1993 CHEVROLET PLYMOUTH ACCLAIM belt

COMPONENT AND SYSTEM INDEX
Name Group-page Name Group-page
BODY ................................... 23-1
AA-VEHICLE BODY COMPONENT SERVICE .......23-11
AC-VEHICLE BODY COMPONENT SERVICE .......23-37
AG-VEHICLE BODY COMPONENT SERVICE .......23-52
AJ/27-VEHICLE CONVERTIBLE BODY COMPONENT SERVICE ............................ 23-86
AJ-VEHICLE BODY COMPONENT SERVICE .......23-71
AP-VEHICLE BODY COMPONENT SERVICE .......23-97
AY-VEHICLE BODY COMPONENT SERVICE .......23-133
BODY DIAGNOSTIC PROCEDURES .............23-2
GENERAL SERVICE INFORMATION .............23-1
PAINT ................................. 23-4
POWER SUNROOF ........................ 23-6
WINDSHIELD ............................ 23-9
BRAKES ..................................5-1
ANTI-LOCK BRAKE SYSTEMÐBENDIX ANTI-LOCK 10 AC/Y BODY ......................... 5-72
ANTI-LOCK BRAKE SYSTEMÐBENDIX ANTI-LOCK 6 AA,AG,AJ,AP BODY .................... 5-113
BRAKE DISC (ROTOR) ...................... 5-53
BRAKE SUPPORT ASSEMBLY .................5-25
FRONT DISC BRAKES ...................... 5-31
GENERAL INFORMATION .....................5-1
HYDRAULIC SYSTEM CONTROL VALVES .........5-26
KELSEY HAYES DOUBLE PIN FAMILY CALIPER .....5-35
KELSEY HAYES DOUBLE PIN NON-FAMILY CALIPER ............................. 5-38
MASTER CYLINDER ....................... 5-66
PARKING BRAKES ........................ 5-57
POWER BRAKES ......................... 5-68
REAR DISC BRAKES ....................... 5-45
REAR WHEEL DRUM BRAKES ................5-18
SERVICE ADJUSTMENTS .....................5-4
WHEEL BEARINGS ........................ 5-70
WHEEL CYLINDERS ....................... 5-23
COOLING SYSTEM ...........................7-1
ACCESSORY DRIVE BELTS ................... 7-24
ENGINE BLOCK HEATER .................... 7-28
GENERAL INFORMATION .....................7-1
SERVICE PROCEDURES ..................... 7-10
SPECIFICATIONS ......................... 7-29
ENGINE ..................................9-1
2.2/2.5L ENGINES .........................9-8
3.0L ENGINE ............................ 9-66
3.3/3.8L ENGINE ......................... 9-98
STANDARD SERVICE PROCEDURES .............9-1
EXHAUST SYSTEM AND INTAKE MANIFOLD .........11-1
GENERAL INFORMATION .................... 11-1
SERVICE PROCEDURES ..................... 11-4
TORQUE SPECIFICATION ................... 11-25
FRAME AND BUMPERS ....................... 13-1
BUMPER AND FASCIA ...................... 13-1
FRAME ................................ 13-9
HEATING AND AIR CONDITIONING ...............24-1
AUTOMATIC TEMPERATURE CONTROL (ATC) .....24-66 COMPONENT SERVICE PROCEDURES
..........24-47
FIXED DISPLACEMENT COMPRESSORÐMODEL 10PA17............................. 24-24
FIXED DISPLACEMENT COMPRESSORÐMODEL SD709P ............................. 24-38
FIXED DISPLACEMENT COMPRESSORÐMODEL TR105 .............................. 24-32
GENERAL INFORMATION .................... 24-1
HEATER AND A/C PERFORMANCE TESTS .........24-6
REFRIGERANT SERVICE PROCEDURES ..........24-8
VACUUM CONTROL SYSTEM DIAGNOSIS .........24-4
VARIABLE DISPLACEMENT COMPRESSORÐMODEL 6C17 ............................... 24-13
INTRODUCTION .......................... Intro.-1
LUBRICATION AND MAINTENANCE ................0-1
CHASSIS AND BODY ....................... 0-19
DRIVETRAIN ............................ 0-16
ENGINE ................................0-8
GENERAL INFORMATION .....................0-1
MANUAL TRANSAXLE CLUTCH ...................6-1
STEERING ................................ 19-1
ACUSTAR STANDARD AND TILT STEERING COLUMN ............................ 19-28
AUTOMATIC TRANSMISSION SHIFTER/IGNITION INTERLOCK .......................... 19-36
GENERAL INFORMATION .................... 19-1
