Chrysler Caravan/Voyager/Town n Country 1984-1995

Rocker Arms and Shafts

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REMOVAL & INSTALLATION



2.2L and 2.5L Engines

See Figures 1 and 2



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Fig. Fig. 1: Rocker arm and lash adjuster-2.2L and 2.5L engines



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Fig. Fig. 2: Compressing a valve spring-2.2L and 2.5L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the valve cover.
  4.  
  5. Rotate the camshaft until the lobe base is on the rocker arm that is to be removed.
  6.  
  7. Slightly depress the valve spring using Chrysler tool-4682 or the equivalent. Slide the rocker off the lash adjuster and valve tip and remove. Label the rocker arms for position identification. Proceed to the next rocker arm and repeat Steps 3 and 4.
  8.  
  9. Remove the lash adjuster, if servicing is necessary.
  10.  

To install:
  1. If the lash adjuster was previously removed, partially fill with oil and install.
  2.  
  3. Rotate the camshaft until lobe base is in position with rocker arm. Slightly depress the valve spring using Chrysler tool 4682 or equivalent. Slide the rocker arm in position.
  4.  

When depressing the valve spring with Chrysler tool 4682, or the equivalent, the valve locks can become dislocated. Check and make sure both locks are fully seated in the valve grooves and retainer.

  1. Install the valve cover.
  2.  
  3. Connect the battery cable.
  4.  

2.6L Engines

See Figure 3



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Fig. Fig. 3: Rocker arm and shaft assemblies-2.6L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the valve cover.
  4.  
  5. Loosen the camshaft bearing cap bolts. Do not remove bolts from bearing cap.
  6.  
  7. Remove the rocker arm, rocker shafts and bearing caps as an assembly.
  8.  
  9. Remove the bolts from the camshaft bearing caps and remove the rocker shafts, waved washers, rocker arms and springs. Keep all parts in order. Note the way the rocker shaft, rocker arms, bearing caps and springs are mounted. The rocker arm shaft on the Left side has 12 oil holes at shaft bottom, and the Right side shaft has 4 oil holes at shaft bottom.
  10.  
  11. Inspect the rocker arms mounting area and rockers for damage. Replace if worn or heavily damaged.
  12.  

To install:
  1. Position the camshaft bearing caps with arrows pointing toward the timing chain and in numerical order.
  2.  
  3. Insert both shafts into the front bearing cap and install bolts to hold shafts in position.
  4.  
  5. Install the wave washers, rocker arms, bearing caps, and springs. Install bolts in the rear cap to retain assembly.
  6.  
  7. Place the assembly into position.
  8.  
  9. Tighten the camshaft bearing cap bolts in sequence to 10 Nm (85 inch lbs.) as followed:
    1. No. 3 Cap
    2.  
    3. No. 2 Cap
    4.  
    5. No. 4 Cap
    6.  
    7. Front Cap
    8.  
    9. Rear Cap
    10.  

  10.  
  11. Repeat Step 12 and increase the torque to 175 inch lbs. (20 Nm).
  12.  
  13. Install the distributor drive gear, timing chain/camshaft sprocket, and sprocket bolt. Tighten the sprocket bolt to 40 ft. lbs. (55 Nm).
  14.  

After servicing the rocker shaft assembly, Jet Valve Clearance (if used) and Intake/Exhaust Valve Clearance must be performed.

  1. Install the water pump (upper shield) and valve cover.
  2.  
  3. Connect the battery cable.
  4.  

3.0L Engines

See Figures 4, 5, 6 and 7



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Fig. Fig. 4: Number 1 bearing cap-3.0L engines



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Fig. Fig. 5: Rocker shaft identification-3.0L engines



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Fig. Fig. 6: Installation of the rocker shaft assembly-3.0L engines



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Fig. Fig. 7: Rocker arm and shaft assemblies-3.0L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the valve cover.
  4.  
  5. Loosen the camshaft bearing cap bolts. Do not remove the bolts from the bearing cap.
  6.  
  7. Remove the rocker arm, rocker shafts and bearing caps as an assembly.
  8.  
  9. Remove the bolts from the camshaft bearing caps and remove the rocker shafts and arms. Keep all parts in order. Note the way the rocker shaft, rocker arms, bearing caps and springs are mounted. The rocker arm shaft on the intake side has a 0.12 in. (3mm) diameter oil passage hole from the cylinder head. The exhaust side does not have this oil passage.
  10.  
  11. Inspect the rocker arm mounting area and rocker for damage. Replace if worn or heavily damaged.
  12.  

To install:
  1. Identify No. 1 bearing cap, (No. 1 and No. 4 caps are similar). Install the rocker shafts into the bearing cap with notches in proper position. Insert the attaching bolts to retain assemble.
  2.  
  3. Install the rocker arms, springs and bearing caps on shafts in numerical sequence.
  4.  
  5. Align the camshaft bearing caps with arrows (depending on cylinder bank).
  6.  
  7. Install the bolts in No. 4 cap to retain assembly.
  8.  
  9. Apply sealant at bearing cap ends.
  10.  
  11. Install the rocker arm shaft assembly.
  12.  

Make sure the arrow mark on the bearing caps and the arrow mark on the cylinder heads are in the same direction. The direction of arrow marks on the front and rear assemblies are opposite to each other.

  1. Tighten the bearing caps bolts to 85 inch lbs. (10 Nm) in the following sequence:
    1. No. 3 Cap
    2.  
    3. No. 2 Cap
    4.  
    5. No. 1 Cap
    6.  
    7. No. 4 Cap
    8.  

  2.  
  3. Repeat Step 13, but increase the torque value to 180 inch lbs. (20 Nm).
  4.  
  5. Install the valve cover.
  6.  
  7. Connect the battery cable.
  8.  

3.3L and 3.8L Engines

See Figures 8 and 9



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Fig. Fig. 8: Left bank rocker shaft assembly-3.3L and 3.8L engines



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Fig. Fig. 9: Rocker arm shaft retainers-3.3L and 3.8L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the upper intake manifold assembly.
  4.  
  5. Remove the rocker arm cover.
  6.  
  7. Remove the 4 rocker shaft retaining bolts and retainers.
  8.  
  9. Remove the rocker arms and shaft assembly.
  10.  
  11. If you are disassembling the rocker shaft, be sure to install the rocker arms in their original locations.
  12.  

To install:
  1. Install the rocker arm and shaft assembly, using the 4 retainers. Tighten the retaining bolts to 21 ft. lbs. (28 Nm).
  2.  

The rocker arm shaft should be torqued down slowly, starting with the center bolts. After installation, allow 20 minutes for tappet bleed down, before engine operation.

  1. Install the rocker cover.
  2.  
  3. Install the crankcase ventilation components and connect the spark plug wires.
  4.  
  5. Install the upper intake manifold assembly.
  6.  
  7. Connect the negative battery cable.
  8.  

 
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