Vue 2002-2005

Valve Covers

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Removal & Installation



2.2L Engine

Before servicing any vehicle, please be sure to read the precautions section, which deals with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.


CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF , unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the Intake Air Temperature (IAT) sensor connector.
  4.  
  5. Loosen the clamp at the air cleaner assembly.
  6.  
  7. Remove the push-pin attachment from the outlet resonator/duct assembly-to-support bracket.
  8.  
  9. Loosen the clamp at the throttle body assembly.
  10.  
  11. Disconnect the PCV fresh air vent hose at the cam cover.
  12.  
  13. Remove the outlet resonator/duct assembly

    Click image to see an enlarged view

    Fig. Outlet Resonator/Duct assembly, removed

  14.  
  15. Remove the ignition module bolts.

    Click image to see an enlarged view

    Fig. Remove ignition module bolts

  16.  
  17. Remove the ignition module assembly.
  18.  
  19. Disconnect the coolant degas hose from the fuel rail.
  20.  
  21. Disconnect the degas hose clamp at the cylinder head and position it away from the cam cover assembly.

    Click image to see an enlarged view

    Fig. Disconnect the degas hose clamp at the cylinder head and position it away from the cam cover assembly

  22.  
  23. Disconnect the ground strap at the rear of the cam cover assembly.
  24.  
  25. Relieve the fuel system pressure as follows:
    1. Connect the SA9127E or equivalent to the fuel pressure connection.
    2.  
    3. Install the bleed hose (3) into an approved container and open the valve (5) to bleed the system pressure. The fuel connections are now safe for servicing.

      Click image to see an enlarged view

      Fig. Connect SA9127E Fuel Pressure Gauge

    4.  
    5. Disconnect the fuel pressure gauge from the fuel pressure connection
    6.  

  26.  
  27. Disconnect the fuel rail bracket and bolt at the rear of the cam cover.
    CAUTION
    Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around the fitting to collect fuel. Place the cloth in an approved container.


    NOTE
    An open-end wrench must be used to support the fuel line to rail connection during loosening/tightening to avoid damaging the fuel rail assembly.



    Click image to see an enlarged view

    Fig. Disconnect the fuel rail bracket and bolt at the rear of the cam cover



    Click image to see an enlarged view

    Fig. An open-ended wrench must be used to support the fuel line to rail

  28.  
  29. While supporting the fuel rail assembly with an open end wrench, loosen the transfer line fitting at the fuel rail.
  30.  
  31. Position the fuel line away from the cam cover assembly.
  32.  
  33. Remove the cam cover assembly bolts.
  34.  
  35. Remove the cam cover assembly.
  36.  

To install:

  1. Visually inspect the camshaft cover gasket for signs of leakage. The camshaft cover gasket is reusable if not damaged.
  2.  
  3. Assemble the camshaft cover and gasket. Use care to make sure the gasket is located in the retaining groove on the camshaft cover.
  4.  
  5. Install the cover on the cylinder head and hand-tighten the bolts.

    Click image to see an enlarged view

    Fig. Install the cover on the cylinder head

  6.  
  7. Tighten the camshaft cover bolts to 89 inch lbs. (10 Nm).
  8.  
  9. Reposition the fuel line assembly.
    NOTE
    An open-end wrench must be used to support the fuel line to rail connection during loosening/tightening to avoid damaging the fuel rail assembly.

  10.  
  11. Install the transfer line fitting to the fuel rail.
  12.  
  13. Tighten the transfer fitting-to-fuel rail to 89 inch lbs. (10 Nm).
  14.  
  15. Connect the fuel rail bracket and bolt to the cylinder head and tighten to 89 inch lbs. (10 Nm)
  16.  
  17. Connect the ground strap to camshaft cover assembly.
  18.  
  19. Tighten the camshaft cover ground strap bolts to 89 inch lbs. (10 Nm).
  20.  
  21. Connect the degas hose and clamp to the cylinder head.
  22.  
  23. Connect the degas hose bracket and bolt to the cylinder head.
  24.  
  25. Tighten the coolant pipe bracket bolt to 89 inch lbs. (10 Nm).
  26.  
  27. Install the ignition module assembly to cam cover and hand tighten the retaining bolts.
  28.  
  29. Tighten the ignition module-to-camshaft cover bolts to 71 inch lbs. (8 Nm).
  30.  
  31. Install the outlet resonator/duct assembly into position.
  32.  
  33. Connect the PCV fresh air vent hose assembly.
  34.  
  35. Tighten the clamp at the throttle body assembly.
  36.  
  37. Position the outlet resonator/duct assembly up with support bracket and install the push-pin.
  38.  
  39. Tighten the clamp at the air cleaner assembly.
  40.  
  41. Connect the IAT sensor connector.
  42.  
  43. Install the air cleaner outlet duct assembly.
  44.  
  45. Connect the negative battery cable.
  46.  

