fuel pump CHEVROLET DYNASTY 1993 Owner's Manual

Wiring Diagram
Name Sheet Number
Optical Horn Switch .........................55
Park Brake Switch ...........................70
Park/Neutral Position Switch ...............13, 15, 38
Parking Switch .............................55
Power Door Lock Switch ..................115, 116
Power Mirror Switch ..................... .97, 99
Power Top Switch ...........................96
Power Window Switch ...................... .111
Reading Lamp Switch ................... .124, 126
Right Door Illuminated Entry Switch ..............109
Right Door Switch ......................... .110
Right Window Lift Switch .................... .111
Seat Belt Switch ....................... .101, 103
Transmission Range Switch ................15, 38, 59
Transmission Pressure Switch ...................36
Turn Signal Cancellation .......................56
Turn Signal Switch ..........................55
Vanity Lamp Switch ............118, 120, 122, 124, 126
Vehicle Speed Control Switch ...................59
Window Lift Switch ..................... .110, 111
Wing Switch ............................ .114
Wiper Switch ..............................66
Temperature Sending Unit .................... .40, 41
Transmission Control Module ...........15, 36, 37, 38, 39
Transmission Control Module Connector .............152
Transmission Pressure Switch .....................36
Transmission Range Switch ................... .15, 38
Trip Computer/EVIC ....................... .86, 171Wiring Diagram
Name Sheet Number
Trip Navigator ...............................87
Trunk Lamp ........................... .122, 124
Turbo III Fuel Injection Ignition System .........30, 31, 32,
33, 34, 35
Turn & Hazard Flasher System ...............56, 57, 58
Combo Flasher .............................56
Diode Package .............................56
Left Front Turn Signal Relay ....................57
Left Rear Turn Signal Relay .....................57
Right Front Turn Signal Relay ...................57
Right Rear Turn Signal Relay ....................57
Turn Signal Cancellation Switch ..................56
Underhood Lamp .............................16
Mercury Switch ............................16
Underhood Light ............................16
Vehicle Speed Control System .....................59
Clockspring ...............................59
Vehicle Speed Control Servo ....................59
Vehicle Speed Control Switch ...................59
Vehicle Speed Sensor .................... .21, 25, 35
Visual Message Center Connector ..................88
Windshield Wiper
termittent ...................66, 67
Low Fluid Level Sensor .......................67
Park Switch ...............................67
Washer Pump Motor .........................67
Wiper Motor ..............................66
Wiper Switch ..............................66
Washer Relay .............................66
8W - 540 WIRING DIAGRAMS AG-AJ BODY Ä

