Cavalier, Sunfire 2001-2005

Valve Covers

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Removal & Installation



  1. Remove the negative battery cable.
  2.  
  3. Remove the resonator and duct assembly.

    Click image to see an enlarged view

    Fig. Remove the resonator bracket/fuel rail cover

  4.  
  5. Remove the resonator bracket/fuel rail cover.
  6.  
  7. Remove left engine wiring harness retainer bracket nut and bracket.
  8.  
  9. Remove wiring harness from retainer on valve rocker arm cover.

    Click image to see an enlarged view

    Fig. Removal of the rocker arm cover bolts

  10.  
  11. Remove the valve rocker arm cover bolts.
  12.  
  13. Remove the valve rocker arm cover.
  14.  
  15. Clean the sealing surface on the cylinder head and the valve rocker arm cover.
  16.  

To install:


NOTE
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  1. Install the valve rocker arm cover.
  2.  
  3. Install the valve rocker arm cover bolts and tighten the bolts to 89 lb inches (10 Nm).
  4.  
  5. Install the resonator bracket/fuel rail cover.
  6.  
  7. Install the resonator bracket/fuel rail cover nuts and tighten the nuts to 18 ft. lbs. (25 Nm).
  8.  
  9. Install wiring harness to retainer on valve rocker arm cover.
  10.  
  11. Install wiring harness retainer bracket and nut.
  12.  
  13. Install the resonator and duct assembly.
  14.  
  15. Connect the negative battery cable and tighten the bolt to 12 ft. lbs. (16 Nm).
  16.  

 
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