1993 CHEVROLET PLYMOUTH ACCLAIM air suspension

LEFT SIDE MOUNT
(1) Raise vehicle on hoist and remove left front
wheel. (2) Remove inter splash shield.
(3) Support the transmission with a transmission
jack. (4) Remove the insulator thru bolt from the mount.
(5) Remove the transmission mount fasteners and
remove mount. (6) Reverse removal procedure for installation. En-
sure that the slide tube is seated into the rail
bracket guides. Refer to (Fig. 3) for bolt tightening
specifications. (7) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.
ENGINE MOUNT RUBBER INSULATORS
Insulator location on (right side) and transmission
bracket (left side) are adjustable to allow right/left
drive train adjustment in relation to drive shaft as-
sembly length. Check and reposition right engine mount insulator
(left engine mount insulator is floating type and will
adjust automatically (Fig. 3). Adjust drive train posi-
tion, if required, for the following conditions:
² Drive shaft distress: See Driveshafts in Suspen-
sion, Group 2.
² Any front end structural damage (after repair).
² Insulator replacement.
ENGINE MOUNT INSULATOR ADJUSTMENT
(1) Remove the load on the engine motor mounts
by carefully supporting the engine and transmission
assembly with a floor jack. (2) Loosen the right engine mount insulator yoke
screw and two turns on yoke nut, then loosen the
front engine mount bracket to front crossmember
screws and nuts. Left engine mount insulator is sleeved over
shaft and long support bolt to provide lateral
movement adjustment with engine weight re-
moved or not. (3) Pry the engine right or left as required to
achieve the proper drive shaft assembly length. See
Drive Shaft in Suspension Group 2 for driveshaft
identification and related assembly length measur-
ing. (4) Tighten right engine mount insulator yoke nut
to 102 N Im (75 ft. lbs.). Then tighten front engine
mount screws and nuts to 54 N Im (40 ft. lbs.) and
center left engine mount insulator. (5) Recheck drive shaft length.
ENGINE ASSEMBLY
REMOVAL
(1) Disconnect battery.
(2) Mark hood position at hinges and remove hood. (3) Drain cooling system. Refer to Cooling System
Group 7 for draining procedure. (4) Disconnect all electrical connections.
(5) Remove coolant hoses from radiator and en-
gine. (6) Remove radiator and fan assembly.
(7) See Fuel System Group 14, For procedures to
release fuel pressure, disconnect fuel lines and accel-
erator cable. (8) Remove air cleaner assembly.
(9) Hoist vehicle and drain engine oil.
(10) Remove air conditioning compressor mounting
bolts and set compressor aside. (11) Disconnect exhaust pipe at manifold.
(12) Remove transmission inspection cover and
mark flex plate to torque converter position. (13) Remove screws holding torque converter to
flex plate and attach C-clamp on bottom of converter
housing to prevent torque converter from coming out. (14) Remove power steering pump mounting bolts
and set pump aside. (15) Remove two lower transmission to block
screws. (16) Remove starter.
(17) Lower vehicles and disconnect vacuum lines
and ground strap. (18) Install transmission holding fixture.
(19) Attach engine lifting hoist and support en-
gine. (20) Remove upper transmission case to block
bolts. (21) See Engine Mounting in (Fig. 2) and separate
mount/insulators as follows: (a) Mark RIGHT insulator on right yoke and en-
gine plate supports. Remove insulator to rails
screws. (b) Remove FRONT engine mount through bolt
and nut.
Fig. 3 Left Insulator Movement
Ä 3.0L ENGINE 9 - 69

(2) Loosen the right engine mount insulator yoke
screw and 2 turns on yoke nut, then loosen the front
engine mount bracket to front crossmember screws and
nuts. Left engine mount insulator is sleeved over
shaft and long support bolt to provide lateral
movement adjustment with engine weight re-
moved or not. (3) Pry the engine right or left as required to achieve
the proper drive shaft assembly length. See Drive
Shaft in Suspension Group 2 for driveshaft identifica-
tion and related assembly length measuring. (4) Tighten right engine mount insulator yoke nut to
102 N Im (75 ft. lbs.). Then tighten front engine mount
screws and nuts to 54 N Im (40 ft. lbs.) and center left
engine mount insulator. (5) Recheck drive shaft length.
ENGINE ASSEMBLY
REMOVAL
(1) Disconnect battery.
