GM Grand Am/Achieva/Calais/Skylark/Somerset 1985-98

Rocker Arm (Valve) Cover

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REMOVAL & INSTALLATION



2.0L and 2.5L Engines

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Detach the breather hoses, the induction tube and air cleaner.
  4.  
  5. On the 2.5L engine, detach the PCV valve and/or hose assembly.
  6.  
  7. On some engines it may be required to remove the EGR valve.
  8.  
  9. Unfasten the accelerator and T.V. cables if in the way of valve cover extraction.
  10.  
  11. Remove the spark plug wires and the clips from the rocker arm cover.
  12.  
  13. Unfasten the bolts, then tap the rocker arm cover gently with a rubber mallet to break the gasket loose, and remove the cover. Do not pry on the cover or damage to the sealing surfaces may result.
  14.  
  15. Using a gasket scraper, clean the gasket mating surfaces of all debris and old gasket material.
  16.  

To install:
  1. Position a new gasket on the rocker arm cover. Be sure to remove the protective paper from the adhesive/cover side of the gasket.
  2.  
  3. Tighten the retainer bolts in sequence or a criss-cross fashion to 6-8 ft. lbs. (8-10 Nm).
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Cylinder head cover bolt tightening sequence-2.5L engine

  1. Connect the PCV valve and/or hose assembly.
  2.  
  3. Fasten the T.V. and accelerator cables.
  4.  
  5. Install the air cleaner assembly.
  6.  
  7. Install the induction tube, the breather hoses and air cleaner.
  8.  
  9. Connect the negative battery cable, start the engine and check for leaks.
  10.  

2.3L and 2.4L Engines
INTAKE CAMSHAFT (DOHC) OR CAMSHAFT (SOHC)

See Figures 2 through 7

  1. Disconnect the negative battery cable.
  2.  
  3. Detach the ignition coil and module assembly electrical connections.
  4.  
  5. Unfasten the ignition coil and module assembly-to-camshaft housing bolts, then remove the assembly by pulling it straight up.
  6.  

Use a spark plug wire removal tool J 36011 or equivalent to remove any connector that may have stuck to the spark plugs. Use the tool by first twisting, then pulling up on the connector assembly.



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Fig. Fig. 2: To remove the ignition coil and module assembly, remove the bolts then lift the assembly straight up-DOHC engine shown



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Fig. Fig. 3: If any of the coil assembly connectors stick to the spark plugs using tool J 36011 in a twisting and pulling motion will remove the connector-SOHC engine shown

  1. Remove the power steering pump pulley.
  2.  
  3. On the 2.3L: engines, detach the oil/air separator (crankcase ventilation system). Leave the hoses attached to the separator, disconnect from the oil fill, front cover, and intake manifold, then remove as an assembly.
  4.  



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Fig. Fig. 4: The oil separator is located in the front of the engine

  1. Unfasten the vacuum line from the fuel pressure regulator and fuel injector harness connector.
  2.  
  3. Disconnect the fuel line retaining clamp from the bracket on top of the intake cam housing.
  4.  
  5. Unfasten the fuel rail-to-camshaft housing retaining bolts, then remove the fuel rail from the cylinder head. Be sure to cover the injector openings in the cylinder head, cover the injector nozzles and leave the fuel lines attached and position the fuel rail aside (on top of the master cylinder).
  6.  
  7. Disconnect the timing chain housing but do not remove form the vehicle.
  8.  
  9. Unfasten the cam housing cover-to-housing retaining bolts and the cam housing-to-cylinder head bolts.
  10.  
  11. Use the reverse of the tightening procedure (in the accompanying figure) when loosening the camshaft housing-to-cylinder head bolts.
  12.  
  13. Push the cover off the housing by threading four of the housing-to-head retaining bolts into the tapped holes in the cover. Make sure to tighten the bolts evenly remove the cover from the vehicle.
  14.  
  15. Remove and discard the cover-to-housing seals and clean the mating surfaces.
  16.  



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the intake cam cover and related components-2.3L and 2.4L engines

To install:
  1. Position new seals on the camshaft cover. Refer to the accompanying figure.
  2.  



Click image to see an enlarged view

Fig. Fig. 6: Intake and exhaust cam housing-to-cover seal locations-colors varie depending on the model year

  1. On models up to 1993:
    1. Apply pipe sealant 1052080 (or equivalent thread locking sealer) to the camshaft housing and cover retaining bolt threads. Using J 366660, install the bolts. tighten the camshaft housing-to-cylinder head bolts to 11 ft. lbs. (15 Nm) plus 75° then tighten in sequence the camshaft housing cover-to-camshaft housing bolts to 11 ft. lbs. (15 Nm) plus 25°. Refer to the accompanying illustration for bolt locations. The illustration has the 1994-98 model specifications in it, but is the same for bolt locations ect.
    2.  

