CTS 2003-2005

Valve Covers

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Removal & Installation



2.8L & 3.6L Engines
Left Side
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine appearance cover.
  4.  
  5. Disconnect the ignition coil electrical connectors.
  6.  
  7. Remove the wiring harness from the side of the camshaft cover by sliding the conduit down and outboard.
  8.  
  9. Remove the wiring conduit retainers from the camshaft cover by rotating the wiring harness conduit retainers counterclockwise.
  10.  
  11. Remove the wiring harness from the front of the camshaft cover.
  12.  
  13. Reposition and secure the wiring harnesses away from the camshaft cover in order to provide clearance.
  14.  
  15. Disconnect the air cleaner duct from the throttle body. Disconnect the positive crankcase ventilation (PCV) hose from the camshaft cover. Remove the intake manifold bolts, but do not separate the upper intake manifold from the lower intake manifold.
  16.  
  17. Remove the intake manifold brace bolts and the brace.
  18.  
  19. Remove and reposition the upper intake manifold with the lower intake manifold in order to gain sufficient clearance for ignition coil removal.
  20.  
  21. Remove the ignition coil bolt.
  22.  
  23. Raise each ignition coil through the camshaft cover from the spark plug tube. DO NOT damage the spark plug or ignition coil perimeter seals.
  24.  
  25. Remove the spark plugs.
  26.  
  27. Remove the camshaft cover.
  28.  
  29. Remove and discard the camshaft cover seal and grommets.
  30.  

To install:

  1. Install a NEW camshaft cover seal and NEW grommets.
  2.  
  3. Wipe the camshaft cover sealing surface on the left cylinder head with a clean, lint-free cloth.
  4.  
  5. Place a bead 8 mm (0.3150 in) in diameter by 4 mm (0.1575 in) in height of RTV sealant, on the engine front cover split lines (1).

    Click image to see an enlarged view

    Fig. Sealant application areas for camshaft cover installation-2.8L & 3.6L engines

  6.  
  7. Place the left camshaft cover into position onto the left cylinder head.
  8.  
  9. Loosely install the left camshaft cover bolts.
  10.  
  11. Tighten the left camshaft cover bolts in the sequence shown to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Left camshaft cover bolt tightening sequence-2.8L & 3.6L engines

  12.  
  13. Install the NEW spark plugs into the left cylinder head and tighten to 15 ft. lbs. (20 Nm).
  14.  
  15. Install each ignition coil through the left camshaft cover into the spark plug tube taking care not to damage the spark plug and/or the seal in the left camshaft cover.
  16.  
  17. Install each ignition coil bolt and tighten to 89 inch lbs. (10 Nm).
  18.  
  19. Install the wiring harness to the front of the camshaft cover.
  20.  
  21. Install the wiring harness conduit retainers to the wiring harness conduit.
  22.  
  23. Install the wiring harness to the side of the camshaft cover.
  24.  
  25. Connect the ignition coil electrical connectors.
  26.  
  27. Install the upper intake manifold with the lower intake manifold.
  28.  
  29. Install the engine cover.
  30.  
  31. Connect the negative battery cable.
  32.  

Right Side
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine appearance cover.
  4.  
  5. Remove the upper intake manifold with the lower intake manifold.
  6.  
  7. Disconnect the ignition coil electrical connectors.
  8.  
  9. Remove the wiring harness from the side of the camshaft cover by sliding the conduit down and outboard.
  10.  
  11. Remove the wiring conduit retainers from the camshaft cover by rotating the wiring harness conduit retainers counterclockwise.
    NOTE
    It is not necessary to disconnect the engine front cover electrical connectors.

  12.  
  13. Remove the wiring harness from the front of the camshaft cover.
  14.  
  15. Reposition and secure the wiring harnesses away from the camshaft cover in order to provide clearance.
  16.  
  17. Remove the ignition coils.
  18.  
  19. Remove the camshaft cover.
  20.  
  21. Remove and discard the camshaft cover seal and grommets.
  22.  

