1993 CHEVROLET PLYMOUTH ACCLAIM check engine

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
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(2) Tighten nuts to 52 N Im (38 ft. lbs.).
(3) Remove connecting rod cap and measure Plas-
tigage (Fig. 16).
CAUTION: Do not rotate crankshaft or the Plasti-
gage may be smeared.
CONNECTING ROD SIDE CLEARANCE
Using a feeler gauge, check connecting rod side
clearance (Fig. 17). Refer to (Fig. 18) for specifica-
tion.
Fig. 14 Identify Piston/Rod Assembly for Cylinder Installation
Fig. 15 Connecting Rod and Cap
Fig. 16 Connecting Rod Checking BearingClearance
Fig. 17 Checking Connecting Rod Side Clearance
Fig. 18 Connecting Rod Clearance Specifications
Ä 3.0L ENGINE 9 - 85

CRANKSHAFT AND CYLINDER BLOCK, ASSEMBLY SERVICE
CRANKSHAFT SERVICE
The crankshaft is supported in four main bearings.
All upper bearing shells in the crankcase have oil
grooves. All lower bearing shells in stalled in the
monoblock main bearing cap are plain. Crankshaft
end play is controlled by thrust washers on the num-
ber three main bearing journal.
CRANKSHAFTÐREMOVAL
(1) Remove front mounted oil pump assembly and
gasket (Figs. 1 and 2). (2) Remove rear oil seal retainer and seal as as-
sembly (Fig. 3). (3) Release monoblock main bearing cap bolts
evenly. Remove lower bearing shells and identify for
reassembly. (4) Lift out crankshaft and remove upper thrust
washers from each side of number three main bear-
ing in the crankcase (Fig. 1).
INSPECTION
Visually check the main and connecting rod bear-
ing journals for wear, scuffs or scoring and replace if
necessary.
CRANKSHAFT OIL CLEARANCE
MECHANICAL MEASUREMENT
Measure the journal outside diameter and the main
bearing inside diameter (Figs. 4 and 5). If the clear-
ance exceeds the specifications limit (Fig. 6). Replace
the main bearing(s) and if necessary replace the
crankshaft.
Fig. 1 Crankshaft and Cylinder Block
Fig. 2 Oil Pump Assembly
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(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
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(3) Apply light coating of engine oil to the entire
circumference of oil seal lip. (4) Install seal assembly on cylinder block and
tighten bolts to 12 N Im (104 in. lbs.)
FRONT CRANKSHAFT OIL PUMP AND OIL
SEAL
(1) Install oil pump gasket and oil pump case
(Figs. 1 and 14). CAUTION: Install bolts, depending on length in lo-
cations shown in (Fig. 14).
(2) Using front crankshaft oil seal installer Special
Tool MB998306 install oil seal in oil pump (Fig. 15).
CYLINDER BLOCK
Inspect cylinder block for scratches, cracks and rust
or corrosion, and repair or replace as required.
Fig. 10 Crankshaft Main Bearing Cap
Fig. 11 Checking Crankshaft End PlayFig. 12 Install Crankshaft Rear Oil Seal
Ä 3.0L ENGINE 9 - 89

(1) Clean cylinder block and check top surface for
distortion with a straight edge and thickness gauge
(Fig. 16). (2) Top surface must be flat within: ²
Standard Value: 0.05 mm (.002 inch)
² Service Limit 0.1 mm (.003 inch)
CAUTION: Maximum of 0.2mm (.008 inch) is permit-
ted. This is a combined total dimension of stock re-
moval from cylinder head (if any) and block top
surface.
BORING CYLINDER
Examine cylinder walls for scuffs, scoring and mea-
sure cylinder bore for out-of-round or taper. If defec-
tive, bore cylinder to oversize. Measure at points
shown in (Fig. 17). Four oversize pistons are available (0.25mm (.010
inch) 0.50mm (.020 inch) 0.75mm (.030 inch) and
1.0mm (.039 inch). Determine oversize piston on ba-
sis of largest cylinder bore.
(1) Bore to specified clearance between the piston
O.D. and cylinder. The measuring point of the piston
O.D. is shown in (Fig. 18). (2) Based on measured piston O.D., calculate bor-
ing finish dimension. Boring finish dimension equals
piston O.D. plus 0.03 to 0.05 mm (.0012 to .002 inch)
Fig. 13 Apply Sealant to Oil Seal Housing
Fig. 14 Oil Pump
Fig. 15 Crankshaft Front Oil Seal
Fig. 16 Distortion Check
Fig. 17 Measure Cylinder Bore
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(clearance between piston O.D. and cylinder) minus
0.02 mm which is the boring margin. (3) Bore all cylinders to calculated boring finish di-
mension. Then bore the final finish dimension (piston
O.D. plus cylinder clearance). (4) Check clearance between piston and cylinder,
clearance should be 0.03 to 0.05 mm (.0012 to .002
inch).
ENGINE LUBRICATION SYSTEM
The lubrication system is a full flow filtration pres-
sure feed type. Oil, stored in the oil pan, is taken in
and discharged by a internal gear type oil pump di-
rectly coupled to the crankshaft and its pressure is
regulated by a relief valve. The oil is fed through an
oil filter and to the crankshaft journals from the oil gallery in the cylinder block. This gallery also feeds
oil under pressure to the cylinder heads. It then
flows from a camshaft bearing cap on each cylinder
head through passages in the rocker shafts to the
rocker arm pivots, auto lash adjusters, and camshaft
journals (Fig. 1).
Fig. 18 Measure Piston
Fig. 1 Engine Oiling
Ä 3.0L ENGINE 9 - 91

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
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