GM Corsica/Beretta 1988-1996 Repair Guide

Rocker Arm (Valve) Cover

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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 Engines

See Figures 1

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the air intake hose from the throttle body and air cleaner.
  4.  
  5. For9999-96 vehicles, remove the cruise, throttle and T.V. cable bracket.
  6.  
  7. Disconnect the crankcase ventilation hose(s).
  8.  
  9. Unfasten the rocker arm (valve) cover bolts, then remove the cover. Remove and discard the gasket.
  10.  
  11. Clean the sealing surfaces of the head and the cover using a suitable degreaser.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: Rocker arm (valve) cover mounting - 2.0L and 2.2L engines

To install:
  1. Position a new gasket, then install the rocker arm (valve) cover. Tighten the retaining bolts to 89 inch lbs. (10 Nm).
  2.  
  3. Connect the crankcase ventilation hose(s).
  4.  
  5. For9999-96 vehicles, install the cruise, throttle and T.V. cable bracket.
  6.  
  7. Connect the air intake hose to the throttle body and air cleaner
  8.  
  9. Connect the negative battery cable. Start the engine and check for leaks.
  10.  

2.3L Engine

The camshaft housing covers and cylinder head are retained by the same bolts. When the bolts are removed to service the camshaft cover, the cylinder head gasket MUST be replaced also. Refer to the Cylinder Head removal procedure for details.

2.8L and 3.1L Engines

See Figures 2, 3, 4 and 5

FRONT COVER - 1988 VEHICLES
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the bracket tube at the cover.
  4.  
  5. Remove the plug wire cover.
  6.  
  7. Disconnect the heater hose at the filler neck.
  8.  
  9. Remove the cover bolts and remove the cover.
  10.  
  11. If the cover adheres to the cylinder head, lightly tap the end of the cover with a soft rubber mallet or palm of the hand.
  12.  


WARNING
Do not distort or scratch the sealing flange.

To install:
  1. Clean the sealing surfaces of the head and the cover.
  2.  
  3. Install a new gasket and make sure it is seated properly in the rocker cover groove.
  4.  
  5. Apply RTV sealant in the notch.
  6.  
  7. Install the rocker cover and tighten the retaining bolts to 6-9 ft. lbs. (8-12 Nm).
  8.  
  9. Install the remaining parts and reconnect the battery cable.
  10.  

FRONT (LEFT) COVER - 1989-93 VEHICLES
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly
  4.  
  5. Position a suitable drain pan under the radiator, then drain the engine coolant.
  6.  
  7. Remove the ignition wire clamps from the coolant tube.
  8.  
  9. Disconnect the coolant tube mount at the head.
  10.  
  11. Disconnect the coolant tube at each end.
  12.  
  13. Disconnect the coolant tube at the water pump and remove the tube.
  14.  
  15. Remove the tube from the rocker cover to air inlet.
  16.  
  17. Remove the ignition wire guide.
  18.  
  19. Remove the cover bolts and remove the cover.
  20.  
  21. If the cover adheres to the cylinder head, lightly tap the end of the cover with a soft rubber mallet or palm of the hand.
  22.  


WARNING
Do not distort or scratch the sealing flange.

To install:
  1. Clean the sealing surfaces of the head and the cover.
  2.  
  3. Install a new gasket and make sure it is seated properly in the rocker cover groove.
  4.  
  5. Apply RTV sealant in the notch.
  6.  
  7. Install the rocker cover and tighten the retaining bolts to 89 inch lbs. (10 Nm).
  8.  
  9. Install the remaining parts and reconnect the battery cable.
  10.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the valve cover attachment - 2.8L and 3.1L (VIN T) engines

FRONT (LEFT) COVER - 1994-96 VEHICLES
  1. Disconnect the negative battery cable.
  2.  
  3. Position a drain pan under the radiator, then partially drain the cooling system to a level below the bypass pipe. Don't forget to close the radiator drain cock.
  4.  
  5. Disconnect the coolant bypass pipe from the water pump and exhaust manifold.
  6.  



Click image to see an enlarged view

Fig. Fig. 3: Unfasten the retaining clamp and disconnect the coolant bypass pipe from the manifold



Click image to see an enlarged view

Fig. Fig. 4: Unfasten the coolant bypass pipe retaining bolts ...



Click image to see an enlarged view

Fig. Fig. 5: ... then remove the bypass pipe from the vehicle

  1. Disconnect the PCV valve from the rocker arm (valve) cover.
  2.  
  3. Unfasten the retaining bolts, then remove the rocker arm cover from the cylinder head.
  4.  
  5. Remove and discard the gasket. Clean the cover and cylinder head surfaces with a suitable degreaser.
  6.  

If the cover sticks to the cylinder head, use your palm or a rubber mallet to gently bump the end of the cover to break it loose.

See Figures 6 and 7



Click image to see an enlarged view

Fig. Fig. 6: Unfasten the rocker arm (valve) cover retaining bolts ...



