THINGS OUTSTANDING / TO DO
What am I doing?
- Replace ????'s with actuals
You are changing the gasket between the cylinder head and the rocker or cam cover.
Why am I doing it?
Maybe yours is leaking, maybe you are doing some other work or maybe you are even just bored? Sorry, I mean the cam cover gasket has a limited life span and dependant on how hard someone crammed it on before you owned the car will also determine its lifespan. Once its had it, you will start losing oil – not good
What do I need?
Selection of torx bits
Brake or carb cleaners
Some old rag
Part No. 60607218 & 60607219
ONLY FOR ALFA ROMEO MODELS WITH METAL TOP CAM COVER
ALFA 156 1.6 TS 16V 2000 > 2003
ALFA GTV 2.0 TS 16V 1996 > 1998
ALFA SPIDER 2.0 TS 16V 1996 > 1998
Part No. 60655592
ALFA ROMEO 166 2.0 TS 16V 1998 > 2006
ALFA GTV 2.0 TS 16V 1998 > 2003 (ONLY FOR MODELS WITH PLASTIC TOP CAM COVER)
ALFA SPIDER 2.0 TS 16V 1998 > 2003 (ONLY FOR MODELS WITH PLASTIC TOP CAM COVER)
How much will it cost?
About £20ish for the gasket
How long will it take?
Approx 1.5hrs unless you have done it before – then much quicker
So how do I do it?
First thing to do is to remove the engine cover, to do this simply undo the 4 x T40 torx bolts which will stay in the cover as you lift it off, remove the oil filler cap and remove. Now replace the filler cap.
To progress, you need to remove the spark plug pack, this is 3 x T?? torx bolts as marked on the picture. Now gently pull the spark caps off the small spark plugs (the ones without the coil packs). Push down on each of the coil pack electrical connectors and pull them towards you. Disconnect the loom near the aircon compressor and undo each of the clips, tuck the loom out of the way. Pull the metal frame up towards you evenly at both ends, perhaps a little bit of effort needed.
Great, that’s the hard bit done
So now there are 9 x T?? torx bolts connecting the rocker cover to the head, slacken them off then go around once more to ensure that they are properly undone. Again, great design here – the bolts will stay in the rocker cover. To the right of the cover, start to pull up, you may have to use a bit of effort as the gasket would have sealed itself. Keep pulling until its clear now flip it over to the right of the engine (no need to remove breather pipes). See your gasket now?
Remove the old gasket from the cover and place to one side. Now you have a good opportunity to poke about and see how your cams are doing. These ones have seen 123k miles and they look like new with little wear. Anyway, being a good sport and as you have done all this hard work so far, you can safety check you cam caps if you wish to ensure no bolts are working their way out (have seen this before and it scares the hell outta ya). For this, just use a 10mm socket with the torque wrench set a 11nm, quick check over each to ensure they are all good.
Now you need to remove all that crap that the old gasket left behind, make sure the head is clean (use the carb cleaner/rag to do this)
Once it’s all shiny, check over the cover and clean if needed. Then add the new gasket to the cover, ensure that all the bases of the bolts have passed through the new seals.
My variator solenoid was leaking so I removed it and checked the seals – slightly worn but not enough to get worried about. I used some cam cover sealant around the mating faces and replaced – worth a check as you need the cover off to do this
Now using a T?? torx bit, undo the cambelt cover slightly – this will give you enough room for the lip to pass back over the rocker cover (don’t want a gap now do we!)
Now double check the seal is in place and offer it over the head trying to line up each of the bolts, once happy – get it in position and do a few of the bolts (inners) up hand tight. Once you are happy, go hand tight on each of the bolts. Then get your torque wrench and set it at 8nm (I used 8 on plenty of other engines but please feel free to correct me) and torque each of the bolts. DO NOT cram the seal down, this will lead to premature failure!
Now tighten the cambelt cover and ensure that the rubber lip goes back over the rocker cover.
The rest is pretty much reversal of removal.
Remember to put the earth wire back on the right hand bolt when connecting the spark packs back up.
Use about 8-10nm torque on the spark pack bolts
Go hand tight, then a touch more when replacing the engine cover
Start her up and make sure there is no oil leaks, keep an eye out over the next few days usage and marvel at the cash you have just saved by doing it DIY