warning CHEVROLET DYNASTY 1993 Service Manual

Wiring Diagram
Name Sheet Number
Splice F35-2 ......................... .113, 115
Splice F35-3 ............................ .114
Splice G5-1 ................ .70, 73, 77, 84, 88, 127
Splice G5-2 ........................... .81, 88
Splice G7 .......................... .21, 24, 35
Splice G9 .......................... .70, 73, 78
Splice G74 ........................ .83, 102, 104
Splice G75 ........................ .83, 102, 104
Splice K4 ............................. .21, 30
Splice K4-1 ......................... .17, 21, 29
Splice K4-2 ...............................32
Splice K4-3 ...............................27
Splice K6 ............................. .29, 30
Splice K7 .......................... .22, 26, 30
Splice K22 ............................ .26, 37
Splice K24 ...............................26
Splice L1 ........................ .129, 133, 137
Splice L7 ............................ .54, 136
Splice L7-1 ........................... .45, 49
Splice L7-2 ........................ .46, 50, 132
Splice L7-3 ............................. .130
Splice L7-4 ............................. .129
Splice L7-5 ............................. .131
Splice L7-6 .......................... .132, 136
Splice L7-7 .......................... .132, 136
Splice L33 ....................... .45, 46, 49, 50
Splice L43 ....................... .45, 46, 49, 50
Splice L50 .......................... .140, 141
Splice L61 ............... .45, 46, 49, 50, 58, 76, 78
Splice L62 .......................... .130, 131
Splice L63 .............................. .130
Splice L94 ......................... .53, 79, 81
Splice M1-1 ............ .16, 73, 77, 87, 121, 123, 125
Splice M1-2 ............... .16, 61, 77, 87, 101, 103,
117, 119, 121, 123, 125
Splice M1-4 ................... .118, 120, 124, 126
Splice M1-5 ............................. .122
Splice M1-6 ............................. .122
Splice M2 ................. .117, 119, 121, 123, 125
Splice M2-1 ......................... .118, 126
Splice P34 .............................. .116
Splice P76-1 ........................... .97, 99
Splice T13 ...............................39
Splice T16 ...............................36
Splice T24 ......................... .13, 14, 15
Splice T41 ............................ .15, 38
Splice V23 .............................. .105
Splice X13 ...............................62
Splice X15 ...............................61
Splice X60 ...............................63
Splice Z0 .......................9,11,21,25,37
Splice Z1 .................9,33,44,46,48,50,100
Splice Z1-2 ...............................68
Splice Z1-3 ........................... .59, 67
Splice Z1-4 ................. .43, 45, 47, 49, 65, 89
Splice Z1-5 .......... .14, 43, 45, 47, 49, 59, 65, 67, 89
Splice Z1-7 ...............................51Wiring Diagram
Name Sheet Number
Splice Z1-8 .......... .43, 45, 47, 49, 52, 56, 60, 90, 93
Splice Z1-9 ........... .97, 99, 109, 111, 113, 114, 115
Splice Z1-10 ...................... .100, 109, 115
Splice Z1-11 ....................... .98, 100, 109
Splice Z1-12 ................... .94, 105, 129, 140
Splice Z1-14 ............................ .129
Splice Z1-15 ......................... .129, 140
Splice Z1-16 ............................ .130
Splice Z1-17 .................. .135, 139, 141, 142
Splice Z1-18 ............................ .141
Splice Z1-19 ......................... .134, 138
Splice Z1-20 ......................... .132, 136
Splice Z1-21 ..............................98
Splice Z1-28 ................. .44, 46, 48, 50, 65, 69
Splice Z2 ................................72
Splice Z2-1 ................... .72, 77, 86, 98, 127
Splice Z3 ................. .52, 55, 66, 73, 101, 103
Splice Z3-1 ................ .52, 55, 66, 73, 121, 123
Splice Z12 ...........................9,21,33
Splice Z13 ...............................37
Splice Z14 ...............................37
Speaker Choke ..............................60
Stereo Radio ....................... .61, 62, 63, 64
Stop Lamp Switch ............................59
Switches ABS Warning Switch .........................70
A/C Blower Switch ..........................90
A/C Cycling Switch ..........................92
A/C High Pressure Switch ......................92
A/C Low Pressure Switch ......................91
Brake Switch ..............................70
Clutch Pedal Position Switch ....................14
Deck Lid Ajar Switch .................... .122, 124
Deck Lid Warning Switch ................83, 102, 104
Dimmer Switch (Slide Control) ...................51
Door Ajar Switch-Left Front .................102, 104
Door Ajar Switch-Right Front ................102, 104
Door Lock Switch ...................... .115, 116
Engine Oil Pressure Switch/Sending Unit ..........40, 41
