1993 CHEVROLET PLYMOUTH ACCLAIM Service Manual

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Page 249 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (7) Install high pressure hose to hydraulic assem-
bly (Fig. 7). Tighten the hose, to hydraulic assembly
fitting to 16 N Im (145 in. lbs)
(8) Fill hydraulic assembly brake fluid reservoir to
top of

Page 250 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual lic assembly with a blunt prying tool (Fig. 12). Use a
rocking motion to help disengage reservoir from
grommets while prying. BE EXTREMELY CARE-
FUL TO AVOID DAMAGING OR PUNCTURING
RESERVOIR DURING

lic assembly with a blunt prying tool (Fig. 12). Use a
rocking motion to help disengage reservoir from
grommets while prying. BE EXTREMELY CARE-
FUL TO AVOID DAMAGING OR PUNCTURING
RESERVOIR DURING THIS PROCEDURE.
(6) Remove the brake fluid level sensor switch
from the reservoir. Remove switch by compressing
the retaining barbs (Fig. 13) on the end of the switch
and then slide switch out of the brake fluid reservoir
(Fig. 14) (7) Using fingers, remove the 3 reservoir grommets
(Fig. 14) from the hydraulic assembly or reservoir, and
discard. Grommets must not to be reused when
reservoir is installed on hydraulic assembly.
INSTALL (1) Thoroughly lubricate the new reservoir grom-
mets with clean brake fluid and install on reservoir
outlet ports (Fig. 14). The new reservoir grommets
supplied with reservoir, must ALWAYS be used. (2) Install brake fluid level switch into brake fluid
reservoir (FIG. 14). (3) Press reservoir into hydraulic assembly BY
HAND , using a rocking motion to help seat reservoir
into hydraulic assembly. Be sure that grommets are
fully seated in the hydraulic assembly. DO NOT AT-
TEMPT TO POUND RESERVOIR INTO HY-
DRAULIC ASSEMBLY, USING A HAMMER. (4) Using needle nose pliers, install the 3 brake fluid
reservoir to hydraulic assembly retaining pins (Fig.
11). Make sure that pins are fully installed with barbs
extending past reservoir on opposite side. (5) Reinstall the high pressure hose, banjo fitting
onto the hydraulic assembly and torque the fitting to
13 N Im (10.0 ft.lbs).
(6) Install the brake fluid spray shield and bladder
accumulator onto the hydraulic assembly. Install the
bladder accumulator by hand to be sure it does not bet
cross threaded. Be sure that the O-Ring on the
bladder accumulator is fully seated into the hy-
draulic assembly. (7) Using Oil Filter Band Wrench, Special Tool C-
4065 or equivalent, (Fig. 10) torque the bladder accu-
mulator to 48 N Im (35 ft. lbs.)
Fig. 12 Remove Reservoir From Hydraulic Assembly
Fig. 13 Fluid Switch Retaining Barbs
Fig. 14 Remove Brake Fluid Level Switch
5 - 100 ANTI-LOCK 10 BRAKE SYSTEM Ä

Page 251 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (8) Fill the hydraulic assembly reservoir to the top
of the screen on the filter/strainer (Fig. 15). Using
fresh clean brake fluid such as Mopar tor equivalent,
conforming to DOT 3 requirements.
PU

