2003 3.4 Front Rocker arm cover removal

[truc0011]

Hello,

Does anyone have good tips for the removal of the front rocker arm cover on a 2003 3.4 Venture/Montana? I have a Montana but I posted in there becuase it seems that more people look at the venture forum and they are the same.

I have a cylinder 2 misfire and need to check my rocker arms but I can't seem to easily get the rocker arm cover off. Do I need to remove the water tube and passenger side strut mount bracket? Or can I do it with just removing the water tube?

If I remember correctly that bracket is extremely hard to remove.

[gmtech1]

Originally Posted by truc0011

Hello,

Does anyone have good tips for the removal of the front rocker arm cover on a 2003 3.4 Venture/Montana? I have a Montana but I posted in there becuase it seems that more people look at the venture forum and they are the same.

I have a cylinder 2 misfire and need to check my rocker arms but I can't seem to easily get the rocker arm cover off. Do I need to remove the water tube and passenger side strut mount bracket? Or can I do it with just removing the water tube?

If I remember correctly that bracket is extremely hard to remove.

Shouldn't have to remove the water pipe or the bracket, just the mount from the bracket. Then you can access the V/C bolt under it.

[truc0011]

Originally Posted by gmtech1

Shouldn't have to remove the water pipe or the bracket, just the mount from the bracket. Then you can access the V/C bolt under it.

I did that and the cover is loose, but I can't seem to get it around the rockers that are sticking out above the head. It hits the water pipe...

[truc0011]

Originally Posted by truc0011

I did that and the cover is loose, but I can't seem to get it around the rockers that are sticking out above the head. It hits the water pipe...

I got the cover off by only removing the water pipe! I found two rockers pulled out, intake and exhaust on cyl 2. What a terrible design

I guess I'll tap them out to 10mm and visit the junk yard for new rockers in the 10 mm size!

[Tech II]

I got the cover off by only removing the water pipe! I found two rockers pulled out, intake and exhaust on cyl 2. What a terrible design

I guess I'll tap them out to 10mm and visit the junk yard for new rockers in the 10 mm size!

Has previous work been done on this head? I've never seen this happen before....

I would heli coil them.....

[truc0011]

Originally Posted by Tech II

I got the cover off by only removing the water pipe! I found two rockers pulled out, intake and exhaust on cyl 2. What a terrible design

I guess I'll tap them out to 10mm and visit the junk yard for new rockers in the 10 mm size!

Has previous work been done on this head? I've never seen this happen before....

I would heli coil them.....

I'm told it is common on the 2003 and newer 3.4. In 2003 the rockers use a 8mm bolt before that it was 10mm.

I stopped at a junk yard tonight and they had a 5 gallon bucket of rockers by the register. He said they go through lots of them, for this very reason!

[Tech II]

Have never seen this happen, unless due to a previous repair, usually a previous lower intake job...

This could be caused by improper procedure......those bolts should be be MANUALLY broken, instead of with a power tool, because it can take out threads or weaken the threads....then if improperly torqued, they can weaken, or damage the threads......so if it is a procedure problem, that can be completely eliminated with a special tool.....this tool rotates the rocker arm enough to remove the the push rod, without loosening the rocker arm bolt/stud nut( in some cases may have to rotate the crank bolt slightly to get more clearance)......highly recommend this tool because it eliminates this problem and saves you valuable time on disassembly/assembly).....Lisle makes it...."Push Rod Remover"

GMTech1, is there a TSB on this?

[truc0011]

Originally Posted by Tech II

Have never seen this...GMTech1, is there a TSB on this?

Every cylinder head guy I've talked to is well aware of it! Google it!

[gmtech1]

No TSB's on it, but I have seen it. In each case that I have seen it was due to improper torque of the rocker arm bolts when reassembled after a LIM job.

[truc0011]

Originally Posted by gmtech1

No TSB's on it, but I have seen it. In each case that I have seen it was due to improper torque of the rocker arm bolts when reassembled after a LIM job.

One head guy also said the torque in the GM manual is way to high....so if you go by that you'll have issues.

Aluminum is the problem....blocks and heads should be made of iron!

[Tech II]

Like I said, it's more technique than anything else.....the one time I saw it happen was because the bolt was removed with an impact gun...this damaged the threads.....when I saw that, every time I did a lower intake job, I "broke" the bolts loose first with a socket and breaker bar....

Then I found out about the push rod removal tool from Lisle, and never had to remove/install that bolt again.....only way to do a lower intake as far as I'm concerned.....

[truc0011]

Originally Posted by Tech II

Like I said, it's more technique than anything else.....the one time I saw it happen was because the bolt was removed with an impact gun...this damaged the threads.....when I saw that, every time I did a lower intake job, I "broke" the bolts loose first with a socket and breaker bar....

Then I found out about the push rod removal tool from Lisle, and never had to remove/install that bolt again.....only way to do a lower intake as far as I'm concerned.....

I agree, no impact guns should be used on any aluminum engine. There is no forgiveness in weak metal.

I'll just keep buying old cars with 3800 engines, if you put an intake gasket in those they last a long time! (and maybe a transmission or two)