Wiring Diagram
Name Sheet Number
Exhaust Gas Recirculation Solenoid 2.5L ..............13
Exhaust Gas Recirculation Diagnostic Solenoid 3.0L. ......20
Fan Control System with A/C and Heater System ......49, 50
A/C Compressor Clutch .......................49
A/C Compressor Clutch Relay ...................50
Fan Control Relay ...........................50
Diode ...................................49
Radiator Fan Fuse ...........................50
Radiator Fan Motor ..........................49
Fan Control System with Heater ....................45
Fan Control Relay ...........................45
Radiator Fan Fuse ...........................45
Radiator Fan Motor ..........................45
Flasher-Hazard ..............................51
Flasher-Turn Signal ............................51
Fog Lamps ........................ .31, 32, 33, 34
Fog Lamp Switch ......................... .31, 33
Front End Lighting ........................ .31, 32
Fog Lamps ............................ .31, 32
Fog Lamp Switch ...........................31
Headlamps-Aero ........................ .31, 32
Park and Turn Signal Lamps ..................31, 32
Side Marker Lamp ....................... .31, 32
Front End Lighting w/DRL .................... .33, 34
Fog Lamps ............................ .33, 34
Fog Lamp Switch ...........................33
Headlamps-Aero ........................ .33, 34
Park and Turn Signal Lamps ..................33, 34
Side Marker Lamp ....................... .33, 34
Fuel Injection Ignition System Engine 2.2L & 2.5L ............... .13, 14, 15, 16, 17
Automatic Shut Down Relay ....................14
Data Link Connector .........................13
Distributor ...............................15
Distributor Ignition Coil .......................14
Engine Coolant Temperature Sensor ...............15
Exhaust Gas Recirculation Solenoid ................13
EVAP/Purge Solenoid .........................13
Fuel Pump Relay ...........................14
Heated Oxygen Sensor ........................17
Idle Air Control Motor ........................16
Injector .................................13
MAP Sensor ..............................15
Powertrain Control Module ...........13, 14, 15, 16, 17
Throttle Position (Sensor) ......................16
Vehicle Speed Sensor ........................15
Fuel Injection Ignition System 3.0L ........18, 19, 20, 21, 22
Automatic Shut Down Relay ....................22
Data Link Connector .........................22
Distributor ...............................18
Distributor Ignition Coil .......................22
Engine Coolant Temperature Sensor ...............18
Exhaust Gas Recirculation Solenoid ................20
EVAP/Purge Solenoid .........................19
Fuel Injectors ..............................19
Fuel Pump Relay ...........................22
Heated Oxygen Sensor ........................18Wiring Diagram
Name Sheet Number
Idle Air Control Motor ........................20
Injectors .................................19
MAP Sensor ..............................20
Power Steering Pressure Switch ..................19
Powertrain Control Module ...........18, 19, 20, 21, 22
Throttle Position (Sensor) ......................20
Vehicle Speed Sensor ........................18
Fuel Pump Motor .............................68
Fuel Tank Sending Unit .........................68
Fuel Tank System .............................68
Fuel Pump Motor ...........................58
Fuel Tank Sending Unit ........................68
Fuse Application Char t.........................1,2
Fuse Block Module ............................76
Fuses Fuse 1 ...............1,31,33,37,41,46,47,65,67
Fuse 2 ........................1,,36,39,61,64
Fuse 3 ..............................2,11,29
Fuse 4 ...........................2,11,35,43
Fuse 5 .............................1,3,5,51
Fuse 6 .........................2,11,35,41,67
Fuse 7 ...........................2,11,46,47
Fuse 9 ...........................1,35,42,65
Fuse 10 ..........................1,31,33,36
Fuse 12 ...............................1,43
Fuse 13 ....................2,3,5,39,44,55,65
Fuse 14 .............................2,11,54
Fuse 15 .............................2,11,51
Fuse 16 .............................2,11,65
Generator .................................4,6
Glove Box Lamp .............................39
Glove Box Lamp Switch .........................39
Hazard Flasher System ...................... .51, 52
Headlamp Switch ...........................1,36
Circuit Breaker .............................36
Optical Horn ..............................36
Headlamp Switch Connector ......................83
Headlamp Switch Controlled Interior Lamps .........37, 38
Headlamp Switch Controlled Interior Lighting .........37, 38
Ash Receiver Lamp ..........................37
Cigar Lighter ..............................37
Cigar Lighter Lamp ..........................37
Transmission Range Lamp .....................37
Heated Oxygen Sensor ...................... .17, 18
Heated Rear Window ..........................67
Heated Rear Window Switch ....................67
Timer ...................................67
Heater Blower Motor Resistor .....................46
Heater System ...............................46
Bi-Level Control Switch .......................46
Blower Motor ..............................46
Blower Slide Control .........................46
Illumination Lamp ...........................46
Resistor .................................46
Horn System ...............................42
Clockspring ...............................42
Horn (Hi-note) .............................42
8W - 718 WIRING DIAGRAMS AP BODY D-P Ä

