HHR 2006-2008

Camshaft (Cylinder Head) Cover

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Removal & Installation



2.0L Engine
  1. Remove the intake manifold cover.
  2.  
  3. Remove the intake manifold cover studs.
  4.  
  5. Remove the air cleaner outlet.
  6.  
  7. Disconnect the engine wiring harness intake and exhaust electrical connectors from the camshaft position actuator solenoid valves.
  8.  
  9. Remove the engine wiring harness clip from the camshaft cover.
  10.  
  11. Remove the engine wiring harness clips from the camshaft cover.
  12.  
  13. Disconnect the engine wiring harness electrical connector from the Evaporative Emission (EVAP) canister purge solenoid valve.
  14.  
  15. Remove the ignition coils.
  16.  
  17. Remove the Heated Oxygen Sensor (HO2S) electrical connector clip from the camshaft cover.
  18.  
  19. Remove the Positive Crankcase Ventilation (PCV) fitting bolt from the turbocharger. Reposition the PCV pipe (with fitting) out of the way.
  20.  
  21. Remove the (PCV) fitting bolt from the turbocharger. Reposition the PCV pipe (with fitting) out of the way.
  22.  
  23. Remove the air inlet grille panel.
  24.  
  25. Remove the electrical harness attached at the rear of the camshaft cover.
    WARNING
    The PCV hose should NOT be disconnected from the camshaft cover as damage to the hose connection will result.

  26.  
  27. Remove the camshaft cover bolts.
  28.  
  29. Remove the camshaft cover.

    Click image to see an enlarged view

    Fig. Camshaft cover 2.0L engine

  30.  
  31. Install the camshaft cover and bolts. Tighten bolts to 89 inch. lbs. (10 Nm).
  32.  
  33. Attach the electrical harness at the rear of the camshaft cover.
  34.  
  35. Install the air inlet grille panel.
  36.  
  37. Install a new o-ring seal to the PCV fitting.
  38.  
  39. Position the PCV pipe (with fitting) and install the PCV fitting bolt to the turbocharger. Tighten to 89 inch. lbs. (10 Nm).
  40.  
  41. Install the HO2S electrical connector clip to the camshaft cover
  42.  
  43. Install the ignition coils.
  44.  
  45. Disconnect the engine wiring harness electrical connector from the evaporative emission (EVAP) canister purge solenoid valve.
  46.  
  47. Install the engine harness clips to the camshaft cover.
  48.  
  49. Install the engine wiring harness clip to the camshaft cover.
  50.  
  51. Connect the engine wiring harness intake and exhaust electrical connectors to the camshaft position actuator solenoid valves.
  52.  
  53. Install the air cleaner outlet.
  54.  
  55. Install the intake manifold cover studs and tighten to 80 inch. lbs. (9 Nm).
  56.  
  57. Install the intake manifold cover.
  58.  

2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the intake manifold cover:
    1. Remove the engine oil fill cap.
    2.  
    3. Grasp the intake manifold cover by the lower right inboard corner and pull up to disengage the cover from the stud.
    4.  
    5. Grasp the intake manifold cover by the upper left corner and pull up to disengage the cover from the stud.
    6.  
    7. Remove the intake manifold cover.
    8.  

  4.  
  5. Remove or disconnect the following:

    The air cleaner outlet resonator
     
    The ignition coils. Refer to Ignition Coil Pack removal and installation

    Click image to see an enlarged view

    Fig. Location of fuel pipe bracket & ground strap stud attached to the Camshaft Cover-2.2L Engine

     
    The fuel pipe bracket nut (1)
     
    The fuel pipe bracket (2) from the ground strap stud
     
    The ground strap stud (3) from the camshaft cover
     
    The ground strap (4) from the camshaft cover

    Click image to see an enlarged view

    Fig. Location of engine wiring harness clips on camshaft cover-2.2L Engine

     
    The engine wiring harness clips (1) and (4) from the stud (2) and camshaft cover (3)
     
    The engine wiring harness clip from the camshaft cover
     
    The camshaft cover bolts
     
    The camshaft cover

    Click image to see an enlarged view

    Fig. Removing the camshaft cover-2.2L Engine

     

  6.  

To install:

  1. Install or connect the following:

    The camshaft cover and bolts. Tighten the bolts to 89 inch lbs. (10 Nm)
     
    The engine wiring harness clip to the camshaft cover
     
    The engine wiring harness clips (1) and (4) to the stud (2) and camshaft cover (3)
     
    The ground strap to the camshaft cover
     
    The ground strap stud to the camshaft cover. Tighten the stud to 89 inch lbs. (10 Nm)
     
    The fuel pipe bracket to the ground strap stud
     
    The fuel pipe bracket nut. Tighten the nut to 89 inch lbs. (10 Nm)
     
    The ignition coils. Refer to Ignition Coil Pack removal and installation
     
    The air cleaner outlet resonator
     

  2.  
  3. Install the intake manifold cover:
    1. Place the intake manifold cover onto the engine over the studs.
    2.  
    3. Push down on the intake manifold cover directly over the lower right stud in order to engage the cover to the stud.
    4.  
    5. Push down on the intake manifold cover directly over the upper left stud in order to engage the cover to the stud.
    6.  
    7. Install the engine oil fill cap.
    8.  

  4.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the intake manifold cover:
    1. Remove the engine oil fill cap.
    2.  
    3. Grasp the intake manifold cover by the lower right inboard corner and pull up to disengage the cover from the stud.
    4.  
    5. Grasp the intake manifold cover by the upper left corner and pull up to disengage the cover from the stud.
    6.  
    7. Remove the intake manifold cover.

      Click image to see an enlarged view

      Fig. Location of the intake (3) and exhaust (2) camshaft position actuator solenoid valve electrical connectors-2.4L Engine

    8.  

  4.  
  5. Remove or disconnect the following:

    The air cleaner outlet duct
     
    The intake (3) and exhaust (2) camshaft position actuator solenoid valve electrical connectors
     
    The ignition coils. Refer to Ignition Coil Pack removal and installation

    Click image to see an enlarged view

    Fig. Location of the engine harness clips (1) and (2)-2.4L Engine

     
    The engine harness clips (1) and (2) from the cover
     
    The fuel feed line retainers (1) and (2) from the engine brackets
     
    The camshaft cover bolts
     
    The camshaft cover

    Click image to see an enlarged view

    Fig. Location of the fuel feed line retainers (1) and (2)-2.4L Engine



    Click image to see an enlarged view

    Fig. Removing the camshaft cover-2.4L Engine

     

  6.  

To install:

  1. Install or connect the following:

    The camshaft cover and bolts. Tighten the bolts to 89 inch lbs. (10 Nm)
     
    The ignition coils. Refer to Ignition Coil Pack removal and installation
     
    The engine harness clips to the cover
     
    The feed line retainers to the engine brackets
     
    The intake and exhaust camshaft position actuator solenoid valve electrical connectors
     
    The air cleaner outlet duct
     

  2.  
  3. Install the intake manifold cover:
    1. Place the intake manifold cover onto the engine over the studs.
    2.  
    3. Push down on the intake manifold cover directly over the lower right stud in order to engage the cover to the stud.
    4.  
    5. Push down on the intake manifold cover directly over the upper left stud in order to engage the cover to the stud.
    6.  
    7. Install the engine oil fill cap.
    8.  

  4.  

 
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