G16 crank case leak

[Old Drill]

My 1996 G16 has an oil leak that I could not find the source of. I put in a new plug and metal o-ring but it still leaked. Last week I finally bit the bullet and pulled out the motor, bought a clutch puller, yanked off the primary clutch and gave the whole thing a good bath with engine degreaser. When I got it all cleaned up I filled it with oil and anxiously peered at the engine with a flashlight in hand, fully expecting to see oil ooze from the crankshaft seal. NOTHING! Instead a small drop of oil would form at the bottom, rear of the crank case cover. I'd wipe it and after a few minutes another drop would form. My thought is that I am going to have to replace the crankcase cover gasket. Can anyone tell me if this job is something I should tackle? or should I bring it to a shop? If I do it myself, should I use RTV sealant along with the new gasket? What are the torque values for the crankcase cover bolts? Is there anything else I should do while I have the cover off? If anyone has done this job before, I would greatly appreciate any and all tips and advice. Thank you in advance for your help!

[cgtech]

You can do it yourself, since the clutch is already off. I would point t that side of the engine up, so the balance shaft and cam will stay in place. A thin smear of rtv wouldn't hurt. I suggest you download the service manual for torque specs.

[Old Drill]

Originally Posted by cgtech

You can do it yourself, since the clutch is already off. I would point t that side of the engine up, so the balance shaft and cam will stay in place. A thin smear of rtv wouldn't hurt. I suggest you download the service manual for torque specs.

Thanks for replying! I have it sitting right side up now like it sits in the cart. Are you saying I should lay it down so that the crankcase cover is facing up?

[CP241]

Yes. Face the cover upwards. Unbolt the cover, and scrape the old gasket. Wire wheel makes this much easier and faster. Then spray both the case and the cover misting surfaces with brake cleaner to clean off any oil residue.

I always use a skim coat of permatex on both sides of the new gasket (old habit) and bolt it all back together. Just let the case sit like that for at least an hour (or overnight) before turning it back over to allow the permatex to set up before contacting oil.

[Old Drill]

Originally Posted by CP241

Yes. Face the cover upwards. Unbolt the cover, and scrape the old gasket. Wire wheel makes this much easier and faster. Then spray both the case and the cover misting surfaces with brake cleaner to clean off any oil residue.

I always use a skim coat of permatex on both sides of the new gasket (old habit) and bolt it all back together. Just let the case sit like that for at least an hour (or overnight) before turning it back over to allow the permatex to set up before contacting oil.

Thanks so much for the help. Along with the new gasket, I ordered a service manual and a torque wrench. Hoping to reassemble this weekend.

[cgtech]

I would avoid the wire wheel myself, too scared of junk flying inside the crankcase. I would just scrape it with a single edge razor blade.