air suspension CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

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)

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

LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol on the label. At the bottom NLGI symbol is the usage and qual-
ity identification letters. Wheel bearing lubricant is
identified by the letter ``G''. Chassis lubricant is iden-
tified by the letter ``L''. The letter following the us-
age letter indicates the quality of the lubricant. The
following symbols indicate the highest quality.
FLUID CAPACITIES
Fuel Tank
AP,AG and AJ ......................................53 L (14 gal.)
AA,AC and AY .....................................60 L (16 gal.)
AA-Flexible Fuel ..................................68 L (18 gal.)
Engine Oil
All.........................................................3.8 L (4.5 qts.)
Cooling System
2.2L ......................................................8.5 L (9.0 qts.)
2.5L ......................................................8.5 L (9.0 qts.)
3.0L ......................................................9.0 L (9.5 qts.)
3.3L ......................................................9.0 L (9.5 qts.)
3.8L ......................................................9.0 L (9.5 qts.)
Includes heater and coolant recovery bottle
Automatic Transaxle
Estimated Service Fill
ALL ......................................................3.8 L (4.0 qts.)
Overhaul Fill Capacity with Torque Converter
Empty
3-speed Fleet .......................................8.7 L (9.2 qts.)
3-speed .................................................8.2 L (8.8 qts.)
4-speed Electronic ................................9.4L (9.9 qts.)
Manual Transaxle
All ..........................................................9.4L (9.9 qts.)
Fill to bottom of fill hole.
Power Steering
All ...........................................................75L (1.5 pts.)
PARTS REQUIRING NO LUBRICATION
Many components on a Chrysler Corporation vehi-
cle require no periodic maintenance. Some compo-
nents are sealed and permanently lubricated. Rubber
bushings can deteriorate or limit damping ability if
lubricated. The following list of components require
no lubrication: ²
Air Pump
² Generator Bushings
² Drive Belts
² Drive Belt Idler/Tensioner Pulley
² Front Wheel Bearings
² Rubber Bushings
² Starter Bearings/Bushings
² Suspension Strut Bearings
² Throttle Control Cable
² Throttle Linkage
² Water Pump Bearings
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT JUMP START A FROZEN BATTERY, PER-
SONAL INJURY CAN RESULT. DO NOT JUMP START WHEN BATTERY INDICA-
TOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY.
REMOVE METALLIC JEWELRY WORN ON HANDS
OR WRISTS TO AVOID INJURY BY ACCIDENTAL
ARCHING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DE-
VICE, DO NOT ALLOW BATTERY VOLTAGE TO EX-
CEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually in-
spect engine compartment for:
² Battery cable clamp condition, clean if necessary.
² Frozen battery.
² Yellow or bright color test indicator, if equipped.
² Low battery fluid level.
² Generator drive belt condition and tension.
² Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, turn off all accessories, place gear selector in
park or neutral, set park brake and operate engine
at 1200 rpm.
NLGI SYMBOL
0 - 4 LUBRICATION AND MAINTENANCE Ä

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

should be above ADD mark. Add fluid only if level is
below ADD mark on dipstick when transaxle is
warm.The automatic transaxle does not require periodic
maintenance when used for general transportation. If
the vehicle is subjected to severe service conditions,
the automatic transaxle will require fluid/filter
change and band adjustments every 24 000 km
(15,000 miles). For additional information, refer to
Severe Service paragraph and Lubrication and Main-
tenance Schedules in General Information section of
this group. The fluid and filter should be changed
when water contamination is suspected. If fluid has
foamy or milky appearance, it is probably contami-
nated. If the fluid appears brown or dark and a foul
odor is apparent, the fluid is burned, transaxle re-
quires maintenance or service. A circular magnet lo-
cated in the transaxle pan, collects metallic particles
circulating in the oil. For proper diagnostic and ser-
vice procedures, refer to Group 21, Automatic Tran-
saxle.
SELECTING AUTOMATIC TRANSAXLE FLUID
Chrysler Corporation recommends Mopar ATF Plus
(automatic transmission fluid type 7176) be used to
add to or replace automatic transaxle fluid. If ATF
Plus is not available use Mopar Dexron II tAuto-
matic Transmission Fluid or equivalent.
DRIVE SHAFT CV AND TRIPOD JOINT BOOTS
The front drive shaft constant velocity and tripod
joint boots (Fig. 5) should be inspected when other
under vehicle service is performed. Inspect boots for
cracking, tears, leaks or other defects. If service re-
pair is required, refer to Group 2, Suspension.
FRONT WHEEL BEARINGS
The front wheel bearings are permanently sealed,
requiring no lubrication. For proper diagnostic and
service procedures refer to Group 2, Suspension.
TIRES
The tires should be inspected at every engine oil
change for proper inflation and condition. The tires
should be rotated at the distance intervals described
in the Lubrication and Maintenance Schedules of the
General Information section in this group. For tire
inflation specifications refer to the Owner's Manual.
A Tire Inflation sticker is located in the driver door
opening. For proper diagnostic procedures, see Group
22, Wheels and Tires.Fig. 2 3-speed Automatic Transaxle Fill hole
Fig. 3 4-speed Automatic Transaxle Fill tube
Fig. 4 Automatic Transaxle DipstickÐTypical
Fig. 5 Drive Shaft Boots
Ä LUBRICATION AND MAINTENANCE 0 - 17

