1993 CHEVROLET PLYMOUTH ACCLAIM tow

INTAKE MANIFOLD
REMOVAL (1) Perform fuel system pressure release procedure
before attempting any repairs. (2) Disconnect negative battery cable.
(3) Remove air cleaner hose to throttle body (Fig.
6).
(4) Remove accelerator and speed control cables.
(5) Disconnect automatic idle speed (AIS) motor
and throttle position sensor (TPS) wiring connectors
(Fig. 7). (6) Disconnect fuel injectors wiring connector.
(7) Remove supply and return lines from the fuel
tube assembly quick connect at frame rail. Open fuel
tube clip around fuel tubes. WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY FUEL SPILLAGE.
(8) Disconnect fuel pressure regulator vacuum hose
from regulator (Fig. 8). (9) Remove PCV vacuum harness, brake booster,
and vacuum vapor harness from intake manifold
(Fig. 8). (10) Remove 8 intake manifold screws and washer
assemblies and remove intake manifold assembly
(Fig. 9).
Fig. 5 Releasing Fuel Pressure
Fig. 6 Air Cleaner Hose to Throttle Body Assembly
Fig. 7 Throttle Position Sensor and Air Idle Control Motor Electrical Connections
Fig. 8 Electrical and Vacuum Hose Connection
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

(7) Disconnect Intercooler to throttle body outlet
hose. Disconnect vacuum hoses from throttle body
and remove harness (Fig. 5).
(8) Disconnect automatic idle speed (AIS) motor
and throttle position sensor (TPS) wiring connectors
(Fig. 6). (9) Remove PCV Breather/Separator box and vac-
uum harness assembly. Remove brake booster, vac-
uum vapor harness and fuel pressure regulator
harness from intake manifold (Fig. 7). (10) Disconnect Fuel Injector Wiring Connector
(Fig. 8). Charge Temperature Wiring Connector (Fig.
7). (11) Remove fuel supply and return hose quick
connect at fuel tube assembly (Fig. 9). WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE
.
(12) Remove 8 intake manifold screws and washer
assemblies and remove intake manifold (Fig. 10).
INSTALLATION
Before installing manifold. Refer to Cleaning and
Inspection of this section to check manifold for dam-
age. (1) Install new intake manifold gasket and intake
manifold onto cylinder head and tighten fasteners to
23 N Im (200 in. lbs.) torque (Fig. 10).
(2) Install PCV Breather/Separator box and vac-
uum harness assembly. Connect brake booster, vac-
uum vapor harness and vacuum hose to fuel pressure
regulator (Fig. 7).
Fig. 1 Air Cleaner and Throttle Body AssemblyÐTurbo III Engine
Fig. 2 Radiator to Cylinder Head Hose
Fig. 3 Distributorless Ignition Coil (DIS) Location
Fig. 4 Accelerator and Speed Control Cables
11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

(e) Remove jumper wires.
(f) Continue fuel system service.
(4) Remove throttle cable and transaxle kickdown
linkage (Fig. 4). (5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 5). (6) Remove vacuum hose harness from throttle body
(Fig. 5). (7) Remove PCV and Brake booster hoses from Air
Intake Plenum. (8) Remove ignition coil from intake plenum (Fig. 6).
(9) Remove wiring connectors from coolant tempera-
ture sensor (Fig. 7). (10) Remove vacuum connections from air intake
plenum vacuum connector. (11) Remove fuel hoses from fuel rail (Fig. 7).
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE. (12) Remove (8) Fasteners from Air Intake Plenum
to Intake Manifold (Fig. 8). (13) Remove air intake plenum (Fig. 9).
(14) Cover intake manifold with suitable cover when
servicing. (15) Remove vacuum hoses from fuel rail and fuel
pressure regulator (Fig. 10). (16) Disconnect Fuel Injector wiring harness from
engine wiring harness (Fig. 11). (17) Remove fuel pressure regulator attaching bolts
and remove regulator from rail (Fig. 12). Be careful
not to damage the rubber injector O-rings upon
removal from the ports. (18) Remove fuel rail attaching bolts and lift fuel rail
assembly from intake manifold. (19) Separate radiator hose from thermostat hous-
ing and heater hose from heater pipe. (20) Remove (8) nut and washer assemblies and
remove intake manifold (Fig. 2).
