New engine, head, etc. So I bought a new Dorman Valve cover and used a blue Fel Pro. Installed, cross pattern 7ft lbs. Leaked out of the back.

Took it off, put MotoSeal back there, 7ft lbs, still leaked down the back. Snugged the bolts down good. Still leaked down the back.

Took off the Dorman VC, put on on level surfaces.. appears straight, not bent.

Installed the VC with the Dorman VC gasket with orange RTV. No leaks down the back but it now leaks on the last rear exhaust manifold bolt.



Any tips on how the hell I can get this thing to seal???

EDIT to add: This is an aftermarket head (J & C Enterprises) if that matters.

 

Use an OEM valve cover, Felpro gasket and torque to spec.

 

Even though it lays nice on a flat surface you think this Dorman VC could still be jacked up and causing these leaks somehow?

 

I haven't held a Dorman VC in my hand but I'd be willing to bet it's not the same quality as OEM. If you're torquing to spec and using new gaskets it shouldn't leak. It'd have to either be a poorly machined head or crappy VC.

 

And of the two I'm betting its a crappy VC. My OEM VC with the felpro gasket hasn't had issues in a year.

 

Actually I was pretty impressed with the VC but maybe its just not formed like it should be. I'm going to get an OEM VC. Already have the fel pro blue.

What is the proper tightening sequence?

 

"Snugged the bolts down good."

Could have already distorted the valve cover.

Tighten the from the center out criss-cross. I just barely "torqued" mine (you can still turn the fasteners) and it hasn't leaked yet. Stock VC with a blue gasket. Is the surface on the head true?

 

How could I tell?

 

Chuck it up on a mill and run an indicator down it

 

FWIW.
I just replaced the gasket, with FelPro blue a couple of weeks ago. This is a 2001 4.0
With 165k miles.
My big torque wrench only reads in foot lbs, so the only thing I had was an old school needle style torque wrench. The inch lb scale wasn't very accurate, so I just snugged them up by hand, to what felt right to me.
Worked fine, no leaks.

BTW, thank you to everyone on this forum for the great posts on how to complete this job.
It only took about 2 hours. I did remove the upper radiator hose and heater hose though. It made removing the cover really easy. A little messier but in my opinion, worth it.