Ram B1500, B2500, B3500, 1999-2003

Distributor

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NOTE
The 3.7L, 4.7L, 5.7L and 8.0L engines do not use a distributor.

Installation



Timing Disturbed
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Set the engine at Top Dead Center (TDC) of the No. 1 cylinder compression stroke.
  4.  
  5. Install the distributor, clamp and bolt.
  6.  
  7. Rotate the distributor so that the rotor aligns with the No. 1 cylinder mark on the Camshaft Position (CMP) sensor. Tighten the clamp bolt to 17 ft. lbs. (23 Nm).

    Click image to see an enlarged view

    Fig. Distributor rotor alignment-3.9L, 5.2L and 8.0L engines

  8.  
  9. Install or connect the following:

    CMP sensor connector
     
    Distributor cap
     
    Air cleaner tube
     
    Negative battery cable
     

  10.  
  11. The final distributor position must be set with a scan tool. Follow the instructions supplied by the scan tool manufacturer.
  12.  

3.9L, 5.2L And 5.9L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Set the engine at Top Dead Center (TDC) of the No. 1 cylinder compression stroke.
  4.  
  5. Install the distributor, clamp and bolt.
  6.  
  7. Rotate the distributor so that the rotor aligns with the No. 1 cylinder mark on the Camshaft Position (CMP) sensor. Tighten the clamp bolt to 17 ft. lbs. (23 Nm).

    Click image to see an enlarged view

    Fig. Distributor rotor alignment-3.9L, 5.2L and 5.9L engines

  8.  
  9. Install or connect the following:

    CMP sensor connector
     
    Distributor cap
     
    Air cleaner tube
     
    Negative battery cable
     
    Engine cover
     

  10.  
  11. The final distributor position must be set with a scan tool. Follow the instructions supplied by the scan tool manufacturer.
  12.  

Timing Not Disturbed
  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    The rotor will rotate clockwise as the gears engage.

  2.  
  3. Position the rotor slightly counterclockwise of the matchmark made during removal.
  4.  
  5. Install the distributor.
  6.  
  7. Align the distributor housing and intake manifold matchmarks and check that the distributor housing matchmark and rotor are also aligned.
  8.  
  9. Install or connect the following:

    Distributor housing clamp and bolt. Tighten the bolt to 17 ft. lbs. (23 Nm).
     
    CMP sensor connector
     
    Distributor cap
     
    Air cleaner tube
     
    Negative battery cable
     

  10.  

3.9L, 5.2L And 5.9L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    The rotor will rotate clockwise as the gears engage.

  2.  
  3. Position the rotor slightly counterclockwise of the matchmark made during removal.
  4.  
  5. Install the distributor.
  6.  
  7. Align the distributor housing and intake manifold matchmarks and check that the distributor housing matchmark and rotor are also aligned.
  8.  
  9. Install or connect the following:

    Distributor housing clamp and bolt. Tighten the bolt to 17 ft. lbs. (23 Nm).
     
    CMP sensor connector
     
    Distributor cap
     
    Air cleaner tube
     
    Engine cover
     
    Negative battery cable
     

  10.  

Removal & Installation




WARNING
Before removing the distributor, be sure you understand the purpose and use of matchmarking the distributor for installation. Otherwise, special equipment may be necessary to reset the ignition timing. Conventional timing lights cannot be used to set ignition timing.

