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Rocker Shafts

REMOVAL & INSTALLATION

1,586cc, 1,796cc and 1,970cc Engines

Fig. 1: Rocker arm assembly used on the 1,586cc, 1,796cc and 1,970cc engines

Fig. 2: Proper positioning of the rocker arm adjusting screw ball — make sure the flat portion of the ball contacts the valve tip

Fig. 3: Exhaust rockers may have a slight offset depending on engine model

NOTE: This operation should only be performed on a cold engine; the bolts which hold the rocker shafts in place also hold the cylinder head to the block.

  1. Raise the hood and cover the fenders.
  2. Disconnect the choke cable, if so equipped.
  3. If equipped, disconnect the air by-pass valve cable.
  4. Disconnect the spark plug wires. Remove the wires from the spark plug wire clips on the rocker covers and position them out of the way.
  5. Remove the rocker cover and discard the gasket.
  6. Remove the rocker arm shaft attaching bolts evenly and remove the rocker arm shafts. To install:
  7. Install the rocker arm assemblies on the cylinder head. Install the balls on each rocker arm as shown. Temporarily tighten the cylinder head bolts to specifications and offset each rocker arm support 1mm (0.04 in.) from the valve stem center. Torque the bolts to specifications.
  8. Adjust the valves cold.
  9. Clean the mating surfaces of the cylinder head and rocker cover.
  10. Install the rocker cover with a new gasket. Torque the bolts to 24–36 in. lbs.
  11. Install the spark plug wire on the plugs. Place the wires in the clips on the rocker cover. Connect the choke and air by-pass valve cable.
  12. Start the engine and check for leaks.
  13. Allow the engine to reach operating temperature, torque the head bolts to specifications and adjust the valves hot.
1,998cc Engine

Fig. 4: Rocker arm torque sequence for the 1,998cc engine

Fig. 5: Removing the rocker arm and shaft assembly — some engines use the cylinder head bolts to retain the assembly, while others have separate rocker arm bolts

  1. Raise the hood and cover the fenders.
  2. Disconnect the accelerator cable, if necessary.
  3. If equipped, disconnect the air by-pass valve cable.
  4. Disconnect the spark plug wires. Remove the wires from the spark plug wire clips on the rocker covers and position them out of the way.
  5. Remove the rocker cover and discard the gasket.
  6. Remove the rocker arm shaft attaching bolts evenly, in the order shown, and remove the rocker arm shafts. To install:
  7. Install the rocker arm assemblies on the cylinder head. Torque the bolts, in the order shown, to 13–20 ft. lbs.
  8. Check the valve adjustment and reset, if necessary.
  9. Clean the mating surfaces of the cylinder head and rocker cover.
  10. Install the rocker cover with a new gasket. Torque the bolts to 24–36 in. lbs.
  11. Install the spark plug wire on the plugs. Place the wires in the clips on the rocker cover. Connect the choke and air by-pass valve cable.
  12. Start the engine and check for leaks.
  13. Allow the engine to reach operating temperature, torque the head bolts to specifications and adjust the valves hot.
2,209cc Diesel Engine

Fig. 6: Exploded view of the diesel rocker arm components

NOTE: This operation should only be performed on a cold engine; the bolts which hold the rocker shafts in place also hold the cylinder head to the block.

  1. Raise the hood and cover the fenders.
  2. Disconnect the accelerator cable, if necessary.
  3. Remove the rocker cover and discard the gasket.
  4. Remove the rocker arm shaft attaching bolts evenly and remove the rocker arm shafts.
  5. Lift out the pushrods, keeping them in order for proper installation. When installing the pushrods, make sure they are seated in the depressed bottom section of the tappets. To install:
  6. Install the rocker arm assemblies on the cylinder head. Torque the bolts to specifications.
  7. Adjust the valves cold.
  8. Clean the mating surfaces of the cylinder head and rocker cover.
  9. Install the rocker cover with a new gasket. Torque the bolts to 24–36 in. lbs.
  10. Install the spark plug wire on the plugs. Place the wires in the clips on the rocker cover. Connect the choke and air by-pass valve cable.
  11. Start the engine and check for leaks.
  12. Allow the engine to reach operating temperature, torque the head bolts to specifications and adjust the valves hot.

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