How to Remove the Valve Cover From a 1995 Sunfire 2.2 Engine

The Pontiac Sunfire was produced from 1995 until 2005. The 1995 Pontiac Sunfire was equipped with a 2.2-liter, in-line, four-cylinder engine, capable of producing up to 120 horsepower and 130 foot-pounds of torque. The 1995 Sunfire has a single valve cover, located on the upper front-side of the engine. Over time the valve cover gasket can begin to leak, due to excess heat, dirt and debris and oil pressure. Replacing the valve cover gasket requires mechanical knowledge and involves working with the throttle control system.

Instructions

1

Open the hood of the Sunfire and set the hood prop rod. Remove the air filter housing lid, using a Phillips screwdriver to loosen the four tie-down screws. Pull the lid up and off of the air filter housing. Loosen the hose clamp for the air intake tube using a ratchet and socket. Remove the air intake tube and filter housing lid completely from your work area.

2

Locate the accelerator control to the left of the throttle body, and remove the cover with a ratchet and socket. Place a tab of 1/2-inch masking tape on each cable on the throttle control lever. Number the cables "1," "2" and "3," from left to right, using a black marker. Remove each cable from the throttle control lever by hand or use needle-nose pliers if necessary. Set the throttle cables to the side of the throttle control bracket. Remove the throttle control bracket using a ratchet and socket.

3

Remove the PCV valve hose from the upper left-hand side of the valve cover, using your hands or pliers. Remove the six mounting bolts and nuts from the valve cover, using a ratchet and socket. Remove the valve cover away from the top of the engine, using a thin flat-head screwdriver to pry the cover loose if needed. Pull the valve cover upward about 1/2 to 1 inch, then remove the cover toward the driver's side of the vehicle horizontally.

4

Remove the old valve cover gasket from the valve cover, using a screwdriver to help pry the gasket loose. Thoroughly clean the gasket mounting surface of the engine and the valve cover, using a razor knife blade. Scrape the residue on the engine mounting surface in a manner that pushes the residue away from the exposed upper engine. Wipe both surfaces with a dry cloth when you are finished scraping.

5

Set the new valve cover gasket onto the engine-mounting surface. Make sure all of the bolt holes are visible through the new gasket to ensure proper alignment. Install the valve cover by moving it right to left underneath the ignition wires. Set the valve cover straight down onto the engine. Tighten the valve cover fasteners in a clockwise pattern. Use a torque wrench to tighten the fasteners to 89 inch-pounds of torque. Install the PCV valve hose back onto the valve cover.

6

Install the accelerator control bracket back onto the engine, tightening the bolts to 18 foot-pounds with a torque wrench and socket. Install the cables back onto the throttle control lever, remembering they are numbered from 1 to 3 in a left to right pattern.

7

Install the air intake tube onto the throttle body, and tighten the hose clamp until it is snug with a ratchet and socket. Install the air filter housing lid and tighten the screws with a Phillips screwdriver.