battery CHEVROLET DYNASTY 1993 Service Manual
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Page 1283 of 2438
WIRING DIAGRAMS AG-AJ BODY
ALPHABETICAL INDEX
Wiring Diagram
Name Sheet Number
A/C Compressor Clutch .........................89
A/C and Heater System ..................... .91, 92
A/C Compressor Clutch Relay ...................91
A/C Low Pressure Switch ......................91
A/C High Pressure Switch ......................92
A/C Cycling Switch ..........................92
ABS Warning Lamp Diode .......................69
Airbag System ........................... .84, 85
Clock Spring ..............................84
Diagnostic Module ..........................84
Interface Grommet ..........................85
Left Airbag Sensor ..........................85
Right Airbag Sensor .........................85
Squib (Airbag Igniter) ........................84
Air Conditioning System ........................90
A/C Blower Motor ...........................90
A/C/Heater Blower Motor Resistor .................90
A/C Switch ...............................90
Blower Switch .............................90
Defrost Switch .............................90
Illumination Lamps Switch .....................90
Alarm, Security Module ....................... .127
Ambient Air Temperature Sensor ...............117, 119
Anti-Lock Brake System (Except Turbo 3) .............170
Anti-Lock Brake System Controller ..........68, 69, 70, 71
Anti-Lock Brake System .................68, 69, 70, 71
ABS Controller .................... .68, 69, 70, 71
ABS Hydraulic Modulator ......................68
ABS Pump Motor Relay .......................68
ABS System Relay ..........................69
ABS Warning Lamp Diode ......................69
ABS Warning Switch Lamp Switch ................70
Brake Switch ..............................70
Left Front Wheel Sensor .......................71
Left Rear Wheel Sensor .......................71
Park Brake Switch ...........................70
Right Front Wheel Sensor ......................71
Right Rear Wheel Sensor ......................71
Automatic Shutdown Relay ..................20, 27, 33
Battery ...........................1,9,11,53,56
Body Computer ......................... .165, 166
Body Computer #1 ............................40
Body Computer (Mechanical Cluster) ..............79, 80
Body Computer #2 ............................40
Body Computer (Electronic Cluster) ...............81, 82
Body Wiring to Left Instrument Panel ...............147
Body Wiring to Right Instrument Panel ...........150, 151
Bulkhead Disconnect (50-Way) ................153, 154
Center High Mounted Stop Lamp (AG) ...............140
Center High Mounted Stop Lamp (J-21) ..............141
Center High Mounted Stop Lamp (J-27) ..............142
Charging System (2.5L and Turbo) ................9,10Wiring Diagram
Name Sheet Number
Battery ...................................9
Data Link Connector ..........................9
Generator ................................10
Power Distribution Center ....................9,10
Powertrain Control Module ......................9
Charging System (3.0L) ..................... .11, 12
Battery ..................................11
Generator ................................12
Power Distribution Center .................. .11, 12
Cigar Lighter ................................51
Circuit Breakers (Fuse Cavity #2) ...........8,42,110, 111
Circuit Breakers (Fuse Cavity #3) ..............5,53,116
Clockspring .......................... .59, 65, 84
Clutch Pedal Position Jumper ..................13, 15
Clutch Pedal Position Switch .....................14
Combo Flasher ..............................56
Data Link Connector ..................9,19,25,34,72
Daytime Running Lights Module Connector ............173
Decklid Lock Sense Switch ..................... .102
Dimming Interior Lamps & Headlamp Switch .........51, 52
Ash Receiver Lamp ..........................51
Cluster Lamps .............................52
Cigar Lighter ..............................51
Console Switch Module .......................51
A/C Heater Control Switch Lamp .................52
Headlamp Switch ...........................51
Fog Lamp Switch ...........................51
Fuse Panel Switch ...........................51
Left Pod Lamps ............................51
Left Switch Pod ............................51
Transmission Range Lamp .....................51
Diode ....................................89
Diode Package ....................... .83, 102, 104
Distributor .............................. .21, 26
Dome and Courtesy Lamps (AG) ...............125, 126
Cargo Lamp ............................. .126
Dome Lamp ............................. .126
Front Reading Lamps ....................... .126
Front Reading Lamp Switch ................... .126
Glove Box Lamp & Switch .................... .125
Halo Light .............................. .125
Liftgate Ajar Switch ........................ .125
Vanity Mirror Lamps ....................... .126
Vanity Mirror Lamp Switch ................... .126
Dome, Reading and Courtesy Lamps (J-27 Only) .....121, 122
Courtesy Lamp ........................... .121
Decklid Ajar Switch ........................ .122
Glove Box Lamp .......................... .121
Halo Light .............................. .121
Left Door Courtesy Lamp .................... .122
Rear Mirror Courtesy Lamp ................... .122
Right Door Courtesy Lamp ................... .121
Ä WIRING DIAGRAMS AG-AJ BODY 8W - 533
Page 1286 of 2438
Wiring Diagram
Name Sheet Number
Fuel Gauge ............................. .107
Fuel Pump Module ........................ .107
Fuel Pump Relay .......................... .108
