CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

RADIATOR DRAINCOCK SERVICE
REMOVAL (1) Turn the drain cock stem counterclockwise to
unscrew the stem. When the stem is unscrewed to
the end of the threads, pull the stem (Fig. 10) from
the radiator tank.
INSTALLATION (1) Push the draincock assembly body into the
tank opening until it snaps into place. (2) Tighten the draincock stem by turning clock-
wise to 2.0-2.7 N Im (18-25 in. lbs.) torque.
RADIATOR COOLANT FLOW CHECK
To determine whether coolant is flowing through
the cooling system, use the following procedure: (1) If engine is cold, idle engine until normal oper-
ating temperature is reached. Then feel the upper ra-
diator hose. If it is hot, coolant is circulating.
WARNING: DO NOT REMOVE RADIATOR PRES-
SURE CAP WITH THE SYSTEM HOT AND UNDER
PRESSURE BECAUSE SERIOUS BURNS FROM
COOLANT CAN OCCUR.
Fig. 9 Cooling ModuleÐTypical
Fig. 8 Pressure Testing Radiator Cap
Fig. 10 Draincock AssemblyÐTypical
Ä COOLING SYSTEM 7 - 19

(2) Remove radiator pressure cap when engine is
cold, Idle engine until thermostat opens, you should
observe coolant flow while looking down the filler
neck. Once flow is detected install radiator pressure
cap.
RADIATOR
REMOVAL
(1) Disconnect negative battery cable from battery.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(2) Drain cooling system. Refer to Draining Cool-
ing System of this section. (3) Remove hose clamps and hoses from the radia-
tor (Fig. 11). Remove coolant reserve system tank to
filler neck tube. (4) Remove automatic transmission hoses, if
equipped. (5) Remove fan and fan support assembly by dis-
connecting fan motor electrical connector. Remove
fan shroud retaining clips, located on the top and
bottom of the shroud for AA, AG, AJ and AP vehi-
cles. AC/AY vehicle retainer clips are located on the
top only. Lift shroud up and out of bottom shroud at-
tachment clips separating shroud from radiator. Fan
damage should always be avoided. (6) Remove upper radiator mounting screws. Dis-
connect the engine block heater wire if equipped. (7) Remove the air conditioning condenser attaching
screws located at the top front of the radiator,if
equipped. Radiator can now be lifted free from engine compart-
ment. Care should be taken not to damage radia-
tor cooling fins or water tubes during removal.
INSTALLATION
(1) Slide radiator down into position behind radiator
support (yoke). (2) Attach air conditioning condenser to radiator, if
equipped, with a force of approximately 10 lbs. to seat
the radiator assembly lower rubber isolators in the
mount holes provided. (3) Tighten radiator mounting screws to 11.9N Im
(105 in. lbs.). (4) Connect automatic transmission hoses, if
equipped. Tighten hose clamps to 4 N Im (35 in. lbs.).
(5) Slide fan shroud, fan and motor down into clips
on lower radiator flange. Replace shroud retaining
clips. (6) Install upper and lower radiator hoses (including
coolant reserve hose). (7) Connect fan motor electrical connection and con-
nect negative battery cable. (8) Fill cooling system with coolant. Refer to Refill-
ing Cooling Systems. in this group.
(9) Operate engine until it reaches normal operating
temperature. Check cooling system and automatic
transmission for correct fluid levels.
Fig. 11 Cooling ModulesÐAll Models
7 - 20 COOLING SYSTEM Ä

