My '98 Catera needs the #1 cyl ignition coil replaced,plus the valve cover gaskets.Is all of this readily accessible when the air cleaner is removed?Or,more importantly,how many components must be removed or disconnected to gain access to these components? Is it necessary to label hoses and connections in insure proper reassembly?Thanks

Lable all necessary on this engine. not only hoses, but sensor elec. connectors can innerchange on various sensors. the plastic is a pain, but be patient and dont force. dont want to break it. not a fun engine to work on.

Not easy but doable. I would mark anything you aren't familiar with to get it back together right. Please let me know if you have any questions, and thanks for using FixYa.


IGNITION COIL REMOVAL & INSTALLATION
3.0L Engine

1. Remove the wiper arms
2. Remove the left and right side air inlet grilles
3. Remove the wiper motor.
4. Detach the power brake booster vacuum connection from the intake plenum.
5. Disconnect the spark plug wiring harness from the ignition coil.
6. Detach the electrical connection from the ignition coil.
7. Remove the bolts from the ignition coil, and remove the coil.

To install:

1. Installation is the reversal of the removal procedure.
2. Tighten the coil bolts to 71 inch lbs. 8 (Nm).
3. Tighten the power brake booster vacuum connection until snug.

valve cover removal & installation3.0L Engine
RIGHT

1. Disconnect the negative battery cable.
2. Remove the intake plenum and the intake manifold.
3. Remove the spark plug boots from the spark plugs, and then the wires from the routing retainers. Make sure they are tagged for proper installation.
4. Remove the rocker arm cover-to-cylinder screws, the cover, and the gasket/seals. Discard the seals.

NOTE Ensure all eight sealing O-rings are accounted for. They may stick to the camshaft bearing caps or fall into the oil return journals in the cylinder head.

Fig. The location of the valve cover O-rings is shown here

Fig. The valve cover sealant application points
To install:

1. Install new valve cover seals. Lightly coat the new seals, including O-rings, with engine oil prior to installation. The oil application will assist in holding the O-ring seals to the valve cover.
2. Apply a thin coat of silicone sealer at the front and back of the seals.
3. Install the valve cover to the cylinder head, and tighten the bolts to 71 inch lbs. (8 Nm).
4. Route the spark plug wires into the retainers, and install the plug boots to the spark plugs.
5. Replace the intake manifold and the intake plenum.
6. Connect the negative battery cable.

LEFT

1. Disconnect the negative battery cable.
2. Remove the intake plenum and the intake manifold.
3. Remove the spark plug boots from the spark plugs, and then the wires from the routing retainers. Make sure they are tagged for proper installation.
4. Remove the oil filler spout.
   1. Unlock the tab.
   2. Twist counterclockwise.
   
   
5. Remove the rocker arm cover-to-cylinder screws, the cover, and the gasket/seals. Discard the seals.

NOTE Ensure all eight sealing O-rings are accounted for. They may stick to the camshaft bearing caps or fall into the oil return journals in the cylinder head.
To install:

1. Install new valve cover seals. Lightly coat the new seals, including O-rings, with engine oil prior to installation. The oil application will assist in holding the O-ring seals to the valve cover.
2. Apply a thin coat of silicone sealer at the front and back of the seals.
3. Install the valve cover to the cylinder head, and tighten the bolts to 71 inch lbs. (8 Nm).
4. Install the oil filler spout.
   1. Insert the spout and twist clockwise.
   2. Ensure the locking tab seats on the valve cover bolt head.
   
   
5. Route the spark plug wires into the retainers, and install the plug boots to the spark plugs.
6. Replace the intake manifold and the intake plenum.
7. Connect the negative battery cable.

INTAKE MANIFOLD REMOVAL & INSTALLATION

3.0L Engine
This vehicle uses a sequential multiport fuel injected engine. Fuel injector connectors must be positioned onto their appropriate fuel injector or engine performance and exhaust emissions may be seriously affected. Fuel injector connectors are numbered to match their cylinders.

1. Remove the intake plenum.
2. Properly relieve the fuel system pressure.
3. Remove the fuel supply and fuel return hose from the fuel rail.
4. Fuel injector electrical harness connector.
5. Remove the intake manifold bolts and the intake manifold.

NOTE Mask off the ports to the intake manifold spacer. If foreign objects enter the engine, severe damage may result.
Clean the intake manifold sealing surfaces with a non-abrasive tool or solvent.
Do not damage machined aluminum surfaces or improper sealing may occur.

Fig. Location of the guide pins for the intake plenum-3.0L enMy '98 Catera needs the - jturcotte_1759.gif>

Fig. Intake My '98 Catera needs the - jturcotte_1760.gifanifold mounting

Fig. The intake manifold bolt locations
To install:

1. Remove the masking from the intake ports.
2. Install the intake manifold, and tighten the intake bolts to 15 ft. lbs. (20 Nm), rotating the tightening sequence.
3. Reconnect the fuel injector electrical harness connector.
4. Couple the fuel supply and fuel return hose,. Tighten the connection to 11 ft. lbs. (15 Nm).

NOTE Counterhold the connections to prevent damage to the fuel rail.

1. Install the intake plenum.
2. Connect the negative battery cable.