boot CHEVROLET DYNASTY 1993 Workshop Manual

POWER STEERING GEAR INDEX
page page
General Information ....................... 25
Outer Tie Rod ........................... 27 Steering Gear Service
..................... 25
GENERAL INFORMATION
The power steering gear (Fig. 1) should NOT be
serviced or adjusted. If a malfunction or oil leak
occurs. The complete steering gear should be
replaced. If a steering gear boot needs to be replaced due to
damage, refer to the power steering gear service sec-
tion in this manual for proper procedure. The power steering system consists of these four
major components. Power Steering Gear, Power Steer-
ing Pump, Pressure Hose, and Return Line. Turning of
the steering wheel is converted into linear travel
through the meshing of the helical pinion teeth with
the rack teeth. Power assist steering is provided by an
open center, rotary type control valve which directs oil
from the pump to either side of the integral rack piston. Road feel is controlled by the diameter of a torsion
bar which initially steers the vehicle. As required
steering effort increases, as in a turn. The torsion bar
twists, causing relative rotary motion between the
rotary valve body and the valve spool. This movement
directs oil behind the integral rack piston, which, in
turn, builds up hydraulic pressure and assists in the
turning effort. The drive tangs on the pinion of the power steering
pump mate loosely with a stub shaft. This is to permit
manual steering control to be maintained if the drive
belt on the power steering pump should break. How-
ever, under these conditions, steering effort will be
increased.
STEERING GEAR SERVICE
The power steering gear should NOT be ser-
viced or adjusted. If a malfunction or oil leak
occurs. The complete steering gear should be
replaced.
REMOVAL
(1) Raise vehicle See Hoisting, Group 0. Put oil drain
pan under vehicle to catch power steering fluid. (2) Remove front road wheels.
(3) Remove both tie rod ends from steering knuckles,
using Puller Special Tool C-3894-A (Fig. 1). (4) Disconnect engine damper strut from crossmem-
ber (if so equipped). (5) Remove the 3 front suspension crossmember at-
taching bolts and the nut (Fig. 2) from the locating
stud. Lower front suspension crossmember, using
Fig. 1 Power Steering Gear Assembly
Ä STEERING 19 - 25

bolts and nut on locating stud (Fig. 2). The right rear
crossmember stud is a pilot that correctly locates
the crossmember. Tighten down this bolt first,
then torque all 4 crossmember fasteners to 122
N Im (90 ft. lbs.).
CAUTION: Proper torque on the crossmember to
frame rail mounting bolts is very important.
(3) Torque the 4 bolts (Fig. 3) attaching the steering
gear assembly to front crossmember, to 68 N Im (50 ft.
lbs.). To ensure proper alignment of the steering
gear tighten left front bolt first. (4) Attach the engine damper strut from the engine
to the crossmember (if so equipped). (5) Attach the fluid tubes (Fig. 3) from the power
steering pump to the fittings on the steering gear.
Torque the fluid pressure line to steering gear tube nut
to 31 N Im (275 in. lbs.).
(6) Mount the outer tie rod ends to the steering
knuckles. Install the tie rod end to steering knuckle
attaching nuts. Torque the tie rod end to steering
knuckle nuts to 52 N Im (38 ft. lbs.). Install cotter pin
in tie rod end. (7) Install the front tire and wheel assemblies on
vehicle. Install the wheel lug nuts and torque to 129
N Im (95 ft. lbs.).
(8) Lower vehicle.
CAUTION: Do not use automatic transmission fluid. (9) Fill power steering pump fluid reservoir to the
(Full-Cold) proper level. (10) Start the engine and let run for a few seconds.
Then turn the engine off.
(11) Add fluid if necessary.
(12) Raise front wheels of vehicle off the ground.
(13) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in
system. Stop engine, check fluid level, and inspect
system for leaks. Fill pump reservoir to correct
level with Mopar t, Power Steering Fluid, or
equivalent. See Checking Fluid Level.