2.4L Engine

Before servicing any vehicle, please be sure to read the precautions section, which deals with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.

  1. Remove the air cleaner outlet duct.
  2.  
  3. Remove the battery box cover.
  4.  
  5. Disconnect the engine wiring harness electrical connectors from the intake and exhaust camshaft position actuator solenoid valves.
  6.  
  7. Remove the ignition coils.
  8.  
  9. Remove the engine harness clips from the cover.
  10.  
  11. Reposition the engine wiring harness out of the way.
  12.  
  13. Remove the fuel feed line retainers from the engine brackets.
  14.  
  15. Remove the camshaft cover bolts.
  16.  
  17. Remove the camshaft cover.
  18.  

To install:

  1. Installation is the reverse of removal, tighten the cover bolts to 89 in. lbs. (10 Nm).
  2.  

3.0L Engine

Before servicing any vehicle, please be sure to read the precautions section, which deals with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.

  1. Remove the camshaft cover bolts.
  2.  
  3. Remove the camshaft cover.
    NOTE
    Ensure that all 8 sealing O-rings are accounted for. O-rings may stick to camshaft bearing caps. O-rings may fall into the oil return journals in the cylinder head.

  4.  
  5. Remove the camshaft cover seals.
  6.  

To install:

  1. Lightly coat the new seals, including the O-rings, with engine oil prior to the installation to assist in holding the O-ring seals to the valve cover.
  2.  
  3. Install the valve cover seals.
  4.  
  5. Apply a thin coat of silicone sealer LOCTITE®5900 or equivalent at the front and at the back of the seals.
  6.  
  7. Install the valve cover to the cylinder head.
  8.  
  9. Install the valve cover bolts.
  10.  
  11. Tighten the camshaft cover bolts to 71 inch lbs. (8 Nm).
  12.  

3.5L Engine
Left Side

Before servicing any vehicle, please be sure to read the precautions section, which deals with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.

  1. Remove the oil level indicator.
  2.  
  3. Remove the oil fill cap.
  4.  
  5. Remove the Positive Crankcase Ventilation (PCV) valve and bolt.

    Click image to see an enlarged view

    Fig. Remove the PCV valve bolt

  6.  
  7. Disconnect the ignition wiring harness from the ignition coils and retaining bracket.
  8.  
  9. Remove the wiring harness bracket bolt from the cylinder head.
  10.  
  11. Remove the bolts (708), and ignition coils (707).

    Click image to see an enlarged view

    Fig. Remove the bolts (708), and ignition coils (707).

  12.  
  13. Remove the bolts (543), grommets (544), valve cover (542) and gasket (541).
  14.  
  15. Remove the seals (540), if required.

    Click image to see an enlarged view

    Fig. Remove the bolts (543), grommets (544), valve cover (542) and gasket (541).

  16.  

To install:

  1. Install NEW seals (540), NEW gasket (541), cover (542), NEW grommets (544) and bolts (543).
  2.  
  3. Tighten the bolts in sequence, as follows:
    1. Tighten the bolts a first pass to 53 inch lbs. (6 Nm).
    2.  
    3. Tighten the bolts a final pass to 106 inch lbs. (12 Nm).

      Click image to see an enlarged view

      Fig. Tighten the bolts in sequence.

    4.  

  4.  
  5. Install the ignition coils (707) and bolts (708). Tighten the bolts to 106 inch lbs. (12 Nm)

    Click image to see an enlarged view

    Fig. Install the bolts (708), and ignition coils (707).

  6.  
  7. Install the wiring harness bracket bolt to the cylinder head. Tighten the bolt to 89 inch lbs. (10 Nm).
  8.  
  9. Connect the ignition wiring harness to the retaining bracket and ignition coils.
  10.  
  11. Install the wiring harness bracket bolt to the cylinder head.
  12.  
  13. Tighten the bolt to 89 inch lbs. (10 Nm).
  14.  
  15. Connect the ignition wiring harness to the retaining bracket and ignition coils.
  16.  
  17. Install the oil level indicator (429) and NEW O-rings (441).

    Click image to see an enlarged view

    Fig. Install the oil level indicator (429) and NEW O-rings (441).

