1993 CHEVROLET PLYMOUTH ACCLAIM Service Manual

center console fuse chart check oil radio controls navigation system brake sensor

Page 1937 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (18) Lower vehicle.
(19) Install the serpentine drive belt. Refer to (Fig.
10) for correct serpentine belt routing. See Cooling,
Group 7 for detailed installation procedure.
CAUTION: Do not use auto

(18) Lower vehicle.
(19) Install the serpentine drive belt. Refer to (Fig.
10) for correct serpentine belt routing. See Cooling,
Group 7 for detailed installation procedure.
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use Mopar T, Power
Steering Fluid, or equivalent.
(20) Fill power steering pump reservoir to correct
fluid level. (21) Connect the negative battery cable on the
negative battery post. (22) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
TURBO III
REMOVE
(1) Disconnect the battery (-) negative cable from
the battery and isolate cable. (2) Raise vehicle See Hoisting, Group 0. Put oil
drain pan under vehicle to catch power steering
fluid. (3) Remove the right front underhood splash shield
for access to the serpentine belt tensioner. (4) Release the tension on the serpentine drive belt
tensioner and remove drive belt from power steering
pump pulley (Fig. 20). Drive belt does not have to be
fully removed from engine.
(5) Remove the power steering fluid return hose at
the steering gear metal tube. Let power steering
fluid drain from the hose and power steering pump
into drain pan. (6) Remove the high pressure fluid line banjo bolt
fitting from the power steering pump. Remove high
pressure power steering fluid line from the power
steering pump. (7) Remove the lower power steering pump to
bracket mounting nut and fluid hose routing clip. Re-
move the 2 bolts and the stud attaching the power
steering pump to its mounting bracket (Fig. 21).
(8) Lower vehicle.
(9) Remove the wiring harness electrical connector
from the H-valve on the air conditioning fluid lines. (10) Remove the power steering pump from the ve-
hicle out through the area between the cylinder head
and the dash panel (Fig. 22).
(11) Transfer the required components from the
failed power steering pump to the replacement power
steering pump. See the appropriate area of this ser-
vice manual section for the component replacement
procedures.
Fig. 20 Turbo III Accessory Drive Belt Routing
Fig. 21 Power Steering Pump Mounting
Fig. 22 Power Steering Pump Removal From Vehicle
Ä STEERING 19 - 19

Page 1938 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual INSTALL (1) Install the power steering pump back into the
vehicle in the reverse order of removal, between cyl-
inder head and dash panel (Fig. 20). (2) Install the wiring harness connector back on
t

INSTALL (1) Install the power steering pump back into the
vehicle in the reverse order of removal, between cyl-
inder head and dash panel (Fig. 20). (2) Install the wiring harness connector back on
the H-valve located on the air conditioning fluid
lines (Fig. 20). (3) Raise vehicle See Hoisting, Group 0.
(4) Install the power steering pump on its mount-
ing bracket, and the hose locator bracket. Install the
bolt/stud and 2 bolts attaching the power steering
pump to its mounting bracket, and the bolts attach-
ing the hose locator bracket (Fig. 19). Torque all fas-
teners to 31 N Im (280 in. lbs.).
(5) Install the power steering fluid pressure hose,
banjo bolt and seal washer onto power steering pump
(Fig. 4). Pressure hose is to be installed so it is
routed to the left of the hose locator bracket (Fig.
19). Torque the banjo bolt to 31 N Im (275 in. lbs.).
Inspect the O-rings on the banjo bolt to ensure
they are not damaged and located correctly. (6) Install the low pressure fluid return hose from
the power steering pump back on the steel tube on
the steering gear (Fig. 4). Install hose clamp, be sure
the hose clamp is installed past the retaining bead
the steel tube. Install the hose routing clip on the
power steering pump bolt/stud, install clip retaining
nut and tighten. (7) Install the serpentine accessory drive belt (Fig.
18). Be sure the belt is correctly installed and
aligned on all pulleys before starting engine. (8) Install the right front underhood splash shield.
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use Mopar T, Power
Steering Fluid, or equivalent.
(9) Fill power steering pump reservoir to correct
fluid level. (10) Connect the negative battery cable on the
negative battery post. (11) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
POWER STEERING PUMP PULLEY SERVICE
SAGINAW VANE SUBMERGED PUMP
REMOVE
(1) Remove the pulley with Puller C-4333 (C-4068)
(Fig. 1).
CAUTION: Do not hammer on power steering pump
pulley. This will damage the pulley and the power
steering pump. (2) Replace pulley if bent, cracked, or loose.
INSTALLATION
(1) Install the pulley with Installer C-4063 (Fig.2).
Do not use the tool adapters.
(2) Ensure that the tool and the pulley remain
aligned with the pump shaft. Prevent the pulley from
being cocked on the shaft. (3) Force pulley flush with the end of the shaft.
Fig. 1 Pulley Removal (Typical)
Fig. 2 Pulley Installation (Typical)
19 - 20 STEERING Ä

Page 1939 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual With Serpentine Belts; Run engine until warm (5
min.) and note any belt chirp. If chirp exists, move
pulley outward approximately 0.5 mm (0.020 in.). If
noise increases, press on 1.0mm (0.040 in.).

With Serpentine Belts; Run engine until warm (5
min.) and note any belt chirp. If chirp exists, move
pulley outward approximately 0.5 mm (0.020 in.). If
noise increases, press on 1.0mm (0.040 in.). Be careful
that pulley does not contact mounting bolts.
SAGINAW T/C STYLE PUMP
REMOVE
(1) Mount power steering pump assembly in a vise
using one of the pump mounting bosses (Fig. 3). Do not
clamp the body of the power steering pump in vise.
Do not press or hammer on the shaft of the
power steering pump in an attempt to remove
the pulley. This will damage the internal compo-
nents of the power steering pump. (2) Remove the power steering pump pulley from the
power steering pump shaft using Puller, Special Tool
C-4333 (Fig. 4).
INSTALL
Do not press or hammer on the shaft of the
power steering pump in an attempt to install the
pulley. This will damage the internal components
of the power steering pump. (1) Place the power steering pump pulley on the end
of the power steering pump shaft. Make sure the pulley
is installed squarely on the end of the shaft (Fig. 5).
CAUTION: When installing the pulley on the Saginaw
T/C style power steering pump. The spacer that is
provided with either the replacement power steering
pump or pulley MUST be used when the pulley is in- stalled on the pump. The spacer provides for the cor-
rect pulley location on the power steering pump to
provide correct accessory drive belt alignment. The
alignment is critical in controlling accessory drive belt
noise. It also prevents the pulley from contacting the
power steering pump when it is installed, causing
power steering pump or pulley damage.
(2) Install the spacer provided with the replacement
power steering pump or power steering pulley into the
hub of the power steering pump pulley (Fig. 5).
(3) Insert the Pulley Installer, Special Tool C-4063,
(without adapters) through hole in spacer. Then
thread it into the end of the power steering pump
shaft (Fig. 6). Tighten the installer into shaft.
Fig. 4 Removing Power Steering Pump Pulley
Fig. 5 Pulley And Spacer Installed On Pump
Fig. 3 Power Steering Pump Mounted In Vise
Ä STEERING 19 - 21

Page 1940 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (4) Hold the Pulley Installer with one wrench so it
will not rotate. Turn hex (Fig. 6) down threaded rod
of installer pushing the pulley onto the shaft of the
power steering pump (Fig. 6). Ensure tha

(4) Hold the Pulley Installer with one wrench so it
will not rotate. Turn hex (Fig. 6) down threaded rod
of installer pushing the pulley onto the shaft of the
power steering pump (Fig. 6). Ensure that the tool
and the pulley remain aligned with the pump shaft
so pulley does not become cocked on shaft.
(5) Continue to push pulley onto shaft of power
steering pump until Pulley Installer, Special Tool
C-4063 will no longer turn. This will ensure the
spacer provided is fully seated against the front of
the power steering pump shaft (Fig. 7). (6) Remove the Pulley Installer, Special Tool
C-4063 from the shaft of the power steering pump.
Remove the supplied spacer from the hub of the
power steering pump pulley and discard.
POWER STEERING PUMP FLUID RESERVOIRS
VANE SUBMERGED PUMP (HAM CAN)
REMOVE
Discard all O-ring seals during disassembly,
they are not re-usable. (1) Remove the filler cap and drain the fluid from
reservoir before removing parts. (2) Remove mounting studs and pressure fitting
(Fig. 1). Rock reservoir by hand or use a soft face
mallet to remove. (3) Remove O-ring seals from housing and reser-
voir (Fig.1). (4) Remove flow control valve and spring from
housing.
INSTALL
Clean all parts before installation. Lubricate
new O-ring seals with Mopar tPower Steering
Fluid or equivalent. (1) Install flow control valve and spring (Fig. 2).
(2) Install new O-ring seals in housing (Fig.1). In-
stall the pump housing assembly into the fluid reser-
voir. Tighten mounting studs to 48 N Im (35 ft. lbs.)
torque. (3) Install fitting in flow control valve bore. Tighten
the fitting to 75 N Im (55 ft. lbs.) torque.
SAGINAW T/C STYLE PUMP WITH INTEGRAL
RESERVOIR
REMOVAL
Discard all O-ring seals during disassembly,
they are not re-usable. (1) Remove pump and clean exterior of pump with
solvent. (2) Remove the filler cap and drain the fluid from
reservoir. (3) Clamp the front hub of the pump in a soft jaw
vice. (4) Pry up tab and slide the retaining clip off (Fig. 3).
(5) Remove fluid reservoir from pump body. Remove
and discard O-ring seal (Fig. 4).
INSTALLATION
(1) Lubricate new O-ring Seal with Mopar Power
Steering Fluid or equivalent. (2) Install seal in housing (Fig. 4).
(3) Install reservoir onto housing (Fig. 4).
Fig. 6 Installing Power Steering Pump Pulley
Fig. 7 Power Steering Pump Pulley Installed
19 - 22 STEERING Ä

Page 1941 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (4) Slide and tap in reservoir retainer clips until
tab locks to housing (Fig. 4). (5) Install pump. Refill reservoir with Mopar
Power Steering Fluid or equivalent.
FLOW CONTROL VALVE FITTING O-RING

Page 1942 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual POWER STEERING PUMPÐINITIAL OPERATION
CAUTION: The fluid level should be checked with
engine off to prevent injury from moving compo-
nents. Use only Mopar TPower Steering Fluid. Do
not use automa

Page 1943 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual POWER STEERING GEAR INDEX
page page
General Information ....................... 25
Outer Tie Rod ........................... 27 Steering Gear Service
..................... 25
GENERAL INFORMATION

POWER STEERING GEAR INDEX
page page
General Information ....................... 25
Outer Tie Rod ........................... 27 Steering Gear Service
..................... 25
GENERAL INFORMATION
The power steering gear (Fig. 1) should NOT be
serviced or adjusted. If a malfunction or oil leak
occurs. The complete steering gear should be
replaced. If a steering gear boot needs to be replaced due to
damage, refer to the power steering gear service sec-
tion in this manual for proper procedure. The power steering system consists of these four
major components. Power Steering Gear, Power Steer-
ing Pump, Pressure Hose, and Return Line. Turning of
the steering wheel is converted into linear travel
through the meshing of the helical pinion teeth with
the rack teeth. Power assist steering is provided by an
open center, rotary type control valve which directs oil
from the pump to either side of the integral rack piston. Road feel is controlled by the diameter of a torsion
bar which initially steers the vehicle. As required
steering effort increases, as in a turn. The torsion bar
twists, causing relative rotary motion between the
rotary valve body and the valve spool. This movement
directs oil behind the integral rack piston, which, in
turn, builds up hydraulic pressure and assists in the
turning effort. The drive tangs on the pinion of the power steering
pump mate loosely with a stub shaft. This is to permit
manual steering control to be maintained if the drive
belt on the power steering pump should break. How-
ever, under these conditions, steering effort will be
increased.
STEERING GEAR SERVICE
The power steering gear should NOT be ser-
viced or adjusted. If a malfunction or oil leak
occurs. The complete steering gear should be
replaced.
REMOVAL
(1) Raise vehicle See Hoisting, Group 0. Put oil drain
pan under vehicle to catch power steering fluid. (2) Remove front road wheels.
(3) Remove both tie rod ends from steering knuckles,
using Puller Special Tool C-3894-A (Fig. 1). (4) Disconnect engine damper strut from crossmem-
ber (if so equipped). (5) Remove the 3 front suspension crossmember at-
taching bolts and the nut (Fig. 2) from the locating
stud. Lower front suspension crossmember, using
Fig. 1 Power Steering Gear Assembly
Ä STEERING 19 - 25

Page 1944 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual transmission jack, so that the steering gear can be
disconnected from the steering column.(6) Remove fluid tubes (Fig. 3) from the power
steering pump to the steering gear. See hose removal
procedure

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