GM Corsica/Beretta 1988-1996 Repair Guide

Cylinder Head

Print

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.

2.0L and 2.2L Engine

The engine should be overnight cold before removing the cylinder head.

1988-90 VEHICLES

See Figure 1

  1. Properly relieve the fuel system pressure, as outlined in Fuel System of this guide. If not already done, disconnect the negative battery cable.
  2.  
  3. Place a suitable container under the radiator, then drain the cooling system.
  4.  
  5. Remove the TBI cover.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the exhaust shield. Disconnect the exhaust pipe.
  10.  
  11. Remove the heater hose from the intake manifold.
  12.  
  13. Disconnect the accelerator and TV cable bracket.
  14.  
  15. Carefully lower the vehicle.
  16.  
  17. Tag and disconnect the vacuum lines at the intake manifold and thermostat.
  18.  
  19. Disconnect the accelerator linkage at the TBI unit and remove the linkage bracket.
  20.  
  21. Tag and disconnect all necessary wires. Disconnect the upper radiator hose from the thermostat.
  22.  
  23. Remove the serpentine belt.
  24.  
  25. Unbolt the power steering pump and lay aside. Do NOT disconnect the fluid lines.
  26.  
  27. Make sure the fuel system pressure is released, then disconnect and plug the fuel lines.
  28.  
  29. Remove the alternator. Remove the alternator brace from the head and remove the upper mounting bracket.
  30.  
  31. Remove the cylinder head cover. Remove the rocker arms and pushrods keeping all parts in order for correct installation.
  32.  
  33. Remove the cylinder head bolts. Remove the cylinder head with the TBI unit, intake and exhaust manifolds still attached. Remove and discard the cylinder head gasket.
  34.  

To install:
  1. The gasket surfaces on both the head and the block must be clean of any foreign matter and free of any nicks or heavy scratches. Bolt threads in the block and the bolts must be clean.
  2.  
  3. Place a new cylinder head gasket in position over the dowel pins on the block. Carefully guide the cylinder head into position.
  4.  
  5. Coat the cylinder head bolts with sealing compound and install them finger-tight.
  6.  
  7. Using a torque wrench, tighten the bolts for 1988-89 vehicles, as follows: tighten the long bolts to 73-83 ft lbs. (11 Nm), in the sequence shown in the illustration and tighten the short bolts to 62-70 ft lbs. (84-95 Nm) in the sequence shown in the illustration.
  8.  
  9. For 1990 vehicles, tighten with a torque wrench in 4 steps as follows:
    1. Tighten all bolts in sequence to 41 ft. lbs. (55 Nm).
    2.  
    3. Tighten all bolts an additional 4° in sequence.
    4.  
    5. Tighten all bolts an additional 4° in sequence.
    6.  
    7. Tighten the long bolts - 8, 4, 1, 1, 5 and 9 an additional 20° and tighten the short bolts - 7, 3, 2, 6 and 10 an additional 10°.
    8.  

  10.  

The short bolts, exhaust side, should end up with a total rotation of 100° and the long bolts, intake side, should end up with a total rotation of 110°.

  1. Reinstall the alternator. Install the power steering pump and brackets.
  2.  
  3. Reconnect the fuel lines and the hoses. Connect the exhaust pipe to the manifold.
  4.  
  5. Install the valve cover and connect the linkage at the TBI unit. Install the air cleaner and fill all the fluids.
  6.  
  7. Connect the negative battery cable, then start the engine and check for leaks. Check the fluid levels, and add if necessary.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the cylinder head bolt tightening sequence for 1988-90 vehicles and the torque specifications for 1988-89 vehicles

1991-96 VEHICLES

See Figure 2

  1. Properly relieve the fuel system pressure, as outlined in Fuel System of this guide. If not already done, disconnect the negative battery cable.
  2.  
  3. Place a suitable container under the radiator, then drain the cooling system.
  4.  
  5. Disconnect the air inlet duct.
  6.  
  7. Tag and disconnect the necessary vacuum lines..
  8.  
  9. Detach and unroute the electrical connections from the following:
    1. Engine Coolant Temperature (ECT) sensor
    2.  
    3. Oxygen sensor
    4.  
    5. Idle Air Control (IAC) valve
    6.  
    7. Throttle Position (TP) sensor
    8.  
    9. Manifold Absolute Pressure (MAP) sensor
    10.  
    11. EVAP canister purge solenoid
    12.  
    13. Fuel injector harness
    14.  