  18.  
  19. Install the NEW O-rings (549 and 550), positive crankcase ventilation (PCV) valve (551) and bolt (552). Tighten the bolt to 106 inch lbs. (12 Nm)
  20.  
  21. Install the NEW O-ring (546) and cap (545).
  22.  

Before servicing any vehicle, please be sure to read the precautions section, which deals with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.

  1. Remove the oil level indicator.
  2.  
  3. Remove the oil fill cap.
  4.  
  5. Remove the Positive Crankcase Ventilation (PCV) valve and bolt.

    Click image to see an enlarged view

    Fig. Remove the PCV valve bolt

  6.  
  7. Disconnect the ignition wiring harness from the ignition coils and retaining bracket.
  8.  
  9. Remove the wiring harness bracket bolt from the cylinder head.
  10.  
  11. Remove the bolts (708), and ignition coils (707).

    Click image to see an enlarged view

    Fig. Remove the bolts (708), and ignition coils (707)

  12.  
  13. Remove the bolts (543), grommets (544), valve cover (542) and gasket (541).
  14.  
  15. Remove the seals (540), if required.

    Click image to see an enlarged view

    Fig. Remove the bolts (543), grommets (544), valve cover (542) and gasket (541)

  16.  

To install:

  1. Install NEW seals (540), NEW gasket (541), cover (542), NEW grommets (544) and bolts (543).
  2.  
  3. Tighten the bolts in sequence, as follows:
    1. Tighten the bolts a first pass to 53 inch lbs. (6 Nm).
    2.  
    3. Tighten the bolts a final pass to 106 inch lbs. (12 Nm).

      Click image to see an enlarged view

      Fig. Tighten the bolts in sequence

    4.  

  4.  
  5. Install the ignition coils (707) and bolts (708). Tighten the bolts to 106 inch lbs. (12 Nm)

    Click image to see an enlarged view

    Fig. Install the bolts (708), and ignition coils (707)

  6.  
  7. Install the wiring harness bracket bolt to the cylinder head. Tighten the bolt to 89 inch lbs. (10 Nm).
  8.  
  9. Connect the ignition wiring harness to the retaining bracket and ignition coils.
  10.  
  11. Install the wiring harness bracket bolt to the cylinder head.
  12.  
  13. Tighten the bolt to 89 inch lbs. (10 Nm).
  14.  
  15. Connect the ignition wiring harness to the retaining bracket and ignition coils.
  16.  
  17. Install the oil level indicator (429) and NEW O-rings (441).

    Click image to see an enlarged view

    Fig. Install the oil level indicator (429) and NEW O-rings (441)

  18.  
  19. Install the NEW O-rings (549 and 550), positive crankcase ventilation (PCV) valve (551) and bolt (552). Tighten the bolt to 106 inch lbs. (12 Nm).
  20.  
  21. Install the NEW O-ring (546) and cap (545).
  22.  

Right Side

Before servicing any vehicle, please be sure to read the precautions section, which deals with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.

  1. Disconnect the vacuum brake booster hose.
  2.  
  3. Disconnect the Manifold Absolute Pressure (MAP) sensor connector.
  4.  
  5. Disconnect the Intake Air Temperature (IAT) sensor connector.
  6.  
  7. Disconnect the Engine Coolant Temperature (ECT) sensor connector.
  8.  
  9. Disconnect the Evaporative (EVAP) purge hose from the purge valve.
  10.  
  11. Remove the intake manifold, as follows:
    1. Remove the bolts (727), EVAP valve with hoses (718) and clamps (719).
    2.  
    3. Remove the Positive Crankcase Ventilation (PCV) hose (548) and clamps (549).
    4.  
    5. Remove the IAT sensor (715) and O-ring (714).
    6.  
    7. Remove the bolts (513) and nuts (514).
    8.  
    9. Remove the cover (512) and gasket (511).
    10.  
    11. Remove the studs (515), if required.

      Click image to see an enlarged view

      Fig. Intake manifold, removed

    12.  
    13. Remove the bolts (508) and nuts (507).
    14.  
    15. Remove the manifold (500), gaskets (520) and spacer (521).

      Click image to see an enlarged view

      Fig. Remove the manifold (500), gaskets (520) and spacer (521)

    16.  
    17. Remove the nuts (503) and bolts (504), if required.
    18.  
    19. Remove the covers (502 and 505), gaskets (501 and 506) and studs (553), if required.
    20.  
    21. Remove the bolts (510) and exhaust gas recirculation (EGR) tube (509), if required.
    22.  
    23. Remove the cap (554).
    24.  
    25. Remove the bolts (729) and dampener (728), if required.

      Click image to see an enlarged view

      Fig. Intake manifold

    26.  

