Dodge Omni/Horizon/Rampage 1978-1989 Repair Guide

Rocker Arm/Shaft

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REMOVAL & INSTALLATION



1.6L Engine

WARNING
Allow the cylinder head to cool before performing this procedure.

  1. Remove the cylinder head cover as previously described in Rocker Arm (Valve) Cover.
  2.  
  3. Loosen the cylinder head bolts evenly, beginning at the ends and working towards the center.
  4.  



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Fig. Fig. 1 Loosen the cylinder head bolts using this sequence

  1. Tie the rocker arm assembly together with safety wire or equivalent.
  2.  



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Fig. Fig. 2 Tie the rocker arm assembly together with safety wire or an equivalent

  1. Remove the bolts and lift the rocker arm assembly off the cylinder head.
  2.  


WARNING
Before disassembly of the rocker arm assemblies, mark the component positions so they be installed in their original order.

  1. To disassemble, remove the retaining wire from the assembly. Slide the rocker shaft end brackets, rockers, and springs from the rocker shafts.
  2.  



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Fig. Fig. 3 If disassembling the shaft, keep all parts in order



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Fig. Fig. 4 Tighten the bolts using this sequence

  1. Check the fit of the rockers on the shafts, also check to see that the oil holes in the shafts are clear. Replace any worn components. If replacing the rocker shafts, the roll pin that secures it to the center bracket (No. 2 or No. 4) must be driven out.
  2.  

To install:

  1. To assemble, position the closed end of each rocker shaft so that they are at the outer ends of the assembly. Insert the rocker shaft into its center bracket (No. 2 or No. 4) with the flat on the shaft aligned with the hole in the bracket, and the plugged end right or left as required. Drive the rollpins back into the brackets.
  2.  
  3. Lubricate the components and assemblies with engine oil.
  4.  
  5. Tie the end brackets with wire to retain them as one assembly.
  6.  
  7. Position each rocker arm assembly on its dowel.
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  9. Lubricate the head bolt threads with engine oil, then install through the rocker shaft brackets. Screw the bolts down finger-tight while checking to see that each rocker adjusting screw engages its pushrod. Remove the retaining wire.
  10.  
  11. Tighten the head bolts in progressive steps to 52 ft. lbs. (6 Nm).
  12.  
  13. Start and run the engine to normal operating temperature, allow to cool down and retighten as described in the previous step. Check valve clearance and adjust as necessary.
  14.  
  15. Install the cylinder head cover as previously described in Rocker Arm (Valve) Cover.
  16.  

2.2L Engine

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, you will need a special tool designed to hook over the camshaft and depress the applicable valve. Use Chrysler tool No. 4682 or an equivalent tool purchased in the aftermarket. To remove a rocker:

  1. Mark the rocker as to its location, unless you expect to remove only one, or one at a time.
  2.  
  3. Turn the engine over, using a wrench on the crankshaft pulley, until the cam that actuates the rocker you want to remove it pointing straight up.
  4.  



Click image to see an enlarged view

Fig. Fig. 5 Rocker arm assembly used on 2.2L engines

  1. Install the 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 part not incorporating either a cam or a bearing journal).
  2.  
  3. 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.
  4.  

To install:

  1. Install the new rocker or reinstall the old one in reverse. Depress the valve just far enough to slide the lever in between the top of the valve stem and the camshaft and still clear the lifter. When the rocker is located on the valve stem and lifter, gradually release the tension on the tool.
  2.  
  3. Repeat the procedure until all the necessary rockers have been replaced.
  4.  

 
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