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

Valves

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REMOVAL & INSTALLATION



Use the following service procedures as a guide for your engine. Machine shop work requires special training and equipment, it is best to send the cylinder head assembly to a reputable machine shop for this kind of repair.

2.2L and 2.5L Except Premier Engines

See Figures 1 through 4

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Fig. Fig. 1: Use Chrysler Special Tool C-4682 to depress the valve springs so that the spring locks can be removed



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Fig. Fig. 2: Special Tool C-3422-B can also be used to depress the valve springs for spring lock removal



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Fig. Fig. 3: Once the springs, spring retainers and spring locks are removed, the valve stem seals can be removed from the cylinder head



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Fig. Fig. 4: Check the clearance between the valve rocker ears and spring retainers-minimum clearance is 0.050 in. (1.25mm)

  1. Remove the cylinder head and rocker arms, as described earlier in this section.
  2.  
  3. Label all cylinder head components (i.e. valves and rocker components) so that they can be installed in their original positions.
  4.  
  5. Situate the cylinder head on a clean, flat work area so that the valves will be free to move downward. You'll need a valve spring compressor tool, such as Chrysler Tool No. 4682 (if the camshaft is still installed on the cylinder head) or C-3422-B (if the camshaft is removed from the cylinder head). Tool 4682 hooks around the thinnest diameter sections of the camshaft and pushes downward on either side of each valve spring retainer. Rotate the camshaft so the first rocker arm is under the base circle of the camshaft (the camshaft lobe should point away from the rocker arm). Tool C-3422-B is shaped like a large C, and is designed to compress the valve springs when the camshaft is removed from the cylinder head.
  6.  
  7. Remove all of the hydraulic lash adjusters from the cylinder head, keeping them in order. Support each valve from underneath as you work on it, then depress each valve spring retainer with the special tool. Remove the keepers from either side of the valve stem and then slowly release spring pressure. Remove the spring and spring retainer from the valve stem.
  8.  
  9. Remove the stem seal by gently prying it side-to-side with a small prytool blade. Work the seal off the guide post and remove it.
  10.  
  11. Repeat Steps 5 and 6 for each valve.
  12.  
  13. Inspect each valve's stem lock grooves for burrs and remove them prior to removing the valve, otherwise the valve guides may be damaged. Pull the valves out of the cylinder head.
  14.  

To install:
  1. Clean the cylinder head and cylinder head components. Inspect the valves, valve guides and valve springs for wear, as described later in this section.
  2.  
  3. Coat the valve stems with clean engine oil, and then insert each valve into the valve guide from the lower side of the cylinder head.
  4.  
  5. Install new valve seals by pushing each firmly and squarely over the guide so that the center bead of the seal lodges in the valve guide groove. The lower edge of the seal must rest on the valve guide boss. Note that if oversize valves have been installed, oversize seals must also be installed. Install the valve springs over the valve stem. Make sure that the springs are seated correctly on the cylinder head.
  6.  
  7. Support the valve you're working on from underneath. Install the valve spring retainer over each spring, depress the spring just enough to expose the grooves for the spring keepers. Make sure to depress the spring squarely so that the spring does not touch the valve stem. Install the keepers securely and raise the retainer slowly, making sure the keepers stay in position. Repeat this step for all valves, as needed.
  8.  
  9. Install each of the hydraulic lash adjusters in its proper position in the cylinder head.
  10.  
  11. Check the valve spring installed height, as described in the following inspection procedures. If it exceeds specifications, valve spring tension will not be adequate. If necessary, install a spring seat under each spring whose height is too great to make it meet specification.
  12.  
  13. Support the head so that the valves will be free to move downward. Install the rockers, each in its original position, in reverse of the removal procedure. Depress the valve spring retainers only enough to install the rockers, and make sure that the keepers remain in position.
  14.  
  15. Check the clearance between the ears of the rocker arm and the spring retainer for each valve with the lash adjuster empty of oil and fully collapsed. The minimum clearance is 0.050 in. (1.25mm). If the minimum clearance is not met, the rocker will have to be machined to create it.
  16.  
  17. After clearance specifications are met, remove the rockers and adjusters, immerse the adjusters in clean engine oil and pump them to prime them with oil.
  18.  
  19. Reinstall the adjusters and rockers.
  20.  

Make sure to allow 10 minutes for the hydraulic lash adjusters to bleed down before installing the cylinder head on the engine, otherwise the hydraulic lash adjusters or valve stems may be damaged.

