1993 CHEVROLET PLYMOUTH ACCLAIM air suspension

AUTOMATIC AIR SUSPENSION DIAGNOSTICS
Ä SUSPENSION AND DRIVESHAFTS 2 - 83

AUTOMATIC AIR SUSPENSION DIAGNOSTICS
2 - 84 SUSPENSION AND DRIVESHAFTS Ä

SERVICE PROCEDURES
CONTROL MODULE (ASCM)
REMOVAL (1) Disconnect negative battery cable.
(2) Remove right side trunk trim panel.
(3) Remove electrical connectors from control mod-
ule and relay (Fig. 11). (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.) torque. (4) Install control module and relay wiring connec-
tors (Fig. 11). (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. 11)
INSTALLATION (1) Push relay onto bracket (relay will Lock into
position.) (2) Install electrical connector. (3) Install trim panel.
COMPRESSOR ASSEMBLY
REMOVAL
(1) Disconnect battery negative cable.
(2) Raise vehicle, see Hoisting, Group 0.
(3) Remove cover from compressor assembly. Re-
move air hose (see AIR LINES) and electrical connec-
tors (Fig. 12) (4) Remove compressor assembly mounting screws
and lower assembly from vehicle. (5) Remove mounting bracket screws and slide
mounting bracket away from compressor.
INSTALLATION (1) Slide mounting bracket on compressor and in-
stall screws and tighten to 8 N Im (70 in. lbs.) torque.
DO NOT OVER TORQUE THESE SCREWS. (2) Install compressor assembly to frame rail and
tighten screws to 8 N Im (70 in. lbs.) torque. DO NOT
OVER TORQUE THESE SCREWS. (3) Connect air hose and electrical connector to com-
pressor assembly. (4) Install cover on compressor assembly and tighten
screws to 6 N Im (40 in. lbs.) torque.
(5) Lower vehicle and connect battery negative
cable. (6) Check operation of the system.
AIR DRYER
REMOVAL
Remove compressor assembly. See COMPRESSOR
ASSEMBLY.
Fig. 11 Control Module and Relay Wiring
Fig. 12 Compressor Assembly
Ä SUSPENSION AND DRIVESHAFTS 2 - 85

(1) Remove dryer-to-compressor retaining screw
(Fig. 13). (2) Rotate dryer assembly 90É to release retaining
tangs from exhaust solenoid housing and withdraw
unit.
INSTALLATION
Inspect O-Ring for damage and location on dryer
assembly. (1) Insert and index air dryer locking tangs into
exhaust solenoid outlet. (2) Rotate air dryer assembly to lock position and
install air dryer-to-compressor retaining screw (Fig.
13).
SOLENOIDS (STRUTS AND AIR SPRINGS)
Front struts and rear springs are equipped with so-
lenoids that control air pressure and volume within
the assemblies. The solenoids are electrically oper-
ated to allow air input, contain air, or release air
pressure, depending on control module commands.
REMOVAL
WARNING: DO NOT ATTEMPT TO REMOVE OR IN-
STALL SOLENOIDS WHILE AIR SUSPENSION
(FRONT STRUTS AND REAR AIR SPRINGS) ARE
SUPPORTING VEHICLE.
Disconnect negative battery cable. Raise vehicle
and remove wheel and tire assembly then remove so-
lenoid(s) as follows: (1) Separate electrical connection to solenoid.
(2) Disconnect air line, see Air Lines and Fittings.
Solenoids have molded square tangs to fit into
stepped notches of the air spring housing. The
notches provide an air relief position and a retaining
position. The retaining position is locked with a re-
taining clip. (3) Remove retaining clip (Fig. 14). (4) Rotate solenoid to first step in housing and al-
low air pressure to vent (Fig. 15).
(5) Rotate solenoid to release slot and remove (Fig.
16).
Fig. 13 Air Dryer Remove/Install
Fig. 14 Remove Retaining Clips
Fig. 15 Release Air Pressure
Fig. 16 Remove Solenoid (Inspect O Ring)
2 - 86 SUSPENSION AND DRIVESHAFTS Ä

