GM Lumina/Silhouette/Transport APVs 1990-1999 Repair Guide

Rocker Arm (Valve) Cover

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REMOVAL AND INSTALLATION



3.1L Engine
LEFT SIDE-FRONT COVER
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Detach the engine harness from the EVRV and the engine strut mount.
  8.  
  9. Disconnect the coolant tube hose at the water pump.
  10.  
  11. Remove the coolant tube bolt from the thermostat housing.
  12.  
  13. Remove the tube bracket nut and tube.
  14.  
  15. Remove the spark plug wire guide bracket.
  16.  
  17. Disconnect the fuel inlet and return lines from the TBI unit.
  18.  
  19. Remove the Idle Air Control (IAC) motor.
  20.  
  21. Remove the Throttle Position (TP) sensor.
  22.  
  23. Pull the PCV valve out of the rocker arm cover.
  24.  
  25. Remove the nuts and reinforcements, then pull the rocker arm cover off of the cylinder head.
  26.  

If the rocker cover sticks to cylinder head, remove it by bumping the end of the rocker arm cover with the palm of your hand or a soft rubber mallet.

  1. Clean the sealing surface on the cylinder head and rocker arm cover with a suitable degreaser.
  2.  

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: Exploded view of a rocker arm cover-3.1L engine

To install:
  1. Install the new gasket, making sure it is properly seated in rocker cover groove.
  2.  
  3. Apply RTV sealer in the notch.
  4.  
  5. Position the rocker arm cover over the gasket and RTV. Install the retainers and tighten to 89 inch lbs. (10 Nm).
  6.  
  7. Install the PCV valve into the grommet on the rocker cover gasket.
  8.  
  9. Install the Throttle Position (TP) sensor and the Idle Air Control (IAC) motor.
  10.  
  11. Attach the fuel inlet and return lines to the TBI assembly.
  12.  
  13. Connect the coolant tube bracket nut and tube.
  14.  
  15. Replace the spark plug wire guide bracket.
  16.  
  17. Install the coolant tube bolt at the thermostat housing.
  18.  
  19. Connect the coolant tube hose to the water pump.
  20.  
  21. Attach the engine harness at the EVRV and to the engine strut mount
  22.  
  23. Install the air cleaner assembly.
  24.  
  25. Fill the cooling system to the proper level.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Inspect for oil leaks at the sealing surfaces, and check for any coolant leaks.
  30.  

RIGHT SIDE-REAR COVER
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Drain the coolant into an approved container.
  6.  
  7. Remove the throttle and TV bracket FROM the TBI assembly. Be careful not to change the TV adjustment.
  8.  
  9. Tag and disconnect any wire assemblies and/or vacuum lines that interfere with the cover removal.
  10.  
  11. Remove the serpentine belt.
  12.  
  13. Remove the alternator as outlined in Engine Electrical of this repair guide, including the mounting brackets and rear brace.
  14.  
  15. Disconnect the coolant hose from the manifold.
  16.  
  17. Remove the nuts and other retainers, then pull the cover off of the cylinder head.
  18.  

If the rocker cover sticks to the cylinder head, remove it by bumping the end of the cover with the palm of your hand or soft rubber mallet.

  1. Clean the gasket mating surfaces on the cylinder head and rocker arm cover with a suitable degreaser.
  2.  

To install:
  1. Install the new gasket, making sure it is properly seated in rocker cover groove.
  2.  
  3. Apply RTV sealer in the notch.
  4.  
  5. Position the rocker arm cover over the gasket and RTV. Install the retainers and tighten to 89 inch lbs. (10 Nm).
  6.  
  7. Attach the coolant hose to the manifold.
  8.  
  9. Install the alternator bracket, alternator, and rear alternator brace. For details, see the procedure located in Engine Electrical of this repair guide.
  10.  
  11. Install the serpentine belt.
  12.  
  13. Attach all wire assemblies and vacuum lines that were disconnected, as tagged during removal.
  14.  
  15. Install the throttle and TV cable bracket assembly.
  16.  
  17. Install the air cleaner assembly.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Fill the cooling system to the proper level.
  22.  
  23. Inspect for oil leaks at the sealing surfaces, and check for any coolant leaks.
  24.  

3.4L Engine
LEFT SIDE-FRONT COVER
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the acoustic engine cover.
  4.  
  5. Remove the engine mount strut.
  6.  
  7. Remove the PCV valve from the rocker arm (valve) cover.
  8.  
  9. Tag, then disconnect the spark plug wires from front spark plugs.
  10.  
  11. Unfasten the retaining bolts, then remove the rocker arm (valve) cover.
  12.  

If the rocker cover sticks to the cylinder head, remove it by bumping the end of the cover with the palm of your hand or soft rubber mallet.

  1. Clean the gasket mating surfaces on the cylinder head and rocker arm cover with a suitable degreaser.
  2.  

See Figure 2

Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the rocker arm (valve) cover-3.4L engine

To install:
  1. Install the new gasket, making sure it is properly seated in rocker cover groove.
  2.  
  3. Apply RTV sealer in the notch.
  4.  

Install the valve rocker cover bolts finger tight before tightening bolts to specification or damage to the valve rocker cover may occur.

  1. Position the rocker arm cover over the gasket and RTV. Install the retainers finger-tight, then tighten to 89 inch lbs. (10 Nm).
  2.  
  3. Reinstall the plug wires onto the front plugs, as tagged during removal.
  4.  
  5. Push the PCV valve back into the grommet on the cover.
  6.  
  7. Install the engine mount strut.
  8.  
  9. Install the acoustic engine cover.
  10.  
  11. Connect the negative battery cable.
  12.  

