timing belt CHEVROLET DYNASTY 1993 Owner's Manual

CAMSHAFT AND CRANKSHAFT TIMING
PROCEDURE
INSTALLATION
(1) Remove air cleaner fresh air duct.
(2) Remove ignition cable cover (Fig. 7).
(3) Remove valve covers and loosen rocker arm as-
semblies about 3 turns as shown in (Fig. 8).
CAUTION: Check lash adjuster for loose or missing
retainers before continuing service procedure.
(4) Align and pin both intake and exhaust cam
sprockets with 3/32 drills or pin punches (Fig. 9). Ac-
cessory Shaft does not need to be timed. (5) Remove spark plugs.
(6) Install a dial indicator in Number 1 spark plug
hole (Fig. 10). (7) Rotate crankshaft till number 1 piston is at
Top Dead Center. Mark the engine block for TDC
reference. (8) Install timing belt and idler pulley in sequence
shown in (Fig. 11). (9) Remove dial indicator from cylinder head (Fig.
10). Remove drills or pins from camshaft sprockets
(Fig. 11). (10) Adjust tension to 445 N (110 lbs.)
New beltor
311 N (70 lbs.) Used belt. Install belt tension gauge on
timing belt (Fig. 12) adjust tensioner until specified
tension is achieved.
CAUTION: Belt tension gauge must be installed be-
tween the belt teeth to get a accurate reading .
(11) Rotate crankshaft clockwise 2 full revolutions
and check alignment of camshaft and crankshaft tim-
ing marks. Do not reverse rotate crankshaft or
attempt to rotate engine using cam or accessory
shaft attaching screw.
CAUTION: Do not allow oil or solvents to contact the
timing belt as they can deteriorate the rubber and
cause tooth skipping.
Fig. 7 Ignition Cable Cover
Fig. 8 Rocker Arm Shaft Assemblies
Fig. 9 Camshafts Pinned Into Position
Fig. 10 Dial Indicator Located in Number 1 Cylinder
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(12) Recheck belt tension, adjust if necessary.
(13) Torque rocker arm shafts in sequence shown
(Fig. 13) to 12 N Im (105 in. lbs.) then to 24 N Im (210
in. lbs.). (14) Install valve covers, spark plugs, ignition cables
and ignition cable cover. (15) Install air cleaner fresh air duct.
(16) Raise vehicle. Install lower timing belt cover
and accessory drive belt tensioner pulley. Refer to
procedure in this section. (17) Lower vehicle. Install right engine mount (Fig.
5). (18) Inspect foam stuffer block condition and posi-
tion (Fig. 14). Stuffer block should be intact and secure
within the engine bracket tunnel. (19) Install upper timing belt cover and PCV tube.
Refer to procedure in this section. (20) Install accessory drive belt. Refer to procedure
in this section.
SERVICING OIL SEALS
Refer to servicing oil seals in this group for proce-
dures. To service the intake cam seal (Turbo III) the
right engine mount must be removed. Refer to
engine mount removal of this Group.
Fig. 13 Rocker Arm ShaftÐInstallation
Fig. 14 Foam Stuffer Block Location
Fig. 11 Camshafts and Crankshaft Timing Marks
Fig. 12 Belt Tension Gauge Location
Ä 2.2/2.5L ENGINE 9 - 35

CRANKSHAFT OIL SEALS SERVICE
(1) Pry out rear seal with screwdriver. Be careful
not to nick or damage crankshaft flange seal surface
or retainer bore (Fig. 2).
(2) Place Special Tool C-4681 on crankshaft (Fig.
3). (3) Lightly coat seal O.D. with Loctite Stud N'
Bearing Mount or equivalent. (4) Place seal over Tool C-4681 and tap in place
with a plastic hammer.
REAR CRANKSHAFT SEAL RETAINER AND OIL SEAL
When retainer removal is required, use Mopar Gas-
ket Maker applied as shown in (Fig. 4) to provide re-
tainer to block sealing during re-installation.
FRONT CRANKSHAFT SEAL RETAINER
See Timing System and Seals Section for timing
belt covers, belt, crankshaft sprocket and oil seals re-
moval and installation. (1) Remove retainer screws (Fig. 5). For reassembly Mopar Gasket Maker is applied to
the retainer as shown in (Fig. 6). This material cures
in the absence of air providing retainer to block seal-
ing. (2) Install retainer and tighten screws to 12 N Im
(105 in. lbs.).
Fig. 2 Removing Rear Crankshaft Oil Seal
Fig. 3 Installing Rear Crankshaft Oil Seal
Fig. 4 Rear Crankshaft Seal Retainer Sealing
Fig. 5 Front Crankshaft Oil Seal Retainer
Fig. 6 Front Crankshaft Seal Retainer Sealing
9 - 42 2.2/2.5L ENGINE Ä

cap and a crankshaft cheek, using care not to dam-
age any bearing surface. Do notloosen main bearing
cap. (2) Use a feeler gauge between number three
thrust bearing and machined crankshaft surface to
determine end play.
CRANKSHAFT BEARING CLEARANCE
(1) Refer to Measuring Main, Connecting Rod
Bearing Clearance in Standard Service Procedures.
Refer to (Fig. 10) for specifications.
CAUTION: Do not rotate crankshaft or the Plasti-
gage maybe smeared.
(2) Install the main bearing shells with the lubri-
cation groove in the cylinder block (Fig. 12). The 1, 2, 4 and 5 main bearings are full groove to pro-
vide full time oiling to the connecting rod. Only
the number 3 is half-groove.
(3) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block tab
slots. (4) Oil the bearings and journals and install crank-
shaft. (5) Install main bearing cap No. 1 on timing belt
end. (6) Install main bearing cap No. 5 on transmission
end. Since the main bearing bolts are torqued using
a new procedure they should be examined BE-
FORE reuse. If the threads are necked down the
bolts should be replaced (Fig. 15).
Fig. 9 Checking Crankshaft End Play
Fig. 10 Crankshaft Specifications
Fig. 11 Checking Crankshaft Oil Clearance with Plastigage
Fig. 12 Installing Main Bearing Upper Shell
9 - 44 2.2/2.5L ENGINE Ä

CYLINDER BLOCK, PISTON AND CONNECTING ROD ASSEMBLY SERVICE
PISTON AND CONNECTING RODÐREMOVAL
(1) Remove top ridge of cylinder bores with a reliable
ridge reamer before removing pistons from cylinder
block. Be sure to keep tops of pistons covered
during this operation . Mark piston with matching
cylinder number (Fig. 2).
(2) Remove oil pan. Ensure connecting rods and
connecting rod caps for cylinder identification. Identify
them if necessary (Fig. 3). (3) Valve relief toward manifold side of engine. Tur-
bocharged engine pistons will have arrow towards
front of engine. (4) Squirt hole on connecting rod must face timing
belt end of engine. (5) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore. (6) Remove connecting rod cap. Install connecting
rod bolt protectors on connecting rod bolts (Fig. 4).
Push each piston and rod assembly out of cylinder
bore. Be careful not to nick crankshaft journals.
(7) After removal, install bearing cap on the mat-
ing rod.
Fig. 1 Cylinder Block, Piston and Connecting Rod Assembly
Fig. 3 Identify Connecting Rod to Cylinder
Fig. 2 Piston Marking
Ä 2.2/2.5L ENGINE 9 - 49

3.0L ENGINE INDEX
page page
Accessory Drive Belt Service ................ 70
Auto Lash Adjuster ....................... 75
Camshaft Service ........................ 76
Checking Engine Oil Pressure ............... 93
Crankshaft and Cylinder Block, Assembly Service . 86
Cylinder Block ........................... 89
Cylinder Head ........................... 78
Cylinder Head and Camshaft Service ......... 75
Engine Assembly ......................... 69
Engine Lubrication System ................. 91
Engine Mounts .......................... 68 Engine Specifications
..................... 95
General Information ....................... 66
Oil Filter and Bracket ..................... 94
Oil Pan ................................ 92
Oil Pump Service ........................ 92
Piston and Connecting Rod Assembly Service . . . 82
Timing Belt InspectionÐIn Vehicle ............ 72
Timing Belt Service ....................... 72
Valve Service ........................... 80
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). BLOCK: The cylinder block is a light weight de-
sign created by reducing thickness in many parts
and a short 10 mm (3/8 inch) block skirt. High rigid-
ity is provided with ribs cast in the outer wall, a full
length water jacket, and a monoblock or beam type, main bearing cap. This single unit four bearing cap
is designed to control vibration of the cylinder block
partition walls.
CRANKSHAFT: A six throw, five weight crank-
shaft is supported by four main bearings with num-
ber three being the thrust bearing. The six separate
connecting rod throws pins reduce torque fluctua-
tions while a torsional vibration damper is used to
control torsion caused vibration of the crankshaft.
Rubber lipped seals are used at front and rear. The
front seal is retained in the oil pump case and the
rear is retained in a block-mounted housing.
3.0L ENGINE
9 - 66 3.0L ENGINE Ä

PISTONS: Are aluminum alloy with a steel strut,
short height, and thin wall so as to be autothermic
and light weight. The piston head with valve re-
cesses, in combination with the cylinder head, forms
a compact spherical head with clearance for total
valve lift with pistons at top dead center. The piston
skirt, top and second ring lands are finished to a ta-
pered roughness for oil retention and high resistance
to scuffing. Piston pins, press-fitted into place, join
the pistons to the connecting rods. CYLINDER HEAD: The alloy cylinder heads fea- ture cross-flow type intake and exhaust ports. Valve
guides and inserts are hardened cast iron. Valves of
heat resistance steel are arranged i
n a V with each
camshaft on center. To improve combustion speed the
chambers are a compact spherical design with a
squish area of approximately 30 percent of the piston
top area. The cylinder heads are common to either
cylinder bank by reversing the direction of installa-
tion. CAMSHAFTS: Two overhead camshafts provide
valve actuation, one front (radiator side of cylinder
bank) and one rear. The front camshaft is provided
with a distributor drive and is longer. Both cam-
shafts are supported by four bearing journals, thrust
for the front camshaft is taken at journal two and
the rear at journal three. Front and rear camshaft
driving sprockets are interchangeable. The sprockets
and the engine water pump are driven by a single
notched timing belt. ROCKER ARM SHAFTS: The shafts are retained
by the camshaft bearing journal caps. Four shafts are
used, one for each intake and exhaust rocker arm as-
sembly on each cylinder head. The hollow shafts pro-
vide a duct for lubricating oil flow from the cylinder
head to the valve mechanisms. ROCKER ARMS: Are of light weight die-cast
with roller type follower operating against the cam
shaft. The valve actuating end of the rocker arms are
machined to retain hydraulic lash adjusters, elimi-
nating valve lash adjustment. VALVES: Are made of heat resistant steel and are
further treated to resist heat. VALVE SPRINGS: Are especially designed to be
short. The valve spring wire cross-section is oval
SPECIFICATIONS
Fig. 1 Engine Identification
Ä 3.0L ENGINE 9 - 67

(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

Fig. 13 Timing Belt System
Fig. 14 Timing Belt Engine Sprocket Timing
Ä 3.0L ENGINE 9 - 73

INSTALLATION
(1) Place camshaft sprocket on camshaft.
(2) Install bolt and washer to camshaft. Using
Spanner Tool MB990775 hold camshaft sprocket and
torque bolt to 95 N Im (70 ft. lbs.) (Fig. 15).
TIMING BELT TENSIONER
(1) Install timing belt tensioner and tensioner
spring. (2) Hook spring upper end to water pump pin and
lower end to tensioner bracket with hook out (Fig. 16).
(3) Turn timing belt tensioner counter-clockwise full
travel in adjustment slot and tighten bolt to tempo-
rarily hold this position (Fig. 17).
INSTALLATIONÐTIMING BELT
(1) Install timing belt on crankshaft sprocket first
and while keeping belt tight on tension side (Fig. 14)
install belt on the front (radiator side) camshaft
sprocket. (2) Then, install on the water pump pulley and on
the rear camshaft sprocket and finally on the timing
belt tensioner. (3) Apply rotating force to the front camshaft
sprocket in opposite direction to tension the belt ten-
sion side, check that all timing marks are lined up (Fig.
14). (4) Install crankshaft sprocket flange (Fig. 12).
(5) Loosen tensioner bolt and allow spring to tension
timing belt. (6) Turn crankshaft two full turns in clockwise di-
rection. Turn smoothly and in clockwise direction
ONLY. (7) Again line up the timing marks on the sprockets
and tighten the timing belt tensioner locking bolt to 25
N Im (250 in. lbs.) torque.
(8) Reassembly belt covers, engine bracket, insula-
tor, crankshaft pulleys, accessories and accessory drive
belts in reverse order.
Fig. 15 Camshaft Sprockets
Fig. 16 Timing Belt Tensioner
Fig. 17 Positioning Belt Tensioner
9 - 74 3.0L ENGINE Ä