DIY Valve Cover Gasket

[99gtlimited]

Ok, so i had to do this a couple of weeks ago on the RH side of my motor so here's a DIY for that, the other side is very much the same just with a couple extra things to remove before you can get to the valve covers well enough (washer fluid tank, battery, oil ill tube...)

First off, here are the parts needed for each side:
2 spark plug gaskets
1 Valve cover gasket (side specific)
6 Valve cover bolt grommets

Here's a picture of what i used for the RH side:

I got these gaskets on ebay and have been very pleased with them so far, only $25 shipped for all parts needed for both sides.

https://sl-i.net/FORUM/images/imported/2009/01/IMG_3957-1.jpg

Installation:

Right hand side (passenger side):
1. Remove Intake system (torque box, tubing, MAF, airbox...)

https://sl-i.net/FORUM/images/imported/2009/01/IMG_39511-1.jpg


2. Remove Spark Plug wires from top of spark plugs and pull them up out of the way. Here's what you should see more or less:

https://sl-i.net/FORUM/images/imported/2009/01/IMG_39501-1.jpg


3. Now go to work removing all 6 10mm bolts holding the valve cover on, some you can use a ratchet others you need to wrench since there isn't a lot of room. Once you have them out you can carefully remove the valve cover. The old gasket should be in the cover still, if not you have to peel it off the head itself.

Valve cover off, shown with old valve cover gasket and spark plug gaskets.
https://sl-i.net/FORUM/images/imported/2009/01/IMG_39471-1.jpg


4. While it's off you can clean out the valve cover, but mostly just make sure the grooves to seat the gaskets are clear. Next you can set the new gaskets in the grooves, they should fit rather snug.

New Gaskets in place:

https://sl-i.net/FORUM/images/imported/2009/01/IMG_39491-1.jpg

Here's a look at the DOHC valve train, notice the orange silicone that the previous owner had used too much of in many places, in turn causing the leak that made me change this out. I carefully cleaned it off with a razor.

https://sl-i.net/FORUM/images/imported/2009/01/IMG_39481-1.jpg


5. Now you can begin installing the valve cover, be sure to tighten the middle two bolts down first then work your way around the outside in a star for proper torquing sequence. These bolts do not need much torque so i be sure not to snap one in the cylinder head.

6. The rest of install is the reverse of taking it apart, just remember to plug everything back in when your done. Here's a look at mine when i was finished.

https://sl-i.net/FORUM/images/imported/2009/01/IMG_39521-1.jpg


As i said earlier, the other side is the same you just have to remove a couple extra things to get more area to work in.

I was inspired to post this to help people after my parents were quoted $420 to do this at a mechanic on their 2001 outback, now i get to go learn to do the SOHC valve covers too! :smt021

[KAG]

Haha...weird - I picked up the parts for this on my way home tonight and planning on getting it done tomorrow. I'm doing the same side too. :cool:

FWIW, it was a little over $50 from the stealership. You got a deal.

Excellent write-up, nice job.

[99gtlimited]

Yeah i called a local dealership here and they wanted like $40 just for the valve cover gaskets then the guy tried to tell me there was only 5 bolts to hold it on even though i told him i had a DOHC motor... so i hung up and went deal hunting online.

long story short, dealerships do not have DEALS.... ever

[rougeben83]

I was inspired to post this to help people after my parents were quoted $420 to do this at a mechanic on their 2001 outback, now i get to go learn to do the SOHC valve covers too! :smt021







This should make it easier, it's what I used when I did mine:

http://www.rs25.com/forums/showthread.php?t=51254

[99gtlimited]

yeah i've seen that one before, thanks for the link though

[decke48]

side note the rtv isnt a bad thing to do but you should only do it were theres sharp edges and dont use much

[99gtlimited]

^^ yeah this was a little too much. on the bottom was actually creating the small oil leak that was dripping on to the crossmember.

[T_F_E]

Excellent write up! wish I would have seen that before I did my a month ago

[99gtlimited]

any of you mods wanna put this up in the threads of note? N/A powertrain would be appropriate, though i imagine it's almost the same for turbo models as well.

[evolegacy]

^^ yeah this was a little too much. on the bottom was actually creating the small oil leak that was dripping on to the crossmember.


y thats what mine is doing right now on both sides, mostly my fault since i just replced the gaskets about a month ago, i think its either faulty gaskets, improper seating, or probably because i didnt tighten the bolts in the correct order....where'd you find that $25 deal online, because im not going to spend $60 at autozone heh.

