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Home >> Saturn >> 2006 >> Relay 3.9 1, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine Mechanical - 3.5L) >> Repair Instructions - On Vehicle >> Valve Rocker Arm Cover Replacement - Left Side >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Removing/Installing Front Ignition Wire Harness
    GM63660Courtesy of GENERAL MOTORS CORP.
  1. Partially drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill LX9) or Cooling System Draining and Filling (Static Fill LZ9) or Cooling System Draining and Filling (Vac-N-Fill) .
  2. Remove the front ignition wire harness at the upper intake manifold and at the spark plugs.
  3. Remove the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement (RPO LX9) .
  4. Disconnect the positive crankcase ventilation (PCV) vacuum hose.
    5. Fig 2: View Of Valve Rocker Arm Cover - Left
    GM54369Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The valve rocker arm cover gasket and sealant must be carefully trimmed away from the lower intake manifold gasket. Failure to do so will damage the lower intake manifold gasket, causing a severe oil leak.
  5. Remove the valve rocker arm cover bolts.
    6. IMPORTANT: When removing the valve rocker arm cover, ensure the gasket stays in place attached to the cylinder head.
  6. Remove the valve rocker arm cover. Bump the end of the valve rocker cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
    7. Fig 3: Identifying Cylinder Head To Lower Intake Manifold Joint
    GM190588Courtesy of GENERAL MOTORS CORP.
  7. Trim the valve cover and sealant away from the lower intake manifold gasket at the cylinder head to the lower intake manifold joints (1).
  8. Remove the valve cover gasket.
  9. Clean the sealing surface on the cylinder head with degreaser.
  10. Clean the valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection .
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