INSPECTION
Check for:
² Damage and cracks of each section (Fig. 13).
² Clogged water passages in end cross overs.
² Check for distortion of the cylinder head mounting
surface using a straightedge and thickness gauge (Fig.
14). Refer to (Fig. 15) for Specifications.
INSTALLATION
(1) Position new intake manifold gaskets on cylinder
head and install intake (cross) manifold. (2) Install (8) nuts and washers and tighten in
several steps in order shown in (Fig. 16) to 20 N Im
(174 in. lbs.). (3) Make sure the injector holes are clean and all
plugs have been removed. (4) Lube injector O-ring with a drop of clean en-
gine oil to ease installation. (5) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports. (6) Install the (3) fuel rail attaching bolts and
torque to 13 N Im (115 in. lbs.).
(7) Install fuel pressure regulator onto fuel rail. In-
stall attaching bolts to intake manifold. Torque reg-
ulator nuts and bracket bolts to 10 N Im (95 in. lbs.)
(Fig. 12). (8) Install fuel supply and return tube hold-down
bolt and the vacuum crossover tube hold-down bolt
and torque to 10 N Im (95 in. lbs.).
(9) Connect fuel injector wiring harness to engine
wiring harness (Fig. 11). (10) Connect vacuum harness to fuel pressure reg-
ulator and fuel rail assembly (Fig. 10). (11) Remove covering from lower intake manifold
and clean surface. (12) Place intake manifold gaskets with beaded
sealant side up on lower manifold. Put air intake in
Fig. 3 Throttle Body Assembly 3.0L
Fig. 4 Throttle Cable Attachment
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 15

(12) Remove the fuel hose quick connect fittings
from the fuel rail using an open end wrench to push
in on the plastic ring located on the end of the fit-
tings. Gently pull the fittings from the fuel rail (Fig.
7).
WARNING: WRAP A SHOP TOWEL AROUND
HOSES TO CATCH ANY GASOLINE SPILLAGE.
(13) Remove direct ignition system (DIS) coils and
generator bracket to intake manifold bolt (Fig. 8). (14) Remove intake manifold bolts and rotate man-
ifold back over rear valve cover (Fig. 9). (15) Cover intake manifold with suitable cover
when servicing (Fig. 10). (16) Remove vacuum harness connector from Fuel
Pressure Regulator. (17) Remove fuel tube retainer bracket screw and
fuel rail attaching bolts (Fig. 10). Spread the retainer
bracket to allow fuel tube removal clearance. (18) Remove fuel rail injector wiring clip from the
generator bracket (Fig. 11). (19) Disconnect cam sensor, coolant temperature
sensor, and engine temperature sensors. (20) Remove fuel injector wiring clip from intake
manifold water tube. (21) Remove fuel rail. Be careful not to damage
the rubber injector O-rings upon removal from their
ports (Fig. 12). (22) Remove upper radiator hose, bypass hose and
rear intake manifold hose (Fig. 13). (23) Remove intake manifold bolts. Remove intake
manifold. (24) Remove intake manifold seal retainers screws
(Fig. 14). Remove intake manifold gasket.
INSPECTION
Check for:
² Damage and cracks of each section.
Fig. 7 Quick Connect Fuel Fittings to Fuel Rail
Fig. 8 Ignition Coils
Fig. 9 Intake Manifold Bolts
Fig. 10 Fuel Rail Attaching Bolts
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 21

FRAME INDEX
page page
Crossmember ........................... 17
Frame Dimensions ........................ 9 General Information
........................ 9
GENERAL INFORMATION
In this section, references are made to Vehicle
Family (Body) codes. To determine the vehicle family
identification code, refer to the Introduction Group at
the front of this manual.
FRAME DIMENSIONS
Frame dimensions are listed in metric scale then
converted to inch scale listed in parenthesis. Engine
compartment charts include front suspension upper
strut damper mounting tower location. All dimen-
sions are from center to center of Principal Locating
Point (PLP), or from center to center of PLP and fas-
tener location.
VEHICLE PREPARATION
Position the vehicle on a level work surface. Using
screw or bottle jacks, adjust the vehicle height to the
specified PLP dimension above the Datum Line
(work surface). Vertical dimensions can be taken
from the datum line to the PLP.
ENGINE COMPARTMENT DIMENSIONS Refer to Fig. 1, 2, 3, 4 or 5.
FRONT FRAME DIMENSIONS Refer to Fig. 6
REAR FRAME DIMENSIONS Refer to Fig. 7, 8, 9, 10 or 11.
Fig. 1 Engine Compartment DimensionsÐAA-Body
Fig. 2 Engine Compartment DimensionsÐAC-Body
Ä FRAME AND BUMPERS 13 - 9

with a minimum octane of 87 may be used. However,
the use of lower octane gasoline will result in re-
duced performance.
FLEXIBLE FUEL AA-BODY VEHICLES
These vehicles will operate on either unleaded gas-
oline with a minimum posted octane of 87 or M85
fuel. M85 fuel is a mixture of 85 percent methanol
and 15 percent unleaded gasoline. The vehicle also
will operate on mixture of M85 and unleaded gaso-
line with a minimum posted octane of 87. Do not
use 100 percent methanol in these vehicles.
THE FOLLOWING IS APPLICABLE TO ALL VEHICLES
Light spark knock at low engine speeds is not
harmful to your engine. However, continued heavy
spark knock at high speeds can cause damage and
should be reported to your dealer immediately. En-
gine damage resulting from operating with a heavy
spark knock may not be covered by the new vehicle
warranty. In addition to using unleaded gasoline with the
proper octane rating, gasolines that contain deter-
gents, corrosion and stability additives are recom-
mended. Using gasolines that have these additives
will help improve fuel economy, reduce emissions,
and maintain vehicle performance. Generally, pre-
mium unleaded gasolines contain more additive than
regular unleaded. Poor quality gasoline can cause problems such as
hard starting, stalling, and stumble. If you experi-
ence these problems, try another brand of gasoline
before considering service for the vehicle.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend gasoline with materials
that contain oxygen such as alcohol, MTBE (Methyl
Tertiary Butyl Ether) and ETBE (Ethyl Tertiary Bu-
tyl Ether). The type and amount of oxygenate used
in the blend is important. The following are generally used in gasoline
blends: Ethanol - (Ethyl or Grain Alcohol) properly blended, is used as a mixture of 10 percent ethanol
and 90 percent gasoline. Gasoline blended with eth-
anol may be used in your vehicle. Methanol - (Methyl or Wood Alcohol) is used in a
variety of concentrations when blended with un-
leaded gasoline. You may find fuels containing 3 per-
cent or more methanol along with other alcohols
called cosolvents. Do not use gasolines containing Methanol.
Use of methanol/gasoline blends may result in
starting and driveability problems and damage criti-
cal fuel system components. Problems that are the result of using methanol/gas-
oline blends are not the responsibility of Chrysler
Motors and may not be covered by the new vehicle
warranty. MTBE/ETBE - Gasoline and MTBE (Methyl Ter-
tiary Butyl Ether) blends are a mixture of unleaded
gasoline blended and up to 15 percent MTBE. Gaso-
line and ETBE (Ethyl Tertiary Butly Ether) are
blends of gasoline and up to 17 percent ETBE. Gas-
oline blended with MTBE or ETBE may be used in
your vehicle. Clean Air Gasoline
Many gasolines are now being blended that con-
tribute to cleaner air, especially in those areas of the
country where pollution levels are high. These new
blends provide a cleaner burning fuel and some are
referred to as reformulated gasoline. In areas of the country where carbon monoxide lev-
els are high, gasolines are being treated with oxy-
genated materials such as ETBE, MTBE and
ethanol. The use of gasoline blended with these ma-
terials also contributes to cleaner air. Chrysler Corporation supports these efforts toward
cleaner air and recommends that you use these gas-
olines as they become available. Materials Added to Fuel
Indiscriminate use of fuel system cleaning agents
should be avoided. Many of these materials intended
for gum and varnish removal may contain active sol-
vents of similar ingredients that can be harmful to
fuel system gasket and diaphragm materials.
