Rocker Arm (Valve) Cover

Fig. 1: If necessary, remove the throttle cable from the cable routing clips

Fig. 2: Remove the breather hose from the valve cover

Fig. 3: Remove the PCV valve and hose from the valve cover

Fig. 4: Twist each spark plug wire to remove it from the spark plug . . .

Fig. 5: . . . then position the wires out of the way

Fig. 6: The upper timing cover is retained by three bolts. Unfasten the bolts . . .

Fig. 7: . . . then carefully remove the cover from the engine

Fig. 8: Remove the valve cover retaining bolts . . .

Fig. 9: . . . then lift the valve cover off of the cylinder head

Fig. 10: Remove the valve cover gasket, thoroughly clean the valve cover and cylinder head, and replace the gasket

Disconnect the negative battery cable.
If necessary, remove the air intake hose.
If necessary, remove the throttle cable from the cable routing clips.
If equipped, remove the breather hose from the valve cover.
Remove the crankcase ventilation tube from the valve cover.
On the 1.6L and 2.0L (DOHC) engines, remove the ignition wire cover.
Label and remove the ignition wires and separators.
Remove the upper timing belt cover.
Remove the valve cover retaining bolts, starting from the outside and working in.
Remove the valve cover and gasket from the cylinder head.
To install:
Clean the valve cover gasket sealing surfaces.
Install new valve cover gaskets and if equipped, O-rings onto the valve covers.
Place the valve cover into position and beginning in the center of the valve cover and working outward, tighten the retaining bolts as follows:
- 1.5L engine: 12–18 inch lbs. (1–2 Nm)
- 1.6L, 1.8L, 2.0L DOHC, and 2.4L engines: 24–36 inch lbs. (2–3 Nm)
- 2.0L SOHC engine: 48–60 inch lbs. (4–5 Nm)
Install the crankcase ventilation tube.
Install the ignition wire separators and the ignition wires.
On the 1.6L and 2.0L (DOHC) engines, install the ignition wire cover.
Install the air intake hose.
Connect the negative battery cable.
Run the engine and check for leaks and proper operation.

Fig. 11: Rocker cover bolt torque sequence — 3.0L DOHC engine

Disconnect the negative battery cable.
Remove the upper intake manifold as described in this section.
On the 3.0L DOHC engine, remove the ignition wire cover.
Remove the ignition wires and spark plugs.
Remove the crankcase ventilation tubes from both valve covers.
Remove the retaining nuts and engine wiring from both valve covers and move aside.
Remove the valve cover retaining bolts and studs.
Remove both valve covers from the engine.
To install:
Clean the valve cover gasket sealing surfaces.
Install new valve cover gaskets onto the valve covers.
Place the valve covers into position.
Reinstall the valve cover retaining bolts and studs and tighten in sequence to:
- 3.0L SOHC engine: 7 ft. lbs. (9 Nm)
- 3.0L DOHC engine: 42–54 inch lbs. (4–5 Nm)
- 3.5L engine: 30 inch lbs. (3 Nm)
Install the engine wiring and tighten the retaining nuts.
Install the crankcase ventilation tubes into both valve covers.
Install the ignition wire separators, the ignition wires, and the spark plugs.
On the 3.0L DOHC engine, install the ignition wire cover.
Install the upper intake manifold as described in this section.
Connect the negative battery cable.
Run the engine and check for leaks and proper operation.