GM S10/S15/Sonoma Pick-Ups 1982-1993 Repair Manual

Rocker Arm (Valve) Cover

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REMOVAL & INSTALLATION



See Figures 1 through 14

1.9L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Tag and disconnect the spark plug wires, then remove the evaporator pipe.
  6.  
  7. Remove the rocker arm cover-to-engine nuts/washers.
  8.  
  9. Remove the rocker arm 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.  
  3. To install, use a new gasket and reverse the removal procedures. Be careful not to overtighten the fasteners and either distort the valve cover (causing and leak) or break the fastener (causing more work).
  4.  



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Fig. Fig. 1: Removing the fuel vapor tubes for access to the rocker cover-2.0L engine



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Fig. Fig. 2: Exploded view of the rocker arm cover mounting and rocker components-2.0L engine



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Fig. Fig. 3: Using J-34144-A, or an equivalent tool, remove the rocker arm cover from the 2.5L engine

2.0L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly and the distributor cap. If necessary, tag and disconnect the spark plug wires from the cap.
  4.  
  5. Remove the fuel vapor canister harness tubes from the rocker arm cover.
  6.  
  7. Disconnect the accelerator cable and remove the PCV valve.
  8.  
  9. Remove the rocker arm cover-to-cylinder head bolts, then remove the cover from the engine.
  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.  
  3. To install, place a 1 / 8 in. bead of RTV sealant around the sealing rail of the cover and reverse the removal procedures. Torque the rocker arm cover-to-cylinder head bolts to 8 ft. lbs. (11 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.  

2.2L Diesel Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the PCV valve from the rocker arm cover and the PCV valve hose.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Remove the rocker arm cover-to-cylinder head bolts and remove the cover from the engine.
  8.  

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.  
  3. To install, use a new gasket and reverse the removal procedures. Torque the rocker arm cover-to-cylinder head bolts to 9-13 ft. lbs. (12-18 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.  

2.5L Engine

A rocker arm cover removal tool (J 34144-A or equivalent) is needed to properly perform this procedure and to prevent damage to the sealing rail of the rocker arm cover.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Disconnect the Positive Crankcase Ventilation (PCV) valve hose, the ignition wires from the rocker arm cover.
  6.  
  7. Remove the Exhaust Gas Recirculation (EGR) valve.
  8.  
  9. Label and disconnect the vacuum hoses. Disconnect and reposition the wiring harness, as necessary.
  10.  
  11. Remove the rocker arm cover-to-cylinder head bolts. Remove the cover using tool J 34144-A or equivalent to break the seal and drive the cover away from the cylinder head.
  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 putty knife, carefully clean the gasket mounting surfaces. Keep debris out of the engine.
  2.  

To install:

Be sure to use solvent to remove any oil or grease that may remain on the sealing surfaces.

  1. Place a 1 / 8 in. bead of RTV sealant around the sealing rail of the cover (or use a new gasket as applicable), then install the rocker arm cover to the cylinder head and tighten the retainers 75 inch lbs. (8 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 vacuum hoses as noted during removal. Reposition the wiring harness and re-engage any connectors.
  4.  
  5. Install the EGR valve.
  6.  
  7. Connect the PCV valve hose and the ignition wires to the rocker cover.
  8.  
  9. Install the air cleaner.
  10.  
  11. Connect the negative battery cable.
  12.  

2.8L Engine
LEFT-SIDE
  1. Disconnect the negative battery cable.
  2.  
  3. If equipped, disconnect the crankcase ventilation pipe.
  4.  
  5. Disconnect the air management hose, the vacuum hose(s), the electrical wires and the pipe bracket. Remove the spark plug wires and clips from the retaining studs.
  6.  
  7. If necessary, relieve the fuel system pressure and disconnect the fuel line(s) for clearance.
  8.  
  9. Remove the rocker arm cover-to-cylinder head bolts/nuts, reinforcements and the cover from the engine.
  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.  

To install:

Be sure to use solvent to remove any oil or grease that may remain on the sealing surfaces.

  1. Place a 1 / 8 in. dab of RTV sealant at the points where the sealing area of the head meets the sealing area of the intake manifold. Install the cover and reinforcements using a new gasket, tighten the retainers 72 inch lbs. (8 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. If removed, connect the fuel lines.
  4.  
  5. Position the spark plug wires and clips back on the retaining studs.
  6.  
  7. Connect the hoses, wires and pipe bracket.
  8.  
  9. If equipped, connect the crankcase ventilation pipe.
  10.  
  11. Connect the negative battery cable.
  12.  

