torque CHEVROLET DYNASTY 1993 Service Manual

(12) Recheck belt tension, adjust if necessary.
(13) Torque rocker arm shafts in sequence shown
(Fig. 13) to 12 N Im (105 in. lbs.) then to 24 N Im (210
in. lbs.). (14) Install valve covers, spark plugs, ignition cables
and ignition cable cover. (15) Install air cleaner fresh air duct.
(16) Raise vehicle. Install lower timing belt cover
and accessory drive belt tensioner pulley. Refer to
procedure in this section. (17) Lower vehicle. Install right engine mount (Fig.
5). (18) Inspect foam stuffer block condition and posi-
tion (Fig. 14). Stuffer block should be intact and secure
within the engine bracket tunnel. (19) Install upper timing belt cover and PCV tube.
Refer to procedure in this section. (20) Install accessory drive belt. Refer to procedure
in this section.
SERVICING OIL SEALS
Refer to servicing oil seals in this group for proce-
dures. To service the intake cam seal (Turbo III) the
right engine mount must be removed. Refer to
engine mount removal of this Group.
Fig. 13 Rocker Arm ShaftÐInstallation
Fig. 14 Foam Stuffer Block Location
Fig. 11 Camshafts and Crankshaft Timing Marks
Fig. 12 Belt Tension Gauge Location
Ä 2.2/2.5L ENGINE 9 - 35

cap and a crankshaft cheek, using care not to dam-
age any bearing surface. Do notloosen main bearing
cap. (2) Use a feeler gauge between number three
thrust bearing and machined crankshaft surface to
determine end play.
CRANKSHAFT BEARING CLEARANCE
(1) Refer to Measuring Main, Connecting Rod
Bearing Clearance in Standard Service Procedures.
Refer to (Fig. 10) for specifications.
CAUTION: Do not rotate crankshaft or the Plasti-
gage maybe smeared.
(2) Install the main bearing shells with the lubri-
cation groove in the cylinder block (Fig. 12). The 1, 2, 4 and 5 main bearings are full groove to pro-
vide full time oiling to the connecting rod. Only
the number 3 is half-groove.
(3) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block tab
slots. (4) Oil the bearings and journals and install crank-
shaft. (5) Install main bearing cap No. 1 on timing belt
end. (6) Install main bearing cap No. 5 on transmission
end. Since the main bearing 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. 15).
Fig. 9 Checking Crankshaft End Play
Fig. 10 Crankshaft Specifications
Fig. 11 Checking Crankshaft Oil Clearance with Plastigage
Fig. 12 Installing Main Bearing Upper Shell
9 - 44 2.2/2.5L ENGINE Ä

Necking can be checked by holding a scale or straight
edge against the threads or by running a M11 x 1.50
nut the full length of the thread. If all the threads
do not contact the scale or if the nut does not run
down smoothly the bolt should be replaced. (7) Before installing the bolts the threads should be
oiled with engine oil. (8) Install both bolts in each cap finger tight, then
alternately torque each bolt to assemble the cap prop-
erly. (9) Tighten the bolts to 41 N Im plus 1/4 turn (30
ft.lbs. plus 1/4 turn). (Fig. 14)
BALANCE SHAFTS
2.2L Turbo III and 2.5L engines are equipped with
two counter rotating balance shafts installed in a
carrier attached to the lower crankcase (Fig. 1). The shafts are interconnected through gears. These
gears are driven by a short chain from the crank-
shaft, to rotate at two times crankshaft speed. This
counterbalances certain engine reciprocating forces.
REMOVAL
Refer to Engine Lubrication and Timing System
and Seals Service of this group for removal procedure
of necessary components to repair balance shafts.
(1) Remove chain cover, guide and tensioner (Fig.
16). Also see Carrier Assembly Removal for service
procedures requiring only temporary relocation of as-
sembly. (2) Remove balance shaft gear and chain sprocket
retaining screws and crankshaft chain sprocket torx
screws. Remove chain and sprocket assembly. (Fig.
17) (3) Remove gear cover retaining stud (double
ended to also retain chain guide). Remove cover and
balance shaft gears (Fig. 18). (4) Remove carrier rear cover and balance shafts.
(Fig. 19). (5) Remove six carrier to crankcase attaching bolts
to separate carrier (Fig. 1).
Fig. 16 Chain Cover, Guide and Tensioner
Fig. 13 Main Bearing Caps
Fig. 14 Installing Main Bearing Caps
Fig. 15 Checking Bolts For Stretching (Necked down)
Ä 2.2/2.5L ENGINE 9 - 45

