Well, as many know, the OEM R8 Oil Cap does not sit perfectly straight on the VR6. I really like the look of the cap, but not having it sit correctly would drive me absolutely crazy, so here is the process involved to re-align things.
The R8 Oil Cap can be purchased here:
[IMG]http://*****************.com/smile/star.gif[/IMG] OEM R8 Oil Cap - Can be purchased HERE [IMG]http://*****************.com/smile/star.gif[/IMG]
small flat blade screw driver
Dremel with sanding drum
Dremel with cutting disc
Dremel with very small grinding tip
The process is pretty straight forward and took me about 30 minutes from start to finish once my little head figured out what needed to happen. In order for the cap to sit like the OEM cap on the VR6, the bottom of the cap needs to be parallel with the upper portion (aka, the raised portion you twist to remove it needs to align parallel with the bottom portion that holds it to the valve cover.
Step 1 - Pry the top and bottom of the cap apart
Using a small flat blade screw driver, carefully pry the upper half of the cap apart from the lower. Look at the top and bottom portions and understand how the alignment tabs work. There are (4) raised tabs around the edge of the upper portion, those tabs slide into the grooves around the lower portion of the cap and are what align the cap. They need to be removed in order to reposition the cap. Note there is a small raised ring that runs around the entire upper portion of the cap, take care not to remove it when sanding as it keeps the upper and lower portions together.
Step 2 - Remove raised tabs around edge of the top portion of the cap
Using the Dremel with a sanding drum, sand off the raised tabs down underneath the raised ring. Once removed, change the Dremel over to a small grinding tip and remove them above the raised ring. Take care not to remove the raised ring when sanding.
Step 3 - Mark alignment slots and tabs
When the caps are apart, you can see the raised alignment tabs in the bottom portion of the cap. Those alignment tags slide into the slots on the upper portion of the cap. (4) new slots will need to be made for everything to align how it needs to be.
Using a pencil, mark all the tabs on the outside edge of the lower portion of the cap. Next, mark all the alignment slots around the outer edge on the upper portion of the cap. Loosely fit the two halves together and you can still see your alignment marks on both the top and bottom portions.
Align the top half of the cap parallel with the lower portion, both must be in the same direction for the cap to sit straight when installed. Once aligned, look at your marks on the lower portion of the cap where the tabs are located. Now mark the upper half of the cap using the pencil to identify where the (4) new slots need to be made.
Step 4 - Cutting new slots
Using the Dremel with a rotary cutting disc, cut the (4) new slots on the upper portion of the cap on the alignment marks you just made. You will notice the new slots will be very close to where the (now sanded off) raised tabs were located. Make sure your slots are wide enough to accept the tabs from the lower portion. My cutting disc happened to be exactly the same width as the factory slots.
Step 5 - Snap together and install
Once all the new tabs are cut into the upper portion, align the upper and lower portion of the caps again making sure the top and bottom portions are parallel. If you marked everything correctly the upper and lower halves will now snap back together with the correct alignment to install on a VR6.
Modified by JonnyKuhns at 10:17 PM 6-21-2009