service CHEVROLET DYNASTY 1993 Service Manual

(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

(9) Mark support assembly to engine bracket if as-
sembly is to be used again. Separate engine mount
insulator from engine mount bracket (Fig. 10). Raise
engine slightly. (10) Remove engine mount bracket (Fig. 10).
(11) Remove timing belt covers (Fig. 11).
TIMING BELT INSPECTIONÐIN VEHICLE
(1) Remove the upper front outer timing belt cover
by loosening the three attaching bolts. (Fig. 11). (2) Inspect both sides of the timing belt drive &
back. Replace belt if any of the following conditions
exist.
² Hardening of back rubber back side is glossy with-
out resilience and leaves no indent when pressed
with fingernail.
² Cracks on rubber back.
² Cracks or peeling of canvas.
² Cracks on rib root.
² Cracks on belt sides.
² Missing teeth.
² Abnormal wear of belt sides. The sides are normal
if they are sharp as if cut by a knife (Fig. 12). (3) If none of the above conditions are seen on the
belt, the belt cover can be reinstalled.
TIMING BELT SERVICE
REMOVAL
(1) Mark belt running direction for installation
(Fig. 14). (2) Loosen timing belt tensioner bolt (Fig. 16) and
remove timing belt. (3) Remove crankshaft sprocket flange shield (Fig.
9).
CAMSHAFT SPROCKETS
REMOVAL
(1) Hold camshaft sprocket with Spanner Tool
MB990775 loosen and remove bolt and washer (Fig.
15). (2) Remove camshaft sprocket from camshaft.
Fig. 10 Right Engine Mount and Engine Mount Bracket
Fig. 11 Timing Belt Covers
Fig. 12 Timing Belt Inspection
9 - 72 3.0L ENGINE Ä

CYLINDER HEAD AND CAMSHAFT SERVICE
CYLINDER HEAD COVER REMOVE
(1) Remove air cleaner assembly.
(2) Disconnect battery and relocate spark plug
wires. (3) Remove vacuum connections.
(4) Remove rocker cover screws and remove cover
(Fig. 2).
INSTALL
(1) Clean cylinder head and cover mating surfaces.
Install new gasket. (2) See (Fig. 2) and apply sealant such as Mopar
Silicone Rubber Adhesive Sealant to cover ends. (3) Install cover and tighten cover bolt washer and
gasket assembly to 10 N Im (88 in. lbs.).
AUTO LASH ADJUSTER
The automatic lash adjusters are precision units in-
stalled in machined openings in the valve actuating
ends of the rocker arms. Do not disassemble the auto
lash adjuster.
FUNCTION CHECK
Check auto adjusters for free play by inserting a
small wire through the air bleed hole in the rocker
arm and VERY LIGHTLY pushing the auto ad-
juster ball check down (Fig. 3). While lightly holding
the check ball down move the rocker up and down to
check for free play. If there is no play replace the ad-
juster.
Fig. 1 Cylinder Head-Camshaft-Valves
Fig. 2 Rocker Cover
Ä 3.0L ENGINE 9 - 75

