Body p CHEVROLET PLYMOUTH ACCLAIM 1993 User Guide

BLEEDING BENDIX ANTILOCK 4 BRAKE SYSTEM......5-3
BASE BRAKE SYSTEM BLEEDING PROCEDURE.........5-3
MASTER CYLINDER FLUID LEVEL................5-3
TESTING FOR FLUID CONTAMINATION.............5-4 WIRING DIAGRAMS AA-BODY
..................8W-1
INDEX...............................8W-1
WIRING DIAGRAMS AJ BODY ..................8W-8
ALPHABETICAL INDEX.....................8W-8

LUBRICATION AND MAINTENANCE
CONTENTS
page page
CHASSIS AND BODY .................... 19
DRIVETRAIN ........................... 16 ENGINE
................................ 8
GENERAL INFORMATION .................. 1
GENERAL INFORMATION INDEX
page page
Classification of Lubricants .................. 1
Fluid Capacities .......................... 4
Fuel Usage .............................. 1
Hoisting Recommendations .................. 5
Introduction .............................. 1 Jump Starting Procedure
.................... 4
Parts and Lubricant Recommendations ......... 1
Parts Requiring No Lubrication ............... 4
Severe Service ........................... 1
Towing Recommendations ................... 7
INTRODUCTION
Chrysler Corporation has compiled recommended
lubrication and maintenance schedules and proce-
dures to help reduce premature wear or failure over
a broad range of operating conditions. When select-
ing the proper maintenance schedule, the climate
and operating conditions must be considered. A vehi-
cle subjected to severe usage requires service more
frequently than a vehicle used for general transpor-
tation.
PARTS AND LUBRICANT RECOMMENDATIONS
When service is required, Chrysler Corporation rec-
ommends that only Mopar tbrand parts, lubricants
and chemicals be used. Mopar tprovides the best en-
gineered products for servicing Chrysler Corporation
vehicles.
SEVERE SERVICE
If a vehicle is operated under any of the following
conditions, it is considered severe service.
² Extremely dusty areas.
² 50% or more of vehicle operation in 32ÉC (90ÉF) or
higher temperatures.
² Prolonged idling ( such as, vehicle operation in
stop and go traffic).
² Frequent short running periods. Not allowing en-
gine to warm to operating temperatures.
² Police or taxi usage.
FUEL USAGE
All Chrysler Corporation engines require the use of
unleaded fuel to reduce exhaust emissions. Use fuel
with a minimum octane rating of 87,(R + M)/2. See
Engine section of this group for Fuel Recommenda-
tions.
CLASSIFICATION OF LUBRICANTS
Only lubricants that are endorsed by the following
organizations standards should be used to service a
Chrysler Corporation vehicle.
² Society of Automotive Engineers (SAE)
² American Petroleum Institute (API)
² National Lubricating Grease Institute (NLGI)
ENGINE OIL
SAE GRADE RATING INDICATES ENGINE OIL VISCOSITY
² SAE 30 = single grade engine oil.
² SAE 5W-30 = multiple grade engine oil.
API QUALITY CLASSIFICATION.
² SG service engine oil is a high quality crankcase
lubricant designed for use in all naturally aspirated
engines.
² SG/CD service engine oil is a high quality crank-
case lubricant designed for use in most naturally as-
pirated and turbocharged gasoline or diesel engines.
GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear lu-
bricants. In addition, API classification defines the
lubricants usage.
Ä LUBRICATION AND MAINTENANCE 0 - 1

(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries. (4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to
negative terminal (-). DO NOT allow clamps at oppo-
site end of cables to touch, electrical arc will result
(Fig. 1). Review all warnings in this procedure. (5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 1).
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(6) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
² Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
² When using a Booster vehicle, disconnect BLACK
cable clamp from battery negative terminal. Discon-
nect RED cable clamp from battery positive terminal.
² Disconnect RED cable clamp from battery positive
terminal on disabled vehicle.
HOISTING RECOMMENDATIONS
Refer to Owner's Manual provided with vehicle for
proper emergency jacking procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN THE ENGINE OR REAR SUSPENSION IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING
CONDITIONS UNSTABLE. PROPERLY SUPPORT OR
SECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
TO HOIST OR JACK VEHICLE SEE FIG. 2 THROUGH 7:
Fig. 1 Jumper Cable Clamp Connections
Fig. 2 Hoisting and Jacking PointsÐAY Body
Fig. 3 Hoisting and Jacking PointsÐAC Body
Ä LUBRICATION AND MAINTENANCE 0 - 5

Fig. 4 Hoisting and Jacking PointsÐAA Body
Fig. 5 Hoisting and Jacking PointsÐAG Body
Fig. 6 Hoisting and Jacking PointsÐAJ Body
Fig. 7 Hoisting and Jacking PointsÐAP Body
0 - 6 LUBRICATION AND MAINTENANCE Ä

tifreeze to achieve adequate protection. A mix table
on the coolant container indicates the amount of an-
tifreeze required to winterize the cooling system
based on the capacity, see Capacity Chart in General
Information section of this group.
SELECTING ANTIFREEZE
Chrysler Corporation recommends Mopar Anti-
freeze/Summer Coolant, or equivalent be used to win-
terize and protect cooling system.
RADIATOR CAP
The radiator cap must be secure to provide proper
pressure release and coolant recovery. Inspect and
test radiator cap when cooling system service is per-
formed or when problem is suspected.
COOLING SYSTEM SERVICE
The cooling system should be drained, flushed and
filled with the proper coolant mixture at the inter-
vals described in the Lubrication and Maintenance
Schedules. Refer to General Information section of
this group. For proper service instructions see Group
7, Cooling System.
ENGINE AIR CLEANER
The engine air cleaner should be serviced at the in-
tervals described in the Lubrication and Mainte-
nance Schedules. Refer to General Information
section of this group. Additional information can be
found in Group 14, Fuel System and Group 25, Emis-
sion System. Inspect all air cleaner hoses or tubes for
damage or leaks when other engine compartment
service is performed. Replace faulty components.
AIR CLEANER SERVICE
CAUTION: The air cleaner cover must be installed
properly for the emissions system and engine con-
troller to function correctly. Do not immerse paper air filter element or temper-
ature sensor in cleaning solvents, damage can re-
sult.
TO SERVICE AIR CLEANER ASSEMBLY: (1) Raise hood of vehicle and inspect all air cleaner
components for damage or improper attachment. (2) Remove air cleaner cover (Fig. 6, 7, 8, 9, or 10).
(3) Remove paper air filter element from air
cleaner body. Hold a shop light on throttle body side
of element. Inspect air intake side of element. If light
is visible through element, blow dust from element
(Fig. 11) and reuse. If element is saturated with oil
or light is not visible, replace filter. If element is sat-
urated with oil, perform crankcase ventilation sys-
tem tests. (4) Remove fiber crankcase filter (Fig. 6, 7, 8, 9, or
10) and clean with solvent, squeeze filter dry and ap- ply small amount of engine oil. If a metallic mesh is
used to retain fiber filter, clean mesh with solvent
and reuse.
(5) Clean inside of air cleaner cover and body with
vacuum or compressed air. If oily, wash with solvent. To Install, reverse the preceding operation.
Fig. 6 Air CleanerÐ3.0L Engine
Fig. 7 Air CleanerÐFlexible Fuel Engine
Fig. 8 Air CleanerÐ16 Valve Engine
Ä LUBRICATION AND MAINTENANCE 0 - 11

