1993 CHEVROLET PLYMOUTH ACCLAIM AA body

(3) Install a NEWouter tripod assembly to inter-
connecting shaft retaining snap ring, into intercon-
necting shaft snap ring groove (Fig. 18). Be sure that
the snap ring is fully seated into the snap ring
groove around the entire interconnecting shaft.
TRIPOD ASSEMBLY INSTALLATION G.K.N. WITH DOUBLE
RING RETENTION
(1) Fasten the (new) boot to the interconnecting
shaft. See Boots Install. (2) Install the inner tripod assembly retaining
snap ring into the retaining groove on the intercon-
necting shaft (Fig. 19). (3) Install the tripod assembly onto the intercon-
necting shaft until it is past the outer snap ring
groove on the shaft (Fig. 17). If required the tripod
assembly can be tapped onto the interconnecting
shaft using a brass drift, on the body of the tripod as-
sembly (Fig. 4). Do not hit the outer tripod assembly
bearings in an attempt to install tripod on intercon-
necting shaft. (4) Install outer tripod assembly to intermediate
shaft retaining snap ring into snap ring groove on
intermediate shaft (Fig. 20).
INNER C/V JOINT HOUSING INSTALLATION
G.K.N.
(1) Distribute 1/2 the amount of the grease provided
into the housing and the remaining amount into the
boot. (2) Position the spring in the housing spring pocket
with the spring cup attached to the exposed end of the
spring (Fig. 21). Place a small amount of grease on the
concave surface of the spring cup.
CAUTION: Care must be taken to ensure proper
spring positioning. The spring must remain centered
in the housing spring pocket when the tripod is
installed and seated in the spring cup (Fig. 13).
(3) Clamp the stub shaft of the housing in a vise.
Use protective caps on jaws of vise so stub shaft
does not get damaged by the vise. Position the
interconnecting shaft and the tripod assembly on top of
Fig. 17 Interconnecting Shaft Snap Ring Groove
Fig. 18 Outer Tripod Retaining Snap Ring Installation
Fig. 19 Inner Snap Ring Installation
Fig. 20 Outer Snap Ring Installation
2 - 36 SUSPENSION AND DRIVESHAFTS Ä

mount have been loosened for any reason, or if vehicle
has experienced front structural damage, driveshaft
lengths must be checked and corrected, if required. A
shorter than required driveshaft length can result in ob-
jectionable noise. A longer than required driveshaft
length may result in potential damage.
Use of the following procedure will ensure satisfac-
tory driveshaft engagement under all normal vehicle
operating conditions. (1) The vehicle must be completely assembled.
Front wheels must be properly aligned and in the
straight ahead position. The vehicle must be in a po-
sition so that the full weight of the body is distrib-
uted to all four tires. A platform hoist, or front end
alignment rack, is recommended.
(2) Using a tape measure or other suitable measuring
device. Measure the direct distance from the inner edge of the outboard boot to the inner edge of the inboard
boot on both driveshafts. This measurement must be
taken at the bottom (six o'clock position) of the drive-
shafts (Fig. 1).
Note that the required dimension varies with car-line,
engine, transaxle, and driveshaft manufacturer (Fig. 2).
(3) If the lengths of both shafts are within the
range specified, no further action is required. If either left or right driveshaft length is not
within the specified range. Refer to Group 09, Engine
Removal and Installation to properly position engine
according to specified driveshaft lengths.
(4) If proper driveshaft lengths cannot be achieved
within the travel limits available in the slotted engine
mounts. Check for any condition that could effect the
side to side position of the measurement locations (e.g.,
engine support brackets, siderail alignment, etc.).
(5) After ensuring proper driveshaft lengths the
transmission shift linkage must be adjusted to en-
sure proper operation. Refer to Transaxle, Group 21.
Fig. 2 Driveshaft Identification and Dimensions
Fig. 19 Left Driveshaft with Damper Weight
Fig. 1 Driveshaft Positioning
Ä SUSPENSION AND DRIVESHAFTS 2 - 49

REAR SUSPENSION INDEX
page page
Coil Springs and Jounce Bumper ............ 51
General Information ....................... 50
Pivot Bushing AC AG AJ AP Body ........... 55
Pivot Bushing AC and AY Body ............. 52 Rear Axle Assembly
...................... 57
Shock Absorbers ......................... 51
Track Bar-Brace-Bracket ................... 52
GENERAL INFORMATION
All front wheel drive passenger cars. Utilize a
Trailing Arm Twist Beam type rear axle in conjunc-
tion with coil (or air) springs (Fig. 1). The blade type
Trailing Arms, attached to body mounted pivots, pro- vide fore and aft location of the suspension while a
Track Bar provides lateral location. Located in line with the spindles. An open channel
section beam axle assures that the rear tires remain
parallel to each other, and essentially perpendicular
Fig. 1 Trailing Arm Rear Suspension
2 - 50 SUSPENSION AND DRIVESHAFTS Ä

