1993 CHEVROLET PLYMOUTH ACCLAIM height adjustment

FRONT SUSPENSION SERVICE PROCEDURES INDEX
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Ball Joints .............................. 13
Hub and Bearing Assembly ................. 20
Knuckle (Front Suspension) ................. 16
Lower Control Arm ....................... 10
Lower Control Arm Pivot Bushings ........... 11 Shock Absorbers (Strut Damper)
............. 10
Strut Damper Assembly ..................... 7
Suspension Coil Springs .................... 9
Sway Bar .............................. 14
Wheel Alignment .......................... 5
WHEEL ALIGNMENT
Front wheel alignment is the proper adjustment of
all interrelated front suspension angles. These angles
are what affects the running and steering of the
front wheels of the vehicle. The method of checking front alignment will vary
depending on the type of equipment being used. The
instructions furnished by the manufacturer of the
equipment should always be followed. With the ex-
ception that the alignment specifications recom-
mended by Chrysler Corporation be used. There are six basic factors which are the founda-
tion to front wheel alignment. These are height,
caster, camber, toe-in, steering axis inclination and
toe-out on turns. Of the six basic factors only camber
and toe in are mechanically adjustable (Fig. 1)
CAUTION: Do not attempt to modify any suspen-
sion or steering components by heating or bending
of the component.
Wheel alignment adjustments and checks should be
made in the following sequence. (1) Camber
(2) Toe
Camber is the number of degrees the top of the
wheel is tilted inward or outward from true vertical.
Inward tilt is negative camber. Outward tilt is posi-
tive camber. Excessive camber is a tire wear factor: negative
camber causes wear on the inside of the tire, while
positive camber causes wear to the outside. Toe
is measured in degrees or inches and is the
distance the front edges of the tires are closer (or far-
ther apart) than the rear edges. See Front Wheel
Drive Specifications for Toesettings.
PRE-ALIGNMENT
Before any attempt is made to change or correct
the wheel alignment factors. The following inspection
and necessary corrections must be made on those
parts which influence the steering of the vehicle. (1) Check and inflate tires to recommended pres-
sure. All tires should be the same size and in good
condition and have approximately the same wear.
Note type of tread wear which will aid in diagnosing,
see Wheels and Tires, Group 22. (2) Check front wheel and tire assembly for radial
runout. (3) Inspect lower ball joints and all steering link-
age for looseness. (4) Check for broken or sagged front and rear
springs. Front suspension must only be checked after the
vehicle has had the following checked or adjusted.
Tires set to recommended pressures, full tank of fuel,
no passenger or luggage compartment load and is on
a level floor or alignment rack. Just prior to each alignment reading. The vehicle
should be bounced (rear first, then front) by grasping
bumper at center and jouncing each end an equal
number of times. Always release bumpers at bottom
of down cycle.
Ä SUSPENSION AND DRIVESHAFTS 2 - 5

the lower clamps and bolts. The center offset in the
sway bar should be oriented toward the front of the
vehicle (Fig. 16)(3) Position bushing retainers on lower control arms
and install bolts (Fig. 16). (4) With lower control arms raised to design height,
tighten all retainer attaching bolts to 70 N Im (50 ft.
lbs.) torque. (5) Lower vehicle.
KNUCKLE (FRONT SUSPENSION)
The front suspension knuckle (Fig. 1) provides for
steering control of the vehicle. Supports the brake
caliper and absorbs the loads exerted during vehicle
braking. It also supports the front (driving) hub and
bearing and stub axle assembly. The front suspension knuckle also provides the abil-
ity to align the front wheels of the vehicle. This is done
by allowing for front wheel camber adjustment and the
ability for front tire Toe adjustments The front suspension knuckle is not a serviceable
component. Do not attempt to straighten or repair the
front suspension knuckle in any way. Service repair or replacement of the front (drive) hub
and bearing, can be done with the front suspension
knuckle remaining on the vehicle.
REMOVAL
(1) Remove the cotter pin, hub nut lock and spring
washer from the front axle (Fig. 2). (2) Loosen hub nut while the vehicle is on the floor
with the brakes applied (Fig. 3). The hub and drive-
shaft are splined together through the knuckle
(bearing) and retained by the hub nut. (3) Raise and support the vehicle. See Hoisting in
Lubrication and Maintenance, Group 0. (4) Remove the wheel lug nuts, front tire and
wheel assembly and hub nut and washer. (5) Remove the brake caliper adapter to steering
knuckle attaching bolts and washers (Fig. 1). Re-
move the brake caliper and adapter from the steering
knuckle and braking disc. Support brake caliper/
adapter assembly using a wire hook and not by hy-
draulic hose (Fig. 4). (6) Remove the braking disc from the front hub/
bearing assembly (Fig. 5). (7) Remove the cotter pin and nut from the tie rod
end. Remove the tie rod end from the steering
knuckle arm using Puller, Special Tool C-3894-A
(Fig. 6). (8) Remove the clamp nut and bolt (Fig. 7) secur-
ing the ball joint stud into the steering knuckle. (9) Separate ball joint stud from knuckle assembly
by prying down on lower control arm. Pull knuckle
assembly out and away from driveshaft (Fig. 8).
Fig. 2 Remove Cotter Pin, Hub Nut Lock, & Spring Washer
Fig. 3 Loosen Hub Nut
Fig. 1 Front Knuckle Assembly (Typical)
2 - 16 SUSPENSION AND DRIVESHAFTS Ä

