Malibu, Malibu MAXX 2006-2008

Valve Covers

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Removal & Installation



2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the air cleaner outlet resonator.
  4.  
  5. Reposition the Positive Crankcase Ventilation (PCV) hose clamp at the valve cover.
  6.  
  7. Remove the PCV hose from the valve cover.
  8.  
  9. Disconnect the engine compartment fuel feed line quick connect fitting from the fuel rail.
  10.  
  11. Remove the engine compartment fuel line clips from the fuel line bracket.
  12.  
  13. Reposition the engine compartment fuel feed line out of the way.
  14.  
  15. Remove the fuel line bracket bolt and bracket.
  16.  
  17. Remove the ignition coils.
  18.  
  19. Remove the engine wiring harness clips from the valve cover.
  20.  
  21. Remove the valve cover bolts.
  22.  
  23. Remove the valve cover.
  24.  
  25. Clean valve cover and cylinder head surface.

    Click image to see an enlarged view

    Fig. 2.2L Engine valve cover removal and installation

  26.  

To install:

  1. Install new gasket.
  2.  
  3. Install the valve cover.
  4.  
  5. Install the valve cover bolts and tighten to 89 inch. lbs. (10 Nm).
  6.  
  7. Install the engine wiring harness clips to the valve cover.
  8.  
  9. Install the ignition coils and tighten the mounting bolts to 89 inch. lbs. (10 Nm).
  10.  
  11. Reconnect the engine wiring harness electrical connectors to the ignition coils.
  12.  

3.5L Engine
Left (Front)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Partially drain the cooling system.

    Click image to see an enlarged view

    Fig. Remove the front ignition wire harness at the upper intake manifold and at the spark plugs

  4.  
  5. Remove the front ignition wire harness at the upper intake manifold and at the spark plugs.
  6.  
  7. Remove the thermostat bypass pipe.
  8.  
  9. Disconnect the Positive Crankcase Ventilation (PCV) vacuum hose.
    NOTE
    The valve rocker arm cover gasket and sealant must be carefully trimmed away from the lower intake manifold gasket. Failure to do so will damage the lower intake manifold gasket, causing a severe oil leak.

  10.  
  11. Remove the valve rocker arm cover bolts.
    NOTE
    When removing the valve rocker arm cover, ensure the gasket stays in place attached to the cylinder head.

  12.  
  13. Remove the valve rocker arm cover. Bump the end of the valve rocker cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
  14.  
  15. Trim the valve cover and sealant away from the lower intake manifold gasket at the cylinder head to the lower intake manifold joints (1).
  16.  
  17. Remove the valve cover gasket.
  18.  
  19. Clean the sealing surface on the cylinder head with degreaser.
  20.  
  21. Clean the valve rocker arm cover.

    Click image to see an enlarged view

    Fig. The removal and installation of the rocker arm cover

  22.  

To install:


NOTE
Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent, at the cylinder head to the lower intake manifold joint.

  1. Apply sealant at the cylinder head to the lower intake manifold joints.
  2.  
  3. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
  4.  
  5. Install the valve rocker cover.
    NOTE
    Use an alternating crisscross pattern when tightening the valve rocker cover bolts.

  6.  
  7. Failure to do so may result in oil leakage from the valve cover due to improper seating of the gasket.
  8.  
  9. Install the valve rocker arm cover bolts, and tighten the bolts to 89 lb inches (10 Nm).
  10.  
  11. Connect the PCV valve vacuum line.
  12.  
  13. Install the thermostat bypass pipe.
  14.  
  15. Install the front ignition wire harness.
  16.  
  17. Refill the cooling system.
  18.  

Right (Rear)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the drive belt.
  6.  
  7. Remove the generator.
  8.  
  9. Remove the generator bracket.
  10.  
  11. Remove the right spark plug wires.
  12.  
  13. Disconnect the vacuum hoses from the evaporative emission (EVAP) purge valve.
  14.  
  15. Remove the EVAP purge valve.
  16.  
  17. Remove the ignition coil bracket with the coils.
  18.  
  19. Remove the ignition coil bracket studs.
  20.  
  21. Remove the vacuum hose from the grommet in the right valve rocker arm cover.
    NOTE
    Valve rocker arm cover gasket and sealant must be carefully trimmed away from the lower intake manifold gasket. Failure to do so will damage the lower intake manifold gasket, causing a severe oil leak.

  22.  
  23. Remove the right valve rocker arm cover bolts.
    NOTE
    When removing the valve rocker arm cover, ensure the gasket stays in place attached to the cylinder head.

  24.  
  25. Remove the valve rocker arm cover. Bump the end of the valve rocker cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
  26.  
  27. Trim the valve gasket and sealant away from the lower intake manifold gasket at the cylinder head to lower intake manifold joints.
  28.  
  29. Remove the valve cover gasket.
  30.  
  31. Clean the sealing surface on the cylinder head with degreaser.
  32.  
  33. Clean the valve rocker arm cover.

    Click image to see an enlarged view

    Fig. Remove the valve rocker cover bolts and cover

  34.  

To install:


NOTE
Apply sealant at the cylinder head to lower intake manifold joint.

