Edit - I know this is a re-post but i thought it might be informative to newer members and although it's done on my 106 the principles remain the same for most cars.


In this guide it will show you how to remove the rocker covers on a 16v 106/VTS engine and then give details on how to go about getting a polished look.


Equipment Used

5mm Allen Key
Stubnosed pliers
Gaffa Tape
Electric Sander
Autosol Metal Polish
80 Grade Sand Paper
400 Grade Wet n Dry
1200 Grade Wet n Dry
Sanding block
Bucket of Water
Detergent
Several Cloths


Section 1 - Removal

This section will detail the removal of the rocker covers and a couple of safety precautions to minimise risk of foreign objects getting into the engine whilst the covers are removed.

Firstly,

Undo all 8 5mm allen bolts that hold the centre coil pack cover inplace between the two rocker covers.

Locate and undo the set of 16 5mm Allen bolts on the covers. See img below for bolt locations



Remove the rocker cover closest to the front of the car. This one is the easier of the two to do.

Be sure that when removing you take care not to rip or damage the rubber seal underneath the cover. Damage to this will result in having to seal it manually with some rocker cover sealant.

Put the cover somewhere safe for the time being thats dirt free.

Use a length of gaffa tape (masking tape can also be used) to cover up the first half of the camshaft ladder. Do the same for the second half until the opening is completely sealed off.



Removing the second cover will require two breather hoses to be disconnected. The points indicated on the image show where there are retaining clips.



Again referring to the image posted earlier on locate and remove the 8 5mm Allen bolts, then lift the rocker cover free.

Section 2 - Paint Removal

Using the electric sander with 80 grade paper, sand the covers until the dull grey of aluminum comes through. It's easily distguinishable from the std grey paint that was put from the factory, wiping down occasionally with a cloth to monitor progress.

Once all the paint is off it should look something like this,



Now the messy bit.

Get you bucket filled half full with water and add a small amount of detergent (Washing up liquid)

Using the sanding block and some 400 grade wet n dry use it to go over the covers, dipping the sanding block in the bucket to remove build up on the paper.

This bit of the preparation is where it counts, the more you do the better the outcome. The 400 grade will remove any marks from the sanding down done with the 80 grade paper.

Once your happy that this stage is complete, remove the 400 grade and repeat with 1200 grade wet n dry

Again this process with the 1200 grade will affect the quailty of finish, so the more time spend doing it the better the result when polished.

Section 3 - Polishing

By now you should have covers that have been sanded & then completed two stages of wet n dry. At this point give the covers a good wipe down to remove any excess dirt.

Liberally spread the autosol polish over the entire surface of the cover.

Using the electric sander, instead of the sand paper replace that with a soft cloth. Buff the covers until the polish has turned a mucky grey colour.

With a second cloth and lots of elbow grease rub the covers until a shiny finish is obtained. Sometimes 2 or three applications of the polish is needed to get a decent shine, but persevere with it and it will come up all shiny.

Once done should look like this



Section 4 - Refitting

Refitting is simply a reversal of removal but take care to wipe down the surface of your rocker cover seal and the underside to make sure there is no dirt there that could damge your engine. Dirt on the actual seal can help oil leaks to occur so it's paramount that they are clean.

Once the covers are refitted and the two hoses reconnected it should look something like this



All thats left to do is to stand back and admire your handy work!