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Plymouth Sundance 1988-1993 Workshop Service Manual Repair

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🏷️ Basic Information Identification Make: Plymouth Model: Sundance Year: 1988-1993 Codes Platform Code: P-body (Chrysler L-body derivative) 👋 Introduction Market Position Segment: Compact car, often positioned as an economical and...
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Plymouth Sundance 1988-1993 Workshop Service Manual Repair
🏷️ Basic Information
Identification
Make:
Plymouth
Model:
Sundance
Year:
1988-1993
Codes
Platform Code:
P-body (Chrysler L-body derivative)
👋 Introduction
Market Position
Segment:
Compact car, often positioned as an economical and practical option.
Competitive Analysis
Competitors:
Ford Escort, Chevrolet Cavalier, Honda Civic, Toyota Corolla.
Key Features
Design:
Aerodynamic styling, front-wheel drive platform, available in hatchback and coupe body styles.
Value Proposition:
Affordable pricing, good fuel economy, decent interior space for its class.
📋 Manual Details
Coverage Areas
Covered Years:
1988, 1989, 1990, 1991, 1992, 1993
Page Count
Estimated Page Count:
Hundreds (typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed coverage including 2.2L and 2.5L naturally aspirated and turbocharged variants, fuel injection systems, ignition, emissions.
Transmission:
Manual (A520, A523) and Automatic (A413, A470) transmissions, including overhaul and diagnosis.
Brakes:
Front disc and rear drum brakes, parking brake system, hydraulic system, troubleshooting.
Suspension:
Front MacPherson strut and rear torsion beam suspension, steering system, alignment specifications.
Electrical:
Complete wiring diagrams for all circuits, battery, charging system, starting system, lighting, instruments, power accessories.
Body:
Body construction, exterior trim, interior trim, doors, windows, seals, body repair procedures.
Procedures Included
Maintenance:
Routine maintenance schedules, fluid changes, filter replacements, lubrication.
Repair:
Step-by-step repair instructions for all major components and systems.
Troubleshooting:
Diagnostic procedures for common problems, electrical and mechanical troubleshooting guides.
Overhaul:
Detailed overhaul procedures for engines and transmissions.
Technical Depth
Depth:
Comprehensive; suitable for professional technicians and advanced DIY enthusiasts. Covers diagnostics, repair, and overhaul.
📊 Manual Specifications
File Format
Compatibility:
Adobe PDF Reader
Additional Requirements:
WinRAR (for potential archive extraction)
Print Quality
Printability:
Full Printable (allows section printing)
Zoom Functionality:
Zoom IN/OUT enabled for detailed viewing
Binding Type
Binding:
Digital (No physical binding)
Paper Type
Paper Type:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
2.2L I4:
Naturally Aspirated (110 hp @ 5000 rpm, 129 lb-ft @ 3200 rpm), Turbocharged (146 hp @ 5200 rpm, 167 lb-ft @ 3200 rpm).
2.5L I4:
Naturally Aspirated (100-114 hp depending on variant), Turbocharged (150 hp @ 5200 rpm, 170 lb-ft @ 3200 rpm).
Performance
Acceleration 0 60:
Varies by engine and transmission, typically 8-11 seconds for turbo models.
Fuel System
Injection:
Electronic Multi-Port Fuel Injection (MPI) for most variants, Carburetor on some early base models.
Ignition
Type:
Distributorless Ignition System (DIS) on later models.
Emission Controls
Systems:
Catalytic converter, EGR (Exhaust Gas Recirculation), PCV (Positive Crankcase Ventilation).
🔧 Transmission
Standard
Manual:
A520 5-speed manual transmission. Later models may feature A523 5-speed.
Optional
Automatic:
A413 3-speed automatic (common), A470 4-speed automatic (less common, often with turbo models).
Features
Gear Ratios:
Detailed gear ratios are provided within the manual for each transmission type.
Fluid Specification
Automatic:
Chrysler ATF+4 or equivalent (refer to manual for specific early year recommendations, often ATF+2 or +3).
Manual:
GL-4 SAE 75W-90 or 80W-90 gear oil (refer to manual for exact specifications).
📐 Dimensions
Exterior
Length:
Approx. 170.1 inches (4320 mm)
Width:
Approx. 66.7 inches (1694 mm)
Height:
Approx. 52.9 inches (1344 mm)
Wheelbase
Wheelbase:
Approx. 97.2 inches (2469 mm)
Weights
Curb Weight:
Approx. 2500-2800 lbs (1134-1270 kg) depending on configuration.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4-star rating (driver) for 1988-1993 models in frontal impact, as per NHTSA testing.
Active Features
ABS:
Anti-lock Braking System (ABS) was an optional feature on some models, particularly higher trims and turbo variants.
Passive Features
Airbags:
Driver-side airbag became standard on most models around 1990-1991. Passenger airbag was not commonly offered.
Seatbelts:
Three-point front seatbelts with pretensioners, lap belts in rear.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM radio with cassette player, optional CD player on later models. Speaker configurations varied by trim.
Driver Assistance
Cruise Control:
Optional feature on many models.
Connectivity
N/A:
Limited by era; no modern connectivity features like Bluetooth or USB.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000 miles or 3 months (conventional oil), or 5,000-7,500 miles (synthetic oil, consult manual).
Spark Plugs:
Every 30,000-60,000 miles, depending on plug type (copper vs. platinum). Refer to manual for specific recommendations.
Timing Belt:
Every 60,000-100,000 miles for 2.2L and 2.5L engines (critical maintenance item; failure can cause catastrophic engine damage).
Fluid Specifications
Engine Oil:
API SG or SH, SAE 5W-30 or 10W-30 (check manual for temperature specific viscosity).
Coolant:
Chrysler 5/100 (50/50 mix of antifreeze and distilled water) or equivalent ethylene glycol based coolant.
Brake Fluid:
DOT 3 brake fluid.
Known Issues
Electrical:
Common issues include faulty instrument cluster gauges, intermittent headlight/taillight operation, and wear in wiring harnesses (e.g., door jamb wiring).
Engine:
Turbocharger oil feed line leaks on turbocharged models, head gasket failures (especially on 2.2L Turbo), carbon buildup in combustion chambers.
Suspension:
Worn strut mounts, ball joints, and tie rod ends are common due to age and mileage.
Fuel System:
Clogged fuel injectors, failing fuel pumps, and worn fuel pressure regulators.
Exhaust:
Rust and deterioration of exhaust components, particularly mufflers and catalytic converters.
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation.
Model Evolution
Introduction:
Introduced in 1984 as a 1985 model, based on the Chrysler L-body platform, with styling heavily influenced by the Dodge Omni.
Facelift:
Received a significant refresh for the 1987 model year, with revised styling, interior, and powertrain updates that carried through 1993.
Production
Manufacturing Location:
Belvidere Assembly Plant, Illinois, USA.
Production End
Model Discontinuation:
Production of the Plymouth Sundance ended in 1994. It was replaced by the Dodge Neon and Plymouth Neon for the 1995 model year.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
While the Sundance itself didn't make the 10Best list, its platform shared with the Dodge Lancer and Chrysler Laser/New Yorker Turbo saw critical acclaim in their respective segments during the mid-to-late 1980s.
Ratings
Fuel Economy:
Generally good for its class, with EPA estimates typically in the mid-20s to low-30s MPG combined, depending on engine and transmission.
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