1993 CHEVROLET PLYMOUTH ACCLAIM check engine

(12) Recheck belt tension, adjust if necessary.
(13) Torque rocker arm shafts in sequence shown
(Fig. 13) to 12 N Im (105 in. lbs.) then to 24 N Im (210
in. lbs.). (14) Install valve covers, spark plugs, ignition cables
and ignition cable cover. (15) Install air cleaner fresh air duct.
(16) Raise vehicle. Install lower timing belt cover
and accessory drive belt tensioner pulley. Refer to
procedure in this section. (17) Lower vehicle. Install right engine mount (Fig.
5). (18) Inspect foam stuffer block condition and posi-
tion (Fig. 14). Stuffer block should be intact and secure
within the engine bracket tunnel. (19) Install upper timing belt cover and PCV tube.
Refer to procedure in this section. (20) Install accessory drive belt. Refer to procedure
in this section.
SERVICING OIL SEALS
Refer to servicing oil seals in this group for proce-
dures. To service the intake cam seal (Turbo III) the
right engine mount must be removed. Refer to
engine mount removal of this Group.
Fig. 13 Rocker Arm ShaftÐInstallation
Fig. 14 Foam Stuffer Block Location
Fig. 11 Camshafts and Crankshaft Timing Marks
Fig. 12 Belt Tension Gauge Location
Ä 2.2/2.5L ENGINE 9 - 35

(2) Install thrust plates and tighten retaining nuts
to6N Im (55 in. lbs.).
(3) Install new camshaft oil seals flush with cylin-
der head surface. Using seal installing special tool C-4680.
CAMSHAFT END PLAY
(1) Using a suitable tool, move camshaft as far
rearward as it will go. (2) Zero dial indicator (Fig. 6).
(3) Move as far forward and backward as camshaft
will go. (4) End play travel: 0.025-0.200mm (.001-.008
inch).
LASH ADJUSTER (TAPPET) NOISE
A tappet-like noise may be produced from several
items. See Lash Adjuster and Tappet Noise-DIAG-
NOSIS in STANDARD SERVICE PROCEDURES,
this Group.
VALVE COMPONENTS REPLACEÐCYLINDER HEAD
NOT REMOVED
ROCKER ARM AND HYDRAULIC LASH
ADJUSTER
REMOVAL
(1) Remove valve cover. Refer to procedure previ-
ously outlined in this section.
(2) Remove rocker arm shaft(s) in sequence shown
in (Fig. 6). Slide rocker off the shaft. Keep rocker
arms in order for reassembly.
CAUTION: Check lash adjusters for loose or miss-
ing retainers before continuing service procedure.
(3) Remove hydraulic lash adjuster.
Fig. 5 Measuring Camshaft Lobe Wear
Fig. 6 Checking Camshaft End Play
Fig. 7 Rocker Arm ShaftÐRemoval
Fig. 8 Rocker Arm and Lash Adjuster AssemblyÐRight and Left
Ä 2.2/2.5L ENGINE 9 - 37

REFACING VALVES AND VALVE SEATS
(1) The intake and exhaust valve seats and valve
face have a 45 degree angle. (2) Inspect the remaining margin after the valves
are refaced (Fig. 11). Exhaust valves with less than
1.07mm (3/64 inch) margin and intake valves with
less than 1.06mm (3/64 inch) margin should be dis-
carded. (3) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be ob-
tained. (4) Measure the concentricity of valve seat using a
valve seat dial indicator. Total runout should not ex-
ceed. 0.1 mm (.004 inch) (total indicator reading). (5) Inspect the valve seat with Prussian blue to de-
termine where the valve contacts the seat. To do
this,coat valve seat LIGHTLYwith Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of the valve face, lower valve seat
with a 15 degrees stone. If the blue is transferred to
the bottom edge of valve face raise valve seat with a
65 degrees stone.
² Intake valve seat diameter 34.0mm (1.338 inch)
² Exhaust valve seat diameter 29.4mm (1.157 inch) Valve seats which are worn or burned can be re-
worked, provided that correct angle and seat width
are maintained. Otherwise cylinder head must be re-
placed. (6) When seat is properly positioned the width of
intake seats should be 1.87mm (0.73 inch) The width
of the exhaust seats should be 2.00mm (.078 inch)
(Fig. 16 Dimension 1). (7) Check valve tip to spring seat dimensions A af-
ter grinding the valve seats or faces. Grind valve tip
to give 55.62 to 55.88 mm (2.190 to 2.200 inch.) over
spring seat when installed in the head (Fig. 17).
Check valve tip for scoring, if necessary, the tip
chamfer should be reground to prevent seal damage
when the valve is installed. (8) Check the valve spring installed height B after
refacing the valve and seat (Fig. 17). Measurement B
is to be taken from the spring seat to the bottom of
the spring retainer. Correct height is 44.0mm (1.73
inches).
Fig. 13 Measuring Valve Guides
Fig. 14 Valve Dimensions
Fig. 15 Refacing Intake and Exhaust Valves
Fig. 16 Refacing Valve Seats
Ä 2.2/2.5L ENGINE 9 - 39

