1993 CHEVROLET PLYMOUTH ACCLAIM heater

INSTALLATIONÐ3.3L AND 3.8L ENGINE
Place a new gasket (dipped in water) on the water
box surface, center thermostat into opening in the in-
take manifold. Place housing over gasket and ther-
mostat, making sure thermostat is in recess provided
(Fig. 13). Bolt housing to intake manifold, tighten
bolts to 28 N Im (250 in. lbs.). Refill cooling system
(see Refilling System ).
COOLANT
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves. Then
carry this heat to the radiator where the tube/fin as-
semblies of these components can give it up to the
air.
PERFORMANCE
Performance is measurable. For heat transfer pure
water excels (Formul a = 1 btu per minute for each
degree of temperature rise for each pound of water).
This formula is altered when necessary additives to
control boiling, freezing, and corrosion are added as
follows:
² Pure Water (1 btu) boils at 100ÉC (212ÉF) and
freezes at 0ÉC (32ÉF).
² 100 Percent Glycol (.7 btu) can cause a hot engine
and detonation and will raise the freeze point to 22ÉC
(-8ÉF).
² 50/50 Glycol and Water (.82 btu) is the recom-
mended combination that provides a freeze point of
-37ÉC(-35ÉF).The radiator, water pump, engine water
jacket, radiator pressure cap, thermostat, tempera-
ture gauge, sending unit and heater are all designed
for 50/50 glycol. Where required, a 56 percent glycol and 44 percent
water mixture will provide a freeze point of-59ÉC
(-50ÉF).
CAUTION: Richer mixtures cannot be measured
with field equipment which can lead to problems
associated with 100 percent glycol.
SELECTION AND ADDITIVES
The use of aluminum cylinder heads, intake mani-
folds, and water pumps requires special corrosion
protection. Mopar Antifreeze, Prestone II, Peak or
antifreeze containing Alugard 340-2, or their equiva-
lent are recommended for best engine cooling with-
out corrosion. When mixed only to a freeze point of
Fig. 11 Thermostat, Housing, and Water BoxÐ3.0L Engine
Fig. 12 Thermostat InstalledÐ3.0L Engine
Fig. 13 Thermostat, Housing and WaterboxÐ3.3Land 3.8L Engine
7 - 14 COOLING SYSTEM Ä

-37ÉC (-35ÉF) to -59ÉC (-50ÉF). If it looses color or
becomes contaminated, drain, flush, and replace with
fresh properly mixed solution.
SERVICE
Coolant should be changed at 52,500 miles or three
years, whichever occurs first, then every two years or
30,000 miles.
ROUTINE LEVEL CHECK
Do not remove radiator cap for routine coolant
level inspections. The coolant reserve system provides a quick visual
method for determining the coolant level without re-
moving the radiator cap. Simply observe, with the
engine idling and warmed up to normal operating
temperature, that the level of the coolant in the reserve
tank (Figs. 5 and 6) is between the minimum and
maximum marks.
ADDING ADDITIONAL COOLANT
The radiator cap should not be removed. When
additional coolant is needed to maintain this level, it
should be added to the coolant reserve tank. Use only
50/50 concentration of ethylene glycol type antifreeze
and water.
SERVICE COOLANT LEVEL
The cooling system is closed and designed to main-
tain coolant level to the top of the radiator. When servicing requires a coolant level check in the
radiator, the engine must be offand notunder pres-
sure. Drain several ounces of coolant from the radiator
drain cock while observing the Coolant Recovery Sys-
tem (CRS) Tank. Coolant level in the CRS tank should
drop slightly. Then remove the radiator cap. The radia-
tor should be full to the top. If not, and the coolant level
in the CRS tank is at the MIN mark there is a air leak
in the CRS system. Check hose or hose connections to
the CRS tank, radiator filler neck or the pressure cap
seal to the radiator filler neck for leaks.
LOW COOLANT LEVEL AERATION
Low coolant level in a cross flow radiator will equal-
ize in both tanks with engine off. With engine at
running operating temperature the high pressure inlet
tank runs full and the low pressure outlet tank drops.
If this level drops below the top of the transmission oil
cooler, air will be sucked into the water pump:
² Transmission oil will become hotter.
² High reading shown on the temperature gauge.
² Air in the coolant will also cause loss of flow through
the heater.
² Exhaust gas leaks into the coolant can also cause the
same problems.
DEAERATION
Air can only be removed from the system by gather-
ing under the pressure cap. On the next heat up it will
be pushed past the pressure cap into the CRS tank by
thermal expansion of the coolant. It then escapes to the
atmosphere in the CRS tank and is replaced with solid
coolant on cool down.
COOLING SYSTEM DRAIN, CLEAN, FLUSH AND
REFILL
Drain, flush, and fill the cooling system at the
mileage or time intervals specified in the Maintenance
Schedule in this Group. If the solution is dirty or rusty
or contains a considerable amount of sediment, clean
and flush with a reliable cooling system cleaner. Care
should be taken in disposing of the used engine coolant
from your vehicle. Check governmental regulations for
disposal of used engine coolant.
DRAINING
To drain cooling system move temperature selector
for heater to full heat with engine running (to provide
vacuum for actuation). Without removing radiator
pressure cap and with system not under pres-
sure, Shut engine off and open draincock. The coolant
reserve tank (Fig. 5) should empty first, then remove
radiator pressure cap. (if not, see Testing Cooling
System for leaks). To vent 2.2/2.5L engines remove the
plug above thermostat housing (Fig. 1). For Turbo III
engines remove coolant temperature sensor in the
thermostat housing (Fig. 2). For 3.3L /3.8L engine
remove the engine temperature sending unit (Fig. 3).
Removal of a plug or other component is required
because the thermostat has no air vent and prevents
air flow through it. This allows the coolant to drain
from the engine block.
Fig. 1 Thermostat Housing Drain/Fill PlugÐ2.2/2.5L Engines
Ä COOLING SYSTEM 7 - 15

