1993 CHEVROLET PLYMOUTH ACCLAIM Service Manual

battery capacity coolant level navigation recommended oil language climate settings

Page 1745 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (1) Loosen fuel filler cap to release fuel tank pres-
sure. (2) Disconnect injector wiring harness connector at
edge of throttle body (Fig. 4). (3) Connect a jumper wire between terminal Num-
ber 1 o

(1) Loosen fuel filler cap to release fuel tank pres-
sure. (2) Disconnect injector wiring harness connector at
edge of throttle body (Fig. 4). (3) Connect a jumper wire between terminal Num-
ber 1 of the injector harness and engine ground. (4) Connect a jumper wire to the positive terminal
Number 2 of the injector harness and touch the bat-
tery positive post for no longer than 5 seconds .
This releases system pressure. (5) Remove jumper wires.
(6) Continue fuel system service.
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ3.0L
(1) Disconnect the fuel rail electrical harness from
the engine harness. Refer to Group 8W, Wiring Dia-
grams. (2) Connect one end of a jumper wire to the A142
circuit terminal of the fuel rail harness connector. (3) Connect the other end of the jumper wire to a
12 volt power source. (4) Connect one end of a jumper wire to a good
ground source. (5) Momentarily ground one of the injectors by
connecting the other end of the jumper wire to an in-
jector terminal in the harness connector. Repeat pro-
cedure for 2 to 3 injectors.
FUEL PUMP ASSEMBLY
The fuel pump assembly consists of the fuel pump
and the reservoir body. The reservoir body takes the place of an internal
fuel tank reservoir. The reservoir maintains fuel at
the pump inlet during all driving conditions, espe-
cially when the fuel level is low. The system uses a positive displacement, gerotor
gear, immersible pump with a permanent magnet
electric motor (Fig. 5). The pump draws fuel through
a strainer and pushes it through the electric motor to
the outlet. The pump contains three check valves.
One valve relieves internal fuel pump pressure and
regulates maximum pump output. Another valve, in-
side the pump assembly in the fuel return circuit,
prevents fuel tank leakage if the line is damaged
during an accident. The third valve, in the pump out-
let, maintains pump pressure during engine off con-
ditions. The fuel pump relay provides voltage to the
fuel pump. All pumps have a maximum stall pres-
sure output of approximately 930 kPa (135 psi). All front wheel drive car fuel systems, except
Turbo III and flexible fuel AA-body vehicles use the
same fuel pump. Turbo III and flexible fuel AA-Body
vehicles each use different fuel pumps although they
look similar to pumps used in other vehicles. Release fuel system pressure before servicing the
fuel tank, fuel pump, fuel lines, fuel filter, or parts of
the fuel rail. Follow the Fuel System Pressure Re-
lease procedure to relieve fuel system pressure.
Fig. 2 Fuel Pressure Test PortÐTypical
Fig. 3 Releasing Fuel PressureÐEngines With Test Ports On Fuel Rail
Fig. 4 Injector Harness ConnectorÐ2.2L/2.5L TBI
Ä FUEL SYSTEMS 14 - 5

Page 1746 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual FUEL SYSTEM PRESSURE
Fuel system pressure is regulated at the fuel rail
or throttle body by a fuel pressure regulator. Refer to
the Fuel System Pressure Chart for pressure specifi-
cations. The chart

FUEL SYSTEM PRESSURE
Fuel system pressure is regulated at the fuel rail
or throttle body by a fuel pressure regulator. Refer to
the Fuel System Pressure Chart for pressure specifi-
cations. The chart reflects system pressure when the
pump is energized with the engine not running and
without vacuum applied to the pressure regulator.
FUEL PUMP PRESSURE TESTÐALL EXCEPT
2.2L/2.5L TBI AND 3.0L MPI
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.
The specifications in the Fuel Pressure chart re-
flect system pressure with the vacuum hose removed
from the pressure regulator. (1) Remove the vacuum hose from the pressure
regulator before checking fuel pressure. (2) Release fuel system pressure. Refer to the Fuel
System Pressure Release procedure in this section. (3) Connect Fuel Pressure Gauge C-4799 to service
port on fuel rail (Fig. 6).
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.
(4) 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. If the gauge reads the specification listed in the
Fuel System Pressure chart, further testing is not re-
quired. If pressure is not correct, record the pressure
and remove gauge. Use the DRBII scan tool ASD
Fuel System Test to pressurize the system. Ensure
fuel does not leak from the fuel rail service valve. In-
stall protective cover on fuel rail service valve. If pressure is below specifications, proceed to Fuel
System Pressure Below Specifications . If pres-
sure is above specifications, proceed to Fuel System
Pressure Above Specifications .
Fuel System Pressure Below Specifications
If the fuel pressure reading in step (4) was below
specifications, test the system according to the fol-
lowing procedure.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING A FUEL SYSTEM HOSE
OR COMPONENT.
(a) Perform Fuel Pressure Release procedure.
(b) Install Fuel Pressure Gauge C-4799 and Fuel
Pressure Test Adapter 6539 in the fuel supply line
between the fuel tank and fuel filter at the rear of
vehicle (Fig. 7). (c) Using the DRBII scan tool, with the ignition
key in the ON position, repeat the ASD Fuel Sys-
tem Test.
Fig. 5 Fuel PumpÐTypical
FUEL SYSTEM PRESSURE
Fig. 6 Fuel Pressure TestingÐEngines With Service Ports
14 - 6 FUEL SYSTEMS Ä

