Chrysler Full-Size Vans 1967-1988 Repair Guide

Engine Overhaul Tips


Most engine overhaul procedures are fairly standard. In addition to specific parts replacement procedures and specifications for your individual engine, this section is also a guide to acceptable rebuilding procedures. Examples of standard rebuilding practice are given and should be used along with specific details concerning your particular engine.

Competent and accurate machine shop services will ensure maximum performance, reliability and engine life. In most instances it is more profitable for the do-it-yourself mechanic to remove, clean and inspect the component, buy the necessary parts and deliver these to a shop for actual machine work.

On the other hand, much of the rebuilding work (crankshaft, block, bearings, piston rods, and other components) is well within the scope of the do-it-yourself mechanic's tools and abilities. You will have to decide for yourself the depth of involvement you desire in an engine repair or rebuild.


The tools required for an engine overhaul or parts replacement will depend on the depth of your involvement. With a few exceptions, they will be the tools found in a mechanic's tool kit (see General Information And Maintenance of this repair guide). More in-depth work will require some or all of the following:

A dial indicator (reading in thousandths) mounted on a universal base
Micrometers and telescope gauges
Jaw and screw-type pullers
Valve spring compressor
Ring groove cleaner
Piston ring expander and compressor
Ridge reamer
Cylinder hone or glaze breaker
Engine stand

The use of most of these tools is illustrated in this guide. Many can be rented for a one-time use from a local parts jobber or tool supply house specializing in automotive work.

Occasionally, the use of special tools is called for. See the information on Special Tools and the Safety Notice before substituting another tool.


Procedures and specifications are given in this guide for inspecting, cleaning and assessing the wear limits of most major components. Other procedures such as Magnaflux® and Zyglo® can be used to locate material flaws and stress cracks. Magnaflux® is a magnetic process applicable only to ferrous materials. The Zyglo® process coats the material with a fluorescent dye penetrant and can be used on any material.

Checking for suspected surface cracks can be more readily made using spot check dye. The dye is sprayed onto the suspected area, wiped off and the area sprayed with a developer. Cracks will show up brightly.


Aluminum has become extremely popular for use in engines, due to its low weight. Observe the following precautions when handling aluminum parts:

Never hot tank aluminum parts (the caustic hot tank solution will eat the aluminum.
Remove all aluminum parts (identification tag, etc.) from engine parts prior to the tanking.
Always coat threads lightly with engine oil or anti-seize compounds before installation, to prevent seizure.
Never overtorque bolts or spark plugs especially in aluminum threads.

Stripped threads in any component can be repaired using any of several commercial repair kits (Heli-Coil®, Microdot®, Keen-serts®, etc.).

When assembling the engine, any parts that will be exposed to frictional contact must be prelubed to provide lubrication at initial start-up. Any product specifically formulated for this purpose can be used, but engine oil is not recommended as a prelube in most cases.

When semi-permanent (locked, but removable) installation of bolts or nuts is desired, threads should be cleaned and coated with Loctite® or another similar, commercial non-hardening sealant.


See Figures 1 through 5

Click image to see an enlarged view

Fig. Fig. 1: Damaged bolt hole threads can be replaced with thread repair inserts

Click image to see an enlarged view

Fig. Fig. 2: Standard thread repair insert (left), and spark plug thread insert

Click image to see an enlarged view

Fig. Fig. 3: Drill out the damaged threads with the specified size bit. Be sure to drill completely through the hole or to the bottom of a blind hole

Click image to see an enlarged view

Fig. Fig. 4: Using the kit, tap the hole in order to receive the thread insert. Keep the tap well oiled and back it out frequently to avoid clogging the threads

Click image to see an enlarged view

Fig. Fig. 5: Screw the insert onto the installer tool until the tang engages the slot. Thread the insert into the hole until it is 1/4-1/2 turn below the top surface, then remove the tool and break off the tang using a punch