Fuel Tank Gauge Level Sending System ............107
Fuse Application Chart (Engine Compartment) ......1,2,3,4
Fuse Application Chart (Instrument Panel) .........5,6,7,8
Fuse Block ............................... .143
Fuses Fuse 1 ...........................8,42,90,93
Fuse 5 ....................8,13,14,39,42,84,96
Fuse 6 ..............................8,42,56
Fuse 7 .............................8,42,105
Fuse 8 ................................5,52
Fuse 9 ................................5,55
Fuse 10 ..........................5,10,12,54
Fuse 11 ..........................5,60,84,88
Fuse 12 ...............................5,63
Fuse 14 .....................7,42,70,73,77,84
Fuse 15 ..........................7,42,59,70
Fuse 17 .........................6,53, 133, 137
Fuse 18 .........................6,53, 133, 137
Fuse 19 ...............................6,54
Fuse 20 ...............................6,54
Fuse 21 ..........................5,10,12,59
Fuse 22 ...............................5,65
Fuse 25 .......................8,94,95,98,100
Fuse 26 ..............8,16,73,77,94, 121, 123, 125
Fuse 27 ..........................7,42,61,63
Fuse 28 .............................7,42,67
Fuse 36 ...........................1,9,11,56
Fuse 37 ..................................1
Fuse 40 ..............................2,9,11
Fuse 41 ..............................2,9,11
Fuse 42 ...........................2,9,11,18
Fuse 43 ..................................2
Fuse 44 .............................2,10,12
Fuse 45 .............................2,10,12
Fuse 46 ..............................2,9,11
Fuse 47 ..............................2,9,11
Fuse 48 .............................1,10,12
Fuse 50 .............................1,10,12
Fuse 51 .............................2,10,12
Fuse 52 .............................4,10,12
Fuse 53 .............................4,10,12
Fuse 55 ..........................2,10,12,13
Fuse 56 ........................3,10,12,54,84
Fuse 57 ..........................3,10,12,54
Fuse 58 .............................1,10,12
Generator .............................. .10, 12
Glove Box Lamp Switch ................... .101, 103
Headlamp Switch ......................... .51, 55
Headlamp Switch System .................. .53, 54, 55
Battery ..................................53
Fog Lamp Relay ............................55
Fog Lamp Switch ...........................55
Headlamp Switch ...........................55
High Beam Relay ...........................53Wiring Diagram
Name Sheet Number
Left Pod Light .............................55
Low Beam Relay ............................53
Optical Horn Switch .........................55
Park Lamp Relay ...........................53
Parking Switch .............................55
Turn Signal Switch ..........................55
Heated Oxygen Sensor ................... .17, 24, 32
Heated Rear Window ......................8,94,95
Heated Rear Window Switch .................8,94,95
Heater System ...............................93
Blower Motor ..............................93
Blower Motor Resistor ........................93
Blower Switch .............................93
Illumination Lamp Switch ......................93
High Beam Relay ...........................6,53
Horn System ...............................65
Clockspring ...............................65
Horn Relay ...............................65
Horn Switch ..............................65
Left Horn (Lo-Note) ..........................65
Right Horn (Hi-Note) .........................65
Idle Air Control Motor ...................... .17, 23
Ignition Coil ............................. .19, 23
Ignition Switch ...........................2,7,42
Instrument Panel Fuse Application Chart ..........5,6,7,8
Intermittent Wiper System .................... .66, 67
Intermittent Windshield Wiper Motor ...............67
Park Switch ...............................67
Washer Relay .............................66
Windshield Washer Low Fluid Level Sensor ...........67
Windshield Washer Pump Motor .................67
Wiper Switch ..............................66
Interface Grommet ............................85
Key Disarm Switch ....................... .115, 116
Lamp Outage Module Connectors ..................174
Lamps A/C Heater Control Lamp ......................52
Ash Receiver Lamp ..........................51
Back-Up Lamps ...........128, 131, 133, 134, 137, 138
Cargo Lamp ............................. .126
Center High Mounted Stop Lamp ..........140, 141, 142
Cluster Lamps .............................52
Console Switch Module Lamp ...................51
Courtesy Lamps ................ .121, 122, 123, 124
Dome Lamp ......................... .118, 126
Dummy Lamp .......................... .45, 46
Fog Lamp-Left ......................... .43, 47
Fog Lamp-Right ........................ .44, 48
Glove Box Lamp ............. .101, 103, 121, 123, 125
Halo Light ....................... .121, 123, 125
Headlamp, High Beam .......43, 44, 45, 46, 47, 48, 49, 50
Headlamp, Low Beam .......43, 44, 45, 46, 47, 48, 49, 50
Illumination Lamp ....................... .90, 93
Left Pod Lamps ......................... .51, 55
License Lamp .................. .128, 131, 133, 137
Park and Turn Signal Lamp-Left ........43, 45, 47, 49, 50
Park and Turn Signal Lamp-Right .......44, 46, 48, 49, 50
8W - 536 WIRING DIAGRAMS AG-AJ BODY Ä
Page 1467 of 2438
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
Page 1571 of 2438
CAUTION: Be sure that the tapped holes maintain
the original centerline.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostaticly
locked, regardless of what caused the problem, these
steps should be used.
