Have a 2005
Boxster
with 85K miles and one of the camshaft plugs has come out multiple times. Any idea what's causing this?
Dealer has tried a number of fixes and tests, but the plug eventually comes back out after driving for a few weeks.
The dealer has tried the following with no luck:
Remove excess sealant from the plug
Inspect the timing belt and valve lever for issues, and none found
Run a crankcase pressure test - no issues
Remove excess sealant from a replaced water pump
Cement the plug into the camshaft (still came out)
The AOS was also replaced about 4000 miles before this started happening.
Something seems to be causing too much pressure but not sure what to check next. Any ideas what to look for?
I am running into the same problem, with the same things tried by the dealership. Did you ever figure out the reason?
I certainly don't know myself, but as I recall in reading about this type of issue (just for info's sake) I seem to recall someone said that an overfilled oil system can lead to this type of issue as well. This is also what causes damage to the AOS, typically, but the key is to fill a little bit less than max... most people reported 1-bar below max is what they fill to.
Again, I have no explanation for why, but just wanted to repeat info I am remembering (vaguely!)...
From what I've read, it is usually caused by a bad AOS. When the AOS was replaced, what brand was used? I've also read that the cheap brand (URO?) fails quickly.
It turns out it was the AOS. At the time the AOS was only a few months old without any obvious issues, but as a last resort the dealership replaced it and the issue went away. Before returning the car to me they drove the car for about 50 miles a day for 2 weeks to make sure everything was working and I haven’t had any issues since then.
They road tested your car for 500 miles?? Really??
No thanks.
I suspect you're a victim of the Infant Mortality part of a bathtub curve for mechanical devices..
I just had the same exact failure on my 2005
Boxster
w/ 119k miles. Pulled into a parking spot and discovered a massive oil leak, which ended up stemming from a missing camshaft plug. The aftermarket AOS I put in the car roughly 2 years ago apparently wasn't up to spec, and the excess pressure eventually caused the plug to pop out. I'd never heard of this issue before, but everything's running smoothly now that the plug has been reinstalled and the AOS replaced with an OEM part.