tow CHEVROLET DYNASTY 1993 Repair Manual

CAUTION: Be sure that the tapped holes maintain
the original centerline.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostaticly
locked, regardless of what caused the problem, these
steps should be used.
CAUTION: Do Not Use Starter Motor To Rotate En-
gine, severe damage may occur.
(1) Inspect air cleaner, induction system and in-
take manifold to insure system is dry and clear of
foreign material. (2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will
catch any fluid that may possibly be in the cylinder
under pressure. (4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket. (5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other). (6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., Connecting
Rods, Pistons, Valves etc.) (7) Repair engine or components as necessary to
prevent this problem from occurring again.
CAUTION: Squirt approximately 1 teaspoon of oil
into cylinders, rotate engine to lubricate the cylin-
der walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Fill engine with specified amount of approved
oil and install new oil filter. (11) Connect negative battery cable.
(12) Start engine and check for any leaks.
Ä ENGINE 9 - 5

Flexible fuel vehicles can operate on a mixture of
up to 85 percent methanol, 15 percent unleaded gas-
oline. These vehicles also operate on mixtures con-
taining a lower percentage of methanol or just pure
unleaded gasoline. Engine components which are required for safe op-
eration using fuel containing methanol alcohol are
identified by a standard green color and/or display
the statement methanol compatible imprinted on the
component. To ensure continued safe operation, these
components must be serviced only with genuine MO-
PAR replacement parts. Methanol compatible parts for the 2.5L FFV (Flex-
ible Fuel Vehicle) engine include, but are not limited
to; the valve stem oil seals, all piston rings, the oil
fill cap, the fuel injectors, fuel rail, fuel pressure reg-
ulator, hoses and the vacuum control harness hose. BLOCK: All four cylinder cast iron blocks have
cast-in recesses in the bottom of each cylinder bore to
provide connecting rod clearance; especially needed
for 2.5L engines. The bores are also siamese to min-
imize engine length. A coolant passage is drilled
cross-ways through the siamese section to enhance
between the bore cooling on some engine types. A
partial open deck is used for cooling and weight re-
duction with oil filter, water pump, and distributor
mounting bosses molded into the front (radiator side)
of the block. Nominal wall thickness is 4.5 mm. Five
main bearing bulkheads and a block skirt extending
3 mm below the crankshaft center line add to the
blocks high rigidity with light weight. CRANKSHAFT: A nodular cast iron crankshaft is
used in TBI engines. A forged steel crankshaft is
used in the Turbo III engine. All engines have 5 main bearings, with number 3 flanged to control
thrust. The 60 mm diameter main and 50 mm diam-
eter crank pin journals (all) have undercut radiuses
fillets that are deep rolled for added strength. To op-
timize bearing loading 4 counterweights are used.
Hydrodynamic seals (installed in diecast aluminum
retainers) provide end sealing, where the crankshaft
exits the block. Anaerobic gasket material is used for
retainer-to-block sealing. No vibration damper is
used. A sintered iron (TBI engine and steel billet
Turbo III engines) timing belt sprocket is mounted
on the crankshaft nose. This sprocket provides mo-
tive power; via timing belt to the camshaft and inter-
mediate shaft sprockets (also sintered iron (TBI
engine and steel billet Turbo III engines) providing
timed valve, distributor, and oil pump actuation. PISTONS: Some Chrysler pistons have cast-in
steel struts at the pin bosses for autothermic control.
All 2.2L and 2.5L piston tops have cuts to provide
valve clearance. Some pistons are dished to provide
various compression ratios. Standard 2.2L and 2.5L
engines are designed for 9.5:1 and 8.9:1 compression
ratios respectively. The 2.5L piston is dished and is a
lightweight design to enhance engine smoothness.
The 2.2L turbo III uses dished pistons providing a
8.3:1 compression ratio. All standard 2.2/2.5L and
2.5L FFV engines use pressed-in piston pins to at-
tach forged steel connecting rods, 2.2L turbo III en-
gine uses a full floating piston pin and connecting
rod assembly. PISTONS RINGS: The 2.2/2.5L engines share
common piston rings throughout, including molybde-
num filled top ring for reliable compression sealing
and a tapered faced intermediate ring for additional
cylinder pressure control. The 2.5L FFV engine fea-
ture all chrome rings for enhanced long term dura-
bility under multi-fueled conditions. CYLINDER HEAD: The cylinder head is cast alu-
minum with in-line valves. The 2.2/2.5L and 2.5L
FFV valves are arranged with alternating exhaust
and intake. The intake and exhaust ports are located
in the rearward, facing side of the head. The Turbo
III valves are arranged in two inline banks, with the
ports of the bank of two intake valves per cylinder
facing toward the radiator side of engine and ports of
the bank of two exhaust valve per cylinder facing to-
ward the dash panel. The intake ports feed fast-burn
design combustion chambers (2.2/2.5L and 2.5L FFV
only) with the spark plug located close to the center
line of the combustion chamber for optimum effi-
ciency. An integral oil gallery within the cylinder
head supplies oil to the hydraulic lash adjusters,
camshaft, and valve mechanisms. CAMSHAFT: The nodular iron camshaft has five
bearing journals (2.2/2.5L and 2.5L FFV). The Turbo
III employs dual camshafts that have nine bearing
journals. Flanges at the rear journal control cam-
Fig. 1 Engine Identification
Ä 2.2/2.5L ENGINE 9 - 9

CAUTION: Make sure clutch cable has been discon-
nected. (20) Remove front engine mount screw and nut.
(21) Remove manual transmission damper.
(22) Remove left insulator through bolt from inside
wheelhouse or insulator bracket to transmission
screws. (23) Remove engine from vehicle.
INSTALLATION
(1) Install hoist to the engine and lower engine
into the engine compartment. SEE: ENGINE MOUNT RUBBER INSULATORS,
THIS GROUP. (2) Align engine mounts and install but do not
tighten until all mounting bolts have been installed.
(3) Install transmission case to cylinder block
mounting screws. Tighten to 95 N Im (70 ft. lbs.)
torque. (4) Remove engine hoist and transmission holding
fixture. (5) Install ground strap.
(6) Install right inner splash shield.
(7) Connect starter. See Electrical Group 8 for in-
stallation. (8) Connect exhaust system. See Exhaust Systems
Group 11 for installation. (9) Manual Transmission: Install transmission
case lower cover. Automatic Transmission: Remove C clamp from
torque converter housing. Align flexplate to torque
converter and install mounting screws. Tighten to 75
N Im (55 ft. lbs.) torque.
(10) Manual Transmission: Connect clutch cable.
See Clutch Group 6. (11) Install power steering pump. Refer to Cooling
System Group 7, Accessory Drive Section for belt
tension adjustment. (12) Connect fuel line, heater hose, and accelerator
cable. (13) Connect all electrical connections and har-
nesses at throttle body and engine. (14) Install oil filter. Fill engine crankcase with
proper oil to correct level. (15) Install air conditioning compressor (if
equipped). See Heater and Air Conditioning, Group
24 for installation. (16) Install air cleaner and hoses.
(17) Install radiator and shroud assembly . Install
radiator hoses. Fill cooling system. See Cooling Sys-
tem Group 7 for filling procedure. (18) Install hood.
(19) Connect battery.
(20) Start engine and run until operating temper-
ature is reached. (21) Adjust transmission linkage, if necessary.
SOLID MOUNT COMPRESSOR BRACKET SERVICE
When service procedures require solid mount
bracket removal and installation for example: cylin-
der head removal, etc., it is important that bracket
fasteners numbered 1 through 7 (Fig. 4) be removed
and installed in sequence, as instructed in Remove
and Install.
ACCESSORIES REMOVAL
(1) Remove (and install/adjust) belts,see Accessory
Drive Belts in Cooling System,Group 7. (2) Remove air conditioning compressor (in vehicle
with lines and set aside) (Fig. 6). (3) Remove generator pivot bolt and remove gener-
ator (in vehicle: turn wiring side up and disconnect,
then rotate generator, pulley end towards engine and
remove). (4) Remove air conditioner compressor belt idler.
SOLID MOUNT BRACKETÐREMOVAL (FIG. 4)
(1) Remove right engine mount yoke screw (see
Engine Remove Fig. 3) securing engine mount sup-
port strut to engine mount bracket. (2) Remove five side mounting bolts #1, #4 , #5,
#6, and #7 (Fig. 4). (3) Remove front mounting nut, #2, and remove
front bolt #3*. (4) Remove front mounting bolt and strut, rotate
solid mount bracket away from engine and slide
bracket on stud until #2 nut mounting stud until
free. Remove spacer from stud.
SOLID MOUNT BRACKETÐINSTALLATION
(1) Put spacer onto stud, then install bracket on
front (#2 nut) mounting stud and slide bracket over
timing belt cover into position. (2) Loosen assembly bracket to engine fasteners
(numbered #1 through #7 in Fig. 6). (3)
CAUTION: Fasteners MUST BE TIGHTENED IN SE-
QUENCE and to specified torque as follows :
² First Bolt #1 to 3.3 N Im (30 in. lbs.)
² Second Nut #2 and Bolt #3 to 54 N Im (40 ft. lbs.).
² Third Bolts #1 (second tightening) #4 and #5 to
54 N Im (40 ft. lbs.).
² Fourth Bolts #6 and #7 to 54 N Im (40 ft. lbs.).
(4) Install generator and compressor. Tighten com-
pressor mounting bracket bolts to 54 N Im (40 ft.
lbs.).
SOLID MOUNT COMPRESSOR BRACKET SERVICEÐTURBO III ENGINE
REMOVAL
(1) Disconnect negative battery cable
9 - 14 2.2/2.5L ENGINE Ä

