Plymouth Sundance 1987-1994 Factory Service Workshop Repair Manual
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🏷️ Basic Information Identification Make: Plymouth Model: Sundance Model Years Covered: 1987-1994 Trim Levels Covered: All 👋 Introduction Market Position Market Position: The Plymouth Sundance was a compact car produced by Chrysler Corporation under its Plymouth brand. It was part of the 'K-car' lineage and positioned as an affordable, practical vehicle for everyday use. This manual targets owners and technicians needing in-depth repair and maintenance information. Competitive Analysis Competitive Analysis: Competed against vehicles like the Chevrolet Cavalier, Ford Escort, and various Japanese compacts from Honda, Toyota, and Nissan during its production run. Its strengths were often perceived as affordability and a relatively spacious interior for its class. Key Features Key Features: Factory-issued documentation, comprehensive system coverage, detailed diagrams and specifications, troubleshooting guides, and maintenance schedules. 📋 Manual Details Coverage Coverage Areas: Engine Mechanical, Engine Electrical, Emission Control, Fuel System, Clutch, Manual Transaxle, Automatic Transaxle, Driveshaft and Axle, Suspension, Steering, Restraint System, Brakes, Body (Interior & Exterior), Body Electrical, Heating, Ventilation, Air Conditioning (HVAC) Pages Page Count: Estimated 1500-2000+ pages (typical for comprehensive factory service manuals of this era) Type Manual Type: Factory Service Workshop Repair Manual Language Language: English Format Format: PDF File Format Details: Searchable PDF with index Compatibility Compatibility: Windows 95/98/ME/XP/Vista/7, Linux, MAC Delivery Shipping Cost: Free Download (No Shipping Cost) 📖 Manual Coverage Systems Systems Covered: Comprehensive coverage of all major vehicle systems including engine, transmission (manual and automatic), drivetrain, suspension, steering, braking, HVAC, electrical, body, and emissions. Procedures Procedures Included: Detailed diagnostic procedures, repair instructions, maintenance schedules, component removal and installation, adjustments, specifications, and troubleshooting guides for all systems. Depth Technical Depth: Factory-level technical depth, suitable for both professional technicians and advanced DIY enthusiasts. Covers everything from basic maintenance to complex engine and transmission rebuilds. Diagnostics Diagnostic Procedures Included: Includes step-by-step diagnostic flowcharts for common drivability issues, electrical faults, and mechanical problems. Covers use of diagnostic tools and reading trouble codes. Rebuilds Engine Rebuild Procedures: Detailed instructions for engine disassembly, inspection, component replacement (pistons, rings, bearings, valves, seals), and reassembly, including torque specifications and clearances. Transmission Rebuild Procedures: Comprehensive guides for rebuilding both manual and automatic transaxles, covering clutch pack replacement, valve body diagnostics, seal and gasket replacement, and gear component servicing. Wiring Electrical Schematics Quality: Includes detailed wiring diagrams for all electrical systems, essential for troubleshooting and repairs of the body electrical system, engine controls, and accessories. Bodywork Body Repair Procedures: Details on body panel alignment, dent repair, rust prevention, interior trim removal and installation, glass replacement, and door/window mechanisms. Hvac HVAC System Diagnostics Repair: In-depth procedures for diagnosing and repairing the heating, ventilation, and air conditioning systems, including refrigerant handling, component replacement (compressor, condenser, evaporator), and control system diagnostics. Restraint Restraint System Information: Covers seat belt operation, adjustments, and replacement. For models with early airbags, it would cover airbag system diagnostics and safety precautions. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution digital scans of original factory manuals, ensuring clarity of text and diagrams. Binding Type Binding Type: Digital (N/A for physical binding) Paper Type Paper Type: Digital (N/A for physical paper type) ⚙️ Engine Specifications Primary Engine Primary Engine Options: 2.2L (135 ci) L4 SOHC (Naturally Aspirated and Turbocharged), 2.5L (153 ci) L4 SOHC (Naturally Aspirated) Performance Typical Horsepower Range: 80-146 hp (depending on engine and year) Typical Torque Range: 110-180 lb-ft (depending on engine and year) Fuel System Fuel System Type: Electronic Fuel Injection (EFI) Engine Management Engine Management System: Chrysler's 'Ultradrive' or similar electronic engine control units (ECUs) with diagnostic capabilities. Emission Control Emission Control Features: Catalytic converter, Oxygen sensors (O2 sensors), Exhaust Gas Recirculation (EGR) system, Positive Crankcase Ventilation (PCV) system. Engine Codes Common Engine Codes: For 2.2L Turbo: Turbo I. For 2.5L: C, E, G. (Refer to manual for specific year/engine code details). 🔧 Transmission Standard Standard Transmission: 5-speed manual transaxle Optional Optional Transmission: 3-speed automatic transaxle (Ultradrive) Features Transmission Features: Front-wheel drive (FWD) transaxle design. 📐 Dimensions Exterior Body Style: 2-door coupe, 4-door sedan, 5-door hatchback (often referred to as 'liftback' or 'hatchback') Wheelbase: Approximately 97.1 inches. Length: Varies by body style, approximately 167-172 inches. Width: Approximately 67.0 inches. Height: Approximately 52-53 inches. Weights Curb Weight Range: Approx. 2500-2800 lbs (depending on body style and options) Gross Vehicle Weight Rating Gvwr: Typically around 3500-3800 lbs 🛡️ Safety Features Passive Features Passive Safety Features: Seat belts (manual lap and shoulder), padded dashboard, energy-absorbing steering column, side guard door beams. Active Features Active Safety Features: Four-wheel disc brakes (optional on some models/years), power-assisted brakes. Ratings NHTSA Crash Test Ratings: Ratings vary by year and testing methodology; generally comparable to other vehicles in its class for the era. Specific year ratings would need to be researched. 💡 Technology Features Infotainment Infotainment Features: Basic AM/FM radio, cassette player. Optional premium sound systems were available. Manual covers wiring...
The Plymouth Sundance was a compact car produced by Chrysler Corporation under its Plymouth brand. It was part of the 'K-car' lineage and positioned as an affordable, practical vehicle for everyday use. This manual targets owners and technicians needing in-depth repair and maintenance information.
Competitive Analysis
Competitive Analysis:
Competed against vehicles like the Chevrolet Cavalier, Ford Escort, and various Japanese compacts from Honda, Toyota, and Nissan during its production run. Its strengths were often perceived as affordability and a relatively spacious interior for its class.
Key Features
Key Features:
Factory-issued documentation, comprehensive system coverage, detailed diagrams and specifications, troubleshooting guides, and maintenance schedules.
📋 Manual Details
Coverage
Coverage Areas:
Engine Mechanical, Engine Electrical, Emission Control, Fuel System, Clutch, Manual Transaxle, Automatic Transaxle, Driveshaft and Axle, Suspension, Steering, Restraint System, Brakes, Body (Interior & Exterior), Body Electrical, Heating, Ventilation, Air Conditioning (HVAC)
Pages
Page Count:
Estimated 1500-2000+ pages (typical for comprehensive factory service manuals of this era)
Type
Manual Type:
Factory Service Workshop Repair Manual
Language
Language:
English
Format
Format:
PDF
File Format Details:
Searchable PDF with index
Compatibility
Compatibility:
Windows 95/98/ME/XP/Vista/7, Linux, MAC
Delivery
Shipping Cost:
Free Download (No Shipping Cost)
📖 Manual Coverage
Systems
Systems Covered:
Comprehensive coverage of all major vehicle systems including engine, transmission (manual and automatic), drivetrain, suspension, steering, braking, HVAC, electrical, body, and emissions.
Procedures
Procedures Included:
Detailed diagnostic procedures, repair instructions, maintenance schedules, component removal and installation, adjustments, specifications, and troubleshooting guides for all systems.
Depth
Technical Depth:
Factory-level technical depth, suitable for both professional technicians and advanced DIY enthusiasts. Covers everything from basic maintenance to complex engine and transmission rebuilds.
Diagnostics
Diagnostic Procedures Included:
Includes step-by-step diagnostic flowcharts for common drivability issues, electrical faults, and mechanical problems. Covers use of diagnostic tools and reading trouble codes.
Rebuilds
Engine Rebuild Procedures:
Detailed instructions for engine disassembly, inspection, component replacement (pistons, rings, bearings, valves, seals), and reassembly, including torque specifications and clearances.
Transmission Rebuild Procedures:
Comprehensive guides for rebuilding both manual and automatic transaxles, covering clutch pack replacement, valve body diagnostics, seal and gasket replacement, and gear component servicing.
Wiring
Electrical Schematics Quality:
Includes detailed wiring diagrams for all electrical systems, essential for troubleshooting and repairs of the body electrical system, engine controls, and accessories.
Bodywork
Body Repair Procedures:
Details on body panel alignment, dent repair, rust prevention, interior trim removal and installation, glass replacement, and door/window mechanisms.
Hvac
HVAC System Diagnostics Repair:
In-depth procedures for diagnosing and repairing the heating, ventilation, and air conditioning systems, including refrigerant handling, component replacement (compressor, condenser, evaporator), and control system diagnostics.
Restraint
Restraint System Information:
Covers seat belt operation, adjustments, and replacement. For models with early airbags, it would cover airbag system diagnostics and safety precautions.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution digital scans of original factory manuals, ensuring clarity of text and diagrams.
For 2.2L Turbo: Turbo I. For 2.5L: C, E, G. (Refer to manual for specific year/engine code details).
🔧 Transmission
Standard
Standard Transmission:
5-speed manual transaxle
Optional
Optional Transmission:
3-speed automatic transaxle (Ultradrive)
Features
Transmission Features:
Front-wheel drive (FWD) transaxle design.
📐 Dimensions
Exterior
Body Style:
2-door coupe, 4-door sedan, 5-door hatchback (often referred to as 'liftback' or 'hatchback')
Wheelbase:
Approximately 97.1 inches.
Length:
Varies by body style, approximately 167-172 inches.
Width:
Approximately 67.0 inches.
Height:
Approximately 52-53 inches.
Weights
Curb Weight Range:
Approx. 2500-2800 lbs (depending on body style and options)
Gross Vehicle Weight Rating Gvwr:
Typically around 3500-3800 lbs
🛡️ Safety Features
Passive Features
Passive Safety Features:
Seat belts (manual lap and shoulder), padded dashboard, energy-absorbing steering column, side guard door beams.
Active Features
Active Safety Features:
Four-wheel disc brakes (optional on some models/years), power-assisted brakes.
Ratings
NHTSA Crash Test Ratings:
Ratings vary by year and testing methodology; generally comparable to other vehicles in its class for the era. Specific year ratings would need to be researched.
💡 Technology Features
Infotainment
Infotainment Features:
Basic AM/FM radio, cassette player. Optional premium sound systems were available. Manual covers wiring diagrams for these systems.
Driver Assistance
Driver Assistance Features:
Limited by era; typically only ABS (Anti-lock Braking System) was an optional advanced feature on some later models. Manual covers ABS system diagnostics.
Connectivity
Connectivity Features:
N/A for this era; no integrated Bluetooth or smartphone connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type. Manual will specify exact intervals.
Tune Up Interval:
Spark plugs, air filter, fuel filter maintenance recommended at intervals outlined in the manual (e.g., 30,000-60,000 miles).
Fluid Specifications
Engine Oil Type:
API SG or higher quality. Viscosity typically 5W-30 or 10W-30 depending on climate. Manual will specify exact type.
Coolant Type:
Ethylene glycol-based antifreeze/coolant. Manual will specify correct mixture and type (e.g., Mopar Antifreeze/Coolant).
Transmission Fluid Type Automatic:
Chrysler ATF+2 or ATF+3 (refer to manual for exact specification, often Dexron II compatible).
Transmission Fluid Type Manual:
API GL-4 gear oil, SAE 75W-90 or 80W-90. Manual will provide specific capacity and type.
Brake Fluid Type:
DOT 3 brake fluid.
Known Issues
Common Issues Electrical:
Flickering dashboard lights, power window/lock failures, issues with instrument cluster grounding or illumination.
Common Issues Engine:
Head gasket leaks (especially on 2.5L), turbocharger issues on turbocharged models, sensor failures (e.g., TPS, MAP).
Common Issues Suspension Steering:
Worn ball joints, tie rod ends, and strut mounts. Power steering pump leaks.
Common Issues Transmission:
Automatic transmission 'slipping' or hard shifting, especially in the Ultradrive. Manual transmission clutch wear.
Common Issues HVAC:
HVAC blower motor failure, blend door actuator issues, refrigerant leaks.
Specifications
Spark Plug Gap:
0.035 inches (0.89 mm) for most 2.2L/2.5L engines. Specifics confirmed in manual.
Tire Pressure Recommendations:
Typically 30-32 PSI for most common tire sizes. Manual will provide exact specifications by vehicle configuration.
Wheel Bolt Pattern:
4x100mm (4.5 inches) on most models.
📚 Vehicle History
Brand Heritage
Brand Heritage Context:
Plymouth was an automotive brand of Chrysler Corporation, known for offering value-oriented vehicles. The Sundance was part of Chrysler's strategic response to the compact car market.
Model Evolution
Model Evolution Summary:
The Sundance was introduced in 1987 as a redesign of the earlier Plymouth Horizon. It shared its platform with the Dodge Shadow and underwent minor styling and feature updates throughout its production run. It was discontinued in 1994.
Production
Production Location:
Manufactured in North America by Chrysler Corporation.
🏆 Awards & Recognition
Recognitions
Recognitions Context:
The Plymouth Sundance and its sibling, the Dodge Shadow, were generally considered competent compact cars for their time. Specific major awards are not commonly associated with this model, but they served their purpose as affordable transportation. The manual is valuable for preserving these vehicles.
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