1993 CHEVROLET PLYMOUTH ACCLAIM check engine

2.2L/2.5L SINGLE POINT FUEL INJECTIONÐON-BOARD DIAGNOSTICS INDEX
page page
60-Way PCM Wiring Connector .............. 46
Circuit Actuation Test Mode ................ 45
Diagnostic Trouble Code Description .......... 42
General Information ....................... 41
High and Low Limits ...................... 42
Ignition Timing Procedure .................. 46 Monitored Circuits
........................ 41
Non-Monitored Circuits .................... 42
State Display Test Mode ................... 45
Systems Test ........................... 45
Throttle Body Minimum Air Flow Check Procedure.46
GENERAL INFORMATION
The powertrain control module (PCM) has been
programmed to monitor many different circuits of the
fuel injection system. If a problem is sensed with a
monitored circuit often enough to indicate an actual
problem, the PCM stores a fault. If the problem is re-
paired or ceases to exist, the PCM cancels the Diag-
nostic Trouble Code after 50 to 100 vehicle key on/off
cycles. Certain criteria must be met for a diagnostic trou-
ble code to be entered into powertrain control module
(PCM) memory. The criteria may be a specific range
of engine RPM, engine temperature, and/or input
voltage to the PCM. It is possible that a diagnostic trouble code for a
monitored circuit may not be entered into memory
even though a malfunction has occurred. This may
happen because one of the diagnostic trouble code
criteria for the circuit has not been met. For exam-
ple , assume that one of the diagnostic trouble code
criteria for a certain sensor circuit is that the engine
must be operating between 750 and 2000 RPM to be
monitored for a diagnostic trouble code. If the sensor
output circuit shorts to ground when engine RPM is
above 2400 RPM (resulting i n a 0 volt input to the
PCM) a diagnostic trouble code will not be entered
into memory. This is because the condition does not
occur within the specified RPM range. There are several operating conditions for which
the PCM does not monitor and set diagnostic trouble
codes. Refer to Monitored Circuits and Non-Moni-
tored Circuits in this section. Stored diagnostic trouble codes can be displayed by
cycling the ignition key On - Off - On - Off - On.
Also, the technician can display fault information us-
ing the DRB II scan tool. The DRBII scan tool con-
nects to the data link connector in the vehicle (Fig.
1,2or3).
MONITORED CIRCUITS
The powertrain control module (PCM) can detect
certain fault conditions in the fuel injection system. Open or Shorted Circuit - The PCM can deter-
mine if the sensor output (input to PCM) is within
proper range, and if the circuit is open or shorted. Output Device Current Flow
- The PCM senses
whether the output devices are hooked up. If there is
a problem with the circuit, the PCM senses whether
the circuit is open, shorted to ground, or shorted
high. Oxygen Sensor - The PCM can determine if the
oxygen sensor is switching between rich and lean
Fig. 1 Data Link Connector LocationÐAA and AP Vehicles
Fig. 2 Data Link Connector LocationÐAC Vehicles
Ä FUEL SYSTEMS 14 - 41

once the system has entered closed loop. Refer to
Modes of Operation in this section for an explanation
of closed loop operation.
NON-MONITORED CIRCUITS
The PCM does not monitor the following circuits,
systems and conditions that could have malfunctions
that result in driveability problems. Diagnostic trou-
ble codes may not be displayed for these conditions.
However, problems with these systems may cause di-
agnostic trouble codes to be displayed for other sys-
tems. For example, a fuel pressure problem will not
register a fault directly, but could cause a rich or
lean condition. This could cause an oxygen sensor
fault to be stored in the PCM. Fuel Pressure - Fuel pressure is controlled by the
fuel pressure regulator. The PCM cannot detect a
clogged fuel pump inlet filter, clogged in-line fuel fil-
ter, or a pinched fuel supply or return line. However,
these could result in a rich or lean condition causing
an oxygen sensor fault. Secondary Ignition Circuit - The PCM cannot
detect an inoperative ignition coil, fouled or worn
spark plugs, ignition cross firing, or open spark plug
cables. Engine Timing - The PCM cannot detect an incor-
rectly indexed timing chain, camshaft sprocket and
crankshaft sprocket. The PCM also cannot detect an
incorrectly indexed distributor. However, these could
result in a rich or lean condition causing an oxygen
sensor fault to be stored in the PCM. Cylinder Compression - The PCM cannot detect
uneven, low, or high engine cylinder compression. Exhaust System
- The PCM cannot detect a
plugged, restricted or leaking exhaust system. Fuel Injector Malfunctions - The PCM cannot
determine if the fuel injector is clogged, the pintle is
sticking or the wrong injector is installed. However,
these could result in a rich or lean condition causing
an oxygen sensor fault to be stored in the PCM. Excessive Oil Consumption - Although the PCM
monitors the exhaust stream oxygen content through
the oxygen sensor when the system is in closed loop,
it cannot determine excessive oil consumption. Throttle Body Air Flow - The PCM cannot detect
a clogged or restricted air cleaner inlet or filter ele-
ment. Evaporative System - The PCM will not detect a
restricted, plugged or loaded evaporative purge can-
ister. Vacuum Assist - Leaks or restrictions in the vac-
uum circuits of vacuum assisted engine control sys-
tem devices are not monitored by the PCM. However,
these could result in a MAP sensor fault being stored
in the PCM. PCM System Ground - The PCM cannot deter-
mine a poor system ground. However, a diagnostic
trouble code may be generated as a result of this con-
dition. PCM Connector Engagement - The PCM cannot
determine spread or damaged connector pins. How-
ever, a diagnostic trouble code may be generated as a
result of this condition.
HIGH AND LOW LIMITS
The powertrain control module (PCM) compares in-
put signal voltages from each input device with es-
tablished high and low limits that are programmed
into it for that device. If the input voltage is not
within specifications and other diagnostic trouble
code criteria are met, a diagnostic trouble code will
be stored in memory. Other diagnostic trouble code
criteria might include engine RPM limits or input
voltages from other sensors or switches that must be
present before a fault condition can be verified.
DIAGNOSTIC TROUBLE CODE DESCRIPTION
When a diagnostic trouble code appears, it indi-
cates the powertrain control module (PCM) has rec-
ognized an abnormal condition in the system.
Diagnostic trouble codes can be obtained from the
malfunction indicator lamp (instrument panel Check
Engine lamp) on the Instrument Panel or from the
DRBII scan tool. Diagnostic trouble codes indicate
the results of a failure but do not identify the failed
component directly.
Fig. 3 Data Link Connector LocationÐAG and AJ Vehicles
14 - 42 FUEL SYSTEMS Ä

SYSTEMS TEST
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE PERFORMING A TEST
WITH THE ENGINE OPERATING.
OBTAINING DIAGNOSTIC TROUBLE CODES
(1) Connect DRBII scan tool to the data link con-
nector located in the engine compartment near the
powertrain control module (PCM). (2) Start the engine if possible, cycle the transaxle
selector and the A/Cswitch if applicable. Shut off
the engine. (3) Turn the ignition switch on, access Read Fault
Screen. Record all the fault messages shown on the
DRBII scan tool. Observe the malfunction indicator
lamp (check engine lamp on the instrument panel).
The lamp should light for 3 seconds then go out (bulb
check).
STATE DISPLAY TEST MODE
The switch inputs used by the powertrain control
module (PCM) have only two recognized states,
HIGH and LOW. For this reason, the PCM cannot
recognize the difference between a selected switch po-
sition versus an open circuit, a short circuit, or a de-
fective switch. If the change is displayed, it can be
assumed that the entire switch circuit to the PCM is
functional. From the state display screen access ei-
ther State Display Inputs and Outputs or State Dis-
play Sensors.
STATE DISPLAY INPUTS AND OUTPUTS
Connect the DRBII scan tool to the vehicle and ac-
cess the State Display screen. Then access Inputs and
Outputs. The following is a list of the engine control
system functions accessible through the Inputs and
Outputs screen. Park/Neutral Switch (automatic transaxle only)
Speed Control Resume
Brake Switch
Speed Control On/Off
Speed Control Set
A/C Switch Sense
S/C (Speed Control) Vent Solenoid
S/C (Speed Control) Vacuum Solenoid
Torque Converter Clutch Solenoid (3 speed auto-
matic transaxle)
A/C Clutch Relay
EGR Solenoid
Auto Shutdown Relay
Radiator Fan Relay
Purge Solenoid
Malfunction Indicator (Check Engine) Lamp
STATE DISPLAY SENSORS
Connect the DRBII scan tool to the vehicle and ac-
cess the State Display screen. Then access Sensor
Display. The following is a list of the engine control
system functions accessible through the Sensor Dis-
play screen. Oxygen Sensor Signal
Coolant Temperature
Coolant Temp Sensor
Throttle Position
Minimum Throttle
Battery Voltage
MAP Sensor Reading
Idle Air Control Motor Position
Added Adaptive Fuel
Adaptive Fuel Factor
Barometric Pressure
Min Airflow Idl Spd
Engine Speed
Fault #1 Key-On Info
Module Spark Advance
Speed Control Target
Fault #2 Key-On Info
Fault #3 Key-On Info
Speed Control Status
Charging System Goal
Theft Alarm Status
Speed Control Switch Voltage
Map Sensor Voltage
Vehicle Speed
Oxygen Sensor State
MAP Gauge Reading
Throttle Opening (percentage)
Total Spark Advance
CIRCUIT ACTUATION TEST MODE
The circuit actuation test mode checks for proper
operation of output circuits or devices which the pow-
ertrain control module (PCM) cannot internally rec-
ognize. The PCM can attempt to activate these
outputs and allow an observer to verify proper oper-
ation. Most of the tests provide an audible or visual
indication of device operation (click of relay contacts,
spray fuel, etc.). With the exception of an intermit-
tent condition, if a device functions properly during
its test, it can be assumed that the device, its associ-
ated wiring, and its driver circuit are in working or-
der.
OBTAINING CIRCUIT ACTUATION TEST
Connect the DRBII scan tool to the vehicle and ac-
cess the Actuators screen. The following is a list of
the engine control system functions accessible
through Actuators screens. Stop All Tests
Ignition Coil #1
Fuel Injector #1
Idle Air Control Motor Open/Close
Ä FUEL SYSTEMS 14 - 45

Radiator Fan Relay
A/C Clutch Relay
Auto Shutdown Relay
Purge Solenoid
S/C Servo Solenoids
Generator Field
Tachometer Output
Torque Converter Clutch Solenoid (3 speed auto-
matic transaxle only)
EGR Solenoid
All Solenoids/Relays
ASD Fuel System Test
Speed Control Vacuum Solenoid
Speed Control Vent Solenoid
THROTTLE BODY MINIMUM AIR FLOW CHECK
PROCEDURE
(1) Connect DRBII scan tool.
(2) Remove air cleaner assembly. Plug the heated
air door vacuum hose. (3) Warm engine in Park or Neutral until the cool-
ing fan has cycled on and off at least once. (4) Hook-up timing check device and tachometer.
(5) Disconnect the coolant temperature sensor and
set basic timing to 12ÉBTDC 62ÉBTDC.
(6) Shut off engine. Reconnect coolant temperature
sensor. (7) Disconnect the PCV valve hose from the intake
manifold nipple. (8) Attach Air Metering Fitting #6457 (Fig. 4) to
the intake manifold PCV nipple. (9) Restart the engine, allow engine to idle for at
least one minute. (10) Using the DRBII scan tool, Access Min Air-
flow Idle Spd in the sensor read test mode. (11) The following will then occur:
² Idle air control motor will fully close.
² Idle spark advance will become fixed.
² Idle fuel will be provided at a set value.
² Engine RPM will be displayed on DRBII scan tool.
(12) Check idle RPM with tachometer. If idle RPM is within the specifications listed below, then the
throttle body minimum air flow is set correctly.
If idle RPM is not within specification replace
throttle body. (13) Shut off engine.
(14) Remove Special Tool number 6457 from in-
take manifold PCV nipple. Reinstall the PCV valve
hose. (15) Remove DRBII scan tool.
(16) Reinstall air cleaner assembly. Reinstall
heated air door vacuum hose. (17) Disconnect timing check device and tachome-
ter.
IGNITION TIMING PROCEDURE
Refer to Group 8D Ignition System
60-WAY PCM WIRING CONNECTOR
Refer to the powertrain control module (PCM) wir-
ing connector descriptions for information regarding
wire colors and cavity numbers (Fig. 5).
Fig. 4 Air Metering Fitting
IDLE SPECIFICATIONS
14 - 46 FUEL SYSTEMS Ä

(7) Ensure the injector lower O-ring has been re-
moved from the pod (Fig. 9).
INSTALLATION
(1) Apply a light coating of clean engine oil on the
O-rings. (2) Place assembly in the pod. Align the injector
wiring terminals with the injector cap fastener hole
(Fig. 10).
(3) Install injector cap with locating notch aligned
with the locating lobe on the injector (Fig. 11). (4) Push down on the cap to ensure a good seal.
(5) Rotate the cap and injector to line up the at-
tachment hole (Fig. 12).
(6) Install injector cap holddown screw (torx-head
screw). Tighten screw to 4-5 N Im (35-45 in. lbs.) torque.
(7) Connect negative cable to battery.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for either 7 minutes, until the test is stopped, or un-
til the ignition switch is turned to the Off position. (8) With the ignition key in ON position, access
the DRBII scan tool ASD Fuel System Test to pres-
surize the fuel system. Check for leaks. (9) Reinstall the air cleaner assembly.
THROTTLE POSITION SENSOR
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove air cleaner.
(3) Disconnect harness connector from throttle po-
sition sensor (Fig. 13). (4) Remove throttle position sensor mounting
screws. (5) Remove throttle position sensor from throttle
shaft.
INSTALLATION
(1) Install throttle position sensor to throttle body,
position toward the front of the vehicle. Tighten
screws to 2 N Im (20 in. lbs.) torque.
(2) Connect 3 way connector at throttle position
sensor.
Fig. 9 Servicing Fuel Injector
Fig. 10 Fuel Injector Installation
Fig. 11 Installing Fuel Injector Cap
Fig. 12 Fuel Injector Installed
14 - 52 FUEL SYSTEMS Ä

(2) Remove sensor using Tool C-4907 (Fig. 21).
Slightly tightening the sensor can ease removal. When the sensor is removed, the exhaust manifold
threads must be cleaned with an 18 mm X 1.5 + 6E
tap. If the same sensor is to be reinstalled, the sensor
threads must be coated with an anti-seize compound
such as Loctite 771-64 or equivalent. New sensors
are packaged with compound on the threads and do
not require additional compound. The sensor must be
tightened to 27 N Im (20 ft. lbs.) torque.
2.5L FLEXIBLE FUEL MULTI-PORT FUEL INJECTIONÐSYSTEM OPERATION
INDEX
page page
Air Conditioning (A/C) Clutch RelayÐPCM Output.61
Air Conditioning Switch SenseÐPCM Input ..... 57
Auto Shutdown (ASD) Relay and Fuel Pump RelayÐPCM Output ..................... 61
Battery VoltageÐPCM Input ................ 58
Brake SwitchÐPCM Input .................. 58
Camshaft Position SensorÐPCM Input ........ 58
CCD BUS .............................. 57
Data Link ConnectorÐPCM Output ........... 62
Duty Cycle Evap Purge SolenoidÐPCM Output . 61
Engine Coolant Temperature SensorÐPCM Input . 58
Fuel InjectorÐPCM Output ................. 62
Fuel Injectors and Fuel Rail Assembly ......... 65
Fuel Pressure Regulator ................... 65
Fuel Supply Circuit ....................... 65
General Information ....................... 55
Generator FieldÐPCM Output ............... 62
Heated Oxygen Sensor (O
2Sensor)ÐPCM Input . 59
Identifying Flexible Fuel Components .......... 55
Idle Air Control MotorÐPCM Output .......... 62 Ignition CoilÐPCM Output
.................. 62
Malfunction Indicator (Check Engine) LampÐPCM Output ............................... 62
Manifold Absolute Pressure (MAP) SensorÐPCM Input ................................ 58
Methanol Concentration SensorÐPCM Input .... 59
Modes of Operation ....................... 63
Powertrain Control Module ................. 57
Radiator Fan RelayÐPCM Output ............ 63
Speed Control SolenoidsÐPCM Output ........ 63
Speed ControlÐPCM Input ................. 60
System Diagnosis ........................ 56
System Operation ........................ 56
TachometerÐPCM Output .................. 63
Throttle Body ............................ 65
Throttle Position Sensor (TPS)ÐPCM Input ..... 60
Torque Converter Clutch SolenoidÐPCM Output . 63
Transaxle Park/Neutral SwitchÐPCM Input ..... 60
Vehicle Speed SensorÐPCM Input ........... 60
GENERAL INFORMATION
In this model year Chrysler began producing AA-
Body vehicles designed to operate on a mixture of
gasoline and methanol. These automobiles are re-
ferred to as Flexible Fuel vehicles. Fuel system com-
ponents designed for use in flexible fuel vehicles are
referred to as Methanol Compatible. Flexible fuel vehicles can operate on a mixture of
up to 85 percent methanol, 15 percent unleaded gas-
oline. These vehicles also operate on mixtures con-
taining a lower percentage of methanol or just pure
unleaded gasoline.
IDENTIFYING FLEXIBLE FUEL COMPONENTS
Flexible Fuel vehicles have unique methanol com-
patible fuel system components. Chrysler identifies
methanol compatible components that could be phys-
ically interchanged with gasoline only parts by color-
ing them green or applying a green label or tag to
them. Even though they may appear physically iden- tical, components for gasoline only AA-body vehicles
must not be used on flexible fuel vehicles.
FLEXIBLE FUEL COMPONENTS
The fuel system of flexible fuel AA-body vehicles
have the following unique methanol compatible com-
ponents.
² Duty Cycle EVAP Purge Solenoid
² Fuel pump module
² Fuel level sensor
² Fuel gauge (gauge cluster).
² Fuel tank
² Fuel pressure regulator (including O-rings)
² Fuel rail
² Fuel injectors (including O-rings)
² Fuel tubes
² Fuel filter
² EVAP canister
² Fuel filler cap
² Fuel filler tube
Fig. 21 Oxygen Sensor Socket
Ä FUEL SYSTEMS 14 - 55

² Methanol Concentration Sensor
² Pressure relief/Rollover valve
² PCV Valve
² All fuel system and emission system hoses and
tubes
SYSTEM OPERATION
The flexible fuel vehicle's 2.5L engine use a se-
quential multi-port electronic fuel injection system
(Fig. 1). The powertrain control module (PCM) oper-
ates the electronic fuel injection system. The PCM
provides precise air/fuel ratios and ignition timing
for all driving conditions.
The PCM regulates the air-fuel ratio, ignition coil
dwell and idle speed. The PCM also operates the
high speed and low speed cooling fans, charging sys-
tem, speed control system and various emission con-
trol devices. Various sensors and switches provide inputs to the
PCM. The PCM converts all inputs into signals and
regulates various systems based on the inputs. The
PCM adjusts the systems it controls to meet chang-
ing operating conditions. Fuel is injected into the intake port above the in-
take valve in precise metered amounts through elec-
trically operated injectors. The PCM operates the
injectors in a specific sequence. The PCM adjusts the
air/fuel ratio based on the percentage of methanol in the fuel. The PCM constantly adjusts injector pulse
width to obtain the ideal air fuel ratio for the current
percentage of methanol in the fuel. Injector pulse
width refers to the amount of time an injector oper-
ates. The PCM adjusts injector pulse width by opening
and closing the ground path to the injectors. Engine
RPM (speed), manifold absolute pressure (air density)
and the percentage of methanol in the fuel are the
primary inputs that determine injector pulse width.
SYSTEM DIAGNOSIS
The powertrain control module (PCM) can test
many of its own input and output circuits. If the
PCM senses a fault in a major system, the PCM
stores a diagnostic trouble code in memory. Technicians can display stored diagnostic trouble
codes by two different methods. The first is to cycle
the ignition switch On - Off - On - Off - On within 5
seconds. Then count the number of times the mal-
function indicator lamp (check engine lamp) on the
instrument panel flashes on and off. The number of
flashes represents the trouble code. There is a slight
pause between the flashes representing the first and
second digits of the code. Longer pauses separate in-
dividual trouble codes.
Fig. 1 Flexible Fuel MPI Components
14 - 56 FUEL SYSTEMS Ä

The second method of reading diagnostic trouble
codes uses the DRBII scan tool. For diagnostic trou-
ble code information, refer to the On-Board Diagnos-
tics section in this group.
CCD BUS
Various modules exchange information through a
communications port called the CCD Bus. The pow-
ertrain control module transmits vehicle load data on
the CCD Bus.
POWERTRAIN CONTROL MODULE
The powertrain control module (PCM) is a digital
computer containing a microprocessor (Fig. 2). The
PCM receives input signals from various switches
and sensors referred to as Powertrain Control Mod-
ule Inputs. Based on these inputs, the PCM adjusts
various engine and vehicle operations through de-
vices referred to as Powertrain Control Module Out-
puts.
PCM Inputs:
² Air Conditioning Controls
² Battery Voltage
² Brake Switch
² Engine Coolant Temperature Sensor
² Camshaft Position Sensor (Distributor Pick-up)
² Manifold Absolute Pressure (MAP) Sensor
² Methanol Concentration Sensor
² Oxygen Sensor
² SCI Receive
² Speed Control System Controls
² Throttle Position Sensor
² Park/Neutral Switch (automatic transaxle)
² Vehicle Speed Sensor
PCM Outputs:
² Air Conditioning Clutch Relay
² Generator Field
² Auto Shutdown (ASD) Relay
² Duty Cycle EVAP Canister Purge Solenoid
² Data Link (Diagnostic) Connector ²
Fuel Injectors
² Idle Air Control Motor
² Ignition Coil
² Malfunction Indicator (Check Engine) Lamp
² Radiator Fan Relay
² Speed Control Solenoids
² Tachometer Output
² Torque Converter Clutch Solenoid
Based on inputs it receives, the PCM adjusts fuel
injector pulse width, idle speed, ignition spark ad-
vance, ignition coil dwell and canister purge opera-
tion. The PCM regulates operation of the radiator
fan, A/C and speed control systems. Also, the PCM
changes generator charge rate by adjusting the gen-
erator field. The PCM adjusts injector pulse width (air-fuel ra-
tio) based on the following inputs.
² Battery voltage
² Coolant temperature
² Exhaust gas content
² Engine speed
² Manifold absolute pressure
² Methanol percentage of fuel
² Throttle position
The PCM adjusts ignition timing based on the fol-
lowing inputs.
² Coolant temperature
² Engine speed
² Manifold absolute pressure
² Methanol percentage of fuel
² Throttle position
The auto shutdown (ASD) and fuel pump relays are
mounted externally. The PCM turns both relays on
and off through the same circuit. The camshaft position sensor (distributor pick-up)
sends a signal to the PCM. If the PCM does not re-
ceive a camshaft position sensor signal within ap-
proximately one second of engine cranking, it
deactivates the ASD and fuel pump relays. When
these relays deactivate, they shut off power to the
fuel injectors, fuel pump, ignition coil, methanol con-
centration sensor and oxygen sensor heater element. The PCM contains a voltage converter that
changes battery voltage to a regulated 8.0 volts to
power the distributor pick-up methanol concentration
sensor and vehicle speed sensor. The PCM also pro-
vides a 5.0 volts supply for the engine coolant tem-
perature sensor, manifold absolute pressure sensor
and throttle position sensor.
AIR CONDITIONING SWITCH SENSEÐPCM INPUT
When the operator puts the A/C or defrost switch
in the ON position and the low pressure and high
pressure switches close, the PCM receives an input.
The input indicates the operator selected air condi-
tioning. After receiving this input, the PCM acti-
vates the A/C compressor clutch by grounding the
Fig. 2 Powertrain Control Module
Ä FUEL SYSTEMS 14 - 57