torque CHEVROLET DYNASTY 1993 Service Manual

(6) Remove Bracket bolts #2 and #3 from rear of
engine. Remove Bracket (Fig. 13).
INSTALLATION (1) Loose assemble bracket to engine.
(2) Tighten bolts #2 and #3 to 3.3 N Im (30 in. lbs.)
(Fig. 13). (3) Tighten timing belt idler pulley and tighten to
54 N Im (40 ft. lbs.) (Fig. 12).
(4) Tighten bolts 32 and #3 to 54 N Im (40 ft. lbs.)
(Fig. 13). (5) Camshaft and Crankshaft timing should be
checked at this time. Adjust as necessary following procedure outlined in
this section. (6) Install power steering pump on bracket tighten
bolts to 28 N Im (250 in. lbs.) torque (Fig. 11).
(7) Install timing belt covers. Refer to procedure
outlined in this section.
CAUTION: Do not use impact wrench on accessory
drive belt tensioner bolt. It may cause damage to
tensioner arm.
(8) Install accessory drive belt tensioner pulley
bolt finger tight. Then tighten bolt to 54 N Im (40 ft.
lbs.) torque. Install accessory drive belt, Refer to
Cooling System Group 7 for procedure.
Fig. 11 Power Steering Pump Attaching Bolts
Fig. 12 Power Steering Pump Bracket and Timing Belt Idler Bolt
Fig. 13 Power Steering Pump/Accessory Drive BeltTensioner Bracket Attaching Bolts
Ä 2.2/2.5L ENGINE 9 - 17

TIMING SYSTEM AND SEALS SERVICEÐEXCEPT TURBO III
Refer to (Fig. 1) for parts identification and torque
specifications
TIMING BELT SERVICE
(1) Remove Solid Mount Compressor Bracket. Re-
fer to procedure outlined in this section. (2) Raise vehicle on a hoist and remove right inner
splash shield (Fig. 2). (3) Remove screws retaining water pump pulley
and bolts retaining crankshaft pulley (Fig. 3) and lay
pullies aside. (4) Remove nuts holding cover to cylinder head.
Fig. 2 Right Inner Splash Shield
Fig. 3 Crankshaft and Water Pump Pulley
Fig. 1 Timing System and Seals
9 - 18 2.2/2.5L ENGINE Ä

(2) Turn camshaft until arrows on hub are inline
with No. 1 camshaft cap to cylinder headline. Small
hole (arrow Fig. 12) must be in vertical center line. (3) Install timing belt.
(4) Rotate crankshaft two full revolutions and re-
check timing.
CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.
(5) Rotate crankshaft till number 1 cylinder is at
the TDC position. (6) Put belt tension Special Tool C-4703 horizon-
tally on large hex of timing belt tensioner pulley and
loosen tensioner lock nut. (7) Reset belt tension Special Tool C-4703 index if
necessary to have axis within 15É of horizontal. (Fig.
13) (8) Turn engine clockwise from TDC two crank revo-
lutions to TDC. Do not reverse rotate crankshaft
or attempt to rotate engine using cam or acces-
sory shaft attaching screw. (9) Hold weighted wrench in position while tighten-
ing bolt on tensioner to 61 N Im (45 ft. lbs.) torque.
(10) Lower engine onto engine mount install mount-
ing bolts and tighten to specifications refer to (Fig. 3). (11) Remove jack from under engine.
(12) Inspect foam stuffer block condition and posi-
tion (Fig. 14). Stuffer block should be intact and secure
within the engine bracket tunnel. (13) Position both halves of timing belt cover to-
gether (Fig. 4). (14) Install fasteners holding cover to cylinder head
and block. Tighten fasteners to 4 N Im (40 in. lbs.)
torque. (15) Valve Timing Check; (timing belt cover in-
stalled). With number one cylinder at TDC, small hole
in sprocket must be centered in timing belt cover hole
(Fig. 12). If hole is not aligned correctly perform
procedure again. (16) Install spark plugs.
Fig. 12 Camshaft Timing
Fig. 13 Adjusting Drive Belt Tension
Fig. 14 Foam Stuffer Block Location
Ä 2.2/2.5L ENGINE 9 - 21

