E85 2.0 rocker cover leak

[StephenZ]

Hello and hoping someone may be able to help. I’ve searched the various threads but can’t find anything directly related to this.
I removed the rocker cover to change the eccentric shaft sensor but having changed the gasket I’m now getting an oil leak at the back of the cover. One of the bolts (middle one at the back) will not tighten with the cover and the gasket in place. The bolt does however screw down ok with the cover so it’s not a faulty bolt or thread, it’s just like the bolt is too short. I’ve swapped the bolt with another one and no difference. I’ve now had the cover off three times and will need to try again. Anyone have any ideas on what may be wrong?
The eccentric shaft sensor swap has worked fine (VDO Continental) and the engine warning light has gone out.
Thank you for any help

 

[enuff_zed]

Looks like there are a few different screw lengths, but not sure which goes where from this diagram.

You haven't said so, but i assume you are using a new gasket?

 

[StephenZ]

Hello enuff_zed and thanks for coming back to me so promptly.
Yes new gasket used and Hylomar blue on the half moons as I’ve read.
There are 2 different lengths of bolts but the 2 longer bolts are in the inside around the shaft motor.
I’m a bit stumped on this one and decided to bit the bullet and get it into the specialist but he has no space until mid April which is a long way away. Gut feeling is this should be an easy job but something isn’t quite right.

 

[enuff_zed]

OK, so reading your first post, you say it will screw down with the cover, implying the gasket is the issue.
What make of gasket did you get?
I was asked to do the same job and the owner supplied a cheap gasket. The section of it that slots up into the cover was too deep, so the gasket protruded and prevented the cover pulling fully down. Could be that?
Or have you missed a small bit of the old gasket, still stuck inside the cover groove and causing the same effect?

 

[StephenZ]

Apologies, that was a typo, it should have said without the cover. The gasket was from Febi after I bought an Elring gasket which wouldn’t fit.
I’m going to take off the cover again this weekend and investigate the issue in more detail.
Will provide an update if I have one.
Thanks again for the suggestions

 

[BumpyZ4]

The first few threads must be stripped. When the cover is removed the bolt goes further in the hole engaging the remaining good threads.

 

[StephenZ]

I suspect you are correct, a stripped thread. First photo is from the front of the engine and the second photo, whilst difficult to see well, is the problem at the back of the engine. Does this mean cylinder head off to have it sorted?

 

[enuff_zed]

I suspect you are correct, a stripped thread. First photo is from the front of the engine and the second photo, whilst difficult to see well, is the problem at the back of the engine. Does this mean cylinder head off to have it sorted?

Should be able to fit a helicoil in there. Any competent garage can do that for you.

 

[StephenZ]

Gents, thanks for your help and suggestions. I decided to buy a £20 helicoil kit off Amazon and have a go myself (thank you YouTube). It wasn’t difficult in the end after I worked out what I needed to do. Took 15 mins and it appears to have worked. Did 40 miles mixed driving after putting the cover back on, got home checked, no signs of oil and no burning oil smells so fairly confident that was the issue. Many thanks again and probably saved a bit of cash visiting the garage.

 

[enuff_zed]

Gents, thanks for your help and suggestions. I decided to buy a £20 helicoil kit off Amazon and have a go myself (thank you YouTube). It wasn’t difficult in the end after I worked out what I needed to do. Took 15 mins and it appears to have worked. Did 40 miles mixed driving after putting the cover back on, got home checked, no signs of oil and no burning oil smells so fairly confident that was the issue. Many thanks again and probably saved a bit of cash visiting the garage.

Excellent. Well done!