How-to Install Taller Valve Covers
The problem: When installing 1.6 roller rockers the clearance of the ugly stock valve covers is to tight.
The solution: Grind the alternator to clear the taller valve covers.
The benefits:
Can install 1.6 roller rockers
Welding not required
Cheaper than $200 composite LT4 valve covers
Looks great!
The Procedure
1. Remove belt & alternator
2. Remove the useless brace that tie the alternator to the intake manifold. Now BEFORE you ask, I haven’t run this brace for about 3 years, many others have run without it for years.
3. Remove that PCV tube from the valve cover to the throttle body.
4. Remove valve covers. ( 8 - 3/8″ bolts)
5. Get a file, Die Grinder, Dremel or something that grind aluminum.
6. Now on the rear of the alternator there is a little round ear as outlined in this picture. That little ear is what needs to be removed. It isn’t much at all and shouldn’t take more than 30 minutes of work or so.
7. This is what the alternator should look like when it is done.
8. This is what the covers had to clear.
9. Put the valve covers and and test fit with the alternator. Everything should clear, but if not, grind a little more.
10. Re-install the alternator and belt.
Here are some final installation pictures:
