4.0 V8 front valve cover removal- PROCEEDURE

[scottyaurorav8]

So I finally got around to installing my new powder coated front valve cover with all new felpro seals. Man am I pleased. Felpro makes a great kit. Better than stock IMO. The rubber is very quality.

So the job was time consuming but well worth it. Much easier than the rear that's for sure.
To start, remove the main large coolant hose and plug it up with a rag then move it to the side. you need to remove the water pump pulley shield or cam shield..whatever you call it. Also the air pump and the silver air tube at the bottom disconnects with a swivel head, extension and 10mm socket. There are 2 - 10mm screws. Next, you will need a 10mm wrench to remove the shield and a 13mm socket for one bolt up top. Then you can move it to the side. Now you can use a ratchet to loosen the tensioner pulley so you can flip the pulley belt to the side. I removed the the tensioner entirely. Just keep the belt there off to the side. Once that's done. Disconnect the air hose and plug for the ignition coil on the valve cover, then you can start to unscrew the coil bolts and valve cover bolts. I recall it being a 10mm socket. I used my electric drill. Super quick. The bolts at the sides and bottoms of the cover were a pain, you will need an assortment of extensions and swivels for sure. Just be patient and manuever them..eventually you will get the right angles to unscrew them. The harness blocks the left side of the valve cover. Just unclip the two fasteners so you can move the harness over to make room for the removal.
Next you will need a pulley removal kit. I got mine from harbor freight for $16.99. Its item #40749. Worked great. You will need a 13/16th wrench and 13mm socket for removal and installation of the pulley. Once its popped off, careful removing the valve cover. Or you will damage the end of the cam. I found it best to remove the little side plate on the valve cover. 3- 7mm screws. Then you can wiggle the cover off. Clean up the heads and reinstall. I torqued the valve cover bolts to 89inch pounds and the coil pack bolts to 45 inch pounds. Took me about 3 hours with water breaks and cleaning stuff. If I missed any details message me for additional tips. I'm glad I saved $498 ( quoted from a shop) haha.

[ejohnson03]

I am trying to remove the Rear Coil Pack.

That stupid Vacuum thing is in the way.

I was able to take out several of the bolts so it could wiggle around enough for me to access the Coil bolts.

However, there just is not enough clearance to remove the Coil Pack.

Where you able to remove that big Silver Vacuum thing?

[scottyaurorav8]

I have the rear valve cover write up on here also. It's a little further down in the 2nd gen section. You'll see it though. Follow that procedure and it should help.

As far as the vacuum. Yes! Huge PITA, but it can be done. The bracket with the EGR
is easy. It unbolts no problem, but the silver air tube funneling down past the valve cover from under the EGR is probably 8 inches long and connects to a junction down below. Its attached by two 10mm nuts. I needed a telescoping mirror with a led light to see each nut, then I used a ratchet with 12" and 18" inch extensions, a swivel and 10mm socket on the end, then kept trying to line the socket up to the nut. I eventually got it but was not easy. A magnatized socket would help, otherwise the nut will fall.

Once you get that and the bolts on the bracket on the valve cover, the whole unit can come out. Did you remove the fuel rail first? The silver fuel canister on the right side of the rail is in the way of the valve cover. The rail needs to come out with the injectors and moved to the side. I found it easier to just unclip whole rail.

The coil pack will come out with a prybar pressing the ac lines back a little. Then you will need a 90 degree angle bit to get the valve cover bolts on the back side and some from underneath with a ratcheting wrench and ratchet with extensions. Advanced auto sells the 90 degree tool. Let me know if you need anymore advice. Check my rear valve cover procedure thread too.