cooling CHEVROLET DYNASTY 1993 Repair Manual

(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

(9) Measure camshaft end play. End Play should
measure .0127 to .304 mm (.005 to .012 inches.) .310
mm (.012 inch. Max.). If not within limits install a new
thrust plate. (10) Each tappet reused must be installed in the
same position from which it was removed. When
camshaft is replaced, all of the tappets must be
replaced .
CAMSHAFT BEARINGSÐENGINE REMOVED FROM
VEHICLE
REMOVAL
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug. (2) Install proper size adapters and horseshoe wash-
ers (part of Tool C-3132-A) at back of each bearing shell
to be removed and drive out bearing shells (Fig. 13).
INSTALLATION
(1) Install new camshaft bearings with Tool
C-3132-A by sliding the new camshaft bearing shell
over proper adapter. (2) Position rear bearing in the tool. Install horse-
shoe lock and by reversing removal procedure, care-
fully drive bearing shell into place. (3) Install remaining bearings in the same manner.
Bearings must be carefully aligned to bring oil holes
into full register with oil passages from the main
bearing. Number two bearing must index with the oil
passage to the left cylinder head and Number three
bearing must index with the oil passage to the right
cylinder head. If the camshaft bearing shell oil holes
are not in exact alignment, remove and reinstall them
correctly. Install a new core hole plug at the rear of
camshaft. Be sure this plug does not leak.
ENGINE CORE OIL AND CAM PLUGS
REMOVAL
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 14).
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 cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Loctite Stud
N' Bearing Mount or equivalent. 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. It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
Fig. 13 Removed Installation of Camshaft Bearings with Tool C-3132AÐTypical
Fig. 14 Core Hole Plug Removal
Fig. 12 Alignment of Timing Marks
Ä 3.3/3.8L ENGINE 9 - 113

for diagnostic and service procedures on the air control
valve and temperature sensor located in the air
cleaner.
INTAKE AND EXHAUST MANIFOLDS SERVICEÐTBI
ENGINE
Intake and exhaust manifolds use a one piece gasket.
Service procedures requiring removal and installation
( of either ) must include both manifolds.
FUEL SYSTEM PRESSURE RELEASE PROCE- DURE
The Fuel System is under a constant pressure
of at least 265 kPa (39 psi). Before servicing the
fuel pump, fuel lines, fuel filter, throttle body or
fuel injector, the fuel system pressure must be
released. (a) Loosen fuel filler cap to release fuel tank pres-
sure. (b) Disconnect injector wiring harness from engine
harness. (c) Connect a jumper wire to ground terminal
Number 1 of the injector harness (Fig. 2) to engine
ground. (d) Connect a jumper wire to the positive terminal
Number 2 of the injector harness (Fig. 2) and touch
the battery positive post for no longer than 5 seconds.
This releases system pressure. (e) Remove jumper wires.
(f) Continue fuel system service.
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs. (2) Disconnect negative battery cable. Drain cool-
ing system. Refer to Cooling System, Group 7 for pro-
cedure. (3) Remove air cleaner and disconnect all vacuum
lines, electrical wiring and fuel lines from throttle
body. (4) Remove throttle linkage.
(5) Loosen power steering pump and remove belt.
(6) Remove power brake vacuum hose from intake
manifold. (7) Disconnect EGR tube from intake manifold and
remove water hoses from water crossover. (8) Raise vehicle and remove exhaust pipe from
manifold. (9) Remove power steering pump assembly and set
aside. (10) Remove intake manifold retaining screws
(Fig. 3). (11) Lower vehicle and remove intake manifold.
(12) Remove exhaust manifold retaining nuts (Fig.
3). (13) Remove exhaust manifold.
Fig. 2 Injector Harness Connector
Fig. 3 Intake and Exhaust Manifold Attaching PointsÐ2.2/2.5L Engines
Fig. 1 Air HeaterÐTBI Engine
11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

EXHAUST MANIFOLD
REMOVAL (1) Disconnect exhaust pipe from manifold articu-
late joint. (2) Disconnect the heated oxygen sensor electrical
connection. (3) Remove 8 exhaust manifold retaining nuts and
remove exhaust manifold (Fig. 9).
CLEANING AND INSPECTION
(1) Discard gasket and clean all gasket surfaces of
manifolds and cylinder head. (2) Test 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.
EXHAUST MANIFOLD
INSTALLATION
(1) Install new two-sided grafoil or equivalent in-
take/exhaust manifold gasket. DO NOT APPLY
SEALER. (2) Set exhaust manifold in place. Install and
tighten retaining nuts, starting at center and pro-
gressing outward in both directions to 23 N Im (200
in. lbs.) torque. Repeat this procedure until all nuts
are at specified torque.
INTAKE MANIFOLD
INSTALLATION
(1) Position intake manifold, install, and tighten 8
retaining screws starting at center and progressing
outward in both directions to 23 N Im (200 in. lbs.)
torque. Repeat this procedure until all screws are at
specified torque (Fig. 9). (2) Install PCV vacuum harness and vacuum vapor
harness (Fig. 8). (3) Connect vacuum hose from fuel pressure regu-
lator. (4) Connect fuel injector wiring connector (Fig. 8).
(5) Close fuel tube clip around fuel tubes and in-
stall fastener. (6) Lubricate the ends of the chassis fuel tubes
with 30 wt oil. Connect fuel supply and return hoses
to chassis fuel tube assembly. pull back on the quick
connect fitting to ensure complete insertion. (Refer to
Fuel Hoses, Clamps and Quick Connect Fittings in
Group 14 Fuel Systems). (7) Connect automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors (Fig.
7). (8) Connect accelerator and speed control cables.
Install brake booster vacuum supply hoses. (9) Reconnect negative battery cable.
(10) Install air cleaner hose to throttle body assem-
bly (Fig. 6). (11) With the DRBII Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is se-
lected.
INTAKE/EXHAUST MANIFOLDS AND
TURBOCHARGER SERVICEÐTURBO III ENGINE
INTAKE MANIFOLD
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs. (2) Disconnect negative battery cable. Drain cool-
ing system. Refer to Cooling System, Group 7. (3) Remove fresh air duct from air filter housing.
Remove inlet hose from the intercooler (Fig. 1). (4) Remove radiator hose to cylinder head (Fig. 2).
(5) Remove DIS Ignition Coils from intake mani-
fold (Fig. 3). (6) Remove accelerator and speed control cables
(Fig. 4).
Fig. 9 Intake and Exhaust Manifolds Attaching Points
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 9

(3) Inspect quick connect fittings for damage, re-
place if necessary Refer to Fuel System, Group 14 for
procedure. Lube tube with clean 30w engine oil, Con-
nect fuel supply and return hoses to chassis tube as-
sembly. Check connection by pulling on connector to
insure it locked into position (Fig. 9). (4) Connect Fuel Injector (Fig. 8), and Charge
Temperature Sensor wiring connectors (Fig. 7).
INTAKE MANIFOLD
(5) Connect Automatic Idle Speed (AIS) and Throt-
tle Position Sensor (TPS) wiring connectors (Fig. 6). (6) Connect vacuum hoses to throttle body (Fig. 5).
(7) Install intercooler to throttle body hose and
clamp. Torque clamp to 3 N Im (30 in. lbs.) (Fig. 5). (8) Connect accelerator and speed control cables
(Fig. 4). (9) Install DIS ignition coil pack. Tighten fasteners
to 12 N Im (105 in. lbs.) torque (Fig. 3).
(10) Install upper radiator hose and spring clamps
(Fig. 2). Fill cooling system, Refer to Cooling System,
Group 7. (11) Install fresh air duct to air filter housing. In-
stall inlet hose assembly to Intercooler. Tighten
clamp to 3 N Im (30 in. lbs.) torque (Fig. 1).
(12) Connect negative battery cable.
(13) With the DRBII Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.
Fig. 5 Intercooler to Throttle Body Hose
Fig. 6 Automatic Idle Speed (AIS) Motor and
Throttle Position Sensor (TPS) Wiring Connectors
Fig. 7 Intake Manifold Electrical and Vacuum Hose Connections
Fig. 8 Camshaft Sensor and Fuel Injectors WiringConnectors
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 11

(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

The exhaust manifolds are made of ductile cast
iron with the front bank and rear bank independent
of each other. The exhaust from the front bank ex-
haust manifold is led through on exhaust crossover
pipe to be combined with the rear bank exhaust at
the exhaust outlet to the exhaust pipe (Fig. 2).
INTAKE PLENUM/MANIFOLD
REMOVAL
(1) Perform fuel system pressure release procedure
(before attempting any repairs). (2) Disconnect negative battery cable. Drain cooling
system. See Cooling System, Group 7. (3) Remove air cleaner to throttle body hose (Fig. 3).
FUEL SYSTEM PRESSURE RELEASE PROCE-DURE
The MPI fuel system is under a constant pres-
sure of about 330 kPa (48 psi). Before servicing
the fuel pump, fuel lines, fuel filter, throttle body
or fuel injector, the fuel system pressure must be
released .
(a) Loosen fuel filler cap to release fuel tank pres-
sure. (b) Disconnect injector wiring harness from engine
harness. (c) Connect a jumper wire to ground terminal
Number 1 of the injector harness (Fig. 1) to engine
ground. (d) Connect a jumper wire to the positive terminal
Number 2 of the injector harness (Fig. 1) and touch
the battery positive post for no longer than 5 seconds.
This releases system pressure.
Fig. 1 Injector Harness Connector
Fig. 2 Intake and Exhaust ManifoldsÐ 3.0L Engine
11 - 14 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

place. Install attaching fasteners (8) and tighten in
several steps in sequence shown (Fig. 17) to 13 N Im
(115 in. lbs.). (13) Connect fuel line to fuel rail (Fig. 7). Torque
hose clamps to 1 N Im (10 in. lbs.).
(14) Connect vacuum harness to air intake ple-
num. (15) Connect coolant temperature sensor electrical
connector to sensor (Fig. 7). (16) Connect PCV and brake booster supply hose
to intake plenum. (17) Connect automatic idle speed (AIS) motor and
throttle position sensor (TPS) electrical connectors
(Fig. 5). (18) Connect vacuum vapor harness to throttle
body (Fig. 5). (19) Install throttle cable and transaxle kickdown
linkage (Fig. 4). (20) Install air inlet hose assembly (Fig. 3).
(21) Install radiator to thermostat housing hose
and heater hose to heater pipe nipple. (22) Fill cooling system, see Refilling System in
Cooling, Group 7. (23) Connect negative battery cable.
(24) With the DRBII Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.
Fig. 5 Electrical and Vacuum Connections to Throttle Body
Fig. 6 Ignition Coil Removal
Fig. 7 Coolant Temperature Sensor Electrical Connections
Fig. 8 Air Intake Plenum to Intake ManifoldAttaching Bolts
Fig. 9 Removing Air Intake Plenum
11 - 16 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä