CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

GENERAL INFORMATION
CONTENTS
page page
CIRCUIT IDENTIFICATION ................. 3
COMPONENT IDENTIFICATION ............. 3
CONNECTORS ........................... 4
FUSIBLE LINKS ......................... 4
HARNESS REPAIR ....................... 4
LOCATING A SYSTEM .................... 3 SECONDARY IGNITION WIRING
............ 1
SPLICE LOCATIONS ...................... 3
SYMBOLS, FUSES AND RELAYS ........... 7
TROUBLESHOOTING WIRING PROBLEMS .... 4
WIRE CODE IDENTIFICATION .............. 2
WIRING DIAGRAM SHEETS AND INDEXES . . . 1
The wiring diagrams contain the latest information
at the time of publication. Throughout this group ref-
erences may be made to a particular vehicle by letter
or number designation. A chart showing the break-
down of these designations is included below.
SECONDARY IGNITION WIRING
Secondary ignition wiring is shown in Figures 1, 2,
3, 4, and 5. For information on distributor operation
or ignition systems refer to Group 8D Ignition Sys-
tems.
WIRING DIAGRAM SHEETS AND INDEXES
The diagrams are organized to show the basic ve-
hicle and all of its options. Add-on or non-factory op-
tions are not covered. The diagram pages are
identified by a sheet number which is located at the
lower right or left hand corner of each sheet. Page
numbers at the top of each page do not apply to
diagram sheets. Diagram sheets show all information relating to
the system. This includes feeds, grounds, switch in-
ternal circuity, connectors, splices, and pin identifica-
tion for controllers and modules.
1993 MODEL CHART
Ä GENERAL INFORMATION 8W - 1

In certain instances a wire may be referenced to
another sheet. When this happens, the wire will be
identified as to what it is ie: feed, ground, etc, and
where its going (Fig. 6). This has been done to aid in
the diagnosis of wiring and component problems.
The index used for the diagrams is located at the be-
ginning of the section. And is in alphabetical order to
identify the main system and all related components.
WIRE CODE IDENTIFICATION
Each wire shown in the diagrams contains a code
(Fig. 7) which identifies the main circuit, part of the
main circuit, gauge of wire, and color. The color is
shown as a two letter code which can be identified by
referring to the Wire Color Code Chart (Fig. 8). If
the wire has a tracer and it is a standard color an
asterisk will follow the main wire color. If the tracer
Fig. 2 Secondary Ignition Wiring 2.2L Turbo III
Fig. 3 Distributor Cap 3.0L V6 Engine
Fig. 1 Secondary Ignition Wiring 2.2L and 2.5L Engine
Fig. 4 Secondary Ignition Wiring 3.0L V6 Engine
Fig. 5 Secondary Ignition Wiring 3.3L and 3.8L V6 Engine
8W - 2 GENERAL INFORMATION Ä

is non-standard the main wire color will have a slash
(/) after it followed by the tracer color.
CIRCUIT IDENTIFICATION
All circuits in the diagrams use an alpha/numeric
code to identify the wire and its function. To identify
which circuit code applies to a system, refer to the
Circuit Identification Code Chart. This chart shows
the main circuits only and does not show the second-
ary codes that may apply to some models.
LOCATING A SYSTEM
To locate a system or component in the diagrams,
refer to the alphabetical index at the front of the di-
agrams. Determine the diagram sheet number. Sheet
numbers are located at the lower right or left hand
corner of each sheet. Page numbers at the top of
the page do not apply to diagram sheets. The diagram index identifies the main system and
all components in that system. There are also sec-
tions of the index that identify specific components
only (for example modules, lamps, etc.). Refer to a
components name in the index if you are unclear as
to what a system may be called. Diagram pages are arranged starting with the bat-
tery and fuses. Then working into charging, starting,
and ignition systems. After this they start at the
front of the vehicle and work to rear of the vehicle.
The diagrams end with connector identification
pages.
COMPONENT IDENTIFICATION
When looking for a components location on the ve-
hicle refer to the wiring and components section.
This section shows the wire harness routing and the
components location in the vehicle. To use this sec-
tion refer to the wiring diagrams for the location of
the component. Then use the component identifica-
tion index to locate the proper figure number.
SPLICE LOCATIONS
Splices are indicated in the diagrams by a diamond
with a splice circuit code within it (Fig. 9 example 1).
If there is more than one splice per circuit a small
box will be connected to it with the splice number in
it (Fig. 9 example 2). To locate a splice in the wiring harness determine
the splice number from the wiring diagrams then re-
fer to the splice location index. This section shows
the general location of the splice in the harness.
Fig. 6 Wiring Diagram Page Sample
Fig. 7 Wire Color Code Identification
Fig. 8 Wire Color Code Chart
Ä GENERAL INFORMATION 8W - 3

