2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement.
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1 VALVE COVER GASKET Valve Rocker Arm Cover Replacement - Left Side Removal Procedure 1. Partially drain the cooling system. Refer to Cooling System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) or Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill). Fig 8: View Of Left Side Spark Plug Wires 2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement. 3. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement. 4. Disconnect the left spark plug wires from the spark plugs. 5. Remove the spark plug wire harness clip from the heater inlet and outlet front pipe bracket. 6. Reposition the spark plug harness. 7. Remove the positive crankcase ventilation (PCV) foul air tube. Refer to Plastic Collar Quick Connect Fitting Service.
2 Fig 9: Locating PCV Foul Air Tube 8. Remove the left engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement - Left Side. 9. Reposition the heater inlet and outlet hose/pipe clamps at the engine inlet and outer pipes.
3 Fig 10: View Of Coolant Inlet & Outlet Hoses/Pipes 10. Remove the heater inlet and outlet hose/pipe clip nuts at the throttle body. 11. Remove the heater inlet and outer hoses/pipes from the engine inlet and outlet pipes. 12. Remove the clips from the throttle body studs. Reposition the hose/pipe assembly. 13. Remove the front heater outlet hose from the outlet heater pipe. Fig 11: Locating Heater Inlet & Outlet Pipe To Vehicle
4 14. Remove the heater inlet and outlet pipe bolt and stud. 15. Remove the heater inlet and outlet pipe from the vehicle. 16. Loosen the valve rocker arm cover bolts. Fig 12: Locating Valve Rocker Arm Cover
5 IMPORTANT: When removing the valve rocker arm cover, ensure the gasket stays in place attached to the cylinder head. 17. Remove the valve rocker arm cover. If necessary, bump the end of the cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head. 18. Cut the RTV in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool. 19. Remove the valve cover gasket. 20. Clean the sealing surface on the cylinder head with degreaser. Installation Procedure IMPORTANT: All gasket mating surfaces need to be free of oil and foreign material. Use cleaner to clean the surfaces. Refer to Sealers, Adhesives, and Lubricants. 1. Install a NEW valve rocker arm cover gasket into the groove in the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover. Fig 13: Identifying Cylinder Head To Lower Intake Manifold Joint 2. Apply sealant at the cylinder head to the surfaces where the cylinder head and intake manifold meet (1). Refer to Sealers, Adhesives, and Lubricants.
6 3. Install the valve rocker arm cover. Fig 14: Locating Valve Rocker Arm Cover NOTE: Refer to Fastener Notice. IMPORTANT: Use an alternating criss-cross pattern when tightening the valve rocker cover bolts. Failure to do so may result in oil leakage from the valve cover due to improper seating of the gasket. 4. Tighten the valve rocker arm cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in). 5. Install the heater inlet and outlet pipe to the vehicle. Fig 15: Locating Heater Inlet & Outlet Pipe To Vehicle 6. Install the heater inlet and outlet pipe bolt and stud.
7 Tighten: 1. Tighten the bolt to 25 N.m (18 lb ft). 2. Tighten the stud to 10 N.m (89 lb in). 7. Install the front heater outlet hose to the outlet heater pipe. 8. Position the hose/pipe assembly. Install the clips to the throttle body studs. Fig 16: View Of Coolant Inlet & Outlet Hoses/Pipes 9. Install the heater inlet and outer hoses/pipes to the engine inlet and outlet pipes. 10. Install the heater inlet and outlet hose/pipe clip nuts at the throttle body. Tighten: Tighten the nuts to 10 N.m (89 lb in). 11. Position the heater inlet and outlet hose/pipe clamps at the engine inlet and outer pipes. 12. Install the left engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement - Left Side. 13. Install the PCV foul air tube. Refer to Plastic Collar Quick Connect Fitting Service. Fig 17: Locating PCV Foul Air Tube
8 14. Position the spark plug harness. Fig 18: View Of Left Side Spark Plug Wires 15. Install the spark plug wire harness clip to the heater inlet and outlet front pipe bracket. 16. Connect the left spark plug wires to the spark plugs. 17. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement. 18. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement. 19. Fill the cooling system. Refer to Cooling System Draining and Filling (LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill) or Cooling System Draining and Filling (LZE, LZ4, LZG, Static Fill). Valve Rocker Arm Cover Replacement - Right Side
