GM Lumina/Grand Prix/Cutlass Supreme/Regal 1988-1996

Rocker Arm (Valve) Cover

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REMOVAL & INSTALLATION



2.2L Engine

See Figure 1



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Fig. Fig. 1: Rocker arm (valve) cover removal and installation-2.2L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner and duct assembly.
  4.  
  5. Tag and disconnect the spark plug wires from the spark plugs, and disconnect the spark plug wire clips from the rocker arm cover and position aside.
  6.  
  7. Detach the PCV hose from the rocker arm cover.
  8.  
  9. Disconnect the throttle cables from the throttle body and remove the throttle cable bracket from the intake plenum and move aside.
  10.  
  11. Unfasten the rocker arm cover bolts, then remove the rocker arm cover from the vehicle. Remove and discard the gasket. Thoroughly clean all gasket mating surfaces.
  12.  

To install:
  1. Install a new gasket into the cut out in the rocker arm cover.
  2.  
  3. Position the rocker arm cover on the cylinder head, then tighten the retaining bolts to 89 inch lbs. (10 Nm).
  4.  
  5. Attach the throttle cable bracket on the intake plenum and connect the throttle control cables to the throttle body.
  6.  
  7. Fasten the spark plug wire clips to the rocker arm cover, then connect the spark plug wires to the spark plugs, as tagged during removal.
  8.  
  9. Attach the PCV hose to the rocker arm cover.
  10.  
  11. Install the air cleaner and duct assembly.
  12.  
  13. Connect the negative battery cable. Check the engine oil level, and add if necessary.
  14.  
  15. Start the engine and verify no leaks.
  16.  

2.3L Engine

The camshaft housing covers and cylinder heads use the same retaining bolts. When the bolts are removed to service the camshaft cover, the cylinder head gasket MUST be replaced also. Refer to the Cylinder Head removal procedure for details.

2.5 Engine

See Figures 2 and 3



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Fig. Fig. 2: On some vehicles, such as this 1990 2.5L engine, you must use a special tool to remove the rocker arm cover



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Fig. Fig. 3: Rocker arm cover bolt tightening sequence

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the spark plug wire guides from the rocket arm (valve) cover and lay wires to the side.
  6.  
  7. Remove the PCV valve and hose from the cover.
  8.  
  9. If necessary for access, remove the EGR valve bolts, valve and gasket.
  10.  
  11. Unfasten the valve cover retaining bolts.
  12.  
  13. Remove the valve cover, using the Rocker Arm Cover Removing tool No. J34144-A or equivalent if necessary, and lightly tap with a rubber hammer.
  14.  

Prying on the cover could cause damage to the sealing surfaces.

To install:
  1. Clean the rocker arm cover with solvent and dry with a clean rag. in. (5mm) diameter bead of RTV sealant or equivalent around the cylinder head sealing surfaces inboard at the bolt holes.
  2.  
  3. Install the rocker arm cover, then tighten the attaching bolts to 80 inch lbs. (9 Nm) using the proper sequence.
  4.  
  5. If removed, install the EGR gasket and valve and secure with the retaining bolts. Tighten the bolts to 16 ft. lbs. (22 Nm).
  6.  
  7. Fasten the spark plug wire guide and the PCV valve and hose to the cover.
  8.  
  9. Install the air cleaner assembly.
  10.  
  11. Connect the negative battery cable.
  12.  

2.8L and 3.1L (VIN T and V) Engines

On the 1991 and later 3.1L engines, a Tech 1®scan tool is needed to perform the "Idle Learn'' procedure.

LEFT (FRONT) COVER

See Figures, 4, 5, 6, 7, 8, 9 and 10

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Fig. Fig. 4: Remove the crankcase vent tube from the rocker arm cover



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Fig. Fig. 5: Unfasten the torque strut-to-engine bracket bolts...



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Fig. Fig. 6: ... then swing the torque strut up out of the way



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Fig. Fig. 7: Remove the the spark plug wire guide, if necessary



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Fig. Fig. 8: Unfasten the rocer arm (valve) cover retaining bolts...



