1993 CHEVROLET PLYMOUTH ACCLAIM timing belt

CYLINDER BLOCK, PISTON AND CONNECTING ROD ASSEMBLY SERVICE
PISTON AND CONNECTING RODÐREMOVAL
(1) Remove top ridge of cylinder bores with a reliable
ridge reamer before removing pistons from cylinder
block. Be sure to keep tops of pistons covered
during this operation . Mark piston with matching
cylinder number (Fig. 2).
(2) Remove oil pan. Ensure connecting rods and
connecting rod caps for cylinder identification. Identify
them if necessary (Fig. 3). (3) Valve relief toward manifold side of engine. Tur-
bocharged engine pistons will have arrow towards
front of engine. (4) Squirt hole on connecting rod must face timing
belt end of engine. (5) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore. (6) Remove connecting rod cap. Install connecting
rod bolt protectors on connecting rod bolts (Fig. 4).
Push each piston and rod assembly out of cylinder
bore. Be careful not to nick crankshaft journals.
(7) After removal, install bearing cap on the mat-
ing rod.
Fig. 1 Cylinder Block, Piston and Connecting Rod Assembly
Fig. 3 Identify Connecting Rod to Cylinder
Fig. 2 Piston Marking
Ä 2.2/2.5L ENGINE 9 - 49

3.0L ENGINE INDEX
page page
Accessory Drive Belt Service ................ 70
Auto Lash Adjuster ....................... 75
Camshaft Service ........................ 76
Checking Engine Oil Pressure ............... 93
Crankshaft and Cylinder Block, Assembly Service . 86
Cylinder Block ........................... 89
Cylinder Head ........................... 78
Cylinder Head and Camshaft Service ......... 75
Engine Assembly ......................... 69
Engine Lubrication System ................. 91
Engine Mounts .......................... 68 Engine Specifications
..................... 95
General Information ....................... 66
Oil Filter and Bracket ..................... 94
Oil Pan ................................ 92
Oil Pump Service ........................ 92
Piston and Connecting Rod Assembly Service . . . 82
Timing Belt InspectionÐIn Vehicle ............ 72
Timing Belt Service ....................... 72
Valve Service ........................... 80
GENERAL INFORMATION
ENGINE IDENTIFICATION NUMBER OR CODE
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 1). BLOCK: The cylinder block is a light weight de-
sign created by reducing thickness in many parts
and a short 10 mm (3/8 inch) block skirt. High rigid-
ity is provided with ribs cast in the outer wall, a full
length water jacket, and a monoblock or beam type, main bearing cap. This single unit four bearing cap
is designed to control vibration of the cylinder block
partition walls.
CRANKSHAFT: A six throw, five weight crank-
shaft is supported by four main bearings with num-
ber three being the thrust bearing. The six separate
connecting rod throws pins reduce torque fluctua-
tions while a torsional vibration damper is used to
control torsion caused vibration of the crankshaft.
Rubber lipped seals are used at front and rear. The
front seal is retained in the oil pump case and the
rear is retained in a block-mounted housing.
3.0L ENGINE
9 - 66 3.0L ENGINE Ä

PISTONS: Are aluminum alloy with a steel strut,
short height, and thin wall so as to be autothermic
and light weight. The piston head with valve re-
cesses, in combination with the cylinder head, forms
a compact spherical head with clearance for total
valve lift with pistons at top dead center. The piston
skirt, top and second ring lands are finished to a ta-
pered roughness for oil retention and high resistance
to scuffing. Piston pins, press-fitted into place, join
the pistons to the connecting rods. CYLINDER HEAD: The alloy cylinder heads fea- ture cross-flow type intake and exhaust ports. Valve
guides and inserts are hardened cast iron. Valves of
heat resistance steel are arranged i
n a V with each
camshaft on center. To improve combustion speed the
chambers are a compact spherical design with a
squish area of approximately 30 percent of the piston
top area. The cylinder heads are common to either
cylinder bank by reversing the direction of installa-
tion. CAMSHAFTS: Two overhead camshafts provide
valve actuation, one front (radiator side of cylinder
bank) and one rear. The front camshaft is provided
with a distributor drive and is longer. Both cam-
shafts are supported by four bearing journals, thrust
for the front camshaft is taken at journal two and
the rear at journal three. Front and rear camshaft
driving sprockets are interchangeable. The sprockets
and the engine water pump are driven by a single
notched timing belt. ROCKER ARM SHAFTS: The shafts are retained
by the camshaft bearing journal caps. Four shafts are
used, one for each intake and exhaust rocker arm as-
sembly on each cylinder head. The hollow shafts pro-
vide a duct for lubricating oil flow from the cylinder
head to the valve mechanisms. ROCKER ARMS: Are of light weight die-cast
with roller type follower operating against the cam
shaft. The valve actuating end of the rocker arms are
machined to retain hydraulic lash adjusters, elimi-
nating valve lash adjustment. VALVES: Are made of heat resistant steel and are
further treated to resist heat. VALVE SPRINGS: Are especially designed to be
short. The valve spring wire cross-section is oval
SPECIFICATIONS
Fig. 1 Engine Identification
Ä 3.0L ENGINE 9 - 67