CAMSHAFT SERVICE
SEE AUTO LASH ADJUSTER FUNCTION CHECK BEFORE DISASSEMBLY
REMOVAL
(1) Install auto lash adjuster retainers. (Fig. 4).
(2) Remove distributor extension (Fig. 1).
(3) When removing camshaft bearing caps do not
remove the bolts from the bearing caps. Remove the
rocker arm, rocker shafts andbearing cap as an as-
sembly.
CAMSHAFT INSPECTION
(1) Inspect camshaft bearing journals for damage
and binding (Fig. 5). If journals are binding,also
check the cylinder head for damage (Fig. 1). Also
check cylinder head oil holes for clogging. (2) Front cylinder head camshaft check the tooth
surface of the distributor drive gear teeth of the cam-
shaft and replace if abnormal wear is evident (Fig.
5). (3) Check the cam surface for abnormal wear and
damage and replace if defective. Also measure the
cam height (Fig. 5) and replace if out of limit, stan-
dard value is 41.25 mm (1.624 inch), wear limitis
40.75 mm (1.604 inch).
CAMSHAFT INSTALL
Lubricate camshaft journals and cams with engine
oil and install camshaft on cylinder head.
ROCKER ARMS
(1) Check rocker arms for wear or damage (Fig. 6).
Replace as necessary. Also see Auto Lash Adjuster.
ROCKER ARM SHAFTS
The rocker arm shaft is hollow and is used as a lu-
brication oil duct. The rocker arm shaft on the inlet
Fig. 3 Auto Lash Adjuster Check
Fig. 4 Auto Lash Adjuster Retainers
Fig. 5 Check Camshafts
Fig. 6 Inspect Rocker Arms
9 - 76 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

install the new cam plug to a depth of 0.5mm (0.020
inch) below the surface of the cylinder head. (6) Replace air cleaner assembly.
CAMSHAFT END SEAL (PLUG) SERVICE ÐOUT OF VEHICLE SERVICE
Install end seal plug with Special Tool MD998306.
(Fig. 13).CYLINDER HEAD
REMOVAL
(1) See Timing System this group for disassembly
and remove camshaft sprockets.
Fig. 10 Assemble Rocker Arm and Shafts
Fig. 11 Distributor Drive
Fig. 12 Install Camshaft Oil Seal
9 - 78 3.0L ENGINE Ä

(2) See Camshaft Rocker Arms Removal.
(3) Remove upper intake manifold assembly. Refer
to Intake and Exhaust Manifolds, Group 11. (4) Remove distributor.
(5) Remove exhaust manifolds and cross over Refer
to Intake and Exhaust Manifolds, Group 11.
(6) Remove cylinder head bolts in sequence shown
in (Fig. 14) and remove cylinder head.
INSPECTION
(1) Before cleaning, check for leaks, damage and
cracks. (2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 15).
(4) Cylinder head must be flat within;
² Standard dimension = less than 0.05mm (.002
inch)
² Service Limit = 0.2mm (.008 inch)
² Grinding Limit = Maximum of 0.2 mm (.008 inch)
is permitted.
CAUTION: This is a combined total dimension of
stock removal from cylinder head if any and block
top surface.
Fig. 13 Install Camshaft End SealÐPlug
Fig. 14 Cylinder Head Bolt Removal Sequence
Fig. 15 Check Cylinder Head
Fig. 16 Cylinder Head Bolt Tightening Sequence
Ä 3.0L ENGINE 9 - 79

INSTALLATION
(1) Clean surfaces of head and block, install head
gasket over locating dowels. (2) Install head on locating dowels.
(3) Install 10mm allen hex head bolts with wash-
ers. (4) Tighten bolts in the order shown in (Fig. 16).
When tightening the cylinder head bolts, tighten
gradually, working in two or three steps and finally
tighten to specified torque of 108 N Im (80 ft. lbs.).
VALVE SERVICE
VALVE AND VALVE SPRINGS
(1) With suitable valve spring compressor, remove
spring retainer locks, retainer, valve spring, spring
seat and valve (Fig. 17). (2) Remove valve stem seals with suitable tool
(Fig. 18). Do not reuse valve stem seals.
VALVES
(1) Check valve stem tip for pitting or depression
at point A (Fig. 19). (2) Check for wear and ridge wear at Point B.
(3) Check for even contact (at face center) with
valve seat, Point C. (4) Check margin. Replace valve if margin is out of
specification (Fig. 20). (5) Check valve guide height (Fig. 20).
(6) Measure valve stem to guide clearance. Refer
to specification (Fig. 21). (7) Measure Valve spring free length and square-
ness (Fig. 22). Refer to (Fig. 21) for specifications.
VALVE SEAT INSPECTION
Inspect the valve seat with Prussian blue to deter-
mine where the valve contacts the seat. To do this,
coat valve seat LIGHTLYwith Prussian blue then
set valve in place. Rotate the valve with light pres-
sure. If the blue is transferred to the center of valve
face, contact is satisfactory. If the blue is transferred
to top edge of the valve face, lower valve seat with a
15 degrees stone. If the blue is transferred to the bot-
tom edge of valve face raise valve seat with a 65 de-
gree stone. (1) Install valve spring seat.
Fig. 17 Remove Valves
Fig. 18 Remove Valve Stem Seals
Fig. 19 Valve Inspection
Fig. 20 Valve Guide Height
9 - 80 3.0L ENGINE Ä