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

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

The MOPAR Silicone Rubber Adhesive Sealant
gasket material or equivalent should be applied in a
continuous bead approximately 3mm (0.120 inch) in
diameter. All mounting holes must be circled. For
corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 inch.)
drop is placed in the center of the gasket contact
area. Uncured sealant may be removed with a shop
towels. Components should be torqued in place while
the sealant is still wet to the touch (within 10 min-
utes). The usage of a locating dowel is recommended
during assembly to prevent smearing of material off
location.
CRANKSHAFT SPROCKET BOLT ACCESS PLUG
An Access plug is located in the right inner fender
shield. Remove the plug and insert proper size
socket, extension and rachet, when crankshaft rota-
tion is necessary.
ENGINE PERFORMANCE
If a loss of performance is noticed, ignition timing
should be checked. If ignition timing is retarded by
9, 18 or 27É indicating 1, 2 or 3 (timing belt or chain)
teeth may have skipped, then, camshaft and acces-
sory shaft timing with the crankshaft should be
checked. Refer to Engine Timing Sprockets and Oil
Seals of the Engine Section. To provide best vehicle performance and lowest ve-
hicle emissions, it is most important that the tune-up
be done accurately. Use the specifications listed on
the Vehicle Emission Control Information label
found in the engine compartment. (1) Test cranking amperage draw. See Starting
Motor Cranking Amperage Draw Electrical Section
of this manual. (2) Tighten the intake manifold bolts to specifica-
tions. (3) Perform cylinder compression test.(a) Check engine oil level and add oil if neces-
sary. (b) Drive the vehicle until engine reaches normal
operating temperature. (c) Select a route free from traffic and other
forms of congestion, observe all traffic laws, and ac-
celerate through the gears several times briskly.
CAUTION: Do not overspeed the engine. The higher
engine speed may help clean out valve seat deposits
which can prevent accurate compression readings.
(d) Remove all spark plugs from engine. As
spark plugs are being removed, check electrodes for
abnormal firing indicators fouled, hot, oily, etc.
Record cylinder number of spark plug for future
reference. (e) Disconnect coil wire from distributor and se-
cure to good ground to prevent a spark from start- ing a fire (Conventional Ignition System). For Direct
Ignition System DIS disconnect the coil connector. (f) Be sure throttle blade is fully open during the
compression check. (g) Insert compression gage adaptor into the #1
spark plug hole in cylinder head. Crank engine until
maximum pressure is reached on gage. Record this
pressure as #1 cylinder pressure. (h) Repeat Step G for all remaining cylinders.
(i) Compression should not be less than (689kPa)
100 psi and not vary more than 25 percent from
cylinder to cylinder. (j) If one or more cylinders have abnormally low
compression pressures, repeat steps 3b through 3h. (k) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question.
The recommended compression pressures are
to be used only as a guide to diagnosing engine
problems. An engine should not be disassembled
to determine the cause of low compression un-
less some malfunction is present. (4) Clean or replace spark plugs as necessary and
adjust gap as specified in Electrical Group 8. Tighten to
specifications. (5) Test resistance of spark plug cables. Refer to
Ignition System Secondary Circuit Inspection Electri-
cal Section Group 8. (6) Inspect the primary wire. Test coil output volt-
age, primary and secondary resistance. Replace parts
as necessary. Refer to Ignition System and make nec-
essary adjustment. (7) Ignition timing should be set to specifications.
(See Specification Label in engine compartment). (8) Test fuel pump for pressure and vacuum. Refer to
Fuel System Group 14, Specifications. (9) The air filter elements should be replaced as
specified in Lubrication and Maintenance, Group 0. (10) Inspect crankcase ventilation system as out
lined in Lubrication and Maintenance, Group 0. For
emission controls see Emission Controls Group 25 for
service procedures. (11) Inspect and adjust accessory belt drives refer-
ring to Accessory Belt Drive in Cooling System, Group
7 for proper adjustments. (12) Road test vehicle as a final test.
HONING CYLINDER BORES
Before honing, stuff plenty of clean shop towels
under the bores, over the crankshaft to keep abrasive
materials from entering crankcase area. (1) Used carefully, the cylinder bore resizing hone
C-823 equipped with 220 grit stones, is the best tool for
this job. In addition to deglazing, it will reduce taper
and out-of-round as well as removing light
9 - 2 ENGINE Ä

2.2/2.5L ENGINES INDEX
page page
Balance Shafts .......................... 45
Camshaft and Crankshaft Timing Procedure .... 34
Camshaft, Crankshaft and Intermediate Shafts Timing Procedure ....................... 20
Camshafts Service ....................... 36
Checking Engine Oil Pressure ............... 60
Crankshaft Oil Seals Service ................ 42
Crankshaft Service ....................... 43
Crankshaft, Intermediate and Balance Shaft Service ............................... 41
Cylinder Block, Piston and Connecting Rod Assembly Service ....................... 49
Cylinder Head ........................... 26
Cylinder Head and Valve Assembly ServiceÐExcept Turbo III ................. 22
Cylinder Head and Valve Assembly ServiceÐTurbo III ...................... 31
Cylinder Head ComponentsÐIn-Vehicle Service . 23
Engine Assembly ......................... 13 Engine Core Plugs
....................... 55
Engine Lubrication System ................. 56
Engine Mounts .......................... 12
Engine Specifications ...................... 62
General Information ........................ 8
Intermediate Shaft Service .................. 47
Lash Adjuster (Tappet) Noise ............... 37
Oil Filter ............................... 61
Oil Pan ................................ 58
Oil Pump Service ........................ 58
Solid Mount Compressor Bracket Service ...... 14
Timing System and Seals ServiceÐ Except Turbo III ........................ 18
Valve Components ReplaceÐCylinder Head Not Removed .......................... 37
Valve ServiceÐCylinder Head Removed ....... 27
Valve Springs and Valve Stem Seals ......... 38
GENERAL INFORMATION
ENGINE IDENTIFICATION NUMBER OR CODE
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 1). METHANOL FUEL COMPATIBILITY IDEN-
TIFICATION Beginning this model year, Chrysler began produc-
ing AA-Body vehicles designed to operate on a mix-
ture of gasoline and methanol. These automobiles are
referred to as Flexible Fuel vehicles.
2.2/2.5L ENGINE SPECIFICATION
9 - 8 2.2/2.5L ENGINE Ä

Flexible fuel vehicles can operate on a mixture of
up to 85 percent methanol, 15 percent unleaded gas-
oline. These vehicles also operate on mixtures con-
taining a lower percentage of methanol or just pure
unleaded gasoline. Engine components which are required for safe op-
eration using fuel containing methanol alcohol are
identified by a standard green color and/or display
the statement methanol compatible imprinted on the
component. To ensure continued safe operation, these
components must be serviced only with genuine MO-
PAR replacement parts. Methanol compatible parts for the 2.5L FFV (Flex-
ible Fuel Vehicle) engine include, but are not limited
to; the valve stem oil seals, all piston rings, the oil
fill cap, the fuel injectors, fuel rail, fuel pressure reg-
ulator, hoses and the vacuum control harness hose. BLOCK: All four cylinder cast iron blocks have
cast-in recesses in the bottom of each cylinder bore to
provide connecting rod clearance; especially needed
for 2.5L engines. The bores are also siamese to min-
imize engine length. A coolant passage is drilled
cross-ways through the siamese section to enhance
between the bore cooling on some engine types. A
partial open deck is used for cooling and weight re-
duction with oil filter, water pump, and distributor
mounting bosses molded into the front (radiator side)
of the block. Nominal wall thickness is 4.5 mm. Five
main bearing bulkheads and a block skirt extending
3 mm below the crankshaft center line add to the
blocks high rigidity with light weight. CRANKSHAFT: A nodular cast iron crankshaft is
used in TBI engines. A forged steel crankshaft is
used in the Turbo III engine. All engines have 5 main bearings, with number 3 flanged to control
thrust. The 60 mm diameter main and 50 mm diam-
eter crank pin journals (all) have undercut radiuses
fillets that are deep rolled for added strength. To op-
timize bearing loading 4 counterweights are used.
Hydrodynamic seals (installed in diecast aluminum
retainers) provide end sealing, where the crankshaft
exits the block. Anaerobic gasket material is used for
retainer-to-block sealing. No vibration damper is
used. A sintered iron (TBI engine and steel billet
Turbo III engines) timing belt sprocket is mounted
on the crankshaft nose. This sprocket provides mo-
tive power; via timing belt to the camshaft and inter-
mediate shaft sprockets (also sintered iron (TBI
engine and steel billet Turbo III engines) providing
timed valve, distributor, and oil pump actuation. PISTONS: Some Chrysler pistons have cast-in
steel struts at the pin bosses for autothermic control.
All 2.2L and 2.5L piston tops have cuts to provide
valve clearance. Some pistons are dished to provide
various compression ratios. Standard 2.2L and 2.5L
engines are designed for 9.5:1 and 8.9:1 compression
ratios respectively. The 2.5L piston is dished and is a
lightweight design to enhance engine smoothness.
The 2.2L turbo III uses dished pistons providing a
8.3:1 compression ratio. All standard 2.2/2.5L and
2.5L FFV engines use pressed-in piston pins to at-
tach forged steel connecting rods, 2.2L turbo III en-
gine uses a full floating piston pin and connecting
rod assembly. PISTONS RINGS: The 2.2/2.5L engines share
common piston rings throughout, including molybde-
num filled top ring for reliable compression sealing
and a tapered faced intermediate ring for additional
cylinder pressure control. The 2.5L FFV engine fea-
ture all chrome rings for enhanced long term dura-
bility under multi-fueled conditions. CYLINDER HEAD: The cylinder head is cast alu-
minum with in-line valves. The 2.2/2.5L and 2.5L
FFV valves are arranged with alternating exhaust
and intake. The intake and exhaust ports are located
in the rearward, facing side of the head. The Turbo
III valves are arranged in two inline banks, with the
ports of the bank of two intake valves per cylinder
facing toward the radiator side of engine and ports of
the bank of two exhaust valve per cylinder facing to-
ward the dash panel. The intake ports feed fast-burn
design combustion chambers (2.2/2.5L and 2.5L FFV
only) with the spark plug located close to the center
line of the combustion chamber for optimum effi-
ciency. An integral oil gallery within the cylinder
head supplies oil to the hydraulic lash adjusters,
camshaft, and valve mechanisms. CAMSHAFT: The nodular iron camshaft has five
bearing journals (2.2/2.5L and 2.5L FFV). The Turbo
III employs dual camshafts that have nine bearing
journals. Flanges at the rear journal control cam-
Fig. 1 Engine Identification
Ä 2.2/2.5L ENGINE 9 - 9

shaft end play. A sintered iron (TBI engine and steel
billet Turbo III engines) timing belt sprocket is
mounted on the cam nose, and a hydrodynamic oil
seal is used for oil control at the front of the cam-
shaft. ACCESSORY SHAFT: The iron accessory shaft
has two bearing journals and is housed in the for-
ward facing side of the block. A hydrodynamic seal,
installed in an aluminum housing attached to the
block, provides retention, shaft thrust, and oil con-
trol. The accessory shaft is driven by the timing belt
through a sintered iron (TBI engine and steel billet
Turbo III engines) sprocket mounted on the nose of
the accessory shaft. The accessory shaft in turn
drives the oil pump and distributor on 2.2/2.5L and
2.5L FFV and the oil pump only on Turbo III. VALVES: The valves are actuated by roller cam
followers which pivot on stationary hydraulic lash
adjusters. The valve train with 40.6 mm (1.60 inch)
diameter intake valves and 35.4 mm (1.39 inch) di-
ameter exhaust valves employ viton rubber valve
stem seals except 2.5L FFv . the 2.5L FFV valve
stem seals are made of special rubber compound
which resist the deteriorating effects of methanol
fuel by-products that enter the oil during combus-
tion. Valve springs, spring retainers, and locks are
conventional. For Turbo III engines the valves are
actuated by roller tipped rocker arms with hydraulic
lash adjusters which pivot on a shaft. The valve train
with 33.88 mm (1.33 in.) diameter intake valves are
arranged in line opposite of the 29.26 mm (1.15 in.)
diameter exhaust valves employ locking valve stem
seals. Valve springs, spring retainers, and locks are
not interchangeable with other engines. BALANCE SHAFTS: 2.2 Turbo III and 2.5L en-
gines are equipped with two counter rotating balance
shafts installed in a carrier attached to the lower
crankcase. The shafts are interconnect through
gears. These gears are driven by a short chain from
the crankshaft, to rotate at two times crankshaft
speed. This counterbalances certain engine recipro-
cating forces. INTAKE MANIFOLDS:
All intake manifolds are
aluminum castings, attached to the cylinder head
with eight bolts. N.A. engines use a four branch de-
sign. This long branch fan design enhances low and
midspeed torque. It also features an integrally cast
water crossover passage to warm incoming fuel/air
mixture, plus an EGR mounting boss and PCV inlet. The Turbo III engine intake manifold is a log type
with tuned runners. The manifold is machined to ac-
cept fuel injectors near the ports of each cylinder. EXHAUST MANIFOLDS: The exhaust manifolds
are made of nodular cast iron for strength and high
temperatures. All naturally aspirated (N.A.) and tur-
bocharged engines exit exhaust gasses through a ma-
chined, articulated joint connection to the exhaust
pipe. 2.2/2.5L and 2.5L FFV manifolds intermesh
with the intake manifold at the cylinder head. N.A. engines use a four branch design with cylin-
ders one and four joined and cylinder two and three
joined to exit at the outlet. The Turbo III engine exhaust manifold also carries
the turbocharger. This manifold has a modified log
type collector with exhaust gasses directed to and
through the turbocharger to exit the conical (articu-
lated joint) outlet machined into the turbocharger ex-
haust elbow. ENGINE LUBRICATION: Refer to Group 0 Lu-
brication and Maintenance for recommended oil to be
used in various engine application. System is full
flow filtration, pressure feed type. The oil pump is
mounted within the crankcase and driven by the ac-
cessory shaft. Pressurized oil is then routed through
the main oil gallery, running the length of the cylin-
der block, supplying main and rod bearings with fur-
ther routing (for 2.2L turbo III and 2.5L engines) to
the lower balance shaft assemblies. Pistons are lubri-
cated from directed holes in the connecting rod as-
semblies. Camshaft and valve mechanisms are
lubricated from a full-length cylinder head oil gallery
supplied from the crankcase main oil gallery.
9 - 10 2.2/2.5L ENGINE Ä

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

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