  12.  
  13. Disconnect the fuel injector connectors.
  14.  
  15. Remove the wiring harness bracket bolt from the valve rocker arm cover.
  16.  
  17. Remove the ignition coils.
  18.  
  19. Remove the bolts (543), grommets (544), valve cover (542) and gasket (541).
  20.  
  21. Remove the seals (540), if required.

    Click image to see an enlarged view

    Fig. Intake manifold

  22.  

To install:

  1. Install NEW seals (540), NEW gasket (541), cover (542), NEW grommets (544) and bolts (543).

    Click image to see an enlarged view

    Fig. Tighten the bolts in sequence

  2.  
  3. Tighten the bolts to 106 inch lbs (12 Nm).
  4.  
  5. Install the ignition coils  and bolts. Tighten the bolts to 106 inch lbs (12 Nm).
  6.  
  7. Install the wiring harness bracket bolt to the valve rocker arm cover. Tighten the bolt to 89 inch lbs. (10 Nm).
  8.  
  9. Connect the fuel injector connectors.
  10.  
  11. Install the intake manifold..
  12.  
  13. Connect the EVAP purge hose .
  14.  
  15. Connect the IAT sensor connector.
  16.  
  17. Connect the MAP sensor connector.
  18.  
  19. Connect the vacuum brake booster hose.
  20.  
  21. Connect the ECT sensor connector.
  22.  

Before servicing any vehicle, please be sure to read the precautions section, which deals with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.

  1. Disconnect the vacuum brake booster hose.
  2.  
  3. Disconnect the Manifold Absolute Pressure (MAP) sensor connector.
  4.  
  5. Disconnect the Intake Air Temperature (IAT) sensor connector.
  6.  
  7. Disconnect the Engine Coolant Temperature (ECT) sensor connector.
  8.  
  9. Disconnect the Evaporative (EVAP) purge hose from the purge valve.
  10.  
  11. Remove the intake manifold, as follows:
    1. Remove the bolts (727), EVAP valve with hoses (718) and clamps (719).
    2.  
    3. Remove the Positive Crankcase Ventilation (PCV) hose (548) and clamps (549).
    4.  
    5. Remove the IAT sensor (715) and O-ring (714).
    6.  
    7. Remove the bolts (513) and nuts (514).
    8.  
    9. Remove the cover (512) and gasket (511).
    10.  
    11. Remove the studs (515), if required.

      Click image to see an enlarged view

      Fig. Intake manifold, removed

    12.  
    13. Remove the bolts (508) and nuts (507).
    14.  
    15. Remove the manifold (500), gaskets (520) and spacer (521).

      Click image to see an enlarged view

      Fig. Remove the manifold (500), gaskets (520) and spacer (521)

    16.  
    17. Remove the nuts (503) and bolts (504), if required.
    18.  
    19. Remove the covers (502 and 505), gaskets (501 and 506) and studs (553), if required.
    20.  
    21. Remove the bolts (510) and exhaust gas recirculation (EGR) tube (509), if required.
    22.  
    23. Remove the cap (554).
    24.  
    25. Remove the bolts (729) and dampener (728), if required.

      Click image to see an enlarged view

      Fig. Removal of the intake manifold

    26.  

  12.  
  13. Disconnect the fuel injector connectors.
  14.  
  15. Remove the wiring harness bracket bolt from the valve rocker arm cover.
  16.  
  17. Remove the ignition coils.
  18.  
  19. Remove the bolts (543), grommets (544), valve cover (542) and gasket (541).
  20.  
  21. Remove the seals (540), if required.

    Click image to see an enlarged view

    Fig. Removal of the intake manifold

  22.  

To install:

  1. Install NEW seals (540), NEW gasket (541), cover (542), NEW grommets (544) and bolts (543).

    Click image to see an enlarged view

    Fig. Tighten the bolts in sequence

  2.  
  3. Tighten the bolts to 106 inch lbs (12 Nm).
  4.  
  5. Install the ignition coils  and bolts. Tighten the bolts to 106 inch lbs (12 Nm).
  6.  
  7. Install the wiring harness bracket bolt to the valve rocker arm cover. Tighten the bolt to 89 inch lbs. (10 Nm).
  8.  
  9. Connect the fuel injector connectors.
  10.  
  11. Install the intake manifold..
  12.  
  13. Connect the EVAP purge hose .
  14.  
  15. Connect the IAT sensor connector.
  16.  
  17. Connect the MAP sensor connector.
  18.  
  19. Connect the vacuum brake booster hose.
  20.  
  21. Connect the ECT sensor connector.
  22.  

 
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