GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Optra 🢒 Engine 🢒 Engine Mechanical - 2.0L (Diesel) 🢒 Valve Rocker Arm Cover Replacement

Removal Procedure

    Warning: Refer to Battery Disconnect Warning in the Preface section.


    Object Number: 1863838 Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the engine cover. Refer to Engine Cover Replacement.
  3. Remove the charge air system hoses and ducts. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement.
  4. Remove the PCV valve and adapter. Refer to Positive Crankcase Ventilation Valve Replacement and Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.

    5. Object Number: 1820568 Size: SH
  5. Remove the fuel pipe-to-injector between the common rail and the injector. Refer to Fuel Injector Fuel Feed Pipe Replacement.
  6. Remove the fuel return line assembly. Refer to Fuel Return Pipe Replacement.

    7. Object Number: 1864043 Size: SH
  7. Remove the timing belt upper cover.
  8. Disconnect the CMP sensor connector.
  9. Remove the vacuum hose.
  10. Disconnect the fuel hose from the high pressure pump.
  11. Remove the brackets for retaining the power steering, fuel, and coolant hoses.
  12. Remove the injectors. Refer to Fuel Injector Replacement.

    13. Object Number: 1864044 Size: SH
  13. Remove the cylinder head cover with the gasket.

Cleaning Procedure
  1. Clean the cylinder head cover sealing surface.
  2. Clean the cylinder head sealing surface.
  3. Clean the cylinder head cover bolts.
  4. Clean the cylinder head cover bolt holes.

Installation Procedure

    Object Number: 1822533 Size: SH
  1. Coat the sealant (LOCTITE 5900) on the camshaft front/rear cap surface.

    2. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1864044 Size: SH
  2. Install the cylinder head cover with a new gasket on the cylinder head.

    3. Tighten
    Tighten the cylinder head cover bolts to 12 N·m (8.9 lb ft).


    Object Number: 1864043 Size: SH
  3. Install the timing belt upper cover.
  4. Install the fuel injector sight shield bracket with coolant return pipe to the surge tank.
  5. Install the fuel return line assembly.
  6. Install the fuel pipe-to-injector between the common rail and the injector. Refer to Fuel Injector Fuel Feed Pipe Replacement.

    7. Tighten

        • Tighten the timing belt upper cover bolts to 11 N·m (97.4 lb in).
        • Tighten the coolant return pipe retaining bolt 9 N·m (79.7 lb in).
        • Tighten the junction block bolts to 11 N·m (97.4 lb in).
        • Tighten the fuel injector sight shield bracket bolt to 11 N·m (97.4 lb in).