Replace the valve cover gasket

[AWD Terror]

The following is by DSMtalk.com Community Member supergoat (http://www.dsmtalk.com/forums/member.php?s=&action=getinfo&userid=11299)

<B>Replace your valve cover gasket</B>

<img src="http://www.dsmtalk.com/forums/images/articles/vc/vc-icon.jpg" align="left" border="0"> It's a fact - eventually all DSMs will need to have their valve cover gaskets replaced. This simple article shows you step by step exactly how to do it - with pictures! (Applies to both 1G and 2G cars too.)
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I needed to change mine so I decided to also do a quick "How-to". :D


Step 1: Gather your tools. :)
http://www.dsmtalk.com/forums/images/articles/vc/vc1.jpg

Step 2: Remove spark plug wire cover
http://www.dsmtalk.com/forums/images/articles/vc/vc2.jpg

Step 3: Remove spark plug wires
http://www.dsmtalk.com/forums/images/articles/vc/vc3.jpg

Step 4: Remove valve cover bolts
http://www.dsmtalk.com/forums/images/articles/vc/vc4.jpg

Step 5: Remove PCV valve hose and vent hose on the side of the valve cover
http://www.dsmtalk.com/forums/images/articles/vc/vc5.jpg

Step 6: Remove valve cover gently and lay it on a soft surface
http://www.dsmtalk.com/forums/images/articles/vc/vc6.jpg

Step 7: Gently peel off the old gasket, making sure to get it all. Don't forget the semi-circle plug on the head.
http://www.dsmtalk.com/forums/images/articles/vc/vc7.jpg

Step 8: Many people use RTV around the whole perimeter for the gaskets which is A) not reccomended by Mitsu and B) has been found (in my experience) to cause more leaks than it helps.

The only places that a *LIGHT* skim-coating of RTV should be uses are on the humps for the end cam caps, and the half-moon gasket.

The only other time you should use any RTV on the gasket surface is if you have a large gouge in it, etc.. The gasket is rubber, and can fill in any imperfections alone, RTV is redundant and can actually cause problems in the long run if used in the wrong places or in excess. (information provided by DSSA)

http://www.dsmtalk.com/forums/images/articles/vc/vc8.jpg

Step 9: Clean off any gasket material still on the head and apply a thin layer of gasket sealant where the new gasket will sit. A scotch brite pad is great for this. A razor works to a point, but the Scotch-brite won't score it and will help smooth out any imperfections in the surface---just don't go overboard with it. (addition by DSSA)

Note: While you're at it, be sure to admire my pretty and very clean head and turbo cams. :D
http://www.dsmtalk.com/forums/images/articles/vc/vc9.jpg

Step 10: Now is a good time to change spark plugs.
http://www.dsmtalk.com/forums/images/articles/vc/vc10.jpg

Here is what my plugs looked like, except not as fuzzy. Mmmm, very lean. :rolleyes:
http://www.dsmtalk.com/forums/images/articles/vc/vc11.jpg


That's it! Installation is the reverse of removal. :D Have fun kids. :)

[AWD Terror]

Great article Supergoat! :)

Here are the Mitsubishi part #'s for the gaskets you'll need to order before you can do the swap:

MD186784 - The main valve cover (rocker cover) gasket (x 1)
MD186785 - Spark plug gaskets (x 4)
MD050536 - Half-moon or semi-circle gasket (x 1)

[These are 2G part numbers - The 1Gs are probably the same]

Other random tips when doing the replacement:
* Getting the valve cover off can be tricky if you've removed all the bolts but it's stuck on. Be gentle when trying to pry it off, you do not want to damage the cover!

* Put a towel over the engine while the valve cover is off to prevent any junk falling in there.

* Clean off as much of the old gasket material from the head as possible. A razor blade helps get it smooth.

* While it's off, now is a good time to clean the valve cover itself (or get it powdercoated. :) ). Check your oil cap for leaks or a worn gasket too.

* Be careful torquing the valve cover bolts when putting it back on - they only require about 4-5 ft/lbs max. If you over-tighten these the valve cover will crack (which is not good).

* After the gasket sealant dries, start the engine and let it warm up. Then re-check the torque on the valve cover bolts.



Questions or comments? Please discuss this article here (http://www.dsmtalk.com/forums/showthread.php?threadid=90241).