GM Corsica/Beretta 1988-1996 Repair Guide

Camshaft, Bearings and Liners

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To perform the following procedures, the engine must be removed from the vehicle.

REMOVAL & INSTALLATION




CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

2.0L and 2.2L Engines

See Figures 1 and 2

1988-90 VEHICLES
  1. Remove the engine from the vehicle and mount on a suitable engine stand.
  2.  
  3. Remove the timing chain and sprockets from the engine.
  4.  
  5. Drain the engine oil into a suitable container, then remove the oil filter.
  6.  
  7. Remove the rocker arm (valve) cover. Loosen the rocker arms, then pivot them 90°. Remove the pushrods and lifters; make sure to note the position of the valve train components for reassembly purposes, as these components MUST be installed in the same positions as they were removed.
  8.  
  9. Remove the oil pump drive.
  10.  
  11. Remove the camshaft thrust plate-to-engine bolts and carefully pull the camshaft from the front of the engine.
  12.  

Use care when removing and installing the camshaft; DO NOT damage the camshaft bearings or the bearing surfaces on the camshaft.

  1. Using a gasket scraper, thoroughly clean the gasket mounting surfaces.
  2.  

Camshaft bearing removal requires the use of tool J 33049 or equivalent camshaft bearing remover/installer.

  1. Remove the camshaft bearings as follows:
    1. Select the proper pilot, nut and thrust washer.
    2.  
    3. Assemble camshaft bearing removal/installation tool J 33049. Make sure to puller nut engages with a sufficient number of threads.
    4.  
    5. Pull out the camshaft bearings.
    6.  

  2.  

Camshaft bearings can NOT be reused once they are removed.



Click image to see an enlarged view

Fig. Fig. 1: Use the proper tool to remove and install the camshaft bearings - 2.0L and 2.2L engines



Click image to see an enlarged view

Fig. Fig. 2: Fabricate a suitable tool to inspect the camshaft bearing oil hole alignment - 2.0L and 2.2L engines

To install:
  1. Install the camshaft bearings, as follows:
    1. Select front, rear and intermediate camshaft bearings.
    2.  
    3. Select the proper pilot, nut and thrust washer.
    4.  
    5. Assemble camshaft bearing removal/installation tool J 33049.
    6.  
    7. Place the bearing onto the tool, then index the oil holes(s) of the bearing with the oil passage(s) in the cylinder block. Pull the bearing into place.
    8.  
    9. Apply GM sealer 1052914 or equivalent to the camshaft plug, then install the camshaft plug.
    10.  
    11. With a piece of 3 / 32 in. brass rod with a 90° bend at the end, probe the bearing oil holes and make sure they are properly aligned.
    12.  

  2.  
  3. Lubricate the lobes of the camshaft with GM E.O.S. 1051396 or equivalent and insert the camshaft into the engine.
  4.  

If a new camshaft is being installed, replace all of the valve lifters. Used lifters can only be used on the camshaft that they were originally installed with; provided they are installed in the exact same position they were removed.

  1. Align the marks on the camshaft and crankshaft sprockets.
  2.  
  3. Install the timing chain and sprocket.
  4.  
  5. To complete the installation, use new gaskets and reverse the removal procedures.
  6.  
  7. Tighten the rocker arm nuts to 11-18 ft. lbs. (15-24 Nm).
  8.  
  9. Fill the cooling system and crankcase with the proper types and amounts of fluids.
  10.  
  11. Connect the negative battery cable, then start the engine and check for leaks. Check the fluid levels and add if necessary.
  12.  

