lock CHEVROLET DYNASTY 1993 Service Manual

CONNECTING RODS
(1) Follow procedure specified in the Standard Ser-
vice Procedures Section for Measuring Main Bearing
Clearance and Connecting Rod Bearing Clearance
(Fig. 22). Refer to specifications (Fig. 25).
CAUTION: Do not rotate crankshaft or the Plastic-
Gage may be smeared.
The rod bearing bolts should be examined be-
fore reuse. If the threads are necked down the
bolts should be replaced (Fig. 23). Necking can be checked by holding a scale or straight
edge against the threads. If all the threads do not
contact the scale the bolt should be replaced.
(2) Before installing the nuts the threads should be
oiled with engine oil.
(3) Install nuts on each bolt finger tight than alter-
nately torque each nut to assemble the cap properly.
(4) Tighten the nuts to 54 N Im PLUS 1/4 turn (40 ft.
lbs. PLUS 1/4 turn) for N/A engines Do not use a
torque wrench for last step. and 68 NIm (50 ft. lbs.)
for Turbo III engines. (5) Using a feeler gauge, check connecting rod side
clearance (Fig. 24). Refer to connecting rod specifica-
tions (Fig. 25).
ENGINE CORE PLUGS
REMOVAL
Using a blunt tool such as a drift or a screwdriver
and a hammer, strike the bottom edge of the cup plug
(Fig. 26). With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig. 26).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious en-
gine problems.
INSTALLATION
Thoroughly clean inside of cup plug hole in cylinder
block or head. Be sure to remove old sealer. Lightly coat
inside of cup plug hole with sealer. Make certain the
new plug is cleaned of all oil or grease. Using proper
drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5mm
(.020 inch) inside the lead-in chamfer (Fig. 26).
It is in not necessary to wait for curing of the seal-
ant. The cooling system can be refilled and the vehi-
cle placed in service immediately.
Fig. 24 Checking Connecting Rod Side Clearance
Fig. 25 Connecting Rod Specifications
Fig. 26 Core Hole Plug Removal
Fig. 23 Checking Bolts for Stretching (Necked)
Ä 2.2/2.5L ENGINE 9 - 55

OIL PAN
A formed steel oil pan provides lower engine pro-
tection as well as serving as the engine oil reservoir
(Fig. 1). Pan side flanges to block are sealed with
gaskets. The oil pickup tube for some 2.2L engines
have a circular strainer and cover. The 2.5L engine
pickup is also unsupported and the lower end has a
box type strainer (Fig. 4).
PRESSURE LUBRICATION
Oil drawn up through the pickup tube is pressur-
ized by the pump and routed through the full flow
filter to the main oil gallery running the length of
the cylinder block (Fig. 2). Modified oil pickup, pump
and check valve provide increased oil flow to the
main oil gallery.
MAIN/ROD BEARINGS
A diagonal hole in each bulkhead feeds oil to each
main bearing. Drilled passages within the crankshaft
route oil from main bearing journals to crankpin
journals.
ACCESSORY SHAFT
Two separate holes supply the accessory shaft for
the N/A engines. For Turbo III engines there is a slot
in the rear shaft bushing that squirts oil onto the
oil pump drive gears (Fig. 2).
BALANCE SHAFTS
The engine balance shafts are lubricated by an ad-
ditional hole that interconnects a passage in one leg
of the balance shaft carrier to route oil down to the
carrier oil gallery. This gallery directly supplies the
balance shafts front bearings and internal machined
passages in the shafts routes oil from front to rear
shaft bearing journals.
TURBOCHARGER (WHERE EQUIPPED)
If turbocharger equipped, pressurized oil from the
main gallery to sending unit hex fitting is piped from
the fitting to the turbocharger bearing housing.
From the housing a hose and tube connection to a
machined hole in the block provides drainback.
CAMSHAFT/HYDRAULIC LIFTERS
A vertical hole at the number five bulkhead routes
pressurized oil through a restrictor up past a cylinder
head bolt to an oil gallery running the length of the
cylinder head. For 2.2/2.5L and 2.5L FFV engines
hydraulic adjusters are supplied directly from this
gallery while diagonal holes supply oil to the cam-
shaft journals. The camshaft journals are partially
slotted to allow a predetermined amount of pressur-
ized oil to pass into the bearing cap cavities with
small holes directed to spray lubricate the camshaft
lobes. For Turbo III engines oil is supplied thru oil
galleries in the head to the camshafts and rocker arm shafts which feed oil to the lash adjusters. Oil is
feed thru the rocker arms to lubricate the rollers and
the camshaft lobes.
SPLASH LUBRICATION
Oil returning to the pan from pressurized compo-
nents supplies lubrication to the valve stems. Cylinder
bores and wrist pins are splash lubricated from di-
rected holes in the connecting rods.
OIL PAN
REMOVAL
(1) Drain engine oil and remove oil pan.
(2) Clean oil pan and all gasket surfaces.
OIL PAN RAIL TO BLOCK SEALING
For all engines side gaskets (Fig. 1) are employed for
rail sealing.
INSTALLATION
(1) Apply Mopar Silicone Rubber Adhesive Sealant
or equivalent at the front seal retainer parting line
(Fig. 3). (2) Install the oil pan side gaskets to the block. Use
heavy grease or Mopar Silicone Rubber Adhesive Seal-
ant or equivalent to hold in place. (3) Apply Mopar Silicone Rubber Adhesive Sealant
or equivalent to ends of new oil pan end seals at
junction of cylinder block pan rail gasket (Fig. 3). (4) Install pan and tighten to (12) M8 screws to 23
N Im (200 in. lbs.) and 1 M6 screws to 12 N Im (105 in.
lbs.).
OIL PUMP SERVICE
OIL PICKUP
(1) Remove screw on pump cover holding oil pick-up
tube to oil pump (Fig. 4). (2) Remove oil pick-up tube. When reinstalling
make sure to use a new O-Ring on pickup tube .
Fig. 3 Sealing, Front and Rear End Seals
9 - 58 2.2/2.5L ENGINE Ä

OIL PUMP REMOVAL
(1) Remove two (2) screws holding oil pump to cyl- inder block assembly (Fig. 5).
INSTALLATION
(1) Apply Mopar Gasket Maker to pump body-to-
block interface (machined surface). (2) Lubricate oil pump rotor & shaft and drive
gear. (3) Turn crankshaft and intermediate shaft until
markings on sprockets are in line (arrows Fig. 6).
(4) Slot in oil pump shaft mustbe parallel to cen-
ter line of crankshaft when intermediate shaft and
crankshaft are properly timed (Fig. 7).
(5) Install pump full depth and rotate back and
forth slightly to ensure proper positioning and align-
ment through full surface contact of pump and block
machined interface surfaces (Fig. 5).
Fig. 4 Oil Pick-Up
Fig. 5 Oil Pump Assembly
Fig. 6 Crankshaft and Intermediate Shaft Timing
Fig. 7 Oil Pump Shaft Alignment
Ä 2.2/2.5L ENGINE 9 - 59

(3) Oil Pressure: Curb Idle25 kPa (4 psi) mini-
mum 3000 RPM 170-550 kPa (25-80 psi).
OIL FILTER
ANTI-DRAIN BACK VALVE
Installation: Apply liquid (Teflon Type) sealant to
valve-to-block threads (Fig. 16). Tighten assembly to
55 N Im (40 ft. lbs.).
FILTER
CAUTION: When servicing the oil filter (Fig. 16)
avoid deforming the filter can by installing the re-
move/install tool band strap against the can-to-base
lockseam. The lockseam joining the can to the base
is reinforced by the base plate.
(1) Turn counter clockwise to remove.
(2) To install, lubricate new filter gasket. Check
filter mounting surface. The surface must be smooth,
flat and free of debris or old pieces of rubber. Screw
filter on until gasket contacts base. Tighten to 3/4 to
1 turn.
Fig. 12 Oil Pump Cover
Fig. 13 Oil Pressure Relief Valve
Fig. 14 Measuring Inner Rotor Thickness
Fig. 15 Checking Oil Pump PressureÐTypical
Fig. 16 Engine Oil Filter and Antidrain Back Valve
Ä 2.2/2.5L ENGINE 9 - 61

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

shaped and provides the same spring tension as
longer springs. Valve spring retainers, locks and
seals are conventional.INTAKE MANIFOLD: The aluminum alloy man-
ifold is a cross type with long runners to improve in-
ertia. The runners, attaching below at the cylinder
head, also attach above and support an air plenum.
The air plenum chamber absorbs air pulsations cre-
ated during the suction phase of each cylinder. EXHAUST MANIFOLDS: Both manifolds are a
log style made of ductile cast iron. Exhaust gasses,
collected from the front cylinder bank, leave the
front manifold through an end outlet and are fed
through an upper crossover tube to the rear mani-
fold. The collected exhaust from both manifolds are
combined, and exit to the exhaust pipe through an
articulated joint. ENGINE LUBRICATION: System is a full flow
filtration, pressure feed type. The oil pump is
mounted in the chaincase cover. The pump inner ro-
tor is driven by the crankshaft. The engine oil pan
contains a baffle plate to control oil level fluctuation
during engine operation.ENGINE MOUNTS
REMOVAL AND INSTALLATION
RIGHT SIDE MOUNT
(1) Remove the right engine mount insulator ver-
tical fasteners from frame rail. (2) Remove the load on the engine motor mounts
by carefully supporting the engine and transmission
assembly with a floor jack. (3) Remove the thru bolt from the insulator assem-
bly. Remove insulator. (4) Reverse removal procedure for installation. Re-
fer to (Fig. 2) for bolt tightening specifications. (5) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.
FRONT MOUNT
(1) Support the engine and transmission assembly
with a floor jack so it will not rotate. (2) Remove the thru bolt from the insulator and
front crossmember mounting bracket. (3) Remove the front engine mount bracket to
front crossmember screws and nuts. Remove the in-
sulator assembly. (4) Reverse removal procedure for installation. Re-
fer to (Fig. 2) for bolt tightening specifications. (5) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.
Fig. 2 Engine Mounting
9 - 68 3.0L ENGINE Ä

LEFT SIDE MOUNT
(1) Raise vehicle on hoist and remove left front
wheel. (2) Remove inter splash shield.
(3) Support the transmission with a transmission
jack. (4) Remove the insulator thru bolt from the mount.
(5) Remove the transmission mount fasteners and
remove mount. (6) Reverse removal procedure for installation. En-
sure that the slide tube is seated into the rail
bracket guides. Refer to (Fig. 3) for bolt tightening
specifications. (7) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.
ENGINE MOUNT RUBBER INSULATORS
Insulator location on (right side) and transmission
bracket (left side) are adjustable to allow right/left
drive train adjustment in relation to drive shaft as-
sembly length. Check and reposition right engine mount insulator
(left engine mount insulator is floating type and will
adjust automatically (Fig. 3). Adjust drive train posi-
tion, if required, for the following conditions:
² Drive shaft distress: See Driveshafts in Suspen-
sion, 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
assembly with a floor jack. (2) Loosen the right engine mount insulator yoke
screw and two turns on yoke nut, then loosen 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
identification and related assembly length measur-
ing. (4) Tighten right engine mount insulator yoke nut
to 102 N Im (75 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) Mark hood position at hinges and remove hood. (3) Drain cooling system. Refer to Cooling System
Group 7 for draining procedure. (4) Disconnect all electrical connections.
(5) Remove coolant hoses from radiator and en-
gine. (6) Remove radiator and fan assembly.
(7) See Fuel System Group 14, For procedures to
release fuel pressure, disconnect fuel lines and accel-
erator cable. (8) Remove air cleaner assembly.
(9) Hoist vehicle and drain engine oil.
(10) Remove air conditioning compressor mounting
bolts and set compressor aside. (11) Disconnect exhaust pipe at manifold.
(12) Remove transmission inspection cover and
mark flex plate to torque converter position. (13) Remove screws holding torque converter to
flex plate and attach C-clamp on bottom of converter
housing to prevent torque converter from coming out. (14) Remove power steering pump mounting bolts
and set pump aside. (15) Remove two lower transmission to block
screws. (16) Remove starter.
(17) Lower vehicles and disconnect vacuum lines
and ground strap. (18) Install transmission holding fixture.
(19) Attach engine lifting hoist and support en-
gine. (20) Remove upper transmission case to block
bolts. (21) See Engine Mounting in (Fig. 2) and separate
mount/insulators as follows: (a) Mark RIGHT insulator on right yoke and en-
gine plate supports. Remove insulator to rails
screws. (b) Remove FRONT engine mount through bolt
and nut.
Fig. 3 Left Insulator Movement
Ä 3.0L ENGINE 9 - 69

(c) Remove LEFT insulator through bolt from in-
side wheelhouse or insulator bracket to transmis-
sion screws.
(22) Remove engine.
INSTALLATION
(1) Attach hoist and lower engine into engine com-
partment. (2) Align engine mounts and install but do not
tighten until all mounting bolts have been installed.
Tighten bolts to torque specified in (Fig. 2). (3) Install transmission case to cylinder block,
tighten bolts to 102 N Im (75 ft. lbs.) torque.
(4) Remove engine hoist and transmission holding
fixture. (5) Remove C clamp from torque converter hous-
ing. Align flex plate to torque converter and install
mounting screws. Tighten to 75 N Im (55 ft. lbs.)
(6) Install transmission inspection cover.
(7) Connect exhaust system at manifold.
(8) Install starter.
(9) Install power steering pump and air condition-
ing compressor. For belt installation Refer to Acces-
sory Belt Drive in Cooling System Group 7. (10) Lower vehicle and connect all vacuum lines.
(11) Connect all electrical connections including
ground strap. (12) Connect fuel lines and accelerator cable. (13) Install radiator and fan assembly. Connect fan
motor electrical lead. Install radiator hoses. Fill cool-
ing system. Refer to Cooling System Group 7 for fill-
ing procedure. (14) Fill engine crankcase with proper oil to cor-
rect level. (15) Install hood.
(16) Connect battery.
(17) Start engine and run until operating temper-
ature is reached. (18) Adjust transmission or linkage if necessary.
ACCESSORY DRIVE BELT SERVICE
REMOVAL
(1) Loosen Adjusting Lock Nut (Fig. 6).
(2) Turn adjusting jack screw counterclockwise to
reduce belt tension. Remove belt. (3) Inspect drive belt for wear and damage (Fig. 5).
(4) Installation: Adjust belt tension to 5/16 deflec-
tion between pulleys (Fig. 6). (5) Install breaker bar into 1/2 square opening in
tensioner. (6) Rotate tensioner clockwise to remove and in-
stall belt (Fig. 7).
Fig. 4 Accessories Mounting Brackets
9 - 70 3.0L ENGINE Ä

ENGINE MOUNT BRACKET REMOVAL
(1) Remove air conditioning compressor to mount-
ing bracket screws and lay compressor aside (Fig. 4). (2) Remove screws attaching air conditioning com-
pressor mounting bracket and adjustable drive belt
tensioner from block and engine mounting bracket.
Remove both assemblies. (3) Remove steering pump/generator belt tensioner
mounting bolt and remove automatic belt tensioner.
(4) Remove two steering pump to engine mounting
bracket screws and one rear support lock nut. (5) Lay power steering pump aside.
(6) Raise vehicle and remove right inner splash
shield (Fig. 8). (7) Remove crankshaft drive pulleys and torsional
damper (Fig. 9). (8) Lower vehicle and place a jack under engine.
Fig. 5 Drive Belt Inspection
Fig. 6 Air Conditioning Belt
Fig. 7 Generator/Power Steering Belt
Fig. 8 Right Inner Splash ShieldÐTypical
Fig. 9 Crankshaft Drive Pulleys
Ä 3.0L ENGINE 9 - 71

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