1993 CHEVROLET PLYMOUTH ACCLAIM Service Manual

wiper blades jump start terminals night vision engine oil glove box ABS

Page 329 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual REMOVE (1) Hold system relay with one hand, while pulling
strait down on the wiring harness connector. Until
connector is free from the relay (do not twist the
connector). (2) Remove screw (Fig. 6)

REMOVE (1) Hold system relay with one hand, while pulling
strait down on the wiring harness connector. Until
connector is free from the relay (do not twist the
connector). (2) Remove screw (Fig. 6) holding the system relay
and bracket to the CAB bracket. Then remove the
system relay and mounting bracket assembly from
the CAB bracket.
INSTALL (1) Mount the system relay and its mounting
bracket assembly to the CAB mounting bracket, with
the mounting screw (Fig. 6). (2) Holding the system relay with one hand, push-
ing the wiring harness connector strait onto the ter-
minals of the relay. Make sure connector is fully
seated onto terminals of the system relay and the
lock on the wiring harness connector is fully engaged
with the relay. (3) Road test vehicle to verify correct operation of
the vehicles's Antilock brake system.
REMOVE/INSTALL PUMP MOTOR RELAY
Find location of Antilock Pump Motor Relay (Fig. 7
& 8), depending on whether the vehicle being ser-
viced has or does not have a power distribution cen-
ter PDC. (1) Hold the Antilock pump motor relay with one
hand, while pulling wiring harness relay connector
strait off the relay terminals. (2) Remove the pump motor relay assembly from
the vehicle. (3) Installation is done in the reverse order off re-
moval. Be sure that the wiring harness connector is
fully seated onto the terminals of the Pump Motor
Relay.
WHEEL SPEED SENSORS
INSPECTION
Inspect tonewheel for missing or broken teeth, this
can cause erratic sensor signals. Tonewheel should show no evidence of contact with
the wheel speed sensor. If contact was made, deter-
mine cause and correct. Excessive runout of the tonewheel can cause er-
ratic wheel speed sensor. Replace assembly if runout
exceeds approximately 0.25 mm (0.010 inch).
FRONT WHEEL SPEED SENSOR (FIG. 9)
REMOVAL
(1) Raise vehicle and remove wheel and tire as-
sembly. (2) Remove screw from grommet retainer clip that
holds the grommet into fender shield (Fig. 9). (3) Remove the 2 screws that fasten the sensor
routing tube to the frame rail.
Fig. 6 System Relay And Bracket Removal
Fig. 7 Pump Motor Relay Location On AA Body W/O Power Distribution Center
Fig. 8 Pump Motor Relay Location On AJ Body WithPower Distribution Center
Ä ANTILOCK 4 BRAKE SYSTEM 5 - 43

Page 330 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (4) Carefully, pull sensor assembly grommet from
fender shield. (5) Unplug speed sensor connector from vehicle
wiring harness. (6) Remove the sensor assembly grommets from
the retainer brackets. (7)

(4) Carefully, pull sensor assembly grommet from
fender shield. (5) Unplug speed sensor connector from vehicle
wiring harness. (6) Remove the sensor assembly grommets from
the retainer brackets. (7) Remove sensor head screw.
(8) Carefully, remove sensor head from steering
knuckle. If the sensor has seized, due to corrosion,
DO NOT USE PLIERS ON SENSOR HEAD. Use
a hammer and a punch and tap edge of sensor ear,
rocking the sensor side to side until free.
INSTALLATION
(1) Connect the wheel speed sensor connector to
the wiring harness. (2) Push sensor assembly grommet into hole in
fender shield. Install clip and screw. (3) Install the 2 screws that fasten the speed sen-
sor routing tube to the frame rail. (4) Install sensor grommets in brackets on fender
shield and strut damper. (5) Coat the speed sensor with High Temperature
Multi-purpose E.P. Grease before installing into the
steering knuckle. Install screw tighten to 7 N Im (60
in. lbs.)
CAUTION: Proper installation of wheel speed sen-
sor cables is critical to continued system operation.
Be sure that cables are installed in retainers. Fail-
ure to install cables in retainers, as shown in this
section, may result in contact with moving parts
and/or over extension of cables, resulting in an
open circuit.
REAR WHEEL SPEED SENSOR (FIGS. 10 AND 11)
REMOVAL
(1) Raise vehicle and remove wheel and tire as-
sembly. (2) Remove sensor assembly grommet from under-
body and pull harness through hole in underbody. (3) Unplug connector from harness.
(4) Remove sensor assembly grommets from
bracket which is screwed into the body hose bracket,
just forward of trailing arm bushing (batwing brack-
et.) (5) Remove sensor and brake tube 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.
This nut also is used to capture the brake tube clip. (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 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.
Fig. 9 Front Wheel Speed Sensor Routing
5 - 44 ANTILOCK 4 BRAKE SYSTEM Ä

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CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual Fig. 11 Body Routing of Rear Speed Sensor Wiring
Fig. 10 Rear Wheel Speed Sensor Routing at Trailing Arm
Ä ANTILOCK 4 BRAKE SYSTEM 5 - 45

Page 332 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual SPECIFICATIONS
SPECIFICATIONS METRIC
BRAKE ACTUATION SYSTEM
TIGHTENING REFERENCE
5 - 46 ANTILOCK 4 BRAKE SYSTEM Ä

Page 333 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual MANUAL TRANSAXLE CLUTCH
CONTENTS
page page
CLEANING PRECAUTIONS ................. 6
CLUTCH CABLE MECHANISM .............. 1
CLUTCH CABLE REPLACEMENT ............ 2
CLUTCH CHATTER COMPLAINTS ....

MANUAL TRANSAXLE CLUTCH
CONTENTS
page page
CLEANING PRECAUTIONS ................. 6
CLUTCH CABLE MECHANISM .............. 1
CLUTCH CABLE REPLACEMENT ............ 2
CLUTCH CHATTER COMPLAINTS ........... 1
CLUTCH DISC REPLACEMENT ............. 5
CLUTCH PEDAL NOISE/POP ............... 2 CLUTCH PEDAL POSITION SWITCH
......... 4
EXCESSIVE CLUTCH SPIN TIME/CLASH INTO REVERSE COMPLAINTS ............ 1
GENERAL INFORMATION .................. 1
RELEASE BEARING AND FORK ............. 6
GENERAL INFORMATION
Throughout this group, references may be made to
a particular vehicle by letter or number designation.
A chart showing the breakdown of these designations
is included in the Introduction Section at the front of
this service manual. The clutch used in all models are a single, dry disc
type with no adjustment for wear being provided in
the clutch itself. The clutch pedal is connected to the release shaft
through a cable and lever. The upper end of the clutch pedal pivots in the
pedal bracket on two nylon bushings. These bushings
do not require periodic lubrication.
CLUTCH CHATTER COMPLAINTS
For all clutch chatter complaints, do the following:
(1) Check for loose, misaligned, or broken engine
and transmission mounts. If present, they should be
corrected at this time. Test vehicle for chatter. If
chatter is gone, there is no need to go any further. If
chatter persists: (2) Check to see if clutch cable routing is correct
and operates smoothly. (3) Check for loose connections in drive train. Cor-
rect any problems and determine if clutch chatter
complaints has been satisfied. If not, (4) Remove transaxle. See Group 21, Manual Tran-
saxle, for procedure. (5) Check to see if the release bearing is sticky or
binding. Replace bearing, if needed. (6) Check linkage for excessive wear on bushings.
Replace all worn parts. A small amount of bearing
grease between the release shaft bushings and the
shaft is beneficial, but not required. (7) Check flywheel and clutch pressure plate for
contamination (dirt, oil) or scored. Replace flywheel
and/or pressure plate, if required. (8) Check to see if the clutch disc hub splines are
damaged. Replace with new disc. (9) Check input shaft splines for damage. Replace
if necessary. (10) Check for uneven wear on clutch fingers.
EXCESSIVE CLUTCH SPIN TIME/CLASH INTO
REVERSE COMPLAINTS
For all excessive clutch spin time/clash into reverse
complaints, do the following: (1) Depress clutch pedal to floor and hold. After
three seconds, shift to reverse. If clash is present,
clutch has excessive spin time. (2) Remove transaxle. See Group 21, Manual Tran-
saxle, for procedure. (3) Check the input shaft spline, clutch disc splines
and release bearing for dry rust. If present, clean
rust off and apply a light coat of bearing grease to
the input shaft splines. Apply grease on the input
shaft splines only where the clutch disc slides. (4) Check to see if the clutch disc hub splines are
damaged, replace with new disc if required. (5) Check the input shaft for damaged splines. Re-
place as necessary. (6) Check for excessive clutch disc runout or
warpage. (7) Install clutch assembly and transaxle.
CLUTCH CABLE MECHANISM
The manual transaxle clutch release system has a
unique self-adjusting mechanism to compensate for
clutch disc wear. This adjuster mechanism is located
within the clutch pedal. The preload spring main-
tains tension on the cable. This tension keeps the
clutch release bearing continuously loaded against
the fingers of the clutch cover assembly. When the pedal is depressed, teeth on the adjuster
and the positioner engage and pull the release cable.
A spring located behind the adjuster ensures proper
tooth engagement. When the pedal is released, the adjuster contacts
the bumper. This separates the adjuster and posi-
tioner teeth, allowing the preload spring to function.
Ä MANUAL TRANSAXLE CLUTCH 6 - 1

