1993 CHEVROLET PLYMOUTH ACCLAIM steering wheel

STEERING WHEEL
WARNING: BEFORE BEGINNING ANY AIR BAG
SYSTEM REMOVAL OR INSTALLATION PROCE-
DURES, REMOVE AND ISOLATE THE BATTERY
NEGATIVE (-) CABLE (GROUND) FROM THE VEHI-
CLE BATTERY. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
THIS COULD RESULT IN ACCIDENTAL AIR BAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY. WHEN AN UNDEPLOYED AIR BAG ASSEMBLY
IS TO BE REMOVED FROM THE STEERING
WHEEL, DISCONNECT BATTERY GROUND CA-
BLE AND ISOLATE. ALLOW SYSTEM CAPACI-
TOR TO DISCHARGE FOR TWO MINUTES.
BEGIN AIR BAG REMOVAL.
REMOVAL
(1) Make sure front wheels are straight, and steer-
ing column is locked in place. (2) Disconnect battery negative cable and isolate.
(3) Wait two minutes for the reserve capacitor to
discharge before removing undeployed module. (4) Remove four nuts attaching air bag module
from the back side of steering wheel. (5) Lift module, and disconnect connector from rear
of module. (6) Remove speed control switch and connector if
so equipped or cover. (7) Remove steering wheel retaining nut.
(8) Remove steering wheel with steering wheel
puller Tool C-3428B.
INSTALLATION
(1) If the clockspring is not properly positioned or if front wheels were moved, follow the clockspring
centering procedure before installing steering wheel.
With the front wheels in the straight ahead position.
Position the steering wheel on the steering column.
Making sure to fit the flats on the hub of the steer-
ing wheel with the formations on the inside of the
clockspring. Pull the air bag and speed control wires
through the lower, larger hole in the steering wheel
and the horn wire through smaller hole at the top.
Make sure not to pinch wires (Fig. 11).
(2) Install retaining nut, and tighten to 61 N Im (45
ft. lbs.) torque. (3) Connect horn wiring lead.
(4) Connect 4-way connector to speed control
switch and attach switch to steering wheel. (5) Connect air bag lead wire to air bag module,
and secure module to steering wheel. (6) Do not connect negative battery cable. Refer to
Air Bag System Check for proper procedure.
STEERING COLUMN SWITCHES
This procedure covers the removal and installation
of the steering wheel and clockspring. Once the
steering wheel and clockspring have been removed,
refer to the appropriate section of this service man-
ual for switch replacement.
WARNING: BEFORE BEGINNING ANY AIR BAG
SYSTEM REMOVAL OR INSTALLATION PROCE-
DURES, REMOVE AND ISOLATE THE BATTERY
NEGATIVE (-) CABLE (GROUND) FROM THE VEHI-
CLE BATTERY. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
THIS COULD RESULT IN ACCIDENTAL AIR BAG
DEPLOYMENT AND POSSIBLE INJURY.
WHEN AN UNDEPLOYED AIR BAG ASSEMBLY
IS TO BE REMOVED FROM THE STEERING
WHEEL, DISCONNECT BATTERY GROUND CA-
BLE AND ISOLATE. ALLOW SYSTEM CAPACI-
Fig. 10 Clockspring (Auto-Locking)
Fig. 11 Steering Wheel Wiring
Ä RESTRAINT SYSTEMS 8M - 7

TOR TO DISCHARGE FOR TWO MINUTES.
BEGIN AIR BAG REMOVAL.
REMOVAL
(1) Disconnect battery negative cable, and isolate.
(2) Wait two minutes for the reserve capacitor to
discharge before removing undeployed module. (3) Remove four nuts attaching air bag module
from the back side of steering wheel. (4) Lift module, and disconnect connector from rear
of module. (5) Remove speed control switch and connector if
so equipped or cover. (6) Remove steering wheel.
(7) Unsnap clockspring, and remove it. (8) Refer to the appropriate section for switch re-
placement.
INSTALLATION
(1) Snap clockspring on to steering column. Assure
the 4 way connector is still seated. (2) Install steering wheel.
(3) Install speed control switch and connector or
cover. (4) Connect clockspring wiring connector to the
module. (5) Install four nuts to module, and tighten to 9 to
11 N Im (80 to 100 in. lbs.) torque.
(6) Do not connect negative battery cable. Refer to
Air Bag System Check for proper procedure.
8M - 8 RESTRAINT SYSTEMS Ä

CHIME WARNING/REMINDER SYSTEM
CONTENTS
page page
BODY CONTROLLER REPLACEMENT ........ 5
CHIME MODULE REPLACEMENT AA and AP BODIES .............................. 5
CHIME SYSTEM DIAGNOSISÐAA AND AP BODIES .............................. 2
CHIME SYSTEM DIAGNOSISÐAC, AG, AJ AND AY BODIES ....................... 3
CHIME WARNING/REMINDER SYSTEM TEST . 1 GENERAL INFORMATION
.................. 1
HEADLAMP SWITCH REPLACEMENT ........ 5
KEY-IN SWITCH REPLACEMENT ............ 5
SEAT BELT BUCKLE REPLACEMENT ........ 5
SEAT BELT BUCKLE SWITCH TEST BUZZER SYSTEM .............................. 1
SERVICE PROCEDURES ................... 5
TIMED BUZZER-RELAY TESTÐAP BODY ..... 1
GENERAL INFORMATION
WARNING: ON VEHICLES EQUIPPED WITH AN AIR
BAG REFER TO THE AIR BAG PORTION OF THIS
SECTION FOR STEERING WHEEL OR SWITCH RE-
MOVAL AND INSTALLATION PROCEDURES.
BUZZER SYSTEM
The seat belt warning system uses both visual and
audible signals. A combined seat belt and key warn-
ing buzzer with a red light on the instrument panel. The system will always illuminate the seat belt
warning lamp for four to eight seconds when the ig-
nition switch is turned to the ON position. Also, only
if the driver does not fasten his seat belt, the buzzer
will sound during the same time interval. Passenger
belts are not connected to the system. A timed buzzer-relay is used to operate the system
for the time period. It consists of a time delay mech-
anism and buzzer assembly. Only the driver's seat
belt buckle has a switch that is connected to the sys-
tem.
CHIME WARNING/REMINDER SYSTEM
The chime warning/reminder system is similar in
operation to the buzzer system except for a more
pleasant sounding tone. This chime type tone sounds
for all three warning/reminder conditions; namely
headlamps left on, keys left in ignition and fasten
seat belt.
TIMED BUZZER-RELAY TESTÐAP BODY
PREPARATION
(1) Remove timed buzzer-relay (Fig. 1).
(2) Connect one end of a jumper wire to a 12 volt
supply. (3) Connect a test lamp equipped with a number
194 lamp or equivalent, between terminal number 3
of relay and ground. (4) Ground terminals 2 and 5 of relay.
TEST
(1) Connect 12 volt jumper wire to terminal num-
ber 4 of timed buzzer-relay, look at test lamp and lis-
ten for buzzer. (2) Test lamp should come on and buzzer should
sound for four to eight seconds and then both should
go off; if not, replace timed buzzer-relay. (3) If operation is okay, check all wiring in vehicle
for opens, shorts, or poor connections.
SEAT BELT BUCKLE SWITCH TEST BUZZER
SYSTEM
Test timed buzzer-relay. If it checks OK, check the
wiring between seat belt buckle and ground. The
wire that goes to terminal 5 of relay from buckle
switch, refer to Fig. 2 and 3. If they check out okay,
replace buckle switch.
CHIME WARNING/REMINDER SYSTEM TEST
FASTEN SEAT BELTS
To test the fasten seat belts function, turn the ig-
nition switch to the ON position with the driver's
seat belt unbuckled. The seat belt warning lamp
should light for four to eight seconds and the tone
should sound three to five times.
Fig. 1 Timed Buzzer-Relay Terminal Identification
Ä CHIME WARNING/REMINDER SYSTEM 8U - 1

HEADLAMPS LEFT ON
To test the headlamps left on function, turn head-
lamps on with drivers door open. Chime should
sound until headlamps are turned off or drivers door
is closed.
KEY LEFT IN IGNITION
To test the key left in ignition function, insert key
into the ignition and open drivers door. Chime
should sound until key is removed from ignition or
drivers door is closed.
CHIME SYSTEM DIAGNOSISÐAA AND AP BODIES
WARNING: ON VEHICLES EQUIPPED WITH AN AIR
BAG REFER TO THE AIR BAG PORTION OF THIS SECTION FOR STEERING WHEEL OR SWITCH RE-
MOVAL AND INSTALLATION PROCEDURES.
CONDITION: NO TONE WHEN IGNITION
SWITCH IS TURNED ON AND DRIVERS SEATBELT OR AUTOMATIC SHOULDER HARNESSIS UNBUCKLED
PROCEDURE
(1) Check seat belt buckle switch (drivers seat) or
rotary switch in automatic shoulder harness retrac-
tor for a ground when unbuckled. (2) Check for battery feed at terminal 6 and igni-
tion feed at terminal 4 of chime module (Fig. 4 and
5).
Fig. 3 Seat Belt Warning System Diagnosis
Fig. 4 Chime Module Terminal IdentificationFig. 2 Buzzer System Wiring Schematic
8U - 2 CHIME WARNING/REMINDER SYSTEM Ä

