Cam cover leak on bank 1? - 986 Forum - The Community for Porsche Boxster & Cayman Owners

greenheckler · 12-14-2013, 05:34 AM

2001 Base with 93K mileage

Can someone provide additional advice on:

1. Whether this is something I can DIY and if there is a tutorial or tips on doing it myself? Pictures?
2. Is this something I need to fix quickly? Indy says that the oil may drip on the exhaust and causing smoke / potential fire.

Thank you

JFP in PA · 12-14-2013, 07:00 AM

Quote:

Originally Posted by greenheckler

2001 Base with 93K mileage

Can someone provide additional advice on:

1. Whether this is something I can DIY and if there is a tutorial or tips on doing it myself? Pictures?
2. Is this something I need to fix quickly? Indy says that the oil may drip on the exhaust and causing smoke / potential fire.

Thank you

It can be done as a DIY, but to remove the cam cover, you will need special tooling to hold the cams (the cover normally does this). You will also need to scrupulously clean the cover and cylinder head mating surfaces, and use a very small bead of Loctite 5900 to create a new seal.

thstone · 12-14-2013, 07:43 AM

This is a common issue and I have the same problem on my 996. I got a few quotes (expen$ive), so I have also been looking into it as DIY.

There is a DIY here, but its performed with the engine removed from the car so not exactly what we're looking for but it does show the key steps:
http://www.pelicanparts.com/techarticles/Boxster_Tech/16-ENGINE-Camshaft_Swap_and_Chain_Tensioner/16-ENGINE-Camshaft_Swap_and_Chain_Tensioner.htm

From what I've read, we'd need special cam holding tools (which are not the standard cam locking tool). This is discussed in the Pelican link above and again here: pulling cam covers

Also, many people have said that its highly likely that the cam tensioner pads will also need replacement. Thus, I worry that this is one of those jobs that can grow in scope and difficulty depending on what is found.

I've also read that a few people ended up with the covers leaking worse than before they started.

Right now, I am leaning towards having a shop do mine but the cost keeps me thinking that maybe I can DIY it and save a bundle.

davedeck · 12-14-2013, 01:26 PM

I have the special cam and liming tools for sale. One is the Pelican tool that sells for $235 and the other is the complete set from Baum that sells for $600. Make me an offer. Used once and I will never tackle the job personally.

woodsman · 12-14-2013, 02:02 PM

I think the 'book' says it's a 4 hr job per side for a Porsche pro.

JFP in PA · 12-14-2013, 03:07 PM

Quote:

Originally Posted by davedeck

I have the special cam and liming tools for sale. One is the Pelican tool that sells for $235 and the other is the complete set from Baum that sells for $600. Make me an offer. Used once and I will never tackle the job personally.

Cam timing tools will not work for this, you need the cam retention tools which are completely different.

thstone · 12-14-2013, 04:33 PM

Quote:

Originally Posted by woodsman

I think the 'book' says it's a 4 hr job per side for a Porsche pro.

That usually means that its a 6 hour job for me PLUS $300 for a part that I break PLUS $150 for another tool that I need to install the part that I broke. That is the life of a DIY mechanic.

greenheckler · 12-15-2013, 07:20 AM

Thanks everyone. I forgot to mention that my indy quoted me roughly $600 for the job. Based on the feedback, the price doesn't sound too far off from the number of hours you all have estimated.

healthservices · 12-17-2013, 07:36 AM

The tool is not hard to make.

Gilles · 12-17-2013, 10:58 AM

Quote:

Originally Posted by thstone

That usually means that its a 6 hour job for me PLUS $300 for a part that I break PLUS $150 for another tool that I need to install the part that I broke. That is the life of a DIY mechanic.

The experience: Priceless :-)
LOL...

.

The Radium King · 12-17-2013, 11:15 AM

before you tear into a cam cover replacement, have you confirmed that it isn't in fact your spark plug tubes that are leaking (a common problem)? also, have you re-torqued the cam cover bolts (in proper sequence) to see if that stopped the leak? have you assessed how much is actually leaking? it is typically just a drip, so risk of fire is small and most live with it.

otherwise, as per stone, you get on a slippery slope where you should think about updated tensioner pads, etc., while in there.

san rensho · 12-17-2013, 11:51 AM

Just take out the 3 or 4 lower cam cover bolts one at a time, clean the bolt meticulously as well as the threads in the head, goober the threads from the head to halfway down the bolt with gasket maker (permatex red works) and reinstall using the proper torque. I did this and while I still get a tiny weep, the leak has almost gone away.

There are also new spec micro-encapsulated bolts that you might want to try.

greenheckler · 01-15-2014, 08:37 PM

I ended up paying one of our forum members to perform this fix since I did not have the time to do it myself. My spark plug tubes were relatively new (recent DIY) so that was not the issue although the area still had a lot of evidence of the tube leak prior to my install. In addition to resealing the cam cover (passenger side), I also had the oil pan resealed since that was leaking. I'll have to keep an eye on it to see if it continues to leak. See before / after photos below.

For those of you in Southern California (specifically Orange County), Allen (aka healthservices in this forum), did a nice job of resealing and cleaning up the area. Feel free to reach out to him via PM if you need some help. He also works on BMWs and Mercedes.

BEFORE

AFTER

OIL PAN

thstone · 01-16-2014, 04:15 PM

I finally had my 996 cam covers resealed by my local indy. $1100. They did a perfect job but it was co$tly.

Jamesp · 01-16-2014, 04:58 PM

Quote:

Originally Posted by thstone

I finally had my 996 cam covers resealed by my local indy. $1100. They did a perfect job but it was co$tly.

ouch. .

san rensho · 01-16-2014, 05:52 PM

Quote:

Originally Posted by thstone

I finally had my 996 cam covers resealed by my local indy. $1100. They did a perfect job but it was co$tly.

How bad was your leak? Did they also replace the tensioner pads and retime the cams when they were there?

thstone · 01-18-2014, 06:45 AM

Quote:

Originally Posted by san rensho

How bad was your leak? Did they also replace the tensioner pads and retime the cams when they were there?

It started as a seep and progressed into a fairly constant drip. The problem was that the drip fell directly on the exhaust headers so I had smoke coming out the back! It looked like the car was getting ready to go up in flames. Didn't do anything other than reseal the covers.