Dodge Omni/Horizon/Rampage 1978-1989 Repair Guide

Valves and Springs

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REMOVAL & INSTALLATION



1.6L Engine
  1. Remove the cylinder head.
  2.  
  3. Compress the valve with a spring compressor tool.
  4.  
  5. Before removing the valves, remove any burrs from the valve stem lock grooves to prevent damage the valve guides. Mark all the valves so they may be installed in their original position.
  6.  

To install:

  1. Coat the valve stems with oil and insert in the cylinder head. Install the spring seat on each guide.
  2.  
  3. Place a protective cap over the end of the valve, or wrap the lock grooves with tape to prevent the edges of the valve from damaging the oil seals.
  4.  
  5. Install the new valve stem seals on all of the valves. The seals should be pushed firmly and squarely over the valve guide and down until it bottoms out.
  6.  
  7. Install the valve springs and retainers. Compress the valve spring only enough to install the locks, being careful not to misalign the direction of compression.
  8.  
  9. The remaining procedures are reverse the removal.
  10.  



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Fig. Fig. 1 Use a valve spring compressor tool to relieve spring tension from the valve caps

  1. Remove the valve retaining locks, spring retainer, spring, valve seals, and the spring seat.
  2.  



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Fig. Fig. 2 A small magnet will help in removal of the valve keys



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Fig. Fig. 3 Remove the valve stem seal from the cylinder head

1.7L Engine
  1. Remove the cylinder head.
  2.  
  3. Compress the valve spring with tool L-4419 or equivalent.
  4.  
  5. Remove the adjusting disc, valve keeper, spring retainer, valve spring and valve.
  6.  
  7. Remove the seal by pulling side-to-side with a pair of long nose pliers or the C-4745 Seal Remover tool may be used.
  8.  
  9. Place a protective cap over the end of the valve, or wrap the lock grooves with tape to prevent the edges of the valve from damaging the oil seals.
  10.  

To install:

  1. Install the valves in the cylinder head.
  2.  
  3. Install the new valve stem seals on all of the valves. The seals should be pushed firmly and squarely over the valve guide with tool L-4421 or equivalent and down until it bottoms out.
  4.  
  5. The remainder of the installation is the reverse the removal procedures.
  6.  

2.2L Engine
  1. Remove the rocker arms, camshaft and cylinder head.
  2.  
  3. Using tool 4682 or equivalent compress the valve spring and remove the valve locks.
  4.  
  5. Remove the valve spring and valve.
  6.  
  7. Remove the seal by pulling side-to-side with a pair of long nose pliers.
  8.  

To install:

  1. Install the spring seat on each guide.
  2.  
  3. Place a protective cap over the end of the valve, or wrap the lock grooves with tape to prevent the edges of the valve from damaging the oil seals.
  4.  
  5. Install the new valve stem seals on all of the valves. The seals should be pushed firmly and squarely over the valve guide and down until it bottoms out.
  6.  


WARNING
When using tool 4682 the valve locks can become dislocated. Check to be certain that both locks are in position after removing the tool.

  1. Install the valve springs and retainers. Compress the valve spring with tool 4682 or equivalent, only enough to install the locks being careful not to misalign the direction of compression.
  2.  
  3. Check the installed spring height of the springs. This measurement should be made from the lower edge of the spring to its upper edge, not including the spring seat.
  4.  
  5. Install the cylinder head, camshaft and rocker arms.
  6.  

VALVE INSPECTION



  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 an angle of 45° by a qualified machine shop.
  4.  



Click image to see an enlarged view

Fig. Fig. 4 A dial gauge may be used to check valve stem-to-guide clearance



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Fig. Fig. 5 Valve stems may be rolled on a flat surface to check for bends

  1. Measure the valve stem for wear at various points and check it against the specifications shown in the Valve Specifications chart.
  2.  



Click image to see an enlarged view

Fig. Fig. 7 Valve dimensions are critical for engine performance

REFACING



Using a valve grinder, resurface the valves according to the specifications given in the Valve Specifications chart.


WARNING
The valve face angle is not always identical to the valve seat angle.

A minimum margin of 0.03 in. (0.8mm) should remain after grinding the valve. The valve stem top should also be squared and resurfaced, by placing the stem in the V-block of the grinder, and turning it while pressing lightly against the grinding wheel.

SPRING INSPECTION



Whenever the valves have been removed for inspection, reconditioning or replacement, the valve springs should be tested. To test the spring tension you will need special tool C-647 or equivalent. Place the spring over the stud on the table and lift the compressing lever to set the tone device. Pull on the torque wrench until a ping is heard. Take a reading on the torque wrench at this instant. Multiply this reading by two. The resulting specification is the spring load at the test length. Refer to the Valve Specifications chart for specifications. Inspect each valve spring for squareness with a steel square and a surface plate, test the springs from both ends. If the spring is more than 0.06 in. (1.5mm) out of square, replace the spring.



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Fig. Fig. 8 Use a caliper gauge to check the valve spring free-length



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Fig. Fig. 9 Check the valve spring for squareness on a flat service, a carpenters square can be used



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Fig. Fig. 10 The valve spring should be straight up and down when placed like this

 
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