1993 CHEVROLET DYNASTY oil

ENGINE LUBRICATION SYSTEM
The lubrication system is a full flow filtration pres-
sure feed type. Oil from the oil pan is pumped by a
internal gear type oil pump directly coupled to the
crankshaft. Its pressure is regulated by a relief valve
located in the Chain Case Cover. The oil is pumped
through an oil filter and feeds a main oil galley.This
oil gallery feeds oil under pressure to the main and
rod bearings, camshaft bearings. Passages in the cyl-
inder block feed oil to the hydraulic lifters and
rocker shaft brackets which feeds the rocker arm piv-
ots (Fig. 1).
OIL PAN SERVICE
REMOVAL
(1) Disconnect negative battery cable, remove en-
gine oil dipstick. (2) Raise vehicle. Drain engine oil.
(3) Remove oil pan screws and remove oil pan.
CLEANING AND INSPECTION
(1) Clean oil pan in solvent and wipe dry with a
clean cloth. Clean all gasket material from mounting
surfaces of pan and block. (2) Inspect oil drain plug and plug hole for stripped
or damaged threads and repair as necessary. Install
a new drain plug gasket. Tighten to 27 N Im (20 ft.
lb.). (3) Inspect oil pan mounting flange for bends or
distortion. Straighten flange if necessary. (4) Clean oil screen and pipe in clean solvent. In-
spect condition of screen.
INSTALLATION
(1) Install oil pick-up tube into Chain Case Cover
tighten screw to 28 N Im (250 in. lbs.) (Fig. 2).
(2) Apply a 1/8 inch bead of Mopar Silicone Rubber
Adhesive Sealant or equivalent, at the parting line of
the chain case cover and the rear seal retainer (Fig. 3). (3) Use a new pan gasket (Fig. 4).
(4) Install pan and tighten screws to 23 N Im (200 in.
lb.).
(5) Lower vehicle and install oil dipstick.
(6) Connect negative battery cable.
(7) Fill crankcase with oil to proper level.
Fig. 1 Engine Oiling System
Fig. 2 Oil Pump Pick-up Tube Service
9 - 122 3.3/3.8L ENGINE Ä

OIL PUMP SERVICE
It is necessary to remove the oil pan, oil pickup
and chain case cover (CCC) to service the oil pump
rotors. The oil pump pressure relief valve can be ser-
viced by removing the oil pan and oil pickup tube.
Refer to Timing Chain Cover Removal and Installa-
tion of this section for procedures.
DISASSEMBLY
(1) To remove the relief valve, proceed as follows: (a) Drill a 3.175mm (1/8 inch) hole into the relief
valve retainer cap and insert a self-threading sheet
metal screw into cap. (b) Clamp screw into a vise and while supporting
chain case cover (CCC), remove cap by tapping
CCC using a soft hammer. Discard retainer cap
and remove spring and relief valve (Fig. 5).
(2) Remove oil pump cover screws, and lift off
cover. (3) Remove pump rotors.
(4) Wash all parts in a suitable solvent and inspect
carefully for damage or wear (Fig. 6).
INSPECTION AND REPAIR
(1) Clean all parts thoroughly. Mating surface of
the chain case cover (CCC) should be smooth. Re-
place pump cover if scratched or grooved. (2) Lay a straightedge across the pump cover sur-
face (Fig. 7). If a .076mm (.003 inch) feeler gauge can
be inserted between cover and straight edge, cover
should be replaced. (3) Measure thickness and diameter of outer rotor.
If outer rotor thickness measures 7.64mm (0.0301
inch.) or less (Fig. 8), or if the diameter is 79.95mm
(3.148 inches.) or less, replace outer rotor. (4) If inner rotor measures 7.64mm (.301 inch) or
less replace inner rotor (Fig. 9).
(5) Slide outer rotor into CCC, press to one side
with fingers and measure clearance between rotor
and CCC (Fig. 10). If measurement is .39mm (.015
inch) or more, replace CCC only if outer rotor is in
specification. (6) Install inner rotor into CCC. If clearance be-
tween inner and outer rotors (Fig. 11) is .203mm
(.008 inch) or more, replace both rotors.
Fig. 3 Oil Pan Sealing
Fig. 4 Oil Pan Gasket Installation
Fig. 5 Oil Pressure Relief Valve
Fig. 6 Oil Pump
Ä 3.3/3.8L ENGINE 9 - 123

(7) Place a straightedge across the face of the CCC,
between bolt holes. If a feeler gauge of .102mm (.004
inch) or more can be inserted between rotors and the
straightedge, replace pump assembly (Fig. 12). ONLY
if rotors are in specs. (8) Inspect oil pressure relief valve plunger for scor-
ing and free operation in its bore. Small marks may be
removed with 400-grit wet or dry sandpaper. (9) The relief valve spring has a free length of
approximately 49.5mm (1.95 inches) it should test
between 19.5 and 20.5 pounds when compressed to
34mm (1-11/32 inches). Replace spring that fails to
meet specifications (Fig. 5).
(10) If oil pressure is low and pump is within speci-
fications, inspect for worn engine bearings or other
reasons for oil pressure loss.
OIL PUMP ASSEMBLY AND INSTALLATION
(1) Assemble pump, using new parts as required.
Install the inner rotor with chamfer facing the
cast iron oil pump cover. (2) Tighten cover screws to 12 N Im (105 in. lbs.). (3) Prime oil pump before installation by filling ro-
tor cavity with engine oil. (4) Install chain case cover slowly refer to Timing
Chain Cover Installation of this section.
Fig. 9 Measuring Inner Rotor Thickness
Fig. 10 Measuring Outer Rotor Clearance in Housing
Fig. 11 Measuring Clearance Between Rotors
Fig. 7 Checking Oil Pump Cover Flatness
Fig. 8 Measuring Outer Rotor Thickness
9 - 124 3.3/3.8L ENGINE Ä

