G6 2005-2007

Valve Covers

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Removal & Installation



2.4L Engine
  1. Remove the air cleaner outlet resonator.
  2.  
  3. Reposition the positive crankcase ventilation (PCV) hose clamp.
  4.  
  5. Remove the PCV hose from the cover.
  6.  
  7. Disconnect the intake and exhaust camshaft position actuator solenoid valve electrical connectors.
  8.  
  9. Remove the fuel feed pipe retainer from the fuel pipe bracket.
  10.  
  11. Remove the fuel feed pipe bracket bolt and bracket.
  12.  
  13. Disconnect and remove the ignition coil electrical connector harness clips from the cover.
  14.  
  15. Remove the ignition coils.
  16.  
  17. Remove the camshaft cover bolts.
  18.  
  19. Remove the camshaft cover.
  20.  

To install:

  1. Install the camshaft cover and bolts and tighten to 89 inch lbs. (10 Nm).
  2.  
  3. Install the ignition coils.
  4.  
  5. Connect the ignition coil electrical connector harness clips to the cover.
  6.  
  7. Install the fuel feed pipe bracket bolt and bracket.
  8.  
  9. Install the fuel feed pipe retainer from the fuel pipe bracket.
  10.  
  11. Connect the intake and exhaust camshaft position actuator solenoid valve electrical connectors.
  12.  
  13. Install the PCV hose from the cover.
  14.  
  15. Install the positive crankcase ventilation (PCV) hose clamp.
  16.  
  17. Install the air cleaner outlet resonator.
  18.  

3.5L Engine
Left Side
  1. Partially drain the cooling system.
  2.  
  3. Remove the intake manifold.
  4.  
  5. Remove the front ignition wire harness at the upper intake manifold and at the spark plugs.
  6.  
  7. Remove the thermostat bypass pipe.
  8.  
  9. Disconnect the positive crankcase ventilation (PCV) vacuum hose.
  10.  
  11. Remove the valve rocker arm cover bolts.
    NOTE
    When removing the valve rocker arm cover, ensure the gasket stays in place attached to the cylinder head.

  12.  
  13. Remove the valve rocker arm cover. Bump the end of the valve rocker cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
  14.  
  15. Trim the valve cover and sealant away from the lower intake manifold gasket at the cylinder head to the lower intake manifold joints.
  16.  
  17. Remove the valve cover gasket.
  18.  
  19. Clean the sealing surface on the cylinder head with degreaser.
  20.  
  21. Clean the valve rocker arm cover.
  22.  

To install:

  1. Apply sealant at the cylinder head to the lower intake manifold joints.
  2.  
  3. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
  4.  
  5. Install the valve rocker cover.
  6.  
  7. Install the valve rocker arm cover bolts and tighten in a criss-cross pattern to 89 inch lbs. (10 Nm).
  8.  
  9. Connect the PCV valve vacuum line.
  10.  
  11. Install the thermostat bypass pipe.
  12.  
  13. Install the front ignition wire harness.
  14.  
  15. Refill the cooling.
  16.  
  17. Install the intake manifold cover.
  18.  

Right Side
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the drive belt.
  4.  
  5. Remove the generator.
  6.  
  7. Remove the generator bracket.
  8.  
  9. Remove the right spark plug wires.
  10.  
  11. Disconnect the vacuum hoses from the evaporative emission (EVAP) purge valve.
  12.  
  13. Remove the EVAP purge valve.
  14.  
  15. Remove the ignition coil bracket with the coils.
  16.  
  17. Remove the ignition coil bracket studs.
  18.  
  19. Remove the vacuum hose from the grommet in the right valve rocker arm cover.
  20.  
  21. Remove the valve rocker arm cover bolts.
    NOTE
    When removing the valve rocker arm cover, ensure the gasket stays in place attached to the cylinder head.

  22.  
  23. Remove the valve rocker arm cover. Bump the end of the valve rocker cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
  24.  
  25. Trim the valve cover and sealant away from the lower intake manifold gasket at the cylinder head to the lower intake manifold joints.
  26.  
  27. Remove the valve cover gasket.
  28.  
  29. Clean the sealing surface on the cylinder head with degreaser.
  30.  
  31. Clean the valve rocker arm cover.
  32.  

