1993 CHEVROLET PLYMOUTH ACCLAIM Index

SPLICE LOCATIONS
CONTENTS
page page
AA C, D, P ........................... 129
AC-AY ............................... 139
AG-BODY ............................ 153 AJ-BODY
............................. 161
AP-BODY ............................ 169
The splice locations shown in this section are di-
vided into sections by vehicle line. When locating a
specific splice, first turn to the appropriate index, then look up the
figure numberthat refers to the
splice. Page numbers at the top of each page do
not refer to figure numbers.
AA C, D, P SPLICE LOCATIONS
Splice Number Fig.
A0 2.5L EFI and Flex Fuel ........................7
A0 3.0L ....................................9
A0-1 2.5L EFI and Flex Fuel .......................7
A1 2.5L EFI and Flex Fuel ........................7
A3 .......................................4
A14 2.5L EFI and Flex Fuel .......................7
A14 3.0L ...................................9
A20 2.5L EFI and Flex Fuel .......................7
A20 3.0L ...................................9
A21-1 2.5L EFI and Flex Fuel ......................7
A21-1 3.0L .................................9
A21-2 2.5L EFI and Flex Fuel ......................8
A21-2 3.0L .................................10
A21-3 3.0L .................................10
A41 3.0L ...................................9
A142 2.5L EFI ...............................11
A142 3.0L .................................13
A142-1 2.5L EFI and Flex Fuel .....................7
A142-1 Flex Fuel .............................12
A142-1 3.0L .................................9
A142-2 3.0L ................................13
A142-3 3.0L ................................13
A142-4 3.0L ................................13
B47 2.5L EFI and Flex Fuel .......................7
B47 3.0L ...................................9
B120 2.5L EFI and Flex Fuel .......................7
B120 3.0L ..................................9
C7 .......................................4
D1 2.5L EFI and Flex Fuel ........................7
D1 3.0L ...................................9
D2 2.5L EFI and Flex Fuel ........................7
D2 3.0L ...................................9
E2-1 ......................................4
E2-2 ......................................4
E17 ......................................4
F20 ......................................4
F30 ......................................4
F35 ......................................5
F35-1 .....................................2
G5 .......................................4
G7-1 2.5L EFI and Flex Fuel .......................8Splice Number Fig.
G7-1 3.0L .................................10
G16 ......................................4
G26 ......................................4
K4 3.0L ...................................13
K4-1 2.5L EFI and Flex Fuel .......................7
K4-2 2.5L EFI ...............................11
K4-2 Flex Fuel ...............................12
K4-2 3.0L .................................13
K6 2.5L EFI and Flex Fuel ........................7
K6 3.0L ....................................9
K7 EFI Only .................................7
K7 Flex Fuel ................................12
K7 3.0L ...................................13
K7-1 Flex Fuel ...............................12
K22 3.0L ...................................9
K24 3.0L ...................................9
L1 .......................................1
L3 2.5L EFI and Flex Fuel ........................8
L3 3.0L ...................................10
L7 .......................................4
L7-1 2.5L EFI and Flex Fuel .......................8
L7-1 3.0L ..................................10
L7-2 2.5L EFI and Flex Fuel .......................8
L7-2 3.0L ..................................10
L7-3 ......................................1
L20 ......................................4
L39 2.5L EFI and Flex Fuel ........................8
L39 3.0L ..................................10
L43 2.5L EFI and Flex Fuel ........................8
L43 3.0L ..................................10
L50 ......................................2
L60 2.5L EFI and Flex Fuel ........................8
L60 3.0L ..................................10
L61 2.5L EFI and Flex Fuel ........................8
L61 3.0L ..................................10
M1.......................................3
M1-2 .....................................4
M1-3 .....................................5
M1-4 .....................................2
Ä SPLICE LOCATIONS 8W - 129

WIRING DIAGRAMS AA-BODY
INDEX
Wiring Diagram
Name Sheet Number
Airbag System ...............................47
Clockspring ...............................47
Diagnostic Module ..........................47
Interface Grommet ..........................47
Sensor-Left ...............................47
Sensor-Right ..............................47
Squibb ..................................47
Air Conditioning Compressor ...................32, 33
Air Conditioning System (2.5L Engine) ...............71
A/C Cycling Switch ..........................71
Blower Motor ..............................71
Blower Switch .............................71
Control Switch .............................71
Damped Pressure Switch ......................71
Defrost Switch .............................71
Illumination Lamp ...........................71
Resistor .................................71
Air Conditioning System (3.0L Engine) ...............72
A/C Switch ...............................72
Blower Motor ..............................72
Blower Switch .............................72
Control Switch .............................72
Damped Pressure Switch ......................72
Defrost Switch .............................72
High Pressure Switch ........................72
Illumination Lamp ...........................72
Resistor .................................72
Anti-Lock Brake System .................41, 42, 43, 44
ABS Pump Motor Relay .......................41
ABS System Relay ..........................43
ABS Warning Lamp Relay ......................43
Brake Switch ..............................44
Controller ....................... .41, 42, 43, 44
Hydraulic Modulator .........................41
Ignition Switch .............................44
Park Brake Switch ...........................44
Wheel Sensors .............................42
Ash Receiver Lamp ...........................52
Automatic Shut-down Relay .................14, 20, 28
Automatic Transmission Park/Neutral Position and Back-Up Lamp Switch ...............................9
Back-Up Lamp Switch ..........................9
Battery ............................1,5,7,39,40
Blower Motor-A/C ............................71
Blower Motor-Heater ...........................71
Brake Switch ...............................44
Brake Warning Lamp Switch ......................11
Bulkhead Disconnect (50-Way) ................112, 113
Center High Mounted Stop Lamp ..........94, 98, 102, 105
Charging System (2.5L) ........................5,6
Battery ...................................5
Generator .................................6Wiring Diagram
Name Sheet Number
Heated Rear Window Switch .....................5
Charging System (3.0L) ........................7,8
Battery ....................................7
Generator .................................8
Ignition Off-Draw Connector .....................7
Cigar Lighter ................................45
Cigar Lighter Lamp ............................52
Circuit Breaker (30 Amp) Fuseblock Cavity #10 .......67, 82
Circuit Breaker (30 Amp) Fuseblock Cavity #13 . . .2, 66, 67, 86
Clockspring ............................. .47, 59
Cluster Printed Circuit Board .................119, 120
Cluster Printed Circuit Board Connectors .............118
Courtesy Lamps .............................76
Daytime Running Light Module ....................57
Deck Lid Ajar Switch ..........................78
Dimmer Switch-Headlamp .....................1,50
Distributor ......................... .15, 21, 22, 27
EGR Solenoid ...............................24
Electrically Heated Rear Window ...................84
Heated Rear Window .........................84
Switch ..................................84
Timer ...................................84
Electronically Tuned Stereo Radio without Name Brand Speakers ................................87
Electronically Tuned Stereo Radio with Name Brand Speakers ................................89
Speaker Choke .............................89
Speaker Relay .............................89
Electronic Cluster ........................... .121
Engine Coolant Sensor ................... .15, 21, 27
Engine Oil and Temperature Warning System (2.5L) .......39
Engine Oil and Temperature Warning System (3.0L) .......40
Engine Oil Pressure Switch/Sending Unit ...........39, 40
Engine Temperature Sending Unit ................39, 40
Engine Starter System (2.5L Engine & 3.0L ATX) .......9,10
Automatic Transmission Park/Neutral Position Switch .....9
Backup Lamp Switch ..........................9
EMCC Solenoid .............................9
Engine Starter Relay ..........................9
Manual Transmission Back-Up Lamp Switch ...........9
Permanent Magnet Engine Starter Motor .............9
Engine Temperature Sending Unit ................39, 40
Exhaust Gas Recirculation Diagnostic Solenoid ........13, 24
Fan Control System with A/C and Heater System (2.5L) ....32
A/C Compressor ............................32
A/C Compressor Clutch Relay ...................32
A/C High Pressure Switch ......................32
Fan Control Relay ...........................32
Radiator Fan Motor ..........................32
Fan Control System with A/C and Heater System (3.0L) ....33
A/C Conditioning Compressor ...................33
A/C Compressor Clutch Relay ...................33
Ä WIRING DIAGRAMS AA-BODY 8W - 181

WIRING DIAGRAMS AC-AY BODY INDEX
Wiring Diagram
Name Sheet Number
ABS Data Link Connector ........................49
Airbag System ........................... .57, 58
Clockspring ...............................57
Diagnostic Module ..........................57
Interface Grommet ..........................58
Sensor-Left ...............................58
Sensor-Right ..............................58
Squib (Airbag Igniter) ........................57
Air Conditioning and Heater System (2.5L) .............53
A/C Switch ...............................53
Blower Motor ..............................53
Compressor ...............................53
Defrost Switch .............................53
Diode ...................................53
Illumination Lamps ..........................53
Low Pressure Switch .........................53
Resistor .................................53
Switch-Blower .............................53
Air Conditioning Variable Output Compressor ..........113
Air Exhaust Solenoid-Automatic Air Load Leveling ........40
Air Suspension System .................41, 42, 43, 44
Air Exhaust Solenoid .........................42
Air Suspension Relay .........................42
Air Suspension System Control Module .......41, 43, 176
Compressor Assembly ........................42
Compressor Motor ..........................42
Height Sensors ............................44
Shock Absorber ............................43
Solenoids ............................ .41, 44
Air Suspension System Control Module .........41, 43, 176
Antennas ............................. .118, 126
Anti-Lock Brake System ............45, 46, 47, 48, 49, 50
ABS System Relay ..........................47
Controller .................. .45, 46, 47, 48, 49, 50
Data Link Connector .........................49
Left Front Wheel Sensor .......................50
Left Rear Wheel Sensor .......................50
Modulator ............................ .45, 48
Pump Motor ..............................46
Pump and Motor Relay .......................46
Right Front Wheel Sensor ......................50
Right Rear Wheel Sensor ......................50
Yellow Lamp Relay ..........................49
Anti-Lock Brake System Controller .....45, 46, 47, 48, 49, 50
Anti-Lock Brake System Modulator Connectors .........172
Anti-Lock Brake System Controller Connector ..........175
Anti-Lock Brake System Modulator ...............45, 48
ATC In-line Connector ........................ .117
Automatic Air Load Leveling System ..............39, 40
Air Exhaust Solenoid .........................40
Compressor Assembly ........................40
Compressor Motor ..........................40Wiring Diagram
Name Sheet Number
Load Leveling Relay .........................40
Shock Absorber ............................40
Automatic Day/Night Mirror .................... .124
Automatic Temperature Control .............115, 116, 117
A/C Blower Motor ......................... .115
Ambient Sensor .......................... .117
ATC Control Switch ........................ .116
ATC In Line Connector ...................... .117
ATC Power Module ........................ .115
In Car Senso r............................ .115
In Car Sensor Motor ....................... .115
Sun Sensor ............................. .115
Water Sensor ............................ .117
Automatic Temperature Control (Radiator and
Compressor 3.3L & 3.8L) .................. .113, 114
A/C Ambient Temperature Switch ................114
A/C Compressor Clutch Relay ...................113
A/C Fan Cutout Switch ...................... .114
A/C High Pressure Cutout Switch ................114
A/C Low Pressure Switch .................... .114
A/C Variable Output Compressor .................113
Diode ................................. .113
Radiator Fan Motor ........................ .113
Radiator Fan Relay ........................ .114
Automatic Shutdown Relay .......................29
Automatic Temperature Control In-line Connector ........206
Automatic Temperature Control Module Connector .......200
Back-Up Lamp Relay ..........................33
Battery ...............................2,5,7,9
Body Computer 2 (Electronic Cluster) .........101, 102, 194
25-Pin Connector ...................... .101, 102
Body Computer 1 (Electronic Cluster) .........103, 104, 195
25-Pin Connector ...................... .103, 104
Data Link Connector ....................... .103