CYLINDER HEAD COVER AND CURTAIN
A curtain aiding air/oil separation is installed on
the cylinder head below the cylinder head cover
(Figs. 1 and 2).
REMOVAL
(1) Remove the cylinder head cover bolts (Fig. 2).
(2) Remove cylinder head cover and curtain from
cylinder head. Do not misplace the rubber bumpers
on curtain.
CLEANING
Before installation, clean cylinder head and cover
mating surfaces. Make certain the rails are flat.
CURTAIN INSTALLATION
Install curtain manifold side first with cutouts over
cam towers and contacting cylinder head floor, then
press opposite distributor side into position below cyl-
inder head rail. Curtain is retained in position with rubber
bumpers (Fig. 1).
COVER SEALING AND INSTALLATION
Before installation, clean cylinder head and cover
mating surfaces. Make certain rails are flat. (1) Install new end seals on valve cover.
(2) Apply form-in-place Mopar Silicone Rubber Ad-
hesive Sealant or equivalent gasket material to cyl-
inder head cover rail (Fig. 3). Refer to procedure
detailed in form-in-place gasket section of Standard
Service Procedures, in this Group.
Caution: Do not allow oil or solvents to contact the
timing belt as they can deteriorate the rubber and
cause tooth skipping.
(3) Install curtain, cover and end seal assembly to
head and tighten to 12 N Im (105 in.lbs.) torque.
CYLINDER HEAD COMPONENTSÐIN-VEHICLE
SERVICE
Removal and installation of cylinder head or cam-
shaft require separation of camshaft timing sprocket
from camshaft. To maintain camshaft, intermediate
shaft, and crankshaft timing during service proce-
dures, the timing belt is left indexed on the sprocket
while the assembly is suspended under light tension
(Fig. 4). When removing the sprocket from the camshaft,
you must maintain adequate tension on the sprocket
and belt assembly to prevent the belt from disengag-
ing with the intermediate or crankshaft timing
sprockets. Refer to Timing System and Seals for re-Fig. 2 Cylinder Head Cover and Curtain
Fig. 3 Cylinder Head Valve Cover Rail SealingFig. 4 Suspending Camshaft Sprocket
Ä 2.2/2.5L ENGINE 9 - 23

Camshaft bearing journals and lobe wear. Lobe
wear should not exceed .25mm (.010 inch). To mea-
sure cam lobe wear (Fig. 8), measure lobe diameter
in two places at the largest diameter (over the nose).
Take first reading with micrometer in unworn area
at the edge of the lobe. Take second reading in the
worn area where rocker arm contacts the lobe. Sub-
tract second reading from the first. The difference is
the cam lobe wear.
CAMSHAFT END PLAY
(1) Oil camshaft journals and install camshaft
without cam followers. Tighten screws to specified
torque. (2) Using a suitable tool, move camshaft as far
rearward as it will go. (3) Zero dial indicator (Fig. 9).
(4) Move camshaft as far forward as it will go.
(5) End play travel: 0.13 - 0.33mm (0.005 - 0.013
inch.). (6) Remove bearing caps and camshaft.
INSTALLATION
(1) Install cam followers in correct order as re-
moved. (2) Align camshaft bearing caps in proper sequence
with Cap No. 1 at timing belt end and Cap No. 5 at
transmission end. Arrows on Caps No. 1, 2, 3, 4
must point toward timing belt to prevent cap break-
age (Fig. 11). (3) Apply Mopar Gasket Maker to No.1 and No.5
bearing cap (Fig. 10). (4) Caps must be installed before camshaft seals
are installed.
LASH ADJUSTER (TAPPET) NOISE
A tappet-like noise may be produced from several
items. Refer to Lash Adjuster and Tappet Noise - Di-
agnosis in Standard Service Procedures, this Group.
VALVE COMPONENTS REPLACEÐCYLINDER HEAD NOT REMOVED
ROCKER ARM AND HYDRAULIC LASH ADJUSTER
REMOVAL
(1) Remove valve cover.
(2) For each rocker arm, rotate cam until base cir-
cle is in contact with rocker arm. Depress valve
spring using Special Tool C-4682 (Fig. 12) and slide
rocker arm out. Keep rocker arms in order for reas-
sembly. (3) Remove hydraulic lash adjuster.
INSTALLATION
(1) Install hydraulic lash adjusters making sure
that adjusters are at least partially full of oil. This is
indicated by little or no plunger travel when the lash
adjuster is depressed. (2) Rotate cam until base circle is in contact posi-
tion with rocker arm. Depress valve spring with Spe-
cial Tool C-4682 (Fig. 12) and slide rocker arm in
place. Keep rockers in order. It is possible for the
Fig. 9 Camshaft End Play
Fig. 10 Cam Tower Cap Sealing
Fig. 11 Camshaft Bearing Caps Installation
Ä 2.2/2.5L ENGINE 9 - 25

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

PISTON PINS
DISASSEMBLY Turbo III engine piston-pin-connecting rod assem-
blies should not be disassembled unless a malfunc-
tion is present or a damaged assembly component is
to be replaced. WARNING: APPROVED SAFETY GLASSES
MUST BE WORN DURING PISTON LOCK
RING REMOVAL OR INSTALLATION TO PRE-
VENT POSSIBLE INJURY FROM FLYING
PARTS.
(1) Carefully, remove piston pin lock rings from
piston, using a small screwdriver in removal notch
(Fig. 10). (2) Discard used lock ring.
(3) Following lock ring removal, attempt to slide
pin out of piston. If pin does not slide out freely by
hand;
² Check for burr on outer edge of lock ring groove. If
one is present, carefully scrape burr away with a
knife or other hand tool, being careful not to damage
lock ring retaining groove. (4) Slide out piston pin to complete disassembly.
(5) Inspect components, discard damaged or exces-
sively worn parts refer to specifications (Fig. 12). If a
piston is replaced, a new pin should be used.
PISTON PINS
REASSEMBLY
(1) Different lock rings are used for turbocharged
engine applications. Consult the Service Note, pro- vided with the lock ring service package, to select
the correct lock rings from the package for your ap-
plication.
(2) Carefully, install one NEWlock ring with gap
towards piston top in lock ring groove. Do not rein-
stall used lock rings. (3) Position connecting rod and slide in lightly oil
piston pinch (4) Install second NEWlock ring with gap towards
piston top in lock ring groove, use small screwdriver
if needed.
CAUTION: BOTH lock rings must be FULLY
SEATED in lock ring grooves or engine failure will
occur.
(5) Check piston pin end play pin movement be-
tween lock rings in assembly.
PISTON RINGÐREMOVAL
(1) ID mark on face of upper and intermediate pis-
ton rings must point toward piston crown. (2) Using a suitable ring expander, remove upper
and intermediate piston rings (Fig. 13). (3) Remove the upper oil ring side rail, lower oil
ring side rail and then oil ring expander from piston. (4) Clean ring grooves of any carbon deposits.
Fig. 11 Engine Piston PinsÐTurbo III, Naturally Aspirated and Flexible Fuel Vehicles
Fig. 12 Piston Pin Specifications
Fig. 13 Piston RingsÐRemoving and Installing
9 - 52 2.2/2.5L ENGINE Ä

