air condition CHEVROLET DYNASTY 1993 Owner's Manual

INSPECTION Replace water pump body assembly if it has any of
these defects: (1) Cracks or damage on the body.
(2) Water leaks from the shaft seal, evident by
coolant traces below the vent hole. (3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the hous-
ing.
ASSEMBLY
Body assembly and housing are serviced as separate
components. (1) Install new O-ring gasket in body O-ring groove.
(2) Assemble pump body to housing and tighten nine
screws to 12 N Im (105 in. lbs.) (Fig. 2).
(3) Rotate pump by hand to check for freedom of
movement. (4) Position water pump pulley to water pump.In-
stall three screws and tighten to 30 N Im (250 in. lbs.).
(5) Position new O-ring in housing to block O-ring
groove.
INSTALLATION (1) On Turbo III engines install the coolant deflector
into the block before installing pump on engine (Fig. 3).
Install spacer between the pump and block for
Turbo III only before tightening pump to speci-
fications. Tighten three top screws (Fig. 1) to 28 N Im
(250 in. lbs.) and lower screw to 68 N Im (50 ft. lbs.).
(2) Install bypass/heater hose and lower radiator
hose. (3) Install generator and air conditioning compres-
sor bracket(s). For solid mount bracket see standard
service procedures in Group 9 Engine. (4) Install generator and air conditioning compres-
sor. (5) Refill cooling system. See
Refilling Cooling
System. (6) Install drive belt, See Accessory Drive Belts,
this Group.
WATER PUMPÐ3.0L ENGINE
The 3.0L pump bolts directly to the engine block,
using a gasket for pump to block sealing (Fig. 4). The
pump is serviced as a unit. The water pump is driven by the timing belt. See
Timing System in Group 9, Engine for component re-
moval providing access to water pump.
REMOVAL (1) Drain cooling system. Refer to Draining Cool-
ing System in this group. (2) Remove mounting bolts.
(3) Separate pump from water inlet pipe (Figs. 4
and 5) and remove.
INSPECTION Replace the water pump if it has any of the follow-
ing defects.
Fig. 4 Water PumpÐ3.0L Engine
Fig. 5 Water Pump Inspection
Fig. 3 Coolant DeflectorÐTurbo III
Ä COOLING SYSTEM 7 - 11

(5) Install drive belt. See Accessory Drive Belts
this group. (6) Install right front lower fender shield.
(7) Refill Cooling System. See Refilling Cooling
System in this section.
ENGINE THERMOSTATS
The 2.2 and 2.5L engine thermostats are located on
the front of the engine (radiator side) in the water
box which is part of the cylinder head construction
(Fig. 9). Turbo III thermostat is located in the water
box located on the driver side of the cylinder head
(Fig. 10). These thermostats do not have an air bleed notch.
The 3.0L engine thermostat is located in a water
box, formed in the timing belt end of the intake man-
ifold. This thermostat has an air bleed valve, located
in the thermostat flange (Fig. 11). The 3.3/3.8L engine thermostat is located in a wa-
ter box, formed in the drive belt side of the intake
manifold (Fig. 13).
DESCRIPTION AND OPERATION
The engine cooling thermostats are wax pellet
driven, reverse poppet choke type. They are designed
to provide the fastest warm up possible by prevent-
ing leakage through them and to guarantee a mini-
mum engine operating temperature of 88 to 93ÉC
(192 to 199ÉF). They also automatically reach wide
open so they do not restrict flow to the radiator as
temperature of the coolant rises in hot weather to
around 104ÉC (220ÉF). Above this temperature the
coolant temperature is controlled by the radiator,
fan, and ambient temperature, not the thermostat.
