Rocker Arm Assembly: Service and Repair

REMOVAL

1. Disconnect battery ground cable and remove air cleaner.
2. Disconnect spark plug wires and remove accessory drive belts, as needed.
3. Mark and disconnect necessary electrical connectors and vacuum hoses, then remove timing belt upper cover and rocker arm cover.

Fig. 5 Camshaft timing marks. 2000cc engine:

4. Rotate crankshaft in normal direction of rotation until No. 1 cylinder is at TDC and crankshaft and camshaft timing marks are aligned, Fig. 5.
5. Place chalk mark between timing belt and camshaft sprocket, remove camshaft sprocket bolt, separate sprocket from camshaft leaving belt in place on sprocket, then secure sprocket and belt on lower timing cover. Take care that sprocket does not disengage from belt and fall, and maintain tension on belt to maintain proper timing. Do not rotate crankshaft after sprocket is removed from camshaft.
6. Evenly loosen camshaft bearing cap/rocker arm retaining bolts in crossing pattern, remove bearing caps and rocker shafts as an assembly, then remove camshaft.

Fig. 21 Rocker arms, rocker shafts & camshaft exploded view. 2000cc engines:

7. Disassemble components in numerical order, Fig. 21, noting position for installation.

INSTALLATION

1. Coat camshaft with suitable assembly lubricant and position cam in head, with camshaft aligned so that valves for No. 1 cylinder are closed (TDC on compression stroke).

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

2. Insert rocker shafts into front bearing cap, installing shaft with oil hole side down and noting that front end of shaft has a cut .16 inch wide, Fig. 17.

Fig. 22 Assembling rocker arms & rocker arm shafts. 2000cc engine:

3. Apply engine oil to I.D. of rocker arms prior to assembly. Assemble rocker arms, springs and remaining bearing caps on rocker shafts, Fig. 22, in positions noted during disassembly.

Fig. 23 Hydraulic lash adjuster & retaining clip installation. 1985-88 2000cc & 2600cc engines:

4. On models with hydraulic lash adjusters, insert each adjuster into rocker arm taking care not to spill fluid from adjuster. Retain adjusters using suitable clips, Fig. 23, to prevent them from falling out during installation.
5. On all models, install assembly onto cylinder head and evenly tighten bolts in crossing pattern until bearing caps are seated. When caps are seated, torque bolts to specifications in crossing pattern.
6. Install sleeve over camshaft and press oil seal into place using suitable driver.
7. Install camshaft sprocket and timing belt, then ensure timing marks are properly aligned.
8. Adjust valves to specifications as outlined, then temporarily install rocker cover.
9. Reverse remaining procedure to complete installation, then check timing belt tension as outlined. After engine reaches normal operating temperature, recheck valve clearances and adjust as needed.

Fig. 24 Applying sealant to semi-circular packing:

10. When installing rocker cover after checking valve clearances, apply suitable sealer to semi-circular packing and cylinder head, Fig. 24, then install rocker cover.