Chrysler Caravan/Voyager/Town n Country 1984-1995

Camshaft and Bearings

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REMOVAL & INSTALLATION



2.2L and 2.5L Engines

See Figures 1 through 11



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Fig. Fig. 1: Suspending the camshaft sprocket to retain the engine timing-2.2L and 2.5L engines



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Fig. Fig. 2: Remove the air pump belt from the pulley



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Fig. Fig. 3: Suspending the camshaft sprocket to retain timing before removing it from the camshaft



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Fig. Fig. 4: Place a wrench on both ends of the camshaft and remove the camshaft sprocket leaving it suspended



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Fig. Fig. 5: Removing the oil shield



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Fig. Fig. 6: Removing the bearing caps



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Fig. Fig. 7: Removing the camshaft from the engine



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Fig. Fig. 8: Removing the seal from the end of the camshaft



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Fig. Fig. 9: Checking the camshaft lobe wear-2.2L and 2.5L engines



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Fig. Fig. 10: Camshaft bearing caps-2.2L and 2.5L engines



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Fig. Fig. 11: Measuring the camshaft end play-2.2L and 2.5L engines

The following procedure is written for engines still in the vehicle.

  1. Disconnect the negative battery cable. Relieve the fuel pressure, if equipped with fuel injection.
  2.  

Removal of the camshaft requires removal of the camshaft sprocket. To maintain proper engine timing, the timing belt can be left indexed on the sprockets and suspended under light pressure. This will prevent the belt from coming off and maintain timing.

  1. Turn the crankshaft so the No. 1 piston is at the TDC of the compression stroke. Remove the upper timing belt cover. Remove the air pump pulley, if equipped.
  2.  
  3. Remove the bolt and the camshaft sprocket, then suspend it tightly so the belt does not lose tension. If it does, the belt timing will have to be reset.
  4.  
  5. Remove the valve cover.
  6.  
  7. Remove the air pump belt from the pulley.
  8.  
  9. If the rocker arms are being reused, mark them for installation identification and loosen the camshaft bearing bolts, evenly and gradually.
  10.  
  11. Using a soft mallet, rap the rear of the camshaft a few times to break the bearing caps loose.
  12.  
  13. Remove the bolts, bearing caps and the camshaft with seals.
  14.  

Before replacing the camshaft, identify factory installed oversized components. To do so, look for the tops of the bearing caps painted green and O/SJ stamped rearward of the oil gallery plug on the rear of the head. In addition, the barrel of the camshaft is painted green and O/SJ is stamped onto the rear end of the camshaft. Installing standard sized parts in an head equipped with oversized parts-or vice versa-will cause severe engine damage.

  1. Check the oil passages for blockage and the parts for damage. Clean all mating surfaces.
  2.  

To Install:
  1. Transfer the sprocket key to the new camshaft. New rocker arms and a new camshaft sprocket bolt are normally included with the camshaft package. Install the rocker arms, lubricate the camshaft and install with end seals installed.
  2.  
  3. Place the bearing caps with No. 1 at the timing belt end and No. 5 at the transaxle end. The camshaft bearing caps are numbered and have arrows facing forward. Tighten the camshaft bearing bolts evenly and gradually to 18 ft. lbs. (24 Nm).
  4.  

Apply RTV silicone gasket material to the No. 1 and 5 bearing caps. Install the bearing caps before the seals are installed.

  1. Mount a dial indicator to the front of the engine and check the camshaft end-play. Play should not exceed 0.006 in. (0.15mm).
  2.  
  3. Install the camshaft sprocket and the new bolt. Install the air pump pulley, if equipped.
  4.  
  5. Install the valve cover with a new gasket.
  6.  
  7. Connect the negative battery cable and check for leaks.
  8.  

2.6L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the valve cover.
  4.  
  5. Remove the camshaft gear retaining bolt and matchmark the distributor gear to its drive gear. Remove the distributor. Pry the distributor drive gear off of the cam gear.
  6.  
  7. Remove the cam gear from the camshaft and allow it to rest on the holder below it.
  8.  
  9. Remove the water pump pulley.
  10.  
  11. Remove the camshaft cap bolts evenly and gradually.
  12.  
  13. Remove the caps, shafts, rocker arms and bolts together as an assembly.
  14.  
  15. Remove the camshaft with the rear seal from the engine.
  16.  

