Tuning Aluminium Valve/Rocker Cover Installation

[Pete145]

Hi everyone.

Well, I've pondered this purchase for a while now (since my 595SS style of conversion), and have finally taken the plunge and ordered an aluminium valve/rocker cover (as well as the appropriate oil filler cap, gasket and gasket rings for the threads).

The top end of my engine has been oil tight for a while now, but I have had issues with leaks from the tin rocker cover not sealing (even Middle Barton Garage put her back together with a leaky rocker cover gasket). So, hopefully, a good quality, sturdy aluminium cover will be just the ticket.

After a bit of research I went for the Axel Gerstl product:

https://webshop.fiat500126.com/katalog/artikelinfo/901/abarth-aluminum-valve-cover-_vertical-letters

Does anyone have any experience doing the switch with this particular cover? I've read some previous threads that talk about the valves fouling on the inside of the cover, and also the studs not being long enough (because they're thicker). I've also heard that the breather hose sometimes doesn't fit as the (brass?) tube is thicker.

The parts arrive today, and I was hoping to tackle the job in the next day or so, any advice would be appreciated before I start!

Pete

 

[Pete145]

I should add, the potential issues listed are related generally to aluminium rocker covers, not necessarily this one. I'm not sure if they apply to this particular one (as I know there are loads on the market).

 

[the hobbler]

Hi peter;
Depending on which carb you have fitted, you might have to do quite a bit of 'fettling'. I had no trouble with mine with regard to stud length. To date, I have had no problems with rockers making unwanted contact with the ally cover. Make sure you use the RUBEROID gasket. As for the breather, I sourced a length of the correct size water-hose (with a right-angle bend in it) and led it down the back of the engine with the hose held in place with a 'P' clip.
Give me a ring at home and I will happily go through any other problems that you may have.

 

[Pete145]

Thanks Hobbler, as always!

I've got the FZD which seems to have plenty of clearance around the standard tin cover, and I "think" the hose already looks about right?

 

[Bambino]

No problems here - fitted straight on.

Tom's right about the gasket - use a similar one on the 3.5L aluminium sump as well.

Chris

 

[Pete145]

Well, I was about to start the job and realised that the oil filler cap is missing its o-ring, so it isn't sealing to the valve/rocker cover!

Have contacted Axel Gerstl, as I assume this is an error (and the oil filler caps would come with the necessary o-ring).

Of course, the rubber from within the existing cap is too large!

 

[Toshi 975]

I bought the same valve cover and did not realise that the filler cap was smaller so did not order one. Buying just the cap was not very economical so ended up buying a Punto cap for about £5 . Same size but does not have the sprung valve which I am going to modify. But if you do not get any joy from AG the Punto cap would get you a new seal.

 

[Pete145]

But if you do not get any joy from AG the Punto cap would get you a new seal.

That's a great tip, thanks!

One last question on this, the consensus 'seems' to be that you replace the nylon locking nuts each time, is this the case? And are the nylon locking nuts M8?

 

[Bleeding Knuckles]

Hi Pete, I have the exact same 'rocker box' as you and have found that my experience is quite different. Although I must say that I am using the later 'Panda 30' head. No problem with the the stud length, but the rocker springs have 'just' contacted the interior surface. Have a trial fit and you will see witness marks where you can make any adjustments by removing material from the inside. My carb is the Weber 30 DGF downdraft twin choke on a low level manifold that does not foul. Now, the gasket has caused me some problems as I have found that the temperature of the engine has made the rubber item go hard and consequently not seal properly. I now use a simple, cheap cork item that does not leak at all. I will say that if you prepare the mating faces by cleaning with methylated spirit (no residue) and then position the cover carefully and tighten down evenly and gently don't go too far, but allow the seal to settle and after 10 mins or so clamp it down, but again not too much to cause the seal to protrude out, only practise will tell you what is just right. Good luck!

Ian.

 

[Toshi 975]

M8 is correct and I use a plain washer over a suitable fibre washer. I am going to try the rocker cover with a smear of gasket sealant a no no gasket. That will be after I have checked the cover base for flatness.

 

[Pete145]

Buying just the cap was not very economical so ended up buying a Punto cap for about £5 .

Quick question, what year Punto was the cap for?

 

[the hobbler]

The best seal I have found for the oil-filler cap came from the plumbing dept of B+Q! Can't remember exactly which one it is but if anybody is interested, I can measure my spare one for the Forum----and it cost pence!

 

[Pete145]

Ha! That's brilliant Hobbler. I measured the outside diameter and it looks like 50mm. Inside diameter is more flexible I guess.

 

[the hobbler]

Morning Peter;
Sorry for slow reply, but at the moment I am not feeling on top of the world--on antibiotics for a chest infection that has been dragging on for about 5 weeks!----not amused. The outside diameter of the seal that I have used for my oil-filler cap is 47.5mm, the internal diameter is 34.5mm and the thickness is 3.2mm. I have a feeling (from measuring my spares) that the seal was originally (externally) 44mm, but has spread a bit with use. The internal measurement is, to a degree, the more important measurement. These seals are thicker than the seal originally supplied with the cap and therefore give a better seal and the cap is less likely to loosed (and therefore leak). One other piece of advice--these ally rocker-covers can be VERY SLOW TO ALLOW FILLING OF OIL---if you are not careful, you will put a fair part of the oil down the breather hose.

 

[Toshi 975]

Quick question, what year Punto was the cap for?

I had a look on ebay and it is described as a febi 12374 to fit 1993-2005 Punto as well as Uno , Tipo , Tempra models

 

[Pete145]

These seals are thicker than the seal originally supplied with the cap and therefore give a better seal and the cap is less likely to loosed (and therefore leak).

Thanks Hobbler. AG has found the seal in the box in their warehouse, it had come off and the picker hadn't noticed. I think I'll still head to B&Q and pick one of these up though!!

 

[Pete145]

Morning Peter;
The outside diameter of the seal that I have used for my oil-filler cap is 47.5mm, the internal diameter is 34.5mm and the thickness is 3.2mm. One other piece of advice--these ally rocker-covers can be VERY SLOW TO ALLOW FILLING OF OIL---if you are not careful, you will put a fair part of the oil down the breather hose.

Well, not a great day in the office (garage) today! I did go to B&Q and picked up a seal, which does fit perfectly and better that the one that arrived in the post today from AG (nice tip). So, armed with what I needed I set myself to work!

The cover did require a small amount of fettling, as it was fouling on the engine shrouds in two corners, just by a couple of mm. I filed the corners away a touch and it sat perfectly.

Now, that's the good news The not so good news is two fold:

1 - The breather pipe isn't long enough to reach around to the nozzle (it's angled on the original and points straight back on the new cover). Not an issue, I just need to source a longer piece of the appropriate hose.

2 - More of an issue, the studs are not long enough to take the increased height of the new rocker cover, and the nuts can't hold a thread. They're about 10-15mm too short.

Does anyone know where to source longer studs? Also worth noting is that during the first week of ownership the studs stripped out of the cylinder head and needed to heli-coiled, so I'm a little nervous about messing around with these studs!

Any advice most welcome!

 

[thepuddlejumper]

I don't know how far the stud protrudes through the new cover, but would it be possible to drill the holes out and use a sleeved nut which would go into the new hole and screw onto the stud, use a thread lock to secure. I did this a few years ago to solve a similar problem, it worked well.

Ralph

 

[Pete145]

That's a nice solution.

Hobbler has been very kind and agreed to send me some stud bolts which we think might be longer. If they're not, this creative approach could well be an option.