1993 CHEVROLET PLYMOUTH ACCLAIM tow bar

PROBLEM
Headlamp door or doors fit poorly, rattle, or bang
when coming open or closed.
CHECK:
² Headlamp door fascia mounting bracket or adjust-
able stops for improper alignment.
² Headlamp door pivot brackets or door/crank lateral
adjustment for improperly aligned collar.
² For missing or worn pivot bushings.
² For defective motor.
HEADLAMP DOORÐAC-BODY
REMOVAL (FIG. 2)
(1) Remove the grill. Refer to Group 23, Body.
(2) Remove the front bumper assembly. Refer to
Group 23, Body. (3) Loosen and separate the grille opening panel
from the front fender on the side of the vehicle af-
fected. Refer to Group 23, Body. (4) Compress torsion bar retainer clip tabs to-
gether and slide the retainer toward the center of the
vehicle. Separate the torsion bar from the door crank
on the side of the vehicle affected. (5) Remove headlamp door side trim covers and
lower trim covers. (6) Remove outer pivot screw, door crank screw,
and loosen the door (lateral) adjustment collar. (7) Remove the door crank from the door and ad-
justment collar. (8) Lower the door from under the grille opening
panel and remove the door from the vehicle.
INSTALLATION
Reverse the preceding operation.
CONCEALED HEADLAMP MOTORÐAC-BODY
REMOVAL (FIG. 2)
(l) Remove the grille. Refer to Group 23, Body.
(2) Compress torsion bar retainers and slide them
toward the center of the vehicle. Separate the torsion
bar from the door cranks. (3) Disconnect the headlamp door drive motor wire
connector. Remove three motor attaching bolts and
separate the drive motor and torsion bar from the ve-
hicle.
INSTALLATION
Reverse the preceding operation.
HEADLAMP DOORÐAY BODY
REMOVAL
(1) Turn headlight switch ON.
Fig. 2 Concealed headlampsÐAC-body
Ä LAMPS 8L - 29

(2) Open hood and locate Power Distribution Cen-
ter forward of the left suspension tower (Fig. 3). (3) Remove cover from the center and pull the
Headlamp Close Relay (Fig. 4) to keep the headlamp
doors from closing. (4) Turn headlight switch OFF.
(5) Remove two grill mounting screws and remove
grill assembly (Fig. 5). (6) Spring tension must be relieved from the head-
lamp doors before removing headlamp motor torsion
bar clips. Locate the thumb wheel on bottom of head-
lamp motor (Fig. 6). Rotate thumb wheel approxi-
mately six to seven turns clockwise to relieve all
tension. (7) Remove torsion bar anchor clip (Fig. 7).
(8) Slide torsion bar sleeve over the torsion bar
(Fig. 8). (9) Remove three clips retaining turn signal lamp
shield to body (Fig. 9), and remove shield. (10) Remove two screws retaining headlamp cover
to headlamp cover bracket (Fig. 10). (11) Remove outer headlamp.
(12) Remove outer pivot screw (Fig. 11).
(13) Remove E-clip and door crank screw (Fig. 12).
(14) Remove three bolts retaining cam pivot to
body and remove cam pivot (Fig. 11). (15) Remove Headlamp door assembly.
INSTALLATION
Reverse the preceding operation. Before installing
torsion bar clips, the holes in the torsion bars, tor-
sion bar sleeves and headlamp door cam pivots must
be in alignment. Refer to Aligning Headlamp Doors.
HEADLAMP DRIVE MOTORÐAY BODY
REMOVAL
(1) Open headlamp doors. Refer to Headlamp Door
paragraph for instructions. (2) Remove grill mounting screws and remove grill
assembly (Fig. 5). (3) Spring tension must be relieved from headlamp
doors before removing the headlamp motor torsion
bar clips. Locate the thumb wheel on bottom of the
headlamp motor (Fig. 6). Rotate thumb wheel ap-
proximately six to seven turns (clockwise) to relieve
all tension. (4) Remove both torsion bar anchor clips (Fig. 7).
(5) Slide torsion bar sleeves over the torsion bar
(Fig. 8).
Fig. 3 Power Distribution Center
Fig. 4 Headlamp Close Relay
Fig. 5 Grill
Fig. 6 Headlamp MotorÐBottom View
8L - 30 LAMPS Ä

REAR WINDOW DEFOGGER
CONTENTS
page page
CONTROL SWITCH/TIMER RELAY MODULE . . 1
GENERAL INFORMATION .................. 1REPAIR GRID LINES, TERMINALS AND PIGTAILS.3
SERVICE PROCEDURES ................... 1
GENERAL INFORMATION
For proper operation of the Rear Window Defogger
system refer to the Owner's Manual. Vehicles equipped with an electrically heated rear
window defogger also have a 40/90 amp generator. The system consists of a rear glass with two verti-
cal bus bars and a series of electrically connected
grid lines fired on the inside surface. A control
switch and a timer relay combined into a single as-
sembly is used on all models (Fig.1).
Circuit protection is provided by a fusible link, lo-
cated in the charging circuit, for the heated grid cir-
cuit and by a fuse for the relay control circuit. When the switch is turned to the ON position, cur-
rent is directed to the rear defogger grid lines. The
heated grid lines heat the rear glass to clear the sur-
face of fog or frost.
CAUTION: Grid lines can be damaged or scraped
off with sharp instruments, care should be taken in
cleaning glass or removing foreign materials, de-
cals or stickers. Normal glass cleaning solvents or
hot water used with rags or toweling is recom-
mended.
CONTROL SWITCH/TIMER RELAY MODULE
The control switch and timer relay are integrated
into a single panel or console mounted assembly. Ac-
tuating the switch energizes the circuit which allows
current to flow through the grid lines. Upon initial
actuation for approximately ten minutes, or until ei-
ther the switch or ignition is turned off. An indicat-
ing lamp illuminates a lens inlaid in the control
switch.
SERVICE PROCEDURES
Electrically heated rear window defogger operation
can be checked in vehicle in the following manner: (1) Turn ignition ON.
(2) Turn rear window defogger control switch ON.
(3) Using a ammeter on the battery. Turn the De-
fogger control switch ON, a distinct increase in am-
perage draw should be noted. (4) The rear window defogger operation can be
checked by feeling the glass. A distinct difference in
temperature between the grid lines and adjacent
clear glass can be detected in three to four minutes
of operation. (5) Using a DC voltmeter (Fig. 2) contact terminal
B with the negative lead, and terminal A with the
positive lead. The voltmeter should read 10-14 volts.
Fig. 1 Rear Window DefoggerÐTypical
Fig. 2 Rear Glass Grid Line TestÐTypical
Ä REAR WINDOW DEFOGGER 8N - 1