RADIATOR HOSES
The hoses are removed using Constant Tension
Clamp pliers to compress hose clamp. A hardened, cracked, swollen or restricted hose
should be replaced. Do not damage radiator inlet and
outlet when loosening hoses. Radiator hoses should be routed without any kinks
and indexed as designed. The use of molded hoses is
recommended. Spring type hose clamps are used in all applica-
tions. If replacement is necessary replace with the
original style spring type clamp.
FANS
All models use electric motor driven cooling system
fans. The fan modules include a motor support which
may (depending on model) include a shroud. The
module is fastened to the radiator by screws with
U-nuts and retaining clips (Fig. 12). All fan motors are one speed. Attempts to reduce
high temperature gauge reading by increasing en-
gine speed, at the same vehicle speed, can increase
high temperature.
SINGLE FAN
There are no repairs to be made to the fan. If the
fan is warped, cracked, or otherwise damaged, it must be replaced with
onlythe recommended part for
adequate strength, performance and safety (Fig. 13).
DUAL FAN MODULEÐAC/AY BODY
The dual fan module (Fig. 11) is a combination of 2
fans mounted in a one piece shroud which are simul-
taneously activated. The dual fan system improves
engine cooling and air conditioning performance in hot
weather and severe driving conditions, while reducing
fan noise and power consumption.
REMOVAL
Disconnect electric motor lead. Remove fan module
to radiator fasteners and retaining clips. Remove as-
sembly from radiator support. To remove fan from motor shaft, bench support the
motor and motor shaft, while removing the fan retain-
ing clip, so that the shaft and motor will not be
damaged by excessive force. Surface or burr re-
moval may be required to remove fan from motor
shaft. (Fig. 13). Do not permit the fan blades to touch
the bench.
INSTALLATION
Slide the fan on motor shaft. Support motor and
shaft as above while installing fan retaining clip.
Install assembly into pocket on lower radiator tank.
Attach retaining clips and fasteners to radiator tank.
Right side fastener is longer on A/C equipped
vehicles . Connect fan motor lead. For wiring dia-
grams of fan motor systems see Wiring Diagrams
Manual
RADIATOR FAN CONTROLÐALL EXCEPT V-6 ENGINE
Fan control is accomplished two ways. The fan al-
ways runs when the air conditioning compressor
clutch is engaged. In addition to this control, the fan is
turned on by the temperature of the coolant which is
sensed by the coolant temperature sensor which
Fig. 12 Servicing Fan Module
Fig. 13 Radiator Fan Retaining ClipÐTypical
Ä COOLING SYSTEM 7 - 21

sends the message to the Engine Controller. The En-
gine Controller turns on the fan through the fan re-
lay. See Wiring Diagrams Manual for circuity and
diagnostics provided.Switching through the Engine Controller provides
fan control for the following conditions.
² The fan will not run during cranking until the en-
gine starts no matter what the coolant temperature
is.
² Fan will run when the air conditioning clutch is
engaged and low pressure cutout switch is closed.
² For 4 cylinder application the fan will run at ve-
hicle speeds above about 40 mph only if coolant tem-
perature reaches 110ÉC (230ÉF). It will turn off when
the temperature drops to 104ÉC (220ÉF). At speeds
below 40 mph the fan switches on at 102ÉC (215ÉF)
and off at 93ÉC (200ÉF).
² This is to help prevent steaming. The fan will run
only below 16ÉC (60ÉF) ambient. Between 38ÉC
(100ÉF) to 97ÉC (195ÉF) coolant temperature, at idle
and then only for three minutes.
RADIATOR FAN CONTROLÐAC/AY BODY V-6 ONLY
For this application, fan control is accomplished
based on coolant temperature, and on A/C head pres-
sure. These vehicles receive the variable displace-
ment compressor. The fan will go on when;
² Coolant temperature reaches 102ÉC (215ÉF) and off
at 93.4ÉC (200ÉF) regardless of vehicle speed.
² When the head pressure reaches 1516.9 kPa (220
psi) and turn off when the pressure reaches 1103 kPa
(160 psi).
TEMPERATURE GAUGE INDICATION
At idle the temperature gauge will rise slowly to
about 5/8 gauge travel. The fan will come on and the
gauge will drop to about 1/2 gauge travel, this is nor-
mal.
ELECTRIC FAN MOTOR
To check out the electric fan motor, disconnect the
fan motor wire connector and connect it with #14
gauge wires to a good 12-volt battery observing cor-
rect polarity per (Fig. 14). If the fan runs normally,
the motor is functioning properly. If not, replace fan
module using the removal and installation instruc-
tions contained in the Fan Section. If the motor is
noticeably overheated (i.e.; wire insulation melted,
motor charred) the system voltage may be too high.
Check charging system, see Group 8A, Battery/Start-
ing/Charging System Diagnostics.
ELECTRIC FAN MOTOR TEST
Equipment required
² Diagnostic Tool DRB II or equivalent
² Volt/Ohm Meter
² Wiring Diagram Manual (1) Run the engine to normal operating tempera-
ture. (2) Check wiring connector in C25, C9, and C26 for
proper engagement, see Wiring Diagram Manual (3) Using a diagnostic tool, plugged into the diag-
nostic connector rearward of the battery, check the
On-Board Diagnostics (OBD) in the Engine Control-
ler for fault codes, see Group 14, Fuel Injection for
instructions. (4) If fault code 88-12-35-55 is detected, proceed to
Step 5. (5) With the ignition switch in the run position,
test for battery voltage (single pin connector) at the
fan relay. Voltage reading OK, proceed to Step 6a.
Voltage at 0-1 volt, proceed to Step 6b. 6(a) With the ignition off, disconnect the 60-way
connector from the Engine Controller (outboard of
battery) and return the ignition to the run position.
Test for battery voltage at cavity 31 of the 60-way
connector (Fig. 15). Voltage reading OK and female
terminal is not damaged, replace the Engine Control-
ler. Voltage reading 0, repair open or short in C27
circuit. (b) With the ignition off, disconnect the 60-way
connector from the Engine Controller (outboard of
battery) and return the ignition to the run position.
Test for battery voltage at the single pin connector
at the fan relay. Voltage reading OK, replace the
Engine Controller. Voltage reading 0-1 volt, pro-
ceed to Step 7.
(7) With ignition in the run position, test for bat-
tery voltage at the wire (C27) in the 3-way connector
of the fan relay. Voltage reading OK, replace the fan
relay. Voltage reading 0, repair open or short in C27
circuit. (8) Turn ignition off, connect the 60-way connector
at the Engine Controller and test the system.
Fig. 14 Electric Fan MotorÐTypical
7 - 22 COOLING SYSTEM Ä