PISTONS: Are aluminum alloy with a steel strut,
short height, and thin wall so as to be autothermic
and light weight. The piston head with valve re-
cesses, in combination with the cylinder head, forms
a compact spherical head with clearance for total
valve lift with pistons at top dead center. The piston
skirt, top and second ring lands are finished to a ta-
pered roughness for oil retention and high resistance
to scuffing. Piston pins, press-fitted into place, join
the pistons to the connecting rods. CYLINDER HEAD: The alloy cylinder heads fea- ture cross-flow type intake and exhaust ports. Valve
guides and inserts are hardened cast iron. Valves of
heat resistance steel are arranged i
n a V with each
camshaft on center. To improve combustion speed the
chambers are a compact spherical design with a
squish area of approximately 30 percent of the piston
top area. The cylinder heads are common to either
cylinder bank by reversing the direction of installa-
tion. CAMSHAFTS: Two overhead camshafts provide
valve actuation, one front (radiator side of cylinder
bank) and one rear. The front camshaft is provided
with a distributor drive and is longer. Both cam-
shafts are supported by four bearing journals, thrust
for the front camshaft is taken at journal two and
the rear at journal three. Front and rear camshaft
driving sprockets are interchangeable. The sprockets
and the engine water pump are driven by a single
notched timing belt. ROCKER ARM SHAFTS: The shafts are retained
by the camshaft bearing journal caps. Four shafts are
used, one for each intake and exhaust rocker arm as-
sembly on each cylinder head. The hollow shafts pro-
vide a duct for lubricating oil flow from the cylinder
head to the valve mechanisms. ROCKER ARMS: Are of light weight die-cast
with roller type follower operating against the cam
shaft. The valve actuating end of the rocker arms are
machined to retain hydraulic lash adjusters, elimi-
nating valve lash adjustment. VALVES: Are made of heat resistant steel and are
further treated to resist heat. VALVE SPRINGS: Are especially designed to be
short. The valve spring wire cross-section is oval
SPECIFICATIONS
Fig. 1 Engine Identification
Ä 3.0L ENGINE 9 - 67

