Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Rocker Arms & Shafts

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Perform fuel system pressure release procedure before attempting any repairs.
  6.  
  7. Loosen timing belt. See timing belt section.
  8.  
  9. Remove the cylinder head cover.
  10.  
  11. Mark rocker arm shaft assemblies so that they are installed in their original positions.
  12.  
  13. Loosen rocker arm shaft bolts in quarter-turn increments and in a crisscross pattern.
  14.  
  15. Remove rocker arm shaft bolts.
  16.  
  17. Remove timing belt, timing belt tensioner and camshaft sprocket.
  18.  

To install:


WARNING
Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping.


NOTE
Clean cylinder head and cover mating surfaces and make sure they are flat.

  1. Install or connect the following:

    Timing belt tensioner and timing belt.
     
    Rocker arm assemblies in correct order as removed and torque the bolts to 250 inch lbs. (28 Nm) in a crisscross pattern.
     
    Cylinder head cover with a new gasket and torque the bolts to 105 inch lbs. (12 Nm)
     
    Ignition coil pack and ignition cables.
     

  2.  

This engine uses an Single Over Head Camshaft (SOHC) running in an aluminum cylinder head. Rocker arm shafts mount directly to the cylinder head. Care must be taken to be sure all valve timing marks align after cylinder head and valve train service. The Hydraulic Lash Adjusters (HLAs) are located in the valve actuating end of the rocker arm and are serviced as an assembly.

  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

  2.  
  3. Relieve the fuel system pressure using the recommended procedure.
  4.  
  5. Disconnect the negative battery cable from the left shock tower.
  6.  
  7. Remove or disconnect the following:

    Spark plug wires
     
    Air inlet duct
     
    Ignition coil pack
     
    Cylinder head cover
     

  8.  
  9. Thoroughly clean the cylinder head cover and gasket mating surfaces. Be sure the gasket mating surfaces are flat.
  10.  
  11. Mark the rocker arm shaft assemblies to identify them for later installation.
  12.  
  13. Remove or disconnect the following:

    Rocker arm shaft bolts
     
    Rocker arm assemblies
     

  14.  
  15. Mark the rocker arm spacers and retainers to identify them for correct installation.
  16.  
  17. Disassemble the rocker arm/shaft assemblies as follows:
    WARNING
    Be sure the rocker arms and spacers are reassembled in the same positions they are removed.



    Bolts from the rocker arm shaft assemblies
     
    Rocker arm/HLA assembly and rocker arm spacers, sliding them off the rocker arm shaft
     



    Click image to see an enlarged view

    Fig. Rocker arm shaft identification-2.0L engine

  18.  

To install:


NOTE
Inspect the rocker arms and shaft for scoring and/or wear on the rollers or damage to the rocker arm. If scoring, wear or damage is present, replace the rocker arm assemblies. The rocker arm shaft is hollow and, therefore, used as an oil lubrication duct. Inspect the oil holes for clogging, using a small wire and clean, if necessary. Inspect the location where the rocker arms mount to the shaft and replace if damaged or worn.

  1. If the camshaft lobes show signs of wear, check the corresponding rocker arm roller for wear or damage. Replace rocker arms/HLAs if worn or damaged. If the camshaft lobes show signs of pitting on the nose, flank or base circle replace the camshaft.
  2.  
  3. Inspect the rocker arms for scoring, wear on the roller or damage to the shaft. Replace parts as necessary. Check that the rocker arm shaft is clean inside and out. Check all oil holes for clogging with a small wire and clean and required.
  4.  
  5. Thoroughly lubricate all rocker arm components and spacers and reinstall the on the rocker arm shaft in the original locations.
  6.  
  7. If the vehicle exhibited a tappet-like noise, the valve lash adjusters built into the rocker arms should be cleaned and checked. Lash adjusters removed from a rocker arm should be returned to their original locations. Replacement of worn or defective lash adjusters would require the replacement of the rocker arm/HLAs as an assembly.
  8.  
  9. Install the a HLA, by using the following procedure:
    1. Lubricate the HLA thoroughly with clean engine oil.
    2.  
    3. Reinstall the HLA into the rocker arm making sure the HLA is at least partially filled with oil.
    4.  
    5. Place the rocker arm in clean engine oil and pump the plunger until the HLA travel is taken up. If travel is not reduced, replace the adjuster with the rocker arm as an assembly.
    6.  
    7. Reinstall the rocker arm back on the rocker arm shaft.
    8.  

