Damaged Valve Cover
 

I had the worst time getting my VC on and off for doing a valve adjustment. I had to stop for something, and didn’t want dirt falling in, so I tried to put the VC on at one point, and it got stuck. I don’t know what’s too tight, I think maybe the CC actuator is in slightly the wrong place or something…. Regardless, it literally got jammed on one of the threaded posts, and when I pulled it, the material in the hole broke off.

https://i.imgur.com/YrHj6KXl.jpg

https://i.imgur.com/mwPNwKNl.jpg

All pieces are accounted for.

https://i.imgur.com/h7Ud97Vl.jpg

I don’t see how this is an issue, I don’t imagine that those spots near down on anything, the nut clamps from the outside, and the VC gasket provides the stand-off. But how concerned should I be about this?

Knock on wood it doesn’t leak!!

Thanks!

Those are basically what dictates how far down the valve cover sits, and in turn how much the gasket is clamped between the cover and the head. The gasket is actually not the standoff. I.e. these are what you file down if you're having leaking issues, so the gasket is clamped tighter. You can see this by putting the cover on without a gasket. But it looks like most of it is there so that shouldn't affect this function. I would be more worried about trying to glue the pieces back and having them fall out into the engine than leaving it the way it is.

Found my handy diagram of what I'm talking about:

https://i.imgur.com/ADvJ5eM.jpg

Yeah. Jb weld or anything else would be a risk. There is lots of material and I use a torque wrench to set it. Thanks for the insight and pic!

Head to a local boat propeller repair shop. They can weld it together.

If you did get it welded, make sure they know that it's crucial they keep that shoulder surface at the exact same height that it is now. If it's taller then it'll leak there, and shorter could make it leak somewhere else.

Too many old engines around to keep using that one. Source another and be more careful with the install.

Use a mirror and light to find the interference. Practice gently without the seal for the next time.

Good point, should be able to find another easy.

The interference seems to be a combination of the bearing towers in the rear, and the cruise control actuator in the front. The cover barely passes by the cc unit. To get it so tight and squeezed through it needs to rub (and chafe) the rear bearing towers. Somehow it got on a stud and jammed crooked, but was also stuck on at least one other of those points.

Which engine? I have spares…

617.952

It's not like the cruise control actuator is welded in place. Remove it.

Hindsight is 20/20. Was hard to tell at first what was getting snagged on what and where.

I do a test removal when I haven't done it for a while. It tips gently to the passenger side and goes on in reverse. Practice helps.

Yeah I have t done it in 10 years. I also have a rubber donut between the air cleaner and VC to minimize vibration. That probably didn’t help.