(8) Fill the hydraulic assembly reservoir to the top
of the screen on the filter/strainer (Fig. 15). Using
fresh clean brake fluid such as Mopar tor equivalent,
conforming to DOT 3 requirements.
PUMP SUPPLY FILTER
REMOVE
(1) Fully de-pressurize the hydraulic accumulator
by pumping brake pedal a minimum of 40 times. Use
procedure described in De-Pressurizing Hydraulic Ac-
cumulator listed earlier in this section.
WARNING: FAILURE TO DE-PRESSURIZE HYDRAU-
LIC ACCUMULATOR, BEFORE PERFORMING THIS
OPERATION, MAY RESULT IN PERSONAL INJURY
AND/OR DAMAGE TO PAINTED SURFACES.
(2) Remove and then reinstall one filler cap from
brake fluid reservoir on hydraulic assembly. (3) Remove brake fluid supply hose from hydraulic
assembly master cylinder at the pump supply filter
(Fig. 16). After hose is removed from pump supply
filter, plug end of hose to stop brake fluid from drain-
ing out of fluid reservoir. (4) Remove brake fluid supply hose (Fig. 16), from
pump supply filter going to the pump motor assem-
bly. (5) Remove pump supply filter (Fig. 16) from at-
taching bracket on front of hydraulic assembly.
INSTALL (1) Attach pump supply filter to attaching bracket
on front of hydraulic assembly (Fig. 16). (2) Install replacement hose clamp, on brake fluid
supply hose to pump motor assembly. (3) Install the brake fluid supply hose to pump mo-
tor assembly, onto the nipple of the pump supply fil-
ter. Position hose clamp on brake fluid supply hose
so that it is past upset bead on nipple, then torque
hose clamp to 1.5 N Im (13.5 in. lbs.).
(4) Remove plug from brake fluid supply hose com-
ing from hydraulic assembly. Install the brake fluid
supply hose from hydraulic assembly, onto the nipple
of the pump supply filter. Position hose clamp on
brake fluid supply hose so that it is past upset bead
on nipple, then torque hose clamp to 1.5 N Im (13.5
in. lbs.). (5) Turn ignition switch to the run position to en-
ergize the pump/motor assembly and pressurize hy-
draulic system. Check for leakage at the hydraulic
assembly to hydraulic bladder accumulator fitting. (6) Again de-pressurize accumulator by pumping
brake pedal a minimum of 40 times as described. Use
procedure in De-Pressurizing Hydraulic Accumulator
in this section of the manual. (7) Then check the brake fluid level in the hydrau-
lic assembly reservoir. If brake fluid level is low, fill
reservoir to proper level (Fig. 15) with Mopar tbrake
fluid or equivalent conforming to DOT 3 require-
ments.
HYDRAULIC BLADDER ACCUMULATOR
REMOVE
(1) Fully de-pressurize the hydraulic accumulator
by pumping brake pedal a minimum of 40 times. Use
procedure described in De-Pressurizing Hydraulic Ac-
cumulator listed earlier in this section.
Fig. 15 ABS Reservoir Fill Level On Filter/Strainer
Fig. 16 Pump Supply Filter
Ä ANTI-LOCK 10 BRAKE SYSTEM 5 - 101

Page 252 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual WARNING: FAILURE TO DE-PRESSURIZE HYDRAU-
LIC ASSEMBLY/ACCUMULATOR PRIOR PERFORM-
ING THIS OPERATION. MAY RESULT IN PERSONAL
INJURY AND/OR DAMAGE TO PAINTED SURFACES
OF THE VEHICLE.
(2) Using Oil Fi

WARNING: FAILURE TO DE-PRESSURIZE HYDRAU-
LIC ASSEMBLY/ACCUMULATOR PRIOR PERFORM-
ING THIS OPERATION. MAY RESULT IN PERSONAL
INJURY AND/OR DAMAGE TO PAINTED SURFACES
OF THE VEHICLE.
(2) Using Oil Filter Band Wrench, Special Tool
C-4065 or equivalent loosen bladder accumulator.
Then remove the bladder accumulator and brake
fluid shield from the hydraulic assembly (Fig. 17).
INSTALL
(1) Install the brake fluid spray shield onto the hy-
draulic accumulator (Fig. 1). (2) Install the bladder accumulator onto the hy-
draulic assembly by hand. Be sure that the O-Ring
on the bladder accumulator is fully seated into the
hydraulic assembly. (3) Using Oil Filter Band Wrench, Special Tool
C-4065 or equivalent, (Fig. 17) torque the bladder ac-
cumulator to 48 N Im (35 ft. lbs.)
(4) Turn ignition switch to the run position to en-
ergize the pump/motor assembly and pressurize hy-
draulic system. Check for leakage at the hydraulic
assembly to hydraulic bladder accumulator fitting. (5) Again de-pressurize accumulator by pumping
brake pedal a minimum of 40 times. Use procedure
described in De-Pressurizing Hydraulic Accumulator
in this section of the service manual. (6) Then check the brake fluid level in the hydrau-
lic assembly reservoir. If brake fluid level is low, fill
reservoir to proper level (Fig. 15) with Mopar tbrake
fluid or equivalent conforming to DOT 3 require-
ments.PROPORTIONING VALVES (FIG. 18)
CAUTION: Proportioning valves should never be dis-
assembled or repaired in any way, repair is by re-
placement only.
REMOVE (1) Fully de-pressurize the hydraulic accumulator by
pumping brake pedal a minimum of 40 times. Use
procedure described in De-Pressurizing Hydraulic Ac-
cumulator listed earlier in this section.
WARNING: FAILURE TO FULLY DE-PRESSURIZE THE
HYDRAULIC ASSEMBLY/ACCUMULATOR PRIOR TO
REMOVING THE PROPORTIONING VALVE. MAY RE-
SULT IN PERSONAL INJURY AND/OR DAMAGE TO
PAINTED SURFACES OF THE VEHICLE.
(2) Remove fresh air intake ducts and air cleaner.
(3) Remove pressure and return hose (Fig. 5) from
hydraulic unit. (See Pressure and Return Hose Section
For Proper Removal Procedure). (4) Remove brake tube from the proportioning valve
that requires servicing. (5) Remove proportioning valve requiring service
from the hydraulic assembly (Fig. 19).
INSTALL (1) Install proportioning valve on hydraulic assem-
bly and tighten to 40 N Im (30 ft. lbs.) torque.
(2) Install brake tube on proportioning valve.
Tighten tube nut to 16 N Im (145 in. lbs.) torque.
(3) Install hydraulic pressure and return hoses.
Torque pressure hose to hydraulic assembly fitting to
16 N Im (145 in. lbs). Torque return hose to metal tube
hose clamp to 1 N Im (10 in. lbs.).
(4) Install fresh air intake duct and air cleaner.
(5) Bleed the affected brake line, see Bleeding Brake
System in this section.
Fig. 17 Remove And Install Bladder Accumulator
Fig. 18 ABS Proportioning Valve
5 - 102 ANTI-LOCK 10 BRAKE SYSTEM Ä

Page 253 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual ELECTRONIC COMPONENTS
CONTROLLER ANTI-LOCK BRAKE (CAB)
REMOVAL (1) Turn vehicle ignition off.
(2) Raise vehicle on hoist, (CAB) access for re-
moval is from the underside of the vehicle (Fig. 1) (3)

Page 254 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual SYSTEM RELAY, ANTI-LOCK WARNING LAMP RELAY AND PUMP/MOTOR RELAYS (FIG. 2)
REMOVE
See (Fig. 2) Power Distribution Center. Find the lo-
cation of the pump/motor relay in the (PDC). Remove
pump/motor r

SYSTEM RELAY, ANTI-LOCK WARNING LAMP RELAY AND PUMP/MOTOR RELAYS (FIG. 2)
REMOVE
See (Fig. 2) Power Distribution Center. Find the lo-
cation of the pump/motor relay in the (PDC). Remove
pump/motor relay by pulling upward and install by
pushing firmly into position. Do not twist the relay
when removing or installing it. See (Fig. 10) in the Relay And Warning Lamp Sec-
tion of this group, for the location of the Anti-Lock
system relay and the Yellow Lamp relay. Remove
the relay from the vehicle using the following proce-
dure. (1) Disconnect the wiring harness connectors from
the relays. Connectors are removed from the relays
by disengaging the connector locking tab from relay
and pulling strait off relay, do not twist. (2) Then remove the relay pack to inner fender at-
taching bolt.
INSTALL The Anti-Lock system and Yellow Lamp relay are
installed using the following procedure. (1) Mount the relay pack to the inner fender with
the anti-rotation tab on the bracket around lip of in-
ner fender hole (Fig. 10). (2) Install the relay pack to inner fender mounting
bolt and torque to 4 N Im (35 in. lbs.). (3) Connect the wiring harness connectors onto the
relays until the locking tabs on the connectors and
relays are fully engaged. Do not twist connectors when
installing them on the relays.
WHEEL SPEED SENSORS
INSPECTION
Inspect tone wheels (Fig. 3) for any missing or broken
teeth, this can cause erratic speed sensor signals.
Tone wheels should show no evidence of contact with
the wheel speed sensor. If contact was made, determine
cause and correct. Excessive runout of the tone wheels can cause erratic
wheel speed sensor signals. Replace assembly if runout
exceeds approximately 0.25 mm (0.010 inch).
FRONT WHEEL SPEED SENSOR
REMOVAL
(1) Raise vehicle and remove front wheel and tire
assembly. (2) Remove screw from clip (Fig. 4) that holds sensor
assembly grommet into fender shield. (3) Carefully, pull sensor assembly grommet from
fender shield. When removing grommet from
fender shield, do not pull on speed sensor cable. (4) Unplug speed sensor cable connector, from ve-
hicle wiring harness. (5) Remove the 2 screws (Fig. 4) that secure the
speed sensor cable, routing tube to the fender well. (6) Remove the 2 sensor assembly grommets from
the retainer bracket, on the strut damper (Fig. 4). (7) Remove speed sensor assembly to steering
knuckle attaching bolt (Fig. 4). (8) Carefully, remove sensor head from steering
knuckle. If the sensor has seized, due to corrosion, use
a hammer and punch to tap edge of sensor ear
Fig. 2 Pump/Motor and Anti-Lock System Relays
Fig. 3 Tone Wheel (Typical)
5 - 104 ANTI-LOCK 10 BRAKE SYSTEM Ä

