AA body CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

WIRING DIAGRAMS AA-BODY
INDEX
Wiring Diagram Name Sheet Number
Anti-Lock Brake System.................41, 42, 43, 44
ABS Pump Motor Relay.......................41
ABS System Relay..........................43
Brake Switch..............................44
Controller.....................41, 42, 43, 44, 114
Data Link Connector.........................44Wiring Diagram Name Sheet Number
Diode-Warning Lamp.........................43
Hydraulic Modulator.........................41
Ignition Switch.............................44
Park Brake Switch...........................44
Wheel Sensors.............................42
ÄWIRING DIAGRAMS AA-BODY 8W - 1

8W - 6 WIRING DIAGRAMS AA-BODYÄ

WIRING DIAGRAMS AJ BODY
ALPHABETICAL INDEX
Wiring Diagram Name Sheet Number
Anti-Lock Brake System.................68, 69, 70, 71
ABS Controller..................68, 69, 70, 71, 170
ABS Hydraulic Modulator......................68
ABS Pump Motor Relay.......................68
ABS System Relay..........................69
ABS Warning Lamp Diode......................69
ABS Warning Switch Lamp Switch................70Wiring Diagram Name Sheet Number
Brake Switch..............................70
Data Link Connector.........................70
Left Front Wheel Sensor.......................71
Left Rear Wheel Sensor.......................71
Park Brake Switch...........................70
Right Front Wheel Sensor......................71
Right Rear Wheel Sensor......................71
8W - 8 WIRING DIAGRAMS AJ BODYÄ

8W - 14 WIRING DIAGRAMS AJ BODYÄ

CHRYSLER
CORPORATION
ENGINEÐCHASSISÐBODY
SERVICE MANUAL
1993 FRONT WHEEL DRIVE
PASSENGER VEHICLES
To order the special service tools used and
illustrated, please refer to the instructions on
inside back cover.
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM
OR BY ANY MEANS, ELECTRONIC, ME-
CHANICAL, PHOTOCOPYING, RECORDING,
OR OTHERWISE, WITHOUT THE PRIOR
WRITTEN PERMISSION OF CHRYSLER
CORPORATION.
Chrysler Corporation reserves the right to make changes in design or to make
additions to or improvements in its products without imposing any obligations
upon itself to install them on its products previously manufactured.
Litho in U.S.A. Copyright 1992 Chrysler Corporation 30M0792
NEXT PAGE©

GROUP TAB LOCATOR
Introduction
0Lubrication and Maintenance
2Suspension/Driveshafts
5Brakes
6Manual Transaxle Clutch
7Cooling System
9Engine
11Exhaust System and Intake Manifold
13Frame and Bumpers
19Steering
21Transaxle
22Wheels/Tires
23Body
24Heating/Air Conditioning
Component and System Index
Service Manual Comment Forms (Rear of Manual)

FOREWORD
The information contained in this service manual has been prepared for the professional automotive
technician involved in daily repair operations. This manual does not cover theory of operation, which is addressed
in service training material. Information describing the operation and use of standard and optional equipment is
included in the Owner's Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the components.
The Component and System Index of this manual identifies the correct group for the component or system to
be serviced. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has a
contents section that lists major topics within the group.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide Chrysler
Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When replacing
fasteners, always use the same type (part number) fastener as removed.
Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.
NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in this
manual may have changed from prior publications. These new terms are in compliance with S.A.E.
recommended practice J1930. This terminology standard (J1930) is required to comply with the 1993
California Air Research Board (CARB) requirements.
FOR INFORMATION NOT CONTAINED IN THIS MANUAL, REFER TO FRONT WHEEL DRIVE
PASSENGER VEHICLES ENGINEÐCHASSISÐBODY OR WIRING DIAGRAMS SERVICE MANUALS.
NEXT PAGE ©

FOREWORD
The information contained in this Service Manual has been prepared for the professional automotive
technician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner's Manual provided with the vehicle.
These diagrams contain the latest information at the time of publication and incorporate the wiring schematic
for the basic vehicle and available optional equipment.
The diagrams are grouped by body type and sales division. The body codes are explained in the General
Information section. (ExampleÐAP-D, P=Shadow, Sundance). To locate a system or component refer to the black
index tabs on the next page. The tab will assist you in locating the desired area of the manual.
An alphabetical index is provided at the beginning of each section to help you in locating a system or
component. All diagrams are identified by SHEET NUMBER which is found in the lower right- or left-hand corner
of the page.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide Chrysler
Corporation with your comments and suggestions.
Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.
NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in this
manual may have changed from prior publications. These new terms are in compliance with S.A.E.
recommended practice J1930. This terminology standard (J1930) is required to comply with the 1993
California Air Research Board (CARB) requirements.
FOR INFORMATION NOT CONTAINED IN THIS MANUAL, REFER TO THE FRONT WHEEL
DRIVE PASSENGER VEHICLES ENGINEÐCHASSISÐBODY OR ELECTRICALÐFUELÐEMISSIONS
SERVICE MANUALS.
NEXT PAGE ©

