Oil pouring out of valve cover

[Trucky McTruckface]

I have just completed a head gasket replacement and had put a new rubber gasket on the valve cover (not the cheap cork one). When I started the motor oil is pouring out of the back side of the valve cover. I had initially torqued the studs to the recommended 7.5 lb and I tried to add more torque to see if this would help. I followed the correct torquing pattern. I did not use any sealant or RTV on the gasket should I have? It's obvious I'm going to have to replace this again but I was wondering if there was anything I missed. I wonder if maybe the cover is Warped? The valve cover leaked a little bit prior to the head gasket rebuild but not like this.

[Trucky McTruckface]

Does anyone at least know the answer to the RTV question? Was I supposed to use any kind of sealant with the rubber gasket?

[greg lousy]

I wouldnt think so. I use the cork and get a couple reuses by using copper spray and going a little tighter each time.
Do you have the big washers installed?
Did any of the little studs on the head spin loose? Ive had a couple do that. Other than that i would just suspect the condition of valve cover. Also i forget.. turbo?

[TylerDurden]

It's also common to put a dab of RTV where the gasket meets the rubber seals at each end.

Have you got the thick metal strips that run along the studs? If not, the nuts will bottom on the shoulder of the studs, and not clamp the cover properly.

The upgrade is to use the G60 gasket with shoulderless studs.

[Trucky McTruckface]

That upgraded gasket it the one I'm using. Yes I have the metal strips as well. I guess I'll take it off and check the studs next. This really doesn't make sense how bad it leaks.

[Fatmobile]

The rubber gasket is for a 2.0,.. with a thicker aluminum valve cover.

The nuts will tighten down on the bald spots in the middle of the studs that were supplied.
You did remove the original studs (with the shoulder) right?

I use set screws that don't have a bald spot where the nuts can't go.

You can use washers.

[Trucky McTruckface]

I had a feeling I had made a stupid mistake. When I was trying to put the studs in that came with the gasket none of them would thread in correctly for some reason. I ended up using the original studs with the shoulder which I'm sure caused the horrible leak. I happened to have a cork gasket which I just put on and it seems to hold fine. Thank you again for all the tips. I will see if I can fab up some studs to correctly hold the rubber gasket if need be in the future.

[diesel freak]

I had a similar problem, changed my valve cover out and used the newer rubber gasket and oil poured out as if there was a crack in my head. Loosing quarts of oil at a time. Turned out that there is a small rubber U shaped gasket that seats at the end of the cover was not in place. An easy fix but an awful scare at the time.

[Fatmobile]

Ever see someone put a valve cover gasket on backwards before?
Me neither before this:
greenrabbitvcbefore by vwfatmobile, on Flickr
It scooped up the oil running down the front of the cover and ran it out the front.
I worked on this guys Rabbit several years ago. I remember him saying it was running really good when I called him and told him the gasket was throwing oil out the front of the head. I don't know how long he ran it like this. Couldn't have been long.
Also it ran like crap so I laughed at him hard when he said it ran good.
He might have been a bit hurt by my laughter but when he got it back he knew why I laughed. Shocked him how good it could really run.

Can anyone tell me his occupation by looking at this picture?

I'm going through his 3rd diesel now. 2 rabbits and a MK2 TD Jetta.

[greg lousy]

... farmer?

[Fatmobile]

Yep, the soybeans gave it away, ha.