(6) Steps (3, 4 or 5) above will confirm system op-
eration. Indicator light illumination means that
there is power available at the output of the relay
only, and does not necessarily verify system opera-
tion. (7) If turning the switch ON produced no distinct
current draw on the ammeter the problem should be
isolated in the following manner: (a) Confirm the ignition switch is ON.
(b) Ensure that the heated rear glass feed wire is
connected to the terminal or pigtail and that the
ground wire is in fact grounded. (c) Ensure that the fusible link and control cir-
cuit fuse is operational and all electrical connec-
tions are secure.
(8) When the above steps have been completed and
the system is still inoperative, one or more of the fol-
lowing is defective: (a) Control switch/timer relay module.
(b) All rear window grid lines would have to be
broken or one of the feed wires are not connected
for the system to be inoperative.
(9) If turning the switch ON produces severe volt-
meter deflection, the circuit should be closely
checked for a shorting condition. (10) If the system operation has been verified but
indicator lamp does not light, replace the switch. (11) For detailed wiring information, refer to group
8W, Wiring Diagrams.
GRID TEST
The horizontal grid lines and vertical bus bar lines
printed and fired on inside surface of rear window
glass (Fig. 2) comprise an electrical parallel circuit.
The electrically conductive lines are composed of a
silver-ceramic material which when fired on glass be-
comes bonded to the glass and is highly resistant to
abrasion. It is possible, however, that a break may
occur in an individual grid line resulting in no cur-
rent flow through the line. To detect breaks in grid
lines the following procedure is required: (1) Turn ignition ON and turn control switch to
ON. The indicator light should come on. (2) Using a DC voltmeter with 0-15 volt range,
contact terminal B with negative lead of voltmeter.
With positive lead of voltmeter, contact terminal A
(Fig. 2). The voltmeter should read 10-14 volts. A
lower voltage reading indicates a poor ground con-
nection. (3) With negative lead of voltmeter, contact a good
body ground point. The voltage reading should not
change. (4) Connect negative lead of voltmeter to terminal
B and touch each grid line at Mid-Point with Posi-
tive lead. A reading of approximately 6 volts indi-
cates a line is good. A reading of 0 volts indicates a
break in line between Mid-Point C and terminal A.
A reading of 10-14 volts indicates a break between Mid-Point C and terminal B. Move toward break and
voltage will change as soon as break is crossed (Figs.
2 and 3).
CONTROL SWITCH/TIMER RELAY MODULE TEST
Control switch/timer relay module may be tested
in-vehicle or bench tested. In vehicle testing is ac-
complished in the following manner: (1) Remove the switch, relay assembly from the in-
strument panel or console, see Group 8E, Instrument
Panel and leave the switch connector plugged in. (2) Turn ignition ON.
(3) Using a DC voltmeter, with 0-15 range, check
voltage at terminals B, I and L. (Figs. 3 and 4). Ter-
minals B and I should confirm a voltage of 10 to 14
volts to ground when the ON switch is pressed. Ter-
minal L should confirm voltage to ground. When ter-
minals B and I show no voltage, trace circuit
upstream of switch/relay module for problem (wiring
cut, fusible link or circuit breaker inoperative, bulk-
head connector not operative, etc.) If terminal L in-
dicates voltage, place switch in Off position. If
voltage at L is still indicated or indicator lamp re-
mains on, the switch/relay module should be re-
placed. (4) If the relay checks out to this point, momen-
tarily operate switch to ON position. The indicator
lamp should come on and remain on for approxi-
mately 10 minutes. Terminal L should confirm volt-
age. If the indicator lamp fails to light or voltage at
terminal L is not confirmed the switch/relay module
should be replaced.
Fig. 3 Systems Electrical Circuit
8N - 2 REAR WINDOW DEFOGGER Ä

CAUTION: Be sure that the tapped holes maintain
the original centerline.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostaticly
locked, regardless of what caused the problem, these
steps should be used.
CAUTION: Do Not Use Starter Motor To Rotate En-
gine, severe damage may occur.
(1) Inspect air cleaner, induction system and in-
take manifold to insure system is dry and clear of
foreign material. (2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will
catch any fluid that may possibly be in the cylinder
under pressure. (4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket. (5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other). (6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., Connecting
Rods, Pistons, Valves etc.) (7) Repair engine or components as necessary to
prevent this problem from occurring again.
CAUTION: Squirt approximately 1 teaspoon of oil
into cylinders, rotate engine to lubricate the cylin-
der walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Fill engine with specified amount of approved
oil and install new oil filter. (11) Connect negative battery cable.
(12) Start engine and check for any leaks.
Ä ENGINE 9 - 5