  1. Apply sealant at the cylinder head to lower intake manifold joints.
  2.  
  3. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
  4.  
  5. Install the right valve rocker arm cover.
    NOTE
    Use an alternating crisscross pattern when tightening the valve rocker cover bolts.

  6.  
  7. Failure to do so may result in oil leakage from the valve cover due to improper seating of the gasket.
  8.  
  9. Install the valve rocker arm cover bolts, and tighten the bolts to 89 lb inches (10 Nm).
  10.  
  11. Install the vacuum hose to the grommet in the right valve rocker arm cover.
  12.  
  13. Install the ignition coil bracket studs.
  14.  
  15. Install the ignition coil bracket with coils.
  16.  
  17. Install the EVAP purge valve.
  18.  
  19. Connect the vacuum hoses to the EVAP purge valve.
  20.  
  21. Install the right spark plug wires.
  22.  
  23. Install the generator bracket.
  24.  
  25. Install the generator.
  26.  
  27. Install the drive belt.
  28.  
  29. Connect the negative battery cable.
  30.  

3.9L Engine
Left (Front)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Partially drain the cooling system.
  4.  
  5. Remove the intake manifold cover.
  6.  
  7. Remove the air cleaner outlet duct.
  8.  
  9. Disconnect the left spark plug wires from the spark plugs.
  10.  
  11. Remove the spark plug wire harness clip from the heater inlet and outlet front pipe bracket.
  12.  
  13. Remove the heater inlet and outer front pipe.
  14.  
  15. Disconnect the positive crankcase ventilation (PCV) foul air tube from the PCV valve.
  16.  
  17. Remove the valve rocker arm cover bolts.
    NOTE
    When removing the valve rocker arm cover, ensure the gasket stays in place attached to the cylinder head.

  18.  
  19. Remove the valve rocker arm cover. Bump the end of the valve rocker cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
  20.  
  21. Trim the valve cover and sealant away from the lower intake manifold gasket at the cylinder head to the lower intake manifold joints.
  22.  
  23. Remove the valve cover gasket.
  24.  
  25. Clean the sealing surface on the cylinder head with degreaser.
  26.  
  27. Clean the valve rocker arm cover.
  28.  

To install:

  1. Apply sealant at the cylinder head to the lower intake manifold joints.
  2.  
  3. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
  4.  
  5. Install the valve rocker cover.
  6.  
  7. Install the valve rocker arm cover bolts and tighten in a criss-cross pattern to 89 inch lbs. (10 Nm).
  8.  
  9. Connect the PCV foul air tube to the PCV valve.
  10.  
  11. Install the heater inlet and outer front pipe.
  12.  
  13. Install the spark plug wire harness clip to the heater inlet and outlet front pipe bracket.
  14.  
  15. Connect the left spark plug wires to the spark plugs.
  16.  
  17. Install the air cleaner outlet duct.
  18.  
  19. Install the intake manifold cover.
  20.  
  21. Fill the cooling system, as necessary.
  22.  

Right (Rear)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the alternator.
  4.  
  5. Disconnect the positive crankcase ventilation (PCV) fresh air tube from the air cleaner outlet duct.
  6.  
  7. Remove the PCV fresh air tube from the right side valve rocker arm cover.
  8.  
  9. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
  10.  
  11. Disconnect the ignition coil electrical connector.
  12.  
  13. Remove the heated oxygen sensor (HO2S) electrical connector clip from the ignition coil.
  14.  
  15. Remove the spark plug wires from the ignition coil.
  16.  
  17. Remove the ignition coil bracket bolts and nuts.
  18.  
  19. Remove the ignition coil with bracket from the engine.
  20.  
  21. Remove the valve rocker arm cover bolts.
    NOTE
    When removing the valve rocker arm cover, ensure the gasket stays in place attached to the cylinder head.

  22.  
  23. Remove the valve rocker arm cover. Bump the end of the cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
  24.  
  25. Cut the room temperature vulcanizing (RTV) sealer in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
  26.  
  27. Remove the valve cover gasket.
  28.  
  29. Clean the sealing surface on the cylinder head with degreaser.
  30.  

To install:

  1. Apply sealant at the cylinder head to the lower intake manifold joints.
  2.  
  3. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
  4.  
  5. Install the valve rocker cover.
  6.  
  7. Install the valve rocker arm cover bolts and tighten in a criss-cross pattern to 89 inch lbs. (10 Nm).
  8.  
  9. Install the ignition coil with bracket to the engine.
  10.  
  11. Install the ignition coil bracket bolts and nuts and tighten to 18 ft. lbs. (25 Nm).
  12.  
  13. Install the spark plug wires to the ignition coil.
  14.  
  15. Install the HO2S electrical connector clip to the ignition coil bracket.
  16.  
  17. Connect the ignition coil electrical connector.
  18.  
  19. Connect the MAP sensor electrical connector.
  20.  
  21. Install the PCV fresh air tube to the right side valve rocker arm cover.
  22.  
  23. Connect the PCV fresh air tube to the air cleaner outlet duct.
  24.  
  25. Install the alternator.
  26.  

 
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