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Bob, Auto Tech
Category: Chevy
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Experience:  Plus 40 years GM, over 30 certified with Chevrolet, ASE certified Master Tech. (Expired, Retired)
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how to change a head gasket on a 1996 chevy corsica 4 ...

Customer Question

how to change a head gasket on a 1996 chevy corsica 4 cyl? i think its a 2.2
Submitted: 9 years ago.
Category: Chevy
Expert:  Bob replied 9 years ago.

Hello, you should find everything you need in the post below. Be sure you have a good machine shop pressure test the head and check it for being warped before you put it back together. Thanks

1991-96 VEHICLES

See Figure 2

  1. Properly relieve the fuel system pressure. If not already done, disconnect the negative battery cable.

  2. Place a suitable container under the radiator, then drain the cooling system.

  3. Disconnect the air inlet duct.

  4. Tag and disconnect the necessary vacuum lines..

  5. Detach and unroute the electrical connections from the following:

    1. Engine Coolant Temperature (ECT) sensor

    2. Oxygen sensor

    3. Idle Air Control (IAC) valve

    4. Throttle Position (TP) sensor

    5. Manifold Absolute Pressure (MAP) sensor

    6. EVAP canister purge solenoid

    7. Fuel injector harness

  6. Disconnect the accelerator, cruise control and TV cables.

  7. Remove the coolant recovery reservoir.

  8. Install engine support fixture, tool J 28467-A equivalent to the engine, then remove the right engine mount.

  9. Remove the serpentine belt.

  10. Remove the alternator rear brace, then remove the alternator.

  11. Disconnect the power steering pump lines, then remove the power steering pump.

  12. Remove the serpentine drive belt tensioners.

  13. Remove the right engine mount bracket.

  14. Tag and disconnect the wires from the spark plugs.

  15. Detach the EVAP canister purge line from beneath the manifold.

  16. Remove the throttle body cable bracket.

  17. Disconnect the upper radiator hose from the coolant outlet.

  18. Remove the intake manifold brace (on the power steering bracket).

  19. Disconnect the coolant inlet hose from the cylinder head.

  20. Using a back-up wrench, disconnect the fuel lines.

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. Remove the spark plug wire bracket.

  3. Remove the engine lift bracket.

  4. Raise and safely support the vehicle.

  5. Disconnect the exhaust pipe from the lower manifold.

  6. Carefully lower the vehicle.

  7. Remove the cylinder head retaining bolts.

  8. If equipped with an automatic transaxle, remove the transaxle fluid level indicator bracket.

  9. Remove the cylinder head from the vehicle. Remove and discard the cylinder head gasket.

  10. 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.

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. Coat the cylinder head bolts with sealing compound and install them finger tight.

  3. Using a torque wrench, tighten the bolts as follows:

    1. Tighten the long bolts in sequence to 5 ft. lbs. (62 Nm).

    2. Tighten the short bolts in sequence to 2 ft. lbs. (58 Nm).

    3. Tighten all bolts in sequence an additional 90° using J 36660, or equivalent torque angle meter.

  4. Install the engine lift bracket.

  5. Install the spark plug wire bracket.

  6. Install the rocker arms and pushrods in the same locations as they were removed from.

  7. Install the rocker arm (valve) cover.

  8. Install the accelerator, cruise control and TV bracket.

  9. Connect the fuel lines and tighten using a back-up wrench.

  10. Attch the vacuum lines and electrical connections at the throttle body, as tagged during removal.

  11. Connect the coolant inlet hose to the cylinder head.

  12. If equipped, install the transaxle fluid level indicator bracket bolt.

  13. Install the intake manifold bracket-to-power steering bracket.

  14. Connect the upper radiator hose to the outlet housing.

  15. Attach the spark plug wires to the plugs, as tagged during removal.

  16. Install the right engine bracket.

  17. Install the serpentine drive belt tensioner.

  18. Install the power steering pump, then connect the fluid lines.

  19. Install the alternator and alternator rear brace.

  20. Install the serpentine drive belt.

  21. Remove the engine support tool.

  22. Install the coolant recovery reservoir.

  23. Install the air cleaner duct.

  24. Connect the accelerator, cruise control and T.V. cables to the throttle body.

  25. Route and attach the following electrical connectors:

    1. Engine Coolant Temperature (ECT) sensor

    2. Oxygen sensor

    3. Idle Air Control (IAC) valve

    4. Throttle Position (TP) sensor

    5. Manifold Absolute Pressure (MAP) sensor

    6. EVAP canister purge solenoid

    7. Fuel injector harness

  26. Connect the vacuum lines, as tagged during removal.

  27. Raise and safely support the vehicle, then attach the exhaust pipe.

  28. Carefully lower the vehicle. Fill all fluids and/or lubricants to the proper levels.

  29. Connect the negative battery cable, then start the engine and check for leaks. Check the fluid levels, and add if necessary.

Click image to see an enlarged view
Fig. 2: Exploded view of the cylinder head mounting and bolt tightening sequence -1991-96 2.2L engines