  2.  
  3. On 1994-98 models:
    1. Apply pipe sealant 1052080 (or equivalent thread locking sealer) to the camshaft housing and cover retaining bolt threads. Using J 366660, install the bolts. tighten the camshaft housing-to-cylinder head bolts to 11 ft. lbs. (15 Nm) plus 90° then tighten in sequence the camshaft housing cover-to-camshaft housing bolts to 11 ft. lbs. (15 Nm) plus 30°. Refer to the accompanying figure.
    2.  

  4.  



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Fig. Fig. 7: Intake and exhaust camshaft bolt tightening sequence-2.3L and 2.4L engines

  1. Fasten the timing chain housing.
  2.  
  3. Uncover fuel injectors, then lubricate new injector O-ring seals with clean engine oil and install on the injectors.
  4.  
  5. Uncover the injector openings in the cylinder head, then install the fuel rail onto the cylinder head. Install the fuel rail-to-cylinder head retaining bolts and tighten to 19 ft. lbs. (26 Nm).
  6.  
  7. Install the fuel line retaining clamp and retainer to the bracket on top of the cam housing.
  8.  
  9. Connect the vacuum line to the fuel pressure regulator. Attach the fuel injector harness connector.
  10.  
  11. On the 2.3L engines, install the oil/air separator assembly. You may want to lubricate the hoses to ease installation.
  12.  
  13. Lubricate the inner surface of the camshaft seal with clean engine oil, then install the seal into the camshaft housing using a seal installer tool such as J 36015, or equivalent.
  14.  
  15. Using the same tool J 36015 or equivalent, install the power steering pump drive pulley onto the intake camshaft.
  16.  
  17. Install the power steering pump assembly and the drive belt. Adjust tension to specification.
  18.  
  19. Fasten any spark plug boot connector assembly that stuck to a spark plug back onto the ignition coil and module assembly.
  20.  
  21. Position the coil and module assembly over the spark plugs, then push the assembly straight down. Make sure it is properly seated.
  22.  
  23. Clean off any loose lubricant from the coil and module assembly-to-camshaft housing bolts. Apply pipe sealant 1052080 (or equivalent thread locking sealer), onto the bolts, then tighten the bolts to 16 ft. lbs. (22 Nm) on the 2.3L engines and 11 ft. lbs. (15 Nm) on the 2.4L engines.
  24.  
  25. Attach the coil and module electrical connector.
  26.  
  27. Connect the negative battery cable, then start the engine and inspect for oil leaks.
  28.  

EXHAUST CAMSHAFT (DOHC ONLY)

See Figures 6 and 7

  1. Disconnect the negative battery cable.
  2.  
  3. Detach the ignition coil and module electrical connection. Remove the coil and module assembly-to-camshaft housing bolts, then remove the assembly by lifting it straight up.
  4.  

Use spark plug wire removal tool J 36011 to disengage any connector that may have stuck to the spark plugs. Use the tool by first twisting, then pulling up on the connector assembly.

  1. Disengage the electrical connection from the oil pressure switch.
  2.  
  3. For vehicles equipped with an automatic transaxle, remove the transaxle fluid level indicator tube assembly from the exhaust camshaft cover, then position it aside.
  4.  
  5. Disconnect, but do not remove from the vehicle, the timing chain housing at the exhaust camshaft housing.
  6.  
  7. Remove the exhaust camshaft cover and gasket, then discard the gasket. Be sure to loosen the housing bolts in the reverse order of the tightening sequence.
  8.  
  9. Clean all old gasket debris from the cover mating surfaces.
  10.  

To install:
  1. Position new camshaft housing-to-cover seals. No sealant is needed.
  2.  
  3. Apply pipe sealant 1052080 (or equivalent thread locking sealer) to the threads of the camshaft housing and cover retaining bolts.
  4.  
  5. Position the cover onto the housing, then tighten the bolts, in sequence, to specification. Tighten the camshaft housing-to-cylinder head bolts to 11 ft. lbs. (15 Nm) plus 90°, and the camshaft housing cover-to-camshaft housing bolts to 11 ft. lbs. (15 Nm) plus 30°.
  6.  
  7. Tighten the timing chain housing retainers.
  8.  
  9. Install the transaxle fluid level indicator tube assembly to the exhaust camshaft cover.
  10.  
  11. Attach the oil pressure switch electrical connector.
  12.  
  13. Reinstall any spark plug boot connectors that may have been stuck to a spark plug, back onto the ignition coil and module assembly.
  14.  
  15. Position the coil and module assembly over the spark plugs then push it straight down making sure it is firmly and properly seated.
  16.  
  17. Clean off any lubricant on the coil and module-to-camshaft housing bolts. Apply pipe sealant 1052080 (or equivalent thread locking sealer) to the bolts, then tighten them to 16 ft. lbs. (22 Nm) on the 2.3L engine and 11 ft. lbs. (15 Nm) on the 2.4L engine. plus 30°.
  18.  
  19. Attach the ignition coil and module assembly electrical connector.
  20.  
  21. Connect the negative battery cable, then start the engine and inspect for leaks.
  22.  

