light CHEVROLET DYNASTY 1993 Service Manual

(5) Turn crankshaft until number one cylinder is
at Top Dead Center (TDC). The timing marks on the
chain sprocket should line up with the parting line
on the left side of number one main bearing cap.
(Fig. 21). (6) Place chain over crankshaft sprocket so that
the nickel plated link of the chain is over the timing
mark on the crankshaft sprocket (Fig. 21). (7) Place balance shaft sprocket into the timing
chain (Fig. 17) so that the timing mark on the
sprocket (yellow dot) mates with the (lower) nickel
plated link on the chain (8) With balance shaft keyways pointing up 12
o'clock) slide the balance shaft sprocket onto the nose
of the balance shaft. The balance shaft may have to
be pushed in slightly to allow for clearance.
THE TIMING MARK ON THE SPROCKET,
THE (LOWER) NICKEL PLATED LINK, AND
THE ARROW ON THE SIDE OF THE GEAR
COVER SHOULD LINE UP WHEN THE BAL-
ANCE SHAFTS ARE TIMED CORRECTLY. (9) If the sprockets are timed correctly install the
balance shaft bolts and tighten to 28 N Im (250 in.
lbs.). A wood block placed between crankcase and
crankshaft counterbalance will prevent crankshaft
and gear rotation.CHAIN TENSIONING
(1) Install chain tensioner loosely assembled.
(2) Position guide on double ended stud making sure
tab on the guide fits into slot on the gear cover. Install
and tighten nut/washer assembly to 12 N Im (105 in.
lbs.). (3) Place a shim 1mm (.039 inch) thick x 70mm (2.75
inch) long or between tensioner and chain. Push ten-
sioner and shim up against the chain. Apply firm
pressure (5.5 to 6.6 lbs.) directly behind the ad-
justment slot to take up all slack (chain must have
shoe radius contact as shown in Fig. 22). (4) With the load applied, tighten top tensioner bolt
first, then bottom pivot bolt. Tighten bolts to 12 N Im
(105 in. lbs.), Remove shim. (5) Install carrier covers and tighten screws to 12
N Im (105 in. lbs.).
INTERMEDIATE SHAFT SERVICE
REMOVAL
CAUTION: The oil pump and distributor must be
removed before attempting to remove intermediate
shaft.
(1) Hold sprocket with Tool C-4687 and adaptor Tool
C-4687-1 when removing or installing screw (Fig. 23). (2) See Timing System and Seals for intermediate
seal removal and replacement. (3) Remove retainer screws (Fig. 24).
(4) Remove retainer and lay aside.
(5) Remove intermediate shaft.Fig. 21 Balance Shaft Timing
Fig. 22 Chain Tension Adjustment
Ä 2.2/2.5L ENGINE 9 - 47

PISTON PINS
DISASSEMBLY Turbo III engine piston-pin-connecting rod assem-
blies should not be disassembled unless a malfunc-
tion is present or a damaged assembly component is
to be replaced. WARNING: APPROVED SAFETY GLASSES
MUST BE WORN DURING PISTON LOCK
RING REMOVAL OR INSTALLATION TO PRE-
VENT POSSIBLE INJURY FROM FLYING
PARTS.
(1) Carefully, remove piston pin lock rings from
piston, using a small screwdriver in removal notch
(Fig. 10). (2) Discard used lock ring.
(3) Following lock ring removal, attempt to slide
pin out of piston. If pin does not slide out freely by
hand;
² Check for burr on outer edge of lock ring groove. If
one is present, carefully scrape burr away with a
knife or other hand tool, being careful not to damage
lock ring retaining groove. (4) Slide out piston pin to complete disassembly.
(5) Inspect components, discard damaged or exces-
sively worn parts refer to specifications (Fig. 12). If a
piston is replaced, a new pin should be used.
PISTON PINS
REASSEMBLY
(1) Different lock rings are used for turbocharged
engine applications. Consult the Service Note, pro- vided with the lock ring service package, to select
the correct lock rings from the package for your ap-
plication.
(2) Carefully, install one NEWlock ring with gap
towards piston top in lock ring groove. Do not rein-
stall used lock rings. (3) Position connecting rod and slide in lightly oil
piston pinch (4) Install second NEWlock ring with gap towards
piston top in lock ring groove, use small screwdriver
if needed.
CAUTION: BOTH lock rings must be FULLY
SEATED in lock ring grooves or engine failure will
occur.
(5) Check piston pin end play pin movement be-
tween lock rings in assembly.
PISTON RINGÐREMOVAL
(1) ID mark on face of upper and intermediate pis-
ton rings must point toward piston crown. (2) Using a suitable ring expander, remove upper
and intermediate piston rings (Fig. 13). (3) Remove the upper oil ring side rail, lower oil
ring side rail and then oil ring expander from piston. (4) Clean ring grooves of any carbon deposits.
Fig. 11 Engine Piston PinsÐTurbo III, Naturally Aspirated and Flexible Fuel Vehicles
Fig. 12 Piston Pin Specifications
Fig. 13 Piston RingsÐRemoving and Installing
9 - 52 2.2/2.5L ENGINE Ä

