You  got gas inside the crankcase of the engine when you turned on the key 
without the gas lines hooked up and this vehicle has an electric fuel pump.  It 
went down through the oil drains in the heads, because the valve covers were 
not installed.  Not exactly sure what set off the accumulated gas mixture in 
the crankcase (it could have been any number of things), but this explosion is 
what bulged your valve covers.

Now, where's that cold beer?
  ----- Original Message ----- 
  From: Robert J. Moore 
  To: [email protected] 
  Sent: Friday, October 27, 2006 10:28 AM
  Subject: [BlindHandyMan] Blown out valve covers


  Hear is a brain teaser for all you mechanics
  A friend and I were replacing the intake manifold gaskets on a Chevy v6.
  Hear is how it went.
  We got it all disassembled, cleaned up and gaskets in place and the manifold
  reinstalled. the valve covers were still off and the distributor was back in
  place. My friend wanted to check some thing and had me turn over the engine.
  After I turned on the key he abruptly said turn off the key . What's up I
  said. I just forgot to hook up the fuel lines to the throttle body.
  Ok no problem. the rest went ok until we went to set the timing and try to
  start it. At this point every thing was back together except the air
  cleaner. After several attempts at turning over the engine and checking the
  timing and the firing order we tried one last time. That is when some thing
  vary strange happened. I heard 2 consecutive back fires which were more
  intense than I had ever heard from an engine before. We checked it out and
  discovered that both of the valve covers had blown outward from the inside.
  Now my question is how could the thing back fire through the valve train. I
  thought that there would only ever be vacuum under the valve cover.
  I think I know what happened.
  re read the above carefully and I think you might figure it out. If you come
  up with the same conclusion I did you get a gold star.
  So what do you all think?
  I will post my conclusion later.

  Ps

  We did get the valve covers streightened out, got the timing wright and it
  runns better than ever and we all lived happelly ever after.



   


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