3.0L Engine
FRONT (LEFT) COVER

See Figures 8 through 12

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the crankcase ventilation pipe.
  4.  
  5. Remove the spark plug wire harness cover, then tag and disconnect the wires at the spark plugs.
  6.  



Click image to see an enlarged view

Fig. Fig. 8: Remove the plastic harness cover shielding the spark plugs wires by simply pulling it off

  1. Unfasten the valve cover nuts, washers and seals, then remove the valve cover and gasket. Discard the gasket and replace any seals that are damaged.
  2.  



Click image to see an enlarged view

Fig. Fig. 9: Using the proper size socket, remove the valve cover retaining nuts



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Fig. Fig. 10: After removing the nuts, remove the washers, then ...



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Fig. Fig. 11: ... remove the seals. Replace any seals that are damaged or leaking

Do NOT pry on the cover to remove it. If it sticks, use your palm or a rubber mallet to bump it rearwards, from the front.

  1. Using a suitable scraper, carefully clean the gasket mounting surfaces. Keep debris out of the engine.
  2.  

To install:
  1. Position a new gasket into the valve cover, then place the cover on the cylinder head. Install the seals, washers and nuts, then tighten to 88 inch lbs. (10 Nm).
  2.  



Click image to see an enlarged view

Fig. Fig. 12: Position a new gasket into the groove on the valve cover

  1. Attach the wires to the spark plugs as tagged during removal, then install the spark plug wire harness cover.
  2.  
  3. Install the crankcase ventilation pipe.
  4.  
  5. Connect the negative battery cable, then start the engine and check for leaks.
  6.  

REAR (RIGHT) COVER
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the ignition coil module, refer to Section2.
  4.  
  5. Remove the serpentine belt.
  6.  
  7. Disengage the alternator wiring, then unfasten the rear mounting bolt and rotate the alternator toward the front of the vehicle.
  8.  
  9. Disconnect the power steering pump from the belt tensioner, then remove the belt tensioner assembly.
  10.  
  11. Remove the engine lift bracket and rear alternator brace.
  12.  
  13. Properly drain the coolant to a level below the heater hose.
  14.  
  15. Remove the throttle body heater hoses.
  16.  
  17. Unfasten the valve cover nuts, washers and seals, then remove the valve cover and gasket from the vehicle. Discard the gasket, inspect the seals for damage and/or leakage and replace if necessary.
  18.  

Do NOT pry on the cover to remove it. If it sticks, use your palm or a rubber mallet to bump it rearwards, from the front.

  1. Using a suitable scraper, carefully clean the gasket mounting surfaces. Keep debris out of the engine.
  2.  

To install:
  1. Position a new gasket in the groove in the valve cover.
  2.  
  3. Place the valve cover on the cylinder head, then install the seals, washers and retaining nuts. Tighten the nuts to 88 inch lbs. (10 Nm).
  4.  
  5. Connect the throttle body heater hoses.
  6.  
  7. Install the rear alternator brace and engine lift bracket.
  8.  
  9. Install the belt tensioner assembly, then secure the power steering pump to the belt tensioner.
  10.  
  11. Rotate the alternator into its original position, then install the rear mounting bolt and attach the wiring.
  12.  
  13. Install the serpentine belt and the ignition coil module.
  14.  
  15. Connect the negative battery cable, then start the engine and check for leaks.
  16.  

3.1L Engine

See Figure 13

FRONT (LEFT) COVER
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system to a level below the coolant pipe on the front of the engine.
  4.  
  5. Remove the coolant bypass hose clamp at the coolant tube.
  6.  
  7. Unfasten the two bolts and nut securing the coolant tube to the cylinder head, then position the tube out of the way.
  8.  
  9. Disconnect the PCV valve from the rocker arm cover.
  10.  
  11. Unfasten the four rocker arm cover bolts, then remove the rocker arm cover. Discard the gasket.
  12.  