(14) Lower front wheels of vehicle back on the
ground. (15) Adjust toe (Refer to Group 2 Suspension).
OUTER TIE ROD
REMOVAL
(1) Loosen inner tie rod to outer tie rod jam nut (Fig.
4). (2) Remove outer tie rod to steering knuckle cotter
pin and attaching nut (Fig. 4). (4) Remove the tie rod end from steering knuckles, using Puller Special Tool C-3894-A (Fig. 5).
(5) Remove outer tie rod from inner tie rod.
INSTALLATION
(1) Install outer tie rod onto inner tie rod. Make
sure jam nut is on inner tie rod (Fig. 4). (2) Do not tighten jam nut.
(3) Install outer tie rod onto steering knuckle. In-
stall tie rod to steering knuckle attaching nut and
torque to 52 N Im (38 ft.lbs.).
CAUTION: During this procedure do not allow the
steering gear boot to become twisted. (See Wheel
Alignment in the suspension section of this service
manual).
(4) Make toe adjustment by turning inner tie rod.
(5) Tighten the inner to outer tie rod jam nut to 75
N Im (55 ft. lbs.) torque. Lubricate tie rod boot groove
with silicone type lubricant before installing outer
boot clamp, making sure boot is not twisted.
Fig. 4 Outer Tie Rod
Fig. 5 Tie Rod End Removal
Ä STEERING 19 - 27

shift lever through all gear ranges. If the gearshift
lever moves smoothly, the cable(s) should NOT be re-
placed. If the gear lever binds replace the cable that
is causing the binding condition. (1) Working over the left front fender, remove the
lock pin from the transaxle gearshift (selector shaft)
housing (Fig. 4).
(2) Reverse the lock pin (so long end is down) and
insert lock pin into same threaded hole. A hole in the
selector shaft will align with the lock pin, allowing
the lock pin to be screwed into the housing. This op-
eration locks the selector shaft in the 3-4 neutral po-
sition. (3) Remove or install gearshift knob (Fig. 5 or 6).
(4) Remove or install boot (Fig. 7) or console. (5) Remove or install selector and crossover cables
(Fig. 8 or 9).
Cable attachment clips must be installed from
the side. Install cable fittings to shifter pins by
pushing with thumb.
Fig. 4 Manual Transaxle Pinned in the Neutral Position to Adjust Gearshift
Fig. 5 Remove Gearshift Knob
Fig. 6 Install Gearshift Knob
Fig. 7 Remove or Install Boot
Fig. 8 Remove Cables
Ä TRANSAXLE 21 - 3

GEARSHIFT HOUSING
Roll pin must be flush with top of lever.
Fig. 1 Gearshift Housing Disassembled
Fig. 2 Remove or Install Roll Pin and LeverFig. 3 Dust Boot
Ä TRANSAXLE 21 - 21

REAR SEAT BACK REMOVAL (FIG. 44)
(1) Hinge seat back forward and disengage push-in
fasteners holding carpet backing to trunk floor. (2) Remove bolts holding outboard hinge pivot
bracket to seat back. (3) Pull seat back outward to disengage inboard
pivot and separate from vehicle.
REAR SEAT BACK INSTALLATION
Reverse the preceding operation.
SEAT BACK BOLSTER CUSHION REMOVAL (FIG. 44)
(1) Remove rear seat cushion and back as neces-
sary. (2) Remove bolts holding outboard back bolster to
quarter panel. (3) Lift bolster upward to disengage hook retainer
on back of bolster and separate from vehicle.
SEAT BACK BOLSTER CUSHION INSTALLATION
Reverse the preceding operation
FRONT CENTER CONSOLE
REMOVAL (FIG. 45)
(1) Position front seats full forward.
(2) Remove access hole plugs on sides of center
arm rest riser and remove bolts holding riser to floor
bracket. (3) Remove coin holder and remove screws holding
arm rest riser to front console. (4) Position front seats full rearward.
(5) Remove radio bezel from instrument panel. Re-
fer to Group 8E, Instrument Panel. Remove screws
holding console to instrument panel. (6) Remove screws holding console to lower instru-
ment panel rail. (7) Remove screws and disengage hook and loop
fastener holding carpet panels to sides of console and
separate panels from console. (8) Remove screws holding console to forward floor
mounting bracket. (9) Remove set screw holding gear selector knob to
shift lever and pull knob from shifter on vehicles
with automatic transaxle. (10) Lift forward edge of PRNDL cover and sepa-
rate cover from console on vehicles with automatic
transaxle. (11) Lift gear shift boot adapter from console and
push adapter through opening in console on vehicles
with manual transaxle. (12) Separate console from floor and remove from
vehicle.
Fig. 42 Manual Front Seat
Fig. 43 Power Front Seat
Fig. 44 Rear Seat Cushion and Back
Ä AA-BODY 23 - 29

QUARTER WINDOW
REMOVAL
(1) Disengage snaps holding sling well to rear deck
panel. (2) From each side of vehicle, Disengage clips hold-
ing sling well to belt reinforcement brace. Drape
sling well over rear seat back into passenger com-
partment. (3) Remove screw holding quarter trim panel and
door weatherstrip to door opening. (4) Remove the cowl trim and scuff plate covers.
(5) Remove the rear seat cushion.
(6) Disconnect rear speaker wire connectors.
(7) Remove screws holding seat back to floor
brackets and rear shoulder belt retractors (Fig. 1).
Separate rear seat back from vehicle. (8) Remove screws holding quarter trim to quarter
panel at the boot latches. (9) Remove screws holding quarter trim to floor
pan kick up. (10) Separate quarter trim from rear reinforce-
ment. Position trim panel out of quarter window re-
moval path (Fig. 3). (11) Raise quarter window approximately 100 mm
(4 in.) from the down position. (12) Remove bolt holding glass stabilizer bumper
to top of quarter panel opening. (13) Disconnect power window motor wire connec-
tor. (14) Remove bolts holding quarter window assem-
bly to quarter panel and lift the assembly through
the opening at the top of the quarter panel.
INSTALLATION
Reverse the preceding operation. Align the quarter
glass to have adequate pressure on the weatherstrips
for proper sealing. Insert sling well drain tubes into
the holes in the floor pan.
FOLDING TOP STORAGE SLING WELL
REMOVAL (FIG. 4)
(1) Disengage snaps holding sling well to rear deck
inner panel. (2) Disengage snaps holding sling well to quarter
inner panels. (3) Disengage snaps holding sling well to back of
quarter trim panels. (4) Remove bolts upper seat back support bar to
quarter trim panels. (5) Separate support bar from vehicle.
(6) Disconnect drain tubes from bottom of sling
well. (7) Pull sling well from the end of the support bar
retainer channel.
INSTALLATION
Reverse the preceding operation.
FOLDING TOP HEADLINING
REMOVAL (FIG. 5)
(1) Disengage snaps and hook and loop fasteners
holding headlining to quarter inner panels. (2) Disengage hook and loop fasteners holding
headlining to roof rails and top header. (3) Disengage clips holding headlining to roof rail
rearward of quarter glass opening. (4) Remove screws holding headlining to third roof
bow. (5) Remove screws holding headlining to second
roof bow. (6) Remove screws holding headlining to first roof
bow. (7) Remove screws holding headlining to top
header. (8) Separate headlining from vehicle.
INSTALLATION
Reverse the preceding operation.Fig. 3 Quarter Trim Panel
Fig. 4 Folding Top Storage Sling Well
Ä AJ/27-BODY 23 - 87

REAR SEAT BACK INSTALLATION
Reverse the preceding operation.
SEAT BACK BOLSTER CUSHION REMOVAL (FIG. 37)
(1) Remove rear seat cushion and back as neces-
sary. (2) Remove bolts holding outboard seat back bol-
ster to quarter panel. (3) Lift bolster upward to disengage hook retainer
on back of bolster and separate from vehicle.
SEAT BACK BOLSTER CUSHION INSTALLATION
Reverse the preceding operation
FRONT CENTER CONSOLE
REMOVAL (FIG. 38)
(1) Position front seats full forward.
(2) Remove gear selector knob and PRNDL on ve-
hicles with automatic transaxle. Remove illumina-
tion lamp socket and position socket out of the way. (3) Lift gear shift boot adapter from console and
push adapter through opening in console on vehicles
with manual transaxle. (4) Remove bolts holding arm rest riser to floor
bracket. (5) Separate rear console from floor and remove
from vehicle. (6) Position front seats full rearward.
(7) Remove radio bezel from instrument panel. Re-
fer to Group 8E, Instrument Panel. Remove screws
holding console to instrument panel. (8) Remove screws holding forward console to
lower instrument panel rail. (9) Remove screws holding forward console to for-
ward brace. (10) Separate forward console from vehicle.
INSTALLATION
Reverse the preceding operation. Verify PRNDL
adjustment before returning vehicle to use.
FLOOR CARPET
REMOVAL (FIG. 39)
(1) Remove cowl trim panels and scuff plates.
(2) Remove front seats and inboard seat belts.
(3) Remove center arm rest and front console.
(4) Remove outboard seat belt lower attaching
bolts. (5) Remove rear seat cushion.
(6) Pull carpet from under B-pillar trim covers.
(7) Fold carpet and remove through front door
opening.
INSTALLATION
Reverse the preceding operation.
OVERHEAD CONSOLE
REMOVAL (FIG. 40)
(1) Remove screws holding overhead console to re-
inforcement bracket. (2) Slide overhead console rearward to separate re-
inforcement bracket retainer tab from console. (3) Lower console from roof and disconnect wire
connectors.
Fig. 37 Rear Seat Back and Bolster
Fig. 38 Front Center Console
Ä AP-BODY 23 - 113

(1) Attach manifold gauge set.
(2) Open the windows of the passenger compart-
ment and set the air conditioning controls to A/C,
RECIRC, and Low blower speed. (3) Start the engine and allow it to warm up to
normal running temperature. (4) If the air conditioning compressor does not en-
gage, disconnect the low pressure cut-off switch.
Place a jumper wire across the terminals in the con-
nector boot. If the compressor still does not engage, a
problem exists in the compressor clutch feed circuit. (6) Hold the engine speed at 1400 rpm.
(7) Following the instructions provided with the
charging equipment being used. Charge through the
suction side of the system. Use enough refrigerant to
clear the sight glass in the filter drier. (8) At the point when the sight glass clears, note
the weight of the refrigerant supply drum or the
level in the charging cylinder. Then add an addi-
tional 340 g (12 oz) of refrigerant to the system. Re- move the jumper wire from the low pressure cut-off
switch connector and connect the cut-off switch.
(9) Test the over all performance of the air condi-
tioner as described in A/C Overall Performance Test
in this Group. Close all valves on the charging equip-
ment and disconnect the hoses from the service ports
as described in the Manifold Gauge Set Connections
section of this Group. Install the service port caps.
DISCHARGING REFRIGERANT SYSTEM
(R-12) refrigerant is a chlorofluorocarbon (CFC)
that can contribute to the depletion of the ozone
layer in the upper atmosphere. To help protect the
ozone layer, an R-12 refrigerant recycling device
must be used. Use this device when it is necessary to
empty the refrigerant system. Contact an automotive
service equipment supplier for refrigerant recycling
equipment. Refer to the operating instructions pro-
vided with the recycling equipment for proper opera-
tion.
EVACUATING REFRIGERANT SYSTEM
If the A/C system has been open to the atmosphere,
it must be evacuated before the system can be
charged. Moisture and air mixed with the refrigerant
will raise the compressor head pressure above accept-
able operating levels. This will reduce the perfor-
mance of the air conditioner and damage the
compressor. Moisture will boil at near room temper-
ature when exposed to vacuum. To evacuate the re-
frigerant system: (1) Connect a suitable charging station, refrigerant
recovery machine, and a manifold gauge set with
vacuum pump. (2) Open the suction and discharge valves and
start the vacuum pump. When the suction gauge
reads -88 kPa (-26 in. Hg) vacuum or greater, close
all valves and turn off vacuum pump. If the system
fails to reach specified vacuum, the refrigerant sys-
tem likely has a leak that must be corrected. If the
refrigerant system maintains specified vacuum for at
least 30 minutes, start the vacuum pump. Then open
the suction and discharge valves, and allow the sys-
tem to evacuate an additional 10 minutes. (3) Close all valves. Turn off and disconnect the
vacuum pump. The refrigerant system is prepared to be charged
with refrigerant.
CHARGING REFRIGERANT SYSTEMÐEMPTY
SYSTEM
CAUTION: Do not over charge refrigerant system,
as excessive compressor head pressure can cause
noise and system failure.
Fig. 6 Testing for A/C LeaksÐTypical Front/Rear A/C System
Ä HEATING AND AIR CONDITIONING 24 - 11

WARNING: AVOID RADIATOR/CONDENSER FAN
BLADES WHEN WORKING IN THE RADIATOR
AREA. FAN IS CONTROLLED BY TEMPERATURE
AND CAN START ANY TIME IGNITION IS ON. PER-
SONAL INJURY CAN RESULT.
(1) Disconnect fan control switch wire connector.
(2) Using a suitable jumper wire, jump across ter-
minals in wire connector. (3) Connect a suitable continuity tester across fan
control switch terminals. (4) Start engine and set idle at 1300 rpm. The ra-
diator fan should run constantly. (5) Set the A/C controls to A/C and high blower.
(6) If the high pressure gauge reads below 1102
kPa (160 psi) there should be no continuity across
the switch terminals.
CAUTION: Do not allow engine to overheat when ra-
diator air flow is blocked.
(7) Block radiator air flow with a suitable cover to
increase the high side pressure to at least 1585 kPa
(230 psi). Electrical continuity should be detected
across the fan control switch terminals. (8) Remove cover from front of vehicle to allow
high side pressure to decrease. When pressure drops
below 1102 kPa (160 psi), continuity should cease. If fan control switch is defective, replace it.
REMOVAL AND INSTALLATION
CAUTION: Refrigerant removal is not necessary
when removing the Condenser Fan Control Switch.
However, a small amount of refrigerant will vent
from the switch port. Review the refrigerant han-
dling section of Safety Precautions and Warnings in
the General Information section of this Group.
(1) Disconnect wire connector from condenser fan
control switch. (2) Loosen and quickly rotate the switch counter-
clockwise and separate from the high pressure line
switch port. To install, reverse the preceding operation.
DIFFERENTIAL PRESSURE CUT-OUT SWITCH
DIAGNOSIS
The Differential Pressure Cut-Out (DPCO) Switch
(Fig. 3) monitors the liquid refrigerant pressure on
the liquid side of the system. The DPCO is located on
the expansion valve. The expansion valve is black in
color when a variable displacement compressor is
used. The DPCO turns off voltage to the compressor
clutch coil when liquid refrigerant pressure drops to
levels that could damage the compressor. The DPCO
is a sealed factory calibrated unit. It must be re-
placed if defective.
DPCO SWITCH DIAGNOSIS
The work area must not be below 10ÉC (50ÉF) to
test the compressor clutch circuit. (1) With gear selector in park or neutral, and park
brake set, start engine and allow to idle. (2) Raise hood and disconnect DPCO switch con-
nector boot. (3) Using a suitable jumper wire, jump across the
terminals inside wire connector boot. (4) If clutch does not engage, the wiring, fuse, re-
lay, ambient switch, or high pressure cut-off switch
can be defective. Refer to Group 8W, Wiring Dia-
grams. (5) If clutch engages, connect a suitable manifold
gauge set. Read low pressure gauge. At pressure 283
kPa (41 psi) and above, DPCO switch will complete
the clutch circuit. If the low pressure gauge reads be-
low 317 kPa (46 psi), the system is low on refrigerant
charge or empty due to a leak. Refer to Testing For
Refrigerant Leaks in the Refrigerant Service Proce-
dures section. (6) Install connector boot on switch and repeat step
number 3. If the clutch does not engage, replace the
DPCO switch.
TEMPERATURE CONTROL CABLEÐAC/AY MODELS
REMOVAL AND INSTALLATION
A Temperature Control Cable is used on non-ATC
heat or heater-A/C systems only. ATC (Automatic
Temperature Control) systems use an electrically op-
erated temperature control. Refer to the ATC section
of this Group. (1) Remove the A/C-Heater control panel assembly.
Refer to A/C-Heater Control Replacement in Group
8E Instrument Panel. Disconnect the cable attaching
flag from the A/C-heater control and remove the ca-
ble from control panel.
Fig. 3 Differential Pressure Cut-Out Switch
24 - 48 HEATING AND AIR CONDITIONING Ä

housing) through the hole in the housing. Feed the
wire harness and connector through the opening and
into the housing (Fig. 19). (3) Work through the air inlet opening (to the left of
the blower motor wheel). Pull the fin-sensing cycling
switch from the A/C evaporator (Fig. 20). The metal
probe on the switch is pushed into the evapora-
tor approximately three inches.
To install, reverse the preceding operation. The
switch probe should not be installed in the original
location (hole). Insert the probe in the evaporator coil
approximately 5 mm (3 to 4 fins) to the right or left of
the position it was removed. This will insure correct
temperature sensing and system performance. Exces-
sive force should not be required for probe insertion.
Care should be taken not to damage the A/C evaporator
coil or the switch probe.
LOW OR DIFFERENTIAL PRESSURE CUT-OFF
SWITCH
The Low Pressure Cut-Off (LPCO) Switch (Fig. 21)
monitors the refrigerant gas pressure on the suction side of the system. The LPCO is located on the ex-
pansion valve, and the expansion valve is silver in
color when a fixed displacement compressor is used.
The LPCO turns off voltage to the compressor clutch
coil when refrigerant gas pressure drops to levels
that could damage the compressor. The LPCO is a
sealed factory calibrated unit. It must be replaced if
defective.
LPCO SWITCH DIAGNOSIS
The work area must not be below 10ÉC (50ÉF) to
test the compressor clutch circuit. (1) With gear selector in park or neutral and park
brake set, start engine and allow to idle. (2) Raise hood and disconnect LPCO switch con-
nector boot. (3) Using a suitable jumper wire, jump across the
terminals inside wire connector boot. (4) If the compressor clutch does not engage, the
cycling clutch switch, wiring, relay, or fuse can be
defective. Refer to Group 8W, Wiring Diagrams. (5) If clutch engages, connect manifold gauge set.
Read low pressure gauge. At pressure above 97 kPa
(14 psi) and above, LPCO switch will complete the
clutch circuit. If the low pressure gauge reads below
172 kPa (25 psi), the system is low on refrigerant
charge or empty due to a leak. Refer to Testing For
Refrigerant Leaks in the Refrigerant Service Proce-
dures section. (6) Install connector boot on switch and repeat step
number 3. If the clutch does not engage, replace the
LPCO switch.
REMOVAL AND INSTALLATION
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION. REFER TO REFRIGERANT
RECOVERY SECTION.
Fig. 21 Low Pressure Cut-Off Switch
Fig. 19 Remove or Install Wire Harness Grommet
Fig. 20 Remove or Install Fin-sensing Cycling Clutch Switch
24 - 54 HEATING AND AIR CONDITIONING Ä