Xoutpost.com - Valve Cover Gasket Installation?????

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Quote:

Originally Posted by Multibeemer (Post 784476)

I'm knee-deep in my valve cover replacement project on my '03 4.4i. I must say, this project is an absolute beast. In all my years of working on cars, this is probably the most difficult thing I've ever run across.

That being said, I managed to get the passenger side done, without having to remove those wretched fuel injector clips. I managed to wrestle the cover off before I learned the clips even existed. One look at the clips, and I told myself that if I could get the valve cover off without removing the clips, I should be able to get it back on. Sure enough, with the help of a bunch of string to firmly attach the gasket to the valve cover while wrestling it back in place, I was able to get it done. I'll post some pictures later on my method.

As for the drivers side, holy crap! There's practically zero clearance past all the coolant hoses. After about two hours of intense struggling, I was finally able to yank the thing out of there. It's a miracle I didn't break it, or damage the mating surface. Or that I didn't even lose a single washer! But now, it's obvious that there's no way I'll be able to get the valve cover back in place with the new gasket without removing the square plastic tunnel that houses the wiring for the coils (I forget the official name of it) which is secured with those damn clips. So, if I don't want to tow the car to a mechanic to finish the job, I'm going to have to get those clips out. One person said they had success with a 9" long Craftsman right angle pick. Any other tips? I've tried removing the clips using a shorter pick but they just stare back at me, mocking me.

And an even bigger question - assuming I can get the clips off, and that I can consequently free up enough room to get the valve cover back on, how on earth do I get the clips back on? There's maybe a 1/2" slit between the head and the plastic channel to work; obviously it's possible, because other people have done it, but how exactly? Thanks.

I ned to do mine as well soon, saw oil in the spark-plug well last month.

So I saw "killcrap" suggestion to use WD40/spray-lube on the clips then pry the electric box gently, the clips should pop-out by itself; no tools etc require. Just wonder if anyone try this?

The WD40 idea sounds too good to be true. Those clips are really tight; I don't see how spraying WD40 on them can help get them loose, but I am willing to try anything. I'm off work today and tomorrow, so I hope I can get this figured out in this timeframe. Wish me luck...

Quote:

Originally Posted by Multibeemer (Post 784525)

I believe "killcrap" is either former BMW tech or still is so I tend to trust him (though I agree it seems to be TGTBT after seeing those clips), but I believe someone at e38.org forums suggests the same thing.

Also to re-install someone says just have the clips in close position and press the elctric box back in until those clips re-snap (all automobile electric connectors work like that).

In any rate I'll try this first cause I can't imagine any pick tool can remove the clips closest to firewall on my 02 4.4i. (it's blocked from view completely)

Thanks for the clarification on how to re-install the connectors. I was kind of hoping this was the case; that at least is one load off my mind.

I spent a fair amount of time stabbing at the clips with a 90 degree snap-on pick, and couldn't get any of them to budge. Someone suggested tying a longer pick; not sure how this will help, but I'm willing to try anything to avoid the indignity of having the car towed to a shop to finish this job.

Some people have commented that this job is easy. Those folks have my undying awe and respect. When the write-up says things like "The TIS is wrong - very wrong," "Prepare to do battle," and "Hide the children, and queue up the pirate language," that to me says, "Look out - this is going to be brutal." And so far, it has been.

OK, I tried the WD40 trick. No luck whatsoever. I have no idea how this is supposed to help, as these clips have an iron grip on the connectors for the box. I think the key to this job, and what separates those who say it's easy (oh, shut up :D) and the rest of us, is the type of tool you have available. It seems that you need just the right shape tip on your pick to be able to maneuver in the tiny available space and grab onto the clip. I'm heading out to some stores to find something that I hope will work better then the pick I have in my tool box.

Quote:

Originally Posted by Multibeemer (Post 784548)

Maybe you should try Triflow instead of WD40 (my bad for not quoting exactly), like post #10 on this thread says:D
http://www.xoutpost.com/bmw-sav-foru...uccessful.html

Thanks for trying though, well let us know what tools you end up with.

OK, I read through the attached link, and specifically killcrap's method with the triflow. I don't know - that sounds pretty risky. It seems like there's a pretty good chance of breaking something using the method he describes. It's probably OK for someone with a lot of experience with this sort of thing, but for those of us on our first go-around, I think I'll stick to the pick method for now. I just bought a new set of picks, so I'm ready to try again. Wish me luck...

Aaaaaarrrrgggggghhhhhh!!!!!!!!!!

This has never happened to me before, but I'm just about ready to give up and tow the car to a mechanic. Those damn clips won't release their death grip on the fuel injector connectors. I went to three stores looking for a pick that might work, and I ended up with a set of Craftsman 9-3/4" picks, but the space is so tight that I can't turn any of them in such a way as to get a sure grip on the clip. In fact, I'm not really sure if what I'm tugging on is the clip, or the plastic connector. I'm trying to grab it from the bottom, as there's a bit more room below the clip than above it, but as I said, I can't really tell if I'm grabbing the clip at all.

And I tried spraying tri-flow on the clips, and prying up on the wiring box, but this is REALLY scary. It just seems like the risk of breaking one of the connectors, or worse, the box, is really high with this method. And then the world would surely come to a swift, violent, and bloody end.

Could somebody who has done this before please chime in with some suggestions as to how to grab these clips so I can pull them off, and specifically what type of tool actually works? Of course, the problem is that this is very difficult to convey in a post. Anybody in the south Austin, Texas area out there who could swing by and point out the error of my ways? I'll pay for your gas...

Sorry, I'm pretty sleep-deprived (I'm on day 3 of this nightmare of a project, with no end in sight). Thanks!

I remove the electric box top then unclip (not the metal clips) the connectors from the inside of the electrical box.

The electrical box cover will come off with a little effort. I used a screw driver to help unhook the fasteners.

Let me see if I can post a pick of inside the of the electrical box. It should show how the connectors can be un hooked.

This will give you more wiggle room to attack the metal clips.

Good Luck.

http://www.xoutpost.com/members/luke...etal-clips.jpg

http://www.xoutpost.com/members/luke...-fuel-rail.jpg

Luke,

Funny you should mention that, as I've already removed the top of the wiring box. I did this to make a little more room to allow me to pull the valve cover, which I was able to do (barely). I knew I would have to undo the clips to remove to wiring box if I'm to have a prayer of getting the valve cover back on. But I didn't think that unclipping the electrical connectors inside the wiring box would improve my access to the metal clips. I'll give that a try; I'm definitely up for anything at this point to avoid the indignity of towing the car to a mechanic, head bowed in shame. Thanks so much for the suggestion.