01-18-2011, 09:57 PM
Join Date: 10-11-10
Member #: 57192
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Valve Cover- Removal and Installation.
1.Disconnect the cable from the negative battery terminal.
2.On 2005 and 2006 2.2L engines, remove the ignition coil assembly from the valve cover.
On 2.0l, 2.4L and 2007 and later 2.2L models, remove the individual coils over each spark plug.
2.0L turbocharged models
3. Raise the vehicle and support it securely on jackstands.
4. Loosen the charge air cooler inlet pipe clamps and remove the pipe.
5.Disconnect the upper engine wiring harness electrical connectors/clips, then set the wiring harness aside.
6. Remove the plastic engine cover.
7. Detach the PVC hose from the valve cover. On turbocharged engines remove the hose at the coupling, but leave it attached to the valve cover.
8.Detach the fuel line bracket from the timing chain end of the valve cover and position the assembly aaway from the valve cover.
9. On 2.0L models relieve the fuel system pressure.
Relieving Fuel Pressure
On most vehicles, the fuel pressure is relieved by staring the engine, then pulling a fuel pump fuse or relay, which disables the fuel pump and stalls the engine. however this might pull a code. So i will tell you the "proper" way to do it. This is just a recommended way of doing it.
Your fuel pressure relief setup has to include a fuel pressure gauge with a hose and suitable fitting for connecting the gauge to the Schrader valve-type test port on the fuel rail, and a bleeder valve so that you can drain off the excess fuel.
1. Remove the fuel filler cap to relieve and pressure in the tank.
2.Locate the Schrader valve on the fuel rail, then unscrew the cap and connect the gauge, run the hose into a gas can or bucket.
3.Open the bleeder valve and let the fuel flow into the container of choice.
Due to the high pressure of the fuel on the turbos (2000psi) you have to due the normal method of bleeding the fuel, just pull the fuel pump fuse or relay and run the engine till it stalls. I suggest letting it sitt a couple hours after to make sure.
Now you have relieved the fuel pressure you can continue with the removal of the valve cover.
10.Remove the whole fuel inlet line.
11. Detach the ground strap from the valve cover.
12. Remove the valve cover bolts then lift the valve cover off. Tap gently with a soft-face hammer if needed to break the seal.
VOILA! you removed the valve cover.
1. Clean the gasket surface on the intake manifold, cylinder head and valve cover. Use a shop rag and some break cleaner or solvent to wipe the crap and gasket material off the sealing surface.
2. Insert a new valve cover gasket into the groove. Make sure it is positioned properly.
3. Install new O Rings and spark plug seals in the valve cover.
4. The remainder of install is the reverse of removal.
TIGHTEN VALVE COVER BOLTS EVENLY AND TO THE RIGHT TORQUE
2.0L - 71 In-Lbs
2.2 and 2.4 - 89 in-lbs