Fog Lamp Switch ........................ .51, 55
Fuse Panel Switch ...........................51
Glove Box Lamp Switch ............101, 103, 123, 125
Headlamp ............................ .51, 55
Heated Rear Window Switch ................8,94,95
Heater Blower Switch .........................93
Horn Switch ..............................65
Ignition Switch .........................2,7,42
Intermittent Wiper Switch ......................66
Key Disarm Switch ..................... .115, 116
Left Door Illuminated Entry Switch ...............109
Left Door Master Window Lift Switch ..............111
Left Window Lift Switch ..................... .110
Lift Gate Ajar Switch ................. .102, 104, 125
Lower Power (Top) Switch .....................96
Lumbar Switch ........................... .114
Manual Transmission Back-Up Lamp Switch ..........14
Mercury Switch ............................16
Ä WIRING DIAGRAMS AG-AJ BODY 8W - 539

WIRING DIAGRAMS AP BODY D-P
ALPHABETICAL INDEX
Wiring Diagram
Name Sheet Number
ABS Hydraulic Modulator Unit .....................27
ABS Pump Motor Relay .........................27
ABS System Controller ................... .26, 27, 28
ABS System Relay ............................28
ABS Yellow Light Relay .........................28
A/C and Heater System ..................... .47, 48
A/C Cycling Switch ..........................48
A/C High Pressure Switch ......................48
A/C Low Pressure Switch ......................48
Blower Motor ..............................47
Blower Switch .............................47
Defrost Switch .............................47
Illumination Lamp ...........................47
Resistor .................................48
A/C Compressor Clutch Relay .....................50
Airbag Diagnostic Module Connector ................78
Airbag System ...............................35
Clockspring ...............................35
Diagnostic Module ..........................35
Sensors .................................35
Squibb (Airbag Igniter) ........................35
Anti-Lock Braking System ..................26, 27, 28
Data Link Connector .........................27
Hydraulic Modulator Unit ......................27
Pump Motor Relay ..........................27
System Controller ..................... .26, 27, 28
System Relay ..............................28
Wheel Sensors .............................26
Yellow Light Relay ..........................28
Anti-Lock Brake System Controller Connector ...........90
Ash Receiver Lamp ...........................37
Automatic Shut Down Relay 2.2L E.F.I. .............2,14
Automatic Shut Down Relay 2.5L E.F.I. .............2,14
Automatic Shut Down Relay 3.0L .................2,22
Back-Up Lamp Relay ..........................23
Back-Up Lamp Switch .......................7,8,9
Battery .................................1,3,5
Brake Warning Lamp Switch ......................11
Body to Instrument Panel Wiring Left ................87
Cargo Lamp ................................40
Center High Mounted Stop Lamp ................70, 72
Charging System .........................3,4,5,6
Battery .................................3,5
Generator ...............................4,6
Ignition Off Draw Connector ...................3,5
Chime, Key-In, Seat Belt Warning, Headlamp On .........43
Cigar Lighter ................................37
Cigar Lighter Lamp ............................37
Circuit Breakers Headlamp Switch ...........................36
Cavity #8 ..........................2,11,57,58
Cavity #11 ..............................1,60Wiring Diagram
Name Sheet Number
Clockspring .......................... .29, 35, 42
Clutch Pedal Position Jumper ...................8,10
Clutch Pedal Position Switch .....................7,9
Courtesy Lamps .............................72
Data Link Connector ..................... .13, 22, 27
Daytime Running Lamp Jumper ....................30
Daytime Running Lamp Module ....................30
Daytime Running Lights Module Connector ............84
Defrost Switch ..............................47
Dimmer Switch\eadlamp .......................1,36
Dimmer Switch-Optical Horn ....................1,36
Diode 49
Distributor 2.2L, 2.5L ..........................15
Distributor 3.0L ..............................18
Distributor Ignition Coil ..................... .14, 22
Dome Lamp System ....................... .39, 40
Cargo Lamp ..............................40
Dome Lamp ..............................40
Glove Box Lamp ............................39
Glove Box Lamp Switch .......................39
Left Front Door Jamb Switch ....................39
Left Rear Door Jamb Switch ....................40
Liftgate Latch Switch .........................40
Right Front Door Jamb Switch ...................39
Right Rear Door Jamb Switch ...................40
