Hi,

I've changed the gaskets on my rear rocker cover and it seems that it is still leaking. I followed instructions as I found on this forum (carefully reshaping so the gasket fits etc) but I feel that it was previously overtightened by someone and this has deformed the cover near the bolts.

A replacement cover is hard to come by and i'm thinking just re-doing the gasket again but with some sealant added. I know the manual says no sealant required but in this situation I believe it will still leak without any. My hope is that any gaps from the deformation will be filled by the sealant and hopefully it can hold for a while at least.

Any suggestions?

Thanks

I had the same problem. I just let a professional do it this week after putting up with the leaking oil burning off the exhaust.... Much happier now although my pocket is lighter...

(sorry can't be much more help than that!)

Firstly, are you sure it's actually leaking? Residual oil can fool you. I cleaned mine religiously before reassembly and days later there was still a slight oil smell and a tiny bit of wetness around the cover. It subsequently dried up and must have been residual oil. First port of call is to make sure it is completely and thoroughly degreased.

Only once you've done that.... Did you check the cover for flatness?

Get another kit and take it off again. Place the cover on a flat table like the kitchen bench and make sure it's not warped.

Clean all the mating surfaces with degreaser (both the cover and the block).

Place the new seal in and very gently crimp it (bend the inner rim towards the outer one so that the seal sits in there and you can shake it upside down without the new seal falling out).. Don't overdo it though or you might bend the outer lip of the cover.

Use a torque wrench, use a torque wrench, use a torque wrench and do it up to 3.5nm (an incredibly low torque).

Then degrease it, drive for a week, and re torque with torque wrench (they will tighten ever so slightly).

I managed to get the torque wrench on all six bolts without taking anything off.

Whatever you do, don't use silicon or similar sealant on the gasket and the spark plug gaskets. I trusted my Pajero to a 'Mechanic' who stuffed up the repair. I then had to get a mate from hunderds of km away to come over and fix it properly. The 'Mechanic' had used sealant EVERYWHERE. End result - after 3 km of driving, 3 of the 6 spark plugs had oil in the tubes. They used too much sealant on the rocker cover gasket, and therefore the cover was too high relative to the sealing faces on the spark plug tubes and they leaked. The system is designed not to need extra sealant, so just make sure that everything is well cleaned and then seated properly.

Firstly, are you sure it's actually leaking? Residual oil can fool you. I cleaned mine religiously before reassembly and days later there was still a slight oil smell and a tiny bit of wetness around the cover. It subsequently dried up and must have been residual oil. First port of call is to make sure it is completely and thoroughly degreased.


Yeah, its been about 6 weeks and I degreased and cleaned thoroughly. When I put my finger in the area between the cover and the head, there is fresh oil which means it still leaking. I've cleaned it and re-tightened but after a few days driving there is clean oil again.

I have to wait for a good weekend to have time to re-do it all again.

Well I used one of Mal's kits, followed his instructions perfectly, and it worked a treat.

Did you use a torque wrench?

Had this problem and now fixed twice.

First time the gasket twisted on the rear which help the oil flow out.

Second time use gasket goo, which i have read in this forum not to use. Inhave notbhad any problmes so far and it has been over 1 month.

The first time i replaced the gasket, i learnt to take my time, check everything twice and tighten bolts once.

Dont know if this would help anyone.

Are you sure it is the rocker cover gasket leaking once it was replaced?.I would check the distributor o ring.They generally need to be replaced together.Just a thought!

Yep, used one of Mal's kits and definitely leaking from the rocker gasket. I run my finger along the back between the rocker cover and head (just above the exhaust manifold) and have fresh oil. Not a lot but enought to slowly seep. I did use a torque wrench.

The gasket was previously changed by the used car dealer when I bought the car and their mechanic used sealant and also didn't change the spark plug tube seals. One of the tube seals was leaking badly which is why I changed it all. I had to clean the rocker cover thoroughly as it had lots of goo stuck on it, particularly in the part where the gasket goes into. I'm thinking using a bit of sealant between where the gasket is and the cover, and not have any between the gasket and the head (if that makes sense). I feel the leak is from the bit where the gasket sits on the cover as I remember it didnt' look in great condition (the 2 pieces of the cover were separating slightly particularly near the bolt holes).

Is it pouring out or just a tiny seam of fresh oil?

Mine had the tiny bit of oil (if I wiped my finger along it) for months after - but it wasn't leaking.

Oil can travel a long way from the source. Definitely check your distributor o-ring.

Did you do the front cover at the same time (and is it okay)?

Mal recommends checking the PCV valve too. If it is partially blocked, the crankcase may be pressurising slightly forcing oil out. Clean out or replace the PCV and see what happens.

Is it pouring out or just a tiny seam of fresh oil?

Mine had the tiny bit of oil (if I wiped my finger along it) for months after - but it wasn't leaking.

Oil can travel a long way from the source. Definitely check your distributor o-ring.

Did you do the front cover at the same time (and is it okay)?

Mal recommends checking the PCV valve too. If it is partially blocked, the crankcase may be pressurising slightly forcing oil out. Clean out or replace the PCV and see what happens.

Tiny seam of fresh oil. But I wipe it away and it comes back. If I don't wipe it then it seems to build up, and I spotted a drop on the exhaust manifold. Will check the o-ring as well. Haven't done the front cover yet but already bought the kit. Its not leaking yet so my motto is if its not broke don't mess with it!

PCV is new as I had replaced it recently (including all hoses) to try and remedy a idle problem (which turned out to be the spark plugs).