Halo Lamp .............................. .104
Relay ................................. .103
Body Computer (Mechanical Cluster w/Visual Message Ctr) ......................... .196, 197
Body Computer (Mechanical Cluster w/o Visual Message Ctr) ......................... .198, 199
Body Computer 1 (Mechanical Cluster w/o Visual Message Ctr) ..................... .108, 109, 110
25-Pin Connector ................... .108, 109, 110
Data Link Connector ....................... .110
Halo Lamp .............................. .108
Key-In Switch ............................ .109
Relay Bank ............................. .108
Body Computer 2 (Mechanical Cluster with Visual Message Ctr) ..................... .105, 106, 107
25-Pin Connector ................... .105, 106, 107
Data Link Connector ....................... .106
Halo Lamp .............................. .106
Key-In Switch ............................ .107
Ä WIRING DIAGRAMS AC-AY BODY 8W - 313

WIRING DIAGRAMS AG-AJ BODY
ALPHABETICAL INDEX
Wiring Diagram
Name Sheet Number
A/C Compressor Clutch .........................89
A/C and Heater System ..................... .91, 92
A/C Compressor Clutch Relay ...................91
A/C Low Pressure Switch ......................91
A/C High Pressure Switch ......................92
A/C Cycling Switch ..........................92
ABS Warning Lamp Diode .......................69
Airbag System ........................... .84, 85
Clock Spring ..............................84
Diagnostic Module ..........................84
Interface Grommet ..........................85
Left Airbag Sensor ..........................85
Right Airbag Sensor .........................85
Squib (Airbag Igniter) ........................84
Air Conditioning System ........................90
A/C Blower Motor ...........................90
A/C/Heater Blower Motor Resistor .................90
A/C Switch ...............................90
Blower Switch .............................90
Defrost Switch .............................90
Illumination Lamps Switch .....................90
Alarm, Security Module ....................... .127
Ambient Air Temperature Sensor ...............117, 119
Anti-Lock Brake System (Except Turbo 3) .............170
Anti-Lock Brake System Controller ..........68, 69, 70, 71
Anti-Lock Brake System .................68, 69, 70, 71
ABS Controller .................... .68, 69, 70, 71
ABS Hydraulic Modulator ......................68
ABS Pump Motor Relay .......................68
ABS System Relay ..........................69
ABS Warning Lamp Diode ......................69
ABS Warning Switch Lamp Switch ................70
Brake Switch ..............................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
Automatic Shutdown Relay ..................20, 27, 33
Battery ...........................1,9,11,53,56
Body Computer ......................... .165, 166
Body Computer #1 ............................40
Body Computer (Mechanical Cluster) ..............79, 80
Body Computer #2 ............................40
Body Computer (Electronic Cluster) ...............81, 82
Body Wiring to Left Instrument Panel ...............147
Body Wiring to Right Instrument Panel ...........150, 151
Bulkhead Disconnect (50-Way) ................153, 154
Center High Mounted Stop Lamp (AG) ...............140
Center High Mounted Stop Lamp (J-21) ..............141
Center High Mounted Stop Lamp (J-27) ..............142
Charging System (2.5L and Turbo) ................9,10Wiring Diagram
Name Sheet Number
Battery ...................................9
Data Link Connector ..........................9
Generator ................................10
Power Distribution Center ....................9,10
Powertrain Control Module ......................9
Charging System (3.0L) ..................... .11, 12
Battery ..................................11
Generator ................................12
Power Distribution Center .................. .11, 12
Cigar Lighter ................................51
Circuit Breakers (Fuse Cavity #2) ...........8,42,110, 111
Circuit Breakers (Fuse Cavity #3) ..............5,53,116
Clockspring .......................... .59, 65, 84
Clutch Pedal Position Jumper ..................13, 15
Clutch Pedal Position Switch .....................14
Combo Flasher ..............................56
Data Link Connector ..................9,19,25,34,72
Daytime Running Lights Module Connector ............173
Decklid Lock Sense Switch ..................... .102
Dimming Interior Lamps & Headlamp Switch .........51, 52
Ash Receiver Lamp ..........................51
Cluster Lamps .............................52
Cigar Lighter ..............................51
Console Switch Module .......................51