Door and Rear Speakers (Radio) ...................66
Door Jamb Switches ....................... .39, 40
Door Lock System-2 Door .................... .61, 62
Door Lock System-4 Door .................... .63, 64
Engine Coolant Temperature Sending Unit .............12
Engine Coolant Temperature Sensor 2.2L ..............15
Engine Coolant Temperature Sensor 2.5L ..............15
Engine Coolant Temperature Sensor 3.0L ..............18
Engine Oil Pressure Sending Unit/Switch ..............12
Engine Oil Pressure Switch .......................12
Engine Oil Pressure and Temperature System ...........12
Engine to Instrument Panel Wiring ..................86
Engine Starter System ....................7,8,9,10
Engine Starter System (Automatic Transmission) .....2,8,10
Back-Up Lamp Switch .........................8
Clutch Pedal Position Jumper ..................8,10
Engine Starter Motor .......................8,10
Engine Starter Relay ........................8,10
Park/Neutral Position Switch .....................8
Transmission EMCC Solenoid ....................8
Engine Starter System (Manual Transmission) ........2,7,9
Back-Up Lamp Switch .......................7,9
Clutch Pedal Position Switch ...................7,9
Engine Starter Motor ........................7,9
Engine Starter Relay ........................7,9
Squib Igniter (Airbag) ........................35
Exhaust Gas Recirculation Solenoid 2.2L ..............13
Ä WIRING DIAGRAMS AP BODY D-P 8W - 717

Wiring Diagram
Name Sheet Number
Horn (Lo-note) .............................42
Horn Relay ...............................42
Horn Switch ..............................42
Idle Air Control Motor ...................... .16, 20
Ignition Coil 2.2L E.F.I. .........................14
Ignition Coil 2.5L E.F.I. .........................14
Ignition Coil 3.0L .............................22
Ignition Off-Draw Connector .....................3,5
Ignition Switch .............................2,11
Brake Warning Lamp Switch ....................11
Park Brake Switch ...........................11
Injector ...................................13
Instrument Panel Illumination Lamps ...........45, 46, 47
Instrument Panel to Left Body Wiring ................88
Instrument Panel to Engine Wiring ..................85
Intermittent Wiper System .................... .53, 54
Control Unit ...............................54
Park Switch ...............................54
Washer Low Fluid Level Sensor ..................53
Washer Pump Motor .........................53
Wiper Motor ..............................54
Wiper Switch ..............................53
Key-In, Seat Belt Warning, Headlamp On, Chime .........43
Lamps Air Conditioning and Heater Switch Lamp ............47
Ash Receiver Lamp ..........................37
Back-Up Lamps .................... .69, 70, 71, 72
Cargo Lamp ..............................40
Center High Mounted Stop Lamp ...............70, 72
Cigar Lighter Lamp ..........................37
Courtesy Lamps ............................72
Dome Lamp ..............................40
Fog Lamp ....................... .31, 32, 33, 34
Glove Box Lamp ............................39
Halo Lamp ...............................44
Headlamp-Aero .................... .31, 32, 33, 34
Heated Rear Window Switch Lamp ................67
Heater Switch Lamp .........................46
Illumination Lamps ....................... .46, 47
License Lamp .......................... .70, 72
Park Lamps-Front .................. .31, 32, 33, 34
Side Marker Lamps-Front ..............31, 32, 33, 34
Side Marker Lamps-Rear ...............69, 70, 71, 72
Stop Lamps ...............................29
Tail/Stop/Turn Signal Lamps-Rear .........69, 70, 71, 72
Transmission Range Lamp .....................37
Turn Signal Lamps-Front ...............31, 32, 33, 34
Underhood Lamp ...........................12
Left Body to Instrument Panel Wiring ................87
Left Front Wheel Sensor ........................26
Left Rear Wheel Sensor .........................26
Liftgate Latch Switch ..........................40
MAP Sensor ............................ .15, 20
Mercury Switch ..............................12
Mirrors-Power ........................... .55, 56
Modules Airbag Diagnostic Module ......................35Wiring Diagram
Name Sheet Number
Daytime Running Lamps Module .................30
Fuse Block Module ..........................76
Powertrain Control Module ...........13, 14, 15, 16, 17,
18, 19, 20, 21, 22, 29
Relay Module ..............................77
Transmission Control Module ...............23, 24, 25
Motors Blower Motor .......................... .46, 47
Engine Starter ........................7,8,9,10
Fuel Pump Motor ...........................68
Idle Air Control Motor ..................... .16, 20
Power Door Locks-2 Door .................. .61, 62
