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2.5L 90 Comanche....Warped Valve cover!?!


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I thought Id start another post since I found the problem to why my valve cover will not seal. The valve cover is warped. The word is to replace it with a metal cover? OR? There is an 1/8inch gap on the drivers side middle....This was is my daily driver, any quick help would be appreciated. I have had no luck finding one locally.

-E.

IF anyone has a spare metal cover, PM me please.

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87....I got the new cover tonight. Got it cleaned up and ready to install. This one does have a slight bow (about a 32nd) but I don't expect it to be dead flat being as its a pull from a 94. But, the one I pulled off would not even sit flat with the gasket on....This one will at least sit fairly flat with the gasket. I'll know more tomorrow when I get to re-installing it. I would've gotten farther, but I also got to climb under the house dryer today to retrieve a ball point pen that went into the lint vent (and all over the load of clothes) Its beer time.

-E.

I will definitely be weighing the option of how much/where to put the RTV. The head surface isn't what I would call the most stellar finish either.

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The head surface isn't what I would call the most stellar finish either

 

The VC/Head mating surface on my 2.5 was as cast! It apparently missed the milling operation entirely. Imagine my surprise at prying the leaky old cover off and finding that :nuts:

 

Mine's the same. Seems to be par for the course for 2.5s. Probably the reason the rubber gasket is so thick.

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O'Reilly's. Thick rubber bugger, which I'm sure would have worked had the cover not been cracked all to hell. Then I got a new valve cover which came with some wierd permatex/foam thing. It worked, so it's still on there. Or was, until tonight, when I started pulling the head.

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1/16th? No way, this thing was closer to 1/4". I didn't RTV anything for the old valve cover, just tried to epoxy the cracks and put a new gasket on. Epoxy didn't hold, and the bolt holes were cracked off in several places, so I bought a new valve cover for 40 bucks.

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wow. ok. I'll look into it. I did get a new "used" cover today. Giving it a go tomorrow. Found out the old cover was an aftermarket cover, seeing them side by side, the OEM cover is much more robust, plus, I'm told by the guy I bought it from, it came off his previous engine and did not leak....(IF I can believe it) His old gasket was not covered in oil, so thats a good sign.....The OEM cover I got is not perfectly flat, but its at least in the ballpark, and I don't expect a used cover to be perfect....just not leaky.

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You still have the 87? Does it leak?

 

She moved to a new home almost 2 yrs ago. I sold the '87 4cyl AX-5 2WD with 19XXXX miles to buy the '90 I-6 AX-15 4WD with 117,000 miles. I pulled the VC on the '87 to replace the lifters and pushrods and drove her for 1.5 yrs with no leaks. I used to have an extra 2.5 OE VC laying around here somewhere. Do you want me to look for it?

 

its about 1/16th thick

 

A 1/16" gasket would not have sealed mine either.

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UPDATE: I found a metal cover from a 94 wrangler. It fits size wise, and all the holes line up. It takes a different gasket, apparently they re-designed the 2.5 cover in 94 and added dimples at the bolt holes so you could not over-tighten the bolts. It will take some slight re-work of the vacuum and PCV valve but It should work very nicely. I will be sure to report back after I convert it. I have the gasket on order, and I'll have to find bolts without the shoulders on them....

-E.

Thanks for listening to my rant :D

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