INSTALL
(1) Inspect O-Ring condition and position on sole-
noid stem. (O-Ring can become dislodged during re-
moval (Fig. 16). (2) Install solenoid with tangs to top ledge of hous-
ing and install retaining clip. (3) Reconnect air line and electrical connection.
STRUT (AIR SUSPENSION) DAMPERASSEMBLY
Service procedures for removal and installation for
(air or steel spring) assemblies are essentially the
same. Except for air venting/recharging and discon-
necting/connecting air lines and electrical connection.
REMOVAL (1) Disconnect battery negative cable.
(2) Hoist vehicle and remove wheel and tire assem-
bly. (3) See AIR LINES AND FITTINGS and discon-
nect air line. (4) Disconnect electrical leads, solenoid and height
sensors. (5) See SOLENOIDS (STRUT AND AIR SPRING)
and vent air spring and remove solenoids. (6) See STRUT DAMPER ASSEMBLY in FRONT
SUSPENSION and remove strut.
DISASSEMBLY/ASSEMBLE Disassembly is restricted to upper mount and bear-
ing housing. The strut shock absorber, air spring
with integral height sensor, solenoid and wiring har-
ness are serviced as an assembly. (1) Hold retaining plate locking washer and re-
move strut rod nut. (2) Remove locking washer, retainer plate, spacer,
flat washer and mount/bearing housing assembly
(Fig. 17). (3) Assemble in reverse order. Hold retainer plate
locking washer with suitable tool and tighten strut
rod nut to 75 N Im (55 ft. lbs.) torque.
INSTALLATION (1) See STRUT DAMPER ASSEMBLY in FRONT
SUSPENSION and install strut. (2) Install solenoid, see: SOLENOIDS (STRUT
AND AIR SPRINGS). (3) Connect electrical leads, solenoid and height
sensor. (4) Charge (inflate) air spring. See RECHARGE-
AIR SPRING to activate spring solenoid and air com-
pressor. Add air for 60 seconds.
RECHARGE AIR SPRING
To activate compressor; Ground Pin S08 to Pin
X20. To Activate Spring Solenoid:
² LF: Ground Pin S31 to X20 ²
RF: Ground Pin S30 to X20
² RR: Ground Pin S32 to X20
AIR SPRINGS REAR
REMOVAL
(1) Disconnect battery negative cable, hoist vehicle
and remove wheel and tire assembly. (2) See AIR LINES AND FITTINGS and discon-
nect air line and electrical connector from solenoid. (3) See SOLENOIDS (STRUT AND AIR SPRINGS)
and vent air from spring. Remove solenoid. (4) Release upper air spring alignment/retainer
clips. (Fig. 18) (5) Remove lower spring to axle nut (Fig. 19).
(6) Pry assembly down to pull alignment studs
through retaining clips (Fig. 20). Remove assembly.
INSTALLATION
(1) Position assembly lower stud into axle seat and
upper alignment pins through frame rail adaptor. (2) Install upper retaining clips.
(3) Install lower spring to axle nut: LOOSE AS-
SEMBLE. (4) Install solenoid and connect air line and electri-
cal connector. (5) Charge (inflate) air spring. See RECHARGING
AIR SPRING and add air for 60 seconds. (6) AFTER partial air recharge tighten lower nut
Fig. 17 Air Strut Upper Mount Assembly
Ä SUSPENSION AND DRIVESHAFTS 2 - 87

² AC, AY Bodies 108 N Im (80 ft. lbs.)
(12) Install brake drum (Fig. 1).
(13) Install washer and nut. Tighten adjusting nut
to 27-34 N Im (240-300 in. lbs.) torque while rotating
wheel. Back off adjusting nut with wrench to com-
pletely release bearing preload. Finger tighten ad-
justing nut. (14) Position nut lock with one pair of slots in-line
with cotter pin hole. Install cotter pin. The end play
should be 0.025-0.076 mm (0.001-0.003 inch). Clean
and install grease cap. (15) Install wheel and tire assembly. Tighten
wheel nut to 129 N Im (95 ft. lbs.) torque.
(16) Lower vehicle.
(17) Check alignment specifications.
Fig. 4 Shim Installation for Toe-InFig. 5 Shim Installation for Positive Camber
Fig. 6 Shim Installation for Negative Camber
2 - 90 SUSPENSION AND DRIVESHAFTS Ä

BRAKE SUPPORT ASSEMBLY
REMOVAL
Back off parking brake adjusting nut to provide
slack in cable. With wheel and brake drum removed, disconnect
hydraulic tube from wheel cylinder.Disconnect park-
ing brake cable and adjuster lever spring (Fig. 1).
Using a suitable tool such as an aircraft type hose
clamp, install the clamp over the retainer on the end
of the parking brake cable (Fig. 2). Compress cable
housing retainer and start housing out of support
plate (Fig. 2). Remove clamp when retainer is free
from the park brake cable mounting hole in the rear
brake support plate. Alternate method is to slide a
14 mm box wrench over housing end fitting com-
pressing the three fingers. Remove attaching bolts and washers and separate
brake support and spindle from rear support trailing
arm.
INSTALLATION
Insert parking brake cable and housing into sup-
port plate. Install support plate, spindle and gasket between
support plate and spindle on to rear suspension mem-
ber. Tighten support plate attaching bolts to 71 N Im
(53 ft. lbs) torque. Attach cable to parking brake lever.
Connect brake tube to wheel cylinder. Tighten
brake tube to wheel cylinder fitting to 17 N Im (145
in. lbs.). Install brake drum and wheel. Adjust and bleed
service brakes. Adjust parking brake.
Fig. 1 Removing Adjuster Lever Spring
Fig. 2 Removing Park Brake Cable From Support Plate
Ä BRAKES 5 - 25

AC BODY C,D
Caption Fig.
Air Suspension Wiring ..........................4
Body Left Side Wiring ...........................8
Body Right Side Wiring ..........................9
Cellular Phone Wiring ...........................7
Deck Lid Wiring ..............................5
Door Wiring (Body) ...........................10
Door Wiring (Front) ...........................11
Door Wiring (Rear) ............................12
Engine Wiring 2.5L ............................27
Engine Wiring 3.0L ............................28
Engine Wiring 3.3L, 3.8L ........................29
Engine Compartment Wiring 2.5L ................18, 19
Engine Compartment Wiring 3.0L .............20, 22, 23
Engine Compartment Wiring 3.3L, 3.8L ..........21, 22, 23Caption Fig.
Front End Lighting (Aero Headlamps) ................32
Front End Lighting (Concealed Headlamps) ............33
Ground Strap Locations .........................30
Heated Rear Window Wiring .......................6
Instrument Panel Wiring .................. .13, 14, 15
Load Leveling Wiring ...........................3
Radiator Fan Assembly .........................31
Rear End Wiring (Chrysler) .......................1
Rear End Wiring (Dodge) ........................2
Steering Column Wiring .........................16
Transmission Wiring 2.5L .......................24
Transmission WIring 3.0L .......................25
Transmission Wiring 3.3L, 3.8L ....................26
Underhood Lamp Wiring ........................17
Ä WIRING AND COMPONENT IDENTIFICATION 8W - 37