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Unread 07-17-2006, 12:13 AM   #1
Vonster
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Install of Aluminum Valve Cover

Need some help with the installation of my new aluminum valve cover. I have tried the valve on for size a ‘dry fit” and it fits perfect.

First, before I continue the instructions I have are crap and I haven’t found anything on any online forums that help so I’m giving this a try before I take in somewhere. Second, everything I have found leads me to believe that every 258 made is different.

I know the valve cover fits and I know all of the holes line up perfect. However, the two holes on the driver side are not deep enough and are not threaded (this is the side near the intake manifold). I’m not sure what these holes were used for but I want to use them for my valve cover ( I read this what I should do). My question is how deep can I drill these holes so that I can use them so nothing gets franked up? Second, can you use RTV on the cork gasket or not? I have heard not to and I have heard its OK…HELP ME….

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Unread 07-17-2006, 12:38 AM   #2
1bflm
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I did some searchin and came up with the following web site that does a step by step on what you have to do. There is a "Notes" section that has some pretty good descriptions on what to watch out for.

http://www.skidmore.edu/~pdwyer/amc/...valvecover.htm

I hope this helps I if you have an issue getting to it I can post the step by step for you. Good luck!
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Unread 07-17-2006, 12:55 AM   #3
Galt
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I just installed one about a month ago. You do have to tap those two holes on the drivers side. I went to far and had to repair it. I broke through into the coolant passage. Whoops. It was an easy fix with some epoxy putty but it would have been better if I didn't have to go through all that.

If you only drill down about a 1/2" you should be fine. Be real carefull though. I would suggest using a dull drill bit. You know how a sharp one likes to get ahead of itself if your not real cautious. I did use RTV on the cork gasket. It's sealing fine. I also did not bother with the nut on the backside by the firewall. It is a PITA to get to.

Have fun.
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Unread 07-17-2006, 01:23 AM   #4
bdmonist
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You could cut off your studs to fit, find shorter studs, or use washers if you are uncomfortable drilling the holes deeper. You won't have to worry about driling too far down if you're not drilling! I would place the RTV on the valve cover, then set the cork gasket on the RTV, let it set for about 45 minutes, then install. I did mine this way and it helped keep the gasket in place where I wanted it while installing it on the head. Tighten the bolts a little at a time and you're good to go
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Unread 07-17-2006, 02:17 AM   #5
Vonster
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Install of Aluminum Valve Cover

Thanks!! I appreciate the assistance from everyone.....I will give it a go with a dull drill bit to about 1/2" below the bottomof the hole but I will use shorter bolts.
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Unread 07-17-2006, 02:43 AM   #6
wm69
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I've put two of these on and didn't drill either one any deeper, just got shorter bolts from lowe's. Get a bottom tap, tap the two holes without drilling them any deeper, get shorter bolts, use RTV, and bolt it on. DON"T overtighten the bolts or you'll crack your valve cover. No more leaks.
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Unread 07-17-2006, 02:45 AM   #7
Shameless Elmer
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Before you start drilling, stick the drill bit into the existing hole in the head. Wrap a piece of tape, duct tape, masking tape or electrical tape 1/2" above the point where the top of the hole meets the drill bit. Put the drill bit in the drill motor and drill the head until the tape reaches the top of the hole. Also, since you have the hole depth marked with tape, go ahead and use a sharp drill bit to make the drilling easier. Be sure to use some lubricating oil while drilling to keep the bit cool.
Be sure to use a "bottoming tap" when you tap out the hole, therwise the threads won't be cut all the way to the bottom of the hole. A "bottoming tap" will be flat on the end, as opposed to having a point on the end.
Also, be sure to cover the area under the valve cover so none of the drill shavings drop into the engine.
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Unread 10-07-2010, 03:27 PM   #8
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Old thread, but I am awakening it. Anyone know off hand what size tap I need to buy? I'm hoping to stop by lowes in about 20/30 mins.

Thanks.
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Unread 10-07-2010, 03:33 PM   #9
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If you click the link in the 2nd post it says a 1/4" by 20.
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Unread 10-12-2010, 01:21 PM   #10
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Can I get the right allen head bolts @ Home Depot of Lowes? Does the grade or finish matter?
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Unread 10-12-2010, 06:02 PM   #11
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Usually when you purchase those Allen head bolts, they come with a black oxide finish. Theres usually enough oil leaking around there to get on them and prevent any rust. All the ones I have seen are made to Grade 8 standards, that should not be a problem anyway, because they don't get that tight. Clean out the hole and use locktite. Most any hardware store should have them.
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Unread 10-12-2010, 06:31 PM   #12
mcmud
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I'd like to point out that while some may not most of the aftermarket V/covers will have flanges adequate for the original large washer nuts to hold the drivers side down omitting the need to bore and tap those two holes.

For instance the one pictured in post #3 seems to be a good example. Notice the width of that flange at the studded head bolts.
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Unread 10-12-2010, 09:53 PM   #13
jatepper
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Quote:
Originally Posted by mcmud View Post
I'd like to point out that while some may not most of the aftermarket V/covers will have flanges adequate for the original large washer nuts to hold the drivers side down omitting the need to bore and tap those two holes.

For instance the one pictured in post #3 seems to be a good example. Notice the width of that flange at the studded head bolts.
My valve cover flange was indeed big enough and I could have used the nuts that go on to the threaded head studs on the driver said, but in my opinion it is not the best idea. I'm sure the Jeep engineers know more then I do, but to me it never made sense to do it like this in the first place.

Took me all of 10 minutes to tap out the holes on the driver side and I was good to go.
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Unread 10-14-2010, 07:38 AM   #14
twoscooterz
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I am getting ready to install an aluminum cover. Where can I get a bottom tap? Napa?
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Unread 10-14-2010, 07:52 AM   #15
benullman
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Quote:
Originally Posted by Galt View Post
I just installed one about a month ago. You do have to tap those two holes on the drivers side. I went to far and had to repair it. I broke through into the coolant passage. Whoops. It was an easy fix with some epoxy putty but it would have been better if I didn't have to go through all that.

If you only drill down about a 1/2" you should be fine. Be real carefull though. I would suggest using a dull drill bit. You know how a sharp one likes to get ahead of itself if your not real cautious. I did use RTV on the cork gasket. It's sealing fine. I also did not bother with the nut on the backside by the firewall. It is a PITA to get to.

Have fun.
not to hijack but, why so you have your heater core hose going to the right side of your jeep? you have a great looking setup (similar to mine) and mine hang down on the left.

Ben
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