Click image to see an enlarged view

Fig. Fig. 7: ... then remove the rocker arm cover from the vehicle

To install:
  1. Position a new gasket and bolt grommets. Make sure the gasket is seated correctly in the rocker arm (valve) cover groove.
  2.  
  3. Apply RTV sealer9052917, or equivalent to the notch shown in the accompanying figure.
  4.  
  5. Position the rocker arm cover in place and secure with the retaining fasteners, finger-tight. Tighten the fasteners to 89 inch lbs. (10 Nm).
  6.  
  7. Connect the PCV valve to the rocker arm cover.
  8.  
  9. Attach the coolant bypass pipe to the water pump and manifold.
  10.  
  11. Add the proper type and amount of coolant to bring up to the correct level.
  12.  
  13. Connect the negative battery cable, then start the vehicle, check for leaks and inspect the coolant level. Add coolant if necessary.
  14.  

REAR (RIGHT) COVER - 1988-93 VEHICLE
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Position a drain pan under the radiator, then drain the cooling system. Don't forget to close the radiator drain cock.
  6.  
  7. Tag and disconnect the vacuum hoses from the intake plenum.
  8.  
  9. Disconnect the airflow tube.
  10.  
  11. Disconnect the EGR tube from the crossover pipe.
  12.  
  13. Remove the spark plug wire guide.
  14.  
  15. Detach the spark plug wire harness from the plenum and plugs.
  16.  
  17. Disconnect the coolant hoses from the throttle base.
  18.  
  19. Tag and detach any wiring from the plenum in order to remove the rocker arm cover.
  20.  
  21. Disconnect the throttle, T.V. and cruise control (if equipped) cables.
  22.  
  23. Remove the bracket from the right side of the plenum.
  24.  
  25. Disconnect the brake booster vacuum supply from the plenum.
  26.  
  27. Remove the serpentine drive belt.
  28.  
  29. Disconnect the exhaust pipe from the crossover.
  30.  
  31. Unbolt the alternator and position it aside.
  32.  
  33. Disconnect the PCV valve from the rocker arm (valve) cover.
  34.  
  35. Unfasten the retaining bolts, then remove the rocker arm cover from the cylinder head. Remove and discard the gasket.
  36.  

If the cover sticks to the cylinder head, lightly tap the end of the cover with a soft rubber mallet or the palm of your the hand. Be careful not to not distort or scratch the sealing flange.

  1. Clean the sealing surfaces of the head and the cover with a suitable degreaser.
  2.  

To install:
  1. Position a new gasket and bolt grommets. Make sure the gasket is seated correctly in the rocker arm (valve) cover groove.
  2.  
  3. Apply RTV sealer9052917, or equivalent to the notch shown in the accompanying figure.
  4.  
  5. Position the rocker arm cover in place and secure with the retaining fastener finger-tight. Tighten the fasteners to 89 inch lbs. (10 Nm).
  6.  
  7. Connect the PCV valve to the valve cover.
  8.  
  9. Install the alternator.
  10.  
  11. Connect the exhaust pipe to the crossover.
  12.  
  13. Install the serpentine drive belt.
  14.  
  15. Connect the brake booster vacuum supply line to the plenum.
  16.  
  17. Install the bracket to the right side of the plenum.
  18.  
  19. Connect the throttle, T.V. and cruise control cables.
  20.  
  21. Attach the necessary wiring to the plenum, as tagged during removal.
  22.  
  23. Connect the coolant hoses to the throttle base.
  24.  
  25. Attach the spark plug wire harness, then secure with the wire guide.
  26.  
  27. Connect the EGR tube to the crossover pipe.
  28.  
  29. Attach the airflow tube.
  30.  
  31. Connect the vacuum hoses to the plenum.
  32.  
  33. Add the proper type and amount of coolant to bring up to the correct level.
  34.  
  35. Connect the negative battery cable, then start the vehicle, check for leaks and inspect the coolant level. Add coolant if necessary.
  36.  

REAR (RIGHT) COVER - 1994-96 VEHICLE
  1. Disconnect the negative battery cable.
  2.  
  3. Detach the rear spark plug wire harness from the upper intake manifold and spark plugs.
  4.  
  5. Disconnect the brake booster vacuum supply from the upper intake manifold.
  6.  
  7. Remove the serpentine drive belt.
  8.  
  9. Remove the alternator and position it aside.
  10.  
  11. Remove the electronic ignition coil and module assembly and remove the EVAP canister purge solenoid.
  12.  
  13. Unfasten the retaining bolts, then remove the rocker arm (valve) cover from the cylinder head.
  14.  

If the cover sticks to the cylinder head, use your palm or a rubber mallet to gently bump the end of the cover to break it loose.

  1. Remove and discard the gasket. Clean the cover and cylinder head surfaces with a suitable degreaser.
  2.  

To install:
  1. Position a new gasket and bolt grommets. Make sure the gasket is seated correctly in the rocker arm (valve) cover groove.
  2.  
  3. Apply RTV sealer9052917, or equivalent to the notch shown in the accompanying figure.
  4.  
  5. Position the rocker arm cover in place and secure with the retaining fasteners, finger-tight. Tighten the fasteners to 89 inch lbs. (10 Nm).
  6.  
  7. Install the alternator and the serpentine drive belt.
  8.  
  9. Connect the brake booster vacuum supply line.
  10.  
  11. Install the EVAP canister purge solenoid and electronic ignition coil and module assembly.
  12.  
  13. Attach the rear spark plug wire harness to the upper intake manifold and spark plugs.
  14.  
  15. Connect the negative batter cable, then start the engine and check for leaks.
  16.  

 
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