INSTALLATION
(1) Lubricate distributor drive gear when installing.
(2) Apply Mopar Gasket Maker as shown in (Fig.
25) and install intermediate shaft retainer. (3) Install retaining screws and torque to 12 N
Im
(105 in. lbs.).
INTERMEDIATE SHAFT BUSHING SERVICE
(1) Remove front bushing using Special Tool
C-4697-2 with Special Tool Handle C-4171 (Fig. 26). (2) Install front bushing using Special Tool
C-4697-1 and Special Tool Handle C-4171 until tool
is flush with block. (3) Remove rear bushing using Special Tool
C-4686-2 and Special Tool Handle C-4171 (Fig. 27). (4) Install rear bushing using Special Tool
C-4686-1 and Special Tool Handle C-4171 until tool
is flush with block.
Fig. 23 Removing/Installing Intermediate Shaft Sprocket
Fig. 24 Intermediate Shaft Retainer
Fig. 25 Intermediate Shaft Retainer Sealing
Fig. 26 Intermediate Shaft Bushing, Front
Fig. 27 Intermediate Shaft BushingÐRear
Fig. 28 Intermediate Shaft Journal Specifications
9 - 48 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

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

LEFT SIDE MOUNT
(1) Raise vehicle on hoist and remove left front
wheel. (2) Remove inter splash shield.
(3) Support the transmission with a transmission
jack. (4) Remove the insulator thru bolt from the mount.
(5) Remove the transmission mount fasteners and
remove mount. (6) Reverse removal procedure for installation. En-
sure that the slide tube is seated into the rail
bracket guides. Refer to (Fig. 3) for bolt tightening
specifications. (7) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.
ENGINE MOUNT RUBBER INSULATORS
Insulator location on (right side) and transmission
bracket (left side) are adjustable to allow right/left
drive train adjustment in relation to drive shaft as-
sembly length. Check and reposition right engine mount insulator
(left engine mount insulator is floating type and will
adjust automatically (Fig. 3). Adjust drive train posi-
tion, if required, for the following conditions:
² Drive shaft distress: See Driveshafts in Suspen-
sion, Group 2.
² Any front end structural damage (after repair).
² Insulator replacement.
ENGINE MOUNT INSULATOR ADJUSTMENT
(1) Remove the load on the engine motor mounts
by carefully supporting the engine and transmission
assembly with a floor jack. (2) Loosen the right engine mount insulator yoke
screw and two turns on yoke nut, then loosen the
front engine mount bracket to front crossmember
screws and nuts. Left engine mount insulator is sleeved over
shaft and long support bolt to provide lateral
movement adjustment with engine weight re-
moved or not. (3) Pry the engine right or left as required to
achieve the proper drive shaft assembly length. See
Drive Shaft in Suspension Group 2 for driveshaft
identification and related assembly length measur-
ing. (4) Tighten right engine mount insulator yoke nut
to 102 N Im (75 ft. lbs.). Then tighten front engine
mount screws and nuts to 54 N Im (40 ft. lbs.) and
center left engine mount insulator. (5) Recheck drive shaft length.
ENGINE ASSEMBLY
REMOVAL
(1) Disconnect battery.
(2) Mark hood position at hinges and remove hood. (3) Drain cooling system. Refer to Cooling System
Group 7 for draining procedure. (4) Disconnect all electrical connections.
(5) Remove coolant hoses from radiator and en-
gine. (6) Remove radiator and fan assembly.
(7) See Fuel System Group 14, For procedures to
release fuel pressure, disconnect fuel lines and accel-
erator cable. (8) Remove air cleaner assembly.
(9) Hoist vehicle and drain engine oil.
(10) Remove air conditioning compressor mounting
bolts and set compressor aside. (11) Disconnect exhaust pipe at manifold.
(12) Remove transmission inspection cover and
mark flex plate to torque converter position. (13) Remove screws holding torque converter to
flex plate and attach C-clamp on bottom of converter
housing to prevent torque converter from coming out. (14) Remove power steering pump mounting bolts
and set pump aside. (15) Remove two lower transmission to block
screws. (16) Remove starter.
(17) Lower vehicles and disconnect vacuum lines
and ground strap. (18) Install transmission holding fixture.
(19) Attach engine lifting hoist and support en-
gine. (20) Remove upper transmission case to block
bolts. (21) See Engine Mounting in (Fig. 2) and separate
mount/insulators as follows: (a) Mark RIGHT insulator on right yoke and en-
gine plate supports. Remove insulator to rails
screws. (b) Remove FRONT engine mount through bolt
and nut.
Fig. 3 Left Insulator Movement
Ä 3.0L ENGINE 9 - 69

