Hello!
Even though this is a Swedish forum, I thought, that I could do a little guide on how to change the valve cover gasket on a D24TIC or D24T engine, it is even simpler for the D24 engine, because it may help someone out when they are planning to do this job. I apologize if some of the technical terms aren't correct, English isn't my first language.
There aren't many tools required all you need is: a ratchet, 10mm socket, 13mm socket/wrench, a 6mm Allen wrench and probably some RTV gasket maker.
As you can see, my gasket was leaking from the back side and one of the valve cover boltholes was stripped by a previous owner. I had to re-thread the hole and replace the old bolt with a bigger one. I hope you don't have the same problem.
3) Remove the two bolts holding the EGR to the intake system, the head is a 6mm Allen and on the other end there is a 13mm nut. You will also have to loosen the clamp holding the EGR to the EGR tube.
5) Remove all of the 10mm valve cover bolts and the two rails that is under them, you should not change the sides of the rails, when reinstalling put them back on the same side.
6) In theory, you should be able to remove the valve cover now, but I found that you should remove the EGR tube going to the exhaust manifold also. It is held in by two 13mm bolts. Spray the bolts with penetrating fluid and try to get a six point socket on them, as the usually are pretty rusty and tight and will round off easily. In my case one came out great but the other one rounded off and I had to hammer a 12mm wrench on it.
7) Remove the valve cover and the old gasket and clean the gasket surface, but don't use a metal, it may scratch the surface, my glorious Swedish tank engine looked like this B)
8) Install the new gasket, It is recommended to put some sort of Silicone gasket sealant to the ends of the gasket, where it goes over the curve.
9) Put the valve cover on, then the rails and then the bolts(don't forget that under one bolt was the alternator wire). NOTE: Do not over tighten the bolts as the threads are pretty fragile. I used a 1/4 inch ratchet to do it. You can always tighten the bolts if you need to, but once you strip it:Q
10) Reassemble everything, I put some black high temperature RTV gasket maker on the intake system, so it wouldn't leak. Connect the EGR tube, the EGR, the intake system, the small vacuum hose and the crankcase ventilation hose and you should be ready.
Thank you for reading the guide, hope it was helpful.
. Gott nytt år på er alla.
