top cover

[andrewward]

I have an oil leek problem coming out of the larger rubber seal at the top of the cover, how can I fix this ? I have bought new set of seals but don't know how to remove the cover or install the new seals ,how can I go about this ?, engine 2.8 TD 1991

[turnturn]

Assuming you mean the valve cover/rocker cover it is quite simple. I've just had mine off in the last couple of days.
There are three small bolts (10mm socket from memory) down the middle of the cover that you remove (these are not actually normal bolts but a boss/nut type thingy).
Also remove the two hoses from the back (1 to intake system, 1 to dipstick/sump) intake side of the cover.
You might have to give the cover a small tap to loosen and then lift off.
Give the cover and it's mating surface a bit of a clean and reassemble with your new large rubber seal and three smaller seals that go under the bolts/boss/nut thingys. The torque for these fasteners is only about 10 ft lbs (from memory, might pay to check or have confirmed by somebody else). Re-attach hoses. Done.

It wouldn't hurt to check your valve to rocker arm clearances while your in there. They should be 0.40mm (0.016") with the engine cold.

[wbski007]

Thanks, turn turn, I'm going to do my tappit clearance's and was wondering what they were suposed to be, 0.016, good deal mate.

[turnturn]

Wayne, 16 thou, that was for the 2.8, not sure if it's the same for your motor.

[geeves]

16 thou/inch or 0.4mm

[wbski007]

ok geeve's thanks

[andrewward]

thanks turnturn, I have checked the top cover and I can see that there is a kind of foam insert cover between the two metal cover parts what is this for, also it is soaked in oil
should I replace this ? , I have removed the air intake hose which goes to the turbo and I have found some oil there also is this normal ?thanks again

[pig75]

The foam is just to make the motor quieter. It is hard to clean. To remove the foam you need to remove the breather pipe from the cover it is a press fit. To remove the pipe find a bolt that is a snug fit in the pipe then grip the pipe with some vice grips and twist the pipe out then you can separate the too covers and clean the foam.

[geeves]

some oil in the intake is nothing to be concerned over. Mine has oil there and never uses a drop. If oil consumption is high you can fit a catch can