Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Rocker Arm (Valve) Cover

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REMOVAL & INSTALLATION



Except Premier and 2.2L Turbo III Models

See Figures 1 through 11

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Fig. Fig. 1: Exploded view of the rocker arm cover for 1981-85 2.2L engines



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Fig. Fig. 2: Unlike the early 2.2L engines (1981-85), the 2.6L engines utilized a rocker arm cover gasket



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Fig. Fig. 3: The 1986-95 2.2L and 2.5L engines (except for Turbo III) used an air/oil separator curtain under the rocker arm cover-note the use of rocker arm gaskets for 1988-90 models



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Fig. Fig. 4: When installing the rocker arm cover gasket and the oil curtain, make sure that the upper rubber spacers are installed in the curtain and that the cutouts in the curtain are situated toward the intake manifold side of the engine



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Fig. Fig. 5: The 2.2L and 2.5L engines revert back to using liquid gasket in 1991 and continue with its use until 1995-apply the liquid gasket as shown



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Fig. Fig. 6: Remove the rocker arm cover attaching bolts and ...



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Fig. Fig. 7: ... remove the rear camshaft seal, then ...



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Fig. Fig. 8: ... lift the rocker arm cover off of the cylinder head



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Fig. Fig. 9: Remove the old gaskets and residual material from the rocker arm cover ...



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Fig. Fig. 10: ... and from the cylinder head surface



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Fig. Fig. 11: Lift the inner curtain off of the cylinder head after the gasket material is cleaned off the head

Since Chrysler jumps back and forth with its use of a sealing liquid gasket and a standard cork or rubber gasket, check with your local parts professional for the correct sealing component for your engine, if confused or unsure.

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the PCV line from the PCV valve.
  4.  
  5. Remove, disconnect or move aside any other lines or hoses which run across the rocker arm cover assembly.
  6.  
  7. On the 2.2L and 2.5L engines, remove the upper timing belt cover retaining nuts and bolts, then remove the upper timing belt cover.
  8.  
  9. Loosen the cover retaining bolts and remove them. Gently rock the cover to free it from the gasket or sealer, then remove it.
  10.  
  11. On 1986 and later models with EFI, remove the air/oil separating curtain located on top of the head just under the valve cover. Be careful to keep the rubber bumpers located at the top of the curtain in place.
  12.  
  13. Pull the old end gaskets from the underside of the rocker arm cover.
  14.  

To install:
  1. Clean the cylinder head and cover mating surfaces. Make certain the rails are flat.
  2.  
  3. If the engine is equipped with the air/oil separating curtain, install it as follows (otherwise, proceed to Step 10). Install the curtain, manifold side first, with the cutouts over the camshaft towers and contacting the cylinder head floor, then press the opposite side (distributor side) into position below the cylinder head rail. The curtain is retained in position with the rubber bumpers.
  4.  
  5. On 1981-87 and 1991-95 2.2L and 2.5L engines, form a gasket on the sealing surface of the head. It is necessary to use an RTV silicone aerobic gasket material (Chrysler Part No. 4318025 or equivalent). Install new end seals; insert the end seal locating tabs into the matching holes in the cover and pull until the barbs on the locating tabs are engaged in the holes.
  6.  
  7. On 1988-90 2.2L and 2.5L engines and all 2.6L engines, install the gasket onto the cam cover (fasten the gasket in place by forcing the tabs through the holes in the cover).
  8.  
  9. Install the reinforcements on both sides of the rocker arm cover, if so equipped. Install the mounting bolts and tighten them alternately from the center out to 105 inch lbs. (12 Nm). Make sure that the 2 mounting studs are installed in the 2 front-most holes (these are used to mount the upper timing belt cover to the cylinder head).
  10.  
  11. Install the upper timing belt cover.
  12.  
  13. Install the hoses, cables or wires which were removed earlier.
  14.  
  15. Connect the negative battery cable.
  16.  

2.2L Turbo III Models

See Figures 12 and 13

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Fig. Fig. 12: The ignition cable cover spans the gap between the two rocker arm covers on the 2.2L Turbo III engines



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Fig. Fig. 13: The 2.2L Turbo III engines use a rocker arm cover sealing gasket rather than liquid gasket like some of the other engines

The 2.2L Turbo III engines utilize two separate rocker arm covers on each bank of valves.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the ignition cable cover retaining fasteners, then lift the cover off of the top of the engine.
  4.  
  5. Remove the upper timing belt cover by removing the upper timing belt cover mounting nuts and bolts.
  6.  
  7. Disconnect the PCV valve hose from the valve.
  8.  
  9. Remove the rocker arm cover hold-down bolts, then lift the rocker arm cover off of the cylinder head. It may be necessary to gently rock the rocker arm cover to free it from the gasket. Remove the second rocker arm cover as well.
  10.  

To install:
  1. Clean the cylinder head and cover mating surfaces. Make sure that the rails are flat.
  2.  


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

  1. Install the rocker arm cover with a new rocker arm cover gasket. Tighten the mounting bolts alternately from the center out to 105 inch lbs. (12 Nm). Install the second rocker arm cover in the same manner.
  2.  
  3. Position the ignition cable cover in place, then install the hold-down fasteners. Tighten the fasteners until snug.
  4.  
  5. Attach the PCV hose to the PCV valve.
  6.  
  7. Install the upper timing belt cover.
  8.  
  9. Connect the negative battery cable.
  10.  

Premier
  1. Disconnect the negative battery cable for safety.
  2.  
  3. Remove the cooling system air bleed hose holders.
  4.  
  5. Disconnect the Crankcase Ventilation (CCV) vacuum hose from the rocker arm cover.
  6.  
  7. Disconnect the CCV fresh air inlet hose from the rocker arm cover.
  8.  
  9. Remove the rocker arm mounting bolts, then lift the cover off the cylinder head.
  10.  

To install:
  1. Thoroughly clean the sealing surface of the cylinder head and the seal on the rocker arm cover.
  2.  
  3. Install the rocker arm cover. Tighten the mounting bolts to 70 inch lbs. (8 Nm).
  4.  
  5. Attach the CCV hoses to the rocker arm cover.
  6.  
  7. Attach the air bleed hose holders, then position the air bleed hose in the holders.
  8.  
  9. Connect the negative battery cable.
  10.  

 
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