CONNECTING RODS
(1) Follow procedure specified in the Standard Ser-
vice Procedures Section for Measuring Main Bearing
Clearance and Connecting Rod Bearing Clearance
(Fig. 22). Refer to specifications (Fig. 25).
CAUTION: Do not rotate crankshaft or the Plastic-
Gage may be smeared.
The rod bearing bolts should be examined be-
fore reuse. If the threads are necked down the
bolts should be replaced (Fig. 23). Necking can be checked by holding a scale or straight
edge against the threads. If all the threads do not
contact the scale the bolt should be replaced.
(2) Before installing the nuts the threads should be
oiled with engine oil.
(3) Install nuts on each bolt finger tight than alter-
nately torque each nut to assemble the cap properly.
(4) Tighten the nuts to 54 N Im PLUS 1/4 turn (40 ft.
lbs. PLUS 1/4 turn) for N/A engines Do not use a
torque wrench for last step. and 68 NIm (50 ft. lbs.)
for Turbo III engines. (5) Using a feeler gauge, check connecting rod side
clearance (Fig. 24). Refer to connecting rod specifica-
tions (Fig. 25).
ENGINE CORE PLUGS
REMOVAL
Using a blunt tool such as a drift or a screwdriver
and a hammer, strike the bottom edge of the cup plug
(Fig. 26). With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig. 26).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious en-
gine problems.
INSTALLATION
Thoroughly clean inside of cup plug hole in cylinder
block or head. Be sure to remove old sealer. Lightly coat
inside of cup plug hole with sealer. Make certain the
new plug is cleaned of all oil or grease. Using proper
drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5mm
(.020 inch) inside the lead-in chamfer (Fig. 26).
It is in not necessary to wait for curing of the seal-
ant. The cooling system can be refilled and the vehi-
cle placed in service immediately.
Fig. 24 Checking Connecting Rod Side Clearance
Fig. 25 Connecting Rod Specifications
Fig. 26 Core Hole Plug Removal
Fig. 23 Checking Bolts for Stretching (Necked)
Ä 2.2/2.5L ENGINE 9 - 55

OIL PUMP REMOVAL
(1) Remove two (2) screws holding oil pump to cyl- inder block assembly (Fig. 5).
INSTALLATION
(1) Apply Mopar Gasket Maker to pump body-to-
block interface (machined surface). (2) Lubricate oil pump rotor & shaft and drive
gear. (3) Turn crankshaft and intermediate shaft until
markings on sprockets are in line (arrows Fig. 6).
(4) Slot in oil pump shaft mustbe parallel to cen-
ter line of crankshaft when intermediate shaft and
crankshaft are properly timed (Fig. 7).
(5) Install pump full depth and rotate back and
forth slightly to ensure proper positioning and align-
ment through full surface contact of pump and block
machined interface surfaces (Fig. 5).
Fig. 4 Oil Pick-Up
Fig. 5 Oil Pump Assembly
Fig. 6 Crankshaft and Intermediate Shaft Timing
Fig. 7 Oil Pump Shaft Alignment
Ä 2.2/2.5L ENGINE 9 - 59

3.0L ENGINE INDEX
page page
Accessory Drive Belt Service ................ 70
Auto Lash Adjuster ....................... 75
Camshaft Service ........................ 76
Checking Engine Oil Pressure ............... 93
Crankshaft and Cylinder Block, Assembly Service . 86
Cylinder Block ........................... 89
Cylinder Head ........................... 78
Cylinder Head and Camshaft Service ......... 75
Engine Assembly ......................... 69
Engine Lubrication System ................. 91
Engine Mounts .......................... 68 Engine Specifications
..................... 95
General Information ....................... 66
Oil Filter and Bracket ..................... 94
Oil Pan ................................ 92
Oil Pump Service ........................ 92
Piston and Connecting Rod Assembly Service . . . 82
Timing Belt InspectionÐIn Vehicle ............ 72
Timing Belt Service ....................... 72
Valve Service ........................... 80
GENERAL INFORMATION
ENGINE IDENTIFICATION NUMBER OR CODE
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 1). BLOCK: The cylinder block is a light weight de-
sign created by reducing thickness in many parts
and a short 10 mm (3/8 inch) block skirt. High rigid-
ity is provided with ribs cast in the outer wall, a full
length water jacket, and a monoblock or beam type, main bearing cap. This single unit four bearing cap
is designed to control vibration of the cylinder block
partition walls.
CRANKSHAFT: A six throw, five weight crank-
shaft is supported by four main bearings with num-
ber three being the thrust bearing. The six separate
connecting rod throws pins reduce torque fluctua-
tions while a torsional vibration damper is used to
control torsion caused vibration of the crankshaft.
Rubber lipped seals are used at front and rear. The
front seal is retained in the oil pump case and the
rear is retained in a block-mounted housing.
3.0L ENGINE
9 - 66 3.0L ENGINE Ä

PISTONS: Are aluminum alloy with a steel strut,
short height, and thin wall so as to be autothermic
and light weight. The piston head with valve re-
cesses, in combination with the cylinder head, forms
a compact spherical head with clearance for total
valve lift with pistons at top dead center. The piston
skirt, top and second ring lands are finished to a ta-
pered roughness for oil retention and high resistance
to scuffing. Piston pins, press-fitted into place, join
the pistons to the connecting rods. CYLINDER HEAD: The alloy cylinder heads fea- ture cross-flow type intake and exhaust ports. Valve
guides and inserts are hardened cast iron. Valves of
heat resistance steel are arranged i
n a V with each
camshaft on center. To improve combustion speed the
chambers are a compact spherical design with a
squish area of approximately 30 percent of the piston
top area. The cylinder heads are common to either
cylinder bank by reversing the direction of installa-
tion. CAMSHAFTS: Two overhead camshafts provide
valve actuation, one front (radiator side of cylinder
bank) and one rear. The front camshaft is provided
with a distributor drive and is longer. Both cam-
shafts are supported by four bearing journals, thrust
for the front camshaft is taken at journal two and
the rear at journal three. Front and rear camshaft
driving sprockets are interchangeable. The sprockets
and the engine water pump are driven by a single
notched timing belt. ROCKER ARM SHAFTS: The shafts are retained
by the camshaft bearing journal caps. Four shafts are
used, one for each intake and exhaust rocker arm as-
sembly on each cylinder head. The hollow shafts pro-
vide a duct for lubricating oil flow from the cylinder
head to the valve mechanisms. ROCKER ARMS: Are of light weight die-cast
with roller type follower operating against the cam
shaft. The valve actuating end of the rocker arms are
machined to retain hydraulic lash adjusters, elimi-
nating valve lash adjustment. VALVES: Are made of heat resistant steel and are
further treated to resist heat. VALVE SPRINGS: Are especially designed to be
short. The valve spring wire cross-section is oval
SPECIFICATIONS
Fig. 1 Engine Identification
Ä 3.0L ENGINE 9 - 67

