Valve cover gasket replacement for morons

[Airgonzo]

Hey folks,

I might have a small oil leak from rear of Valve Cover on my L400 and was thinking about changing the gasket myself. Two simple questions from a callow and uninitiated Delica mechanic such as myself:

1. Where is the best place to get a gasket? I noticed Mardy and RSI may have some in stock. Do Napa/Lordco etc carry them and if so would they be under Delica parts or a different vehicle that also has 4M40?

2. I haven't started pulling Intercooler etc off to get at the cover yet so I can't see it all that well, but from my vantage I can't see any bolts holding it in place other than maybe the one on top that holds tranny fluid dipstick. What am I missing? Is that it?

Any or tricks or advice?

Thanks,

Kevin.

[Rising Sun Auto Import]

When you replace a rocker cover gasket , I advise you to replace exact size of rocker cover bolt seals, cylinder head camshaft end seals at the same time.
If you miss to replace those seals, problem occurs in near future.
To replace them is way too easy, just be cautious for cleaning valve cover and surface.

Steven

[jessef]

1. You will have to source the valve cover gasket from a JDM supplier. 4M40 was not sold in Canada = no support local parts shops.

2. steps :

-Four 10mm bolts hold the intercooler on, undo those
-rear/passenger side corner of intercooler are two electric grommet plugs. Unplug them.
-rear/drivers side corner of intercooler are two 10mm bolts threaded in from the side holding the vacuum switches. undo those
-loosen the intercooler pipe clamps and slide the hoses off
-remove intercooler

-undo the two 12mm bolts that hold the valve cover on (they are in mid/section on the top of the valve cover)

-tap the valve cover with soft mallet or your palm to get it loose and remove it (it will be oily inside so be quick and turn it upside down once out)

-remove old gasket from valve cover
-remove old half-moon seals from cylinder head

-use brakeclean or similar to clean both cylinder head and valve cover surfaces paying close attention to the halfmoon seal area as it tends to seep out oil if not seated and sealed properly

-put new valve cover gasket into gasket groove on the underside of the valve cover

-use RTV sealant and squeeze a thin 1/16" bead along the halfmoon section (front and rea) on the cylinder head and have the bead follow up a 1/4" on the top section where the main valve cover sits
-install the front and rear half moon seals lightly
-take your time and reinstall the valve cover with the new gasket

-replace the cone pressure gaskets used on the 12mm valve cover retaining bolts

-finger thread in the two 12mm retaining bolts and then tighten down lightly until you feel pressure. similar to oil filter install.

-reinstall intercooler in reverse as per above

-check your oil levels

When you replace a rocker cover gasket , I advise you to replace exact size of rocker cover bolt seals

There is no reason to reuse the old one's when the gasket kit comes with new one's.

4M40 valve cover gasket kit :
2pc Valve cover bolt cone seal
2pc valve cover half-moon seal
1pc valve cover gasket

cylinder head camshaft end seals at the same time.
If you miss to replace those seals, problem occurs in near future.

No need to scare the OP stating that a problem will occur in the near future.

Better stated would be saying a problem 'may' occur if the engine sat for years and the there was no oil up there leading to dried out cam seals, then sure. But the engine oil keeps the seals lubricated.
There is no reason to buy new cam seals if the one's in there are not dried out and it is simple to check visually.
The same applies to the rear main seal, crank seal,etc...

[Airgonzo]

Excellent! Many thanks, Jesse. That's exactly what I needed - even a moron should be able to follow those instructions, with a little luck so can I. I picked up the sealant today while at Crappy Tire and I'll have to source out the gasket set before my next days off. Hopefully have time to get my hands dirty next week.

Thanks again,

Kevin.