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.
  16.  
  17. Install the intake manifold.
  18.  
  19. Install the distributor and oil pump driveshaft.
  20.  
  21. Install the distributor.
  22.  
  23. Check the engine oil level.
  24.  


WARNING
Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

  1. Connect the negative battery cable.
  2.  
  3. Start the engine and check for leaks.
  4.  
  5. Install the engine cover.
  6.  

Camshaft Bearings

See Figure 9

  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.  

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. 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.

Click image to see an enlarged view

Fig. Fig. 9: 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.  

Inspection

Camshaft Lobe Lift

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.  

 
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