GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 Bonneville 🢒 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. Disconnect the right spark plug wires from the spark plugs and coils. Refer to Spark Plug Wire Replacement in Engine Controls - 3.8L.
  4. Remove the right spark plug wires and cover from the right valve rocker arm cover.
  5. On supercharged models, disconnect the hoses and electrical connector from the evaporative emission (EVAP) canister purge solenoid located above the right valve rocker arm cover.
  6. On supercharged models, remove the EVAP canister purge valve from the EVAP canister purge valve mounting bracket.

    7. Important: It is not necessary to remove the heater hoses from the drive belt tensioner. When the tensioner has been removed from the engine, it can be repositioned out of the way with the hoses still attached.

  7. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .

    8. Object Number: 347473 Size: SH
  8. Remove the 2 nuts attaching the fuel injector sight shield bracket to the right exhaust manifold studs.
  9. Remove the fuel injector sight shield bracket.

    10. Object Number: 406021 Size: SH
  10. Remove the right 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 valve rocker arm cover.
  12. Remove the right valve rocker arm cover gasket.
  13. Clean the sealing surface on the cylinder head.
  14. Clean the valve rocker arm cover bolts of all thread locking adhesive.
  15. Clean and inspect the valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection .

Installation Procedure

    Object Number: 406021 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 right 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 right valve rocker arm cover bolts.

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


    Object Number: 347473 Size: SH
  5. Install the fuel injector sight shield bracket.
  6. Install the fuel injector sight shield bracket nuts.

    7. Tighten
    Tighten the nuts to 30 N·m (22 lb ft).

  7. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  8. On supercharged models, install the EVAP canister purge valve on the EVAP canister purge valve mounting bracket.
  9. On supercharged models, connect the electrical connector and hoses to the EVAP solenoid.
  10. Install the right spark plug wires and cover to the left valve rocker arm cover.
  11. Connect the right spark plug wires to the spark plugs and coils. Refer to Spark Plug Wire Replacement in Engine Controls - 3.8L.
  12. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  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. Inspect for oil leaks.