1993 CHEVROLET PLYMOUTH ACCLAIM Service Manual

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Page 1713 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is se-
l

Page 1714 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual EXHAUST MANIFOLDS
REMOVAL (1) Raise vehicle and disconnect exhaust pipe from
rear (cowl side) exhaust manifold at articulated joint. (2) Disconnect Oxygen Sensor lead wire at the rear
exhaust manifol

Page 1715 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (2) Attach exhaust pipe to exhaust manifold and
tighten shoulder bolt to 28 N Im (250 in. lbs.)
(3) Attach crossover pipe to exhaust manifold and
tighten bolt to 69 N Im (51 ft. lbs.)
(4) Connect

Page 1716 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (4) Remove throttle cable (Fig. 3). Remove wiring
harness from throttle cable bracket.
(5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle

Page 1717 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (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 fue

Page 1718 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual ² Clogged water passages in end cross overs and
clogged gas passages.
INTAKE MANIFOLD
INSTALLATION
(1) Clean all surfaces of cylinder block and cylin-
der heads. (2) Place a drop (about 1/4 in. d

Page 1719 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (7) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports (Fig. 12). (8) Install the (4) fuel rail attaching bolts and
tighten to 22

(7) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports (Fig. 12). (8) Install the (4) fuel rail attaching bolts and
tighten to 22 N Im (200 in. lbs.) torque (Fig. 10).
(9) Install fuel tube retaining bracket screw and
tighten to 4 N Im (35 in. lbs.) torque (Fig. 10).
(10) Reconnect cam sensor, coolant temperature
sensor and engine temperature sensors (Fig. 11). (11) Install fuel injector harness wiring clips on
the generator bracket and intake manifold water
tube (Fig. 11). (12) Connect fuel pressure regulator vacuum line.
(13) Remove covering on lower intake manifold
and clean surface. (14) Place intake manifold gasket on lower mani-
fold. Put upper manifold into place and install bolts
finger tight. (15) Install the generator bracket to intake mani-
fold bolt and the cylinder head to intake manifold
strut bolts. Do not torque.
(16) Tighten intake manifold bolts to 28 N Im (250
in. lbs.) torque in the sequence shown in (Fig. 9). (17) Tighten generator bracket to intake manifold
bolt to 54 N Im (40 ft. lbs.) torque (Fig. 8).
(18) Tighten the cylinder head to intake manifold
strut bolts to 54 N Im (40 ft. lbs.) torque (Fig. 5).
(19) Connect ground strap, MAP and heated oxy-
gen sensor electrical connectors (Fig. 6). (20) Connect charge temperature sensor electrical
connector (Fig. 5). (21) Connect vacuum harness to intake plenum
(Fig. 5). (22) Using a new gasket, connect the EGR tube
flange to the intake manifold and tighten to 22 N Im
(200 in. lbs.) torque. (23) Clip wiring harness into the hole in the throt-
tle cable bracket. (24) Connect the wiring connectors to the throttle
position sensor TPS and automatic idle speed AIS
motor (Fig. 4). (25) Connect vacuum harness to throttle body (Fig.
4). (26) Install the direct ignition system DIS coils.
Tighten fasteners to 12 N Im (105 in. lbs.) torque
(Fig. 8). (27) Lubricate the ends of the chassis fuel tubes
with 30 wt oil. Connect fuel supply and return hoses
to chassis fuel tube assembly. pull back on the quick
connect fitting to ensure complete insertion (Fig. 7).
(Refer to Fuel Hoses, Clamps and Quick Connect Fit-
tings in Group 14 Fuel Systems). (28) Install throttle cable (Fig. 3).
(29) Connect fuel injector wiring harness.
(30) Install air cleaner and hose assembly (Fig. 2).
(31) Connect negative battery cable. Fill Cooling
System. See Cooling System, Group 7. (32) With the DRBII Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is se-
lected.
EXHAUST MANIFOLDS
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
rear cowl side exhaust manifold at articulated joint. (2) Separate EGR tube from rear manifold and dis-
connect Heated Oxygen Sensor lead wire (Fig. 16). (3) Remove Generator/Power Steering Support
Strut (Fig. 16). (4) Remove bolts attaching cross-over pipe to man-
ifold (Fig. 16).
Fig. 15 Intake Manifold Gasket Sealing
Fig. 16 EGR Tube, Heated Oxygen Sensor and Generator/Power Steering Strut
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 23

Page 1720 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (5) Remove bolts attaching rear manifold to cylin-
der head and remove manifold. (6) Lower vehicle and remove screws attaching
front heat shield to front manifold (Fig. 17). (7) Remove bolts fastenin

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