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

SUSPENSION AND DRIVESHAFTS
CONTENTS
page page
AUTOMATIC AIR LOAD LEVELING SYSTEM . 59
AUTOMATIC AIR SUSPENSION ............ 73
DRIVESHAFTS ......................... 25
FRONT SUSPENSION ..................... 2
FRONT SUSPENSION SERVICE PROCEDURES . 5 GENERAL INFORMATION
.................. 1
REAR (STUB) AXLE ALIGNMENT ALL MODELS ............................ 89
REAR SUSPENSION ..................... 50
SPECIFICATIONS ....................... 91
GENERAL INFORMATION
Throughout this group, references may be made to
a particular vehicle by letter or number designation.
A chart showing the breakdown of these designations
is included in the Introduction section at the front of
this Service Manual. An independent MacPherson Type front suspension
is used on these vehicles. Vertical shock absorbing
struts attach to the upper fender reinforcement and the steering knuckle to provide upper steering
knuckle position. Lower control arms are attached
inboard to a crossmember and outboard to the steer-
ing knuckle through a ball joint to provide lower
steering knuckle position. During steering maneu-
vers, the strut (through a pivot bearing in the upper
retainer) and the steering knuckle turn as an assem-
bly (Fig. 1).
Fig. 1 Front Suspension (Typical)
Ä SUSPENSION AND DRIVESHAFTS 2 - 1

Compressor, Special Tool C-4838. It is required
that five coils be captured within the jaws of the
tool (Fig. 11).
SPRING RETAINER UPPER
Ensure that upper spring retainer is positioned
properly, see; step (4), Assemble (Strut Damper).
SPRING SEAT LOWER
During assembly of the coil spring to strut damper.
Ensure that lower coil spring end is seated in strut
damper spring seat recess refer to (Fig. 9) in assem-
ble (Strut Damper) section.
SHOCK ABSORBERS (Strut Damper)
INSPECTION
Inspect for evidence of fluid leaking from around
the strut assembly shaft seal at the upper end of the
reservoir. (Actual leakage will be a stream of fluid
running down the side and dripping off lower end of
unit. A slight amount of seepage around the strut
rod is not unusual and does not affect performance.
LOWER CONTROL ARM
The lower control arm if damaged, is serviced only
as a complete component. Do not attempt to repair or
straighten a broken or bent lower control arm. The serviceable components of the lower control
arm are, the ball joint assembly, and both pivot
bushings. The service procedure to replace these com-
ponents is detailed in the specific component sections
of this group.
REMOVAL (ASSEMBLY)
(1) Raise vehicle. See Hoisting in Lubrication,
Group 0 of this service manual. (2) Remove the ball joint stud to steering knuckle
clamp nut and bolt (Fig. 1). (3) Remove the sway bar to lower control arm re-
tainer on both sides of the vehicle (Fig. 2). Then ro-
tate the sway bar down away from the lower control
arms. (4) Separate the steering knuckle from the ball
joint stud (Fig. 1). (5) Remove the front and rear control arm pivot
bushing to crossmember attaching nuts and bolts
(Fig. 2). Then remove the lower control arm from the
crossmember.
CAUTION: Pulling steering knuckle out from vehicle
after releasing from ball joint can separate inner
C/V joint. See Driveshafts.
Fig. 11 Identifying Coil Springs
Fig. 1 Control Arm To Steering Knuckle Attachment
Fig. 2 Lower Control Arm Typical
2 - 10 SUSPENSION AND DRIVESHAFTS Ä

control arm. Be sure that the flanges of the bushing
are fully expanded around the control arm bushing
holes. (5) If the position of the large lower control arm
pivot bushing (Fig. 11) moved during bushing instal-
lation. Install a nut and bolt through the bushing
sleeve and tighten it down (Fig. 11). Using a wrench
rotate the bolt until the bushing is in the correct po-
sition (Fig. 10)
BALL JOINTS
The lower front suspension ball joints operate with
no free play. See Inspection Ball Joint Wear to deter-
mine if the ball joint is worn and requires replace-
ment. The ball joints are replaceable as an assembly, do
not attempt any type of repair on the ball joint as-
sembly. The replacement procedure for the ball joint
assembly is detailed in this section. The ball joint housing is a pressed fit into the
lower control arm with the joint stud retained in the
steering knuckle by a (clamp) bolt.
INSPECTION BALL JOINT WEAR
With the weight of the vehicle resting on the road
wheels. Grasp the grease fitting as shown in (Fig. 12)
and with no mechanical assistance or added force at-
tempt to move the grease fitting.
If the ball joint is worn the grease fitting will move
easily. If movement is noted,replacement of the ball
joint is recommended.
BALL JOINT REMOVAL
(1) Pry off seal.
(2) Position Receiving Cup Special Tool C-4699-2
to support lower control arm while receiving ball
joint assembly (Fig. 13). (3) Install Remover/Installer Special Tool,
C-4699-1 (Fig. 13) over ball joint stud and against
the ball joint upper housing. (4) Press down against the ball joint upper hous-
ing, to remove ball joint assembly from lower control
arm.
Fig. 9 Bushing Installer Tools
Fig. 10 Bushing And Tool Position For Installation In Control Arm
Fig. 11 Positioning Control Arm Bushing
Fig. 12 Checking Ball Joint Wear
Ä SUSPENSION AND DRIVESHAFTS 2 - 13

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