Valve Cover: Service and Repair

Valve Rocker Arm Cover Replacement

Removal Procedure





1. Drain the cooling system.
2. Disconnect the power brake booster Vacuum hose.
3. Remove the air cleaner outlet resonator.
4. Remove the throttle body.





5. Remove the spark plug wire harness retainer from the thermostat assembly.
6. Remove the spark plug wires from the spark plugs.

Important: Do not bend the thermostat assembly pipe out of the way in order to remove the valve rocker arm cover.

7. Remove the water outlet housing.





8. Disconnect the fuel injector harness electrical connector.
9. Remove the fuel injector harness electrical connector from the bracket on the valve rocker arm cover.
10. Remove the engine wiring harness from the bracket.
11. Move and secure the engine wiring harness out of the way.





12. Remove the engine wiring harness bracket at the rear of the engine using the following procedure:
12.1. Loosen the bolt at the rear of the cylinder head.
12.2. Remove the 2 bolts that secure the bracket to the valve rocker arm cover.
12.3. Slide the bracket off of the bolt at the rear of the cylinder head.





13. Remove the air cleaner outlet resonator bracket.

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





14. Remove the rocker arm cover bolts, stud (1) and bracket (2).
15. Remove the rocker arm cover.
16. Remove the rocker arm cover gasket.
17. Clean all sealing surfaces and the valve rocker arm cover.

Installation Procedure





1. Install a new rocker arm cover gasket in the groove around the rocker arm cover, if the old gasket was removed.
2. Install the rocker arm cover to the cylinder head.
3. Install the rocker arm cover bolts, stud (1) and bracket (2).

Notice: Refer to Fastener Notice in Service Precautions.





4. Install the rocker arm cover bolts in sequence
^ Tighten the rocker arm cover bolts to 10 Nm (89 inch lbs.).





5. Install the air cleaner outlet resonator bracket and bolts.
^ Tighten the air cleaner outlet resonator bracket bolts to 10 Nm (89 inch lbs.).





6. Install the wiring harness bracket to the rear of the engine by using the following procedure:
6.1. Slide the bracket over the bolt at the rear of the cylinder head.
6.2. Install the 2 bolts that secure the bracket to the valve rocker arm cover.
7. Tighten the bolts in the following order:
7.1. Tighten the 2 bolts to the valve rocker arm cover to 10 Nm (89 inch lbs.).
7.2. Tighten the bolt at the rear of the cylinder head to 25 Nm (18 ft. lbs.).





8. Position the engine wiring harness.
9. Install the engine wiring harness to the bracket.
10. Install the fuel injector harness electrical connector to the bracket on the valve rocker arm cover.
11. Connect the fuel injector harness electrical connector.
12. Install the water outlet housing.
13. Install the throttle body.





14. Install the spark plug wires to the spark plugs.
15. Install the spark plug wire harness retainer to the thermostat assembly.
16. Install the air cleaner outlet resonator.





17. Connect the power brake booster vacuum hose.
18. Fill the engine cooling system.