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    Jeep Wagoneer/Commando/Cherokee 1984-1998

    Rocker Arm (Valve) Cover

    Print

    Removal & Installation



    2.1L Diesel Engine
    1. Disconnect the negative battery cable
    2.  
    3. Disconnect vacuum and oil breather hoses that route over the rocker arm cover.
    4.  
    5. Remove the rocker arm cover retaining bolts. Remove the cover.
    6.  
    7. Remove the cover gasket, clean the mating surfaces and install the new gasket.
    8.  
    9. Install the retaining bolts and tighten them to 35 inch lbs. (4 Nm). Reconnect vacuum and oil breather hoses that were disconnected during removal.
    10.  

    2.5L Engine

    See Figures 1, 2, 3, 4, 5 and 6

    1. Remove the air cleaner and the PCV valve molded hose.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 1: Disconnect the PCV hose from the cover

    1. Disconnect the fuel line at the fuel pump and swivel to allow removal of the rocker arm cover (carbureted engines).
    2.  
    3. Disconnect or remove any vacuum or air hoses to provide access to the rocker arm cover.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 2: Unplug the fresh air hose from the valve cover

    To avoid damaging the rocker arm cover, DO NOT pry the cover upward until the RTV seal has been broken.



    Click image to see an enlarged view

    Fig. Fig. 3: Remove the bolts securing the cover to the head



    Click image to see an enlarged view

    Fig. Fig. 4: Lift the vacuum pipe from the studs



    Click image to see an enlarged view

    Fig. Fig. 5: Remove the valve cover from the head



    Click image to see an enlarged view

    Fig. Fig. 6: If necessary, use a putty knife or razor blade to break the seal. Pry only where indicated

    1. Remove the rocker arm cover retaining bolts. Break the RTV seal by gently tapping the cover.
    2.  
    3. Thoroughly clean old sealer from head and cover. Examine rocker arm cover for cracks or bent rails.
    4.  

    To install:
    1. Apply a 1 / 8 in. (3mm) bead of RTV sealant along the entire length of the rocker arm cover rail. Allow the sealant to set-up for a few seconds.
    2.  
    3. While the sealant is still fluid, install the rocker arm cover on the cylinder head. Take care not to get any sealant on the rocker arms or valve train components.
    4.  
    5. Install rocker arm cover retaining bolts and tighten to 115 inch lbs. (13 Nm).
    6.  
    7. Reposition and connect all previously disconnected vacuum and air hoses. Install the PCV valve and hose. Install the air cleaner.
    8.  

    2.8L Engine

    See Figure 7

    LEFT SIDE
    1. Disconnect the battery cables.
    2.  
    3. Disconnect the hoses, wire connectors and pipe bracket Remove the spark plug wires and clips from the retaining stud.
    4.  
    5. Remove the rocker arm cover retaining bolts. Break the RTV seal by gently tapping the cover.
    6.  
    7. Thoroughly clean old sealer from head and cover. Examine rocker arm cover for cracks or bent rails.
    8.  

    To install:
    1. Apply a 1 / 8 in. (3mm) bead of RTV sealant along the entire length of the rocker arm cover rail. Allow the sealant to set-up for a few seconds.
    2.  
    3. While the sealant is still fluid, install the rocker arm cover on the cylinder head. Take care not to get any sealant on the rocker arms or valve train components.
    4.  
    5. Install rocker arm cover retaining bolts and tighten to 8 ft. lbs. (11 Nm).
    6.  
    7. Connect all previously disconnected wires, hoses and brackets. Reconnect the battery cables.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 7: Valve cover used on 2.8L engines

    RIGHT SIDE
    1. Disconnect the battery cables.
    2.  
    3. Remove the air cleaner, air injection diverter and coil bracket.
    4.  
    5. Disconnect the air hose from the air injection manifold, wire connectors and vacuum hoses.
    6.  
    7. Remove the spark plug wires and clip from the retaining stud.
    8.  
    9. Disconnect the carburetor controls and remove from the bracket.
    10.  
    11. Remove the rocker arm cover retaining bolts. Break the RTV seal by gently tapping on the cover.
    12.  
    13. Thoroughly clean old sealer from head and cover. Examine rocker arm cover for cracks or bent rails.
    14.  

    To install:
    1. Apply a 1 / 8 in. (3mm) bead of RTV sealant along the entire length of the rocker arm cover rail. Allow the sealant to set-up for a few seconds.
    2.  
    3. While the sealant is still fluid, install the rocker arm cover on the cylinder head. Take care not to get any sealant on the rocker arms or valve train components.
    4.  
    5. Install rocker arm cover retaining bolts and tighten to 8 ft. lbs. (11 Nm).
    6.  
    7. Connect all previously disconnected wires, hoses and brackets. Reconnect the carburetor controls, air injection diverter valve and coil bracket. Install the air cleaner and reconnect the battery cables.
    8.  

    4.0L Engine
    1. Remove the hoses and cruise control servo (if equipped).
    2.  
    3. Remove the rocker arm cover retaining bolts. Break the RTV seal by gently tapping on the cover.
    4.  
    5. Thoroughly clean old sealer from head and cover. Examine rocker arm cover for cracks or bent rails.
    6.  

    To install:
    1. Apply a 1 / 8 in. (3mm) bead of RTV sealant along the entire length of the rocker arm cover rail. Allow the sealant to set-up for a few seconds.
    2.  
    3. While the sealant is still fluid, install the rocker arm cover on the cylinder head. Take care not to get any sealant on the rocker arms or valve train components.
    4.  
    5. Install rocker arm cover retaining bolts and tighten to 85 inch lbs. (10 Nm).
    6.  
    7. Install the PCV molded hoses and cruise control servo (if equipped).
    8.  

    5.2L and 5.9L Engines
    1. Disconnect the negative battery cable.
    2.  
    3. Label and disconnect any and all necessary hoses from the cylinder head cover.
    4.  
    5. If removing the left cylinder head cover, remove the coolant tube bracket.
    6.  
    7. Remove the spark plug wires from the holders and disconnect them from the spark plugs.
    8.  
    9. Loosen the bolts, then remove the cylinder head cover and gasket. The steel backed silicon gasket can be used again if not damaged.
    10.  

    To install:
    1. Install the cylinder head cover and gasket. On the left cover, install the coolant tube bracket. Tighten the cylinder head cover retaining bolts to 95 inch lbs. (11 Nm).
    2.  
    3. Connect the spark plug wires to the spark plugs and install the wires in the holders.
    4.  
    5. Connect all hoses that were disconnected during the removal procedure.
    6.  
    7. Connect the negative battery cable.
    8.  

     
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