To install:

  1. Install a NEW camshaft cover seal and NEW grommets.
  2.  
  3. Wipe the camshaft cover sealing surface on the right cylinder head with a clean, lint-free cloth.
  4.  
  5. Place a bead 8 mm (0.3150 in) in diameter by 4 mm (0.1575 in) in height of RTV sealant, on the engine front cover split lines (1).

    Click image to see an enlarged view

    Fig. Sealant application areas for camshaft cover installation-2.8L & 3.6L engines

  6.  
  7. Place the camshaft cover into position onto the right cylinder head.
  8.  
  9. Loosely install the camshaft cover bolts.
  10.  
  11. Tighten the right camshaft cover bolts in the sequence shown to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Right camshaft cover bolt tightening sequence-2.8L & 3.6L engines

  12.  
  13. Install the NEW spark plugs into the right cylinder head and tighten to 15 ft. lbs. (20 Nm).
  14.  
  15. Install each ignition coil through the right camshaft cover into the spark plug tube taking care not to damage the spark plug and/or the seal in the right camshaft cover.
  16.  
  17. Install each ignition coil bolt and tighten to 89 inch lbs. (10 Nm).
  18.  
  19. Install the wiring harness to the front of the camshaft cover.
  20.  
  21. Install the wiring harness conduit retainers to the wiring harness conduit.
  22.  
  23. Install the wiring harness to the side of the camshaft cover.
  24.  
  25. Connect the ignition coil electrical connectors.
  26.  
  27. Install the upper intake manifold with the lower intake manifold.
  28.  
  29. Install the engine cover.
  30.  
  31. Connect the negative battery cable.
  32.  

3.1L Engine
Left Side (Front)
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant into a suitable container for reuse, if the coolant is not contaminated.
  4.  
  5. Tag for identification and remove the left side (front) spark plug wires.
  6.  
  7. Remove the automatic transaxle vacuum modulator pipe.
  8.  
  9. Remove the right engine mount strut through bolt at the engine side and then swing the strut forward out of the way.
  10.  
  11. Remove the PCV valve from the rocker arm cover by pulling the valve from its rubber grommet.
  12.  
  13. Remove the thermostat bypass pipe.
  14.  
  15. Remove the valve cover bolts and remove the cover from the engine. Do not pry it off. Bump the cover sideways with a rubber mallet if it is stuck. Discard the gasket.
  16.  

To install:



Click image to see an enlarged view

Fig. Remove the PCV (crankcase vent tube) from the rubber grommet



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Fig. Unfasten the torque strut through bolt . . .



Click image to see an enlarged view

Fig. . . . and swing the torque strut up out of the way



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Fig. Remove the spark plug wire guide, if necessary



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Fig. Unfasten the rocker arm (valve) cover retaining bolts . . .



Click image to see an enlarged view

Fig. . . . then remove the cover from the cylinder head. Do not pry on the cover during removal



Click image to see an enlarged view

Fig. Remove and discard the cover gasket

  1. Clean all parts well including the sealing surfaces on both the cylinder head and the cover gasket flange.
  2.  
  3. Install a new gasket. Apply sealant, GM #12345739, or equivalent, at the cylinder head to lower intake manifold joint.
  4.  
  5. Install the rocker arm cover and hand tighten the cover bolts. Torque to 89 inch lbs. (10 Nm).
  6.  
  7. Install the remaining components in the reverse order of the removal process.
  8.  
  9. Refill the cooling system and check the engine oil level. Add as necessary.
  10.  
  11. Connect the negative battery cable. Start the engine and verify no coolant or oil leaks.
  12.  

Right Side (Rear)
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belt. Please see Section 1.
  4.  
  5. Remove the alternator and brackets. Please see Section 2.
  6.  
  7. Remove the rear spark plug wires.
  8.  
  9. Remove the ignition coil bracket with the coils, the purge solenoid and the vacuum canister solenoid.
  10.  
  11. Remove the vacuum hose from the air duct at the rear cylinder head cover.
  12.  
  13. Remove the rocker arm cover bolts and remove the cover from the engine. Do not pry it off. Bump the cover sideways with a rubber mallet if it is stuck. Discard the gasket.
  14.  