[jey]

any of you mods wanna put this up in the threads of note? N/A powertrain would be appropriate, though i imagine it's almost the same for turbo models as well.

Done.

[99gtlimited]

thanks jey!!!

[warrior]

Another tip that you might want to add.

Those two half moons sometimes need replacing too. It's a good idea to swap them out but make sure you use Subaru Gasket Maker or another type of gasket maker on the underside of them. :smt023

[beckleysuby51]

awsome riteup i did my using this a a guide and had no problems except the hardcore chevy shopteacher tellim me i was wrong lol

[99gtlimited]

^^how so?

[green97gt]

what did you torque your bolt to? or just "gudintight"? i just got mine from ebay, gonna do them tonight.

also, is there a gasket for the black box/square on top that the air/breather(?) hose comes out of? cause im pretty sure these are leaking for me as well.

thanks.

[99gtlimited]

These bolts don't require much torque at all, and it is very easy to strip them. I think factory spec is below 5 ft-lb...

The gasket set was made by a company called Eristic Gasket, and they sell tons of these on ebay, they work just fine but don't have the warranty Fel-Pro and others have.

[green97gt]

yeah, mine are Eristic, the look pretty decent. and you cant beat the price.

and ive got the same driping on the Xmember problem, im wondering if this is the cause of the HOT smell all the time.. we will see, i should be getting my motor mounts, and front seals fairly soon...

[99gtlimited]

the smell is most likely from oil dripping on the exhaust manifold, the x-member doesn't get that hot and would just collect a lot of dirt and grime in the oil, but you can wipe it off.

[green97gt]

got them off, now its almost dark and raining. so ill put them on in the morning.

i noticed some oil in the torque box, not alot, not enought to drip out, but just a few little drip marks on the bottom of the torque box, has anyone else seen this?
also a small amount of smoke coming out of he hose that connect theplastics of the air intake ducts to the crankcase.
so i assume thats where the oil in the torque box is coming from.

99gtlimited, when you did your valve covers, did you replace the gasket on the little black box on top of the covers? if so did you get it at the auto stores, or did you have to go to the dealership?

thanks.

[99gtlimited]

I didn't replace that gasket, not really sure where to get it either... call subaru and find a part # i guess.


The oil in the torque box is from the those lines running from the valve cover to the box, it is caused by increased pressure in the valve cover, and a little bit of oil comes out with the air and goes back into the intake tract. You can get a catch can to remedy this if it really bothers you, but N/A cars don't tend to have as much of a problem as turbo cars since the pressure after the compression stroke is higher in Forced Induction applications.

[green97gt]

yeah, not really worried about it, untill it becomes TO MUCH oil in there...

thanks... your writeup was very helpful, as well as some gearwrenches....

[99gtlimited]

Glad it was of use to you!

If anybody needs a LH side valve cover gasket or the spark plug gaskets for EJ25D, Let me know i have 2 extra Sitting around... I'll give you a good deal, PM me!

[green97gt]

so, upon closer investigation... my valve cover gasket has two tabs that my valve cover does not... in the pictures 99gtlimited posted of his valve covers, you can see one of the two tabs in the about 2 or 3 inch long 45 degree angle and one of the taps in the 6 inch or so length right next to the 45 degreee space....

i ordered gaskets for a 97 gt... but since i know this motor has been swapped at one point, it must have been swapped with an older/newer motor, any ideas???

i found an imprint on the inside of the valve cover that says

"795-2

25RH"

so maybe this motor came from a 95?

im deciding now wether i want to cut the tabs off, or order new gaskets..this is a wrench in the works..

thanks guys.

now i notice that in the pictures 99gt posted, his have extra tabs too....

old vs new the old one has the wrench in it.
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs151.snc1/5608_1121550442059_1326025800_30386003_1026769_n.jpg

the valve cover
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs131.snc1/5608_1121553362132_1326025800_30386018_1714853_n.jpg

99gtlimited; what did you do to solve this problem?

[99gtlimited]

Interesting, I've never seen that before, My '99 has the spot for the tabs so I'm guessing you might have the early version of the 2.5 from a '96? I Imagine you could just cut the tabs off with a razor and be fine, as long as you do a clean job of it and it still seals well. Do you have a picture of your heads with the cover off? it might give me insight into what motor you have and why your covers are different.

