2.3L 4-cylinder - Vins a & D Chevrolet Beretta I

ENGINE IDENTIFICATION

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

Note. This article has been updated with information as per General Motors Technical Service Bulletin 27-61-13, issued August 15, 1994.

Engine may be identified by the eighth character of the Vehicle Identification Number (VIN), stamped on metal tab located on top of left corner of instrument panel. The eighth character identifies the engine model.

Engine code, located on cylinder block, may be required when ordering replacement parts. Traceability and verification labels are attached to the front housing. (Scheme 10) Engine is available in standard DOHC (VIN D), or high output DOHC (VIN A) versions. See ENGINE IDENTIFICATION CODES table.

ENGINE IDENTIFICATION CODES

Scheme 10

VALVE CLEARANCE ADJUSTMENT

Hydraulic valve lifters are used. Adjustment is not required.

TROUBLE SHOOTING

Note. To trouble shoot mechanical engine components, see appropriate table in TROUBLE SHOOTING article in GENERAL INFORMATION.

GENERAL PRECAUTION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal. (Scheme 26)-20.

FUEL PRESSURE RELEASE

1. Loosen fuel tank cap to release fuel tank pressure. Raise and support vehicle. Disconnect fuel pump electrical connector at gas tank. Start engine, and operate it until it stalls.
2. Crank engine for an additional 3 seconds to release residual line pressure. Disconnect negative battery cable. Reconnect fuel pump.

Removal (Beretta, Cutlass Calais, Grand Am & Skylark)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__fuel-pressure-release) . Disconnect negative battery cable and drain cooling system. Discharge A/C system (if equipped). Drain crankcase.
2. Remove heater hose at thermostat housing and radiator inlet hose. Remove air cleaner-to-throttle body duct. Remove upper radiator support and cooling fan. On A/C-equipped vehicles, remove compressor/condenser hose assembly at compressor, and discard "O" rings.
3. On all vehicles, disconnect 2 vacuum hoses from front of engine. Disconnect and place aside electrical connections for alternator, A/C compressor (if equipped), injector harness, IAC and TPS from throttle body, MAP sensor, MAT sensor, vacuum purge solenoid and starter solenoid.
4. Remove ground connections at front engine mount bracket and negative battery cable from transaxle. Disconnect electrical connections for ignition coil and module, coolant sensors, oil pressure sensor/switch, power steering switch, knock sensor, oxygen sensor, crankshaft position sensor and speed sensor.
5. On automatic transaxle vehicles, disconnect park/neutral/back-up light switch. On manual transaxle vehicles, disconnect backup light switch and position harness aside. On all vehicles, disconnect brake booster vacuum hose from throttle body.
6. Remove throttle cable and bracket. Remove power steering rear bracket along with brake booster vacuum tube. Check valve hose from vacuum tube. Replace if necessary. Remove power steering pivot bolt, pump and drive belt. Position pump aside with hoses attached. Disconnect fuel lines. Clean any spilled fuel.
7. On automatic transaxle vehicles, disconnect shift cables, T.V. cables and transaxle cooler pipes. On manual transaxle vehicles, disconnect shift cables and remove clutch actuator cylinder. On all vehicles, disconnect exhaust manifold and remove heat shield.
8. Remove radiator and heater outlet hoses from radiator. Remove front engine mount nut and install Engine Support (J- 28467-A). Disconnect vacuum lines and pull vacuum harness back through front lift bracket. Raise and support vehicle. Remove front wheels.
9. Remove radiator air deflector and right lower splash shield. Separate ball joints from steering knuckles. Support suspension support, crossmember and stabilizer shaft with suitable holding fixture. Remove retaining bolts, and remove suspension supports, crossmember and stabilizer shaft as an assembly.
10. Install Drive Axle Boot Protector (J- 34754) on drive axle boots, and remove axle shaft from transaxle and position aside. Remove nuts from transaxle mount, and remove rear engine mount through bolts. Remove rear engine mount body bracket. Support engine and transaxle assembly from below. Lower vehicle onto support.
11. Remove transaxle through bolt. Mark threads on engine upper support fixture hooks for installation reference. Remove engine upper support fixture. Raise vehicle slowly from engine and transaxle assembly. Separate engine from transaxle.