TRACK BAR-BRACE-BRACKET (FIG. 4)
REMOVAL
(1) Raise vehicle, see Hoisting, Group 0.
(2) Raise rear axle to curb height, with jack stands
(Fig. 5). (3) Remove track bar-to-axle pivot bolt. And re-
move track bar-to-frame pivot bolt. Remove track
bar. (4) Remove diagonal brace-to-underbody stud nut.
Remove diagonal brace. (5) Remove two track bar bracket-to-frame rail
bolts. Remove bracket.
INSTALLATION
(1) Position support bracket on frame rail, install
and tighten (2) bolts to 54 N Im (40 ft. lbs.) torque.
(2) Fit diagonal brace into support bracket and
over underbody stud, tighten stud nut to 75 N Im (55
ft. lbs.) torque. (3) Fit track bar to diagonal brace, loose assemble
pivot bolt with nut and washer on rear side. Attach
the other end of track bar to bracket on axle and
tighten to 95 N Im (70 ft. lbs.) torque. Tighten nut on
track bar-to-frame bolt to 75 N Im (55 ft. lbs.) torque.
PIVOT BUSHING AC AND AY BODY
REMOVE FROM VEHICLE
(1) Raise vehicle (see Hoisting, Group 0). Remove
brake hose mounting bracket screw (Fig. 5). (2) Detach park brake cable at connector and from
hanger bracket (Fig. 5).
Fig. 4 Track Bar Brace Bracket
Fig. 5 Remove Brake Hose Mounting Bracket Screw and Park Brake Cable
2 - 52 SUSPENSION AND DRIVESHAFTS Ä

PIVOT BUSHING AC AG AJ AP BODY
REMOVE FROM VEHICLE
(1) Raise vehicle (see Hoisting, Group 0). Remove
brake hose mounting bracket screw (Fig. 1). (2) Detach park brake cable at connector and from
hanger bracket (Fig. 1).
WARNING: WHEN REMOVING THE REAR AXLE
PIVOT BUSHING ON VEHICLES EQUIPPED WITH EI-
THER REAR COIL SPRINGS OR AIR SUSPENSION.
THE REAR AXLE MUST BE SUPPORTED BY THE
AXLE AND TRAILING ARM TO ENSURE ADEQUATE
SUPPORT OF REAR AXLE. (3) Support the rear axle assembly at both the axle
channel and the trailing arm with jack stands (Fig.
2). Then remove lower shock absorber to rear axle
mounting bolt (Fig. 2).
(4) Remove hanger bracket to frame rail bolts (Fig.
3). (5) Lower axle assembly down enough to remove
pivot bolt and hanger bracket (Fig. 3). Right side
trailing arm shown.
PIVOT BUSHING REMOVAL FROM AXLE AS- SEMBLY
Remove bushing with Remover/Installer Spe-
cial Tool C-4702-7 Press. And 3 piece set, Special
Tool C-4212 and C-4366-1 (Receiver Support
Bridge, Bushing Remover/Installer and Bushing
Remover). (1) Install receiver (support) cup C-4366-1 into base
of press C-4212 and Bushing Remover Cup C-4702-7
onto screw. (2) Position assembly with receiver bridge support-
ing trailing arm while turning screw to begin bushing
removal. (3) After bushing has begun to move replace bushing
remover/installer (round disc) with bushing remover
(oval shaped disc). Use this assembly to finish pressing
bushing out of trailing arm (Fig. 4).
PIVOT BUSHING INSTALLATION
(1) Align the bushing with the bushing mounting
hole in the trailing arm bracket (Fig. 5). Tap bushing in
slightly to hold it in position on trailing arm. (2) Assemble Bushing Installer Special Tool
C-4702-2 onto press screw and Support Cup Special
Fig. 1 Remove Brake Hose Mounting Bracket Screw and Park Brake Cable
Fig. 2 Remove Pivot Bushing Hanger Bracket Bolts
Fig. 3 Remove Hanger Bracket
Fig. 4 Tools Installed To Remove Bushing
Ä SUSPENSION AND DRIVESHAFTS 2 - 55