firmly and press down the portion to be installed un-
til side rail is in position. Do not use a piston ring
expander. (Fig. 19).
(3) Install upper side rail first and then the lower
side rail. (4) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 8). (5) Position piston ring end gaps as shown in (Fig.
19). (6) Position oil ring expander gap at least 45É from
the side rail gaps but noton the piston pin center or
on the thrust direction. Staggering ring gap is impor-
tant for oil control.
PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION
(1) Before installing pistons and connecting rod as-
semblies into the bore, besure that compression ring
gaps are staggered so that neither is in line with oil
ring rail gap. (2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 19).
(3) Immerse the piston head and rings in clean en-
gine oil, slide the ring compressor, over the piston and tighten with the special wrench (Fig. 20).
Be sure
position of rings does not change during this
operation .
(4) The valve cut should be toward the manifold side
of the engine (Fig. 21). (5) Install connecting rod bolt protectors on rod bolts
(Fig. 4). (6) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert rod
and piston into cylinder bore and guide rod over the
crankshaft journal. (7) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal. (8) Install rod caps. Install nuts on cleaned and oiled
rod bolts and tighten nuts to 54 N Im (40 ft. lb.) Plus 1/4
turn for N/A engines and 68 N Im (50 ft. lbs.) for turbo
III engines.
Fig. 19 Piston Ring End Gap Position
Fig. 20 Installing Piston
Fig. 21 Piston Markings
Fig. 22 Checking Connecting Rod Bearing Clear- ance
9 - 54 2.2/2.5L ENGINE Ä

PISTON AND CONNECTING ROD ASSEMBLY SERVICE
(1) Mark Identify Pistons. The pistons are not in-
terchangeable from bank to bank (Fig. 2). Pistons
with the letter R and arrow toward the front of en-
gine are to be installed in cylinders 1-3-5. Pistons
with the letter L and arrow toward the front of en-
gine are to be installed in cylinders 2-4-6.
(2) Mark connecting rod and cap with cylinder
number (Fig. 3). (3) Remove piston rings (Fig. 4).
CYLINDER BORE INSPECTION
(1) Measure the cylinder bore at three levels in di-
rections A and B (Fig. 5). Top measurement should be 12mm (.50 inch) down and bottom measurement
should be 10mm (.38 inch) up. (2) Standard bore dimension: 91.1mm (3.587 inch)
(3) Maximum out-of-round or taper: 0.02mm (.0008
inch)
FITTING PISTONS
Measure approximately 2mm (.080 inch) above the
bottom of the piston skirt and across the thrust face.
(Fig. 6), See Boring Cylinder in Cylinder Block.
FITTING PISTON RINGS
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 16mm (0.63 inch) from bottom of
Fig. 1 Pistons, Connecting Rods
Fig. 2 Mark Pistons
Fig. 3 Mark Matching Parts
9 - 82 3.0L ENGINE Ä

PISTON RINGSÐINSTALLATION
(1) The No. 1 and No. 2 piston rings have a differ-
ent cross section. Install rings with manufacturers
mark and size mark facing up, to the top of the pis-
ton (Fig. 10).
CAUTION: Install piston rings in the following or-
der:
(a) Oil ring expander.
(b) Upper oil ring side rail.
(c) Lower oil ring side rail.
(d) No. 2 Intermediate piston ring.
(e) No. 1 Upper piston ring.
(2) Install the side rail by placing one end between
the piston ring groove and the expander. Hold end
firmly and press down the portion to be installed un-
til side rail is in position. Do Not use a piston ring
expander (Fig. 11).
(3) Install upper side rail first and then the lower
side rail. (4) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 12). (5) Position piston ring end gaps as shown in (Fig.
13). (6) Position oil ring expander gap at least 45É from
the side rail gaps but noton the piston pin center or
on the thrust direction. (7) Connecting rod front mark 72 must always face
forward, toward timing belt end. (Fig. 14) (8) Install the piston and connecting rod assembly
into there respective bore from the cylinder block
top.
CAUTION: Piston assemblies are not to be inter-
changed from bank to bank.
(9) Check alignment marks made during disassem-
bly and that bearing position notches new or used
are on the same side as shown in (Fig. 15).
CONNECTING ROD CLEARANCE
(1) Following procedures specified in the Standard
Service Procedures Section for Measuring Main Bear-
ing Clearance and Connecting Rod Bearing Clear-
ance. (Fig. 16). Refer to (Fig. 18) for specifications.
Fig. 10 Piston Ring Installation
Fig. 11 Installing Side Rail
Fig. 12 Installing Upper and Intermediate Rings
Fig. 13 Piston Ring End Gap Position
9 - 84 3.0L ENGINE Ä