  10.  
  11. Before installing the rocker arm and shaft assemblies, set the crankshaft to 3 notches Before Top Dead Center (BTDC) on the crankshaft sprocket.
    NOTE
    When installing the intake rocker arm/shaft assembly, be sure the plastic rocker arm spacers do not interfere with the spark plug tubes. If there is interference, rotate the plastic spacers until they are at the proper angle. Do not rotate the spacers by forcing down on the shaft assembly or damage to the spark plug tubes will occur.

  12.  
  13. Reinstall the rocker arm and shaft assemblies with the small notches in the rocker shafts pointing up and toward the timing belt side of the engine. Install the retainers in their original positions on the exhaust and intake shafts. Tighten the bolts in proper sequence to 17 ft. lbs. (23 Nm).

    Click image to see an enlarged view

    Fig. Rocker arm shaft notch locations-2.0L engine



    Click image to see an enlarged view

    Fig. Rocker arm shaft tightening sequence-2.0L engine

  14.  
  15. Install or connect the following:

    Cylinder head cover using a new gasket. Torque the bolts to 105 inch lbs. (12 Nm)
     
    Ignition coil pack. Torque the fasteners to 17 ft. lbs. (23 Nm)
     
    Spark plug wires
     
    Air cleaner inlet duct
     
    Negative battery cable
     

  16.  
  17. Check to be sure all electrical, vacuum and fluid connections are reattached as required.
  18.  
  19. An oil and filter change are recommended.
  20.  
  21. Start the engine and check for leaks. Test drive the vehicle to check for proper operation.
  22.  

2.4L & 3.0L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure using the recommended procedure.
  4.  
  5. Loosen timing belt. See timing belt section.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Breather hose
     
    Positive Crankcase Ventilation (PCV) hose and valve
     
    Rocker arm cover
     
    Rocker shaft cap
     
    Rocker arms and shafts
     

  8.  

To install:

  1. Install or connect the following:

    Rocker arms and shafts. When properly aligned, torque the rocker shaft cap to 23 ft. lbs. (31 Nm).
     
    Oil seals
     
    Rocker arm cover with a new gasket
     
    PCV valve with a new gasket
     
    PCV hose
     
    Breather hose
     
    Negative battery cable
     

  2.  

2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Loosen timing belt. See timing belt section.
  8.  
  9. If removing the right (firewall) side rocker arm/shaft assembly, remove the upper intake manifold (air intake plenum), which is a 2-piece unit of aluminum alloy.
  10.  
  11. Remove the valve cover(s).
  12.  
  13. Identify the rocker arm shaft assemblies before removal.
  14.  
  15. Install the auto lash adjuster retainers Special Tool MD 998443 to keep the auto lash adjusters from falling out of the rocker arms when the rocker arm assembly is removed.
  16.  
  17. Remove the rocker arm shaft assemblies.
    NOTE
    The hydraulic automatic lash adjusters are precision units installed in the machined openings in the rocker arm units. Do not disassemble the auto lash adjusters.

  18.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the cylinder head valve train assembly-2.5L engine

  1. The rocker arm shafts are hollow and used as a lubrication oil duct. Ensure all valve train parts are clean. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if necessary. Check all oil holes for clogging with a small wire and clean as required. If any rockers were removed, lubricate and install them on the shafts in their original positions.
  2.  
  3. For the right cylinder head, install the rocker arm and shaft assemblies with the FLAT in the rocker arm shafts facing toward the timing belt side of the engine.
  4.  
  5. For the left cylinder head, install the rocker arm and shaft assembly with the FLAT in the rocker arm shaft facing toward the transaxle side of the engine.
  6.  
  7. Install the retainers and spring clips in their original positions on the exhaust and intake shafts. Torque the retainer bolts to 23 ft. lbs. (31 Nm) working from the center, outward. Remove the valve lash retainer tools that may have been installed at disassembly.
  8.  
  9. Inspect the spark plug tube seals located on the ends of each tube. These seals slide onto each tube to seal the cylinder head cover to the spark plug tube. If these seals show signs of hardness and/or cracks, they should be replaced.
  10.  
  11. Install or connect the following:

    Valve cover(s)
     
    Upper intake manifold (plenum), if necessary
     
    All remaining electrical connectors and tighten the air tube connections
     
    Negative battery cable
     

  12.  
  13. An oil and filter change is recommended.
  14.  
  15. Start the engine and check for leaks, abnormal noises and vibrations.
  16.  

