1993 CHEVROLET PLYMOUTH ACCLAIM roof

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

VARIANCE SETTING PROCEDURE
There are two methods for setting variance while
in variance set mode. If the CAL symbol is on proce-
dure 2 must be used.
PROCEDURE 1
(1) Turn ignition switch to the on position.
(2) Press and hold the Comp/Temp button till the
display is turned OFF. (3) While continuing to hold Comp/Temp button
depress and hold US/Metric button until the VAR
symbol lights in approximately 5 seconds. (4) Release buttons.
(5) To determine the zone number which, corre-
sponds with your geographic area refer to Fig. 4.
(6) Press the US/Metric button until the zone num-
ber matches the display. (7) Press the Comp/Temp button to finish setting
of variation. (8) Variation is complete.
PROCEDURE 2 (1) Move away from any large metal objects like
buildings, or bridges. With the engine running and
the doors closed point vehicle true north. (2) Press and hold Comp/Temp button. The display
will go blank. (3) While continuing to hold Comp/Temp button
depress and hold the US/Metric button until the
VAR symbol lights in approximately 5 seconds. (4) Release buttons.
(5) Press the Comp/Temp button to finish setting
of variation. (6) Variation is complete.
DEMAGNETIZING PROCEDURE
Do not attach magnetic devices, such as magnetic
CB antennas to the vehicle roof, as they can cause
the compass to give false readings. Every vehicle has its own magnetic field. This
magnetic field is created by the various processes a
steel roof goes through when the vehicle is built. A
magnetic field also can be created if the roof is sub-
jected to A magnet, example:
² Magnetic c.b. antenna
² Magnetic tipped screwdriver and etc.
If the roof becomes magnetized use a demagnetiz-
ing Tool 6029 to demagnetize the roof. In this demagnetizing procedure you will use the
demagnetizing tool to demagnetize the roof and
mounting screws in the overhead console. It is impor-
tant that you follow the instructions below exactly.
The mounting screws and the mounting brackets
around the compass area are steel, and therefore aid
in the degaussing of the roof panel. (1) Be sure the ignition switch is in the OFF posi-
tion before you begin the demagnetizing procedure. (2) Open the sun glass compartment to gain access
to the overhead console mounting screws. (3) Plug the demagnetizing tool into a standard
110/115 volt AC outlet, keeping the demagnetizing
tool at least 12 inches away from the compass area
when plugging it in. (4) Slowly approach the console mounting screw
with the plastic coated tip of the tool for at least 2
seconds. (5) With the demagnetizing tool still energized,
slowly back it away from the screw until the tip is at
least 12 inches from the screw head. (6) After you have pulled at least 12 inches from
the last screw, remove the demagnetizing tool from
inside of the vehicle and disconnect it from the elec-
trical outlet. (7) Place an 8 1/2 in. X 11 in. piece of paper
lengthwise on the roof of vehicle directly above com-
pass. The purpose of the paper is to protect the roof
panel from scratches and define the area to be de-
magnetized.
Fig. 4 Variance Settings
8C - 4 OVERHEAD CONSOLE Ä

(8) Plug in the demagnetizing tool, keeping it at
least 2 feet away from the compass unit. (9) Slowly approach the center of the roof panel at
the windshield with the demagnetizing tool plugged
in.
² Contact the roof panel with the tip of the tool.
² Using slow sweeping motions of 1/2 inch between
sweeps
² Move the tool approximately 4 inches either side of
the centerline, and at least 11 inches back from the
windshield. (10) With the demagnetizing tool still energized,
slowly back away from the roof panel until the tip is
at least two feet from the roof before unplugging the
tool. (11) Recalibrate compass.
COMPASS DIAGNOSTICS
To place the unit into the diagnostics mode, turn
the vehicle ignition off. Depress the Comp/Temp but-
ton while turning on the ignition/run switch. The
display will then show DO. There are three tests that
can be performed when in the diagnostics mode.
Press the U.S./Metric button to choose test desired
(Fig. 5).
Test 1 (d1) determines the magnetic field strength
at the compass. The compass displays compensation
numbers which, correspond to the current magnetic
field strength at the compass. The letter N is dis-
played in the compass portion of the display. While a
number which, corresponds to the magnetic field
strength in the North/South direction is displayed.
The temperature portion of the display or the letter
W is displayed in the compass portion of the display. A number which, corresponds to the magnetic field
strength in the East/West direction is displayed in
the temperature portion of the display. For proper
compass operation the numbers should be between 1
and 14. A number of 7 or 8 is ideal (no vehicle mag-
netism) while numbers approaching 1 or 14 show
that the vehicle is highly magnetic. If the numbers
show that the vehicle is highly magnetic, perform
the demagnetized procedure in this Group and retest
for magnetism at compass. Test 2 (d2) checks the electronic circuits of the
compass, temperature. If the test passes d2 will be
displayed, and if the test fails F2 will be displayed.
Refer to Body Diagnostic Procedure Manual for fur-
ther testing procedures. Test 3 (d3) performs a walking segment test which,
sequentially puts different directions and numbers on
the display. If any segment fails, replace the compass
module.
SELF-DIAGNOSTIC TEST
(1) With the ignition switch in the OFF position si-
multaneously press the Comp/Temp button and the
US/Metric button. (2) Turn ignition switch ON.
(3) Continue to hold both buttons until the display
performs a walking segment test. This checks for
open or shorted segments. To repeat the test press
the Comp/Temp button. (4) Press the US/Metric button, all segments will
light for about 2 seconds. To repeat the test press the
Comp/Temp button. (5) Press the US/Metric button to return to normal
operation.
OVERHEAD CONSOLE REPLACEMENT
(1) Unscrew the mounting screw in sun glass bin
compartment (Fig. 6).
(2) Slide console forward toward windshield until
the console unhooks from roof bracket. (3) Disconnect wire harness from console.
(4) For installation reverse above procedures.
Fig. 5 Terminal Identification
Fig. 6 Overhead Console Mounting
Ä OVERHEAD CONSOLE 8C - 5

COMPASS MODULE REPLACEMENT
(1) Remove overhead console.
(2) Using a small screwdriver, release the 2 snaps
at rear of compass module. (3) After releasing the 2 snaps, slide compass mod-
ule rearward until free of mounting bar. (4) For installation reverse above procedures.
AMBIENT TEMPERATURE SENSOR
(1) Raise and support vehicle on safety stands.
(2) From behind front bumper fascia, remove screw
attaching sensor to front lower crossmember (Fig. 7). (3) For installation, reverse above procedures.
AC AND AY BODY
INDEX
page page
Ambient Temperature Sensor ............... 12
Automatic Calibration Set Procedure ........... 8
Bezel/Button Switch Removal ............... 10
Bus Accessed Diagnostics .................. 10
Console Removal ........................ 10
Electronic Board Assembly Replacement ....... 10
Electronic Vehicle Information Center (EVIC) Overhead Console ....................... 6 Engine Compartment Node Removal
.......... 12
EVIC Self Check Diagnostics ................ 8
Manual Calibration Set Procedure ............. 8
Map Reading Lamps/Power Sunroof Switch Removal .............................. 11
Overhead Reading/Courtesy Lamp Console ..... 11
Wiring Harness Removal ................... 10
ELECTRONIC VEHICLE INFORMATION CENTER
(EVIC) OVERHEAD CONSOLE
The Electronic Vehicle Information Center is a
computer controlled warning system which, monitors
various sensors used on the vehicle. The system sup-
plements the warning indicators in 8the instrument
cluster. Visual warning messages are displayed by a
digital display in the overhead console (Fig. 1).
When a warning message has been activated, a
tone will sound to attract the driver's attention. The
warning message will then be displayed on the over-
head console until the condition is corrected or a new
display function is called up. A tone will announce each new warning condition.
For complete diagnostic procedures for the EVIC
systems, refer to the Body-Chassis Diagnostic Test
Procedures Manual. The EVIC has a 24 function system that provides
the driver with visual messages when a warning con-
dition exists. These messages are displayed on the
overhead console. For complete EVIC overhead console operating in-
structions, refer to the Owners Manual provided with
the vehicle.
EVIC BUTTON FUNCTIONS
TIME button will display:
² Time of day
² Day of week
² Day of month
² Month of year
The body controller is the source of this informa-
tion. The EVIC function buttons are used to reset
and display this data.
² To set HOURS, press TIME button and within four
seconds press the SET button. An arrow will appear
on the display and point to the hours. Press and hold
the SET button to advance the hours or INFO button
to set back the hours.
² To set MINUTES, press TIME button. The arrow
will point to the minutes. Press and hold the SET
button to advance the minutes or INFO button to set
back the minutes.
Fig. 7 Ambient Temperature Sensor
Fig. 1 EVIC Overhead Console
8C - 6 OVERHEAD CONSOLE Ä

MAP READING LAMPS/POWER SUNROOF SWITCH
REMOVAL
SWITCH REPLACEMENT
(1) Remove console, refer to Console Replacement.
(2) Disconnect switch wiring connector from re-
taining bracket. (3) Pry switch out of bezel snap tabs.
(4) Replace switch.
(5) For installation reverse above procedures.
LAMP/LENS REMOVAL
(1) Remove lens by inserting a flat blade tool into
slot located on the left side of lens. Pry lens to the
side and swing down as it unhooks from housing
(Fig. 4). (2) Replace lamp as necessary.
(3) Position lens with the center tabs on the left
side of lens snap into place. The lens are identified
with L and R on the reverse side. Do not reverse the
lens or it may damage the lens tabs.
POWER SUNROOF SWITCH/BEZEL REMOVAL
(1) Remove console, refer to Overhead Reading/
Courtesy Lamp Console Replacement. (2) Disconnect switch wiring connector from re-
taining bracket. (3) Pry switch out of bezel. Replace switch. If nec-
essary, push carefully at top closest to roof of bezel to
disengage trim bezel and pivot bezel out of housing. (4) Replace switch.
(5) For installation reverse above procedures.
OVERHEAD READING/COURTESY LAMP CONSOLE
The two reading/courtesy lamps are actuated by
pressing on the switch (Fig. 7):
² Courtesy lamps for when a door is opened
² Illuminated entry system is activated
² Headlamp switch is turned fully clockwise
The map lamp console also includes:
² A cubby storage bin. ²
Power sunroof switch, if equipped.
READING/COURTESY LAMP CONSOLE
REMOVAL
(1) Remove screws from visor tip-pin retainers.
(2) Slide console forward until free from retainer
bracket. (3) Disconnect wiring.
(4) For installation reverse above procedures. For
vehicles equipped with sunroof, avoid sliding console
to install. Install screws for console attachment and
push at rear of unit to snap over mounting bracket
for engagement.
LAMP/LENS REMOVAL
(1) Remove lens by inserting a flat blade tool be-
tween the round end of lamp lens and housing. Pry
lens from the housing. Pivot the lens and remove
(Fig. 7). (2) Replace lamp as necessary.
(3) Position lens into housing by locating lens
pivot and snap into place.
OVERHEAD CONSOLE WIRING HARNESS REMOVAL
(1) Remove console, refer to Overhead Reading/
Courtesy Lamp Console Removal. (2) Disconnect wiring connector from retaining
bracket. (3) Remove four screws attaching lamp housing to
console bezel. (4) Remove wiring and lamp housing.
(5) Remove lamp and replace assembly.
(6) For installation, reverse above procedures.
Fig. 6 EVIC Overhead Console Connector
Fig. 7 Reading/Courtesy Lamp Console
Ä OVERHEAD CONSOLE 8C - 11

(4) Drive the vehicle 1 to 3 complete circles. The
CAL light will then go off, showing the compass is
calibrated. If the compass portion of the display:
² It does not display.
² Readings are not accurate after calibration.
² The vehicle may have too much magnetism for the
compass to be accurate.
² The compass circuitry is not working properly.
² Refer to Variance Procedure, Demagnetizing Pro-
cedure and/or Compass Diagnostics.
VARIANCE PROCEDURE
Variance is the difference between magnetic North
and geographic North. In some areas the difference
between magnetic and geographic North is great
enough to cause the compass to give false readings. If
this occurs, the variance must be set. To set the variance, depress and hold down both
the Comp/Temp button and the U.S./Metric button.
The display will go off and after 5 seconds the VAR
light will come on. Release both buttons. Using the
zone map (Fig. 5) to find your geographic location,
note the zone which, you are in. Press the U.S./Met-
ric button until the zone number appears on the dis-
play. Press the Comp/Temp button to enter your zone
number. Do not attach magnetic devices, such as magnetic
CB antennas to the vehicle roof, as they can cause
the compass to give false readings.
DEMAGNETIZING PROCEDURE
Every vehicle has its own magnetic field. This
magnetic field is created by the various processes a
steel roof goes through when the vehicle is built. A
magnetic field also can be created if the roof is sub-
jected to a magnet, example:
² Magnetic c.b. antenna
² Magnetic tipped screwdriver and etc.
If the roof becomes magnetized use a demagnetizer
tool 6029 to demagnetize the roof. In this demagnetizing procedure you will use the
demagnetizing tool to demagnetize the roof and
mounting screws in the overhead console. It is impor-
tant that you follow the instructions below exactly.
The mounting screws and the mounting brackets
around the compass area are steel, and therefore aid
in the demagnetizing of the roof panel. (1) Be sure the ignition switch is in the OFF posi-
tion before you begin the demagnetize procedure. (2) Open the sun glass compartment to gain access
to the overhead console mounting screws. (3) Plug the demagnetizing tool into a standard
110/115 volt AC outlet, keeping the demagnetizing
tool at least 12 inches away from the compass area
when plugging it in. (4) Slowly approach the console mounting screw
with the plastic coated tip of the tool for at least 2
seconds. (5) With the demagnetizing tool still energized,
slowly back it away from the screw until the tip is at
least 12 inches from the screw head. (6) After you have pulled at least 12 inches from
the last screw, remove the demagnetizing tool from
inside of the vehicle and disconnect it from the elec-
trical outlet. (7) Place an 8 1/2 X 11 inch piece of paper length-
wise on the roof of vehicle directly above compass.
The purpose of the paper is to protect the roof panel
from scratches and define the area to be demagne-
tized. (8) Plug in the demagnetizing tool, keeping it at
least 2 feet away from the compass unit. (9) Slowly approach the center of the roof panel at
the windshield with the demagnetizing tool plugged
in. (10) Contact the roof panel with the tip of the tool.
Using slow sweeping motions of 1/2 inch between
sweeps. Move the tool approximately 4 inches either
side of the centerline and at least 11 inch back from
the windshield. (11) With the demagnetizing tool still energized,
slowly back away from the roof panel until the tip is
at least 2 feet from the roof before unplugging the
tool.
Fig. 5 Variance Zone Map
Ä OVERHEAD CONSOLE 8C - 17

OVERHEAD CONSOLE REPLACEMENT
(1) Unscrew the mounting screw in sun glass bin
compartment (Fig. 8).
(2) Slide console forward toward windshield until
the console unhooks from roof bracket. (3) Disconnect wire harness from console.
(4) For installation reverse above procedures.
COMPASS MODULE REPLACEMENT
(1) Remove overhead console.
(2) Using a small screwdriver, release the 2 snaps
at rear of compass module (Fig. 9).
(3) After releasing the 2 snaps, slide compass mod-
ule rearward until free of mounting bar. (4) For installation reverse above procedures.
ELECTRONIC VEHICLE INFORMATION CENTER
(EVIC) REMOVAL
(1) Use a straight edge tool to pry out one end of
the EVIC center and continue to disengage six clips
along the length of the message center. (2) Remove the EVIC center and disconnect the
wiring. (3) For installation reverse the above procedures.
AMBIENT TEMPERATURE SENSOR REMOVAL
(1) Raise and support vehicle on safety stands.
(2) From behind front bumper fascia, remove screw
attaching sensor to radiator closure panel (Fig. 10).
(3) For installation, reverse above procedures.
ENGINE NODE SENSOR REMOVAL
(1) Raise and support vehicle on safety stands.
(2) From behind front bumper fascia, remove
screws attaching engine node to bumper fascia (Fig.
11). (3) For installation, reverse above procedures.
Fig. 8 Overhead Console Mounting
Fig. 9 Compass Module Removal
Fig. 10 Ambient Temperature Sensor
Fig. 11 Engine Node
8C - 20 OVERHEAD CONSOLE Ä

(5) The variation may need to be adjusted. The
variation is the difference between magnetic north
and true north. To set variation refer the to Varia-
tion Setting Procedure. If the compass portion of the display is not lit or
compass readings are not accurate after calibration.
The vehicle may have too much magnetism for the
compass to be accurate or the compass circuitry is
not working properly. Refer to Variance Procedure,
Demagnetizing Procedure and/or Compass Diagnos-
tics.
VARIANCE PROCEDURE
Variance is the difference between magnetic North
and geographic North. In some areas the difference
between magnetic and geographic North is great
enough to cause the compass to give false readings. If
this occurs, the variance must be set.
VARIANCE SETTING PROCEDURE
To set the variance, depress and hold down both
the Comp/Temp button and the U.S./Metric button.
The display will go off and after 5 seconds the VAR
light will come on. Release both buttons. Using the
zone map (Fig. 3) to find your geographic location,
note the zone which you are in. Press the U.S./Metric button until the zone number appears on the display.
Press the Comp/Temp button to enter your zone
number. Do not attach magnetic devices, such as magnetic
CB antennas to the vehicle roof, as they can cause
the compass to give false readings.
DEMAGNETIZING PROCEDURE
Every vehicle has its own magnetic field. This
magnetic field is created by the various processes a
steel roof goes through when the vehicle is built. A
magnetic field also can be created if the roof is sub-
jected to a magnet, example:
² Magnetic c.b. antenna
² Magnetic tipped screwdriver, etc.
If the roof becomes magnetized use a demagnetiz-
ing tool 6029 to demagnetize the roof. In this demagnetizing procedure you will use the
demagnetizing tool to demagnetize the roof and
mounting screws in the overhead console. It is impor-
tant that you follow the instructions below exactly.
The mounting screws and the mounting brackets
around the compass area are steel, and therefore aid
in the demagnetizing of the roof panel. (1) Be sure the ignition switch is in the OFF posi-
tion before you begin the demagnetize procedure. (2) Open the sun glass compartment to gain access
to the overhead console mounting screws.
Fig. 2 Overhead Console
8C - 22 OVERHEAD CONSOLE Ä