2.5L Premier Engine

See Figures 5 and 6

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Fig. Fig. 5: While supporting the valve head from underneath, depress the valve springs and remove the valve locks



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Fig. Fig. 6: Mark the components so that they can be installed in their original positions-exploded view of intake and exhaust valves

The 2.5L Premier engine is only found in the Eagle Premier, all other 2.5L engines are manufactured by Chrysler.

  1. Remove the cylinder head from the engine, as described earlier in this section.
  2.  
  3. Use a valve spring compressor tool, or equivalent, to compress each valve spring.
  4.  
  5. While the spring is compressed, remove the valve locks from the valve stem.
  6.  
  7. Slowly release the spring, then remove the spring retainer, the spring and the valve stem seal.
  8.  
  9. Discard the valve stem seal.
  10.  
  11. Use an Arkansas smooth stone or a jeweler's file to remove any burrs from the top of the valve stem, especially around the spring lock groove.
  12.  
  13. Perform Steps 3-6 for all valves in the cylinder head.
  14.  
  15. Slide the valves out of the cylinder head and position them aside in order so that they can be reinstalled in the same order.
  16.  

To install:
  1. Thoroughly clean the valves and cylinder head. Inspect the valves, the valve guides and the valve springs for damage, as described later in this section.
  2.  
  3. Lightly lubricate the stem and install the valve in its original valve guide bore.
  4.  
  5. Install the replacement valve stem over the valve stems and onto the valve guide boss.
  6.  

If oversized stems are used, oversized oil seals must also be used.

  1. Position the valve spring and retainer on the cylinder head and compress the valve spring with the spring compressor tool. Install the valve locks and release the tool.
  2.  
  3. Lightly tap the valve spring from side-to-side with a rubber hammer to ensure that the spring is properly seated on the cylinder head. Also tap the retainer and the lock area to seat the locks to the retainer.
  4.  
  5. Repeat Steps 9-12 for all valves.
  6.  
  7. Install the cylinder head onto the engine, then install the camshaft, if removed.
  8.  

2.6L Engine

See Figures 7, 8, 9 and 10

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Fig. Fig. 7: Cross-section view of the intake and exhaust valves, valve springs, spring retainers, valve stem locks and rocker arms installed on the cylinder head



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Fig. Fig. 8: Exploded view of a pair of intake and exhaust valves removed from the cylinder head



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Fig. Fig. 9: Once the valves, springs, retainers and locks are removed, the valve stem seals can be removed from the cylinder head with a pair of pliers



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Fig. Fig. 10: Tap a new valve stem oil seal into position with Special Tool MD998005 and a hammer

  1. Remove the cylinder head as described above.
  2.  
  3. Label all of the cylinder head components so that they can be assembled into their original positions.
  4.  
  5. Remove the camshaft bearing caps and rocker shafts as an assembly. For more details, refer to the camshaft removal and installation and rocker arms/shafts removal and installation procedures in this section. Leave the bolts in the front and rear bearing caps.
  6.  
  7. Using a spring compressor designed for use on overhead cam engines with inclined valves, depress each valve spring, remove keepers, spring retainer, and spring, then remove each valve from the combustion chamber of the cylinder head. Support each valve while removing the valve keepers so that you do not have to depress the spring unnecessarily.
  8.  
  9. Remove each jet valve by unscrewing it with a special socket wrench designed for this purpose. Pull out the used valve stem seals with a pair of pliers.
  10.  
  11. Repeat Steps 2 and 3 for all of the valves in the cylinder head.
  12.  

To install:
  1. Clean the cylinder head and related components with a suitable solvent. Inspect the valves, valve springs, and valve guides, as described later in this section.
  2.  
  3. Valve stems should be coated with oil before each valve is installed.
  4.  
  5. Assemble the cylinder head, as follows:
    1. Slide the valve into the cylinder head.
    2.  
    3. Install new valve seals onto the cylinder head by tapping them lightly with a special installer such as Chrysler part No. MD998005.
    4.  
    5. Set the valve spring over the valve stem so that it sits flush on the cylinder head.
    6.  
    7. Position the spring retainer on the spring.
    8.  
    9. Depress the valve spring and retainer, while supporting the valve from underneath.
    10.  
    11. Install the valve keepers in the grooves in the end of the valve stem.
    12.  
    13. Slowly release the valve spring until the keepers are held in place. Make sure you do not depress the retainers unnecessarily.
    14.  
    15. Check installed height and compare it with specification. If installed height is excessive, install a thicker spring seat until specifications are met by disassembling the valves, springs, and retainers again. Position the spring seats on the cylinder head, then reassemble the cylinder head components.
    16.  

