G60 Valve cover assistance - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• G60 Valve cover assistance by DieselBalz on 06 Jul, 2011 17:32
• Remember this thread? http://www.vwdiesel.net/forum/index.php?topic=28034.msg236997#msg236997
  
  
  So I finally found one, got it polished up, ordered the gasket as indicated by that thread, and went to put it on Sunday. Pulled off the old one, carefully laid the gasket in place, gingerly placed the new VC on, and tightened everything down. Started it up, leakin oil like crazy. I could also see that the gasket was not compressed down.
  
  I actually purchased two gaskets just to be on the safe side. So I pull it off, and I can see a little ring around the base of the stud. I tried poking at it to see if it would come off, but it appears to be part of it, but honestly I don't know. Here is a pic for reference.
  
  
  
  The new gasket is a one piece and has these little rings on it already. The old one does not. Another pic for reference.
  
  
  
  So was the recommended gasket the wrong one? Are those little rings fixed? If so, do ya think just removing them carefully from the new gasket solve the issue? Thanks for any assistance.
• #1 by DieselBalz on 06 Jul, 2011 18:14
• Here is the before during after shots (when I thought it was done)
  
  
  
  
  
  
  
  
  
• #2 by theman53 on 06 Jul, 2011 19:56
• you need M6-1.0 x 30mm studs or socket set screws or M6-1.0 x 20mm bolts of any kind and take out the shouldered studs.
• #3 by DieselBalz on 06 Jul, 2011 20:03
• So youre saying I have to remove the stud all together and replace them?
• #4 by fatmobile on 06 Jul, 2011 20:33
• Right, the rubber gaskets need different studs.
   With the "solid" rubber gasket set; there is a metal piece inside the rubber that keeps it stiff,.. it's more of a valve cover gasket upgrade kit, that set usually comes with the studs.
   Even with the upgrade kits; I use long set screws, some poeple have had problems with the studs. The bald spot in the center of the stud can keep the nut from threading down far enough to stop leaks.
  
   There is also a very flexible rubber gasket that doesn't come with studs.
   I don't like them, they can squeeze out from under the valve cover between studs because they are too flexible.
   
• #5 by Powered by Spearco on 06 Jul, 2011 20:50
• Why even use different studs, just use bolts from the top. You could even buy nice chrome headed bolts that would look even better than crusty nuts on that beautiful valve cover.
  
  Just say'n.
• #6 by DieselBalz on 06 Jul, 2011 22:22
• I cut the little rings outta the spare gasket. Used an exacto knife and some steady hands. Just got back from a quick 5 mile round trip run on my "test course"
  
  All good. No leakage/seepage. Now I gotta polish the VC again cause I finger effed the hell outta it takin it on and off. . Once I realized those little shoulders were permanent, I grabbed the spare gasket, cut one of the rings out, and test fitted it, the remaining hole fit perfectly around the shoulder. From there it was cut out the rest and finish the job. Yes, at 1 oclock in the morning on a work night.
  
  I really wanted to drive my Dub to work tomorrow. My F150 is all floaty and doesnt have that used german car smell...
• #7 by theman53 on 07 Jul, 2011 05:16
• Yes, but now you have to do that every gasket you put in. The other way you just buy a gasket and put it on. Either way is fine but the other way is work only done once.
• #8 by DieselBalz on 07 Jul, 2011 08:57
• Ehh, it took me five minutes to cut out the rings. Easier and cheaper.
  
  Now that I have a shiny vc, I'm really seeing how fugly everything else looks under the bonnet.
• #9 by CRSMP5 on 07 Jul, 2011 09:32
• fyi swallowtails/74-77ish had no step too..
  
  next.. the step is smaller then the copper pieces you removed.. aka thinner.. that means your crushing the rubber gasket which shortens life...
• #10 by R.O.R-2.0 on 07 Jul, 2011 09:44
• Quote from: CRSMP5 on 07 Jul, 2011 09:32

  fyi swallowtails/74-77ish had no step too..
  
  next.. the step is smaller then the copper pieces you removed.. aka thinner.. that means your crushing the rubber gasket which shortens life...
  

  
  yes, all the 1.5L engines had the shoulderless studs.. thats what my 1.6 now has in it, with an ABA valve cover, and gasket..
  
  the ABA VC is better than the stock diesel cover if you can get away with running it.. made from much thicker metal.
• #11 by vanagonturbo on 07 Jul, 2011 12:55
• FWIW, all ABAs also have shoulderless studs..
• #12 by R.O.R-2.0 on 07 Jul, 2011 13:06
• Quote from: vanagonturbo on 07 Jul, 2011 12:55

  FWIW, all ABAs also have shoulderless studs..
  

  
  NO WAY!!!
  
  you have got to be kidding me!!!
  
  lol. 
• #13 by vanagonturbo on 07 Jul, 2011 16:02
• Honest! :p