lug pattern CHEVROLET DYNASTY 1993 Service Manual

(14) Lower vehicle.
(15) Align the front wheels of the vehicle. Use the
procedure listed under Wheel Alignment, in the
Front Suspension Service Procedures section of this
service manual.
HUB AND BEARING ASSEMBLY
The Unit III Front Hub and Bearing (Fig. 1) is used
on all Front Wheel Drive Applications. All hub and bearing assemblies mount to the steer-
ing knuckle the same way, but very by the wheel size
on the vehicle. Vehicles equipped with 14 inch wheels
have a 4 inch wheel mounting stud pattern. Vehicles
equipped with 15 inch wheels hav e a 4 1/2 inch wheel
mounting stud pattern. If a hub and bearing assembly
needs to be replaced, be sure that the replacement
assembly has the same size wheel mounting stud
pattern as the original part.
This unit is serviced only as a complete assembly
(Fig. 1). It is mounted to the steering knuckle by four
mounting bolts that are removed from the rear of the
steering knuckle (Fig. 2).
REMOVAL
Replacement of the front (drive) hub and bearing
assembly can be done without having to remove the
steering knuckle from the vehicle. (1) Remove cotter pin, hub nut lock, and spring
washer (Fig. 3). (2) Loosen hub nut while the vehicle is on the floor
with the brakes applied (Fig. 4). The hub and drive-
shaft are splined together through the knuckle
(bearing assembly) and retained by the hub nut. (3) Raise vehicle, see Hoisting Recommendations in
Group 0 of this service manual. (4) Remove the hub nut and the washer from the
stub axle (Fig. 3). (5) Remove the wheel lug nuts, and tire and wheel
assembly from the vehicle.
Fig. 16 Install Washer and Hub Nut
Fig. 17 Tighten Hub Nut
Fig. 18 Install Spring Washer, Nut Lock, & Cotter Pin
Fig. 1 Unit III Front Hub And Bearing Assembly
2 - 20 SUSPENSION AND DRIVESHAFTS Ä

EXTERIOR LAMP SWITCHES AND HEADLAMP ALIGNMENT INDEX
page page
Headlamp Adjustment Using Alignment Screen .... 3
Headlamp Alignment ....................... 3
Headlamp Alignment Preparation .............. 3 Headlamp Dimmer Switch
................... 3
Headlamp Switch .......................... 3
HEADLAMP SWITCH
Service procedures for the headlamp switch can be
found in Group 8E, Instrument Panel and Gauges. More
information can be found in Wiring Diagrams manual.
HEADLAMP DIMMER SWITCH
The headlamp dimmer switch is incorporated into
the turn signal switch. Proper procedures can be found
in Group 8J, Turn Signal and Flashers. More informa-
tion can be found in Group 8W, Wiring Diagrams.
HEADLAMP ALIGNMENT
Headlamps can be aligned using the screen method
provided in this section. Alignment Tool C4466-A or
equivalent can also be used. Refer to instructions
provided with the tool for proper procedures. The
preferred headlamp alignment setting is 0 for the
left/right adjustment and 0 for the up/down ad-
justment.
HEADLAMP ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation. (2) Inspect and correct damaged or defective compo-
nents that could interfere with proper headlamp align-
ment. (3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is not heavily loaded.
(6) Fuel tank should be FULL. Add 2.94 kg (6.5 lbs.)
of weight over the fuel tank for each estimated gallon of
missing fuel.
HEADLAMP ADJUSTMENT USING ALIGNMENT
SCREEN
ALIGNMENT SCREEN PREPARATION (FIG. 1 AND 2)
(1) Position vehicle on a level surface perpendicular
to a flat wall 7.62 meters (25 ft) away from front of
headlamp lens. (2) If necessary, tape a line on the floor 7.62 meters
(25 ft) away from and parallel to the wall.
(3) From the floor up 1.27 meters (5 ft), tape a line on
the wall at the centerline of the vehicle. Sight along the
centerline of the vehicle (from rear of vehicle forward) to
verify accuracy of the line placement.
(4) Rock vehicle side-to-side three times to allow
suspension to stabilize. (5) Jounce front suspension three times by pushing
downward on front bumper and releasing. (6) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for up/down
adjustment reference. (7) Measure distance from the centerline of the ve-
hicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
side of vehicle centerline. Use these lines for left/right
adjustment reference.
HEADLAMP ADJUSTMENT (FIG. 3, 4, 5, 6 OR 7)
A properly aimed low beam headlamp will project the
top edge of low beam hot spot on the alignment screen
from 50 mm (2 in.) above to 50 mm (2 in.) below the
headlamp centerline. The side-to-side left edge of low
beam hot spot should be from 50 mm (2 in.) left to
50mm (2 in.) right of headlamp centerline (Fig. 1). The
preferred headlamp alignment is 0 for the
up/down adjustment and 0 for the left/right ad-
justment. The high beams on a vehicle with aero
headlamps cannot be aligned. The high beam pattern
should be correct when the low beams are aligned
properly. To adjust headlamp alignment, rotate alignment
screws to achieve the specified low beam hot spot
pattern.
CAUTION: Do not cover an illuminated headlamp for
more then 15 seconds. Lamp will overheat and burn
or melt cover.
To adjust headlamps, rotate alignment screws to
achieve the specified high intensity pattern (Fig. 1 or
2).
FOG LAMP ALIGNMENT (FIG. 8)
Prepare an alignment screen. Refer to Alignment
Screen Preparation paragraph in this section. A prop-
erly aligned fog lamp will project a pattern on the
alignment screen 100 mm (4 in.) below the fog lamp
centerline and straight ahead.
Ä LAMPS 8L - 3

(4) Hold engine sprocket with Special Tool C-4687
(with adaptor Tool C-4687-1) while removing/install-
ing screw (Fig. 8). The 2.5L Engine camshaft/inter-
mediate shaft sprockets have an off-set hub and are
identified with a six-hole pattern .
(5) Remove crankshaft seal using Special Tool
6341. Remove intermediate and camshaft seals using
Special Tool C-4679 (Fig. 10).
CAUTION: Do not nick shaft seal surface or seal
bore.
(6) Shaft seal lip surface must be free of varnish,
dirt or nicks. Polish with 400 grit paper if necessary. (7) Install engine crankshaft seal into retainer us-
ing Special Tool 6342 and 6343. Install Intermediate and Camshaft seals using Special Tool C-4680. In-
stall seals until flush (Fig. 10).
CAMSHAFT, CRANKSHAFT AND INTERMEDIATE
SHAFTS TIMING PROCEDURE
(1) Remove all spark plugs. Turn crankshaft and
intermediate shaft until markings on sprockets are
in line, see arrows (Fig. 11 ).
Fig. 9 Removing Crankshaft, Intermediate Shaft and Camshaft Oil Seal
Fig. 8 Removing/Installing Camshaft or IntermediateShaft Sprocket Screw
Fig. 10 Installing Crankshaft,Intermediate Shaft, and Camshaft Seal
Fig. 11 Crankshaft and Intermediate Shaft Timing
9 - 20 2.2/2.5L ENGINE Ä

(8) Position zipper upper half listing at index
marks on the third roof bow. Verify that start end of
zipper upper half is at the same end as the rear win-
dow half. (9) Install staples to hold zipper listing to third
roof bow (Fig. 8). (10) Position top cover hold down listing at index
marks on third roof bow. (11) Install staples to hold top cover listing to third
roof bow (Fig. 8). (12) Position stay straps at index marks on the
third roof bow. (13) Install staples to hold stay straps to third roof
bow. (14) Zip rear window into position.
(15) Fold rear of top cover, tack strips and rear
window up and over the third roof bow to the rear of
the top opening (Fig. 8). (16) Position top cover at index marks at each end
of rear tack strip. (17) Install staples to hold top cover to rear tack
strip (Fig. 6). (18) Position side and rear tack strips behind quar-
ter and deck panels. (19) Install bolts to hold side tack strips to inside
of quarter panels (Fig. 6). (20) Install bolts to hold rear tack strip to deck
panel. (21) Latch top header to windshield header and in-
spect top cover for excess wrinkling. If wrinkling is
apparent, the top cover and rear window apron must
be repositioned on the tack strips. (22) Route wire harnesses through pockets at each
side of window and connect ends to terminals on
glass. (23) Install sling well and rear section of headlin-
ing.
FOLDING TOP COVER
REMOVAL
(1) Release folding top latches and allow top cover
to relax. (2) Remove headlining.
(3) Disengage snaps holding top storage sling well
to rear deck and quarter panels. (4) Position sling well out of the way.
(5) Remove bolts holding rear tack strip to inner
deck panel. (6) Separate rear tack strip from deck panel.
(7) Remove bolts holding side tack strips to inside
of quarter panels. (8) Separate tack strips from quarter panels.
CAUTION: Cover all painted and upholstered sur-
faces to avoid damage while performing the follow-
ing operations. (9) Reposition tack strips above rear deck and
quarter panels. (10) Using a grease pencil, mark location of outer
top cover on rear tack strip to aid installation. (11) Remove staples holding top cover to rear tack
strip. (12) Fold rear of top cover, tack strips and rear
window up and over the third (rear) roof bow. (13) Unzip and separate rear window from vehicle.
(14) Mark location of top cover hold down listing
on third roof bow. (15) Remove staples holding top cover listing to
third roof bow. (16) Remove screws holding roof rail tension cable
springs to roof rear roof rail behind quarter glass
opening. (17) Pull quarter glass weatherstrips from roof rail
channels. (18) Remove screws holding roof rail channels to
roof rails. (19) Separate roof rail channels from vehicle.
(20) Separate top cover listing from adhesive on
roof rail. (21) Lower folding top to the mid point.
(22) Pull top header weatherstrip from retaining
channel. Separate first 50 mm (2 in.) of weather strip
from roof rail channels. (23) Remove screws holding weatherstrip channel
to top header. (24) Separate channel from top header.
(25) Remove staples holding top header feature
strip to top header. (26) Separate feature strip from header.
(27) Mark location or top cover on top header.
(28) Remove staples holding top cover to header.
(29) Close folding top, do not latch.
(30) Remove rubber plugs holding roof rail tension
cable ends into key-hole slots in roof rails (31) Disengage roof rail tension cables from roof
rails. (32) Pull tension cables from rear of pockets on
back of top cover. (33) Remove screws holding top cover retainer rod
to second roof bow. (34) Separate retainer rod from second roof bow.
(35) Remove screws holding top cover retainer rod
to first roof bow. (36) Separate retainer rod from first roof bow.
(37) Separate top cover from vehicle.
(38) Pull retainer rod from listing pockets on back
of top cover.
INSTALLATION
The new top cover must be trimmed to the same
size and shape as the old top cover to minimize wrin-
kling after installation. Use the rear sections of the
old top as a pattern.
23 - 90 AJ/27-BODY Ä

