1993 CHEVROLET DYNASTY sensor

(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

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.
TURBOCHARGER
REMOVAL
The turbocharger is removed from below the vehi-
cle. Cylinder head removal for component accessibil-
ity is not required. (1) Disconnect negative battery cable. Remove Air
Cleaner assembly (Fig. 1). (2) From Above: Remove front engine mount
through bolt and rotate engine (Top) forward away
from cowl. Refer to Engine Removal in Engine,
Group 9. (3) Remove Air Cleaner Support (Fig. 1).
(4) Disconnect Heated Oxygen sensor lead wire
and vacuum lines. (5) Separate coolant return line from water box
and turbocharger housing (Fig. 11). Remove return
line from turbocharger.
(6) Separate oil feed line from turbocharger hous-
ing (Fig. 12). (7) Remove three (two upper and one lower driver's
side) nuts retaining turbocharger to manifold (Fig.
12). (8) From Below: Remove right front wheel and
tire assembly. (9) See Suspension, Group 2, and remove right
driveshaft assembly. Air deflector may need to be removed from cross-
member. (10) Separate oil drain back tube fitting from tur-
bocharger housing and remove fitting and hose (Fig.
13). (11) Remove turbocharger to block support bracket
(Fig. 13). (12) Remove one remaining turbocharger to mani-
fold retaining nut (Fig. 12).
Fig. 11 Coolant Tube Routing
Fig. 12 Turbocharger Attaching Nuts
Fig. 9 Fuel Supply and Return Hose Connections
Fig. 10 Intake Manifold Attaching Bolts.
11 - 12 EXHAUST SYSTEM AND INTAKE MANIFOLD 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

(e) Remove jumper wires.
(f) Continue fuel system service.
(4) Remove throttle cable and transaxle kickdown
linkage (Fig. 4). (5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 5). (6) Remove vacuum hose harness from throttle body
(Fig. 5). (7) Remove PCV and Brake booster hoses from Air
Intake Plenum. (8) Remove ignition coil from intake plenum (Fig. 6).
(9) Remove wiring connectors from coolant tempera-
ture sensor (Fig. 7). (10) Remove vacuum connections from air intake
plenum vacuum connector. (11) Remove fuel hoses from fuel rail (Fig. 7).
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE. (12) Remove (8) Fasteners from Air Intake Plenum
to Intake Manifold (Fig. 8). (13) Remove air intake plenum (Fig. 9).
(14) Cover intake manifold with suitable cover when
servicing. (15) Remove vacuum hoses from fuel rail and fuel
pressure regulator (Fig. 10). (16) Disconnect Fuel Injector wiring harness from
engine wiring harness (Fig. 11). (17) Remove fuel pressure regulator attaching bolts
and remove regulator from rail (Fig. 12). Be careful
not to damage the rubber injector O-rings upon
removal from the ports. (18) Remove fuel rail attaching bolts and lift fuel rail
assembly from intake manifold. (19) Separate radiator hose from thermostat hous-
ing and heater hose from heater pipe. (20) Remove (8) nut and washer assemblies and
remove intake manifold (Fig. 2).
INSPECTION
Check for:
² Damage and cracks of each section (Fig. 13).
² Clogged water passages in end cross overs.
² Check for distortion of the cylinder head mounting
surface using a straightedge and thickness gauge (Fig.
14). Refer to (Fig. 15) for Specifications.
INSTALLATION
(1) Position new intake manifold gaskets on cylinder
head and install intake (cross) manifold. (2) Install (8) nuts and washers and tighten in
several steps in order shown in (Fig. 16) to 20 N Im
(174 in. lbs.). (3) Make sure the injector holes are clean and all
plugs have been removed. (4) Lube injector O-ring with a drop of clean en-
gine oil to ease installation. (5) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports. (6) Install the (3) fuel rail attaching bolts and
torque to 13 N Im (115 in. lbs.).
(7) Install fuel pressure regulator onto fuel rail. In-
stall attaching bolts to intake manifold. Torque reg-
ulator nuts and bracket bolts to 10 N Im (95 in. lbs.)
(Fig. 12). (8) Install fuel supply and return tube hold-down
bolt and the vacuum crossover tube hold-down bolt
and torque to 10 N Im (95 in. lbs.).
(9) Connect fuel injector wiring harness to engine
wiring harness (Fig. 11). (10) Connect vacuum harness to fuel pressure reg-
ulator and fuel rail assembly (Fig. 10). (11) Remove covering from lower intake manifold
and clean surface. (12) Place intake manifold gaskets with beaded
sealant side up on lower manifold. Put air intake in
Fig. 3 Throttle Body Assembly 3.0L
Fig. 4 Throttle Cable Attachment
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 15