CLEANING
Drain cooling system (see: Draining Cooling Sys-
tem ) and refill with clean water (see: Refilling
Cooling System ). Run engine with radiator cap in-
stalled until upper radiator hose is hot. Stop engine
and drain water from system. If water is dirty, fill,
run and drain system again until water runs clear.
REVERSE FLUSHING
Reverse flushing of the cooling system is the forc-
ing of water through the cooling system, using air
pressure in a direction opposite to that of the normal
flow of water. This is only necessary with dirty sys-
tems and evidence of partial plugging.
RADIATOR Drain cooling system and remove radiator hoses
from engine. Install suitable flushing gun in radiator
lower hose. Fill radiator with clean water and turn
on air in short blasts. CAUTION: Internal radiator pressure must not ex-
ceed 138 kPa (20 psi) as damage to radiator may re-
sult. Continue this procedure until water runs clear.
ENGINE
Drain radiator (see: Draining Cooling System )
and remove hoses from radiator. Remove engine
thermostat and reinstall thermostat housing. Install
suitable flushing gun to thermostat housing hose.
Turn on water, and when engine is filled, turn on
air, but no higher than 138 kPa (20 psi) in short
blasts. Allow engine to fill between blasts of air.
Continue this procedure until water runs clean. In-
stall thermostat using a new housing gasket. Fill
cooling system (See Refilling Cooling System ).
CHEMICAL CLEANING
One type of corrosion encountered with aluminum
cylinder heads is aluminum hydroxide deposits. Cor-
rosion products are carried to the radiator and depos-
ited when cooled off. They appear as dark grey when
wet and white when dry. This corrosion can be re-
moved with a two part cleaner (oxalic acid and neu-
tralizer) available in auto parts outlets. Follow
manufacturers directions for use.
REFILLING
First clean system to remove old glycol, see Cooling
System Cleaning. Fill system using antifreeze described in Coolant
section. Fill 50 percent of capacity with 100 percent
glycol. Then complete filling system with water. The
2.2/2.5L engines require venting by removal of the
plug on top of the water box (Fig. 1). Turbo III en-
gines require venting by removing the coolant tem-
perature sensor on top of the thermostat housing
(Fig. 2). The 3.3/3.8L Engines require removal of the
Engine Temperature Sending Unit on the front of
the cylinder head (Fig. 3). The thermostat in these
engines do not allow air flow through them. When
coolant reaches the vent holes;
² Install vent plug and tighten to 20 N Im (15 ft. lbs.)
for 2.2/2.5L Engines.
² Install Coolant Temperature Sensor and tighten to
27 N Im (20 ft. lbs.) for Turbo III Engine.
² Install Engine Temperature Sending Unit and
tighten to 7 N Im (60 in. lbs.) for 3.3/3.8L Engines.
Continue filling system until full, this provides bet-
ter heater performance. Be careful not to spill
coolant on drive belts or the generator. Fill coolant reserve system to at least the MAX
mark with 50/50 solution. It may be necessary to add
coolant to the reserve tank to maintain coolant level
between the MAX and MIN mark after three or four
warm-up, cool down cycles and trapped air has been
removed.
Fig. 2 Coolant Temperature SensorÐTurbo III Drain/Fill
Fig. 3 Engine Temperature Sending UnitÐ3.3L and 3.8L Drain/Fill
7 - 16 COOLING SYSTEM Ä