CYLINDER HEAD COVER AND CURTAIN
A curtain aiding air/oil separation is installed on
the cylinder head below the cylinder head cover
(Figs. 1 and 2).
REMOVAL
(1) Remove the cylinder head cover bolts (Fig. 2).
(2) Remove cylinder head cover and curtain from
cylinder head. Do not misplace the rubber bumpers
on curtain.
CLEANING
Before installation, clean cylinder head and cover
mating surfaces. Make certain the rails are flat.
CURTAIN INSTALLATION
Install curtain manifold side first with cutouts over
cam towers and contacting cylinder head floor, then
press opposite distributor side into position below cyl-
inder head rail. Curtain is retained in position with rubber
bumpers (Fig. 1).
COVER SEALING AND INSTALLATION
Before installation, clean cylinder head and cover
mating surfaces. Make certain rails are flat. (1) Install new end seals on valve cover.
(2) Apply form-in-place Mopar Silicone Rubber Ad-
hesive Sealant or equivalent gasket material to cyl-
inder head cover rail (Fig. 3). Refer to procedure
detailed in form-in-place gasket section of Standard
Service Procedures, in this Group.
Caution: Do not allow oil or solvents to contact the
timing belt as they can deteriorate the rubber and
cause tooth skipping.
(3) Install curtain, cover and end seal assembly to
head and tighten to 12 N Im (105 in.lbs.) torque.
CYLINDER HEAD COMPONENTSÐIN-VEHICLE
SERVICE
Removal and installation of cylinder head or cam-
shaft require separation of camshaft timing sprocket
from camshaft. To maintain camshaft, intermediate
shaft, and crankshaft timing during service proce-
dures, the timing belt is left indexed on the sprocket
while the assembly is suspended under light tension
(Fig. 4). When removing the sprocket from the camshaft,
you must maintain adequate tension on the sprocket
and belt assembly to prevent the belt from disengag-
ing with the intermediate or crankshaft timing
sprockets. Refer to Timing System and Seals for re-Fig. 2 Cylinder Head Cover and Curtain
Fig. 3 Cylinder Head Valve Cover Rail SealingFig. 4 Suspending Camshaft Sprocket
Ä 2.2/2.5L ENGINE 9 - 23

Camshaft bearing journals and lobe wear. Lobe
wear should not exceed .25mm (.010 inch). To mea-
sure cam lobe wear (Fig. 8), measure lobe diameter
in two places at the largest diameter (over the nose).
Take first reading with micrometer in unworn area
at the edge of the lobe. Take second reading in the
worn area where rocker arm contacts the lobe. Sub-
tract second reading from the first. The difference is
the cam lobe wear.
CAMSHAFT END PLAY
(1) Oil camshaft journals and install camshaft
without cam followers. Tighten screws to specified
torque. (2) Using a suitable tool, move camshaft as far
rearward as it will go. (3) Zero dial indicator (Fig. 9).
(4) Move camshaft as far forward as it will go.
(5) End play travel: 0.13 - 0.33mm (0.005 - 0.013
inch.). (6) Remove bearing caps and camshaft.
INSTALLATION
(1) Install cam followers in correct order as re-
moved. (2) Align camshaft bearing caps in proper sequence
with Cap No. 1 at timing belt end and Cap No. 5 at
transmission end. Arrows on Caps No. 1, 2, 3, 4
must point toward timing belt to prevent cap break-
age (Fig. 11). (3) Apply Mopar Gasket Maker to No.1 and No.5
bearing cap (Fig. 10). (4) Caps must be installed before camshaft seals
are installed.
LASH ADJUSTER (TAPPET) NOISE
A tappet-like noise may be produced from several
items. Refer to Lash Adjuster and Tappet Noise - Di-
agnosis in Standard Service Procedures, this Group.
VALVE COMPONENTS REPLACEÐCYLINDER HEAD NOT REMOVED
ROCKER ARM AND HYDRAULIC LASH ADJUSTER
REMOVAL
(1) Remove valve cover.
(2) For each rocker arm, rotate cam until base cir-
cle is in contact with rocker arm. Depress valve
spring using Special Tool C-4682 (Fig. 12) and slide
rocker arm out. Keep rocker arms in order for reas-
sembly. (3) Remove hydraulic lash adjuster.
INSTALLATION
(1) Install hydraulic lash adjusters making sure
that adjusters are at least partially full of oil. This is
indicated by little or no plunger travel when the lash
adjuster is depressed. (2) Rotate cam until base circle is in contact posi-
tion with rocker arm. Depress valve spring with Spe-
cial Tool C-4682 (Fig. 12) and slide rocker arm in
place. Keep rockers in order. It is possible for the
Fig. 9 Camshaft End Play
Fig. 10 Cam Tower Cap Sealing
Fig. 11 Camshaft Bearing Caps Installation
Ä 2.2/2.5L ENGINE 9 - 25

