Question about Harley Davidson XLH Sportster 883 Motorcycles

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How to install rocker cover gaskets - XLH Sportster 883 Harley Davidson Motorcycles

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To replace the rocker box gaskets, you'll have to remove the bolts on top of the rocker boxes to get them off. You may have to remove the fuel tank(s) and seat. You didn't tell me what year and model bike you're working on. Once you have these bolts off, you can replace the gaskets between the center and the upper parts, the inner gasket and the umbrella if your bike is equipped with them.

To replace the gaskets under the lower plate, work with one plate at the time. Remove the spark plugs and jack the rear wheel off the ground. Put the transmission in high gear and bump the engine over until the piston is at top dead center in the cylinder your working on with both vavles closed. Start by removing the three 1/4" hex head bolts and the two 1/4' socket head bolts. Then, remove the 5/16" bolts on the pushrod side of the engine. Tap the rocker shafts out and remove the rocker arms. Remove the other two 5/16" bolts. Lift the lower plate and replace the gaskets. Do not mix up the pushrods. They are usually color coded as to which position they go in.

To reinstall the lower plate, place the rocker box on top of the cylinder and start all bolts except the two 5/16" bolts on the push rod side of the engine. Put the rocker arms in place and push the shafts through them. Start the remaining two bolts. At this point, your lower rocker box plate is "floating" above the cylinder head. Tighten the four large bolts down until they are all flush with the top of the plate. Then, tighten them down 1/4 turn at the time until they are snug. Then, tighten the six smaller bolts down until they are barely snug. Torque the larger bolt to 15-18 foot pounds and the smaller bolts to 10-13 foot pounds. Wait for the tappest to bleed down to where you can turn them by hand to do the other cylinder. Do it the exact same way as you did the first one.

To install the middle and upper plates, put the center gasket and all other gaskets in place and align the plate. Install the socket head bolts in the top and torque to 100 Inch pounds.

Put the transmission in neutral and lower the bike. Reinstall the spark plugs, the tank(s) and the seat.

Good Luck
Steve

Posted on Sep 05, 2010

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Oil pressure sensor replaced 9/14/2015started to leak oil again. Valve cover gasket replaced 1/6/2016 9/14/2015 now leaking oil again


When you replace the rocker cover gaskets, clean the surfaces where the gasket contacts the heads and the rocker cover with alcohol and a rag. Make sure there is absolutely no oil residue on either surface. Use a silicon sealer and spread it on the side of the gasket that will touch the head. Position it and use the head bolts temporarily as guide pins to hold the gasket in place until the sealant dries COMPLETELY. Remove the bolts. Now put more sealant on the surface of the rocker cover and install the cover on the gasket gently so as not to disturb the gasket. Install the cover bolts and tighten firmly but not so as to squeeze or deform the gasket. If dine correctly, the gasket will not leak.

Jan 13, 2016 | 2007 Saab 9-3 Aero Convertible

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Leaks oil from rocker cover. repaired 3 times. is this a common fault? what is the solution?


The rocker cover will leak oil..............

1. If the rocker cover has been damaged due to poor mechanical fitment and is no longer perfectly straight; or
2. The rocker cover bolts are not torqued evenly at the correct ft/lbs specification; or
3. If the rocker cover bolts have been excessively torqued in which event the cover will distort and the gasket will be excessively compressed; or
4. The gasket is in poor condition and needs to be renewed; or

5. The gasket fitting is sloppy done in which event you can assume the cover will not have been properly fitted either.

I would be buying a new rocker cover (or a straight used one) before doing the next repair because your original is probably deformed now and will likely never seal properly.

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Oil leak from rocker cover


It is most probably the rocker cover gasket. This is enough to install, you just need to source the correct part from your local parts store or dealer. Remove bolts and rocker cover and replace seal. Ensure on replacement, that you use a sealant that is compatible with oxygen sensors, I use PERMATEX ULTRA-BLU RTV Silicone. That seams to work a treat.

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Pajero io 1.8 water leak at the back of the cylinder head, guide me ho to fix!


Cylinder Head Removal & Installation To Remove:
  1. Remove the intake manifold.
  2. Remove the timing belt.
  3. Disconnect the exhaust pipe from the manifold.
  4. Remove the water outlet pipe and o-rings.
  5. Remove the water passage assembly.
  6. Remove the water pipe assembly.
  7. Remove the breather hose and spark plug cables from the rocker covers.
  8. Remove the rocker cover.
  9. Disconnect the camshaft position sensor connector.
  10. Loosen the cylinder head mounting bolts in 3 steps, using the reverse of the installation sequence. Lift the cylinder head assembly and remove the head gasket.
To Install:
  1. Clean the engine and cylinder head sealing surfaces.
  2. Install the new gasket on the engine with the identification mark facing up and to the front.
  3. Using 3 even steps, torque the head bolts in sequence, to 76-83 ft-lbs. (105-115 Nm). Cylinder head bolt tightening sequence 7924ug13l.gif
  4. Connect the camshaft position sensor connector.
  5. Install the rocker cover.
  6. Install the breather hose and spark plug cables from the rocker covers.
  7. Install the water pipe assembly.
  8. Install the water passage assembly.
  9. Install the water outlet pipe and o-rings.
  10. Disconnect the exhaust pipe from the manifold.
  11. Install the timing belt.
  12. Install the intake manifold.
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Oct 19, 2010 | 2001 Mitsubishi Montero

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Cam gears pulled out when changing gear box gasket trouble reinstalling due to tappets line cams up but front exhaust to tight to install


I'd be interested in knowing how the cam chest cover cam off changing a gear box gasket but.

In order to get the cams back in and to insure their proper timing, I'd put the rocker arms out. I'd pull them all out but you're free to do whatever you wish. Remove the top and middle rocker cover on the front clinder. Remove the large bolt that hold the lower plate and the rocker arm for the front cylinder in. Tap the rocker arm shaft out of the rocker arm and remove the rocker arm. You can then get your cam into position. Now, to get rocker shaft back in, rotate the engine until the front exhaust cam has the valve in it's closed position. Reinstall the rocker arm and shaft and torque the bolt to 25 foot pounds. Reassemble the upper and middle rocker box covers.

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2 Answers

I need rocker torque for 2003 pontiac with 3.1liter


Left side:

To install:
  1. Lubricate all the valvetrain components with engine oil.
  2. Install or connect the following:
    • Pushrods and the rocker arms and tighten the bolts to 14 ft. lbs. (19 Nm) plus 30 degrees
    • Rocker arm cover using a new gasket and tighten the rocker cover bolts to 89 inch lbs. (10 Nm)
    • PCV valve to the rocker arm cover
    • Coolant tube with the thermostat bypass hose and tighten the bolt to 98 inch lbs. (11 Nm) and the nut to 18 ft. lbs. (25 Nm)
    • AIR check valve pipe and torque the adapters to 22 ft. lbs. (30 Nm)
    • Engine mount strut and torque the bolt to 35 ft. lbs. (48 Nm)
    • Spark plug wires
    • Negative battery cable
Right side:

To install:
  1. Lubricate all the valve train components with engine oil.
  2. Install or connect the following:
    • Pushrods and the rocker arms and tighten the bolts to 14 ft. lbs. (19 Nm) plus 30 degrees
    • Rocker arm cover using a new gasket and tighten the rocker cover bolts to 89 inch lbs. (10 Nm)
    • Power brake booster vacuum pipe to the plenum
    • EVAP solenoid and ignition coil assembly
    • Spark plug wires
    • Alternator bracket and torque the bolts to 37 ft. lbs. (50 Nm)
    • Alternator and torque the bolts to 37 ft. lbs. (50 Nm)
    • Accessory drive belt
    • Negative battery cable
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1 Answer

Im trying to find out what the torque specs are for the over head valve cover and top head unit of a 2002 buell blast


Clyinder and head:
In a cross patern
Tighten bolts to 8-10 ft-lbs (11-14 Nm).
Tighten bolts to 13-15 ft-lbs (18-20 Nm).
Loosen all bolts.
After screws are loosened from initial torque, tighten
head bolts in three stages. Tighten fasteners in
increasing numerical sequence (i.e. – 1, 2, 3 and 4). Tighten each screw to 8-10 ft-lbs (11-14 Nm).
Tighten each screw to 13-15 ft-lbs (18-20 Nm).
Mark cylinder head and head screw shoulder with a line.
Turn all bolts an additional 85 -95 .

Rocker Cover

Slowly snug all fasteners
in small increments (one turn at a time). Use a cross
pattern on the four large bolts) that fasten the lower
rocker box to head. This will bleed the tappets.
Tighten bolts to 18-22 ft-lbs (24-30 Nm).
Tighten bolts to 11-13 ft-lbs (15-18 Nm).
Tighten bolts to 135-155 in-lb (15-18 Nm).
Install upper rocker covers.
Place a new inner gasket on lower rocker box
assembly.
Place a new lower gasket on lower rocker cover.
Install upper rocker cover using screws with washers
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1 Answer

How to change out valve cover gaskets on a 1989 Lincoln Town Car


This is All you need for this Repair, ALSO Be Sure ALL GASKET SURFACES ARE VERY CLEAN. This Engine Requires MORE than MOST ALL Engines do for this Repair.

REMOVAL

  1. To remove a valve rocker arm cover from the RH cylinder head, disconnect PCV closure tube from oil fill stand pipe at rocker cover.
  2. Remove the Thermactor bypass valve and air supply hoses as necessary to provide clearance.
  3. Disconnect the spark plug wires from the spark plugs using Spark Plug Wire Remover T74P-6666-A or equivalent. Do not pull on wire. Remove the wires and bracket assembly from the rocker arm cover attaching stud and position the wires out of the way. ALSO MARK THEM AS TO WHERE THEY CAME FROM !!!
  4. Remove upper intake manifold.
  5. Remove attaching bolts and remove the cover.
INSTALLATION

  1. Clean the valve rocker arm cover(s) and the cylinder head gasket surface(s). Position a new service valve rocker cover gasket.
  2. Position the cover(s) on the cylinder head(s). The cover is tightened in two steps. Tighten the bolts to 14-18 N.m (10-13 lb-ft). Two minutes later, tighten the bolts to the same specification.
  3. Install the crankcase ventilation tube in the RH cover.
  4. Install upper intake manifold.
  5. Install the spark plug wires and bracket assembly on the rocker arm cover attaching stud. Connect the spark plug wires. Install the air intake duct assembly.
  6. Install the Thermactor bypass valve and air supply hoses (if required).

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2 Answers

I need to change valve cover gaskets. What's the best procedure?


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