1991-96 VEHICLES
  1. Remove the engine and transaxle assembly from the vehicle and mount on an engine stand.
  2.  
  3. Remove the serpentine drive belt.
  4.  
  5. Remove the alternator and brackets.
  6.  
  7. Remove the power steering pump.
  8.  
  9. Remove the serpentine drive belt tensioner.
  10.  
  11. Remove the water pump pulley.
  12.  
  13. If not already done, drain the engine oil into a suitable container, then remove the oil filter.
  14.  
  15. Remove the crankshaft pulley and hub.
  16.  
  17. Remove the rocker arm (valve) cover.
  18.  
  19. Remove the rocker arms and pushrods.
  20.  
  21. Remove the valve lifters.
  22.  
  23. Remove the crankshaft front cover.
  24.  
  25. Remove the cam sprocket, timing chain and tensioner.
  26.  
  27. Remove the oil pump drive.
  28.  
  29. Remove the camshaft thrust plate and remove the camshaft carefully without damaging the bearings.
  30.  
  31. Remove the camshaft bearings, if necessary, as follows:
    1. Select the proper pilot, nut and thrust washer.
    2.  
    3. Assemble tool J 33049 or equivalent, making sure the puller nut engages a sufficient number of threads.
    4.  
    5. Pull out the bearings.
    6.  

  32.  

To install:
  1. Install the camshaft bearings, if necessary, as follows:
    1. Select new front rear and intermediate camshaft bearings.
    2.  
    3. Select the proper pilot, nut and thrust washer.
    4.  
    5. Assemble tool J 33049 or equivalent, place the bearing onto the tool and index the oil hole(s) of the bearing with the oil passage(s) in the cylinder block.
    6.  
    7. Pull the bearing into place.
    8.  
    9. Use a 3 / 32 in. (2.4mm) brass rod with a 90° bend and probe the bearing holes to verify that they are properly aligned.
    10.  

  2.  
  3. Coat the camshaft lobes with and bearings with GM Engine Oil Supplement (E.O.S.) 1051396 or equivalent and insert the camshaft and thrust plate in the engine.
  4.  
  5. Tighten the thrust plate bolts to 106 inch lbs. (12 Nm).
  6.  
  7. Install the timing chain and sprockets.
  8.  
  9. Install the crankcase front cover.
  10.  
  11. Install the valve lifters in the same bores from which they were removed.
  12.  

If a new camshaft is installed, replace all the valve lifters.

  1. Install the oil pump drive.
  2.  
  3. Install the rocker arms and pushrods.
  4.  
  5. Install the rocker cover.
  6.  
  7. Install the crankshaft pulley hub and pulley.
  8.  
  9. Install the water pump pulley.
  10.  
  11. Install the serpentine drive belt tensioner.
  12.  
  13. Install the power steering pump.
  14.  
  15. Install the alternator and brackets.
  16.  
  17. Install the serpentine drive belt.
  18.  
  19. Install the engine and transaxle assembly.
  20.  
  21. Install the oil filter.
  22.  
  23. Fill the cooling system and crankcase with the proper types and amounts of fluids.
  24.  
  25. Connect the negative battery cable, then start the engine and check for leaks. Check the fluid levels and add if necessary.
  26.  

2.3L Engine

See Figures 3, 4, 5, 6 and 7

INTAKE CAMSHAFT, HOUSING AND LIFTERS - 1990-93 VEHICLES

Any time the camshaft housing to cylinder head bolts are loosened or removed, the camshaft housing to cylinder head gasket must be replaced.

  1. Relieve the fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Remove ignition coil and module assembly electrical connections mark or tag, if necessary.
  4.  
  5. Remove 4 ignition coil and module assembly to camshaft housing bolts and remove assembly by pulling straight up. Use a special spark plug boot wire remover tool to remove connector assemblies if stuck to the spark plugs.
  6.  



Click image to see an enlarged view

Fig. Fig. 3: Remove the ignition coil and module assembly - 2.3L engine

  1. Remove the idle speed power steering pressure switch connector.
  2.  
  3. Loosen 3 power steering pump pivot bolts and remove drive belt.
  4.  
  5. Disconnect the 2 rear power steering pump bracket to transaxle bolts.
  6.  
  7. Remove the front power steering pump bracket to cylinder block bolt.
  8.  
  9. Disconnect the power steering pump assembly and position aside.
  10.  
  11. Using special tools remove power steering pump drive pulley from intake camshaft.
  12.  
  13. Remove oil/air separator bolts and hoses. Leave the hoses attached to the separator, disconnect from the oil fill, chain housing and intake manifold. Remove as an assembly.
  14.  
  15. Remove vacuum line from fuel pressure regulator and fuel injector harness connector.
  16.  
  17. Disconnect fuel line retaining clamp from bracket on top of intake camshaft housing.
  18.  
  19. Remove fuel rail to camshaft housing attaching bolts.
  20.  
  21. Remove fuel rail from cylinder head. Cover injector openings in cylinder head and cover injector nozzles. Leave fuel lines attached and position fuel rail aside.
  22.  



