Service Procedure

Service Procedure

Important
The service procedure contained in this recall is different from the service procedure found in the appropriate service manual. As a result, the labor time allowance has been revised to correspond with this new service procedure. In the near future the service manual and labor time guide will be updated with this new information.

1997 - 2003 3.8L L67 Left Valve Cover Gasket Replacement Along with Removal and Installation of Retainer for 1-3-5 Spark Plug Wires





Important
Clean the area around the tube/oil fill cap before removing the tube/oil fill cap in order to prevent contaminants from falling into the valve cover opening.

1. Remove the fuel injector sight shield (1).

1. Twist counterclockwise to unlock the tube/oil fill cap from the valve cover.
2. Remove the upper intake manifold cover nut holding the fuel injector sight shield to the fuel injector rail brace stud.
3. Lift the fuel injector sight shield up at the front and slide the tab out of the engine bracket.
4. Re-install the tube/oil fill cap in the valve cover to prevent engine oil contamination.





2. Remove the left engine mount strut (2).

1. Remove the bolt and the nut from the left engine mount strut at the left engine mount strut bracket on the engine (1).
2. Remove the bolt and the nut from the left engine mount strut at the left engine mount strut bracket on the upper radiator support (1).
3. Remove the engine mount strut (2).





3. Remove the 1-3-5 spark plug plastic retaining channel (cover) clip/bracket from the engine and discard (1).





4. If present, remove any plastic (polypropylene) conduit (1) from the spark plug wires at the front of the engine (should only be found on spark plug wires 1 and 5).

Important
It is not necessary to remove the spark plug wires from the spark plugs.

5. Remove all six spark plug wires from the ignition coils only. Set the spark plug wires aside.





6. Remove the supercharger drive belt (1).
Lift or rotate the supercharger drive belt tensioner using a 15 mm box end wrench on the pulley nut and remove the belt.





7. Remove the supercharger drive belt tensioner (1) and idler pulley (2).

1. Remove the supercharger drive belt tensioner nut and remove belt tensioner (1) from the engine.
2. Remove the idler pulley bolt (2).
3. Remove the drive belt idler pulley (2) from the engine.





Important
It is not necessary to remove the ignition coils/module or the 14-way connector (1) from the left engine mount strut bracket.

8. Remove the left engine mount strut bracket as assembly (1).

1. Remove the left engine mount strut bracket assembly nuts.
2. Remove the stud holding the electronic ignition control module ground and left engine mount strut bracket assembly to the cylinder head.
3. Remove the left engine mount strut bracket assembly (1) from the cylinder head and set aside.

Danger
Do not use a brake cleaner, or equivalent to remove the oil residue from the exhaust manifold; doing so may cause an engine fire.

Notice
Before the removal of the left or front engine valve cover, use an engine degreaser or equivalent in order to remove the oil residue from the exhaust manifold and the oil and dirt residue from the cylinder head and engine block. It may be necessary to use a brush or scraper.





9. Remove the left or front engine valve cover (1).

1. Remove the valve cover bolts.

Important
If the valve rocker arm cover (1) adheres to the cylinder head, remove the valve cover by bumping the end of the valve cover with palm of hand or with a soft rubber mallet.

2. Remove the valve cover from the engine cylinder head.
3. Remove the valve cover gasket.
4. Clean the sealing surface on the cylinder head and the valve cover with a engine degreaser or equivalent.
5. Clean the valve cover bolts of all dirt, grime or thread locking adhesive.





10. Install a new left or front valve cover gasket (1) , P/N 24503937, and make sure that valve cover gasket is seated properly in the valve cover groove.

1. Install the valve cover and gasket (1) to the cylinder head.
2. Install the six valve cover bolts and six new grommets.

- Replace with new grommets, P/N 25534749 (package - qty.5).
- Two packages will be needed. Save the other four grommets for future repairs.

3. Apply medium strength thread lock compound (blue), GM P/N 12345382 (in Canada use P/N 10953489) or equivalent, to the six valve cover bolt threads.

Tighten
Tighten the valve cover bolts to 10 Nm (89 lb in).