  10.  
  11. Disconnect the accelerator, cruise control and TV cables.
  12.  
  13. Remove the coolant recovery reservoir.
  14.  
  15. Install engine support fixture, tool J 28467-A equivalent to the engine, then remove the right engine mount.
  16.  
  17. Remove the serpentine belt.
  18.  
  19. Remove the alternator rear brace, then remove the alternator.
  20.  
  21. Disconnect the power steering pump lines, then remove the power steering pump.
  22.  
  23. Remove the serpentine drive belt tensioners.
  24.  
  25. Remove the right engine mount bracket.
  26.  
  27. Tag and disconnect the wires from the spark plugs.
  28.  
  29. Detach the EVAP canister purge line from beneath the manifold.
  30.  
  31. Remove the throttle body cable bracket.
  32.  
  33. Disconnect the upper radiator hose from the coolant outlet.
  34.  
  35. Remove the intake manifold brace (on the power steering bracket).
  36.  
  37. Disconnect the coolant inlet hose from the cylinder head.
  38.  
  39. Using a back-up wrench, disconnect the fuel lines.
  40.  

When valve train components are removed for service, they should be kept in order. They must be installed in the same location, with the mating surface from which they were removed.

  1. Remove the rocker arm (valve) cover, then remove the rocker arms and pushrods, keeping them in order for installation.
  2.  
  3. Remove the spark plug wire bracket.
  4.  
  5. Remove the engine lift bracket.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Disconnect the exhaust pipe from the lower manifold.
  10.  
  11. Carefully lower the vehicle.
  12.  
  13. Remove the cylinder head retaining bolts.
  14.  
  15. If equipped with an automatic transaxle, remove the transaxle fluid level indicator bracket.
  16.  
  17. Remove the cylinder head from the vehicle. Remove and discard the cylinder head gasket.
  18.  
  19. The gasket surfaces on both the head and the block must be clean of any foreign matter and free of any nicks or heavy scratches. Bolt threads in the block and the bolts must be clean.
  20.  

To install:
  1. Place a new cylinder head gasket in position over the dowel pins on the block. Carefully guide the cylinder head into position.
  2.  
  3. Coat the cylinder head bolts with sealing compound and install them finger tight.
  4.  
  5. Using a torque wrench, tighten the bolts as follows:
    1. Tighten the long bolts in sequence to 5 ft. lbs. (62 Nm).
    2.  
    3. Tighten the short bolts in sequence to 2 ft. lbs. (58 Nm).
    4.  
    5. Tighten all bolts in sequence an additional 90° using J 36660, or equivalent torque angle meter.
    6.  

  6.  
  7. Install the engine lift bracket.
  8.  
  9. Install the spark plug wire bracket.
  10.  
  11. Install the rocker arms and pushrods in the same locations as they were removed from.
  12.  
  13. Install the rocker arm (valve) cover.
  14.  
  15. Install the accelerator, cruise control and TV bracket.
  16.  
  17. Connect the fuel lines and tighten using a back-up wrench.
  18.  
  19. Attch the vacuum lines and electrical connections at the throttle body, as tagged during removal.
  20.  
  21. Connect the coolant inlet hose to the cylinder head.
  22.  
  23. If equipped, install the transaxle fluid level indicator bracket bolt.
  24.  
  25. Install the intake manifold bracket-to-power steering bracket.
  26.  
  27. Connect the upper radiator hose to the outlet housing.
  28.  
  29. Attach the spark plug wires to the plugs, as tagged during removal.
  30.  
  31. Install the right engine bracket.
  32.  
  33. Install the serpentine drive belt tensioner.
  34.  
  35. Install the power steering pump, then connect the fluid lines.
  36.  
  37. Install the alternator and alternator rear brace.
  38.  
  39. Install the serpentine drive belt.
  40.  
  41. Remove the engine support tool.
  42.  
  43. Install the coolant recovery reservoir.
  44.  
  45. Install the air cleaner duct.
  46.  
  47. Connect the accelerator, cruise control and T.V. cables to the throttle body.
  48.  
  49. Route and attach the following electrical connectors:
    1. Engine Coolant Temperature (ECT) sensor
    2.  
    3. Oxygen sensor
    4.  
    5. Idle Air Control (IAC) valve
    6.  
    7. Throttle Position (TP) sensor
    8.  
    9. Manifold Absolute Pressure (MAP) sensor
    10.  
    11. EVAP canister purge solenoid
    12.  
    13. Fuel injector harness
    14.  

