Valve Cover: Service and Repair

Valve Cover and Gasket

Supercharged 3.8L:

Removal

1. Disconnect ignition wires from spark plugs.

2. Remove ignition wire separators from valve cover retaining stud bolts.

3. If LH valve cover is being removed, proceed with the following steps:

a. Remove oil filler cap.

b. Remove charge air cooler (CAC) tubes.

c. Remove crankcase ventilation tube.

d. Remove engine oil cooler inlet tube and hose.

4. If RH valve cover is being removed, proceed with the following steps:

a. Partially drain cooling system.

b. Remove positive crankcase ventilation valve (PCV valve).

c. Remove air cleaner outlet tube.

d. Remove oil filler pipe.

e. Remove heater hose and position aside.

f. Disconnect fuel lines.

g. Remove throttle body.

5. Remove valve cover retaining bolts and stud bolts, valve cover and valve cover gasket.


Installation

1. Position a new valve cover gasket into groove on valve cover.

NOTE: Lightly oil bolt and stud threads before installation. Using solvent, clean cylinder head and valve cover sealing surfaces to remove all gasket material and dirt.


2. Position valve cover on the cylinder head and install retaining bolts. Note location of ignition wire routing clip stud bolts. Tighten retaining bolts to 9-12 N-m (7-9 lb-ft).

3. If LH valve cover is being installed, proceed with the following steps:

a. Install oil filler cap.

b. Install charge air cooler (CAC) tubes.

c. Install crankcase ventilation tube.

d. Install engine oil cooler inlet tube and hose.

4. If RH valve cover is being installed, perform the following:

a. Install positive crankcase ventilation valve.

b. Install throttle body.

c. Reconnect fuel lines.

d. Reconnect heater hose.

e. Install oil filler pipe.

f. Install air cleaner outlet tube.

g. Install ignition wire separators.

h. Connect ignition wires to spark plugs.

i. Refill cooling system.

j. Start engine and check for oil and coolant leaks.