Valve Cover: Service and Repair

Valve Cover





Valve Cover - Ignition Coil and Wires









Valve Cover - Connections









Valve Cover









Removal

1. Disconnect the battery ground cable. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.

2. Remove the intake manifold assembly. For additional information, refer to Intake Manifold Service and Repair.

3. Position aside the Cylinder Head Temperature (CHT) sensor cover.

4. Disconnect the CHT sensor electrical connector.

5. Disconnect the engine wiring harness support bracket retainers from the valve cover studs.

6. Disconnect the spark plug wires from the spark plugs. For additional information, refer to Engine Ignition - 2.3L Service and Repair.

7. Disconnect the ignition coil electrical connector.

8. Remove the 4 bolts and the ignition coil and spark plug wires as an assembly.

9. Disconnect the Camshaft Position (CMP) sensor electrical connector.

10. Remove the bolt and the CMP sensor.

11. Disconnect the crankcase ventilation tube quick connect coupling. For additional information, refer to Fuel System - General Information Quick Connect Coupling.

12. Remove the 10 bolts, the 4 stud bolts and the valve cover.

13. 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 cylinder head sealing surfaces with metal surface prep and silicone gasket remover. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.

14. Remove and discard the 4 valve cover gaskets.

Installation

1. Install 4 new valve cover gaskets.

2. Position the valve cover and install the 10 bolts and 4 stud bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





3. Connect the crankcase ventilation tube quick connect coupling. For additional information, refer to Fuel System - General Information Quick Connect Coupling.

4. NOTE: Apply clean engine oil to the O-ring seal prior to installation.

Install the CMP sensor and the bolt.

- Tighten to 7 Nm (62 lb-in).

5. Connect the CMP sensor electrical connector.

6. Position the ignition coil and install the 4 bolts.
- Tighten to 6 Nm (53 lb-in).

7. Connect the ignition coil electrical connector.

8. Connect the spark plug wires to the spark plugs. For additional information, refer to Engine Ignition - 2.3L Service and Repair.

9. Install the engine wiring harness support bracket retainers onto the valve cover studs.

10. Connect the CHT sensor electrical connector.

11. Position back the CHT sensor boot.

12. Install the intake manifold. For additional information, refer to Intake Manifold Service and Repair.

13. Connect the battery ground cable. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.