replacing the camshaft solenoid on 1-3 side and everything works great except one of the dreaded green plugs keeps popping out.

What sealant works best on these plugs? Thanks!

Paul · 08-04-2013, 03:33 PM

No sealant works best.

clearyje · 08-04-2013, 03:44 PM

I've cleaned and replaced the one (new) plug 5 times and after running the engine about 2 minutes the plug begins to slowly back out. I'm ready to apply something that will help hold the plug in place.

JFP in PA · 08-04-2013, 07:16 PM

Quote:

Originally Posted by clearyje

I've cleaned and replaced the one (new) plug 5 times and after running the engine about 2 minutes the plug begins to slowly back out. I'm ready to apply something that will help hold the plug in place.

You do and you will have even more problems. The green plugs go in dry, no sealant of any kind. Your problem lies elsewhere as noted above; too much sealant on the cam cover, excess cover sealant blocking an oil passage way, etc.

clearyje · 08-05-2013, 04:33 PM

Removed cam cover. I applied sealant to liberally and am now cleaning up the overage. Some of the sealant found its way into the oil channels and clogged the oil hole on the exhaust cam.
If you don't succeed at first try again.
This time I apply a thin coat of sealant.

JFP in PA · 08-05-2013, 05:13 PM

Quote:

Originally Posted by clearyje

Removed cam cover. I applied sealant to liberally and am now cleaning up the overage. Some of the sealant found its way into the oil channels and clogged the oil hole on the exhaust cam.
If you don't succeed at first try again.
This time I apply a thin coat of sealant.

Not a thin coat, just a very tiny bead of Loctite 518 is all it takes.....

clearyje · 08-05-2013, 06:25 PM

Where can I find loctite 518. Thanks!

JFP in PA · 08-06-2013, 03:25 AM

Quote:

Originally Posted by clearyje

Where can I find loctite 518. Thanks!

We get it from a local supplier that carries the line, give some parts stores a call, it is very popular. It is also available online.

clearyje · 08-07-2013, 11:14 AM

Called all the part stores around Atlanta with no success. Finally, Graingers in Marietta, Ga came thru @ $24 a tube. Now off to install cam cover. Thanks for your help.