GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

    Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

    The High Voltage Disabling procedure will perform the following tasks:

       • Identify how to disable high voltage.
       • Identify how to test for the presence of high voltage.
       • Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
    Failure to follow the procedures exactly as written may result in serious injury or death.


    Object Number: 1965809  Size: SH
  1. Disable the high voltage system. Refer to High Voltage Disabling.
  2. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement.
  3. Remove the generator control module 3 phase cable clip nut (1).
  4. Remove the generator control module 3 phase cable clip from the engine bracket (2).
  5. Reposition the generator control module 3 phase cables out of the way.

  6. Object Number: 1696893  Size: SH
  7. Remove the connector position assurance (CPA) retainer (2).
  8. Disconnect the engine harness electrical connector (1) from the ignition coil wire harness.
  9. Remove the engine wiring harness (electronic throttle control branch) clip (6) from the ignition coil bracket stud.
  10. Reposition the engine wiring harness (electronic throttle control branch) as necessary.

  11. Object Number: 1970079  Size: SH
  12. Remove the heater inlet hose (2) from the heater hose bracket (3).

  13. Object Number: 1970080  Size: SH
  14. Remove the surge tank outlet hose (2) from the heater hose bracket (3).

  15. Object Number: 1970081  Size: SH
  16. Remove the heater hose bracket nut (1) and bracket (2).

  17. Object Number: 1402028  Size: SH
  18. Remove the spark plug wires (724) from the ignition coils.
  19. • Twist each plug wire 1/2 turn.
    • Pull only on the boot in order to remove the wire from the ignition coil.
  20. Remove the ignition coil bracket studs (720).
  21. Remove the ignition coil bracket (719).

  22. Object Number: 1696757  Size: SH
  23. Remove the positive crankcase ventilation (PCV) tube (1) from the valve rocker cover (2).

  24. Object Number: 832211  Size: SH
  25. Loosen the valve rocker arm cover bolts.
  26. Remove the valve rocker arm cover.

  27. Object Number: 490696  Size: SH
  28. Remove and discard the old gasket (1).

  29. Object Number: 1559860  Size: SH
  30. Remove the oil fill cap (424) from the oil fill tube (423), if necessary.
  31. Remove and discard the oil fill tube, if necessary.

Installation Procedure

Note: 

   • All gasket surfaces should be free of oil or other foreign material during assembly.
   • DO NOT reuse the valve rocker arm cover gasket.
   • If the oil fill tube has been removed from the rocker arm cover, install a NEW fill tube during assembly.


    Object Number: 1559860  Size: SH
  1. Lubricate the O-ring seal (422) of the NEW oil fill tube with clean engine oil.
  2. Insert the NEW oil fill tube (423) into the rocker arm cover.
  3. Rotate the tube clockwise until locked in the proper position.

  4. Install the oil fill cap (424) into the tube.
  5. Rotate the cap clockwise until locked in the proper position.


    Object Number: 490696  Size: SH
  6. Install a NEW rocker cover gasket (1) into the valve rocker arm cover lip.

  7. Object Number: 832211  Size: SH
  8. Install the valve rocker arm cover.
  9. Caution: Refer to Fastener Caution in the Preface section.

  10. Tighten the rocker arm cover bolts.
  11. Tighten
    Tighten the bolts to 12 N·m (106 lb in).


    Object Number: 1696757  Size: SH
  12. Install the PCV tube (1) to the valve rocker cover (2).

  13. Object Number: 1402028  Size: SH
  14. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the ignition coil bracket studs.
  15. Position the ignition coil bracket (719) onto the rocker cover.
  16. Install the ignition coil bracket studs (720).
  17. Tighten
    Tighten the studs to 12 N·m (106 lb in).

  18. Install the spark plug wires (724) to the ignition coils.

  19. Object Number: 1970081  Size: SH
  20. Install the heater hose bracket (2) and nut (1).
  21. Tighten
    Tighten the nut to 9 N·m (80 lb in).


    Object Number: 1970080  Size: SH
  22. Install the surge tank outlet hose (2) to the heater hose bracket (3).

  23. Object Number: 1970079  Size: SH
  24. Install the heater inlet hose (2) to the heater hose bracket (3).

  25. Object Number: 1699546  Size: SH
  26. Position the generator battery cable as necessary.
  27. Install the generator battery cable clip (1) to the ignition coil bracket stud.

  28. Object Number: 1235686  Size: SH
  29. Position the engine wiring harness (electronic throttle control branch) as necessary.
  30. Install the engine wiring harness (electronic throttle control branch) clip to the ignition coil bracket stud.
  31. Connect the engine harness electrical connector (1) to the ignition coil wire harness.
  32. Install the CPA retainer (2).

  33. Object Number: 1965809  Size: SH
  34. Position the generator control module 3 phase cables to the bracket channel.
  35. Install the generator control module 3 phase cable clip to the tab (3) on the engine bracket (2).
  36. Install the generator control module 3 phase cable clip nut (1).
  37. Tighten
    Tighten the nut to 9 N·m (80 lb in).

  38. Enable the high voltage system. Refer to High Voltage Enabling.
  39. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement.