engine CHEVROLET DYNASTY 1993 Owner's Manual

The power steering pump drive belt should be in-
spected at the time and distance interval described in
the Lubrication and Maintenance Schedules. Refer to
the General Information section of this group.
POWER STEERING FLUID INSPECTION
WARNING: ENGINE MUST NOT BE RUNNING WHEN
INSPECTING POWER STEERING FLUID LEVEL,
PERSONAL INJURY CAN RESULT.
CAUTION: Do not over fill power steering reservoir
when adding fluid, seal damage and leakage can re-
sult.
TO INSPECT FLUID LEVEL:
(1) Position vehicle on a level surface with engine
at normal running temperature. (2) Turn OFF engine and remove ignition key.
(3) Using a wiping cloth, clean oil and dirt residue
from around power steering reservoir cap. (4) Remove reservoir cap or dipstick and wipe off
fluid. (5) Install cap or dipstick.
(6) Remove cap or dipstick. Holding handle or cap
above tip of dipstick, read fluid level (Fig. 4, 5, or 6).
Add fluid if reading is below cold level mark on dip-
stick.
REAR WHEEL BEARINGS
INSPECTION
The rear wheel bearings should be packed with
new lubricant at the distance interval described in the Lubrication and Maintenance Schedules. Refer to
the General Information section of this group. The
bearings should be inspected for contamination and
wear before they are cleaned. Slight discoloration of
bearing rollers and race cup is normal. If metal
Fig. 3 Ball Joint Lubrication
Fig. 4 Power Steering Reservoir DipstickÐ2.2L or 2.5L Engine
Fig. 5 Power Steering Reservoir DipstickÐ3.0L Engine
Fig. 6 Power Steering Reservoir DipstickÐ3.3L or3.8L Engine
0 - 20 LUBRICATION AND MAINTENANCE Ä

BRAKE RESERVOIR LEVEL INSPECTION
WARNING: DO NOT ALLOW PETROLEUM OR WATER
BASE LIQUIDS TO CONTAMINATE BRAKE FLUID,
SEAL DAMAGE AND BRAKE FAILURE CAN RESULT.
RELIEVE PRESSURE IN ANTI-LOCK BRAKE SYS-
TEM BEFORE ADDING BRAKE FLUID TO RESER-
VOIR. IF NOT, BRAKE FLUID COULD DISCHARGED
FROM THE RESERVOIR POSSIBLY CAUSING PER-
SONAL INJURY.
The brake reservoir level should be inspected when
other under hood service is performed. It is normal
for the reservoir level to drop as disc brake pads
wear. When fluid must be added, use Mopar, Brake
Fluid or equivalent. Use only brake fluid conforming
to DOT 3, Federal, Department of Transportation
specification. To avoid brake fluid contamination, use
fluid from a properly sealed container. On vehicles with anti-lock brakes, depressurize the
system before inspecting fluid level. Turn OFF the
ignition and remove the key. Pump the brake pedal
at least 50 times to relieve the pressure in the sys-
tem.
On all vehicles, if fluid should become low after sev-
eral thousand kilometers (miles), fill the reservoir to
level marks on the side of the reservoir (Fig. 8 or 9).
HEADLAMPS
The headlamps should be inspected for intensity
and aim whenever a problem is suspected. When lug-
gage compartment is heavily loaded, the headlamp
aim should be adjusted to compensate for vehicle
height change. For proper service procedures, refer to
Group 8L, Lamps. DRIVER SUPPLEMENTAL AIRBAG SYSTEM
If the AIRBAG indicator lamp does not light at all,
stays lit or lights momentarily or continuously while
driving, a malfunction may have occurred. Prompt service is required. Refer to Group 8M, Restraint
Systems for proper diagnostic procedures.
BODY LUBRICATION
Body mechanisms and linkages should be inspected,
cleaned and lubricated as required to maintain ease of
operation and to prevent corrosion and wear. Before a component is lubricated, oil, grease and dirt
should be wiped off. If necessary, use solvent to clean
component to be lubricated. After lubrication is com-
plete, wipe off excess grease or oil. During winter season, external lock cylinders should
be lubricated with Mopar, Lock Lubricant or equiva-
lent to ensure proper operation when exposed to water
and ice. To assure proper hood latching component operation,
use engine oil to lubricate the lock, safety catch and
hood hinges when other under hood service is per-
formed. Mopar, Multi-purpose Grease or equivalent
should be applied sparingly to all pivot and slide
contact areas.
USE ENGINE OIL ON:
² Door hingesÐHinge pin and pivot points.
² Hood hingesÐPivot points.
² Luggage compartment lid hingesÐPivot points.
USE MOPAR LUBRIPLATE OR EQUIVALENT ON:
² Door check straps.
² Hood counterbalance springs.
² Luggage compartment lid latches.
² Luggage compartment lid prop rod pivots.
² Ash tray slides.
² Fuel Fill Door latch mechanism.
² Park brake mechanism.
² Front seat tracks.
Fig. 8 Anti-lock Brake Reservoir
Fig. 9 Master Cylinder Brake ReservoirÐExcept
Anti-lock
0 - 22 LUBRICATION AND MAINTENANCE Ä

DRIVESHAFTS INDEX
page page
C/V Joint Boots Handling and Cleaning ........ 44
Damper Weights ......................... 48
Driveshaft Identification .................... 27
Driveshaft Positioning Specifications .......... 48
Driveshaft Reconditioning Procedure .......... 31
Driveshafts, Remove Install ................. 27 General Information
....................... 25
Inner C/V Joint .......................... 32
Intermediate Shaft Assembly Recondition ...... 41
Outer C/V Joint .......................... 37
Service Procedures ....................... 27
GENERAL INFORMATION
Chrysler front wheel drive vehicles use two different
driveshaft systems. Some vehicles use an equal length
system while other vehicles use an unequal length sys-
tem (Fig. 1). The equal length system has short solid interconnect-
ing shafts of equal length on the left and right sides.
The unequal length system has a short solid intercon-
necting shaft on the left side with a longer tubular or
solid interconnecting shaft on the right.
The driveshaft assemblies can be serviced in the same
manner for both systems. With the exception of a rubber
washer seal attached to the right inner (Constant Veloc- ity) C/V joint, on an equal length installation. The equal
length system also has an intermediate shaft attached to
a cardan joint (U-joint). With a stub shaft splined into
the right side of the transaxle with a bearing and
bracket assembly fastened to the right rear of the engine
block.
The driveshaft assemblies are three piece units. Each
driveshaft has a Tripod Joint, an Interconnecting Shaft
and a Rzeppa joint. The Tripod Joint is splined into the
transaxle side gear, or into the intermediate shaft on
the right side of an equal length system. The Rzeppa
joint has a stub shaft that is splined into the wheel hub.
Fig. 1 Front-Wheel-Drive Driveshaft Systems
Ä SUSPENSION AND DRIVESHAFTS 2 - 25

DRIVESHAFT RECONDITIONING PROCEDURE
Driveshaft reconditioning and/or boot replacement
for all front wheel drive vehicles is essentially the same
per C/V joint. Note: that lubricant requirements and quanti-
ties are different for Inner Joints than for Outer
Joints, and type being serviced. Use only the
recommended lubricants. See (Fig. 1) for the exploded view of the front drive
shaft components and there location in the assembly. Driveshaft requirements are different for vari-
ous vehicle models, engines, and transaxles, and
often change from one model year to the next. Driveshaft parts will be different to accommodate
this. Therefore, when replacing parts, be sure to use
only those specified in the service parts catalog. For
the exact model year, model, engine, transaxle, and
type being serviced.
Fig. 1 Driveshaft Components
Fig. 21 Install Wheel And Tire Assembly
Fig. 20 Install Spring Washer, Nut Lock, & New Cot- ter Pin
Ä SUSPENSION AND DRIVESHAFTS 2 - 31