TESTING SYSTEM FOR LEAKS
With engine not running, wipe the radiator filler
neck sealing seat clean. The radiator should be full. Attach a radiator pressure tester to the radiator, as
shown in (Fig. 4) and apply 104 kPa (15 psi) pres-
sure. If the pressure drops more than 2 psi in 2 min-
utes inspect all points for external leaks. All hoses, radiator and heater, should be moved
while at 15 psi since some leaks occur while driving
due to engine rock, etc.
If there are no external leaks after the gauge dial
shows a drop in pressure, detach the tester. Start en-
gine and run the engine to normal operating temper-
ature in order to open the thermostat and allow the
coolant to expand. Re-attach the tester. If the needle
on the dial fluctuates it indicates a combustion leak,
usually a head gasket leak.
WARNING: WITH TOOL IN PLACE PRESSURE
BUILDS UP FAST. ANY EXCESSIVE AMOUNT OF
PRESSURE BUILT UP BY CONTINUOUS ENGINE
OPERATION MUST BE RELEASED TO A SAFE
PRESSURE POINT. NEVER PERMIT PRESSURE TO
EXCEED 138 KPA (20 PSI).
If the needle on the dial does not fluctuate, race
the engine a few times. If an abnormal amount of
coolant or steam is emitted from the tail pipe, it may
indicate a faulty head gasket, cracked engine block
or cylinder head. There may be internal leaks which can be deter-
mined by removing the oil dip-stick. If water glob-
ules appear intermixed with the oil it will indicate a internal leak in the engine. If there is an internal
leak, the engine must be disassembled for repair.
COOLANT RECOVERY SYSTEM (CRS)
This system works in conjunction with the radiator
pressure cap to utilize thermal expansion and con-
traction of the coolant to keep the coolant free of
trapped air. It provides a volume for expansion and
contraction, provides a convenient and safe method
for checking coolant level and adjusting level at at-
mospheric pressure without removing the radiator
pressure cap. It also provides some reserve coolant to
cover minor leaks and evaporation or boiling losses.
All vehicles are equipped with this system (Figs. 5
and 6).
See Coolant Level Check Service, Deaeration and
Pressure Cap sections for operation and service. Ve-
hicles equipped with the electric monitor system use
a level sensor in the CRS tank, see Group 8E Elec-
trical for service.
Fig. 4 Pressure Testing Cooling System
Fig. 5 Coolant Recovery System Typical
Fig. 6 Coolant Recovery SystemÐAC-AY Models
Ä COOLING SYSTEM 7 - 17

(2) Remove radiator pressure cap when engine is
cold, Idle engine until thermostat opens, you should
observe coolant flow while looking down the filler
neck. Once flow is detected install radiator pressure
cap.
RADIATOR
REMOVAL
(1) Disconnect negative battery cable from battery.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(2) Drain cooling system. Refer to Draining Cool-
ing System of this section. (3) Remove hose clamps and hoses from the radia-
tor (Fig. 11). Remove coolant reserve system tank to
filler neck tube. (4) Remove automatic transmission hoses, if
equipped. (5) Remove fan and fan support assembly by dis-
connecting fan motor electrical connector. Remove
fan shroud retaining clips, located on the top and
bottom of the shroud for AA, AG, AJ and AP vehi-
cles. AC/AY vehicle retainer clips are located on the
top only. Lift shroud up and out of bottom shroud at-
tachment clips separating shroud from radiator. Fan
damage should always be avoided. (6) Remove upper radiator mounting screws. Dis-
connect the engine block heater wire if equipped. (7) Remove the air conditioning condenser attaching
screws located at the top front of the radiator,if
equipped. Radiator can now be lifted free from engine compart-
ment. Care should be taken not to damage radia-
tor cooling fins or water tubes during removal.
INSTALLATION
(1) Slide radiator down into position behind radiator
support (yoke). (2) Attach air conditioning condenser to radiator, if
equipped, with a force of approximately 10 lbs. to seat
the radiator assembly lower rubber isolators in the
mount holes provided. (3) Tighten radiator mounting screws to 11.9N Im
(105 in. lbs.). (4) Connect automatic transmission hoses, if
equipped. Tighten hose clamps to 4 N Im (35 in. lbs.).
(5) Slide fan shroud, fan and motor down into clips
on lower radiator flange. Replace shroud retaining
clips. (6) Install upper and lower radiator hoses (including
coolant reserve hose). (7) Connect fan motor electrical connection and con-
nect negative battery cable. (8) Fill cooling system with coolant. Refer to Refill-
ing Cooling Systems. in this group.
(9) Operate engine until it reaches normal operating
temperature. Check cooling system and automatic
transmission for correct fluid levels.
Fig. 11 Cooling ModulesÐAll Models
7 - 20 COOLING SYSTEM Ä

ENGINE BLOCK HEATER
DESCRIPTION AND OPERATION
On all models an engine block heater is available as
an optional accessory. The heater, operated by ordinary
house current (110 Volt A.C.) through a power cord and
connector behind the radiator grille, provides easier
engine starting and faster warm-up when vehicle is
operated in areas having extremely low temperatures.
The heater is mounted in a core hole (in place of a core
hole plug) in the engine block, with the heating ele-
ment immersed in coolant (Fig. 9). The power cord must be secured in its retainer
clips, and not positioned so it could contact link-
ages or exhaust manifolds and become damaged. If unit does not operate, trouble can be in either the
power cord or the heater element. Test power cord for
continuity with a 110-volt voltmeter or 110-volt test
light; test heater element continuity with an ohmmeter
or 12-volt test light.
REMOVAL
(1) Drain coolant from radiator and cylinder block.
Refer to Cooling System Drain, Clean, Flush and Re-
fill of this section for procedure. (2) Detach power cord plug from heater.
(3) Loosen screw in center of heater. Remove
heater assembly.
INSTALLATION
(1) Thoroughly clean core hole and heater seat.
(2) Insert heater assembly with element loop posi-
tioned upward.
(3) With heater seated, tighten center screw se-
curely to assure a positive seal. (4) Fill cooling system with coolant to the proper
level, vent air, and inspect for leaks. Pressurize sys-
tem with Radiator Pressure Tool before looking for
leaks.
Fig. 9 Engine Block Heater
7 - 28 COOLING SYSTEM 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

(11) Remove two screws from fuse block and lower
fuse block. (12) Remove three screws from hood release and
lower hood release handle. (13) Remove flasher relay from bracket on center
distribution duct. (14) Remove screw from ATC sensor motor assem-
bly and unhook from bracket if equipped. (15) Remove the radio ground screw above flasher
relay mount. (16) Remove center distribution duct screw from
left instrument panel lower brace, then remove four
screws to remove left lower brace.
(17) Remove five nuts on steering column and drop
column, then remove two upper column attaching studs.
(18) Remove two screws and pull out compact disc
player or cubby box, disconnect Co-Axial cable from
compact disc player. (19) Remove Electronic Vehicle Information Center
(E.V.I.C.) or Traveler from vehicle. (20) Remove radio.
(21) Remove A.T.C., A/C or heater controls. (22) Squeeze latches on side of Rear Window defog-
ger switch and remove. (23) Snap off cluster lower trim bezel, switch pod
vent grille, speaker grilles and defroster grilles. (24) Remove switch pod assembly.
(25) Remove cluster assembly.
(26) Remove dash speakers.
(27) Snap out bezel with or without message center
and disconnect wiring. (28) Open glovebox door, squeeze sides and roll
glovebox completely open. Remove glovebox light
switch, and disconnect wires. (29) Loosen right cowl side pivot bolt through
glovebox opening then close glovebox. (30) Loosen left cowl side pivot.
(31) Remove four screw attachments at top of in-
strument panel and roll panel out. (32) Pull wiring, antenna cable, A/C cable and vac-
uum lines out of instrument panel. Disconnect demis-
ter hose and remove instrument panel with ducts
attached. (33) Transfer ducts and brackets onto new panel.
(34) For instrument panel roll up, reverse
above procedures.
INTERIOR LAMP REMOVAL
The Dome, Floor Console and Door Lamps operate
when the doors are open or headlamp switch is
placed in courtesy position.
DOME LAMP
(1) Pry either the forward or rearward edge of the
dome lamp to free it from retaining bracket. (2) Pry either the forward or rearward edge of the
lens away from the bezel and replace lamp. (3) For installation reverse above procedures.
FRONT HEADER READING LAMP
Pull lamp from headliner. Disconnect wiring and
replace lamp.
FLOOR CONSOLE LAMP
Pry along top edge of lamp and pivot lamp out of
floor console, the lens does not remove. Remove lamp
and twist out lamp socket. Replace lamp.
DOOR LAMPS
Pry along bottom edge of lamp and pivot lamp out
of door trim panel, the lens does not remove. Remove
lamp and twist out lamp socket. Replace lamp.
DOOR REFLECTORS
Pry reflector away from the door trim panel, and
replace.
TRUNK LAMP
Remove lens by prying lens out of trunk trim panel
and replace bulb.
Fig. 33 Transmission Range Cable
Fig. 34 Cable Adjustment
Ä INSTRUMENT PANEL AND GAUGES 8E - 57