COMPONENT AND SYSTEM INDEX
Name Group-page Name Group-page
BODY ................................... 23-1
AA-VEHICLE BODY COMPONENT SERVICE .......23-11
AC-VEHICLE BODY COMPONENT SERVICE .......23-37
AG-VEHICLE BODY COMPONENT SERVICE .......23-52
AJ/27-VEHICLE CONVERTIBLE BODY COMPONENT SERVICE ............................ 23-86
AJ-VEHICLE BODY COMPONENT SERVICE .......23-71
AP-VEHICLE BODY COMPONENT SERVICE .......23-97
AY-VEHICLE BODY COMPONENT SERVICE .......23-133
BODY DIAGNOSTIC PROCEDURES .............23-2
GENERAL SERVICE INFORMATION .............23-1
PAINT ................................. 23-4
POWER SUNROOF ........................ 23-6
WINDSHIELD ............................ 23-9
BRAKES ..................................5-1
ANTI-LOCK BRAKE SYSTEMÐBENDIX ANTI-LOCK 10 AC/Y BODY ......................... 5-72
ANTI-LOCK BRAKE SYSTEMÐBENDIX ANTI-LOCK 6 AA,AG,AJ,AP BODY .................... 5-113
BRAKE DISC (ROTOR) ...................... 5-53
BRAKE SUPPORT ASSEMBLY .................5-25
FRONT DISC BRAKES ...................... 5-31
GENERAL INFORMATION .....................5-1
HYDRAULIC SYSTEM CONTROL VALVES .........5-26
KELSEY HAYES DOUBLE PIN FAMILY CALIPER .....5-35
KELSEY HAYES DOUBLE PIN NON-FAMILY CALIPER ............................. 5-38
MASTER CYLINDER ....................... 5-66
PARKING BRAKES ........................ 5-57
POWER BRAKES ......................... 5-68
REAR DISC BRAKES ....................... 5-45
REAR WHEEL DRUM BRAKES ................5-18
SERVICE ADJUSTMENTS .....................5-4
WHEEL BEARINGS ........................ 5-70
WHEEL CYLINDERS ....................... 5-23
COOLING SYSTEM ...........................7-1
ACCESSORY DRIVE BELTS ................... 7-24
ENGINE BLOCK HEATER .................... 7-28
GENERAL INFORMATION .....................7-1
SERVICE PROCEDURES ..................... 7-10
SPECIFICATIONS ......................... 7-29
ENGINE ..................................9-1
2.2/2.5L ENGINES .........................9-8
3.0L ENGINE ............................ 9-66
3.3/3.8L ENGINE ......................... 9-98
STANDARD SERVICE PROCEDURES .............9-1
EXHAUST SYSTEM AND INTAKE MANIFOLD .........11-1
GENERAL INFORMATION .................... 11-1
SERVICE PROCEDURES ..................... 11-4
TORQUE SPECIFICATION ................... 11-25
FRAME AND BUMPERS ....................... 13-1
BUMPER AND FASCIA ...................... 13-1
FRAME ................................ 13-9
HEATING AND AIR CONDITIONING ...............24-1
AUTOMATIC TEMPERATURE CONTROL (ATC) .....24-66 COMPONENT SERVICE PROCEDURES
..........24-47
FIXED DISPLACEMENT COMPRESSORÐMODEL 10PA17............................. 24-24
FIXED DISPLACEMENT COMPRESSORÐMODEL SD709P ............................. 24-38
FIXED DISPLACEMENT COMPRESSORÐMODEL TR105 .............................. 24-32
GENERAL INFORMATION .................... 24-1
HEATER AND A/C PERFORMANCE TESTS .........24-6
REFRIGERANT SERVICE PROCEDURES ..........24-8
VACUUM CONTROL SYSTEM DIAGNOSIS .........24-4
VARIABLE DISPLACEMENT COMPRESSORÐMODEL 6C17 ............................... 24-13
INTRODUCTION .......................... Intro.-1
LUBRICATION AND MAINTENANCE ................0-1
CHASSIS AND BODY ....................... 0-19
DRIVETRAIN ............................ 0-16
ENGINE ................................0-8
GENERAL INFORMATION .....................0-1
MANUAL TRANSAXLE CLUTCH ...................6-1
STEERING ................................ 19-1
ACUSTAR STANDARD AND TILT STEERING COLUMN ............................ 19-28
AUTOMATIC TRANSMISSION SHIFTER/IGNITION INTERLOCK .......................... 19-36
GENERAL INFORMATION .................... 19-1
POWER STEERING GEAR ................... 19-25
POWER STEERING PUMPS ..................19-1
SPECIFICATIONS AND TIGHTENING REFERENCE . . . 19-42
SUSPENSION AND DRIVESHAFTS .................2-1
AUTOMATIC AIR LOAD LEVELING SYSTEM ........2-59
AUTOMATIC AIR SUSPENSION ................2-73
DRIVESHAFTS ........................... 2-25
FRONT SUSPENSION .......................2-2
FRONT SUSPENSION SERVICE PROCEDURES .......2-5
GENERAL INFORMATION .....................2-1
REAR (STUB) AXLE ALIGNMENT ALL MODELS .....2-89
REAR SUSPENSION ....................... 2-50
SPECIFICATIONS ......................... 2-91
TRANSAXLE .............................. 21-85
41TE FOUR SPEED AUTOMATIC TRANSAXLE ......21-85
41TE FOUR SPEED TRANSAXLE HYDRAULIC SCHEMATICS ........................ 21-170
41TE ON-BOARD DIAGNOSTICS .............21-145
A-523, A-543, and A-568 MANUAL TRANSAXLE ....21-1
SPECIFICATIONS ........................ 21-183
THREE SPEED TORQUEFLITE AUTOMATIC TRANSAXLE .......................... 21-35
THREE SPEED TRANSAXLE HYDRAULIC SCHEMATICS ........................ 21-162
WHEELSÐTIRES ........................... 22-1
SPECIFICATIONS ......................... 22-8
TIRE SERVICE PROCEDURES .................22-1
WHEELS SERVICE PROCEDURES ..............22-6