(8) Insert balls into raceway by tilting cage and in-
ner race assembly (Fig. 7). (9) Fasten boot to shaft. See Boots Install.
(10) On G.K.N. units insert the new circlip, pro-
vided with kit in shaft groove. Do not over expand
or twist circlip during assembly (Fig. 8). The S.S.G.
unit has a reusable circlip retainer that is an inte-
gral part of driver assembly.
(11) Position outer joint on splined end with hub
nut on stub shaft. Engage splines, and tap sharply
with mallet (Fig. 9). (12) Check that circlip is properly seated by at-
tempting to pull joint from the shaft. (13) Locate large end of boot over joint housing
checking that boot is not twisted. (14) Fasten boot to housing. See Boots Install.
INTERMEDIATE SHAFT ASSEMBLY RECONDITION
Reconditioning of intermediate shaft assembly (Fig.
1), for Equal Length Drive Shaft System vehicles is
the same for manual and automatic transaxles.
INTERMEDIATE SHAFT ASSEMBLY
REMOVE
(1) Remove right driveshaft. See Driveshaft As-
semblies Remove. (2) Remove speedometer pinion from the extension
housing (Fig. 2). (3) Remove the two bolts which mount the bearing
assembly bracket to the engine block (Fig. 1). (4) Remove assembly from transaxle extension by
pulling outward on the yoke (Fig. 3).
UNIVERSAL JOINT AND ROLLER
Disassemble
(1) Mark relationship of shaft to shaft to ensure
proper alignment at assembly. Apply penetrating oil
to bushings and remove snap rings. (2) Support yoke in vise and place a socket large
enough to receive bushing on top of yoke. A 1-1/8
inch socket is suitable (Fig. 4). (3) Striking socket with hammer will cause yoke to
move down and bushing to move up out of yoke into
socket. (4) After removing one bushing, turn parts in a
vise and remove other bushing in same manner.
Assemble (1) Hold cross in position between yoke ears with
one hand and start one bushing assembly into yoke
with other hand (Fig. 5). (2) Continue to hold cross in position, then ham-
mer bushing assembly into yoke and install snap
ring. (3) Install opposite bushing and snap ring in the
same manner.
Fig. 7 Inserting Balls into Raceway
Fig. 8 Installing New Circlip
Fig. 9 Position Joint onto Shaft Splines
Ä SUSPENSION AND DRIVESHAFTS 2 - 41

(3) Swing the bracket into position on the engine and
loosely install the screws through the slotted holes. (4) Push the intermediate shaft assembly into the
transaxle as far as it can travel. Hold the assembly in
this position and tighten the screws (bracket to engine
block) to 54 N Im (40 ft. lbs.) torque. This will ensure
full seal engagement between the journal on the
intermediate shaft and the seal in the transaxle
extension. (5) Distribute a liberal amount of grease in side
spline and pilot bore on bearing end of intermediate
shaft. Use MOPAR Multi-Purpose Lubricant, or
equivalent. (6) Install speedometer pinion (Fig. 9).
(7) Install right driveshaft. See Driveshaft Assem-
blies Install.
C/V JOINT BOOTS Handling and Cleaning
It is vitally important during anyservice procedures
requiring boot handling. That care be taken not to
puncture or tear the boot by over tightening clamps,
misuse of tool(s) or pinching the boot. Pinching can
occur by rotating the C/V joints (especially the tripod)
beyond normal working angles.
The driveshaft boots are not compatible with oil, gaso-
line, or cleaning solvents. Care must be taken that boots
never come in contact with any of these liquids. The only
acceptable cleaning agent for driveshaft boots is
soap and water. After washing, boot must be thor-
oughly rinsed and dried before reusing.
BOOTS INSPECT
Noticeable amounts of grease on areas adjacent to or
on the exterior of the C/V joint boot. Is the first
indication that a boot is punctured, torn or that a
clamp has loosened. When a C/V joint is removed for
servicing of the joint. The boot should be properly
cleaned and inspected for cracks, tears and scuffed
areas on interior surfaces. If any of these conditions
exist, boot replacement is recommended.
BOOTS INSTALL
THE HARD PLASTIC BOOTS REQUIRE APPROXI-
MATELY 100TIMES THE CLAMPING FORCE OF THE
RUBBER BOOT. THE CLAMPS USED ON THE RUB-
BER BOOTS DO NOT HAVE THE TYPE OF LOAD
CAPACITY REQUIRED. TO SEAL THE HARD PLASTIC
BOOTS AND SHOULD NOT BE USED FOR THIS PUR-
POSE.
Rubber boots appear only on the inner joints of
certain driveshafts.
Fig. 9 Install Speedometer PinionFig. 1 C/V Joint Boot Positioning G.K.N.
Fig. 8 Installing Intermediate Shaft Assembly
2 - 44 SUSPENSION AND DRIVESHAFTS Ä