length of the spring to be tested is 33.34mm (1-5/16
inches). Turn table of Tool C-647 until surface is in line
with the 33.34mm (1-5/16 inch) mark on the threaded
stud and the zero mark on the front. Place spring over
stud on the table and lift compressing lever to set tone
device. Pull on torque wrench until ping is heard. Take
reading on torque wrench at this instant. Multiply this
reading by two. This will give the spring load at test
length. Fractional measurements are indicated on the
table for finer adjustments. Refer to specifications to
obtain specified height and allowable tensions. Discard
the springs that do not meet specifications.
VALVE INSTALLATION
(1) Coat valve stems with clean engine oil and insert
them in cylinder head. (2) Check valve tip to spring seat dimension A after
grinding the valve seats or faces. Grind valve tip to give
49.541 to 51.271 mm (1.950 to 2.018 inch.) over spring
seat when installed in the head (Fig. 17). Check valve
tip for scoring, if necessary, the tip chamfer should be
reground to prevent seal damage when the valve is
installed. (3) Install new cup seals on all valve stems and over
valve guides (Fig. 24). Install valve springs and valve
retainers.
(4) Compress valve springs with Valve Spring Com-
pressor Tool C-3422-B, with adapter 6412 install locks
and release tool. If valves and/or seats are re-
ground, measure the installed height of springs
dimension B, make sure measurements is taken
from top of spring seat to the bottom surface of
spring retainer. If height is greater than 1-19/32
inches, (40.6mm), install a 1/32 inch (.794mm)
spacer in head counterbore to bring spring
height back to normal 1-17/32 to 1-19/32 inch (39.1
to 40.6mm) .
REPLACE VALVE STEM SEALS OR VALVE
SPRINGS, CYLINDER HEAD NOT REMOVED
(1) Perform fuel system pressure release procedure
before attempting any repairs (2) Disconnect negative battery cable. (3) Remove Air Cleaner Cover and hose assembly.
(4) Remove Intake Manifold; Refer to
Intake/Exhaust Manifold 3.3/3.8L Engine Group 11
Exhaust System and Intake Manifolds of this manual
for removal procedure. (5) Remove cylinder head covers and spark plugs.
(6) Remove connector wire from ignition coils.
(7) Using suitable socket and flex handle at crank-
shaft pulley retaining screw, turn engine so the num-
ber 1 piston is at Top Dead Center on the compression
stroke. (8) Remove rocker arms with rocker shaft and in-
stall a dummy shaft. The rocker arms should not be
disturbed and left on shaft. (9) With air hose attached to spark plug adapter
installed in number 1 spark plug hole, apply 90 to 100
psi air pressure (620.5 to 689 kPa). This is to hold
valves into place while servicing components. (10) Using Tool C-4682 or Equivalent compress
valve spring and remove retainer valve locks and valve
spring. (11) The intake valve stem seals should be pushed
firmly and squarely over the valve guide using the
valve stem as guide. Do Not Forceseal against top of
guide. When installing the valve retainer locks, com-
press the spring only enoughto install the locks.
CAUTION:Do not pinch seal between retainer and top
of valve guide .
(12) Follow the same procedure on the remaining 5
cylinders using the firing sequence 1-2-3-4-5-6. Make
sure piston in cylinder is at TDC on the valve
spring that is being covered. (13) Remove spark plug adapter tool .
(14) Remove dummy shaft and install rocker shaft
assembly and tighten screws to 28 N Im (250 in. lbs.).
Fig. 24 Checking Valve Installed Height
Fig. 25 Installing Valve, Cup Seal, Spring and Re-
tainer
Ä 3.3/3.8L ENGINE 9 - 107

CAUTION: See Figure 14 to determine side gear
thrust washer thickness. Side gear end play must be
within.001 to .013 inch.Four select thrust washes are available: .032, .037,
.042, and .047 inch.
Side gear thrust washers are available in 4
select thicknesses: .032, .037, .042, and .047 inch. Measure the depth from the differential case to the
machined surface in 3 places, as shown in Figure 13.
Then measure the height of raised stepon the ring
gear. The difference, minus the proper side gear end
play (.001 to .013 inch) is the proper thrust washer
thickness. For the other side gear: After assembling the differ-
ential side gears, pinion gears, and pinion gears with
the pinion gear washers but withoutthe side gear
thrust washers. Rotate the assembly two full revolu-
tions both clockwise and counterclockwise. Set up dial indicator as shown in Figure 14 and
record end play. Rotate side gear 90 degrees and record another end play. Again, rotate side gear 90
degrees and record a final end play.
Using the smallest end play recorded, shim that side
gear to within .001 to .013 inch.
CAUTION: After reassembly of the differential assem-
bly, insert the inner joint housing spline from a drive
shaft into the side gear. By hand, turn the side gear
with the joint housing spline. If the side gear will NOT
turn, or it feels very tight, remove the ring gear and
install a thinner side gear thrust washer.
Side gear thrust washers are available in four
select thicknesses: .032, .037, .042, and .047 inch.
BEARING ADJUSTMENT PROCEDURE
GENERAL RULES ON SERVICING BEARINGS
(1) Take extreme care when removing and installing
bearing cups and cones. Use only an arbor press for
installation, as a hammer may not properly align the
bearing cup or cone. Burrs or nicks on the bear-
Fig. 12 Differential Gears
Fig. 13 Determine Proper Side Gear Thrust Washer Thickness
Fig. 10 Remove or Install Pinion Shafts
Fig. 11 Remove or Install 4 Pinion Gears and 2 Side Gears
Ä TRANSAXLE 21 - 31

