Chrysler MD178782 Exhaust Rocker Arm

To remove the rocker arm assemblies from a 2.0L engine, position the number one piston at Top Dead Center, disconnect the negative battery cable from the ground stud on the left shock tower, and remove the valve cover. Before removing the rocker arm shafts, mark the front shaft as the intake rocker arm shaft and the rear shaft as the exhaust. Loosen the rocker arm shaft bolts gradually until the valve spring pressure is relieved, then completely loosen the bolts without removing them to keep the assembly intact. Lift the rocker arms and shaft assemblies from the cylinder head, securing any dislodged hydraulic valve lash adjusters with electrical tape if necessary. Disassemble the rocker arm shaft components, marking all parts for reassembly in their original locations. For a 2.4L engine, remove both camshafts, then lift off the rocker arms and hydraulic valve lash adjusters, ensuring each is returned to its original location. Inspect the rocker arms and lash adjusters for wear or damage, replacing any that show signs of excessive wear. Before installation, ensure the lash adjusters are partially filled with engine oil, and if necessary, pump the plunger to eliminate excessive travel. Reinstall the rocker arms in their original locations, ensuring plastic spacers are correctly positioned, and install the rocker arm assemblies with the notches facing up. Tighten the rocker arm bolts in sequence to the specified torque, then follow the reverse steps for installation. After starting the engine, expect initial "tapping" noises from the adjusters; if they do not become silent after a warm-up and speed increase, replace the defective assembly. For the 2.4L engine, follow similar procedures for installation and testing of the lash adjusters and rocker arms.

To remove the rocker arm assemblies, first disconnect the negative battery cable from the ground stud on the left shock tower and position the number one piston at Top Dead Center. Remove the valve cover(s) as needed and identify each rocker arm and shaft according to its proper location, ensuring not to interchange them to avoid premature wear. Loosen the rocker arm shaft bolts gradually until they can be loosened by hand, leaving them in place to prevent the assembly from falling apart. Lift the rocker arms and shaft assemblies from the cylinder head, taking care that the hydraulic valve lash adjusters do not become dislodged; secure them with vinyl tape if necessary. Disassemble the rocker arm shaft components while keeping track of their positions, ideally using lengths of wire to maintain order. Visually inspect the rocker arms for excessive wear or damage, replacing them if necessary, and carefully check each lash adjuster for signs of wear, particularly on the surface that contacts the valve tip. If the lash adjusters are clogged or if there are concerns about their condition, consider replacing the rocker arm/lash adjuster assembly. Inspect all rocker arm shaft components for cracks or excessive wear, replacing any damaged parts. Before installation, ensure the lash adjusters are partially filled with engine oil; if there is excessive plunger travel, pump the plunger in clean engine oil until the travel is eliminated. Install the rocker arms and springs onto the shafts in their original locations, ensuring the springs are correctly positioned. On the right cylinder head, install the rocker arm assemblies with the flat at the end of each shaft toward the timing belt, and on the left cylinder head, position them toward the transaxle. Tighten the rocker arm shaft bolts in the specified sequence to the required torque. The remaining installation steps follow the reverse order of removal. After re-starting the engine, expect some "tapping" noises from the adjusters due to air in the lubrication system; to bleed the air, allow the engine to reach operating temperature and gradually raise the speed from idle to 3,000 rpm and back to idle. If the adjusters do not become silent after several attempts, replace the defective rocker arm/lash adjuster assembly.