GM S-Series Pick-ups and SUV's 1994-1999 Repair Guide

Rocker Arm (Valve) Cover

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REMOVAL & INSTALLATION



2.2L Engine
1994-97 models

See Figures 1 through 15



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Fig. Fig. 1: View of the rocker arm cover-1996 2.2L model shown

  1. Disconnect the negative battery cable and remove the air duct assembly.
  2.  
  3. Disconnect the throttle cable and remove the cable support linkage.
  4.  
  5. If equipped, disconnect the cruise control cable assembly.
  6.  
  7. Remove the PCV valve and pipe assembly.
  8.  
  9. Tag and disconnect the spark plug wires and move them out of the way.
  10.  
  11. Disconnect the power brake booster vacuum hose.
  12.  
  13. Loosen and remove the rocker cover retaining bolts, then remove the cover from the engine.
  14.  

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 putty knife, carefully clean the gasket mounting surfaces. Keep debris out of the engine.
  2.  



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Fig. Fig. 2: Unfasten the throttle linkage cover retaining bolt ...



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Fig. Fig. 3: ... and remove the cover



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Fig. Fig. 4: Disconnect the throttle cable from the linkage



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Fig. Fig. 5: Use a suitable prytool to pry the cable retaining clip from the cable support bracket and slide the cable out of the bracket



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Fig. Fig. 6: Unfasten the retainers attaching the front cable support bracket from the upper intake manifold and the valve cover



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Fig. Fig. 7: Unfasten the rear cable support bracket bolt and set the cable and bracket aside



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Fig. Fig. 8: Unscrew the crankcase vent valve retainer ...



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Fig. Fig. 9: ... and pull the pipe and valve assembly from the valve cover



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Fig. Fig. 10: Disconnect the PCV valve hose from the valve



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Fig. Fig. 11: Disconnect the spark plug wires and move them aside



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Fig. Fig. 12: Disconnect the brake booster vacuum hose clamp using pliers ...



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Fig. Fig. 13: ... and disconnect the hose, then set the hose assembly aside



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Fig. Fig. 14: Remove the valve cover retaining bolts



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Fig. Fig. 15: Lift the valve cover and move it backwards until it clears the hoses at the front of the engine, then remove the valve cover

To install:
  1. Install the rocker arm cover to the engine using a new gasket, then tighten the retainers to 89 inch lbs. (10 Nm). Be careful not to overtighten the fasteners and either distort the valve cover (causing and leak) or break the fastener (causing more work).
  2.  
  3. Connect the spark plug wires.
  4.  
  5. Install the PCV valve and pipe assembly.
  6.  
  7. Connect the brake booster vacuum hose.
  8.  
  9. If equipped, install the cruise control cable assembly.
  10.  
  11. Connect the throttle cable and secure the cable support linkage. Tighten the bracket bolts to 10 ft. lbs. (25 Nm) and the bracket nut to 22 ft. lbs. (30 Nm).
  12.  
  13. Connect the air duct to the inlet, then connect the negative battery cable.
  14.  

1998-99 models

See Figure 16

  1. Disconnect the negative battery cable and remove the air cleaner outlet resonator.
  2.  
  3. Disconnect the vacuum brake booster hose.
  4.  
  5. Disconnect the throttle cable and cruise control cables.
  6.  
  7. Tag and disconnect the spark plug wires from the spark plugs, then remove the spark plug wire retainer from the heater hose pipe.
  8.  
  9. Remove the PCV valve hose.
  10.  
  11. Remove the throttle body assembly.
  12.  
  13. Unfasten the heater hose pipe bracket-to-air cleaner outlet resonator bracket bolt.
  14.  
  15. Remove the air cleaner resonator bracket.
  16.  
  17. Remove the engine wiring harness bracket by unfastening the bolt at the rear of the cylinder head and the two bolts that attach the bracket to the valve cover, then slide the bracket of the bolt at the rear of the cylinder head.
  18.  
  19. Note the location of the studs before removal , then loosen and remove the rocker cover retaining bolts and studs. Remove the cover from the engine.
  20.  

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 putty knife, carefully clean the gasket mounting surfaces. Keep debris out of the engine.
  2.  

