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Old 12-05-2008, 07:52 AM   #1 (permalink)
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Default Help! Found a surprise under the Valve Cover

Hi everyone... My 91 8V Auto Tracker had a bit of an oil leak, so I decided to fix it myself. I'm pretty sure the main source of it is a faulty valve cover gasket because it was leaking from the front corner of the valve cover.

Now I've done brakes and changed an oil pan gasket, changed a timing belt on my Metro, changed a water pump in my Trans Am, and put an exhaust manifold on this vehicle, but this is the first time I've ever torn *into* an engine, and I'm a bit intimidated. I know, I can almost hear the laughter now...a measly valve cover? Just run with me, k?

So, I pulled the Tracker into the garage, popped the hood, and went to work. I managed to get everything out of the way and then pulled the valve cover..and indeed the gasket looked absolutely shot in the problem area, however, as I examined things closer (Hmmmm, so THAT'S a camshaft! )I noticed a hole where there shouldn't be a hole:



and closer up:



Pulling out my trusty FSM that I snagged from EBay per suggestion here (THANKS JTGH!!!), I believed the missing culprit to be a "Rocker Arm Shaft Screw" (figure 69, page 6A1-22 of the 91 FSM). Now I figured it couldn't just be *gone*, so I pulled out a magnetic retrieval tool, which has a cameo as the pointer in the above photos, and went fishing around in the oil that surrounded the rockers and springs. After a few minutes...BINGO!!



To say I was a little surprised to find this mangled little thing would be an understatement. Sooooo here's my questions:

1. Is this a common screw that I can get from my local bolt/screw supply place, or do I need to hit the junkyard?

2. Is there anything special I need to do besides screw it back in?

3. Is this really bad?

4. Do I need to check anything else in here before I put it back together?
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Old 12-05-2008, 09:14 AM   #2 (permalink)
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It's happened to me, and to others:

http://www.suzuki-forums.com/suzuki-...ng-screws.html

36 in/lbs isn't a whole lot of torque to keep them in place.

I'm running without some right now, and unless Jerry says different, I'll wait until I adjust the valves to replace them.
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Old 12-05-2008, 02:39 PM   #3 (permalink)
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36, inch lbs, (sorry , but that is not correct. please forgive my correction)

its 102 inch/lbs ,right?

yes get a real screw,not a soft hardware crap screw,
its metric and countersunk, i dought youd find one, in a local store.
but sometimes they have a turnstill bolt display rack full of screws
but countersunk, nah. (i hope im wrong) CS angle is critical,dont guess. please.

91 suz, fsm page 6a65,
7.0-8.5 lb-ft (math 8.5 x 12 = 102 inch/lbs )

the only screws that run 3 ft/lbs (36 inch lbs ) is valve cover screws.

cheers and happy holiday !

PS ,torque them all.

on that post you you can see after92 , suz.started STAKING THEM !

NO TSB on it , just a mfg, change, procedure. ( nice ,not)
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Old 12-05-2008, 04:35 PM   #4 (permalink)
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Hotanddry - Thanks for the link to the other thread. This one was the result of a little bit of panic after being up and rather sleep deprived. Didn't think to check out the "search" option first. I should have known that my problem probably wasn't a new one. I had pool league last night and drank a few cans of Red Bull so I was wide awake when I got home and started at about 1:30am, but pretty out of it by the time I found the problem and posted this.

JTGH - Luckily because there are a few major industries around here, there is are actually two bolt and screw supply specialty shops down in Springdale. Of course, at 84 cents a screw, this may well be the first non-$#@! expensive dealer item I've run into, and well worth the little extra trip. YAY

Also gives me a good excuse to swing down to Harbor Freight to pick up an in/lb torque wrench. (oh darn! )

Thanks alot for both your input. I'm sure I'll have more questions soon!
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