CHECKING ENGINE OIL PRESSURE
Check oil pressure using gauge at oil pressure
switch location. Oil pressure should be 34.47 kPa ( 5
psi.) at idle or 205 to 551 kPa (30 to 80 psi.) at 3000
RPM. (1) Remove pressure sending unit and install oil
pressure gauge (Fig. 13).
CAUTION: If oil pressure is 0 at idle, Do Not Run
engine at 3000 RPM .
(2) Warm engine at high idle until thermostat
opens.
OIL FILTER
CAUTION: When servicing the oil filter (Fig. 16)
avoid deforming the filter can by installing the re-
move/install tool band strap against the can-to-base
lockseam. The lockseam joining the can to the base
is reinforced by the base plate.
(1) Using Tool C-4065, unscrew filter from base
and discard (Fig. 14). (2) Wipe base clean, then inspect gasket contact
surface. (3) Lubricate gasket of new filter with clean en-
gine oil. (4) Install and tighten filter to 20 N
Im (15 ft. lbs.)
torque after gasket contacts base. Use filter wrench
if necessary. (5) Start engine and check for leaks.
Fig. 12 Measuring Clearance Over RotorsFig. 13 Checking Oil Pump Pressure
Fig. 14 Oil Filter
Ä 3.3/3.8L ENGINE 9 - 125

SERVICE PROCEDURES INDEX
page page
Exhaust Pipes, Mufflers and Tailpipes .......... 4
Intake and Exhaust Manifolds ServiceÐTBI Engine.6Intake and Exhaust ManifoldsÐFlexible Fuel Engine.7
Intake and Exhaust ManifoldsÐTBI Engine ...... 5
Intake/Exhaust Manifold ServiceÐ3.0L Engine . . . 13
Intake/Exhaust Manifold ServiceÐ3.3/3.8L Engines.19
Intake/Exhaust Manifolds and Turbocharger ServiceÐTurbo III Engine .................. 9
Intake/Exhaust Manifolds ServiceÐFlexible Fuel Engines ............................... 7
EXHAUST PIPES, MUFFLERS AND TAILPIPES
REMOVAL
(1) Raise vehicle on hoist and apply penetrating oil
to clamp bolts and nuts of component being removed. (2) Tail pipes are integral with the muffler (Fig. 5).
Remove clamp at slip joint. Separate at slip joint. (3) Remove clamps and supports (Figs. 6, 7, 8, and 9)
from exhaust system to permit alignment of parts
during assembly. (4) When removing tailpipe, raise rear of vehicle to
relieve body weight from rear springs to provide clear-
ance between pipe and rear axle parts. (5) Clean ends of pipes and/or muffler to assure
mating of all parts. Discard broken or worn insulators,
rusted clamps, supports and attaching parts. When replacement is required on any compo-
nent of the exhaust system, it is most important
that original equipment parts (or their equiva-
lent) be used;
² To insure proper alignment with other parts in the
system.
² Provide acceptable exhaust noise levels and does not
change exhaust system back pressure that could affect
emissions and performance.
INSTALLATION
(1) Assemble ball joint connection pipes, supports
and clamps loosely to permit alignment of all parts.
Fig. 6 Insulator Tail Pipe and Muffler Support
Fig. 7 Underfloor Converter or Extension Pipe SupportÐ2 Places
Fig. 5 Tail Pipe with MufflerÐTypical
11 - 4 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

(7) Disconnect Intercooler to throttle body outlet
hose. Disconnect vacuum hoses from throttle body
and remove harness (Fig. 5).
(8) Disconnect automatic idle speed (AIS) motor
and throttle position sensor (TPS) wiring connectors
(Fig. 6). (9) Remove PCV Breather/Separator box and vac-
uum harness assembly. Remove brake booster, vac-
uum vapor harness and fuel pressure regulator
harness from intake manifold (Fig. 7). (10) Disconnect Fuel Injector Wiring Connector
(Fig. 8). Charge Temperature Wiring Connector (Fig.
7). (11) Remove fuel supply and return hose quick
connect at fuel tube assembly (Fig. 9). WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE
.
(12) Remove 8 intake manifold screws and washer
assemblies and remove intake manifold (Fig. 10).
INSTALLATION
Before installing manifold. Refer to Cleaning and
Inspection of this section to check manifold for dam-
age. (1) Install new intake manifold gasket and intake
manifold onto cylinder head and tighten fasteners to
23 N Im (200 in. lbs.) torque (Fig. 10).
(2) Install PCV Breather/Separator box and vac-
uum harness assembly. Connect brake booster, vac-
uum vapor harness and vacuum hose to fuel pressure
regulator (Fig. 7).
Fig. 1 Air Cleaner and Throttle Body AssemblyÐTurbo III Engine
Fig. 2 Radiator to Cylinder Head Hose
Fig. 3 Distributorless Ignition Coil (DIS) Location
Fig. 4 Accelerator and Speed Control Cables
11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

(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