COMPONENT AND SYSTEM INDEX
Name Group-page Name Group-page
AUDIO SYSTEM ............................ 8F-1
ANTENNAS ............................ 8F-20
COMPACT DISC PLAYER ................... 8F-30
RADIOS ............................... 8F-1
SPEAKERS ............................. 8F-24
BATTERY/STARTER/GENERATOR SERVICE ..........8B-1
BATTERY REMOVAL, INSTALLATION AND SERVICE . . 8B-1
GENERATOR ............................ 8B-9
SPECIFICATIONS ........................ 8B-12
STARTER .............................. 8B-4
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS ........................... 8A-1
BATTERY TEST PROCEDURES ON-VEHICLE .......8A-3
FAULT CODESÐON BOARD DIAGNOSTICS .......8A-23
GENERAL INFORMATION .................... 8A-1
GENERATOR TEST PROCEDURES ON VEHICLE ....8A-19
IGNITION OFF DRAW (IOD) ..................8A-9
SPECIFICATIONS ........................ 8A-28
STARTER TEST PROCEDURES ON VEHICLE ......8A-11
CHIME WARNING/REMINDER SYSTEM ............8U-1
EMISSION CONTROL SYSTEMS .................25-1
EVAPORATIVE EMISSION CONTROLS ...........25-1
EXHAUST EMISSION CONTROLS ..............25-17
FUEL SYSTEMS ............................ 14-1
2.2L TURBO III MULTI-PORT FUEL INJECTIONÐ GENERAL DIAGNOSIS ................... 14-95
2.2L TURBO III MULTI-PORT FUEL INJECTIONÐ ON-BOARD DIAGNOSTICS ................14-100
2.2L TURBO III MULTI-PORT FUEL INJECTIONÐ SERVICE PROCEDURES .................14-107
2.2L TURBO III MULTI-PORT FUEL INJECTIONÐ SYSTEM OPERATION .................... 14-83
2.2L/2.5L SINGLE POINT FUEL INJECTIONÐ GENERAL DIAGNOSIS ................... 14-35
2.2L/2.5L SINGLE POINT FUEL INJECTIONÐ ON-BOARD DIAGNOSTICS .................14-41
2.2L/2.5L SINGLE POINT FUEL INJECTIONÐ SERVICE PROCEDURES .................. 14-48
2.2L/2.5L SINGLE POINT FUEL INJECTIONÐ SYSTEM OPERATION .................... 14-24
2.5L FLEXIBLE FUEL MULTI-PORT FUEL INJECTIONÐGENERAL DIAGNOSIS ..........14-66
2.5L FLEXIBLE FUEL MULTI-PORT FUEL INJECTIONÐON-BOARD DIAGNOSTICS ........14-70
2.5L FLEXIBLE FUEL MULTI-PORT FUEL INJECTIONÐSERVICE PROCEDURES .........14-77
2.5L FLEXIBLE FUEL MULTI-PORT FUEL INJECTIONÐSYSTEM OPERATION ...........14-55
3.0L MULTI-PORT FUEL INJECTIONÐGENERAL DIAGNOSIS .......................... 14-125
3.0L MULTI-PORT FUEL INJECTIONÐON-BOARD DIAGNOSTICS ........................ 14-130
3.0L MULTI-PORT FUEL INJECTIONÐSERVICE PROCEDURES ........................ 14-138
3.0L MULTI-PORT FUEL INJECTIONÐSYSTEM OPERATION ......................... 14-113
3.3L AND 3.8L MULTI-PORT FUEL INJECTIONÐ GENERAL DIAGNOSIS ................... 14-157 3.3L AND 3.8L MULTI-PORT FUEL INJECTIONÐ
