Pontiac Fiero 1984-1988 Repair Guide

Rocker Arm Cover and Pushrods

Print

REMOVAL & INSTALLATION



4-2.5L Engine


Click image to see an enlarged view

Fig. Fig. 1 Cylinder head and rocker cover RTV sealant application-four-cylinder engines



Click image to see an enlarged view

Fig. Fig. 2 Remove the valve cover by using a pair of J-34144-A tools and then gently tapping the cover with a hammer



Click image to see an enlarged view

Fig. Fig. 3 Exploded view of the valve mechanisms-2.5L engine


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the air cleaner assembly (Refer to ).
  2.  
  3. Remove the PCV valve and hose.
  4.  
  5. Remove the accelerator and throttle valve TV cables.
  6.  
  7. Remove the valve cover bolts.
  8.  
  9. Disconnect and mark the wires from the spark plugs and clips.
  10.  
  11. Remove the valve cover by using the Rocker Arm Cover Removing tool No. J34144-A or equivalent and lightly tap with a rubber hammer.
  12.  

Prying on the cover could cause damage to the sealing surfaces.

  1. Remove the rocker arm bolt and ball.
  2.  
  3. If replacing the pushrod only, loosen the rocker arm bolt and swing the arm clear of the pushrod.
  4.  
  5. Remove the rocker arm and pushrod. If removing more than one, label each part to ensure the part is placed in its original location.
  6.  

To install:

  1. Clean the rocker arm cover with solvent and dry with a clean rag.
  2.  
  3. Install the pushrod into the same hole as removed. Place the guide, rocker arm, ball and nut over the stud and finger-tighten the nut.
  4.  
  5. Make sure the camshaft is on the base of the cam lob (valve in the closed position) before tightening the rocker arm nut. Torque the rocker arm nut to 24 ft. lbs. (32 Nm).
  6.  
  7. Apply a continuous 5mm diameter bead of RTV sealant or equivalent around the cylinder head sealing surfaces inboard at the bolt holes.
  8.  

Keep the sealant out of the bolt holes.

  1. Install the rocker arm cover and torque the attaching bolts to 4 ft. lbs. (5 Nm).
  2.  
  3. Install the spark plug wires and clips, PCV valve and hose, accelerator and TV cable and air cleaner assembly.
  4.  

6-2.8L Engine


Click image to see an enlarged view

Fig. Fig. 4 Rocker arm cover and retainers-V6 engines



Click image to see an enlarged view

Fig. Fig. 5 Valve train components and their locations-V6 engines



Click image to see an enlarged view

Fig. Fig. 6 Adjust the valve lash until all lash is removed-V6 engines

FRONT ROCKER ARM COVER
  1. Disconnect the negative (-) battery cable.
  2.  
  3. Remove the rear engine compartment lid and side panels with an assistant.
  4.  


CAUTION
Personal injury may result if the engine compartment lid torsion rod retaining bolts are removed. The torsion bolts do not have to be removed to remove the compartment lid.

  1. Disconnect the vacuum boost line and tube.
  2.  
  3. Disconnect the throttle and downshift cables and bracket.
  4.  
  5. Disconnect the cruise control cable, if applicable.
  6.  
  7. Disconnect the ground cable.
  8.  
  9. Remove the PCV valve from the cover.
  10.  
  11. Remove the oil dip stick tube.
  12.  
  13. Mark and disconnect the spark plug wires and bracket.
  14.  
  15. Remove the engine lift hook.
  16.  
  17. Remove the rocker arm cover bolts and carefully remove the cover by bumping with a rubber mallet. If prying is necessary do not distort the sealing flange.
  18.  
  19. Remove the rocker arm nuts.
  20.  

Keep all components in order so that they may be installed in the same location.

  1. Remove the rocker arm pivot balls, arms and pushrods.
  2.  
  3. Before installation, coat the bearing surfaces of the rocker arms and pivot balls with Molykote® or equivalent.
  4.  

To install:

  1. Install the pushrods, rocker arms and pivot balls. Make sure the pushrods are seated in the valve lifters.
  2.  
  3. Adjust the rocker arm nuts until lash is eliminated.
  4.  
    1. Valve Lash Adjustment: rotate the engine until the mark on the torsional damper lines up with the "0" mark on the timing tab, with the engine in the No. 1 firing position. This may be determined by placing fingers on the No. 1 rocker arms as the mark on the damper comes near the "0" mark. If the valves are not moving, the engine is in the No. 1 firing position. With the engine in the No. 1 firing position, the following valves may be adjusted:

      Exhaust-1, 2, 3
       
      Intake-1, 5, 6
       

    2.  
    3. Back out the adjusting nut until lash is felt at the pushrod, then turn the adjusting nut until all lash is removed. This can be determined by rotating the pushrod while turning the adjusting nut. When lash has been removed, turn the adjusting nut in 1 1 / 2 additional turns to center the lifter plunger.
    4.  
    5. Crank the engine one revolution until the timing tab "0" mark and torsional damper mark are again in alignment. This is the No. 4 firing position. With the engine in this position, the following valves may be adjusted:

      Exhaust-4, 5, 6
       
      Intake-2, 3, 4
       

    6.  
    7. Clean the rocker arm cover with soap and water and dry before installation.
    8.  
      1. Clean the surfaces on the cylinder head.
      2.  
      3. Place a 3mm diameter dot of RTV sealer, at the intake manifold and cylinder head split line.
      4.  
      5. Apply a continuous 5mm diameter bead of RTV sealer to the rocker arm cover mating surfaces. Install the rocker arm cover gasket, using care to line up the holes in the gasket with the bolt holes in the cylinder head.
      6.  
      7. Install the four rocker arm cover bolts and torque to 90 inch lbs. (10 Nm).
      8.  

    9. Install the spark plug wires and bracket in the same location as removal.
    10.  
    11. Install the oil dipstick tube, PCV valve and hose, ground cable, cruise control cable, and throttle control cable.
    12.  
    13. Install the engine compartment lid in the same location as removal with an assistant.
    14.  
    15. Connect the negative (-) battery cable.
    16.  


REAR ROCKER ARM COVER


Click image to see an enlarged view

Fig. Fig. 7 Unfasten the torque reaction rod bolt ...



Click image to see an enlarged view

Fig. Fig. 8 ... then swing the torque reaction rod up



Click image to see an enlarged view

Fig. Fig. 9 Remove the bolt connecting the cylinder head bracket to the torque reaction rod bracket



Click image to see an enlarged view

Fig. Fig. 10 If necessary, remove the bracket from the engine



Click image to see an enlarged view

Fig. Fig. 11 Unfasten the rocker arm cover retaining bolts ...



Click image to see an enlarged view

Fig. Fig. 12 ... then remove the rocker arm cover from the vehicle



Click image to see an enlarged view

Fig. Fig. 13 Remove the old rocker arm cover gasket and replace it with a new one during installation

  1. Disconnect the negative (-) battery cable.
  2.  
  3. Remove the torque reaction rod bolt at the cylinder head bracket.
  4.  
  5. Swing the torque reaction rod up and remove the bolt connecting the cylinder head bracket-to-bracket at the front of the engine.
  6.  
  7. Loosen the lower bolt of the torque reaction rod bracket at the front of the engine.
  8.  
  9. Remove the upper two bolts of the torque reaction rod bracket at the front of the engine.
  10.  
  11. Remove the bolt at the torque reaction rod at the exhaust manifold connector.
  12.  
  13. Disconnect the wiring harness between the rocker arm cover and lower intake plenum.
  14.  
  15. Remove the four rocker arm cover bolts and remove the cover by tapping with a rubber hammer.
  16.  

To install:

  1. Install the pushrods, rocker arms and pivot balls. Make sure the pushrods are seated in the valve lifters.
  2.  
  3. Adjust the rocker arm nuts until lash is eliminated.
  4.  
    1. Valve Lash Adjustment: rotate the engine until the mark on the torsional damper lines up with the "0" mark on the timing tab, with the engine in the No. 1 firing position. This may be determined by placing fingers on the No. 1 rocker arms as the mark on the damper comes near the "0" mark. If the valves are not moving, the engine is in the No. 1 firing position. With the engine in the No. 1 firing position, the following valves may be adjusted:

      Exhaust-1, 2, 3
       
      Intake-1, 5, 6
       

    2.  
    3. Back out the adjusting nut until lash is felt at the pushrod, then turn the adjusting nut until all lash is removed. This can be determined by rotating the pushrod while turning the adjusting nut. When lash has been removed, turn the adjusting nut in 1 1 / 2 additional turns to center the lifter plunger.
    4.  
    5. Crank the engine one revolution until the timing tab "0" mark and torsional damper mark are again in alignment. This is the No. 4 firing position. With the engine in this position, the following valves may be adjusted:

      Exhaust-4, 5, 6
       
      Intake-2, 3, 4
       

    6.  
    7. Clean the rocker arm cover with soap and water and dry before installation. Clean the cylinder head mating surface with a gasket scraper and clean rag to remove old gasket material.
    8.  
    9. Place a 1 / 8 in. (3mm) dot of RTV sealer or equivalent at the intake manifold and cylinder head split line.
    10.  
    11. Apply a continuous 5mm bead of RTV sealer to the rocker arm cover. Install the new gasket onto the cover and apply another bead of RTV sealer to the gasket.
    12.  
    13. Install the rocker arm cover onto the cylinder head, using care to line up the holes in the gasket with the bolt holes in the cylinder head.
    14.  
    15. Install the four rocker arm cover bolts and torque to 90 inch lbs. (10 Nm).
    16.  
    17. Install the wiring harness between the rocker arm cover and lower intake plenum.
    18.  
    19. Install the bolt to the torque reaction rod bracket at cylinder head and exhaust manifold.
    20.  
    21. Tighten the lower torque reaction rod bolt at front of the engine.
    22.  
    23. Install and tighten all torque reaction rod bracket bolts.
    24.  
    25. Connect the negative (-) battery cable.
    26.  


 
label.common.footer.alt.autozoneLogo