  50.  
  51. Connect the vacuum lines, as tagged during removal.
  52.  
  53. Raise and safely support the vehicle, then attach the exhaust pipe.
  54.  
  55. Carefully lower the vehicle. Fill all fluids and/or lubricants to the proper levels.
  56.  
  57. Connect the negative battery cable, then start the engine and check for leaks. Check the fluid levels, and add if necessary.
  58.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the cylinder head mounting and bolt tightening sequence -1991-96 2.2L engines

2.3L Engine

See Figures 3, 4 and 5

  1. Properly relieve the fuel system pressure, as outlined in Fuel System of this information.
  2.  
  3. If not already done, disconnect the negative battery cable. Drain the engine coolant into a clean container for reuse.
  4.  
  5. Disconnect the heater inlet and throttle body heater hoses from water outlet. Disconnect upper radiator hose from water outlet.
  6.  
  7. Remove the exhaust manifold.
  8.  
  9. Remove the intake and exhaust camshaft housings.
  10.  
  11. Unfasten the retaining bolt/screw, then remove the engine oil cap and dipstick. Pull the oil fill tube upward to unseat it from the block.
  12.  
  13. Tag and detach the injector harness electrical connector.
  14.  
  15. Disconnect the throttle body-to-air cleaner duct. Remove the throttle cable and bracket and position it aside.
  16.  
  17. Remove the throttle body from the intake manifold with the electrical harness, hoses and cable attached, then position the assembly aside.
  18.  
  19. Tag and disconnect the Manifold Absolute Pressure (MAP) sensor vacuum hose from intake manifold.
  20.  
  21. Remove the intake manifold bracket-to-block bolt, then remove the intake manifold brace.
  22.  
  23. Detach the electrical connectors from the Manifold Absolute Pressure (MAP) sensor, Intake Air Temperature (IAT) sensor and purge solenoid.
  24.  
  25. Tag and detach the 2 coolant sensor connections.
  26.  
  27. Remove the cylinder head-to-block bolts, in the reverse order of the tightening sequence. Remove the cylinder head, then remove and discard the gasket.
  28.  

Clean all gasket surfaces with plastic or wood scraper. Do not use any sealing material.

To install:
  1. Install the cylinder head gasket on the cylinder block, then carefully position the cylinder head in place.
  2.  
  3. Sparingly coat the head bolt threads with clean engine oil, allowing any excess oil to drain off before installing.
  4.  
  5. Tighten the cylinder head bolts to the proper torque, in the sequences shown in the accompanying figures.
  6.  
  7. Attach the electrical connectors to the Manifold Absolute Pressure (MAP) sensor, Intake Air Temperature (IAT) sensor and purge solenoid.
  8.  
  9. Install the intake manifold brace and secure with the manifold-to-block bracket bolt.
  10.  
  11. Connect the MAP sensor vacuum hose to the intake manifold.
  12.  
  13. Install the throttle body on the intake manifold with the electrical harness, hoses and cable attached.
  14.  
  15. Connect the throttle body-to-air cleaner duct. Install the throttle cable and bracket.
  16.  
  17. Attach the injector harness electrical connector.
  18.  
  19. Attach the 2 coolant sensor connections.
  20.  
  21. Install the oil cap and dipstick. Install the oil fill tube into the block and secure with the retaining bolt/screw.
  22.  
  23. Install the exhaust and intake camshaft housings.
  24.  
  25. Install the exhaust manifold.
  26.  
  27. Connect the heater inlet and throttle body heater hoses to the water outlet. Connect the upper radiator hose to the water outlet.
  28.  
  29. Fill the cooling system and connect the negative battery cable.
  30.  
  31. Start the engine, allow it to reach operating temperature then check for leaks. Check the coolant level and add, if necessary.
  32.  