9 Removal Procedure 1. Remove the generator. Refer to Generator Replacement (RPOs LZE/LZ4/LZ8). Fig 19: View Of PCV Tube & Air Inlet Duct 2. Disconnect the positive crankcase ventilation (PCV) fresh air tube from the air cleaner outlet duct. Refer to Plastic Collar Quick Connect Fitting Service. 3. Remove the PCV fresh air tube from the right side valve rocker arm cover. 4. Disconnect the right side spark plug wires from the spark plugs. Fig 20: Locating Right Side Spark Plug Wires & Ignition Coil 5. Disconnect the right side spark plug wires from the ignition coil. 6. Remove the right side spark plug harness clip from the ignition coil bracket. 7. Remove the spark plug harness. 8. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1). Fig 21: View Of MAP Sensor Electrical Connector
10 9. Disconnect the ignition coil electrical connector (6). 10. Remove the engine harness clip from the ignition coil bracket. 11. Remove the heated oxygen sensor (HO2S) electrical connector clip (1) from the ignition coil bracket. Fig 22: Identifying HO2S Electrical Connector 12. Remove the ignition coil bracket nuts. Fig 23: View Of Ignition Coil
11 13. Remove the ignition coil bracket bolts. 14. Remove the ignition coil. 15. Remove the coolant crossover pipe. Refer to Engine Coolant Crossover Pipe Replacement (LZE/LZ4/LZ8). 16. Loosen the valve rocker arm cover bolts. Fig 24: View Of Valve Rocker Arm Cover & Gasket IMPORTANT: When removing the valve rocker arm cover, ensure the gasket stays in place attached to the cylinder head. 17. Remove the valve rocker arm cover. Bump the end of the cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head. 18. Cut the room temperature vulcanizing (RTV) sealer in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool. 19. Remove the valve cover gasket. 20. Clean the sealing surface on the cylinder head with degreaser.
12 Installation Procedure IMPORTANT: All gasket mating surfaces need to be free of oil and foreign material. Use cleaner to clean the surfaces. Refer to Sealers, Adhesives, and Lubricants. 1. Install a NEW valve rocker arm cover gasket into the groove in the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover. Fig 25: Identifying Cylinder Head To Lower Intake Manifold Joint 2. Apply sealant at the cylinder head to the surfaces where the cylinder head and intake manifold meet (1). Refer to Sealers, Adhesives, and Lubricants. 3. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover. Fig 26: View Of Valve Rocker Arm Cover & Gasket
13 4. Install the right valve rocker arm cover. NOTE: Refer to Fastener Notice. IMPORTANT: Use an alternating criss-cross pattern when tightening the valve rocker cover bolts. Failure to do so may result in oil leakage from the valve cover due to improper seating of the gasket. 5. Tighten the valve rocker arm cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in). 6. Install the coolant crossover pipe. Refer to Engine Coolant Crossover Pipe Replacement (LZE/LZ4/LZ8). 7. Install the ignition coil. Fig 27: View Of Ignition Coil 8. Install the ignition coil bracket bolts. 9. Install the ignition coil bracket nuts. Tighten: Tighten the bolts/nuts to 25 N.m (18 lb ft).
14 10. Install the HO2S electrical connector clip (1) to the ignition coil bracket. Fig 28: Identifying HO2S Electrical Connector 11. Install the engine harness clip to the ignition coil bracket. Fig 29: View Of MAP Sensor Electrical Connector 12. Connect the ignition coil electrical connector (6). 13. Connect the MAP sensor electrical connector (1). 14. Install the spark plug harness. Fig 30: Locating Right Side Spark Plug Wires & Ignition Coil
15 15. Connect the right side spark plug wires to the spark plugs. 16. Connect the right side spark plug wires to the ignition coil. 17. Install the right side spark plug harness clip to the ignition coil bracket. 18. Install the PCV fresh air tube to the right side valve rocker arm cover. Fig 31: View Of PCV Tube & Air Inlet Duct 19. Connect the PCV fresh air tube to the air cleaner outlet duct. Refer to Plastic Collar Quick Connect Fitting Service. 20. Install the generator. Refer to Generator Replacement (RPOs LZE/LZ4/LZ8).
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Page 1 of 39 Evan Groenke From: Daniel Lelovic [dlelovic@rogers.com] Sent: May 8, 2005 12:08 PM To: 'Evan Groenke' Subject: 2.5L Engine Re-assembly SECTION 303-01B: Engine 2.5L 2000 Contour/Mystique Workshop
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Page 1 of 31 Evan Groenke From: Daniel Lelovic [dlelovic@rogers.com] Sent: May 8, 2005 12:06 PM To: 'Evan Groenke' Subject: 2.5 L Engine Disassembly SECTION 303-01B: Engine 2.5L 2000 Contour/Mystique Workshop
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