GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 Bonneville 🢒 Engine 🢒 Engine Mechanical - 3.8L 🢒 Valve Rocker Arm Cover Replacement - Left 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. Disconnect the left spark plug wire harness and position aside.

    4. Object Number: 217748 Size: SH
  4. Remove the evaporative emission (EVAP) purge solenoid bracket.
  5. Disconnect the left spark plug wires from the spark plugs and coils. Refer to Spark Plug Wire Replacement in Engine Controls - 3.8L.
  6. Remove the left spark plug wires and cover from the left valve rocker arm cover.

    7. Object Number: 406018 Size: SH
  7. Remove the left valve rocker arm cover bolts.

    8. 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 palm of hand or with a soft rubber mallet.

  8. Remove the left valve rocker arm cover.
  9. Remove the left valve rocker arm cover gasket.
  10. Clean the sealing surface on the cylinder head.
  11. Clean the valve rocker arm cover bolts of all thread locking adhesive.
  12. Clean and inspect the valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection .

Installation Procedure

    Object Number: 406018 Size: SH

    Important: Ensure the valve rocker arm cover gasket is seated properly in the valve rocker arm cover groove.

  1. Install the new valve rocker arm cover gasket.
  2. Install the left valve rocker arm cover to the cylinder head.
  3. Apply thread lock compound GM P/N 12345493 (Canadian P/N 10953488) or equivalent, to the valve rocker arm cover bolt threads.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the left valve rocker arm cover bolts.

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

  5. Install the left spark plug wires and cover to the left valve rocker arm cover.
  6. Connect the left spark plug wires to the spark plugs and coils. Refer to Spark Plug Wire Replacement in Engine Controls - 3.8L.
  7. Connect the left spark plug wire harness.

    8. Object Number: 217748 Size: SH
  8. Install the EVAP purge valve to the bracket on the engine.
  9. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  11. Inspect for oil leaks.