Chrysler Full-Size Vans 1989-1998 Repair Guide

Rocker Arm (Valve) Cover

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6 and 7

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Remove the ignition wire separators from the studs on the valve cover.
  8.  
  9. To remove the passenger's side valve cover:
    1. Remove the PCV valve and hose from the valve cover.
    2.  

  10.  
  11. To remove the driver's side valve cover:
    1. Remove the bracket on the cowl-to-radiator support brace that retains the oil fill tube.
    2.  
    3. Remove the oil fill tube by twisting upward.Note the bolt and stud locations prior to removing the valve cover.
    4.  

  12.  
  13. Remove the retaining bolts and studs from the valve cover. It may be necessary to tap the valve cover slightly with a soft mallet to loosen; do not pry on the valve cover.
  14.  
  15. Remove the valve cover from the cylinder head.
  16.  



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Fig. Fig. 1: The ignition wire separators just slide off the valve cover studs



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Fig. Fig. 2: Remove the wire harness from the inner valve cover studs



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Fig. Fig. 3: The PCV valve is removable from the valve cover with a twist



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Fig. Fig. 4: The oil fill tube is removed from the front of the vehicle



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Fig. Fig. 5: Loosen the bolts and studs that retain the valve cover, and note their locations for reassembly



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Fig. Fig. 6: When loosened, lift the valve cover up to clear the rocker arms and remove it



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Fig. Fig. 7: Make sure that the valve cover and cylinder head are clean before installing with a new gasket

To install:
  1. Clean all gasket mating surfaces thoroughly.
  2.  
  3. Lubricate all bolt and stud threads prior to installation.
  4.  
  5. Install a new valve cover gasket on the cylinder head and align the fastener holes.
  6.  
  7. Install the valve cover on the cylinder head.
  8.  

Although the manufacturer does not specify a torque sequence, it is recommended that you start from the center and work your way outward, alternating sides of the valve cover. Remember to tighten evenly to prevent valve cover distortion.

  1. Install the retaining bolts and studs, and tighten to 95 inch lbs. (11 Nm).
  2.  
  3. Install the ignition wire separators on the valve cover retaining studs.
  4.  
  5. To install the driver's side valve cover:
    1. Install the oil fill tube back into the valve cover.
    2.  
    3. Install the bracket on the cowl-to-radiator support brace for the oil fill tube.
    4.  

  6.  
  7. To install the passenger's side valve cover:
    1. Install the PCV hose and valve into the valve cover.
    2.  

  8.  
  9. Install the air cleaner assembly.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Check the engine oil level.
  14.  


WARNING
Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

  1. Start the engine and check for leaks.
  2.  
  3. Install the engine cover.
  4.  

 
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