Valve Rocker Arm Cover Replacement. Pontiac Sun Runner - 2WD (Canada) 1998

For 1990-2009 cars

### Removal Procedure

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the air intake pipe from the ACL intake hose and the throttle hose. Refer to Air Intake Pipe Replacement.
3. Remove three bolts and the air intake bracket from the cylinder head.
4. Remove three bolts and the throttle cover from the intake manifold.
5. Remove the accelerator cable (3) and kickdown cable (4) (automatic transmission equipped vehicles) from the throttle body bellcrank (1).
6. Remove the following from the throttle body:

• | One bolt

• | One nut

• | One screw

• | The accelerator cable bracket (2)

7. Remove the (PCV) valve hose and the PCV valve form the cylinder head cover.
8. Remove the secondary (spark plug) wires from the spark plugs and the cylinder head cover.
9. Remove six bolts and the cylinder head cover (1) from the cylinder head (2).
10. Remove the cylinder head cover gasket and four O-rings from the cylinder head.
11. Clean the sealing surfaces on the cylinder head and the cylinder head cover.

### Installation Procedure

Important: A new cylinder head cover gasket and O-rings MUST be used whenever the cylinder head cover removal and installation is performed. Ensure that the new gasket and O-rings are correctly positioned during the cylinder head cover installation.

1. Install the new cylinder head cover gasket (1) and four O-rings (2) to the cylinder head cover.

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.

2. Install the cylinder head cover (1) to the cylinder head (2). Secure the cover with six bolts.

Tighten
Tighten the cylinder head cover bolts to 10 N·m (89 lb in).

3. Install the secondary (spark plug) wires to the cylinder head cover and spark plugs.
4. Install the (PCV) valve and the PCV valve hose to the cylinder head cover.
5. Install the accelerator cable bracket (2) to the throttle body. Secure the bracket with one screw, one bolt and one nut.

Tighten
Tighten the throttle body nut and bolt to 23 N·m (17 lb ft).

6. Install the accelerator cable (3) and the kickdown cable (4) (automatic transmission equipped vehicles) to the throttle body bellcrank.
7. Adjust the accelerator cable as necessary. Refer to Engine Controls.
8. Adjust the kickdown cable (automatic transmission equipped vehicles) as necessary. Refer to Automatic Transmission.
9. Install the throttle cover to the intake manifold. Secure the cover with three bolts.

Tighten
Tighten the throttle cover bolts to 15 N·m (11 lb ft).

10. Install the intake pipe bracket to the cylinder head. Secure the bracket with three bolts.

Tighten
Tighten the air intake pipe bracket bolts to 15 N·m (11 lb ft).

11. Install the air intake pipe to the throttle body hose and the ACL intake hose. Refer to the Air Intake Pipe Replacement.
12. Connect the negative battery cable. Refer to Battery Replacement in Engine Electrical.