Click image to see an enlarged view

Fig. Fig. 3: Cylinder head bolt torque specifications and tightening sequence -1990-91 2.3L engines



Click image to see an enlarged view

Fig. Fig. 4: Head bolt tightening sequence and specifications -1992-93 2.3L engines



Click image to see an enlarged view

Fig. Fig. 5: Cylinder head bolt tightening sequence specifications -1994 2.3L engines

2.8L AND 3.1L Engines

See Figure 6

LEFT SIDE
  1. Properly relieve the fuel pressure, as outlined in Fuel System of this information.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. For 1988-93 vehicles, remove the air cleaner assembly. For 1994-96 vehicles, remove the top half of the air cleaner assembly and throttle body duct.
  6.  
  7. Place a suitable drain pan under the radiator and drain the cooling system.
  8.  
  9. Unfasten the rocker arm (valve) cover attaching bolts, then remove the rocker arm cover(s).
  10.  
  11. Remove the intake manifold and plenum.
  12.  
  13. Remove the engine strut bracket.
  14.  
  15. Remove the exhaust crossover.
  16.  
  17. Remove the left side exhaust manifold.
  18.  
  19. Tag and disconnect the spark plug wires from the left cylinder head.
  20.  
  21. Loosen the rocker arms nuts, turn the rocker arms and remove the pushrods. Keep all of the components in order so they may be installed in their original positions.
  22.  
  23. Disconnect the oil level indicator tube assembly.
  24.  
  25. Unfasten the cylinder head-to-block bolts; starting with the outer bolts and working toward the center. Remove the cylinder head from the vehicle. Remove and discard the cylinder head gasket.
  26.  
  27. Clean the gasket mounting surfaces. Inspect the surfaces of the cylinder head, block and intake manifold damage and/or warpage. Clean the threaded holes in the block and the cylinder head bolt threads.
  28.  

To install:
  1. Align a new cylinder head gasket over the dowels on the block with the note This Side Up facing the cylinder head.
  2.  
  3. Position the cylinder head over the gasket on the block.
  4.  
  5. Sparingly coat the cylinder head bolt threads 1052080 or equivalent sealant, then install the bolts hand-tight.
  6.  
  7. Using the proper torque sequence (shown the accompanying figure), tighten the bolts to 33 ft. lbs. (4 Nm). After all bolts are tightened to 33 ft. lbs. (4 Nm), rotate the torque wrench another 90° or 1 / 4 turn. This will apply the correct torque to the bolts.
  8.  
  9. Position a new intake manifold gasket.
  10.  
  11. Install the pushrods in the same order that they were removed. Tighten the rocker arm nuts to 14-20 ft. lbs. (19-27 Nm).
  12.  
  13. Install the intake manifold and plenum.
  14.  
  15. Install the rocker arm (valve) cover and secure with the retaining bolts.
  16.  
  17. Install the oil level indicator tube assembly.
  18.  
  19. Connect the spark plug wires to the plugs, as tagged during removal.
  20.  
  21. Install the left exhaust manifold.
  22.  
  23. Install the crossover pipe.
  24.  
  25. Install the engine strut bracket.
  26.  
  27. For 1988-93 vehicles, install the air cleaner assembly. For 1994-96 vehicles, install the top half of the air cleaner assembly and throttle body duct.
  28.  
  29. Fill the cooling system and connect the negative battery cable.
  30.  
  31. Start the engine, allow it to reach operating temperature then check for leaks. Check the coolant level and add, if necessary.
  32.  



