Valve Cover Removal and Inspection / Installation

1. Remove bolts holding valve covers.

2. Remove valve cover and discard gasket and bolts.

3. Clean valve cover and cylinder head flange surfaces.

4. 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 DP300 or RTV.

NOTE:
Let RTV 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.

5. Using a good straight edge, check the valve cover sealing surface for straightness and for any damage to the valve cover.

6. If the valve cover sealing surface is distorted more than 1.0 mm. (0.040 in.) across the entire length, REPLACE THE VALVE COVER.

7. If fitted, inspect new cover and fill any deep surface scratches with a very thin layer of WURTH DP300 or RTV.

Installation





1. To aid assembly place six small dots of "super glue" at the points indicated on the illustration (figure 1).

2. Install gasket in valve cover recess, paying attention to the fit of the gasket onto the valve cover.

3. Install valve cover onto cylinder head with four new bolts.

NOTE:
New style bolts must be used. These bolts have an integral acrylic seal under the head.





4. Tighten the bolts in the sequence shown (figure 2) in two stages.

^ Stage one: 4 Nm. (3 lbf.ft.).
^ Stage two: 9 Nm. (7 lbf.ft.).

5. Position fuel pipes.

6. Install breather hose on valve cover, tighten clamp.

7. Install coolant hoses to intake manifold, tighten bolts.

8. Install spark plug wires to spark plugs and retaining clips.

9. Connect purge pipe from charcoal canister at plenum, tighten clamp.