Jeep Wrangler/YJ 1987-1995 Repair Guide

Rocker Arm (Valve) Cover

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REMOVAL & INSTALLATION



2.5L Engine

See Figures 1, 2, 3, 4 and 5



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Fig. Fig. 1: Disconnect the crankcase ventilation vacuum hose from the valve cover



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Fig. Fig. 2: Disconnect the fresh air inlet hose from the valve cover



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Fig. Fig. 3: Remove the cover mounting bolts



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Fig. Fig. 4: Disconnect the vacuum hose from the valve cover studs



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Fig. Fig. 5: Remove the valve cover from the engine

  1. Disconnect the PCV vacuum hose from the valve cover.
  2.  
  3. Remove the cover mounting bolts and remove the cover from the head.
  4.  

To install:

A cured gasket is part of the cylinder head cover. Remove any original sealer from the cover sealing surface using a fabric cleaner. The original grey gasket material should not be removed. If pieces are missing, the cover must be replaced.

  1. Thoroughly clean the sealing surface of the cylinder head and the seal on the cover.
  2.  
  3. Install the cylinder head cover and tighten the mounting bolts to 44 inch lbs. (5 Nm).
  4.  
  5. Connect the PCV vacuum hose to the valve cover.
  6.  

4.0L Engine
1991 VEHICLES
  1. Disconnect the PCV vacuum hoses from the valve cover.
  2.  
  3. Remove the cover mounting bolts and remove the cover from the head.
  4.  

To install:

A cured gasket is part of the cylinder head cover. Remove any original sealer from the cover sealing surface using a fabric cleaner. The original grey gasket material should not be removed. If pieces are missing the cover must be replaced.

  1. Thoroughly clean the sealing surface of the cylinder head and the seal on the cover.
  2.  
  3. Install the cylinder head cover and tighten the mounting bolts to 55 inch lbs. (6 Nm).
  4.  
  5. Connect the PCV vacuum hoses to the valve cover.
  6.  

1992-95 VEHICLES
  1. Disconnect the PCV vacuum and fresh air inlet hoses from the valve cover.
  2.  
  3. Remove the cover mounting bolts and remove the cover from the head.
  4.  

To install:

A cured gasket is part of the cylinder head cover. Remove any original sealer from the cover sealing surface using a fabric cleaner. The original grey gasket material should not be removed. If pieces are missing the cover must be replaced.

  1. Thoroughly clean the sealing surface of the cylinder head and the seal on the cover.
  2.  
  3. Install the cylinder head cover and tighten the mounting bolts to 85 inch lbs. (10 Nm).
  4.  
  5. Connect the PCV vacuum and fresh air inlet hoses to the valve cover.
  6.  

4.2L Engine

See Figure 6



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Fig. Fig. 6: Cylinder head (rocker arm) cover-4.2L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner and the PCV molded hose.
  4.  
  5. Disconnect the distributor vacuum advance hose at the distributor.
  6.  
  7. Disconnect the fuel pipe at the fuel pump. Rotate the pipe as necessary to provide clearance for the cover removal.
  8.  
  9. Remove the PCV valve from the cylinder head and disconnect the PCV shut-off valve vacuum hose.
  10.  
  11. Remove the vacuum switch and bracket assembly from the cover.
  12.  
  13. Tag and remove all necessary vacuum and air hoses.
  14.  
  15. Remove the cover retaining nuts.
  16.  
  17. Break the seal with a clean putty knife or razor blade. Don't attempt to remove the cover until the seal is broken. To remove the cover, pry where indicated at the bolt holes.
  18.  
  19. Rotate the cover toward the passenger side and remove the cover.
  20.  

To install:
  1. Clean the mating surfaces of the cover and head.
  2.  
  3. Run a 1 / 8 in. (3mm) bead of RTV sealer around the mating surface of the head, then install the cover within 10 minutes. Don't allow any of the RTV material to drop into the engine!
  4.  
  5. Install replacement seals on the cylinder head cover attaching studs.
  6.  
  7. Install the cylinder head cover and install and tighten the cover nuts to 28 inch lbs. (3 Nm).
  8.  
  9. Install and tighten the cylinder head cover bolts to 55 inch lbs. (6 Nm).
  10.  
  11. Reposition and install all hoses.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Check and add engine oil as necessary.
  16.  

Allow the sealer to cure for at least 1 or 2 hours before starting the engine.

 
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