POWER STEERING GEAR ................... 19-25
POWER STEERING PUMPS ..................19-1
SPECIFICATIONS AND TIGHTENING REFERENCE . . . 19-42
SUSPENSION AND DRIVESHAFTS .................2-1
AUTOMATIC AIR LOAD LEVELING SYSTEM ........2-59
AUTOMATIC AIR SUSPENSION ................2-73
DRIVESHAFTS ........................... 2-25
FRONT SUSPENSION .......................2-2
FRONT SUSPENSION SERVICE PROCEDURES .......2-5
GENERAL INFORMATION .....................2-1
REAR (STUB) AXLE ALIGNMENT ALL MODELS .....2-89
REAR SUSPENSION ....................... 2-50
SPECIFICATIONS ......................... 2-91
TRANSAXLE .............................. 21-85
41TE FOUR SPEED AUTOMATIC TRANSAXLE ......21-85
41TE FOUR SPEED TRANSAXLE HYDRAULIC SCHEMATICS ........................ 21-170
41TE ON-BOARD DIAGNOSTICS .............21-145
A-523, A-543, and A-568 MANUAL TRANSAXLE ....21-1
SPECIFICATIONS ........................ 21-183
THREE SPEED TORQUEFLITE AUTOMATIC TRANSAXLE .......................... 21-35
THREE SPEED TRANSAXLE HYDRAULIC SCHEMATICS ........................ 21-162
WHEELSÐTIRES ........................... 22-1
SPECIFICATIONS ......................... 22-8
TIRE SERVICE PROCEDURES .................22-1
WHEELS SERVICE PROCEDURES ..............22-6

LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol on the label. At the bottom NLGI symbol is the usage and qual-
ity identification letters. Wheel bearing lubricant is
identified by the letter ``G''. Chassis lubricant is iden-
tified by the letter ``L''. The letter following the us-
age letter indicates the quality of the lubricant. The
following symbols indicate the highest quality.
FLUID CAPACITIES
Fuel Tank
AP,AG and AJ ......................................53 L (14 gal.)
AA,AC and AY .....................................60 L (16 gal.)
AA-Flexible Fuel ..................................68 L (18 gal.)
Engine Oil
All.........................................................3.8 L (4.5 qts.)
Cooling System
2.2L ......................................................8.5 L (9.0 qts.)
2.5L ......................................................8.5 L (9.0 qts.)
3.0L ......................................................9.0 L (9.5 qts.)
3.3L ......................................................9.0 L (9.5 qts.)
3.8L ......................................................9.0 L (9.5 qts.)
Includes heater and coolant recovery bottle
Automatic Transaxle
Estimated Service Fill
ALL ......................................................3.8 L (4.0 qts.)
Overhaul Fill Capacity with Torque Converter
Empty
3-speed Fleet .......................................8.7 L (9.2 qts.)
3-speed .................................................8.2 L (8.8 qts.)
4-speed Electronic ................................9.4L (9.9 qts.)
Manual Transaxle
All ..........................................................9.4L (9.9 qts.)
Fill to bottom of fill hole.
Power Steering
All ...........................................................75L (1.5 pts.)
PARTS REQUIRING NO LUBRICATION
Many components on a Chrysler Corporation vehi-
cle require no periodic maintenance. Some compo-
nents are sealed and permanently lubricated. Rubber
bushings can deteriorate or limit damping ability if
lubricated. The following list of components require
no lubrication: ²
Air Pump
² Generator Bushings
² Drive Belts
² Drive Belt Idler/Tensioner Pulley
² Front Wheel Bearings
² Rubber Bushings
² Starter Bearings/Bushings
² Suspension Strut Bearings
² Throttle Control Cable
² Throttle Linkage
² Water Pump Bearings
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT JUMP START A FROZEN BATTERY, PER-
SONAL INJURY CAN RESULT. DO NOT JUMP START WHEN BATTERY INDICA-
TOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY.
REMOVE METALLIC JEWELRY WORN ON HANDS
OR WRISTS TO AVOID INJURY BY ACCIDENTAL
ARCHING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DE-
VICE, DO NOT ALLOW BATTERY VOLTAGE TO EX-
CEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually in-
spect engine compartment for:
² Battery cable clamp condition, clean if necessary.
² Frozen battery.
² Yellow or bright color test indicator, if equipped.
² Low battery fluid level.
² Generator drive belt condition and tension.
² Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, turn off all accessories, place gear selector in
park or neutral, set park brake and operate engine
at 1200 rpm.
NLGI SYMBOL
0 - 4 LUBRICATION AND MAINTENANCE Ä

ENGINE INDEX
page page
Engine Oil Filter .......................... 9
Battery ................................ 15
Crankcase Ventilation System ............... 13
Drive Belts ............................. 14
Emission Control System ................... 14
Engine Air Cleaner ....................... 11
Engine Cooling System .................... 10 Engine Oil
............................... 8
Frequency of Engine Oil and Filter Changes ..... 8
Fuel Filter .............................. 14
Fuel Recommendations .................... 14
Ignition Cables, Distributor Cap, and Rotor ..... 14
Rubber and Plastic Component Inspection ...... 15
Spark Plugs ............................ 14
FREQUENCY OF ENGINE OIL AND FILTER
CHANGES
ENGINE OIL
Road conditions as well as your kind of driving af-
fect the interval at which your oil should be changed.
Check the following to determine if any apply to you:
² Frequent short trip driving less than 8 kilometers
(5 miles)
² Frequent driving in dusty conditions
² Frequent trailer towing
² Extensive idling (such as vehicle operation in stop
and go traffic)
² More than 50% of your driving is at sustained
high speeds during hot weather, above 32ÉC (90ÉF) If any of these apply to you then change your en-
gine oil every 4 800 kilometers (3,000 miles) or 3
months, whichever comes first. If none of these apply to you then change your oil
every 12 000 kilometers (7,500 miles) or 6 months,
whichever comes first. If none of these apply and the vehicle is in com-
mercial type service such as, Police, Taxi or Limou-
sine and principally used for highway driving of 40
kilometers (25 miles) or more between stations, the
engine oil should be changed every 8 000 kilometers
(5,000 miles) or 6 months, whichever comes first.
FLEXIBLE FUEL VEHICLES
Flexible fuel is corrosive and contributes to engine
oil contamination. When flexible fuel is being used,
the engine oil should be changed every 8 000 kilome-
ters (5,000 miles) or 6 months, whichever comes first.
OIL FILTER
The engine oil filter should be replaced with a new
filter at every second oil change.
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE IR-
RITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED
BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EX-
POSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL
FUEL, THINNER, OR SOLVENTS, HEALTH PROB-
LEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE
OIL PROPERLY. CONTACT YOUR DEALER OR
GOVERNMENT AGENCY FOR LOCATION OF COL-
LECTION CENTER IN YOUR AREA.
BREAK-IN PERIOD
CAUTION: Wide open throttle operation in low
gears, before engine break-in period is complete,
can damage engine.
On a Chrysler Corporation vehicle an extended
break-in period is not required. Driving speeds of not
over 80-90 km/h (50-55 mph) for the first 100 km (60
miles) is recommended. Hard acceleration and high
engine rpm in lower gears should be avoided.
SELECTING ENGINE OIL
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase lu-
bricant. Engine or Turbocharger failure can result.
The factory fill engine oil is a high quality, energy
conserving, crankcase lubricant. The Recommended
SAE Viscosity Grades chart defines the viscosity
grades that must be used based on temperature in
the region where vehicle is operated and optional
equipment.
NON-FLEXIBLE FUEL VEHICLES Chrysler Corporation recommends that Mopar mo-
tor oil, or equivalent, be used when adding or chang-
ing crankcase lubricant. The API symbol (Fig. 1) on
the container indicates the viscosity grade, quality
and fuel economy ratings of the lubricant it contains.
Use ENERGY CONSERVING II motor oil with API
SERVICE SG or SG/CD classification.
0 - 8 LUBRICATION AND MAINTENANCE Ä

PCV SYSTEM TEST
Refer to group 25, Emission Control System for
proper procedures to test PCV system.
FUEL RECOMMENDATIONS
Chrysler Corporation recommends that only fuel pur-
chased from a reputable retailer be used. Use high qual-
ity, unleaded gasoline to provide satisfactory
driveability and highest fuel economy. Gasoline contain-
ing detergent and corrosion control additives are desire-
able. If the engine develops spark knock (audible ping),
poor performance, hard starting or stalling, purchase
fuel from another source. Engine performance can vary
when using different brands of gasoline with the same
octane rating. Occasional light engine spark knock un-
der heavy acceleration, at low speed or when vehicle is
heavily loaded is not harmful. Extended periods of
spark knock under moderate acceleration or at cruising
speed can damage the engine. The cause of excessive
spark knock condition must be diagnosed and corrected.
For diagnostic procedures refer to Group 14, Fuel Sys-
tem and Powertrain Diagnostic Procedures manual.
SELECTING GASOLINE
CAUTION:Do not use fuel containing METHANOL
(methyl or wood alcohol), damage to fuel system
will result. Do not use leaded gasoline, damage to catalytic
converter will result and vehicle will not conform to
emission control standards.
ETHANOL, MTBE OR ETBE BLENDS
All Chrysler Corporation vehicles are designed to
use unleaded gasoline ONLY. Gasohol blends, con-
taining 10% Ethanol (ethyl or grain alcohol) 90% un-
leaded gasoline can be used provided it has adequate
octane rating. Fuel blends containing up to 15% MTBE (Methyl
Tertiary Butyl Ether) and 85% unleaded gasoline can
be used. Fuel blends containing up to 17% ETBE
(Ethyl Tertiary Butyl Ether) and 83% unleaded gas-
oline can also be used. Fuel blended with ethanol, MTBE or ETBE are
also referred to as reformulated or clean air gasoline.
These fuels contribute less emissions to the atmo-
sphere. Chrysler Corporation recommends that
blended fuels be used when available
METHANOL BLENDS Using gasoline blended with methanol can result
in starting and driveability problems. Deterioration
of fuel system components will result. Methanol in-
duced problems are not the responsibility of Chrysler
Corporation and may not be covered by the vehicle
warranty. NON-TURBOCHARGED ENGINES
Use regular unleaded gasoline having a minimum
octane rating of 87 (R+M)/2. Higher octane premium
unleaded gasoline can be used if desired.
2.2L 16 VALVE TURBOCHARGED ENGINE
Use premium unleaded gasoline having a mini-
mum octane rating of 91 (R+M)/2. Gasoline with oc-
tane rating less than 91 (R+M)/2 can be used if
recommended gasoline is not available. Low octane
gasoline will reduce engine performance.
FLEXIBLE FUEL VEHICLES
CAUTION: Do not use 100% methanol, damage to
fuel system can result. Use unleaded regular gasoline having a minimum
octane rating of 87 (R=M)/2 and M85 fuel that is
85% methanol and 15% unleaded gasoline, or a mix-
ture of these two.
FUEL FILTER
The fuel filter requires service only when a fuel
contamination problem is suspected. For proper diag-
nostic and service procedures refer to Group 14, Fuel
System,
IGNITION CABLES, DISTRIBUTOR CAP, AND
ROTOR
Inspect and test ignition cables, distributor cap and
rotor when the spark plugs are replaced. Oil and
grime should be cleaned from the ignition cables and
distributor cap to avoid possible spark plug fouling.
Mopar, Foamy Engine Degreaser, or equivalent is
recommended for cleaning the engine compartment.
For proper service and diagnostic procedures refer to
Group 8D, Ignition System.
SPARK PLUGS
Ignition spark plugs should be replaced at the
mileage interval described in the Lubrication and
Maintenance Schedules. Refer to the General Infor-
mation section of this group. For proper service pro-
cedures refer to Group 8D, Ignition Systems.
DRIVE BELTS
Inspect and adjust drive belts at the interval de-
scribed in the Lubrication and Maintenance Sched-
ules. Refer to General Information section of this
group. For proper inspection and adjustment proce-
dures, see Group 7, Cooling System.
