Chrysler Full-Size Trucks 1997-2000 Repair Guide

Camshaft, Bearings and Lifters

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REMOVAL & INSTALLATION



2.5L, 3.9L, 5.2L, 5.9L, 8.0L
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fan, shrouds and radiator.
  4.  
  5. Unbolt the A/C compressor and place it aside.
  6.  
  7. Remove the intake manifold.
  8.  
  9. Remove the valve covers.
  10.  
  11. Remove and label the rocker arms and pivots.
  12.  
  13. Remove and label the pushrods.
  14.  
  15. On 2.5L engines, remove the tappets.
  16.  
  17. On other models,
    1. Remove the yoke retainer and label the aligning yokes for each cylinder, keeping them in order to ensure installation in their original locations.
    2.  

  18.  



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Fig. Exploded view of a set of tappets (lifters), aligning yoke, and yoke retainer-5.9L engine shown



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Fig. Remove the bolts that hold the yoke retainer to the engine block-5.2 engine shown



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Fig. Lift the yoke retainer off of the engine block



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Fig. Remove the aligning yoke for each lifter you are servicing, noting its location

  1. Slide a hydraulic valve tappet remover/installer into the bore and remove each lifter keeping them in order to ensure the installation in their original locations.
  2.  
  3. If the lifter or bore in the cylinder block is scored, ream the bore to the next oversize and replace with oversize lifters.
  4.  



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Fig. Inspect the lifter for wear after removing; also inspect the bore for wear



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Fig. The camshaft, as seen through the top of the engine block

  1. Remove the vibration damper, timing case cover, and timing chain and sprockets.
  2.  
  3. Remove the distributor and lift out the oil pump and distributor driveshaft. Mark position first to ease reassembly.
  4.  



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Fig. The distributor drive gear is located in the distributor bore and is driven by the camshaft; the distributor must first be removed in order to access the drive gear

  1. Remove the camshaft thrust plate, if fitted.
  2.  
  3. On the 2.5L engine, remove the camshaft.
  4.  
  5. On "V" engines, install a long bolt into the front of the camshaft and remove the cam with caution.
  6.  



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Fig. The camshaft thrust plate is located on the front of the engine block, under the timing chain camshaft sprocket

  1. See camshaft bearing section if replacing camshaft and bearings.
  2.  

To install:

  1. If a new camshaft is fitted, all the tappets should be replaced as well.
  2.  
  3. Prior to installation, lubricate the camshaft lobes and bearings journals. It is recommended that 1 pt. of Crankcase Conditioner be added to the initial crankcase oil fill.
  4.  
  5. Insert the camshaft into the engine block within 2 in. (51mm) of its final position in the block.
  6.  
  7. Have an assistant support the camshaft with a suitable tool to prevent the camshaft from contacting the plug in the rear of the engine block.
  8.  
  9. Position the suitable tool against the rear side of the cam gear and be careful not to damage the cam lobes.
  10.  
  11. Replace the camshaft thrust plate, if fitted. If camshaft end-play exceeds 0.010 in. (0.254mm), install a new thrust plate. It should be 0.002-0.006 in. (0.051-0.152mm) with the new plate.
  12.  
  13. Install the timing chain and sprockets, timing gear cover, vibration damper, and pulley.
  14.  
  15. To install the lifters:
    1. Lubricate the lifters.
    2.  
    3. Install the lifters in their original locations if installing the old ones.
    4.  
    5. Ensure that the oil feed hole in the side of the lifter faces up (away from the crankshaft).
    6.  
    7. Install the yokes and yoke retainer. Tighten the bolts to 200 inch lbs. (23 Nm).
    8.  

  16.  
  17. The remainder of the procedure is the reverse of removal.
  18.  

4.7L Engine

WARNING
Cams can be removed after the cylinder head covers are taken off if special tool 8350 (timing chain wedge) is available. If not, removal of the timing chain cover is required in order to reset chain tensioners.

  1. Remove the cylinder head covers.
  2.  
  3. alilgn the crankshaft damper mark with the TDC mark on the cover and both cam sprocket V8 marks to the 12 o'clock position.
  4.  
  5. Mark secondary timing chains relative to the sprocket.
  6.  
  7. Loosen, but Do NOT remove, the cam sprocket bolts.
  8.  
  9. Use timing chain wedge 8350 between the timing chain strands to keep the tensioners from extending when the sprocket are removed.
  10.  
  11. Remove the sprocket. See procedures above.
  12.  
  13. Starting at the ends of the cam and working inward, loosen the cam bearing cap bolts 1 / 2 turn at a time until loose.
  14.  
  15. Mark the rocker arms for position.
  16.  
  17. Remove the cam bearing caps and camshaft.
  18.  



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Fig. Cam bearing bolt tightening sequence-4.7L engine

To install:

  1. Lube all parts with clean engine oil.
  2.  
  3. Install the left side camshaft so the sprocket dowel is near the 1 o'clock position.
  4.  
  5. Tighten the bearing cap bolts in 1 / 2 turn increments, starting in the middle and working out (see illustration). Final torque in 100 inch lbs. (11 Nm).
  6.  
  7. Assemble and install the timing chain sprocket assembly as outlined in the relevant section.
  8.  

Diesel Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the cylinder head covers.
  4.  
  5. Remove the rocker pedestal and arm assemblies.
  6.  
  7. Remove the pushrods.
  8.  
  9. Remove the drive belt.
  10.  
  11. Drain the cooling system. Remove the fan assembly, radiator and all related parts.
  12.  
  13. Remove the crankshaft pulley.
  14.  
  15. Remove the front gear cover.
  16.  
  17. Remove the fuel pump.
  18.  
  19. Insert the special dowels into the pushrod holes and onto the top of each lifter. When properly installed, the dowels can be used to hold the tappets up securely. Wrap rubber bands around the top of the dowels to prevent them from dropping down.
  20.  



