CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

INSTALLATION
WARNING: FUEL PRESSURE RELIEF/ROLLOVER
VALVES DESIGNED FOR GASOLINE ONLY VEHI-
CLES CANNOT BE USED ON FLEXIBLE FUEL AA-
BODY VEHICLES. WHEN SERVICING THE FUEL
SYSTEM OF A FLEXIBLE FUEL VEHICLE, ONLY
USE ORIGINAL EQUIPMENT OR EQUIVALENT RE-
PLACEMENT COMPONENTS. (1) Install the rubber grommet in the fuel tank by
working it around the curled lip of the tank (Fig. 13).
CAUTION: Only use power steering fluid to lubri-
cate the pressure relief/rollover valve grommet.
(2) Lightly lubricate the grommet with power
steering fluid only and push the valve downward into
the grommet. Twist valve until properly positioned. (3) Install fuel tank (refer to fuel tank installa-
tion).
ACCELERATOR PEDAL AND THROTTLE CABLE INDEX
page page
Accelerator Pedal ........................ 21 Throttle Cable........................... 22
ACCELERATOR PEDAL
CAUTION: When servicing the accelerator pedal,
throttle cable or speed control cable, do not dam-
age or kink the control cable core wire.
REMOVAL
(1) Working from the engine compartment, hold
the throttle body throttle lever in the wide open po-
sition. Remove the throttle cable from the throttle
body cam. (2) From inside the vehicle, hold up the pedal and
remove the cable retainer and throttle cable from the
upper end of the pedal shaft (Fig. 1 and Fig. 2).
(3) Working from the engine compartment, remove
nuts from accelerator pedal assembly studs (Fig. 1).
Remove assembly from vehicle.
INSTALLATION
(1) Position accelerator pedal assembly on dash
panel. Install retaining nuts. Tighten retaining nuts
to 12 N Im (105 in. lbs.) torque.
Fig. 1 Accelerator Pedal and Throttle CableÐFront
View
Fig. 13 Installing Pressure Relief/Rollover Valve
Fig. 2 Accelerator Pedal and Throttle CableÐRearView
Ä FUEL SYSTEMS 14 - 21

(2) From inside the vehicle, hold up the pedal and
install the throttle cable and cable retainer in the
upper end of the pedal shaft. (3) From the engine compartment, hold the throt-
tle body lever in the wide open position and install
the throttle cable.
THROTTLE CABLE
REMOVAL
(1) Working from the engine compartment, hold
throttle lever in the wide open position and remove
the throttle cable from the throttle body cam (Fig. 3,
4, 5, 6 and 7).
(2) From inside the vehicle, hold the throttle pedal
up and remove the cable retainer and cable from up-
per end of pedal shaft (Fig. 1 and Fig. 2). (3) Remove retainer clip from throttle cable and
grommet at the dash panel (Fig. 2). (4) From the engine compartment, pull the throttle
cable out of the dash panel grommet. The grommet
should remain in the dash panel. (5) Remove the throttle cable from the throttle
bracket by carefully compressing both retaining tabs
simultaneously. Gently pull throttle cable from throt-
tle bracket.
INSTALLATION
(1) From the engine compartment, push the hous-
ing end fitting into the dash panel grommet. (2) Install cable housing (throttle body end) into
the cable mounting bracket on the engine. (3) From inside the vehicle, hold up pedal and feed
throttle cable core wire through hole in upper end of
the pedal shaft. Install cable retainer (Fig. 2). (4) Install cable retainer clip (Fig. 2).
(5) From the engine compartment, rotate the throt-
tle lever to the wide open position and install throt-
tle cable.