14 - 2 FUEL SYSTEMS Ä

REMOVAL
(1) Perform the Fuel System Pressure Release pro-
cedure. (2) ) Remove the fuel filter retaining screw (Fig.
13). Remove fuel filter from mounting plate.
(3) Wrap a shop towel around hoses to absorb fuel.
Remove quick-connect fittings at filter and fuel supply
tube. Refer to Quick-Connect Fittings in this section.
INSTALLATION
WARNING: FUEL FILTERS DESIGNED FOR GASO-
LINE ONLY VEHICLES CANNOT BE USED ON
FLEXIBLE FUEL AA-BODY VEHICLES. WHEN SER-
VICING THE FUEL SYSTEM OF A FLEXIBLE FUEL
VEHICLE, ONLY USE ORIGINAL EQUIPMENT OR
EQUIVALENT REPLACEMENT COMPONENTS.
(1) Connect quick-connect fuel fittings to the filter
and fuel supply line. Refer to Quick-Connect Fittings
in this section. (2) Position filter assembly on mounting plate and
tighten mounting screw to 8 N Im (75 in. lbs.) torque.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for either 7 minutes, until the test is stopped, or un-
til the ignition switch is turned to the Off position.
(3) Place the ignition key in the ON position. Us-
ing the DRBII scan tool, access ASD Fuel System
Test. The ASD Fuel System Test will activate the
fuel pump and pressurize the system. Inspect for
leaks.
FUEL HOSES, CLAMPS, AND QUICK CONNECT
FITTINGS
HOSES AND CLAMPS
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS. WHEN SERVICING FLEXIBLE FUEL VEHICLES,
WEAR METHANOL RESISTANT GLOVES AND EYE
PROTECTION AND AVOID BREATHING FUMES. DO
NOT ALLOW METHANOL/GASOLINE MIXTURES TO
CONTACT SKIN. SERVICE VEHICLES IN WELL VEN-
TILATED AREAS AND AVOID IGNITION SOURCES.
NEVER SMOKE WHILE SERVICING THE VEHICLE.
WARNING: FUEL SYSTEM HOSES AND TUBES DE-
SIGNED FOR GASOLINE ONLY VEHICLES CANNOT
BE USED ON FLEXIBLE FUEL VEHICLES. WHEN
SERVICING THE FUEL SYSTEM OF A FLEXIBLE
FUEL VEHICLE, ONLY USE ORIGINAL EQUIPMENT
OR EQUIVALENT REPLACEMENT COMPONENTS.
Inspect all hose connections (clamps and quick con-
nect fittings) for completeness and make sure they
are not leaking. Hoses that are cracked, scuffed,
swelled, rub against other vehicle components or
show any sign of wear, should be replaced.
When installing hoses, route them away from compo-
nents they could rub against. Avoid contact with clamps
or other components that cause abrasions or scuffing.
Ensure rubber hoses are properly routed and avoid heat
sources. The clamps have rolled edge to prevent the clamp
from cutting into the hose. Only use clamps that are
original equipment or equivalent. Other types of clamps
may cut into the hoses and cause high pressure fuel
leaks. Tighten hose clamps to 1 N Im (10 in. lbs.) torque.
QUICK CONNECT FITTINGS
Most fuel lines have quick connect fittings. The fit-
tings speed up the installation and removal of fuel
lines (Fig. 14). Quick connect fittings consist of a metal casing, a
black plastic release ring, a metal locking retainer,
and internal O-rings.
METAL QUICK CONNECT FITTINGS
The fuel filter and fuel rail use steel quick-connect
fittings. The fitting contains non-serviceable sealed
O-rings. The fittings contain a plastic disconnect tool.