Installation

1. Assemble engine to transaxle. Ensure bolts are in correct locations. On automatic transaxle vehicles, clean torque converter-to-flywheel bolt holes and apply sealant to bolts.
2. Position engine and transaxle assembly under engine compartment and lower vehicle until transaxle mount is indexed. Install transaxle bolt. Install engine support fixture and adjust to previous setting. Raise vehicle and remove lower engine and transaxle support.
3. Install rear mount to body bracket and tighten bolt to 55 ft. lbs. (75 N.m). Install rear mount nut and tighten nut to 46 ft. lbs. (62 N.m). See «TORQUE SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__torque-specifications) at end of this article.
4. Install transaxle through bolt, washer and nut. Tighten to 40 ft. lbs. (54 N.m) while maintaining equal gaps within .008" (2 mm). If gaps are not equal to within .008" (2 mm), idle shake and harsh transaxle engagement will occur.
5. Reverse removal procedure for remaining components. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__torque-specifications) at end of this article. After installation, evacuate and charge A/C system. Check and fill all fluids.

Removal (Cutlass Supreme & Grand Prix)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__fuel-pressure-release) . Scribe alignment marks on hood hinge, and remove hood. Disconnect negative battery cable and drain cooling system.
2. Discharge A/C system (if equipped). Drain crankcase. Remove heater hose at thermostat housing and radiator inlet hose. Remove air cleaner to throttle body duct. Remove upper radiator support and cooling fan. On A/C-equipped vehicles, remove compressor/condenser hose assembly at compressor, and plug hose and compressor openings. Discard "O" rings.
3. On all vehicles, disconnect 2 vacuum hoses from front of engine. Disconnect and place aside electrical connections for alternator, A/C compressor (if equipped), injector harness, starter solenoid and IAC and TPS at throttle body.
4. Remove ground connections at front engine mount bracket and negative battery cable from transaxle. Disconnect electrical connections for ignition coil and module, coolant sensors, oil pressure sensor/switch, knock sensor and oxygen sensor.
5. Disconnect brake booster vacuum hose from throttle body. Remove throttle cable and bracket. Remove power steering pump, hydraulic lines and front and rear brackets. Remove power steering pivot bolt and drive belt. Disconnect fuel lines. Clean any spilled fuel.
6. Remove torque strut mounts and transaxle fill tube. Remove exhaust heat shield and serpentine belt. Remove transaxle-to-cylinder block bolts. Raise and support vehicle. Disconnect exhaust pipe from manifold and remove exhaust-to-transaxle brace. Remove remaining transaxle-to-cylinder block bolts.
7. Remove radiator lower outlet hose. Remove torque converter cover. Mark torque converter-to-flywheel position. Remove torque converter bolts. Remove transaxle-to-engine brace and lower engine mount.
8. Lower vehicle and support transaxle. Install engine lift fixture. Disconnect vacuum lines and pull vacuum harness back through front lift bracket. Remove engine assembly.

1. Assemble engine to transaxle. Ensure bolts are in correct locations. Clean torque converter-to-flywheel bolt holes and apply sealant to bolts. Raise vehicle. Install transaxle-to-engine brace.
2. Reverse removal procedure for remaining components. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__torque-specifications) at end of this article. After installation, evacuate and charge A/C system. Check and fill all fluids.

Removal

1. Disconnect negative battery cable. Drain cooling system. Disconnect vacuum hose from MAP sensor. Disconnect electrical connectors from MAP and MAT sensors, purge solenoid and fuel injectors.
2. Disconnect vacuum hoses from intake manifold, fuel pressure regulator and purge solenoid to canister. Remove air cleaner duct and vent tube to air cleaner duct. Remove throttle cable bracket and power brake booster hose.
3. Disconnect intake manifold hoses. Remove oil/air separator with hoses attached at separator. Remove oil/air separator hoses at timing chain cover or housing and oil filler tube. Remove oil filler cap and oil dipstick.
4. Remove oil filler tube bolt and tube. Remove intake manifold support brace. Remove manifold nuts and bolts. Remove intake manifold and gasket.

Note. Install intake manifold gasket with numbered side facing toward intake manifold.

1. To install, reverse removal procedure using a NEW gasket on intake manifold and throttle body. Install intake manifold bolts and nuts finger tight. Tighten bolts and nuts to specification in sequence. See «TORQUE SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__torque-specifications) table at the end of this article. Also (Scheme 11)
2. Using engine oil, lubricate and install NEW "O" rings on oil fill tube. To complete installation, reverse removal procedure. Fill cooling system (as necessary).

Scheme 11

1. Remove oxygen sensor connector. Remove upper heat shield. Raise and support vehicle. Remove exhaust manifold brace bolt. Remove exhaust pipe-to-manifold nuts.
2. Disconnect exhaust pipe from exhaust manifold. Lower vehicle. Remove exhaust manifold nuts. Remove exhaust manifold, lower heat shield, seals and gasket. If replacing exhaust manifold, transfer oxygen sensor, bolts, nuts, lower heat shield and exhaust manifold studs to new manifold.

To install, reverse removal procedure using NEW gasket. Tighten bolts to specification in sequence. (Scheme 11) Also refer to the TORQUE SPECIFICATIONS table. If oxygen sensor was removed, coat threads with anti-seize compound before installation.