Fig. 3 Throttle Cable Attachment to Throttle BodyÐ2.2L/2.5L TBI Engine
Fig. 4 Throttle Cable Attachment to ThrottleBodyÐ2.5L MPI Flexible Fuel Engine
Fig. 5 Throttle Cable Attachment to Throttle BodyÐTurbo III Engine
Fig. 6 Throttle Cable Attachment to Throttle BodyÐ3.0L Engine
14 - 22 FUEL SYSTEMS Ä

Fig. 7 Throttle Cable Attachment to Throttle BodyÐ3.3L and 3.8L Engines
Ä FUEL SYSTEMS 14 - 23

2.2L/2.5L SINGLE POINT FUEL INJECTIONÐSYSTEM OPERATION INDEX
page page
Air Conditioning (A/C) Clutch RelayÐPCM Output.28
Air Conditioning Switch SenseÐPCM Input ..... 26
Auto Shutdown (ASD) Relay and Fuel Pump RelayÐPCM Output ..................... 29
Battery VoltageÐPCM Input ................ 26
Brake SwitchÐPCM Input .................. 26
EVAP Canister Purge SolenoidÐPCM Output . . . 29
CCD Bus .............................. 25
Coolant Temperature SensorÐPCM Input ...... 26
Data Link ConnectorÐPCM Output ........... 30
Distributor (Hall Effect) Pick-UpÐPCM Input .... 26
Electric Electronic Gas RecirculationÐPCM Output.30
Fuel InjectorÐPCM Output ................. 31
Fuel Pressure Regulator ................... 33
General Information ....................... 24
Generator FieldÐPCM Output ............... 31
Heated Oxygen Sensor (O
2Sensor)ÐPCM Input . 27
Idle Air Control MotorÐPCM Output .......... 29 Ignition CoilÐPCM Output
.................. 31
Malfunction Indicator Lamp (Check Engine)ÐPCM Output ............................... 30
Manifold Absolute Pressure (MAP) SensorÐPCM Input ................................ 27
Modes of Operation ....................... 32
Part Throttle Unlock SolenoidÐPCM Output .... 31
Powertrain Control Module ................. 25
Radiator Fan RelayÐPCM Output ............ 31
Speed Control SolenoidsÐPCM Output ........ 31
Speed ControlÐPCM Input ................. 27
System Diagnosis ........................ 25
TachometerÐPCM Output .................. 32
Throttle Body ............................ 33
Throttle Position Sensor (TPS)ÐPCM Input ..... 28
Transaxle Park/Neutral SwitchÐPCM Input ..... 28
Vehicle Speed SensorÐPCM Input ........... 28
GENERAL INFORMATION
The computer regulated, Electronic Fuel Injection
System (Fig. 1) provides a precise air/fuel ratio for
all driving conditions. The fuel injection system is
controlled by the powertrain control module (PCM).
The PCM is a pre-programmed digital computer. The
PCM regulates ignition timing, air-fuel ratio, emission
control devices, cooling fan, charging system, speed con-
trol, and idle speed. The PCM can adapt its requirement
to meet changing operating conditions.
Fig. 1 Electronic Fuel Injection Components
14 - 24 FUEL SYSTEMS Ä

Various sensors provide the inputs necessary for
the PCM to correctly regulate fuel flow at the fuel
injector. These include the manifold absolute pres-
sure, throttle position, oxygen sensor, coolant tem-
perature, and vehicle speed sensors. In addition to
the sensors, various switches and relays provide im-
portant information and system control. The inputs
include the park/neutral switch and air conditioning
clutch switch. The outputs include the auto shutdown
relay and fuel pump relay. All inputs to the PCM are converted into signals.
Based on these inputs the PCM adjusts air-fuel ratio,
ignition timing and other controlled outputs. The
PCM adjusts the air-fuel ratio by changing the injec-
tor pulse width. Injector pulse width is the period of
time the injector is energized.
SYSTEM DIAGNOSIS
The PCM tests many of its own input and output
circuits. If a fault is found in a major system, the in-
formation is stored in memory. Technicians can dis-
play fault information through the instrument panel
Malfunction Indicator lamp (instrument panel Check
Engine lamp) or by connecting the DRBII scan tool.
For diagnostic trouble code information, refer to On
Board Diagnostics in 2.2L/2.5L Single Point Fuel In-
jectionÐGeneral Diagnosis section of this group.
CCD BUS
Various modules exchange information through a
communications port called the CCD Bus. The pow-
ertrain control module (PCM) 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 that are referred to as PCM Inputs.
