1993 CHEVROLET PLYMOUTH ACCLAIM ignition

(b) Refer to sending unit removal Group 14, Fuel.
(c) Connect sending unit wire and jumper wire
as described in the test procedure.
(5) If fuel gauge now checks within specifications,
original sending unit is electrically okay, check fol-
lowing as a possible cause: (a) Ground wire from sending unit to left side
cowl for continuity. (b) Sending unit deformed. Make sure sending
unit float arm moves freely and pick up tube is not
bent upwards creating an interference with bottom
of tank and inspect float. (c) Sending unit improperly installed. Install
properly. (d) Mounting flange on fuel tank for sending
unit deformed. Feel for interference fit of sending
unit to bottom of tank. It is permissible to bend
pick up tube down a little near mounting flange to
gain interference fit. (e) Fuel tank bottom deformed, causing improper
positioning of sending unit pick up tube. Replace or
repair tank and recheck sending unit.
GAUGE CALIBRATION
(1) Remove the gauge.
(2) Check for ignition voltage and ground to the
gauge. (3) With the ignition key in the OFF position, re-
place gauge. Turn the ignition key to the ON posi-
tion. To test oil pressure gauge engine must be
running. When testing oil or temperature gauge the
engine should be at normal operating temperature.
Record the gauge position. (4) Remove gauge and record the resistance be-
tween the sending unit pin and the gauge ground
pin. When checking gauges, it is important to have
the same engine temperature and speed when noting
gauge position. The time between gauge reading and
measuring should be kept to a minimum. (5) The resistance Chart (Fig. 21), is general
guidelines for checking the gauge position against
the sending unit resistance. Because of only a few specific points of gauge posi-
tion versus sending unit resistance, a good estimate
is need when the resistance falls between gradua-
tions. Even when the resistance corresponds to grad-
uations, the gauge has a tolerance of 64 ohms.
Volt gauge: The calibration dot on the volt gauge
corresponds to 13 volts between the gauge ignition
and ground pins. If voltage varies from this, estimate
proper gauge position with input voltage.
VOLTMETER REPLACEMENT
(1) Remove cluster bezels and mask (Fig. 22).
(2) Remove screws attaching gauge assembly to
cluster. (3) Pull rearward to disengage gauge from gauge
pins. (4) For installation reverse above procedures.
OIL PRESSURE GAUGE REPLACEMENT
(1) Remove cluster bezels and mask/lens (Fig. 22).
(2) Remove screws attaching gauge assembly to
cluster.
(3) Pull rearward to disengaged gauge from gauge
pins.
(4) For installation reverse above procedures.
FUEL AND TEMPERATURE GAUGE ASSEMBLY REPLACEMENT
(1) Remove cluster bezel and mask/lens (Fig. 22).
(2) Remove oil pressure gauge.
(3) Remove screws attaching gauge assembly to
cluster.
(4) Pull rearward to disengage gauge from gauge
pins.
(5) For installation reverse above procedures.
SPEEDOMETER SYSTEM
AC body vehicles are equipped with electronically
driven speedometer and odometer assemblies. The unit
has the same appearance as a conventional speedometer
but it eliminates the cable-driven mechanical system. A
signal is sent from a transmission-mounted vehicle
speed sensor to the speedometer circuitry through the
wiring harness. By eliminating the speedometer cable,
instrument cluster service and removal is improved. Re-
fer to Fig. 23 Speedometer Diagnosis Chart. When the speedometer is out of calibration. The elec-
tronic automatic transaxle vehicle speed sensor output
must be calibrated to reflect the different combinations
of equipment. The procedure is called Pinion Factor, re-
fer to Group 21, Transaxle for the procedure.
Fig. 21 Gauge Resistance
8E - 30 INSTRUMENT PANEL AND GAUGES Ä

SPEEDOMETER ODOMETER ASSEMBLY REPLACEMENT
(1) Remove cluster bezel and mask/lens.
(2) Remove volt gauge.
(3) Remove screws attaching gauge assembly to
cluster. (4) Pull speedometer rearward to disengage from
gauge pins.
(5) For installation: Position speedometer on gauge
pins and push firmly until seated and reverse above
procedures.
SPEEDOMETER CIRCUIT TESTING
(1) Using the DRB II, check vehicle speed sensor
for fault code and for proper speed indication. Refer
to Powertrain Diagnostics Procedure Manual, Speed
Control System Test. (2) Remove speedometer from cluster.
(3) With ignition on check for battery voltage
across ignition and ground pins (Fig. 24). (4) Check for continuity from vehicle speed sensor
signal pin to connector at speed sensor.
VEHICLE SPEED SENSOR REPLACEMENT
(1) Remove harness connector from sensor and
make sure the weather seal is on harness connector
(Figs. 25 and 26). (2) Remove sensor retaining bolt.
(3) Pull sensor and pinion gear assembly out of
transaxle. If necessary, carefully pry loose with a flat
blade screwdriver. (4) Remove pinion gear from sensor.
Fig. 22 Cluster with Mask and Lens Removed
Fig. 23 Speedometer Diagnosis
Ä INSTRUMENT PANEL AND GAUGES 8E - 31

ELECTRONIC CLUSTER
SELF DIAGNOSTIC SYSTEM
The electronic clusters have an internal diagnostics
routing to isolate problems within the cluster or CCD
Bus. Using the cluster Self-Diagnostic Test will deter-
mine whether the problem is within the cluster or
outside of cluster (Fig. 29 and 30). Successful completion of the Self Diagnostic Test
indicates that the problem is in the CCD Bus, inter-
facing modules, connectors, or sensors outside of the
cluster. Refer to Fig. 31 for terminal listing.
CONDITION: CLUSTER DISPLAYS DO NOT ILLUMINATE AFTER VEHICLE IS STARTED
PROCEDURE
(1) Check fuses and verify battery and ignition
voltage at cluster connector. (2) Check ground from cluster connector to instru-
ment panel ground stud.
CONDITION: CLUSTER ASTERISK (*) FLASHES, CLUSTER DISPLAYS NOTINDICATING CORRECT DATA.
PROCEDURE
CCD bus problem. Use the Body Chassis Diagnos-
tic Manual to diagnose CCD Bus.
CONDITION: SPEEDOMETER AND ODOMETER ARE INOPERATIVE OR OPERATESINTERMITTENTLY
PROCEDURE
(1) If speedometer reads 0, or odometer is blank,
and cluster asterisk is flashing, use the Body Chassis
Diagnostic Manual to diagnose CCD Bus problem. (2) If cluster asterisk is not flashing, check for de-
fective vehicle speed sensor or speed sensor wiring.
CONDITION: OIL GAUGE, FUEL GAUGE, TEMPERATURE GAUGE, OR VOLTAGE GAUGEINOPERATIVE
PROCEDURE
If any gauge gives no indication and cluster aster-
isk is flashing, use the Body Chassis Manual to diag-
nose CCD Bus problem. If cluster asterisk is not flashing:
(1) Check for defective sending unit or wiring. (a) Sending units and wiring can be checked by
grounding the connector leads, at the sending unit,
in the vehicle. (b) With the ignition in the ON position, a
grounded input will cause the oil, fuel, or temper-
ature gauge to read maximum. (2) If the problem is with the oil, temperature, or
fuel gauge, check the body controller. If the problem
is with the voltage gauge, check the powertrain con-
trol module operation.
CONDITION: CLUSTER DISPLAY DOES NOT DIM WHEN HEADLAMP SWITCH ISACTIVATED AND RHEOSTAT ROTATED
PROCEDURE
If the cluster asterisk is flashing, Refer to the Body
Chassis Diagnostic Manual to diagnose the CCD Bus. If the cluster asterisk is not flashing:
(1) Check fuses in headlamp circuit.
(2) Check for loose connections or defective wiring
for headlamp switch to body controller. (3) Check for defective headlamp switch. The elec-
tronic instrument cluster receives the display inten-
sity status from the body controller via the CCD Bus.
CONDITION: SEAT BELT WARNING LAMP DOES NOT ILLUMINATE
PROCEDURE
Turn on ignition. Lamp should illuminate for six
seconds. If not: (1) Check for burned out lamp and retest.
(2) Replace cluster.
CONDITION: LOW WASHER, DOOR/DECK, OR MALFUNCTION INDICATOR (CHECK ENGINE)LAMP, DO NOT ILLUMINATE
PROCEDURE
(1) Perform cluster self-diagnostics to determine if
lamp will illuminate. If lamp does not, check for
burned out lamp, replace and retest. (2) If cluster asterisk is flashing, Refer to the Body
Chassis Diagnostic Manual to diagnose CCD Bus. (3) If cluster asterisk is not flashing:(a) For low washer fluid or door/deck, check in-
puts to body controller. (b) For malfunction indicator (check engine),
check powertrain control module operation.
CONDITION: ODOMETER DISPLAY IS BLANK. THE ODOMETER VALUE IS NO LONGERRETAINED IN THIS ELECTRONIC CLUSTER.THIS TAKES PLACE IN THE BODYCONTROLLER
PROCEDURE
(1) If cluster asterisk is flashing, Refer to the Body
Chassis Diagnostic Manual to diagnose CCD Bus. (2) If cluster asterisk is not flashing, perform clus-
ter self-diagnostics. If code 921 appears in the odom-
eter display, replace body controller for odometer
failure.
8E - 34 INSTRUMENT PANEL AND GAUGES Ä

(4) Remove panel top cover by pushing forward
and prying up, using a straight edge to assist in the
removal. (5) Disconnect bulkhead connector at brace under
instrument panel at left side. (6) Remove glovebox/ash receiver module and right
instrument panel silencer. (7) Remove center panel support brace and air bag
diagnostic module assembly. (8) Disconnect wiring to airbag module.
(9) Remove upper and lower cluster bezels.
(10) Remove steering column cover.
(11) Remove steering column mounting nuts and
lower steering column. (12) Unhook shift indicator cable eyelet from steer-
ing column actuator. (13) Unlatch lock tab in shift indicator column in-
sert and squeeze legs together to remove from steer-
ing column. (14) Remove cluster assembly while guiding trans-
mission range indicator guide tube through access
hole in the base panel. (15) Remove instrument panel steering column
opening support/hood release handle assembly. (16) Remove two steering column upper studs and
loosen side cowl tie-down bolts. (17) Remove steering column tilt lever.
(18) Remove upper and lower lock housing shroud.
(19) Remove lower fixed shroud.
(20) Remove upper fixed shroud (snaps in place).
(21) Disconnect airbag pigtail, ignition switch and
halo light/key buzzer switch wiring. (22) Disconnect Multi-function switch by loosening
connector jack screw and pulling connector from
switch. (23) Disconnect airbag pigtail from wiring trough
housing by pulling two push fasteners. (24) Remove wiring trough from steering column.
(25) Remove defroster ducts.
(26) Remove five screws along fence line and roll
panel down, attach a hook to hold in position. (27) Open hood and remove plenum grill.
(28) Disconnect washer bottle, resistor block and
under hood lamp wiring. Washer bottle must be re-
moved to gain access. (29) Remove grommet and pull plenum wiring into
vehicle through plenum panel. (30) Disconnect right demister hose from instru-
ment panel. (31) Disconnect antenna cable.
(32) Disconnect right and left 25 way body wiring
connectors. (33) Disconnect A/C heater control cables, wiring
connectors and vacuum harness. (34) Remove right side panel ground wire.
(35) Disconnect body controller wiring.
(36) Remove instrument panel assembly from vehi-
cle. (37) For installation reverse above procedures.
INTERIOR LAMP REPLACEMENT
The reading, overhead console and door lamps op-
erate when the doors are open or headlamp switch is
placed in courtesy position. Front overhead lamps re-
fer to Group 8C, Overhead Console.
TRUNK LAMP
The lamp has easily accessible without removing
components.
DOOR LAMP
Pry along the forward edge of the lens and pivot
lens out of the door trim panel. Remove lamp. To re-
move lamp housing, remove door trim panel. Refer to
Group 23, Body. Disconnect all wiring. Remove
screws, if so equipped securing lamp housing to trim
panel, and replace housing.
CÐPILLAR READING/COURTESY LAMP
Pry along the rearward edge of the lamp and pivot
lamp out from quarter trim panel. Disconnect wiring
and remove lamp cover. Replace lamp. The lamp operates when the doors are open or the
headlamp switch is turned to the courtesy mode. The
lamp will function as a reading lamp when the doors
are closed and the button switch on the lamp is de-
pressed.
ROOF RAIL READING
Pry along the bottom edge of the lens and pivot
lens out. Replace lamp. To remove the lamp, remove
the screw which retains the coat hook. Remove the
garnish molding. Disconnect the wiring harness. Re-
move the two clips which retain the lamp to the
molding. Replace lamp. The lamp operates like the
C-pillar reading/courtesy lamp.
Ä INSTRUMENT PANEL AND GAUGES 8E - 41

AG AND AJ BODIES INDEX
page page
Cigar Lighter Removal ..................... 55
Cluster and Gauge Service and Testing ....... 43
Electronic Cluster ........................ 50
Electronic Vehicle Information Center (EVIC) .... 42
Engine Compartment Node ................. 55
Gauges ................................ 44 General Information
....................... 42
Instrument Panel Roll Down Procedure ........ 56
Interior Lamp Removal .................... 57
Mechanical/Electronic Cluster Removal ........ 43
Switch and Panel Component Service ......... 51
Switch Pod Assembly Removal .............. 43
GENERAL INFORMATION
CONVENTIONAL INSTRUMENT CLUSTER
The conventional instrument cluster incorporates
magnetic type gauges (Fig. 1).
The readings are only accurate when the ignition
switch is in the ON position.
TACHOMETER DRIVE MODULE
The tachometer drive module is an electronic mod-
ule used to drive a magnetic tachometer in a conven-
tional instrument cluster.
MESSAGE CENTER
The message center provides the driver with infor-
mation in addition to the standard vehicle instru-
mentation. A bezel will light up with door ajar,
washer fluid, deck ajar and alarm set information.
For vehicles without message center a plain bezel is
used.
ELECTRONIC VEHICLE INFORMATION CENTER
(EVIC)
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 the instrument
cluster. Visual warning messages are displayed by a
digital display (Fig. 2). Refer to Group 8C, Overhead
Console.
ELECTRONIC INSTRUMENT CLUSTER
The electronic instrument cluster uses vacuum flu-
orescent displays to display:
² Oil pressure
² System voltage
² Engine temperature
² Fuel level
² Speedometer and tachometer readings as well as
all warning indicators. The electronic cluster is eas-
ily distinguished from the conventional cluster by its
digital and linear display (Fig. 3.
ELECTRONIC CLUSTER DIMMING
The electronic cluster display is dimmed from day-
time to nighttime intensity when the head]lamp
switch is turned on. This intensity can be controlled
using the headlamp switch sliding rheostat. An additional detent on the headlamp switch rheo-
stat will allow daytime intensity while driving with
headlamps ON in daytime.
Fig. 1 Conventional Instrument Cluster
Fig. 2 EVIC
Fig. 3 Electronic Instrument Cluster
8E - 42 INSTRUMENT PANEL AND GAUGES Ä

ELECTRONIC DIGITAL CLOCK
The electronic digital clock is in the radio. The
clock and radio each use the display panel built into
the radio. A digital readout indicates the time in
hours and minutes whenever the ignition switch is in
the ON or ACC position. When the ignition switch is in the ON or OFF po-
sition, or when the radio frequency is being dis-
played, time keeping is accurately maintained. The procedure for setting the clock varies slightly
with each radio. The correct procedure is described
under the individual radio operating instructions re-
ferred to in the Owner's manual supplied with the
vehicle.
WARNING LAMPS
The AG & AJ Body instrument clusters have warn-
ing lamps or indicators with the electronic cluster for
six different systems. These include low oil pressure,
check gauges, brake system, air bag, seat belt, mal-
function indicator (check engine) lamp.
CLUSTER AND GAUGE SERVICE AND TESTING
CAUTION: Disconnect negative battery cable, in en-
gine compartment, before servicing instrument
panel. When power is required for test purposes,
reconnect battery cable for test only. Disconnect negative battery cable after test and be-
fore continuing service procedures. It is not necessary to remove instrument cluster
from vehicle for gauge replacement. Gauges must be pulled straight out, when remov-
ing or pins may be damaged.
SWITCH POD ASSEMBLY REMOVAL
(1) Disconnect negative battery cable.
(2) Pry up edge of panel vent grille, using a
straight flat edge tool to disengage clips, then re-
move grille (Fig. 4). (3) Remove two screws located under panel vent
grille. (4) Remove two screws underneath switch POD as-
sembly. (5) With tilt steering adjust steering wheel to the
lowest setting. (6) Pull switch module rearward to remove module
and disconnect all wire connections. (7) For Installation reverse above procedures.
Tighten all screws to 2 N Im (20 in. lbs.) torque.
MECHANICAL/ELECTRONIC CLUSTER REMOVAL
CLUSTER MASK AND LENS REMOVAL
(1) Remove switch pod assembly (Fig. 4).
(2) Remove tilt column lever if equipped.
(3) Remove steering column trim cover.
Fig. 4 Switch POD Assembly
Ä INSTRUMENT PANEL AND GAUGES 8E - 43

(4) Remove six screws holding the cluster mask
and lens assembly. (5) Pull cluster mask and lens rearward to remove
(Fig. 5 and 6).
(6) For installation reverse above procedures.
CLUSTER ASSEMBLY REMOVAL
(1) Disconnect battery to assure no Air Bag Sys-
tem fault codes are stored. (2) Remove switch pod assembly.
(3) Unscrew tilt column lever if equipped.
(4) Remove steering column trim cover.
(5) Remove attaching screws on cluster and pull
cluster rearward. (6) Tilt cluster to disconnect wiring connections
and turbo gauge hose if equipped, then remove clus-
ter. (7) For installation reverse above procedures.
GAUGES
MULTIPLE GAUGE INOPERATIVE
Volt, speedometer, tachometer and other gauges
appear to malfunction: (1) Remove cluster
(2) Check for ignition voltage at cavity 9 of the red
cluster connector and ground. If no voltage, repair as
necessary (Fig. 7).
(3) Check for ground continuity between cavity 14
of the red cluster connector and ground. If no ground,
repair as necessary. (4) If OK and pins or connectors are not distorted,
replace printed circuit board. (5) Install cluster.
GAUGE CALIBRATION/INOPERATIVE
(1) Remove gauge in question (Fig. 8 through 11).
(2) With the ignition key ON, check for ignition
voltage at ignition pin of gauge and ground. Check
ground pin of gauge for continuity to ground. (a) If no voltage or ground, check at cluster red
connector pin 9 for ignition voltage and pin 14 for
ground. (b) If no voltage or ground, repair as necessary.
Refer to 8W, Wiring Diagrams. (c) If there is voltage or ground, check cluster for
distorted terminals. If terminals are OK, replace
printed circuit board.
Fig. 5 Cluster Mask and Lens
Fig. 6 Cluster with Mask Removed
Fig. 7 Conventional Cluster Connectors
8E - 44 INSTRUMENT PANEL AND GAUGES Ä

(f) If there is a difference in readings, check
printed circuit board for contact to cluster connec-
tors. (g) If OK and contacts are not distorted, replace
printed circuit board. (h) If everything checks out OK, refer to Sending
Unit Test.
(4) The Gauge Resistance Chart (Fig. 12), is gen-
eral guidelines for checking the gauge position
against the sending unit resistance. Because of only
a few specific points of gauge position versus sending
unit resistance, a good estimate is needed when the
resistance falls between graduations. Even when the
resistance corresponds to graduations, the gauge has
a tolerance of 64 ohms.
Volt gauge: The calibration dot on the volt gauge
corresponds to 13 volts between the gauge ignition
and ground pins. If voltage varies from this, estimate
proper gauge position with input voltage.
TACHOMETER AND TURBO GAUGE REMOVAL
(1) Remove switch pod assembly.
(2) Remove steering column trim cover.
(3) Remove cluster mask and lens assembly.
(4) Remove screws attaching tachometer to cluster
housing. (5) Pull tachometer rearward to remove.
(6) Disconnect turbo gauge hose. If turbo hose can-
not be disconnected, remove cluster. (7) For installation reverse above procedures.
TACHOMETER CIRCUIT TESTING
(1) Remove cluster. (2) Check for battery voltage at cavity 8 of the in-
strument cluster red connector (Fig.6). (3) With the ignition in the ON position, check for
battery voltage at cavity 9 of the instrument cluster
red connector. (4) Check cavity 14 of the instrument cluster red
connector for continuity to ground. (5) Check for tachometer signal from the power-
train control module by connecting an AC DIGITAL
VOLTMETER to cavity 6 of the instrument cluster
black connector and ground. A reading of at least 1.0
volt should be present with the engine running (Fig.
7). (a) If voltage is within specification, go to step 7.
(b) If voltage is NOT within specification, per-
form steps 6.
(6) If there is less than 1.0 volt at cavity 6, check
for continuity between cavity 6 and pin 43 of the
powertrain control module connector. (a) If continuity is OK, between cavity 6 and pin
43 of the powertrain control module connector, re-
place the powertrain control module. (b) No continuity check the connectors for dam-
aged pins or terminal push outs or defective wire.
(7) If all tests performed test good replace the ta-
chometer drive module. (8) If the tachometer continues to be inoperative,
replace the tachometer assembly.
VOLTMETER, TEMPERATURE GAUGE, OIL PRESSURE GAUGE AND FUEL GAUGEASSEMBLYÐREMOVAL
(1) Remove pod switch assembly.
(2) Remove steering column trim cover.
(3) Remove cluster mask and lens assembly.
(4) Remove screws attaching gauge assembly to
cluster. (5) Pull rearward to remove gauge assembly.
(6) For installation reverse above procedures.
SENDING UNIT TEST
It is not necessary to remove instrument clus-
ter from vehicle for gauge replacement. When removing gauge assemblies from cluster,
gauge must be pulled straight out, not twisted, or
damage to gauge pin may result. When a problem occurs with a cluster gauge, be-
fore disassembling the cluster to check the gauge,
check for a defective sending unit or wiring. (1) Sending units and wiring can be checked by
grounding the connector leads, at the sending unit,
in the vehicle. (2) With the ignition in the ON position; a
grounded input will cause the oil, fuel or tempera-
ture gauge to read at or above maximum.
Fig. 12 Gauge Resistance
8E - 46 INSTRUMENT PANEL AND GAUGES Ä