Can't Get Valve Cover Off - Help

[golf4dj]

OK, follow-up post. I was able to put everything back together yesterday with no real problems following the DIY video linked in the first post and reversing the order that I took things apart. Everything works great and job is done!!!!!


Couple of notes that may help others. The DIY videos from the X3 are great but there is a couple nuances with our X5 3.0si.

1. There is a metal bracket on the back rear portion of the valve cover (circled in first picture on this post) that serves no other purpose than to attach the decorative cover on top of the engine. I did not realize it but I bent this bracket inwards at least 1/2 to 3/4 inch when removing the valve cover to clear a couple AC lines. I did not realize that I had bent bracket until I tried to attach the decorate engine cover and it would not fit before bending it back into place. Anyway, the bracket appears to be attached to the valve cover with 2 torx screws. Removing this bracket would allow the valve cover to come off with relative ease. It will be very difficult to see and remove these screws but I believe very worthwhile. I spent over 3 hours just trying to get the valve cover off before pulling like heck and bending that bracket. Others have likely seen a video where someone actually removed the AC lines to get the cover off on their X5. I don't have equipment to bleed the AC system so that was not a desirable option. I am pretty sure that removing the bracket would solve the problem.

2. I also removed the plastic cover that was protecting the 2 flexible electrical conduits (second picture in this post). This allowed me even more room.

3. Most of the bolts have a pressed fitting that slides into the valve cover. Most are the same shape and size with the exception of two bolts (back left corner of valve cover and front right corner of valve cover if I remember right). The individual from the DIY video in the first post indicates that these can be removed completely from the valve cover during removal (they can and I did). The problem is lining the bolts back up and seating them within the valve cover if the valve cover is in its place (not much room, difficult to see and get leverage). I could not get the back left corner bolt to seat into place and had to remove the valve cover again and set those bolts before re-positioning the valve cover. If you remove all the bolts during removal I would recommend that you re-seat the ones in the hard to reach places before setting the valve cover back on.

4. I would recommend investing in a 1/4 torque wrench. Hard to believe how light the torque setting of 6NM (53 inch lbs?) really is. I read where several individuals broke the bolts and I can see why. Harbor Freight may be your friend here as places like HD, Lowes and the Auto Parts Stores don't really stock these and if they do they run around $60 - $70 on the low end. I purchased one from Harbor Freight for $15 on sale.

Final thoughts. The Oil Filter Housing gasket repair was quite simple and easy following the DIY video from same guy linked above (took me about 1 1/2 hours). The valve cover gasket replacement while not very difficult requires a lot of patience and perseverance. I spent the better part of a day and a half getting it all done with at least half of that associated with things I got stuck on. An Independent quoted me just over $1100 to replace valve cover gaskets, spark plugs, and the oil filter housing gasket. I would do it again if I had to thinking it would only take about 3 - 5 hours. Hopefully this thread will help others.

DJ