Based on these inputs, the PCM adjusts various en-
gine and vehicle operations through devices that are
referred to as PCM Outputs. PCM Inputs:
² Air Conditioning Controls
² Battery Voltage
² Brake Switch
² Coolant Temperature Sensor
² Distributor (Hall Effect) Pick-up
² Manifold Absolute Pressure (MAP) 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
Idle Air Control Motor
² Auto Shutdown (ASD) Relay
² Canister Purge Solenoid
² Malfunction Indicator (Check Engine) Lamp
² Data Link Connector (Diagnostic Connector)
² Electronic EGR Transducer
² Fuel Injector
² Ignition Coil
² Part Throttle Unlock Solenoid (Automatic Tran-
saxle)
² Radiator Fan Relay
² Speed Control Solenoids
² Tachometer Output
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 EGR,
cooling fan, A/C and speed control systems. 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 (distributor pick-up)
² manifold absolute pressure
² throttle position
The PCM adjusts ignition timing based on the fol-
lowing inputs.
² coolant temperature
² engine speed (distributor pick-up)
² manifold absolute pressure
² throttle position
The Auto Shutdown (ASD) and Fuel Pump relays
are mounted externally, but turned on and off by the
PCM through the same circuit. The distributor pick-up signal is sent to the PCM.
If the PCM does not receive a distributor signal
within approximately one second of engine cranking,
Fig. 2 PCM
Ä FUEL SYSTEMS 14 - 25

it de-activates the ASD relay and fuel pump relay.
When these relays are deactivated, power is shut off
from the fuel injector, fuel pump, ignition coil, 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 and vehicle speed sen-
sor. The PCM also provides a 5.0 volts supply for the
coolant temperature sensor, manifold absolute pres-
sure sensor and throttle position sensor.
AIR CONDITIONING SWITCH SENSEÐPCM INPUT
ALL VEHICLES EXCEPT AC-BODY
When the air conditioning or defrost switch is put
in the ON position and the low pressure and high
pressure switches are closed, the PCM receives an in-
put indicating that the air conditioning has been se-
lected. After receiving this input, the PCM activates
the A/C compressor clutch by grounding the A/C
clutch relay. The PCM also adjusts idle speed to a
scheduled RPM to compensate for increased engine
load.
AC-BODY VEHICLES
When the air conditioning or defrost switch is put
in the ON position and the low pressure switch, high
pressure switch and electronic cycling switch close,
the PCM receives an air conditioning select input.
After receiving this input, the PCM activates the
A/C compressor clutch by grounding the A/C com-
pressor clutch relay. The PCM also adjusts idle speed
to a scheduled RPM to compensate for increased en-
gine load.
BATTERY VOLTAGEÐPCM INPUT
The PCM monitors the battery voltage input to de-
termine fuel injector pulse width and generator field
control. If battery voltage is low, the PCM increases
injector pulse width.
BRAKE SWITCHÐPCM INPUT
When the brake switch is activated, the PCM re-
ceives an input indicating that the brakes are being
applied. After receiving the input, the PCM vents the
speed control servo. Venting the servo turns the
speed control system off.
COOLANT TEMPERATURE SENSORÐPCM INPUT
The coolant temperature sensor is installed behind
the thermostat housing and ignition coil in the hot
box. The sensor provides an input voltage to the
PCM (Fig. 3). As coolant temperature varies, the sen-
sors resistance changes, resulting in a different input
voltage to the PCM. The PCM demands slightly richer air-fuel mixtures
and higher idle speeds until the engine reaches nor-
mal operating temperature. This sensor is also used for cooling fan control.
DISTRIBUTOR (HALL EFFECT) PICK-UPÐPCM
INPUT
The distributor pick-up supplies engine speed to
the PCM. The distributor pick-up is a Hall Effect de-
vice (Fig. 4).
A shutter (sometimes referred to as an interrupter)
is attached to the distributor shaft. The shutter con-
tains four blades, one per engine cylinder. A switch
plate is mounted to the distributor housing above the
Fig. 3 Coolant Temperature Sensor
Fig. 4 Distributor Pick-UpÐTypical
14 - 26 FUEL SYSTEMS Ä

shutter. The switch plate contains the distributor
pick-up which is a Hall Effect device and magnet.