(2) Install boot onto interconnecting shaft, position
boot on the flat between the locating shoulders (Fig. 16).
(3) Position clamp on boot and crimp bridge of
clamp with Crimper Special Tool C-4124.
(4) Install the C/V Joint following the procedure
outlined under Inner C/V Joint Assemble .
(5) Position the large end of boot on housing and
install clamp, crimp bridge of clamp with Crimper,
Special Tool C-4124.
CAUTION: During any service procedures where
knuckle and driveshaft are separated, thoroughly
clean seal and wear sleeve with suitable solvent
and lubricate BOTH components at assembly. Do
not allow solvent to contact boot.
Lubricate wear sleeve (and seal) with Mopar Multi-
Purpose Lubricant, or equivalent, as follows: Wear Sleeve: Apply a full circumference 6 mm
(1/4 inch) bead of lubricant to seal contact area. See
(Fig. 11), Driveshaft Assemblies Install. Seal: Fill lip to housing cavity (full circumference)
and wet seal lip with lubricant.
S.S.G INNER C/V JOINT LARGE CLAMP (MANUAL TRANS ONLY)
(1) Install small clamp and inner C/V joint housing
according to the procedures outlined in this manual. (2) Position the boot over the outer C/V joint.
(3) Slide the large band clamp over the boot and
position it evenly in the groove on the inner C/V
joint boot. (Fig. 17). (4) Use Clamp Locking Tool Snap-On YA3050 or
equivalent shown in (Fig. 18) to install the clamp on
the boot. (5) Place the prongs of the clamp locking tool in
the holes on the clamp and squeeze together until
the two ends meet (Fig. 18).
DAMPER WEIGHTS
Damper weights are used on the left driveshaft as-
semblies of all front wheel drive vehicles (Fig. 19).
These weights are attached to the interconnecting
shaft and are available as a separate service part. They should be removed from the driveshaft assem-
bly during driveshaft positioning specification proce-
dures. When the weights are attached between the
locating shoulders, tighten the fasteners to the fol-
lowing specifications:
² S.S.G. Ð 28 N Im (21 ft. lbs.)
² G.K.N. Ð 30 N Im (23 ft. lbs.)DRIVESHAFT POSITIONING SPECIFICATIONS
Front wheel drive vehicles have engine mounts with
slotted holes allowing for side to side positioning of the
engine. If the vertical bolts on right or left upper engine
Fig. 16 Right Inner C/V Joint S.S.G.
Fig. 17 Boot Clamp Installed
Fig. 18 Locking Boot Clamp
2 - 48 SUSPENSION AND DRIVESHAFTS Ä

mount have been loosened for any reason, or if vehicle
has experienced front structural damage, driveshaft
lengths must be checked and corrected, if required. A
shorter than required driveshaft length can result in ob-
jectionable noise. A longer than required driveshaft
length may result in potential damage.
Use of the following procedure will ensure satisfac-
tory driveshaft engagement under all normal vehicle
operating conditions. (1) The vehicle must be completely assembled.
Front wheels must be properly aligned and in the
straight ahead position. The vehicle must be in a po-
sition so that the full weight of the body is distrib-
uted to all four tires. A platform hoist, or front end
alignment rack, is recommended.
(2) Using a tape measure or other suitable measuring
device. Measure the direct distance from the inner edge of the outboard boot to the inner edge of the inboard
boot on both driveshafts. This measurement must be
taken at the bottom (six o'clock position) of the drive-
shafts (Fig. 1).
Note that the required dimension varies with car-line,
engine, transaxle, and driveshaft manufacturer (Fig. 2).
(3) If the lengths of both shafts are within the
range specified, no further action is required. If either left or right driveshaft length is not
within the specified range. Refer to Group 09, Engine
Removal and Installation to properly position engine
according to specified driveshaft lengths.
(4) If proper driveshaft lengths cannot be achieved
within the travel limits available in the slotted engine
mounts. Check for any condition that could effect the
side to side position of the measurement locations (e.g.,
engine support brackets, siderail alignment, etc.).
(5) After ensuring proper driveshaft lengths the
transmission shift linkage must be adjusted to en-
sure proper operation. Refer to Transaxle, Group 21.
Fig. 2 Driveshaft Identification and Dimensions
Fig. 19 Left Driveshaft with Damper Weight
Fig. 1 Driveshaft Positioning
Ä SUSPENSION AND DRIVESHAFTS 2 - 49

(3) Check solenoid to volume canister joint.
² Front strut to solenoid valve connection.
² Rear spring to solenoid valve connection.
(4) Check air line for ruptures, cuts, splits or heat
damage. Use a soap and water solution or a liquid de-
veloped for leak detection.
SYSTEM OPERATION
ENGINE RUN OPERATION
The system will compensate for load
addition/removal when.
² The trunk and all doors are closed.
² The engine speed exceeds 600 R.P.M.
² Throttle angle is less than 65 degrees.
² The brake is not applied.
² You are not cornering above 10 mph.
² There is not a charging system problem with the
vehicle.
ENGINE OFF OPERATION
After passengers/load is removed from the vehicle
the system will correct the vehicle attitude after:
² The trunk and all doors are closed.
² The ignition switch is in the OFF position.
Opening the a door or trunk wakes up the body
computer and the air suspension module. The air
suspension system is now capable of leveling, if
required.
LONG TERM IGNITION OFF OPERATION
The system is capable of one an additional leveling
cycle. After 2 continuous hours of ignition key off and
no door open or trunk open activities. This feature is
implemented to eliminate possible ice freeze-up be-
tween the tire and the inner fender shield.
SYSTEM OPERATION INHIBITORS
The air suspension system is inhibited when:
² The trunk is open.
² A door(s) is/are open.
² The brake pedal is engaged.
² The throttle is at the wide open position.
² The charging system fails.
The maximum compressor pump or exhaust
time is 3 minutes.
SYSTEM FAILURES
Vehicles equipped with air suspension and overhead
console. Will alert the driver of an air suspension
system malfunction. A warning Check Air Suspension
will appear on the overhead console screen.
SAFETY CONCERNS
WARNING: REAR AIR SPRINGS MUST BE DEFLATED
BEFORE BEING REMOVED FROM THE VEHICLE.
WARNING: OPEN TRUNK, OR DOOR(S) OR REMOVE
GROUND STRAP FROM BATTERY BEFORE HOIST-
ING OR JACKING A VEHICLE DURING MECHANICAL
REPAIRS.
WARNING: IF THE VEHICLE NEEDS SERVICE OR
REPAIR OF THE REAR SHOCK ABSORBERS OR
REAR AXLE PIVOT BUSHINGS. THE REAR AIR
SPRINGS MUST HAVE THE AIR PRESSURE RE-
MOVED BEFORE THE VEHICLE CAN BE SERVICED
SAFELY.
SHIPPING MODE
(1) Removing shipping height signal for customer
use.
² Use DRB II tester and 1991 Chassis (Air Suspen-
sion) service cartridge.
² Follow DRB II requirements to cancel shipping
height message in the body computer.
² Connect the Ignition Off Draw (I.O.D.) circuit.
The connection of the IOD circuit will cancel
the Shipping height signal. (2) Return to shipping height.
² Set shipping command in the body computer using
the DRB II and the 1991 Chassis (Air suspension)
service cartridge.
² Disconnect the I.O.D. connector.
DIAGNOSIS
INITIAL DIAGNOSTIC CHECK
(1) Check for blown or missing fuses.
Fig. 9 Compressor Current Draw Test
2 - 78 SUSPENSION AND DRIVESHAFTS Ä

(2) Check all connectors for correct assembly. Check
all connectors for incorrectly installed termi-
nals. (3) Check pin #21 for minimum of 9.5 volts.
(4) Check pin #20 for minimum of 9.5 volts (with
ignition key on). (5) Check voltage at pins #5 and #16. The measure-
ment should exceed 0 volts. (6) Check pin #19 for continuity.
(7) The engine speed should exceed 680 rpm during
idle. All doors and trunk must be closed for the
system to function.
DIAGNOSTICS PROCEDURES
(1) Use the D.R.B. II tester and the 1991 air suspen-
sion diagnostic service cartridge to begin the trouble-
shooting process. (2) Use the D.R.B. mating connector under the dash
(drivers side) to plug-in the D.R.B. II test connector
(Fig. 10). (3) The tester will conduct a complete check of the
suspension system status. (4) The tester will list the steps to follow to access
and diagnose the failure. (5) A Volt/Ohm meter can be used for some diagnos-
tic testing.
HEIGHT SENSOR CHECK
If a sensor signal/signals are missing. Follow the
repair procedure listed below. (1) Check ground circuit continuity. (Remember
front and rear grounds are on different circuits. (2) For front ground circuit continuity check circuit
S 33. (3) For rear ground circuit continuity check circuit
X20. (4) Refer to control module pin out chart and wiring
diagram (see Group 8F in wiring diagram manual) for
individual circuit details. (5) If open circuits are not found replace the compo-
nent. Complete circuit testing and connector assem-
blies before replacing a strut or right rear shock. (6) To measure resistance values, see Height Sensor
Logic Chart and Initial Diagnostic Check in System
Operation.
HEIGHT SENSOR LOGIC CHART
Ä SUSPENSION AND DRIVESHAFTS 2 - 79