CAUTION: Do Not Use Starter Motor To Rotate En-
gine, severe damage may occur.
(1) Inspect air cleaner, induction system and in-
take manifold to insure system is dry and clear of
foreign material. (2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will
catch any fluid that may possibly be in the cylinder
under pressure. (4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket. (5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other). (6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., Connecting
Rods, Pistons, Valves etc.) (7) Repair engine or components as necessary to
prevent this problem from occurring again.
CAUTION: Squirt approximately 1 teaspoon of oil
into cylinders, rotate engine to lubricate the cylin-
der walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Fill engine with specified amount of approved
oil and install new oil filter. (11) Connect negative battery cable.
(12) Start engine and check for any leaks.
Ä ENGINE 9 - 5
Page 1579 of 2438
² Drive shaft distress: See Driveshafts in Suspension,
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 as-
sembly with a floor jack. (2) Loosen the right engine mount insulator vertical
fasteners, and 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 identifica-
tion and related assembly length measuring. (4) Tighten right engine mount insulator vertical
bolts to 68 N Im (50 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) Scribe hood hinge outline on hood and remove
hood. (3) Drain cooling system.
(4) Remove hoses from radiator and engine.
(5) Remove radiator and fan assembly.
(6) Remove air cleaner and hoses.
(7) Remove air conditioning compressor mounting
bolts and set compressor aside, if equipped. (8) Remove power steering pump mounting bolts
and set pump aside (9) Remove oil filter.
(10) Disconnect fuel line, heater hose and acceler-
ator cable. (11) Disconnect all electrical connections and har-
nesses at throttle body and engine. (12) Manual Transmission
(a) Disconnect clutch cable.
(b) Remove transmission case lower cover.
(c) Disconnect exhaust pipe at manifold.
(d) Disconnect starter and lay aside.
(e) Install transmission holding fixture.
(13) Automatic Transmission
(a) Disconnect exhaust pipe at manifold.
(b) Disconnect starter and lay aside.
(c) Remove transmission case lower cover.
(d) Mark flex plate to torque converter.
(e) Remove screws holding torque converter to
flex plate.
(14) Attach C clamp on front bottom of torque con-
verter housing to prevent torque converter from com-
ing out. (15) Install transmission holding fixture.
(16) Remove right inner splash shield (Fig. 5).
(17) Remove ground strap.
(18) To lowerengine separate right engine
bracket from yoke bracket To raiseengine remove
long bolt through yoke and insulator. IF INSULA-
TOR TO RAIL SCREWS ARE TO BE REMOVED,
MARK INSULATOR POSITION ON SIDE RAIL TO
INSURE EXACT INSTALLATION (Fig. 4). (19) Remove transmission case to cylinder block
mounting screws.Fig. 5 Right Inner Splash Shield
Fig. 4 Left Insulator Movement
Ä 2.2/2.5L ENGINE 9 - 13
Page 1580 of 2438
CAUTION: Make sure clutch cable has been discon-
nected. (20) Remove front engine mount screw and nut.
(21) Remove manual transmission damper.
(22) Remove left insulator through bolt from inside
wheelhouse or insulator bracket to transmission
screws. (23) Remove engine from vehicle.
