GM Full Size Vans 1987-1997 Repair Guide

Valve/Cylinder Head Cover

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REMOVAL & INSTALLATION



Gasoline Engines

See Figures 1 through 7



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Fig. Fig. 1: Exploded view of a typical 4.3L rocker arm cover mounting

  1. Disconnect the negative battery cable. Remove the air cleaner assembly.
  2.  
  3. If applicable, remove the coolant recovery reservoir.
  4.  
  5. Remove the engine cover.
  6.  
  7. Tag, disconnect and reposition as necessary any vacuum or PCV hoses that obstruct the cylinder head covers.
  8.  
  9. If applicable, remove the EGR tube.
  10.  
  11. Disconnect electrical wire(s) (spark plug, etc.) from the cylinder head cover clips. You may also have to remove or move the alternator brace and PCV pipe.
  12.  
  13. Unbolt and remove the cover(s).
  14.  

Do not pry the covers off if they seem stuck. Instead, gently tap around each cover with a rubber mallet until the old gasket or sealer breaks loose.



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Fig. Fig. 2: Loosen the valve cover retaining bolts using a wrench or ratchet and suitable driver ...



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Fig. Fig. 3: ... then remove the bolts from the cover



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Fig. Fig. 4: Lift and remove the valve cover from the cylinder head



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Fig. Fig. 5: Remove the old gasket from the mating surfaces and discard it

To install:
  1. Install a new gasket or apply RTV (or any equivalent) sealer to the cover prior to installation. If using sealer, follow directions on the tube.
  2.  
  3. Install the cover and mounting bolts. Tighten the bolts as follows:

    1987-95 4.3L engines: 90 inch lbs. (10 Nm)
     
    1987-95 5.0L, 5.7L engines: 95 inch lbs. (11 Nm)
     
    1996-97 4.3L, 5.0L and 5.7L engines: 106 inch lbs. (12 Nm)
     
    1987-91 7.4L engines: 115 inch lbs. (13 Nm)
     
    1992-97 7.4L engines: 60 inch lbs. (7 Nm)
     

  4.  
  5. If equipped, install the EGR tube.
  6.  
  7. Connect and reposition all vacuum and PCV hoses, and reconnect electrical and/or spark plug wires at the cover clips. Install the air cleaner.
  8.  
  9. If applicable, install the coolant recovery reservoir.
  10.  
  11. Install the engine cover.
  12.  
  13. Reconnect the battery cable.
  14.  



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Fig. Fig. 6: Cylinder head cover - 4.3L, 5.0L and 5.7L engines



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Fig. Fig. 7: Correct RTV application on the cylinder head cover

Diesel Engines
RIGHT SIDE
  1. Remove the engine cover.
  2.  
  3. Remove the intake manifold.
  4.  
  5. Remove the fuel injection lines for all except the No. 5 and No. 7 injectors.
  6.  
  7. Disconnect the glow plug wires.
  8.  
  9. Remove the wiring harness from the clip.
  10.  
  11. Remove the CDR valve.
  12.  
  13. Remove the cover bolts.
  14.  
  15. Remove the cover. If the cover sticks, jar it loose with a plastic or rubber mallet. NEVER pry it loose!
  16.  
  17. Installation is the reverse of removal. Clean all old RTV gasket material from the mating surfaces. Apply a 5 / 16 in. (8mm) bead of sealer to the head mating surfaces. Tighten the cover bolts to 16 ft. lbs. (22 Nm).
  18.  
  19. Install the engine cover.
  20.  

LEFT SIDE
  1. Remove the engine cover.
  2.  
  3. Remove the intake manifold.
  4.  
  5. Remove the fuel injection lines.
  6.  
  7. On vans with air conditioning, remove the upper fan shroud.
  8.  
  9. On vans with air conditioning, remove the compressor drive belt.
  10.  
  11. On vans with air conditioning, remove the left exhaust manifold.
  12.  
  13. Remove the dipstick tube
  14.  
  15. On vans with air conditioning, dismount the compressor and move it out of the way. It may be possible to avoid disconnecting the refrigerant lines. If not, Discharge the system and disconnect the lines. Cap all openings at once. see General Information & Maintenance for discharging procedures.
  16.  
  17. Remove the dipstick tube front bracket from the stud.
  18.  
  19. Remove the wiring harness brackets.
  20.  
  21. Remove the rocker arm cover bolts and fuel return bracket.
  22.  
  23. Remove the cover. If the cover sticks, jar it loose with a plastic or rubber mallet. NEVER pry it loose!
  24.  
  25. Installation is the reverse of removal. Clean all old RTV gasket material from the mating surfaces. Apply a 5 / 16 in. (8mm) bead of sealer to the head mating surfaces. Tighten the cover bolts to 16 ft. lbs. (22 Nm).
  26.  
  27. Install the engine cover.
  28.  

 
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