Rocker Arm Assembly: Service and Repair
Valve Rocker Arm and Hydraulic Valve Lash Adjuster Replacement
Tools Required
- J 43655 Camshaft Support Holding Tool
- SA9127E Gauge Bar Set
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the intake air temperature (IAT) sensor connector.
3. Loosen the clamp at the air cleaner assembly.
4. Remove the push pin attachment from the outlet resonator/duct assembly to the support bracket.
5. Loosen the clamp at the throttle body assembly.
6. Disconnect the PCV fresh air vent hose at the cam cover.
7. Remove the outlet resonator/duct assembly.
8. Remove the ignition module assembly with the bolts.
9. Disconnect the coolant de-gas hose clips from the fuel rail.
10. Disconnect the ground strap at the rear of the cam cover assembly.
11. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.
12. Disconnect the SA9127E after pressure has been relieved.
13. Disconnect the fuel rail bracket and the bolt at the rear of the cam cover.
Caution: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around the fitting to collect fuel. Place the cloth in an approved container.
Notice: An open-end wrench must be used to support the fuel line to rail connection during loosening/tightening to avoid damaging the fuel rail assembly.
14. While supporting the fuel rail assembly with an open-end wrench, loosen the transfer line fitting at the fuel rail.
15. Position the fuel line away from the cam cover assembly.
16. Remove the cam cover assembly bolts.
17. Remove the cam cover assembly.
18. If intake camshaft is being removed, Remove the purge solenoid from the power steering plate.
19. Remove the power steering block off the plate.
Notice: To avoid valve piston contact, No. 1 cylinder piston must be positioned at approximately 60 degrees before-top dead center (BTDC). Pistons are properly positioned when the diamond shaped hole on the intake camshaft sprocket is located at 12 o'clock.
Important: To rotate the camshaft(s), use a 24 mm open-end wrench on the camshaft flats. Camshaft(s) should be rotated in a clockwise direction only (facing camshaft sprockets from passenger side of the vehicle).
20. Locate the No. 1 piston to approximately 60 degrees before top dead center (BTDC) (diamond shaped hole on the intake camshaft sprocket at 12 o'clock position).
Remove the spark plugs. This will ease rotation effort.
Important: When removing guide bolts do not drop down into front cover.
21. Remove the upper timing chain guide.
Notice: During the camshaft removal procedure, the pistons are locked in position by the J43655 camshaft support holding tool. Do not rotate the engine crankshaft or tool damage and timing reset will be required. Camshafts can be rotated only after the #1 piston is at 60� BTDC and the sprocket has been disengaged from the camshaft.
22. Remove front camshaft caps.
Important: Lubricate the sprocket pins with clean motor oil. These will allow sprockets to easily slide on the sprocket pins.
23. Install J 43655 through the sprocket holes from the timing chain side of the sprocket towards the rear of the engine.
24. With the guide pin installed in the sprocket, align the guide pins into the slots on the support plate.
25. Tighten the support bracket to the cylinder head.
Tighten
Tighten the support plate to cylinder head to 10 Nm (89 lb in).
26. Install wingnuts and tighten.
27. Hold each camshaft in place using 24 mm open-end wrench and carefully remove the camshaft sprocket timing chain retaining bolts and washers. Discard the torque-to-yield (TTY) bolts.
Important: When sliding the timing chain and the sprockets onto the guide pins, be sure the timing chain is positioned properly on the adjustable and fixed guide or guide damage will occur. Care should be taken when removing the camshaft sprocket from the camshaft.
Important: Camshafts are spring loaded and may rotate. Care should be taken until all spring tension is removed from the camshaft.
28. Slide camshaft sprockets away from the camshafts.
29. To release the spring tension on the camshaft, after the camshaft is disengaged from the sprocket, rotate the camshaft using a 24 mm wrench to a neutral position.
30. Uniformly loosen and remove the remaining camshaft bearing cap bolts.
31. Carefully pull the camshafts straight up to avoid damaging the cylinder head thrust surfaces.
Important: When servicing the cylinder head components. Components should be kept in order to assure proper assembly.
32. Remove rocker arms followers.
Notice: After cylinder block, head, or lifter replacement, it will be necessary to allow the engine to idle for 3-5 minutes. If the lifters are noisy, warm the engine up at less than 200 RPM. After the coolant temperature has reached approximately 85�C (185�F), cycle the engine RPM from idle to 300 RPM for approximately 10 minutes or drive the vehicle 8 kilometers (5 miles) to purge the air. If the air cannot be purged, the faulty lifters will have to be replaced.
Important: During camshaft removal procedure, the pistons are locked by the J 43655 and SHOULD NOT be rotated. Tool damage may result and timing chain re-timing will be required.
33. Remove the lash adjusters.
Installation Procedure
Notice: If a valve seal is removed after it has been installed, it must be discarded. The valve stem lock groove will cut the seal's lip during removal. Use extreme care when installing valve retainers and do not damage the valve stems.
1. Install lubricated lash adjusters in their correct locations.
2. Install rocker arms followers.
3. Lubricate camshaft bearing journals with clean engine oil and install both camshafts.
4. When installing camshafts, attempt to position the camshaft slot in line with the notch on the sprockets.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
5. Install all bearing caps except for front cap and rear intake camshaft cap, if serviced. Tighten down the bearing cap uniformly.
Tighten
Tighten the camshaft bearing cap bolts to 10 Nm (89 lb in).
Notice: Verify the timing chain is properly positioned on the fixed guide or guide damage will occur.
Important: Ensure that the alignment slots are correctly aligned with notches in the camshaft sprockets before the final torque is applied.
Important: Verify the camshafts are properly timed as outlined in this section prior to starting the engine.
6. Slide the camshaft sprocket(s) and timing chain on guide pins toward the camshafts. Rotate camshafts with 24 mm open-end wrench to properly align the camshafts and sprockets.
7. Install a new camshaft sprocket bolts and tighten. This will pull the camshaft sprockets and camshafts together.
Hold the camshaft with 24 mm open-end wrench during the tightening.
Tighten
Tighten the camshaft sprocket bolts to 85 Nm(63 lb ft) + 30 degrees.
8. Remove J 43655.
9. Install the front camshaft caps.
Tighten
Tighten the camshaft bearing cap bolts to 10 Nm (89 lb in).
Important: Apply Permatex Medium Blue P/N 21485277 to upper timing chain guide bolts.
10. Install upper timing chain guide and bolts.
Tighten
Tighten the timing chain guide bolts to 10 Nm (89 lb in).
Important: Apply Permatex� Flange Sealant 5131 Purple to cylinder head near the rear intake cap as shown.
11. Install the rear intake camshaft bearing cap.
Tighten
Tighten the intake camshaft rear cap to 25 Nm (18 lb ft).
12. Install power steering block off plate.
Tighten
Tighten the Power Steering Block Off Plate to 25 Nm (18 lb ft).
13. Visually inspect the camshaft cover gasket for signs of leakage. The camshaft cover gasket is reusable if not damaged.
14. Assemble camshaft cover and gasket. Use care to make sure that the gasket is located in the retaining groove on the camshaft cover.
15. Install the cover on the cylinder head and hand-tighten the bolts.
Tighten
Tighten the camshaft cover bolts to 10 Nm (89 lb in).
Notice: An open-end wrench must be used to support the fuel line to rail connection during loosening/tightening to avoid damaging the fuel rail assembly.
16. Re-position the fuel line assembly.
17. Install the transfer line fitting at the fuel-to-fuel rail.
Tighten
Tighten the transfer line fitting-to-fuel rail to 10 Nm (89 lb in).
18. Connect the fuel rail bracket and the bolt to the cylinder head.
Tighten
Tighten the fuel line bracket bolt to 10 Nm (89 lb in).
19. Connect the ground strap to the camshaft cover assembly.
Tighten
Tighten the camshaft cover ground strap bolts to 10 Nm (89 lb in).
20. Connect the degas hose and clamp to the cylinder head.
21. Connect the degas hose bracket and the bolt to the cylinder head.
22. Install the spark plugs.
Tighten
- Tighten the spark plugs to 20 Nm (15 lb in).
- Tighten the coolant pipe bracket bolts to 10 Nm (89 lb in).
23. Install ignition module assembly to the cam cover and hand tighten the retaining bolts.
Tighten
Tighten ignition module-to-camshaft cover to 8 Nm (71 lb in).
24. Position the outlet resonator/duct assembly into position.
25. Connect PCV fresh air vent hose assembly.
26. Tighten the clamp at the throttle body assembly.
27. Position the outlet resonator/duct assembly up with support bracket and install the push-pin.
28. Tighten the clamp at the air cleaner assembly.
29. Connect the intake air temperature (IAT) sensor connector.
30. Connect the negative battery cable.
Tighten
Tighten the battery terminal bolt to 17 Nm (13 lb ft).