1991 Plymouth Sundance Service and Repair Manual

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Factory-Grade Data

1991 Plymouth Sundance service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Built for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and use wiring diagrams and system sections to diagnose problems faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical coverage with wiring diagrams
  • Coverage across key systems: engine, transmission, brakes, steering, suspension, HVAC, and more

Trims covered

  • RS Hatchback 4-Door
  • RS Hatchback 2-Door
  • High Line Hatchback 4-Door
  • America Hatchback 2-Door
  • High Line Hatchback 2-Door
  • America Hatchback 4-Door

Engines covered

  • 2.5L 2507CC 153Cu. In. l4 GAS SOHC Naturally Aspirated
  • 2.5L 2507CC 153Cu. In. l4 GAS SOHC Turbocharged
  • 2.2L 135Cu. In. l4 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1991 Plymouth Sundance Recalls & Complaints

NHTSA #96V22900018/11/1996Component: STEERING: STEERING WHEEL/HANDLE BAR

THE STEERING WHEEL ARMATURE STAMPING CAN CRACK AND SEPARATE FROM THE CENTER HUB ATTACHMENT TO THE STEERING COLUMN.

Consequence

IF THE STEERING WHEEL SEPARATES FROM THE CENTER HUB ATTACHMENT TO THE STEERING COLUMN, LOSS OF CONTR

Remedy

DEALERS WILL INSPECT THE STEERING WHEEL FOR ARMATURE CRACKS IN THE CENTER HUB ATTACHMENT AREA. ANY

NHTSA #97V07800010/05/1997Component: SEATS:FRONT ASSEMBLY:RECLINER

THE LOWER SEAT BACK ATTACHING BOLT ON THE DRIVER'S SEAT CAN FAIL AND SEPARATE.

Consequence

IF THE BOLT FAILS WHILE THE VEHICLE IS BEING DRIVEN, THE DRIVER COULD LOSE CONTROL OF THE VEHICLE, I

Remedy

DEALERS WILL REPLACE THE LOWER SEAT BACK ATTACHING BOLT ON THE DRIVER'S SEAT WITH A HIGHER STRENGTH

NHTSA #99V21200006/08/1999Component: SEATS:FRONT ASSEMBLY:RECLINER

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE LOWER SEAT BACK ATTACHING BOLT ON THE DRIVER SEAT CAN FAIL AND SEPARATE.

Consequence

IF THE BOLT FAILS WHILE THE VEHICLE IS BEING DRIVEN, THE DRIVER COULD LOSE CONTROL OF THE VEHICLE, I

Remedy

DEALERS WILL REPLACE THE LOWER SEAT BACK ATTACHING BOLT ON THE DRIVER'S SEAT WITH A HIGHER STRENGTH

NHTSA #90V16200004/09/1990Component: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER

FRONT DISC BRAKE CALIPER GUIDE PIN BOLTS MAY NOT HAVE BEEN ADEQUATELY TORQUED AND COULD LOOSEN.

Consequence

THIS COULD CAUSE REDUCED BRAKING EFFECTIVENESS AND COULDRESULT IN AN ACCIDENT.

Remedy

PROPERLY TORQUE FRONT BRAKE CALIPER GUIDE PIN BOLTS TO 250 POUNDS.

TSB #621898

AUTOMATIC TRANSMISSION FLUID USAGE ATF+4. *TT *MJ

TSB #620059

SUBJECT REGARDING AIRBAG / CLOCK SPRING SERVICE FOR VARIOUS MODELS INCLUDING 2002 MODEL YEAR JEEP LIBERTY. *TT

TSB #618049

SUBJECT REGARDING WIRE SPLICE REPAIRS. *SB

TSB #615688

SUBJECT REGARDING CHILD SEAT TETHER ANCHORS. *TT

TSB #6092304

SUBJECT REGARDING NON-DEPLOYED AIRBAG HANDLING PROCEDURES. *TT

TSB #612160

SUBJECT ON THE CHILD SEAT TETHER ANCHORS. *MJS

TSB #610635

SUBJECT REGARDING CHILD SEAT TETHER ANCHORS. *TT

TSB #609995

THIS BULLETIN PROVIDES A REVISED WIRE SPLICE PROCEDURE AND RELATED PARTS. *TT

Showing the 8 most recent of 21 technical service bulletins on file with NHTSA.

19950608Component: SEAT BELTS:FRONT:WEBBINGCrash reported12 injured

SHOULDER SEAT BELT DID NOT RESTRAIN PASSENGER IN REAR RIGHT SEAT DURING REAR END IMPACT, PASSENGER SUSTAINED HEAD/NECK INJURIES. *AK

19960229Component: AIR BAGS:FRONTALCrash reported

BUSINESS AREA HAD BROKEN WATER LINE; ROAD WAS ICY; ANOTHER VEHICLE WAS STOPPED, SLID INTO REAR OF VEHICLE, AIRBAG POPPED OUT, DID NOT INFLATE. *AK

19950503Component: POWER TRAIN:AUTOMATIC TRANSMISSION:PARK/NEUTRAL START INTERLOCK SWITCHCrash reported

AUTO-TRAN: CAN REMOVE KEYS FROM IGNITION WITHOUT GEAR IN PARK POSITION; CAN SHIFT GEARS WITHOUT IGNITION SWITCH TURNED; ROLLED ONTO STREET; HIT PARKED CAR. TT

19990830Component: STRUCTURE:BODY:HATCHBACK/LIFTGATE:SUPPORT DEVICE/STRUT1 injured

HATCHBACK STRUTS FAIL TO KEEP LID UP, FALLS EVERYTIME ITS OPENED CAUSING SERVERE BACK INJURY TO OWNER. *YC

Showing the 4 most serious of 32 complaints filed with NHTSA.

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