Bonneville, LeSabre, Park Avenue 2000-2005

Valve Covers

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Removal & Installation



3.8L Engine
Left Side
  1. Remove the fuel injector sight shield.
  2.  
  3. Disconnect the left spark plug wire harness and position aside.
  4.  
  5. Remove the left valve rocker arm cover bolts.
    NOTE
    If the valve rocker arm cover adheres to the cylinder head, remove the valve rocker arm cover by bumping the end of the valve rocker arm cover with palm of hand or with a soft rubber mallet.

  6.  
  7. Remove the left valve rocker arm cover.
  8.  
  9. Remove the left valve rocker arm cover gasket.
  10.  
  11. Clean the sealing surface on the cylinder head.
  12.  
  13. Clean the valve rocker arm cover bolts of all thread locking adhesive.
  14.  
  15. Clean and inspect the valve rocker arm cover.
  16.  

To install:

  1. Install the new valve rocker arm cover gasket. Make sure that valve rocker arm cover gasket is seated properly in the valve rocker arm cover groove.
  2.  
  3. Install the left valve rocker arm cover to the cylinder head.
  4.  
  5. Apply thread lock compound, to the valve rocker arm cover bolt threads.
  6.  
  7. Install the left valve rocker arm cover bolts and tighten to 89 inch lbs. (10 Nm).
  8.  
  9. Connect the left spark plug wire harness.
  10.  
  11. Install the fuel injector sight shield.
  12.  

Right Side
  1. Remove the fuel injector sight shield.
  2.  
  3. Disconnect the right spark plug wire harness and position aside.
  4.  
  5. Remove the drive belt tensioner.
  6.  
  7. Disconnect the vacuum brake booster hose from the vacuum connections and position aside.
  8.  
  9. Remove the 2 nuts attaching the fuel injector sight shield bracket to the right exhaust manifold studs.
  10.  
  11. Remove the fuel injector sight shield bracket.
  12.  
  13. Remove the right valve rocker arm cover bolts.
    NOTE
    If the valve rocker arm cover adheres to the cylinder head, remove the valve rocker arm cover by bumping the end of the valve rocker arm cover with the palm of your hand or a soft rubber mallet.

  14.  
  15. Remove the right valve rocker arm cover.
  16.  
  17. Remove the right valve rocker arm cover gasket.
  18.  
  19. Clean the sealing surface on the cylinder head.
  20.  
  21. Clean the valve rocker arm cover bolts of all threadlocker adhesive.
  22.  
  23. Clean and inspect the valve rocker arm cover.
  24.  

To install:

  1. Install the new valve rocker arm cover gasket. Make sure that the valve rocker arm cover gasket is seated properly in the valve rocker arm cover groove.
  2.  
  3. Install the right valve rocker arm cover to the cylinder head.
  4.  
  5. Apply thread lock compound, to the valve rocker arm cover bolt threads.
  6.  
  7. Install the right valve rocker arm cover bolts and tighten to 89 inch lbs. (10 Nm).
  8.  
  9. Install the 2 nuts attaching the fuel injector sight shield bracket to the right exhaust manifold studs and tighten to 22 ft. lbs. (30 Nm).
  10.  
  11. Install the drive belt tensioner.
  12.  
  13. Connect the vacuum brake booster hose to the vacuum connections.
  14.  
  15. Connect the right spark plug wire harness.
  16.  
  17. Install the fuel injector sight shield.
  18.  

4.6L Engine
Left Side
  1. Remove the fuel injector sight shield.
  2.  
  3. Partially drain the cooling system.
  4.  
  5. Remove the radiator inlet hose from the water housing crossover.
  6.  
  7. Disconnect the Positive Crankcase Ventilation (PCV) fresh air tube from the camshaft cover.
  8.  
  9. Remove the ignition coil cassette.
  10.  
  11. Remove the 4 spark plug boots.
  12.  
  13. Disconnect the cable harness clips at the front of the camshaft cover and position the cable harness aside.
  14.  
  15. Remove the secondary air injection (AIR) valve bracket nut closest to the center of the engine.
  16.  
  17. Pry outward slightly on the AIR valve bracket in order to gain clearance to remove the water pump drive belt shield nut.
  18.  
  19. Remove the water pump drive belt shield fasteners.
  20.  
  21. Remove the water pump drive belt shield.
  22.  
  23. Disconnect the water pump drive belt.
  24.  
  25. Loosen the 2 bolts attaching the water pump belt tensioner to the water crossover.
  26.  
  27. Remove the water pump belt tensioner.
  28.  
  29. Remove the plastic dust cap from the end of the intake camshaft.
  30.  
  31. Remove the water pump drive pulley from the intake camshaft.
  32.  
  33. Remove the 3 camshaft seal retainer bolts.
  34.  
  35. Remove the camshaft seal.
  36.  
  37. Remove the camshaft cover bolts.
  38.  
  39. Lift the camshaft drive end of the camshaft cover up.
  40.  
  41. Remove the camshaft cover reward to clear the water pump drive shaft.
  42.  
  43. 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.
  44.  
  45. Clean and inspect the camshaft cover.
  46.  

To install:

  1. 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.

  2.  
  3. Insert the intake camshaft end through the hole in the camshaft cover.
  4.  
  5. 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.
  6.  
  7. Install the 9 camshaft cover bolts and tighten to 89 inch lbs. (10 Nm).
  8.  
  9. Lubricate the camshaft seal lips with engine oil.
  10.  
  11. Push the camshaft seal into position around the intake camshaft using the protective sleeve supplied with the seal.
  12.  
  13. Coat the bolt threads with sealant.
  14.  
  15. Install the camshaft seal bolts and tighten to 27 inch lbs. (3 Nm).
  16.  
  17. Place the water pump drive pulley in position on the intake camshaft.
  18.  
  19. Install the water pump pulley using the installer tool J-38823. During installation, the tool will bottom out on the camshaft at the proper depth.
  20.  
  21. Install the plastic dust cap into the end of the camshaft.
  22.  
  23. Position the water pump belt tensioner to the water crossover.
  24.  
  25. Tighten the water pump belt tensioner bolts 89 inch lbs. (10 Nm).
  26.  
  27. Connect the water pump drive belt.
  28.  
  29. Install the water pump drive belt shield.
  30.  
  31. Install the water pump drive belt shield fasteners.
  32.  
  33. Connect the cable harness clips to the cable harness at the front of the camshaft cover.
  34.  
  35. Install the spark plug boots onto the coil cassette. Ensure that the boots are fully seated against the cassette.
  36.  
  37. Install the ignition coil cassette.
  38.  
  39. Connect the PCV fresh air tube to the left camshaft cover.
  40.  
  41. Connect the radiator inlet hose to the water housing crossover.
  42.  
  43. Install the fuel injector sight shield.
  44.  
  45. Fill the cooling system.
  46.  

Right Side
  1. Remove the fuel injector sight shield.
  2.  
  3. Disconnect the Positive Crankcase Ventilation (PCV) dirty air tube from the camshaft cover.
  4.  
  5. Disconnect the oxygen sensor wire.
  6.  
  7. Disconnect the vacuum tubes from the secondary air injection (AIR) vent solenoid.
  8.  
  9. Disconnect the AIR vent solenoid electrical connector.
  10.  
  11. Remove the AIR control valve bracket.
  12.  
  13. Remove the nut securing the AIR tube.
  14.  
  15. Remove the ignition coils.
  16.  
  17. Disconnect the cable harness clips at the front of the camshaft cover and position the cable harness aside.
  18.  
  19. Remove the 9 camshaft cover bolts.
  20.  
  21. Remove the camshaft cover.
  22.  
  23. 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.
  24.  
  25. Clean and inspect the camshaft cover.
  26.  

To install:

  1. 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.

  2.  
  3. Install the camshaft cover and tighten the bolts to 89 inch lbs. (10 Nm).
  4.  
  5. Insure that the spark plug seals are in position.
  6.  
  7. Install the ignition coils.
  8.  
  9. Install the AIR control valve bracket.
  10.  
  11. Connect the cable harness clips to the cable harness at the front of the camshaft cover.
  12.  
  13. Connect the AIR vent solenoid electrical connector.
  14.  
  15. Connect the vacuum tubes to the AIR vent solenoid.
  16.  
  17. Connect the oxygen sensor wire.
  18.  
  19. Connect the PCV dirty air tube to the camshaft cover.
  20.  
  21. Position the intake manifold sight shield to the engine.
  22.  
  23. Install the 2 intake manifold sight shield nuts and tighten to 27 inch lbs. (3 Nm).
  24.  

 
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