(2) Mark hood position at hinges and remove hood.
(3) Drain cooling system. Refer to Cooling System,
Group 7 for procedure. (4) Disconnect all electrical connections.
(5) Remove coolant hoses from radiator and engine.
(6) Remove radiator and fan assembly.
(7) See Fuel System, Group 14, to release fuel pres-
sure. Disconnect fuel lines and accelerator cable. (8) Remove air cleaner assembly.
(9) Hoist vehicle and drain engine oil.
(10) Remove air conditioning compressor mounting
bolts and set compressor aside. (11) Disconnect exhaust pipe at manifold.
(12) Remove transmission inspection cover and
mark flex plate to torque converter position. For disas-
sembly procedure for the all wheel drive vehicle refer to
Group 21 Transaxle. (13) Remove screws holding torque converter to
flex plate and attach C-clamp on bottom of converter
housing to prevent torque converter from counting
out. (14) Remove power steering pump mounting bolts
and set pump aside. (15) Remove two lower transmission to block
screws. (16) Remove starter.
(17) Lower vehicles and disconnect vacuum lines
and ground strap. (18) Install transmission holding fixture.
(19) Attach engine lifting hoist and support en-
gine. (20) Remove upper transmission case to block
bolts. (21) See Engine Mounting in (Fig. 3) and separate
mount/insulators as follows: (a) Mark RIGHT insulator on right rails sup-
ports. Remove insulator to rails screws. (b) Remove FRONT engine mount through bolt
and nut. (c) Remove LEFT insulator through bolt from in-
side wheelhouse or insulator bracket to transmis-
sion screws.
(22) Remove engine.
INSTALLATION
(1) Attach hoist and lower engine into engine com-
partment. (2) Align engine mounts and install but do not
tighten until all mounting bolts have been installed.
Tighten bolts to torque specified in (Fig. 3). (3) Install transmission case to cylinder block,
tighten bolts to 102 N Im (75 ft. lbs.) torque.
(4) Remove engine hoist and transmission holding
fixture. (5) Remove C-clamp from torque converter hous-
ing. Align flex plate to torque converter and install
mounting screws. Tighten to 75 N Im (55 ft. lb-
s.)torque. Refer to Group 21 transaxle for the all
wheel drive installation procedure. (6) Install transmission inspection cover.
(7) Connect exhaust system at manifold.
(8) Install starter.
(9) Install power steering pump and air condition-
ing compressor. For belt installation see Accessory
Belt Drive in Cooling System Group 7. (10) Lower vehicle and connect all vacuum lines.
(11) Connect all electrical connections including
ground strap. (12) Connect fuel lines and accelerator cable.
(13) Install radiator and fan assembly. Reconnect
fan motor electrical lead. Reinstall radiator hoses.
Fill cooling system. See Cooling System Group 7 for
filling procedure. (14) Fill engine crankcase with proper oil to cor-
rect level.
Fig. 4 Left Insulator Movement
Ä 3.3/3.8L ENGINE 9 - 101

CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is se-
lected.
TURBOCHARGER
REMOVAL
The turbocharger is removed from below the vehi-
cle. Cylinder head removal for component accessibil-
ity is not required. (1) Disconnect negative battery cable. Remove Air
Cleaner assembly (Fig. 1). (2) From Above: Remove front engine mount
through bolt and rotate engine (Top) forward away
from cowl. Refer to Engine Removal in Engine,
Group 9. (3) Remove Air Cleaner Support (Fig. 1).
(4) Disconnect Heated Oxygen sensor lead wire
and vacuum lines. (5) Separate coolant return line from water box
and turbocharger housing (Fig. 11). Remove return
line from turbocharger.
(6) Separate oil feed line from turbocharger hous-
ing (Fig. 12). (7) Remove three (two upper and one lower driver's
side) nuts retaining turbocharger to manifold (Fig.
12). (8) From Below: Remove right front wheel and
tire assembly. (9) See Suspension, Group 2, and remove right
driveshaft assembly. Air deflector may need to be removed from cross-
member. (10) Separate oil drain back tube fitting from tur-
bocharger housing and remove fitting and hose (Fig.
13). (11) Remove turbocharger to block support bracket
(Fig. 13). (12) Remove one remaining turbocharger to mani-
fold retaining nut (Fig. 12).
Fig. 11 Coolant Tube Routing
Fig. 12 Turbocharger Attaching Nuts
Fig. 9 Fuel Supply and Return Hose Connections
Fig. 10 Intake Manifold Attaching Bolts.
11 - 12 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

(13) Disconnect articulated exhaust pipe joint from
turbocharger housing. (14) Remove turbocharger coolant inlet line assem-
bly from engine (Fig. 11). (15) Lift turbocharger off manifold mounting studs
and lower assembly down and out of vehicle.
EXHAUST MANIFOLD
REMOVAL
Remove 9 exhaust manifold retaining fasteners and
remove exhaust manifold (Fig. 14).
CLEANING AND INSPECTION
(1) Discard gasket and clean all gasket surfaces of
manifolds and cylinder head. (2) Test manifold gasket surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (.006 in. per foot) of manifold length. (3) Inspect manifolds for cracks or distortion. Re-
place manifold if necessary.
EXHAUST MANIFOLD
INSTALLATION
(1) Install new manifold gasket. DO NOT APPLY
SEALER . (2) Set exhaust manifold in place. Tighten retain-
ing nuts and bolt, starting at center and progressing
outward in both directions to 23 N Im (200 in. lbs.)
torque. Repeat this procedure until all fasteners are
at specified torque (Fig. 14).
TURBOCHARGER
INSTALLATION
(1) Position turbocharger on exhaust manifold. Ap-
ply antiseize compound to threads and install the
lower (passenger side) retaining nut (Fig. 12).
Tighten nut to 54 N Im (40 ft. lbs.) torque.
(2) Apply thread sealant to lower (inlet) coolant
line fitting and install fitting into turbocharger hous-
ing (Fig. 11). (3) Install lower coolant line assembly to engine
(Fig. 11). (4) Install oil drain back tube and fitting (with
new gasket) to turbocharger housing (Fig. 13). (5) Install turbocharger to block support bracket
and install screws finger tight (Fig. 13). Tighten
block screw FIRST to 54 N Im (40 ft. lbs.) torque,
then tighten screw to turbocharger housing to 27
N Im (20 ft. lbs.) torque.
(6) Reposition exhaust pipe. Tighten articulated
joint shoulder bolts to 28 N Im (250 in. lbs.) torque.
(7) See Suspension, Group 2, and install right
driveshaft and wheel and tire assembly. Install air
deflector on crossmember. (8) From Above: Install three turbocharger to
manifold retaining nuts. Tighten to 54 N Im (40 ft.
lbs.) torque (Fig. 12). (9) Reconnect Heated Oxygen sensor electrical con-
nection and vacuum lines. (10) Attach oil feed line to turbocharger bearing
housing. Tighten fitting to 14 N Im (125 in. lbs.)
torque (Fig. 12). (11) Install coolant line and tighten fittings to 41
N Im (30 ft. lbs.) torque (Fig. 11).
(12) Install air cleaner support (Fig. 1).
(13) Align front engine mount in crossmember
bracket. Install through bolt and tighten to 54 N Im
(40 ft. lbs.) torque. (14) Install air cleaner assembly (Fig. 1).
(15) Fill cooling system. Refer to Cooling System,
Group 7 for procedure.
INTAKE/EXHAUST MANIFOLD SERVICEÐ3.0L
ENGINE
The intake system has a large air intake plenum of
aluminum alloy and a cross type intake manifold
(Fig. 2).
Fig. 13 Oil Return Tube and Support Bracket
Fig. 14 Exhaust ManifoldÐTurbo III Engine
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 13

bolts and nut on locating stud (Fig. 2). The right rear
crossmember stud is a pilot that correctly locates
the crossmember. Tighten down this bolt first,
then torque all 4 crossmember fasteners to 122
N Im (90 ft. lbs.).
CAUTION: Proper torque on the crossmember to
frame rail mounting bolts is very important.
(3) Torque the 4 bolts (Fig. 3) attaching the steering
gear assembly to front crossmember, to 68 N Im (50 ft.
lbs.). To ensure proper alignment of the steering
gear tighten left front bolt first. (4) Attach the engine damper strut from the engine
to the crossmember (if so equipped). (5) Attach the fluid tubes (Fig. 3) from the power
steering pump to the fittings on the steering gear.
Torque the fluid pressure line to steering gear tube nut
to 31 N Im (275 in. lbs.).
(6) Mount the outer tie rod ends to the steering
knuckles. Install the tie rod end to steering knuckle
attaching nuts. Torque the tie rod end to steering
knuckle nuts to 52 N Im (38 ft. lbs.). Install cotter pin
in tie rod end. (7) Install the front tire and wheel assemblies on
vehicle. Install the wheel lug nuts and torque to 129
N Im (95 ft. lbs.).
(8) Lower vehicle.
CAUTION: Do not use automatic transmission fluid. (9) Fill power steering pump fluid reservoir to the
(Full-Cold) proper level. (10) Start the engine and let run for a few seconds.
Then turn the engine off.
(11) Add fluid if necessary.
(12) Raise front wheels of vehicle off the ground.
(13) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in
system. Stop engine, check fluid level, and inspect
system for leaks. Fill pump reservoir to correct
level with Mopar t, Power Steering Fluid, or
equivalent. See Checking Fluid Level.
(14) Lower front wheels of vehicle back on the
ground. (15) Adjust toe (Refer to Group 2 Suspension).
OUTER TIE ROD
REMOVAL
(1) Loosen inner tie rod to outer tie rod jam nut (Fig.
4). (2) Remove outer tie rod to steering knuckle cotter
pin and attaching nut (Fig. 4). (4) Remove the tie rod end from steering knuckles, using Puller Special Tool C-3894-A (Fig. 5).
(5) Remove outer tie rod from inner tie rod.
INSTALLATION
(1) Install outer tie rod onto inner tie rod. Make
sure jam nut is on inner tie rod (Fig. 4). (2) Do not tighten jam nut.
(3) Install outer tie rod onto steering knuckle. In-
stall tie rod to steering knuckle attaching nut and
torque to 52 N Im (38 ft.lbs.).
CAUTION: During this procedure do not allow the
steering gear boot to become twisted. (See Wheel
Alignment in the suspension section of this service
manual).
(4) Make toe adjustment by turning inner tie rod.
(5) Tighten the inner to outer tie rod jam nut to 75
N Im (55 ft. lbs.) torque. Lubricate tie rod boot groove
with silicone type lubricant before installing outer
boot clamp, making sure boot is not twisted.
Fig. 4 Outer Tie Rod
Fig. 5 Tie Rod End Removal
Ä STEERING 19 - 27

CAUTION: If the vehicle is equipped with two oil
coolers (one in the radiator tank, one in front of the
radiator) they must be flushed separately. Do not
attempt to flush both coolers at one time. (1) Disconnect the cooler lines at the transmission.
(2) Using a hand suction gun filled with mineral
spirits, reverse flush the cooler. Force mineral spirits
into the From Cooler line of the cooler (Fig. 7) and
catch the exiting spirits from the To Coolerline.
Observe for the presence of debris in the exiting
fluid. Continue until fluid exiting is clear and free
from debris.
(3) Using compressed air in intermittent spurts,
blow any remaining mineral spirits from the cooler,
again in the reverse direction. (4) To remove any remaining mineral spirits from
the cooler, one (1) quart of automatic transmission
fluid should be pumped through the cooler before re-
connecting. (5) If at any stage of the cleaning process, the
cooler does not freely pass fluid, the cooler must be
replaced.
OIL COOLER FLOW CHECK
After the new or repaired transmission has been
installed, filled to the proper level with automatic
transmission fluid. The flow should be checked using
the following procedure: (1) Disconnect the From coolerline at the trans-
mission and place a collecting container under the
disconnected line. (2) Run the engine at curb idle speed , with the
shift selector in neutral. (3) If the fluid flow is intermittent or it takes more
than 20 seconds to collect one quart of automatic
transmission fluid, the cooler should be replaced. CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(4) If flow is found to be within acceptable limits,
reconnect the cooler line. Then fill transmission to
the proper level, using the approved type of auto-
matic transmission fluid.
TRANSAXLE REMOVAL AND INSTALLATION
Transaxle removal does NOT require engine re-
moval. See Group 7-Cooling, to drain engine cooling sys-
tem and remove coolant return extension (3.0 liter
engine only). (1) The transaxle and torque converter must be re-
moved as an assembly; otherwise, the torque con-
verter drive plate, pump bushing or oil seal may be
damaged. The drive plate will not support a load;
therefore, none of the weight of the transaxle should
be allowed to rest on the drive plate during removal. (2) Disconnect negative battery cable.