To install:
  1. Clean all the gasket surfaces completely.
  2.  
  3. Install the rocker arm cover using a new gasket, then tighten the retaining bolts to 90 inch lbs. (10 Nm).
  4.  
  5. Connect the PCV valve to the rocker arm cover.
  6.  
  7. Position the coolant tube and connect the thermostat bypass hose.
  8.  
  9. Install the coolant tube mounting nut and bolts. Tighten the screw at the water pump to 106 inch lbs. (12 Nm), the bolt at the corner of the cylinder head to 18 ft. lbs. (25 Nm) and the nut to 18 ft. lbs. (25 Nm).
  10.  
  11. Properly refill the cooling system.
  12.  
  13. Connect the negative battery cable, then start the vehicle. Check for leaks.
  14.  



Click image to see an enlarged view

Fig. Fig. 13: Exploded view of the rocker arm and gasket assembly-3.1L engine

REAR (RIGHT) COVER
  1. Disconnect the negative battery cable.
  2.  
  3. Tag and disconnect the spark plug wires from the spark plugs and upper intake plenum wire retainer, then position out of the way.
  4.  
  5. Disconnect the power brake booster vacuum pipe from the intake plenum.
  6.  
  7. Remove the serpentine belt.
  8.  
  9. Remove the alternator.
  10.  
  11. Disconnect and remove the ignition assembly and EVAP canister purge solenoid as an assembly.
  12.  
  13. Remove the four rocker arm cover bolts, then remove the rocker arm cover. Discard the gasket.
  14.  

To install:
  1. Clean all the gasket surfaces completely.
  2.  
  3. Install the rocker arm cover using a new gasket, then tighten the rocker cover bolts to 90 inch lbs. (10 Nm).
  4.  
  5. Install the alternator.
  6.  
  7. Install the serpentine belt.
  8.  
  9. Connect the power brake booster vacuum pipe to the plenum.
  10.  
  11. Install the EVAP solenoid and ignition assembly.
  12.  
  13. Connect the spark plug wires to the wire retainers on the plenum and the spark plugs as tagged during removal.
  14.  
  15. Properly refill the cooling system.
  16.  
  17. Connect the negative battery cable, then start the vehicle and check for leaks.
  18.  

3.3L Engine

See Figure 14

FRONT (LEFT) COVER
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belt.
  4.  
  5. Unfasten the alternator-to-brace bolt, then remove the brace.
  6.  
  7. Remove the spark plug wire harness.
  8.  
  9. Unfasten the retainers, then remove the valve cover and gasket. Discard the gasket.
  10.  

Do NOT pry on the cover to remove it. If it sticks, use your palm or a rubber mallet to bump it rearwards, from the front.

  1. Using a suitable scraper, carefully clean the gasket mounting surfaces. Keep debris out of the engine.
  2.  

To install:
  1. Position a new gasket into the groove on the valve cover, then place the cover on the cylinder head. Tighten the retainers to 88 inch lbs. (10 Nm).
  2.  
  3. Install the spark plug wire harness.
  4.  
  5. Position the alternator brace, then secure using the retaining bolt.
  6.  
  7. Install the accessory drive belt.
  8.  
  9. Connect the negative battery cable, then start the engine and check for leaks.
  10.  



Click image to see an enlarged view

Fig. Fig. 14: Exploded view of the valve cover and gasket assembly-3.3L engine shown

REAR (RIGHT) COVER
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belt.
  4.  
  5. Loosen, but do not remove, the power steering pump bolts, then slide the pump forward.
  6.  
  7. Remove the power steering pump braces.
  8.  
  9. Tag and disconnect the spark plug wires.
  10.  
  11. Unfasten the valve cover retainers, then remove the cover and gasket from the vehicle. Discard the gasket.
  12.  

Do NOT pry on the cover to remove it. If it sticks, use your palm or a rubber mallet to bump it rearwards, from the front.

  1. Using a suitable scraper, carefully clean the gasket mounting surfaces. Keep debris out of the engine.
  2.  

To install:
  1. Position a new gasket into the groove on the valve cover, then place the cover on the cylinder head. Apply thread lock compound 12345493 or equivalent, then tighten the retainers to 88 inch lbs. (10 Nm).
  2.  
  3. Connect the spark plug wires as tagged during removal.
  4.  
  5. Install the power steering pump braces.
  6.  
  7. Slide the power steering pump back to its original position, then tighten the pump mounting bolts.
  8.  
  9. Install the accessory drive belt.
  10.  
  11. Connect the negative battery cable, then start the engine and inspect for leaks.
  12.  

 
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