1. Disconnect negative battery cable, and drain cooling system. Disconnect heater hoses and throttle body coolant hoses.
2. Remove exhaust manifold. See EXHAUST MANIFOLD. Remove intake manifold. See INTAKE MANIFOLD.
3. Remove camshaft housings. For SOHC and DOHC intake side camshaft housing, see «INTAKE CAMSHAFT & HOUSING (DOHC)/CAMSHAFT &»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__intake-camshaft-housing-dohccamshaft) HOUSING (SOHC). For DOHC exhaust side, see «EXHAUST CAMSHAFT & HOUSING»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__exhaust-camshaft-housing-dohc) (DOHC).
4. Remove oil fill tube bolt. Remove oil filler cap, oil dipstick and oil filler tube. Disconnect fuel injector connector. Remove air cleaner duct and throttle body cable bracket. Remove brake booster hose from throttle body.
5. Remove throttle body from intake manifold with electrical harness and throttle cable attached. Disconnect electrical and vacuum connectors to MAP sensor. Remove intake manifold brace.
6. Disconnect MAT sensor, purge solenoid and coolant sensor electrical connectors. Remove upper radiator hose. Remove cylinder head bolts in reverse order of tightening sequence. (Scheme 12) Remove cylinder head and gasket.

Note. The following procedures have been updated with information as per General Motors Technical Service Bulletin 27-61-13, issued 08/15/1994, titled: NEW CYLINDER HEAD GASKET/BOLTS TIGHTENING PROC: SMU

Scheme 12

1. Remove cylinder head assembly. See «CYLINDER HEAD»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__cylinder-head). Disassemble, clean and inspect the timing belt tensioner assembly, paying special attention to the oil feed and drain holes. Ensure oil holes are free of dirt to allow proper oil flow. If varnish is present in the tensioner bore or plunger, plunger may stick in the bore. Lightly polish the plunger or bore with Scotch Brite or equivalent.
2. Clean all parts before reassembly. DO NOT use any other method or technique to clean plunger or bore. If plunger still does not operate smoothly, replace damaged or worn parts. Place tensioner assembly in clean storage area until needed for reassembly. CAUTION: DO NOT use any cleaning material or method that can remove metal from plunger or plunger bore.
3. Inspect cylinder head bolts for damaged threads or damaged heads caused by improper use of tools. Replace cylinder head bolts as necessary. NOTE: DO NOT use abrasive pads to clean cylinder head or block surfaces. Abrasive pads can damage cylinder head or block. Abrasive pads should not be used for the following reasons: Abrasive pads produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and has been known to cause internal engine damage. Abrasive pads can remove enough material to round cylinder head surfaces. This affects the gasket's ability to seal, especially in the narrow seal areas between combustion chambers and coolant jackets. The cylinder head gasket will leak if these edges are rounded. Abrasive pads can also remove enough metal to affect cylinder head flatness. It takes about 15 seconds to remove 0.008" (0.203 mm) of metal from cylinder head with abrasive pad. If cylinder head flatness is out of specification, cylinder head gasket will not seal and the gasket will leak.
4. Thoroughly clean the cylinder head and block surfaces. Carefully remove all gasket material. Use a razor blade type scraper. (Scheme 12) NOTE: Use a NEW razor blade for each cylinder head. Hold blade as parallel to the gasket surface as possible. This keeps the razor blade from gouging or scratching gasket surfaces. CAUTION: DO NOT gouge or scratch the gasket surfaces. DO NOT gouge or scrape the combustion chamber surfaces. The appearance of the gasket surface is not important, but the feel is. There will be indentations from the gasket left in the cylinder head after all gasket material is removed. These small indentations will be filled in by the new gasket.
5. Check the cylinder head surface for proper flatness. Refer to «CYLINDER HEAD OVERHAUL»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d) procedures in this article. Also, refer to the «CYLINDER HEAD REUSAGE SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d) table.
6. Inspect the cylinder head surface for corrosion or cracks. The combustion seal area will leave a "shadow" mark on the cylinder head. (Scheme 13) If there are signs of corrosion outside of the outside diameter (OD) of the combustion seal area, cylinder head may be reused. (Scheme 13) If any corrosion extends into the combustion seal area and/or if cracks are found, replace cylinder head.

Scheme 13

CYLINDER HEAD REUSAGE SPECIFICATIONS

Note. The following procedures have been updated with information as per General Motors Technical Service Bulletin 27-61-13, issued 08/15/1994, titled: NEW CYLINDER HEAD GASKET/BOLTS TIGHTENING PROCEDURE .

