Valve Rocker Arm Cover Replacement - Left

REMOVAL PROCEDURE





1. Disconnect the vacuum brake booster hose.
2. Remove the air cleaner outlet resonator.
3. Remove the accelerator control cable from the throttle body.
4. Remove the cruise control cable from the throttle bracket.





5. Remove the spark plug wire harness retainer from the heater hose pipe.
6. Remove the spark plug wires from the spark plugs.





7. Remove the EGR valve pipe from the EGR valve adapter and the intake manifold.
8. Remove the EGR valve.
9. Remove the throttle body.





10. Remove the electrical connector for the fuel injectors from the bracket.
11. Remove the engine wiring harness bracket at the rear of the engine using the following procedure:
11.1. Loosen the bolt at the rear of the cylinder head.
11.2. Remove the two bolts that secure the bracket to the valve rocker arm cover.
11.3. Slide the bracket off of the bolt at the rear of the cylinder head.





12. Remove the bolts and the following brackets:
^ Air cleaner outlet resonator bracket
^ Fuel injector electrical connector bracket

13. Heater hose pipe bracket bolt.

IMPORTANT: The valve rocker arm cover bolt under the heater hose pipe bracket can be removed without removing the heater hose pipe.

14. Remove the valve rocker arm cover bolts and stud.





IMPORTANT: The valve rocker arm cover gasket is reusable. Only replace the valve rocker arm cover gasket if it is damaged.

15. Remove the valve rocker arm cover.
16. Clean all sealing surfaces.

INSTALLATION PROCEDURE





1. Clean the sealing surfaces where the cylinder head and the rocker arm cover meet. Use a suitable cleaning solvent.
2. Inspect the sealing flanges of the rocker arm cover for distortion.
3. Install a new rocker arm cover gasket in the groove around the rocker arm cover, if the old gasket was removed.
4. Install the valve rocker arm cover to the cylinder head.





5. Install the valve rocker arm cover bolts and the fuel injector electrical connector bracket.

6. Tighten the rocker arm cover bolts and stud in sequence.
^ Tighten the stud and bolts to 10 Nm (89 inch lbs.).





7. Install the heater hose pipe bracket bolt.
8. Install the air cleaner outlet resonator bracket and bolts.
^ Tighten the heater hose pipe bolt and the air cleaner outlet resonator bracket bolts to 25 Nm (18 ft. lbs.).





9. Install the engine wiring harness bracket to the rear of the engine by using the following procedure:
9.1. Slide the bracket over the bolt at the rear of the cylinder head.
9.2. Install the two bolts that secure the bracket to the valve rocker arm cover.

10. Tighten the bolts in the following order:
10.1. Tighten the two bolts to the valve rocker arm cover to 10 Nm (89 inch lbs.).
10.2. Tighten the bolt at the rear of the cylinder head to 25 Nm (18 ft. lbs.).

11. Install the electrical connector for the fuel injectors to the bracket.





12. Install the EGR valve.
13. Install the EGR valve pipe with new gaskets and the bolts to the EGR valve adapter and the intake manifold.
^ Tighten the EGR valve pipe to the EGR valve adapter bolts to 25 Nm (18 ft. lbs.).
^ Tighten the EGR valve pipe to intake manifold bolts to 10 Nm (89 inch lbs.).

14. Install the throttle body.
15. Install the accelerator control cable to the mounting bracket and throttle body.
16. Install the cruise control cable to the throttle bracket.





17. Install the spark plug wires to the spark plugs.
18. Install the spark plug wire harness retainer to the heater hose pipe.
19. Install the air cleaner outlet resonator.





20. Connect the vacuum brake booster hose.