Rocker Cover Replacement

[BZG Wagon]

My rocker cover is leaking and it's time for replacement (st215 3sgte Caldina). What are the steps involved?

I'm thinking:
1) Remove intake & i/c. Is there anything else I need to remove?
2) Undo bolts and pry the cover off (is a flat head screwdriver the best)?
3) Scrape off the old gasket & clean the rocker cover. Is it safe to use a solvent to disolve any further reminance of the gasket? What's the best way to scrape off the gasket too (flat head again or is should I buy some sort of scraper)?
4) Replace gasket - do I need to use any gasket gue?
5) Torque bolts.

What happens if some of the old gasket falls down into the motor? Anything to worry about or will it get picked up by the oil filter? Is it good practice to do an oil change straight after?

[Grrrrrrr!]

2) Undo bolts and pry the cover off (is a flat head screwdriver the best)?

Dont pry the cover off, you'll probably scratch the sealing surface and it'll never stop leaking. Usually a few taps with a soft face mallet on the side of the rocker cover will break them loose (if thats even required).

3) Scrape off the old gasket & clean the rocker cover. Is it safe to use a solvent to disolve any further reminance of the gasket? What's the best way to scrape off the gasket too (flat head again or is should I buy some sort of scraper)?

It'll be a rubber seal, just pull it out of the slot in the cover and drop it into the bin. Will look a bit like this

Pick the bits of RTV in the corners off then clean with thinners etc to get the surfaces nice and clean so the next lot of RTV sticks properly

4) Replace gasket - do I need to use any gasket gue?

Yep, see if you can find the service manual for that engine, but usually its a small bead of RTV in the corners where it goes over the cam caps and dizzy cap etc.

5) Torque bolts.

Yep, again, use setting from service manual if you can find it. Don't over do it.

[allencr]

Tighten it? If it has acorn nuts, they may be bottoming out & adding a small washer will be enough to now tighten & clamp it down leak free.
DO NOT mar scratch gouge scrape nick ding the mating surfaces with screwdriver when prying apart.
Replace the rubber bonded washers if you've pried them off, ripping out bits of their ID that have molded formed into the stud threads. Don't replace if you've unscrewed them & they're undamaged.