The new gaskets look much nicer than the old one though for sure, nice and thick, just make sure they seat and seal properly...

[green97gt]

am i wrong, or does the picture you posted showing you old gasket not have the tabs???

[99gtlimited]

am i wrong, or does the picture you posted showing you old gasket not have the tabs???


that does seem to be the case strangely enough, never noticed that. The gasket was leaking right at the point where the tab on the 45 deg part is supposed to be. You got a sharp set of eyes there bud!

[green97gt]

hmmm...ill try cutting the tabs off.... ill try to get toy a pic off the heads with the valve cover off....


damnit...grrrrr....

time for a drink.

[green97gt]

ok, here are some pics of the head with the valve cover off. perhaps you can be more specific as to what your looking for? these were taken in the dark/rain in my driveway with a crappy camera.

so you think maybe someone swapped this with a 96? anything is possible...

http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs131.snc1/5608_1121562842369_1326025800_30386025_5928585_n.jpg

http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs131.snc1/5608_1121564442409_1326025800_30386027_2141485_n.jpg

the valve cover gaskets i bout, according to the seller are for 97-99

hmmmmm

moar drink...

[99gtlimited]

The 96 have HLA's (hydraulic lash adjusters...i think?) and are actually considered a better head than the 97-99. To be honest I would just cut the tabs and not worry about it, Just make sure it seats all the way in the groove and creates a good seal with the cyl. head

[green97gt]

how can you tell the difference between the lifters just by eyeballing them?

ive already cutthe tabs and plan on putting it on tommorrow, well see...

[99gtlimited]

did you get it fixed???

[green97gt]

yep.

you werent kidding on those bolts being easy to strip either....

the top middle one had goofed up threads on the head, and the first few on the bolt when i removed it to get the old valve cover gasket off.

figured id be able to salvage/reuse/make do one more time....i was wrong.

drilled out the head and tapped it, put in a heliciol, which i had never used before and was skeptical, chased the threads on the bolt, and it seems to have worked well, at least its not leaking anymore. i was just glad it was one of the bolts on the top of the engine, instead of the bottom.

got my motor mounts and front end seals in the mail today.

[hellaGT]

Just got my gasket set from ebay today, doing this tomorrow :smt026

[hellaGT]

I had the same problem that green97gt had. The old gasket didn't have those tabs that the new one has.. or had cuz I cut them off. So far no leakage (knock on wood)

[hellaGT]

So the new valve cover gaskets are leaking more than the old... it must be because of the tabs I had to cut off.

I then realized that I had installed a JDM engine which was a 96-98 model, had it rebuilt by risingsunengines.com. Went to kregan and saw a picture of 97 model gaskets and they didn't have the extra tabs. Going to install these in the morning.

[datdookie]

so yeah, i did this on my sister car but she has 2001 impreza rs. I was just wandering if this step would work too for a phase 1 2.2.

[99gtlimited]

It should be pretty much the same, just use your intuition and label connections if you're bad at remembering. Good luck

[datdookie]

I just did this today and it was pretty much the same but more simple.

[Bd4mp-dub]

i wish i would have found these gaskets cheaper i paid 100 dollars for the 10 bolt washers 4 plugs gaskets a 2 valve gaskets!!!

[99gtlimited]

i wish i would have found these gaskets cheaper i paid 100 dollars for the 10 bolt washers 4 plugs gaskets a 2 valve gaskets!!!

sorry to hear that... BUT,

better than paying upwards of $400 to have a dealership do it for you...

[Bd4mp-dub]

yeah man it was a pretty fun project lol! gave me something to do haha! when i bought them the guy asked when i was going to set up an appt to have them out it lol. when i told him i was doing it myself he gave me one crazy look

[Drakien]

Thanks for the write up! The 2.2 was WAY easy to do!

Yay for tight working space!

https://sl-i.net/FORUM/images/imported/2010/02/382310718-1.jpg

https://sl-i.net/FORUM/images/imported/2010/02/382310770-1.jpg

[Okin DaVanh]

I gotta do a 99 Forester in the morning.... thanks for making the research easier! I let you know how I made out.




******edit********


Thanks to this DIY, it was a breeze and nearly identical on Forester.