To install:

  1. Clean all parts well including the sealing surfaces on both the cylinder head and the cover gasket flange.
  2.  
  3. Install a new gasket. Apply sealant, GM #12345739, or equivalent, at the cylinder head to lower intake manifold joint.
  4.  
  5. Install the rocker arm cover and hand tighten the cover bolts. Torque to 89 inch lbs. (10 Nm).
  6.  
  7. Install the remaining components in the reverse order of the removal process.
  8.  

3.2L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the intake manifold.
  4.  
  5. On the left side, remove the left ignition coil.
  6.  
  7. Disconnect the Camshaft Position (CMP) sensor and knock sensor connectors and the vacuum pipe retainer.
  8.  
  9. Disconnect the heated oxygen sensor connector from the rear of the throttle body heater inlet hose/pipe.
  10.  
  11. Remove the bolt securing the throttle body heater inlet hose/pipe to the engine rear lift bracket and position aside.
  12.  
  13. Remove the left camshaft cover bolts  and the cover.
  14.  
  15. On the right side, remove the ignition coil.
  16.  
  17. Remove the knock sensor wire harness bolt and bracket.
  18.  
  19. On both sides, remove the camshaft cover from the cylinder head.
    NOTE
    Ensure all 8 sealing O-ring seals are accounted for. The O-ring seals may stick to the camshaft bearing caps or they may fall into the oil return journals in the cylinder head.

  20.  
  21. Remove the camshaft cover seals.
  22.  
  23. Clean and inspect the cylinder head sealing surface.
  24.  
  25. Clean and inspect the camshaft covers.
  26.  

To install:

  1. Lightly coat the new O-ring seals with clean engine oil prior to installation to assist in holding the O-ring seals to the camshaft cover.
  2.  
  3. Install the camshaft cover seals to the camshaft cover.
  4.  
  5. Apply a thin coat of silicone sealer to the corners of the front and back of the seals.
  6.  
  7. Apply a 3 mm (0.12 in) bead of silicone sealer at the front and rear of the camshaft cover between the seals.
  8.  
  9. Position the camshaft cover to the cylinder head, aligning the datum with the hole in the cylinder head.
  10.  
  11. Install the camshaft cover bolts and tighten to 71 inch lbs. (8 Nm).
  12.  
  13. On the right side, install the knock sensor wire harness bolt and bracket.
  14.  
  15. Install the ignition coil.
  16.  
  17. On the left side, install the bolt securing the throttle body heater inlet hose/pipe to the engine rear lift bracket.
  18.  
  19. Connect the heated oxygen sensor connector to the rear of the throttle body heater inlet hose/pipe.
  20.  
  21. Connect the CMP sensor and knock sensor connectors and the vacuum pipe retainer.
  22.  
  23. On the both sides, install the ignition coils.
  24.  
  25. Install the intake manifold.
  26.  
  27. Connect the negative battery cable.
  28.  

3.4L Engine
VIN E Engine
Left Side (Front)


Click image to see an enlarged view

Fig. Left side (front) rocker arm cover and sealant locations-3.4L (VIN E) engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Tag for identification and remove the left (front) spark plug wires. Please see Section 1.
  6.  
  7. Remove the AIR check valve/pipe.
  8.  
  9. Remove the thermostat bypass hose and pipe.
  10.  
  11. Remove the PCV valve from the rubber grommet in the rocker arm cover.
  12.  
  13. Remove the rocker arm cover bolts and remove the cover from the engine. Do not pry it off. Bump the cover sideways with a rubber mallet if it is stuck. Discard the gasket.
  14.  

To install:

  1. Clean all parts well including the sealing surfaces on both the cylinder head and the cover gasket flange. Install a new cover gasket. Apply sealant GM #12345739 or equivalent at the cylinder head to lower intake manifold joint at both ends of the lower intake manifold.
  2.  
  3. Install the rocker arm cover and install the cover bolts. Torque to 89 inch lbs. (10 Nm).
  4.  
  5. Install the remaining components in the reverse order of the removal process.
  6.  
  7. Refill the cooling system.
  8.  