  1. Remove the splash shield, if equipped.
  2.  
  3. Remove the air cleaner assembly and connecting tubes if necessary for access.
  4.  
  5. On V-8 engines, remove the throttle body and plenum.
  6.  
  7. Disconnect the distributor low tension wires at the connector.
  8.  
  9. Disconnect the high-tension lead from the coil.
  10.  
  11. Some setups may require disconnecting the spark plug wires from the cap to allow removal. If this is the case, mark each wire before disconnecting.
  12.  
  13. Remove the screws or unfasten the clips that secure the cap and remove it.
  14.  
  15. The engine need not be specially positioned to remove the distributor, but if there is any chance at all that the crankshaft might be moved after the distributor is removed, it will be best to remove it after the No. 1 cylinder is set to Top Dead Center (TDC) on the compression stroke .
  16.  
  17. Proceed as follows:
    1. The No. 1 cylinder is the FRONT cylinder on 2.5L engines and the FRONT LEFT cylinder on V-6 and V-8 engines.
    2.  
    3. TDC can be achieved by slowly rotating the engine and noting when the index mark on the crankshaft harmonic balancer lines up with the "0" or "TDC" mark on the timing plate, but you must get the cylinder on the compression stroke. Refer to the next step.
    4.  
    5. With the TDC marks aligned, check the distributor rotor. It should be pointing at the No. 1 cylinder terminal of the cap. If not, turn the crank 360º and try again.
    6.  
    7. The compression stroke can also be determined by feeling for pressure at the spark plug hole as the engine is rotated. If you can't feel any pressure, turn the crankshaft 360º and try again.
    8.  

  18.  


NOTE
Another way to find TDC on the compression stroke is to use a clever little tool known as a "TDC whistle" available at many auto parts stores. Threaded into the plug hole, the whistle will sound as the compression rises and the piston reaches TDC.

  1. At this point, check that the rotor is pointing to the "CYL NO. 1" mark on the camshaft position sensor mounting plate (if fitted).
  2.  
  3. After the engine is correctly positioned, proceed with distributor removal as follows.
  4.  
  5. Matchmark the position of the distributor housing relative to the engine block.
  6.  
  7. Matchmark the position of the distributor shaft or rotor relative to the distributor housing. Remember that both alignments will have to be restored when the distributor is installed.
  8.  
  9. Remove the distributor hold-down bolt and clamp.
  10.  
  11. Carefully lift the distributor assembly out of the engine. Note that the rotor will turn as the driven gear unmeshes with the drive gear. When clear of the drive gear, matchmark the position of the rotor. This will be the starting position when reinstalling the distributor.
  12.  

3.9L, 5.2L And 5.9L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner tube
     
    Distributor cap
     
    Camshaft Position (CMP) sensor connector
     

  4.  
  5. Matchmark the distributor housing and the rotor.
  6.  
  7. Matchmark the distributor housing and the intake manifold.
  8.  
  9. Remove the distributor.

    Click image to see an enlarged view

    Fig. Crankshaft pulley and timing chain cover marks aligned at Top Dead Center (TDC)

  10.  


WARNING
Base ignition timing is not adjustable on any engine. Distributors do not have built in centrifugal or vacuum assisted advance. Base ignition timing and timing advance are controlled by the Powertrain Control Module (PCM). Because a conventional timing light can not be used to adjust distributor position after installation, note position of distributor before removal.

  1. Remove the engine cover.
  2.  
  3. Remove air cleaner assembly.
  4.  
  5. Disconnect negative cable from battery.
  6.  
  7. Remove distributor cap from distributor (two screws). Mark the position of distributor housing in relationship to engine or dash panel. This is done to aid in installation.
  8.  
  9. Before distributor is removed, the number one cylinder must be brought to the Top Dead Center (TDC) firing position, as follows:
    1. Attach a socket to the Crankshaft Vibration Damper mounting bolt.
    2.  
    3. Slowly rotate engine clockwise, as viewed from front, until indicating mark on crankshaft vibration damper is aligned to 0 degree (TDC) mark on timing chain cover.

      Click image to see an enlarged view

      Fig. Alignment marks (1) between the timing chain cover (2) and crankshaft vibration damper (3)

    4.  
    5. The distributor rotor should now be aligned to the CYL. NO. 1 alignment mark (stamped) into the camshaft position sensor. If not, rotate the crankshaft through another complete 360 degree turn. Note the position of the number one cylinder spark plug cable (on the cap) in relation to rotor. Rotor should now be aligned to this position.

      Click image to see an enlarged view

      Fig. CMP sensor alignment mark (1) in relation to the rotor (2) and distributor (3)

    6.  

  10.  
  11. Disconnect Camshaft Position (CMP) sensor wiring harness from main engine wiring harness.
  12.  
  13. Remove distributor rotor from distributor shaft.
  14.  
  15. Remove distributor hold-down clamp bolt and clamp.

