Alero, Grand Am 1999-2005

Valve Covers

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Removal & Installation



2.4L Engine
Exhaust Camshaft
  1. Disconnect the negative battery cable.
  2.  
  3. Detach the ignition coil and module electrical connection. Remove the coil and module assembly-to-camshaft housing bolts, then remove the assembly by lifting it straight up.
    NOTE
    Use spark plug wire removal tool J 36011 to disengage any connector that may have stuck to the spark plugs. Use the tool by first twisting, then pulling up on the connector assembly.

  4.  
  5. Disengage the electrical connection from the oil pressure switch.
  6.  
  7. For vehicles equipped with an automatic transaxle, remove the transaxle fluid level indicator tube assembly from the exhaust camshaft cover, then position it aside.
  8.  
  9. Disconnect, but do not remove from the vehicle, the timing chain housing at the exhaust camshaft housing.
  10.  
  11. Remove the exhaust camshaft cover and gasket, then discard the gasket. Be sure to loosen the housing bolts in the reverse order of the tightening sequence.
  12.  
  13. Clean all old gasket debris from the cover mating surfaces.
  14.  

To install:

  1. Position new camshaft housing-to-cover seals. No sealant is needed.
  2.  
  3. Apply pipe sealant 1052080 (or equivalent thread locking sealer) to the threads of the camshaft housing and cover retaining bolts.
  4.  
  5. Position the cover onto the housing, then tighten the bolts, in sequence, to specification. Tighten the camshaft housing-to-cylinder head bolts to 11 ft. lbs. (15 Nm) plus 90°, and the camshaft housing cover-to-camshaft housing bolts to 11 ft. lbs. (15 Nm) plus 30°.
  6.  
  7. Tighten the timing chain housing retainers.
  8.  
  9. Install the transaxle fluid level indicator tube assembly to the exhaust camshaft cover.
  10.  
  11. Attach the oil pressure switch electrical connector.
  12.  
  13. Reinstall any spark plug boot connectors that may have been stuck to a spark plug, back onto the ignition coil and module assembly.
  14.  
  15. Position the coil and module assembly over the spark plugs then push it straight down making sure it is firmly and properly seated.
  16.  
  17. Clean off any lubricant on the coil and module-to-camshaft housing bolts. Apply pipe sealant 1052080 (or equivalent thread locking sealer) to the bolts, then tighten them to 16 ft. lbs. (22 Nm) on the 2.3L engine and 11 ft. lbs. (15 Nm) on the 2.4L engine. plus 30°.
  18.  
  19. Attach the ignition coil and module assembly electrical connector.
  20.  
  21. Connect the negative battery cable, then start the engine and inspect for leaks.
  22.  

Intake Camshaft
  1. Disconnect the negative battery cable.
  2.  
  3. Detach the ignition coil and module assembly electrical connections.
  4.  
  5. Unfasten the ignition coil and module assembly-to-camshaft housing bolts, then remove the assembly by pulling it straight up.
    NOTE
    Use a spark plug wire removal tool J 36011 or equivalent to remove any connector that may have stuck to the spark plugs. Use the tool by first twisting, then pulling up on the connector assembly.



    Click image to see an enlarged view

    Fig. To remove the ignition coil and module assembly, remove the bolts then lift the assembly straight up

  6.  
  7. Remove the power steering pump pulley.
  8.  
  9. Unfasten the vacuum line from the fuel pressure regulator and fuel injector harness connector.
  10.  
  11. Disconnect the fuel line retaining clamp from the bracket on top of the intake cam housing.
  12.  
  13. Unfasten the fuel rail-to-camshaft housing retaining bolts, then remove the fuel rail from the cylinder head. Be sure to cover the injector openings in the cylinder head, cover the injector nozzles and leave the fuel lines attached and position the fuel rail aside (on top of the master cylinder).
  14.  
  15. Disconnect the timing chain housing but do not remove form the vehicle.
  16.  
  17. Unfasten the cam housing cover-to-housing retaining bolts and the cam housing-to-cylinder head bolts.
  18.  
  19. Use the reverse of the tightening procedure (in the accompanying figure) when loosening the camshaft housing-to-cylinder head bolts.
  20.  
  21. Push the cover off the housing by threading four of the housing-to-head retaining bolts into the tapped holes in the cover. Make sure to tighten the bolts evenly remove the cover from the vehicle.
  22.  
  23. Remove and discard the cover-to-housing seals and clean the mating surfaces.

    Click image to see an enlarged view

    Fig. Exploded view of the intake cam cover and related components-2.4L engines

  24.  

