Disconnect the negative battery cable. Remove the air cleaner assembly and air inlet duct.
Disconnect the PCV valve, fresh air hose and any remaining vacuum hoses or electrical connectors from the valve cover.
Remove the 2 fasteners and washers from the silicone insulators located in the top of the valve cover.
Disconnect the de-aeration line from the cylinder head outlet (located at one end of the cover) and from the support bracket. Have a rag handy to wipe up the small amount of coolant which may escape from the line. The MAP sensor (1991-94 models only) and de-aeration line may remain attached to the cover.
Carefully remove the valve cover and gasket from the engine. If the cover does not come off easily, tap the sides gently with a rubber mallet to loosen the cover. Do not pry against the mating surfaces or damage may occur.
Inspect the silicone insulators located in the valve cover fastener bores and replace if cracked or deteriorated.
Inspect the valve cover gasket which is bonded to the cover flange. If it is damaged, or if replacement is necessary to assure a proper seal, remove the gasket from the cover and clean the old RTV from the flange surface using a chlorinated solvent and a wire brush. Most carburetor cleaners or brake clean solvents should be appropriate.
If the gasket is to be replaced, apply a thin 0.08 in. (2mm) bead of RTV to the cover flange. Firmly press the flat side of the gasket into the flange and install the cover while the RTV is still wet to assure a proper bond. RTV should only be placed between the cover flange and gasket, but NOT onto the cylinder head mating surface, so that the gasket will separate from the head easily and may be reused.
Apply a small 0.2 in. (5mm) bead of RTV to the cylinder head T-joints where the head meets the front cover to assure a good seal. This is the only spot where RTV will be placed between the cylinder head and the cover gasket.
Install the valve cover and gasket, then install the washers and fasteners. Tighten the fasteners to 22 ft. Lbs. (30 Nm). Connect the de-aeration line to the support bracket and to the cylinder head.
Connect the PCV valve, fresh air hose and any remaining vacuum hoses or electrical connectors to the valve cover.
Install the air cleaner assembly and air inlet duct, then carefully tighten the fasteners. Connect the negative battery cable.
Monday, August 23rd, 2010 AT 9:41 PM