100e 2.0 Rocker Cover gasket - how to fit bolts??

Posted: Sat May 17, 2003 7:03 pm

Car is a 1992 100e 2.0 Estate.

Slight leak from front of r'cover gasket ( closest to front of car ).
Bought replacement r'cover gasket from VAG ( as recommended )
THis came with 4No. 44mm brass bolts -( divided into a 2/3 and 1/2 length each threaded ,

and 8No. 32mm slightly shorter steel bolts, also threaded, but these ones 1/2 and 1/2.

Presume these are the bolts that hold the rocker cover in place.

How do get a grip on the existing ones to remove them, and likewise, how do you then fit the replacement ones?

thanks for any help.
Confused

UltraUser Joined: Jan 21, 2003 Posts: 4230

Sounds like you bought the VAG conversion kit which has bigger studs and a much better quality gasket . The gasket has larger holes which take the new studs. With the cover off you can grip the old studs with a pair of grips and unscrew them out, they should not be that tight. Screw the new ones straight in by hand, that is tight enough as the nuts will hold them in ok. Make sure cover and the top of the head are spotless and free of oil before placing the new gasket. No sealer is required however a smidgeon of Blue Hylomar would help to seal. While the cover is off check the front camshaft oil seal isn`t leaking down the back of the top pulley.
Happy spannering. Evil or Very Mad

Posted: Wed Jul 23, 2003 1:11 am

Managed to get the old studs out - but they were in too tight for pliers, pipe wrench, spanner, various tools lent by local mechanic, etc. etc.

ended up having to file two sides of the studs stud down flat to be able to unscrew them.

Had thought about giving up with the new studs, BUT the new gasket won't seat flush over the old studs, as they have a collar that won't go though the holes in the new gaskets.