PISTON AND CONNECTING ROD ASSEMBLY SERVICE
(1) Mark Identify Pistons. The pistons are not in-
terchangeable from bank to bank (Fig. 2). Pistons
with the letter R and arrow toward the front of en-
gine are to be installed in cylinders 1-3-5. Pistons
with the letter L and arrow toward the front of en-
gine are to be installed in cylinders 2-4-6.
(2) Mark connecting rod and cap with cylinder
number (Fig. 3). (3) Remove piston rings (Fig. 4).
CYLINDER BORE INSPECTION
(1) Measure the cylinder bore at three levels in di-
rections A and B (Fig. 5). Top measurement should be 12mm (.50 inch) down and bottom measurement
should be 10mm (.38 inch) up. (2) Standard bore dimension: 91.1mm (3.587 inch)
(3) Maximum out-of-round or taper: 0.02mm (.0008
inch)
FITTING PISTONS
Measure approximately 2mm (.080 inch) above the
bottom of the piston skirt and across the thrust face.
(Fig. 6), See Boring Cylinder in Cylinder Block.
FITTING PISTON RINGS
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 16mm (0.63 inch) from bottom of
Fig. 1 Pistons, Connecting Rods
Fig. 2 Mark Pistons
Fig. 3 Mark Matching Parts
9 - 82 3.0L ENGINE Ä

PISTON RINGSÐINSTALLATION
(1) The No. 1 and No. 2 piston rings have a differ-
ent cross section. Install rings with manufacturers
mark and size mark facing up, to the top of the pis-
ton (Fig. 10).
CAUTION: Install piston rings in the following or-
der:
(a) Oil ring expander.
(b) Upper oil ring side rail.
(c) Lower oil ring side rail.
(d) No. 2 Intermediate piston ring.
(e) No. 1 Upper piston ring.
(2) Install the side rail by placing one end between
the piston ring groove and the expander. Hold end
firmly and press down the portion to be installed un-
til side rail is in position. Do Not use a piston ring
expander (Fig. 11).
(3) Install upper side rail first and then the lower
side rail. (4) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 12). (5) Position piston ring end gaps as shown in (Fig.
13). (6) Position oil ring expander gap at least 45É from
the side rail gaps but noton the piston pin center or
on the thrust direction. (7) Connecting rod front mark 72 must always face
forward, toward timing belt end. (Fig. 14) (8) Install the piston and connecting rod assembly
into there respective bore from the cylinder block
top.
CAUTION: Piston assemblies are not to be inter-
changed from bank to bank.
(9) Check alignment marks made during disassem-
bly and that bearing position notches new or used
are on the same side as shown in (Fig. 15).
CONNECTING ROD CLEARANCE
(1) Following procedures specified in the Standard
Service Procedures Section for Measuring Main Bear-
ing Clearance and Connecting Rod Bearing Clear-
ance. (Fig. 16). Refer to (Fig. 18) for specifications.
Fig. 10 Piston Ring Installation
Fig. 11 Installing Side Rail
Fig. 12 Installing Upper and Intermediate Rings
Fig. 13 Piston Ring End Gap Position
9 - 84 3.0L ENGINE Ä