Cam Shaft Plugs Keep Blowing Out

[makegoodchoices]

Wayne,

I had a leak in my spark plug tube and a small leak in my valve cover on the passenger side. I replaced all 6 spark plug tubes and resealed both valve covers on my 2001 Porsche Boxster 2.7. I installed new camshaft plugs and waited 48 hours before I drove my car and the camshaft plugs keep coming out on the driver side. It appears that too much pressure is building up and forcing the plugs to pop out. I called Porsche and they told me to check the breathing tube which was clogged and replaced, but the camshaft plugs keep coming out. What is causing the plugs to keep coming out? Any suggestions.

[Wayne 962]

Okay, some clarifying questions:

- What do you mean exactly by "camshaft plugs"? Do you mean the green ones at the end of the cams?

- You say plug(s) - plural. So, one falls out, and then others are falling out after the first one falls out?

I've heard of weird things happening when the air-oil separator is failing. What happens is that the crankcase vacuum increases quite a bit (makes the oil cap difficult to remove). You also might hear a whistling noise through some of the front seals. BUT, this is the opposite, where there seems to be potentially a positive crankcase vacuum, if I am understanding the problem correctly.

More info needed...

-Wayne

[spongebob]

Wayne, when you say "makes the oil cap difficult to remove" how difficult is that?
I need some force ( not much) to remove mine and when removed engine does not run perfect anymore.
Signs of a failing AOS?

[makegoodchoices]

The green plugs pop out on the driver side. The pressure seems to build up and the green plugs pop out and cause the oil to spill out. it is currently only happening on one side.

[makegoodchoices]

Wayne - just one of the green plugs will pop out. You can watch it slowly come out after pressure builds up. The green plug that comes out which is only one, is the driver side lower back one of the three on each side. Please let me know if you need more info. Thanks for your assistance!

[JFP in PA]

Are you using any type of sealant on the green plugs?

[syncroid]

Has the cam cover been recently resealed on the offending side? If so, then there is sealer blocking the oil drain back hole in the cam cover. A common cause of the cam plugs popping out.

[Wayne 962]

When the air oil separator is failing it's very difficult to remove the cap by hand. I can't do it sometimes.

Wayne

Wayne, when you say "makes the oil cap difficult to remove" how difficult is that?

I need some force ( not much) to remove mine and when removed engine does not run perfect anymore.

Signs of a failing AOS?

[Wayne 962]

Sounds like Syncroid is on the right track. I haven't seen this personally, but I would remove both valve covers and check the squeeze out from your sealant.

Wayne

[JFP in PA]

Originally Posted by syncroid

Has the cam cover been recently resealed on the offending side? If so, then there is sealer blocking the oil drain back hole in the cam cover. A common cause of the cam plugs popping out.

That is exactly where I was going with my question...........

[makegoodchoices]

I appreciate everyone's help! I did reseal both sides of my valve covers and had my valves adjusted. I'll make sure the sealant is not blocking the oil drain. Wayne - should I go ahead and replace both of the air oil separator now? My car has 91k miles on it. Anything else I should do with the valve covers off again? Thanks for your help.

[JFP in PA]

Originally Posted by makegoodchoices

I did reseal both sides of my valve covers and had my valves adjusted.

Ummmmmmmm.......there is no way to adjust the cam followers on the M96/97; they are hydraulically operated....................

[syncroid]

When you get your cam covers back off look where the arrow is pointing and see if the little passage is blocked by sealer. Sorry about the picture. not really clear but that is the area you want to look.

[makegoodchoices]

Thanks syncroid for your help and picture!! I appreciate your assistance very much.

[syncroid]

Originally Posted by makegoodchoices

Thanks syncroid for your help and picture!! I appreciate your assistance very much.

I've got your back. Pelican is a great resource! Thanks Wayne.

[very~worn~944]

Before you go through the hassle of removing the valvecover (although over applying sealant seams VERY plausible; HOW were the valves "adjusted"?) check the oil scavenge pump. If it was installed upside down it fills the head with oil...popping the plugs out.

[txhokie4life]

you have sealant in some of the channels and the high pressure is being diverted and pushing the cam plug out.

You might be able to clean out the sealant from the cam plug -- but more than likely you'll have to
remove the cover and reseal it -- less is more in this case.

It's happened numerous times to my M96 engine rebuilder.

m

[makegoodchoices]

You all have been awesome in assisting me! I appreciate your suggestions to help fix my problem. No the valves were not adjusted, my error in my statement. Thanks again for your help!

[notthistime36]

I had the plug to pop out so I changed the AOS. that was about a month ago. I haven't rebuilt the engine so sealant blocking a tube is not an issue. I did not use sealant when I reinstalled the plug after replacing the AOS. The plug popped out again today. Before I install another plug Is there another issue that I may be missing? Also should i use sealant on the new plug and if so what type of sealant will keep it from popping out. Milage on car is 112k.

Thanks in advance

Raymond

[JFP in PA]

Those plugs should not be put in with sealant, I have installed literally hundreds of them and never with sealant and none of them popped out; your problem lies elsewhere...................