1988 Plymouth Sundance Repair Manual

The 1988 Plymouth Sundance is a compact front-wheel drive vehicle available in sedan and coupe body styles. This repair manual covers maintenance, troubleshooting, and repair procedures for the 2.2L and 2.5L engines, automatic and manual transmissions, braking system, suspension, electrical systems, and body components. Below are key sections for specifications, maintenance schedules, repair procedures, and troubleshooting.

1. Vehicle Specifications 2. Maintenance Schedule 3. Engine Repair 4. Transmission Service 5. Brake System 6. Suspension & Steering 7. Electrical System 8. Cooling System 9. Fuel System 10. Body & Interior 11. Troubleshooting

Vehicle Specifications

Key specifications for the 1988 Plymouth Sundance models.

Specification	Description
Engine Options	2.2L I4 (97 hp), 2.5L I4 (100 hp)
Transmission	3-speed automatic, 5-speed manual
Drivetrain	Front-wheel drive
Fuel System	Electronic fuel injection
Brake System	Front disc, rear drum
Wheelbase	97.0 inches
Length	171.3 inches
Curb Weight	2,400-2,600 lbs
Fuel Capacity	13.0 gallons
Oil Capacity	4.0 quarts (with filter)

Maintenance Schedule

Recommended maintenance intervals for optimal performance.

Oil and filter change: Every 3,000 miles or 3 months
Air filter replacement: Every 15,000 miles
Spark plugs: Every 30,000 miles
Timing belt: Every 60,000 miles
Coolant flush: Every 30,000 miles or 2 years
Brake fluid: Every 30,000 miles or 2 years
Transmission fluid: Every 30,000 miles

WARNING! Always use jack stands when working under vehicle. Wear safety glasses.

Engine Repair

Common engine repair procedures and specifications.

Spark plug replacement: Gap 0.035 inches
Valve adjustment: Hydraulic lifters - no adjustment required
Timing belt replacement: Align marks on cam and crank sprockets
Compression test: 150-180 psi (minimum 100 psi)
Oil pressure: 25-80 psi at 2000 RPM

CAUTION! Allow engine to cool before working. Disconnect battery when servicing electrical components.

Transmission Service

Automatic Transmission: Dexron II/Mercon fluid, 7.5 quarts capacity
Manual Transmission: 75W-90 gear oil, 2.2 quarts capacity
Shift Linkage: Adjust for proper gear engagement
Clutch: Hydraulic system - bleed when replacing
Differential: Integrated with transaxle

Brake System

Brake system maintenance and repair procedures.

Front Disc Brakes: Rotor minimum thickness 0.810 inches, Pad minimum 0.125 inches

Rear Drum Brakes: Drum maximum diameter 8.030 inches, Shoe minimum 0.040 inches

Brake bleeding: Start with wheel farthest from master cylinder. Use DOT 3 brake fluid.

Suspension & Steering

Front: MacPherson struts with coil springs. Rear: Twist beam axle with coil springs.

Strut replacement: Support vehicle, remove wheel, disconnect sway bar link
Ball joints: Check for play - replace if excessive movement
Tie rod ends: Replace if boot torn or excessive play
Wheel alignment: Toe-in 0° ± 0.25°, Camber -0.5° ± 0.5°

Tip: Always replace suspension components in pairs.

Electrical System

Battery: 12V, 525 CCA. Alternator: 65-78 amps. Starter: 1.4 kW.

Battery testing: Load test - minimum 9.6V under load
Charging system: Voltage 13.5-14.5V at 2000 RPM
Fuse panel: Located under dashboard
Wiring diagrams: Color-coded for circuit identification
Light bulbs: Headlight 4651, Brake light 1157, Turn signal 1156

WARNING! Disconnect battery before electrical work. Avoid short circuits.

Cooling System

Capacity: 9.0 quarts. Thermostat: Opens at 195°F. Pressure cap: 16 psi.

Fuel System

Fuel pump pressure: 14.5 psi. Injector resistance: 14-16 ohms.

CAUTION! Relieve fuel pressure before servicing. No smoking near fuel system.

Body & Interior

Body panel alignment procedures. Interior trim removal. Glass replacement.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, or compression issue	Check fuel pressure, spark plugs, compression test
Poor fuel economy	Dirty air filter, bad O2 sensor	Replace air filter, test O2 sensor
Brake vibration	Warped rotors	Resurface or replace rotors
Overheating	Coolant leak, thermostat stuck	Pressure test system, replace thermostat
Electrical issues	Bad alternator, corroded connections	Test charging system, clean battery terminals

Technical Support: Chrysler Technical Service Bulletins available for common issues

Parts: Genuine Mopar parts recommended for optimal performance