The shutter blades rotate through the distributor
pick-up. As the shutter blades pass through the pick-
up, they interrupt the magnetic field. The Hall effect
device in the pick-up senses the change in the mag-
netic field and switches on and off (which creates
pulses), generating the input signal to the PCM. The
PCM calculates engine speed through the number of
pulses generated.
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐPCM INPUT
The PCM supplies 5 volts to the MAP sensor. The
MAP sensor converts intake manifold pressure into
voltage. The PCM monitors the MAP sensor output
voltage. As vacuum increases, MAP sensor voltage
decreases proportionately. Also, as vacuum decreases,
MAP sensor voltage increases proportionately. During cranking, before the engine starts running,
the PCM determines atmospheric air pressure from
the MAP sensor voltage. While the engine operates,
the PCM determines intake manifold pressure from
the MAP sensor voltage. Based on MAP sensor voltage and inputs from
other sensors, the PCM adjusts spark advance and
the air/fuel mixture. The MAP sensor mounts on the dash panel (Fig. 5).
A vacuum hose connects the sensor to the throttle
body.
HEATED OXYGEN SENSOR (O2SENSOR)ÐPCM
INPUT
The O2sensor is located in the exhaust manifold
and provides an input voltage to the PCM. The input
tells the PCM the oxygen content of the exhaust gas
(Fig. 6). The PCM uses the information to fine tune
the air-fuel ratio by adjusting injector pulse width. The O
2sensor produces voltages from 0 to 1 volt,
depending upon the oxygen content of the exhaust
gas. When a large amount of oxygen is present
(caused by a lean air-fuel mixture), the sensor pro-
duces a low voltage. When there is a lesser amount
present (rich air-fuel mixture), it produces a higher
voltage. By monitoring the oxygen content and con-
verting it to electrical voltage, the sensor acts as a
rich-lean switch. The oxygen sensor is equipped with a heating ele-
ment that keeps the sensor at proper operating tem-
perature during all operating modes. Maintaining
correct sensor temperature at all times allows the
system to enter into closed loop operation sooner.
Also, it allows the system to remain in closed loop
operation during periods of extended idle. In Closed Loop operation the PCM monitors the O
2
sensor input (along with other inputs) and adjusts
the injector pulse width accordingly. During Open
Loop operation the PCM ignores the O
2sensor input.
The PCM adjusts injector pulse width based on a pre-
programmed (fixed) oxygen sensor input value and
inputs from other sensors.
SPEED CONTROLÐPCM INPUT
The speed control system provides four separate
voltages (inputs) to the PCM. The voltages corre-
spond to the On/Off, Set, and Resume. The speed control ON voltage informs the PCM
that the speed control system has been activated.
The speed control SET voltage informs the PCM that
a fixed vehicle speed has been selected. The speed
control RESUME voltage indicates the previous fixed
speed is requested. The speed control OFF voltage
tells the PCM that the speed control system has de-
activated. Refer to Group 8H for further speed con-
trol information.
Fig. 5 Manifold Absolute Pressure (MAP) Sensor Location
Fig. 6 Heated Oxygen Sensor
Ä FUEL SYSTEMS 14 - 27

TRANSAXLE PARK/NEUTRAL SWITCHÐPCM
INPUT
The park/neutral switch is located on the auto-
matic transaxle housing (Fig. 7). Manual transaxles
do not use park neutral switches. The switch pro-
vides an input to the PCM. The input indicates
whether the automatic transaxle is in Park, Neutral,
or a drive gear selection. This input is used to deter-
mine idle speed (varying with gear selection), fuel in-
jector pulse width, and ignition timing advance. The
park neutral switch is sometimes referred to as the
neutral safety switch.
THROTTLE POSITION SENSOR (TPS)ÐPCM INPUT
The Throttle Position Sensor (TPS) is mounted on
the throttle body and connected to the throttle blade
shaft (Fig. 8). The TPS is a variable resistor. The
sensor provides an input signal (voltage) to the PCM
representing throttle blade position. As the position
of the throttle blade changes, the resistance of the
TPS changes.