To install:

  1. Position new seals on the camshaft cover. Refer to the accompanying figure.

    Click image to see an enlarged view

    Fig. Intake and exhaust cam housing-to-cover seal locations-colors vary depending on the model year

  2.  
  3. Apply pipe sealant 1052080 (or equivalent thread locking sealer) to the camshaft housing and cover retaining bolt threads. Using J 366660, install the bolts. tighten the camshaft housing-to-cylinder head bolts to 11 ft. lbs. (15 Nm) plus 90° then tighten in sequence the camshaft housing cover-to-camshaft housing bolts to 11 ft. lbs. (15 Nm) plus 30°. Refer to the accompanying figure.

    Click image to see an enlarged view

    Fig. Intake and exhaust camshaft bolt tightening sequence-2.4L engines

  4.  
  5. Fasten the timing chain housing.
  6.  
  7. Uncover fuel injectors, then lubricate new injector O-ring seals with clean engine oil and install on the injectors.
  8.  
  9. Uncover the injector openings in the cylinder head, then install the fuel rail onto the cylinder head. Install the fuel rail-to-cylinder head retaining bolts and tighten to 19 ft. lbs. (26 Nm).
  10.  
  11. Install the fuel line retaining clamp and retainer to the bracket on top of the cam housing.
  12.  
  13. Connect the vacuum line to the fuel pressure regulator. Attach the fuel injector harness connector.
  14.  
  15. Lubricate the inner surface of the camshaft seal with clean engine oil, then install the seal into the camshaft housing using a seal installer tool such as J 36015, or equivalent.
  16.  
  17. Using the same tool J 36015 or equivalent, install the power steering pump drive pulley onto the intake camshaft.
  18.  
  19. Install the power steering pump assembly and the drive belt. Adjust tension to specification.
  20.  
  21. Fasten any spark plug boot connector assembly that stuck to a spark plug back onto the ignition coil and module assembly.
  22.  
  23. Position the coil and module assembly over the spark plugs, then push the assembly straight down. Make sure it is properly seated.
  24.  
  25. Clean off any loose lubricant from the coil and module assembly-to-camshaft housing bolts. Apply pipe sealant 1052080 (or equivalent thread locking sealer), onto the bolts, then tighten the bolts to 11 ft. lbs. (15 Nm).
  26.  
  27. Attach the coil and module electrical connector.
  28.  
  29. Connect the negative battery cable, then start the engine and inspect for oil leaks.
  30.  

3.1L Engine
Left Side (Front)
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system to a level below the coolant pipe on the front of the engine.
  4.  
  5. Remove the coolant bypass hose clamp at the coolant tube.
  6.  
  7. Unfasten the two bolts and nut securing the coolant tube to the cylinder head, then position the tube out of the way.
  8.  
  9. Disconnect the PCV valve from the rocker arm cover.
  10.  
  11. Unfasten the four rocker arm cover bolts, then remove the rocker arm cover. Discard the gasket.

    Click image to see an enlarged view

    Fig. Exploded view of the rocker arm and gasket assembly-3.1L engine

  12.  

To install:

  1. Clean all the gasket surfaces completely.
  2.  
  3. Install the rocker arm cover using a new gasket, then tighten the retaining bolts to 90 inch lbs. (10 Nm).
  4.  
  5. Connect the PCV valve to the rocker arm cover.
  6.  
  7. Position the coolant tube and connect the thermostat bypass hose.
  8.  
  9. Install the coolant tube mounting nut and bolts. Tighten the screw at the water pump to 106 inch lbs. (12 Nm), the bolt at the corner of the cylinder head to 18 ft. lbs. (25 Nm) and the nut to 18 ft. lbs. (25 Nm).
  10.  
  11. Properly refill the cooling system.
  12.  
  13. Connect the negative battery cable, then start the vehicle. Check for leaks.
  14.  

Right Side (Rear)
  1. Disconnect the negative battery cable.
  2.  
  3. Tag and disconnect the spark plug wires from the spark plugs and upper intake plenum wire retainer, then position out of the way.
  4.  
  5. Disconnect the power brake booster vacuum pipe from the intake plenum.
  6.  
  7. Remove the serpentine belt.
  8.  
  9. Remove the alternator.
  10.  
  11. Disconnect and remove the ignition assembly and EVAP canister purge solenoid as an assembly.
  12.  
  13. Remove the four rocker arm cover bolts, then remove the rocker arm cover. Discard the gasket.

    Click image to see an enlarged view

    Fig. Exploded view of the rocker arm and gasket assembly-3.1L engine

  14.  

To install:

  1. Clean all the gasket surfaces completely.
  2.  
  3. Install the rocker arm cover using a new gasket, then tighten the rocker cover bolts to 90 inch lbs. (10 Nm).
  4.  
  5. Install the alternator.
  6.  
  7. Install the serpentine belt.
  8.  
  9. Connect the power brake booster vacuum pipe to the plenum.
  10.  
  11. Install the EVAP solenoid and ignition assembly.
  12.  
  13. Connect the spark plug wires to the wire retainers on the plenum and the spark plugs as tagged during removal.
  14.  
  15. Properly refill the cooling system.
  16.  
  17. Connect the negative battery cable, then start the vehicle and check for leaks.
  18.  

