Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Rocker Arm (Camshaft/Valve) Cover

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REMOVAL & INSTALLATION



SOHC Engine

See Figures 1, 2 and 3

  1. Disconnect the negative battery cable. Remove the air cleaner assembly and air inlet duct.
  2.  
  3. Disconnect the PCV valve, fresh air hose and any remaining vacuum hoses or electrical connectors from the valve cover.
  4.  
  5. Remove the 2 fasteners and washers from the silicone insulators located in the top of the valve cover.
  6.  
  7. Disconnect the de-aeration line from the cylinder head outlet (located at one end of the cover) and from the support bracket. Have a rag handy to wipe up the small amount of coolant which may escape from the line. The MAP sensor (1991-94 models only) and de-aeration line may remain attached to the cover.
  8.  
  9. Carefully remove the valve cover and gasket from the engine. If the cover does not come off easily, tap the sides gently with a rubber mallet to loosen the cover. Do not pry against the mating surfaces or damage may occur.
  10.  

To install:
  1. Inspect the silicone insulators located in the valve cover fastener bores and replace if cracked or deteriorated.
  2.  
  3. Inspect the valve cover gasket which is bonded to the cover flange. If it is damaged, or if replacement is necessary to assure a proper seal, remove the gasket from the cover and clean the old RTV from the flange surface using a chlorinated solvent and a wire brush. Most carburetor cleaners or brake clean solvents should be appropriate.
  4.  
  5. If the gasket is to be replaced, apply a thin 0.08 in. (2mm) bead of RTV to the cover flange. Firmly press the flat side of the gasket into the flange and install the cover while the RTV is still wet to assure a proper bond. RTV should only be placed between the cover flange and gasket, but NOT onto the cylinder head mating surface, so that the gasket will separate from the head easily and may be reused.
  6.  
  7. Apply a small 0.2 in. (5mm) bead of RTV to the cylinder head T-joints where the head meets the front cover to assure a good seal. This is the only spot where RTV will be placed between the cylinder head and the cover gasket.
  8.  
  9. Install the valve cover and gasket, then install the washers and fasteners. Tighten the fasteners to 22 ft. lbs. (30 Nm). Connect the de-aeration line to the support bracket and to the cylinder head.
  10.  
  11. Connect the PCV valve, fresh air hose and any remaining vacuum hoses or electrical connectors to the valve cover.
  12.  
  13. Install the air cleaner assembly and air inlet duct, then carefully tighten the fasteners. Connect the negative battery cable.
  14.  



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Fig. Fig. 1: Remove the air cleaner assembly along with any hoses, cables or wires that may interfere



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Fig. Fig. 2: Disconnect the de-aeration hose from the cylinder head and the support bracket, but it may remain attached to the cover



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Fig. Fig. 3: Exploded view of the SOHC valve cover assembly

DOHC Engine

See Figures 4 through 11

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the fresh air hose from the cover fitting and the PCV valve from the cover grommet.
  4.  
  5. On 1991-94 models, disconnect the vacuum hose and electrical connector from the EGR solenoid located at the end of the camshaft cover, near the EGR valve and the engine lifting bracket.
  6.  

On 1991-94 models, if it is preferred or necessary, the bolt may be removed from the EGR solenoid to disconnect the solenoid from the camshaft cover.

  1. The original spark plug wires are numbered, if the numbers are illegible or if the wires have been replaced with non-labeled parts, tag the wires for installation purposes. Disconnect the spark plug wires from the plugs.
  2.  
  3. Remove the fasteners, washers and insulators, then remove the camshaft cover and gasket from the engine. If the cover is stuck, tap the sides gently using a rubber mallet. Do not damage the aluminum cylinder head by prying the cover loose.
  4.  

To install:
  1. Inspect the silicone insulators through which the camshaft cover fasteners are installed and replace if cracked or deteriorated.
  2.  
  3. Inspect the camshaft cover gasket which is bonded to the cover flange. If it is damaged, or if replacement is necessary to assure a proper seal, remove the gasket from the cover and clean the old RTV from the flange surface using a chlorinated solvent and a wire brush. Most carburetor cleaners or brake clean solvents should be appropriate.
  4.  
  5. If the gasket is to be replaced, apply a thin 0.08 in. (2mm) bead of RTV to the cover flange. Firmly press the flat side of the gasket into the flange and install the cover while the RTV is still wet to assure a proper bond. RTV should only be placed between the cover flange and gasket, but NOT onto the cylinder head mating surface, so that the gasket will separate from the head easily and may be reused.
  6.  
  7. Apply a small 0.2 in. (5mm) bead of RTV to the cylinder head T-joints where the head meets the front cover to assure a good seal. This is the only spot where RTV will be placed between the cylinder head and the cover gasket.
  8.  
  9. Install the camshaft cover and gasket using the washers and fasteners. Tighten the fasteners uniformly and in the proper sequence to 89 inch lbs. (10 Nm).
  10.  
  11. Connect the wires to the spark plugs as labeled.
  12.  
  13. If equipped, connect the electrical plug and vacuum hose to the EGR solenoid valve.
  14.  
  15. Install the PCV valve to the grommet and the fresh air hose to the fitting.
  16.  
  17. Connect the negative battery cable.
  18.  



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Fig. Fig. 4: Loosen the camshaft cover retaining fasteners with a Torx® driver



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Fig. Fig. 5: Remove the camshaft cover fasteners, washers and insulators. Examine for cracks or deterioration and replace, if necessary



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Fig. Fig. 6: Lift the camshaft cover from the top of the engine. If the cover is stuck, tap it with a rubber mallet



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Fig. Fig. 7: Examine the camshaft cover inside and out for cracks or damage



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Fig. Fig. 8: Examine the camshaft cover gasket material for signs of deterioration, and replace if necessary



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Fig. Fig. 9: If gasket replacement is necessary, carefully remove the old gasket from the camshaft cover surfaces



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Fig. Fig. 10: Exploded view of the DOHC camshaft cover and gasket assembly



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Fig. Fig. 11: Camshaft cover torque sequence-DOHC engine

 
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