OPERATION AND TESTING
The thermostat is operated by a wax filled con-
tainer (pellet) which is sealed so that when heated to
a predetermined temperature. The wax expands
enough to overcome the closing spring and water
pump pressure, which forces the valve to open. Cool-
ant leakage into the pellet will cause a thermostat to
fail open. Do not attempt to free up a thermostat
with a screwdriver. The open too soon type failure mode is included in
the onboard diagnosis. The check engine light will
not be lit by an open too soon condition. If it has
failed open, code 17 will be set. Do not change a ther-
mostat for lack of heat by gauge or heater perfor-
mance, unless code 17 is present, see diagnosis for
other probable causes. Failing shut is the normal
long term mode of failure, and normally, only on
high mileage vehicles. The temperature gauge will
indicate this, Refer to diagnosis in this section.
REMOVAL
(1) Drain cooling system down to thermostat level
or below. (2) Remove thermostat housing bolts and housing
(Figs. 9, 10, 11 and 13). (3) Remove thermostat, discard gasket and clean
both gasket sealing surfaces.
INSTALLATIONÐ2.2/2.5L AND TURBO III ENGINES
Place a new gasket (dipped in clean water) on wa-
ter box surface, center thermostat in water box on
gasket. Place housing over gasket and thermostat,
making sure thermostat is in the thermostat hous-
ing. Bolt housing to water box (Figs. 9 and 10).
Tighten bolts to 28 N Im (250 in. lbs.). Refill cooling
system (see Refilling System ).
INSTALLATIONÐ3.0L ENGINE
Center thermostat in water box pocket. Check that
the flange is seated correctly in the countersunk por-
tion of the intake manifold water box (Figs. 11 and
12). Install new gasket on water box. Install housing
over gasket and thermostat and tighten bolts to 12
N Im (133 in. lbs. torque).
Fig. 9 Thermostat, Housing, and Water BoxÐ2.2/
2.5L Engine
Fig. 10 Thermostat, Housing, and Water BoxÐTurbo III
Ä COOLING SYSTEM 7 - 13

(2) Remove radiator pressure cap when engine is
cold, Idle engine until thermostat opens, you should
observe coolant flow while looking down the filler
neck. Once flow is detected install radiator pressure
cap.
RADIATOR
REMOVAL
(1) Disconnect negative battery cable from battery.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(2) Drain cooling system. Refer to Draining Cool-
ing System of this section. (3) Remove hose clamps and hoses from the radia-
tor (Fig. 11). Remove coolant reserve system tank to
filler neck tube. (4) Remove automatic transmission hoses, if
equipped. (5) Remove fan and fan support assembly by dis-
connecting fan motor electrical connector. Remove
fan shroud retaining clips, located on the top and
bottom of the shroud for AA, AG, AJ and AP vehi-
cles. AC/AY vehicle retainer clips are located on the
top only. Lift shroud up and out of bottom shroud at-
tachment clips separating shroud from radiator. Fan
damage should always be avoided. (6) Remove upper radiator mounting screws. Dis-
connect the engine block heater wire if equipped. (7) Remove the air conditioning condenser attaching
screws located at the top front of the radiator,if
equipped. Radiator can now be lifted free from engine compart-
ment. Care should be taken not to damage radia-
tor cooling fins or water tubes during removal.
INSTALLATION
(1) Slide radiator down into position behind radiator
support (yoke). (2) Attach air conditioning condenser to radiator, if
equipped, with a force of approximately 10 lbs. to seat
the radiator assembly lower rubber isolators in the
mount holes provided. (3) Tighten radiator mounting screws to 11.9N Im
(105 in. lbs.). (4) Connect automatic transmission hoses, if
equipped. Tighten hose clamps to 4 N Im (35 in. lbs.).
(5) Slide fan shroud, fan and motor down into clips
on lower radiator flange. Replace shroud retaining
clips. (6) Install upper and lower radiator hoses (including
coolant reserve hose). (7) Connect fan motor electrical connection and con-
nect negative battery cable. (8) Fill cooling system with coolant. Refer to Refill-
ing Cooling Systems. in this group.
(9) Operate engine until it reaches normal operating
temperature. Check cooling system and automatic
transmission for correct fluid levels.
