Rocker Arm Assembly: Service and Repair

Fig. 4 Camshaft timing marks. 1600cc engines:

REMOVAL

1. Disconnect breather and purge hoses, then remove air cleaner.
2. Disconnect spark plug wires at spark plugs, then remove upper timing belt cover.
3. Rotate crankshaft until camshaft sprocket mark is aligned with mark on timing belt upper under cover,. This will position No. 1 cylinder at top dead center compression stroke.
4. Place alignment mark on timing belt in line with mark on camshaft sprocket.
5. Remove camshaft sprocket attaching bolt, then remove camshaft sprocket with timing belt attached to sprocket. The timing belt lower cover incorporates a sprocket holder which will hold camshaft sprocket in position. If clearance between sprocket and holder is excessive, insert a piece of timing belt approximately 2 inches long or other suitable material between sprocket and holder. This will prevent the timing belt from becoming dislodged from the crankshaft sprocket. After sprocket has been removed from camshaft, use care not to rotate crankshaft.
6. Remove camshaft spacer if equipped, then remove upper timing belt under cover.
7. Remove rocker arm cover and gasket, then remove camshaft bearing attaching bolts.
8. Remove rocker arms, rocker shafts and camshaft bearing caps as an assembly from cylinder head. Remove camshaft bearing cap bolts, then remove bearing caps, rocker arms and springs from rocker shafts.
9. On models less silent shaft, remove oil seal, distributor drive gear and camshaft as an assembly, then remove oil seal and distributor drive gear from camshaft.
10. On models with silent shaft, remove oil seal and distributor drive gear from camshaft, then remove camshaft from cylinder head.

INSTALLATION

1. Lubricate camshaft lobes and bearing surfaces with engine oil. Then position camshaft on cylinder head.
2. Check camshaft endplay, which should be 0.002 to 0.006 inch.
3. If removed, position distributor drive gear on camshaft.

Fig. 17 Rocker arm shaft installation, 1600cc, 2000cc engines:

4. On all models, position intake and exhaust rocker shafts into front camshaft bearing cap. Position shafts as shown in Fig. 17. Install bearing cap bolts retaining shafts in position.
5. Assemble rocker arms, spring and bearing caps. After installing rear camshaft bearing caps, insert bolts through rear bearing caps to retain rocker shaft components. When installing rocker arms, note that intake rocker arms have two adjusting screws.

Fig. 18 Camshaft installation. 1600cc engine:

6. Position camshaft so that camshaft key is 41° from cylinder head rocker arm cover mounting surface, as viewed from front of engine, Fig. 18.
7. On all models, position rocker arm assemblies on cylinder head, then install camshaft bearing cap attaching bolts. Torque camshaft bearing cap bolts to 7 ft. lbs., starting at the center bearing cap and working outward and alternating from side to side. Torque bolts to a final toque of 14-15 ft. lbs. in the same sequence.

Fig. 19 Camshaft front oil seal installation. 1600cc engine:

8. Lubricate camshaft front oil seal lips with engine oil, then install seal into camshaft front bearing bore using tool MD998284 or equivalent, Fig. 19. Tap seal into bore until tool contacts distributor drive gear.
9. Install upper timing belt under cover, then lubricate camshaft spacer with engine oil and install spacer on camshaft.
10. Pull camshaft sprocket upward and install on camshaft. If dowel hole on camshaft sprocket cannot be aligned with dowel on camshaft spacer, use a screwdriver at the two projections located to the rear of the No. 2 exhaust cam lobe to rotate the camshaft slightly to align dowel and dowel hole.
11. Install camshaft sprocket bolt and torque to 44-57 ft. lbs. on 1984-85 models or 59-72 ft. lbs. on 1986-88 models. Check to ensure that crankshaft pulley, camshaft sprocket and timing belt to camshaft sprocket marks are aligned.
12. Set valves to cold clearance of 0.003 inch for intake and jet valves and 0.007 inch for exhaust valves. Refer to "Valves, Adjust."
13. Temporarily install rocker arm cover.
14. Start engine and allow to reach operating temperature, then adjust valves to warm clearance, referring to "Valves, Adjust" and Valve Specifications Chart.

Fig. 20 Applying sealer for rocker cover installation. 1600cc engine:

15. Remove rocker arm cover and apply sealer at locations indicated in Fig. 20.
16. Reinstall rocker arm cover and tighten attaching bolts.
17. Connect spark plug wires, then install air cleaner and connect breather and purge hoses.