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Rocker arm issues are common in that car. They can happen without any reason. This is not going to be cheap to look at. When the head was repaired it had to be removed. The timing chain might not have been properly tensioned. That would cause the timing chain to slip and then you have pistons slapping valves and spark plugs. This cause rocker arms and pushrods to bend or break and also can damage pistons.
I could be the bushings in the rocker arms and the rocker arm shafts. Bring the piston to top dead center on the cylinder that has the noise. Both valves should be closed. Allow about five minutes for the tappets to bleed down on that cylinder. When you can spin both of the pushrods with your fingers, remove the 5/16 inch bolts on the right hand side (pushrod side) of the head. This should allow you to push the rocker arm shaft out and remove the rocker arm. You may have to gently tap the rocker arm shafts out but it should not be difficult to get them out. Do not mix the rocker arms and their shafts up. Keep them together. Check the bushings in the rocker arms and the rocker arm shafts for wear. The bushings can be replaced and use new rocker arm shafts if this turns out out to be the problem. Check the face of the rocker arm where it pushes down on the valve stem for wear as well.
Move the intake secondary rocker arm A for the No. 1 cylinder. The secondary rocker arm A should move independently of the secondary rocker arm B.
If the intake secondary rocker arm A moves freely, go to step 5.
If the intake secondary rocker arm A does not move, remove the secondary rocker arms as an assembly, then check that the pistons in the secondary rocker arms move smoothly. If any rocker arm needs replacing, replace the secondary rocker arms as an assembly, then retest.
Repeat step 4 on the remaining intake secondary rocker arms with each piston at TDC. When all the secondary rocker arms pass the test, go to step 6.
Check that the air pressure on the shop air compressor gauge indicates over 400 kPa (4.0 kgf/cm2, 57 psi).
Install a 10 x 1.0 mm adapter to the inspection hole, then connect the air pressure regulator
With the specified air pressure applied, move the intake secondary rocker arm A for the No. 1 cylinder. The secondary rocker arm A and secondary rocker arm B should move together. If the intake secondary rocker arm A does not move, remove the secondary rocker arms as an assembly, and check that the pistons in the secondary rocker arms move smoothly. If any rocker arm needs replacing, replace the secondary rocker arms as an assembly, then retest.
1.5 and 1.8 engines: * Install the rocker arm and shaft assemblies. Tighten the rocker arm shaft retainer bolts to 23 ft. lbs. (32 Nm). * Check valve adjustment and install the valve cover. Tighten the
valve cover bolts to 16 inch lbs. (1.8 Nm) for the 1.5L engine or to 29
inch lbs. (3.3 Nm) for the 1.8L engine.
2.0 engine * Lubricate the rocker shaft with clean engine oil and install the rockers and springs in their proper places. * Install the rocker shaft assemblies on the engine. Tighten the bolts gradually and evenly to 21-25 ft. lbs. (29-35 Nm).
2.4 engine
Fig. Rocker arm shafts and components-2.4L engine
* Fit the rocker shaft springs from above and position them so that
they are at right angles to the plug side. Install the rocker springs
before installing the exhaust side rocker shaft and rocker arm assembly.
* Install the exhaust side rocker shaft assembly in the engine.
Tighten the rocker shaft mounting bolts gradually and evenly to 23 ft.
lbs. (32 Nm). * Remove the lash adjuster retaining tools. * Install the rocker cover and tighten the mounting bolts to 30 inch lbs. (3 Nm). * Reinstall the spark plug wires to the spark plugs.
YOU HAVE TO REMOVE VALVE COVERS LOOSEN REMOVE ROCKER ARMS ASSEMBLY KEEP ROCKER ARM ASSEMBLY IN ORDER SO THEY GO BACK IN THE ORIGINAL POSITION.YOU HAVE TO REMOVE INTAKE MANIFOLD ALSO.YOU NEED A REPAIR MANUAL FOR TORQUE SEQUENCE ON THE INTAKE MANIFOLD AND ROCKER ARMS TORQUE.
I'd be interested in knowing how the cam chest cover cam off changing a gear box gasket but.
In order to get the cams back in and to insure their proper timing, I'd put the rocker arms out. I'd pull them all out but you're free to do whatever you wish. Remove the top and middle rocker cover on the front clinder. Remove the large bolt that hold the lower plate and the rocker arm for the front cylinder in. Tap the rocker arm shaft out of the rocker arm and remove the rocker arm. You can then get your cam into position. Now, to get rocker shaft back in, rotate the engine until the front exhaust cam has the valve in it's closed position. Reinstall the rocker arm and shaft and torque the bolt to 25 foot pounds. Reassemble the upper and middle rocker box covers.
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