RIGHT-SIDE (1982-87)
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the air management hoses, then remove the air management valve and coil bracket(s).
  4.  
  5. Disconnect the vacuum hose(s), the electrical wires and the pipe bracket, as applicable.
  6.  
  7. If equipped, remove the spark plug wires and clips from the retaining studs.
  8.  
  9. Disconnect the carburetor or throttle body linkage and controls and the brackets.
  10.  
  11. Remove the rocker arm cover-to-cylinder head bolts/nuts and the cover from the engine.
  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 putty knife, carefully clean the gasket mounting surfaces. Keep debris out of the engine.
  2.  

To install:

Be sure to use solvent to remove any oil or grease that may remain on the sealing surfaces.

  1. Place a 1 / 8 in. dab of RTV sealant at the points where the sealing area of the head meets the sealing area of the intake manifold. Install the cover and reinforcements using a new gasket, tighten the retainers 72 inch lbs. (8 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 throttle linkage and controls at the brackets.
  4.  
  5. If equipped, secure the spark plug wires and clips to the retaining studs.
  6.  
  7. Connect the vacuum hose(s), electrical wires and the pipe bracket, as applicable.
  8.  
  9. Install the air management valve and coil bracket(s), then connect the air management hoses.
  10.  
  11. Connect the negative battery cable.
  12.  

RIGHT-SIDE (1988-93)
  1. Disconnect the negative battery cable and remove the air cleaner assembly.
  2.  
  3. Remove the ignition coil and bracket.
  4.  
  5. Remove spark plug wires from the bracket on the rocker arm cover stud, then remove the PCV valve and vacuum pipe.
  6.  
  7. Remove the throttle, cruise control and TV cables (as applicable) along with the bracket at the throttle body.
  8.  
  9. Remove the alternator and lay it aside.
  10.  
  11. Remove the rocker arm cover-to-cylinder head bolts/nuts, reinforcements and the cover from the engine.
  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 putty knife, carefully clean the gasket mounting surfaces. Keep debris out of the engine.
  2.  

To install:

Be sure to use solvent to remove any oil or grease that may remain on the sealing surfaces.

  1. Place a 1 / 8 in. dab of RTV sealant at the points where the sealing area of the head meets the sealing area of the intake manifold. Install the cover and reinforcements using a new gasket, tighten the retainers 72 inch lbs. (8 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 alternator.
  4.  
  5. Install the throttle, cruise control and TV cables (as applicable) along with the bracket.
  6.  
  7. Install the vacuum pipe and the PCV valve.
  8.  
  9. Position the spark plug wires in the bracket at the rocker arm cover stud.
  10.  
  11. Install the ignition coil and bracket.
  12.  
  13. Install the air cleaner assembly, then connect the negative battery cable.
  14.  



Click image to see an enlarged view

Fig. Fig. 4: If any component brackets interfere with cover removal, loosen the bracket retainers



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Fig. Fig. 5: In this case the coil and air management valve bracket must be removed



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Fig. Fig. 6: Disconnect any vapor or breather hoses from the valve cover and/or air cleaner



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Fig. Fig. 7: Release any wiring harnesses from cover mounted clips



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Fig. Fig. 8: For the 2.8L engine, throttle return springs must be removed from the cover bracket



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Fig. Fig. 9: If necessary, remove the throttle cable C-clip so the cable linkage may be disconnected



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Fig. Fig. 10: With the C-clip removed, the linkage may be freed from the carburetor or throttle body



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Fig. Fig. 11: Once the throttle linkage is disconnected, the cable may be removed from any cover mounted brackets



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Fig. Fig. 12: Loosen and remove the valve cover retainers



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Fig. Fig. 13: Lift the valve cover from the cylinder head



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Fig. Fig. 14: Be careful not to get dirt or debris into the exposed cylinder head and oil passages

4.3L Engine, Except MFI-Turbo

See Figure 15

RIGHT SIDE
  1. Disconnect the negative battery cable, then remove the air cleaner.
  2.  
  3. Remove PCV valve, then disconnect the heater pipe at the manifold.
  4.  
  5. Remove the emissions relays with their bracket and lay them aside.
  6.  
  7. Remove the wiring harness from the retaining clips and lay it aside.
  8.  
  9. Remove the spark plug wires from the clips.
  10.  
  11. Move the dipstick tube aside; on most vehicles you will have to first remove the dipstick tube bracket from the cylinder head.
  12.  
  13. Remove the rocker arm cover bolts, then remove the cover from the cylinder head.
  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.  