The PCM supplies approximately 5 volts to the
TPS. The TPS output voltage (input signal to the
PCM) represents the throttle blade position. The
PCM receives an input signal voltage from the TPS
varying in an approximate range of from 1 volt at
minimum throttle opening (idle) to 4 volts at wide open throttle. Along with inputs from other sensors,
the PCM uses the TPS input to determine current
engine operating conditions. The PCM adjusts fuel
injector pulse width and ignition timing based on
these inputs.
VEHICLE SPEED SENSORÐPCM INPUT
The vehicle speed sensor is located in the transaxle
extension housing (Fig. 9). The sensor input is used
by the PCM to determine vehicle speed and distance
traveled.
The speed sensor generates 8 pulses per sensor rev-
olution. These signals, along with a closed throttle
signal from the TPS, determine if a closed throttle
deceleration or normal idle condition (vehicle
stopped) exists. Under deceleration conditions, the
PCM adjusts the idle air control motor to maintain a
desired MAP value. Under idle conditions, the PCM
adjusts the idle air control motor to maintain a de-
sired engine speed.
AIR CONDITIONING (A/C) CLUTCH RELAYÐPCM
OUTPUT
The PCM operates the air conditioning clutch relay
ground circuit. The radiator fan relay supplies bat-
tery power to the solenoid side of the A/C clutch re-
lay. The air conditioning clutch relay will not
energize unless the radiator fan relay energizes. The
PCM energizes the radiator fan relay when the air
conditioning or defrost switch is put in the ON posi-
tion and the low pressure and high pressure switches
close. With the engine operating, the PCM cycles the air
conditioning clutch on and off when the A/C switch
closes with the blower motor switch in the on posi-
tion. When the PCM senses low idle speeds or wide
open throttle through the throttle position sensor, it
de-energizes the A/C clutch relay. The relay contacts
open, preventing air conditioning clutch engagement.
Fig. 7 Park/Neutral Switch
Fig. 8 Throttle Position Sensor
Fig. 9 Vehicle Distance (Speed) SensorÐTypical
14 - 28 FUEL SYSTEMS Ä

On AC, AG and AJ models, the A/C clutch is lo-
cated in the power distribution center. Refer to the
Wiring and Component Identification section of
Group 8W. ON AA and AP models, the A/C clutch relay is
mounted to the inner fender panel, next to the driv-
ers side strut tower (Fig. 10).
AUTO SHUTDOWN (ASD) RELAY AND FUEL PUMP
RELAYÐPCM OUTPUT
The PCM operates the auto shutdown (ASD) relay
and fuel pump relay through one ground path. The
PCM operates the relays by switching the ground
path on and off. Both relays turn on and off at the
same time. The ASD relay connects battery voltage to the fuel
injector and ignition coil. The fuel pump relay con-
nects battery voltage to the fuel pump and oxygen
sensor heating element. The PCM turns the ground path off when the igni-
tion switch is in the Off position. Both relays are off.
When the ignition switch is in the On or Crank po-
sition, the PCM monitors the distributor pick-up sig-
nal. From the distributor signal, the PCM
determines engine speed and ignition timing (coil
dwell). If the PCM does not receive a distributor sig-
nal when the ignition switch is in the Run position,
it will de-energize both relays. When the relays are
de-energized, battery voltage is not supplied to the
fuel injector, ignition coil, fuel pump and oxygen sen-
sor heating element. On AC, AG and AJ models, the ASD relay and fuel
pump relay are located in the power distribution cen-
ter. Refer to the Wiring and Component Identifica-
tion section of Group 8W. On AA and AP models, the ASD relay and fuel
pump relay are mounted on the drivers side fender
well, next to the strut tower (Fig. 10).
IDLE AIR CONTROL MOTORÐPCM OUTPUT
The idle air control motor is mounted on the throt-
tle body (Fig. 11). The PCM operates the idle air con-
trol motor. The PCM adjusts engine idle speed
through the idle air control motor to compensate for
engine load or ambient conditions.