CAUTION: Make sure clutch cable has been discon-
nected. (20) Remove front engine mount screw and nut.
(21) Remove manual transmission damper.
(22) Remove left insulator through bolt from inside
wheelhouse or insulator bracket to transmission
screws. (23) Remove engine from vehicle.
INSTALLATION
(1) Install hoist to the engine and lower engine
into the engine compartment. SEE: ENGINE MOUNT RUBBER INSULATORS,
THIS GROUP. (2) Align engine mounts and install but do not
tighten until all mounting bolts have been installed.
(3) Install transmission case to cylinder block
mounting screws. Tighten to 95 N Im (70 ft. lbs.)
torque. (4) Remove engine hoist and transmission holding
fixture. (5) Install ground strap.
(6) Install right inner splash shield.
(7) Connect starter. See Electrical Group 8 for in-
stallation. (8) Connect exhaust system. See Exhaust Systems
Group 11 for installation. (9) Manual Transmission: Install transmission
case lower cover. Automatic Transmission: Remove C clamp from
torque converter housing. Align flexplate to torque
converter and install mounting screws. Tighten to 75
N Im (55 ft. lbs.) torque.
(10) Manual Transmission: Connect clutch cable.
See Clutch Group 6. (11) Install power steering pump. Refer to Cooling
System Group 7, Accessory Drive Section for belt
tension adjustment. (12) Connect fuel line, heater hose, and accelerator
cable. (13) Connect all electrical connections and har-
nesses at throttle body and engine. (14) Install oil filter. Fill engine crankcase with
proper oil to correct level. (15) Install air conditioning compressor (if
equipped). See Heater and Air Conditioning, Group
24 for installation. (16) Install air cleaner and hoses.
(17) Install radiator and shroud assembly . Install
radiator hoses. Fill cooling system. See Cooling Sys-
tem Group 7 for filling procedure. (18) Install hood.
(19) Connect battery.
(20) Start engine and run until operating temper-
ature is reached. (21) Adjust transmission linkage, if necessary.
SOLID MOUNT COMPRESSOR BRACKET SERVICE
When service procedures require solid mount
bracket removal and installation for example: cylin-
der head removal, etc., it is important that bracket
fasteners numbered 1 through 7 (Fig. 4) be removed
and installed in sequence, as instructed in Remove
and Install.
ACCESSORIES REMOVAL
(1) Remove (and install/adjust) belts,see Accessory
Drive Belts in Cooling System,Group 7. (2) Remove air conditioning compressor (in vehicle
with lines and set aside) (Fig. 6). (3) Remove generator pivot bolt and remove gener-
ator (in vehicle: turn wiring side up and disconnect,
then rotate generator, pulley end towards engine and
remove). (4) Remove air conditioner compressor belt idler.
SOLID MOUNT BRACKETÐREMOVAL (FIG. 4)
(1) Remove right engine mount yoke screw (see
Engine Remove Fig. 3) securing engine mount sup-
port strut to engine mount bracket. (2) Remove five side mounting bolts #1, #4 , #5,
#6, and #7 (Fig. 4). (3) Remove front mounting nut, #2, and remove
front bolt #3*. (4) Remove front mounting bolt and strut, rotate
solid mount bracket away from engine and slide
bracket on stud until #2 nut mounting stud until
free. Remove spacer from stud.
SOLID MOUNT BRACKETÐINSTALLATION
(1) Put spacer onto stud, then install bracket on
front (#2 nut) mounting stud and slide bracket over
timing belt cover into position. (2) Loosen assembly bracket to engine fasteners
(numbered #1 through #7 in Fig. 6). (3)
CAUTION: Fasteners MUST BE TIGHTENED IN SE-
QUENCE and to specified torque as follows :
² First Bolt #1 to 3.3 N Im (30 in. lbs.)
² Second Nut #2 and Bolt #3 to 54 N Im (40 ft. lbs.).
² Third Bolts #1 (second tightening) #4 and #5 to
54 N Im (40 ft. lbs.).
² Fourth Bolts #6 and #7 to 54 N Im (40 ft. lbs.).
(4) Install generator and compressor. Tighten com-
pressor mounting bracket bolts to 54 N Im (40 ft.
lbs.).
SOLID MOUNT COMPRESSOR BRACKET SERVICEÐTURBO III ENGINE
REMOVAL
(1) Disconnect negative battery cable
9 - 14 2.2/2.5L ENGINE Ä

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

(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. 2). (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. lbs.)
(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 Refer to Acces-
sory 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. Connect fan
motor electrical lead. Install radiator hoses. Fill cool-
ing system. Refer to Cooling System Group 7 for fill-
ing procedure. (14) Fill engine crankcase with proper oil to cor-
rect level. (15) Install hood.
(16) Connect battery.
(17) Start engine and run until operating temper-
ature is reached. (18) Adjust transmission or linkage if necessary.
ACCESSORY DRIVE BELT SERVICE
REMOVAL
(1) Loosen Adjusting Lock Nut (Fig. 6).
(2) Turn adjusting jack screw counterclockwise to
reduce belt tension. Remove belt. (3) Inspect drive belt for wear and damage (Fig. 5).
(4) Installation: Adjust belt tension to 5/16 deflec-
tion between pulleys (Fig. 6). (5) Install breaker bar into 1/2 square opening in
tensioner. (6) Rotate tensioner clockwise to remove and in-
stall belt (Fig. 7).
Fig. 4 Accessories Mounting Brackets
9 - 70 3.0L ENGINE Ä

(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