(9) Mark support assembly to engine bracket if as-
sembly is to be used again. Separate engine mount
insulator from engine mount bracket (Fig. 10). Raise
engine slightly. (10) Remove engine mount bracket (Fig. 10).
(11) Remove timing belt covers (Fig. 11).
TIMING BELT INSPECTIONÐIN VEHICLE
(1) Remove the upper front outer timing belt cover
by loosening the three attaching bolts. (Fig. 11). (2) Inspect both sides of the timing belt drive &
back. Replace belt if any of the following conditions
exist.
² Hardening of back rubber back side is glossy with-
out resilience and leaves no indent when pressed
with fingernail.
² Cracks on rubber back.
² Cracks or peeling of canvas.
² Cracks on rib root.
² Cracks on belt sides.
² Missing teeth.
² Abnormal wear of belt sides. The sides are normal
if they are sharp as if cut by a knife (Fig. 12). (3) If none of the above conditions are seen on the
belt, the belt cover can be reinstalled.
TIMING BELT SERVICE
REMOVAL
(1) Mark belt running direction for installation
(Fig. 14). (2) Loosen timing belt tensioner bolt (Fig. 16) and
remove timing belt. (3) Remove crankshaft sprocket flange shield (Fig.
9).
CAMSHAFT SPROCKETS
REMOVAL
(1) Hold camshaft sprocket with Spanner Tool
MB990775 loosen and remove bolt and washer (Fig.
15). (2) Remove camshaft sprocket from camshaft.
Fig. 10 Right Engine Mount and Engine Mount Bracket
Fig. 11 Timing Belt Covers
Fig. 12 Timing Belt Inspection
9 - 72 3.0L ENGINE Ä

CYLINDER HEAD AND CAMSHAFT SERVICE
CYLINDER HEAD COVER REMOVE
(1) Remove air cleaner assembly.
(2) Disconnect battery and relocate spark plug
wires. (3) Remove vacuum connections.
(4) Remove rocker cover screws and remove cover
(Fig. 2).
INSTALL
(1) Clean cylinder head and cover mating surfaces.
Install new gasket. (2) See (Fig. 2) and apply sealant such as Mopar
Silicone Rubber Adhesive Sealant to cover ends. (3) Install cover and tighten cover bolt washer and
gasket assembly to 10 N Im (88 in. lbs.).
AUTO LASH ADJUSTER
The automatic lash adjusters are precision units in-
stalled in machined openings in the valve actuating
ends of the rocker arms. Do not disassemble the auto
lash adjuster.
FUNCTION CHECK
Check auto adjusters for free play by inserting a
small wire through the air bleed hole in the rocker
arm and VERY LIGHTLY pushing the auto ad-
juster ball check down (Fig. 3). While lightly holding
the check ball down move the rocker up and down to
check for free play. If there is no play replace the ad-
juster.
Fig. 1 Cylinder Head-Camshaft-Valves
Fig. 2 Rocker Cover
Ä 3.0L ENGINE 9 - 75

