KV6 Camshaft end caps

[roperman]

Hi,
just trying to put some new camshaft end caps on my KV6. Is there an easy way of doing it? The left hand (front) one I can't even get a hammer in there never mind swing it. When I tap the right hand (rear) one it doesn't really seem to go in.

Danny

[jn12]

Hi Danny,

I use a long bit of wood to press the rear one in and take the front bumper off and headlight and tap the front one in. Might sound mad but it is a lot quicker then messing on and worrying if you have them in correctly.

John

[Canonite]

Is it not quicker to remove the battery box and throttle body?

[roperman]

Was considering bumper off, i'll see how the rear one goes on with a big lever first. Not a lot of room at the front mind so gonna be another hours work faffing with the bumper most likely.

Canonite - i meant the ones on the front belt end.

[riaanF]

Why do these caps come off? My Mech replaced ONE of them and now the other one came off too. He says something about too much pressure in my engine? Is this an indicator that the engine is shot? I have got NO idea about engines but this must be the car I have spent the most money on yet. I am so livid about this.

[KWIL]

Someone on the Forum has a method that uses a long adjustable carpenter's cramp.


I have oil seals fitted and I am afraid they have leaked twice.

[vitesse]

Originally Posted by riaanF

Why do these caps come off? My Mech replaced ONE of them and now the other one came off too. He says something about too much pressure in my engine? Is this an indicator that the engine is shot? I have got NO idea about engines but this must be the car I have spent the most money on yet. I am so livid about this.

Could be a sign of a worn engine, but if you're not blowing blue smoke then more likely lack of maintenance. The caps blow when there's too much crankcase pressure unable to vent. There are four breather pipes, but the two smaller ones are often blocked (95% of cars I've looked at). The front pipe is easily accessible, but not the rear one. There are also two gauze filters inside each cam cover, these get dirty but I wouldn't think they get totally blocked.

I've got the 1.8 cam seals instead, smaller surface area to the excesses gases and less likely to "pop". Fortunately mine don't leak, but I fitted them myself, moral there somewhere

Regards

[Rich in Vancouver]

I just re-use the caps with a bit of sealant on the interference face.
Never had a problem on the 3 engines I have done this with.
Other people have mentioned using conventional seals in place of the cap type.
If your engine is over-pressurizing the breathers in the cam covers may be plugged. These can be cleaned out.

[SD1too]

Originally Posted by riaanF

Why do these caps come off?

Because new caps are rigid and need to be inserted fully and perfectly on the axis which is at best extremely difficult. Your problem is very unlikely to be pressure related and virtually certain to be imperfect fitting. Please read on for the best solution i have seen.

Originally Posted by KWIL

Someone on the Forum has a method that uses a long adjustable carpenter's cramp.

Yes, that is member Mr Toad. We had replaced a camshaft in his ZT-T and he produced the tool that Kwil has mentioned and both caps were fitted quickly, perfectly and without drama. Unfortunately most people are resistant to spending money on a tool to complete a task which they may never encounter again which is a shame.

Originally Posted by Rich in Vancouver

I just re-use the caps ...

Before I knew about Mr Toad's method I did this too on the LH bank. Be aware though that it does depend upon very careful removal because the outer ribbed surface and circular form must not be damaged. Mine's been in for over 20,000 miles now and it hasn't leaked.

Simon

[KWIL]

That's it Simon, a woodworker's F Clamp long enough to cover front to back of engine and deep enough to enable the clamping points to reach down to the sealing Covers.