Page 334 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual CLUTCH PEDAL NOISE/POP
The mechanism which automatically adjusts the
clutch cable to compensate for clutch wear may emit
a loud clicking or pop noise under certain circum-
stances. The cause of this

Page 335 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual Fig. 2 Self-Adjusting Clutch Release Mechanism
Ä MANUAL TRANSAXLE CLUTCH 6 - 3

Page 336 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual CLUTCH PEDAL POSITION SWITCH
The clutch pedal position switch functions as a
safety interlock device. It prevents possible engine
cranking with the clutch engaged. The clutch pedal position switch is

CLUTCH PEDAL POSITION SWITCH
The clutch pedal position switch functions as a
safety interlock device. It prevents possible engine
cranking with the clutch engaged. The clutch pedal position switch is wired in series
between the starter relay coil and the ignition
switch. The clutch pedal position switch is mounted to a
bracket located next to the clutch pedal. The switch
is held in place by four plastic wing tabs. The clutch pedal position switch has an adjustable
striker plate. The striker plate is located on the left
side of the clutch pedal (Fig. 3).
DIAGNOSIS
Disconnect clutch pedal position switch harness
from instrument panel wiring harness. Using a ohm
meter, check for continuity between the two termi-
nals in the connector on the switch harness. There
should be no continuity between the terminals when
the switch is in its neutral (fully extended) position.
When the switch is depressed more than 1.25 mm
(0.050) the ohm meter should show continuity. If all ohm meter readings are correct and the
switch does not operate correctly, adjustment is re-
quired. Refer to Switch Adjustment Procedure to ad-
just switch.
REMOVAL
(1) Disconnect electrical harness to switch connec-
tor. (2) Depress wing tabs on switch and push switch out
of mounting bracket. Then slide wires through slot in
bracket.
INSTALLATION
(1) Slide switch wires through slot in switch bracket.
(2) Line up switch tab with slot in switch bracket
and push switch into position. Do not pull on the switch
wires to seat switch into bracket, switch damage may
occur. (3) After installation, the switch must be adjusted
and checked for proper operation. Refer to Switch
Adjustment Procedure.
ADJUSTMENT PROCEDURE
When performing switch adjustment, the floor mat
should be removed before beginning adjustment proce-
dures. (1) Set the park brake.
(2) Disconnect clutch cable at the transaxle end of
the cable. (3) Depress clutch pedal, loosen adjusting nut and
slide the striker plate forward to fully compress the
clutch pedal position switch plunger. (4) Tighten adjusting nut to 12 N Im (105 in. lbs.).
(5) Reconnect clutch cable.
The clutch pedal position switch is now ad-
justed. A final check is required to insure that the
switch is ``made'' below the clutch release point. (1) With the park brake set and the vehicle IN
NEUTRAL turn the key to the start position. The
vehicle should not crank. If the vehicle cranks do
not continue with this test. Recheck the switch and
switch adjustment to determine the cause. If the ve-
hicle does not crank proceed to step 2. (2) With the park brake set and the vehicle IN
GEAR turn the key to the start position.
WARNING: BEFORE PERFORMING STEP THREE BE
SURE THAT THE AREA IN FRONT OF THE VEHICLE
IS CLEAR OF OBSTRUCTIONS AND PEOPLE. VE-
HICLE MAY MOVE WHEN PERFORMING THIS TEST.
(3) Slowly depress the clutch pedal and feel for any
vehicle motion when the starter is energized. If there is
no motion the switch is properly adjusted. If motion is
felt, repeat the adjustment procedure.
Fig. 3 Clutch Pedal Position Switch and Components
6 - 4 MANUAL TRANSAXLE CLUTCH Ä

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