(c) Remove LEFT insulator through bolt from in-
side wheelhouse or insulator bracket to transmis-
sion screws.
(22) Remove engine.
INSTALLATION
(1) Attach hoist and lower engine into engine com-
partment. (2) Align engine mounts and install but do not
tighten until all mounting bolts have been installed.
Tighten bolts to torque specified in (Fig. 2). (3) Install transmission case to cylinder block,
tighten bolts to 102 N Im (75 ft. lbs.) torque.
(4) Remove engine hoist and transmission holding
fixture. (5) Remove C clamp from torque converter hous-
ing. Align flex plate to torque converter and install
mounting screws. Tighten to 75 N Im (55 ft. lbs.)
(6) Install transmission inspection cover.
(7) Connect exhaust system at manifold.
(8) Install starter.
(9) Install power steering pump and air condition-
ing compressor. For belt installation Refer to Acces-
sory Belt Drive in Cooling System Group 7. (10) Lower vehicle and connect all vacuum lines.
(11) Connect all electrical connections including
ground strap. (12) Connect fuel lines and accelerator cable. (13) Install radiator and fan assembly. Connect fan
motor electrical lead. Install radiator hoses. Fill cool-
ing system. Refer to Cooling System Group 7 for fill-
ing procedure. (14) Fill engine crankcase with proper oil to cor-
rect level. (15) Install hood.
(16) Connect battery.
(17) Start engine and run until operating temper-
ature is reached. (18) Adjust transmission or linkage if necessary.
ACCESSORY DRIVE BELT SERVICE
REMOVAL
(1) Loosen Adjusting Lock Nut (Fig. 6).
(2) Turn adjusting jack screw counterclockwise to
reduce belt tension. Remove belt. (3) Inspect drive belt for wear and damage (Fig. 5).
(4) Installation: Adjust belt tension to 5/16 deflec-
tion between pulleys (Fig. 6). (5) Install breaker bar into 1/2 square opening in
tensioner. (6) Rotate tensioner clockwise to remove and in-
stall belt (Fig. 7).
Fig. 4 Accessories Mounting Brackets
9 - 70 3.0L ENGINE Ä

INSTALLATION
(1) Place camshaft sprocket on camshaft.
(2) Install bolt and washer to camshaft. Using
Spanner Tool MB990775 hold camshaft sprocket and
torque bolt to 95 N Im (70 ft. lbs.) (Fig. 15).
TIMING BELT TENSIONER
(1) Install timing belt tensioner and tensioner
spring. (2) Hook spring upper end to water pump pin and
lower end to tensioner bracket with hook out (Fig. 16).
(3) Turn timing belt tensioner counter-clockwise full
travel in adjustment slot and tighten bolt to tempo-
rarily hold this position (Fig. 17).
INSTALLATIONÐTIMING BELT
(1) Install timing belt on crankshaft sprocket first
and while keeping belt tight on tension side (Fig. 14)
install belt on the front (radiator side) camshaft
sprocket. (2) Then, install on the water pump pulley and on
the rear camshaft sprocket and finally on the timing
belt tensioner. (3) Apply rotating force to the front camshaft
sprocket in opposite direction to tension the belt ten-
sion side, check that all timing marks are lined up (Fig.
14). (4) Install crankshaft sprocket flange (Fig. 12).
(5) Loosen tensioner bolt and allow spring to tension
timing belt. (6) Turn crankshaft two full turns in clockwise di-
rection. Turn smoothly and in clockwise direction
ONLY. (7) Again line up the timing marks on the sprockets
and tighten the timing belt tensioner locking bolt to 25
N Im (250 in. lbs.) torque.
(8) Reassembly belt covers, engine bracket, insula-
tor, crankshaft pulleys, accessories and accessory drive
belts in reverse order.
Fig. 15 Camshaft Sprockets
Fig. 16 Timing Belt Tensioner
Fig. 17 Positioning Belt Tensioner
9 - 74 3.0L ENGINE Ä

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