Power Door Locks-4 Door .................. .63, 64
Power Mirror ..............................56
Power Seat ...............................60
Power Window-2 Door ........................57
Power Window-4 Door ........................58
Radiator Fan Motor ...................... .45, 49
Washer Pump Motor .........................53
Wiper ..................................54
Optical Horn ..............................1,36
Overhead Console ............................41
A/C Ambient Temperature Sensor .................41
Power Door Lock System-2 Door ................61, 62
Connector and Door Lock Switch Function .........61, 62
Left Front Door Motor ........................61
Left Front Door Switch ........................61
Right Front Door Motor .......................62
Right Front Door Switch .......................62
Power Door Lock System-4 Door ................63, 64
Left Front Door Motor ........................63
Left Front Door Switch ........................63
Left Rear Door Motor ........................63
Right Front Door Motor .......................64
Right Front Door Switch .......................64
Right Rear Door Motor .......................64
Power Mirrors ........................... .55, 56
Dual Mirror Control Switch .....................55
Left Motors ...............................56
Power Mirror Switch .........................55
Right Motors ..............................56
Switch Function ............................55
Power Seat System-Left Bucket ....................60
Powertrain Control Module ............13, 14, 15, 16, 17,
18, 19, 20, 21, 22
Powertrain Control Module Connector .............79, 80
Power Window Connector and Switch Functions .........59
Power Window System-2 Door ....................57
Console Master Switch ........................57
Left Front Motor ............................57
Right Front Motor ...........................57
Power Window System-4 Door ....................58
Console Master Switch ........................58
Left Front Motor ............................58
Left Rear Motor ............................58
Left Rear Switch ............................58
Right Front Motor ...........................58
Ä WIRING DIAGRAMS AP BODY D-P 8W - 719

Wiring Diagram
Name Sheet Number
Right Rear Motor ...........................58
Right Rear Switch ...........................58
Printed Circuit Board ....................... .74, 75
Printed Circuit Board Connectors ...................73
Radiator Fan Fuse ......................... .45, 50
Radio Speakers-Door and Rear ....................66
Radio-Stereo ................................65
Name Brand Speaker Relay .....................65
Rear Lighting ....................... .69, 70, 71, 72
Back-Up Lamps .................... .69, 70, 71, 72
Center High Mounted Stop Lamps ..............70, 72
Courtesy Lamps ............................72
License Lamps ......................... .70, 72
Side Marker Lamps ................. .69, 70, 71, 72
Tail, Stop and Turn Signal Lamps .........69, 70, 71, 72
Relay Module ...............................77
Relays ABS System Relay ..........................28
A/C Compressor Clutch Relay ...................50
ABS Yellow Light Relay .......................28
ABS Pump Motor Relay .......................27
Automatic Shut Down ....................2,14,22
Back-Up Lamp Relay .........................23
Engine Starter Relay ....................7,8,9,10
Fuel Pump ............................ .14, 22
Horn ...................................42
Fan Control Relay ....................... .45, 50
Name Brand Speaker .........................65
Safety Shut Down Relay .......................25
Time Delay ...............................44
Right Front Wheel Sensor .......................26
Right Instrument Panel Interface ...................89
Right Rear Wheel Sensor ........................26
Seat Belt Warning System and Courtesy Lamps .......43, 44
Halo Lamp ...............................44
Seat Belt Warning Chime ......................43
Seat Belt Switch ............................44
Time Delay Relay ...........................44
Seat-Power System, Left ........................60
Sensors ABS Wheel Sensors ..........................26
A/C Ambient Temperature Sensor .................41
Airbag ..................................35
Engine Coolant Temperature ..................15, 18
Heated Oxygen ......................... .17, 18
MAP ................................ .15, 20
Output Speed Sensor .........................24
Throttle Position ........................ .16, 20
Turbine Speed .............................24
Vehicle Speed Sensor ..................... .15, 18
Washer Low Fluid Sensor ......................53
Solenoids EVAP/Purge Solenoid ..................... .13, 19
Exhaust Gas Recirculation .................. .13, 20