(1) On old top cover mark a line from the top of
the quarter glass opening to the center of rear glass
opening on each side of the top. (2) Using a suitable cutting tool, cut the rear quar-
ter sections off of old top. (3) Mark locations of old top cover on side tack
strips. (4) Remove staples holding old top cover to side
tack strips. (5) Using quarter sections cut from old top cover as
a pattern, mark lower tack strip edge of new top to
same size and shape as old top. (6) Trim excess material from new top cover.
(7) Position side tack strips under edge of new top
and align index marks. (8) Install staples 100 mm (4 in.) apart to hold top
cover to side tack strips. (9) Install retainer rod in listing pockets on back of
top cover. (10) Position top cover over top bows on vehicle
and center top cover side to side. (11) Mate retainer rod to first roof bow.
(12) Install screws to hold top cover retainer rod to
first roof bow. (13) Mate retainer rod to second roof bow.
(14) Install screws to hold top cover retainer rod to
second roof bow. (15) Route roof rail tension cables through rear of
pockets on back of top cover. (16) Connect roof rail tension cables to key-hole
slots in roof rails. (17) Install rubber plugs to hold roof rail tension
cable ends into key-hold slots in roof rails. (18) Apply suitable contact adhesive to roof rail
rear of quarter glass opening and back of top cover
hold down listing. (19) Stick top cover listing to roof rail.
(20) Place roof rail weatherstrip channel in proper
position. (21) Install screws to hold channel to roof rail.
(22) Position top cover listing at index marks on
third roof bow. (23) Install staples 10 mm (0.3 in.) apart to hold
top cover listing to third roof bow. (24) Zip rear window into position.
(25) Fold rear of top cover, tack strips and rear
window down and over the third roof bow. (26) Position top cover at index marks on rear tack
strip. (27) Install staples 100 mm (4 in.) apart to hold
top cover to rear tack strip.
CAUTION: Cover all painted and upholstered sur-
faces to avoid damage while performing the follow-
ing operations.
(28) Reposition tack strips under rear deck and
quarter panels. (29) Place side tack strips in position behind quar-
ter panels. (30) Install enough bolts to temporarily hold side
tack strips to inside of quarter panels. (31) Place rear tack strip in position behind deck
panel. (32) Install enough bolts to temporarily hold rear
tack strip to inner deck panel. (33) Close and latch folding top.
(34) Pull top cover forward over top of windshield
and hold cover material taut. (35) Mark location of froward lower edge of top
header on top cover material. (36) Release top latches and lower top to mid-
point. (37) Align marks on top material to front lower
edge of top header. (38) Verify that top cover will be wrinkle free and
aligned side to side. (39) Install staples 10 mm (0.3 in.) apart to hold
top cover to header. (40) Place top header feature strip in position un-
der top header. (41) Install staples 10 mm (0.3 in.) apart to hold
feature strip to top header. (42) Place weatherstrip channel in position under
top header. (43) Install screws to hold channel to top header.
(44) Insert top header weatherstrip into header
and roof rail channels. (45) Install screws to hold roof rail tension cable
springs to roof rear roof rail behind quarter glass
opening. (46) Close and latch top windshield header.
(47) Inspect top cover for excess wrinkling. If ex-
cess wrinkles are apparent, the top cover must be re-
positioned on the tack strips. (48) If top cover is smooth, release top header
latches to allow top cover to relax. (49) Remove bolts holding tack strips to deck and
quarter panels. (50) Install staples 10 mm (0.3 in.) apart to hold
top cover to rear and side tack strips. (51) Place side and rear tack strips in position.
(52) Install bolts to hold tack strips to deck and
quarter panels. (53) Insert quarter glass weatherstrips into roof
rail channels. (54) Place sling well into position.
(55) Engage snaps to hold sling well to rear deck
and quarter panels. Verify that drain tube is con-
nected to bottom of sling well. (56) Install headlining.
(57) Close top and latch header to windshield
header.
Ä AJ/27-BODY 23 - 91