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Fig. Fig. 9: ... then remove the cover from the cylinder head.Do not pry on the cover during removal



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Fig. Fig. 10: Remove and discard the rocker arm cover gasket

  1. Remove the air cleaner assembly.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Properly drain the engine coolant into a suitable container.
  6.  
  7. Remove the ignition wire clamps and guide from the coolant tube.
  8.  
  9. Remove the coolant tube mount at the left cylinder head, the coolant tube at each end, coolant tube at the water pump, then remove the coolant tube.
  10.  
  11. Remove the crankcase vent tube.
  12.  
  13. Unfasten the torque strut-to-engine bracket bolts, then swing the torque strut up, out of the way.
  14.  
  15. If necessary for access, remove the ignition wire guide.
  16.  
  17. Unfasten the rocker arm (valve) cover retaining bolts, then remove the cover. If the cover is stuck to the cylinder head, remove it by bumping the end of the cover with the palm of your hand or a soft rubber mallet. Do not pry on the cover to remove it.
  18.  

Prying on the cover could cause damage to the sealing surfaces.

To install:
  1. Clean all sealing surfaces on the cylinder head and rocker cover with degreaser and a gasket scraper.
  2.  
  3. Position a new gasket and install new bolt grommets. Make sure the gasket is properly seated in the rocker arm cover groove.
  4.  
  5. Apply a continuous 3 / 16 in. (5mm) diameter bead of RTV sealant surfaces inboard at the bolt holes.
  6.  
  7. Install the rocker cover and tighten the retaining bolts to 89 inch lbs. (10 Nm).
  8.  
  9. Fasten the torque strut-to-engine bracket bolt and tighten the nut to 41 ft. lbs. (56 Nm).
  10.  
  11. Install the ignition wire guide.
  12.  
  13. Connect the crankcase vent tube to the rocker arm cover.
  14.  
  15. Install the coolant tube, coolant tube hose at the water pump, coolant tube at each end and coolant tube mount at the cylinder head.
  16.  
  17. Install the ignition wire clamp at the coolant tube.
  18.  
  19. Properly fill the cooling system with the proper type and amount of coolant.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. If equipped with a 1991 or later 3.1L engine perform the following "Idle Learn'' procedure, as follows:
    1. Install a Tech 1® scan tool.
    2.  
    3. Turn the ignition to the ON position, engine not running.
    4.  
    5. Select IAC SYSTEM , then IDLE LEARN in the MISC TEST mode.
    6.  
    7. Place the transaxle inPark or neutral, as applicable.
    8.  
    9. Proceed with idle learn as directed by the scan tool.
    10.  

  24.  
  25. Start the engine and check for correct operation.
  26.  

RIGHT (REAR) COVER
  1. Remove the air cleaner assembly.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Properly drain the engine coolant into a suitable container.
  6.  
  7. Detach the vacuum hoses at the intake plenum.
  8.  
  9. Remove the EGR tube at the crossover pipe.
  10.  
  11. Remove the ignition wire guide and harness at the intake plenum and at spark plugs.
  12.  
  13. Detach the coolant hoses at the throttle base and electrical wiring from the intake plenum.
  14.  
  15. Remove the throttle, TV and cruise control cables from the throttle body assembly.
  16.  
  17. Remove the bracket from the right side of the intake plenum.
  18.  
  19. Disconnect the brake booster vacuum hose from the plenum.
  20.  
  21. Remove the serpentine belt.
  22.  
  23. Remove the coolant recovery bottle, exhaust pipe at the crossover and engine struts at the engine.
  24.  
  25. Rotate the engine as outlined earlier in this section.
  26.  
  27. Remove the alternator and set aside.
  28.  
  29. Remove the PCV valve from the rocker cover.
  30.  
  31. Unfasten the four rocker cover retaining bolts, then remove the cover.
  32.  

Prying on the cover could cause damage to the sealing surfaces.

