Valve Cover: Service and Repair

Valve Cover

Special Tool(s)






Material(s)






Removal

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to Jacking and Lifting

2. Release the fuel pressure. REFER to Fuel System Pressure Release .

3. Disconnect the battery ground cable. REFER to Battery Disconnect .

4. Disconnect the EVAP (Evaporative Emission) canister purge valve electrical connector and vapor tube. REFER to Quick Connect Coupling .





5. Loosen the 4 retainers and remove the underbody shield.





6. Remove the ACL (Air Cleaner) outlet pipe, the turbocharger inlet pipe and the CAC (Charge Air Cooler) inlet/intermediate inlet tube assembly. REFER to Intake Air System Components - Exploded View .

7. Remove the coil-on-plug assemblies. REFER to Ignition Coil-On-Plug .

8. Disconnect the fuel supply tube from the fuel jumper tube and the fuel jumper tube from the fuel injection pump. REFER to Quick Connect Coupling .

- Detach the 2 fuel tube retainers from the intake manifold.
- Remove the bolt and the fuel jumper tube.






9. Remove the oil level indicator.

- Remove the nut, the bolt and the CAC (Charge Air Cooler) intermediate tube mounting bracket.






10. Disconnect the FRP (Fuel Rail Pressure) sensor and the MAP (Manifold Absolute Pressure) sensor electrical connectors.





11. Disconnect the 5 engine wiring harness electrical connectors.

- Detach the 6 wiring harness retainers.






12. Disconnect the 2 vacuum hoses from the vacuum reservoir.

- Disconnect the vacuum tube quick connect coupling. REFER to Quick Connect Coupling .
- Detach the 3 vacuum hose retainers.






13. Loosen the 14 valve cover retainers and remove the valve cover.

- Discard the valve cover gasket.






14. NOTE: The VCT (Variable Camshaft Timing) solenoid seals should only be replaced if they are damaged.
Remove any damaged VCT (Variable Camshaft Timing) solenoid seals using the 205-153 (T80T-4000-W) and 303-1247/1.





Installation

1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean and inspect the sealing surfaces.

2. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.
Using the 205-153 (T80T-4000-W) and 303-1247/2 , install new VCT (Variable Camshaft Timing) solenoid seals.





3. NOTE: The valve cover must be secured within 10 minutes of sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep.

Apply a 5.5 mm (0.216 in) drop of Silicone Gasket and Sealant to the 6 locations shown.





4. Using a new gasket install the valve cover.
- Tighten in the sequence shown to 10 Nm (89 lb-in).





5. Connect the 2 vacuum hoses to the vacuum reservoir.

- Connect the vacuum tube quick connect coupling. REFER to Quick Connect Coupling .
- Attach the 3 vacuum hose retainers.






6. Connect the 5 engine wiring harness electrical connectors.

- Attach the 6 wiring harness retainers.






7. Connect the FRP (Fuel Rail Pressure) sensor and the MAP (Manifold Absolute Pressure) sensor electrical connectors.





8. Install the CAC (Charge Air Cooler) intermediate tube mounting bracket, the nut and the bolt.
- Tighten to 8 Nm (71 lb-in).

- Install the oil level indicator.






9. Connect the fuel supply tube from the fuel jumper tube and the fuel jumper tube from the fuel injection pump. REFER to Quick Connect Coupling .

- Attach the 2 fuel tube retainers to the intake manifold.
- Install the fuel jumper tube bolt.
- Tighten to 8 Nm (71 lb-in).





10. Install the coil-on-plug assemblies. REFER to Ignition Coil-On-Plug .

11. Install the ACL (Air Cleaner) outlet pipe, the turbocharger inlet pipe and the CAC (Charge Air Cooler) inlet/intermediate inlet tube assembly. REFER to Intake Air System Components - Exploded View .

12. Install the underbody shield and the 4 retainers.





13. Connect the EVAP (Evaporative Emission) canister purge valve electrical connector and vapor tube. REFER to Quick Connect Coupling .





14. Connect the battery ground cable. REFER to Battery Disconnect .