Removal & Installation
2.1L Diesel Engine
- Disconnect the negative battery cable. Remove the rocker arm cover and gasket.
- Remove the rocker shaft retaining bolts. Remove the rocker arm shaft assembly from the vehicle.
- Installation is the reverse of the removal procedure. Be sure to use new gaskets and adjust the valves as required. Tighten the bolts to 20 ft. lbs. (27 Nm).
See Figures 1, 2 and 3
- Remove the rocker arm cover.
- Remove the two capscrews at each bridge and pivot assembly. Alternately loosen the bolts one turn at a time to avoid damaging the bridges.
- Remove the bridges, pivots and rocker arms. Keep them in order.
- While the rocker arm is removed, inspect the pivot surface area. Replace any rocker arms that are scuffed, pitted or excessively worn.
- Inspect the valve stem tip contact surface. Replace any rocker arm that is pitted or excessively worn.
- Installation is the reverse of removal. Loosely install the capscrews then alternately tighten to 19 ft. lbs. (26 Nm).
- Install the rocker arm cover.
See Figure 4
- Remove the rocker arm cover.
- Remove the rocker arm hold-down nuts, pivots and rocker arms. Keep them in order.
- Installation is the reverse of removal. Apply a thin coat of Molykote®, or equivalent, to the bearing surfaces of the rocker arms and pivots. Tighten the rocker arm nut until it just touches the valve stem.
Rotate the engine until the No. 1 piston is at TDC of the compression stroke. The
mark on the timing scale should be aligned with the timing pointer and the rotor should be at the No. 1 spark plug tower of the distributor cap. The following valves can be adjusted:
Exhaust-1, 2, 3
- Turn the adjusting nut until it backs off of the stem slightly, then tighten it until it just touches the stem. Then, turn the nut 1 1 / 8 turns more to center the tappet plunger.
Rotate the engine one complete revolution more. This will bring No. 4 piston to TDC compression. At this point, the following valves may be adjusted:
Exhaust-4, 5, 6
- Install rocker arm covers. Start engine and check ignition timing and idle speed.
See Figure 5
- Disconnect the negative battery cable.
- Remove the cylinder head cover and gasket.
- Remove the rocker arm bolts and remove the rocker arm pivots and rocker arms. Keep the rocker arm assemblies in order so they can be reinstalled in their original locations.
- Remove the pushrods, keeping them in order so they can be reinstalled in their original locations.
- Rotate the crankshaft until the V8 mark lines up with the TDC mark on the timing chain cover (located 147° ATDC from the No. 1 firing mark).
Do not rotate or crank the engine during or immediately after rocker arm installation. Allow about 5 minutes for the hydraulic lifters to bleed down.
- Install the pushrods in their original locations. Make sure they are seated in the lifters.
- Lubricate the pushrod tips, rocker arm bearing surfaces and rocker arm pivots with clean engine oil.
- Install the rocker arm and pivot assemblies in their original locations. Tighten the bolts to 21 ft. lbs. (28 Nm).
- Install the cylinder head cover and gasket.
- Connect the negative battery cable.