1. Clean each head bolt seat boss on cylinder head. Clean all cylinder block bolt holes. Using a nylon bristle brush, clean the bolt hole threads. CAUTION: DO NOT use a tap to clean the head bolt holes. Make sure all puddles of oil and coolant have been removed from bolt holes. If not, the tightening sequence will not obtain the proper clamp load because of hydrostatic lock. If the cylinder head bolt holes are not cleaned, the head gasket may leak.
2. Sparingly apply clean engine oil to the threads and the bottom side of the flange of the bolt(s). (Scheme 14)and (Scheme 15). WARNING: The following tightening procedure MUST be followed to ensure gasket life. Failure to follow the procedures exactly can result in cylinder head gasket leakage.
3. Install and tighten cylinder head retaining bolts to specification and in sequence. See «TORQUE SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__torque-specifications). Also refer to Fig. (Scheme 16). After initial tightening on all ten bolts, further tighten all bolts an additional 90 degrees.

Scheme 14

Scheme 15

Scheme 16

1. Drain cooling system enough to remove coolant surge tank. Remove coolant surge tank. Remove serpentine drive belt. Remove alternator. Reinstall alternator through bolt, and attach Engine Support (J-28467-A).
2. Remove upper cover bolts and engine lift bracket. Disconnect vent hose from cover (if equipped). Remove right engine mount and engine lift bracket. On A/T models, remove upper engine strut.
3. On all models, raise and support vehicle. Remove right front wheel and lower splash shield. Remove crankshaft balancer and lower cover bolts. Lower vehicle. Remove front timing case cover and gaskets.

To install, reverse removal procedure using NEW gasket. Lubricate front seal with grease before installing crankshaft balancer. To complete installation, reverse removal procedure. Fill with coolant. Tighten nuts and bolts to specification. Refer to the TORQUE SPECIFICATIONS table.

Removal & Installation

Remove front timing case cover. See FRONT TIMING CASE COVER . Support cover, and drive seal from rear of cover. Note direction of seal installation. To install seal, use Seal Installer (J-36010).

Scheme 17

1. Remove front timing case cover. See «FRONT TIMING CASE»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d) COVER. Rotate crankshaft clockwise (viewed from front of engine) until camshaft sprocket timing pin alignment holes align with holes of timing chain housing. (Scheme 17)
2. Ensure crankshaft sprocket timing marks align with mark on cylinder block. Crankshaft sprocket keyway should point upward and align with center line of cylinder bores.
3. Remove all timing chain guides. Raise and support vehicle. Remove timing chain tensioner shoe retainer. Ensure all timing chain slack is above chain tensioner. Remove chain tensioner and shoe assembly.
4. Disengage timing chain from wear grooves in tensioner shoe to remove shoe. To disengage from grooves, slide screwdriver blade under timing chain while pulling shoe outward.
5. If timing chain tensioner shoe removal is difficult, lower vehicle. Using Camshaft Sprocket Wrench (J-39579), hold intake camshaft sprocket and remove sprocket bolt and washer. CAUTION: Remove camshaft sprocket using puller. DO NOT pry sprocket from camshaft or damage to sprocket and timing chain housing can occur.
6. Remove washer from sprocket bolt, and reinstall bolt into camshaft by hand. Using puller, remove intake camshaft sprocket by using sprocket relief holes. Remove chain tensioner bolts and tensioner. Remove timing chain.

1. Install camshaft sprocket (if removed). Apply Sealant (12345493) to camshaft sprocket bolt. Install bolt and washer. Using camshaft sprocket wrench, tighten bolt to specification. Refer to the «TORQUE SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__torque-specifications) table. For camshaft positioning, install Camshaft Alignment Pins (J-36008) in camshaft sprockets holes and timing chain housing.
2. If camshafts are out of position and must be rotated more than1/8 turn for pin installation, rotate crankshaft 90 degrees clockwise from TDC to provide valve clearance. Once camshafts are positioned and alignment pins are installed, rotate crankshaft counterclockwise back to TDC. DO NOT rotate crankshaft clockwise to TDC.
3. On DOHC models, install timing chain on exhaust camshaft, idler and crankshaft sprockets. Remove alignment dowel pin from intake camshaft. Using camshaft sprocket wrench, rotate intake camshaft counterclockwise enough to slide timing chain over intake cam sprocket. Release camshaft sprocket wrench. Timing chain will tighten between camshaft sprockets.
4. On SOHC models, remove alignment dowel pin from camshaft. Using camshaft sprocket wrench, rotate camshaft sprocket counterclockwise enough to slide timing chain over cam sprocket. Release camshaft sprocket wrench. Timing chain will tighten between camshaft sprocket. 5 5) On all models, ensure alignment pin fully engages and slides easily on intake camshaft (DOHC) or camshaft (SOHC). Ensure all timing marks align. Repeat procedure if alignment pin fails to slide easily.
5. With alignment pin installed, raise vehicle on hoist. With slack removed from chain, ensure timing marks on crankshaft and cylinder block are aligned. If marks are not aligned, position chain one tooth forward or rearward, remove slack and recheck marks.
6. To reposition timing chain tensioner to zero position, form a keeper from a piece of heavy gauge wire. Apply slight force on tensioner blade to compress plunger.
7. Insert a small screwdriver into reset access hole, and pry ratchet pawl away from ratchet teeth while forcing plunger completely into hole. Install keeper between access hole and blade.
8. Install tensioner to chain housing. Ensure long end is toward crankshaft. Install timing chain tensioner bolts, and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__torque-specifications) .
9. Lower vehicle enough to reach and remove alignment dowel pins. Rotate crankshaft clockwise 2 full rotations, and align crankshaft timing mark with mark on cylinder block.
10. Reinstall alignment dowel pins. If engine is timed correctly, pins will slide in easily. Install timing chain guides. To complete installation, reverse removal procedure.