To install:
  1. Install the rocker arm cover to the engine using a new gasket, then tighten the retainers to 89 inch lbs. (10 Nm) in the sequence illustrated. Be careful not to overtighten the fasteners and either distort the valve cover (causing and leak) or break the fastener (causing more work).
  2.  
  3. Install the wiring harness bracket and its retainers. Tighten the bracket-to-valve bracket bolts to 89 inch lbs. (10 Nm) and the bolt at the rear of the cylinder head to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the air cleaner resonator bracket. Tighten the nuts to 97 inch lbs. (11 Nm).
  6.  
  7. Attach the heater hose bracket to the air cleaner resonator and tighten the bolt to 10 ft. lbs. (14 Nm).
  8.  
  9. Install the throttle body assembly.
  10.  
  11. Install the spark plug wire retainer and attach the spark plug wires to the plugs.
  12.  
  13. Install the PCV valve hose.
  14.  
  15. Connect the throttle cable and cruise control cable.
  16.  
  17. Connect the vacuum brake booster hose.
  18.  
  19. Install the air cleaner outlet resonator and connect the negative battery cable.
  20.  



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Fig. Fig. 16: Valve cover retainer tightening sequence-1998-99 models

4.3L Engine
RIGHT SIDE-1994-95 Models

See Figures 17, 18, 19 and 20



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Fig. Fig. 17: Tag and disengage the necessary electrical connections and vacuum lines



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Fig. Fig. 18: Unfasten the rocker arm cover bolts



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Fig. Fig. 19: Remove the rocker arm cover from the engine



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Fig. Fig. 20: Remove the old rocker arm cover gasket

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner.
  4.  
  5. On 1995 (VIN W) engines, remove the PCV valve and pipe assembly.
  6.  
  7. On 1995 (VIN W) engines, remove the coil with the bracket and lay to one side.
  8.  
  9. Remove the EGR controller and MAP sensor bracket.
  10.  
  11. Tag and disconnect the necessary vacuum lines.
  12.  
  13. Remove the wiring harness from the retaining clips and lay it aside.
  14.  
  15. Remove the rocker arm cover bolts, then remove the cover from the cylinder head.
  16.  

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 putty knife, carefully clean the gasket mounting surfaces. Keep debris out of the engine.
  2.  

To install:
  1. Install the rocker arm cover to the engine using a new gasket, then tighten the retainers to 89 inch lbs. (10 Nm). Be careful not to overtighten the fasteners and either distort the valve cover (causing and leak) or break the fastener (causing more work).
  2.  
  3. Install the EGR controller and MAP sensor bracket.
  4.  
  5. Connect the vacuum lines as noted during removal.
  6.  
  7. On 1995 (VIN W) engines, install the coil with the bracket.
  8.  
  9. On 1995 (VIN W) engines, install the PCV valve and pipe assembly.
  10.  
  11. Position and secure electrical wiring harness in the retaining clips.
  12.  
  13. Install the air cleaner.
  14.  
  15. Connect the negative battery cable.
  16.  

LEFT SIDE-1994-95 MODELS
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. If necessary, remove the crankcase ventilation pipe.
  6.  
  7. If equipped, remove the pencil brace, then disconnect the power brake vacuum line at the booster.
  8.  
  9. Remove the rocker arm cover bolts, then remove the cover.
  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 putty knife, carefully clean the gasket mounting surfaces. Keep debris out of the engine.
  2.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize you exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

To install:
  1. Install the rocker arm cover to the engine using a new gasket, then tighten the retainers to 89 inch lbs. (10 Nm). Be careful not to overtighten the fasteners and either distort the valve cover (causing and leak) or break the fastener (causing more work).
  2.  
  3. Connect the power brake booster vacuum line to the booster.
  4.  
  5. If equipped, install the pencil brace.
  6.  
  7. If removed, install the crankcase ventilation pipe
  8.  
  9. Install the air cleaner assembly.
  10.  
  11. Connect the negative battery cable.
  12.  

RIGHT SIDE-1996-98 MODELS
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Tag and disconnect the spark plug wires.
  6.  
  7. If equipped, remove the vent tube.
  8.  
  9. Disconnect the wiring bracket at the generator bracket.
  10.  
  11. Unfasten the oil level dipstick tube brace bolt, then move the heater hoses aside
  12.  
  13. Unfasten the rocker arm cover bolts.
  14.  
  15. Remove the rocker arm cover and gasket.
  16.  
  17. Using a putty knife, carefully clean the gasket mounting surfaces. Keep debris out of the engine.
  18.  