Page 255 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (Fig. 5), rocking the sensor side to side until free. DO
NOT USE PLIERS ON SENSOR HEAD.
INSTALLATION (1) Connect the wheel speed sensor cable connec-
tor, to the vehicle wiring harness. (2) Push

(Fig. 5), rocking the sensor side to side until free. DO
NOT USE PLIERS ON SENSOR HEAD.
INSTALLATION (1) Connect the wheel speed sensor cable connec-
tor, to the vehicle wiring harness. (2) Push sensor assembly grommet into hole in
fender shield. Install clip and screw (Fig. 4). Torque
screw to 4 N Im (35 in. lbs.).
(3) Install speed sensor cable grommets in bracket
on strut damper (Fig. 4). (4) Install speed sensor cable routing tube to fender
well (Fig. 4). Torque both screws to 4 N Im (35 in. lbs.).
(5) Coat the speed sensor with High Temperature
Multi-purpose E.P. Grease before installing into the
steering knuckle. Install speed sensor attaching screw
and tighten to 7 N Im (60 in. lbs.)
CAUTION: Proper installation of wheel speed sensor
cables is critical to continued system operation. Be
sure that cables are routed correctly and installed in
all retainers. Failure to properly route and install
cables in retainers, as shown in this section. May
result in contact with moving parts and/or over ex-
tension of cables, resulting in an open circuit.
REAR WHEEL SPEED SENSOR (FIGS. 6 AND 8)
REMOVAL
(1) Raise vehicle and remove wheel and tire assem-
bly. (2) Remove sensor assembly grommet from under-
body and pull harness through hole in underbody. (3) Unplug connector from harness.
(4) Remove sensor grommet bracket screw from
body hose bracket, just forward of trailing arm bush-
ing. (5) Remove sensor assembly clip, located on the
inboard side of trailing arm. (6) Remove sensor wire fastener from rear brake
hose bracket. (7) Remove outboard sensor assembly retainer nut.
(8) Remove sensor head screw.
(9) Carefully, remove sensor head from adapter as-
sembly. If the sensor has seized, due to corrosion, DO
NOT USE PLIERS ON SENSOR HEAD. Use a ham-
mer and a punch (Fig. 7) and tap edge of sensor ear,
rocking the sensor side to side until free.
INSTALLATION
Installation is reverse order of removal. Be sure to
coat sensor with High Temperature Multi-purpose E.P.
Grease before installing into adapter assembly.
Tighten screw to 7 N Im (60 in. lbs.) torque. Avoid
getting grease on the pickup area of the speed sensor
assembly.
Fig. 4 Front Wheel Speed Sensor Routing
Fig. 5 Removing Speed Sensor (Typical)
Ä ANTI-LOCK 10 BRAKE SYSTEM 5 - 105

Page 256 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual DUAL FUNCTION PRESSURE SWITCH
REMOVE
WARNING: FAILURE TO DE-PRESSURIZE THE HY-
DRAULIC ACCUMULATOR PRIOR TO REMOVING
DUAL FUNCTION PRESSURE SWITCH. WILL RESULT
IN PERSONAL INJURY AND/OR DAMAGE TO
PA

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