Replacing leaking Valve Cover Gaskets

[jjeffri]

I recently discovered my valve covers to be leaking oil at a reasonable rate. I decided it would be a good idea to replace the valve cover gaskets to alleviate this problem. I purchased the gaskets for about $20 and decided to do the job myself. The first step of the process is to remove the intake plenum from above the driver side engine, since the engine is a V-6 there are two gaskets for two covers and the intake plenum sits on top of the driver side cover. I removed the air intake hoses and while I was in there cleaned out the throttle body with some carb cleaner (as described elsewhere in this forum).

 

I then began what proved to be the daunting task of removing the intake plenum. The plenum is bolted to the engine with 5 cap head screws right down the center of the engine and thus the passenger side of the plenum. It is also connected to a myriad of coolant hoses, air lines, and electrical lines. I removed the throttle cable and the cruise control cable (I also adjusted these two cables to remove some slack while I was in here). I removed all but one coolant hose which is located behind the plenum up against the rear of the engine compartment.

 

I unfortunately couldn't loosen this hose. I managed to move the hose clip down a little bit, but not enough to clear the barb on the tube that the hose goes over. Therefore, I was unable to remove this hose and I was thus unable to remove the intake plenum, and thus could not get into the valve cover and thus couldn't change the gaskets, which was the whole point of my fruitless excercises (which incidentally caused me to miss some football). I did clean the intake gasket while I was in there, but I that doesn't really mean much.

 

Does anyone have any experience with removing hard to get to hoses? Is there a special tool that I don't own and have never seen? I would really like to avoid the $200 that a mechanic would charge for this procedure if possible. I am considering cutting the hose to remove the plenum and then replacing the hose with a new one. It should be easier to install a new hose, and once the plenum is out of the way I can actually reach back and remove the old hose.

[88pathoffroad]

90 degree angle long handled needlenose pliers? Or you could cut the hose, pull the intake off, and replace it with a longer loop of new hose if you don't mind the way it'd look. It'd be easier than trying to put a little short hose back on in a tight spot.

[jjeffri]

Thanks 88, I may end up cutting the hose, as that seems to be the easiest way unless I can find some long pliers to borrow. I like the idea of putting a longer loop of hose, I don't care how it looks, in fact you can't see the hose without removing some of the others anyway. If I get the plenum off I will take some pictures of the procedure.

-J

[k9sar]

I opted not to cut mine. Instead, I chose the "lots of cussin and bloody knuckles" approach.

[fixinto]

I recently discovered my valve covers to be leaking oil at a reasonable rate. I decided it would be a good idea to replace the valve cover gaskets to alleviate this problem. I purchased the gaskets for about $20 and decided to do the job myself. The first step of the process is to remove the intake plenum from above the driver side engine, since the engine is a V-6 there are two gaskets for two covers and the intake plenum sits on top of the driver side cover. I removed the air intake hoses and while I was in there cleaned out the throttle body with some carb cleaner (as described elsewhere in this forum).

 

I then began what proved to be the daunting task of removing the intake plenum. The plenum is bolted to the engine with 5 cap head screws right down the center of the engine and thus the passenger side of the plenum. It is also connected to a myriad of coolant hoses, air lines, and electrical lines. I removed the throttle cable and the cruise control cable (I also adjusted these two cables to remove some slack while I was in here). I removed all but one coolant hose which is located behind the plenum up against the rear of the engine compartment.

 

I unfortunately couldn't loosen this hose. I managed to move the hose clip down a little bit, but not enough to clear the barb on the tube that the hose goes over. Therefore, I was unable to remove this hose and I was thus unable to remove the intake plenum, and thus could not get into the valve cover and thus couldn't change the gaskets, which was the whole point of my fruitless excercises (which incidentally caused me to miss some football). I did clean the intake gasket while I was in there, but I that doesn't really mean much.

 

Does anyone have any experience with removing hard to get to hoses? Is there a special tool that I don't own and have never seen? I would really like to avoid the $200 that a mechanic would charge for this procedure if possible. I am considering cutting the hose to remove the plenum and then replacing the hose with a new one. It should be easier to install a new hose, and once the plenum is out of the way I can actually reach back and remove the old hose.

yep i just did it this weekend. i know the hose your talkin about a real pita man, couldnt even really get ur hand in there to give it a good wiggle. soooooo a fold out locking razor knife and a new hose 3 second fix. =) the hose is like what a couple of bux a foot at auto zone. but word to the wise, the 2 on the driver side dont need to be removed and they r special order if u do "break or cut" them. the sharp angle makes the want to mash together in the middle when u just get normal hose to replace them. its the Coolant hose under ur vent screw in ur intake on the driver side and the pcv hose right beside it. so leave em on if they r good. after u cut that hose in the back there r 2 electrical connectors in the back of the plenum, one gray the other kindof orange. "cant see the orangish brown one from the back but i managed to Lift up on the front of the plenum with everything else unhooked and prop it up with a 2x4 layin longways across the engine bay. reached back there with a screw driver to "gently" push the release tab and pull it off. i think the hoses were the original 1996 hoses cause they were pretty much glued to the fittings when i got it out of there, was no getting them off. and be sure u plug everything else up and save that pita for last when reinstalling. the pipe that it went on in mine had a bit of corrosion on it so i scotched brighted it using wd40 as a lube. cleaned up decent but the left over corrosion as little as it is, acts like barbs when u try to pull it off again. so save that for the very very last lol. have fun, i know i did.

[Alkorahil]

I opted not to cut mine. Instead, I chose the "lots of cussin and bloody knuckles" approach.

 

I tried and tested repair method!

 

 

 

I have created new cuss words using this method and even spoken in tounges a few times.

[Alkorahil]

90 degree angle long handled needlenose pliers? Or you could cut the hose, pull the intake off, and replace it with a longer loop of new hose if you don't mind the way it'd look. It'd be easier than trying to put a little short hose back on in a tight spot.

 

cut the hose or get the pliers, if you buy the pliers they will cost as much if not more than the replacement cost of the hose....but then you get new tools.....