1993 CHEVROLET PLYMOUTH ACCLAIM ignition

(3) With the ignition switch ON, an open (discon-
nected sending unit wire) causes the oil, fuel or tem-
perature gauge to read below low, empty or cold
indicators. (4) If steps 2 and 3 check OK, refer to the individ-
ual sending unit test procedures.
FUEL TANK SENDING UNIT TEST
Refer to Group 14, Fuel for test procedure.
CHECK GAUGES WARNING LAMP TESTS
The check gauges warning lamp will illuminated
when the ignition key is turned to the ON position.
The lamp will illuminate if the engine oil pressure
drops below a safe level. The check gauge lamp will
light for high engine temperature or for low voltage. To test the system turn ignition key to the ON po-
sition. If the lamp fails to light, inspect for a broken
or disconnected wire at the oil pressure combination
sending unit, which is located at the front of the en-
gine (Fig. 13). If the wire at the connector checks
good pull connector loose from the switch terminal
and with a jumper wire ground connector to the en-
gine. With the ignition key turned to the ON posi-
tion check the warning lamp. If lamp still fails to
light, inspect for a burned lamp. If lamp still fails to
light, inspect for a burned out lamp or disconnected
socket in the cluster.
To test the switch disconnect the switch electrical
connector. Attach positive lead of an ohmmeter to
the switch terminal for the gray (GY) wire and the
negative lead to an engine ground. With the engine
off, there should be continuity in the system. Start
the engine. With the engine running, the ohmmeter
should show no continuity. If the above results are
not obtained, replace the switch.
COMBINATION OIL SENDING UNIT TEST
The combination oil sending unit has two func-
tions: (1) The normal closed circuit keeps the oil pressure
warning lamp on until there is oil pressure. (2) The sending unit provides a resistance that
varies with oil pressure. To test the normally closed oil lamp circuit, discon-
nect the locking connector and measure the resis-
tance between the switch terminal and the metal
housing. The ohmmeter should read 0 ohms. Start
the engine (Fig. 14).
If there is oil pressure, the ohmmeter should read
an open circuit. To test the sending unit, measure the resistance
between the sending unit terminal and the metal
housing. The ohmmeter should read open. Start the
engine. The ohmmeter should read between 30 to 55 ohms,
depending on engine speed, oil temperature, and oil
viscosity. If the above results are not obtained, replace the
sending unit.
SEAT BELT WARNING SYSTEM
For testing of this system refer to Group 8U,
Chime Warning/Reminder System.
MALFUNCTION INDICATOR (CHECK ENGINE) SYSTEM
For testing this system refer to the Body Diagnos-
tic Procedures booklet.
BRAKE SYSTEM WARNING LAMP TEST
The brake warning lamp illuminates when parking
brake is applied with ignition key turned ON. The
same lamp will also illuminate should one of the two
service brake systems fail when brake pedal is ap-
plied. To test system turn ignition key ON, and ap-
ply parking brake. If lamp fails to light, inspect for a
burned out lamp, disconnected socket, a broken or
disconnected wire at switch. The lamp also lights
when the ignition switch is turned to START. Refer
to Brake System Warning Lamp Diagnosis Chart
(Fig. 15). To test service brake warning system, raise vehicle
on a hoist and open a wheel cylinder bleeder while aFig. 13 Combination Oil Sending Unit
Fig. 14 Combination Oil Sending Unit Test
Ä INSTRUMENT PANEL AND GAUGES 8E - 47