Transmission EMCC Solenoid ....................8
Transmission Solenoid ........................25
Speakers, Radio ..............................66Wiring Diagram
Name Sheet Number
Splices Splice A0-1 ...........................1,2,4,6
Splice A0-2 ............................2,4,6
Splice A1 ..............................2,4,6
Splice A2 ..............................2,4,6
Splice A3 ..............................1,36
Splice A3-1 ............................1,4,6
Splice A4 ..............................2,3,5
Splice A4-1 ............................2,4,6
Splice A11 .............................1,4,6
Splice A14 .............................2,4,6
Splice A14-1 ..............................14
Splice A14-2 ..............................22
Splice A15 .............................1,3,5
Splice A15-1 ...........................1,3,5
Splice A16 .............................2,4,6
Splice A20 ...............................28
Splice A21 ...............................11
Splice A21-1 ..........................2,13,21
Splice A21-2 ........................... .13, 21
Splice A21-3 ..............................23
Splice A142-1 .............................14
Splice A142-2 ..........................4,6,14
Splice B47 ...............................28
Splice C7 ............................. .46, 48
Splice D1 ................................24
Splice D2 ................................24
Splice E2 .............. .31, 33, 37, 41, 46, 47, 65, 67
Splice E2-1 ............ .31, 33, 37, 41, 46, 47, 65, 67
Splice F20 .......................... .35, 41, 67
Splice F20-1 .........................7,8,9,23
Splice F30 .......................... .35, 42, 65
Splice F35 ............................ .61, 63
Splice G5 ............................. .35, 43
Splice G7 .......................... .15, 18, 30
Splice K4 ................................15
Splice K4-1 ........................... .15, 18
Splice K4-2 ........................... .19, 20
Splice K6 ............................. .16, 20
Splice K7-1 ........................... .15, 18
Splice K22 ...............................20
Splice K24 ...............................18
Splice L3 ............................. .31, 33
Splice L4 ............................. .31, 33
Splice L7-1 ........................... .32, 34
Splice L7-2 ........................... .31, 33
Splice L7-3 ...............................36
Splice L7-4 ........................... .69, 71
Splice L7-5 ........................... .31, 33
Splice L20 ..............................1,36
Splice L39 ............................ .31, 33
Splice L50 ...............................52
Splice L60 ............................ .31, 33
Splice L60-1 ..............................52
Splice L61 ............................ .32, 34
Splice L61-1 ..............................52
Splice M1-1 ...................... .39, 44, 55, 65
8W - 720 WIRING DIAGRAMS AP BODY D-P Ä

Wiring Diagram
Name Sheet Number
Splice M1-3 ........................... .40, 55
Splice M2-1 ...............................39
Splice P33 ............................ .62, 64
Splice P34 ............................ .62, 64
Splice Q1 ................................58
Splice T13 ...............................24
Splice T16 ...............................25
Splice T41 ...............................23
Splice T41-1 ............................9,10
Splice X2 ................................42
Splice X2-1 ...............................42
Splice X13 ...............................66
Splice X15 ...............................66
Splice Z0 .................................3
Splice Z0-1 ...............................14
Splice Z0-2 ...............................21
Splice Z1 ......... .40, 44, 55, 57, 60, 61, 63, 68, 69, 71
Splice Z1-1 ...................... .38, 46, 47, 66
Splice Z1-2 ......................... .31, 33, 42
Splice Z1-3 ......................... .32, 34, 42
Splice Z1-4 ............7,27,28,29,32,34,42,45,49
Splice Z1-5 .................... .55, 57, 60, 61, 63
Splice Z1-6 ...............................38
Splice Z1-7 ........................... .70, 72
Splice Z1-8 ........................... .67, 70
Splice Z1-10 ........................... .32, 34
Splice Z1-11 ........................ .32, 34, 42
Splice Z1-12 .............. .55, 57, 60, 61, 63, 69, 71
Splice Z1-14 ........................... .27, 28
Splice Z2 ................................38
Splice Z12 ............................ .14, 21
Splice Z13 ...............................25
Splice Z14 ...............................25
Steering Column Connectors ......................81
Steering Multi-Function Switch Column Connectors .......82
Stereo Radio ................................65
Stop Lamp System ............................29
Stop Lamp Switch ............................29
Switches A/C Cycling Clutch Switch ......................48