Fig. 11 Cooling ModulesÐAll Models
7 - 20 COOLING SYSTEM Ä

RADIATOR HOSES
The hoses are removed using Constant Tension
Clamp pliers to compress hose clamp. A hardened, cracked, swollen or restricted hose
should be replaced. Do not damage radiator inlet and
outlet when loosening hoses. Radiator hoses should be routed without any kinks
and indexed as designed. The use of molded hoses is
recommended. Spring type hose clamps are used in all applica-
tions. If replacement is necessary replace with the
original style spring type clamp.
FANS
All models use electric motor driven cooling system
fans. The fan modules include a motor support which
may (depending on model) include a shroud. The
module is fastened to the radiator by screws with
U-nuts and retaining clips (Fig. 12). All fan motors are one speed. Attempts to reduce
high temperature gauge reading by increasing en-
gine speed, at the same vehicle speed, can increase
high temperature.
SINGLE FAN
There are no repairs to be made to the fan. If the
fan is warped, cracked, or otherwise damaged, it must be replaced with
onlythe recommended part for
adequate strength, performance and safety (Fig. 13).
DUAL FAN MODULEÐAC/AY BODY
The dual fan module (Fig. 11) is a combination of 2
fans mounted in a one piece shroud which are simul-
taneously activated. The dual fan system improves
engine cooling and air conditioning performance in hot
weather and severe driving conditions, while reducing
fan noise and power consumption.
REMOVAL
Disconnect electric motor lead. Remove fan module
to radiator fasteners and retaining clips. Remove as-
sembly from radiator support. To remove fan from motor shaft, bench support the
motor and motor shaft, while removing the fan retain-
ing clip, so that the shaft and motor will not be
damaged by excessive force. Surface or burr re-
moval may be required to remove fan from motor
shaft. (Fig. 13). Do not permit the fan blades to touch
the bench.
INSTALLATION
Slide the fan on motor shaft. Support motor and
shaft as above while installing fan retaining clip.
Install assembly into pocket on lower radiator tank.
Attach retaining clips and fasteners to radiator tank.
Right side fastener is longer on A/C equipped
vehicles . Connect fan motor lead. For wiring dia-
grams of fan motor systems see Wiring Diagrams
Manual
RADIATOR FAN CONTROLÐALL EXCEPT V-6 ENGINE
Fan control is accomplished two ways. The fan al-
ways runs when the air conditioning compressor
clutch is engaged. In addition to this control, the fan is
turned on by the temperature of the coolant which is
sensed by the coolant temperature sensor which
Fig. 12 Servicing Fan Module
Fig. 13 Radiator Fan Retaining ClipÐTypical
Ä COOLING SYSTEM 7 - 21

sends the message to the Engine Controller. The En-
gine Controller turns on the fan through the fan re-
lay. See Wiring Diagrams Manual for circuity and
diagnostics provided.Switching through the Engine Controller provides
fan control for the following conditions.
² The fan will not run during cranking until the en-
gine starts no matter what the coolant temperature
is.
² Fan will run when the air conditioning clutch is
engaged and low pressure cutout switch is closed.
² For 4 cylinder application the fan will run at ve-
hicle speeds above about 40 mph only if coolant tem-
perature reaches 110ÉC (230ÉF). It will turn off when
the temperature drops to 104ÉC (220ÉF). At speeds
below 40 mph the fan switches on at 102ÉC (215ÉF)
and off at 93ÉC (200ÉF).
² This is to help prevent steaming. The fan will run
only below 16ÉC (60ÉF) ambient. Between 38ÉC
(100ÉF) to 97ÉC (195ÉF) coolant temperature, at idle
and then only for three minutes.
RADIATOR FAN CONTROLÐAC/AY BODY V-6 ONLY
For this application, fan control is accomplished
based on coolant temperature, and on A/C head pres-
sure. These vehicles receive the variable displace-
ment compressor. The fan will go on when;
² Coolant temperature reaches 102ÉC (215ÉF) and off
at 93.4ÉC (200ÉF) regardless of vehicle speed.
² When the head pressure reaches 1516.9 kPa (220
psi) and turn off when the pressure reaches 1103 kPa
(160 psi).
TEMPERATURE GAUGE INDICATION
At idle the temperature gauge will rise slowly to
about 5/8 gauge travel. The fan will come on and the
gauge will drop to about 1/2 gauge travel, this is nor-
mal.
ELECTRIC FAN MOTOR
To check out the electric fan motor, disconnect the
fan motor wire connector and connect it with #14
gauge wires to a good 12-volt battery observing cor-
rect polarity per (Fig. 14). If the fan runs normally,
the motor is functioning properly. If not, replace fan
module using the removal and installation instruc-
tions contained in the Fan Section. If the motor is
noticeably overheated (i.e.; wire insulation melted,
motor charred) the system voltage may be too high.
Check charging system, see Group 8A, Battery/Start-
ing/Charging System Diagnostics.
ELECTRIC FAN MOTOR TEST
Equipment required
² Diagnostic Tool DRB II or equivalent
² Volt/Ohm Meter
² Wiring Diagram Manual (1) Run the engine to normal operating tempera-
ture. (2) Check wiring connector in C25, C9, and C26 for
proper engagement, see Wiring Diagram Manual (3) Using a diagnostic tool, plugged into the diag-
nostic connector rearward of the battery, check the
On-Board Diagnostics (OBD) in the Engine Control-
ler for fault codes, see Group 14, Fuel Injection for
instructions. (4) If fault code 88-12-35-55 is detected, proceed to
Step 5. (5) With the ignition switch in the run position,
test for battery voltage (single pin connector) at the
fan relay. Voltage reading OK, proceed to Step 6a.
Voltage at 0-1 volt, proceed to Step 6b. 6(a) With the ignition off, disconnect the 60-way
connector from the Engine Controller (outboard of
battery) and return the ignition to the run position.
Test for battery voltage at cavity 31 of the 60-way
connector (Fig. 15). Voltage reading OK and female
terminal is not damaged, replace the Engine Control-
ler. Voltage reading 0, repair open or short in C27
circuit. (b) With the ignition off, disconnect the 60-way
connector from the Engine Controller (outboard of
battery) and return the ignition to the run position.
Test for battery voltage at the single pin connector
at the fan relay. Voltage reading OK, replace the
Engine Controller. Voltage reading 0-1 volt, pro-
ceed to Step 7.
(7) With ignition in the run position, test for bat-
tery voltage at the wire (C27) in the 3-way connector
of the fan relay. Voltage reading OK, replace the fan
relay. Voltage reading 0, repair open or short in C27
circuit. (8) Turn ignition off, connect the 60-way connector
at the Engine Controller and test the system.
Fig. 14 Electric Fan MotorÐTypical
7 - 22 COOLING SYSTEM Ä

ACCESSORY DRIVE BELTS INDEX
page page
2.2/2.5L Engine Belts Remove/Install-Adjust .... 24
3.0L Engine Belts Remove/Install and Adjust .... 25
3.3/3.8L and Turbo III Engine Accessory Drive Belt Remove and Install
..................... 26
General Information ....................... 24
GENERAL INFORMATION
PROPER BELT TENSION
Satisfactory performance of the belt driven accesso-
ries depends on belt condition (Fig. 1) and proper belt
tension. Two tensioning methods are given in order
of preference:
² Belt tension gauge method.
² Torque equivalent method.
The belt tension gauge method is usually restricted
to use after the vehicle has been raised on a hoist
and the splash shield has been removed.
BELT TENSION GAUGE METHOD Use belt tensioning Special Tool Kit C-4162 for:
² For conventional belts and Poly-V belts.
Adjust the belt tension for a NeworUsed belt as
prescribed in the Belt Tension Chart.
TORQUE EQUIVALENT METHOD Adjustable accessory brackets provided with a
13mm (1/2 in.) square hole for a torque wrench can
use an equivalent torque value for belt adjustment. Equivalent torque values for adjusting these acces-
sory drive belts are specified on the Belt Tension
Charts .