INSTALLATION
(1) Install hoist to the engine and lower engine
into the engine compartment. SEE: ENGINE MOUNT RUBBER INSULATORS,
THIS GROUP. (2) Align engine mounts and install but do not
tighten until all mounting bolts have been installed.
(3) Install transmission case to cylinder block
mounting screws. Tighten to 95 N Im (70 ft. lbs.)
torque. (4) Remove engine hoist and transmission holding
fixture. (5) Install ground strap.
(6) Install right inner splash shield.
(7) Connect starter. See Electrical Group 8 for in-
stallation. (8) Connect exhaust system. See Exhaust Systems
Group 11 for installation. (9) Manual Transmission: Install transmission
case lower cover. Automatic Transmission: Remove C clamp from
torque converter housing. Align flexplate to torque
converter and install mounting screws. Tighten to 75
N Im (55 ft. lbs.) torque.
(10) Manual Transmission: Connect clutch cable.
See Clutch Group 6. (11) Install power steering pump. Refer to Cooling
System Group 7, Accessory Drive Section for belt
tension adjustment. (12) Connect fuel line, heater hose, and accelerator
cable. (13) Connect all electrical connections and har-
nesses at throttle body and engine. (14) Install oil filter. Fill engine crankcase with
proper oil to correct level. (15) Install air conditioning compressor (if
equipped). See Heater and Air Conditioning, Group
24 for installation. (16) Install air cleaner and hoses.
(17) Install radiator and shroud assembly . Install
radiator hoses. Fill cooling system. See Cooling Sys-
tem Group 7 for filling procedure. (18) Install hood.
(19) Connect battery.
(20) Start engine and run until operating temper-
ature is reached. (21) Adjust transmission linkage, if necessary.
SOLID MOUNT COMPRESSOR BRACKET SERVICE
When service procedures require solid mount
bracket removal and installation for example: cylin-
der head removal, etc., it is important that bracket
fasteners numbered 1 through 7 (Fig. 4) be removed
and installed in sequence, as instructed in Remove
and Install.
ACCESSORIES REMOVAL
(1) Remove (and install/adjust) belts,see Accessory
Drive Belts in Cooling System,Group 7. (2) Remove air conditioning compressor (in vehicle
with lines and set aside) (Fig. 6). (3) Remove generator pivot bolt and remove gener-
ator (in vehicle: turn wiring side up and disconnect,
then rotate generator, pulley end towards engine and
remove). (4) Remove air conditioner compressor belt idler.
SOLID MOUNT BRACKETÐREMOVAL (FIG. 4)
(1) Remove right engine mount yoke screw (see
Engine Remove Fig. 3) securing engine mount sup-
port strut to engine mount bracket. (2) Remove five side mounting bolts #1, #4 , #5,
#6, and #7 (Fig. 4). (3) Remove front mounting nut, #2, and remove
front bolt #3*. (4) Remove front mounting bolt and strut, rotate
solid mount bracket away from engine and slide
bracket on stud until #2 nut mounting stud until
free. Remove spacer from stud.
SOLID MOUNT BRACKETÐINSTALLATION
(1) Put spacer onto stud, then install bracket on
front (#2 nut) mounting stud and slide bracket over
timing belt cover into position. (2) Loosen assembly bracket to engine fasteners
(numbered #1 through #7 in Fig. 6). (3)
CAUTION: Fasteners MUST BE TIGHTENED IN SE-
QUENCE and to specified torque as follows :
² First Bolt #1 to 3.3 N Im (30 in. lbs.)
² Second Nut #2 and Bolt #3 to 54 N Im (40 ft. lbs.).
² Third Bolts #1 (second tightening) #4 and #5 to
54 N Im (40 ft. lbs.).
² Fourth Bolts #6 and #7 to 54 N Im (40 ft. lbs.).
(4) Install generator and compressor. Tighten com-
pressor mounting bracket bolts to 54 N Im (40 ft.
lbs.).
SOLID MOUNT COMPRESSOR BRACKET SERVICEÐTURBO III ENGINE
REMOVAL
(1) Disconnect negative battery cable
9 - 14 2.2/2.5L ENGINE Ä
Page 1581 of 2438
(2) Remove Accessory Drive Belt. Refer to Cooling
System Group 7 for procedure. (3) Remove accessory drive belt idler pulley (Fig.
7).