A/C Heater Control Switch Lamp .................52
Headlamp Switch ...........................51
Fog Lamp Switch ...........................51
Fuse Panel Switch ...........................51
Left Pod Lamps ............................51
Left Switch Pod ............................51
Transmission Range Lamp .....................51
Diode ....................................89
Diode Package ....................... .83, 102, 104
Distributor .............................. .21, 26
Dome and Courtesy Lamps (AG) ...............125, 126
Cargo Lamp ............................. .126
Dome Lamp ............................. .126
Front Reading Lamps ....................... .126
Front Reading Lamp Switch ................... .126
Glove Box Lamp & Switch .................... .125
Halo Light .............................. .125
Liftgate Ajar Switch ........................ .125
Vanity Mirror Lamps ....................... .126
Vanity Mirror Lamp Switch ................... .126
Dome, Reading and Courtesy Lamps (J-27 Only) .....121, 122
Courtesy Lamp ........................... .121
Decklid Ajar Switch ........................ .122
Glove Box Lamp .......................... .121
Halo Light .............................. .121
Left Door Courtesy Lamp .................... .122
Rear Mirror Courtesy Lamp ................... .122
Right Door Courtesy Lamp ................... .121
Ä WIRING DIAGRAMS AG-AJ BODY 8W - 533

WIRING DIAGRAMS AP BODY D-P
ALPHABETICAL INDEX
Wiring Diagram
Name Sheet Number
ABS Hydraulic Modulator Unit .....................27
ABS Pump Motor Relay .........................27
ABS System Controller ................... .26, 27, 28
ABS System Relay ............................28
ABS Yellow Light Relay .........................28
A/C and Heater System ..................... .47, 48
A/C Cycling Switch ..........................48
A/C High Pressure Switch ......................48
A/C Low Pressure Switch ......................48
Blower Motor ..............................47
Blower Switch .............................47
Defrost Switch .............................47
Illumination Lamp ...........................47
Resistor .................................48
A/C Compressor Clutch Relay .....................50
Airbag Diagnostic Module Connector ................78
Airbag System ...............................35
Clockspring ...............................35
Diagnostic Module ..........................35
Sensors .................................35
Squibb (Airbag Igniter) ........................35
Anti-Lock Braking System ..................26, 27, 28
Data Link Connector .........................27
Hydraulic Modulator Unit ......................27
Pump Motor Relay ..........................27
System Controller ..................... .26, 27, 28
System Relay ..............................28
Wheel Sensors .............................26
Yellow Light Relay ..........................28
Anti-Lock Brake System Controller Connector ...........90
Ash Receiver Lamp ...........................37
Automatic Shut Down Relay 2.2L E.F.I. .............2,14
Automatic Shut Down Relay 2.5L E.F.I. .............2,14
Automatic Shut Down Relay 3.0L .................2,22
Back-Up Lamp Relay ..........................23
Back-Up Lamp Switch .......................7,8,9
Battery .................................1,3,5
Brake Warning Lamp Switch ......................11
Body to Instrument Panel Wiring Left ................87
Cargo Lamp ................................40
Center High Mounted Stop Lamp ................70, 72
Charging System .........................3,4,5,6
Battery .................................3,5
Generator ...............................4,6
Ignition Off Draw Connector ...................3,5
Chime, Key-In, Seat Belt Warning, Headlamp On .........43
Cigar Lighter ................................37
Cigar Lighter Lamp ............................37
Circuit Breakers Headlamp Switch ...........................36
Cavity #8 ..........................2,11,57,58
Cavity #11 ..............................1,60Wiring Diagram
Name Sheet Number
Clockspring .......................... .29, 35, 42
Clutch Pedal Position Jumper ...................8,10
Clutch Pedal Position Switch .....................7,9
Courtesy Lamps .............................72
Data Link Connector ..................... .13, 22, 27
Daytime Running Lamp Jumper ....................30
Daytime Running Lamp Module ....................30
Daytime Running Lights Module Connector ............84
Defrost Switch ..............................47
Dimmer Switch\eadlamp .......................1,36
Dimmer Switch-Optical Horn ....................1,36
Diode 49
Distributor 2.2L, 2.5L ..........................15
Distributor 3.0L ..............................18