(9) Mark support assembly to engine bracket if as-
sembly is to be used again. Separate engine mount
insulator from engine mount bracket (Fig. 10). Raise
engine slightly. (10) Remove engine mount bracket (Fig. 10).
(11) Remove timing belt covers (Fig. 11).
TIMING BELT INSPECTIONÐIN VEHICLE
(1) Remove the upper front outer timing belt cover
by loosening the three attaching bolts. (Fig. 11). (2) Inspect both sides of the timing belt drive &
back. Replace belt if any of the following conditions
exist.
² Hardening of back rubber back side is glossy with-
out resilience and leaves no indent when pressed
with fingernail.
² Cracks on rubber back.
² Cracks or peeling of canvas.
² Cracks on rib root.
² Cracks on belt sides.
² Missing teeth.
² Abnormal wear of belt sides. The sides are normal
if they are sharp as if cut by a knife (Fig. 12). (3) If none of the above conditions are seen on the
belt, the belt cover can be reinstalled.
TIMING BELT SERVICE
REMOVAL
(1) Mark belt running direction for installation
(Fig. 14). (2) Loosen timing belt tensioner bolt (Fig. 16) and
remove timing belt. (3) Remove crankshaft sprocket flange shield (Fig.
9).
CAMSHAFT SPROCKETS
REMOVAL
(1) Hold camshaft sprocket with Spanner Tool
MB990775 loosen and remove bolt and washer (Fig.
15). (2) Remove camshaft sprocket from camshaft.
Fig. 10 Right Engine Mount and Engine Mount Bracket
Fig. 11 Timing Belt Covers
Fig. 12 Timing Belt Inspection
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Fig. 13 Timing Belt System
Fig. 14 Timing Belt Engine Sprocket Timing
Ä 3.0L ENGINE 9 - 73

INSTALLATION
(1) Place camshaft sprocket on camshaft.
(2) Install bolt and washer to camshaft. Using
Spanner Tool MB990775 hold camshaft sprocket and
torque bolt to 95 N Im (70 ft. lbs.) (Fig. 15).
TIMING BELT TENSIONER
(1) Install timing belt tensioner and tensioner
spring. (2) Hook spring upper end to water pump pin and
lower end to tensioner bracket with hook out (Fig. 16).
(3) Turn timing belt tensioner counter-clockwise full
travel in adjustment slot and tighten bolt to tempo-
rarily hold this position (Fig. 17).
INSTALLATIONÐTIMING BELT
(1) Install timing belt on crankshaft sprocket first
and while keeping belt tight on tension side (Fig. 14)
install belt on the front (radiator side) camshaft
sprocket. (2) Then, install on the water pump pulley and on
the rear camshaft sprocket and finally on the timing
belt tensioner. (3) Apply rotating force to the front camshaft
sprocket in opposite direction to tension the belt ten-
sion side, check that all timing marks are lined up (Fig.
14). (4) Install crankshaft sprocket flange (Fig. 12).
(5) Loosen tensioner bolt and allow spring to tension
timing belt. (6) Turn crankshaft two full turns in clockwise di-
rection. Turn smoothly and in clockwise direction
ONLY. (7) Again line up the timing marks on the sprockets
and tighten the timing belt tensioner locking bolt to 25
N Im (250 in. lbs.) torque.
(8) Reassembly belt covers, engine bracket, insula-
tor, crankshaft pulleys, accessories and accessory drive
belts in reverse order.
Fig. 15 Camshaft Sprockets
Fig. 16 Timing Belt Tensioner
Fig. 17 Positioning Belt Tensioner
9 - 74 3.0L ENGINE Ä

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
9 - 84 3.0L ENGINE Ä

(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
9 - 88 3.0L ENGINE Ä