The quick-connect fitting consists of the O-rings, cas-
ing, disconnect tool and a retainer (Fig. 14). When the
Fig. 13 Fuel Filter
Fig. 14 Metal Quick-Connect Fittings
14 - 10 FUEL SYSTEMS Ä

fuel tube enters the fitting, the retainer locks the shoul-
der of the nipple in place and the O-rings seal the tube.
CAUTION: Quick-connect fittings are not serviced
separately. Do not attempt to repair damaged quick-
connect fittings or fuel tubes. Replace the complete
fuel tube/quick-connect fitting assembly.
When installing fuel tubes, route them in the holders
along the frame rail, fuel tank and the rear of the en-
gine.
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
WHEN SERVICING FLEXIBLE FUEL VEHICLES,
WEAR METHANOL RESISTANT GLOVES AND EYE
PROTECTION AND AVOID BREATHING FUMES. DO
NOT ALLOW METHANOL/GASOLINE MIXTURES TO
CONTACT SKIN. SERVICE VEHICLES IN WELL VEN-
TILATED AREAS AND AVOID IGNITION SOURCES.
NEVER SMOKE WHILE SERVICING THE VEHICLE.
(1) Disconnect negative cable from the battery.
(2) Perform the Fuel Pressure Release Procedure.
Refer to the Fuel Pressure Release Procedure in this
section. (3) Remove any loose dirt from quick connect fit-
tings.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY FUEL SPILLAGE.
(4) Push the quick connect fitting toward the fuel
tube while depressing the built-in release tool. Then
slightly twist the fitting and pull it off the fuel tube
(Fig. 14). (5) Cover the fitting to prevent contamination.
TUBE/FITTING SERVICE
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
WHEN SERVICING FLEXIBLE FUEL VEHICLES,
WEAR METHANOL RESISTANT GLOVES AND EYE
PROTECTION AND AVOID BREATHING FUMES. DO
NOT ALLOW METHANOL/GASOLINE MIXTURES TO
CONTACT SKIN. SERVICE VEHICLES IN WELL VEN-
TILATED AREAS AND AVOID IGNITION SOURCES.
NEVER SMOKE WHILE SERVICING THE VEHICLE.
If a quick connect fitting needs service, the follow-
ing procedure must be followed: (1) Disconnect the battery negative battery cable.
(2) Perform the Fuel System Pressure Release Pro-
cedure.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY FUEL SPILLAGE. (3) Remove the quick connect fitting from the fuel
tube by pushing in on the plastic ring located on the
end of the fitting. Gently pull the fitting from the
fuel tube. (4) Cut off the crimp ferrules at each end of the
hose, taking care not to damage the quick connect
fitting or the fuel tube. (5) Discard the ferrules and hose.
WARNING: FUEL SYSTEM HOSES AND TUBES DE-
SIGNED FOR GASOLINE ONLY VEHICLES CANNOT
BE USED ON FLEXIBLE FUEL VEHICLES. WHEN
SERVICING THE FUEL SYSTEM OF A FLEXIBLE
FUEL VEHICLE, ONLY USE ORIGINAL EQUIPMENT
OR EQUIVALENT REPLACEMENT COMPONENTS.
(6) Replace the hose using original equipment or
equivalent hose. (7) Attach the replacement hose to the quick con-
nect fitting and fuel tube using the correct hose
clamps (Fig. 15). Original equipment hose clamps
have a special rolled edge construction to prevent the
edge of the clamp cutting into the hose. Only original
equipment clamps or equivalent may be used in this
system. Other types of clamps may cut into the hoses
and cause high pressure fuel leaks. (8) Tighten hose clamps to 1 N Im (10 in. lbs.)
torque.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for either 7 minutes, until the test is stopped, or un-
til the ignition switch is turned to the Off position.
(9) Use the DRBII scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
CHASSIS FUEL TUBES
Figures 16 and 17 show fuel system component lo-
cations and chassis fuel tube routings.
Fig. 15 Quick Connect Fuel Fittings
Ä FUEL SYSTEMS 14 - 11