To install:

  1. Apply sealant at the cylinder head to the lower intake manifold joints.
  2.  
  3. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
  4.  
  5. Install the valve rocker cover.
  6.  
  7. Install the valve rocker arm cover bolts and tighten in a criss-cross pattern to 89 inch lbs. (10 Nm).
  8.  
  9. Install the vacuum hose to the grommet in the right valve rocker arm cover.
  10.  
  11. Install the ignition coil bracket studs.
  12.  
  13. Install the ignition coil bracket with coils.
  14.  
  15. Install the EVAP purge valve.
  16.  
  17. Connect the vacuum hoses to the EVAP purge valve.
  18.  
  19. Install the right spark plug wires.
  20.  
  21. Install the generator bracket.
  22.  
  23. Install the generator.
  24.  
  25. Install the drive belt.
  26.  
  27. Connect the negative battery cable.
  28.  

3.6L Engine
Left Side
  1. Remove the ignition coils.
  2.  
  3. Disconnect and remove the engine harness from the camshaft cover.
  4.  
  5. Remove the upper intake manifold.
  6.  
  7. Remove the left camshaft cover bolts.
  8.  
  9. Remove the left camshaft cover from the left cylinder head.
  10.  
  11. Clean the mating surfaces of the cylinder head and the camshaft cover.
  12.  
  13. Install the EN 46101 onto the spark plug tubes of the left cylinder head.

    Click image to see an enlarged view

    Fig. EN 46101 Protectors -spark plug tubes

  14.  

To install:

  1. Install new camshaft cover bolt grommets prior to installing the camshaft cover bolts.
  2.  
  3. Place a bead 0.3150 inch. (8 mm) in diameter by 0.1575 inch. (4 mm) in height of RTV sealant, GM P/N 12378521 (Canadian P/N 88901148) or equivalent, on the engine front cover split lines.
  4.  
  5. Place the left camshaft cover into position onto the left cylinder head.
  6.  
  7. Loosely install the left camshaft cover bolts.
  8.  
  9. Tighten the left camshaft cover bolts to 89 inch. lbs., in the sequence shown.

    Click image to see an enlarged view

    Fig. Left camshaft cover tightening sequence 3.6L engine

  10.  
  11. Connect and install the engine harness to the camshaft cover.
  12.  
  13. Install the upper intake manifold.
  14.  
  15. Remove the EN 46101 from the spark plug tubes of the left cylinder head.
  16.  
  17. Install the ignition coils.
  18.  

Right Side
  1. Remove the ignition coils.
  2.  
  3. Remove the upper intake manifold.
  4.  
  5. Disconnect and remove the engine harness from the camshaft cover.
  6.  
  7. Remove the right camshaft cover bolts.
  8.  
  9. Remove the right camshaft cover from the right cylinder head.
  10.  
  11. Clean the mating surfaces of the cylinder head and the camshaft cover.
  12.  
  13. Install the EN 46101 onto the spark plug tubes of the left cylinder head.
  14.  

To install:

  1. Install new camshaft cover bolt grommets prior to installing the camshaft cover bolts.
  2.  
  3. Place a bead 0.3150 inch. (8 mm) in diameter by 0.1575 inch. (4 mm) in height of RTV sealant, GM P/N 12378521 (Canadian P/N 88901148) or equivalent, on the engine front cover split lines (1).

    Click image to see an enlarged view

    Fig. 3.6L Engine front cover split lines (1)

  4.  
  5. Place the right camshaft cover into position onto the right cylinder head.
  6.  
  7. Loosely install the right camshaft cover bolts.
  8.  
  9. Tighten the right camshaft cover bolts to 89 inch. lbs., in the sequence shown.

    Click image to see an enlarged view

    Fig. Right camshaft cover tightening sequence 3.6L engine

  10.  
  11. Connect and install the engine harness to the camshaft cover.
  12.  
  13. Install the upper intake manifold.
  14.  
  15. Remove the EN 46101 from the spark plug tubes of the right cylinder head.
  16.  
  17. Install the ignition coils.
  18.  

3.9L Engine
Left Side
  1. Partially drain the cooling system.
  2.  
  3. Remove the intake manifold cover.
  4.  
  5. Remove the air cleaner outlet duct.
  6.  
  7. Disconnect the left spark plug wires from the spark plugs.
  8.  
  9. Remove the spark plug wire harness clip from the heater inlet and outlet front pipe bracket.
  10.  
  11. Remove the heater inlet and outer front pipe.
  12.  
  13. Disconnect the positive crankcase ventilation (PCV) foul air tube from the PCV valve.
  14.  
  15. Remove the valve rocker arm cover bolts.
    NOTE
    When removing the valve rocker arm cover, ensure the gasket stays in place attached to the cylinder head.

  16.  
  17. Remove the valve rocker arm cover. Bump the end of the valve rocker cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
  18.  
  19. Trim the valve cover and sealant away from the lower intake manifold gasket at the cylinder head to the lower intake manifold joints.
  20.  
  21. Remove the valve cover gasket.
  22.  
  23. Clean the sealing surface on the cylinder head with degreaser.
  24.  
  25. Clean the valve rocker arm cover.
  26.  

To install:

  1. Apply sealant at the cylinder head to the lower intake manifold joints.
  2.  
  3. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
  4.  
  5. Install the valve rocker cover.
  6.  
  7. Install the valve rocker arm cover bolts and tighten in a criss-cross pattern to 89 inch lbs. (10 Nm).
  8.  
  9. Connect the PCV foul air tube to the PCV valve.
  10.  
  11. Install the heater inlet and outer front pipe.
  12.  
  13. Install the spark plug wire harness clip to the heater inlet and outlet front pipe bracket.
  14.  
  15. Connect the left spark plug wires to the spark plugs.
  16.  
  17. Install the air cleaner outlet duct.
  18.  
  19. Install the intake manifold cover.
  20.  
  21. Fill the cooling system, as necessary.
  22.  

Right Side
  1. Remove the alternator.
  2.  
  3. Disconnect the positive crankcase ventilation (PCV) fresh air tube from the air cleaner outlet duct.
  4.  
  5. Remove the PCV fresh air tube from the right side valve rocker arm cover.
  6.  
  7. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
  8.  
  9. Disconnect the ignition coil electrical connector.
  10.  
  11. Remove the heated oxygen sensor (HO2S) electrical connector clip from the ignition coil.
  12.  
  13. Remove the spark plug wires from the ignition coil.
  14.  
  15. Remove the ignition coil bracket bolts and nuts.
  16.  
  17. Remove the ignition coil with bracket from the engine.
  18.  
  19. Remove the valve rocker arm cover bolts.
    NOTE
    When removing the valve rocker arm cover, ensure the gasket stays in place attached to the cylinder head.

  20.  
  21. Remove the valve rocker arm cover. Bump the end of the cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
  22.  
  23. Cut the room temperature vulcanizing (RTV) sealer in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
  24.  
  25. Remove the valve cover gasket.
  26.  
  27. Clean the sealing surface on the cylinder head with degreaser.
  28.  

To install:

  1. Apply sealant at the cylinder head to the lower intake manifold joints.
  2.  
  3. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
  4.  
  5. Install the valve rocker cover.
  6.  
  7. Install the valve rocker arm cover bolts and tighten in a criss-cross pattern to 89 inch lbs. (10 Nm).
  8.  
  9. Install the ignition coil with bracket to the engine.
  10.  
  11. Install the ignition coil bracket bolts and nuts and tighten to 18 ft. lbs. (25 Nm).
  12.  
  13. Install the spark plug wires to the ignition coil.
  14.  
  15. Install the HO2S electrical connector clip to the ignition coil bracket.
  16.  
  17. Connect the ignition coil electrical connector.
  18.  
  19. Connect the MAP sensor electrical connector.
  20.  
  21. Install the PCV fresh air tube to the right side valve rocker arm cover.
  22.  
  23. Connect the PCV fresh air tube to the air cleaner outlet duct.
  24.  
  25. Install the alternator.
  26.  

 
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