A/C Switch ...............................47
A/C Heater Blower Switch ......................47
A/C High Pressure Switch ......................48
A/C Low Pressure Switch ......................48
Back-Up Lamp Switch .....................7,8,9
Blower Switch-A/C Heater ......................47
Brake Warning Lamp Switch ....................11
Clutch Pedal Position Switch ...................7,9
Defrost Switch .............................47
Door Lock Switch (2-dr) ................... .61, 62
Door Lock Switch (4-dr) ................... .63, 64
Door Jamb Switch ....................... .39, 40
Dual Mirror Control Switch .....................55
Engine Oil Pressure Switch .....................12
Fog Lamp Switch ........................ .31, 33
Glove Box Lamp Switch .......................39
Hazard Flasher Switch ........................52Wiring Diagram
Name Sheet Number
Headlamp Switch .........................1,36
Heated Rear Window Switch ....................67
Heater Bi-level Control Switch ...................46
Horn Switch ..............................42
Ignition Switch ...........................2,11
Liftgate Latch Switch .........................40
Mercury Switch ............................12
Park Brake Switch ...........................11
Park/Neutral Position Switch .....................8
Park/Neutral Start Switch ......................23
Power Mirrors Switch ........................55
Power Seat Switch ..........................60
Power Steering Pressure Switch ..................19
Power Window Switch (2 Dr) ...................57
Power Window Switch (4 Dr) ...................58
Seat Belt Warning Switch ......................44
Speed Control Switch ........................29
Stop Lamp Switch ..........................29
Transmission Range Switch .....................25
Transmission Solenoids and Pressure Switch ..........25
Turn Signal Flasher Switch .....................52
Vehicle Speed Control Switch ...................29
Wiper Park Switch ..........................54
Wiper Switch ..............................53
Temperature Sending Unit .......................18
Time Delay Relay .............................44
Throttle Position (Sensor) 2.2L ....................16
Throttle Position (Sensor) 2.5L ....................16
THrottle Position (Sensor) 3.0L ....................20
Transmission Control Module Connector ..............91
Transmission Control System ................23, 24, 25
Back-up Lamp Relay .........................23
Output Speed Sensor .........................24
Park/Neutral Switch ..........................23
Safety Shut Down Relay .......................25
Transmission Control Module ...............23, 24, 25
Transmission Range Switch .....................25
Transmission Solenoids and Pressure Switch ..........25
Turbine Speed Sensor ........................24
Transmission EMCC Solenoid ......................8
Transmission Solenoid Connector ..................92
Transmission Solenoids and Pressure Switch ...........25
Turn and Hazard Flasher System .................51, 52
Hazard Flasher ......................... .51, 52
Switch ..................................52
Turn Signal Flasher ..........................51
Turn Signal Lamps ..........31, 32, 33, 34, 69, 70, 71, 72
Underhood Lamp .............................12
Vehicle Speed Control Servo ......................29
Vehicle Speed Control and Stop Lamp System ..........29
Clockspring ................................29
Powertrain Control Module .......................29
Stop Lamp Switch with Vehicle Speed Control ..........29
Stop Lamp without Vehicle Speed Control .............29
Vehicle Speed Control Servo ......................29
Vehicle Speed Control Switch .....................29
Wiper System ........................... .53, 54
Ä WIRING DIAGRAMS AP BODY D-P 8W - 721

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

(15) Install hood.
(16) Connect battery.
(17) Start engine and run until operating temper-
ature is reached. (18) Adjust transmission or linkage if necessary.
ROCKER ARMS AND SHAFT ASSEMBLY
REMOVAL
(1) Remove upper intake manifold assembly. Refer
to Intake and Exhaust Manifolds, Group 11. (2) Disconnect spark plug wires by pulling on the
boot straight out in line with plug. (3) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover. (4) Remove cylinder head cover and gasket.
(5) Remove four rocker shaft bolts and retainers.
(6) Remove rocker arms and shaft assembly.
(7) If rocker arm assemblies are disassembled for
cleaning or replacement. Assemble rocker arms in
their original position.Refer to (Fig. 5) for rocker arm
for positioning on the shaft.
INSTALLATION
(1) Install rocker arm and shaft assemblies with
the stamped steel retainers in the four positions,
tighten to 28 N Im (250 in. lbs.) (Fig. 5).
