V6 rocker gasket replacement

[cwilliams255]

Replacing the rocker gasket on my v6 as I have a slight weep and wanted to have a look around to make sure everything looked ok. Got new gasket and washers but I think there is supposed to be some spacers on the bolts to stop the gasket being over tightened. There were the remains of 3 of these in various states, anyone know for sure what I’m expecting to see? Lush projects diagram and workshop manual aren’t helping me or I’m looking in the wrong place. If you see my attached image you can see the remains on the rocker studs on cam caps 2-1 and 2-2 (what the hell is going on with the cam cap numbering too?)

You have to open the image to see it clearly

Northern Bongolow may have described these as tubes in previous rocker gasket discussions

[Gsmifff]

Hello there, looks like the remains of the seal that goes around the stud. Probably baked on and very hard. If you go gentle with a blade or try wiggling them off with long nose pliers you'll end up with a nice clean stud

[cwilliams255]

Thanks, I managed to find another thread which confirmed the same, just remains of the rubber from the washers

Now is there anyway to get the driver side off without dismantling half the top of the engine? Seems to be struggling to get enough clearance

[cwilliams255]

Rang bongo spares, intake manifold needs slackening off. Have my answer, now just need to work out if it’s a job for tonight in the dark or save for the weekend - oh how I wish I had a garage!

[Northern Bongolow]

There are metal tubes / spacers on the diesel that go down through the rubber, don't know about the petrols.

[Gsmifff]

You can get the drivers side off without loosening inlet manifold but it is tight. I moved the air intake pipe and the fuel lines for plenty of clearance. When you come to refit try it a few times without the gasket just to get the feel and the angle of dangle.

[cwilliams255]

Thanks, I did get it off exactly as you described actually, loosening air pipes and fuel lines. I dropped a bolt from passenger side oil line that I loosened and to retrieve it I loosened off intake manifold anyway so refitting should be a tiny bit easier. I’ve got to fix slight coolant leak from thermostat (?) t at front top of engine so having the hump off no big deal and I’ve learnt to take apart even more of a bongo than before. Also discovered throttle cable is pretty slack will check how far it moves with foot to floor and adjust I assume that’s best method

[cwilliams255]

Still working on this, drivers side gasket was obviously knackered but I’ve also found what the previous owner described as a broken cam cap. Luckily the description was slightly worse than the actual problem I found. It was damaged when he got the cambelt changed, it looks to me like the garage tried to lever the rocker cover off against the intake manifold and nearest stud and subsequently broke the stud and casting

It’s been repaired in not exactly the most artisan fashion and the gasket mating surface is terrible

Seems to be a combination of silicon and chemical metal or something, mostly rock hard rather than soft.

Anyone got any advice for cleaning this up? It wasn’t actually leaking here before as far as I can tell but there was significant sealant on the old gasket. I’d prefer the gasket to work as intended without copious silicon though. Was going to carefully dremmel it smooth and polish but there will be some gaps - what should I fill these with?

I assume this part is line bored with the rest so swapping it isn’t going to be an option unless anyone thinks otherwise?

[Bob]

That is quite the, er, 'repair'.

[cwilliams255]

Cleaned up reasonably well, filled the big gaps with some quicksteel and a smear of three bond 1207b to deal with any minor imperfections and so far so good

Getting a dremmel in was hardest bit made even more difficult by side conversion so seat can only open to about 45 degrees and has to be supported with wood

[Bob]

Much nicer.