  6.  
  7. If equipped, install the jet valves by screwing them in. Tighten the jet valves to 14 ft. lbs. (19 Nm). The jet valves themselves have springs, retainers, keepers, and seals. Refer to the following procedure for jet valve disassembly.
  8.  
  9. Make sure in final assembly to set the jet valve clearance after the head bolts are tightened and before setting intake valve clearance. Both must finally be set with the engine hot.
  10.  
  11. Install the rocker arms and camshaft on the cylinder head, then install the cylinder head onto the engine.
  12.  

JET VALVE DISASSEMBLY AND ASSEMBLY

See Figures 11 through 14

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Fig. Fig. 11: Use Tool MD998309 to compress the jet valve's spring, then remove the spring keepers



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Fig. Fig. 12: Exploded view of the jet valve-make sure to coat all components with clean engine oil prior to reassembly



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Fig. Fig. 13: Gently drive a new jet valve stem seal into place with Tool MD998308 and a hammer



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Fig. Fig. 14: Install the jet valve in the cylinder head and tighten to 14 ft. lbs. (19 Nm)


WARNING
Make certain that the Jet Valve Socket wrench is not tilted with respect to the centerline of the jet valve. Any misalignment may bend the valve stem.

  1. Remove the jet valve from the cylinder head by loosening it with a socket wrench.
  2.  
  3. Using Tool MD998309 to compress the spring, remove the retainer lock and retainer.
  4.  

Do not mix the parts of the jet valve assemblies.

  1. Pull the valve stem and seal off with a pair of pliers.
  2.  
  3. When assembling, use engine oil to lubricate all of the parts of the jet valve assembly.
  4.  
  5. Using Tool MD998309 to compress the spring, install the retainer and retainer lock.
  6.  
  7. Install a new O-ring lubricated with engine oil on the jet valve.
  8.  
  9. Install the jet valve in the cylinder head and tighten it to 14 ft. lbs. (19 Nm).
  10.  

INSPECTION



See Figures 15 and 16

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Fig. Fig. 15: Valve stems may be rolled on a flat surface to check for bends



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Fig. Fig. 16: Use a micrometer to check the valve stem diameter

2.2L (Except Turbo III) and 2.5L Except Premier Engines

See Figure 17

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Fig. Fig. 17: Inspect the valves for any damage, such as bent stems, pitting or scratching, nicks or incorrect face angle

  1. Clean the valves thoroughly and discard burned, warped, or cracked valves.
  2.  
  3. If the valve face is only lightly pitted, the valve may be refaced to the correct angle by a qualified machine shop.
  4.  
  5. Measure the valve stem for wear at various points and check it against the specifications shown in the "Valve Specifications'' chart.
  6.  
  7. Once the valve face has been cleaned up, the margin must also be checked. This is the thickness of the valve head below the face. Valves must also meet standards as to head diameter and length. If the valves do not match specifications, new valves must be purchased.
  8.  

VALVE STEM-TO-GUIDE CLEARANCE

See Figure 18

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Fig. Fig. 18: To measure the valve-to-guide clearance, move the valve head toward and away from the dial indicator and read the fluctuation

  1. Clean the valve stem with lacquer thinner or a similar solvent to remove all gum and varnish. Clean the valve guides using solvent and an expanding wire-type valve guide cleaner (a rifle cleaning brush works well here).
  2.  
  3. Use a dial indicator to measure the lateral movement of the valve head (stem-to-guide clearance) with the valve installed in its guide and with the valve head approximately 0.40 in. (10mm) off the valve seat, as follows:
    1. Position a dial indicator so that the indicator shaft is seated against the side of the valve head above the combustion chamber.
    2.  
    3. Push the head as far away from the dial indicator as it will travel, then zero the dial indicator.
    4.  
    5. Push the valve head toward the dial indicator as far as it will go and read the measurement on the indicator.
    6.  
    7. Position the dial indicator against the valve head 90 degrees around the head from its original position and repeat Steps 7b and 7c.
    8.  

  4.  
  5. Refer to the Valve Specifications chart for the correct clearance allowable. If indicated movement exceeds the correct specification, have the valve guide reamed by a reputable machine shop to accommodate an oversized valve stem. Also, if the 2 measurements are different, this indicates the extent of out-of-roundness in the valve guide.
  6.  

Valve seats should be reground after reaming the valve guides to ensure that the valve seat is concentric to the valve guide.

2.2L Turbo III Engine

See Figure 17

  1. Clean all carbon deposits from the combustion chambers, valve ports, valve stems, valve stem guides and cylinder head.
  2.  
  3. Clean all grime and gasket material from the cylinder head gasket surface.
  4.  
  5. Inspect for cracks in the combustion chambers and valve ports.
  6.  
  7. Inspect for cracks in the gasket surface at each coolant passage.
  8.  
  9. Inspect valves for burned, cracked or warped heads. Inspect for scuffed or bent valve stems.
  10.  
  11. Replace the valves if any such damage is evident.
  12.  

VALVE STEM-TO-GUIDE CLEARANCE

See Figure 19

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Fig. Fig. 19: On the 2.2L Turbo III engines, measure the valve guides at the positions shown

  1. Remove the valve from the cylinder head.
  2.  
  3. Clean the valve stem with lacquer thinner or a similar solvent to remove all gum and varnish. Clean the valve guides using solvent and an expanding wire-type valve guide cleaner (a rifle cleaning brush works well here).
  4.  
  5. Insert a telescoping gauge into the valve stem guide bore, with contacts crosswise to the cylinder head. Position the gauge at the top of the valve guide bore. Remove and measure the telescoping gauge with a micrometer.
  6.  
  7. Insert the telescoping gauge into the valve stem guide bore so that it is at the mid-point of the valve guide. Remove and measure the telescoping gauge with a micrometer.
  8.  
  9. Once again, insert the telescoping gauge into the valve stem guide bore. Position the gauge at the very bottom of the valve guide bore. Remove and measure the telescoping gauge with a micrometer.
  10.  
  11. Repeat all 3 measurements with the gauge turned perpendicular (90 degrees) from the first positions.
  12.  
  13. Compare the crosswise-to-lengthwise measurements to determine out-of-roundness. Compare the 3 measurements (top, mid-point and bottom) for valve guide taper or uneveness. If the measurements differ excessively (refer to the Valve Specifications chart), have the guide bore reamed by a reputable automotive machine shop to accommodate an oversized valve stem.
  14.  
  15. Compare the measured valve guide bore diameter with specifications. If the measurement differs from specifications, have the guide bore reamed by a reputable machine shop to accommodate an oversized valve stem.
  16.  

Valve seats should be reground after reaming the valve guides to ensure that the valve seat is concentric to the valve guide.

2.5L Premier Engine

See Figures 20 and 21

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Fig. Fig. 20: Use a small telescoping gauge to measure the inside diameter of the valve guides or ...



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Fig. Fig. 21: ... measure the valve-to-guide clearance with a dial indicator as shown

The 2.5L Premier engine is only found in the Eagle Premier, all other 2.5L engines are manufactured by Chrysler.

  1. Clean all carbon deposits from the combustion chambers, valve ports, valve stems, valve stem guides and cylinder head.
  2.  
  3. Clean all grime and gasket material from the cylinder head gasket surface.
  4.  
  5. Inspect for cracks in the combustion chambers and valve ports.
  6.  
  7. Inspect for cracks in the gasket surface at each coolant passage.
  8.  
  9. Inspect valves for burned, cracked or warped heads. Inspect for scuffed or bent valve stems.
  10.  
  11. Replace the valves if any such damage is evident.
  12.  

VALVE STEM-TO-GUIDE CLEARANCE

The valve stem-to-guide clearance may be measured by either of the following 2 methods:

Preferred Method-
  1. Remove the valve from the cylinder head.
  2.  
  3. Clean the valve stem with lacquer thinner or a similar solvent to remove all gum and varnish. Clean the valve guides using solvent and an expanding wire-type valve guide cleaner (a rifle cleaning brush works well here).
  4.  
  5. Insert a telescoping gauge approximately 3 / 8 in. (9.5mm) into the valve stem guide bore from the valve spring side of the head, with contacts crosswise to the cylinder head. Remove and measure the telescoping gauge with a micrometer.
  6.  
  7. Repeat the measurement with the contacts lengthwise to the cylinder head.
  8.  
  9. Compare the crosswise-to-lengthwise measurements to determine out-of-roundness. If the measurements differ by more than 0.0025 in. (0.064mm), have the guide bore reamed by a reputable machine shop to accommodate an oversized valve stem.
  10.  
  11. Compare the measured valve guide bore diameter with specifications (0.313-0.314 in. or 7.95-7.97mm). If the measurement differs from specifications by more than 0.003 in. (0.076mm), have the guide bore reamed by a reputable machine shop to accommodate an oversized valve stem.
  12.  

Valve seats must be reground after reaming the valve guides to ensure that the valve seat is concentric with the valve guide.