Distributor Ignition Coil ..................... .14, 22
Dome Lamp System ....................... .39, 40
Cargo Lamp ..............................40
Dome Lamp ..............................40
Glove Box Lamp ............................39
Glove Box Lamp Switch .......................39
Left Front Door Jamb Switch ....................39
Left Rear Door Jamb Switch ....................40
Liftgate Latch Switch .........................40
Right Front Door Jamb Switch ...................39
Right Rear Door Jamb Switch ...................40
Door and Rear Speakers (Radio) ...................66
Door Jamb Switches ....................... .39, 40
Door Lock System-2 Door .................... .61, 62
Door Lock System-4 Door .................... .63, 64
Engine Coolant Temperature Sending Unit .............12
Engine Coolant Temperature Sensor 2.2L ..............15
Engine Coolant Temperature Sensor 2.5L ..............15
Engine Coolant Temperature Sensor 3.0L ..............18
Engine Oil Pressure Sending Unit/Switch ..............12
Engine Oil Pressure Switch .......................12
Engine Oil Pressure and Temperature System ...........12
Engine to Instrument Panel Wiring ..................86
Engine Starter System ....................7,8,9,10
Engine Starter System (Automatic Transmission) .....2,8,10
Back-Up Lamp Switch .........................8
Clutch Pedal Position Jumper ..................8,10
Engine Starter Motor .......................8,10
Engine Starter Relay ........................8,10
Park/Neutral Position Switch .....................8
Transmission EMCC Solenoid ....................8
Engine Starter System (Manual Transmission) ........2,7,9
Back-Up Lamp Switch .......................7,9
Clutch Pedal Position Switch ...................7,9
Engine Starter Motor ........................7,9
Engine Starter Relay ........................7,9
Squib Igniter (Airbag) ........................35
Exhaust Gas Recirculation Solenoid 2.2L ..............13
Ä WIRING DIAGRAMS AP BODY D-P 8W - 717

ENGINE
CONTENTS
page page
2.2/2.5L ENGINES ....................... 8
3.0L ENGINE .......................... 66 3.3/3.8L ENGINE
....................... 98
STANDARD SERVICE PROCEDURES ......... 1
STANDARD SERVICE PROCEDURES INDEX
page page
Crankshaft Sprocket Bolt Access Plug .......... 2
Engine Performance ....................... 2
Form-In-Place Gaskets ..................... 1
Honing Cylinder Bores ..................... 2
Hydrostatic Locked Engine .................. 5 Lash Adjuster (Tappet) Noise Diagnosis
........ 4
Measuring Main Bearing Clearance and Connecting Rod Bearing Clearance ................... 3
Repair of Damaged or Worn Threads .......... 4
FORM-IN-PLACE GASKETS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure ob-
taining the desired results. Bead size, continuity, and
location are of great importance. Too thin a bead can
result in leakage while too much can result in spill-
over which can break off and obstruct fluid feed
lines. A continuous bead of the proper width is essen-
tial to obtain a leak-free joint. Two types of form-in-place gasket materials are
used in the engine area. Mopar Silicone Rubber Ad-
hesive Sealant and anaerobic gasket materials, each
have different properties and cannot be used inter-
changeably.
MOPAR SILICONE RUBBER ADHESIVE SEALANT
Mopar Silicone Rubber Adhesive Sealant or equiv-
alent, normally black in color, is available in three
ounce tubes. Moisture in the air causes the Mopar
Silicone Rubber Adhesive Sealant material to cure.
This material is normally used on flexible metal
flanges. It has a shelf life of one year and will not
properly cure if over age. Always inspect the package
for the expiration date before use.
MOPAR GASKET MAKER
MOPAR Gasket Maker is an anaerobic type gasket
material normally red in color. The material cures in
the absence of air when squeezed between two metal-
lic surfaces. It will not cure if left in the uncovered tube. It is normally red in color. The anaerobic ma-
terial is for use between two machined surfaces. Do
not used on flexible metal flanges.
GASKET DISASSEMBLY
Parts assembled with form-in-place gaskets may be
disassembled without unusual effort. In some in-
stances, it may be necessary to lightly tap the part
with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
may also be lightly tapped into the joint but care
must be taken not to damage the mating surfaces.
SURFACE PREPARATION
Scrape clean or wire brush all gasket surfaces re-
moving all loose material. Inspect stamped parts to
assure gasket rails are flat. Flatten rails with a ham-
mer on a flat plate if required. Gasket surfaces must
be free of oil and dirt. Make sure old gasket material
is removed from blind attaching holes.
