REMOVAL & INSTALLATION

1. On carbureted engines, remove the air cleaner. On fuel injected engines, loosen the clamps and remove the air intake crossover. On turbocharged engines, loosen the clamps at either end and disconnect the turbocharger outlet line.
2. Disconnect/remove the PCV valve at the rocker arm cover.

   NOTE: On 3.0L engines, PCV valve removal is only necessary when servicing the right side rocker arm cover.

   Fig. 1: Unfasten any cable brackets which are attached to the cylinder head cover

   Fig. 2: Unfasten the cylinder head cover retaining bolts with the correct size socket

   Fig. 3: Lift the cover from the cylinder head

   Fig. 4: Remove the used gasket from the cylinder head cover

   Fig. 5: Apply RTV sealant to the cylinder head cover prior to installing the gasket — 1.6L engine

   Fig. 6: On the 2.2L engine, be sure to apply sealant to the arrowed areas of the cylinder head

   Fig. 7: Install new seal washers with the bolts on 2.0L and 3.0L engines (3.0L right side cylinder head cover shown)

3. If so equipped, unfasten the choke cable and the air bypass valve cable.
4. Unfasten the retaining bolts, then remove the rocker arm cover.
5. Using a suitable scraper, carefully remove all traces of old gasket material and/or sealant from the rocker arm cover and cylinder head mating surface. Be careful not to dislodge any material into the exposed cylinder head.

   To install:

6. Position a new gasket on the rocker arm cover. On the 1.6L engine (turbo and non-turbo), apply a suitable RTV sealant to the groove in the cover prior to installing the new gasket. On the 2.2L engine (turbo and non-turbo), apply sealant to the corners of the cylinder head, as indicated by the arrows in the accompanying illustration, before installing the cover.
7. On the 2.0L (turbo and non-turbo) and 3.0L engines, install new seal washers with the bolts.
8. Tighten the bolts in several stages, going back and forth across the cover. You can use the following torque figures for most 1983–89 engines, but the important point is to tighten the bolts evenly and just until they are slightly snug. The recommended torque values are:
   • 1.6L Engine: 3.6–6.5 ft. lbs. (5–9 Nm)
   • 2.0L Engine: 2.2–2.9 ft. lbs. (3–4 Nm)
   • 2.2L Engine: 4.3–5.7 ft. lbs. (6–8 Nm)
   • 3.0L Engine: 2.5–3.3 ft. lbs. (3.4–4.5 Nm)
9. If applicable, fasten the choke cable and the air bypass valve cable.
10. On turbocharged engines, connect the turbocharger outlet line.
11. Install/connect the PCV valve and the air cleaner or air intake crossover.
12. Start the engine and allow it to reach normal operating temperature. Check for oil leaks.