1. Preparation is Key:
* Consult a Repair Manual: A Haynes or Chilton manual specific to your year and model Cavalier is invaluable. It will show you the exact location of bolts, hoses, and wires, and often provides tips for difficult removals.
* Gather Tools: You'll need sockets (likely 10mm and possibly others), a ratchet, extensions, a wrench (for stubborn bolts), possibly a breaker bar for extra leverage, and plenty of rags or shop towels. A plastic scraper might help remove old gasket material.
* Warm the Engine (Slightly): A slightly warm engine can help loosen the gasket. Avoid overheating. A few minutes of idling is sufficient.
* Drain the Oil: This is crucial. You'll inevitably spill some oil during this process, and a full drain minimizes the mess.
2. Removing the Valve Cover:
* Disconnect Everything: Before touching any bolts, disconnect any electrical connectors, vacuum lines, and PCV hoses connected to the valve cover. Take pictures beforehand if you're unsure about reassembly.
* Locate the Bolts: Identify all the valve cover bolts. There are usually several.
* Loosen the Bolts: Start by loosening the bolts *slightly*, working your way around in a star pattern to avoid warping the valve cover. Don't remove them completely yet.
* The Oil Reservoir Issue: This is where the challenge arises. The close proximity of the oil filter housing/reservoir often prevents the valve cover from lifting straight up. You may need to:
* Wiggle and Pry Gently: Carefully use a plastic pry tool (or a flathead screwdriver wrapped in cloth to protect the valve cover) to gently work the valve cover loose from the cylinder head. Work your way around the perimeter.
* Slight Rocking Motion: Gently rock the valve cover back and forth while loosening the bolts to help it clear the oil reservoir.
* Check for Interference: Make sure there's nothing else interfering (a wire, hose, etc.) that might be preventing removal.
* Remove the Bolts Completely: Once you have the valve cover slightly loose, remove all the bolts.
* Lift Off the Valve Cover: Carefully lift the valve cover. Be aware of any remaining oil.
3. Cleaning and Replacing:
* Clean the Valve Cover and Cylinder Head: Remove the old gasket material from both surfaces. Use a plastic scraper and a clean rag. Be sure to get all traces of old gasket, ensuring a proper seal for the new one.
* Install the New Gasket: Apply a thin, even layer of gasket sealant (if recommended by the gasket manufacturer) to the new gasket and carefully place it on the cylinder head.
* Replace the Valve Cover: Carefully lower the valve cover onto the cylinder head, aligning it with the gasket.
* Tighten the Bolts: Tighten the bolts in a star pattern, using the torque specification found in your repair manual. Over-tightening can crack the valve cover.
4. Reassembly:
* Reconnect Everything: Reconnect all the hoses, wires, and connectors you disconnected earlier.
* Refill with Oil: Refill the engine with the correct type and amount of oil, as specified in your owner's manual.
* Check for Leaks: After running the engine for a short time, check for any oil leaks around the valve cover.
Important Considerations:
* If you're uncomfortable working on your car, take it to a mechanic. This is not a beginner-level repair, and improper installation can lead to serious engine damage.
* Use the correct type of gasket. Using the wrong gasket can lead to leaks.
* Be careful not to damage the valve cover or cylinder head.
By following these steps carefully and consulting a repair manual, you should be able to replace your Chevy Cavalier's valve cover successfully. Remember to prioritize safety and precision throughout the process.
