Valve cover <em>Nissan Sunny FB15</em>: how to replace, which part numbers to choose and why it leaks

Nissan Sunny FB15 — a reliable car, but even it eventually develops problems with the crankcase ventilation system and valve cover seals. If you notice oil streaks on the engine, the smell of burnt oil, or increased lubricant consumption, this part is often the culprit. Unlike more modern models, where the lid is made of plastic, FB15 It is metal, which has its pros and cons.

In this article we will figure out why valve covers leak on Nissan Sunny FB15 (engine GA15DE), how to properly remove and install it, which original and similar spare parts are suitable, and we will also give advice on sealing. We will pay special attention to typical replacement errors that lead to repeated leaks. If you are planning a DIY repair, here you will find step-by-step instructions with nuances for this particular model.

Signs of a bad valve cover Nissan Sunny FB15

The first symptoms of valve cover problems often go unnoticed until the leak becomes critical. On FB15 Due to the design of the engine, oil can leak not only outside, but also into the intake manifold through the ventilation system. This leads to oiling of the throttle valve and unstable operation of the engine.

The main signs that it’s time to check the lid:

• 🔴 Oil drips on the cylinder block from the cover side (especially noticeable after long-term parking).
• 🔥 Burnt oil smell from under the hood - grease gets onto the exhaust manifold.
• 🛢️ Increased oil consumption (more than 500 ml per 1000 km) without visible leaks from below.
• 🌀 Oily air filter - a sign of oil entering through the crankcase ventilation.
• ⚠️ Floating speed at idle speed due to throttle contamination.

On Sunny FB15 Most often, leaks occur in three places: along the perimeter of the gasket, in the area of the breather (ventilation valve) and near the fastening bolts. If you ignore the problem, oil will begin to enter the combustion chambers, which will lead to carbon deposits on the valves and reduced compression.

⚠️ Attention: If an emulsion (light foam) appears on the dipstick, this is not always a sign of a broken cylinder head gasket. On FB15 This picture may arise due to condensation entering the oil through a leaky valve cover during short trips in winter.

Original articles and analogues for valve covers Nissan Sunny FB15

For engine GA15DE (1.5 l) the following original parts fit:

• 🔧 Valve cover assembly — 13270-5M000 (metal, with breather).
• 🛡️ Valve cover gasket — 13276-5M000 (rubber, it is recommended to change each time it is removed).
• 🔩 Fastening bolts (8 pcs.) — 13278-5M000 (it is advisable to replace them, as the old ones may be deformed).
• 🌀 Crankcase ventilation valve (PCV) — 13275-5M000 (often clogs and requires cleaning or replacement).

Among the analogues, the following have proven themselves well:

Manufacturer	Article	Note	Price, rub.
Ajusa	10144600	Gasket, soft rubber, fits without modifications	800–1200
Elring	728.170	Reinforced gasket, recommended for turbo engines	1500–1800
Victor Reinz	71-33893-00	Kit with seals for bolts	1200–1600
Nipparts	J132765M000	Budget option, may require pruning	600–900

Important: On some analogs (for example, Nipparts) bolt holes can be offset by 1–2 mm. Before installation, be sure to apply the gasket to the cover and check the match!

If the valve cover is deformed (for example, after an impact or overheating), it is better to replace it entirely. Restoring geometry by welding or straightening rarely gives long-term results due to the internal stresses of the metal.

Step-by-step instructions for replacing valve covers with Nissan Sunny FB15

To work you will need:

• 🔧 Set of sockets and keys (10 mm, 12 mm).
• 🔩 Torque wrench (tightening torque - 8–10 N m).
• 🧴Sealant Loctite 574 or Permatex Ultra Black (only for joints, not for the entire gasket!).
• 🧼 Carburetor cleaner or kerosene for degreasing.
• 🧽 Lint-free rags.

Procedure:

1. Remove the negative terminal from the battery. Disconnect the high-voltage wires and the ignition coil connector. On FB15 the coil is attached to the cover, so it needs to be removed together with the bracket (2 10 mm bolts).

2. Unscrew the clamps and remove the crankcase ventilation hoses. Pay attention to the condition of the valve PCV - if it is clogged, it needs to be cleaned or replaced.

3. Unscrew the 8 bolts securing the cover (4 on each side). Start at the corners to release pressure evenly on the gasket.

4. Carefully pry off the cap with a flathead screwdriver (do not use a chisel!). If the gasket is stuck, pour cleaner over the joint and wait 5–10 minutes.

5. Remove the old gasket and clean the seats on the cylinder head and cover. Do not use metal brushes - they leave scratches, which will later lead to leaks.

6. Apply a thin layer of sealant to the corners of the cylinder head (where the gasket meets the semi-circular recesses). Install a new gasket and cover, then tighten the bolts to two stages:

   • 🔹 Preliminary - 5 Nm.
   • 🔹 Final - 8–10 Nm (according to the “cross pattern”).

Make sure the PCV valve is clean and working|Check the integrity of the new gasket|Degrease the joints of the head and cover|Apply sealant only to the problem areas (not the entire gasket!)|Tighten the bolts with a torque wrench-->

After assembly, start the engine and check:

• No oil leaks around the perimeter of the cover.
• Speed stability (if the speed fluctuates, check the air leaks through the ventilation hoses).
• Oil pressure (there should be no warning light on the dashboard).

⚠️ Attention: If after replacement the leak appears again after 100–200 km, the problem may not be in the gasket, but in deformed plane of the cover or block head. In this case, grinding on a special machine will be required.