To install:
  1. Install the rocker arm cover to the engine using a new gasket, then tighten the retainers to 90 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. Reposition the dipstick guide tube and secure using the bracket.
  4.  
  5. Install the spark plug wires and the electrical wiring harness in the retaining clips.
  6.  
  7. Reposition and secure the emissions relays and bracket.
  8.  
  9. Connect the heater pipe to the manifold and install the PCV valve.
  10.  
  11. Install the air cleaner, then connect the negative battery cable.
  12.  



Click image to see an enlarged view

Fig. Fig. 15: Rocker arm cover mounting-4.3L engine

LEFT SIDE
  1. Disconnect the negative battery cable and properly relieve the fuel system pressure.
  2.  
  3. Remove the air cleaner and heater (heat stove) pipe.
  4.  
  5. Remove the crankcase ventilation pipe.
  6.  
  7. Disconnect the fuel pipes at the throttle body, release the retaining clips and move the pipes aside.
  8.  
  9. Remove the alternator rear bracket.
  10.  
  11. Release the spark plug wires from the retaining clips, then disconnect the power brake vacuum line at the intake manifold.
  12.  
  13. Remove the rocker arm cover bolts, then remove the cover.
  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.  

To install:
  1. Install the rocker arm cover to the engine using a new gasket, then tighten the retainers to 90 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 intake manifold, then secure the spark plug wires to the retaining clips.
  4.  
  5. Install the alternator rear bracket.
  6.  
  7. Reconnect the fuel pipes to the throttle body, then secure the pipes using the retaining clips.
  8.  
  9. Install the crankcase ventilation pipe.
  10.  
  11. Install the air cleaner and heat stove.
  12.  
  13. Connect the negative battery cable.
  14.  

4.3L MFI-Turbo

RIGHT SIDE

  1. Disconnect the negative batter cable, then properly drain the engine cooling system and charge air cooling system.
  2.  
  3. Disconnect the charge air cooler clamps, hoses and ducts, then remove the charge air cooler.
  4.  
  5. Remove the PCV hoses and valves, then disconnect the turbocharger oil feed hose from the turbocharger.
  6.  
  7. Remove the air cleaner and duct, then disengage the oxygen sensor connector.
  8.  
  9. Disconnect the heater inlet hose from the lower intake manifold, then remove the charge air cooler lateral (center) support.
  10.  
  11. Remove the rocker arm cover retaining bolts, then remove the cover from the cylinder head.
  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 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. Connect the heater inlet hose, then connect the turbocharger oil feed hose and tighten the fitting to 16 ft. lbs. (22 Nm).
  4.  
  5. Install the PCV hoses and valves, then engage the oxygen sensor connector.
  6.  
  7. Install the charge air cooler lateral support to the lower intake manifold, then finger-tighten the nut.
  8.  
  9. Install the charge air cooler, then tighten the lateral support nut.
  10.  
  11. Install the charge air cooler clamps and hoses, then install the air cleaner and duct.
  12.  
  13. Connect the negative battery cable, then properly refill the engine cooling system and the charge air cooling system.
  14.  

LEFT SIDE
  1. Disconnect the negative battery cable, then drain the charge air cooling system.
  2.  
  3. Remove the serpentine drive belt, then unbolt the alternator and position it aside.
  4.  
  5. Disconnect the power brake hose.
  6.  
  7. Tag and disengage both the vacuum hoses and electrical connectors from the EVRV solenoid, ignition coil and the MAP sensor. All are located on the multi-use bracket.
  8.  
  9. Disconnect the charge air cooler inlet pipe, then remove the multi-use bracket.
  10.  
  11. Remove the rocker arm cover retaining bolts, then remove the cover from the cylinder head.
  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 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 multi-use bracket, then connect the charge air cooler inlet pipe.
  4.  
  5. Engage the vacuum hoses and electrical wiring connectors to the components located on the multi-use bracket.
  6.  
  7. Connect the power brake hose.
  8.  
  9. Reposition and secure the alternator, then install the serpentine drive belt.
  10.  
  11. Connect the negative battery cable, then properly refill the charge air cooling system.
  12.  

 
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