Honda GCV160 Valve Cover & Oil System?

14 years ago

Thought I'd share something I discovered the other day, and also ask a few questions:

I have a Honda lawn mower with the GCV160 engine. Great engine, other than the cam/valve cover is in a vulnerable area and is pretty flimsy. While mowing the other day, my wife told me that the motor died immediately after bumping into a porch swing. The cam cover was bent, so I was pretty sure that a valve was being held open by the dented cover, so I pulled it off to check (had to chase the cover with a screw driver to get the cover off; probably could reuse if I had to - but the screw on the valve clearance adjuster had poked a hole in the cover). Prior to removing the cover, the mower would backfire almost immediately when rope was first pulled, but not attempt to start.

After removing the valve cover, it started on the first pull-the dented cover had indeed been holding a valve open. Thought I'd share this with everyone, as I'm sure this has to happen a lot with these mowers...the cover is just too flimsy to be in such a vulnerable area.

I've ordered a replacement, but also ordered a cast aluminum version for a GSV190...hopefully, it'll fit and eliminate this issue in the future. Anyone know for sure or not if it'll fit? Only cost $9.00...

I do have a couple of questions, however: When I started the mower, it slung quite a bit of oil with the valve cover removed.

1) Is the oil forced to the rocker arm / cam area? Looked like it was coming out around a port on the block close to the cam, but couldn't be sure.

2) How does the oil that lubricates the cam area get back to the sump? Looking down the gallery for the timing belt drive back down to the crank gear for the timing belt, it looks like this entire area is separate from the main sump (sealed off from the crank area). Is it sealed, and, if so, how would the oil lubricating the top end get back to the sump?

3) Anything I need to know/do special when putting the cover back on? I was just going to use some form-a-gasket. Just want to make sure this area isn't sealed and that I don't need to put some lube oil in before sealing...

Thanks for any help you can give me with this.

VFRoj

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ssewalk1

6 years ago

Post is close to 10 yrs old who,s the Real idiot !

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Comments (12)

1saxman
14 years ago
1) Definitely
2) Trust me, it gets back to the sump
3) Special sealant req'd. - I would use the stuff they seal 2-cycle crankcases with.

You can get a brush guard for the Lawn-Boy 22271 and attach it to your mower in front of the engine. Also a good idea about the cast-aluminum cam cover for the GSV 190. If it doesn't work for you, I'll take it off your hands as a spare for my 22271.
vfroj
Original Author
14 years ago
Thanks for the quick reply. I do have another question:

Since I can't see around the crankshaft at the far end of the timing belt gallery, can anyone tell me the configuration of this area? Is there an opening around the shaft where oil is just splashed up on the timing belt?

It looks like the timing belt is used to take oil up to the "top end" (camshaft, rocker arms, valve springs, etc...). Looks like a pretty slick design, getting the benefits of a pressurized system without the complexity.
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Hi Guys Further update, IÂve had another hour with the mower this evening. Before attempting the cam cover removal I thought IÂd check the ignition timing. To do this I removed the red plastic cowling removed the plug and turned the engine by hand to TDC,inserted a thin metal rod to touch the top of the piston, and turned the engine to measure the down stroke (I make it approx 55mm). This gives 55mm X 2 =110 mm for the total down and upstroke of the piston, this is achieved in 360 degrees rotation of the crank. So a bit of maths (please correct me if IÂm wrong on this one) 360 degree of crank is 110mm piston movement 1 degree of crank = 110/360 piston movement =0.3mm piston movement 10 degree of crank = 110/360 x10 piston movement =3mm piston movement. ( I took 10 degrees as an optimum ignition timing for an engine). I marked a position on the started ring with fluorescent paint and marked TDC and 10 degrees before TCD and 10 degrees after TDC on the red plastic cowling adjacent to one of the slots in the cowling so I could strobe through it to the starter ring fluorescent mark. Re-attached the cowling connected the strobe and the engine ran with the timing showing about 10 degrees BTDC on this crude measurement. Increasing the engine speed did not alter the timing after the usual 20 seconds at about 2,000 - 2500 RPM the fault reoccurred but the ignition timing stayed constant until the engine stopped. I think this has eliminated ignition problems. Have I missed anything before removing the cam cover ? Cheers Pete
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zoulas
14 years ago
The cover is metal. You would have to slam it into something ar least as hard to dent it. Must have been some impact. Porch swing?? Also, the mower deck sticks out more than the valve cover so a tree stump would not do it. I really cannot see how an object could be at that perfect height and have the mass to dent the cover, I am not doubting what you are saying, just seems to be unlikely.
tarheelman
14 years ago
FWIW, there's a diagram of the GC engine's internals in this PDF file from Honda Engines' website. It gives the reader an illustration of how the timing belt carries oil from the crankcase up to the top end.

Here is a link that might be useful: Honda GC engine brochure
vfroj
Original Author
14 years ago
The swing is a porch-type swing on an A-frame in the yard. The bottom-front of the swing is at the exact height to hit the cam cover; the plastic cover is flexible enough to give and let the cam cover take the impact. The swing is usually pushed back gently with the mower, and allowed to come forward with the mower, with no real impact. Just got "out of synch" and the mower was going forward while the swing was coming backwards...I could see where other obstacles could cause a similar issue.

It's amazing how the sound and commotion of the running mower seems to limit the perceived impacts of routine mowing. Try pushing your mower around obstacles like you were mowing with the engine off...

Anyway, I'm hoping the cast aluminum cam cover will help prevent any such issues in the future (along with more careful "driving"...)
vfroj
Original Author
14 years ago
Update on Cam / Valve Cover swap:

Just wanted to let everyone know that the cast aluminum valve cover for the GSV190 will replace the pressed sheetmetal cover for the GCV160. I paid $9 for the cast aluminum version, which isn't too bad; unfortunately, the gasket cost me an additional $9 (kind of a rip off, but whatcha going to do?).

Anyway,it's pretty much a bolt on change, other than having to get 4 longer bolts, due to the 1/2" thicker flanges on the cast aluminum cover. Went with M6-1.0 x 25 mm.

This is a fairly cheap, easy mod. Would be even cheaper if using gasket maker vs the real gasket...

The new cast cover is very thick and should hold up much better than the thin pressed sheet metal cover. Again, I'm surprised by how thin and flimsy this part is to be in such an exposed area. I guess that's why the GSV series has the better cover...
mdstamen
6 years ago
I am having a time locating the Valve cover you mentioned. Can you give us a part number?
mdstamen
6 years ago
After a real search I found that vfrog is full of crap. This is why I question everything. The valve cover will fit, but it will not cover the cylinder head properly. And another lie the gasket is less than $2. It will bolt up, but it will not seal and it will leak. And tsaxman you said you had a LawnBoy with the GSV 190. You must be another Bull**^%. You should have picked it up. So, be careful what you hear here because some of these guys are ROYAL IDIOTS.
yt125
6 years ago
Amen!
1saxman
6 years ago
Why is that so unbelievable? It is true that they only made a few of them in 2007 for Lawn-Boy but Toro made the same mower for years except it red and white instead of green and orange - the 22156. The Lawn-Boy version was the 22271 as I said earlier. I'm still using it and its still the best 21" mower ever made in my book.
ssewalk1
6 years ago
1. Ignore mdstamens,s comments Sax he,s a Royal Ass ! Your working knowledge has been proven over the yrs Bud !

Honda GCV160 Valve Cover & Oil System?

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