[Benders]

Op: did you use any RTV or gasket maker in the sharp corners when you did your gasket like was later sugested? If so which corners did you use some, and did you use high temp silicone RTV, or gasket maker? (Yes, there is a difference) ha ha
Thanks,

-Ben

[99gtlimited]

I used RTV on the sharp corners of the head and some gasket maker on the bottom where it had been leaking previously.

[harrymaneuvers]

I just ordered my parts to do this repair. Found out that my local subaru dealer (Maita Subaru) has an online ordering site that prices parts under MSPR... and then I can just come in and pay/pick up my order.


Mechanical Catalog - Subaru
Valve cover gasket, legacy/outback, w/o turbo - 2.5l 2005 2 $12.71 $0.00 $25.42
Status: Ordered
OEM Catalog

GSKT SPARK PL PIP 4 $3.50 $0.00 $14.00
Status: Ordered
OEM Catalog

WASHER ROCKER COVER 10 $2.86 $0.00 $28.60
Status: Ordered
Sub Total $68.02
Tax $5.95
Shipping $0.00
Handling Fee $0.00


Total $73.97


I will be doing half this weekend and half next weekend.

[harrymaneuvers]

Passenger side valve cover gasket, spark plug gaskets, and spark plugs changed. It was actually much easier than I expected... maybe an extra 10 minutes more than the time it takes to replace just the spark plugs.

I did notice that it looks like either the rear main seal or the oil seperator plate is leaking and my passenger side front cam seal might be leaking as well. When I had the timing belt and water pump done, the mechanic (I was helping/watching) replaced the front main seal but it didnt look like the cam seals were leaking at all so we left them alone... that was 30k miles ago... so maybe it is just time.

[harrymaneuvers]

Drivers side is done. Just had to remove the battery, windshield washer bottle and the oil filler neck.

My spark plug boots were all leaking pretty bad to the point where each spark plug hole had a fair amount of sludged oil down at the bottom of them, on top of the spark plug where it is threaded in.

How would everyone else try to clean that sludge out? I ended up wrapping a paper towel over a long 3/8 extension and running it all the way down there... It would only pick up as much as the paper towel would absorb though.

[burningindulge]

So these are the gaskets i need according to subaru parts.
http://www.subarupartsforyou.com/cp_par ... artid=3497 (http://www.subarupartsforyou.com/cp_partdetail.php?partid=3497)
But what are the grommets for?

[harrymaneuvers]

the grommets/washers are for ever bolt that attaches the valve cover...

[Felipe]

Im about to do this. Just wondering if i should do it before, after or during an oil change and How much oil was/is lost while doing this?

[Felipe]

My spark plug boots were all leaking pretty bad to the point where each spark plug hole had a fair amount of sludged oil down at the bottom of them, on top of the spark plug where it is threaded in.

How would everyone else try to clean that sludge out? I ended up wrapping a paper towel over a long 3/8 extension and running it all the way down there... It would only pick up as much as the paper towel would absorb though.

:-( same here

[Odycee]

Im about to do this. Just wondering if i should do it before, after or during an oil change and How much oil was/is lost while doing this?
Most of the oil drains to the pan so you will have a few drops at most if park overnight.

Spray brake fluid on the valve cover and let it soak will remove the sludge.

[hansvonaxion]

I skipped through this thread cos I just had mine changed... I noticed people talking about tabs and no tabs, well the guy told me that the JDM EJ20 has 2 types of rocker cover and gasket and there's no way to know which one is on the engine until they pull it off and check - one has more tabs on the inside - the guys assembling the engines just grabbed whichever. Now surely this doesn't apply to USDM NA engines but it seemed a strange coincidence.

And I was given some good advice, put the side you're doing on ramps so the oil drains to the opposite side.

[1839cc]

I just did this on the red car (2.2). Took about 40 minutes for both sides start to finish. I didn't lose any oil, but it's about two quarts low, so maybe that's why. Very easy to do. I left the oil filler neck attached and used it like a handle. Didn't have any sharp corners or use any RTV.

Old gaskets snapped apart when removed. Definitely time for a change. At 303k I don't think they were the originals. Certainly hope not.

[GTDrifter]

I've done this on my rs and the girls outback...both with new engines and both times I couldn't get the passenger cover off so I just replaced it with what little room I had

[Garrison]

I have done this process twice now with ebay gaskets and both times the leak I have has continued. From the corners on the bottom it drips onto the crossmember and then onto the exhaust.

But the good news is, I have given up on this car. I'll drive it until the engine gives and then start parting her out.