SPEEDOMETER/ODOMETER ASSEMBLY REMOVAL
(1) Remove switch pod assembly.
(2) Remove cluster, refer to Cluster Removal.
(3) Remove mask and lens assembly.
(4) Remove tachometer, turbo gauge.
(5) Remove volt, temperature, oil and fuel gauge
assemblies. (6) Remove the speedometer/odometer assembly
from the cluster housing. (7) Disconnect pigtail connector from the cluster
printed circuit board. (8) For installation reverse above procedures. Lis-
ten for the pigtail connector to snap in place.
SPEEDOMETER CIRCUIT TESTING
(1) Using DRB II, check vehicle speed sensor for
speed sensor fault code and for proper speed indica-
tion. Refer to Powertrain Diagnostics Procedure
Manual; Speed Control Test (Fig. 18). (2) Remove cluster, but do not disconnect cluster
wiring. (3) With ignition ON check for battery voltage
across the ignition pin and ground pin of speedome-
ter connector. (4) Check for continuity from vehicle speed sensor
signal pin to connector at speed sensor. (5) Check cluster to body for continuity to ground.
(6) If all these tests prove good, replace speedome-
ter.
VEHICLE SPEED SENSOR REPLACEMENT
(1) Remove harness connector from sensor and
make sure weather seal is on harness connector. (2) Remove sensor retaining bolt (Fig. 19).
(3) Pull sensor and pinion gear assembly out of
transaxle. If necessary carefully pry loose with a flat
blade screwdriver (Fig. 20). (4) Remove pinion gear from sensor.
(5) For installation reverse above procedures. Seat
the sensor assembly by hand to ensure proper gear
engagement. Tighten retaining bolt to 7 N Im (60 in.
lbs.) torque.
ELECTRONIC AUTOMATIC TRANSAXLE VEHICLE SPEED SENSOR REPLACEMENT
The output vehicle speed sensor is located to the
left of the manual shift lever. (1) Raise and support vehicle on safety stands.
(2) Remove vehicle speed sensor (Fig. 21).
(3) For installation, reverse above procedures.
Fig. 17 Speedometer Diagnosis
Fig. 18 Speedometer
Ä INSTRUMENT PANEL AND GAUGES 8E - 49

Perform cluster Self Diagnostic Test to determine
whether problem is within cluster or outside of clus-
ter. Refer to Fig. 24 and 25.
Successful completion of the SELF DIAGNOSTIC
TEST indicates that the problem is in the wiring,
connectors or sensors out side of the cluster.
CLUSTER ASSEMBLY REMOVAL
The electronic cluster which is serviced as an as-
sembly is removed with the same procedure as the
conventional cluster.
CONDITION: CLUSTER DISPLAYS DO NOT ILLUMINATE AFTER VEHICLE IS STARTED
(1) Check fuses and verify battery and ignition
voltage at cluster connector. (2) Check ground from cluster connector to instru-
ment panel ground stud.
SWITCH AND PANEL COMPONENT SERVICE
HEADLAMP SWITCH
The headlamp switch is located on the left side of
the switch pod. The switch controls the headlamps,
parking lamps, fog lamps and instrument light dim- ming. If any of the switches require replacement the
entire headlamp switch assembly must be replaced
(Fig. 26 and 27).
REMOVAL
(1) Remove switch pod assembly from the instru-
ment panel. DO NOT attempt to remove instrument
cluster dimmer switch or wiper delay switch knob,
they are not removable. (2) Remove turn signal switch lever by pulling
straight out of switch pod. (3) Remove screws from bottom of switch pod.
(4) Separate inner and outer switch pod halves and
remove turn signal switch to gain access to screw. (5) Remove five inner switch pod panel screws and
3 screws from underneath the switch pod. Separate
the inner bezel from the outer bezel. (6) Remove switch mounting screws before discon-
necting linkage. (7) Disconnect switch linkage from buttons. Pull
the linkage straight up from the switch/button to dis-
engage it and remove switch.
Fig. 23 Mechanical Cluster Lamp Location
Ä INSTRUMENT PANEL AND GAUGES 8E - 51

AP BODY INDEX
page page
Cluster and Gauge Service and Testing ....... 58
Gauges ................................ 61
General Information ....................... 58 Instrument Panel Replacement
.............. 72
Interior Lamp Replacement ................. 73
Switch and Panel Component Service ......... 67
GENERAL INFORMATION
INSTRUMENT CLUSTER
There are two conventional instrument cluster as-
semblies available. The clusters incorporates mag-
netic type gauges and an electronically driven
speedometer and odometer assembly (Fig. 1 and 2).
MAGNETIC GAUGES
All gauges on the AP Body clusters are the mag-
netic type gauges. When the ignition switch is in the
OFF position each gauge, except for the voltmeter
and tachometer will show a reading. However, 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 the magnetic tachometer in the
high line cluster. This module is located on top of the instrument
cluster.
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 OFF position, or
when the radio frequency is being displayed, 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-
fer to the Sound Systems Manual supplied with the
vehicle.
WARNING LAMPS AND INDICATOR LIGHTS
The instrument cluster has warning and indicators
lamps for eight different systems:
² Low oil pressure
² Brake warning
² Seat belt warning
² Malfunction indicator (check engine) lamp
² Air Bag
² High beam indicator
² Right and left turn signals.
² Anti-lock (ABS)
CLUSTER AND GAUGE SERVICE AND TESTING
CAUTION: Disconnect the negative battery cable
before servicing the instrument panel. When power
is required for test purposes, reconnect battery ca-
ble for test only. Disconnect the negative battery
cable after test and before continuing service pro-
cedures.
SENDING UNIT TEST
Check for a defective sending unit or wiring, when
a problem occurs with a cluster gauge. Do this before
disassembling the cluster. (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 fuel or temperature
gauge to read at or above maximum.
Fig. 1 Instrument Cluster With Tachometer
Fig. 2 Instrument Cluster Without Tachometer
8E - 58 INSTRUMENT PANEL AND GAUGES Ä