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the fuel rail and lines - 2.3L engine

  1. Disconnect timing chain and housing but do not remove from the engine.
  2.  
  3. Remove intake camshaft housing cover-to-camshaft housing attaching bolts.
  4.  

The camshaft housing-to-cylinder head bolts MUST be loosened and removed in the reverse order of the tightening sequence.

  1. Remove intake camshaft housing to cylinder head attaching bolts. Use the reverse of the tightening procedure when loosening camshaft housing to cylinder head attaching bolts. Leave 2 bolts loosely in place to hold the camshaft housing while separating camshaft cover from housing.
  2.  
  3. Push the cover off the housing by threading 4 of the housing to head attaching bolts into the tapped holes in the cam housing cover. Tighten the bolts in evenly so the cover does not bind on the dowel pins.
  4.  
  5. Remove the 2 loosely installed camshaft housing to head bolts and remove cover, discard gaskets.
  6.  
  7. Note the position of the chain sprocket dowel pin for reassembly. Remove the camshaft, being careful not to damage the camshaft oil seal from camshaft or journals.
  8.  
  9. Remove intake camshaft oil seal from camshaft and discard seal. This seal must be replaced any time the housing and cover are separated.
  10.  



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the camshaft housing, cover and gaskets - 2.3L engine



Click image to see an enlarged view

Fig. Fig. 6: Intake and exhaust camshaft housing-to-cover seals

To install:

If the camshaft is being replaced, the lifters must also be replaced. Lubricate the camshaft lobes, journals and lifters with camshaft and lifter prelube. The camshaft lobes and journals must be adequately lubricated or engine damage could occur upon start up.

  1. Install camshaft in same position as when removed. The timing chain sprocket dowel pin should be straight up and line up with the centerline of the lifter bores.
  2.  
  3. Install new camshaft housing-to-camshaft housing cover seals into cover. Do not use sealer.
  4.  

Cam housing to cover seals are all different.

  1. Apply locking type sealer to camshaft housing and cover attaching bolt threads.
  2.  

The camshaft housing bolts MUST be tightened in sequence.

  1. Install bolts and tighten to 11 ft. lbs. (15 Nm). Rotate the bolts an additional 75°, for 1990-93 vehicles or 90° for 1994 vehicles, in sequence.
  2.  

Tighten the 2 rear bolts that hold fuel pipe to camshaft housing to 11 ft. lbs. (15 Nm), then rotate the bolts an additional 25° for 1990-93 vehicles or 30° for 1994 vehicles.



Click image to see an enlarged view

Fig. Fig. 7: Intake and exhaust camshaft bolt tightening sequences - 2.3L engine

  1. Install timing chain housing and timing chain.
  2.  
  3. Uncover fuel injectors and install new fuel injector ring seals lubed with engine oil.
  4.  
  5. Install fuel rail to cylinder head.
  6.  
  7. Install fuel rail to camshaft housing attaching bolts.
  8.  
  9. Connect fuel line retaining clamp to bracket on top of intake camshaft housing.
  10.  
  11. Install vacuum line to fuel pressure regulator and fuel injector harness connector.
  12.  
  13. Install oil/air separator bolts and hoses.
  14.  
  15. Install power steering pump drive pulley to intake camshaft.
  16.  
  17. Install the power steering pump assembly.
  18.  
  19. Install the front power steering pump bracket to cylinder block bolt.
  20.  
  21. Connect the 2 rear power steering pump bracket to transaxle bolts.
  22.  
  23. Tighten the 3 power steering pump pivot bolts and install serpentine belt.
  24.  
  25. Connect the idle speed power steering pressure switch connector.
  26.  
  27. Install ignition module assembly and the 4 ignition coil and module assembly to camshaft housing bolts.
  28.  

