Help! Cam Cover Oil Leak , Cam Plug , Oil Tube , Oil Leak

[zee]

I would appreciate advice on the following issue with my car. I have a 1999 Carrera C4 (996) cabrio with 70000 miles (6 Speed) C4 Cab. A few days ago I noticed a little bit of oil drops under the car. The oil leak was on the right (drivers side). I got it checked from my guy and he said that the right side cam cover was leaking and it needed to reseal it. He said that it was half a day of work. I told him to go ahead and do it.

So he resealed the cam cover and everything was bone dry under the car.I drove it to work the next day (50 miles) and when i parked i could see smoke coming from the rear and a lot of oil dripping onto the exhaust. I took it to a shop nearby. They put the car in the air and checked. The oil leak was from the upper cam plug which is above the exhaust pipe. It was dripping on the hot exhaust and burning up and you could smell it. See attached pictures. The cam cover was dry. I told them that I had just got the cam re-sealed. They told me that who ever did the cam cover didnt do a good job and they clogged / blocked the oil tubes in the process of sealing it. They said that was creating pressure on the cam and oil tubes and thats why the cam plug is leaking. They said if creates a lot of pressure its going to blow out the cam plug. They said to fix it they would have to take out the cam cover again and re-seal the cam cover all over again and clean the oil tubes. And that would stop the oil leak. They told me my best bet is to take it back to my guy and have him re-seal it.

So i took the car to my guy and told him exactly what the shop people told me. He told me that he re-sealed it properly and it does not need to be re-sealed. He said the oil tubes can not be blocked and that there is always pressure there. He said that i just need to put new cam plugs and that would stop the leak. I never had a oil leak from the cam plug until he resealed the cam cover. He said he is going to check and confirm with me.

He calls me back and tells me that he is going to put a new cam plug and put a special adhesive around and on top of it to seal the leak properly. He said that the special adhesive is going to take 12 hours to cure.

I am just worried that he might use special glues that turn into steel once you put them on and that the pressure might crack the cam if something is blocked. Please advice to want is happening and what needs to be done and what the guy is saying is correct. What should i do? Should i take the car somewhere else and have then clean the oil tubes and reseal the cam cover again or i should just have my guy put new cam plugs and the special adhesive.

Any advice would be appreciated. Thanks in advance.

Edited January 24, 2008 by zee

[phillipj]

I have exactly the same problem with my 996 C2. I have about the same mileage you do. I'm not sure where my leak is coming from either.

As far as I know the special sealer (or adhesive) is a Porsche silicon. I would't be concerned about it turning to "Steel". There is no gasket on the cam cover. Only the silicon sealer is used. I would assume that your mechanic is using the same sealer on the cam plugs.

Please let me know if the additional repairs (the cam plugs) cured your problem. Also if you could let me know the cost of the repair I woould appreciate it.

Thanks,

Phillip

[zee]

I paid my mechanic $700 for parts, oil change and labor to re-seal the cam cover. I doubt I will be paying more to stop the leak as i already paid. The cam cover leak is completely gone. The leak is coming from the cam plug (top green plug in the first picture) and dropping onto the exhaust pipe. I think he is using something special to stop the leak from the cam plug and he is not using the Porsche Silicon becuase he said that thing needs 12 hours to cure and harden. I think he might just try to permanently seal the leak and it might do damage to the engine. He said that there was also a small crack that he is going to sand and fill up as well??????

The other person i took it to told me that all he needs to do is clean the oil tube which is clogged with the prior sealant and re-seal the cam cover and that would fix the oil leak from the cam plug. He would charge me $700 too.

Ill let you know what happens

[phillipj]

I paid my mechanic $700 for parts, oil change and labor to re-seal the cam cover. I doubt I will be paying more to stop the leak as i already paid. The cam cover leak is completely gone. The leak is coming from the cam plug (top green plug in the first picture) and dropping onto the exhaust pipe. I think he is using something special to stop the leak from the cam plug and he is not using the Porsche Silicon becuase he said that thing needs 12 hours to cure and harden. I think he might just try to permanently seal the leak and it might do damage to the engine. He said that there was also a small crack that he is going to sand and fill up as well??????

The other person i took it to told me that all he needs to do is clean the oil tube which is clogged with the prior sealant and re-seal the cam cover and that would fix the oil leak from the cam plug. He would charge me $700 too.

Ill let you know what happens

Zee,

Hopefully others on this forum (that are much smarter than me) will reply to your post. The 12 hour curing time does sound a bit odd. I hope this turns out well for you.

Phillipj

[zee]

I had the cam cover taken out and it turned out that I had a crack where the upper cam plug fits. The crack is on the cam cover and not the cylinder head. I might have to replace the cam cover and the cylinder head which is going to cost a lot of $$$. My mechanic is looking into other options that might work.

[Loren]

I had the cam cover taken out and it turned out that I had a crack where the upper cam plug fits. The crack is on the cam cover and not the cylinder head. I might have to replace the cam cover and the cylinder head which is going to cost a lot of $$$. My mechanic is looking into other options that might work.

That is a very odd problem. What did the crack look like? hairline or did it look like something hit it?

The head and cam cover a machined matched set - so both have to be replaced.

[zee]

A chunk of piece is missing. It looks like it hit the body. Attached are pictures. Does anyone have a estimate how much it would cost to get the head and cam cover replaced?

Thanks

[zee]

is this something that can be welded and machined at a fabrication shop? does insurance cover this?

[Loren]

Hmm... it does look like something struck it to me.

I would take it to the best machine shop in town and ask if they can re-weld and machine the damage.

FYI...

cylinder head complete -- MSRP $2566.08

[zee]

Thanks Loren. How much hours of labor am i looking at in addition to the complete cylinder head? Does anyone know a good machine shop in town that could do this kind of work?

[Loren]

The Porsche book says 6-7 hours.

What city/state do you live in?