FAN SHROUD
All vehicles have fan shrouds to improve fan air
flow efficiency. These fan shrouds cover less than full
radiator frontal area to prevent the shroud from re-
stricting air flow at high speeds. The shroud supports the electric fan motor and fan.
For removal and installation see Radiator Section.
AUTOMATIC TRANSMISSION OIL COOLERS
Oil coolers are internal oil to coolant type, mounted
in the radiator left tank (Fig. 16). Rubber oil lines
feed the oil cooler and the automatic transmission.
Use only approved transmission oil cooler hose. Since
these are molded to fit space available, molded hoses
are recommended. Tighten Oil Cooler Hose Clamps
to4N Im (35 in. lbs.).
Fig. 15 Engine Controller 60-Way Connector from
Terminal End
Fig. 16 Transmission Oil Cooler
Ä COOLING SYSTEM 7 - 23

ACCESSORY DRIVE BELTS INDEX
page page
2.2/2.5L Engine Belts Remove/Install-Adjust .... 24
3.0L Engine Belts Remove/Install and Adjust .... 25
3.3/3.8L and Turbo III Engine Accessory Drive Belt Remove and Install
..................... 26
General Information ....................... 24
GENERAL INFORMATION
PROPER BELT TENSION
Satisfactory performance of the belt driven accesso-
ries depends on belt condition (Fig. 1) and proper belt
tension. Two tensioning methods are given in order
of preference:
² Belt tension gauge method.
² Torque equivalent method.
The belt tension gauge method is usually restricted
to use after the vehicle has been raised on a hoist
and the splash shield has been removed.
BELT TENSION GAUGE METHOD Use belt tensioning Special Tool Kit C-4162 for:
² For conventional belts and Poly-V belts.
Adjust the belt tension for a NeworUsed belt as
prescribed in the Belt Tension Chart.
TORQUE EQUIVALENT METHOD Adjustable accessory brackets provided with a
13mm (1/2 in.) square hole for a torque wrench can
use an equivalent torque value for belt adjustment. Equivalent torque values for adjusting these acces-
sory drive belts are specified on the Belt Tension
Charts .
2.2/2.5L ENGINE BELTS REMOVE/INSTALL-
ADJUST
AIR CONDITIONING COMPRESSOR
(1) Loosen the idler bracket pivot screw A and
locking screws B (Fig. 2) to remove and install belt
and/or adjust belt tension.
ACCESSORY DRIVE BELTS DIAGNOSIS
Fig. 1 Drive Belt Inspection
7 - 24 COOLING SYSTEM Ä

(2) Adjust belt tension by applying torque to
square hole C on idler bracket. Adjust tension to
specification given in Belt Tension Chart. (3) Tighten in order, first, locking screws B then
pivot screw A to 54 N Im (40 ft. lbs.).
POWER STEERING PUMPÐS TYPE
(1) From on top of the vehicle loosen locking screw G.
(2) From under the vehicle loosen the pivot screw
and pivot nut H . (3) After installing a new belt adjust belt tension
with 1/2 in. breaker bar installed in adjusting
bracket. See tension specification in chart. (4) Tighten locking screw G to 54 N Im (40 ft. lbs.).
(5) Tighten pivot screw H and the pivot nut to 54
N Im (40 ft. lbs.)
GENERATOR BELT
(1) Loosen T-Bolt locking nut E and adjusting
screw F to remove and install Poly V belt and/or ad-
just belt tension. (2) Tighten adjusting screw F to adjust belt tension
to specification shown in Belt Tension Chart. (3) Tighten T-Bolt locking nut E to 54 N Im (40 ft.
lbs.).
3.0L ENGINE BELTS REMOVE/INSTALL AND
ADJUST
AIR CONDITIONING BELT
To remove and install the air conditioning com-
pressor drive belt, first loosen the idler pulley lock
nut, then turn the adjusting screw to raise or lower
the idler pulley (Figs. 3 and 4).
To adjust the air conditioning drive belt, loosen
the idler pulley nut (Fig. 3) and adjust belt tension
Fig. 2 Accessory Drive BeltsÐ2.2 and 2.5L Engines
Fig. 3 Accessory Drive BeltsÐ3.0L Engine
Ä COOLING SYSTEM 7 - 25

by tightening adjusting screw (Figs. 3 and 4 ).
Tighten pulley nut to 54 N Im (40 ft. lbs.) after ad-
justment.
GENERATOR/POWER STEERING PUMP BELT
The Poly-V generator/power steering pump belt is
provided with a dynamic tensioner (Fig. 5) to main-
tain proper belt tension. To remove or install this
belt, Release tension by rotating the tensioner clock-
wise
3.3/3.8L AND TURBO III ENGINE ACCESSORY
DRIVE BELT REMOVE AND INSTALL
GENERATOR, POWER STEERING PUMP, AIR
CONDITIONING COMPRESSOR AND WATER
PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic
tensioner (Figs. 7 and 8) to maintain proper belt ten-
sion. To remove or install this belt. (1) Raise vehicle on hoist.
(2) Remove right front splash shield.
(3) Release tension by rotating the tensioner clock-
wise (Figs. 7 and 8). (4) Reverse above procedure to install.
Fig. 5 Release Belt Tensioner
Fig. 6 Belt Tension Chart
Fig. 4 Air Conditioning Belt Idler
7 - 26 COOLING SYSTEM Ä

Fig. 7 Accessory Drive BeltÐ2.2L Turbo III Engine
Fig. 8 Accessory Drive BeltÐ3.3/3.8L Engines
Ä COOLING SYSTEM 7 - 27

ENGINE BLOCK HEATER
DESCRIPTION AND OPERATION
On all models an engine block heater is available as
an optional accessory. The heater, operated by ordinary
house current (110 Volt A.C.) through a power cord and
connector behind the radiator grille, provides easier
engine starting and faster warm-up when vehicle is
operated in areas having extremely low temperatures.
The heater is mounted in a core hole (in place of a core
hole plug) in the engine block, with the heating ele-
ment immersed in coolant (Fig. 9). The power cord must be secured in its retainer
clips, and not positioned so it could contact link-
ages or exhaust manifolds and become damaged. If unit does not operate, trouble can be in either the
power cord or the heater element. Test power cord for
continuity with a 110-volt voltmeter or 110-volt test
light; test heater element continuity with an ohmmeter
or 12-volt test light.
REMOVAL
(1) Drain coolant from radiator and cylinder block.
Refer to Cooling System Drain, Clean, Flush and Re-
fill of this section for procedure. (2) Detach power cord plug from heater.
(3) Loosen screw in center of heater. Remove
heater assembly.
INSTALLATION
(1) Thoroughly clean core hole and heater seat.
(2) Insert heater assembly with element loop posi-
tioned upward.
(3) With heater seated, tighten center screw se-
curely to assure a positive seal. (4) Fill cooling system with coolant to the proper
level, vent air, and inspect for leaks. Pressurize sys-
tem with Radiator Pressure Tool before looking for
leaks.
Fig. 9 Engine Block Heater
7 - 28 COOLING SYSTEM Ä