Trying to replace driver side valve cover gasket. Cover is butting up against a hose. Could someone please identity what this hose is? Trying to remove it safely. Thank you

 

ahhhhhhh, memories.

That is a PITA to remove the driver's side cover, but it's not impossible.

First off, that is your Air Conditioning line. If you removed your AC system, then you could probably just remove that AC line if you want. But if you have AC, then I would highly recommend that you do not disconnect the line because it's an even bigger PITA to reseal these old systems. Best to leave them as is.

But to remove the valve cover on an IDI van, you do not need to remove that line. Instead, here is the procedure.

1. Undo the valve cover bolts.
1a. (not specific to most IDI vans, but I notice this in your particular van due to an improperly installed diesel injector cap) Remove the diesel return line at the front of the valve cover.
2. From the inside of the van, reach your left arm through the doghouse and use the back of your hand to push the AC line toward the front of the van.
3. While still pushing the AC line with the back of your left hand, grab the front of the VC with your left hand, and then use your right hand to lift the back of the valve cover off.

Since your left arm is moving the AC line out of the way, you should be able to finagle the valve cover off with your right arm. It will not just come off and it will take some time to find a way to curve it around the components on top of the heads. I think i curved it up clockwise toward the intake manifold, iirc.

Since the AC line is somewhat flexible, you should be able to accomplish this. But it is not very flexible, so it takes a decent amount of strength with the back of your left hand to push it forward. Also, you will have maybe 5/8" clearance from the rocker arms to the doghouse wall, so it will be exceptionally difficult to reinstall the new valve cover gasket. The best way is to use some permatex to hold the gasket in place to the underside of the valve cover, then reinstall using the same arm location technique as described above, but in reverse. Push the AC line forward with the back of your left hand and hold the front of the VC with that same hand, also supporting the back of the VC with your right hand. There is no delicate way to accomplish this, so be sure to have a spare gasket if you F one up trying to weasel it on the head.

Most of all, good luck.


Other issues I noticed in your setup is the use of FRAM diesel filter. You might want to upgrade to a filter setup on the rail, like the R&D Stage 1 deal. Much better filtration without restriction. Also, you should re-orient your injector cap to the correct direction.

 

If you want to make it a little easier to extract the VC and reinstall it, you could jack up the engine, remove the passenger side engine mount, then set the engine down on that side on a block or something. Do not just let the engine rest on the cross member cuz it will cut or dent the oil pan.

By removing the passenger side engine mount, it will tip the engine to that side, and afford you maybe an extra half inch to work the VC off and on.

You do not need to do this to remove the VC, and it would add an hour of f'ing around to your project, but if you have the jack and tools, it might be nice to know that you can replace the VC gasket without janking it up.

To see the engine tipping procedure, I showcased it when I did my head gaskets with the engine in the van on my blog: 1988 E250 Van 7.3 IDI Head Gasket Job (without pulling the engine) ? IDI Online

 

Thanks Genscripter!

I ended up pulling the hose toward me from the front of the engine to get it off the components. Then to put it on I just pushed the VC against the hose to get it stuck against a rocker from inside the van, then back outside to pull the hose forward and rest the VC. Props on getting the VC on with the back pressure of your hand. Could not get it on that way

Looking forward to rotating the engine if I have to work the other VC

Thanks for the return cap suggestion. Its nice not look like a total kook out here. And also your fuel filter suggestion.