Click image to see an enlarged view

Fig. Fig. 6: Exploded view of the cylinder head mounting and bolt tightening sequence - 2.8L and 3.1L engines

RIGHT SIDE
  1. Properly relieve the fuel pressure, as outlined in Fuel System of this guide.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. For 1988-93 vehicles, remove the air cleaner assembly. For 1994-96 vehicles, remove the top half of the air cleaner assembly and throttle body duct.
  6.  
  7. Place a suitable drain pan under the radiator and drain the cooling system.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Disconnect the exhaust pipe from the crossover.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Remove the exhaust crossover heat shield. Remove the crossover from the right manifold.
  16.  
  17. Remove the right exhaust manifold-to-cylinder head bolts and exhaust manifold.
  18.  
  19. Tag and disconnect the spark plug wires from the plugs.
  20.  
  21. Remove the rocker arm (valve) cover.
  22.  
  23. Remove the intake manifold and plenum.
  24.  
  25. Loosen the rocker arms nuts, turn the rocker arms and remove the pushrods. Keep all of the components in order so they may be installed in their original positions.
  26.  
  27. Remove the cylinder head-to-engine bolts, starting with the outer bolts and working towards the center of the head.
  28.  
  29. Lift the cylinder head from the engine. Remove and discard the cylinder head gasket.
  30.  
  31. Throughly clean the gasket mounting surfaces, and cylinder head bolt threads and holes. Inspect the parts for damage and/or warpage; if necessary, have them machined or replace them.
  32.  

To install:
  1. Align a new cylinder head gasket over the dowels on the block with the note This Side Up facing the cylinder head.
  2.  
  3. Position the cylinder head over the gasket on the block.
  4.  
  5. Sparingly coat the cylinder head bolt threads 1052080 or equivalent sealant, then install the bolts hand-tight.
  6.  
  7. Using the proper torque sequence (shown the accompanying figure), tighten the bolts to 33 ft. lbs. (4 Nm). After all bolts are tightened to 33 ft. lbs. (4 Nm), rotate the torque wrench another 90° or 1 / 4 turn. This will apply the correct torque to the bolts.
  8.  
  9. Position a new intake manifold gasket.
  10.  
  11. Install the pushrods in the same order as they were removed. Tighten the rocker arm nuts to 14-20 ft. lbs. (19-27 Nm).
  12.  
  13. Install the intake manifold and plenum.
  14.  
  15. Install the rocker arm (valve) cover and secure with the retaining bolts.
  16.  
  17. Connect the spark plug wires to the plugs, as tagged during removal.
  18.  
  19. Install the right exhaust manifold and secure with the manifold-to-cylinder head bolts.
  20.  
  21. Install the crossover heat shield.
  22.  
  23. Raise the vehicle and support it safely.
  24.  
  25. Connect the exhaust pipe to the exhaust manifold and install the exhaust manifold-to-exhaust pipe bolts.
  26.  
  27. Carefully lower the vehicle.
  28.  
  29. For 1988-93 vehicles, install the air cleaner assembly. For 1994-96 vehicles, install the top half of the air cleaner assembly and throttle body duct.
  30.  
  31. Fill the cooling system and connect the negative battery cable.
  32.  
  33. Start the engine, allow it to reach operating temperature then check for leaks. Check the coolant level and add, if necessary.
  34.  

See Figures 7, 8, 9, 10 and 11



Click image to see an enlarged view

Fig. Fig. 7: Unfasten the retainer, then remove the oil level dipstick tube assembly



Click image to see an enlarged view

Fig. Fig. 8: Starting with the outermost bolts, unfasten the cylinder head-to-block bolts ...



Click image to see an enlarged view

Fig. Fig. 9: ... then remove the cylinder head from the vehicle



Click image to see an enlarged view

Fig. Fig. 10: Remove and discard the cylinder head gasket. The gasket MUST be replaced anytime the head is removed



Click image to see an enlarged view

Fig. Fig. 11: The correct tightening sequence and specifications are essential to prevent cylinder head leakage

 
label.common.footer.alt.autozoneLogo