Huge oil leak from bottom right of cam cover

[misterp]

Grrrrr

Sometimes I think the car gods don't want me to enjoy cars as just when things are looking up, they quickly come crashing back to earth!
I'm possibly over dramatising but after getting the engine fired and running for the first time in 5 years, I find that it's spewing oil badly out of the lower right hand side of the rocker gasket.

The bad news is that it looks like it's been badly helicoiled and stopping the cap head from tightening down fully and so allowing the gasket to leak. Ive made a rubber 4mm thick gasket to try and combat this problem but it seems that no matter what I do..it won't tighten down and stop the leak.
The PITA is that it's the fixing opposite the shock tower, meaning access is limited to get a drill and/or remove the helicoil.

Any advise on how to fix this? Copious amounts to instant gasket?
Any tips on getting a drill to it and possibly removing the old helicoil and re-doing it?

Thanks

Andrew

[matt of the vivas]

If i read this right, the bolt is bottoming out in the helicoil before it clamps the rocker cover down?
Surely then the easiest way round it is to shorten the bolt slightly?

[dursley92]

or is the helicoil sitting proud of the head surface?

[xvivalve]

Are you using the allen key operated cap headed screws?*

If it is bottoming out them simply use sufficient washers under the cap head to allow you to torque it down.

*If your cap heads are conventional posidrive, then replace them. £7.00/set posted.

[misterp]

Thanks for the replies..

As you probably know, given the location and the angle Its tricky to see some of the detail. Ive ordered a set of LED mirrors to hopefully get a better view of things.

or is the helicoil sitting proud of the head surface?

Nope..I checked that as originally I figured that may be the issue, but flush and a few mm below the surface

Are you using the allen key operated cap headed screws?*

If it is bottoming out them simply use sufficient washers under the cap head to allow you to torque it down.

*If your cap heads are conventional posidrive, then replace them. £7.00/set posted.

New set of 5/16 UNC capheads are being used. Im using SS, but Im getting some galling so may change back to the mild steel type.

Ive also tried packing with a few more spring washers, and whilst it tightens down to a point where Im unable to tighten further, it still leaks down on that bottom right hand corner.
I also thought it may be the gasket slipping, so instant gasket-ed the rubber gasket in place on the cover...and it still leaks.

I think what has happened is the previous owner has drilled but then not fully tapped down the hole before inserting the helicoil. Whats then happened is that they have wound the helicoil in and at the lower point, with no threads lower down the hole (or the thread being shallower) its tapered the helicoil inwards (so image a cone type of thing).

When I screw the caphead in it 'bottoms out' or locks before all the others.

I may turn this the other way round..If I fit a set of 5/16 UNC studs in the holes, then use a set of domed 5/16 UNC nuts to bolt it down it will remove this problem.
Only consideration is that can you still get the cover on and off with 1" or so of stud sticking up?

Another thought is that is there anything else in that area that could cause an oil leak?
Although I 'think' its the cam cover gasket leaking is there anything else around that area (either back of head or under the exhaust manifold) that can leak? The oil is not being burnt on the exhaust though...so wherever it is coming from in that region, its missing the exhaust luckily.

Its difficult to see under there being a slant engine and then from underneath the subframe gets in the way

Anyway...sorry for the long winded reply.

[tony g]

If the helicoil is causing the thread to bind, I would make a stud from a cut down bolt and screw it in as far as it can go. Then use a nut to tighten. I think youll be pushing your luck trying a 5/16 thread down there, not much casting plus unless the engine is out getting to the one next to strut will be a pig to drill/tap.

Tony

[misterp]

If the helicoil is causing the thread to bind, I would make a stud from a cut down bolt and screw it in as far as it can go. Then use a nut to tighten. I think youll be pushing your luck trying a 5/16 thread down there, not much casting plus unless the engine is out getting to the one next to strut will be a pig to drill/tap.

Tony

Ah..makes sense...the PO has already drilled and helicoiled 5/16 UNC.

That was my assessment of the whole remove, re-drill, re-helicoil option..a right PITA!

I`ll just try the stud with that lower corner for the time being then if it stops the leak I at least know Im on the right track.

Thanks

[Jon Tilson]

Finding it hard to see how the oil isnt getting on the manifold and smoking like a good'un....

They dont actually take a lot of sealing....sufficient spring washers should do the job with a decent gasket and goo...

You sure you dont have a head gasket oil way damaged.....

Sorry to rain on your parade...

Jonners

[misterp]

Hi Jon,

Thats my fear....Unfortunately when I got the car, the previous owner had fitted the replacement head



So...I really don't know if it has been done correctly. It has good compression though and it all seems OK, runs well and has a good turn of speed without any noises.
I may get the boreoscope out and see if I can get a good look under there, but I can tell its definitely leaking from that area as when I put a bit of old rag between the exhaust and the area of the flange, it gets oil on it.
I think its just the bolt not tightening down at all, so I`ll try the stud approach and go from there.
What I need to do (if I cant get a decent resolution by tightening it) is to clean it thoroughly and then run the engine for a bit to get the oil to circulate and then check to see where is coming from.

Cheers

Andrew

[misterp]

Just posting that photo has made me see one bit Ive missed.

The bl&!#$@dy front 1/2 moon rubber seal.

Not sure if its the cause of my oil puddle and how it might make its way to the rear of the engine, but its possible its finding its way to the lowest point and dripping from there.

Job #1

[tony g]

Was it stuck to the gasket?

Tony

[misterp]

Nope..just plain old forgot to fit it!

Getting old

[misterp]

Well...now im pi$$ed off

So..removed the cover, fitted the rubber seals and had a look at the suspect helicoil..and its been fitted by a rock ape.

Goodness knows how they actually got it to fit, but its all over the shop and to make it doubly worse, I dont think there is any other option that to remove the head and re-do the insert as I cant get to it properly even with a 90 degree drill as there is just not enough space.

Sooo..head off

Please..someone humor me..and please tell me that I can remove the head fairly easily?
Apart from the 2 upper fixings holding the front of the cam chain cover to the lower section, the inlet manifold and the exhaust manifold, once Ive secured the cam sprocket to its carrier and removed the fixings, the head should be free to come off?

Best option? or easier to take the whole engine out?

Im going to have a beer

[Mahesh]

Just humouring you,

Your head will come off easily, dependent on what the rock ape has or has not done.
(in your hands or errupting volcano style)

[Tony Burd]

If you undo the engine mount on the exhaust side, you might be able to jack up that side of the engine enough to get a drill in? Worth a go before you whip the head off.