(3) Disconnect transaxle shift linkage.
(4) Install engine support fixture and support en-
gine (Fig.1).
(5) Remove upper bell housing upper bolts.
(6) Raise vehicle. Remove front wheels. Refer to
Suspension, Group 2 to remove wheel hub nut and
both drive shafts. (7) Remove left plastic splash to gain access to the
transaxle (Fig. 2). (8) Remove torque converter dust shield to gain ac-
cess to torque converter bolts (Fig. 3). (9) Mark torque converter and drive plate with
chalk, for reassembly. Remove torque converter
mounting bolts. (10) Disconnect electrical connectors at transmis-
sion range switch and Park/Neutral Position Switch
(Fig. 4).
Fig. 7 Cooler Line Location
Fig. 1 Engine Support Fixture (Typical)
Ä TRANSAXLE 21 - 99

ponents. Under extremes of suspension and steering
travel tire damage may occur.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED RATING CAN
CAUSE SUDDEN TIRE FAILURE.
ROTATION
DIRECTIONAL TREAD PATTERN TIRES
Some vehicles are fitted with special high-perfor-
mance tires having a directional tread pattern de-
signed to improve traction on wet pavement. To obtain the full benefits of this design, the tires
must be installed so that they rotate in the correct
direction. This is indicated by arrows on the tire
sidewalls. When wheels and tires are being installed, extra
care is needed to ensure that this direction of rota-
tion is maintained. Refer to Owner's Manual for rotation schedule.
NONDIRECTIONAL TIRES
Tires on the front and rear axles of vehicles oper-
ate at different loads and perform different steering,
driving, and braking functions. For these reasons,
they wear at unequal rates, and tend to develop ir-
regular wear patterns. These effects can be reduced
by timely rotation of tires. Rotation will increase
tread life, help to maintain mud, snow, and wet trac-
tion levels, and contribute to a smooth, quiet ride. The suggested rotation method is the forward-cross
tire rotation method. This method takes advantage of
current tire industry practice which now allows cross
rotation of radial-ply tires. Refer to the owner's man-
ual (usually found in the glove box) for additional in-
formation. Other rotation methods may be used, but
may not have all the benefits of the recommended
method. Always check air pressure and wheel nut tightness
after rotation. Do NOT use oil or grease on studs
or nuts. Refer to Owner's Manual for rotation schedule.
TREAD WEAR INDICATORS
Tread wear indicators (Fig. 3) are molded into the
bottom of the tread grooves. When tread is 1.6 mm
(1/16 in.), the tread wear indicators will appear as a
13 mm (1/2 in.) band. Tire replacement is necessary when indicators ap-
pear in two or more grooves, or if localized balding
occurs.
REPAIRING LEAKS
For proper repairing, a radial tire must be removed
from the wheel. Repairs should only be made if the
defect or puncture is in the tread area otherwise the
tire should be replaced. Deflate tire completely before dismounting tire
from the wheel. Use lubrication such as a mild soap
solution when dismounting or mounting tire. Use
tools free of burrs or sharp edges which could dam-
age the tire or wheel rim. Before mounting tire on wheel, make sure all rust
scale is removed from the rim and repaint if neces-
sary. Install wheels on vehicle, progressively tightening
wheel nuts to 129 N Im (95 ft. lbs.) torque (See
Wheels).
TIRE NOISE OR VIBRATION
Radial-ply tires are sensitive to force impulses
caused by improper mounting, wheel irregularities,
or imbalance. To determine if the tires are causing the noise or
vibration, drive the vehicle over a smooth portion of
highway at different speeds and note the effect of ac-
celeration and deceleration on noise level. Differen-
tial and exhaust noise will change in intensity as
speed varies, while tire noise will usually remain
constant.
TIRE WEAR PATTERNS
Under inflation results in faster wear on shoulders
of tire. Over inflation causes faster wear at center of tread.
Excessive camber causes the tire to run at an angle
to the road. One side of tread is worn more than the
other. Excessive toe-in or toe-out causes wear on the
tread edges of the tire, from dragging of tire. There
is a feathered effect across the tread (Fig. 4).
Fig. 3 Tread Wear Indicators
Ä WHEELSÐTIRES 22 - 3