WARNING: THE ROCKER ARM SHAFT
SHOULD BE TORQUED DOWN SLOWLY,
STARTING WITH THE CENTERMOST BOLTS.
ALLOW 20 MINUTES TAPPET BLEED DOWN
TIME AFTER INSTALLATION OF THE
ROCKER SHAFTS BEFORE ENGINE OPERA-
TION. (2) Clean cylinder head cover gasket surface. In-
spect cover for distortion and straighten if necessary. (3) Clean head rail if necessary. Install a new gas-
ket and tighten cylinder head cover fasteners to 12
N Im (105 in. lbs.).
(4) Install closed crankcase ventilation system and
evaporation control system. (5) Install spark plug wires.
(6) Install upper intake manifold assembly. Refer to
Exhaust Systems and Intake Manifolds Group 11.
CYLINDER HEADS
The alloy aluminum cylinder heads shown in (Fig. 6)
are held in place by 9 bolts. The spark plugs are located
in peak of the wedge between the valves.
REMOVAL
(1) Drain cooling system refer to Cooling System
Group 7 for procedure and disconnect negative battery
cable. Remove intake manifold, and throttle body. Refer to
Group 11 Exhaust System and Intake Manifold. (2) Disconnect coil wires, sending unit wire, heater
hoses and by-pass hose. (3) Remove closed ventilation system, evaporation
control system and cylinder head covers. (4) Remove exhaust manifolds.
(5) Remove rocker arm and shaft assemblies. Re-
move push rods and identify to insure installation
in original locations. (6) Remove the 9 head bolts from each cylinder head
and remove cylinder heads (Fig. 7).
Fig. 5 Rocker Arm Location Left Blank
Fig. 6 Cylinder Head Assembly
Fig. 7 Cylinder Head Bolts Location
9 - 102 3.3/3.8L ENGINE Ä

(8) Place new cylinder head cover gaskets in position
and install cylinder head covers. Tighten to 12 N Im
(105 in. lbs.).
INTAKE MANIFOLD SEALING
The intake manifold gasket is a one-piece stamped
steel gasket with a sealer applied from the manufac-
turer. This gasket has end seals incorporated with it. WARNING: INTAKE MANIFOLD GASKET IS
MADE OF VERY THIN METAL AND MAY CAUSE
PERSONAL INJURY, HANDLE WITH CARE. (1) Clean all surfaces of cylinder block and cylinder
heads. (2) Place a drop ( about 1/4 in. diameter) of Mopar
Silicone Rubber Adhesive Sealant or equivalent, onto
each of the fourmanifold to cylinder head gasket
corners (Fig. 13).
(3) Carefully install the intake manifold gasket (Fig.
14). Torque end seal retainer screws to 12 N Im (105 in.
lbs.). (4) Install intake manifold and (8) bolts and torque
to1N Im (10 in. lbs.). Then tighten bolts to 22 N Im
(200 in. lbs.) in sequence shown in (Fig. 15). Then
tighten again to 22 N Im (200 in. lbs.). After intake
manifold is in place, inspect to make sure seals are in place.
Refer to Group 11 Exhaust System and
Intake Manifold to complete Intake Manifold Assem-
bly. (5) Install exhaust manifolds and tighten bolts to
27 N Im (20 ft. lb.) and nuts to 20 N Im (15 ft. lbs.).
(6) Adjust spark plugs to specification in Electrical
Section, Group 8, and install the plugs.
VALVE SERVICE
VALVES AND VALVE SPRINGS
The valves are arranged in line in the cylinder
heads and inclined 18 degrees. The rocker shaft sup-
port are cast integral with the heads.
REMOVAL
(1) With cylinder head removed, compress valve
springs using Valve Spring Compressor Tool
C-3422-B with adapter 6412 as shown in (Fig. 16). (2) Remove valve retaining locks, valve spring re-
tainers, valve stem seals and valve springs.
Fig. 14 Intake Manifold Gasket Retainers
Fig. 15 Intake Manifold Removal and Installation
Fig. 12 Rocker Arm Shaft Retainers
Fig. 13 Intake Manifold Gasket Sealing
9 - 104 3.3/3.8L ENGINE Ä

CLEANING AND INSPECTION
(1) Discard gaskets and clean all gasket surfaces
on both manifolds and on cylinder head. (2) Test gasket surfaces of manifolds for flatness
with a straight edge. Surfaces must be flat within
0.15mm per 300mm (.006 in. per foot) of manifold
length. (3) Inspect manifolds for cracks and distortion.