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

EXHAUST MANIFOLDS
REMOVAL (1) Raise vehicle and disconnect exhaust pipe from
rear (cowl side) exhaust manifold at articulated joint. (2) Disconnect Oxygen Sensor lead wire at the rear
exhaust manifold (Fig. 18). (3) Remove bolts attaching cross-over pipe to man-
ifold (Figs. 2 and 19). (4) Remove nuts attaching rear manifold to cylin-
der head and remove manifold.
(5) Lower vehicle and remove screws attaching
front heat shield to front manifold (Fig. 2). (6) Remove bolts fastening crossover pipe to front
exhaust manifold and nuts fastening manifold to cyl-
inder head. Remove assemblies.
INSPECTION
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface and exhaust crossover mounting surface with
a straightedge and thickness gauge (Fig. 20).
INSTALLATION Install the gaskets with the numbers 1-3-5 em-
bossed on the top on the rear bank and those with
numbers 2-4-6 on the front (Radiator side) bank (Fig.
21). (1) Install rear exhaust manifold and tighten at-
taching nuts to 20 N Im (175 in. lbs.).
Fig. 15 Intake Plenum and Cylinder Head Mounting
Surface Specifications
Fig. 16 Nut Tightening Sequence for Intake (Cross) Manifold
Fig. 17 Intake Plenum Tightening Sequence
Fig. 18 Separate Articulated Joint, DisconnectOxygen Sensor Wire
Fig. 19 Crossover Pipe
11 - 18 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

(2) Attach exhaust pipe to exhaust manifold and
tighten shoulder bolt to 28 N Im (250 in. lbs.)
(3) Attach crossover pipe to exhaust manifold and
tighten bolt to 69 N Im (51 ft. lbs.)
(4) Connect heated oxygen sensor lead (Fig. 18).
(5) Install front exhaust manifold and attach ex-
haust crossover. (6) Install front manifold heat shield and tighten
attaching screws to 15 N Im (130 in. lbs.) (Fig. 2).
INTAKE/EXHAUST MANIFOLD SERVICEÐ3.3/3.8L
ENGINES
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.
FUEL SYSTEM PRESSURE RELEASE PROCE- DURE
The MPI fuel system is under a constant pressure
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 Num-
ber 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. (e) Remove jumper wires.
(f) Continue fuel system service.
(3) Remove air cleaner to throttle body hose assem-
bly (Fig. 2).
Fig. 20 Check Exhaust Manifold Mounting Surface
Fig. 21 Identify Exhaust Manifold Gaskets
Fig. 1 Injector Harness Connectors
Fig. 2 Throttle Body AssemblyÐ3.3/3.8L Engines
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 19

(4) Remove throttle cable (Fig. 3). Remove wiring
harness from throttle cable bracket.
(5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 4). (e) Remove jumper wires.
(f) Continue fuel system service.
(6) Remove vacuum hose harness from throttle
body (Fig. 4). (7) Remove PCV and brake booster hoses from air
intake plenum (Fig. 5). (8) Remove EGR tube flange from intake plenum
(Fig. 5). (9) Disconnect Charge Temperature Sensor electri-
cal connector. Remove vacuum harness connectors
from Intake Plenum (Fig. 5).
(10) Remove cylinder head to intake plenum strut
(Fig. 5). (11) Disconnect MAP Sensor and heated Oxygen
Sensor electrical connection. Remove the engine
mounted ground strap (Fig. 6).
Fig. 3 Throttle Cable Attachment
Fig. 4 Electrical and Vacuum Connection to Throttle Body
Fig. 5 Electrical and Vacuum Connections To IntakeManifold
Fig. 6 MAP Sensor Electrical Connector
11 - 20 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä