torque CHEVROLET PLYMOUTH ACCLAIM 1993 Service 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 ELECTRICALÐFUELÐEMISSIONS 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. 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. 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
California Air Research Board (CARB) requirements.
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

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

flakes are visible in the used lubricant or the bearing
rollers and race cup is discolored, the bearing and
race cup should be replaced. For proper service pro-
cedures, see Group 5, Brakes. Replace the inner seal
whenever the wheel bearings are serviced.
REAR WHEEL BEARING LUBRICATION
CAUTION: Combining two types of lubricant can
cause bearing failure. Wash used or new bearings
with a suitable solvent and blot dry with a lint free
cloth before packing with new lubricant.
WARNING: DO NOT ALLOW BEARING TO SPIN AT
HIGH RPM WHEN USING COMPRESSED AIR TO
BLOW CLEANING SOLVENT FROM BEARING.
BEARING CAGE CAN EXPLODE, CAUSING PER-
SONAL INJURY.
TO LUBRICATE REAR WHEEL BEARINGS:
(1) Hoist rear wheels off the ground and support ve-
hicle on safety stands. Refer to Hoisting Recommenda-
tions in the General Information section of this group.
(2) Remove rear wheels.
(3) Remove brake caliper on vehicles with rear disc
brakes. For proper procedure, see Group 5, Brakes. (4) Remove rear wheel hub (drum) assembly and
remove inner grease seal (Fig. 7). For proper service
procedure, see Group 5, Brakes. (5) Inspect bearings, refer to Inspection paragraph
of this procedure. Wash used lubricant from bearings
with solvent and blot or blow dry. (6) Using a bearing packing device, lubricate the
bearings with Mopar, Wheel Bearing Grease or
equivalent. (7) With a wiping cloth, clean used lubricant form
wheel hub assembly and axle spindle. (8) Install inner wheel bearing in the hub assem-
bly, small end of bearing toward hub. With a finger,
smooth out grease around the outside of bearing. (9) Using a seal driver, install new inner hub seal.
(10) Install wheel hub (drum) assembly on axle
spindle. (11) Install outer wheel bearing over the spindle
end, small end of bearing toward hub. With a finger,
smooth out grease around the outside of bearing. (12) Install washer and spindle nut. While rotating
hub, tighten spindle nut to 27 to 34 N Im (240 to 300
in. lbs.) torque. Loosen spindle nut one quarter turn.
Hand tighten spindle nut. (13) Install spindle nut lock cover, cotter pin and
grease cap. (14) Install disc brake caliper on vehicles with disc
brakes. CAUTION: Pump brake pedal several times before
driving vehicle to verify brake operation.
(15) Install wheel and lower vehicle.
BRAKES
BRAKE PAD AND LINING INSPECTION
The brake pads and linings should be inspected at dis-
tance intervals described in the Lubrication and Main-
tenance Schedules. Refer to the General Information
section of this group. If brake pads or linings appear ex-
cessively worn, the brakes would require service. For
proper service procedures, refer to Group 5, Brakes.
BRAKE HOSE INSPECTION
WARNING: IF FRONT WHEEL, REAR AXLE, OR AN-
TI-LOCK UNIT BRAKE HOSE OUTER COVER IS
CRACKED, CHAFED, OR BULGED, REPLACE HOSE
IMMEDIATELY. BRAKE FAILURE CAN RESULT.
The front wheel, rear axle and anti-lock unit (if
equipped) brake hoses should be inspected at time
and distance intervals described in the Lubrication
and Maintenance Schedules. Refer to the General In-
formation section of this group. A hose must be re-
placed if it has signs of cracking, chafing, fatigue or
bulging. For proper service procedures, refer to
Group 5, Brakes.
BRAKE LINE INSPECTION
The metal brake lines should be inspected when other
under vehicle service is preformed. If a line is pinched,
kinked, or corroded, it should be repaired. For proper
service procedures, refer to Group 5, Brakes.
Fig. 7 Rear Wheel Bearings
Ä LUBRICATION AND MAINTENANCE 0 - 21

WHEEL ALIGNMENT SERVICE PROCEDURE
CAMBER AA, AJ BODIES (1) Prepare vehicle as described in the Pre-Align-
ment procedure. (2) Loosen cam and knuckle bolts (each side) (Fig.
2). (3) Rotate cam bolt (Fig. 2) to move top of wheel in
or out to specified camber. (4) Tighten the cam bolts and nuts to 100 N Im (75
ft. lbs.) plus1/4 turn beyond specified torque.
CAMBER AC, AG, AP, AY BODIES (1) Prepare vehicle as described in the Pre-Align-
ment procedure. (2) Position vehicle on alignment equipment and
read camber as instructed by equipment manufactur-
er's procedure. (3) Using extensions and appropriate tools. Re-
move the strut assembly to steering knuckle attach-
ing bolts from vehicle (Fig. 2). Replace the original
attaching bolts with the bolts provided in the align-
ment, Cam And Bolt Service Package. (4) Rotate the alignment adjusting cam bolt, (Fig.
2) to obtain the specified camber setting for the ve-
hicle. See the Specifications Section at the end of this
group for the camber setting for the vehicle being
serviced. (5) Using the appropriate extensions and tools.
Carefully reach around the tire and tighten the
knuckle bolts enough to hold the camber setting.
Finish by tightening the bolts to 100 N Im (75 ft.lbs.)
plus 1/4 turn beyond specified torque.
TOE
(1) Prepare vehicle as described in the Pre-Align-
ment procedure. (2) Center steering wheel and hold with steering
wheel clamp. (3) Loosen tie rod locknuts. Rotate rods to align toe
to specifications (Fig. 3).
CAUTION: Do not twist tie rod to steering gear rub-
ber boots during adjustment. (4) Tighten tie rod locknuts to 75 N Im (55 ft.lbs.)
torque. (5) Adjust steering gear to tie rod boots at tie rod.
(6) Remove steering wheel clamp.
STRUT DAMPER ASSEMBLY
REMOVAL
(1) Loosen wheel nuts.
(2) Raise vehicle, see Hoisting in Lubrication and
Maintenance, Group 0. (3) Remove wheel and tire assembly.
Where service procedure includes assembly of
original strut (shock absorber) to original
knuckle. Mark cam adjusting bolt (Fig. 4), on
AA, and AJ bodies only. Mark outline of strut
on knuckle as shown in (Fig. 1). on AC, AG, AP
and AY bodies. (4) Remove cam bolt, knuckle bolt(s), washer
plate(s) and brake hose to damper bracket retaining
screw (Fig. 4). (5) Remove strut damper to fender shield mount-
ing nut washer assemblies.
Fig. 2 Alignment Adjustment Locations
Fig. 3 Front Wheel Toe Adjustment
Ä SUSPENSION AND DRIVESHAFTS 2 - 7

INSPECTION
Inspect for evidence of fluid running from the up-
per 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 be-
tween the strut rod and strut shaft seal is not un-
usual and does not affect performance of the strut
assembly.
INSTALLATION
(1) Install unit into fender reinforcement and in-
stall retaining nuts and washer assemblies (Fig. 1).
Tighten the 3 nuts to 27 N Im (20 ft. lbs.) torque.
(2) Position steering knuckle neck into strut as-
sembly. Position washer plate and install cam and
knuckle bolts (Fig. 4). (3) Attach brake hose retainer to damper, tighten
the screw to 13 N Im (10 ft. lbs.) torque (Fig. 4).
(4) Index strut to original outline on the knuckle
neck, or align mark on cam bolt with the mark that
was put on the strut to steering knuckle bracket
(Fig. 4). (5) Plac e a 4 inch (or larger) C clamp on the strut
and knuckle as shown in (Fig. 5). Tighten the clamp
just enough to eliminate any looseness between the
knuckle and the strut. Check alignment of the index marks and tighten the bolts to 100 N
Im (75 ft. lbs.)
plus 1/4 turn beyond specified torque. Remove the
(C) clamp.
(6) Install wheel and tire assembly. Tighten the
wheel nuts to 129 N Im (95 ft. lbs.) torque.
DISASSEMBLY (STRUT DAMPER)
(1) Compress front coil spring with Spring Com-
pressor, Special Tool C-4838 (Fig. 6).
(2) Hold end of strut shaft from rotating with
wrench, while loosening strut shaft nut. Remove nut
from shaft (Fig. 7). (3) Remove the upper strut mount from the strut
assembly. (4) Remove coil spring from the strut assembly.
Mark spring for installation back on the same
side of the vehicle (Fig. 11).
CAUTION: see Suspension Coil Springs before re-
leasing coil from Tool C-4838.
(5) Inspect strut damper, mount assembly (Fig. 8)
for:
Fig. 4 Strut Damper Removal
Fig. 5 Strut Damper Installation
Fig. 6 Compressing Coil Spring
2 - 8 SUSPENSION AND DRIVESHAFTS Ä

(a) Severe deterioration of rubber isolator; re-
tainers for cracks and distortion and bond failure of
retainers and rubber isolators. (b) Bearings for binding.
(c) Shock Absorber for flat spots over full stroke
also see, Shock Absorbers, (strut damper).
ASSEMBLE (STRUT DAMPER)
(1) Mount the strut assembly in a vertical position.
(2) Place the compressed spring onto the strut as-
sembly, so the end of the coil is seated in the seat re-
cess in lower spring mount (Fig. 9). (3) Install the dust shield, isolator (if so equipped)
jounce bumper, spacer (as required), and spring seat
onto the top of the strut shaft (Fig. 8). (4) Position top spring seat alignment tab correctly
with respect to bottom bracket (Fig. 9). (5) Install the rebound retainer and shaft nut (Fig.
8). (6) Tighten the strut shaft nut using, Strut Rod
Socket And Holder, Special Tool L-4558. Torque strut
shaft nut to 75 N Im (55 ft. lbs.) plus 1/4 turn (Fig. 10).
WARNING: THIS STEP MUST BE DONE BEFORE
SPRING COMPRESSOR, SPECIAL TOOL C-4838 IS
RELEASED FROM THE COIL SPRING.
(7) Verify coil spring is aligned correctly with respect
to bottom bracket (Fig. 9). (8) Release Spring Compressor Tool C-4838.
SUSPENSION COIL SPRINGS
Springs are rated separately for each side of vehicle
depending on optional equipment and type of service.
During service procedures where both springs are
removed, mark springs (Chalk, Tape, etc.) (Fig. 11) to
ensure installation in original position. If the coils
springs require replacement. Be sure that the
springs needing replacement, are replaced with
springs meeting the correct load rating for the
vehicle and its specific options. During service procedures requiring the re-
moval or installation of a coil spring with Spring
Fig. 7 Loosening Strut Assembly Shaft Nut
Fig. 8 Mount Assembly
Fig. 9 Spring Seat Alignment Notch Position to Bracket
Fig. 10 Tighten Strut Rod Nut with Tool
Ä SUSPENSION AND DRIVESHAFTS 2 - 9

Inspect lower control arm for distortion. Check
bushings for severe deterioration.
INSTALLATION (ASSEMBLY)
(1) Position the lower control arm into the cross-
member. Install front and rear pivot bushing to
crossmember attaching bolts. Then loosely assemble
nuts to bolts (Fig. 2). (2) Install ball joint stud into steering knuckle and
install clamp bolt (Fig. 1). Tighten clamp bolt to 145
N Im (105 ft. lbs.).
(3) Position sway bar and bushings against the
lower control arms. Install sway bar to control arm
retainers. Install retainer bolts and tighten to 70
N Im (50 ft. lbs.).
(4) Lower vehicle so the suspension is supporting
vehicles weight (control arm at design height).
Tighten the lower control arm to crossmember at-
taching bolts to 169 N Im (125 ft. lbs.) torque.
LOWER CONTROL ARM PIVOT BUSHINGS
When performing the replacement procedure on the
lower control arm pivot bushings, the following se-
quence must be followed. When removing the pivot
bushings from the lower control arm, the large bush-
ing must be removed first then the small bushing.
When installing the pivot bushings into the lower
control arm, the small bushing must be installed
first then the large bushing. This sequence must be
used when removal and replacement of bushings is
done using Bushing Remover/Installer, Special Tool
6602.
LARGE BUSHING
REMOVE
(1) Position and clamp lower control arm in a vise.
(2) Assemble the washer, thrust bearing and large
bushing disk, Special tool 6602-5 onto the threaded
rod from Bushing Remover/Installer, Special Tool
6602 (Fig. 3). (3) Install the tools assembled in step 2 above into
the large bushing of the lower control arm (Fig. 4).
Then assemble the remaining Special Tools, Cup
6602-2, thrust bearing, washer and long nut onto the
threaded rod (Fig. 4) from Bushing Remover/In-
staller, Special Tool 6602.
(4) Hold the long nut stationary. Using a deep
socket turn the long threaded rod until the large
pivot bushing is pushed out of the lower control arm.
SMALL BUSHING
REMOVE
(1) Remove the special tools from the lower control
arm that were used for the removal of the large pivot
bushing. (2) Remove the large Bushing Disc, Special Tool
6602-5 from the threaded rod. Leave the thrust bear-
ing and washer on the threaded rod. Install the small
Bushing Disc, Special Tool 6602-3 on the threaded
rod and against thrust bearing (Fig. 5).
Fig. 3 Bushing Removal Tools
Fig. 4 Tool Assembled For Bushing Removal
Fig. 5 Bushing Removal Tools
Ä SUSPENSION AND DRIVESHAFTS 2 - 11