A compression ball sleeve nut and sleeve for 3/16
inch tubing with ball sleeve connector and an inter-
nal pipe T-fitting. Can be used to attach the tubing
to the pressure gauge. (3) Cycle ignition from OFF to ON.
(4) Apply a load to the rear of the vehicle (two as-
sistants or approximately 300-325 lbs.) to run com-
pressor and raise the vehicle. (5) Remove the load applied in Step 4. Allow the
system to exhaust and lower the vehicle. (6) When no more air can be exhausted, the gauge
should indicate 69 to 152 kPa (10 to 22 psi). (7) Remove the pressure gauge and nylon tubing.
Attach the air line between the dryer and shock ab-
sorber. Repeat Steps 3, 4, and 5 to ensure system air
pressure is in the shocks.
LEAK CHECKS
(1) Repeat Residual Air Check Steps 1, 2, 3, and 4.
Allow the system to fill until gauge reads 483 to 621
kPa (70 to 90 psi). If compressor is permitted to run until it reaches
its maximum output pressure, the vent solenoid
valve will function as a relief valve. The resulting
leak down, when compressor shuts off, will indicate a
false air leak. (2) With load still applied, disconnect wire harness
connector from the control module, then remove ap-
plied load. Vehicle should rise. Cycle ignition switch
to OFF. (3) Observe if pressure leaks down or holds steady
(wait approximately 15 minutes). (A) If system will not inflate beyond 345 kPa (50
psi). A severe leak may be indicated. Check for a
pinched pressure line between compressor and
shocks. (B) The standard soap solution check procedure is
acceptable. (C) If pressure holds steady, perform the diagnosis
procedures.
SYSTEM OPERATION
RAISING VEHICLE HEIGHT
When weight is added to the rear suspension. The
body of the vehicle is lowered, moving the height
sensor down. This action will activate the internal time delay
circuit. After a time delay of 12 to 18 seconds. The
control module (CM) activates the ground circuit to
the compressor relay. With the relay energized, the compressor motor
runs and air is sent through the system. As the
shock absorbers inflate, the body moves upward to a
corrected position. When the body reaches the correct
height, the control module (CM) stops the compressor
operation.
LOWERING VEHICLE HEIGHT
When the weight is removed from the vehicle. The
body moves upward, which allows the height sensor
to move upward and activate the internal time delay
circuit. After a time delay of 12 to 18 seconds. The (CM)
activates the exhaust solenoid circuit. Air is ex-
hausted from the shock absorbers through the air
dryer and exhaust solenoid to the atmosphere. As the body lowers, the height sensor is lowered to-
ward its original position. When the body reaches the
original vehicle height, the (CM) opens the exhaust
solenoid valve circuit.
COMPRESSOR PERFORMANCE TEST
This test can be performed on the vehicle. It is
used to evaluate compressor current draw, pressure
output, and leak down. (1) Disconnect the compressor motor wiring har-
ness connector. (2) Disconnect air line between dryer and right
shock absorber. (3) Connect an air pressure gauge into the system
(Fig. 5). (4) Connect an ammeter in series between the red
wire terminal on compressor connector and a 12 volt
power source. Also, connect a ground wire from the
black wire terminal on the compressor connector to a
good ground on the frame (Fig. 6). (5) If the current draw to the compressor motor ex-
ceeds 21 amperes, replace the compressor assembly. (6) When the air pressure stabilizes at 827 kPa
(120 psi), disconnect the (+) wire lead from the con-
nector. Replace the compressor assembly if any of the
following conditions exists:
Fig. 5 Pressure Gauge Installed in System
Ä SUSPENSION AND DRIVESHAFTS 2 - 61