The throttle body has an air bypass passage that
provides air for the engine at idle (the throttle blade
is closed). The idle air control motor pintle protrudes
into the air bypass passage and regulates air flow
through it. The PCM adjusts engine idle speed by moving the
idle air control motor pintle in and out of the bypass
passage. The adjustments are based on inputs the
PCM receives from the throttle position sensor, speed
sensor (distributor pick-up coil), coolant temperature
sensor, and various switch operations (brake, park/
neutral, air conditioning). Deceleration die out is also
prevented by increasing airflow when the throttle is
closed quickly after a driving (speed) condition.
EVAP CANISTER PURGE SOLENOIDÐPCM
OUTPUT
Vacuum for the Evaporative Canister is controlled
by the EVAP Canister Purge Solenoid (Fig. 12). The
solenoid is controlled by the PCM. The PCM operates the solenoid by switching the
ground circuit on and off based on engine operating
conditions. When grounded, the solenoid energizes
and prevents vacuum from reaching the evaporative
canister. When not energized, the solenoid allows
vacuum to flow to the canister. During warm-up and for a specified time period af-
ter hot starts, the PCM grounds the purge solenoid.
Vacuum does not operate the evaporative canister
valve.
Fig. 10 Relay Identification
Fig. 11 Idle Air Control Motor
Ä FUEL SYSTEMS 14 - 29

The PCM removes the ground to the solenoid when
the engine reaches a specified temperature and the
time delay interval has occurred. When the solenoid is
de-energized, vacuum flows to the canister purge
valve. Vapors are purged from the canister and flow to
the throttle body. The purge solenoid is also energized during certain
idle conditions to update the fuel delivery calibration.
MALFUNCTION INDICATOR LAMP (CHECK
ENGINE)ÐPCM OUTPUT
The Malfunction Indicator lamp (instrument panel
Check Engine lamp) comes on each time the ignition
key is turned ON and stays on for 3 seconds as a bulb
test. The malfunction indicator lamp warns the opera-
tor that the PCM has entered a Limp-in mode. During
Limp-in-Mode, the PCM attempts to keep the system
operational. The malfunction indicator lamp signals
the need for immediate service. In limp-in mode, the
PCM compensates for the failure of certain components
that send incorrect signals. The PCM substitutes for
the incorrect signals with inputs from other sensors. Signals that can trigger the Malfunction Indi-
cator Lamp.
² Coolant Temperature Sensor
² Manifold Absolute Pressure Sensor
² Throttle Position Sensor
² Battery Voltage Input
² An Emissions Related System
² Charging system
The malfunction indicator lamp can also be used to
display diagnostic trouble codes. Cycle the ignition
switch on, off, on, off, on, within five seconds and any
diagnostic trouble codes stored in the PCM will be
displayed. Refer to the 2.2L/2.5L Single Point Fuel
InjectionÐOn-Board Diagnostics section in this group.
DATA LINK CONNECTORÐPCM OUTPUT
The data link connector provides the technician with
the means to connect the DRBII scan tool to diagnosis
the vehicle.
ELECTRIC ELECTRONIC GAS
RECIRCULATIONÐPCM OUTPUT
The electronic exhaust gas recirculation transducer
(EET) is a back pressure transducer/electric vacuum
solenoid assembly (Fig. 13). The EET assembly mounts
above the EGR valve (Fig. 14).
The solenoid turns the vacuum supply to the trans-
ducer on and off. The electric vacuum solenoid portion
of the EET energizes when the PCM provides a ground
path. When the solenoid energizes, vacuum is pre-
vented from flowing to the transducer. When the sole-
noid de-energizes, vacuum flows to the transducer. The
solenoid energizes during engine warm-up, closed
throttle (idle or cruise), wide open throttle, and rapid
acceleration/deceleration. If the solenoid wire con-
nector is disconnected, the EGR valve will oper-
ate at all times.
Fig. 12 EVAP Canister Purge Solenoid
Fig. 13 Electronic EGR Recirculation Transducer
Fig. 14 EGR Valve and Electric EGR Transducer
14 - 30 FUEL SYSTEMS Ä