2.2/2.5L ENGINE BELTS REMOVE/INSTALL-
ADJUST
AIR CONDITIONING COMPRESSOR
(1) Loosen the idler bracket pivot screw A and
locking screws B (Fig. 2) to remove and install belt
and/or adjust belt tension.
ACCESSORY DRIVE BELTS DIAGNOSIS
Fig. 1 Drive Belt Inspection
7 - 24 COOLING SYSTEM Ä

(2) Adjust belt tension by applying torque to
square hole C on idler bracket. Adjust tension to
specification given in Belt Tension Chart. (3) Tighten in order, first, locking screws B then
pivot screw A to 54 N Im (40 ft. lbs.).
POWER STEERING PUMPÐS TYPE
(1) From on top of the vehicle loosen locking screw G.
(2) From under the vehicle loosen the pivot screw
and pivot nut H . (3) After installing a new belt adjust belt tension
with 1/2 in. breaker bar installed in adjusting
bracket. See tension specification in chart. (4) Tighten locking screw G to 54 N Im (40 ft. lbs.).
(5) Tighten pivot screw H and the pivot nut to 54
N Im (40 ft. lbs.)
GENERATOR BELT
(1) Loosen T-Bolt locking nut E and adjusting
screw F to remove and install Poly V belt and/or ad-
just belt tension. (2) Tighten adjusting screw F to adjust belt tension
to specification shown in Belt Tension Chart. (3) Tighten T-Bolt locking nut E to 54 N Im (40 ft.
lbs.).
3.0L ENGINE BELTS REMOVE/INSTALL AND
ADJUST
AIR CONDITIONING BELT
To remove and install the air conditioning com-
pressor drive belt, first loosen the idler pulley lock
nut, then turn the adjusting screw to raise or lower
the idler pulley (Figs. 3 and 4).
To adjust the air conditioning drive belt, loosen
the idler pulley nut (Fig. 3) and adjust belt tension
Fig. 2 Accessory Drive BeltsÐ2.2 and 2.5L Engines
Fig. 3 Accessory Drive BeltsÐ3.0L Engine
Ä COOLING SYSTEM 7 - 25

by tightening adjusting screw (Figs. 3 and 4 ).
Tighten pulley nut to 54 N Im (40 ft. lbs.) after ad-
justment.
GENERATOR/POWER STEERING PUMP BELT
The Poly-V generator/power steering pump belt is
provided with a dynamic tensioner (Fig. 5) to main-
tain proper belt tension. To remove or install this
belt, Release tension by rotating the tensioner clock-
wise
3.3/3.8L AND TURBO III ENGINE ACCESSORY
DRIVE BELT REMOVE AND INSTALL
GENERATOR, POWER STEERING PUMP, AIR
CONDITIONING COMPRESSOR AND WATER
PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic
tensioner (Figs. 7 and 8) to maintain proper belt ten-
sion. To remove or install this belt. (1) Raise vehicle on hoist.
(2) Remove right front splash shield.
(3) Release tension by rotating the tensioner clock-
wise (Figs. 7 and 8). (4) Reverse above procedure to install.
Fig. 5 Release Belt Tensioner
Fig. 6 Belt Tension Chart
Fig. 4 Air Conditioning Belt Idler
7 - 26 COOLING SYSTEM Ä

relay to starter solenoid for loose or corroded connec-
tions. Particularly at starter terminals.
² Repeat test. If engine still fails to crank properly,
trouble is within starter or starter mounted solenoid,
and it must be removed for repairs. Refer to Group
8B, Battery/Starter/Generator Service, Starter re-
placement.
STARTER RELAY TEST
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN PARK OR NEUTRAL WITH THE
PARKING BRAKE APPLIED
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests. (2) Perform the preceding starter solenoid tests
BEFORE performing starter relay tests. Refer to
Starter Solenoid Test. (3) Locate and remove the starter relay. For
starter relay locations, refer to Starter Solenoid Test
(Fig. 13 or 14). (4) After the starter relay has been located and re-
moved, refer to Starter Relay Tests (Fig. 15).
