Rocker Arm Assembly: Service and Repair

Removal

1. Disconnect battery ground cable.
2. Remove front grille and hood latch.
3. Disconnect horn electrical connector.
4. Remove header panel.
5. Remove radiator. Refer to Cooling System / Radiator / Service and Repair. Service and Repair
6. Remove timing belt. Refer to Timing Components / Timing Belt / Service and Repair. Service and Repair
7. Using tool No. J41840, or equivalent, hold camshaft timing belt gear, then remove camshaft gear bolt.
8. Remove cylinder head cover. Refer to Valve Cover / Service and Repair. Service and Repair
9. Remove distributor from case.

Fig. 29 Distributor Case Replacement.:

10. Remove distributor case, Fig. 29.

Fig. 30 Valve Lash Adjustment.:

11. Loosen all valve lash adjusting screw locknuts and adjusting screws, Fig. 30, until all rocker arms rotate freely.

Fig. 31 Camshaft Carrier Bolt Removal Sequence.:

12. Remove camshaft carrier bolts gradually in order, Fig. 31. Camshaft carrier bolts removed in random order may result in camshaft damage.
13. Remove camshaft carrier caps and camshaft.

Fig. 32 Rocker Arm Shaft Plug Replacement.:

14. Remove rocker arm shaft plug from cylinder head, Fig. 32.
15. Timing belt inner cover from cylinder head.

Fig. 33 Exhaust & Intake Rocker Arm Replacement.:

Fig. 34 Exploded View Camshaft & Rocker Arm Components.:

16. Remove all intake rocker arms with clips, Fig. 33 from rocker arm shaft, Fig. 34.
17. Remove six rocker arm attaching bolts from cylinder head.
18. Push rocker arm shaft back through rear of cylinder head and remove O-ring.
19. Remove exhaust rocker arms, rocker arm springs, and rocker arm shaft by pulling rocker arm shaft through front of cylinder head.


Installation

Prior to assembly, apply a coating of clean engine oil to all rocker arm components.

1. Push rocker arm shaft through front of cylinder head, slide exhaust rocker arms and rocker arm springs on shaft.
2. Push rocker arm shaft back through rear of cylinder head until end of shaft appears, then install new O-ring.
3. Place flat machined surface of rocker arm shaft facing down and mating with flat in cylinder head surface.
4. Install six rocker arm shaft bolts in cylinder head and tighten to specifications.
5. Fill rocker arm shaft bolt holes with clean engine oil.
6. Install all intake rocker arms with clips on rocker arm shaft.
7. Install camshaft and camshaft carrier caps noting the following:
a. Apply a coating clean engine oil to camshaft.
b. Camshaft carrier caps are marked with numbers and directional arrows.
c. Number one cap is installed at the front of cylinder head with arrow pointing toward the front of cylinder head.
d. Install remaining carrier caps in numerical order with arrows facing toward front of cylinder head.
e. Apply RTV silicone rubber sealant to bottom of number six carrier cap.

Fig. 35 Camshaft Carrier Cap Bolt Tightening Sequence.:

f. Gradually tighten camshaft carrier cap bolts in order,Fig. 35, to specification.
8. Apply clean engine to camshaft seal, then install seal in cylinder head flush with carrier surface.
9. Install timing belt inside cover to cylinder head and tighten to specification.
10. Install rocker arm shaft plug into cylinder head and tighten to specification.

Fig. 36 Camshaft Timing Belt Gear Alignment.:

11. Align dwell pin with slot in camshaft timing belt gear, Fig. 36, then using tool No. J41840, or equivalent, install camshaft timing belt gear on camshaft and tighten to specifications.
12. Install timing belt. Refer to Timing Components / Timing Belt / Service and Repair.
13. Apply silicone to base of distributor case, Fig. 29, install and tighten to specifications.
14. Install distributor.
15. Adjust valve lash. Refer to Valve, Intake/Exhaust / Adjustments. Adjustments
16. Install valve cover. Refer to Valve Cover / Service and Repair.
17. Install radiator. Refer to Cooling System / Radiator / Service and Repair.
18. Install header panel, hood latch and front grille.
19. Connect battery ground cable.