How2 - C20XE/C20LET/X20XEV Change the Cam Cover Gasket

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How2 - C20XE/C20LET/X20XEV Change the Cam Cover Gasket

Post by humbucker »

A common failure with many Cavalier engines is the cam cover gasket. This can be attributed to a number of things; a poorly fitted gasket, the overtightening of cam cover bolts or even breather blockages. The job on the C20XE/C20LET/XEV is fairly straightforward; well, it’s a lot easier than the same job on a V6 so be thankful for that at least!

Ideally you should only use the parts listed below. Non genuine gaskets can be a poor fit and you may find yourself having to replace them again in a very short space of time. Elring are the OE manufacturer of many cam cover gaskets so you should be fine with those, but if in doubt order the items from your local Vauxhall parts desk. You may also want to take the opportunity to replace the spark plugs as full access is afforded to you when doing this job.

90485251 Gasket Sealant x1 (black stuff only, do not use grey or green sealant)
90466638 Cam Cover Gasket x1 (for C20XE, C20LET)
90501944 Cam Cover Gasket x1 (for X20XEV)
90528438 Cam Cover O-rings x10 (for X20XEV)

If you want to renew your bolts then you’ll need these part numbers. Entirely optional, depends on the condition of the old ones. Up to you, but the bolt sizes are here which at the very least might prove useful when checking you have the tools for the job:

11073041 M6x18 Spark plug cover bolts x2 (for C20XE, C20LET)
11090921 M6x65 Cam cover to head bolts x19 (for C20XE, C20LET)
11071693 M6x12 Spark plug cover bolts x2 (for X20XEV)
11097861 M6x30 Cam cover to head bolts x10 (for X20XEV)

First of all remove the spark plug cover from the cam cover. On the C20XE/LET this is the signature red/black L piece with the Vauxhall logo on it staring you in the face when you open the bonnet, and on the XEV it is a black plastic strip that says ‘ECOTEC’ along the middle. A couple of small bolts hold this in place. Once this has been removed you will be able to pull the HT leads from each of the spark plugs. Remember which lead connects to which plug (although the length of the lead is usually the giveaway). A common means of identification is to label each HT lead head with the number cylinder it relates to e.g. 1, 2, 3, 4. Once you have disconnected the HT leads you should be left with something that looks like this:

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Loosen the clips attaching the front breather pipe that protrudes from the of the cam cover. There are two clips, one at the top of the pipe and one at the bottom. The pipe is located at the front of the cam cover down by the dipstick:

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Once the clips are loose you can then undo the bolts that hold the cam cover in place. There are 19 on the XE/LET if memory serves, and 10 on the XEV. Put them to one side. You should now be able to lift the cam cover off, and the old gasket will probably come off with it.

Once you have the the cam cover off, remove the old gasket. Carefully remove any gasket, sealant or dirt from the cam cover mating surface as well as the mating surface on the head. Be sure that no manky old gasket falls into the head.

Once you are satisfied that the mating surfaces are clean, take your new gasket and carefully position it on the underside of the cam cover. It should press firmly into place and should be a snug fit:

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Before refitting the cam cover, put a tiny bead of sealant along the half-moon cutout on the head (pictured here back/right on the head), and a very small amount either side of the camshaft bearing caps each end of the head. These areas are prone to leaking so this gives us a little more support, although be sure to use a minimal amount; we only want to hold the gasket in place, not glue it down!

Place the cam cover back on to the head and refit the breather hose at the same time. Make sure the cam cover is firmly in place and the replace/renew your camshaft cover to cylinder head bolts (nb. if you are working with an X20XEV then remember to replace the O-rings that sit between the bolts and the cam cover). Be sure to tighten the bolts to only 8Nm! This is vital to prevent further leaks as overtightening will compromise the gasket. Tighten the breather hose clips, refit the spark plugs and reinstall the spark plug cover. You’re done! Have a celebratory cup o’ tea!

The following picture shows the reassembled cam cover complete with new gasket. If you look at the bottom corner of the cam cover/gasket you can just make out the tiny amount of sealant used to hold the gasket in place and prevent leaking from this point. As mentioned before, you don’t need a lot so don’t go crazy with it!

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Looking for the C25XE V6 cam cover gasket guide? That can be found here: viewtopic.php?f=42&t=2872.
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