REMOVAL & INSTALLATION
When disassembling the valve train components, always keep the parts in order so that they can be assembled into their original locations. This is most important when all of the old components are to be reused.Except 2.5L Premier, 2.2L Turbo III and 2.6L Engines
See Figures 1, 2 and 3
The rocker arms may be removed very easily after camshaft removal. In case they are to be removed as a group for inspection or to proceed further with disassembly, mark each as to location for installation in the same position.
If the rockers are to be removed in order to gain access to a valve or lifter (camshaft installed), you will need a special tool designed to hook over the camshaft and depress the applicable valve, such as Chrysler Tool C-4682-A or equivalent.
- Remove the valve cover. Mark the rocker as to its location, unless you expect to remove only one at a time.
- Rotate the crankshaft, using a wrench on the crankshaft pulley, until the camshaft lobe that actuates the rocker you want to remove is pointing straight up.
- Install the valve spring compressing tool so that the jaws on its fulcrum fit on either side of the valve cap. Then, clip the hook at its forward end over the adjacent thin section of the camshaft (a portion not incorporating either a cam or a bearing journal).
- Lift the rocker gently at the lash adjuster end (the end opposite the tool). Pull downward gently on the outer end of the tool lever just until the rocker can be disengaged from the lifter. Pull it out from between the valve and camshaft.
- Remove the hydraulic lash adjuster from the cylinder head.
Visually check the roller on the rocker arm and replace if dent, damage or seizure is evident. Check the roller for smooth rotation, replace if its binds or there is an excessive play. Check the valve contact surface for possible damage when performing this repair.
- Install the hydraulic lash adjusters making sure that the adjusters are at least partially full of engine oil. This is indicated by little or no plunger travel when the lash adjuster is depressed.
- If the engine was rotated while the rocker arms were removed from the cylinder head, position the camshaft so that the lobe for the specific valve, on which the rocker arm is to be installed, is pointing straight up (the base circle of the camshaft should be toward the cylinder head).
- Depress the valve, with the special tool as during removal, just far enough to slide the rocker arm in between the top of the valve stem and the camshaft and still clear the hydraulic lash adjuster. When the rocker is correctly positioned on the valve stem and lifter, gradually release the tension on the tool.
- Repeat the procedure until all the necessary rockers have been replaced.
- Check and make sure the locks on the the valve springs are in the proper location, then install the valve cover.
See Figures 4 through 7
Unlike the other engines covered by this information, the 2.2L Turbo III engines utilize a rocker arm shaft for each bank of rocker arms.
- Remove the rocker arm covers, as described earlier in this section.
- Loosen the rocker arm shaft mounting bolts in the sequence shown in the accompanying illustration. Remove the mounting bolts, then lift the rocker arm shaft with the rocker arms off of the cylinder head. Be careful, the rocker arms will slide off the shaft if given the chance.
- Before removing the second rocker arm shaft assembly, identify the first rocker arm shaft assembly for installation.
- Slide the rocker arms off of the shaft, keeping them in order for reassembly.
- Remove the second rocker arm shaft from the cylinder head in the same manner.
- Remove the hydraulic lash adjusters from each rocker arm.
- Slide the rocker arms onto the shaft in their original positions.
- Install the hydraulic lash adjusters, making sure that the adjusters are at least partially full of engine oil. This is indicated by little or no plunger travel when the lash adjuster is depressed.
- Position the rocker arm shaft assemblies onto the cylinder head and tighten the mounting bolts in the sequence shown to 18 ft. lbs. (24 Nm).
- Install the rocker arm covers, as described earlier in this section.
See Figure 8
The following procedure can be performed with the engine in the vehicle or with the engine removed.
- Remove the rocker arm cover, as described earlier in this section.
- Remove the 2 capscrews at each bridge and pivot assembly. Alternately loosen the capscrews one turn at a time to avoid damaging the bridges.
- Check for rocker arm bridges which are causing misalignment of the rocker arm to the valve tip area.
- Remove the bridges, pivots and corresponding pair of rocker arms and place them on a work surface in the same order as removed.
- Remove the pushrods and place them on the bench in the same order as removed.
- Clean all of the components with cleaning solvent and used compressed air to blow out the oil passages in the rocker arms and pushrods.
- Inspect the pivot surface area of each rocker arm. Replace any that are scuffed, pitted, cracked or excessively worn.
- Inspect the valve stem tip contact surface of each rocker arm and replace any rocker arm that is deeply pitted.
- Inspect each pushrod end for excessive wear and replace as required. If any pushrod is excessively worn because of lack of oil, replace it and inspect the corresponding hydraulic tappet for excessive wear (this requires removal of the cylinder head).
- Inspect the pushrods for straightness by rolling them on a flat surface and with a light shining between the rod and the flat surface; if the light can be seen unevenly under the pushrod, it is bent.
- A wear pattern along the length of the pushrods is not normal. Inspect the cylinder head for interference if this condition exists.
- Lubricate the ball ends of the pushrods with Mopar® Engine Oil Conditioner, or equivalent, and install the pushrods in their original locations. Ensure that the bottom end of each pushrod is centered in the tappet plunger cap seat.
- Lubricate the area of the rocker arm that the pivot contacts with the same engine conditioner and install the rocker arms, pivots and bridge above each cylinder in their original positions.
- Loosely install the capscrews through each bridge.
- At each bridge, tighten the capscrews alternately, one turn at a time, to avoid damaging the bridge. Tighten the capscrews to 19 ft. lbs. (26 Nm).
- Install the rocker arm cover, as described earlier in this section.
See Figures 9 through 13
When removing the sprocket from the camshaft, you must maintain adequate tension on the sprocket and chain assembly to prevent the chain from disengaging with the crankshaft timing gear. Use Special Tool C-4852, or equivalent, and a stretch cord.
- Disconnect the negative battery cable.
- Remove the rocker arm cover, as described earlier in this section.
- Loosen the large center bolt holding the camshaft sprocket to the camshaft; do not remove it, just loosen it.
- Matchmark the timing chain to the camshaft sprocket.
- Turn the crankshaft pulley clockwise until the timing marks align on both the cylinder head and engine block, and the crankshaft pulley and engine block. This sets the engine at Top Dead Center (TDC) for the No.1 cylinder on its compression stroke. Once this position is established, the engine MUST NOT be rotated during repairs.
- Position the Special Tool C-4852, or equivalent, over the timing chain gear.
- Remove the center bolt from the sprocket and remove the small distributor drive gear.
- Pull the camshaft sprocket with the chain attached out from the camshaft and hang it from the camshaft sprocket holder. Do not allow the chain to come off the camshaft or crankshaft sprockets.
If a camshaft gear holding apparatus is not available, removal of the timing chain and covers is necessary.
- Loosen but do not remove the camshaft bearing cap bolts (not the outer or cylinder head bolts). Start at an inner, or center, bolt and work outward in a circular pattern, loosening each bolt a little at a time.
- Remove the bolts after all are loosened. Hold the ends so the assembly stays together and remove the rocker shaft assembly from the cylinder head.
Before disassembling the rocker shaft assemblies, mark the components as to their original positions for ease of reassembly.
- Place the assembly on a clean work bench. Remove the bolts (which retain the bearing caps in position on the shafts) 2 at a time along with the associated cap, washers, springs and rockers. Continue until all parts are disassembled. Keep all parts in original order. All parts that will be re-used must be in original positions.
- Inspection of parts should include verifying that the pads that follow the cam lobes are not worn excessively and that the oil holes are clear. Replace the rockers and/or shafts, if rockers are loose on the shafts. Replace the rocker arms if excessive wear, nicks or similar damage is found.
- Install the left and right side rocker shafts into the front bearing cap. The rear end of the left (intake) rocker arm shaft has a notch. Align the mating marks on the front of each rocker shaft with the mating marks on the front bearing cap. Insert the bolts to hold the shafts in the cap.
- Install the wave washer so that the rounded side bulges toward the timing chain.
- Coat the inner surfaces of the rockers and the upper bearing surfaces of the bearing caps with clean engine oil and assemble rockers, springs, and the remaining bearing caps in order. Note that the rockers are labeled for cylinders 2, 3 and 4. While similar in shape, they must be reinstalled in their original position. Use mounting bolts to hold the caps in place after each is assembled. When the assembly is complete, position it on the head and start all mounting bolts into the head until finger-tight.
- Tighten the attaching bolts for the rocker assembly to 15 ft. lbs. (20 Nm), working from the center outward.
- Without removing tension from the timing chain, remove the camshaft sprocket from the suspension tool and position it against the front of the camshaft. Make sure the locating tang on the sprocket goes into the hole in the front of the camshaft.
- Install the distributor drive gear, making certain it is properly seated. Install the sprocket bolt and tighten it finger-tight, then to 40 ft. lbs. (54 Nm).
- Apply sealant to the flat face of the half-circle plug in the head. Install the rocker arm cover and gasket. For more details, refer to the rocker arm procedure earlier in this section.
- Connect the negative battery cable.