(4) Remove air conditioning compressor and set
aside (Fig. 8). (5) Remove generator attaching bolts set aside
(Fig. 8). (6) Remove timing belt covers. Refer to procedure
outlined in this section. (7) Remove right engine mount yoke bolt. Remove
the fasteners holding the strut into place. Remove
strut from engine (Fig. 9). (8) Remove accessory drive belt idler pulley
bracket (Fig. 9). (9) Remove timing belt. Refer to procedure out-
lined in this section. (10) Remove 2 bolts holding solid mount compres-
sor into place, Rotate bracket off engine (Fig. 7).
INSTALLATION
(1) Loosely assemble the bracket to engine with #1
and #2 bolts tighten to 3.3 N Im (30 in. lbs.) (Fig. 8).
(2) Install timing belt. Refer to procedure outlined
in this section. Install timing belt covers. Refer to
procedure outlined in this section. (3) Install strut on stud. Tighten nut #3 and bolt
#4, torque to 54 N Im (40 ft. lbs.) (Fig. 9). Loosen #1
and #2 bolts, then torque to 54 N Im (40 ft. lbs.) (Fig.
10).Install yoke bolt and torque to 102 N Im (75 ft.
lbs.). (4) Install accessory drive belt idler pulley and
bracket (Fig. 8). (5) Install accessory drive belt tensioner pulley
(Fig. 7). (6) Install generator (Fig. 8).
(7) Install air conditioning compressor (Fig. 8).
(8) Install accessory drive belt. Refer to Cooling
System Group 7 for procedure. (9) Connect negative battery cable.
Fig. 6 Solid Mount Compressor Bracket 2.2 & 2.5L Engines
Fig. 7 Accessory Drive System
Ä 2.2/2.5L ENGINE 9 - 15
Page 1592 of 2438
valve spring retainer locks to become dislocated
when depressing the valve spring. Check and make
sure the locks are in their proper location. (3) Install valve cover as previously outlined in
this section.
VALVE SPRINGS AND VALVE STEM SEALS
REMOVAL
(1) Remove rocker arms as previously outlined in
this section. (2) Rotate crankshaft until piston is at TDC on
compression. (3) With air hose attached to adapter tool installed
in spark plug hole, apply 90-120 psi air pressure. (4) Using Special Tool C-4682 (Fig. 12) compress
valve springs and remove valve locks. (5) Remove valve spring.
(6) Remove valve stem seal by gently prying side-
to-side with a screwdriver blade. Once dislodged from
guide post, seal may be easily removed.
INSTALLATION
CAUTION: Flexible Fuel Vehicle Valve use unique
valve stem oil seals they are green in color. Stan-
dard valve stem oil seals are NOT to be interchanged
with Flexible Fuel Vehicles engines.
(1) Install valve seals (Fig. 13) as outlined in step
(2) of Valve Gear Reassembly - After Valve Ser-
vice in this section.
(2) Using Special Tool C-4682 compress valve
springs only enough to install locks. Correct align-
ment of tool is necessary to avoid nicking valve
stems (air pressure required), piston at TDC. (3) Install rocker arms as previously outlined in
this section.
CYLINDER HEAD
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs. Refer to Fuel Sys-
tem Group 14 (2) Disconnect negative battery cable. Drain cool-
ing system. Refer to Cooling System, Group 7. (3) Remove air cleaner and disconnect all vacuum
lines, electrical wiring and fuel lines from throttle
body. (4) Remove throttle linkage.
(5) Loosen power steering pump and remove belt.
(6) Remove power brake vacuum hose from intake
manifold. (7) Remove water hoses from water crossover.
(8) Raise vehicle and remove exhaust pipe from
manifold. (9) Remove power steering pump assembly and set
aside. (10) Disconnect coil wiring connector and coil wire
from coil. (11) Disconnect dipstick tube from thermostat
housing and ROTATEbracket from stud. DO NOT
bend the bracket or tube. (12) See Solid Mount Compressor Bracket in
STANDARD SERVICE PROCEDURES, this Group. (13) Remove cylinder head bolts.
INSPECT HEAD AND CAMSHAFT BEARINGJOURNALS
(1) Cylinder head must be flat within 0.1mm (.004
inch) (Fig. 14). (2) Inspect camshaft journals for scoring and jour-
nal caps for oversize markings. When servicing cyl-
inder head or camshaft, it is necessary to be certain
that oversized camshafts are used only in oversized
heads. Identify oversize components as follows:
Fig. 12 Removing and Installing Valve SpringFig. 13 Valve Stem Seals
9 - 26 2.2/2.5L ENGINE Ä
Page 1635 of 2438
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
Page 1636 of 2438
(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