POWER SUNROOF INDEX
page page
Adjustment Bracket ........................ 7
Drain Channel ............................ 7
Drive Cable Locators ....................... 7
Drive Cables ............................. 8
General Information ........................ 6
Glass Panel ............................. 7 Glass Vertical Height Adjustment
.............. 6
Guide Assembly .......................... 8
Motor and Drive Gears ..................... 7
Sunshade ............................... 8
Wind Deflector ........................... 6
GENERAL INFORMATION
All sunroofs are equipped with drain tubes that are
located in the A, B or C-pillars. The drain tubes
must be kept open to prevent water from entering
the passenger compartment.
LUBRICATION
(1) Lubricate cables with Lubriplate or equivalent
when cables are replaced. (2) Periodically clean dirt from guide rail covers.
DRAIN TUBES
² Inspect the drain holes, located in the trough
around the sunroof opening to verify they are clear.
Inspection should be performed at least once a year
or when problems are suspected. If drain hose or
tubes are plugged, use compressed air or blunt flexi-
ble wire to clear them. If tubes cannot be cleared,
they must be repaired.
² The lower ends of the rear drain tubes are located
in the rear quarter panel drop wells. To clear rear
drain tubes, use compressed air or blunt flexible wire
from the lower ends of the tubes.
GLASS VERTICAL HEIGHT ADJUSTMENT
GLASS VERTICAL ADJUSTMENT (FIG. 1)
(1) Open glass to vent position.
(2) Slide upper half of mechanism covers rearward
until clips disengage and separate covers from vehi-
cle. (3) Close glass panel, separately loosen adjusting
bolts and individually adjust the corners of glass. (4) Adjust front of glass panel to 1.0 mm (0.040 in.)
below top surface of roof panel. (5) Adjust rear of glass to 1.0 mm (0.040 in.) above
top surface of roof panel. (6) Secure adjustment bolts and install cover.
WIND DEFLECTOR
WIND DEFLECTOR REMOVAL (FIG. 2)
(1) Open sun roof glass panel.
(2) Remove screws holding wind deflector to sun
roof unit side rail. (3) Separate wind deflector from vehicle.
WIND DEFLECTOR INSTALLATION
Reverse the preceding operation.
WIND DEFLECTOR ADJUSTMENT (FIG. 2)
(1) Open sunroof.
Fig. 1 Glass Adjustment
Fig. 2 Deflector Assembly
23 - 6 BODY Ä

(2) position wind deflector so 19 mm (0.75 in.)
above top surface of roof panel and 1 mm (0.040 in.)
rearward of roof panel forward edge. (3) Secure wind deflector to sunroof unit.
GLASS PANEL
GLASS PANEL REMOVAL
(1) Remove wind deflector mechanism covers (Fig.
1). (2) Position glass to vent position.
(3) Position sunshade full rearward.
(4) Loosen nuts holding glass panel to side adjust-
ment brackets. (5) Slide glass panel rearward 12 mm (0.5 in.) and
separate glass from sunroof unit.
GLASS PANEL INSTALLATION
(1) Position glass panel in opening with logo rear-
ward and slide panel forward 12 mm (0.5 in.). (2) Verify that attaching nuts are below top sur-
face of glass adjustment brackets. (3) Close sunroof to center glass panel in roof open-
ing. (4) Tighten center screws to hold adjustment.
(5) Open glass to vent position and tighten nuts to
8N Im (70.8 in-lbs.).
(6) Close glass and check alignment.
(7) Install the mechanism covers.
(8) Adjust wind deflector, if necessary.
ADJUSTMENT BRACKET
ADJUSTMENT BRACKET REMOVAL (FIG. 3)
(1) Remove wind deflector, mechanism covers and
glass panel. (2) Move glass carriage to vent position and re-
move rearward adjustment bolt from adjustment
bracket. (3) Lift rear of adjustment bracket to highest ver-
tical position and disengage front of bracket from
unit.
ADJUSTMENT BRACKET INSTALLATION
Reverse the preceding operation. Adjust glass, and
wind deflector as necessary.
DRAIN CHANNEL
DRAIN CHANNEL REMOVAL
(1) Remove wind deflector mechanism covers and
glass panel. (2) Locate glass carriage to vent position and drain
channel in full forward position. (3) Remove screws holding drain channel to sup-
port frame.
DRAIN CHANNEL INSTALLATION
Reverse the preceding operation.
DRIVE CABLE LOCATORS
DRIVE CABLE LOCATORS REMOVAL (FIG. 4)
(1) Position glass 19 mm (0.75 in.) until rearward
until cable locator is visible. (2) Remove screws holding drive cable locator to
unit. (3) Remove travel limiting micro switch grommet
and disconnect wire connector. (4) Insert a small screwdriver under rear edge of
locator and pry locator from track.
DRIVE CABLE LOCATORS INSTALLATION
Reverse the preceding operation. The small out-
board lip underneath cable locator slips under bottom
slot on guide track. After locator is seated install
screws.
MOTOR AND DRIVE GEARS
MOTOR AND DRIVE GEAR REMOVAL (FIG. 5)
(1) Open sunroof to vent position.
(2) Remove head lining.
Fig. 3 Glass Height Vertical Adjustment
Fig. 4 Removing Cable Drive Locator
Ä BODY 23 - 7