Right Side Valve Cover Procedure
Right Side Valve Cover Gasket and Valve Cover Bolt RepairDepressurize fuel system and drain cooling system as follows:
1. Remove front door seal from right "A" post.
2. Remove lower "A" post trim panel.
3. Pull relay "A" from base (figure 1).
4. Start and run engine, when sufficient fuel has been used to cause fuel line pressure to drop, injectors will become inoperative, causing engine to stall.
5. Switch off engine.
WARNING: Some fuel pressure will remain in system. The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.
6. Disconnect battery negative lead.
7. Disconnect purge hose from charcoal canister at plenum.
8. Remove breather hose from valve cover.
9. Remove spark plug wires from plugs and retaining clips.
10. Place absorbent cloth around fuel feed hose at fuel rail.
11. On model year 1996 vehicles, perform the following
^ Remove bolt securing coolant hose brackets and nut securing bracket to manifold.
^ Loosen hose clip and disconnect coolant return hose from pipe. Loosen clip and disconnect fuel return hose from pipe.
^ Disconnect fuel hose from injector pipe.
^ Drain cooling system.
Valve Cover Removal and Inspection
1. Remove four valve cover bolts.
2. Moving fuel pipes aside and remove valve cover.
3. Remove and discard valve cover gasket and four bolts.
4. Clean valve cover and cylinder head flange surfaces.
5. Inspect the mating surface on the cylinder head for any damage to the aluminum:
^ Remove any burrs and check for scratches that are deep enough to be felt with a fingernail.
^ Fill any deep scratches in the aluminum with a very thin layer (enough to fill the surface imperfection) of Blue Sealant WURTH DP3OO or RTV.
NOTE: Let sealant dry before reinstalling the valve cover and new gasket. Filling any deep scratches will help ensure there are no leak paths under the new gasket.
6. Using a good straight edge, check the valve cover sealing surface for straightness and for any damage to the valve cover.
7. If the valve cover sealing surface is distorted more than 1.0 mm. (0.040 in.) across the entire length, REPLACE THE VALVE COVER.
8. If fitted, inspect new cover, and fill any deep surface scratches with a very thin layer of WURTH DP3OO or RTV.
Installation
1. To aid assembly place six small dots of "super glue" at the points indicated on the illustration (figure 2).
2. Install gasket in valve cover recess, paying attention to the fit of the gasket onto the valve cover lip.
NOTE: New style bolts must be used. These bolts have an integral acrylic seal under the head.
3. Install valve cover onto cylinder head with four new bolts.
4. Tighten the bolts in the sequence shown (figure 3) in two stages.
^ Stage one: 4 Nm. (3 lbf. ft).
^ Stage two: 9 Nm. (7 lbf. ft).
5. Position fuel pipes.
6. Connect fuel feed and return hoses (96MY).
7. Connect coolant pipes to hoses and secure brackets (96MY).
8. Install breather hose on valve cover.
9. Install coolant pipes to intake manifold and tighten bolts.
10. Install spark plug wires to spark plugs and retaining clips.
11. Connect purge pipe from charcoal canister at plenum.