D Turbo Guides: Rocker Cover Gasket

[londondan86]

Quick guide for changing the rocker cover gasket. Some of this may apply to other models such as the NAD but this guide is aimed at the DT so adjust to suit.

Symptoms: Oil around the top of the engine, usually noticeable down the back.

Cause: Failed gasket.

Tools needed: (intercooler)6mm allen key,13mm socket, flat head screwdriver
(rocker cover)10mm socket, 8mm socket

Parts needed: Rocker cover Gasket (obviously), d-seal.

First task is to get the intercooler off, explained here. Once off you need to remove a fuel line bracket with an 8mm socket (just off picture, green arrow). Slacken off and remove the breather pipe (blue) then remove the 3 bolts securing the cover (red). Loosen each one of gradually and recover the fuel line bracket on the cam pulley end as you remove them.



Once all the bolts are out carefully pull the cover off to reveal the cam shaft. With the cover away from the engine start separating the old gasket from the cover, mine had gone like a rigid plastic and snapped off into 4-5 bits. Clean up both surfaces with a rag and fit the new gasket. Not sure if this was needed but I put a thin layer of fresh engine oil all the way round the gasket to help it seal.




Finally put the cover back on and get the bolts in finger tight, set your torque wrench to 20 Nm and tighten them from the middle out, again the Haynes says nothing of the tightening sequence but seemed to make sense. Note: Over tightening the rocker cover bolts will ruin the brand new gasket you have just fitted!



Replace intercooler with a new d-seal.

Done.

[CJ_Derv]

Good Guide, I run a 6 bar oil pump spring and have only ever been able to get this to seal by using some gasket seal on either side of the new gasket.

CJ

[4WayDiablo]

Also when removing the old gasket I like to run a Stanley around the edge and get it properly clean before putting the new one on :-)

[306__xrdt]

My bad i have overtighting the new rocker cover gasket, 1 month ago must i trow itt away and get a new one? ore can i losen the bolts to 20 nm?
Thanks for answer

[londondan86]

My bad i have overtighting the new rocker cover gasket, 1 month ago must i trow itt away and get a new one? ore can i losen the bolts to 20 nm?
Thanks for answer

Chances are you will have ruined the gasket, been there myself mate. At least they're not too expensive.

[306__xrdt]

Already bought a new one but to bad they dont have seal for the intercooler ebay might do the trick

[Mattcheese31]

Already bought a new one but to bad they dont have seal for the intercooler ebay might do the trick

yes they have them . . .there you go . .

http://www.ebay.co.uk/itm/Citroen-Peugeo..._500wt_969

[Daniel306]

Dose anyone know the part number for the breather pipe marked in blue

[306__xrdt]

Already bought a new one but to bad they dont have seal for the intercooler ebay might do the trick

yes they have them . . .there you go . .

http://www.ebay.co.uk/itm/Citroen-Peugeo..._500wt_969

Already bought one

---

Dose anyone know the part number for the breather pipe marked in blue

I have one ekstra breather pipe part number on that one is REF: 504240
not sure if it is correct but you can tray it out

[Ricky]

Just seen this guide, I tried tightening mine to 20nm and it sheared the thread

[306__xrdt]

Mine rocker cover bolts snapped off on 20 nm...so i found new bolts and allot off less nm on this bolts now.
Might be different zise on the rocker cover i quess....

[Mattcheese31]

i always finger tight them and then nip 'em round a bit . . .doesn't take much . .