RIGHT SIDE-REAR COVER
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the acoustic engine cover.
  4.  
  5. Remove the serpentine belt.
  6.  
  7. Remove the alternator, bracket, and braces as outlined in Engine Electrical .
  8.  
  9. Tag and disconnect the spark plug wires from the ignition module/coil assembly.
  10.  
  11. Remove the ignition coil mounting bracket with the coils, purge solenoid and vacuum canister solenoid still attached.
  12.  
  13. Tag and disconnect the vacuum lines from the valve cover.
  14.  
  15. Unfasten the retaining bolts, then remove the rocker arm (valve) cover.
  16.  

If the rocker cover sticks to the cylinder head, remove it by bumping the end of the cover with the palm of your hand or soft rubber mallet.

  1. Clean the gasket mating surfaces on the cylinder head and rocker arm cover with a suitable degreaser.
  2.  

To install:
  1. Install the new gasket, making sure it is properly seated in rocker cover groove.
  2.  
  3. Apply RTV sealer in the notch.
  4.  

Install the valve rocker cover bolts finger tight before tightening bolts to specification or damage to the valve rocker cover may occur.

  1. Position the rocker arm cover over the gasket and RTV. Install the retainers finger-tight, then tighten to 89 inch lbs. (10 Nm).
  2.  
  3. Reattach the vacuum lines to the valve cover, as tagged during removal.
  4.  
  5. Install the ignition coil bracket with the other parts still attached.
  6.  
  7. Connect the plug wires to the ignition module/coil assembly, being careful to keep them in the proper order.
  8.  
  9. Install the alternator, bracket, and braces as outlined in Engine Electrical .
  10.  
  11. Install the serpentine belt.
  12.  
  13. Install the acoustic engine cover.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Inspect the work for any oil leaks, make sure of the proper fluid levels.
  18.  

3.8L Engine
LEFT SIDE-FRONT COVER
  1. If necessary for access, unfasten the retaining bolts, then remove the bracket and motor mount for access to the rocker arm (valve) cover.
  2.  

See Figures 3 and 4

Click image to see an enlarged view

Fig. Fig. 3: Unfastening the two bracket retaining bolts ...



Click image to see an enlarged view

Fig. Fig. 4: ... and the front motor mount, provides more access for removal of the valve cover

  1. Remove the accessory drive belt (serpentine belt).
  2.  
  3. Unfasten the alternator brace bolt, then remove the brace.
  4.  
  5. Tag and disconnect the wires from the front bank of spark plugs, then position the harness aside.
  6.  

See Figure 5

Click image to see an enlarged view

Fig. Fig. 5: Tag and disconnect the plug wires, and move the harness aside

  1. Loosen the six rocker arm cover bolts completely, then remove the bolts. Pull the rocker arm cover off of the cylinder head.
  2.  

See Figure 6

Click image to see an enlarged view

Fig. Fig. 6: Completely loosen the six attaching bolts without removing them

If cover sticks to the cylinder head, remove it by bumping the end of the cover with the palm of your hand or a soft rubber mallet.

See Figures 7, 8 and 9

Click image to see an enlarged view

Fig. Fig. 7: Remove the rocker arm cover; the studs and grommets can be removed at the workbench



Click image to see an enlarged view

Fig. Fig. 8: If the gasket stuck to the cylinder head mating surface, it must be removed before assembly



Click image to see an enlarged view

Fig. Fig. 9: Exploded view of the rocker arm cover, including the gasket.

To install:
  1. Position a new gasket, then place the cover onto the gasket.
  2.  
  3. Install the cover retaining bolts and tighten the bolts to 89 inch lbs. (10 Nm).
  4.  
  5. Reconnect the spark plug wires, as attached during removal.
  6.  
  7. Install the alternator brace and secure with the retaining bolt.
  8.  
  9. Install the accessory drive belt (serpentine belt).
  10.  
  11. Check for any fluid leaks.
  12.  

RIGHT SIDE-REAR COVER
  1. Remove the accessory drive belt (serpentine belt).
  2.  
  3. Loosen the power steering pump bolts, then slide the pump forward to gain the necessary clearance. Do not disconnect the fluid lines.
  4.  
  5. Remove the power steering pump braces, as necessary, to gain access.
  6.  
  7. Tag and disconnect the spark plug wires, from the rear bank of spark plugs.
  8.  
  9. Remove the retaining bolts, then pull the cover off of the cylinder head.
  10.  

If the rocker cover sticks to the cylinder head, remove it by bumping the end of the cover with the palm of your hand or soft rubber mallet.

  1. Clean the gasket mating surfaces on the cylinder head and rocker arm cover with a suitable degreaser.
  2.  

To install:
  1. Install the new gasket, making sure it is properly seated in rocker cover groove.
  2.  
  3. Apply RTV sealer in the notch.
  4.  
  5. Position the rocker arm cover over the gasket and RTV. Install the retainers and tighten to 89 inch lbs. (10 Nm).
  6.  
  7. Reconnect the spark plug wires, as tagged during removal.
  8.  
  9. Install and tighten the power steering pump braces.
  10.  
  11. Slide the power steering pump back to its proper position and tighten the mounting bolts.
  12.  
  13. Install the accessory drive belt (serpentine belt).
  14.  
  15. Check for any fluid leaks.
  16.  

 
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