Installing Cam Spray Bar Plugs

[Ed Cavalier]

I'm finally putting my engine, a 2.7, back together and I just spent an inordinate amount of time putting-in the cam spray bar plugs. I had to put-in three. After driving each one in as far as it would go, each one still protruded a good 1/16" inch. I took them down flush with a file and sanding block, but that was a lot of effort. Even though I'm done, I'm curious about how I should have gotten those plugs in. The factory manual mentions that the plugs should be pressed-in 3 mm below flush. Perhaps the trick is to have a hydraulic press that can "swallow" an 18" long cam carrier? Lacking such a press, anyone know the way to do it?

[rcwaldo]

I know its a little after the fact, but heating the cam tower to at least 200F and freezing the plugs would have helped.

A little green loctite on the plugs adds a safety measure.
You can also stake them into place with a small punch.

Please be sure you got those spray rails clocked correctly as they can be installed upside down.

Its great you removed them since this is the only proper way to ensure there isnt junk in there.

I did find all kinds of small debris in these very tubes when I rebuilt the 2.7 a few years ago. Great piece of mind

[afterburn 549]

If its not too late...consider a pipe plugs (will be much ezer next time too!!)......that way should you have to take it apart again =ez

[Jim Williams]

Ed,

The factory manual mentions that the plugs should be pressed-in 3 mm below flush.

I think the spec on seating the plugs is to go 0.3 mm below the surface. Maybe that is what you intended to type? They shouldn't be that much trouble to install. I use some Loctite 574 as a sealant on the plugs, and tap them in with a hammer and small drift.

[Ed Cavalier]

Thanks all!

Yes Jim, I meant 0.3 mm not 3 mm. I guess the key is that they need to be flush, or recessed, so as not to interfere with the chain case. I'm surprised that yours went in easily. I was giving them some pretty healthy blows with a hammer and brass drift but they just wouldn't get in there. I did coat them with Loctite retaining compound. Certainly Chris' suggestion to heat the carrier and cool the plug would have helped. If I go there again, I might go with afterburn 549's pipe plug idea. (Which is an idea that Walt Fricke also espouses. I believe that Walt goes into his engine quite a bit more often than I ever want to!) Hopefully I won't be down this road again anytime soon!

Regards,
Ed

[Alan Cottrill]

Originally posted by afterburn 549
If its not too late...consider a pipe plugs (will be much ezer next time too!!)......that way should you have to take it apart again =ez

anyone done this? what size plug would I use 1/8" NPT?

thanks,

[afterburn 549]

I have done it ,pc of cake!.....go dwn to Ace and get 4 plugs drill and tap, I for get what size ,but in the end you will be happy about the job