    Click image to see an enlarged view

    Fig. Remove the distributor hold-down clamp bolt (1) and clamp (2), then remove the distributor.

  16.  
  17. Remove the distributor from vehicle.
    WARNING
    Do not crank engine with distributor removed. Distributor/crankshaft relationship will be lost.

  18.  

Timing Disturbed

Use this procedure if the crankshaft was moved after the distributor assembly was removed.

  1. Position the No. 1 cylinder at TDC on the compression stroke. Refer to the "Removal" procedure, above, for instructions on doing this.
  2.  
  3. Check the condition of the driven gear.
  4.  
  5. Check that the distributor shaft rotates without binding.
  6.  
  7. Check the condition of the O-ring. Replace if damage. Smear the O-ring with a bit of grease to ease assembly.
  8.  
  9. You will be installing the distributor so that the rotor points at the No. 1 cylinder terminal on the distributor cap (see Firing Orders). Remember also that the tongue at the base of the distributor shaft must engage the slot in the oil pump shaft. This shaft can be turned with a screwdriver, if needed, to position it to accept the distributor shaft. On the 2.5L engine, the oil pump shaft slot should be just slightly CCW of the 10 o'clock position. On other engines, "eyeball" the pump shaft before attempting to install the distributor.
  10.  
  11. On 2.5L engines the rotor should be locked in position by using a 3 / 16 " pin inserted into the plastic ring through the "2.5" alignment hole. New distributors have a plastic pin already in place.
  12.  
  13. Carefully lower the assembly into the mounting hole. As the gears mesh, the rotor will begin to turn. Remember that the tongue at the end of the distributor shaft must engage the slot in the oil pump shaft.
  14.  
  15. When the assembly is seated, align the distributor housing and engine block matchmarks. The rotor should point to the No. 1 cylinder terminal on the distributor cap. On some engines the camshaft position sensor "CYL NO. 1" mark will aid in alignment: the rotor should align with the notch.
  16.  
  17. If no alignment marks were made, align the centerline of the distributor base slot with the hold-down bolt hole.
  18.  
  19. Don't forget to remove the locating pin on 2.5L engines.
  20.  
  21. The remainder of the procedure is the reverse of removal. Install and tighten the hold-down bolt to 17 ft. lbs. (22 Nm).
  22.  



Click image to see an enlarged view

Fig. Exploded view of distributor assembly-typical



Click image to see an enlarged view

Fig. Removing splash shield screws-2.5L engines



Click image to see an enlarged view

Fig. TDC alignment marks-typical. Some engines may use "0" instead of "TDC"



Click image to see an enlarged view

Fig. Distributor clamp bolt-V-8 shown



Click image to see an enlarged view

Fig. Removing the distributor assembly



Click image to see an enlarged view

Fig. Oil pump shaft slot alignment for distributor installation-2.5L shown. Slot alignment must be taken into account on all engines



Click image to see an enlarged view

Fig. TDC alignment marks-typical. Some engines may use "0" instead of "TDC"



Click image to see an enlarged view

Fig. Rotor pointing to "CYL NO. 1" alignment mark-V-6, V-8

Timing Not Disturbed

If the engine was not rotated after the distributor was removed, successful installation can be achieved by aligning the matchmarks. Proceed as follows:

  1. Check the condition of the driven gear.
  2.  
  3. Check that the distributor shaft rotates without binding.
  4.  
  5. Check the condition of the O-ring. Replace if damage. Smear the O-ring with a bit of grease to ease assembly.
  6.  
  7. Position the rotor to align with the last matchmark made as the assembly was removed.
  8.  
  9. Carefully lower the assembly into the mounting hole. As the gears mesh, the rotor will begin to turn. Remember that the tongue at the end of the distributor shaft must engage the slot in the oil pump shaft.
  10.  
  11. When fully seated, check alignments: line up the engine block and distributor housing marks. The rotor and distributor housing mark should also align.
  12.  
  13. Install and tighten the hold-down bolt to 17 ft. lbs. (22 Nm).
  14.  
  15. The remainder of the installation procedure is the reverse of removal.
  16.  

 
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