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Fig. Insert the tappet dowels to hold the tappets up securely-diesel engine

  1. Rotate the crankshaft to align the crankshaft to camshaft timing marks.
  2.  



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Fig. Align the crankshaft to the camshaft on the diesel engine as shown

  1. Remove the bolts from the thrust plate.
  2.  



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Fig. Insert the thrust plate bolts on the diesel engine in the location shown

  1. Remove the camshaft and thrust plate.
  2.  
  3. Press the gear from the camshaft and remove the key.
  4.  

To install:

  1. Install the key on the camshaft.
  2.  
  3. Heat the camshaft gear to 250ºF (121ºC) for 45 minutes. Lubricate the gear mount surface with Lubriplate 105®. Install the gear to the camshaft with the timing marks facing away from the shaft.
  4.  
  5. Lubricate the camshaft bores, lobes, journals and thrust washer with Lubriplate 105®.
  6.  


NOTE
Do NOT push the camshaft in too far or it may dislodge the plug in the rear of the camshaft bore, possibly creating a leak.

  1. Install the camshaft and thrust washer so the "E" timing mark on the injection pump gear aligns with the "C" timing mark on the camshaft gear and the timing mark on the crankshaft gear align with those on the camshaft gear.
  2.  
  3. Install the thrust washer bolts and tighten to 18 ft. lbs. (24 Nm).
  4.  
  5. Check the endplay of the camshaft. The specification is 0.006-0.010 in. (0.152-0.254mm).
  6.  
  7. Check the backlash of the camshaft gear. The specification is 0.003-0.013 in. (0.080-0.330mm).
  8.  
  9. Install the tappets and pushrods.
  10.  
  11. Install the rocker pedestal and arm assemblies.
  12.  
  13. Install the front cover and crankshaft pulley.
  14.  
  15. Install the drive belt and fan assembly.
  16.  
  17. Install the fuel pump.
  18.  
  19. Adjust the valves.
  20.  
  21. Install the cylinder head covers.
  22.  
  23. Connect the negative battery cable and check for leaks.
  24.  

INSPECTION



Camshaft Lobe Lift (3.9L, 5.2L, 5.9L Engines)

NOTE
Check the lift of each lobe in consecutive order and make a note of the reading.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the valve cover(s).
  6.  
  7. Remove the intake manifold.
  8.  
  9. Remove the rocker arm stud nut or fulcrum bolts, fulcrum seat and rocker arm.
  10.  
  11. Make sure the pushrod is in the valve tappet socket. Install a dial indicator so that the actuating point of the indicator is in the push rod socket (or the indicator ball socket adapter is on the end of the pushrod) and in the same plane as the pushrod movement.
  12.  
  13. Disconnect the I terminal and the S terminal at the starter relay. Install an auxiliary starter switch between the battery and S terminals of the start relay.
  14.  
  15. Crank the engine with the ignition switch off. Turn the crankshaft over until the tappet is on the base circle of the camshaft lobe. At this position, the push rod will be in its lowest position.
  16.  
  17. Zero the dial indicator. Continue to rotate the crankshaft slowly until the push rod is in the fully raised position.
  18.  
  19. Compare the total lift recorded on the dial indicator with the specification shown on the Camshaft Specification chart.
  20.  
  21. To check the accuracy of the original indicator reading, continue to rotate the crankshaft until the indicator reads zero. If the left on any lobe is below specified wear limits listed, the camshaft and the valve lifter operating on the worn lobe(s) must be replaced.
  22.  
  23. Remove the dial indicator and auxiliary starter switch.
  24.  
  25. Install the rocker arm, fulcrum seat and stud nut or fulcrum bolts. Check the valve clearance. Adjust if required.
  26.  
  27. Install the intake manifold.
  28.  
  29. Install the valve cover(s).
  30.  
  31. Install the engine cover.
  32.  
  33. Connect the negative battery cable.
  34.  

Camshaft Bearings
  1. Remove the engine.
  2.  
  3. Remove the camshaft, flywheel and crankshaft.
  4.  
  5. Push the pistons to the top of the cylinder.
  6.  
  7. Remove the camshaft rear bearing bore plug.
  8.  
  9. Remove the camshaft bearings with a bearing removal tool. Select the proper size expanding collet and back-up nut and assemble on the mandrel. With the expanding collet collapsed, install the collet assembly in the camshaft bearing and tighten the back-up nut on the expanding mandrel until the collet fits the camshaft bearing.
  10.  
  11. Assemble the puller screw and extension (if necessary) and install on the expanding mandrel. Wrap a cloth around the threads of the puller screw to protect the front bearing or journal.
  12.  
  13. Tighten the pulling nut against the thrust bearing and pulling plate to remove the camshaft bearing. Be sure to hold a wrench on the end of the puller screw to prevent it from turning.
  14.  



Click image to see an enlarged view

Fig. Removal/installation of the camshaft bearings using a bearing installer/remover tool kit

  1. To remove the front bearing, install the puller from the rear of the cylinder block.
  2.  

To install:

  1. Position the new bearings at the bearing bores, and press them in place. Be sure to center the pulling plate and puller screw to avoid damage to the bearing. Failure to use the correct expanding collet can cause severe bearing damage. Align the oil holes in the bearings with the oil holes in the cylinder block before pressing bearings into place.
  2.  
  3. Install the camshaft rear bearing bore plug.
  4.  
  5. Install the camshaft, crankshaft, flywheel and related parts.
  6.  
  7. Install the engine.
  8.  

 
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