Clean any loose lubricant that is present on the ignition coil and module assembly to camshaft housing bolts. Apply Loctite® 592 or equivalent onto the ignition coil and module assembly to camshaft housing bolts. Install the bolts and tighten to 13 ft. lbs. (18 Nm).

  1. Connect ignition coil and module assembly electrical connectors.
  2.  
  3. Connect the negative battery cable.
  4.  

EXHAUST CAMSHAFT, HOUSING AND LIFTERS

Any time the camshaft housing-to-cylinder head bolts are loosened or removed, the camshaft housing-to-cylinder head gasket must be replaced.

  1. Relieve the fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Remove electrical connection from ignition coil and module assembly.
  4.  
  5. Remove 4 ignition coil and module assembly to camshaft housing bolts and remove assembly by pulling straight up. Use a special tool to remove connector assembly if stuck to the spark plugs.
  6.  
  7. Detach the electrical connection from oil pressure switch.
  8.  
  9. Remove transaxle fluid level indicator tube assembly from exhaust camshaft cover and position aside.
  10.  
  11. Remove the exhaust camshaft cover and gasket.
  12.  
  13. Disconnect timing chain and housing but do not remove from the engine.
  14.  

The camshaft housing-to-cylinder head bolts MUST be loosened and removed in the reverse order of the tightening sequence.

  1. Remove exhaust camshaft housing to cylinder head bolts. Use the reverse of the tightening procedure when loosening camshaft housing while separating camshaft cover from housing.
  2.  
  3. Push the cover off the housing by threading 4 of the housing to head attaching bolts into the tapped holes in the camshaft cover. Tighten the bolts in evenly so the cover does not bind on the dowel pins.
  4.  
  5. Remove the 2 loosely installed camshaft housing to cylinder head bolts and remove cover, discard gaskets.
  6.  
  7. Loosely reinstall 1 camshaft housing to cylinder head bolt to hold the camshaft housing in place during camshaft and lifter removal.
  8.  
  9. Note the position of the chain sprocket dowel pin for reassembly. Remove camshaft being careful not to damage the camshaft or journals.
  10.  
  11. If removing the camshaft housing, remove the valve lifters. Keep the lifters in order so they can be reinstalled in the same location.
  12.  
  13. Remove the camshaft housing and gasket.
  14.  

To install:
  1. Install the camshaft housing and gasket.
  2.  
  3. Loosely install one camshaft housing-to-cylinder head bolt to hold the housing in place.
  4.  

Used lifters must be returned to their original position in the camshaft. If the camshaft is being replaced, the lifters must also be replaced. Lubricate camshaft lobe, journals and lifters with camshaft and lifter prelube. The camshaft lobes and journals must be adequately lubricated or engine damage could occur upon start up.

  1. Install the lifters into the lifter bores.
  2.  
  3. Install camshaft in same position as when removed. The timing chain sprocket dowel pin should be straight up and line up with the centerline of the lifter bores.
  4.  
  5. Install new camshaft housing-to-camshaft housing cover seals into cover, no sealer is needed.
  6.  

Cam housing to cover seals are all different.

  1. Remove the bolt holding the housing in place. Apply locking type sealer to camshaft housing and cover attaching bolt threads.
  2.  

To install:
  1. Install the camshaft housing cover to the camshaft housing.
  2.  
  3. Install the retaining bolts and tighten, in the sequence shown in the accompanying figure, to 11 ft. lbs. (15 Nm), then rotate, in sequence, an additional 75° for 1990-93 vehicles or 90° for 1994 vehicles.
  4.  
  5. Install the timing chain housing and timing chain.
  6.  
  7. Install the exhaust camshaft housing cover, using a new gasket, then tighten to 10 ft. lbs. (14 Nm).
  8.  
  9. Attach the oil pressure switch electrical connector.
  10.  
  11. Reinstall any spark plug boot connector that was stuck to a spark plug back onto the ignition coil assembly.
  12.  
  13. Locate the ignition coil and module assembly over the spark plugs and push straight down to properly seat the assembly.
  14.  