To install:
  1. Clean all sealing surfaces on the cylinder head and rocker cover with degreaser and a gasket scraper.
  2.  
  3. Install a new gasket and bolt grommets. Make sure the gasket is properly seated in the rocker cover groove.
  4.  
  5. Apply a continuous 3 / 16 in. (5mm) diameter bead of RTV sealant or equivalent around the cylinder head sealing surfaces inboard at the bolt holes.
  6.  
  7. Install the rocker cover and tighten the retaining bolts to 89 inch lbs. (10 Nm).
  8.  
  9. Attach the PCV valve to the rocker cover.
  10.  
  11. Install the alternator.
  12.  
  13. Rotate the engine to the proper position.
  14.  
  15. Install the torque struts to the engine, exhaust pipe at the crossover and the coolant recovery bottle.
  16.  
  17. Install the serpentine belt.
  18.  
  19. Install the brake booster vacuum hose and support bracket in the intake plenum.
  20.  
  21. Connect the throttle, TV and cruise control linkage to the intake plenum.
  22.  
  23. Attach all necessary electrical wiring to the intake plenum.
  24.  
  25. Install the coolant hoses to the throttle base and ignition wire harness.
  26.  
  27. Install the EGR tube at the crossover pipe.
  28.  
  29. Properly refill the cooling system with the specified type and amount of engine coolant.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Install the air cleaner assembly.
  34.  
  35. If equipped with a 1991 or later 3.1L engine perform the following "Idle Learn'' procedure, as follows:
    1. Install a Tech 1® scan tool.
    2.  
    3. Turn the ignition to the ON position, engine not running.
    4.  
    5. Select IAC SYSTEM , then IDLE LEARN in the MISC TEST mode.
    6.  
    7. Place the transaxle inPark or neutral, as applicable.
    8.  
    9. Proceed with idle learn as directed by the scan tool.
    10.  

  36.  
  37. Start the vehicle and check for oil, coolant, vacuum and exhaust leaks.
  38.  

3.1L (VIN M) Engine

See Figure 11



Click image to see an enlarged view

Fig. Fig. 11: Rocker arm (valve) cover removal and installation-1995 3.1L (VIN M) engine shown

LEFT (FRONT) COVER
  1. Properly drain the engine coolant into a suitable container.
  2.  
  3. Remove the air cleaner and duct assembly.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the thermostat bypass pipe clip nut.
  8.  
  9. Remove the automatic transaxle vacuum modulator pipe assembly.
  10.  
  11. Remove the right engine mount strut assembly from the engine. For details, please refer to the procedure located earlier in this section.
  12.  
  13. Disconnect the upper radiator hose from the engine assembly.
  14.  
  15. Detach the PCV valve hose from the cover.
  16.  
  17. Remove the heater outlet hose and the thermostat bypass pip assemblies.
  18.  
  19. Unfasten the rocker arm cover retaining bolts/screws, then remove the cover and gasket from the cylinder head. Discard the gasket.
  20.  
  21. Thoroughly clean the rocker arm cover and cylinder head mating surfaces.
  22.  

To install:
  1. Apply sealant No. 12345739 or equivalent at the cylinder head-to-lower manifold joint.
  2.  
  3. Position a new gasket, then install the rocker arm cover and hand-tighten all the retaining bolts. After all the bolts are installed, tighten them to 89 inch lbs. (10 Nm).
  4.  
  5. Install the heater outlet hose and thermostat bypass pipe assemblies.
  6.  
  7. Connect the PCV valve to the rocker arm cover.
  8.  
  9. Attach the upper radiator hose assembly to the engine.
  10.  
  11. Install the right engine mount strut, as outlined earlier in this section.
  12.  
  13. Install the automatic transaxle vacuum modulator pipe.
  14.  
  15. Fasten the thermostat bypass pipe clip nut.
  16.  
  17. Install the air cleaner and duct assembly.
  18.  
  19. Refill the engine cooling system with the proper type and amount of coolant, then add two engine coolant sealant pellets 3634621 or equivalent.
  20.  
  21. Connect the negative battery cable, then properly bleed the cooling system.
  22.  

RIGHT (REAR) COVER
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine drive belt.
  4.  
  5. Remove the engine mount strut assemblies from the engine.
  6.  
  7. Rotate the engine, as outlined earlier in this section.
  8.  
  9. Detach the electrical connectors from the ignition coil, then remove the coil assembly from the vehicle.
  10.  
  11. Remove the plastic cover from the shock tower.
  12.  
  13. Remove the alternator front and rear braces, then remove the alternator from the vehicle.
  14.  
  15. Remove the EGR valve and position it aside.
  16.  
  17. Unfasten the retaining bolts/screws, then remove the cover and gasket from the vehicle. Discard the gasket.
  18.  
  19. Thoroughly clean the rocker arm cover and cylinder head mating surfaces.
  20.  

To install:
  1. Apply sealant No. 12345739 or equivalent at the cylinder head-to-lower manifold joint.
  2.  
  3. Position a new gasket, then install the rocker arm cover and hand-tighten all the retaining bolts. After all the bolts are installed, tighten them to 89 inch lbs. (10 Nm).
  4.  
  5. Install the EGR valve assembly.
  6.  
  7. Install the alternator and the alternator front and rear braces.
  8.  
  9. Attach the plastic cover to the shock tower.
  10.  
  11. Install the ignition coil and attach the electrical connectors.
  12.  
  13. Rotate the engine back to its original position.
  14.  
  15. Install the engine mount struts, as outlined earlier in this section.
  16.  
  17. Install the serpentine drive belt.
  18.  
  19. Connect the negative battery cable, then start the engine and check for leaks and proper operation.
  20.  

3.8L Engine

See Figure 12



Click image to see an enlarged view

Fig. Fig. 12: Rocker arm (valve) cover mounting-1995 3.8L engine shown

LEFT SIDE (FRONT COVER)
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine lift bracket from the exhaust manifold studs.
  4.  
  5. Remove the fuel injector sight shield.
  6.  
  7. For 1993-96 vehicles, remove the serpentine drive belt.
  8.  
  9. For 1993-96 vehicles, unfasten the alternator-to-brace bolt, then remove the alternator brace.
  10.  
  11. Tag and disconnect the spark plug cables from the plugs, then remove the wire cover from the valve cover.
  12.  
  13. Remove the valve cover retaining bolts and remove the cover with a light tap with a rubber mallet, if necessary.
  14.  

To install:
  1. Installation is the reverse of the removal procedure. Be sure to thoroughly clean and dry all parts prior to installing them.
  2.  
  3. Replace the gasket, apply thread-locking compound to the threads, and tighten the retaining bolts to 89 inch lbs. (10 Nm).
  4.  
  5. Connect the negative battery cable, then start the engine and check for leaks.
  6.  

RIGHT SIDE (REAR COVER)
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the coolant recovery bottle.
  4.  
  5. Remove the serpentine drive belt.
  6.  
  7. Without disconnecting the hoses, remove the power steering pump and position aside.
  8.  
  9. Remove the fuel injector sight shield.
  10.  
  11. Remove the canister purge sensor valve from the bracket and remove the power steering pump support braces.
  12.  
  13. Tag and disconnect the spark plug wires from the spark plugs.
  14.  
  15. Remove the engine lift brackets from the exhaust manifold studs.
  16.  
  17. Unfasten the valve cover retaining bolts, then remove the cover. If necessary use a light tap with a rubber mallet on the cover to remove it.
  18.  

To install:
  1. Be sure to thoroughly clean and dry all parts prior to installing them.
  2.  
  3. Replace the gasket, apply thread-locking compound to the threads, and tighten the retaining bolts to 89 inch lbs. (10 Nm).
  4.  
  5. Install the engine lift brackets to the exhaust manifold studs. Tighten the nuts to 41 ft. lbs. (55 Nm).
  6.  
  7. Connect the spark plug wires, as tagged during removal.
  8.  
  9. Install the power steering pump support braces.
  10.  
  11. Attach the canister purge sensor valve to the bracket.
  12.  
  13. Install the fuel injector sight shield.
  14.  
  15. Position and secure the power steering pump.
  16.  
  17. Install the serpentine drive belt.
  18.  
  19. Install the coolant recovery bottle.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Run the engine and check for leaks.
  24.  

 
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