belt CHEVROLET DYNASTY 1993 Manual Online

(9) Mark support assembly to engine bracket if as-
sembly is to be used again. Separate engine mount
insulator from engine mount bracket (Fig. 10). Raise
engine slightly. (10) Remove engine mount bracket (Fig. 10).
(11) Remove timing belt covers (Fig. 11).
TIMING BELT INSPECTIONÐIN VEHICLE
(1) Remove the upper front outer timing belt cover
by loosening the three attaching bolts. (Fig. 11). (2) Inspect both sides of the timing belt drive &
back. Replace belt if any of the following conditions
exist.
² Hardening of back rubber back side is glossy with-
out resilience and leaves no indent when pressed
with fingernail.
² Cracks on rubber back.
² Cracks or peeling of canvas.
² Cracks on rib root.
² Cracks on belt sides.
² Missing teeth.
² Abnormal wear of belt sides. The sides are normal
if they are sharp as if cut by a knife (Fig. 12). (3) If none of the above conditions are seen on the
belt, the belt cover can be reinstalled.
TIMING BELT SERVICE
REMOVAL
(1) Mark belt running direction for installation
(Fig. 14). (2) Loosen timing belt tensioner bolt (Fig. 16) and
remove timing belt. (3) Remove crankshaft sprocket flange shield (Fig.
9).
CAMSHAFT SPROCKETS
REMOVAL
(1) Hold camshaft sprocket with Spanner Tool
MB990775 loosen and remove bolt and washer (Fig.
15). (2) Remove camshaft sprocket from camshaft.
Fig. 10 Right Engine Mount and Engine Mount Bracket
Fig. 11 Timing Belt Covers
Fig. 12 Timing Belt Inspection
9 - 72 3.0L ENGINE Ä

Fig. 13 Timing Belt System
Fig. 14 Timing Belt Engine Sprocket Timing
Ä 3.0L ENGINE 9 - 73

INSTALLATION
(1) Place camshaft sprocket on camshaft.
(2) Install bolt and washer to camshaft. Using
Spanner Tool MB990775 hold camshaft sprocket and
torque bolt to 95 N Im (70 ft. lbs.) (Fig. 15).
TIMING BELT TENSIONER
(1) Install timing belt tensioner and tensioner
spring. (2) Hook spring upper end to water pump pin and
lower end to tensioner bracket with hook out (Fig. 16).
(3) Turn timing belt tensioner counter-clockwise full
travel in adjustment slot and tighten bolt to tempo-
rarily hold this position (Fig. 17).
INSTALLATIONÐTIMING BELT
(1) Install timing belt on crankshaft sprocket first
and while keeping belt tight on tension side (Fig. 14)
install belt on the front (radiator side) camshaft
sprocket. (2) Then, install on the water pump pulley and on
the rear camshaft sprocket and finally on the timing
belt tensioner. (3) Apply rotating force to the front camshaft
sprocket in opposite direction to tension the belt ten-
sion side, check that all timing marks are lined up (Fig.
14). (4) Install crankshaft sprocket flange (Fig. 12).
(5) Loosen tensioner bolt and allow spring to tension
timing belt. (6) Turn crankshaft two full turns in clockwise di-
rection. Turn smoothly and in clockwise direction
ONLY. (7) Again line up the timing marks on the sprockets
and tighten the timing belt tensioner locking bolt to 25
N Im (250 in. lbs.) torque.
(8) Reassembly belt covers, engine bracket, insula-
tor, crankshaft pulleys, accessories and accessory drive
belts in reverse order.
Fig. 15 Camshaft Sprockets
Fig. 16 Timing Belt Tensioner
Fig. 17 Positioning Belt Tensioner
9 - 74 3.0L ENGINE Ä

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

(Fig. 9) are different, one has end positioning tabs,
while the other is plain. One pairof each thrust
washers are installed into the block and one pair
into the main bearing cap (Fig. 9). (2) Apply a thin film of grease to plain side of
thrust washers and position them on each side of
number three main bearing. Grooved surface towards
crankshaft. (3) Oil the bearings and journals and install crank-
shaft. (4) Install lower main bearing shells without oil
grooves in monoblock cap. (5) Install one pair of thrust washers in cap. Refer
to Thrust Bearings (Fig. 9). (6) Carefully install bearing cap with arrows (Fig.
10) toward timing belt end. (7) Oil the bearing cap bolt threads, install and
tighten bolts progressively in sequence shown in
(Fig. 9) to 80 N Im (60 ft. lbs.) torque.
CHECKING CRANKSHAFT END PLAY
(1) Mount a dial indicator to front of engine, locat-
ing probe on nose of crankshaft (Fig. 11). (2) Move crankshaft all the way to the rear of its
travel. (3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to (Fig. 6) for specifica-
tion.
CRANKSHAFT OIL SEALS SERVICE
REAR CRANKSHAFT SEAL RETAINER
(1) Install rear crankshaft oil seal in housing with
Special Tool MD998718 (Fig. 12). (2) Apply (Mopar Silicone Rubber Adhesive Seal-
ant or equivalent) to oil seal housing (Fig. 13) per
procedure detailed in form-in-place gasket section in
Standard Service Procedures.
Fig. 9 Install Main Bearings
Fig. 8 Measuring Clearance
9 - 88 3.0L ENGINE Ä

OIL PAN
The oil pan is made of sheet metal and is provided
with a baffle-plate to prevent fluctuations in the oil
level while the vehicle is running (Fig. 2).
OIL PAN SEALING AND INSTALLATION
Oil pan to crankcase sealing is provided with Mo-
par Silicone Rubber Adhesive Sealant or equivalent
gasket material. See Form-In-Place Gaskets in Stan-
dard Service Procedures. (1) Apply sealant as shown in (Fig. 3).
(2) Install pan and tighten screws to 6 N Im (50 in.
lbs.) in sequence shown in (Fig. 4).
OIL PUMP SERVICE
The oil pump assembly is mounted on the timing
belt end of the cylinder block with the inner pump
rotor indexed and installed on the crankshaft nose.
(Fig. 5). The oil pump case also retains the crankshaft front
oil seal and provides oil pan front end closure.
REMOVAL
Remove accessory drive system. Refer to Accessory
Drive Service in this group. Remove 5 bolts that attach oil pump to block (Fig.
6).
INSPECTION OIL PUMP
(1) Check oil pump case for damage and remove
rear cover. (2) Remove pump rotors and inspect case for exces-
sive wear. (3) Measure clearance between case and inner ro-
tor (Fig. 8). (4) Insert the rotor into the oil pump case (Figs. 9
and 10) and measure clearance with a feeler gauge
as indicated.
Fig. 2 Oil Pan
Fig. 3 Oil Pan Sealing
Fig. 4 Oil Pan Screw Tightening Sequence
Fig. 5 Oil Pump-Installed
Fig. 6 Oil Pump Assembly
9 - 92 3.0L ENGINE Ä

(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