Page 1747 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual ² If pressure is at least 5 psi higher than reading
recorded in step (4), replace fuel filter. ² If no change is observed, gently squeeze the re-
turn hose. If fuel pressure increases, replace pr

² If pressure is at least 5 psi higher than reading
recorded in step (4), replace fuel filter. ² If no change is observed, gently squeeze the re-
turn hose. If fuel pressure increases, replace pressure
regulator. If gauge reading does not change while
squeezing the return hose, the problem is either a
plugged inlet strainer or defective fuel pump. Fuel System Pressure Above Specifications
If the fuel pressure reading in step (4) was above
specifications, test the system according to the fol-
lowing procedure.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING A FUEL SYSTEM HOSE
OR COMPONENT.
(a) Perform Fuel Pressure Release procedure.
(b) Remove the fuel return line hose from the
fuel pump at fuel tank. (c) Connect Fuel Pressure Test Adapter 6541 to
the return line (Fig. 8). Place the other end of
adapter 6541 into an approved gasoline container
or a container approved for methanol/gasoline mix-
tures (minimum 2 gallon size). All return fuel will
flow into container. (d) Using the DRBII scan tool, with the ignition
key in the ON position, repeat the ASD Fuel Sys-
tem Test.
² If pressure is now correct, replace fuel pump as-
sembly. ² If pressure is still above specifications, remove
fuel return hose from chassis fuel tubes (at engine).
Attach Fuel Pressure Test Connect Adapter 6541 to
the fuel return hose and place other end of hose in
clean container (Fig. 9). Repeat test. If pressure is
now correct, check for restricted fuel return line. If
no change is observed, replace fuel pressure regula-
tor.
FUEL PUMP PRESSURE TESTÐ2.2L/2.5L TBI and
3.0L MPI ENGINES
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING A FUEL SYSTEM HOSE
OR COMPONENT.
The specifications in the Fuel Pressure chart re-
flect system pressure with the vacuum hose removed
from the pressure regulator. Remove the vacuum line
from the pressure regulator on 3.0L engines before
testing fuel system pressure. The pressure regulators
on 2.2L/2.5L TBI engines are not vacuum assisted. (1) Perform fuel system pressure release.
(2) Remove fuel supply hose quick connector from
the chassis lines (at the engine). (3) Connect Fuel Pressure Gauge C-4799 to Fuel
Pressure Test Adapter 6539 (Fig. 10). Install the
adapter between fuel supply hose and chassis fuel
line assembly.
Fig. 7 Fuel Pressure TestFig. 8 Fuel Pressure Return Test
Fig. 9 Fuel Return Connection
Ä FUEL SYSTEMS 14 - 7

Page 1748 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual 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 posi