Cylinder Head: Top of bearing caps painted green
and O/SJ stamped rearward of oil gallery plug on end
of head. Camshaft: Barrel of camshaft painted greenand
O/SJ stamped on end of shaft.
CLEANING
Remove all gasket material from cylinder head and
block. Be careful not gouge or scratch the aluminum
head sealing surface.
INSTALLATION
CAUTION: Head bolt diameter is 11mm. These bolts
are identified with 11 on the head of the bolt. 10mm
bolts will thread into the 11mm hole but will strip the
cylinder block bolt hole .
Since the Cylinder head bolts are torqued us-
ing a new procedure they should be examined
BEFORE reuse. If the threads are necked down
the bolts should be replaced (Fig. 16) .
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. (1) Before installing the bolts the threads should be
oiled with engine oil. (2) Install both bolts in each cap finger tight, then
alternately torque each bolt to assemble the cap prop-
erly. (3) Tighten the cylinder head bolts in the sequence
shown in (Fig. 17). Using the 4 step torque turn
method, tighten according to the following values:
² First All to 61 N Im (45 ft. lbs.)
² Second All to 88 N Im (65 ft. lbs.)
² Third All (again) to 88 N Im (65 ft., lbs.)
² Fourth + 1/4 Turn Do not use a torque wrench
for this step. Bolt torque after 1/4 turn should be over 90 ft. lbs. If
not, replace the bolt. (4) Rotate dipstick tube or bracket onto stud.
Tighten bracket retaining nut to 23 N Im (200 in.
lbs.)
VALVE SERVICEÐCYLINDER HEAD REMOVED
VALVES AND VALVE SPRINGS
REMOVAL
(1) With cylinder head removed, compress valve
Fig. 15 Cylinder Head Gaskets
Fig. 16 Checking Bolts for Stretching (Necking)
Fig. 17 Cylinder Head Tightening Sequence
Fig. 14 Checking Cylinder Head Flatness
Ä 2.2/2.5L ENGINE 9 - 27

springs using Tool C-3422-B. (2) Remove valve retaining locks, valve spring re-
tainers, valve stem seals and valve springs. (3) Before removing valves, remove any burrs
from valve stem lock grooves to prevent damage
to the valve guides. Identify valves to insure instal-
lation in original location.
VALVE INSPECTION (1) Clean valves thoroughly and discard burned,
warped and cracked valves. (2) Measure valve stems for wear.
(3) If valve stems are worn more than 0.05 mm (.002
inch.) replace valve.
VALVE GUIDES
(1) Remove carbon and varnish deposits from inside
of valve guides with a reliable guide cleaner. (2) Checking Valve Guide Wear:
² Insert valve with valve head positioned 10 mm (.400
inch) above cylinder head gasket surface.
²
Move valve to and from the indicator (Fig. 17). The
total dial indicator reading should not exceed the amount
specified in (Fig. 18). Readings should be taken for length-
wise and crosswise (with respect to cylinder head) move-
ment for each valve. Ream the guides for valves with
oversize stems if dial indicator reading is excessive or if
the stems are scuffed or scored.
(3) Service valves with oversize stems and oversize
seals are available in 0.15mm, (.005 inch) 0.40mm,
(.015 inch) and 0.80mm(.031 inch) oversize. Oversize seals must be used with oversize
valves. Reamers sizes to accommodate the oversize valve
stem are shown in (Fig. 18)
(4) Slowly turn reamer by hand and clean guide thor-
oughly before installing new valve. Do not attempt to
ream the valve guides from standard directly to
0.80mm (.030 inch). Use step procedure of 0.15mm
(.005 inch), 0.40mm (.015 inch) and 0.80mm (.030 inch) so the valve guides may be reamed true in
relation to the valve seat. After reaming guides, the
seat runout should be measured and resurfaced if
necessary. Refer to Refacing Valves and Valve Seats.
Replace cylinder head if guide does not clean
up with 0.80 mm (.030 inch) oversize reamer, or if
guide is loose in cylinder head.
TESTING VALVE SPRINGS
(1) Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should be
tested. As an example, the compression length of the
spring to be tested is 33.34mm (1-5/16 inches). Turn table
of Tool C-647 until surface is in line with the 33.34mm
(1-5/16 inch) mark on the threaded stud and the zero
mark on the front. Place spring over stud on the table and
lift compressing lever to set tone device (Fig. 20). Pull on
torque wrench until ping is heard. Take reading on torque
wrench at this instant. Multiply this reading by two. This
will give the spring load at test length. Fractional mea-
surements are indicated on the table for finer adjust-
ments. Refer to specifications to obtain specified height
and allowable tensions. Discard the springs that do not
meet specifications.
Fig. 18 Checking Wear on Valve GuideÐTypical
Fig. 19 Valve Guide Specification
Fig. 20 Testing Valve Spring with Tool C-647
9 - 28 2.2/2.5L ENGINE Ä

