I'm a newbie here but have been driving and working my XJ 4.0 for many years...

My wife has an '03 KJ w/the 3.7 motor and it has developed an oil leak around the passenger side Valve cover. At 122K miles right now. Of course the Drivers side looks to be an EASY replacement but the Passenger side has what looks like the AC Hard Lines and Coolant lines running over the Valve Cover. I have not tried to remove the Valve cover yet, but wanted to know if there are any tricks or tips to getting this done?

I shouldn't need to remove the plugs/coils/fuel injectors should I? Can I somehow move those hardlines w/out disconnecting them or is it even necessary to do that in order to change out the Valve Cover gaskets?

Any write-ups / pics would be greatly appreciated. I always like to read or walk my way thru a project before attempting it w/no guidance.

thanks.

I replaced both of my valve cover gaskets recently, and 03 with 130,000 so it sounds identical to your case. I will post some pictures later this evening so you can see what all I had to remove.

To answer your question, you do NOT have to remove the heater core metal lines that run over the VC. simply pop them out of the plastic clip that holds them by the oil filler neck. you will also have to remove the coolant over flow reservoir, air intake, and oil filler neck. Its all really pretty easy. The gasket is.. odd. Like a very hard rubber/plastic, but it works. fixed my problem. Also be sure to clean up the head and the valve cover surface that it mates to.

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2003 limited 3.7L V6
Vader Edition

http://www.cardomain.com/ride/3219059

Thanks for the info. Appreciate the words and look forward to seeing pics.

New set of questions... I've started removing things to get access to the Valve Cover and I'm having problems getting the bottom part of the air box removed. Are there some hidden screws holding this to the frame or do I simply need to pull harder to get the darn thing out?



Also, these plastic clips holding the water lines are not really easy to figure out how to remove them... there are a couple little tabs I see holding them, but I tried bending those tabs and broke one of them off and the clips still won't budget. Any help on getting this apart?





Overall pic of where I'm stuck.



Oh... and when removing vacuum and lines I notice that the hose that attached under the Air Intake and to the back of the valve cover (pass side) has a nice split and it looks like some oil was leaking f/there. I'll have to try and replace that line if anyone can give me a part # It would be greatly appreciated.

Thanks

I can help you out with the air box and the hose don't really know what to do with those clips. With the air box stand at the passenger side fender grab the side of the box furthest from you and pull towards you. You will have to pull hard but it will pop loose then from there just manipulate it till the rest let go. And with the hose don't got with to the stealership just go find some hose with the same inner diameter and an oil resistant rating and cut your own easier and cheaper.

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My CRD Build Thread
Soon to Come:more lights

The clips for the heater core just need some more manipulating. Flat blade screw driver will break it loose. Even if the clip doesnt reclip they wont move around enough to cause any issues. And if you are concerned with the clip not reclosing, just put a zip tie around it to keep it closed properly. Pics coming soon.

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2003 limited 3.7L V6
Vader Edition

http://www.cardomain.com/ride/3219059

didnt have as many pics as i though I did, but here is the ultimate goal.



Redsnake if your still having issues ill PM you my cell # to make this go a lil faster.

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2003 limited 3.7L V6
Vader Edition

http://www.cardomain.com/ride/3219059

Thanks guys... I was able to get the air box out, but on those clips holding the coolant lines I just busted them. Seems like most of the plastic was dry-heat rotted and busted anyhow.

Got the new gasket on and a new hose that I cut to work out at Autozone... Got it all back together and now I'm going to top-op the coolant and hope she doesn't burn anymore or stink like cooking oil. I have another 'issue' maybe. There has been for the longest time what looks like sludge in the Oil Filler Neck. Since I removed it this time to get the Valve Cover off, I decided to clean it. It looked even worse than before w/a rust-color like sludge covering the inside of the Oil Filler Neck and the 'plug' that goes in there. Here is a pic ... let me know if you think this is normal, a problem or what. If it is a problem what do you think it is? The condition of the Engine under the Valve Cover looked brand new. I'm religious about changing oil (Mobil 1 5W-30) and doing maintenance on this thing.

The sludge you found is pretty normal in a lot of them , esp. ones that make a lot of short trips. Nothing to worry about seems to happen more in colder weather as well

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MUDD'S MOTORSPORT'S We do IFS lift installs ,
03 OVERLAND EDITION /Kilby-Skidrow-Mopar-4XGuard skids/ 2.5 inch TOTAL CONTROL JBA coilovers -JBA Arms/MOABS-31 FALKEN WILDPEAK AT3W / 4.10's etc, 04 Kilimanjaro Edition loaded, plus 05 KJ limited