VALVE GEAR REASSEMBLY AFTER VALVE SERVICE
(1) Coat valve stems with lubrication oil and insert
in cylinder head. (2) Install new valve stem seals on all valves. The
valve stem seals should be pushed firmly and
squarely over valve guide. The lower edge of the seal
should be resting on the valve guide boss. (3) Install valve spring seats and springs and re-
tainers. Compress valve springs only enough to in-
stall locks, taking care not to misalign the direction
of compression. Nicked valve stems may result from
misalignment of the valve spring compressor.
CAUTION: When depressing the valve spring retain-
ers with Valve Spring Compressor Tool C-3422-B
with adopters 6537 and 6526 (Fig. 11) the locks can
become dislocated. Check to make sure both locks
are in their correct location after removing tool.
(4) Check installed height of springs. Measurement
B is to be taken from the spring seat to the bottom of
the spring retainer. Correct height is 44.0mm (1.73
inches). If seats have been ground an additional
spring seat may be required to maintain correct in-
stalled spring height (Fig. 17). (5) Install camshaft and rocker arms as previously
described, see Camshaft-Install.
Fig. 17 Checking Valve Tip Height and Spring Installed Height
9 - 40 2.2/2.5L ENGINE Ä

CRANKSHAFT SERVICE
CRANKSHAFT MAIN BEARINGS
Bearing caps are not interchangeable and should
be marked at removal to insure correct assembly.
Upper and lower bearing halves are NOT inter-
changeable. Lower main bearing halves of 1, 2, 4 and
5 are interchangeable. Upper main bearing halves of
1, 2, 4 and 5 are interchangeable (Fig. 7).
CRANKSHAFT MAIN JOURNALS
The crankshaft journals should be checked for ex-
cessive wear, taper and scoring. Limits of taper or
out-of-round on any crankshaft journals should be
held to .025mm (.001 inch). Journal grinding should
not exceed .305mm (.012 inch) under the standard
journal diameter. Do NOT grind thrust faces of Num-
ber 3 main bearing. Do NOT nick crank pin or bear-
ing fillets. After grinding, remove rough edges from
crankshaft oil holes and clean out all passages.
CAUTION: With the nodular cast iron crankshafts
used it is important that the final paper or cloth pol-
ish after any journal regrind be in the same direc-
tion as normal rotation in the engine.
Upper and lower Number 3 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves
in the engine (Fig. 7). All bearing cap bolts removed
during service procedures are to be cleaned and oiled
before installation. Bearing shells are available in
standard and the following undersized: 0.025mm
(.001 inch), .051mm (.002 inch), .076mm (.003 inch),
.254mm (.010 inch), and .305mm (.012 inch). Never
install an undersize bearing that will reduce clear-
ance below specifications.
MAIN BEARING SERVICEÐCRANKSHAFT NOT REMOVED
REMOVAL
(1) Remove oil pan and identify bearing caps before
removal. (2) Remove bearing caps one at a time. Remove
upper half of bearing by inserting Special Main Bear-
ing Tool C-3059 (Fig. 8) into the oil hole of crankshaft. (3) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
INSTALLATION Only one main bearing should be selectively
fitted while all other main bearing caps are prop-
erly tightened. When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side. (1) Start bearing in place, and insert Main Bearing
Tool C-3059 into oil hole of crankshaft (Fig. 8). (2) Slowly rotate crankshaft counter-clockwise slid-
ing the bearing into position. Remove Special Main
Bearing Tool C-3059.
CHECKING CRANKSHAFT END PLAY
(1) Mount a dial indicator to front of engine, locating
probe on nose of crankshaft (Fig. 9). (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. 10) for specifications.
OPTIONAL CRANKSHAFT END PLAY CHECK
(1) Move crankshaft all the way to the rear of its
travel using a lever inserted between a main bearingFig. 7 Main Bearing Identification
Fig. 8 Removing and Installing Upper Main Bearing With Special Tool C-3059
Ä 2.2/2.5L ENGINE 9 - 43

