Aurora 2001-2003

Valve Covers

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Removal & Installation



3.5L Engine
Front Bank
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
    NOTE
    Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.


    NOTE
    The battery is located beneath the rear seat cushion.

  4.  
  5. Remove the automatic transaxle filler tube.
  6.  
  7. Remove the 2 fuel injector sight shield nuts at the front of the fuel injector sight shield.
  8.  
  9. Lift the fuel injector sight shield up at the front and slide out of the engine bracket.
  10.  
  11. Remove the fuel injector sight shield bracket bolts and bracket.
  12.  
  13. Disconnect the PCV fresh air tube from the camshaft cover.
  14.  
  15. Disconnect the engine wiring harness clips at the front of the camshaft cover and position aside.
  16.  
  17. Disconnect the oxygen sensor electrical connector and remove the connector end from the camshaft cover.
  18.  
  19. Remove the ignition coil assembly from the camshaft cover.
    NOTE
    Use only the spark plug boot special removal tool to remove the spark plug boots. Prying or using regular pliers could damage the boots.

  20.  
  21. Remove the spark plug boots using the J 43094 or a suitable spark plug boot puller.
  22.  
  23. Remove the camshaft cover retaining bolts.
    NOTE
    The right camshaft cover perimeter and spark plug seals should be reused unless they are damaged or if the perimeter seal is pulled from its groove during removal.

  24.  
  25. Lift the camshaft cover off the cylinder head evenly.
  26.  

To install:

  1. Clean and inspect the camshaft cover.
  2.  
  3. If necessary, assemble the camshaft cover.
  4.  
  5. Wipe the right cylinder head sealing surface with a clean, lint-free cloth.
  6.  
  7. Inspect the right camshaft cover perimeter and spark plug seals for damage. Check to make sure the perimeter seal is not pulled from its groove. Replace the seals if they are damaged or pulled from the groove.
  8.  
  9. Place the camshaft cover in position on the cylinder head.
  10.  
  11. Install the camshaft cover retaining bolts and tighten to 80 inch lbs. (9 Nm)
  12.  
  13. Push the spark plug boots onto the ignition coil assembly.
  14.  
  15. Install the ignition coil assembly to the camshaft cover.
  16.  
  17. Install or connect the following:

    PCV fresh air tube
     
    Oxygen sensor electrical connector
     
    Engine wiring harness clips
     
    Fuel injector sight shield bracket
     
    Fuel injector sight shield bracket bolts and tighten to 71 inch lbs. (8 Nm)
     

  18.  
  19. Insert the tab of the fuel injector sight shield under the engine bracket.
  20.  
  21. Lower the fuel injector sight shield.
  22.  
  23. Align the holes in the fuel injector sight shield with the studs.
  24.  
  25. Install the 2 fuel injector sight shield nuts onto the studs and tighten the nuts to 27 inch lbs. (3 Nm)
  26.  
  27. Install the automatic transaxle filler tube.
  28.  
  29. Reconnect the negative battery cable and reinstall the rear seat cushion.
  30.  

Rear Bank
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
    NOTE
    Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.


    NOTE
    The battery is located beneath the rear seat cushion.

  4.  
  5. Remove the 2 fuel injector sight shield nuts at the front of the fuel injector sight shield.
  6.  
  7. Lift the fuel injector sight shield up at the front and slide out of the engine bracket.
  8.  
  9. Remove the oil level indicator tube.
  10.  
  11. Disconnect the PCV dirty air tube from the camshaft cover.
  12.  
  13. Remove the ignition coil assembly from the left camshaft cover.
    NOTE
    Use only the spark plug boot special removal tool to remove the spark plug boots. Prying or using regular pliers could damage the boots.

  14.  
  15. Remove the spark plug boots using the J 43094 or a suitable spark plug boot removal tool.
  16.  
  17. Disconnect and set aside the engine wiring harness and fuel injector harness from the camshaft cover retainers.
  18.  
  19. Remove the camshaft cover retaining bolts.
    NOTE
    The left camshaft cover seals (perimeter and spark plug) should be reused unless they are damaged or if the perimeter seal is pulled from its groove during removal.

  20.  
  21. Lift the camshaft cover off the left cylinder head evenly.
  22.  
  23. If necessary, disassemble the camshaft cover.
  24.  

To install:

  1. Clean and inspect the camshaft cover.
  2.  
  3. If necessary, assemble the camshaft cover.
  4.  
  5. Wipe the cylinder head sealing surface with a clean, lint-free cloth.
  6.  
  7. Inspect the camshaft cover seals (perimeter and spark plug) for damage. Check to make sure the perimeter seal is not pulled from its groove. Replace the seals if they are damaged or pulled from the groove.
  8.  
  9. Place the camshaft cover in position on the cylinder head.
  10.  
  11. Install the left camshaft cover retaining bolts and tighten to 80 inch lbs. (9 Nm)
  12.  
  13. Connect the engine wiring harness and fuel injector harness to the left camshaft cover retainers.
  14.  
  15. Push the spark plug boots onto the ignition coil assembly.
  16.  
  17. Install the ignition coil assembly to the camshaft cover.
  18.  
  19. Connect the PCV dirty air tube to the camshaft cover.
  20.  
  21. Install the oil level indicator tube.
  22.  
  23. Insert the tab of the fuel injector sight shield under the engine bracket.
  24.  
  25. Lower the fuel injector sight shield.
  26.  
  27. Align the holes in the fuel injector sight shield with the studs.
  28.  
  29. Install the 2 fuel injector sight shield nuts onto the studs and tighten the nuts to 27 inch lbs. (3 Nm)
  30.  

4.0L Engine
Front Bank
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
    NOTE
    Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.


    NOTE
    The battery is located beneath the rear seat cushion.

  4.  
  5. Remove or disconnect the following:

    2 nuts from the intake manifold sight shield
     
    Sight shield from the engine
     
    PCV dirty air tube
     
    Oxygen sensor wire
     
    Vacuum tubes from the secondary AIR vent solenoid
     
    Secondary AIR vent solenoid electrical connector
     
    Secondary AIR control valve bracket
     
    Ignition coil cassette
     
    4 spark plug boots
     
    Cable harness clips at the front of the camshaft cover and position the cable harness aside.
     
    9 camshaft cover bolts.
     
    Camshaft cover
     

  6.  
  7. Discard the camshaft cover perimeter seals and spark plug seals if there is any evidence of damage or if the seal comes out of the groove in the cover during removal.
  8.  

To install:

  1. Clean and inspect the camshaft cover.
  2.  
  3. Install the camshaft cover seal as required.
    NOTE
    Be careful to prevent the exposed section of the camshaft cover seal from being damaged by the edge of the cylinder head casting.

  4.  
  5. Install the camshaft cover.
  6.  
  7. Install the 9 camshaft cover bolts and tighten to 89 inch lbs. (10 Nm)
  8.  
  9. Install or connect the following:

    Spark plug boots onto the coil cassette
     
    Secondary AIR control valve bracket
     
    Cable harness clips to the cable harness
     
    Secondary AIR vent solenoid electrical connector
     
    Vacuum tubes to the secondary AIR vent solenoid
     
    Oxygen sensor wire
     
    PCV dirty air tube
     

  10.  
  11. Position the intake manifold sight shield to the engine.
  12.  
  13. Install the 2 intake manifold sight shield nuts and tighten to 27 inch lbs. (3 Nm)
  14.  
  15. Reconnect the negative battery cable and reinstall the rear seat cushion.
  16.  

Rear Bank
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
    NOTE
    Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.


    NOTE
    The battery is located beneath the rear seat cushion.

  4.  
  5. Remove the 2 nuts from the intake manifold sight shield.
  6.  
  7. Remove the sight shield from the engine.
  8.  
  9. Partially drain the cooling system.
  10.  
  11. Position the J 38185 or a suitable cooling hose clamp to remove the radiator inlet hose from the water housing crossover.
  12.  
  13. Disconnect the PCV fresh air tube from the camshaft cover.
  14.  
  15. Remove the ignition coil cassette.
  16.  
  17. Remove the 4 spark plug boots.
  18.  
  19. Disconnect the cable harness clips at the front of the camshaft cover and position the cable harness aside.
  20.  
  21. Remove the secondary AIR valve bracket nut closest to the center of the engine.
  22.  
  23. Pry outward slightly on the secondary AIR valve bracket in order to gain clearance to remove the water pump drive belt shield nut.
  24.  
  25. Remove the water pump drive belt shield fasteners.
  26.  
  27. Remove the water pump drive belt shield.
  28.  
  29. Disconnect the water pump drive belt.
  30.  
  31. Loosen the 2 bolts attaching the water pump belt tensioner to the water crossover.
  32.  
  33. Remove the water pump belt tensioner.
  34.  
  35. Remove the plastic dust cap from the end of the intake camshaft.
  36.  
  37. Remove the water pump drive pulley from the intake camshaft using the J 38825 or a suitable pulley puller.
  38.  
  39. Remove the 3 camshaft seal retainer bolts.
    NOTE
    DO NOT reuse the camshaft seal.

  40.  
  41. Remove the camshaft seal.
  42.  
  43. Remove the 9 camshaft cover bolts.
  44.  
  45. Lift the camshaft drive end of the camshaft cover up.
  46.  
  47. Remove the camshaft cover reward to clear the water pump drive shaft.
  48.  
  49. Discard the camshaft cover perimeter seals and spark plug seals if there is any evidence of damage or if the seal comes out of the groove in the cover during removal.
  50.  

To install:

  1. Clean and inspect the camshaft cover.
  2.  
  3. Install the camshaft cover seal as required.
    NOTE
    Be careful to prevent the exposed section of the camshaft cover seal from being damaged by the edge of the cylinder head casting.

  4.  
  5. Insert the intake camshaft end through the hole in the camshaft cover.
  6.  
  7. Work the camshaft cover into position by pivoting the cover down and to the left allowing the cover to clear the camshaft drive chain and then aligning the bolt holes.
  8.  
  9. Install the 9 camshaft cover bolts and tighten to 89 inch lbs. (10 Nm)
  10.  
  11. Install the NEW seal as follows:
    1. Lubricate the camshaft seal lips with engine oil.
    2.  
    3. Push the camshaft seal into position around the intake camshaft using the protective sleeve supplied with the seal.
    4.  
    5. Coat the bolt threads with sealant GM P/N 1052080 (Canadian P/N 10953480) or equivalent.
    6.  
    7. Install the camshaft seal bolts and tighten to 27 inch lbs. (3 Nm)
    8.  

  12.  
  13. Place the water pump drive pulley in position on the intake camshaft.
  14.  
  15. Install the water pump pulley using the J 38823 or a suitable pulley installer.
  16.  
  17. Install the plastic dust cap into the end of the camshaft.
  18.  
  19. Position the water pump belt tensioner to the water crossover and tighten the bolts to 89 inch lbs. (10 Nm)
  20.  
  21. Connect the water pump drive belt.
  22.  
  23. Install the water pump drive belt shield.
  24.  
  25. Install the water pump drive belt shield fasteners and tighten to 89 inch lbs. (10 Nm)
  26.  
  27. Connect the cable harness clips to the cable harness at the front of the camshaft cover.
  28.  
  29. Install the spark plug boots onto the coil cassette. Ensure that the boots are fully seated against the cassette.
  30.  
  31. Install the ignition coil cassette.
  32.  
  33. Connect the PCV fresh air tube to the left camshaft cover.
  34.  
  35. Position the J 38185 or clamp in order to connect the radiator inlet hose to the water housing crossover.
  36.  
  37. Position the intake manifold sight shield to the engine.
  38.  
  39. Install the 2 intake manifold sight shield nuts and tighten the nuts to 27 inch lbs. (3 Nm)
  40.  
  41. Fill the cooling system.
  42.  
  43. Reconnect the negative battery cable and reinstall the rear seat cushion.
  44.  

 
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