GM Cavalier/Sunfire 1995-2000 Repair Guide

Rocker Arm (Valve) Cover

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REMOVAL & INSTALLATION



On the 2.3L and 2.4L engines, there is no valve cover. The engines feature a cover over the cylinder head and camshaft housing. The cover has integrated camshaft bearing caps located on the bottom of the cover.

2.2L Engine

See Figures 1 through 14



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Fig. Fig. 1: Remove the throttle pulley cover



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Fig. Fig. 2: Disconnect the cruise control (if equipped) ...



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Fig. Fig. 3: ... TV (throttle valve or transmission kickdown) and ...



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Fig. Fig. 4: ... accelerator cables from the throttle body



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Fig. Fig. 5: Slide the cables out of the bracket



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Fig. Fig. 6: Remove the bracket retaining bolts and ...



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Fig. Fig. 7: ... remove the bracket



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Fig. Fig. 8: Remove the PCV hose from the intake manifold



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Fig. Fig. 9: The valve cover is retained by six bolts



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Fig. Fig. 10: Remove the valve cover retaining bolts and ...



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Fig. Fig. 11: ... carefully lift the valve cover and remove it from the engine



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Fig. Fig. 12: Remove the old gasket from the valve cover



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Fig. Fig. 13: Thoroughly clean the gasket mating surfaces of the cylinder head and ...



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Fig. Fig. 14: ... the valve cover

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner outlet duct.
  4.  
  5. Disconnect the accelerator control, cruise control (if equipped), and T.V. cables at the accelerator control bracket.
  6.  
  7. Remove the accelerator control bracket.
  8.  
  9. Disconnect the PCV valve hose.
  10.  
  11. Unfasten the retaining bolts, then remove the rocker arm (valve) cover from the vehicle. Remove and discard the gasket.
  12.  
  13. Clean off the cylinder head and cover sealing surfaces.
  14.  

To install:
  1. Position a new rocker arm gasket, then install the cover. Tighten the retaining bolt to 89 inch lbs. (10 Nm).
  2.  
  3. Connect the PCV valve hose.
  4.  
  5. Install the accelerator control bracket. Tighten the retaining bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Attach the accelerator control, cruise control (if equipped) and TV cables at the control bracket.
  8.  
  9. Install the air cleaner outlet duct.
  10.  
  11. Connect the negative battery cable, then start the engine and check for leaks.
  12.  

 
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