How to Replace the Valve Cover Gasket in a Saturn Ion

Offering a lot of interior room and large cargo space, your 2003 through 2005 Saturn Ion allows you to carry a lot passengers and gear. Because of this you can move more in fewer trips. This might cut back on mileage but you still need to perform maintenance on your Ion. One form of this maintenance is to replace the valve cover gasket.

Instructions

1

Disconnect the negative battery cable. Using a T-30 6-point star, remove the cover bolts and the fuel rail cover. Remove the ignition coils, the ground strap and stud. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover.

2

Disconnect the fuel feed pipe from the fuel rail. Move the fuel feed pipe out of the way allowing access to the valve cover. Using a 10 mm wrench, remove the valve cover bolts. Remove the valve cover.

3

Remove the old valve cover gasket. Using automotive engine cleaner and a clean cloth rag clean the gasket seating area to remove any debris, particles or oil.

4

Place the new gasket in the gasket seating area. Place the valve cover back into place. Install the bolts. Using a torque wrench tighten the bolts in sequence starting in the middle and moving outward.

5

Install the ground strap to the valve cover. Install the ignition coils. Reconnect the fuel feed pipe to the fuel rail. Install the fuel pipe bracket. Connect the PCV hose to the valve cover.