Rocker Arm Assembly: Service and Repair

Fig. 1 Cylinder Head-Camshaft-Valves:

Fig. 2 Rocker Cover:

REMOVE VALVE COVERS
1. Remove air cleaner assembly.
2. Disconnect battery and relocate spark plug wires.
3. Remove vacuum connections.
4. Remove rocker cover screws and remove cover.

REMOVE CAMSHAFT SPROCKETS
Refer to Engine/Timing Components/Timing Belt/Service and Repair, for disassembly and remove camshaft sprockets.
Service and Repair

Fig. 3 Auto Lash Adjuster Check:

CHECK AUTO LASH ADJUSTER FUNCTION
Check auto adjusters for free play by inserting a small wire through the air bleed hole in the rocker arm and VERY LIGHTLY push the auto adjuster ball check down. While lightly holding the check ball down move the rocker up and down to check for free play. If there is no play replace the adjuster.

NOTE: Do not disassemble the auto lash adjuster.

Fig. 4 Auto Lash Adjuster Retainers:

REMOVE CAMSHAFTS
1. Install auto lash adjuster retainers.

Fig. 11 Distributor Drive:

2. Remove distributor extension.
3. When removing camshaft bearing caps do not remove the bolts from the bearing caps. Remove the rocker arm, rocker shafts and bearing cap as an assembly.

Fig. 5 Check Camshafts:

INSPECT CAMSHAFTS
1. Inspect camshaft bearing journals for damage and binding. If journals are binding, also check the cylinder head for damage Fig. 1. Also check cylinder head oil holes for clogging.
2. Front cylinder head camshaft check the tooth surface of the distributor drive gear teeth of the camshaft and replace if abnormal wear is evident.
3. Check the cam surface for abnormal wear and damage and replace if defective. Also measure the cam height Fig. 5.and replace if out of limit, standard value is 41.25 mm 1.624 inch, wear limit is 40.75 mm 1.604 inch.

Fig. 6 Inspect Rocker Arms:

INSPECT ROCKER ARMS
Check rocker arms for wear or damage. Replace as necessary.

INSPECT ROCKER ARM SHAFTS

Fig. 7 Rocker Arm Shaft Identification:

NOTE: The rocker arm shaft is hollow and is used as a lubrication oil duct. The rocker arm shaft on the inlet side has a 3mm diameter oil passage hole from the cylinder head. The exhaust side does not have this oil passage.

1. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if heavily damaged or worn.
2. Check oil holes for clogging with small wire, clean as required.


INSTALL CAMSHAFTS
Lubricate camshaft journals and cams with engine oil and install camshaft on cylinder head.

Fig. 8 Camshaft Bearing Caps Position:

REASSEMBLE ROCKER ARMS
1. Align the camshaft bearing caps with arrows depending on cylinder bank, directed as shown. and in numerical order.

Fig. 9 Number One Camshaft Bearing Cap:

NOTE: Identify number one bearing cap number one and number four caps are similar.

Fig. 10 Assemble Rocker Arm And Shafts:

2. Install rocker shafts into bearing cap number one with end notches positioned as shown in Figs. 9 and 10 note that the machined portion of the rocker shaft is facing down.
3. Insert attaching bolts to retain assembly.

INSTALL ROCKER ARM SHAFT ASSEMBLY
1. Apply Mopar Silicone Rubber Adhesive Sealant at bearing cap ends as shown in.
2. Install the rocker arm shaft assembly making sure that the arrow mark on the bearing cap and the arrow mark on the cylinder head are in the same direction.

NOTE: The direction of arrow marks on the front and rear assemblies are opposite to each other.

3. Tighten bearing cap bolts in the following order to 10 Nm 85 in. lbs. First # 3, then # 2, # 1 and # 4.
4. Repeat step 3 increasing the torque to 20 Nm 180 in.lbs.

Fig. 11 Distributor Drive:

5. Install distributor drive adaptor assembly Fig. 11.

INSTALL VALVE COVERS
1. Clean cylinder head and cover mating surfaces. Install new gasket.
2. See Fig. 2 and apply sealant such as Mopar Silicone Rubber Adhesive Sealant to cover ends.
3. Install cover and tighten cover bolt washer and gasket assembly to 10 Nm (88 in. lbs.).