3.4L Engine
Left Side
  1. Partially drain the cooling system.
  2.  
  3. Remove the front ignition wire harness at the upper intake manifold and at the spark plugs.
  4.  
  5. Remove the thermostat bypass pipe.
  6.  
  7. Disconnect the Positive Crankcase Ventilation (PCV) vacuum hose.
    NOTE
    The valve rocker arm cover gasket and sealant must be carefully trimmed away from lower intake manifold gasket. Failure to do so will damage the lower intake manifold gasket, causing a severe oil leak.

  8.  
  9. Remove the valve rocker cover bolts.
    NOTE
    When removing the valve rocker arm cover, ensure the gasket stays in place attached to the cylinder head.


    NOTE
    Remove the valve rocker cover. Bump the end of the valve rocker cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.

  10.  
  11. Trim the valve cover gasket and sealant away from the lower intake manifold gasket at the cylinder head to lower intake manifold joints (1).

    Click image to see an enlarged view

    Fig. Trim the valve cover gasket and sealant away from the lower intake manifold gasket at the cylinder head to lower intake manifold joints (1)

  12.  
  13. Remove the valve cover gasket.
  14.  
  15. Clean the sealing surface on the cylinder head with degreaser.
  16.  
  17. Clean the valve rocker arm cover.
    NOTE
    All gasket mating surfaces need to be free of oil and foreign material. Use GM P/N 12346139 (Canadian P/N 10953463) or equivalent, to clean surfaces.

  18.  

To install:


NOTE
Apply sealant GM P/N 12378521 (Canadian P/N 88901148), or equivalent at the cylinder head to lower intake manifold joint.

  1. Apply sealant at the cylinder head to lower intake manifold joints (1).

    Click image to see an enlarged view

    Fig. Apply sealant at the cylinder head to lower intake manifold joints (1)

  2.  
  3. Install a new gasket to the valve rocker cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
  4.  
  5. Install the valve rocker cover.
  6.  
  7. Install the valve rocker cover bolts and tighten them to 89 inch lbs. (10 Nm).
  8.  
  9. Connect the PCV valve vacuum line.
  10.  
  11. Install the thermostat bypass pipe.
  12.  
  13. Install the front ignition wire harness.
  14.  
  15. Fill the cooling system.
  16.  

Right Side
  1. Remove the generator bracket.
  2.  
  3. Remove the right rear spark plug wires.
  4.  
  5. Remove the ignition coil bracket with the coils, the purge solenoid and the vacuum canister solenoid.
  6.  
  7. Remove the vacuum hose from the grommet in the right rear valve rocker arm cover.
    NOTE
    Valve rocker arm cover gasket and sealant must be carefully trimmed away from lower intake manifold gasket. Failure to do so will damage the lower intake manifold gasket, causing a severe oil leak.

  8.  
  9. Remove the valve rocker cover bolts.
    NOTE
    When removing the valve rocker arm cover, ensure the gasket stays in place attached to the cylinder head.


    NOTE
    Remove the valve rocker cover. Bump the end of the valve rocker cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.

  10.  
  11. Trim the valve cover gasket and sealant away from the lower intake manifold gasket at the cylinder head to lower intake manifold joints (1).

    Click image to see an enlarged view

    Fig. Trim the valve cover gasket and sealant away from the lower intake manifold gasket at the cylinder head to lower intake manifold joints (1)

  12.  
  13. Remove the valve cover gasket.
  14.  
  15. Clean the sealing surface on the cylinder head with degreaser.
  16.  
  17. Clean the valve rocker arm cover.
    NOTE
    All gasket mating surfaces need to be free of oil and foreign material. Use GM P/N 12346139 (Canadian P/N 10953463) or equivalent, to clean surfaces.

  18.  

To install:


NOTE
Apply sealant GM P/N 12378521 (Canadian P/N 88901148), or equivalent at the cylinder head to lower intake manifold joint.

  1. Apply sealant at the cylinder head to lower intake manifold joints (1).

    Click image to see an enlarged view

    Fig. Apply sealant at the cylinder head to lower intake manifold joints (1)

  2.  
  3. Install a new gasket to the valve rocker cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
  4.  
  5. Install the valve rocker cover.
  6.  
  7. Install the valve rocker cover bolts and tighten them to 89 inch lbs. (10 Nm).
  8.  
  9. Install the vacuum hose to the grommet in the right rear valve rocker arm cover.
  10.  
  11. Install the ignition bracket with coils, the purge solenoid and the vacuum canister solenoid.
  12.  
  13. Install the right rear spark plug wires.
  14.  
  15. Install the generator bracket and generator.
  16.  

 
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