1993 CHEVROLET PLYMOUTH ACCLAIM AA body

DEFROSTER DUCT ADAPTER
REMOVAL AND INSTALLATION
AA BODY On AA body, the instrument panel must be rolled
down to service duct. Refer to Group 8E, Instrument
Panel.
AC, AP, AY BODY
(1) Remove air distribution duct.
(2) Separate the defroster adapter from the heater-
A/C unit and pull the adapter downward and out
from under the instrument panel. To install, reverse the preceding operation.
DEFROSTER DUCT
REMOVAL AND INSTALLATION
AA, AG, AND AJ BODY
On AA, AG, and AJ Body, the instrument panel
must be rolled down to service duct. Refer to Group
8E, Instrument Panel.
AC, AP, AY BODY
(1) Remove the air distribution duct.
(2) Remove the defroster duct adapter.
(3) Remove the instrument panel top cover. Refer
to Group 8E, Instrument Panel. (4) Locate and remove defroster duct attaching
screws at the ends of each outlet (Fig. 10). (5) Allow the defroster duct to drop downward and
remove it from the vehicle. To install, reverse the preceding operation.
HEATER HOSES
REMOVAL AND INSTALLATION
Review Cooling System Precautions before
proceeding with this operation. (1) Drain engine cooling system. Refer to Group 7,
Cooling System. (2) Loosen clamps at each end of hose to be re-
moved (Figs. 11 or 12).
(3) Carefully rotate hose back and forth while tug-
ging slightly away from connector nipple.
CAUTION: When removing hoses from heater core
inlet or outlet nipples DO NOT exert excess pres-
sure. The heater core may become damaged and
leak engine coolant into heater-A/C unit.
Fig. 9 Air Distribution DuctsÐTypical
Fig. 10 Removing or Installing Defroster DuctÐTypical
Fig. 11 Heater Hose RoutingÐ2.2 L, 2.5 LEnginesÐTypical
Ä HEATING AND AIR CONDITIONING 24 - 51

HEATER-A/C UNIT ASSEMBLYÐREMOVAL AND
INSTALLATION
AP, AC, AY BODY PROCEDURE
WARNING: IF EQUIPPED WITH A/C, THE REFRIG-
ERATION SYSTEM MUST BE COMPLETELY EMPTY
BEFORE PROCEEDING WITH THIS OPERATION.
(1) Disconnect battery NEGATIVE cable.
(2) Drain radiator and disconnect heater hoses at
unit. Tape heater tubes to keep from leaking during
removal. Refer to Group 7, Cooling System. (3) Remove A/C condensate drain and disconnect
vacuum lines. (4) Inside passenger compartment, perform as fol-
lows, according to body designation. (a) AC-body, remove right upper and lower un-
der-panel silencers. (b) AP & AC-bodies, remove steering column
cover. (c) AC-body, remove left under-panel silencer.
(5) Position front seat or right front seat full rear. (a) AP-body, remove right A-pillar trim.
(b) Remove right cowl side trim.
(6) Remove glove box. (a) AC-body, remove right instrument panel re-
inforcement.
(7) AP-body only: (a) Remove right instrument panel lower mount-
ing screw. (b) Remove center bezel.
(c) Remove lower center module cover.
(d) Remove floor console.
(e) Remove instrument panel support brace (from
steering column opening to right cowl side at bot-
tom of instrument panel). (f) Remove instrument panel to support bracket
(below glove box opening). (g) Remove ash receiver.
(h) Remove radio.
(i) Remove panel top cover.
(j) Remove three right side panel to fence (below
windshield) attaching screws.
(8) AC-body, remove ash receiver.
(9) AP body, pull right lower side of instrument
panel rearward. (10) Remove center distribution and defroster
adapter ducts. (11) AP and AC-bodies, disconnect relay module.
(12) AP-body, remove instrument panel to unit
bracket. (13) AP-body, remove lower air distribution duct.
(14) Disconnect blower motor wire connector.
(15) Disconnect demister hoses from top of unit.