inside of the hood in the engine compartment and
Group 25, Emission Control Systems for proper ser-
vice procedures.
BATTERY
Inspect battery tray, hold down and terminal con-
nections when other under hood service is performed.
For proper diagnostic procedures refer to Group 8A,
Battery/Starting/Charging System Diagnostics. For
service and cleaning procedures refer to Group 8B,
Battery/Starter Service.
RUBBER AND PLASTIC COMPONENT INSPECTION
CAUTION: Plastic hoses or wire harness covers will
melt or deform when exposed to heat from exhaust
system or engine manifolds. Position plastic or rubber components away from
moving parts in engine compartment or under vehi-
cle, or damage will result. Do not allow rubber engine mounts or other com-
ponents to become oil contaminated, repair cause
of oil contamination and clean area. All rubber and plastic components should be in-
spected when engine compartment or under vehicle
service is performed. When evidence of deterioration
exists, replacement is required. To reduce deteriora-
tion of rubber components, Chrysler Corporation rec-
ommends Mopar Foamy Engine Degreaser or
equivalent be used to clean engine compartment of
oil and road grime.
EXHAUST SYSTEM ISOLATOR AND HANGER
The exhaust system should be inspected when un-
der vehicle service is performed. The exhaust system
should not make contact with under body, brake ca-
bles, brake/fuel lines, fuel tank or suspension compo-
nents. Slight cracking in rubber isolator or hanger is
acceptable. Severely cracked or broken rubber compo-
nents must be replaced. For proper service proce-
dures see Group 11, Exhaust System and Intake
Manifold.
Ä LUBRICATION AND MAINTENANCE 0 - 15

DRIVETRAIN INDEX
page page
Automatic Transaxle ...................... 16
Automatic Transaxle Floor Shift .............. 16
Clutch and Gearshift Linkage ............... 16
Drive Shaft Cv and Tripod Joint Boots ........ 17 Front Wheel Bearings
..................... 17
Manual Transaxle ........................ 16
Tires .................................. 17
CLUTCH AND GEARSHIFT LINKAGE
If the clutch or gearshift begins to operate with dif-
ficulty, squeak or grunt, the cables and linkage
should be lubricated before service replacement is
performed. For proper lubrication and service proce-
dures refer to Group 6, Clutch, or Group 21, Manual
Transaxle.
MANUAL TRANSAXLE
The manual transaxle should be inspected for oil
leaks and proper oil level when other under vehicle
service is performed. To inspect the transaxle oil
level, position the vehicle on a level surface. Remove
fill plug (Fig. 1) from the transaxle side cover. The
oil level should not be below 4 mm (3/16 in) from the
bottom of the oil fill opening. The manual transaxle does not require periodic
maintenance. The oil should be changed only when
water contamination is suspected. If oil has a foamy
or milky appearance it probably is contaminated. A
circular magnet located behind the differential cover
collects metallic particles circulating in the oil. For
proper diagnostic and service procedures, refer to
Group 21, Manual Transaxle.
SELECTING MANUAL TRANSAXLE OIL
Chrysler Corporation recommends Mopar Engine
Oil, SG or SG/CD SAE 5W-30, or equivalent, be used
to fill a 5-speed transaxle.
AUTOMATIC TRANSAXLE FLOOR SHIFT
If the automatic transaxle floor shift mechanism
becomes difficult to operate or starts to make objec-
tionable noise, the mechanism should be lubricated
before service repair is performed. To lubricate the
shift mechanism, remove console as necessary. Refer
to Group 23, Body. Apply a film of Mopar Multipur-
pose Grease or equivalent, to slide surfaces and pawl
spring. For additional information, refer to Group 21,
Transaxle.
AUTOMATIC TRANSAXLE
The automatic transaxle should be inspected for
fluid leaks and proper fluid level when other under
hood service is performed.
CAUTION: To minimize fluid contamination, verify
that dipstick is seated in the fill hole or tube after
fluid level reading is taken.
TO INSPECT THE TRANSAXLE FLUID LEVEL: (1) Position the vehicle on a level surface.
(2) Start engine and allow to idle in PARK for at
least 60 seconds. The warmer the transaxle fluid, the
more accurate the reading. (3) While sitting in driver seat, apply brakes and
place gear selector in each position. Return gear se-
lector to park. (4) Raise hood and remove transaxle fluid level in-
dicator (dipstick) and wipe clean with a suitable
cloth. (5) Install dipstick and verify it is seated in fill
hole or tube (Fig. 2 or 3).
CAUTION: Do not overfill automatic transaxle, leak-
age or damage can result.
(6) Remove dipstick, with handle above tip, take
fluid level reading (Fig. 4). If the vehicle has been
driven for at least 15 minutes before inspecting fluid
level, transaxle can be considered hot and reading
should be above the WARM mark. If vehicle has run
for less than 15 minutes and more than 60 seconds
transaxle can be considered warm and reading
Fig. 1 Manual Transaxle Fill Plug
0 - 16 LUBRICATION AND MAINTENANCE Ä