TIMING CHAIN HOUSING

Note. Remove water pump and exhaust manifold if replacing timing chain housing. Timing chain housing gasket and camshaft housing gasket can be removed without removing timing chain housing from vehicle.

1. Disconnect negative battery cable. Remove front timing case cover. See «FRONT TIMING CASE COVER»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d) . Remove timing chain and camshaft sprockets. See «TIMING CHAIN & SPROCKETS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d) .
2. If removing housing from vehicle, remove exhaust manifold. See «EXHAUST MANIFOLD»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d) . Drain cooling system. Remove lower front cover stud.
3. Remove oil/air separator hose from timing chain housing (except high output models). Remove water pump. See WATER PUMP.
4. For housing removal, remove timing chain housing-to-belt tensioner bracket brace. Remove oil pan-to-timing chain housing bolts. Remove timing chain housing bolts. Remove timing chain housing and gaskets.

1. Inspect oil pan gasket. Replace gasket if damaged. Inspect silicone strips of oil pan gasket for damage. Minor damage can be repaired using silicone sealant.
2. Ensure dowel pins are installed in cylinder block. To install, reverse removal procedure using NEW gaskets. Install all housing bolts finger tight before tightening to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__torque-specifications) table at the end of this article. Coat coolant pipe "O" rings with antifreeze before installation. Refill cooling system.

TIMING CHAIN IDLER SPROCKETS & BEARING

Note. Replace bearing whenever idler sprocket is removed.

1. Remove timing chain housing. See «TIMING CHAIN HOUSING»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__timing-chain-housing). Remove bearing snap ring. (Scheme 18) Install Remover/Installer Plate (J-36998-4) on front side of timing chain housing with 3 alignment pins engaged into front cover bolt holes.
2. Using Handle (J-36998-2), press sprocket from bearing. Reposition remover/installer plate on rear of chain housing over water pump studs. Using Remover/Installer (J-36998-1) and Handle (J-36998-2), press bearing from timing chain housing.

Scheme 18

1. Clean groove in timing chain housing. Coat new bearing-to-housing surfaces with Sealant (12345493). Install remover/installer plate on front side of chain housing with 3 alignment pins engaged into front cover bolt holes.
2. Using remover/installer and handle, press bearing into timing chain housing. Reposition remover/installer plate on rear of chain housing over water pump studs.
3. Using remover/installer and handle, install idler sprocket. Install bearing snap ring. Install timing chain housing. See «TIMING CHAIN HOUSING»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__timing-chain-housing) .

INTAKE CAMSHAFT & HOUSING (DOHC)/CAMSHAFT & HOUSING (SOHC)

Note. Replace camshaft housing gasket whenever camshaft housing bolts are loosened or removed.

1. Disconnect negative battery cable. Disconnect ignition coil and module assembly electrical connector. Remove ignition coil and module bolts. Remove assembly by pulling straight up. (Scheme 19)
2. Disconnect power steering pressure switch connector (if equipped). Remove power steering pump, and position it aside with hoses attached. Remove power steering pump drive pulley from intake camshaft using Pulley Remover (J-38781) and Forcing Screw (J-38343-4). (Scheme 19)
3. Remove oil/air separator with hoses attached at separator. Remove oil/air separator hoses at timing chain cover or housing and oil filler tube. Disconnect fuel pressure regulator vacuum line and fuel injector harness connector.
4. Remove fuel line clamp from top of intake camshaft housing. Remove fuel rail bolts. Remove fuel rail from cylinder head with fuel lines attached, and position it aside.
5. Cover cylinder head injector openings and injector nozzles. Disconnect, but DO NOT remove, timing chain housing. See «TIMING CHAIN HOUSING»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__timing-chain-housing). DO NOT remove housing from vehicle.
6. Remove camshaft housing cover bolts. Remove camshaft housing bolts in reverse order of tightening sequence. (Scheme 20) Leave 2 bolts loosely in place to hold camshaft housing while separating camshaft housing cover from camshaft housing.
7. Install 4 bolts into tapped holes of camshaft housing cover. Evenly tighten bolts to remove camshaft housing cover. Remove 2 loosely installed camshaft housing bolts, and remove housing cover. NOTE: If removing valve lifters, mark component locations for installation reference. Store lifters upside-down (opposite of installed position) in engine oil to prevent bleed-down.
8. Note chain sprocket dowel pin position for reassembly. Remove camshaft and camshaft seal. Remove valve lifters, cam housing and gasket.

Inspection

Inspect camshaft journal diameter, lobe lift and oil clearance. See CAMSHAFT table under ENGINE SPECIFICATIONS. Inspect lifter O.D. and bore I.D. See CAMSHAFT HOUSING OVERHAUL . Replace components as necessary.

Note. Replace lifters if new camshaft is installed. If replacing camshaft or lifter, add Engine Oil Supplement (1052367) to oil. Lube camshaft lobes and journals.

1. Reverse removal procedure. Ensure dowel pins are installed in cylinder head and lifters are installed in original locations. Coat camshaft with Lubricant (12345501) before installation.
2. Install seal between camshaft housing and cover. Apply thread sealant to camshaft housing and cover bolts. Tighten camshaft housing retaining bolts in sequence. (Scheme 20) Also refer to the «TORQUE SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__torque-specifications) table.
3. Lubricate camshaft seal with oil, and install seal using Seal Installer (J-36009). Apply thread sealant to ignition coil and module bolts.

Scheme 19

Scheme 20

EXHAUST CAMSHAFT & HOUSING (DOHC)

Note. Replace camshaft housing gasket whenever camshaft housing bolts are loosened or removed.

1. Disconnect negative battery cable. Disconnect ignition coil and module assembly electrical connector. Remove ignition coil and module retaining bolts, and remove assembly by pulling straight up. (Scheme 19)
2. Disconnect oil pressure switch connector. On A/T models, remove transaxle fluid level tube from exhaust camshaft cover, and position tube aside. On all models, remove camshaft cover. Disconnect, but DO NOT remove, timing chain housing. See «TIMING CHAIN HOUSING»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__timing-chain-housing). DO NOT remove housing from vehicle.
3. Remove camshaft housing bolts in reverse order of tightening sequence. (Scheme 20) Leave 2 bolts loosely in place to hold camshaft housing while separating camshaft housing cover from housing.
4. Install 4 bolts into tapped holes of camshaft housing cover. Evenly tighten bolts to remove camshaft housing cover. Remove 2 cam housing bolts and housing cover. Note position of chain sprocket dowel pin for installation reference. Remove camshaft.

Note. If removing valve lifters, mark component locations for reassembly reference. Store lifters upside-down (opposite of installed position) in engine oil to prevent bleed-down.

Inspect camshaft journal diameter, lobe lift and oil clearance. See CAMSHAFT table under ENGINE SPECIFICATIONS. Inspect lifter O.D. and bore I.D. See CAMSHAFT HOUSING OVERHAUL . Replace components as necessary.

Note. Replace lifters if new camshaft is installed. If replacing camshaft or lifter, add Engine Oil Supplement (1052367) to oil. Lube camshaft lobes and journals.

1. To install, reverse removal procedure. Ensure dowel pins are installed in cylinder head and lifters are in original locations. Coat camshaft with Lubricant (12345501) before installation.
2. Install seal between camshaft housing and cover. Apply thread sealant to camshaft housing and cover bolts.
3. Tighten camshaft housing retaining bolts to specification and in sequence. Refer to Fig. (Scheme 20). Also refer to torque specifications in the «TORQUE SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__torque-specifications) table at the end of this article. Apply thread sealant to ignition coil and module bolts.

1. Remove transaxle assembly. On M/T models, mark clutch pressure plate and flywheel for installation reference and remove. On A/T models, remove flexplate.
2. Remove seal housing bolts, seal housing and gasket. (Scheme 21) Using 2 wood blocks, support transaxle side of seal housing across dowel pin and center bolt holes on both sides of seal opening.
3. Using small chisel in seal relief grooves, drive seal evenly from seal housing. Note direction of seal installation.

1. Replace oil pan gasket if cuts, deformation or separation from aluminum carrier in inner silicone bead exists. Inspect silicone strips at top of aluminum carrier at oil pan, cylinder block and seal housing joint areas. Use silicone sealant to repair damaged silicone strips.
2. Lubricate NEW seal lip with engine oil. Using Crankshaft Rear Seal Installer (J-36005), install seal into housing. To install, reverse removal procedure using NEW gasket. Apply Sealant (12345493) to flywheel or flexplate bolts before installation.
3. Align reference marks on pressure plate and flywheel (M/T models). Tighten retaining bolts and nuts to specification. Refer to the «TORQUE SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__torque-specifications) table at the end of this article.