  1. Before servicing the vehicle, refer to the Precautions section. to prevent the negative battery cable from accidentally grounding.
  2.  
  3. Relieve the fuel system pressure using the recommended procedure.
  4.  
  5. Disconnect the negative battery cable from the left shock tower.
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud

  6.  
  7. If removing the right (firewall) side rocker arm/shaft assembly, remove the upper intake manifold (air intake plenum), which is a 2-piece unit of aluminum alloy. Use care working with light alloy parts.
  8.  
  9. Remove the or disconnect the air intake plenum using the following procedure:

    Fuel supply tube from the fuel rail. Squeeze the tabs together and pull the fuel tube/quick-connect fitting assembly off the fuel tube nipple
     
    Manifold Absolute Pressure (MAP) sensor and Intake Air Temperature (IAT) sensor electrical connections
     
    Plenum support bracket bolt located rearward of the MAP sensor
     
    Air inlet resonator-to-intake manifold bolt
     
    Throttle body air inlet hose clamp
     
    Air cleaner housing cover and inlet hoses
     
    Throttle Position (TP) sensor electrical connector and Idle Air Control (IAC) motor electrical connections
     
    Throttle cable by sliding it out of the bracket
     
    Speed control cable by sliding it out of its bracket (if equipped)
     
    Exhaust Gas Recirculation (EGR) tube from the intake manifold
     
    Plenum support bracket bolt from the rear of the EGR tube
     
    Upper intake plenum
     

  10.  
  11. Remove or disconnect the following:

    Spark plug wires
     
    Cylinder head cover
     

  12.  
  13. Identify the rocker arm shaft assemblies before removal.
  14.  
  15. Install the auto lash adjuster retainers Special Tool MD 998443, to keep the auto lash adjusters from falling out of the rocker arms when the rocker arm assembly is removed.
  16.  
  17. Loosen the fasteners and remove the rocker arm shaft assemblies.
    NOTE
    The hydraulic automatic lash adjusters are precision units installed in the machined openings in the rocker arm units. Do not disassemble the auto lash adjusters from the rocker arms.

  18.  

To install:

  1. The rocker arm shafts are hollow and used as a lubrication oil duct. Be sure all valve train parts are clean. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if necessary. Check all oil holes for clogging with a small wire and clean as required. If any rockers were removed, lubricate and install the on the shafts in their original positions.
  2.  
  3. For the right cylinder head, install the rocker arm and shaft assemblies with the FLAT in the rocker arm shafts facing the timing belt side of the engine. For the left cylinder head, install the rocker arm and shaft assembly with the FLAT in the rocker arm shaft facing the transaxle side of the engine. Install the retainers and spring clips in their original positions on the exhaust and intake shafts. Tighten the retainer bolts to 23 ft. lbs. (31 Nm) working from the center, outward. Remove the valve lash retainer tools that should have been installed at disassembly.

    Click image to see an enlarged view

    Fig. The flats on the rocker arm shaft aids proper orientation-2.5L engine



    Click image to see an enlarged view

    Fig. Rocker arm shaft tightening sequence-2.5L engine

  4.  
  5. Inspect the spark plug tube seals located on the ends of each tube. These seals slide onto each tube to seal the cylinder head cover to the spark plug tube. If these seals show signs of hardness and/or cracking, they should be replaced.
  6.  
  7. Clean the cylinder head and cover mating surfaces.
  8.  
  9. Install or connect the following:

    Cylinder head cover using a new gasket. Torque bolts to 88 inch lbs. (10 Nm)
     
    Spark plug wires
     
    Upper intake manifold (plenum) using a new gasket. Tighten the bolts to 13 ft. lbs. (18 Nm)
     
    Plenum support bracket bolts
     
    EGR tube
     
    Throttle and speed control cables
     
    TP sensor, MAP sensor, IAT sensor and IAC motor electrical connectors
     
    Air inlet resonator, air inlet hose and air cleaner housing cover
     
    All remaining electrical connectors
     
    Air tube connections
     
    Negative battery cable
     

  10.  
  11. An oil and filter change is recommended.
    WARNING
    Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

  12.  
  13. Start the engine and check for leaks, abnormal noises and vibrations.
  14.  

2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure using the recommended procedure.
  4.  
  5. Remove the negative battery cable.
  6.  
  7. Remove the rocker arm cover and rotate the engine until the cam lobe is on its base circle.
  8.  
  9. Using special tools 8215-A and 8216-A, depress the valve spring enough to release the tension on the rocker arm.
  10.  
  11. Remove the rocker arm from the cylinder head.
  12.  

To install:

  1. Lubricate the rocker arms with clean engine oil.
  2.  
  3. Depress the valve spring far enough to install the rocker arm.
  4.  
  5. Install the rocker arm into its original position over the valve and lash adjuster.
  6.  
  7. Install the rocker arm cover.
  8.  
  9. Connect the negative battery cable.
  10.  

 
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