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.
(4) 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. If the gauge reads the pressure shown in the Fuel
System Pressure chart, further testing is not re-
quired. If pressure is not correct, record the pressure
and remove gauge. If pressure is below specifications, proceed to Fuel
System Pressure Below Specifications . If pressure
is above specifications, proceed to Fuel System
Pressure Above Specifications .
Fuel System Pressure Below Specifications
If the fuel pressure reading in step (4) was below
specifications, test the system according to the fol-
lowing procedure.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING A FUEL SYSTEM HOSE
OR COMPONENT.
(a) Perform Fuel Pressure Release procedure.
(b) Install Fuel Pressure Gauge C-4799 and Fuel
Pressure Adapter 6433 in the fuel supply line (Fig.
7) between the fuel tank and fuel filter. (c) Using the DRBII scan tool, with the ignition
key in the ON position, repeat the ASD Fuel Sys-
tem Test.
² If pressure is at least 5 psi higher than reading
recorded in step (4), replace fuel filter. ² If no change is observed, gently the squeeze re-
turn hose. If fuel pressure increases, replace pressure
regulator. If the gauge reading does not change while
squeezing the return hose, the problem is either a
plugged inlet strainer or defective fuel pump. Fuel System Pressure Above Specifications If the fuel pressure reading in step (4) was above
specifications test the system according to the follow-
ing procedure.
WARNING: FUEL SYSTEM PRESSURE MUST BE
RELEASED BEFORE A FUEL SYSTEM HOSE OR
COMPONENT IS DISCONNECTED.
(a) Perform Fuel Pressure Release procedure.
(b) Install Fuel Pressure Gauge C-4799 and Fuel
Pressure Adapter 6433 in the fuel supply line be-
tween the fuel tank and fuel filter (Fig. 7). (c) Remove the fuel return line hose from the
fuel pump at fuel tank. Connect Fuel Pressure Test
Adapter 6541 to the return line (Fig. 8). Place the
other end of adapter 6541 into an approved gaso-
line container or a container approved for gasoline/
methanol mixtures (minimum 2 gallon size). All
return fuel will flow into container. (d) Using the DRBII scan tool, with the ignition
key in the ON position, repeat the ASD Fuel Sys-
tem Test.
² If pressure is now correct, replace fuel pump as-
sembly. ²
If pressure is still above specifications, remove fuel
return hose from chassis fuel tubes (at engine). Attach
Fuel Pressure Test Connect Adapter 6541 to the fuel re-
turn hose and place other end of hose in clean approved
gasoline container or a container approved for metha-
nol/gasoline mixtures (Fig. 9). Repeat test. If pressure is
now correct, check for restricted fuel return line. If no
change is observed, replace fuel pressure regulator.
MECHANICAL MALFUNCTIONS
Mechanical malfunctions are more difficult to diag-
nose with this system. The powertrain control mod-
ule (PCM) compensates for some mechanical
malfunctions. If engine performance problems are en-
countered, and no fault codes are displayed, the prob-
lem may be mechanical rather than electronic.
FUEL PUMP MODULE 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.
Remove the fuel tank to service the fuel pump. Re-
fer to Fuel Tank Section for fuel tank removal. (1) Using a hammer and a brass drift punch care-
fully tap lock ring counter clockwise to release pump
(Fig. 11).
Fig. 10 Fuel Pressure Gauge and Adapter
14 - 8 FUEL SYSTEMS Ä

Page 1749 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (2) Remove fuel pump and O-ring seal from tank.
Discard old seal.
FUEL PUMP MODULE INSTALLATION
WARNING: FUEL PUMP MODULES DESIGNED FOR
GASOLINE ONLY VEHICLES CANNOT BE USED ON
FLEXIBLE FUEL AA-BODY

(2) Remove fuel pump and O-ring seal from tank.
Discard old seal.
FUEL PUMP MODULE INSTALLATION
WARNING: FUEL PUMP MODULES DESIGNED FOR
GASOLINE 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) Wipe seal area of tank clean and place a new
O-ring seal in position on pump. (2) Position fuel pump in tank with locking ring.
(3) Using a hammer and brass drift, drive ring
around in clockwise direction to lock pump in place.
CAUTION: Over tightening the pump lock ring
may result in a leak.
(4) Install tank. Refer to the Fuel Tank Section in
this Group.
FUEL PUMP STRAINER 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.
REMOVAL
(1) Remove fuel pump module. Refer to Fuel Pump
Module in this section. (2) Bend locking tabs on fuel pump reservoir as-
sembly to clear locking tangs on the fuel pump
strainer (Fig. 12). (3) Pull strainer off.
(4) Remove strainer O-ring from the fuel pump
reservoir body. (5) Remove any contaminants by washing the in-
side of the fuel tank.
INSTALLATION
WARNING: FUEL STRAINERS (AND O-RINGS) DE-
SIGNED FOR GASOLINE ONLY VEHICLES CANNOT
BE USED ON FLEXIBLE FUEL AA-BODY VEHICLES.
WHEN SERVICING THE FUEL SYSTEM OF A FLEX-
IBLE FUEL VEHICLE, ONLY USE ORIGINAL EQUIP-
MENT OR EQUIVALENT REPLACEMENT
COMPONENTS.
(1) Lubricate the strainer O-ring with Mopar Sili-
cone Spray Lube. (2) Insert strainer O-ring into outlet of strainer so
that it sits evenly on the step inside the outlet. (3) Push strainer onto the inlet of the fuel pump
reservoir body. Make sure the locking tabs on the
reservoir body lock over the locking tangs on the
strainer. (4) Install fuel pump module. Refer to Fuel Pump
Module in this section.
FUEL FILTERÐALL VEHICLES
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.
Fig. 11 Fuel Pump Service
Fig. 12 Fuel Strainer Service
Ä FUEL SYSTEMS 14 - 9

Page 1750 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual 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 t

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

Page 1751 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual 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 re

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

Page 1752 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual Fig. 16 Fuel Tank, Filter, and Chassis Line RoutingÐExcept Flexible Fuel AA-Body
14 - 12 FUEL SYSTEMS Ä

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