1993 CHEVROLET PLYMOUTH ACCLAIM brake

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

(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries. (4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to
negative terminal (-). DO NOT allow clamps at oppo-
site end of cables to touch, electrical arc will result
(Fig. 1). Review all warnings in this procedure. (5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 1).
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(6) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
² Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
² When using a Booster vehicle, disconnect BLACK
cable clamp from battery negative terminal. Discon-
nect RED cable clamp from battery positive terminal.
² Disconnect RED cable clamp from battery positive
terminal on disabled vehicle.
HOISTING RECOMMENDATIONS
Refer to Owner's Manual provided with vehicle for
proper emergency jacking procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN THE ENGINE OR REAR SUSPENSION IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING
CONDITIONS UNSTABLE. PROPERLY SUPPORT OR
SECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
TO HOIST OR JACK VEHICLE SEE FIG. 2 THROUGH 7:
Fig. 1 Jumper Cable Clamp Connections
Fig. 2 Hoisting and Jacking PointsÐAY Body
Fig. 3 Hoisting and Jacking PointsÐAC Body
Ä LUBRICATION AND MAINTENANCE 0 - 5

TOWING RECOMMENDATIONS
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use of a wheel lift or flat bed towing device (Fig. 8) is
recommended. When using a wheel lift towing de-
vice, be sure the unlifted end of disabled vehicle has
at least 100 mm (4 in.) ground clearance. If mini-
mum ground clearance cannot be reached, use a tow-
ing dolly. If a flat bed device is used, the approach
angle should not exceed 15 degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums or rotors.
A towed vehicle should be raised until lifted wheels
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo-
site end of the vehicle, especially when towing over
rough terrain or steep rises in the road. If necessary,
remove the wheels from the lifted end of the vehicle
and lower the vehicle closer to the ground, to in-
crease the ground clearance at the opposite end of
the vehicle. Install lug nuts on wheel attaching studs
to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
² 4-speed automatic transaxle vehicles can be flat
towed at speeds not to exceed 72 km/h (44 mph) for
not more than 160 km (100 miles). The steering col-
umn must be unlocked and gear selector in neutral.
² 3-speed automatic transaxle vehicles can be flat
towed at speeds not to exceed 40 km/h (25 mph) for
not more than 25 km (15 miles). The steering column
must be unlocked and gear selector in neutral.
² Manual transaxle vehicles can be flat towed at any
legal highway speed with no distance restrictions.
The steering column must be unlocked and gear se-
lector in neutral. WARNING: DO NOT ALLOW TOWING ATTACH-
MENT DEVICES TO CONTACT THE FUEL TANK OR
LINES, FUEL LEAK CAN RESULT. DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER, OR BUMPER ENERGY ABSORBER
UNITS. DO NOT VENTURE UNDER A LIFTED VEHICLE IF
NOT SUPPORTED PROPERLY ON SAFETY
STANDS. DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE. USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other un-
der vehicle components when attaching towing
device to vehicle. Remove or secure loose or protruding objects
from a damaged vehicle before towing. Refer to state and local rules and regulations be-
fore towing a vehicle. Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
TOWINGÐFRONT WHEEL LIFT
Chrysler Corporation recommends that a vehicle be
towed with the front end lifted, whenever possible.
TOWINGÐREAR WHEEL LIFT
If a front wheel drive vehicle cannot be towed with
the front wheels lifted, the rear wheels can be lifted
provided the following guide lines are observed.
CAUTION: Do not use steering column lock to se-
cure steering wheel during towing operation.
² Unlock steering column and secure steering wheel
in straight ahead position with a clamp device de-
signed for towing.
² Verify that front drive line and steering compo-
nents are in good condition.
² 4-speed automatic transaxle vehicles can be towed
at speeds not to exceed 72 km/h (44 mph) for not
more than 160 km (100 miles). The gear selector
must be in neutral position.
² 3-speed automatic transaxle vehicles can be towed
at speeds not to exceed 40 km/h (25 mph) for not
more than 25 km (15 miles). The gear selector must
be in neutral position.
² 3-speed automatic transaxle vehicles can be towed
at speeds not to exceed 40 km/h (25 mph) for not
more than 25 km (15 miles). The gear selector must
be in neutral position.
Fig. 8 Recommended Towing Devices
Ä LUBRICATION AND MAINTENANCE 0 - 7