To install:
  1. Install the rocker arm cover to the engine using a new gasket.
  2.  
  3. Install new bolt grommets, then tighten the retainers to 106 inch lbs. (12 Nm). Be careful not to overtighten the fasteners and either distort the valve cover (causing and leak) or break the fastener (causing more work).
  4.  
  5. Engage the wiring bracket to the generator bracket.
  6.  
  7. Install the vent tube and engage the spark plug wires.
  8.  
  9. Install the air cleaner assembly.
  10.  
  11. Connect the negative battery cable.
  12.  

RIGHT SIDE-1999-99 MODELS
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the PCV tube from the valve cover and air inlet duct.
  4.  
  5. Tag and disconnect the spark plug wires from the plugs.
  6.  
  7. Remove the EVAP canister purge solenoid valve.
  8.  
  9. Unfasten the heater hose retainer above the valve cover.
  10.  
  11. Move the heater hoses to one side and wire them aside so that they stay there.
  12.  
  13. Unfasten the bolt attaching the engine wiring harness bracket to the alternator.
  14.  
  15. Unplug the Crankshaft Position (CKP) sensor electrical connection, then move the wiring harness aside.
  16.  
  17. Unfasten the rocker arm cover bolts.
  18.  
  19. Remove the rocker arm cover and gasket.
  20.  
  21. Using a putty knife, carefully clean the gasket mounting surfaces. Keep debris out of the engine.
  22.  

To install:
  1. Install the rocker arm cover to the engine using a new gasket.
  2.  
  3. Install new bolt grommets, then tighten the retainers to 106 inch lbs. (12 Nm). Be careful not to overtighten the fasteners and either distort the valve cover (causing and leak) or break the fastener (causing more work).
  4.  
  5. Place the wiring harness into position, then attach CKP sensor electrical connection.
  6.  
  7. Place the heater hoses into position and fasten the heater hose retainer.
  8.  
  9. Attach the EVAP canister purge solenoid valve.
  10.  
  11. Connect the spark plug wires.
  12.  
  13. Install the PCV tube.
  14.  
  15. Connect the negative battery cable.
  16.  

LEFT SIDE-1996-99 MODELS
  1. Disconnect the negative battery cable and disconnect the air duct from the inlet.
  2.  
  3. If necessary on 1996 models, disengage the A/C compressor and bracket and move the compressor to one side.
  4.  
  5. Remove the PCV valve and pipe assembly.
  6.  
  7. Tag and disconnect the spark plug wires from the spark plugs.
  8.  
  9. On 1999 and later models, unplug the Engine Coolant Temperature (ECT) sensor electrical connection.
  10.  
  11. On 1999 and later models, partially drain the coolant, then disconnect the radiator inlet hose from the thermostat housing outlet.
  12.  
  13. On 1999 and later models, remove the EGR valve inlet pipe from the exhaust and intake manifolds.
  14.  
  15. Unfasten the rocker arm cover bolts.
  16.  
  17. Remove the rocker arm cover and gasket.
  18.  
  19. Using a putty knife, carefully clean the gasket mounting surfaces. Keep debris out of the engine.
  20.  

To install:
  1. Install the rocker arm cover to the engine using a new gasket.
  2.  
  3. Install new bolt grommets, then tighten the retainers to 106 inch lbs. (12 Nm). Be careful not to overtighten the fasteners and either distort the valve cover (causing and leak) or break the fastener (causing more work).
  4.  
  5. On 1999 and later models, attach the EGR valve inlet pipe from the exhaust and intake manifolds. Tighten the pipe-to-intake manifold nut to 18 ft. lbs. (25 Nm), the pipe-to-exhaust manifold nut to 22 ft. lbs. (30 Nm) and the pipe clamp bolt to 18 ft. lbs. (25 Nm).
  6.  
  7. On 1999 and later models, connect the radiator inlet hose to the thermostat housing outlet and fill the cooling system.
  8.  
  9. On 1999 and later models, attach the ECT sensor electrical connection.
  10.  
  11. Connect the spark plug wires.
  12.  
  13. On 1996 models, if removed, install the A/C compressor bracket and compressor.
  14.  
  15. Install the PCV valve and pipe assembly.
  16.  
  17. Engage the air duct to the inlet and connect the negative battery cable.
  18.  

 
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