CHASSIS AND BODY INDEX
page page
Body Lubrication ......................... 22
Brakes ................................ 21
Headlamps ............................. 22
Lower Ball Joints ......................... 19 Power Steering
.......................... 19
Rear Wheel Bearings ..................... 20
Steering Linkage ......................... 19
STEERING LINKAGE
INSPECTION
The steering linkage and steering gear should be in-
spected for wear, leaks or damage when other under ve-
hicle service is performed. The rack and pinion steering
gear end boots should not have excess oil or grease res-
idue on the outside surfaces or surrounding areas
(Fig.1). If boot is leaking, it should be repaired. For
proper service procedures, see Group 19, Steering.
The tie rod end seal should fit securely between the
steering knuckle and tie rod end (Fig.2). The steering
linkage should be lubricated at the time and distance
intervals described in the Lubrication and Mainte-
nance Schedules. Refer to General Information sec-
tion of this group.
TIE ROD END LUBRICATION
Lubricate the steering linkage with Mopar, Multi-
mileage Lube or equivalent. Using a wiping cloth,
clean grease and dirt from around grease fitting and
joint seal. Using a grease gun, fill tie rod end until
lubricant leaks from around the tie rod end side of
the seal (Fig.2). When lube operation is complete,
wipe off excess grease.
LOWER BALL JOINTS
INSPECTION
The front suspension lower ball joints should be in-
spected for wear, leaks or damage when other under ve- hicle service is performed. The ball joint seal should fit
securely between the steering knuckle and lower control
arm (Fig. 3). The ball joints should be lubricated at the
time and distance intervals described in the Lubrication
and Maintenance Schedules. Refer to the General Infor-
mation section of this group.
BALL JOINT LUBRICATION
CAUTION: Do not over fill ball joint with grease,
damage to seal can result.
Lubricate the ball joints with Mopar, Multi-mile-
age Lube or equivalent. Using a wiping cloth, clean
grease and dirt from around grease fitting and joint
seal. Using a grease gun, fill ball joint until seal
starts to swell (Fig. 3). When lube operation is com-
plete, wipe off excess grease.
POWER STEERING
The power steering fluid level should be inspected
when other under hood service is performed. If the
fluid level is low and system is not leaking, use Mo-
par, Power Steering Fluid or equivalent. The power
steering system should be inspected for leaks when
other under vehicle service is performed. For proper
service procedures, refer to Group 19, Steering.Fig. 1 Inspect Steering Linkage
Fig. 2 Tie Rod End Lubrication
Ä LUBRICATION AND MAINTENANCE 0 - 19