ON-BOARD DIAGNOSTICS ................14-162
3.3L AND 3.8L MULTI-PORT FUEL INJECTIONÐ SERVICE PROCEDURES .................14-169
3.3L AND 3.8L MULTI-PORT FUEL INJECTIONÐ SYSTEM OPERATION ................... 14-145
ACCELERATOR PEDAL AND THROTTLE CABLE ....14-21
FUEL DELIVERY SYSTEM .................... 14-3
FUEL TANKS ........................... 14-14
GENERAL INFORMATION .................... 14-1
SPECIFICATIONS ........................ 14-178
HORNS ................................. 8G-1
IGNITION SYSTEMS ......................... 8D-1
2.2L TBI, 2.5L TBI, 2.5L MPI AND 3.0L IGNITION SYSTEMSÐDIAGNOSTIC PROCEDURES .......8D-11
2.2L TBI, 2.5L TBI, 2.5L MPI AND 3.0L IGNITION SYSTEMSÐSERVICE PROCEDURES ..........8D-14
2.2L TBI, 2.5L TBI, 2.5L MPI AND 3.0L IGNITION SYSTEMSÐSYSTEM OPERATION ............8D-1
2.2L TURBO III, 3.3L AND 3.8L IGNITION SYSTEMÐDIAGNOSTIC PROCEDURES ........8D-35
2.2L TURBO III, 3.3L AND 3.8L IGNITION SYSTEMÐSYSTEM OPERATION ............8D-24
2.2L TURBO III, 3.3L AND 3.8L IGNITION SYSTEMSÐSERVICE PROCEDURES ..........8D-39
IGNITION SWITCH ....................... 8D-45
SPECIFICATIONS ........................ 8D-47
INSTRUMENT PANEL AND GAUGES ...............8E-1
AA BODY .............................. 8E-1
AC AND AY BODIES ...................... 8E-23
AG AND AJ BODIES ...................... 8E-42
AP BODY ............................. 8E-58
LAMPS .................................. 8L-1
BULB APPLICATION TABLE ..................8L-38
CONCEALED HEADLAMPS ..................8L-27
EXTERIOR LAMP SWITCHES AND HEADLAMP ALIGNMENT ........................... 8L-3
EXTERIOR LAMP SYSTEMS .................8L-25
EXTERIOR LAMPSÐAA BODY ................8L-7
EXTERIOR LAMPSÐAC BODY ...............8L-10
EXTERIOR LAMPSÐAG BODY ...............8L-14
EXTERIOR LAMPSÐAJ BODY ................8L-16
EXTERIOR LAMPSÐAP BODY ...............8L-19
EXTERIOR LAMPSÐAY-BODY ................8L-22
GENERAL INFORMATION .................... 8L-1
ILLUMINATED ENTRY SYSTEM ...............8L-33
OVERHEAD CONSOLE ........................ 8C-1
AA BODY .............................. 8C-1
AC AND AY BODY ........................ 8C-6
AG AND AJ BODIES ...................... 8C-13
AP BODY ............................. 8C-21
POWER LOCKS ............................ 8P-1
POWER MIRRORS ..........................8T-1
POWER SEATS ............................ 8R-1
POWER WINDOWS .......................... 8S-1
REAR WINDOW DEFOGGER .................... 8N-1
RESTRAINT SYSTEMS ....................... 8M-1
TURN SIGNALS AND HAZARD WARNING FLASHER ....8J-1
VEHICLE SPEED CONTROL .................... 8H-1