To install:
  1. Install a new roll pin to the camshaft. Lubricate the camshaft and install with the rear seal in place. Install the camshaft in position so the hole in the gear will line up with the roll pin.
  2.  
  3. Install the rocker caps, shafts and arms assembly. Tighten the camshaft bearing cap bolts in the following order to 85 inch lbs. (10 Nm): No. 3, No. 2, No. 4, front cap, rear cap. Repeat the sequence increasing the torque to 175 inch lbs. (19 Nm).
  4.  
  5. Install the gear to the camshaft engaging the roll pin. Install the distributor drive gear and install the bolt and washer. Tighten the bolt to 40 ft. lbs. (54 Nm). Install the distributor.
  6.  
  7. Install the valve cover and all related parts.
  8.  

3.0L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly and valve covers.
  4.  
  5. Install auto lash adjuster retainers MD998443, or equivalent, on the rocker arms.
  6.  
  7. If removing the right side (front) camshaft, remove the distributor extension.
  8.  
  9. Remove the camshaft bearing caps but do not remove the bolts from the caps.
  10.  
  11. Remove the rocker arms, rocker shafts and bearing caps, as an assembly.
  12.  
  13. Remove the camshaft from the cylinder head.
  14.  
  15. Inspect the bearing journals on the camshaft, cylinder head and bearing caps.
  16.  

To Install:
  1. Lubricate the camshaft journals and camshaft with clean engine oil and install the camshaft in the cylinder head.
  2.  
  3. Align the camshaft bearing caps with the arrow mark (depending on cylinder numbers) and in numerical order.
  4.  
  5. Apply sealer at the ends of the bearing caps and install the assembly.
  6.  
  7. Tighten the bearing cap bolts, in the following sequence: No. 3, No. 2, No. 1 and No. 4 to 85 inch lbs. (10 Nm).
  8.  
  9. Repeat the sequence, increasing torque to 175 inch lbs. (18 Nm).
  10.  
  11. Install the distributor extension, if it was removed.
  12.  
  13. Install the valve cover and all related components.
  14.  

3.3L and 3.8L Engines

See Figures 12 and 13



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Fig. Fig. 12: Camshaft thrust plate-3.3L and 3.8L engines



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Fig. Fig. 13: Camshaft and sprocket assembly-3.3L and 3.8L engines

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine from the vehicle.
  6.  
  7. Remove the intake manifold, cylinder heads, timing chain cover and timing chain from the engine.
  8.  
  9. Remove the rocker arm and shaft assemblies.
  10.  
  11. Label and remove the pushrod and lifters.
  12.  
  13. Remove the camshaft thrust plate.
  14.  
  15. Install a long bolt into the front of the camshaft to facilitate its removal. Remove the camshaft being careful not to damage the cam bearings with the cam lobes.
  16.  

To install:
  1. Install the camshaft to within 2 in. (51mm) of its final installation position.
  2.  
  3. Install the camshaft thrust plate and 2 bolts and tighten to 10 ft. lbs. (12 Nm).
  4.  
  5. Place both camshaft and crankshaft gears on the bench with the timing marks on the exact imaginary center line through both gear bores as they are installed on the engine. Place the timing chain around both sprockets.
  6.  
  7. Turn the crankshaft and camshaft so the keys line up with the key ways in the gears when the timing marks are in proper position.
  8.  
  9. Slide both gears over their respective shafts and use a straight edge to check timing mark alignment.
  10.  
  11. Measure camshaft end-play. If not within specifications, replace the thrust plate.
  12.  
  13. If the camshaft was not replaced, lubricate and install the lifters in their original locations. If the camshaft was replaced, new lifters must be used.
  14.  
  15. Install the pushrods and rocker shaft assemblies.
  16.  
  17. Install the timing chain cover, cylinder heads and intake manifold.
  18.  
  19. Install the engine in the vehicle.
  20.  
  21. When everything is bolted in place, change the engine oil and replace the oil filter.
  22.  

If the camshaft or lifters have been replaced, add 1 pint (0.47 L) of Mopar crankcase conditioner, or equivalent when replenishing the oil to aid in break in. This mixture should be left in the engine for a minimum of 500 miles (800 km) and drained at the next normal oil change.

  1. Fill the radiator with coolant.
  2.  
  3. Connect the negative battery cable, set all adjustments to specifications and check for leaks.
  4.  

INSPECTION



  1. Inspect the camshaft bearing journals for wear or damage.
  2.  
  3. Inspect the cylinder head and check oil return holes.
  4.  
  5. Check the tooth surface of the distributor drive gear teeth of the right camshaft for wear or damage.
  6.  
  7. Check both camshaft surfaces for wear or damage.
  8.  
  9. Remove the distributor drive adaptor seal.
  10.  
  11. Check camshaft lobe height and replace if out of limit. Standard value is 1.61 in. (41mm).
  12.  

 
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