11. Install the left engine mount strut bracket assembly to the cylinder head (1).

1. Install the left engine mount strut bracket nuts and stud.
2. Install the stud holding the electronic ignition control module ground and left engine mount strut bracket assembly to the cylinder head.

Tighten
Tighten the left engine mount strut bracket nuts and stud to 50 Nm (37 lb ft).

12. Install all six spark plug wires to the ignition coils.
7mm Four-Wire Retainer P/N 88891792





13. Install a 7 mm four-wire retainer, P/N 88891792 (1) (Qty 5/pack) to spark plug wire number 4, then to spark plug wires 1, 3 and 5. If not available, use 8 mm spark plug four-wire retainer (1), P/N 14066248 (Qty 10/pack), or equivalent 7mm aftermarket spark plug wire retainer. Save the other 7 mm or 8 mm spark plug four-wire retainers for future repairs.

7mm Two-Wire Retainer P/N 12132229





1. Install a 7 mm two-wire retainer, P/N 12132229 (Qty 10/pack) to spark plug wires 3 and 5 only (1). Save the other 7mm spark plug two-wire retainers for future repairs.





2. Install the 7 mm four-wire retainer, P/N 88891792 to spark plug wire number 4 (1) then to spark plug wires 1, 3 and 5 (2). Make sure that spark plug wires 2, 4 and 6 are secured to the original retainers and under the left engine mount strut bracket.





Important
Ensure that spark plug wires 3 and 5 are routed behind the oil level indicator and lift bracket. Ensure that the two-wire retainer (3), P/N 12132229, is positioned above the 3 spark plug wire boot. Do NOT position the retainer (3) above an exhaust runner.

3. Install the 7 mm two-wire spark plug retainer, P/N 12132229 (Qty 10) to spark plug wires 3 and 5 only (3). Make sure the spark plug retainer (3) is approximately 50 mm (2 in) from the oil level indicator.





14. First install the supercharger drive belt idler pulley and bolt (2). Then install the supercharger drive belt tensioner and nut (1).

Tighten
Tighten both the supercharger drive belt idler pulley bolt and supercharger drive belt tensioner nut to 50 Nm (37 lb ft).





Install the supercharger drive belt (1).
Lift or rotate the drive belt tensioner using a 15 mm box end wrench on the pulley nut and install the supercharger drive belt.





15. Install left engine mount strut bracket (2).

1. Install the bolt and the nut to the left engine mount strut at the left engine mount strut bracket on the upper radiator support (1).

Tighten
Tighten the engine mount strut bolt to 48 Nm (35 lb ft).

Important
If equipped, the P-clip on the engine wiring harness must be vertical to the left engine mount strut bracket when installed.

2. Install the bolt and the nut to the left engine mount strut at the left engine mount strut bracket on the engine (1).

Tighten
Tighten the engine mount strut bolt to 48 Nm (35 lb ft).





16. Install fuel injector sight shield (1).

1. Remove by twisting counterclockwise to unlock the tube/oil fill cap from the left valve cover.
2. Insert the tab of the fuel injector sight shield under the engine bracket.
3. Place the hole of the fuel injector sight shield onto the oil fill neck of the left valve cover.





Important
Make sure the new 7 mm two-wire retainer (2) is approximately 50 mm (2 in) from the oil level indicator. Double check to ensure that no retainers, conduit, or other flammable materials were dropped onto the exhaust manifold. Remove any foreign material found on or near the exhaust manifold.

Important
Make sure the newly installed 7 mm four-wire (1) and 7 mm two-wire (2) spark plug retainers are not in contact with the fuel injector sight shield, engine mount strut bracket or the exhaust manifold. Double check the retainers to ensure that they are securely latched. If the retainer appears damaged in any way, remove it and replace it with a new retainer.

4. Install the tube/oil fill cap into the left valve cover and twist clockwise in order to lock the detent on the tube into the notch in the valve cover.

Tighten
Tighten the fuel injector sight shield cover nut to 3 Nm (27 lb in).

17. Inspect for the proper oil level.
18. Inspect for any oil leaks.