Neon, 2000-2005

Valve Covers

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Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. If equipped, remove the air cleaner inlet duct.

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    Fig. After disconnecting the spark plug wires, remove the cover mounting bolts

    After disconnecting the spark plug wires, remove the cover mounting bolts
  4.  
  5. Remove the ignition coil pack.

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    Fig. Remove the ignition coil mounting bracket retainers . . .

    Remove the ignition coil mounting bracket retainers . . .

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    Fig. . . . then lift the coil assembly up and off of the valve cover

    . . . then lift the coil assembly up and off of the valve cover

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    Fig. You must also remove the studs that the coil bracket mounts over. There is one in the front and one in the rear

    You must also remove the studs that the coil bracket mounts over. There is one in the front and one in the rear
  6.  
  7. Unfasten the valve cover retaining bolts, then remove the valve cover.

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    Fig. After all of the retainers are removed, you can lift the valve cover off

    After all of the retainers are removed, you can lift the valve cover off

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    Fig. While the valve cover is off, inspect the spark plug tube seals and replace if necessary

    While the valve cover is off, inspect the spark plug tube seals and replace if necessary

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    Fig. Remove and discard the gasket and replace with a new one during installation

    Remove and discard the gasket and replace with a new one during installation

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    Fig. Use rag and suitable solvent to clean the mating surfaces

    Use rag and suitable solvent to clean the mating surfaces
  8.  
  9. Remove and discard the cover gasket. Inspect the spark plug well gaskets and replace if necessary. Thoroughly clean the cover and cylinder head mating surfaces. Make sure the cylinder head cover mating surfaces is flat.
  10.  

To install:

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Fig. Rocker arm (valve) cover gasket locations and tightening sequence

Rocker arm (valve) cover gasket locations and tightening sequence


WARNING
Do not let any oil or solvents come in contact with the timing belt, as they can deteriorate the rubber and cause tooth skipping.

  1. Install new gasket(s). For DOHC engines, apply a suitable RTV sealant at the camshaft cap corners and at the top edges of the 1 / 2 round seal. Position the cover on the head and install the retainers.
  2.  
  3. For SOHC engines, tighten the retainers to 9 ft. lbs. (12 Nm).
  4.  
  5. For DOHC engines, tighten the retainers in order, as follows:
    1. Step 1: Tighten all fasteners to 40 inch lbs. (4.5 Nm).
    2.  
    3. Step 2: Tighten all fasteners to 6.5 inch lbs. (9 Nm).
    4.  
    5. Step 3: Tighten all fasteners to 9 ft. lbs. (12 Nm).
    6.  

  6.  
  7. Install the ignition coil pack. Tighten the retainers to 17 ft. lbs. (23 Nm) for SOHC engines or to 9 ft. lbs. (12 Nm) for DOHC engines.
  8.  
  9. If equipped, install the air cleaner inlet duct.
  10.  
  11. Connect the negative battery cable.
  12.  

 
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