nook
+1y
Its hard to troubleshoot without actually having some hands on experience of the noises and symptoms but my 2 cents worth I'll throw along.
If the valve cover was over tightened and hitting, pulling the #4 plug wire should make no difference, the rockers are still moving up and down.
You ruled out the exhaust leak already, too tight exhaust valve causing popping out # 4 cyl?
Worse case scenario, bearing or piston problem on #4, you mention the noise goes away when the #4 wire is pulled, typical of a rod knock, you unload the cylinder by cutting the spark. Hopefully its something simple and not internal. Good luck.