metal clip from oil filler cap in engine ! - Alfa Romeo Forum
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(Post Link) post #1 of 18 Old 04-06-07 Thread Starter
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Not Happy metal clip from oil filler cap in engine !

Just been topping up the engine oil in my 75 2.0 TS and part of the oil filler cap has fallen into the engine block through the oil filler hole.

The offending item is one of the two metal clips that hold the filler cap in place on the engine. One half became detached and has fallen into the engine block.

Now I'm scared to start the engine in case the engine self destructs !

What do you think ? Thoughts anyone ?

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Re: metal clip from oil filler cap in engine !

Take the rocker cover off. Will need a new gasket only a few £. Then when its off you can polish it a little .

Its an easy job and you will be able to get the offending item out, and no don't start the engine.
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Re: metal clip from oil filler cap in engine !

Gavin,

Thankyou for your quick and very helpful reply.

I've ordered some new sump and rocker cover gaskets (plus a new oil
cap) and am planning on removing the rocker cover to see if this
reveals the location of the offending item.

One slight problem, I've never removed the rocker cover before, can
anyone give me a simple overview of what I need to do ?

I'm hoping that the rocker cover will be removable without
disconnecting the 8x ignition leads ?

I can also see what looks like a distributer cap connected to the
front of the rocker cover and a rubber pipe connected to the side of
the rocker cover (is this part of the cooling system) ?

Is the sump easy to remove/replace ?

PS> The engine is a 2.0TS (1991) - UK spec.

Thanks....... Robin.
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Re: metal clip from oil filler cap in engine !

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Originally Posted by roti155 View Post
Gavin,

Thankyou for your quick and very helpful reply.

I've ordered some new sump and rocker cover gaskets (plus a new oil
cap) and am planning on removing the rocker cover to see if this
reveals the location of the offending item.

One slight problem, I've never removed the rocker cover before, can
anyone give me a simple overview of what I need to do ?

I'm hoping that the rocker cover will be removable without
disconnecting the 8x ignition leads ?

I can also see what looks like a distributer cap connected to the
front of the rocker cover and a rubber pipe connected to the side of
the rocker cover (is this part of the cooling system) ?

Is the sump easy to remove/replace ?

PS> The engine is a 2.0TS (1991) - UK spec.

Thanks....... Robin.
I think the leads need to come off, mark them up at the plugs with masking tape etc.

If it's a fairly large diameter pipe (20mm) it's a breather from the rocker cover I believe (from memory it's been a while.....)

I think the dizzy can stay where it is (if not, mark it's position prior to removal), and you should be able to undo all the mounting bolts and pull the cover up after removing all of the above.
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Re: metal clip from oil filler cap in engine !

Hi. I will sort out a pic showing what to, and not to take off.
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Re: metal clip from oil filler cap in engine !

Ok LOL. Not a very great pic off a how to. But gives you an idea.

The red screws hold on the plate that covers the spark plugs. The leads go under this. There is 4 Allen key bolts to take out. Take them out and pull off the plate.

Then pull off the HT leads. Be careful don't break them. (little tip. I used to mark them with tip ex, 1 mark for the first lead, 2 marks for the second lead and so on) And put them aside.

Then take off all the Allen keys around the rocker cover. Ive marked a few out in yellow. But there is more around the back ect.

Then take off the breather pipe there should be a jubilee clip on the pipe. Mine has not got one as i am working on my engine.
engine.jpg

The cover will come off. Just a little wiggle as it is held on with sealer.

Just remember to clean the two contact surfaces before you replace it.

Here's the pic sorry my engine is a bit different. It does not have a dizzy cap and only 4 leads, as it has been converted into a single spark with throttle boddies and electric engine management ect. But its nearly the same. Plus mine is all dirty lol.

Hope this helps. If you get stuck let me no.

Young Alfisti

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Re: metal clip from oil filler cap in engine !

OK, I've now got the cam cover off and have successfully located and removed the missing piece of the filler cap. Wo hoo !!

I now have another slight problem... The new gasket set I have received includes 2x rubber bridge shaped gasket items. I can see that these fit over the Dizzy at the front of the engine and also a similar shaped object at the rear of the engine. My problem is that there is a 3rd bridged shaped area to the left of the front of the engine. I have marked this in the yellow area on the attached picture. Should there also be replacement rubber gasket item for this area as well ?
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Re: metal clip from oil filler cap in engine !

Well to be honest yes i would have thought so. Try using the same gasket you will get away it I'm sure.
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Re: metal clip from oil filler cap in engine !

hey gavin ,
need to change my roker gasket.was lookin in the forum and came across. this ....is it as easy as you make it sound..//2l ts ...


roti how did u get on in the end ....pls let me know as im about to attempt it
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Re: metal clip from oil filler cap in engine !

Yep easy. Just read what i wrote and it should be fine. Just be careful not to get any dirt grim and bits of gasket in the engine.

And tighten down the cover evenly.
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Re: metal clip from oil filler cap in engine !

GAV
took the caseing off ..may sound like a daft question but.is there a way to take out the plug leads.
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Re: metal clip from oil filler cap in engine !

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Originally Posted by gavin dack View Post
Yep easy. Just read what i wrote and it should be fine. Just be careful not to get any dirt grim and bits of gasket in the engine.

And tighten down the cover evenly.
What he said.....

But....DO NOT...overtighten. You can snap rocker cover bolts quite easily and they can be a right fanny on to get out afterwards if you do.
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Re: metal clip from oil filler cap in engine !

got the leads off but 1 ....as gavin said be carefull in case i break it ....its just to hard to get off,,,,shall i use force ///or just give it to a mechanic
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Re: metal clip from oil filler cap in engine !

Quote:
Originally Posted by SANJ View Post
got the leads off but 1 ....as gavin said be carefull in case i break it ....its just to hard to get off,,,,shall i use force ///or just give it to a mechanic
use long nose pliers on that plug cap.... never pull on lead!!!!
any other questions just ask....
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Re: metal clip from oil filler cap in engine !

when you say use long nose pliers on that cap ...would that not be the same as me pulling it off..all 3 come off but the third one wont move..so i cant see how the long nose pliers would help
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Re: metal clip from oil filler cap in engine !

Get low on the cap not on the lead like spence said. Grip it quiet hard wigely it about and side to said. You wont hurt it. I have one any way if you break it
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Re: metal clip from oil filler cap in engine !

Thanks
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Re: metal clip from oil filler cap in engine !

All
got the rocker gasket changed as i found out it was still under warranty...came home last night ..and yet this morning there was oil again on the floor ...checked around the rocker today and it was bone dry ....i have even had the oil filter changed as it had a crack.....checked the oil level and it is perfect ....could it be that is is comein out of a breather pipe(that is if it has one).cant work out wot the hell is going on ..and its driveing me up the wall..ive taken it to garages to get this problem solved a number of times and they were the only two probs found....sump has been checked...and so on and nothing,,,.pls help
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