side has a 3mm diameter oil passage hole from the
cylinder head. The exhaustsidedoes not have this
oil passage (Fig. 7). (1) Check the rocker arm mounting portion of the
shafts for wear or damage. Replace if heavily dam-
aged or worn. (2) Check oil holes for clogging with small wire,
clean as required (Fig. 7).
REASSEMBLE
(1) Align the camshaft bearing caps with arrows
(depending on cylinder bank) directed as shown in
(Fig. 8) and in numerical order. Identify number one bearing cap number one and
number four caps are similar (Fig. 9). (2) Install rocker shafts so that bearing cap num-
ber one with end notches positioned as shown in Fig-
ure 9 that the machined portion of the rocker shaft is
facing down. (3) Insert attaching bolts to retain assembly.
ASSEMBLE ROCKER ASSEMBLY
Install the rocker arms, bearing caps and springs.
Springs are the same and can be used at all
locations on the rocker arm shafts (Figs. 8 and 10).
Insert bolts in number four bearing cap to retain
assembly.
INSTALL ROCKER ARM SHAFT ASSEMBLY
(1) Apply Mopar Silicone Rubber Adhesive Sealant
at bearing cap ends as shown in (Fig. 8). (2) Install the rocker arm shaft assembly making
sure that the arrow mark on the bearing cap and the
arrow mark on the cylinder head are in the same
direction (Fig. 8). The direction of arrow marks on the front and
rear assemblies are opposite to each other. (3) Tighten bearing cap bolts in the following order
to 10 N Im (85 in. lbs.). First #3, then #2, #1 and #4.
(4) Repeat step 3 increasing the torque to 20 N Im
(180 in.lbs.). (5) Install distributor drive adaptor assembly (Fig.
11).
CAMSHAFT OIL SEAL SERVICEÐ ENGINE OUT OF VEHICLE
(1) Apply light coat of engine oil to the camshaft oil
seal lip. (2) Install the oil seal using camshaft oil seal in-
staller tool MD998713 (Fig. 12).
CAMSHAFT END SEAL (PLUG) SERVICEÐ IN VEHICLE SERVICE
(1) Remove air cleaner assembly from engine.
(2) Use a small punch and a hammer, carefully
remove cam plug from cylinder head. (3) Clean the area of the cylinder head where the
new cam plug will be installed. (4) Apply a light coating of Mopar Silicone Rubber
Adhesive Sealant to the outer diameter of the NEW
cam plug. (5) Using a suitable installing tool and a hammer,
Fig. 7 Rocker Arm Shaft Identification
Fig. 8 Camshaft Bearing Caps Position
Fig. 9 Number One Camshaft Bearing Cap
Ä 3.0L ENGINE 9 - 77

INSTALLATION
(1) Clean surfaces of head and block, install head
gasket over locating dowels. (2) Install head on locating dowels.
(3) Install 10mm allen hex head bolts with wash-
ers. (4) Tighten bolts in the order shown in (Fig. 16).
When tightening the cylinder head bolts, tighten
gradually, working in two or three steps and finally
tighten to specified torque of 108 N Im (80 ft. lbs.).
VALVE SERVICE
VALVE AND VALVE SPRINGS
(1) With suitable valve spring compressor, remove
spring retainer locks, retainer, valve spring, spring
seat and valve (Fig. 17). (2) Remove valve stem seals with suitable tool
(Fig. 18). Do not reuse valve stem seals.
VALVES
(1) Check valve stem tip for pitting or depression
at point A (Fig. 19). (2) Check for wear and ridge wear at Point B.
(3) Check for even contact (at face center) with
valve seat, Point C. (4) Check margin. Replace valve if margin is out of
specification (Fig. 20). (5) Check valve guide height (Fig. 20).
(6) Measure valve stem to guide clearance. Refer
to specification (Fig. 21). (7) Measure Valve spring free length and square-
ness (Fig. 22). Refer to (Fig. 21) for specifications.
VALVE SEAT INSPECTION
Inspect the valve seat with Prussian blue to deter-
mine where the valve contacts the seat. To do this,
coat valve seat LIGHTLYwith Prussian blue then
set valve in place. Rotate the valve with light pres-
sure. If the blue is transferred to the center of valve
face, contact is satisfactory. If the blue is transferred
to top edge of the valve face, lower valve seat with a
15 degrees stone. If the blue is transferred to the bot-
tom edge of valve face raise valve seat with a 65 de-
gree stone. (1) Install valve spring seat.
Fig. 17 Remove Valves
Fig. 18 Remove Valve Stem Seals
Fig. 19 Valve Inspection
Fig. 20 Valve Guide Height
9 - 80 3.0L ENGINE Ä