INSTALLATION
(1) Install a new intake and exhaust manifold gas-
ket. Coat steel gasket lightly with Gasket Sealer on
manifold side. Do notcoat composition gasket with
(any) sealer. (2) Set exhaust manifold in place. Tighten retain-
ing nuts starting at center and progressing outward
in both directions to 23 N Im (200 in. lbs.) torque. Re-
peat this procedure until all nuts are at specified
torque. (3) Set intake manifold in place.
(4) Raise vehicle and tighten retaining screws
starting at center and progressing outward in both
directions to 23 N Im (200 in. lbs.) torque (Fig. 3). Re-
peat this procedure until all screws are at specified
torque. (5) Reverse removal procedures 1-9 for installation.
(6) With the DRBII Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is se-
lected.
INTAKE AND EXHAUST MANIFOLDSÐFLEXIBLE
FUEL ENGINE
INTAKE MANIFOLD
The manifold is die-cast aluminum with upper ple-
num and 4 tubes lower runners. These attach to the
cylinder head, with each runner leading directly to a
cylinder. The manifold is also machined for fuel rail attach-
ment and injector installation. The throttle body is
installed on the upper plenum of the manifold.
EXHAUST MANIFOLD
All high strength iron casting that intermesh with
the intake manifold. For standard engines a four
branch design collects and directs exhaust gases to
the conical (articulated joint connection) outlet.
INTAKE/EXHAUST MANIFOLDS
SERVICEÐFLEXIBLE FUEL ENGINES
Intake and exhaust manifolds use a one piece gas-
ket. Service procedures requiring removal and instal-
lation of either must include both manifolds.
SERVICE PRECAUTIONS
Methanol is more toxic than gasoline. Always re-
lease fuel system pressure before servicing fuel sys-
tem components and wear methanol resistant gloves
and eye protection. Avoid breathing methanol vapors or ingesting
methanol. Headaches, dizziness and even uncon-
sciousness could result from breathing these vapors.
Serious injury, blindness and even death could result
from ingesting methanol. Methanol vapors are extremely flammable and can
travel along the ground. Service vehicles in well ven-
tilated areas and avoid ignition sources. Never
smoke while servicing the vehicle. Do not allow methanol to contact skin. Prolonged
contact with methanol can cause dry skin or an al-
lergic skin reaction. Also, prolonged contact could re-
sult in absorption through the skin.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
WEAR METHANOL RESISTANT GLOVES AND EYE
PROTECTION WHILE SERVICING THE FUEL SYS-
TEM.
(a) Disconnect negative cable from battery.
(b) Remove fuel filler cap.
(c) Remove the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 4).
(d) Place the open end of fuel pressure release
hose, tool number C-4799-1, into an approved gas-
oline container. Connect the other end of hose
C-4799-1 to the fuel pressure test port (Fig. 5).
Fuel pressure will bleed off through the hose into
the gasoline container. Fuel gauge C-4799-A con-
tains hose C-4799-1.
Fig. 4 Fuel Pressure Test Port
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7

INTAKE MANIFOLD
REMOVAL (1) Perform fuel system pressure release procedure
before attempting any repairs. (2) Disconnect negative battery cable.
(3) Remove air cleaner hose to throttle body (Fig.
6).
(4) Remove accelerator and speed control cables.
(5) Disconnect automatic idle speed (AIS) motor
and throttle position sensor (TPS) wiring connectors
(Fig. 7). (6) Disconnect fuel injectors wiring connector.
(7) Remove supply and return lines from the fuel
tube assembly quick connect at frame rail. Open fuel
tube clip around fuel tubes. WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY FUEL SPILLAGE.
(8) Disconnect fuel pressure regulator vacuum hose
from regulator (Fig. 8). (9) Remove PCV vacuum harness, brake booster,
and vacuum vapor harness from intake manifold
(Fig. 8). (10) Remove 8 intake manifold screws and washer
assemblies and remove intake manifold assembly
(Fig. 9).
Fig. 5 Releasing Fuel Pressure
Fig. 6 Air Cleaner Hose to Throttle Body Assembly
Fig. 7 Throttle Position Sensor and Air Idle Control Motor Electrical Connections
Fig. 8 Electrical and Vacuum Hose Connection
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä