1993 CHEVROLET PLYMOUTH ACCLAIM jump start

LUBRICATION AND MAINTENANCE
CONTENTS
page page
CHASSIS AND BODY .................... 19
DRIVETRAIN ........................... 16 ENGINE
................................ 8
GENERAL INFORMATION .................. 1
GENERAL INFORMATION INDEX
page page
Classification of Lubricants .................. 1
Fluid Capacities .......................... 4
Fuel Usage .............................. 1
Hoisting Recommendations .................. 5
Introduction .............................. 1 Jump Starting Procedure
.................... 4
Parts and Lubricant Recommendations ......... 1
Parts Requiring No Lubrication ............... 4
Severe Service ........................... 1
Towing Recommendations ................... 7
INTRODUCTION
Chrysler Corporation has compiled recommended
lubrication and maintenance schedules and proce-
dures to help reduce premature wear or failure over
a broad range of operating conditions. When select-
ing the proper maintenance schedule, the climate
and operating conditions must be considered. A vehi-
cle subjected to severe usage requires service more
frequently than a vehicle used for general transpor-
tation.
PARTS AND LUBRICANT RECOMMENDATIONS
When service is required, Chrysler Corporation rec-
ommends that only Mopar tbrand parts, lubricants
and chemicals be used. Mopar tprovides the best en-
gineered products for servicing Chrysler Corporation
vehicles.
SEVERE SERVICE
If a vehicle is operated under any of the following
conditions, it is considered severe service.
² Extremely dusty areas.
² 50% or more of vehicle operation in 32ÉC (90ÉF) or
higher temperatures.
² Prolonged idling ( such as, vehicle operation in
stop and go traffic).
² Frequent short running periods. Not allowing en-
gine to warm to operating temperatures.
² Police or taxi usage.
FUEL USAGE
All Chrysler Corporation engines require the use of
unleaded fuel to reduce exhaust emissions. Use fuel
with a minimum octane rating of 87,(R + M)/2. See
Engine section of this group for Fuel Recommenda-
tions.
CLASSIFICATION OF LUBRICANTS
Only lubricants that are endorsed by the following
organizations standards should be used to service a
Chrysler Corporation vehicle.
² Society of Automotive Engineers (SAE)
² American Petroleum Institute (API)
² National Lubricating Grease Institute (NLGI)
ENGINE OIL
SAE GRADE RATING INDICATES ENGINE OIL VISCOSITY
² SAE 30 = single grade engine oil.
² SAE 5W-30 = multiple grade engine oil.
API QUALITY CLASSIFICATION.
² SG service engine oil is a high quality crankcase
lubricant designed for use in all naturally aspirated
engines.
² SG/CD service engine oil is a high quality crank-
case lubricant designed for use in most naturally as-
pirated and turbocharged gasoline or diesel engines.
GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear lu-
bricants. In addition, API classification defines the
lubricants usage.
Ä LUBRICATION AND MAINTENANCE 0 - 1

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

(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries. (4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to
negative terminal (-). DO NOT allow clamps at oppo-
site end of cables to touch, electrical arc will result
(Fig. 1). Review all warnings in this procedure. (5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 1).
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(6) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
² Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
² When using a Booster vehicle, disconnect BLACK
cable clamp from battery negative terminal. Discon-
nect RED cable clamp from battery positive terminal.
² Disconnect RED cable clamp from battery positive
terminal on disabled vehicle.
HOISTING RECOMMENDATIONS
Refer to Owner's Manual provided with vehicle for
proper emergency jacking procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN THE ENGINE OR REAR SUSPENSION IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING
CONDITIONS UNSTABLE. PROPERLY SUPPORT OR
SECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
TO HOIST OR JACK VEHICLE SEE FIG. 2 THROUGH 7:
Fig. 1 Jumper Cable Clamp Connections
Fig. 2 Hoisting and Jacking PointsÐAY Body
Fig. 3 Hoisting and Jacking PointsÐAC Body
Ä LUBRICATION AND MAINTENANCE 0 - 5

against modulator assembly. Then torque proportion-
ing valve to 35 N Im (26 ft. lbs.) torque.
(3) Install hydraulic brake line on proportioning
valve and hand start tube nut into proportioning valve.
Torque tube nut to 18 N Im (159 in. lbs.) torque.
(4) Using approved battery jumper cables, attach
battery, to the vehicles negative and positive battery
cables (Fig. 8). (5) Bleed the vehicles base brake and Antilock brake
hydraulic systems. Refer to Bleeding Bendix Antilock 4
Brake System in this service manual supplement for
required bleeding procedure. (6) Install battery acid shield (Fig. 9) onto the ABS
modulator assembly. Be sure acid shield is securely
attached to modulator assembly before installing
battery tray.
(7) Install battery tray in vehicle. Then install the 4
bolts (Fig. 10) attaching battery tray to inner fender
and frame rail. Torque the 4 battery tray attaching
bolts to 20 N Im (175 in.lbs.).
(8) If equipped, install speed control vacuum reser-
voir on battery tray. Install the 2 speed control vacuum
reservoir attaching bolts (Fig. 11). Torque the 2
vacuum reservoir attaching bolts to 4 N Im (30 in. lbs.).
(9) Install battery tray access cover (Fig. 12) on
bottom of battery tray. The access cover MUST be
on battery tray, before battery is installed in
battery tray.
Fig. 8 Battery Connected To Vehicle For Bleeding Modulator Assembly
Fig. 7 Proportioning Valve Removal From Modulator Assembly
Fig. 9 Modulator Assembly Acid Shield Installed
Fig. 10 Battery Tray Installation And Attaching Bolts
5 - 40 ANTILOCK 4 BRAKE SYSTEM Ä

(5) With test light still connected, connect milli-
amp meter between battery negative post and nega-
tive battery cable (Fig. 20). Do not open any doors or
turn on any electrical accessories with the test light
disconnected and the milliamp meter connected.
Meter may be damaged.
(6) Disconnect test light. Milliamp meter reading
should be less than 30 milliamperes. If low amperage
IOD is not within specifications, disconnect: (a) The 60 way connector at the Powertrain Con-
trol Module located outboard of the battery. Refer
to Group 8D, Ignition for more information. (b) The 25 way connectors on the Body Control-
ler if equipped. (c) The circuits to the clock and radio.
(d) The wiring harness from the generator. Refer
to Generator Testing.
Check each component until excessive IOD is found.
Each time the test light or milliamp meter is dis-
connected and connected, all electronic timer func-
tions will be activated. Tests must be repeated from
the beginning. Test light or meter MUST remain connected for all
tests.
VEHICLES EQUIPPED WITH ELECTRONIC AUTOMATIC TRANSMISSION, LOADLEVELING SUSPENSION, OR ALARM SYSTEM
This vehicles will have temporary high IOD of 15
amps or more for up to 65 minutes. This higher IOD can often mask another problem and should be con-
sidered when performing IOD testing. Testing for higher IOD will be the same as in the
previous IOD tests. However, certain additional pro-
cedures should be followed.
² WITH ALARM SYSTEM: After disconnecting bat-
tery and hooking up test light, cycle the key lock on
the driver's door to disarm the alarm. The parking
lamps should stop flashing. Also locate the Power Distribution Center. This
Center is located in front of the left front strut tower
(Fig. 21). Remove the cover from the Center and re-
move the 50 amp fuse.
² WITH ELECTRONIC AUTOMATIC TRANSMIS-
SION: If equipped with this option, and high or low
IOD is suspected, allow an additional 25 minutes
minimum of electronic shut off time. To defeat the timer, disconnect the 60-way connec-
tor on the Transmission Controller. This controller is
located on the right inner fender.
² WITH AUTOMATIC LOAD LEVELING SYSTEM:
If equipped with this option, and high or low IOD is
suspected, allow an additional 65 minutes minimum
of electronic shut off time. To defeat the timer, open the trunk lid, locate the
Automatic Load Leveling computer, located inside
right rear wheel house, and disconnect the 11-way
connector. Close the trunk lid. If equipped with an electrical trunk closing feature,
temporarily install a heavy gauge jumper wire be-
tween the disconnected negative cable and the nega-
tive battery post. When this jumper is installed the
trunk lid should automatically close. Do not discon-
nect the test light as all electronic timing features
will be activated and all IOD tests must be repeated
from the beginning. Remove the temporarily installed jumper wire.
Fig. 20 Low Amperage IOD Test
Fig. 21 Power Distribution Center
8A - 10 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Ä

STARTER TEST PROCEDURES ON VEHICLE INDEX
page page
Diagnostic Preparation ..................... 11
General Information ....................... 11 Starter Control Circuit Tests
................ 15
Starter Feed Circuit Tests .................. 11
GENERAL INFORMATION
The starting system (Fig. 1) has:
² Ignition switch
² Starter relay (Fig. 2)
² Neutral starting and back-up switch with auto-
matic transmissions
² Clutch pedal mounted starter interlock switch
with manual transmissions
² Wiring harness
² Battery
² Starter motor with an integral solenoid
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
less than 20 amps.
DIAGNOSTIC PREPARATION
Before going on with starting system diagnostics,
verify: (1) The battery top, posts, and terminals are clean.
(2) The generator drive belt tension and condition
is correct. (3) The battery state-of-charge is correct.
(4) The battery will pass load test.
(5) The battery cable connections at the starter
and engine block are clean and free from corrosion. (6) The wiring harness connectors and terminals
are clean and free from corrosion. (7) Proper circuit grounding.
(8) Refer to Starter System Diagnostics (Fig. 3).
STARTER FEED CIRCUIT TESTS
The following procedure will require a suitable
volt/ampere tester (Fig. 4).
CAUTION: Ignition system also must be disabled to
prevent engine start while performing the following
tests.
(1) Connect a volt-ampere tester (Fig. 4) to the bat-
tery terminals (Fig. 5). Refer to the operating in-
structions provided with the tester being used. (2) Disable ignition system as follows:
² VEHICLES WITH CONVENTIONAL DISTRIBU-
TORS: Disconnect the ignition coil cable from the
distributor cap. Connect a suitable jumper wire be-
tween the coil cable end-terminal and a good body
ground (Fig. 6).
Fig. 1 Starting Components/Wiring
Fig. 2 Starter Relay
Ä BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 11

STARTER FEED CIRCUIT RESISTANCE TEST
Before going on with this operation, review Diag-
nostic Preparation and Starter Feed Circuit Tests.
The following operation will require a voltmeter, ac-
curate to 1/10 of a volt.
CAUTION: Ignition system also must be disabled to
prevent engine start while performing the following
tests.
(1) Disable ignition system as follows:
² VEHICLES WITH CONVENTIONAL DISTRIBU-
TORS: Disconnect the ignition coil cable from the
distributor cap. Connect a suitable jumper wire be-
tween the coil cable end-terminal and a good body
ground (Fig. 6).
² VEHICLES WITH DIRECT IGNITION SYSTEM:
Disconnect the ignition coils electrical connector (Fig.
7). (2) With all wiring harnesses and components
properly connected, perform the following: (a) Connect the negative lead of the voltmeter to
the negative battery post, and positive lead to the
negative battery cable clamp (Fig. 9). Rotate and
hold the ignition switch in the START position.
Observe the voltmeter. If voltage is detected, cor-
rect poor contact between cable clamp and post. (b) Connect positive lead of the voltmeter to the
positive battery post, and negative lead to the pos-
itive battery cable clamp. Rotate and hold the igni-
tion switch key in the START position. Observe the
voltmeter. If voltage is detected, correct poor con-
tact between the cable clamp and post.
(c) Connect negative lead of voltmeter to nega-
tive battery terminal, and positive lead to engine
block near the battery cable attaching point (Fig.
10). Rotate and hold the ignition switch in the
START position. If voltage reads above 0.2 volt,
correct poor contact at ground cable attaching point. If voltage reading is still above 0.2 volt after
correcting poor contacts, replace ground cable.
(3) Remove starter heat shield. Refer to Starter re-
placement to gain access to the starter motor and so-
lenoid connections. Perform the following steps: (a) Connect positive voltmeter lead to the starter
motor housing and the negative lead to the nega-
tive battery terminal (Fig. 11). Hold the ignition
switch key in the START position. If voltage reads
above 0.2 volt, correct poor starter to engine
ground.
(b) Connect the positive voltmeter lead to the
positive battery terminal, and negative lead to bat-
tery cable terminal on starter solenoid (Fig. 12).
Rotate and hold the ignition switch key in the
START position. If voltage reads above 0.2 volt,
correct poor contact at battery cable to solenoid
connection. If reading is still above 0.2 volt after
correcting poor contacts, replace positive battery
cable. (c) If resistance tests do not detect feed circuit
failures, remove the starter motor and go to Bench
Testing Starter Solenoid.
Fig. 9 Test Battery Connection Resistance
Fig. 10 Test Ground Circuit Resistance
Fig. 11 Test Starter Motor Ground
8A - 14 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Ä

STARTER CONTROL CIRCUIT TESTS
The starter control circuit has:
² Starter solenoid
² Starter relay (Fig. 2)
² Neutral starting and back-up switch with auto-
matic transmissions
² Clutch pedal mounted starter interlock switch
with manual transmissions
² Ignition switch
² Battery
² All related wiring and connections
CAUTION: Before performing any starter tests, the
ignition system must be disabled.
² VEHICLES EQUIPPED WITH A CONVEN-
TIONAL DISTRIBUTOR: Disconnect coil wire from
distributor cap center tower. Secure wire to a good
ground to prevent engine from starting (Fig. 6).
² VEHICLES EQUIPPED WITH DIRECT IGNI-
TION SYSTEM: Unplug the coils electrical connector
(Fig. 7).
STARTER SOLENOID TEST
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN PARK OR NEUTRAL WITH THE
PARKING BRAKE APPLIED
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests. (2) Perform this starter solenoid test BEFORE per-
forming the starter relay test. (3) Raise the vehicle.
(4) Perform a visual inspection of the starter/
starter solenoid for corrosion, loose connections or
faulty wiring. (5) Lower the vehicle.
(6) Locate the starter relay as follows:
² On AC, AG, AJ and AY Bodies the relay is located
in the Power Distribution Center. This Center is mounted near the front of the left front strut tower
(Fig. 13). The position of the starter relay within this
Center will be shown on the Center cover.
² On AA/AP Bodies the relay is located on the front
of the left front strut tower (Fig. 14).
(7) Remove the starter relay from the connector.
(8) Connect a remote starter switch or a jumper
wire between the battery positive post and terminal
87 on the starter relay connector. To decide the
starter relay terminal numbers, refer to the Starter
Relay Tests.
² If engine now cranks, starter/starter solenoid is
good. Go to the starter relay test.
² If engine does not crank with this test, or solenoid
chatters, check wiring and connectors from starter
Fig. 12 Test Positive Battery Cable Resistance
Fig. 13 Starter Relay LocationÐAC, AG, AJ, and AY Bodies
Fig. 14 Starter Relay LocationÐAA/AP Body
Ä BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 15