NEUTRAL STARTING AND BACK-UP SWITCH
AUTOMATIC TRANSMISSION ONLY
For electrical diagnostics, when checking starter
circuits, refer to Starter Relay Tests (Fig. 15). For replacement of switch, refer to Group 21, Tran-
saxle, Neutral Starting and Switch Replacement.
STARTER INTERLOCK SWITCHÐCLUTCH PEDAL MOUNTED
MANUAL TRANSMISSION ONLY
For electrical diagnostics, refer to the Starter Relay
Tests. For replacement and/or adjustment of the switch,
refer to Group 6, Manual Transaxle Clutch, Manual
Transaxle Starter Interlock Switch.
IGNITION SWITCH TEST
After testing the starter solenoid and relay, test ig-
nition switch and wiring. Refer to Group 8D, Ignition
Systems, or the Front Wheel Drive Car Wiring Dia-
grams Service Manual. Check all wiring for opens or
shorts, and all connectors for being loose or corroded.
BENCH TESTING STARTER SOLENOID
(1) Disconnect field coil wire from field coil termi-
nal (Fig. 16 or 17). (2) Check for continuity between solenoid terminal
and field coil terminal with a continuity tester. Con-
tinuity should be detected (Fig. 18 or 19). (3) Check for continuity between solenoid terminal
and solenoid housing (Fig. 20 or 21). Continuity
should be detected. If continuity is detected, solenoid
is good. (4) If continuity is not detected in either test, sole-
noid has an open circuit and is defective. If equipped
with:
² BOSCH STARTER: Replace the solenoid.
² NIPPONDENSO STARTER: Replace the starter
assembly.
8A - 16 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Ä

GENERATOR INDEX
page page
General Information ........................ 9
Generator ReplacementÐ2.2L Turbo Engine (With 16 Valve Cylinder Head) ............. 10 Generator ReplacementÐ2.2L/2.5L Engine
...... 9
Generator ReplacementÐ3.0L Engine ......... 10
Generator ReplacementÐ3.3L/3.8L Engine ..... 11
GENERAL INFORMATION
This section will cover generator removal and instal-
lation only. Information covering generator on-vehicle
testing and diagnosis can be found in Group 8A,
Battery/Starting/Charging Systems Diagnostics. To
identify the generator, refer to the Generator Specifi-
cation chart at the rear of this section. These generators are not intended to be disas-
sembled for service. It must be replaced as an
assembly.
GENERATOR REPLACEMENTÐ2.2L/2.5L ENGINE
Removal and repositioning of A/C compressor (with-
out disconnecting refrigerant lines) is necessary on
some models to gain access to generator. (1) Disconnect battery negative cable (Fig. 1).
(2) If Equipped With Air Conditioning:
(a) Remove the A/C drive belt. Refer to Group 7,
Cooling System. (b) Remove the four bolts retaining the A/C com-
pressor to the mounting bracket (Fig. 2). (c) Without disconnecting the A/C refrigerant
lines, position the A/C compressor to allow generator
removal.
WARNING: THE A/C REFRIGERANT SYSTEM IS UN-
DER PRESSURE EVEN WHEN THE ENGINE IS OFF.
REFER TO THE SAFETY PRECAUTIONS AND WARN-
INGS SECTION IN HEATING AND A/C, GROUP 24,
BEFORE PERFORMING ANY SERVICE OPERATION. (3) Remove the generator drive belt. Refer to Group
7, Cooling System. (4) Remove the two generator mounting bolts (Fig.
3) and position the generator to gain access to all the
wire connectors. If equipped with:
² BOSCH GENERATOR: Remove B+ terminal nut,
field terminal nuts, and ground harness hold down
nuts (Fig. 4). Remove wire connector assembly.
² NIPPONDENSO GENERATOR: Remove nuts
from field terminals, ground terminal, wire harness
Fig. 1 Remove Battery Negative (-) Cable
Fig. 2 A/C Compressor ReplacementÐ2.2 L/2.5 L Engine
Fig. 3 Remove/Install Generator
Ä BATTERY/STARTER/GENERATOR SERVICE 8B - 9