1993 CHEVROLET PLYMOUTH ACCLAIM Service Manual

overheating ESP key fob battery oil capacity reset infotainment system wiring diagram

Page 1617 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual tions. Correct piston to bore clearance must be estab-
lished in order to assure quiet and economical
operation. Chrysler engines use pistons designed specifically for
each engine model. Clearance

Page 1618 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual PISTON PINS
DISASSEMBLY Turbo III engine piston-pin-connecting rod assem-
blies should not be disassembled unless a malfunc-
tion is present or a damaged assembly component is
to be replaced. WARNING

PISTON PINS
DISASSEMBLY Turbo III engine piston-pin-connecting rod assem-
blies should not be disassembled unless a malfunc-
tion is present or a damaged assembly component is
to be replaced. WARNING: APPROVED SAFETY GLASSES
MUST BE WORN DURING PISTON LOCK
RING REMOVAL OR INSTALLATION TO PRE-
VENT POSSIBLE INJURY FROM FLYING
PARTS.
(1) Carefully, remove piston pin lock rings from
piston, using a small screwdriver in removal notch
(Fig. 10). (2) Discard used lock ring.
(3) Following lock ring removal, attempt to slide
pin out of piston. If pin does not slide out freely by
hand;
² Check for burr on outer edge of lock ring groove. If
one is present, carefully scrape burr away with a
knife or other hand tool, being careful not to damage
lock ring retaining groove. (4) Slide out piston pin to complete disassembly.
(5) Inspect components, discard damaged or exces-
sively worn parts refer to specifications (Fig. 12). If a
piston is replaced, a new pin should be used.
PISTON PINS
REASSEMBLY
(1) Different lock rings are used for turbocharged
engine applications. Consult the Service Note, pro- vided with the lock ring service package, to select
the correct lock rings from the package for your ap-
plication.
(2) Carefully, install one NEWlock ring with gap
towards piston top in lock ring groove. Do not rein-
stall used lock rings. (3) Position connecting rod and slide in lightly oil
piston pinch (4) Install second NEWlock ring with gap towards
piston top in lock ring groove, use small screwdriver
if needed.
CAUTION: BOTH lock rings must be FULLY
SEATED in lock ring grooves or engine failure will
occur.
(5) Check piston pin end play pin movement be-
tween lock rings in assembly.
PISTON RINGÐREMOVAL
(1) ID mark on face of upper and intermediate pis-
ton rings must point toward piston crown. (2) Using a suitable ring expander, remove upper
and intermediate piston rings (Fig. 13). (3) Remove the upper oil ring side rail, lower oil
ring side rail and then oil ring expander from piston. (4) Clean ring grooves of any carbon deposits.
Fig. 11 Engine Piston PinsÐTurbo III, Naturally Aspirated and Flexible Fuel Vehicles
Fig. 12 Piston Pin Specifications
Fig. 13 Piston RingsÐRemoving and Installing
9 - 52 2.2/2.5L ENGINE Ä

Page 1619 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual FITTING RINGS
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12mm (.50 in

Page 1620 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual firmly and press down the portion to be installed un-
til side rail is in position. Do not use a piston ring
expander. (Fig. 19).
(3) Install upper side rail first and then the lower
side rail. (4

Page 1621 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual CONNECTING RODS
(1) Follow procedure specified in the Standard Ser-
vice Procedures Section for Measuring Main Bearing
Clearance and Connecting Rod Bearing Clearance
(Fig. 22). Refer to specification

CONNECTING RODS
(1) Follow procedure specified in the Standard Ser-
vice Procedures Section for Measuring Main Bearing
Clearance and Connecting Rod Bearing Clearance
(Fig. 22). Refer to specifications (Fig. 25).
CAUTION: Do not rotate crankshaft or the Plastic-
Gage may be smeared.
The rod bearing bolts should be examined be-
fore reuse. If the threads are necked down the
bolts should be replaced (Fig. 23). Necking can be checked by holding a scale or straight
edge against the threads. If all the threads do not
contact the scale the bolt should be replaced.
(2) Before installing the nuts the threads should be
oiled with engine oil.
(3) Install nuts on each bolt finger tight than alter-
nately torque each nut to assemble the cap properly.
(4) Tighten the nuts to 54 N Im PLUS 1/4 turn (40 ft.
lbs. PLUS 1/4 turn) for N/A engines Do not use a
torque wrench for last step. and 68 NIm (50 ft. lbs.)
for Turbo III engines. (5) Using a feeler gauge, check connecting rod side
clearance (Fig. 24). Refer to connecting rod specifica-
tions (Fig. 25).
ENGINE CORE PLUGS
REMOVAL
Using a blunt tool such as a drift or a screwdriver
and a hammer, strike the bottom edge of the cup plug
(Fig. 26). With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig. 26).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious en-
gine problems.
INSTALLATION
Thoroughly clean inside of cup plug hole in cylinder
block or head. Be sure to remove old sealer. Lightly coat
inside of cup plug hole with sealer. Make certain the
new plug is cleaned of all oil or grease. Using proper
drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5mm
(.020 inch) inside the lead-in chamfer (Fig. 26).
It is in not necessary to wait for curing of the seal-
ant. The cooling system can be refilled and the vehi-
cle placed in service immediately.
Fig. 24 Checking Connecting Rod Side Clearance
Fig. 25 Connecting Rod Specifications
Fig. 26 Core Hole Plug Removal
Fig. 23 Checking Bolts for Stretching (Necked)
Ä 2.2/2.5L ENGINE 9 - 55

Page 1622 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual ENGINE LUBRICATION SYSTEM
Fig. 1 Engine Lubrication Components
9 - 56 2.2/2.5L ENGINE Ä

Page 1623 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual Fig. 2 Engine Lubrication System
Ä 2.2/2.5L ENGINE 9 - 57

Page 1624 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual OIL PAN
A formed steel oil pan provides lower engine pro-
tection as well as serving as the engine oil reservoir
(Fig. 1). Pan side flanges to block are sealed with
gaskets. The oil pickup tube for s

OIL PAN
A formed steel oil pan provides lower engine pro-
tection as well as serving as the engine oil reservoir
(Fig. 1). Pan side flanges to block are sealed with
gaskets. The oil pickup tube for some 2.2L engines
have a circular strainer and cover. The 2.5L engine
pickup is also unsupported and the lower end has a
box type strainer (Fig. 4).
PRESSURE LUBRICATION
Oil drawn up through the pickup tube is pressur-
ized by the pump and routed through the full flow
filter to the main oil gallery running the length of
the cylinder block (Fig. 2). Modified oil pickup, pump
and check valve provide increased oil flow to the
main oil gallery.
MAIN/ROD BEARINGS
A diagonal hole in each bulkhead feeds oil to each
main bearing. Drilled passages within the crankshaft
route oil from main bearing journals to crankpin
journals.
ACCESSORY SHAFT
Two separate holes supply the accessory shaft for
the N/A engines. For Turbo III engines there is a slot
in the rear shaft bushing that squirts oil onto the
oil pump drive gears (Fig. 2).
BALANCE SHAFTS
The engine balance shafts are lubricated by an ad-
ditional hole that interconnects a passage in one leg
of the balance shaft carrier to route oil down to the
carrier oil gallery. This gallery directly supplies the
balance shafts front bearings and internal machined
passages in the shafts routes oil from front to rear
shaft bearing journals.
TURBOCHARGER (WHERE EQUIPPED)
If turbocharger equipped, pressurized oil from the
main gallery to sending unit hex fitting is piped from
the fitting to the turbocharger bearing housing.
From the housing a hose and tube connection to a
machined hole in the block provides drainback.
CAMSHAFT/HYDRAULIC LIFTERS
A vertical hole at the number five bulkhead routes
pressurized oil through a restrictor up past a cylinder
head bolt to an oil gallery running the length of the
cylinder head. For 2.2/2.5L and 2.5L FFV engines
hydraulic adjusters are supplied directly from this
gallery while diagonal holes supply oil to the cam-
shaft journals. The camshaft journals are partially
slotted to allow a predetermined amount of pressur-
ized oil to pass into the bearing cap cavities with
small holes directed to spray lubricate the camshaft
lobes. For Turbo III engines oil is supplied thru oil
galleries in the head to the camshafts and rocker arm shafts which feed oil to the lash adjusters. Oil is
feed thru the rocker arms to lubricate the rollers and
the camshaft lobes.
SPLASH LUBRICATION
Oil returning to the pan from pressurized compo-
nents supplies lubrication to the valve stems. Cylinder
bores and wrist pins are splash lubricated from di-
rected holes in the connecting rods.
OIL PAN
REMOVAL
(1) Drain engine oil and remove oil pan.
(2) Clean oil pan and all gasket surfaces.
OIL PAN RAIL TO BLOCK SEALING
For all engines side gaskets (Fig. 1) are employed for
rail sealing.
INSTALLATION
(1) Apply Mopar Silicone Rubber Adhesive Sealant
or equivalent at the front seal retainer parting line
(Fig. 3). (2) Install the oil pan side gaskets to the block. Use
heavy grease or Mopar Silicone Rubber Adhesive Seal-
ant or equivalent to hold in place. (3) Apply Mopar Silicone Rubber Adhesive Sealant
or equivalent to ends of new oil pan end seals at
junction of cylinder block pan rail gasket (Fig. 3). (4) Install pan and tighten to (12) M8 screws to 23
N Im (200 in. lbs.) and 1 M6 screws to 12 N Im (105 in.
lbs.).
OIL PUMP SERVICE
OIL PICKUP
(1) Remove screw on pump cover holding oil pick-up
tube to oil pump (Fig. 4). (2) Remove oil pick-up tube. When reinstalling
make sure to use a new O-Ring on pickup tube .
Fig. 3 Sealing, Front and Rear End Seals
9 - 58 2.2/2.5L ENGINE Ä

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