(16) For Non-ATC equipped vehicles, disconnect
the temperature control cable flag from the bottom of
the heater-A/C unit. Then un-clip the cable from the
left side of the heat distribution duct. Swing the ca-
ble out of the way to the left. Disconnect the vacuum
lines at the unit. (17) For ATC equipped vehicles, disconnect the in-
strument panel wiring from the rear face of the ATC
control unit. (18) AC body, disconnect right 25-way connector
bracket and fuse block from panel. (19) Fold floor right side carpet back (except AC
body). (20) From engine compartment, remove four unit
attaching nuts. (21) Remove unit hanger strap lower screw, and
rotate strap. (22) Move heater-A/C unit rearward to clear
mounting studs, and lower unit. (23) AP-body, remove demister adapter from top of
unit. (24) While pulling the lower right of instrument
panel rearward: (a) Slide unit upright from under instrument
panel for AP-body. (b) Except for AP-body, rotate unit while pulling
from under instrument panel.
To install, reverse the preceding operation.
Fig. 5 Blower Motor and Wheel Assembly
Fig. 6 Blower Wheel Retaining Ring Removal and Installation
Ä HEATING AND AIR CONDITIONING 24 - 61

AA BODY PROCEDURE
WARNING: IF EQUIPPED WITH A/C, THE REFRIG-
ERATION SYSTEM MUST BE COMPLETELY EMPTY
BEFORE PROCEEDING WITH THIS OPERATION. Refer to Group 8E and Group 23 for component re-
moval and installation when performing this opera-
tion. (1) Perform steps 1 through 7 of Blower Motor re-
moval and installation. (2) Remove relay panel above glove compartment
opening. (3) Disconnect the A/C vacuum line connector and
radio noise capacitor connectors. (4) Remove left windshield pillar trim cover.
(5) Remove left lower side cowl trim cover.
(6) Remove hood release handle mechanism attach-
ing screws. (7) Remove steering column trim covers.
(8) Disconnect parking brake release mechanism
connecting rod. Gain access through fuse panel open-
ing. (9) Remove lower left instrument panel silencer.
(10) Remove lower left instrument panel reinforce-
ment. (11) Remove instrument panel center (radio) bezel.
(12) Remove forward floor console.
(13) Remove the radio.
(14) Remove the heater-A/C control.
(15) Remove cigar lighter.
(16) Remove message center/trip computer, if
equipped. (17) Disconnect side window demister tubes from
top of heat A/C unit. (18) Remove steering column upper attaching bolts
and allow the steering wheel to rest on the driver
seat cushion. (19) Remove upper instrument panel (defroster
outlet) cover. (20) Remove upper instrument panel attaching
screws from below the windshield opening. (21) Loosen (do not remove) the left lower cowl in-
strument panel attaching screw. (22) Remove the right lower cowl instrument panel
attaching screw.
CAUTION: Protect the passenger seat cover from
soiling or damage using a suitable cover.
(23) Carefully pull the right side of the instrument
panel away from the vehicle. Allow the instrument
panel to rest on the passenger seat cushion.
CAUTION: Before proceeding with the next opera-
tion, review the Safety Precautions and Warnings at
the front of this Group. (24) From the engine compartment, drain the cool-
ing system and disconnect the heater hoses from the
heater core nipples. Plug the nipples to avoid spilling
coolant inside the vehicle. (25) Disconnect the refrigerant lines from the ex-
pansion-valve at the dash panel on the right side of
the vehicle. Seal the refrigerant lines to prevent con-
tamination. (26) Remove the expansion valve from the evapo-
rator plate. Seal the valve to avoid contamination. (27) Remove the condensate drain tube.
(28) Remove heater-A/C unit to dash panel attach-
ing nuts. (29) From inside the vehicle, pull rearward on the
heater-A/C unit to clear the dash panel silencer and
remove the unit from the vehicle. To install, reverse the preceding operation. Refill
cooling system and test for leaks. Evacuate and
charge the refrigerant system and test overall perfor-
mance.
AG, AJ BODY PROCEDURE
WARNING: IF EQUIPPED WITH A/C, THE REFRIG-
ERATION SYSTEM MUST BE COMPLETELY EMPTY
BEFORE PROCEEDING WITH THIS OPERATION.
(1) Disconnect the battery negative cable.
(2) Drain the coolant from cooling system. Refer to
Group 7, Cooling System. (3) Remove the air conditioner expansion valve (if
equipped). (4) Disconnect the heater hoses from heater core.
Then plug or cap the tubes on heater core. This will
prevent spilling coolant into the interior of vehicle
during unit removal. (5) Remove the condensate drain tube.
(6) Disconnect the A/C-heater vacuum supply line
from vacuum supply nipple (in the engine compart-
ment). (7) Remove the four A/C-heater assembly-to-dash
panel attaching nuts. (8) Remove the passenger side front seat. Refer to
Group 23, Body. (9) Remove the kick panel/sill cover at right door
opening. (10) Remove the body computer (Fig. 6) located at
the lower right section of the right front door pillar. (11) Remove the glove box assembly. Refer to
Group 8E, Instrument Panel. (12) Remove the carpeted panels from both sides of
the console. (13) Un-clip the radio antenna cable from the
metal support (Fig. 6) located behind and below the
glove box opening. (14) Instrument panel removal is not necessary to
remove the A/C-heater assembly from the vehicle.
24 - 62 HEATING AND AIR CONDITIONING Ä

Although, part of the lower instrument panel must
be cut. The cut line is marked: CUT HERE FOR
A/C HTR REMOVAL. This cut line is stamped (indented) into the right-
outer side of the instrument panel padding (outboard
of the glove box opening). Using a hacksaw blade,
cut the instrument panel padding along the indented
line from point A to point B (Fig. 7). CUT THE
PLASTIC ONLY . Do not cut the metal support be-
hind the instrument panel padding.
(15) Remove the metal support behind and below
the glove box opening, and the previously cut piece of
the instrument panel that is riveted to it. (16) Remove the radio choke, security alarm mod-
ule and the lamp outage module from above the
glove box opening (if equipped). (17) Remove the plastic cover under the steering
column. (18) Remove the metal support under the steering
column. (19) AJ Body only: Remove the under-panel si-
lencer pad from under the glove box opening. (20) Remove the lower heat distribution duct (3
screws). (21) Remove the air distribution duct through the
opening at the left side of instrument panel. (22) Reach through glove box opening and discon-
nect the demister hoses from the top of the A/C-heat-
er assembly. (23) Disconnect the temperature control cable from
the bottom of the A/C-heater assembly and position
out of the way. (24) Disconnect wiring at the blower motor and
fin-sensing cycling clutch switch electrical connectors. (25) Un-plug the antenna cable from the radio.
(26) Remove the metal (A/C-heater-to-instrument
panel) hanger strap from the upper part of the A/C-
heater assembly. (27) Roll back the floor carpeting from under the
A/C-heater assembly far enough to avoid restricting
unit removal. (28) Remove the A/C-heater assembly through the
opening on the right side of the console, and remove
unit from vehicle. The instrument panel (to the left side of the glove box
opening) must be slightly folded back to remove the
unit from the vehicle. If wrinkles appear in the instru-
ment panel after the unit has been installed, they may
be removed using a heat gun. Refer to Installation AG,
AJ Body for instructions. To install, reverse steps (28) through (13). If wrinkles
have appeared in the instrument panel, apply low heat
from a heat gun over the wrinkled area. Do not
overheat the instrument panel padding or the
surrounding area. Reverse steps (12) through (1). If equipped with A/C,
evacuate and charge the refrigerant system.
HEATER-A/C UNIT RECONDITION
The following operation requires the removal of the
heater-A/C unit assembly from the vehicle. Refer to
Heater-A/C Unit Assembly removal and installation in
this Group.
DISASSEMBLE
(1) Place the heater-A/C unit on a suitable work
surface. (Fig. 1).
(2) Locate and remove one retaining nut from the
blend-air door pivot shaft.
Fig. 7 Cut Line For A/C-heater RemovalÐAG/AJ Body
Fig. 1 Position Heater-A/C Unit for Disassembly andReassembly
Ä HEATING AND AIR CONDITIONING 24 - 63

(3) Remove the two aspirator mounting screws.
(4) Disconnect the aspirator intake hose from the
instrument panel. (5) Remove sensor/aspirator and it's wiring har-
ness from vehicle. To install, reverse the preceding operation.
WATER TEMPERATURE SENSOR
The water temperature sensor is located on the
heater core mounting plate (Fig. 17). This is a ther-
mistor which will pick up on the engines coolant
temperature. The computer control uses this informa-
tion to control the cold engine lockout time. The wa-
ter temperature sensor is not serviceable and must
be replaced if found to be defective. The Water Temperature Sensor is located on the
heater hose mounting plate between the heater hose
nipples.
REMOVAL AND INSTALLATION
(1) The A/C-heater housing assembly must be re-
moved for Water Temperature Sensor replacement.
Refer to Heater-A/C Unit Housing Removal and In-
stallationÐAC/AY Body for procedures. (2) Remove sensor mounting screw (Fig. 18).
(3) Disconnect the sensor pigtail wiring harness
from the main wiring harness and remove sensor
from vehicle. To install, reverse the preceding operation. When
tightening the sensor mounting screw, allow the sen-
sor to rotate and contact the upper heater hose nip-
ple. This will aid in sensor efficiency.
SUN SENSOR
The sun sensor (Fig. 19) is mounted on the driver
side of the vehicle on top of the instrument panel.
This is not a thermistor type sensor but rather a
photo diode. For this reason the sun sensor responds
to sun light intensity rather than temperature. It is
used to aid in determining proper mode door position.
The sun sensor is not serviceable and must be re-
placed if found to be defective.
REMOVAL AND INSTALLATION
(1) Carefully pry up the sensor from the instru-
ment panel with a screwdriver (Fig. 20). Place a rag
under the screwdriver to prevent scratching of the
instrument panel. (2) Disconnect the sensor at the wiring harness.
To install, reverse the preceding operation. Snap
the sensor securely to the instrument panel.
Fig. 16 In-Car Temperature Sensor/Aspirator Assembly Removal and Installation
Fig. 17 Water Temperature Sensor
Fig. 18 Water Temperature Sensor Removal and Installation
Ä HEATING AND AIR CONDITIONING 24 - 71

(b) Does the blower motor operate at its highest
speed ? (c) Feel the outlet temperature. Does it get hot
and then cycle cold ? (d) Does the air flow switch from DEFROST out-
lets and then cycle to PANEL outlets?
If you can answer NO to any of these questions,
proceed to step 4, otherwise proceed to step 5. (4) If you answered NO to:
SYMPTOM A
The display symbols and indicators do not illumi-
nate. Diagnostic Trouble Codes are not displayed.
TEST
After self-diagnostic test is complete, select a mode
that will display the malfunction.
ACTION
If the ATC system operates properly, and the dis-
play does not, replace ATC control panel computer.
SYMPTOM B
The blower motor does not operate.
CAUTION: Stay clear of blower motor and power
module (PM) heat sink. Do not run system for more
than 10 minutes with PM removed from A/C unit.
TEST Check all power module and blower motor connec-
tions. Use a voltmeter to test for 12 volts (ignition)
at both ends of the fuse with ignition ON. If fuse is
good, test the green wire at the blower motor connec-
tor for 12 volts (ignition) to body ground. Turn ignition to the ON position.
With the blower motor still connected, check for 12
volts to body ground on the black/tan wire of the
blower motor two way connector. Check for 12 volts at the Power Module pin #4
(BK/TN). Check for continuity from the Power Module pin
#3 (BK) to chassis ground. Replace the Power Module.
ACTION If 12 volts is not detected, repair feed circuit. Refer
to the Front Wheel Drive Car-Wiring Diagrams Ser-
vice Manual. If 12 volts is not detected, repair wires of the
blower motor or replace the blower motor. If 12 volts is not present, repair wire from the
blower motor connector to the Power Module. If circuit is open, repair ground circuit of the Power
Module. Replace the Power Module (power transistor open).
SYMPTOM C
The outlet air temperature does not become hot
and then cycle to cold during self-test operation. Di-
agnostic Trouble Codes are not displayed.
TEST/ACTION
Make sure the blend-air door is properly attached
to the actuator. If cold air is not discharged from the outlets, check
the base A/C refrigerant system. Make sure heating operation works correctly, (wa-
ter level, thermostat, heater hoses, heater core, etc.).
SYMPTOM D
Air does not flow from DEFROST outlets and then
cycle to PANEL outlets during self-test operation.
TEST/ACTION Check linkages from the mode door actuator for
binding. Check for proper door travel in the unit.
(5) The computer will do one of two things:
² Will return to the control settings that were se-
lected before the Diagnostic Test was started. This
means the test is over. If Diagnostic Trouble Codes
did not occur, and answers to questions (a), (b), (c),
and (d) were YES, the entire system is operating cor-
rectly.
² The blower motor will stop and the computer will
flash a Diagnostic Trouble Code number from 01
through 28. Record the number and then depress the
PANEL button to advance to the next test. If the
ATC control flashes one or more codes 23 to 28, the
digits on the display will flash alternating Zeros. If
you do nothing, these codes will remain stored within
the ATC control computer. After all repairs have
been made erase fault codes. Refer to Erasing Diag-
nostic Trouble Codes 23 through 28 from ATC Con-
trol in this section. Repair all Diagnostic Trouble Codes in the order
that they have been indicated, and then retest the
system. If any blend door test fails, all remaining
blend door tests will be skipped. IF any mode door
tests fail, all remaining mode door tests will be
skipped. Diagnostic Test can be stopped at any time by de-
pressing any button other than PANEL.
DIAGNOSTIC TROUBLE CODE DEFINITIONS
Non-computer aided diagnostics should be per-
formed first. Hood of vehicle should be closed during
the diagnostic test to keep engine heat from effecting
the ambient temperature sensor. Also refer to the wiring Pin out charts.
² DIAGNOSTIC TROUBLE CODE 1
Involves the wiring or the ATC control head.
² DIAGNOSTIC TROUBLE CODES 2, 13, 14, 15,
20, and 23
Ä HEATING AND AIR CONDITIONING 24 - 73

EMISSION CONTROL SYSTEMS
CONTENTS
page page
EVAPORATIVE EMISSION CONTROLS ....... 1EXHAUST EMISSION CONTROLS .......... 17
GENERAL INFORMATION
Throughout this group, references may be made to
a particular vehicle by letter designation. The Intro- duction Section at the front of this manual contains a
chart showing the breakdown of the designations.
EVAPORATIVE EMISSION CONTROLS
INDEX
page page
Canister Purge SolenoidÐExcept 3.0L and 2.5L MPI ............................. 13
Crankcase Vent Filter ..................... 16
Duty Cycle EVAP Purge Solenoid ............ 13
Evaporation Control System ................ 13 PCV Valve Test
......................... 15
Positive Crankcase Ventilation (PCV) Systems . . 15
Pressure-Vacuum Filler Cap ................ 14
Vacuum Schematics ....................... 2
Vehicle Emission Control Information Label ...... 1
VEHICLE EMISSION CONTROL INFORMATION
LABEL
All models have a Vehicle Control Information
(VECI) Label. Chrysler permanently attaches the la-
bel to the middle of the hood (Fig. 1, 2, or 3). It can-
not be removed without defacing information and
destroying the label. The label contains the vehicle's emission specifica-
tions and vacuum hose routings. Route all hoses ac-
cording to the diagram on the VECI label. If any difference exists between the label and the
Service Manual, refer to the label. The labels
shown are examples.
Fig. 1 Underhood Label LocationÐAA Body
Ä EMISSION CONTROL SYSTEMS 25 - 1

ENGINE VACUUM SCHEMATICÐ2.5L MPI FLEXIBLE FUEL AA-BODY
Ä EMISSION CONTROL SYSTEMS 25 - 7