Chrysler Full-Size Trucks 1989-1996 Repair Guide

Distributor Cap and Rotor

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REMOVAL & INSTALLATION



See Figures 1, 2, 3 and 4

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the distributor cap retaining screws and spark plug wires from the cap. If there is no wire retainer, be sure to tag all wires before disconnecting them from the distributor cap. Tagging wires will help preserve the proper firing order and greatly ease cap installation.
  4.  

An alternate way to change caps is to situate the new cap next to the old (with the wires still attached) and simply swap the wires one-by-one from the old cap to the new cap in the exact same order.

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Fig. Fig. 1: Remove the coil wire from the center of the cap



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Fig. Fig. 2: Remove the old cap with its wires attached, then transfer the wires one-by-one

  1. On 2.5L engines, remove the distributor splash shield.
  2.  
  3. On V6 and V8 engines, unfasten the retaining clips and lift off the cap assembly.
  4.  
  5. Scribe or paint a mark on the edge of the distributor housing to indicate the position of the rotor. This will serve as a reference upon reinstallation.
  6.  



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Fig. Fig. 3: White correction fluid makes an excellent quick paint for marking the rotor position



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Fig. Fig. 4: Remove the rotor from the shaft

Although most rotors can only be installed in one direction, it is still wise to note the position of the rotor before removal to assure proper installation and ignition timing.

  1. Remove the rotor attaching screw(s), if equipped, and note the position of the rotor, then remove the rotor from the distributor.
  2.  

To install:
  1. Install the rotor facing in the direction noted earlier, then if applicable, secure the rotor using the attaching screw(s).
  2.  
  3. Install the cap to the distributor assembly and secure using the housing retainers.
  4.  
  5. Install the spark plug wires and retainer to the cap. If no wire retainer is used, carefully connect the wires to the cap as tagged during removal.
  6.  
  7. Connect the negative battery cable.
  8.  

INSPECTION



See Figures 5 and 6

Remove the distributor cap and wipe it clean with a dry lint-free cloth. Visually inspect the cap for cracks, carbon paths, broken towers, or damaged rotor buttons. Also check for white deposits on the inside (caused by condensation entering through cracks). Replace any cap that has charred or eroded terminals. The inside flat surface of a terminal end (faces toward the rotor) will indicate some evidence of erosion from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip.



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Fig. Fig. 5: Inspect the outside of the cap for any of the kinds of damage or wear that would warrant replacement



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Fig. Fig. 6: Look carefully at the inside of the cap for signs of significant damage or wear

 
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