Clean any loose lubricant that is present on the ignition coil and module assembly to camshaft housing bolts.

  1. Apply Loctite® 592 or equivalent to the ignition coil and module assembly to camshaft housing bolts. Install and hand start the ignition coil and module assembly bolts. Tighten to 15 ft. lbs. (20 Nm).
  2.  
  3. Attach the ignition coil and module assembly electrical connectors.
  4.  
  5. Connect the negative battery cable.
  6.  

2.8L and 3.1L Engine

See Figure 8, 9 and 10

  1. Relieve the fuel system pressure. If not already done, disconnect the negative battery cable.
  2.  
  3. Drain the cooling system and the engine oil into suitable containers.
  4.  
  5. Remove the engine from the vehicle and mount on a suitable engine stand.
  6.  

Be sure to the valve train components in order for reassembly purposes.

  1. Remove the valve lifters.
  2.  
  3. Remove the timing chain (front) cover, then remove the timing chain and sprockets.
  4.  



Click image to see an enlarged view

Fig. Fig. 8: Before removing the timing chain, make sure the timing marks are aligned - 2.8L and 3.1L engines

  1. If equipped, remove the camshaft thrust plate bolts, then remove the thrust plate.
  2.  

The camshaft journals are all the same size. Use extreme care when removing or installing the camshaft not to damage the camshaft bearings or the bearing journals of the camshaft.

  1. Install a camshaft bolt in the camshaft bolt hole, then carefully rotate and pull the camshaft from the bearings out of the front of the engine.
  2.  
  3. Using a gasket scraper, clean gasket mounting surfaces.
  4.  

Camshaft bearing removal requires the use of tool J 33049 or equivalent camshaft bearing remover/installer.

  1. If necessary, remove the camshaft bearings as follows:
    1. Select the proper expander assembly.
    2.  
    3. Assemble camshaft bearing removal/installation tool J 33049.
    4.  
    5. Carefully tap out the camshaft bearings.
    6.  

  2.  

Camshaft bearings can NOT be reused once they are removed.



Click image to see an enlarged view

Fig. Fig. 9: Use the proper tool to remove and install the camshaft bearings - 2.8L and 3.1L engines



Click image to see an enlarged view

Fig. Fig. 10: Fabricate a suitable tool to inspect the camshaft bearing oil hole alignment - 2.8L and 3.1L engines

To install:
  1. Install the camshaft bearings, as follows:
    1. Select front, rear and intermediate camshaft bearings.
    2.  
    3. Select the proper expander assembly.
    4.  
    5. Assemble camshaft bearing removal/installation tool J 33049.
    6.  
    7. Place the bearing onto the tool, then index the oil holes(s) of the bearing with the oil passage(s) in the cylinder block. Tap the bearing into place.
    8.  
    9. Looking from the front of the engine block, index the front bearing oil holes at 4 and 7 o'clock.
    10.  
    11. Index all other bearing oil holes at 4 o'clock.
    12.  
    13. With a piece of 3 / 32 in. brass rod with a 90° bend at the end, probe the bearing oil holes and make sure they are properly aligned.
    14.  

  2.  
  3. If installing a new camshaft, lubricate the camshaft lobes with GM E.O.S. 1051396 or equivalent and insert the camshaft in the engine.
  4.  

If a new camshaft is being used replace all of the lifters. Used lifters can only be used on the camshaft that they were originally installed with; provided they are installed in the exact same position they were removed.

  1. Align the camshaft and crankshaft sprocket marks. Install the timing chain and sprocket.
  2.  
  3. Install the front cover and valve train components. Tighten the rocker arm nuts to 14-20 ft. lbs. (19-27 Nm).
  4.  
  5. To complete the installation, reverse the removal procedures. Start the engine, allow it to reach normal operating temperatures and check for leaks.
  6.  

 
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