The wiring diagrams also indicate what harness
the splice is located in. To identify the harness an
abbreviated call out is placed next to the main splice
(Fig. 6).
CONNECTORS
Connectors shown in the diagram sheets are
viewed from the terminal end unless otherwise spec-
ified. For viewing bulkhead, powertrain control mod-
ule, and transmission control module connectors refer
to the rear of the wiring diagrams. This area shows
major connectors for pin and cavity information.
TROUBLESHOOTING WIRING PROBLEMS
When troubleshooting wiring problems there are
six steps which can aid in the procedure. The steps
are listed and explained below. (1) Verify the problem.
(2) Verify any related symptoms. Perform opera-
tional checks on components that are in the same cir-
cuit as the problem area. Refer to the wiring
diagram fuse application chart. (3) Analyze the symptoms. Use the wiring dia-
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue. (4) Isolate the problem area. (5) Repair the problem.
(6) Verify proper operation. For this step check for
proper operation of all items on the circuit repaired.
Refer to the wiring diagram fuse application chart.
FUSIBLE LINKS
Vehicle wiring harnesses are equipped with fusible
links to protect the harness in the event of a short in
the system. Fusible links are color coded to indicate
wire gauge and size. Refer to the fusible link chart
for color and gauge identification (Fig. 10).
HARNESS REPAIR
FUSIBLE LINK REPLACEMENT
CAUTION: Do not replace blown fusible links with a
standard wire. Only use fusible type wire with hyp-
alon insulation or damage to the electrical system
could occur. Also make sure correct gauge of wir-
ing is used. Refer to the wiring diagrams for proper
gauge and color.
Fig. 9 Wiring Splice Examples
Fig. 10 Fusible Link Chart
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When a fusible link blows it is important to find
out what the problem is. They are placed in the sys-
tem for protection against shorts. Which can be
caused by a component failure or wiring failures. Do
not just replace the fusible link to correct the
problem. When diagnosing a faulty fusible link it is impor-
tant to check the wire carefully. In some instances
the link may be blown and it will not show through
the insulation, the wire should be checked over its
entire length for internal breaks. (1) Disconnect battery negative cable.
(2) Cut out the blown portion of the fusible link.
(3) Strip 1 inch of insulation from each end of the
existing fusible link. (4) Place a piece of heat shrink tubing over one
side of the fusible link. Make sure the tubing will be
long enough to cover and seal the entire repair area. (5) Cut a replacement piece of fusible link approx-
imately two inches longer than the piece removed. (6) Remove one inch of insulation from each end of
the replacement fusible link. (7) Spread the strands of wire apart on each of the
exposed wires (Fig. 11 example 1). (8) Push the two ends of the wire together until
the strands of wire are close to the insulation (Fig.
11 example 2). (9) Twist the wires together (Fig. 11 example 3).
(10) Solder the wires together using rosin core type
solder only. Do not use acid core type solder.
(11) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing. (12) Secure the fusible link to the existing ones to
prevent chafing or damage to the insulation. (13) Connect battery and test all affected systems.
WIRING REPAIR
When replacing or repairing a wire, it is important
that the correct gauge be used as shown in the wir-
ing diagrams. The wires must also be held securely
in place to prevent damage to the insulation. (1) Disconnect battery negative cable.
(2) Remove 1 inch of insulation from each end the
wire. (3) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area. (4) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1). (5) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11 ex-
ample 2). (6) Twist the wires together (Fig. 11 example 3).
(7) Solder the connection together using rosin core
type solder only. Do not use acid core solder. (8) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing. (9) Secure the wire to the existing ones to prevent
chafing or damage to the insulation. (10) Connect battery and test all affected systems.
CONNECTOR REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector that is to be repaired
from its mating half. (3) Remove connector locking wedge (Fig. 12).
(4) Position the connector locking finger away from
the terminal. Pull on the wire to remove the termi-
nal from the connector (Fig. 13).
Fig. 11 Wire Repair
Fig. 12 Connector Locking Wedge Tab
Ä GENERAL INFORMATION 8W - 5

(5) Reset the terminal locking tang, if it has one.
(6) Insert the removed wire in the same cavity on
the repair connector. (7) Repeat steps four thru six for each wire in the
connector. Check that all wires are inserted into the
proper cavities. For connector pin out identification
refer to the wiring diagrams. (8) Insert the connector locking wedge into the re-
paired connector. (9) Connect connector to its mating half.
(10) Connect battery and test all affected systems.
CONNECTOR AND TERMINAL ASSEMBLY REPLACEMENT
(1) Disconnect Battery.
(2) Disconnect the connector being repaired form
its mating half. (3) Cut off the existing wire connector directly be-
hind the insulator. Remove six inches of tape from
the harness. (4) Stagger cut all wires on the harness side about
1/2 inch apart (Fig. 14). (5) Remove 1 inch of insulation from each wire on
the harness side. (6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall
length is the same as the original (Fig. 14). (7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area. (9) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1). (10) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11 ex-
ample 2). (11) Twist the wires together (Fig. 11 example 3). (12) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing. (14) Repeat steps 8 thru 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. (16) Reconnect the repaired connector.
(17) Connect battery and test all affected systems.
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired form
its mating half. (3) Remove connector locking wedge (Fig. 12).
(4) Position the connector locking finger away from
the terminal. Pull on the wire to remove the termi-
nal from the connector (Fig. 13). (5) Cut the wire 6 inches from the back of the con-
nector. (6) Remove 1 inch of insulation from the wire on
the harness side. (7) Select a wire from the terminal repair assem-
bly that best matches the color wire being repaired. (8) Cut the repair wire to the proper length and re-
move 1 inch of insulation. (9) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area. (10) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1). (11) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11 ex-
ample 2). (12) Twist the wires together (Fig. 11 example 3).
(13) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
Fig. 13 Connector Locking Finger and Locking
Wedge
Fig. 14 Stagger Cutting Wires
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(14) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing. (15) Insert the repaired wire into the connector.
(16) Install the connector locking wedge and recon-
nect the connector to its mating half. (17) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. (18) Connect battery and test all affected systems.
SYMBOLS, FUSES AND RELAYS
Various symbols are used throughout the wiring
diagrams. These symbols can be identified by refer-
ring to the symbol identification chart (Fig. 15). For fuse block, relay bank, or power distribution
center information refer to the fuse charts and relay
bank section.
CAUTION: When replacing a blown fuse it is impor-
tant to replace it with a fuse having the correct am-
perage rating. The use of a fuse with a rating other
than indicated may result in an electrical overload.
If a proper rated fuse continues to blow, it indicates
a problem that should be corrected.
Ä GENERAL INFORMATION 8W - 7

Fig. 15 Symbol Identification
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FUSE CHARTS AND RELAY BANKS
INDEX
Caption Fig.
Fuse Block and Relay Bank AA Body .................1
Fuse Block AC, AY Body .........................2
Fuse Block AG, AJ Body .........................3
Fuse Block and Relay Bank AP Body .................4Caption Fig.
Power Distribution Center AC, AY Body ................7
Power Distribution Center AG, AJ Body ................8
Relay Bank AC, AY Body .........................5
Relay Bank AG, AJ Body .........................6
Ä FUSE CHARTS AND RELAY BANKS 8W - 9

Fig. 1 Fuse Block and Relay Bank AA-Body
8W - 10 FUSE CHARTS AND RELAY BANKS Ä