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Old 04-04-2009, 11:37 PM   #1
Scooby Guru
Member#: 71092
Join Date: Sep 2004
Chapter/Region: MWSOC
Location: Delaware County, Ohio
2005 2.5RS Wagon
Regal Blue Pearl

Default Knocked Cam Plug In To Far. Any Way to Save?

I'm not sure how similar my EJ253's heads are to y'all's fancy-pants DOHC turbo heads, so I'm going to give you guys too much info at the risk of telling you things you already know.

The EJ253 heads stack up like this (top of the list is facing the outside world, bottom of the list is against the headgasket):

Valve rocker cover
In/Ex Valve Rocker Assemblies
Cam Cap (sort of a metal frame that holds the cam against the head)
Head body

The ends of the camshaft protrude out the front and the back of the complete head. On the front, there's a ring-shaped Cam Seal. On the back, there's a disc-shaped Cam Plug that just covers the entire hole the cam pokes out of. According to the factory manual, the Cam Plug and Cam Seal are to be inserted after the Cam Cap and Rocker Assemblies have been torqued into place.

Well, it all went perfectly until I tried to put the Cam Plug into place. I gave it a little too much of a hit with the hammer and drove it in until the center of the Plug hit the cam itself. This means that if I were to start the motor, the cam would be grinding a hole into the Cam Plug.

I need to pull the Cam Plug out about 1/8-3/16 of an inch. There's no way to push on it from the inside. Can any of you think of a way to pull the Cam Plug out without having to totally remove and reinstall the Rocker Assemblies, Cam Cap, and camshaft a second time?

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Old 04-05-2009, 12:40 PM   #2
Turn in Concepts
Member#: 93646
Join Date: Aug 2005
Chapter/Region: MWSOC
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Dig it out and replace it with a new one. If you were to get it out without killing it you would likely see that it would be deformed. This will lead to a leak. Trust me. Just replace it. They are like $5.

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