28-04-2012, 07:47 PM
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.
![[Image: img20120428170009.jpg]](http://img849.imageshack.us/img849/574/img20120428170009.jpg)
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.
![[Image: img20120428171216.jpg]](http://img217.imageshack.us/img217/200/img20120428171216.jpg)
![[Image: img20120428171303.jpg]](http://img685.imageshack.us/img685/6407/img20120428171303.jpg)
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!
![[Image: img20120428173228.jpg]](http://img215.imageshack.us/img215/8041/img20120428173228.jpg)
Replace intercooler with a new d-seal.
Done.
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.