EMISSION CONTROL SYSTEM
Inspect all emission control components and hoses
when other under hood service is performed. Refer to
emission system Vacuum Hose Label located on the
0 - 14 LUBRICATION AND MAINTENANCE Ä

The power steering pump drive belt should be in-
spected at the time and distance interval described in
the Lubrication and Maintenance Schedules. Refer to
the General Information section of this group.
POWER STEERING FLUID INSPECTION
WARNING: ENGINE MUST NOT BE RUNNING WHEN
INSPECTING POWER STEERING FLUID LEVEL,
PERSONAL INJURY CAN RESULT.
CAUTION: Do not over fill power steering reservoir
when adding fluid, seal damage and leakage can re-
sult.
TO INSPECT FLUID LEVEL:
(1) Position vehicle on a level surface with engine
at normal running temperature. (2) Turn OFF engine and remove ignition key.
(3) Using a wiping cloth, clean oil and dirt residue
from around power steering reservoir cap. (4) Remove reservoir cap or dipstick and wipe off
fluid. (5) Install cap or dipstick.
(6) Remove cap or dipstick. Holding handle or cap
above tip of dipstick, read fluid level (Fig. 4, 5, or 6).
Add fluid if reading is below cold level mark on dip-
stick.
REAR WHEEL BEARINGS
INSPECTION
The rear wheel bearings should be packed with
new lubricant at the distance interval described in the Lubrication and Maintenance Schedules. Refer to
the General Information section of this group. The
bearings should be inspected for contamination and
wear before they are cleaned. Slight discoloration of
bearing rollers and race cup is normal. If metal
Fig. 3 Ball Joint Lubrication
Fig. 4 Power Steering Reservoir DipstickÐ2.2L or 2.5L Engine
Fig. 5 Power Steering Reservoir DipstickÐ3.0L Engine
Fig. 6 Power Steering Reservoir DipstickÐ3.3L or3.8L Engine
0 - 20 LUBRICATION AND MAINTENANCE Ä

COOLING SYSTEM
CONTENTS
page page
ACCESSORY DRIVE BELTS ............... 24
ENGINE BLOCK HEATER ................. 28
GENERAL INFORMATION .................. 1 SERVICE PROCEDURES
.................. 10
SPECIFICATIONS ....................... 29
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.
COOLING SYSTEM
The cooling system consists of an engine cooling
module, thermostat, coolant, a water pump to circu-
late the coolant. The engine cooling module may con-
sist of a radiator, electric fan motor, shroud, radiator
pressure cap, coolant reserve system, transmission oil
cooler, hoses, clamps, air condition condenser, trans-
mission oil lines and charge air cooler.
² When Engine is cold: Thermostat is closed, cooling
system has no flow through the radiator. The coolant
bypass flows through the engine only. ²
When Engine is warm: Thermostat is open, cooling
system has bypass flow and coolant flow through ra-
diator. Its primary purpose is to maintain engine temper-
ature in a range that will provide satisfactory engine
performance and emission levels under all expected
driving conditions. It also provides hot water (cool-
ant) for heater performance and cooling for auto-
matic transmission oil. It does this by transferring
heat from engine metal to coolant, moving this
heated coolant to the radiator, and then transferring
this heat to the ambient air. Coolant flow circuits for 2.2L and 2.5L engine
equipped vehicles are shown in (Fig 1). Turbocharged
equipped engines coolant routing and plumbing are
shown in (Fig 2). The 3.0L engine coolant routing is
shown in (Fig 3). The 3.3L and 3.8L engine coolant
routing is shown in (Fig 5).
Fig. 1 Cooling System OperationÐ2.2/2.5L Engines
Ä COOLING SYSTEM 7 - 1

INSPECTION Replace water pump body assembly if it has any of
these defects: (1) Cracks or damage on the body.
(2) Water leaks from the shaft seal, evident by
coolant traces below the vent hole. (3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the hous-
ing.
ASSEMBLY
Body assembly and housing are serviced as separate
components. (1) Install new O-ring gasket in body O-ring groove.
(2) Assemble pump body to housing and tighten nine
screws to 12 N Im (105 in. lbs.) (Fig. 2).
(3) Rotate pump by hand to check for freedom of
movement. (4) Position water pump pulley to water pump.In-
stall three screws and tighten to 30 N Im (250 in. lbs.).
(5) Position new O-ring in housing to block O-ring
groove.
INSTALLATION (1) On Turbo III engines install the coolant deflector
into the block before installing pump on engine (Fig. 3).
Install spacer between the pump and block for
Turbo III only before tightening pump to speci-
fications. Tighten three top screws (Fig. 1) to 28 N Im
(250 in. lbs.) and lower screw to 68 N Im (50 ft. lbs.).
(2) Install bypass/heater hose and lower radiator
hose. (3) Install generator and air conditioning compres-
sor bracket(s). For solid mount bracket see standard
service procedures in Group 9 Engine. (4) Install generator and air conditioning compres-
sor. (5) Refill cooling system. See
Refilling Cooling
System. (6) Install drive belt, See Accessory Drive Belts,
this Group.
WATER PUMPÐ3.0L ENGINE
The 3.0L pump bolts directly to the engine block,
using a gasket for pump to block sealing (Fig. 4). The
pump is serviced as a unit. The water pump is driven by the timing belt. See
Timing System in Group 9, Engine for component re-
moval providing access to water pump.
REMOVAL (1) Drain cooling system. Refer to Draining Cool-
ing System in this group. (2) Remove mounting bolts.
(3) Separate pump from water inlet pipe (Figs. 4
and 5) and remove.
INSPECTION Replace the water pump if it has any of the follow-
ing defects.
Fig. 4 Water PumpÐ3.0L Engine
Fig. 5 Water Pump Inspection
Fig. 3 Coolant DeflectorÐTurbo III
Ä COOLING SYSTEM 7 - 11

(1) Damage or cracks on the pump body.
(2) Coolant leaks, if the shaft seal is leaking, evi-
dent by traces of coolant leaks from vent hole A in
(Fig. 5). (3) Impeller rubs inside of pump.
(4) Excessively loose or rough turning bearing.
INSTALLATION (1) Clean all gasket and O-ring surfaces on pump
and water pipe inlet tube. (2) Install new O-ring on water inlet pipe (Fig. 6).
Wet the O-ring with water to facilitate assembly.
CAUTION: Keep the O-ring free of oil or grease.
(3) Install new gasket on water pump and install
pump inlet opening over water pipe, press assembly
to cause water pipe insertion into pump housing. (4) Install pump to block mounting bolts and
tighten to 27 N Im (20 ft. lbs.).
(5) See Timing System in Engine, Group 9 and in-
stall timing belt. Reassemble engine. (6) Fill cooling system. See Refilling Cooling Sys-
tem.
WATER PUMPÐ3.3L AND 3.8L ENGINES
The pump has a die cast aluminum body and a
stamped steel impeller. It bolts directly to the chain
case cover, using an O-ring for sealing. It is driven
by the back surface of the Poly-V Drive Belt.
REMOVAL (1) Drain Cooling System. Refer to Draining Cool-
ing System in this group. (2) Remove Poly V Drive Belt.
(3) Remove right front lower fender shield.
(4) Remove pump pulley bolts and remove pulley.
(5) Remove pump mounting screws (Fig. 7). Re-
move pump. (6) Remove and discard O-ring seal. (7) Clean O-ring groove and O-ring surfaces on
pump and chain case cover. Take care not to scratch
or gouge sealing surface.
INSPECTION
Replace the water pump if it has any of the follow-
ing defects. (1) Damage or cracks on the pump body.
(2) Coolant leaks; if the seal is leaking, evident by
traces of coolant leaks from vent hole. (3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or chain-
case cover.
INSTALLATION
(1) Install new O-ring in O-ring groove (Fig. 8).
(2) Install pump to chain case cover. Torque screws
to 12 N Im (105 in. lbs.).
(3) Rotate pump by hand to check for freedom of
movement. (4) Position pulley on pump. Install screws and
torque to 30 N Im (250 in. lbs.).
Fig. 6 Water Pipe O-Ring
Fig. 7 Water PumpÐ3.3L and 3.8L Engines
Fig. 8 Water Pump Body
7 - 12 COOLING SYSTEM Ä