GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Impala 🢒 Engine 🢒 Engine Mechanical - 3.8L 🢒 Valve Rocker Arm Cover Replacement - Right Side

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  3. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  4. Remove the AIR valve, if equipped. Refer to Secondary Air Injection Shutoff Valve Replacement in Engine Controls - 3.8L.
  5. Remove the AIR pipe, if necessary. Refer to Secondary Air Injection Shut-Off Valve Outlet Pipe/Hose Replacement in Engine Controls - 3.8L.
  6. Remove the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
  7. Remove the right side spark plug wires from the spark plugs. Refer to Spark Plug Wire Replacement in Engine Controls - 3.8L.

    8. Object Number: 371090 Size: SH
  8. Remove the fuel injector sight shield bracket nuts and bracket.

    9. Object Number: 153580 Size: SH
  9. Remove the right side lift bracket nut, bolt and lift bracket.

    10. Object Number: 406021 Size: SH
  10. Remove the right side valve rocker arm cover bolts.

    11. Important: If the valve rocker arm cover adheres to the cylinder head, remove the valve rocker arm cover by bumping the end of the valve rocker arm cover with the palm of your hand or a soft rubber mallet.

  11. Remove the right side valve rocker arm cover.
  12. Remove the right side valve rocker arm cover gasket.
  13. Clean the valve rocker arm cover mating surface.
  14. Clean the valve rocker arm cover bolts of all thread locking adhesive.

Installation Procedure

    Object Number: 406021 Size: SH
  1. Install the new valve rocker arm cover gasket. Make sure that the valve rocker arm cover gasket is seated properly in the valve rocker arm cover groove.
  2. Install the right side valve rocker arm cover.
  3. Apply thread lock compound GM P/N 1234593 or equivalent to the valve rocker arm cover bolt threads.

    4. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4. Install the right valve rocker arm cover bolts.

    5. Tighten
    Tighten the right side valve rocker arm cover bolts to 10 N·m (89 lb in).


    Object Number: 153580 Size: SH
  5. Install the right side lift bracket, nut and bolt.

    6. Tighten
    Tighten the right side lift bracket nut and bolt to 30 N·m (22 lb ft).


    Object Number: 371090 Size: SH
  6. Install the fuel injector sight shield bracket to the exhaust manifold studs.
  7. Install the fuel injector sight shield bracket nuts.

    8. Tighten
    Tighten the fuel injector sight shield bracket nuts to 30 N·m (22 lb ft).

  8. Install the right side spark plug wires to the spark plugs. Refer to Spark Plug Wire Replacement in Engine Controls - 3.8L.
  9. Install the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
  10. Install the AIR pipe, if necessary. Refer to Secondary Air Injection Shut-Off Valve Outlet Pipe/Hose Replacement in Engine Controls - 3.8L.
  11. Install the AIR valve, if equipped. Refer to Secondary Air Injection Shutoff Valve Replacement in Engine Controls - 3.8L.
  12. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  13. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  15. Check and fill crankcase as necessary
  16. Inspect for oil leaks.