REAR LEVELING DIAGNOSTIC PROCEDURES
SELF-DIAGNOSTICS
A self-diagnostic procedure is available for the ser-
vice technician to use to detect system malfunctions.
BEFORE DIAGNOSTICS TEST
Check the 20 amp fuse (position W40) and the 30
amp circuit breaker (position W5) to be assured they
are functional components. Check all connectors that link the system into the
main body wiring harness. These include compressor,
height sensor, control module, (Fig. 7) and relay.
Also check the underbody to in trunk and leveling
harness to main body harness connectors. Also, check
all air lines, connectors, and other components for
correct installation.
TEST LAMP PIN OPERATION
The monitor lamp pin output will be activated (test
lamp on) if the detection of abnormal system opera-
tion is determined by the CM.
AFTER COMPLETION OF REPAIRS
To initiate diagnostics, disconnect the test ground
wire then reconnect for repair verification.
TERMINATION OF SELF-DIAGNOSTICS
The self-diagnostic operation is terminated when
any of the following takes place:
² Disconnecting the diagnostic input from the
ground circuit.
² Turn the ignition switch to the off position.
When the self-diagnostic operation is terminated.
The control module resumes normal operation unless
it ceases operation. Due to it detecting a system mal-
function.
TEST WEIGHT
Weight between 275-300 lbs. must be added to rear
of vehicle before diagnostic testing begins.
DIAGNOSTICS (TO START PROCESS)
(1) Remove protective connector cover from diag-
nostic connector. (2) Insert wire into diagnostic ground pin. Then at-
tach to compressor ground pin, or as an alternate, in-
sert wire into diagnostic ground pin. Then ground
other end of test wire to body structure or a control
module fastener.
IGNITION
The following self diagnostic operation is initiated
by connecting the diagnostic ground pin to ground af-
ter ignition switch is turned ON. A monitor lamp
must be connected between the Test Lamp Ground
Pin and the Test Lamp Feed Pin to display the con-
trol module diagnostics status. See (Fig. 8) for diag-
nostic test pin locations.
OPERATION
(1) The compressor relay output. From the control
module (CM), is activated until the vehicle is in the
high position. The maximum relay output operation
time is 150 610 seconds. If the expected position is
not obtained, the CM ceases self-diagnostics and any
further operation. (I.e. neither operates the compres-
sor relay or exhaust outputs). The monitor lamp out-
put is continuously activated until ignition is cycled
from OFF to ON or 60 61 minutes has elapsed after
ignition was turned off. See Diagnostics Chart 1. (2) The monitor lamp output should flash to indi-
cate the position of the height sensor. The sensor
should be in the high position. A continuously
lighted monitor lamp will indicate a system failure.
Such as the compressor relay output has operated for
150 610 seconds but the height sensor did not move
to the high position within the right shock absorber).
See Diagnostic Chart 1. (3) Next the exhaust solenoid output is activated
until the vehicle is in the low position. The maxi-
mum exhaust solenoid operation time is 120 610 sec-
onds. If the expected position is not obtained, the
module ceases self-diagnostics and any further oper-
ation. The monitor lamp output is lighted continu-
ously until ignition is cycled from OFF to ON or 60
6 1 minutes has elapsed after ignition is turned off.
See Diagnostic Chart 4. (4) The monitor lamp should flash to indicate the
height sensor is in the low position. A continuouslyFig. 7 Control Module Connector
Fig. 8 Diagnostic Test Pin Location
Ä SUSPENSION AND DRIVESHAFTS 2 - 65

CONTROL MODULE
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove right side trunk trim panel.
(3) Remove electrical connectors from control mod-
ule and relay (Fig. 9). (4) Remove control module mounting screws and
remove assembly.
INSTALLATION
(1) Install relay on the control module mounting
bracket (if required). (2) Place control module in mounting position.
(3) Install mounting screws and tighten to 2-3 N Im
(19-29 in. lbs.). (4) Install control module and relay wiring connec-
tors (Fig. 9). (5) Install right side trunk trim panel.
(6) Connect negative battery cable.
COMPRESSOR RELAY
REMOVAL
(1) Remove right side trunk trim panel.
(2) Remove electrical connector from relay.
(3) Remove relay from control module mounting
bracket by prying out on locating clip (Fig. 10).
INSTALLATION
(1) Push relay onto bracket (relay will Lock into
position). (2) Install electrical connector.
(3) Install trim panel.
RIGHT SHOCK ABSORBER (WITH HEIGHT
SENSOR)
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle, see Hoisting, Group 0.
(3) Remove tire assembly.
(4) Disconnect height sensor connector, located on
right rear frame rail. (5) Remove both air lines connected to shock ab-
sorber ports. (6) Remove shock, see Shock Absorbers, Removal.
INSTALLATION
(1) Install shock assembly, see Shock Absorbers,
Installation. (2) Route height sensor wire through clip on shock
bracket, then tie strap to fuel filler tube. (3) Snap height sensor connector into underbody
harness connector. (4) Insert air lines.
(5) Install wheel/tire assembly.
Fig. 9 Control Module and Relay Wiring
Fig. 10 Control Module Connector
2 - 72 SUSPENSION AND DRIVESHAFTS Ä