wheel torque CHEVROLET DYNASTY 1993 Workshop Manual

(2) Loosen the right engine mount insulator yoke
screw and 2 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 identifica-
tion and related assembly length measuring. (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 procedure. (4) Disconnect all electrical connections.
(5) Remove coolant hoses from radiator and engine.
(6) Remove radiator and fan assembly.
(7) See Fuel System, Group 14, to release fuel pres-
sure. Disconnect fuel lines and accelerator 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. For disas-
sembly procedure for the all wheel drive vehicle refer to
Group 21 Transaxle. (13) Remove screws holding torque converter to
flex plate and attach C-clamp on bottom of converter
housing to prevent torque converter from counting
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. 3) and separate
mount/insulators as follows: (a) Mark RIGHT insulator on right rails sup-
ports. Remove insulator to rails screws. (b) Remove FRONT engine mount through bolt
and nut. (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. 3). (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. lb-
s.)torque. Refer to Group 21 transaxle for the all
wheel drive installation procedure. (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 see Accessory
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. Reconnect
fan motor electrical lead. Reinstall radiator hoses.
Fill cooling system. See Cooling System Group 7 for
filling procedure. (14) Fill engine crankcase with proper oil to cor-
rect level.
Fig. 4 Left Insulator Movement
Ä 3.3/3.8L ENGINE 9 - 101

(2) Clean varnish deposits from inside of tappet
body above plunger cap. (3) Invert tappet body and remove plunger cap,
plunger, flat or ball check valve, check valve spring,
check valve retainer and plunger spring. Check valve
could be flat or ball.
CLEANING AND ASSEMBLY
(1) Clean all tappet parts in a solvent that will re-
move all varnish and carbon. (2) Replace tappets that are unfit for further ser-
vice with new assemblies. (3) If plunger shows signs of scoring or wear, valve
is pitted, or valve seat on end of plunger indicates
any condition that would prevent valve from seating,
install a new tappet assembly. (4) Assemble tappets (Fig. 27).
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets in their original positions.
(3) With roller tappets, install aligning yokes with
(Fig. 26). (4) Install yoke retainer and torque screws to 12
N Im (105 in. lbs.) (Fig. 26).
(5) Install cylinder heads. Refer to cylinder head
installation of this section for procedure. (6) Start and operate engine. Warm up to normal
operating temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all hy-
draulic tappets have filled with oil and have become
quiet.
VALVE TIMING
(1) Remove front valve cover and all 6 spark plugs.
(2) Rotate engine until the #2 piston is at TDC of
the compression stroke. (3) Install a degree wheel on the crankshaft pulley.
(4) With proper adaptor, install a dial into #2
spark plug hole. Using the indicator find TDC on the
compression stroke. (5) Position the degree wheel to zero.
(6) Remove dial indicator from spark plug hole. (7) Place a 5.08mm (.200 inch) spacer between the
valve stem tip of #2 intake valve and rocker arm
pad. Allow tappet to bleed down to give a solid tap-
pet effect. (8) Install a dial indicator so plunger contacts the
#2 intake valve spring retainer as nearly perpendic-
ular as possible. Zero the indicator. (9) Rotate the engine clockwise until the in take
valve has lifted .254mm (0.010 inch).
CAUTION: Do not turn crankshaft any further clock-
wise as intake valve might bottom and result in se-
rious damage.
(10) Degree wheel should read 3 degrees BTDC to
4 degrees ATDC.
TIMING CHAIN COVER, OIL SEAL AND CHAIN
COVER
REMOVAL
(1) Disconnect battery.
(2) Drain cooling system. Refer to Cooling System
Group 7 for procedure. (3) Support engine and remove right engine
mount. (4) Raise vehicle on hoist. Drain engine oil.
(5) Remove oil pan and oil pump pick-up. It may
necessary to remove transmission inspection cover. (6) Remove right wheel and inner splash shield.
(7) Remove drive belt. Refer to Cooling System
Group 7 for procedure. (8) Remove A/C compressor and set aside.
(9) Remove A/C compressor mounting bracket.
(10) Remove crankshaft pulley (Fig. 1).
(11) Remove idler pulley from engine bracket.
(12) Remove engine bracket (Fig. 2).
(13) Remove cam sensor from chain case cover
(Fig. 3).
Fig. 27 Hydraulic Roller Tappet Assembly
Fig. 1 Removing Crankshaft Pulley
Ä 3.3/3.8L ENGINE 9 - 109

(3) Rotate crankshaft so that the oil pump drive
flats are vertical. (4) Position oil pump inner rotor so the mating
flats are in the same position as the crankshaft drive
flats (Fig. 6). (5) Install cover onto crankshaft. Make sure the oil
pump is engaged on the crankshaft correctly or se-
vere damage may result. (6) Install chain case cover screws and torque to 27
N Im (20 ft. lbs.).
(7) Install crankshaft oil seal (Fig. 7).
(8) Install crankshaft pulley (Fig. 8).
(9) Install engine bracket (Fig. 2) torque screws to
54 N Im (40 ft. lbs.).
(10) Install idler pulley on engine bracket. (11) Install cam sensor Refer to Ignition System
Group 8D for installation procedure. (12) Install A/C compressor mounting bracket.
(13) Install A/C compressor.
(14) Install drive belt Refer to Cooling System
Group 7 for installation procedure. (15) Install inner splash shield and wheel.
(16) Install oil pump pick-up and oil pan and
transmission inspection cover if removed. (17) Install engine mount.
(18) Fill crankcase with oil to proper level.
(19) Fill cooling system Refer to Cooling System
Group 7 for procedure. (20) Connect battery.
TIMING CHAIN COVER EXTERNAL OIL SEAL
REMOVAL
(1) Raise vehicle on hoist. Remove right wheel and
inner splash shield. (2) Remove drive belt. (Refer to Cooling System
Group 7) for procedure. (3) Remove crankshaft pulley (Fig. 1).
Fig. 5 Alignment of Timing Marks
Fig. 6 Timing Chain Case Cover Gaskets and O-Rings
Fig. 7 Install Crankshaft Oil Seal
Fig. 8 Installing Crankshaft Pulley
Ä 3.3/3.8L ENGINE 9 - 111

(4) Using Tool C-4991 to remove oil seal (Fig. 9).
Be careful not to damage that crankshaft seal sur-
face of cover.
INSTALLATION (1) Install new seal by using Tool C-4992 (Fig. 7).
(2) Place seal into opening with seal spring to-
wards the inside of engine. Install seal until flush
with cover. (3) Install crankshaft pulley using plate L-4524.
Thrust Bearing/washer and 5.9 inch screw (Fig. 8). (4) Install drive belt (Refer to Cooling System
Group 7) for installation procedure. (5) Install inner splash shield and wheel.
CAMSHAFT
REMOVALÐENGINE REMOVED FROM VEHICLE
Remove intake manifold, cylinder head covers, cyl-
inder heads, timing chain case cover and timing
chain. (1) Remove rocker arm and shaft assemblies.
(2) Remove push rods and tappets; identify so each
part will be replaced in its original location. (3) Remove camshaft thrust plate (Fig. 10).
(4) Install a long bolt into front of camshaft to fa-
cilitate removal of the camshaft; remove camshaft,
being careful not to damage cam bearing with the
cam lobes.
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 2 inches
of its final position in cylinder block. Whenever an engine has been rebuilt or a new
camshaft or tappets have been installed, add one
pint of Chrysler Crankcase Conditioner or
equivalent to engine oil to aid in break in. The oil
mixture should be left in engine for a minimum
of 805km (500 miles) and drained at the next
normal oil change. (2) Install camshaft thrust plate with two screws as
shown in (Fig. 10). Tighten to 12 N Im (105 in. lbs.)
torque. (3) Rotate crankshaft so the timing arrow is to the
12 O'clock position. (4) Place timing chain around camshaft sprocket
and place the timing mark to the 6 O'clock position. (5) Align the dark colored links with the dot on the
camshaft sprocket, place timing chain around crank-
shaft sprocket with the dark colored link lined up with
the dot on the sprocket and install camshaft sprocket
into position. (6) Using straight edge to check alignment of timing
marks (Fig. 5). (7) Install the camshaft bolt. Tighten bolt to 54 N Im
(40 ft. lbs.). (8) Rotate crankshaft 2 revolutions. Timing marks
should line up. If timing marks do not line up, remove
cam sprocket and realign.
Fig. 9 Removing Crankshaft Oil Seal
Fig. 10 Camshaft Thrust Plate
Fig. 11 Camshaft and Sprocket Assembly
9 - 112 3.3/3.8L ENGINE Ä

(13) Disconnect articulated exhaust pipe joint from
turbocharger housing. (14) Remove turbocharger coolant inlet line assem-
bly from engine (Fig. 11). (15) Lift turbocharger off manifold mounting studs
and lower assembly down and out of vehicle.
EXHAUST MANIFOLD
REMOVAL
Remove 9 exhaust manifold retaining fasteners and
remove exhaust manifold (Fig. 14).
CLEANING AND INSPECTION
(1) Discard gasket and clean all gasket surfaces of
manifolds and cylinder head. (2) Test manifold gasket surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (.006 in. per foot) of manifold length. (3) Inspect manifolds for cracks or distortion. Re-
place manifold if necessary.
EXHAUST MANIFOLD
INSTALLATION
(1) Install new manifold gasket. DO NOT APPLY
SEALER . (2) Set exhaust manifold in place. Tighten retain-
ing nuts and bolt, starting at center and progressing
outward in both directions to 23 N Im (200 in. lbs.)
torque. Repeat this procedure until all fasteners are
at specified torque (Fig. 14).
TURBOCHARGER
INSTALLATION
(1) Position turbocharger on exhaust manifold. Ap-
ply antiseize compound to threads and install the
lower (passenger side) retaining nut (Fig. 12).
Tighten nut to 54 N Im (40 ft. lbs.) torque.
(2) Apply thread sealant to lower (inlet) coolant
line fitting and install fitting into turbocharger hous-
ing (Fig. 11). (3) Install lower coolant line assembly to engine
(Fig. 11). (4) Install oil drain back tube and fitting (with
new gasket) to turbocharger housing (Fig. 13). (5) Install turbocharger to block support bracket
and install screws finger tight (Fig. 13). Tighten
block screw FIRST to 54 N Im (40 ft. lbs.) torque,
then tighten screw to turbocharger housing to 27
N Im (20 ft. lbs.) torque.
(6) Reposition exhaust pipe. Tighten articulated
joint shoulder bolts to 28 N Im (250 in. lbs.) torque.
(7) See Suspension, Group 2, and install right
driveshaft and wheel and tire assembly. Install air
deflector on crossmember. (8) From Above: Install three turbocharger to
manifold retaining nuts. Tighten to 54 N Im (40 ft.
lbs.) torque (Fig. 12). (9) Reconnect Heated Oxygen sensor electrical con-
nection and vacuum lines. (10) Attach oil feed line to turbocharger bearing
housing. Tighten fitting to 14 N Im (125 in. lbs.)
torque (Fig. 12). (11) Install coolant line and tighten fittings to 41
N Im (30 ft. lbs.) torque (Fig. 11).
(12) Install air cleaner support (Fig. 1).
(13) Align front engine mount in crossmember
bracket. Install through bolt and tighten to 54 N Im
(40 ft. lbs.) torque. (14) Install air cleaner assembly (Fig. 1).
(15) Fill cooling system. Refer to Cooling System,
Group 7 for procedure.
INTAKE/EXHAUST MANIFOLD SERVICEÐ3.0L
ENGINE
The intake system has a large air intake plenum of
aluminum alloy and a cross type intake manifold
(Fig. 2).
