GM Corsica/Beretta 1988-1996 Repair Guide

Timing Chain Cover and Seal

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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.

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 Figure 1

The following procedure requires the use of a special tool.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine belt and tensioner.
  4.  
  5. For 1993-96 vehicles perform the following:
    1. Install engine support fixture J 28467-A, or equivalent.
    2.  
    3. Remove the engine mount assembly.
    4.  
    5. Remove the alternator rear brace, then remove the alternator from the vehicle.
    6.  
    7. Unbolt the power steering pump, then position it aside, with the fluid lines attached.
    8.  

  6.  
  7. Raise the vehicle and support it safely.
  8.  
  9. Drain the engine oil into a suitable container.
  10.  
  11. Remove the oil pan-to-front cover bolts, then remove the oil pan from the vehicle.
  12.  
  13. Remove the wheel and tire assembly.
  14.  
  15. Remove the right front inner fender splash.
  16.  
  17. Unscrew the center bolt from the crankshaft pulley and install tool J 24420-B on their pulley, then turn the puller screw and remove the pulley.
  18.  
  19. Remove the front cover-to-block bolts and then remove the front cover. If the front cover is difficult to remove, use a plastic mallet.
  20.  

The oil seal can be replaced with the cover either on or off the engine. If the cover is on the engine, remove the crankshaft pulley and hub first. Pry out the seal using a large prytool, being careful not to scratch or distort the seal mating surface. Install the new seal so that the open side or helical side is towards the engine. Press it into place with a seal driver made for the purpose. General Motors recommends a tool, J-35468 Seal Centering Tool. Install the hub if removed.



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the timing chain cover - 2.0L and 2.2L engines

To install:
  1. The surfaces of the block and front cover must be clean and free of oil. Use a new gasket and place the cover over the dowel pins. Tighten the bolts to 89-97 inch lbs. (10-11 Nm).
  2.  
  3. Apply RTV sealant to the keyway in the pulley and place the crankshaft pulley in position over the key on the crankshaft. Pull the crankshaft as follows:

    Install tool J 29113 into the crankshaft so that at least 6mm of thread is engaged.
     
    Pull the pulley into position and remove the tool from the pulley.
     

  4.  
  5. Tighten the pulley retaining bolt to 66-88 ft. lbs. (89-119 Nm).
  6.  
  7. Install the inner fender splash shield, then install the wheel and tire assembly.
  8.  
  9. Install the oil pan.
  10.  
  11. Carefully lower the vehicle.
  12.  
  13. For 1994-96 vehicles, perform the following:
    1. Position the power steering pump and install the mounting bolts.
    2.  
    3. Install the alternator and rear brace.
    4.  
    5. Install the engine mount, then remove the lifting device.
    6.  

  14.  
  15. Install the serpentine drive belt tensioner and the belt.
  16.  
  17. Fill the crankcase with the proper type and amount of engine oil.
  18.  
  19. Connect the negative battery cable.
  20.  

2.3L Engine

See Figure 2

  1. Disconnect the negative battery cable.
  2.  
  3. Properly drain the cooling system into a suitable container. Remove coolant recovery reservoir.
  4.  
  5. Remove the serpentine drive belt.
  6.  

To avoid personal injury when rotating the serpentine belt tensioner, use a 13mm wrench that is at least 24 in. (610mm) long.

  1. For 1992-94 vehicles perform the following:
    1. Remove the alternator and position it aside.
    2.  
    3. Reinstall the alternator through bolt, then install engine support fixture J 28467-A or equivalent.
    4.  

  2.  
  3. Remove the upper timing chain cover fasteners.
  4.  
  5. Disconnect the cover vent hose.
  6.  
  7. For 1992-94 vehicles, remove the right engine mount and mount bracket.
  8.  
  9. For 1990-91 vehicles, remove the engine lift bracket.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Remove right front wheel and tire assembly, then remove right lower splash shield.
  14.  
  15. Remove crankshaft balancer assembly.
  16.  
  17. Remove lower timing chain cover fasteners.
  18.  
  19. Carefully lower the vehicle, then remove the timing chain (front) cover. Inspect the gasket and replace if it is damaged.
  20.  
  21. If oil seal removal is necessary, support the front cover and drive the oil seal out of the back (timing chain side) of the cover.
  22.  
  23. If the seal was removed, use front cover crankshaft seal installer, tool J 36010 or equivalent, to install the seal in the cover. The tool will properly position the seal in the cover.
  24.  

To install:


Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the front cover seal installation - 2.3L engines

  1. Install the gasket and/or seals into the front cover.
  2.  
  3. Place the nuts on the studs to retain the cover, then install the bolts. Tighten the fasteners to 106 inch lbs. (12 Nm).
  4.  
  5. Install the engine lift bracket. Raise and safely support the vehicle. Install the remaining front cover bolts. Tighten the fasteners accessible at this time to 106 inch lbs. (12 Nm).
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Install the remaining cover fasteners and tighten to 106 inch lbs. (12 Nm).
  10.  
  11. Lubricate the front oil seal and the sealing surface of the crankshaft balancer with chassis grease 1051344 or equivalent.
  12.  
  13. Install the crankshaft balancer.
  14.  
  15. Install the right splash shield and wheel and tire assembly.
  16.  
  17. Carefully lower the vehicle.
  18.  
  19. For 1990-91 vehicles, install the engine lift bracket.
  20.  

The right engine mount and bracket bolts must be replaced with new bolts anytime they are removed.

  1. For 1992-94 vehicles perform the following:
    1. Install the engine mount bracket and the right engine mount, using NEW bolts.
    2.  
    3. Install the alternator.
    4.  
    5. Remove the engine support fixture.
    6.  

  2.  
  3. Install the serpentine drive belt.
  4.  
  5. Connect the coolant vent hose.
  6.  
  7. Install the coolant recovery reservoir.
  8.  
  9. Fill the cooling system with the proper type and amount of coolant.
  10.  
  11. Connect the negative battery cable, then start the engine and check for leaks. Check the fluid levels, and add if necessary.
  12.  

2.8L and 3.1L Engines

See Figures 3 and 4

1988-94 VEHICLES
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a suitable container.
  4.  
  5. Remove the coolant recovery reservoir.
  6.  
  7. Remove the serpentine belt and belt tensioner.
  8.  
  9. Unbolt the power steering pump, then position it aside. Do NOT disconnect the fluid lines.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Remove the right side wheel and tire assembly, then remove the inner splash shield.
  14.  
  15. Remove the flywheel cover from the transaxle.
  16.  
  17. Remove the crankshaft (harmonic) balancer.
  18.  
  19. Remove the serpentine belt idler pulley.
  20.  
  21. Remove the oil pan.
  22.  
  23. Remove the lower timing chain cover retaining bolts.
  24.  
  25. Carefully lower the vehicle.
  26.  
  27. Disconnect the radiator hose from the water pump.
  28.  
  29. Remove the bypass pipe from the front cover.
  30.  
  31. Disconnect the EVAP canister purge hose.
  32.  
  33. Unfasten the upper timing chain (front) cover bolts, then remove the front cover from the vehicle.
  34.  
  35. Clean all the gasket mounting surfaces on the front cover and block and place a new gasket to the front cover sealing surface. Apply a sealer (1052080 or equivalent) as shown to the ends of the gasket.
  36.  

The oil seal can be replaced with the cover either on or off the engine. If the cover is on the engine, remove the crankshaft pulley and hub first. Pry out the seal using a large prytool, being careful not to scratch or distort the seal mating surface. Install the new seal so that the open side or helical side is towards the engine. Press it into place with a seal driver made for the purpose. General Motors recommends a tool, J-35468 Seal Centering Tool. Install the hub if removed.



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the timing chain cover and gasket - 1988-93 2.8L and 3.1L engines



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the timing chain front cover - 1994 - 96 3.1L engine

To install:
  1. Place the front cover on the engine and install the upper front cover bolts. Tighten the (4) bolts, in the accompanying figure, to 20 ft. lbs. (27 Nm) for 1988-92 vehicles or to 15 ft. lbs. (21 Nm) for 1993-94 vehicles. Tighten the (5) bolts to 38 ft. lbs. (48 Nm) for 1988-92 vehicles or to 35 ft. lbs. (45 Nm) for 1993 vehicles.
  2.  
  3. For 1994 vehicles, tighten the front cover retaining bolts to 15 ft. lbs. (20 Nm).
  4.  
  5. Raise the vehicle and support it safely.
  6.  
  7. Install the oil pan.
  8.  
  9. Install the lower cover bolts. Tighten the (4) bolts, in the accompanying figure, to 20 ft. lbs. (27 Nm) for 1988-92 vehicles or to 15 ft. lbs. (21 Nm) for 1993-94 vehicles. Tighten the (5) bolts to 38 ft. lbs. (48 Nm) for 1988-92 vehicles or to 35 ft. lbs. (45 Nm) for 1993 vehicles.
  10.  
  11. Install the serpentine belt idler pulley.
  12.  
  13. Install the crankshaft (harmonic) balancer.
  14.  
  15. Install the flywheel cover on the transaxle.
  16.  
  17. Install the inner splash shield and the wheel and tire assembly.
  18.  
  19. Carefully lower the vehicle.
  20.  
  21. Connect the radiator hose to the water pump.
  22.  
  23. Attach the bypass pipe to the front cover.
  24.  
  25. Connect the canister purge hose.
  26.  
  27. Position the power steering pump and secure with the mounting bolts.
  28.  
  29. Install the serpentine belt tensioner and belt.
  30.  
  31. Fill the cooling system with the proper type and amount of coolant.
  32.  
  33. Connect the battery cable, then start the engine and check for leaks.
  34.  

1995-96 VEHICLES

See Figures 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 and 16

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a suitable container.
  4.  
  5. Install engine support fixture J 28467-A, or equivalent.
  6.  
  7. Remove the engine mount bracket support.
  8.  
  9. Remove the serpentine drive belt.
  10.  
  11. Unbolt the power steering pump, then position it aside but do NOT disconnect the fluid lines.
  12.  
  13. If equipped, loosen the top 2 A/C compressor bolts.
  14.  
  15. Disconnect the coolant bypass pipe from the water pump and manifold.
  16.  
  17. Detach the radiator hose from the coolant outlet housing.
  18.  
  19. Remove the upper front cover bolts.
  20.  
  21. Raise and safely support the vehicle.
  22.  
  23. Drain the engine oil into a suitable container.
  24.  
  25. Remove the right front wheel and tire assembly. Remove the splash shield.
  26.  
  27. Remove the flywheel inspection cover.
  28.  
  29. Remove the crankshaft balancer.
  30.  
  31. Remove the serpentine drive belt tensioner.
  32.  



Click image to see an enlarged view

Fig. Fig. 5: After removing the wheel and tire assembly, unfasten the retainers ...



Click image to see an enlarged view

Fig. Fig. 6: ... then remove the right side inner splash shield



Click image to see an enlarged view

Fig. Fig. 7: Attach a suitable puller to the crankshaft balancer ...



Click image to see an enlarged view

Fig. Fig. 8: ... then remove the crankshaft balancer from the front cover



Click image to see an enlarged view

Fig. Fig. 9: Unfasten the serpentine drive belt tensioner retaining bolt ...



Click image to see an enlarged view

Fig. Fig. 10: ... then remove the drive belt tensioner from the vehicle

  1. Remove the engine mount strut.
  2.  
  3. Detach the right wheel speed sensor connector and wire harness from the suspension support.
  4.  
  5. Remove the right side ball joint.
  6.  
  7. Detach the stabilizer shaft from the right suspension support and the right control arm.
  8.  
  9. Remove the right suspension support.
  10.  
  11. If equipped, remove the A/C compressor-to-pan bolts.
  12.  
  13. Remove the oil filter and oil filter adapter.
  14.  
  15. Remove the engine mount strut bracket.
  16.  
  17. Remove the engine-to-transaxle brace.
  18.  
  19. Remove the starter motor.
  20.  
  21. Remove the oil pan.
  22.  
  23. Remove the crankshaft sensor.
  24.  
  25. Remove the lower timing chain (front) cover bolts, then remove the from cover from the vehicle..
  26.  



Click image to see an enlarged view

Fig. Fig. 11: Unfasten the Crankshaft Position (CKP) sensor retaining bolts ...



Click image to see an enlarged view

Fig. Fig. 12: ... then remove the CKP sensor from the timing chain (front) cover



Click image to see an enlarged view

Fig. Fig. 13: Unfasten the lower timing chain cover retaining bolts ...



Click image to see an enlarged view

Fig. Fig. 14: ... then remove the timing chain cover from the vehicle

The oil seal can be replaced with the cover either on or off the engine. If the cover is on the engine, remove the crankshaft pulley and hub first. Pry out the seal using a large prytool, being careful not to scratch or distort the seal mating surface. Install the new seal so that the open side or helical side is towards the engine. Press it into place with a seal driver made for the purpose. General Motors recommends a tool, J-35468 Seal Centering Tool. Install the hub if removed.

  1. Clean all the gasket mounting surfaces on the front cover and block and place a new gasket to the front cover sealing surface. Apply a sealer (1052080 or equivalent) as shown to the ends of the gasket.
  2.  



Click image to see an enlarged view

Fig. Fig. 15: The front cover oil seal (see arrow) can be removed with the cover on or off the engine



Click image to see an enlarged view

Fig. Fig. 16: Use a scraper to carefully remove any remaining gasket material from the timing chain cover mating surfaces

To install:
  1. Place the front cover on the engine. Install the lower front cover bolts. Tighten the small bolts to 15 ft. lbs. (20 Nm) and the large bolts to 35 ft. lbs. (47 Nm).
  2.  
  3. Install the crankshaft sensor.
  4.  
  5. Install the oil pan and starter motor.
  6.  
  7. Install the engine-to-transaxle brace.
  8.  
  9. Install the engine mount strut bracket.
  10.  
  11. Install the oil filter adapter and the filter.
  12.  
  13. If equipped, install the A/C compressor-to-oil pan bolts.
  14.  
  15. Install the right suspension support.
  16.  
  17. Attach the stabilizer shaft to the right suspension support and control arm.
  18.  
  19. Install the right ball joint.
  20.  
  21. Attach the right wheel speed sensor connector and wire harness to the suspension support.
  22.  
  23. Install the engine mount strut.
  24.  
  25. Install the drive belt tensioner.
  26.  
  27. Install the crankshaft balancer and the flywheel inspection cover.
  28.  
  29. Install the right splash shield and tire and wheel assembly.
  30.  
  31. Carefully lower the vehicle.
  32.  
  33. Install the upper two front cover bolts and tighten to 15 ft. lbs. (20 Nm).
  34.  
  35. Connect the radiator hose to the coolant outlet housing.
  36.  
  37. Attach the coolant bypass pipe to the water pump and the manifold.
  38.  
  39. Raise and safely support the vehicle
  40.  
  41. If equipped, install the A/C compressor top bolts.
  42.  
  43. Place the power steering pump into position, then secure with the mounting bolts.
  44.  
  45. Install the serpentine drive belt.
  46.  
  47. Install the engine mount support bracket and bolts. Tighten the 8mm bolts to 15 ft. lbs. (20 Nm) and the 12mm bolts to 30 ft. lbs. (40 Nm). Tighten all of the bolts an additional 45°.
  48.  
  49. Install the engine mount assembly, then remove the engine support fixture.
  50.  
  51. Fill the cooling system and crankcase with the proper types and amounts of fluids.
  52.  
  53. Connect the negative battery cable, then start the engine and check for leaks. Check the fluid levels and add if necessary.
  54.  

 
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