Astro, Safari 1997-2005

Valve Covers

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Removal & Installation



Left Side
  1. Disconnect the negative battery cable for safety.
  2.  
  3. From inside the vehicle, remove the engine cover. For details, please refer to Section 1 of this manual.
  4.  
  5. Remove the air cleaner box and intake duct.
  6.  
  7. Remove the PCV valve and oil fill tube.
  8.  
  9. Remove the serpentine drive belt.
  10.  
  11. If equipped, unbolt the air conditioning compressor and bracket, then slide the assembly forward without disconnecting or damaging the refrigerant lines.
  12.  
  13. Remove the EGR tube.
  14.  
  15. Disconnect the spark plug wires from the brackets. If any of the wires will interfere with cover removal, they should be TAGGED and disconnected from the spark plugs for additional clearance.
  16.  
  17. Remove the rocker arm cover-to-cylinder head bolts, then remove the cover and gasket.
  18.  
  19. Using a plastic scraper, clean the gasket mounting surfaces.
  20.  
  21. Using a new gasket, install the rocker cover and tighten the retainers to 90 inch lbs. (10 Nm).
  22.  
  23. The remainder of installation is the reverse of the removal procedure.
  24.  
  25. Connect the negative battery cable, then start the engine and check for leaks.
  26.  
  27. Once the engine has cooled, install the engine cover.
  28.  

Right Side
  1. Disconnect the negative battery cable for safety.
  2.  
  3. From inside the vehicle, remove the engine cover. For details, please refer to Section 1 of this manual.
  4.  
  5. Disconnect the spark plug wires from the brackets. If any of the wires will interfere with cover removal, they should be TAGGED and disconnected from the spark plugs for additional clearance.
  6.  
  7. Disconnect the vent tube.
  8.  
  9. Remove the purge solenoid and bracket from the engine.
  10.  
  11. Disengage the wiring harness at the rocker arm cover, then remove the bracket.
  12.  
  13. Remove the rocker arm cover-to-cylinder head bolts, then remove the cover and gasket.
  14.  
  15. Using a plastic scraper, clean the gasket mounting surfaces.
  16.  
  17. Using a new gasket, install the rocker cover and tighten the retainers to 90 inch lbs. (10 Nm).
  18.  
  19. Installation of the remaining components is the reverse of the removal procedure.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Start the engine and check for leaks.
  24.  
  25. Once the engine has cooled, install the engine cover.
  26.  

 
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