cap and a crankshaft cheek, using care not to dam-
age any bearing surface. Do notloosen main bearing
cap. (2) Use a feeler gauge between number three
thrust bearing and machined crankshaft surface to
determine end play.
CRANKSHAFT BEARING CLEARANCE
(1) Refer to Measuring Main, Connecting Rod
Bearing Clearance in Standard Service Procedures.
Refer to (Fig. 10) for specifications.
CAUTION: Do not rotate crankshaft or the Plasti-
gage maybe smeared.
(2) Install the main bearing shells with the lubri-
cation groove in the cylinder block (Fig. 12). The 1, 2, 4 and 5 main bearings are full groove to pro-
vide full time oiling to the connecting rod. Only
the number 3 is half-groove.
(3) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block tab
slots. (4) Oil the bearings and journals and install crank-
shaft. (5) Install main bearing cap No. 1 on timing belt
end. (6) Install main bearing cap No. 5 on transmission
end. Since the main bearing bolts are torqued using
a new procedure they should be examined BE-
FORE reuse. If the threads are necked down the
bolts should be replaced (Fig. 15).
Fig. 9 Checking Crankshaft End Play
Fig. 10 Crankshaft Specifications
Fig. 11 Checking Crankshaft Oil Clearance with Plastigage
Fig. 12 Installing Main Bearing Upper Shell
9 - 44 2.2/2.5L ENGINE Ä

Necking can be checked by holding a scale or straight
edge against the threads or by running a M11 x 1.50
nut the full length of the thread. If all the threads
do not contact the scale or if the nut does not run
down smoothly the bolt should be replaced. (7) Before installing the bolts the threads should be
oiled with engine oil. (8) Install both bolts in each cap finger tight, then
alternately torque each bolt to assemble the cap prop-
erly. (9) Tighten the bolts to 41 N Im plus 1/4 turn (30
ft.lbs. plus 1/4 turn). (Fig. 14)
BALANCE SHAFTS
2.2L Turbo III and 2.5L engines are equipped with
two counter rotating balance shafts installed in a
carrier attached to the lower crankcase (Fig. 1). The shafts are interconnected through gears. These
gears are driven by a short chain from the crank-
shaft, to rotate at two times crankshaft speed. This
counterbalances certain engine reciprocating forces.
REMOVAL
Refer to Engine Lubrication and Timing System
and Seals Service of this group for removal procedure
of necessary components to repair balance shafts.
(1) Remove chain cover, guide and tensioner (Fig.
16). Also see Carrier Assembly Removal for service
procedures requiring only temporary relocation of as-
sembly. (2) Remove balance shaft gear and chain sprocket
retaining screws and crankshaft chain sprocket torx
screws. Remove chain and sprocket assembly. (Fig.
17) (3) Remove gear cover retaining stud (double
ended to also retain chain guide). Remove cover and
balance shaft gears (Fig. 18). (4) Remove carrier rear cover and balance shafts.
(Fig. 19). (5) Remove six carrier to crankcase attaching bolts
to separate carrier (Fig. 1).
Fig. 16 Chain Cover, Guide and Tensioner
Fig. 13 Main Bearing Caps
Fig. 14 Installing Main Bearing Caps
Fig. 15 Checking Bolts For Stretching (Necked down)
Ä 2.2/2.5L ENGINE 9 - 45

CYLINDER BLOCK CLEANING AND INSPECTION
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking. (2) If new core plugs are installed, Refer to Engine
Core Oil and Cam Plugs. (3) Examine block and cylinder bores for cracks or
fractures.
CYLINDER BORE INSPECTION
The cylinder walls should be checked for out-of-
round and taper with Tool C-119 (Fig. 5). The cylin-
der bore out-of-round is 0.050 mm (.002 inch)
maximum and cylinder bore taper is .125 mm (.005
inch) maximum. If the cylinder walls are badly
scuffed or scored, the cylinder block should be re-
bored and honed, and new pistons and rings fitted.
Whatever type of boring equipment is used, boring
and honing operation should be closely coordinated
with the fitting of pistons and rings in order that
specified clearances may be maintained. Refer to Honing Cylinder Bores outlined in the Standard
Service Procedures for specification and proce-
dures.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 5). Top measurement should be
10mm ( 3/8 inch) down and bottom measurement
should be 10mm ( 3/8 inch.) up from bottom of bore.
Refer to (Fig. 6) for specifications.
SIZING PISTONS
Piston and cylinder wall must be clean and dry.
Piston diameter should be measured 90 degrees to
piston pin at size location shown in (Fig. 7). Cylinder
bores should be measured halfway down the cylinder
bore and transverse to the engine crankshaft center
line shown in (Fig. 5). Refer to (Fig. 6) for specifica-
Fig. 5 Checking Cylinder Bore Size
Fig. 6 Piston Size Location and Clearance Chart
Fig. 4 Connecting Rod Protectors
9 - 50 2.2/2.5L ENGINE Ä