Chrysler Full-Size Vans 1989-1998 Repair Guide

Camshaft, Bearings and Lifters

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REMOVAL & INSTALLATION



Camshaft and Lifters

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

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the intake manifold.
  6.  
  7. Remove the valve covers.
  8.  
  9. Remove and label the rocker arm shafts (if equipped) or rocker arms and pivots.
  10.  
  11. Remove and label the pushrods.
  12.  
  13. Remove the lifters (tappets) as follows:
    1. Remove the yoke retainer and label the aligning yokes for each cylinder, keeping them in order to insure installation in their original locations.
    2.  
    3. Slide a hydraulic valve tappet remover/installer into the bore and remove each lifter keeping them in order to insure the installation in their original locations.
    4.  
    5. If the lifter or bore in the cylinder block is scored, ream the bore to the next oversize and replace with oversize lifters.
    6.  

  14.  
  15. Remove the timing gear cover, the camshaft and the crankshaft sprockets, and the timing chain.
  16.  
  17. Remove the distributor and lift out the oil pump and distributor driveshaft.
  18.  



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Fig. Fig. 1: Exploded view of a set of tappets (lifters), aligning yoke, and yoke retainer



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Fig. Fig. 2: Remove the bolts that hold the yoke retainer to the engine block



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Fig. Fig. 3: Lift the yoke retainer off of the engine block



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Fig. Fig. 4: Remove the aligning yoke for each lifter you are servicing, noting its location



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Fig. Fig. 5: Inspect the lifter for wear after removing; also inspect the bore for wear



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Fig. Fig. 6: The camshaft, as seen through the top of the engine block



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Fig. Fig. 7: 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 (on 5.2L and 5.9L engines).
  2.  



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Fig. Fig. 8: The camshaft thrust plate is located on the front of the engine block, under the timing chain camshaft sprocket

  1. Install a long bolt into the front of the camshaft and remove the camshaft, being careful not to damage the cam bearings with the cam lobes.
  2.  
  3. See camshaft bearing information if replacing camshaft and bearings.
  4.  

To install:
  1. 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.
  2.  
  3. Insert the camshaft into the engine block within 2 in. (51mm) of its final position in the block.
  4.  
  5. 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.
  6.  
  7. Position the suitable tool against the rear side of the cam gear and be careful not to damage the cam lobes.
  8.  
  9. Replace the camshaft thrust plate. 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.
  10.  
  11. Install the timing chain and sprockets, timing gear cover, vibration damper, and pulley.
  12.  
  13. To install the lifters:
    1. Lubricate the lifters.
    2.  
    3. Install the lifters in their original locations if installing the old ones.
    4.  
    5. Insure 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.  

  14.  
  15. Install the pushrods, rocker arms and pivots or the rocker shafts (if equipped), and valve covers.