FORM-IN-PLACE GASKET APPLICATION
Assembling parts using a form-in-place gasket re-
quires care but it's easier then using precut gaskets. MOPAR Gasket Maker material should be applied
sparingly 1mm(0.040 inch.) diameter or less of seal-
ant to one gasket surface. Be certain the material
surrounds each mounting hole. Excess material can
easily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing the material off location.
Ä ENGINE 9 - 1

2.2/2.5L ENGINES INDEX
page page
Balance Shafts .......................... 45
Camshaft and Crankshaft Timing Procedure .... 34
Camshaft, Crankshaft and Intermediate Shafts Timing Procedure ....................... 20
Camshafts Service ....................... 36
Checking Engine Oil Pressure ............... 60
Crankshaft Oil Seals Service ................ 42
Crankshaft Service ....................... 43
Crankshaft, Intermediate and Balance Shaft Service ............................... 41
Cylinder Block, Piston and Connecting Rod Assembly Service ....................... 49
Cylinder Head ........................... 26
Cylinder Head and Valve Assembly ServiceÐExcept Turbo III ................. 22
Cylinder Head and Valve Assembly ServiceÐTurbo III ...................... 31
Cylinder Head ComponentsÐIn-Vehicle Service . 23
Engine Assembly ......................... 13 Engine Core Plugs
....................... 55
Engine Lubrication System ................. 56
Engine Mounts .......................... 12
Engine Specifications ...................... 62
General Information ........................ 8
Intermediate Shaft Service .................. 47
Lash Adjuster (Tappet) Noise ............... 37
Oil Filter ............................... 61
Oil Pan ................................ 58
Oil Pump Service ........................ 58
Solid Mount Compressor Bracket Service ...... 14
Timing System and Seals ServiceÐ Except Turbo III ........................ 18
Valve Components ReplaceÐCylinder Head Not Removed .......................... 37
Valve ServiceÐCylinder Head Removed ....... 27
Valve Springs and Valve Stem Seals ......... 38
GENERAL INFORMATION
ENGINE IDENTIFICATION NUMBER OR CODE
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 1). METHANOL FUEL COMPATIBILITY IDEN-
TIFICATION Beginning this model year, Chrysler began produc-
ing AA-Body vehicles designed to operate on a mix-
ture of gasoline and methanol. These automobiles are
referred to as Flexible Fuel vehicles.
2.2/2.5L ENGINE SPECIFICATION
9 - 8 2.2/2.5L ENGINE Ä

(2) Turn camshaft until arrows on hub are inline
with No. 1 camshaft cap to cylinder headline. Small
hole (arrow Fig. 12) must be in vertical center line. (3) Install timing belt.
(4) Rotate crankshaft two full revolutions and re-
check timing.
CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.
(5) Rotate crankshaft till number 1 cylinder is at
the TDC position. (6) Put belt tension Special Tool C-4703 horizon-
tally on large hex of timing belt tensioner pulley and
loosen tensioner lock nut. (7) Reset belt tension Special Tool C-4703 index if
necessary to have axis within 15É of horizontal. (Fig.
13) (8) Turn engine clockwise from TDC two crank revo-
lutions to TDC. Do not reverse rotate crankshaft
or attempt to rotate engine using cam or acces-
sory shaft attaching screw. (9) Hold weighted wrench in position while tighten-
ing bolt on tensioner to 61 N Im (45 ft. lbs.) torque.
(10) Lower engine onto engine mount install mount-
ing bolts and tighten to specifications refer to (Fig. 3). (11) Remove jack from under engine.
(12) Inspect foam stuffer block condition and posi-
tion (Fig. 14). Stuffer block should be intact and secure
within the engine bracket tunnel. (13) Position both halves of timing belt cover to-
gether (Fig. 4). (14) Install fasteners holding cover to cylinder head
and block. Tighten fasteners to 4 N Im (40 in. lbs.)
torque. (15) Valve Timing Check; (timing belt cover in-
stalled). With number one cylinder at TDC, small hole
in sprocket must be centered in timing belt cover hole
(Fig. 12). If hole is not aligned correctly perform
procedure again. (16) Install spark plugs.
Fig. 12 Camshaft Timing
Fig. 13 Adjusting Drive Belt Tension
Fig. 14 Foam Stuffer Block Location
Ä 2.2/2.5L ENGINE 9 - 21