Scheme 21

1. Oil flow check valve is located on front of cylinder block. (Scheme 21) Oil flow valve can be removed using Oil Flow Check Valve Tool (J-38123) or modified 3/16" x 4" round-head screw.
2. Grind or file flats on screw head, parallel to screw slot. Modify screw so screw head can be installed past indentations on check valve. Install oil flow check valve tool or modified screw into check valve. NOTE: Use care during removal to ensure check ball remains in oil flow check valve during removal. Locate check ball if it is missing.
3. Rotate check valve tool or bolt 90 degrees so it will lock into check valve indentations. Using slide hammer, pull check valve from cylinder block.

Use slide hammer and oil flow check valve tool or drift punch and hammer to seat NEW check valve into seat area.

Valve lifters can only be removed once camshaft and camshaft housing have been removed. Refer to INTAKE CAMSHAFT & HOUSING and EXHAUST CAMSHAFT & HOUSING . Install NEW valve lifters if camshaft is replaced.

1. Water pump is driven by timing chain idler sprocket and is mounted on rear of timing chain housing. (Scheme 22) Disconnect negative battery cable. Drain cooling system. Disconnect oxygen sensor, and remove exhaust heat shields.
2. Remove exhaust manifold. See «EXHAUST MANIFOLD»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d). Disconnect outlet pipe from water pump cover, oil pan and transaxle.
3. Remove water pump nuts. Remove water pump and cover assembly. Remove water pump cover bolts.

Scheme 22

1. Install water pump cover on water pump body with bolts finger tight. Lubricate water pump drive splines with grease. Install water pump and water pump cover on cylinder block.
2. Install nuts on timing chain housing finger tight. Lubricate outlet pipe "O" ring with antifreeze. Install "O" ring and outlet pipe with bolts finger tight.
3. Tighten bolts and nuts to specification in sequence. Tighten pump-to-timing chain housing nuts, then pump cover-to-pump body bolts, then pump cover-to-cylinder block bolts and then outlet pipe-to-cover bolts. See «TORQUE SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__torque-specifications) table at the end of this article.
4. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. Fill cooling system.

1. Raise and support vehicle. Drain crankcase. Drain cooling system. Remove flywheel cover. Remove right front wheel. Remove splash shield. Remove serpentine drive belt.
2. Remove engine mount strut from strut bracket. Remove air conditioning compressor, and position it aside. Remove engine strut bracket bolts, and set bracket aside. Remove radiator outlet pipe bolts.
3. Remove air conditioning and radiator outlet pipes from suspension supports. Remove exhaust manifold brace. Remove oil pan-to-flywheel cover bolt and nut. Remove flywheel cover stud. Remove radiator outlet pipe from lower radiator hose and oil pan. Disconnect oil level sensor connector. Remove oil pan bolts, pan and gasket.

1. Install oil pan and NEW gasket. Loosely install oil pan bolts. Place spacer in approximate installed location, but allow clearance to tighten pan bolt located directly above spacer.
2. Tighten oil pan bolts to specification. (Scheme 23) To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__torque-specifications) table at the end of this article. (Scheme 23)

Scheme 23

Cylinder Head

Check cylinder head warpage at deck surface and manifold surfaces. Resurface cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Replace head if metal removed exceeds .010" (.25 mm).

Valve Guides

Ream valve guides for an oversized valve if valve stem oil clearance is not within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Valve Seat

Valve seats may be reground (if necessary). Seat replacement information is not available from manufacturer.

Valve Seat Correction Angles

If seat is too wide after grinding, use a 20-degree or 70-degree stone to narrow seat. Use 20-degree stone to lower seat and 70-degree stone to raise seat.

CAMSHAFT HOUSING OVERHAUL

Measure valve lifter O.D. and lifter bore I.D. Determine oil clearance. Inspect camshaft housing warpage. Replace components if necessary. See VALVE LIFTERS table under ENGINE SPECIFICATIONS. Also (Scheme 26)-20.

Valve Installed Height

Measure valve installed height from top of valve stem to top of camshaft housing. Distance should be .984-1.004" (25.00-25.50 mm).

Piston & Rod Assembly

Position arrow on top of piston toward front of engine and connecting rod oil hole toward exhaust manifold side of engine. (Scheme 24)

Scheme 24

Piston Rings

Install piston rings with identification mark toward top of piston and rings properly spaced. (Scheme 24)

Note. Check oil pump drive gear backlash if drive gear is replaced. See OIL PUMP DRIVE GEAR BACKLASH under ENGINE OILING.

Crankshaft Oil Pump Drive Gear

1. Inspect crankshaft oil pump drive gear. If replacement is required, drill a hole between 2 teeth of drive gear. Using chisel, split gear and remove it from crankshaft.
2. Ensure crankshaft is free of burrs. Preheat oven to 392°F (200°C) for one hour. Apply Tempilstik (J-24731-425) on replacement gear teeth. Heat gear in oven for 25-30 minutes. Ensure Tempilstik starts to melt.
3. Install gear on crankshaft. Ensure gear is fully seated against crankshaft counterweight.

ENGINE LUBRICATION SYSTEM

Crankshaft-driven oil pump forces pressurized oil through oil filter to main gallery. A by-pass valve in engine block allows continuous oil flow in case oil filter is restricted. Oil is distributed from gallery to crankshaft and timing chain hydraulic tensioner. (Scheme 25)

Connecting rod bearings are oiled by passages through crankshaft. Piston cooling is provided through an oil cooling hole in connecting rod. Oil passes through oil flow check valve into cylinder head and then into each camshaft housing. Cast passages feed each valve lifter and drilled passages feed each camshaft bearing surface.

Crankcase Capacity

Oil capacity is 4 qts. (3.8L) without oil filter.

Oil Pressure

Oil pressure should be at least 15 psi (1.05 kg/cm 2 ) at 900 RPM or 30 psi (2.11 kg/cm 2 ) at 2000 RPM with engine at normal operating temperature.

Scheme 25

Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Remove oil pump assembly.

Note. DO NOT remove drive gear and shaft from pump housing.

Disassembly & Inspection

1. Remove oil pump screen and gerotor (oil pump) cover. Remove pressure regulator valve. Remove gerotor pump.
2. Inspect components for flaking and damage. Measure outer gerotor cavity depth. Measure outer gerotor diameter, thickness and tip clearance between both gerotors. Replace pump assembly if clearances are not within specification. See «OIL PUMP SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d) table.

OIL PUMP SPECIFICATIONS

Coat components with oil before reassembly. To reassemble, reverse disassembly procedure. Check oil pump drive gear backlash. See OIL PUMP DRIVE GEAR BACKLASH .

OIL PUMP DRIVE GEAR BACKLASH

1. With oil pump removed from engine, remove driven gear cover and screen assembly from oil pump. Install oil pump on block. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/beretta/i-1987-1996/remont/mechanical/#23l-4-cylinder-vins-a-d__torque-specifications) table at the end of this article. Install dial indicator on cylinder block with stem resting against oil pump drive gear tooth.
2. Measure oil pump drive gear backlash. Ensure crankshaft does not rotate. Backlash should be .009-.020" (.23-.51 mm). If backlash is not to specification, replace oil pump.
3. If backlash is okay, remove oil pump. Reinstall driven gear cover and screen assembly to pump. Install oil baffle (if removed). Reinstall oil pump assembly.

DOHC ENGINE COMPONENTS

Note. For a legend of components for DOHC illustrations, see LEGEND FOR FIGURES 17 & 18 .

Exploded View Of 2.3L DOHC Engine Components (See Legend - Table 4) Courtesy of General Motors Corp. Scheme 26

Exploded View of 2.3L DOHC Cylinder Head Components (See Legend - Table 4) Courtesy of General Motors Corp. Scheme 27

LEGEND FOR FIGURES 17 & 18

SOHC ENGINE COMPONENTS

Note. For a legend of components for SOHC illustrations, see LEGEND FOR FIGURES 19 & 20 .

Exploded View of 2.3L SOHC Engine Components (See Legend - Table 5) Courtesy of General Motors Corp. Scheme 28

Exploded View of 2.3L SOHC Cylinder Head Components (See Legend - Table 5) Courtesy of General Motors Corp. Scheme 29

LEGEND FOR FIGURES 19 & 20

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECS

CONNECTING RODS SPECIFICATIONS

CONNECTING RODS SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

VALVES & VALVE SPRINGS SPECIFICATIONS

VALVES & VALVE SPRINGS SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

VALVE LIFTERS SPECIFICATIONS

VALVE LIFTERS SPECIFICATIONS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
• ENGINE IDENTIFICATION CODES
• FUEL PRESSURE RELEASE
• TORQUE SPECIFICATIONS
• INTAKE CAMSHAFT & HOUSING (DOHC)/CAMSHAFT &
• EXHAUST CAMSHAFT & HOUSING
• CYLINDER HEAD
• TIMING CHAIN HOUSING
• CAMSHAFT HOUSING OVERHAUL
• OIL PUMP DRIVE GEAR BACKLASH