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

DRIVETRAIN INDEX
page page
Automatic Transaxle ...................... 16
Automatic Transaxle Floor Shift .............. 16
Clutch and Gearshift Linkage ............... 16
Drive Shaft Cv and Tripod Joint Boots ........ 17 Front Wheel Bearings
..................... 17
Manual Transaxle ........................ 16
Tires .................................. 17
CLUTCH AND GEARSHIFT LINKAGE
If the clutch or gearshift begins to operate with dif-
ficulty, squeak or grunt, the cables and linkage
should be lubricated before service replacement is
performed. For proper lubrication and service proce-
dures refer to Group 6, Clutch, or Group 21, Manual
Transaxle.
MANUAL TRANSAXLE
The manual transaxle should be inspected for oil
leaks and proper oil level when other under vehicle
service is performed. To inspect the transaxle oil
level, position the vehicle on a level surface. Remove
fill plug (Fig. 1) from the transaxle side cover. The
oil level should not be below 4 mm (3/16 in) from the
bottom of the oil fill opening. The manual transaxle does not require periodic
maintenance. The oil should be changed only when
water contamination is suspected. If oil has a foamy
or milky appearance it probably is contaminated. A
circular magnet located behind the differential cover
collects metallic particles circulating in the oil. For
proper diagnostic and service procedures, refer to
Group 21, Manual Transaxle.
SELECTING MANUAL TRANSAXLE OIL
Chrysler Corporation recommends Mopar Engine
Oil, SG or SG/CD SAE 5W-30, or equivalent, be used
to fill a 5-speed transaxle.
AUTOMATIC TRANSAXLE FLOOR SHIFT
If the automatic transaxle floor shift mechanism
becomes difficult to operate or starts to make objec-
tionable noise, the mechanism should be lubricated
before service repair is performed. To lubricate the
shift mechanism, remove console as necessary. Refer
to Group 23, Body. Apply a film of Mopar Multipur-
pose Grease or equivalent, to slide surfaces and pawl
spring. For additional information, refer to Group 21,
Transaxle.
AUTOMATIC TRANSAXLE
The automatic transaxle should be inspected for
fluid leaks and proper fluid level when other under
hood service is performed.
CAUTION: To minimize fluid contamination, verify
that dipstick is seated in the fill hole or tube after
fluid level reading is taken.
TO INSPECT THE TRANSAXLE FLUID LEVEL: (1) Position the vehicle on a level surface.
(2) Start engine and allow to idle in PARK for at
least 60 seconds. The warmer the transaxle fluid, the
more accurate the reading. (3) While sitting in driver seat, apply brakes and
place gear selector in each position. Return gear se-
lector to park. (4) Raise hood and remove transaxle fluid level in-
dicator (dipstick) and wipe clean with a suitable
cloth. (5) Install dipstick and verify it is seated in fill
hole or tube (Fig. 2 or 3).
CAUTION: Do not overfill automatic transaxle, leak-
age or damage can result.
(6) Remove dipstick, with handle above tip, take
fluid level reading (Fig. 4). If the vehicle has been
driven for at least 15 minutes before inspecting fluid
level, transaxle can be considered hot and reading
should be above the WARM mark. If vehicle has run
for less than 15 minutes and more than 60 seconds
transaxle can be considered warm and reading
Fig. 1 Manual Transaxle Fill Plug
0 - 16 LUBRICATION AND MAINTENANCE Ä

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

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

BRAKE RESERVOIR LEVEL INSPECTION
WARNING: DO NOT ALLOW PETROLEUM OR WATER
BASE LIQUIDS TO CONTAMINATE BRAKE FLUID,
SEAL DAMAGE AND BRAKE FAILURE CAN RESULT.
RELIEVE PRESSURE IN ANTI-LOCK BRAKE SYS-
TEM BEFORE ADDING BRAKE FLUID TO RESER-
VOIR. IF NOT, BRAKE FLUID COULD DISCHARGED
FROM THE RESERVOIR POSSIBLY CAUSING PER-
SONAL INJURY.
The brake reservoir level should be inspected when
other under hood service is performed. It is normal
for the reservoir level to drop as disc brake pads
wear. When fluid must be added, use Mopar, Brake
Fluid or equivalent. Use only brake fluid conforming
to DOT 3, Federal, Department of Transportation
specification. To avoid brake fluid contamination, use
fluid from a properly sealed container. On vehicles with anti-lock brakes, depressurize the
system before inspecting fluid level. Turn OFF the
ignition and remove the key. Pump the brake pedal
at least 50 times to relieve the pressure in the sys-
tem.
On all vehicles, if fluid should become low after sev-
eral thousand kilometers (miles), fill the reservoir to
level marks on the side of the reservoir (Fig. 8 or 9).
HEADLAMPS
The headlamps should be inspected for intensity
and aim whenever a problem is suspected. When lug-
gage compartment is heavily loaded, the headlamp
aim should be adjusted to compensate for vehicle
height change. For proper service procedures, refer to
Group 8L, Lamps. DRIVER SUPPLEMENTAL AIRBAG SYSTEM
If the AIRBAG indicator lamp does not light at all,
stays lit or lights momentarily or continuously while
driving, a malfunction may have occurred. Prompt service is required. Refer to Group 8M, Restraint
Systems for proper diagnostic procedures.
BODY LUBRICATION
Body mechanisms and linkages should be inspected,
cleaned and lubricated as required to maintain ease of
operation and to prevent corrosion and wear. Before a component is lubricated, oil, grease and dirt
should be wiped off. If necessary, use solvent to clean
component to be lubricated. After lubrication is com-
plete, wipe off excess grease or oil. During winter season, external lock cylinders should
be lubricated with Mopar, Lock Lubricant or equiva-
lent to ensure proper operation when exposed to water
and ice. To assure proper hood latching component operation,
use engine oil to lubricate the lock, safety catch and
hood hinges when other under hood service is per-
formed. Mopar, Multi-purpose Grease or equivalent
should be applied sparingly to all pivot and slide
contact areas.
USE ENGINE OIL ON:
² Door hingesÐHinge pin and pivot points.
² Hood hingesÐPivot points.
² Luggage compartment lid hingesÐPivot points.
USE MOPAR LUBRIPLATE OR EQUIVALENT ON:
² Door check straps.
² Hood counterbalance springs.
² Luggage compartment lid latches.
² Luggage compartment lid prop rod pivots.
² Ash tray slides.
² Fuel Fill Door latch mechanism.
² Park brake mechanism.
² Front seat tracks.
Fig. 8 Anti-lock Brake Reservoir
Fig. 9 Master Cylinder Brake ReservoirÐExcept
Anti-lock
0 - 22 LUBRICATION AND MAINTENANCE Ä