Removing rocker cover?

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sw20GTS
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Removing rocker cover?

Post by sw20GTS »

Hi all,

I noticed that there's a slight leak from my rocker cover breather pipe so I am getting a new grommet to replace it. Since the rocker cover is covered with grease, I decide to give it a clean.

As you can imagine, it's pretty hard cleaning it in-situ since lots of things obstruct it and the degreaser has a warning not to touch any electrical items.

So I guess the best way is to remove the rocker cover. However, me being a complete newbie have no idea how to do that. I roughly know which bolts to remove etc but I am wondering if anyone could give me a more comprehensive guide?

Do I need a torque wrench so I do not overtighten the bolts? Do I need to replace the whole gasket set? If I do, any tips on how? (pictures would help :P) Is it a relatively complex thing to do? I also would like to paint the cover to freshen it up a bit.

Thanks for any advice given.
sjm1984
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Re: Removing rocker cover?

Post by sjm1984 »

i've just finished painting a spare rocker cover for my rev3 tubby.

few layers of heat treatment paint and primer and a few layers of diamond white paint.

Looks lush =P~

I'm just waiting on some new rocker cover bolt set i bought of ebay and then when i get my clutch changed by pacific works i'll just get luke & co to change it for me \:D/
toxo
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Re: Removing rocker cover?

Post by toxo »

Gasket is in 2 parts (one for the outer seal and one for the 2 middle sparkplugs) and is available from Toyota. It's different depending on engine revision.

There are 10 bolts holding the rocker cover on. 3 long ones in the middle, and then around the outside - 3 on the long edge turbo side, and 4 on the long edge throttlebody side. You'll need to remove as much intake tract as you can, including unbolting (but not removing as that involves disturbing coolant pipes) the throttlebody. Obviously HT leads, intercooler pipes etc all need to come off. There's a plastic box containing some engine loom that runs over the cambelt end which you'll need to pull out of the way (having disconnected the 3 plugs on the end near the intercooler) and you'll need to remove the top cambelt cover.

I would recommend replacing the washers, also available from Toyota, as yours have probably perished and melted themselves to the rocker cover.

You will also need some silicon paste type stuff as due to some genius design the gasket doesn't seal everything! You need to put 6 blobs of sealant down next to the cam gears and distributor.

Easy DIY job - don't overtighten the bolts as you'll snap the rocker cover. Finger tight + half a turn should be enough. Should take about 2 hours to remove & refit.

Part numbers:
Rev3 Turbo Gasket 1: 11213-88480 (£12.40)
Rev3 Turbo Gasket 2: 11214-88480 (£4.45)
Rev3 Washer (you need 10): 90210-07001 (76p each)

Edit: Just rewrote this because I realised you have a rev3!

Bottom half of this image shows you were to put the sealant, torque specs and that you have to tighten the bolts uniformly. However it does incorrectly state that there are 12 bolts, and that was the torque setting I was using when I snapped my rocker cover.
Image
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sw20GTS
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Re: Removing rocker cover?

Post by sw20GTS »

Very informative toxo! Thanks! ;)

Going to get the parts first before I start doing it then. A lot of stuff have to come off to get the cover off as well it seems.

Just to double check, as long as I let the engine cool down there no real danger or explosions or fluid leakage? :P Also, should I cover up the exposed engine head with something while I take the cover off to clean and paint?

edit: Oh, just noticed you said you snapped your cover with that torque setting? o.0 Well I guess I'm just going by hand then.

I have the electronic version of the service manual as well. Reading it atm.
Last edited by sw20GTS on Thu Sep 10, 2009 12:04 pm, edited 2 times in total.
ashley
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Re: Removing rocker cover?

Post by ashley »

One thing to remember- dont sand or grit blast the cover to clean it before painting, you'll never be able to clean all the grit out properly and risk wrecking your engine. :thumleft:
sw20GTS
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Re: Removing rocker cover?

Post by sw20GTS »

ashman wrote:One thing to remember- dont sand or grit blast the cover to clean it before painting, you'll never be able to clean all the grit out properly and risk wrecking your engine. :thumleft:


Nah I probably will use the Halfords engine degreaser for the cover. Gonna get some high temp paint too. Thinking of something subtle... but don't think there's much choice for high temp paints in Halfords.
sjm1984
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Re: Removing rocker cover?

Post by sjm1984 »

sw20GTS wrote:
ashman wrote:One thing to remember- dont sand or grit blast the cover to clean it before painting, you'll never be able to clean all the grit out properly and risk wrecking your engine. :thumleft:


Nah I probably will use the Halfords engine degreaser for the cover. Gonna get some high temp paint too. Thinking of something subtle... but don't think there's much choice for high temp paints in Halfords.


What i did was a few layers of high temp paint and then primer and then a few layer of white
sw20GTS
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Re: Removing rocker cover?

Post by sw20GTS »

sjm1984 wrote:
sw20GTS wrote:
ashman wrote:One thing to remember- dont sand or grit blast the cover to clean it before painting, you'll never be able to clean all the grit out properly and risk wrecking your engine. :thumleft:


Nah I probably will use the Halfords engine degreaser for the cover. Gonna get some high temp paint too. Thinking of something subtle... but don't think there's much choice for high temp paints in Halfords.


What i did was a few layers of high temp paint and then primer and then a few layer of white


Hmmm, normal paint on top of the high temp paint? Would that work?
sjm1984
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Re: Removing rocker cover?

Post by sjm1984 »

the finish is fantastic

i'll get some pics up later
sw20GTS
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Re: Removing rocker cover?

Post by sw20GTS »

sjm1984 wrote:the finish is fantastic

i'll get some pics up later


Just curious though, did you cover up the exposed engine head while you paint or is it safe just to let it sit?
toxo
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Re: Removing rocker cover?

Post by toxo »

I covered mine with a bin bag, but my rocker cover was off for a fortnight!
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sw20GTS
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Joined: Thu Aug 20, 2009 9:29 am
Location: Corby

Re: Removing rocker cover?

Post by sw20GTS »

Right, might plan things out since I'm a newbie so want to leave more time for errors.

Had a look around engine bay just to get familiarized with things. The grease is very apparent near the breather pipe (opposite the engine oil cover) but I'm getting the grommet from Toyota later so hopefully that'll fix the leak.

Oh btw, anyone have any experience removing the washer jet nozzle? The damn thing is locked tight. So I just use a slim plier and squeeze both the ends as seen from under the hood?

I've got myself some Yaris nozzle head which apparently is better because of its fan spray pattern. Should fit into MR2 MK2 with some modification to grommet. Just need to know how to safely remove the current one just in case...
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