Alternate Method-
  1. Clean the valve stem with lacquer thinner or a similar solvent to remove all gum and varnish. Clean the valve guides using solvent and an expanding wire-type valve guide cleaner (a rifle cleaning brush works well here).
  2.  
  3. Use a dial indicator to measure the lateral movement of the valve stem (stem-to-guide clearance) with the valve installed in its guide and with the valve head just off the valve seat, as follows:
    1. Position a dial indicator so that the indicator shaft is seated against the side of the valve stem above the cylinder head.
    2.  
    3. Push the valve stem tip as far away from the dial indicator as it will travel, then zero the dial indicator.
    4.  
    5. Push the valve stem tip toward the dial indicator as far as it will go and read the measurement on the indicator.
    6.  
    7. Position the dial indicator against the valve stem 90 degrees around the stem from its first position and repeat Steps 7b and 7c.
    8.  

  4.  
  5. Correct clearance is 0.001-0.003 in. (0.025-0.076mm). If indicated movement exceeds the specification, have the valve guide reamed by a reputable machine shop to accommodate an oversized valve stem. Also, if the 2 measurements are different, this indicates the extent of out-of-roundness in the valve guide.
  6.  

Valve seats must be reground after reaming the valve guides to ensure that the valve seat is concentric with the valve guide.

2.6L Engine

See Figure 22

Click image to see an enlarged view

Fig. Fig. 22: Inspect the positions shown for excessive wear, scoring or pitting-replace the valves if any damage is evident

  1. Clean all carbon deposits from the combustion chambers, valve ports, valve stems, valve stem guides and cylinder head.
  2.  
  3. Clean all grime and gasket material from the cylinder head gasket surface.
  4.  
  5. Inspect for cracks in the combustion chambers and valve ports. Inspect for cracks in the gasket surface at each coolant passage. Inspect valves for burned, cracked or warped heads. Inspect for scuffed or bent valve stems. Replace the valves if any such damage is evident.
  6.  
  7. Check the tip of the stem for pitting (A).
  8.  
  9. Check the stem-to-guide clearance (B). It must meet the specifications in the Valve Specifications chart.
  10.  
  11. Check the valve head margin, which must meet specifications.
  12.  
  13. If the valves are deemed reusable, have the valves refaced by a reputable, competent automotive machine shop.
  14.  

REFACING



Because of the high cost of equipment and the high level of skill required for valve and valve seat refacing, it is recommended that you should have the valves and seats refaced by a reputable automotive machine shop.

  1. The intake and exhaust valves and seats should be refaced until they exhibit the angle shown in the Valve Specification chart. Have a reputable automotive machine shop perform this work.
  2.  
  3. Inspect the remaining margin after the valves are refaced. If the margin does not meet the specifications in the Valve Specification chart, the valves should be disposed of and new ones acquired.
  4.  
  5. When refacing the valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained.
  6.  
  7. Measure the concentricity of the valve seat using a valve seat dial indicator. Total runout should not exceed the value shown in the Valve Specifications or Engine Rebuilding SPECIFICATION CHARTS.
  8.  
  9. Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, perform the following:
    1. Coat the valve seat lightly with Prussian blue, then set the valve in place in the cylinder head.
    2.  
    3. Rotate the valve with light pressure applied to the valve head.
    4.  
    5. Remove the valve from the cylinder head.
    6.  
    7. Inspect the valve seat. If the blue is transferred to the center of the valve face, contact is satisfactory. If the blue is transferred to the top edge of the valve face, lower the valve seat with a 15 degree stone. If the blue is transferred to the bottom edge of the valve face, raise the valve seat with a 65 degree stone.
    8.  

  10.  

Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced.

  1. When the seat is properly positioned, the width of the intake seats should meet the specifications shown in either the Valve Specification chart or the Engine Rebuilding Specifications chart.
  2.  
  3. Check the valve tip-to-valve spring seat dimensions after grinding the seats or faces, Grind the valve tip to bring the measurements within specifications. Also inspect the valve spring installed height after refacing the valve and seat, as described later in this section.
  4.  


WARNING
If the valve stem tip is ground excessively to bring it within specifications, check rocker arm-to-valve stem geometry and the clearance between the rocker arm and the valve spring retainer (2.2L and 2.5L Except Premier engines).

  1. If the valve stem tip is ground excessively to bring it within specifications, check rocker arm-to-valve stem geometry and the clearance between the rocker arm and the valve spring retainer (2.2L and 2.5L Except Premier engines). If the rocker arm-to-spring retainer clearance is too small, grind the rocker arm ears to provide the correct amount of space.
  2.  

 
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