FUEL TANK SENDING UNIT TEST
Refer to Group 14, Fuel for test procedures.
LOW OIL PRESSURE WARNING LAMP TEST
The low oil pressure warning lamp will illuminate
when the ignition key is turned to the ON position
without engine running. The lamp also illuminates
should the engine oil pressure drop below a safe oil
pressure level. To test the system turn ignition key to the ON po-
sition. If the lamp fails to light, inspect for a broken
or disconnected wire at the oil pressure combination
unit, located at the front of the engine (Fig. 3). If the
wire at the connector checks good, pull connector
loose from the switch and with a jumper wire ground
connector to the engine. With the ignition key turned
to the ON position check the warning lamp. If lamp
still fails to light, inspect for a burned out lamp or
disconnected socket in the cluster.
COMBINATION OIL SENDING UNIT TEST
The combination oil sending unit has two func-
tions: (1) The normal closed circuit keeps the oil pressure
warning lamp on until there is oil pressure (Fig. 4).
(2) The sending unit provides a resistance that
varies with oil pressure. To test the normally closed oil lamp circuit, discon-
nect the locking connector and measure the resis-
tance between the switch terminal and the metal
housing. The ohmmeter should read continuity. Start
the engine. If there is oil pressure, the ohmmeter should read
an open circuit. To test the sending unit, measure the resistance
between the sending unit terminal and the metal
housing. The ohmmeter should no continuity. Start
the engine. The ohmmeter should read between 30 to 55 ohms,
depending on engine speed, oil temperature and oil
viscosity. If the above results are not obtained, replace the
sending unit.
SEAT BELT WARNING SYSTEM
For testing of this system refer to Group 8M, Re-
straint Systems.
AIR BAG WARNING SYSTEM
For testing of this system refer to Group 8M, Re-
straint Systems.
MALFUNCTION INDICATOR (CHECK ENGINE) SYSTEM
For testing of this system using DRB II, refer to
the Body Powertrain Diagnostic Procedures.
BRAKE SYSTEM WARNING LAMP TEST
The brake warning lamp illuminates when parking
brake is applied with ignition key turned ON. The
same lamp will also illuminate should one of the two
service brake systems fail when brake pedal is ap-
plied. Refer to Brake system warning Lamp Diagno-
sis (Fig. 5). To test system turn ignition key ON and apply
parking brake. If lamp fails to light, inspect for a
burned out lamp, disconnected socket, a broken or
disconnected wire at switch. The lamp also lights
when the ignition switch is turned to start. To test service brake warning system, raise vehicle
on a hoist and open a wheel cylinder bleeder while a
helper depresses brake pedal and observes warning
lamp. If lamp fails to light, inspect for a burned out
lamp, disconnected socket, a broken or disconnected
wire at switch. If lamp is not burned out and wire continuity is
proven, replace brake warning switch in brake line
Tee fitting mounted on frame rail in engine compart-
ment below master cylinder (Fig. 6).
CAUTION: If wheel cylinder bleeder was opened
check master cylinder fluid level.
Fig. 3 Combination Oil Sending Unit
Fig. 4 Combination Oil Sending Unit Test
Ä INSTRUMENT PANEL AND GAUGES 8E - 59