Right Side (Rear)
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belt. Please see Section 1.
  4.  
  5. Remove the alternator and the alternator brackets. Please see Section 2.
  6.  
  7. Tag for identification and remove the right side spark plug wires.
  8.  
  9. Tag for identification and remove the vacuum hoses from the evaporative canister purge solenoid valve.
  10.  
  11. Remove the evaporative canister purge solenoid valve and the AIR check valve/pipe.
  12.  
  13. Remove the ignition coil bracket with the coils in place.
  14.  
  15. Remove the vacuum hose from the grommet in the right rocker arm cover.
  16.  
  17. Remove the rocker arm cover bolts and remove the cover from the engine. Do not pry it off. Bump the cover sideways with a rubber mallet if it is stuck. Discard the gasket.
  18.  

To install:

  1. Clean all parts well including the sealing surfaces on both the cylinder head and the cover gasket flange. Install a new cover gasket. Apply sealant GM #12345739 or equivalent at the cylinder head to lower intake manifold joint at both ends of the lower intake manifold.
  2.  
  3. Install the rocker arm cover and install the cover bolts. Torque to 89 inch lbs. (10 Nm).
  4.  
  5. Install the remaining components in the reverse order of the removal process.
  6.  

3.8L Engine
Left Side (Front)


Click image to see an enlarged view

Fig. Rocker arm (valve) cover mounting -3.8L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine lift bracket from the exhaust manifold studs.
  4.  
  5. Remove the acoustic/cosmetic engine cover.
  6.  
  7. Remove the right side "wish bone" shaped engine strut by removing the through bolts.
  8.  
  9. Tag for identification and remove the left (front) spark plug wires. Please see Section 1.
  10.  
  11. Remove the spark plug wire cover retainer clip from the rocker arm cover.
  12.  
  13. Remove the rocker arm cover bolts and remove the cover from the engine. Do not pry it off. Bump the cover sideways with a rubber mallet if it is stuck. Discard the gasket.
  14.  

To install:

  1. Clean all parts well including the sealing surfaces on both the cylinder head and the cover gasket flange. Clean any thread-locking compound from the rocker arm cover bolts.
  2.  
  3. Install a new gasket making sure the gasket is properly seated in the cover groove. Install the cover. Apply thread-locking compound GM #12345493 or equivalent to the bolt threads and install the cover bolts. Torque to 89 inch lbs. (10 Nm).
  4.  
  5. Install the remaining components in the reverse order of the removal process.
  6.  

Right Side (Rear)
  1. Disconnect the negative battery cable
  2.  
  3. Remove the acoustic/cosmetic engine cover.
  4.  
  5. Remove the rear alternator brace.
  6.  
  7. Tag for identification and remove the right (rear) spark plug wires.
  8.  
  9. Remove the engine cover retaining bracket from the exhaust manifold studs.
  10.  
  11. Remove the right (rear) engine lift bracket from the exhaust manifold studs.
  12.  
  13. Remove the rocker arm cover bolts and remove the cover from the engine. Do not pry it off. Bump the cover sideways with a rubber mallet if it is stuck. Discard the gasket.
  14.  

To install:

  1. Clean all parts well including the sealing surfaces on both the cylinder head and the cover gasket flange. Clean any thread-locking compound from the rocker arm cover bolts.
  2.  
  3. Install a new gasket making sure the gasket is properly seated in the cover groove. Install the cover. Apply thread-locking compound GM #12345493 or equivalent to the bolt threads and install the cover bolts. Torque to 89 inch lbs. (10 Nm).
  4.  
  5. Install the remaining components in the reverse order of the removal process.
  6.  

5.7L Engine
Left Side
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine appearance cover.
  4.  
  5. Disconnect the spark plug wires from the ignition coils.
  6.  
  7. Disconnect the ignition coil wire harness main electrical connector.
  8.  
  9. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold.
  10.  
  11. Disconnect the EVAP canister purge tube from the EVAP canister purge solenoid valve.
  12.  
  13. Remove the EVAP canister purge tube.
  14.  
  15. Disconnect the EVAP canister purge tube from the EVAP canister purge solenoid valve.
  16.  
  17. Disconnect the EVAP canister purge tube from the fuel feed pipe.
  18.  
  19. Remove the EVAP canister purge tube.
  20.  
  21. Disconnect the EVAP canister purge tube from the connector at the rear of the right head.
  22.  
  23. Disconnect the EVAP canister purge solenoid valve electrical connector.
  24.  
  25. Remove the EVAP canister purge solenoid valve from the bracket.
  26.  
  27. Remove the ignition coil bracket studs.
  28.  
  29. Remove the ignition coil bracket.
  30.  
  31. Loosen the valve rocker arm cover bolts.
  32.  
  33. Remove the valve rocker cover.
  34.  
  35. Remove the gasket from the rocker cover. Discard the OLD gasket.
  36.  
  37. Clean and inspect the rocker arm cover.
  38.  

