Cam Steel Expansion Plug Blew

[kbrandsma]

I have the same exact issue on MY98 986 5 speed as Dharn55 did in 2009 above.  I have 180K on the clock.  I recently dropped the engine and replaced cam timing chain glides on both banks and a new actuator/solenoid on Bank 2.  While I was at it I also replaced the IMS, RMS, Clutch, Flywheel, water pump, AOS and the (IMS to Camshafts) chain pads.  On restart the green cap and steel compression plug blew on intake camshaft on Bank 1 (Boxster passenger side) on the side opposite the actuator and cam timing chain. 

 

What are the options usually used? 

1. Is threading and adding a screw plugs to the cam shafts that Dharn55 did (above) the only option?
2. Can new expansion plugs be purchased and pressed into place?
3. Do I do intake and exhaust cams or just the cam that popped?
4. Bank 2 is holding do I leave that one alone?

 

I'd be interested in what others recommend or have done.  Thanks!

 

KBrandsma

Edited November 24, 2018 by kbrandsma

[JFP in PA]

1 hour ago, kbrandsma said:

I have the same exact issue on MY98 986 5 speed as Dharn55 did in 2009 above.  I have 180K on the clock.  I recently dropped the engine and replaced cam timing chain glides on both banks and a new actuator/solenoid on Bank 2.  While I was at it I also replaced the IMS, RMS, Clutch, Flywheel, water pump, AOS and the ( IMS to Camshafts) chain pads.  On restart the green cap and steel compression plug blew on intake camshaft on Bank 1 (Boxster passenger side) on the side opposite the actuator and cam timing chain. 

 

What are the options usually used? 

1. Is threading and adding a screw plugs to the cam shafts that Dharn55 did (above) the only option?
2. Can new expansion plugs be purchased and pressed into place?
3. Do I do intake and exhaust cams or just the cam that popped?
4. Bank 2 is holding do I leave that one alone?

 

I'd be interested in what others recommend or have done.  Thanks!

 

KBrandsma

 

Afraid you are at a cross road here for multiple reasons.  First, Porsche does not sell the plugs as a part, and I am unaware of any aftermarket source.  Second, even if you could source a suitable plug, there is no guarantee it would not do this again.  The threaded plug is the way to go, but you are going to need to find a machine shop to drill and tap them without blocking the oil passages near the ends.  The treaded plug is the “once and done” approach to this problem.

[kbrandsma]

Thanks JFP,

 

Do I just do the threaded plug replacement on the end where the steel compression plug popped out?  Or both ends? Other cam shaft? Other bank?

 

Kbrandsma

Edited November 27, 2018 by kbrandsma

[JFP in PA]

23 minutes ago, kbrandsma said:

Thanks JFP,

 

Do I just do the threaded plug replacement on the end where the steel compression plug popped out?  Or both ends? Other cam shaft? Other bank?

 

Kbrandsma

 

That call is yours, but considering that you need to pull the cam to do this, I would do them all and be done with it, otherwise you will always be worrying if the one you didn't do will be next.

[txhokie4life]

Too much sealant blocking the oil passage.

take the cover off, remove the sealant

 

reseal with less sealant and you should be fine.

Use new green plugs

 

mike

[JFP in PA]

13 hours ago, txhokie4life said:

Too much sealant blocking the oil passage.

take the cover off, remove the sealant

 

reseal with less sealant and you should be fine.

Use new green plugs

 

mike

 

Mike,  he is dealing with the small metal plugs in the ends of the cams blowing out, not the green cam cover plugs.

[kbrandsma]

Getting ready to tackle the cam shaft compressed steel plug after the winter holiday and ran a quick check for codes with my Durametric.  I found P1602 (Supply Voltage Open Circuit) and  P0341 (Camshaft Sensor Bank 1 Short to B+).

 

I am assuming P1602 was due to removing power for an extended time when dropping the engine. 

 

Could  the P0341 code be caused by the blown cam shaft plug?

Edited January 13, 2019 by kbrandsma

[JFP in PA]

10 hours ago, kbrandsma said:

Getting ready to tackle the cam shaft compressed steel plug after the winter holiday and ran a quick check for codes with my Durametric.  I found P1602 (Supply Voltage Open Circuit) and  P0341 (Camshaft Sensor Bank 1 Short to B+).

 

I am assuming P1602 was due to removing power for an extended time when dropping the engine. 

 

Could  the P0341 code be caused by the blown cam shaft plug?

 

Seriously doubt it.