Typical replacement mistakes and how to avoid them

Even experienced craftsmen sometimes make mistakes that lead to repeated leaks. Here are the most common:

1. Bolt tightening. On FB15 The valve cover is aluminum, and when the tightening torque exceeds 12 Nm, it becomes deformed. Use a torque wrench!

2. Using low-quality sealant. Silicone sealants (eg. ABRO>) peel off over time. Take only those specialized for oil systems.

3. Forgetting to clean the breather. If the valve PCV clogged, the pressure in the crankcase increases, and the oil is squeezed out through the gasket.

4. Install the gasket without cleaning the joints. Even small particles of old rubber or oil will break the seal.

5. Do not check the flatness of the lid. Place it on the glass and shine it with a flashlight - if there are gaps of more than 0.1 mm, the cover needs to be sanded.

Another common problem is oil getting into spark plug wells. This occurs if the gasket has moved during installation or the bolts are not tightened evenly. To avoid this, before assembly, check that all holes on the gasket line up with the guides on the cylinder head.

What should I do if the oil continues to leak after changing it?

1. Check the pressure in the crankcase ventilation system (close the breather fitting with your finger while the engine is running - a slight vacuum should be felt).

2. Inspect the cover for cracks (especially near the breather hole).

3. Check the condition of the oil seals - if they are worn, the oil will rise up and leak through the cover.

4. Make sure you use oil with the viscosity recommended for GA15DE (5W-30 or 10W-40). Oil that is too thin seeps through microcracks more easily.

How to extend valve cover life: prevention

To avoid frequent gasket replacements, follow these guidelines:

• 🔄 Change the oil every 7–8 thousand km. Old oil loses viscosity and leaks through the gasket more easily.
• 🛢️ Use quality oils with permission API SL/CF or higher. Cheap lubricants contain aggressive additives that corrode rubber.
• 🌀 Clean the crankcase ventilation system every 30 thousand km. A clogged breather increases crankcase pressure.
• 🔥 Avoid overheating the engine. At temperatures above 120°C, the gasket “hardens” and loses its elasticity.
• ⚙️ Check the tightening torque of the bolts after the first 500 km (sometimes the gasket “shrinks”).

On Sunny FB15 pay special attention ventilation hoses. Over time, they crack, and air begins to be sucked in through microcracks, which leads to an imbalance of pressure in the crankcase. Inspect them at every maintenance.

💡

Regular cleaning of the PCV valve (every 20 thousand km) reduces the load on the valve cover gasket and prevents leaks.

Cost of work in the service vs. self-replacement

Prices for replacing valve covers in services vary depending on the region and service station level:

Type of work	Cost, rub.	Time
Replacing the valve cover gasket	1500–2500	1–1.5 hours
Replacing the valve cover assembly	3000–4500	2–3 hours
Cleaning the crankcase ventilation system	800–1200	30–40 minutes
Grinding the cover/cylinder head plane	2000–3500	3–5 hours

If you replace it yourself, your costs will be limited to the cost of spare parts (from 800 rubles for a gasket to 5000 rubles for a complete cover). However, if you do not have experience or a special tool (torque wrench), the risk of error is high. For example, overtightening the bolts can lead to a crack in the cover, and undertightening can lead to a repeat leak.

It is most profitable to change the valve cover gasket at the same time as other work that requires removing the cover, for example:

• By adjusting the valves (every 40–50 thousand km for GA15DE).
• Replacing oil seals.
• Cleaning the throttle valve.

Frequently asked questions about valve covers Nissan Sunny FB15

Is it possible to drive with an oil leak from the valve cover?

Short-term - yes, but the risks are high:

• Oil getting on the timing belt (if the leak is severe) can cause it to slip or break.
• Oil dripping onto the exhaust manifold may catch fire (especially on a hot engine).
• Loss of oil leads to oil starvation and wear of the camshafts.

If the leak is more than 100 ml/1000 km, repairs are necessary in the next 1–2 weeks.

What is the difference between the valve cover gasket for GA15DE and GA16DE?

Although the engines GA15DE And GA16DE similar, gaskets are not interchangeable:

• On GA15DE (FB15) the hole for the breather is shifted closer to the front of the cover.
• On GA16DE The gasket is 5 mm wider (due to the different location of the spark plug wells).
• Mounting bolts on GA16DE longer (12 mm versus 10 mm at GA15DE).

Installing the gasket from GA16DE on FB15 will lead to a leak in the area of the 4th cylinder.

How to check if the valve cover is deformed?

A simple way without a special tool:

1. Remove the lid and place it on a flat glass surface (for example, on a glass table).
2. Shine a flashlight from the side - if a gap of more than 0.1 mm is visible, the cover is bent.
3. Check the diagonals with a ruler (from corner to corner) - the difference should not exceed 0.5 mm.

If there is deformation, the cover can be sanded on a machine (cost ~2000 rubles) or replaced.

Do I need to use sealant when replacing the gasket?

On Nissan Sunny FB15 sealant required only in three places:

• In the semicircular recesses at the corners of the block head (where the gasket meets the metal).
• Around the hole for the breather.
• At the junction of the gasket with the back of the cover (oil often accumulates there).

Apply a thin layer (no more than 1 mm) of sealant Loctite 574 or Permatex Ultra Black. Avoid silicone sealants - they do not withstand temperature stress.

Why does the oil leak more after replacing the gasket?

Probable reasons:

• Gasket installed upside down (on some analogues the holes are asymmetrical).
• Bolts are tightened not according to plan (first the middle, then the corners).
• Block head plane deformed (check with a ruler).
• The crankcase ventilation system is clogged (check the valve PCV and hoses).
• A low-quality sealant was used that did not polymerize.

Solution: Remove the cover, clean the joints and repeat installation with a new gasket.