Seized stud rocker cover!

[christhemann]

Seized studs, always a bugger!

Just in the process of replacing rocker cover gasket with the uprated "rubber" type as I was advised to.
This involves removing the old studs and replacing them with the new shoulderless type.

Managed to get 7 of the 8 out, but one is proving very hard to say the least.
Any ideas would be appreciated!

I've tried the usual, locking two nuts together, no luck.
Even ruined the thread by locking mole grips on trying to remove it.
Finally tried hacksawing a slot in the top and putting a flat head screwdriver on, but when turning it out the bolt just
split in half at the top! (only a slim stud anyway, m6 I think).
Theres only about 2 cm left of the stud!

As a last resort I tried sticking 2 nuts onto it with JB weld, will try tonight but not sure it'll work.

[ianaudia4]

Stud removal tool?

[walkinginperu]

Use a bit of soft metal (ali, brass) as a drift, place it on top of the stud and then hit hard with a hammer. The shock might loosen off the threads if they are corroded. WD40 obviosuly, and maybe try applying some heat if all else fails. Stud extractor may work, but i find them temperamental.

[christhemann]

Done it!
Thanks for the comment walkinginperu.

That was my last resort last night after trying to drill it, cut and slot etc etc.
There was a notch cut in the top, so placed a flathead screwdriver in the side and tapped with a hammer carefully (if thats possible! lol).

Finally freed it up, and got the rocker cover all sorted.
On to the next task now. Hmm, rear wheel bearings I think then rear bushes.

Thanks all.

[whiteshark]

Where did you get the rubber rocker cover from. Are they any good. Just replaced mine with a Cork one and I'm waiting for oil to spill/ leak again out into the exhaust manifold, however, no oil leaks yet. Has any one else experience of this or should I fit an oil catcher as I think the oil maybe is spilling out from the air housing. (Hot air from the rocker cover breather tube into the air housing oily) Pissed off wiping oil from my manifold and it spilling down the back of the engine.

[christhemann]

Got mine from www.vwspares.co.uk
He's very useful and does only quality german parts, which I find much better and cheaper than GSF!

The gasket is listed under MK1 Golf as "Diesel" type, and you need 8 replacement studs to fit it.
Well worth doing, as I replaced mine with the cork type twice in 3 years!

Also worth cleaning out your rocker cover and breather.

[ianaudia4]

The rubber gasket can be bought from the dealers, if you order a rocker gasket that's what you get (it's actually from a MK3 Golf!), I paid £15 ish and that included the studs, well recommended.

[whiteshark]

Thanks for the replies. Will see how this latest cork one lasts then get on the case of fitting a rubber one. Thanks for the advice.

[christhemann]

Looks like the new rubber rocker cover gasket, as recently fitted to the Scala is still leaking!

I replaced all the studs, tightened them as much as possible and fitted in nuts. Then torqued according to haynes (something tiny like 10-15nm).
But there is oil leaking down the inside of the cambelt cover, also onto exhaust manifold and dripping down the back of the sump.

First off I thought it was the cam / crank seals, but can't be as it's too high!
Seems like changing to a rubber gasket has introduced more leaks that there was to begin with on the old cork one.

Anyone fitted one, have any tips? I was told not to put any sealant on it, so cleaned all the old stuff off and fitted it dry.

Cheers,
Chris

[davep]

Perhaps the torque setting in the Haynes manual is relevent to a cork gasket only. I'd take it up to three white knuckles (about 40nm) ;)

Seriously, i dunno, but the torque value might need to be different.

[PeteGLi]

Check the intermediate shaft oil seal.

[Nate]

first off, clean all the oil from the engine with some degreaser. it can get spread around very quickly. then take it for a short run and see where fresh oil has appeared

[PeteGLi]

You will need to remove the top cam belt cover to see where the leak is coming from. My money is on the intermediate shaft.

[MikeH]

If it is still the cam cover seal (and that's possible, check the flatness of the mating face of the cam cover, and also its cleanliness, and also of the mating face on the head - any dirt, bits of old gasket, or damage to the ali of the head will cause a leak.

If the surfaces are clean and straight, I've never had a problem getting a cam cover to seal with one of those rubber gaskets - even re-using them for the nth time, and on a replacement head.

Sound advice above about cleaning all the existing oil off to see where it's coming from.

If it is the intermediate shaft, I think you'll have to take the bottom cambelt cover off as well, to see it.

[christhemann]

Cheers for the comments.

I made a point to clean the face of the head and the inside of the rocker cover really well, didn't see/feel any damage.
Will get the timing covers top / bottom off and have a closer look.