CYLINDER HEAD AND VALVE ASSEMBLY
SERVICEÐTURBO III
CYLINDER HEAD COVER SEALING
(1) Before installation, clean cylinder head and cover
mating surfaces. Make certain rails are flat.
Caution: Do not allow oil or solvents to contact the
timing belt as they can deteriorate the rubber and
cause tooth skipping.
(2) Install covers and gasket assembly to head and
torque to 12 N Im (105 in.lbs.).
CYLINDER HEAD
REMOVAL
Refer to Intake and Exhaust Manifold Service in
Exhaust Systems and Intake Manifold Group 11 for
removal procedure for the intake and exhaust mani-
folds. (1) The Timing Belt and Solid Mount Compressor
Mount Bracket must be removed before the cylinder
head can be removed. Refer to procedure outlined in
this group for service procedures. (2) Remove cylinder head bolts.
(3) Cylinder head must be flat within 0.1mm (.004
inch) (Fig. 2).
INSTALLATION
CAUTION: The Turbo III head gasket is not the same
as any other engine head gasket (Fig. 3).
CAUTION: Head bolt diameter is 11mm. These bolts
are Unique to this engine application they are not
interchangeable with other engines.
The Cylinder head bolts are torqued using a
new procedure they should be examined BE-
FORE reuse. If the threads are necked down the
bolts should be replaced. (Fig. 4 ). 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.
Fig. 2 Checking Cylinder Head Flatness
Fig. 3 Cylinder Head Gaskets
Fig. 4 Checking Bolts for StretchingÐNecking
Fig. 1 Cylinder Head Valve Cover and Gasket As- sembly
Ä 2.2/2.5L ENGINE 9 - 31

Before installing the bolts, the threads should be
cleaned and oiled. Tighten the cylinder head bolts in the sequence
shown in (Fig. 5 ). Using the 4 step torque turn
method, tighten according to the following values:
² First All to 61 N Im (45 ft. lbs.)
² Second All to 88 N Im (65 ft. lbs.)
² Third All (again) to 88 N Im (65 ft., lbs.)
² Fourth + 1/4 Turn Do not use torque wrench
for this step.
² Bolt torque after 1/4 turn should be over 90 ft. lbs.
If not, replace the bolt. Refer to Intake and Exhaust Manifold Service in
Exhaust Systems and Intake Manifold Group 11 for
installation procedure. Refer to the Timing Belt and Solid Mount Com-
pressor Mount Bracket service procedures in this
group for installations procedures.
TIMING BELT COVER SERVICEÐTURBO III
ENGINE
REMOVAL
(1) Remove PCV tube and upper timing belt cover
screws (Fig. 1). Remove upper cover. (2) Remove accessory drive belt. Refer to Cooling
System Group 7 for procedure. (3) Raise vehicle on a hoist and remove right
wheel and inner splash shield (Fig. 2).
(4) Remove water pump pulley and crankshaft pul-
ley retaining bolts (Fig. 3), remove pulleys. (5) Remove lower accessory drive belt idler and
tensioner pulley (Fig. 4).
Fig. 1 Timing Belt Cover Screws
Fig. 5 Cylinder Head Tightening Sequence
Fig. 2 Right Inner Splash Shield
Fig. 3 Crankshaft and Water Pump Pulleys
9 - 32 2.2/2.5L ENGINE Ä

CAUTION: Do not use a impact wrench to remove
pulley bolts. (6) Remove lower timing belt cover fasteners (Fig.
1). Remove cover.
INSTALLATION (1) Raise vehicle on hoist. Install lower timing belt
cover and tighten fasteners to 12 N Im (105 in. lbs.)
torque (Fig. 4).
CAUTION: Do not use impact wrench on accessory
drive belt tensioner bolt. It may cause damage to
tensioner arm. Accessory drive belt tensioner pul-
ley bolt must be installed finger tight. (2) Install accessory drive belt tensioner pulley
bolt finger tight. Then tighten bolt to 54 N Im (40 ft.
lbs.) torque (Fig. 4). (3) Install crankshaft and water pump pulleys
(Fig. 3). (4) Install inner splash shield and wheel (Fig. 2).
(5) Install accessory drive belt. Refer to Cooling
System Group 7 for procedure. (6) Install upper timing belt cover and tighten
screws to 4 N Im (36 in. lbs.) torque. Install PCV tube
(Fig. 1).
TIMING BELT
REMOVAL
(1) Remove timing belt cover refer to timing belt
cover service of this section for procedure. (2) Lift engine with Engine Support Tool C-4852.
Separate right engine mount (Fig. 5). (3) Raise vehicle on a hoist. Remove lower acces-
sory drive belt idler pulley bracket assembly (Fig. 6). (4) Loosen timing belt tensioner, remove timing
belt and idler pulley (Fig. 6). (5) Lower vehicle
Fig. 4 Timing Belt Cover and Tensioner
Fig. 5 Right Engine MountÐTypical
Fig. 6 Remove Timing Belt
Ä 2.2/2.5L ENGINE 9 - 33