REMOVAL & INSTALLATION
2.0L SOHC Engine
See Figure 1
This engine uses a Single Overhead Camshaft (SOHC) running in an aluminum cylinder head. Rocker arm shafts mount directly to the cylinder head. Care must be taken to make sure that all valve timing marks align after cylinder head and valve train service. The hydraulic lash adjusters are located in the valve actuating end of the rocker arm and are serviced as an assembly.
- Disconnect the negative battery cable from the left strut tower. 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.
- Properly relieve the fuel system pressure, as described in Fuel System .
- Remove the rocker arm (valve) cover, as described earlier in this section.
- Mark the rocker arm shaft assemblies to identify them for later installation.
- Remove the rocker arm shaft bolts and remove the rocker arm assemblies from the cylinder head.
- Mark the rocker arm spacers and retainers to identify them for correct installation. Disassemble the rocker arm/shaft assemblies by removing the attaching bolts from the rocker arm shaft.
- Slide the rocker arm/hydraulic lash adjuster assembly and rocker arm spacers off the rocker arm shaft. Be sure the rocker arms and spacers are re-assembled in the same positions from which they are removed.
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.
- If the camshaft lobes show signs of wear, check the corresponding rocker arm roller for wear or damage. Replace the rocker arms/hydraulic lash adjuster if worn or damaged. If the camshaft lobes show signs of pitting on the nose, flank or base circle, replace the camshaft.
- Thoroughly lubricate all rocker arm components and spacers, and reinstall on the rocker arm shaft in their original locations.
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/hydraulic lash adjusters as an assembly. To install a lash adjuster, use the following procedure.
- Lubricate the lash adjuster thoroughly with clean engine oil.
- Reinstall the adjuster into the rocker arm, making sure the adjuster is at least partially filled with oil.
- Place the rocker arm in clean engine oil and pump the plunger until the lash adjuster travel is taken up. If travel is not reduced, replace the adjuster with the rocker arm as an assembly.
- Reinstall the rocker arm back on the rocker arm shaft.
- Before installing the rocker arm and shaft assemblies, set the crankshaft to 3 notches before TDC on the crankshaft sprocket.
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.
- 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 200-250 inch lbs. (23-28 Nm).
- Install a new gasket and valve cover, as described in the rocker arm cover procedure, earlier in this section.
- Check to be sure that all electrical, vacuum and fluid connections are securely fastened.
An engine oil and filter change is recommended.
- Reconnect the negative battery cable.
- Start the engine and check for leaks. Test drive vehicle to check for proper operation.
See Figures 2, 3 and 4
- Disconnect the negative battery cable. On Cirrus, Stratus, Breeze or Sebring convertible models, disconnect the negative battery cable from the left strut tower. 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.
- Relieve the fuel system pressure using the recommended procedure. Refer to Fuel System .
- 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. Refer to the intake manifold removal procedure, later in this section.
- Remove the rocker arm (valve) cover(s), as described earlier in this section.
- Identify the rocker arm shaft assemblies before removal.
- Install the auto lash adjuster retainers, Special Tool MD 998443 or equivalent, to keep the auto lash adjusters from falling out of the rocker arms when the rocker arm assembly is removed.
- Loosen the attaching fasteners and remove the rocker arm shaft assemblies from the cylinder head.
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.
- The rocker arm shafts are hollow and used as a lubrication oil duct. Make 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 rocker arms were removed, lubricate and install them on the shafts in their original positions.
- Install the rocker arm and shaft assemblies with the FLAT in the rocker arm shafts facing toward the timing belt side of the engine for the right cylinder head. 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. Install the retainers and spring clips in their original positions on the exhaust and intake shafts. Tighten the retainer bolts to 276 inch lbs. (31 Nm) working from the center, outward. Remove the valve lash retainer tools that were installed at disassembly.
- 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.
- Install the rocker arm (valve) cover(s), as described earlier in this section.
- Install the upper intake manifold (plenum), if necessary. Refer to intake manifold procedure.
- Check to be sure that all remaining electrical connectors have been fastened. Tighten the air tube connections.
An engine oil and filter change is recommended.
- Connect the negative battery cable. Start the engine and check for leaks, abnormal noises and vibrations.