Chrysler Full-Size Trucks 1989-1996 Repair Guide

Distributor

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REMOVAL



See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10

  1. Remove the splash shield (if equipped).
  2.  



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Fig. Fig. 1: Use a Phillips screwdriver to remove the retaining screws for the distributor pickup lead and splash shield-2.5L engine



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Fig. Fig. 2: Once detached, remove the splash shield on 2.5L engines to gain access to the distributor

  1. If necessary, remove the air cleaner assembly and connecting tubes.
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  3. Unplug the pickup lead wire connector(s) from the wiring harness.
  4.  



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Fig. Fig. 3: Unscrew the distributor cap retaining screws-2.5L engine

  1. Leaving the distributor wires connected, unfasten the clips or screws that retain the distributor cap and lift off the cap.
  2.  



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Fig. Fig. 4: Rotor alignment mark-V6 and V8 engines



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Fig. Fig. 5: Remove the distributor hold-down clamp-V6 and V8 engines



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Fig. Fig. 6: Remove the cap with the wires connected-2.5L engine shown



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Fig. Fig. 7: Remove the ignition rotor by simply lifting it out-2.5L engine

If insufficient clearance is obtained by removing the cap with the wires still connected, all or some of the spark plug wires should be tagged and disconnected from the cap for better access.



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Fig. Fig. 8: Unbolt and remove the distributor hold-down clamp



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Fig. Fig. 9: Install the ignition rotor by aligning the grooves-V6 and V8 engines



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Fig. Fig. 10: When fully detached, lift the distributor out of the vehicle

  1. Bump the engine around until the rotor is pointing at No. 1 cylinder firing position, with the timing marks on the front case and crank pulley are aligned. Disconnect the negative battery cable from the battery.
  2.  
  3. Mark the distributor body and the engine block to indicate the position of the distributor in the block. Mark the distributor body to indicate the rotor position. These marks are used as guides when installing the distributor.
  4.  
  5. Remove the distributor hold-down bolt and bracket. Carefully lift the distributor from the engine. The shaft may rotate slightly as the distributor is removed. Make a note of where the movement stops. That is where the rotor must point when the distributor is reinstalled into the block.
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INSTALLATION



Ignition Timing Undisturbed
  1. If the crankshaft has not been rotated while the distributor was removed from the engine, use the reference marks made before removal to correctly position the distributor in the block. The shaft may have to be rotated slightly to engage the intermediate shaft gear (V6 and V8).
  2.  
  3. Install the distributor while holding the rotor in position, allowing it to move only enough to engage the slot in the drive gear.
  4.  
  5. Install pickup coil leads and distributor cap. Make sure all high tension wires are firmly snapped in cap towers. Install distributor hold-down clamp screw and tighten to 200 inch lbs. (22.5 Nm).
  6.  

Ignition Timing Disturbed

See Figures 11 and 12

Perform this procedure if the crankshaft was rotated or otherwise distributed (for example, during engine rebuilding) after the distributor was removed.

  1. Rotate the crankshaft until the No. 1 cylinder is at Top Dead Center (TDC) of the compression stroke. The simplest way to do this is to remove the spark plug from the No. 1 cylinder and place your thumb over the hole. Slowly turn the engine by hand in the normal direction of rotation until compression is felt at the hole.
  2.  

Other ways to check for TDC of the compression stroke: The most fail-safe (and time consuming) way is to remove the cylinder head cover and crank the engine until both the intake and exhaust valves are closed. Or you could use a compression gauge to determine that as you rotate the engine, the piston is coming up on compression. Also there are specialty tools available that screw in the sparkplug hole (like a compression tester) and whistle as you rotate the engine into its compression stroke. In all cases, verify the timing mark is at 0 degrees when you believe you have found TDC.

  1. Ensure that the indicating mark on the crankshaft vibration damper is aligned to the 0 degree (TDC) mark on the timing chain cover.
  2.  



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Fig. Fig. 11: Distributor hold-down bolt location-2.5L engine

  1. Clean the distributor mounting at the engine and distributor base. Lightly oil the rubber O-ring seal on the distributor housing.
  2.  



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Fig. Fig. 12: Distributor hold-down bolt location-V6 and V8 engines

  1. Hold the distributor over the mounting pad on the cylinder block so that the distributor body flange coincides with the mounting pad and the rotor points to the No. 1 cylinder firing position.
  2.  
  3. Install the distributor while holding the rotor in position, allowing it to move only enough to engage the slot in the drive gear.
  4.  
  5. Install pickup coil leads and distributor cap. Make sure all high tension wires are firmly snapped in cap towers. Install distributor hold-down clamp screw and tighten to 200 inch lbs. (22.5 Nm).
  6.  

 
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