(5) Reconnect battery.
GAUGES
CAUTION: During the removal and installation
watch overlays are not damage.
It is not necessary to remove instrument cluster
from vehicle for gauge replacement. When removing gauge assemblies from cluster,
gauge must be pulled straight out, not twisted, or
damage to gauge pins may result.
MULTIPLE GAUGE INOPERATIVE
Volt, speedometer, tachometer and other gauges
appear to malfunction. Also check warning indicator
lamps: (1) Remove cluster
(2) Check for ignition voltage at pin E of the red
connector. If no voltage, repair as necessary (Fig. 8). (3) Check for ground continuity between pin C of
the gray connector. If no ground, repair as necessary. (4) If voltage and ground OK and pins or connec-
tors are not distorted, replace printed circuit board. (5) Install cluster.
SINGLE GAUGE INOPERATIVE (FIG. 9 AND10)
(1) Remove gauge in question. (2) With the ignition key ON, check for ignition
voltage at ignition pin of gauge. Check for ground at
ground pin of gauge. (a) If no voltage or ground, remove cluster and
check pin E red connector for ignition voltage or
pin C gray connector for ground (Fig. 8). (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.
(3) When testing the temperature gauge, allow the
engine to run until the vehicle reaches a normal op-
erating temperature. Turn ignition OFF and remove
gauge from cluster.
² When checking the temperature and oil pressure
gauges, it is important to have the same engine tem-
perature and engine speed when noting gauge posi-
tion.
² The time between gauge position reading and
sending unit measuring should be kept to a mini-
mum.
² When testing oil pressure gauge, engine needs to
be running. (a) Measure and record the resistance between
sending unit pin and ground pin of the gauge in
question. Refer to Gauge Calibration.
Fig. 7 Upper Instrument Panel Components
Ä INSTRUMENT PANEL AND GAUGES 8E - 61

(f) If everything checks out OK, refer to Sending
Unit Test.
(4) With the ignition switch in the ON position,
check for battery voltage across the ignition pin and
the ground pin. (5) If fuel gauge meets specifications check fuel
tank and original fuel tank sending unit as follows: (a) Carefully remove fuel tank sending unit from
tank. (b) Refer to sending unit removal Group 14,
Fuel. (c) Connect sending unit wire and jumper wire
as described in the test procedure.
(6) 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) Resistance Chart (Fig. 11), is general guide-
lines 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 needed 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.
FUEL GAUGE REPLACEMENT
(1) Remove instrument cluster bezel.
(2) Remove mask and lens.
(3) If equipped with tachometer, remove three re-
taining screws and pull the tach straight back.
Fig. 10 Instrument Cluster Without Tachometer
Ä INSTRUMENT PANEL AND GAUGES 8E - 63

(4) Remove two retaining screws and pull fuel
gauge straight back. (5) For installation reverse above procedures.
TEMPERATURE GAUGE REPLACEMENT
(1) Remove instrument cluster bezel (Fig. 7).
(2) Remove mask and lens.
(3) Remove two retaining screws and pull temper-
ature gauge straight back. (4) For installation reverse above procedures.
VOLTMETER REPLACEMENT
(1) Remove instrument cluster bezel (Fig. 7).
(2) Remove mask and lens.
(3) Remove three speedometer retaining screws
and pull the speedometer straight back and set aside. (4) Remove two voltmeter retaining screws and
pull voltmeter straight back. (5) For installation, place voltmeter on gauge pins
and push until gauge is securely seated in cluster
and reverse above procedures.
TACHOMETER REPLACEMENT
(1) Remove instrument cluster bezel.
(2) Remove mask and lens.
(3) Remove three retaining screws and pull ta-
chometer straight back. (4) For installation, place tachometer on gauge
pins and push until gauge is securely seated in clus- ter and reverse above procedures.
TACHOMETER CIRCUIT TESTING
(1) Remove cluster.
(2) Check for battery voltage at cavity J if instru-
ment cluster gray connector. (3) With the ignition in the ON position, check for
battery voltage at cavity K of the instrument cluster
gray connector (Fig. 8). (4) Check cavity F of the instrument cluster red
connector for continuity to ground (Fig. 8). (5) Check for tachometer signal from the power-
train control module by connecting an AC DIGITAL
VOLTMETER to cavity H of the instrument cluster
gray connector and ground. A reading of at least 1.0
volts should be present with the engine running. (a) If voltage is within specification, go to step 7.
(b) If voltage is NOT within specification, per-
form steps 5 and 6.
(6) If there is less than 1.0 volts at cavity H check
for continuity between cavity H of the instrument
cluster and pin 43 of the powertrain control module
connector (Fig. 12). Also, check the connector at the
powertrain control module for damaged pins or ter-
minal push outs. (7) If voltage is less than 1.0 volts at cavity H and
there is continuity between cavity H of the instru-
Fig. 11 Gauge Resistance
8E - 64 INSTRUMENT PANEL AND GAUGES Ä