Fig. 13 Oil Return Tube and Support Bracket
Fig. 14 Exhaust ManifoldÐTurbo III Engine
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 13

SYSTEMS TEST
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE PERFORMING A TEST
WITH THE ENGINE OPERATING.
OBTAINING DIAGNOSTIC TROUBLE CODES
(1) Connect DRBII scan tool to the data link con-
nector located in the engine compartment near the
powertrain control module (PCM). (2) Start the engine if possible, cycle the transaxle
selector and the A/Cswitch if applicable. Shut off
the engine. (3) Turn the ignition switch on, access Read Fault
Screen. Record all the fault messages shown on the
DRBII scan tool. Observe the malfunction indicator
lamp (check engine lamp on the instrument panel).
The lamp should light for 3 seconds then go out (bulb
check).
STATE DISPLAY TEST MODE
The switch inputs used by the powertrain control
module (PCM) have only two recognized states,
HIGH and LOW. For this reason, the PCM cannot
recognize the difference between a selected switch po-
sition versus an open circuit, a short circuit, or a de-
fective switch. If the change is displayed, it can be
assumed that the entire switch circuit to the PCM is
functional. From the state display screen access ei-
ther State Display Inputs and Outputs or State Dis-
play Sensors.
STATE DISPLAY INPUTS AND OUTPUTS
Connect the DRBII scan tool to the vehicle and ac-
cess the State Display screen. Then access Inputs and
Outputs. The following is a list of the engine control
system functions accessible through the Inputs and
Outputs screen. Park/Neutral Switch (automatic transaxle only)
Speed Control Resume
Brake Switch
Speed Control On/Off
Speed Control Set
A/C Switch Sense
S/C (Speed Control) Vent Solenoid
S/C (Speed Control) Vacuum Solenoid
Torque Converter Clutch Solenoid (3 speed auto-
matic transaxle)
A/C Clutch Relay
EGR Solenoid
Auto Shutdown Relay
Radiator Fan Relay
Purge Solenoid
Malfunction Indicator (Check Engine) Lamp
STATE DISPLAY SENSORS
Connect the DRBII scan tool to the vehicle and ac-
cess the State Display screen. Then access Sensor
Display. The following is a list of the engine control
system functions accessible through the Sensor Dis-
play screen. Oxygen Sensor Signal
Coolant Temperature
Coolant Temp Sensor
Throttle Position
Minimum Throttle
Battery Voltage
MAP Sensor Reading
Idle Air Control Motor Position
Added Adaptive Fuel
Adaptive Fuel Factor
Barometric Pressure
Min Airflow Idl Spd
Engine Speed
Fault #1 Key-On Info
Module Spark Advance
Speed Control Target
Fault #2 Key-On Info
Fault #3 Key-On Info
Speed Control Status
Charging System Goal
Theft Alarm Status
Speed Control Switch Voltage
Map Sensor Voltage
Vehicle Speed
Oxygen Sensor State
MAP Gauge Reading
Throttle Opening (percentage)
Total Spark Advance
CIRCUIT ACTUATION TEST MODE
The circuit actuation test mode checks for proper
operation of output circuits or devices which the pow-
ertrain control module (PCM) cannot internally rec-
ognize. The PCM can attempt to activate these
outputs and allow an observer to verify proper oper-
ation. Most of the tests provide an audible or visual
indication of device operation (click of relay contacts,
spray fuel, etc.). With the exception of an intermit-
tent condition, if a device functions properly during
its test, it can be assumed that the device, its associ-
ated wiring, and its driver circuit are in working or-
der.
OBTAINING CIRCUIT ACTUATION TEST
Connect the DRBII scan tool to the vehicle and ac-
cess the Actuators screen. The following is a list of
the engine control system functions accessible
through Actuators screens. Stop All Tests
Ignition Coil #1
Fuel Injector #1
Idle Air Control Motor Open/Close
Ä FUEL SYSTEMS 14 - 45

SYSTEM TESTS
WARNING: APPLY PARKING BRAKE AND/OR BLOCK
WHEELS BEFORE PERFORMING ANY TEST ON AN
OPERATING ENGINE.
OBTAINING DIAGNOSTIC TROUBLE CODES
(1) Connect DRBII scan tool to the data link connec-
tor located in the engine compartment near the pow-
ertrain control module (PCM). (2) Start the engine if possible, cycle the transaxle
selector and the A/Cswitch if applicable. Shut off the
engine. (3) Turn the ignition switch on, access Read Fault
Screen. Record all the fault messages shown on the
DRBII scan tool. Observe the malfunction indicator
lamp (Check Engine lamp on the instrument panel).
The lamp should light for 3 seconds then go out (bulb
check). Diagnostic trouble code erasure; access erase
diagnostic trouble code data
STATE DISPLAY TEST MODE
The switch inputs used by the powertrain control
module (PCM) have only two recognized states, HIGH
and LOW. For this reason, the PCM cannot recognize
the difference between a selected switch position ver-
sus an open circuit, a short circuit, or a defective
switch. If the change is displayed, it can be assumed
that the entire switch circuit to the PCM is functional.
From the state display screen access either State
Display Inputs and Outputs or State Display Sensors.
STATE DISPLAY INPUTS AND OUTPUTS
Connect the DRBII scan tool to the vehicle. Access
the State Display screen. Then access Inputs and
Outputs. The following is a list of the engine control
system functions accessible through the Inputs and
Outputs screen. Park/Neutral Switch
Speed Control Resume
Brake Switch
Speed Control On/Off
Speed Control Set
A/C Switch Sense
S/C Vent Solenoid
S/C Vacuum Solenoid
A/C Clutch Relay
EGR Solenoid
Auto Shutdown Relay
Radiator Fan Relay
Purge Solenoid
Torque Converter Clutch Solenoid
Malfunction Indicator Lamp (Check Engine Lamp)
STATE DISPLAY SENSORS
Connect the DRBII scan tool to the vehicle and ac-
cess the State Display screen. Then access Sensor
Display. The following is a list of the engine control
system functions accessible through the Sensor Dis-
play screen. Battery Temperature
Oxygen Sensor Signal
Engine Coolant Temperature
Engine Coolant Temp Sensor
Throttle Position
Minimum Throttle
Battery Voltage
MAP Sensor Reading
Idle Air Control Motor Position
Adaptive Fuel Factor
Barometric Pressure
Min Airflow Idle Speed
Engine Speed
Fault #1 Key-On Info
Module Spark Advance
Speed Control Target
Fault #2 Key-on Info
Fault #3 Key-on Info
Speed Control Status
Speed Control Switch Voltage
Charging System Goal
Theft Alarm Status
Map Sensor Voltage
Vehicle Speed
Oxygen Sensor State
MAP Gauge Reading
Throttle Opening (percentage)
Total Spark Advance
CIRCUIT ACTUATION TEST MODE
The circuit actuation test mode checks for proper
operation of output circuits or devices which the pow-
ertrain control module (PCM) cannot internally rec-
ognize. The PCM can attempt to activate these
outputs and allow an observer to verify proper oper-
ation. Most of the tests provide an audible or visual
indication of device operation (click of relay contacts,
spray fuel, etc.). Except for intermittent conditions, if
a device functions properly during testing, assume
the device, its associated wiring, and driver circuit
working correctly.
OBTAINING CIRCUIT ACTUATION TEST
Connect the DRBII scan tool to the vehicle and ac-
cess the Actuators screen. The following is a list of
the engine control system functions accessible
through Actuators screens. Stop All Tests
Ignition Coil #1
Fuel Injector #1
Fuel Injector #2
Fuel Injector #3
14 - 134 FUEL SYSTEMS Ä

INSTALL
(1) Install power steering pressure switch into fit-
ting on power steering pressure hose by hand until
fully seated. Then torque power steering pressure
switch to 12 N Im (106 in. lbs.).
(2) Install vehicle wiring harness connector onto
power steering pressure switch. Be sure latch on wir-
ing harness connector is fully engaged with locking
tab on power steering pressure switch.
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use Mopar T, Power
Steering Fluid, or equivalent.
(3) Fill power steering pump reservoir to correct
fluid level. (4) Connect negative cable back on negative post of
battery. (5) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
POWER STEERING HOSES
Service all power steering hoses with the vehicle
raised on a hoist. Cap all open ends of hoses, power
steering pump fittings and steering gear ports to pre-
vent entry of foreign material into the components.
WARNING: POWER STEERING OIL, ENGINE PARTS
AND EXHAUST SYSTEM MAY BE EXTREMELY HOT
IF ENGINE HAS BEEN RUNNING. DO NOT START
ENGINE WITH ANY LOOSE OR DISCONNECTED
HOSES. DO NOT ALLOW HOSES TO TOUCH HOT
EXHAUST MANIFOLD OR CATALYST.
For part reference and part location on the vehicle
being serviced, refer to Figs. 3 to 6. These show the
hose bracket locations, hose routings and fitting loca-
tions by the engine application of the vehicle. Use
these figure numbers when referring to the removal
or installation procedures for the power steering
hoses listed below.
REMOVAL
(1) Remove vehicle's wiring harness connector (if
applicable to vehicle being serviced) from the power
steering pressure switch (Fig .1&2).
(2) Remove bolts from power steering hose routing
brackets to crossmember attachment points. (3) Disconnect power steering hose at opening clos-
est to power steering gear assembly. Drain power
steering fluid from power steering pump and hose
through open end of hose. (4) Disconnect opposite end of hose and remove
power steering hose assembly from vehicle. (5) Discard O-ring or sealing washer located at end
of tube. (6) Remove power steering pressure switch, from
the removed power steering hose for installation into
the replacement power steering hose.
INSTALLATION
(1) Install the removed power steering pressure
switch into replacement power steering pressure
hose. Torque power steering pressure switch to 12
N Im (106 in. lbs.).
Fig. 3 Power Steering Hose Routing 2.2 & 2.5L
Fig. 4 Power Steering Hose Routing 3.0L
Ä STEERING 19 - 11

INSTALL (1) Install power steering pump back in vehicle,
laying it on the steering gear. Do not mount it to the
power steering pump bracket. (2) Install generator back on the lower generator
bracket and install bolt and nut (Fig. 19). Do not
tighten bolt at this time. (3) Install the generator bracket back on engine and
intake manifold. Loosely install the 4 generator
bracket to engine attaching bolts (Fig. 19). Be sure
the SPACER (Fig. 18) is installed between the
engine mounting strut and the generator
bracket. (4) Temporarily install the serpentine belt tensioner
bolt through both generator brackets. This will align
all generator bracket mounting holes (Fig. 15). Then
torque the 4 generator bracket to engine and intake manifold mounting bolts to 54 N
Im (40 ft.
lbs.). Then remove the serpentine belt tensioner from
bracket. It will be installed on the bracket in a
later step. (5) Tighten the bolt holding the engine bracket as-
sembly to the engine support assembly (Fig. 18) to 150
N Im (110 ft. lbs.).
(6) Attach the engine wiring harness routing clip to
the generator bracket. (7) Install the generator to generator bracket attach-
ing bolt (Fig. 19). Torque bolt to 54 N Im (40 ft. lbs.).
Tighten the lower generator pivot bolt to 54 N Im (40 ft.
lbs.). (8) Install the power steering pump fluid reservoir
and tube/hose assembly onto the power steering pump
bracket and generator bracket (Fig. 17). Torque the 2
bolts holding the reservoir to the generator bracket to
5N Im (45 in. lbs.). Torque the 1 bolt holding the
tube/hose assembly to the power steering pump
bracket to 12 N Im (105 in. lbs.).
(9) Raise vehicle See Hoisting, Group 0.
(10) Install the strut assembly power
steering/generator bracket to engine (Fig. 16). Torque
the nut and bolt holding the strut assembly to bracket
and the exhaust manifold stud to 54 N Im (40 ft. lbs).
(11) Install the serpentine drive belt tensioner onto
the power steering/generator bracket (Fig. 15). Install
the tensioner to bracket retaining nut and torque to 54
N Im (40 ft. lbs.).
(12) Install the power steering pump on bracket, by
aligning the 3 mounting holes in pump with mounting
holes in bracket (Fig. 14). Install the 3 power steering
pump to bracket mounting bolts. Torque power steer-
ing pump mounting bolts to 54 N Im (40 ft. lbs.).
(13) Install the support strut, engine block to power
steering pump on pump stud (Fig. 14). Install the nut
and bolt holding the strut to the power steering pump
and engine block and torque to 54 N Im (40 ft. lbs.).
(14) Install the power steering fluid pressure line
onto the output fitting of the power steering pump (Fig.
12). Torque the pressure line pump fitting nut to 31
N Im (275 in. lbs.). Before connecting the pressure
line to power steering pump inspect the O-ring
on the pressure line for damage. (15) Install vehicle's wiring harness connector (if
applicable to vehicle being serviced) onto the power
steering pressure switch (Fig. 11). (16) Install the power steering fluid, low pressure
return hose on the power steering pump low pressure
fitting (Fig. 12). Then install the hose from the remote
reservoir onto the power steering pump (Fig. 13). Be
sure all hose clamps are properly reinstalled. (17) Install right front tire and wheel on vehicle.
Install the wheel stud nuts and torque to 129 N Im (95
ft. lbs.).
Fig. 18 Engine Bracket Support Assembly
Fig. 19 Generator Mounting
19 - 18 STEERING Ä

INSTALL (1) Install the power steering pump back into the
vehicle in the reverse order of removal, between cyl-
inder head and dash panel (Fig. 20). (2) Install the wiring harness connector back on
the H-valve located on the air conditioning fluid
lines (Fig. 20). (3) Raise vehicle See Hoisting, Group 0.
(4) Install the power steering pump on its mount-
ing bracket, and the hose locator bracket. Install the
bolt/stud and 2 bolts attaching the power steering
pump to its mounting bracket, and the bolts attach-
ing the hose locator bracket (Fig. 19). Torque all fas-
teners to 31 N Im (280 in. lbs.).
(5) Install the power steering fluid pressure hose,
banjo bolt and seal washer onto power steering pump
(Fig. 4). Pressure hose is to be installed so it is
routed to the left of the hose locator bracket (Fig.
19). Torque the banjo bolt to 31 N Im (275 in. lbs.).
Inspect the O-rings on the banjo bolt to ensure
they are not damaged and located correctly. (6) Install the low pressure fluid return hose from
the power steering pump back on the steel tube on
the steering gear (Fig. 4). Install hose clamp, be sure
the hose clamp is installed past the retaining bead
the steel tube. Install the hose routing clip on the
power steering pump bolt/stud, install clip retaining
nut and tighten. (7) Install the serpentine accessory drive belt (Fig.
18). Be sure the belt is correctly installed and
aligned on all pulleys before starting engine. (8) Install the right front underhood splash shield.
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use Mopar T, Power
Steering Fluid, or equivalent.
(9) Fill power steering pump reservoir to correct
fluid level. (10) Connect the negative battery cable on the
negative battery post. (11) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
POWER STEERING PUMP PULLEY SERVICE
SAGINAW VANE SUBMERGED PUMP
REMOVE
(1) Remove the pulley with Puller C-4333 (C-4068)
(Fig. 1).
CAUTION: Do not hammer on power steering pump
pulley. This will damage the pulley and the power
steering pump. (2) Replace pulley if bent, cracked, or loose.
INSTALLATION
(1) Install the pulley with Installer C-4063 (Fig.2).
Do not use the tool adapters.
(2) Ensure that the tool and the pulley remain
aligned with the pump shaft. Prevent the pulley from
being cocked on the shaft. (3) Force pulley flush with the end of the shaft.
Fig. 1 Pulley Removal (Typical)
Fig. 2 Pulley Installation (Typical)
19 - 20 STEERING Ä