BRAKE RESERVOIR LEVEL INSPECTION
WARNING: DO NOT ALLOW PETROLEUM OR WATER
BASE LIQUIDS TO CONTAMINATE BRAKE FLUID,
SEAL DAMAGE AND BRAKE FAILURE CAN RESULT.
RELIEVE PRESSURE IN ANTI-LOCK BRAKE SYS-
TEM BEFORE ADDING BRAKE FLUID TO RESER-
VOIR. IF NOT, BRAKE FLUID COULD DISCHARGED
FROM THE RESERVOIR POSSIBLY CAUSING PER-
SONAL INJURY.
The brake reservoir level should be inspected when
other under hood service is performed. It is normal
for the reservoir level to drop as disc brake pads
wear. When fluid must be added, use Mopar, Brake
Fluid or equivalent. Use only brake fluid conforming
to DOT 3, Federal, Department of Transportation
specification. To avoid brake fluid contamination, use
fluid from a properly sealed container. On vehicles with anti-lock brakes, depressurize the
system before inspecting fluid level. Turn OFF the
ignition and remove the key. Pump the brake pedal
at least 50 times to relieve the pressure in the sys-
tem.
On all vehicles, if fluid should become low after sev-
eral thousand kilometers (miles), fill the reservoir to
level marks on the side of the reservoir (Fig. 8 or 9).
HEADLAMPS
The headlamps should be inspected for intensity
and aim whenever a problem is suspected. When lug-
gage compartment is heavily loaded, the headlamp
aim should be adjusted to compensate for vehicle
height change. For proper service procedures, refer to
Group 8L, Lamps. DRIVER SUPPLEMENTAL AIRBAG SYSTEM
If the AIRBAG indicator lamp does not light at all,
stays lit or lights momentarily or continuously while
driving, a malfunction may have occurred. Prompt service is required. Refer to Group 8M, Restraint
Systems for proper diagnostic procedures.
BODY LUBRICATION
Body mechanisms and linkages should be inspected,
cleaned and lubricated as required to maintain ease of
operation and to prevent corrosion and wear. Before a component is lubricated, oil, grease and dirt
should be wiped off. If necessary, use solvent to clean
component to be lubricated. After lubrication is com-
plete, wipe off excess grease or oil. During winter season, external lock cylinders should
be lubricated with Mopar, Lock Lubricant or equiva-
lent to ensure proper operation when exposed to water
and ice. To assure proper hood latching component operation,
use engine oil to lubricate the lock, safety catch and
hood hinges when other under hood service is per-
formed. Mopar, Multi-purpose Grease or equivalent
should be applied sparingly to all pivot and slide
contact areas.
USE ENGINE OIL ON:
² Door hingesÐHinge pin and pivot points.
² Hood hingesÐPivot points.
² Luggage compartment lid hingesÐPivot points.
USE MOPAR LUBRIPLATE OR EQUIVALENT ON:
² Door check straps.
² Hood counterbalance springs.
² Luggage compartment lid latches.
² Luggage compartment lid prop rod pivots.
² Ash tray slides.
² Fuel Fill Door latch mechanism.
² Park brake mechanism.
² Front seat tracks.
Fig. 8 Anti-lock Brake Reservoir
Fig. 9 Master Cylinder Brake ReservoirÐExcept
Anti-lock
0 - 22 LUBRICATION AND MAINTENANCE Ä

BALL JOINT INSTALLATION
(1) By hand, position ball joint assembly into the
ball joint bore of the lower control arm. Be sure the
ball joint assembly is not cocked in the bore of the
control arm, this will cause binding of the ball joint
assembly. (2) Position assembly in press with Installer Tool
C-4699-2 supporting control arm (Fig. 14). (3) Install the Remover/Installer, Special Tool
C-4699-1 over the ball joint stud and down on the
lower body of the ball joint assembly (Fig. 14). (4) Carefully align all pieces. Using an arbor press
apply pressure against the ball joint assembly, until
ball joint is fully seated against bottom surface of
control arm. Do not apply excessive pressure against
the control arm.
BALL JOINT SEAL INSTALLATION
(1) Support ball joint housing with Installer, Spe-
cial Tool C-4699-1 (Fig. 15). Position new seal over
ball joint stud and against ball joint housing.
(2) With 1-1/2 inch socket, press seal onto ball
joint housing until it is squarely seated against top
surface of control arm as shown in (Fig. 15).
SWAY BAR
The sway bar interconnects the front lower control
arms of the vehicle and attaches to the crossmember
(Fig. 1). Jounce and rebound movements affecting one
wheel are partially transmitted to the opposite wheel
to stabilize body roll. Attachment to the crossmember, and front lower
control arms is through rubber-isolated bushings. All
parts are serviceable, and the sway bar to crossmem-
ber bushings are split for easy removal and installa-
tion. The split in the sway bar to crossmember
bushing should be positioned toward the front of the
vehicle.
LOWER CONTROL ARM SWAY BAR RETAINER ATTACHMENT HOLE THREAD REPAIR
If threaded holes in lower control arm, for attach-
ment of sway bar retainers (Fig. 1) become damaged.
The threaded holes are repairable and do not require
replacement of lower control arm. If threads are damaged or stripped on the lower
control arm. An initial repair attempt should be
Fig. 13 Removing Ball Joint
Fig. 14 Installing Ball Joint
Fig. 15 Installing Ball Joint Seal
2 - 14 SUSPENSION AND DRIVESHAFTS Ä