To install:

  1. Install a NEW rocker cover gasket into the valve rocker cover lip.
  2.  
  3. Install the valve rocker arm cover.
  4.  
  5. Tighten the valve rocker cover bolts to 106 inch lbs. (12 Nm).
  6.  
  7. Install the ignition coil bracket.
  8.  
  9. Apply threadlock to the threads of the ignition coil bracket studs.
  10.  
  11. Install the ignition coil bracket studs and tighten the bolts to 106 inch lbs. (12 Nm).
  12.  
  13. Install the EVAP canister purge solenoid valve to the bracket.
  14.  
  15. Connect the EVAP canister purge solenoid valve electrical connector.
  16.  
  17. Connect the EVAP canister purge tube to the connector at the rear of the right head.
  18.  
  19. Install the EVAP canister purge tube.
  20.  
  21. Connect the EVAP canister purge tube to the fuel feed pipe.
  22.  
  23. Connect the EVAP canister purge tube to the EVAP canister purge solenoid valve.
  24.  
  25. Install the EVAP canister purge tube.
  26.  
  27. Connect the EVAP canister purge tube to the EVAP canister purge solenoid valve.
  28.  
  29. Connect the EVAP canister purge tube from the intake manifold.
  30.  
  31. Connect the ignition coil wire harness main electrical connector.
  32.  
  33. Connect the spark plug wires to the ignition coils.
  34.  
  35. Install the fuel injector sight shield.
  36.  
  37. Connect the battery negative cable.
  38.  

Right Side
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine appearance cover.
  4.  
  5. Disconnect the spark plug wires from the ignition coils.
  6.  
  7. Remove the PCV tube from the throttle body and rocker arm cover.
  8.  
  9. Disconnect the spark plug wires from the ignition coils.
  10.  
  11. Disconnect the ignition coil wire harness main electrical connector.
  12.  
  13. Remove the ignition coil bracket studs.
  14.  
  15. Remove the ignition coil bracket.
  16.  
  17. Loosen the valve rocker arm cover bolts.
  18.  
  19. Remove the valve rocker arm cover.
  20.  
  21. Remove the gasket from the rocker cover. Discard the OLD gasket.
  22.  
  23. Remove the oil fill cap from the oil fill tube.
  24.  
  25. Do not remove the oil fill tube, unless replacement is necessary due to signs of leakage.
  26.  
  27. Clean and inspect the valve rocker arm cover.
  28.  

To install:

  1. Lubricate the O-ring seal of the NEW oil fill tube with clean engine oil, if removed.
  2.  
  3. Insert the NEW oil fill tube into the rocker arm cover, if necessary. Rotate the tube clockwise until locked in the proper position.
  4.  
  5. Install the oil fill cap into the tube. Rotate the cap clockwise until locked in the proper position.
  6.  
  7. Install a NEW rocker cover gasket into the valve rocker cover lip.
  8.  
  9. Install the valve rocker arm cover.
  10.  
  11. Tighten the valve rocker cover bolts to 106 inch lbs. (12 Nm).
  12.  
  13. Install the ignition coil bracket.
  14.  
  15. Apply threadlock to the threads of the ignition coil bracket studs.
  16.  
  17. Install the ignition coil bracket studs and tighten the bolts to 106 inch lbs. (12 Nm).
  18.  
  19. Connect the ignition coil wire harness main electrical connector.
  20.  
  21. Install the spark plug wires to the ignition coils.
  22.  
  23. Install the PCV tube to the throttle body and rocker arm cover.
  24.  
  25. Install the fuel injector sight shield.
  26.  
  27. Connect the battery negative cable.
  28.  

 
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